Airless Spray

THE BASICS
OF AIRLESS SPRAYING
Information on Basic Components,
Spray Technology and Safety
P R O V E N Q U A L I T Y. L E A D I N G T E C H N O L O G Y.
MADE IN THE USA WITH

GLOBAL COMPONENTS
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A World Leader in Fluid Handling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Graco Advantage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Advantages of Airless Sprayers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Key Components of an Airless Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air-Assisted Airless Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Airless Spray Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How Airless Sprayers are Rated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selecting A Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Spray Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
The Beyond the Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sprayer Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Only on a Graco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accident & Near Miss Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 The Basics - An Overview of Airless Sprayers

A World Leader in Fluid Handling Systems
Founded in 1926, Graco is the world leader in fluid handling systems and
components. Once a quiet family-owned business, Graco Inc. has become the
world’s premier manufacturer of fluid handling equipment and systems.
Graco equipment squeezes tomato paste onto millions of frozen pizzas;
pumps oil and lubricating fluids into millions of cars; applies paint to homes,
business and industrial installations; and helps give cars made around the
world their high-gloss finishes.
Working closely with specialized distributors, Graco offers systems, products
and technologies that set the quality standards in a wide range of fluid
handling applications. Graco applications include spray finishing and paint
circulation, lubrication, sealants and adhesives along with power application
equipment for the contractor industry. Graco’s ongoing research investments
in fluid management and control will continue to provide innovative solutions to
a global market.
Contractor Equipment Division

Graco’s Contractor Equipment Division (CED) offers a complete product line
for the professional contractor including:
• Handheld airless sprayers
• Electric-powered airless sprayers
• Gas mechanical sprayers
• Gas hydraulic sprayers
• HVLP fine finish sprayers
• Air-Assisted airless sprayers
• Texture sprayers
• Road and parking lot stripers
• Thermoplastic application equipment
• Line removal equipment
• Sport field stripers
• Roofing spray equipment
• Pressure washers
• Air powered corrosion control equipment
• A full line of parts and accessories, such as spray tips, guns and hoses
The Basics - An Overview of Airless Sprayers 2

The Graco Advantage
Graco Inc., is recognized as the quality leader
in the airless sprayer market. As the industry
leader, Graco offers the largest line of quality
painting equipment and accessories in the
world. Graco has achieved high market
preference—painting contractors have known
and trusted the Graco name for over 60 years.
Graco works hard to meet the needs

of today’s painting contractor. Ongoing
improvement to existing products and
continuous innovation are key factors in
developing premier products. Graco invests
more money on research and development
than competitors and it shows in the
quality and durability of Graco airless spray
equipment.
In addition to Graco’s experience in the airless market and the company’s
commitment to research and development, is the genuine effort to educate
professional contractors about the advantages of airless spray equipment.
Ongoing support is always available and is simply a phone call away with
the Graco A+ Service commitment to exceed customer expectations each
and every time by providing outstanding service through timely, accurate and
effective responses to inquiries and orders, as well as service and technical
assistance.
Add to this Graco’s sales and training efforts and it is clear there is more to
Graco than great products. Here at Graco, customer service is our first priority.
It is great people that make Graco the brand-of-choice among professional
painting, texturing and striping contractors.

The Basics Coatings
There are many paint manufacturers in the United States manufacturing
millions of gallons of architectural and protective coatings annually.
Architectural coatings are primarily decorative coatings used to coat anything
from homes to commercial and industrial buildings.
Protective coatings are primarily corrosion control coatings used to coat
anything from bridges to water towers, preserving concrete and steel. Often
these coatings are two-component materials.
The majority of coatings are sold at paint stores, generally to professional
painting contractors.
Virtually every coating contains four basic components:

• Binder, Resin, or Polymer—holds together the other components
prior to application and forms a protective film on the surface (the
surface is also called a substrate) to which the coating is applied.
Binders can be oils, varnishes and proteins.
• Pigment—fine solid particles that hide the surface providing
decorative colors and sometimes corrosion resistance. Raw
umber, a type of iron ore, is used extensively as a pigment and is
olive green in color.
• Solvent—helps the flow of the coating material and aids in
application. For example, water is a solvent for sugar. However,
in many coating formulations, a chemical referred to as a solvent,
may not be dissolving anything, but simply diluting or thinning the
formulation.
• Additives—in general, manufacturers put additives into coatings
for one or more reasons, including aiding in manufacturing,
enhancing application characteristics, or improving the properties
of the coating once it is cured. For example, some additives help
prevent mildew from forming once the coating has cured.

