Graco AIRLESSCO SP400 Hi Boy Operating instructions

3A1181B
ENG
Repair
Electric Airless Sprayers
For portable spray application of architectural paints and coatings. For professional use
only.
Not approved to European explosive atmosphere requirements.
Models
24F562(SP400 Hi Boy)
24F564 (Mustang 4700 Hi Boy)
24F561 (SP400 Stand)
24F563 (Mustang 4700 Stand)
3300 psi (22.7MPa, 227 bar) Maximum Working Pressure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
3A1180
312363 312365 312364
English Français Español
312362
ti11608a
ti16088a
SP400 Stand Model 24F561
Mustang 4700 Stand Model 24F563
SP400 HiBoy Model 24F562
Mustang 4700 HiBoy Model 24F564

Warnings
23A1181B
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion 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, 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.
WARNINGWARNINGWARNING
WARNING
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that
is properly installed and grounded in accordance with all local codes and ordinances.
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either
flat blade terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a
qualified electrician.
• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug
illustrated in the figure below.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
Extension Cords:
• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that
accepts the plug on the product.
• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG
(2.5 mm2) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.

Warnings
3A1181B 3
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.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity
creates a risk of fire or explosion in the presence of paint or solvent fumes. 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 Airlessco conductive or
grounded high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump
assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• 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 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.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
WARNINGWARNINGWARNING
WARNING

Warnings
43A1181B
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
SKIN INJECTION HAZARD
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 nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Airlessco nozzle tips.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure
before removing the nozzle tip to clean.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure for turning off the unit.
• 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.
• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
• This system is capable of producing 3000 psi. Use Airlessco replacement parts or accessories that are
rated a minimum of 3000 psi.
• 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.
WARNINGWARNINGWARNING
WARNING

Warnings
3A1181B 5
WARNINGWARNINGWARNING
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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 leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure for turning off the unit.
• 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 Airlessco.
• Do not use the hose as a strength member to pull or lift the equipment.
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.
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.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure, page 7 and disconnect all power sources.
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 MSDSs 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
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This 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.

Installation
63A1181B
Installation
Grounding and Electric
Requirements
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
The sprayers require:
110-120V Units: 100-130 VAC, 50/60 Hz, 11A, 1 phase,
circuit with a grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
Do not use the sprayer if the electrical cord has a dam-
aged ground contact. Only use an extension cord with
an undamaged ground contact.
Recommended extension cords:
• 110-120V: 3-wire, 12 AWG (2.5 mm2) minimum.
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent and Oil-based fluids: follow local code. Use
only conductive metal pails placed on a grounded sur-
face such as concrete. Do not place the pail on a non-
conductive surface such as paper or cardboard, which
interrupts grounding continuity.
Grounding the metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to ground
such as a water pipe.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
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Pressure Relief Procedure
3A1181B 7
Pressure Relief Procedure
Follow this Pressure Relief Procedure whenever you
are instructed to relieve pressure, stop spraying, check
or service equipment or install or clean spray tip.
1. Turn OFF power and turn pressure control to lowest
pressure setting.
2. Hold gun against side of grounded metal flushing
pail. Trigger gun to relieve pressure.
3. Turn prime valve down.
If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure gradually,
then loosen completely. Clear hose or tip obstruction.
4. Engage trigger safety lock on gun if unit is being
shut down or left unattended.
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General Repair Information
83A1181B
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Trouble-
shooting, page 9.
• Overspray may build up in the air passages.
Remove any overspray and residue from air pas-
sages and openings in the enclosures whenever
you service sprayer.
• Do not operate the sprayer without the motor shroud
in place. Replace if damaged. Motor shroud directs
cooling air around motor to prevent overheating and
insulates the control board from accidental electric
shock.
Flammable materials spilled on hot, bare, motor
could cause fire or explosion. To reduce risk of burns,
fire or explosion, do not operate sprayer with cover
removed.
To reduce risk of serious injury, including electric
shock:
• Do not touch moving or electric parts with fingers
or tools while testing repair.
• Unplug sprayer when power is not required for
testing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
NOTICE
• Do not run sprayer dry for more than 30
seconds. Doing so could damage pump
packings.
• Protect the internal drive parts of this sprayer
from water. Openings in the cover allow for air
cooling of the mechanical parts and
electronics inside. If water gets in these
openings, the sprayer could malfunction or be
permanently damaged.
• Prevent pump corrosion and damage from
freezing. Never leave water or water-base
paint in sprayer when its not in use in cold
weather. Freezing fluids can seriously damage
sprayer. Store sprayer with Pump Armor to
protect sprayer during storage.

Troubleshooting
3A1181B 9
Troubleshooting
Problem Cause Solution
Basic Fluid Pressure 1. Pressure control knob setting.
Motor will not run if set at mini-
mum (fully counter-clockwise).
Slowly increase pressure setting to
see if motor starts.
2. Spray tip or fluid filter may be
clogged.
Relieve pressure, page 7. Then
clear clog or clean gun filter. Refer
to gun instruction manual, 312363.
Basic Mechanical 1. Pump frozen or hardened paint Thaw sprayer if water or
water-based paint has frozen in
sprayer. Place sprayer in warm area
to thaw. Do not start sprayer until
thawed completely. If paint hard-
ened (dried) in sprayer, replace
pump packings. See Displace-
ment Pump Replacement, page
13.
2. Displacement pump connecting
rod pin. Pin must be completely
pushed into connecting rod and
retaining spring must be firmly in
groove or pump pin.
Push pin into place and secure with
spring retainer. See Displacement
Pump Replacement, page 13.
3. Motor. Remove drive housing
assembly. See Drive Housing
Replacement, page 15. Try to
rotate fan by hand.
Replace motor if fan won’t turn. See
Motor Replacement, page 27.

Troubleshooting
10 3A1181B
Basic Electrical
See wiring diagram, page 28
1. Electric supply. ON/OFF switch in
OFF position. Meter must read
100-130 Vac; 210-260 Vac.
Turn ON/OFF switch to ON position.
Reset building circuit breaker,
replace building fuses. Try another
outlet.
2. Extension cord. Check extension
cord continuity with volt meter.
Replace extension cord.
3. Sprayer power supply cord.
Inspect for damage such as bro-
ken insulation or wires.
Replace power supply cord. See
Power Cord Replacement, page
26.
4. Fuse. Check replaceable fuse on
control board (next to ON/OFF
switch).
Replace fuse after completing
motor inspection. See Fuse
Replacement, page 21.
5. Motor leads are securely fas-
tened and properly connected to
control board.
Replace loose terminals; crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.
6. Motor thermal switch. Yellow
motor leads must have continuity
through thermal switch.
Replace motor. See Motor
Replacement, page 27.
7. Brush cap missing or loose brush
lead connections.
Install brush cap or replace brushes
if leads are damaged. See Motor
Brush Replacement, page 18.
8. Brush length which must be
greater than 1/4 in. (6 mm).
NOTE: Brushes do not wear at
the same rate on both sides of
motor. Check both brushes.
Replace brushes. See Motor
Brush Replacement, page 18.
9. Motor armature commutator for
burn spots, gouges and extreme
roughness.
Remove motor and have motor
shop resurface commutator if possi-
ble. See Motor Replacement,
page 27.
10. Motor armature for shorts using
armature tester (growler) or per-
form Spin Test,page 16.
Replace motor. See Motor
Replacement, page 27.
11. Pressure control not plugged in
to control board.
Insert pressure control connector
into control board.
Problem Cause Solution