The Basics . . . Coatings
Paints and other coatings are rated by the volume of solids they contain. While
virtually everyone in the architectural coatings industry refers to the “low,”
“medium,” and “high” solid content of coatings, there are no set amounts or
limits placed on these categories. A typical set of values for coatings is:
• Low Solids = 20-30% solids
• Medium Solids = 30-50% solids All coatings contain
• High Solids = Up to 100% solids solids which are
abrasive. Through
normal use the spray
tip and parts of the
pump will show wear.
Typical Solids Content of Popular Coatings

Low High
Lacquers & Oil-based Acrylics Elastomerics Block Fillers

Stains Primers
Enamels Interior Exterior Specialty

Latex Latex Coatings
Keeping in mind the typical amount of solids found in coatings (low, medium,
or high), allows an easy method for displaying the solids content of popular
architectural coatings.
Defining Airless
Airless spray atomizes, or breaks up fluid into small droplets without the use
of compressed air. In an airless system, fluid is pumped under high pressure
through a spray tip. The tip size and pressure is what determines the material
flow rate.
The tip also creates the fan pattern. In contrast, air spray systems inject
compressed air into the fluid stream of paint to achieve atomization.

The Basics . . . Advantages of Airless Sprayers
In airless spray, the fast moving high-pressure liquid stream provides the
Atomized Fluid energy necessary to
overcome the fluid’s
Disrupted
viscosity (resistance to
Sheet
flow) and surface tension
(a force that bonds the
Airless Spray Tip
surface of a liquid together)
to form a fine spray.
In the depiction of spray
from a gun, high pressure
forces fluid through a small
nozzle (spray tip). The fluid
emerges as a solid stream
(sheet) at a high speed.
When the solid stream
hits the air, it becomes
disrupted. This disruption
breaks the fluid into fragments initially, then ultimately very small droplets that
form the spray pattern.
Scan to watch the video online
What Is
Airless Spraying
graco.com/BasicsOfAirless-Chapter1
Advantages of Airless Sprayers

Airless sprayers provide an easy and economical way to apply coatings.
Professional contractors prefer to use airless sprayers for several reasons, the
most popular being:
• Speed—airless spraying is faster, thus, more jobs can be completed in
less time, using less labor. Airless spraying is up to 10 times faster than
brushing or rolling.
• Quality—airless sprayers produce an even coat of paint on all types of
surfaces, leaving a consistent and high quality finish.
• Versatility—airless sprayers can
be used for a wide range of coating Did you know?
materials, including interior and exterior
jobs, and can easily be transported from If you took a shower
job site to job site. today, you used a very
simple airless spray.

The Basics . . . Advantages of Airless Sprayers
Research conducted by the Painting and Decorating Contractors of
America (PDCA), an association of painting contractors and related industry
professionals, indicates that airless spraying can save painters between 50%
and 75% of their painting time. Airless spray is:
• At least 10 times faster than brush applications
• At least 4 times faster than roller applications
Using a brush or roller application might seem cost-effective in the short-term,
but in the long-run labor can cost at least twice as much!
Airless Spray for Uniform Coverage
It is important to consider how much faster spraying is compared to other

methods. Equally important to your customer is how spraying gives a
consistent quality finish, even over rough surfaces.
Airless spraying allows you to:
• Finish jobs quicker
• Complete more jobs with less labor (fewer people headaches)
• Provide a consistent mil build so coatings perform better
• Apply a smooth quality finish

The Basics . . . Key Components of an Airless Sprayer

A
Components of B
an Airless Sprayer
D E
E
A
B
C
C
Did you know?

D
The pump is often called the heart
of the system. Many contractors
refer to a sprayer unit as “the
pump”. Most consider the pump to
be the most important component
ti7494b
ti7494b
of the sprayer.
A Spray Tip
• Controls the amount of fluid sprayed by using different orifice sizes
• Orifice shape determines the spray pattern.
• Many Graco tips can be turned to the reverse position by hand to blow out clogs
B Motor & Drive System
• A heavy duty system that drives the pump
C Pressure Control
• Used to regulate the fluid pressure delivered from the pump
D Pump
• Also called the Fluid Section
• Delivers a steady stream of high pressure fluid through the hose to the spray gun
E Gun
• Acts as the on/off valve for the material

Cross-section of
good fan
The Basics . . . Atomized, evenly Air-Assisted Airless

distributed fan pattern
Air-Assisted Airless tails

(Heavy at edges with gaps inside) Heavy
Gaps
fingers
Material is delivered to the gun at
lower pressure than traditional airless
(500 – 1500 psi vs. 1500 – 3000 psi) and is Tails in spray
partially atomized through a small tip. Full pattern from low
pressure Cross-section
atomization is achieved by adding a small of fan with tails
Low pressure spray with no added air
amount of air (5 – 35 psi) to the edges of
the spray fan – resulting in a softer pattern, Cross-section
of good fan
more control, higher transfer efficiency,
and less overspray. Atomized, evenly
Low pressure spray with

A Spray Tip/Air Cap air “assisting” the spray pattern
• Controls the amount of fluid

sprayed by using different
orifice sizes and directs air E
into the spray fan
B Gun F
• Acts as the on/off valve for
the material
C Air Adjustment Valve
A
• Utilizes air passages to deliver
B H
air closer to tip- resulting G
in a softer, more consistent
pattern from start to finish C
easily under pressure D

D Bonded Fluid/Air Hose
• Fluid hose bonded with air
hose eliminates managing two
separate hoses
E Motor & Drive System
• A heavy duty system that drives the pump
F Digital Display
• Used to regulate the fluid pressure delivered from the pump
• Tight pressure control and fast response when spraying
G Proven Endurance Pump
• Piston pump allows for consistent priming and pumping of
even the heaviest materials
• Proven design and rugged construction
H Air Compressor
• Integrated compressor supplies air to the gun

The Basics . . . Air Spray Tips
Choosing &
Understanding Spray Tips
Airless Spray Tips

This, small, exchangeable part plays a big role.
An airless spray tip:
• Determines the fluid flow = the amount of
coating applied
• Determines the spray pattern (fan width)
Selecting the correct spray tip for the job is an important decision.
Did you know?

Graco uses a color-coding system to identify tip types.
- General SwitchTips are blue or black
- Fine Finish and Low Pressure tips are green
- LineLazer and FieldLazer tips are yellow
- Graco Heavy-Duty tips are gray
Breaking the Code

XXX - 515
First 1-2 digits when doubled, is Last two digits are orifice size in
spray pattern fan width. A 515 thousandths of an inch, a 515
has a 10-inch fan width when has a 0.015 inch orifice.
sprayed 12 inches from surface.
5 x 2 = 10
Graco Tips
All Graco tips are made out of the highest grade of tungsten carbide, the
most abrasive-resistant material used in the manufacturing of airless spray
tips. Because each tip has its own particular use in the market place, Graco
offers the following spray tip selection:

The Basics . . . Airless Spray Tips
Reverse-A-Clean (RAC) Most widely used reversible tip on the market and can
®
be used for a variety of coatings from lacquers to mastics. Reversible tips are an
ideal way to eliminate downtime. With a reversible tip, clogs are cleared easily
by simply spraying through the tip when in the reverse position. Contractors
can change tip sizes in seconds, without removing the tip guard and housing.
Reversible Tips are available in over 90 sizes and are rated at pressures up to
5000 PSI (blue or black handle).
Low Pressure SwitchTip This tip incorporates a two-stage atomization process
and creates a soft, feathered spray pattern at half the pressure, reducing
overspray and extending tip and sprayer life. It allows the user to do fine finish
work with an airless pump, which is faster than air spray or HVLP. Plus, it’s
fully swappable and comes in a full range of sizes that work on all Graco airless
sprayers, using the same tips on handhelds and large airless sprayers.
WideRAC SwitchTip This tip covers double the surface area in half the time with
™
extra wide 24 inch (61 cm) pattern. WideRAC tips are made for higher production,
new construction applications which require larger airless sprayers.
WideRAC Conversion
When you use WideRAC, be sure
RAC 5 or RAC X WideRAC
to increase the flow rate of the tip
414 or 515 1221 or 1223 to ensure the same mil build and
417 or 517 1223 or 1225 rate of application (arm speed).
419 or 519 1225 or 1227 Also, make sure your airless
sprayer can support the larger
421 or 621 1229 or 1231
tip size.
523 or 623 1233 or 1235
525 or 625 1235 or 1237
Heavy Duty SwitchTip This tip is used for heavy coatings which require higher
pressures to atomize. Heavy duty tips are still reversible, but add an extra thick
twist lever to allow rotation in very sticky coatings such as coal tars and mastics
(gray handle).
LineLazer & FieldLazer SwitchTip Used with the LineLazer & FieldLazer Spray
™ ™
Units. Regular tips are designed for an overlapping spray technique. The LineLazer
& FieldLazer tips are designed to provide a consistent pattern without soft edges
to create clean, laser sharp lines (yellow handle).
Contractor Flat Tip Standard airless tip available in a variety of sizes that are less
™
expensive to purchase than RAC tips. If plugging occurs, the tip must be removed
from the gun and cleaned or replaced.
Fine Finish Flat Tip Sprays as fine a finish as the fine finish RAC but must
be removed for cleaning when plugged. Typically, coatings used for fine
finish applications plug easily (i.e., lacquers). Therefore, if this tip is used, it is
recommended that a Tip Filter Kit be used as well.

Rating Spray Tips

Spray tips are rated in terms of orifice size. The amount of paint that flows
through the sprayer onto the surface depends on the tip size and pressure setting.
• Size the spray tip according
to the job and the tip rating of Recommended Tip Sizes for
the sprayer. Make sure that Common Coating Materials
the sprayer can support the Lacquer or Stain .009 to .013
tip you are planning to use. Oil Base Paint .013 to .015
• Consider the paint/coating Latex Paint .015 to .019
that will be sprayed – Heavy Latex Paint & .021 to .025
lacquers, stains, and enamels Smooth Elastomeric
are light coatings that are Elastomeric & BlockFiller .025 to .035+
sprayed with small tips, while
exterior latex paints are much
heavier coatings that require larger
spray tips.
• Multiple spray guns can be used with
one sprayer. Make sure the multiple
gun tip rating of the sprayer can
support the tip sizes you plan to use.
Many paint manufacturers

will specify recommended
spray tip sizes directly on
the container or product
specification sheet.
Ultra Max II 695 Ultra Max II 795 Ultra Max II 1095 Ultra Max II 1595
SERIES TYPE STANDARD PROCONTRACTOR STANDARD PROCONTRACTOR STANDARD PROCONTRACTOR IRONMAN STANDARD PROCONTRACTOR IRONMAN
Cart Design–
MODEL
Hi-Boy–16W892 16W902 16W903 16W907

Part Number 16W894 16W895 16W896 16W899 16W900 16W901
Lo-Boy–16W893 (Canada) 16W936 (Canada) 16W937 (Canada) 16W938
Maximum Tip Size 0.031 0.033 0.035 0.039

Maximum psi (bar) 3300 (227) 3300 (227) 3300 (227) 3300 (227)
Maximum gpm (lpm) 0.95 (3.6) 1.10 (4.1) 1.20 (4.5) 1.35 (5.1)
SPECIFICATIONS
MaxPower Motor hp 2.0 Brushless DC 2.2 Brushless DC 2.4 Brushless DC 2.8 Brushless DC
Control SmartControl 3.0 SmartControl 3.0 SmartControl 3.0 SmartControl 3.0
Weight lb (kg) 93 (42) Standard Hi-Boy 98 (44) Standard 120 (55) Standard 125 (56) Standard
Gun Support:
1 Gun 0.031 0.033 0.035 0.039
2 Guns 0.023 0.025 0.027 0.029
3 Guns — 0.019 0.021 0.023

Which tip puts out more paint,

XXX-517 or XXX-317?
The answer . . . each tip has the same size orifice
(.017") that allows the same flow of material, so the
output is the same.
But . . .
The 517 tip sprays the paint in a larger area
(10" fan width) and the mil build (thickness) is less
than the 317 tip (6" fan).
Tip Wear
Tip wear can cost you hundreds of dollars in wasted paint and labor. Choosing
the right spray tip is essential for ensuring a quality finish no matter which
coating material is being sprayed. All spray tips will wear with normal use.
It is important to understand the wear effect coatings have on spray tips.
All coatings contain solids that are abrasive; some are more abrasive than
others. For example, latex paint may be very abrasive because of the solids
used in the manufacturing process. The level of abrasiveness often depends
upon how finely the solids have been ground. Graco tips are made out of the
highest grade of tungsten carbide, the most abrasive resistant material used in
manufacturing airless spray tips.

Effects of Tip Wear

When a tip wears, the size of the tip orifice increases and the fan width
decreases. Tip wear affects the spray pattern. If the fan size has lost 25% of
its original size, then it is time to replace the spray tip. Continuing to spray
would simply result in a poor quality spray job, and a substantial waste of
paint and labor.
Spray Pattern Width
12 in. Worn Worn Worn

to 9 in. to 7 in. to 3.5 in
Example: When a tip that had a 12-inch fan pattern is reduced to a 9-inch
fan when worn, it will output 40% more paint on 25% less area. Overlapping
to achieve a consistent mil thickness becomes impossible. The chart above
illustrates the effects of a worn tip on a spray pattern.
Tips for extending the life of spray tips:

• Spray at the lowest pressure necessary to
atomize material
• Strain the coating material prior to spraying,
using a nylon strainer bag
• Use correct size filters
• Clean filter after each use
• Use a soft bristle brush to clean tips

Using a worn tip wastes paint and labor

Assume that paint costs $15 per gallon, labor costs $25 an hour, and the
contractor sprays 5 gallons of paint per hour. If the contractor is using a worn
tip (a 12 inch fan width worn to 9 inch) he will spend an additional $36.25 in
wasted paint and labor per hour. If the painter continues to use the worn tip it
will cost him about $300 per day!
Good Tip Worn Tip
12 in 9 in
Proper coverage and a quality finish Excessive mil build in the center
of the pattern
If abrasive materials are sprayed at too high of pressure, the spray tip will wear
a lot faster, wasting both paint and money.
Greater Pressure = Greater Wear.
Turn down the pressure as low as it can go while still spraying a good spray
pattern to reduce your tip and pump wear. Turning down the pressure also
saves paint by reducing overspray.

The Basics . . . How Airless Sprayers are Rated
How Airless Sprayers are Rated by Manufacturers

Airless sprayers are typically rated using these methods:
• Maximum tip size (with one gun, with two guns, etc.)
• Gallons per minute (gpm)
• Pounds per square inch or the maximum pressure (psi)
• Horse power (hp)
gpm—(gallons per minute) a flow rate measurement associated with the
pump’s output capacity and the tip orifice (hole) size. CAUTION: There is no
industry standard for rating a sprayer’s output capacity.
psi—(pounds per square inch) a pressure measurement.
The pressure rating (e.g., 3300 psi) is the maximum working pressure (stall
pressure) of the sprayer. That is, the maximum amount of pressure the
sprayer is able to build. However, the pressure at the tip does not equal the
maximum working pressure. Hose length, tip size, the type of coating being
sprayed, and even the filters impact the amount of pressure available at the tip
while spraying.
Typical maximum airless Typical atomization pressures

sprayer pressure ratings: needed for airless applications:
• 2000 psi • 800-1100 psi for lacquers
• 2800 psi • 1200-1800 psi for stains
• 3000 psi • 2000+ for latex coatings
• 3300 psi
• 4000 psi
hp—(horse power) a performance rating for the sprayer’s motor or engine.

There are a variety of motor types, operating speeds and torque capabilities
available. This makes horsepower a confusing rating method for distributors
and end-users alike. Some contractors prefer to have the biggest motor
available because they believe it means more power and longer sprayer life.
This is not necessarily true, the motor and sprayer should be matched to the
jobs requirements.
Overall, the tip size rating is the most useful rating method for
selecting tips and sprayers for your job.

The Basics . . . How Airless Sprayers are Rated
Maximum Tip Size—a rating that
indicates the largest tip size (i.e., orifice) Did you know?
a sprayer is capable of supporting, All Graco sprayers are rated for
while maintaining a good spray pattern.
maximum tip sizes using the
The maximum tip size will depend on
the type of coating being sprayed and most common coating material,
the amount of pressure needed to latex paint, at 2,000 psi.
atomize the coating.
Selecting A Sprayer: Eight Questions To Ask
What types of materials will you spray? Now and in the future?
The types of materials you spray will determine the size of the tips you use. If
you plan to spray a variety of materials you have to consider buying a sprayer
with more versatility.
How many gallons per week will you spray?
Purchasing a part-time sprayer to do a full-time job has disappointed many
contractors. In the long run, saving money on a sprayer that is inadequate for
the job, or not durable enough, will cost a lot in lost labor.
What power sources are available? Will most jobs be indoors or outdoors?
Your answers will help choose a unit family (gas, electric, battery or compressed
air) based on power sources alone.
What types of surfaces will you be spraying?
Will you be spraying on drywall, exterior siding, or concrete? You have to
consider the tip sizes needed as well as the quality of finish required in order to
choose the best sprayer for the job.
How many spray guns will you use at one time, now and in the future?
If you plan to use more than one gun at a time, then you have to purchase a
unit that has the ability to handle multiple guns.
What types of jobs will you bid?
Each job has its own requirements. New construction, residential work, and
commercial jobs all vary in terms of: coatings used, crew size needed, and
power sources available.
What hose lengths will you use?
Hose length depends on the job site, material being sprayed, tip size, and
hose diameter. Your sprayer must be able to support the length of hose. Most
Graco sprayers use DC motors, which are able to support longer extension cord
lengths than either AC or universal motors.
How much do you want to spend on a sprayer?
Buying a sprayer is an investment. You do not want to over-buy or under-buy.
Keep in mind the cliché, “You can pay now or pay later”. Downtime resulting
from an undersized, overworked sprayer or poor quality equipment can quickly
wipe out any savings from the initial low purchase cost of the sprayer.

The Basics . . . Selecting A Sprayer
Traditional Airless Sprayers
Entry Small Large Small Gas Large Gas Large Gas Air
Sprayer
Electric Electric Electric (Mechanical) (Mechanical) (Hydraulic) Assisted
Productivity Low Medium High Medium High High Medium
Interior/
Interior/
Interior/ Exterior, New
Interior/ Exterior, New
Exterior, New Construction, Interior/ Interior/ Interior/
Exterior, New Construction,
Construction, Repaint, Exterior, New Exterior, New Exterior, New
Construction, Repaint/
Type of Repaint/ Remodel, Construction, Construction, Construction,
Heavy Remodel,
Applications Remodel, Property Heavy Heavy Wood and
Commercial, Property
Property Maintenance, Commercial, Commercial, Metal
Property Maintenance,
Maintenance Light Industrial Industrial Finishing
Maintenance Light
Commercial
Commercial
Latex Paints Latex Paints

and Primers, and Primers,
Stains,
Lacquers & Interior/Exterior Latex Paints Acrylics Paints Acrylics Paints
Stains, Interior/ Lacquers,
Stains, Interior/ Latex, Oil and Primers and Primers, Oil and Primers, Oil
Exterior Latex, Latex,Enamels
Typical Enamels &
Exterior Latex, Based Primers, Acrylics, Paints Based Paints Based Paints
& Acrylics,
Materials Acrylics, Oil
Enamels Acrylics, Block and Primers,Oil and Primers, and Primers,
Primers,
& Acrylics, Fillers and Based Paints Elastomeric, Elastomeric,
Based Primers Polyurethane,
Elastomerics Drywall and Primers Block Fillers, Block Fillers,
Varnish
Gypsum and Gypsum and
Drywall Drywall
Gallons Up to 150 Up to 500 Up to 1000 Up to 500 Up to 1000 Up to 1000 Up to 150

per Week
Power 120V Electric 120V Electric 120V Electric Gas Engine Gas Engine Gas Engine 120V Electric
Sources
Number 1 1 Up to 3 1 Up to 4 Up to 6 1
of Guns
*Maximum 200 200 300 300 300 300 200
Hose Length
*Maximum hose length will change depending on material thickness, hose diameter, and tip size.
Handheld Airless Sprayers
Ultra Airless UltraMax Airless
Sprayer
Handheld Sprayers Handheld Sprayers
Size of Application Up to 3 Gallons Up to 3 Gallons
Any job less than 3 gallons: Walls, Ceilings, Any job less than 3 gallons: Walls, Ceilings,
Types of Doors, Siding, Garage Doors, Fences, Shutters, Doors, Siding, Garage Doors, Fences, Shutters,
Applications Decks, Trim, Cabinets, Bookcases, Molding, Stair Decks, Trim, Cabinets, Bookcases, Molding, Stair
Railings, and Furniture Railings, and Furniture
Interior/Exterior Latex Paints and Primers, Oil- Interior/Exterior Latex Paints and Primers, Oil-
Based Paints and Primers, Acrylics, Enamels, Based Paints and Primers, Acrylics, Enamels,
Typical Materials Stains, Water-borne Lacquers Only, Varnishes, Stains, Lacquers, Varnishes, Urethanes,
Urethanes, and Sealers and Sealers
.008 – .016 RAC X FF LP

™
.008 – .016 RAC X FF LP
Tip Performance (Fine Finish Low Pressure) (Fine Finish Low Pressure)
Sprays architectural water-based

Most materials that can be cleaned with water,
Material & Solvent mineral spirits or paint thinner. Do not use
and solvent-based coatings including
Compatibility materials which state “flammable” on packaging.
“flammables” and
“hot” solvents.

The Basics . . . Spray Techniques
Spraying
Techniques
A good spray pattern indicates that the paint or coating is completely atomized
and distributed evenly on the surface. Several techniques help determine the
quality of the spray pattern and the quality of the finish.
• Adjusting the pressure
• Aiming of the spray pattern
• Movement of the spray gun
The following techniques ensure a long-lasting quality finish.
Adjusting the pressure for spraying

It is best to spray at the lowest pressure that completely atomizes the coating.
The pressure control should be set at a low-pressure setting and slowly
increased until the paint is completely atomized. If the spray pattern has
fingers or tails, then the pressure should be increased.
Cross-section of
good fan
Atomized, evenly
tails
(Heavy at edges with gaps inside) Heavy
Gaps
fingers
Tails in spray
pattern from low
pressure Cross-section
of fan with tails
Note: If the maximum pressure of the sprayer is not enough to achieve a

good spray pattern, a spray tip with a smaller orifice should be used. To test
the quality of the spray pattern, test patterns should be sprayed on scraps of
cardboard or other waste material.

Aiming the Spray Pattern

The spray gun should be held approximately 12 inches (30.5 cm) from the
surface, and aimed straight (both horizontally and vertically) at the surface.
Extremely large tips will require you to move further away to achieve a good
spray pattern.
12 in.
(30 cm)
even Spray gun aimed

finish
straight at surface
Tilting the gun in one direction

or the other to spray at an angle
causes an uneven finish.
thick
Spray gun tilted downward

or upward will produce an
uneven uneven finish
finish
thin
thin thick thin

even uneven
finish finish
The spray gun should move across the surface with the wrist flexed to keep
the gun pointed straight at the surface. “Fanning” the gun to direct the spray
at an angle will cause an uneven finish.

Triggering Technique
The spray gun should be triggered after beginning the stroke (also called the
lead stroke) and released before ending the stroke (also called the lag stroke).
The gun should move during both the trigger squeeze and trigger release.
This technique prevents blotches of thick coating at the beginning and end of
each stroke.
start trigger continue release end
stroke gun stroke trigger stroke
Overlapping Technique
This technique ensures that an even amount of coating has been sprayed
onto the surface. The spray gun should be aimed so that the tip points at the
edge of the previous stroke, overlapping each stroke by 50%. To maximize
efficiency when spraying on broad, open surfaces, like ceilings and bare walls,
the outside edges of walls should be sprayed first. The middle can then be
sprayed quickly, requiring less precise strokes.
Gun should be aimed

here in order to overlap
stroke by 50%

Painting Inside Corners

When spraying corners the gun should be aimed into the corner, spraying
along the corner, rather than spraying back and forth across the corner.
Gun should be
aimed into corner
Controlling the Thickness of the Coating

(Mil Build, 1 Mil = .001 in)
The key to proper coverage is controlling the coat thickness. Here are some
helpful hints to ensure proper coverage and a quality finish:
Do not adjust the pressure to make the coat thicker or thinner. The pressure
should be adjusted to the lowest pressure with a good spray pattern.
If the coating is too thick or running down the surface, one or more of the
following will help:
• Move the spray gun faster
• Choose a smaller tip orifice size; be sure the sprayer is rated to handle
the size tip being used
• Choose a tip with a wider fan
• Make sure the spray gun is far enough away from the surface
(about 12 inches)
If the finish is not covering the surface, one or more of the following will help:
• Move the spray gun slower
• Choose a larger tip
• Choose a tip with a narrower fan width
• Make sure the spray gun is close enough to the surface (about 12 inches)

Common Spray Technique Errors
Pressure Set too High

It is easy to just crank up the pressure control to the maximum and slap on the
material. For professional results, turn down the pressure as low as you can
without getting tails. You will:
• Reduce wear on your pump
• Reduce wear on your spray tip
• Spray a more consistent even finish
• Reduce the amount of overspray (wasted paint)
Holding Down the Trigger too Long

It is easy to just pull the trigger and keep moving up and down or side to
side, overlapping and moving down the wall spraying constantly. If you are
not triggering the gun every time you change directions you will have at least
double the mil thickness in every spot you change directions. In the right
light or over time, your customer may be able to see these heavy areas. As
explained earlier, you should trigger the gun on each stroke and be moving
into and out of each trigger pull.

The Basics . . . Summary
Basics Summary: Questions Answered

What four basic components does virtually every coating contain?
• Binder, Pigment, Solvent, Additives
What determines a fluids flow rate in an airless spray system?

• Tip orifice size and pressure
What are three major advantages of using an airless sprayer?

• Speed, Quality, Versatility
How are airless sprayers rated by equipment manufacturers?

• Maximum tip size, Gallons per minute, Maximum pressure in psi,
Horse Power
What are the four major components of every airless sprayer?

• Motor and Drive System, Pump, Pressure Control, Spray Gun/Tip
Explain how the last three numbers of a spray tip tell you the orifice size
and spray pattern fan width.
• First digit when doubled is the fan width in inches
• Last two digits are the orifice size in thousandths of an inch
Why do spray tips wear and how does that affect your production and
job costs?
• Coatings have abrasive materials in them and wear tips under
high pressure
• A worn tip reduces the fan width and increases fluid flow, increasing
labor and paint costs
Why is the 50% overlap method the best way to get an even quality
spray finish?
• Spray tips are designed for a 50% overlap so you get a smooth even
finish with no visible lines
What are two spray technique mistakes many new contractors make?
• Spraying at too high of a pressure
• Not triggering the gun properly at the start and stop of each stroke

Beyond the Basics Sprayer Motors
Sprayer Motors
Sprayer pumps can be operated from three different power sources: electric
motor, gas engine, or compressed air. In all electric and gas sprayers, the
motor or engine creates a rotating motion that is transferred to the drive
source of the fluid pump. Most of Graco’s sprayers use crankshafts and
connecting rods to convert the rotating motion into the reciprocating action of
the fluid pump. Hydraulics can also be used to transfer power from the source
to the pump in the case of hydraulic sprayers.
In compressed air motors, the flow of air through the motor causes the motor
piston and rod to move up and down. This reciprocating motion is then
transferred from the motor connecting rod to the fluid displacement rod in
the pump.

Beyond the Basics . . . Sprayer Motors
Electric Sprayers
There are four types of motors available on airless sprayers: Universal, AC,
DC and Brushless DC. The following chart compares the advantages and
disadvantages of each type of motor.
Motors Advantages Disadvantages

Universal Price is the big advantage of Although fan cooled, Universal
Universal motors—they are less motors are not totally enclosed.
expensive to manufacture than They have the shortest life
either AC or DC motors. expectancy because they run at
10,000-20,000 RPM (3-5 times
faster than AC or DC motors).
AC A long life motor when used in Need constant, continuous power

controlled conditions. supply to perform properly.
Long extension cords and

generators often cause overheating
which could permanently damage
the motor.
Maximum length of extension cord

is 100 feet.
DC The DC motor is more forgiving DC motors are heavier and more

of power fluctuations because it expensive.
can run at variable speeds.
Allows the user to run longer

extension cords 12 AWG or
larger (up to 300 feet) and
generators.
Brushless A long life motor in a variety of A heavier motor than an AC. Most
DC conditions. It is more forgiving expensive motor compared to AC
of power fluctuations because it or DC motors.
can run at variable speeds.
Brushless DC motors are
smaller, lighter, more efficient,
and require less maintenance
over time than DC motors.
Allows the use of longer

extension cords 12 AWG or
larger (up to 300 feet) and
generators.

Beyond the Basics . . . Sprayer Motors
DC Motor Technology Changes

In recent years DC motor technology has continued to improve. They:
• deliver higher output – increases flow rates
• have a much lower amp draw – allow longer cords, fewer nuisance trips
• are smaller and lighter – easier to move
• run cooler – longer life
• many are brushless – no open sparking
• have more horsepower – motors don’t work as hard, longer life
• are TEFC (totally enclosed fan cooled) – protects components from dirt,
dust and overspray
Gas Engines
A direct drive gas engine develops the horsepower to drive the pump and the
electrical energy to power the clutch. This is known as a “direct drive” system.
Direct drive units are the most energy efficient gas powered sprayers.
A hydraulic unit uses a gas engine to drive a hydraulic pump. The hydraulic
pump draws hydraulic oil from a reservoir and pumps it to the hydraulic motor.
This causes the hydraulic motor to reciprocate and power the fluid pump. This
is known as a “hydraulic” system.
Handheld Airless Sprayers

Graco has developed a line of handheld sprayers that utilize airless technology,
referred to as ProSpray Technology. The breakthrough ProSpray Technology
delivers Graco’s professional piston-pump design in a handheld sprayer giving
painting contractors and consumers the freedom to spray wherever they want
with true airless performance.
These handheld sprayers are operated by electric power or battery power
sources, and are designed for small jobs and touch-up work (1-3 gallons). The
advantages of handheld sprayers are the professional spray finish, ultimate
portability on the job and quick setup/cleanup compared to using a larger airless
sprayer for small jobs. Startup, spray and cleanup can be done in minutes.
The handheld sprayers are similar to a traditional airless sprayer where they
have a gun and pump built into the sprayer. The only major difference is that a
handheld sprayer does not have an airless hose, making it easier to startup, less
wasted material and easy to clean for small jobs.
There are several categories of handheld sprayers that are designed to spray
specific materials.

Beyond the Basics . . . Pumps
The Proof is in the Pump

There is much discussion about pumps in the sprayer market; after all, most
consider the pump the most important component of a sprayer. Contractors
often refer to a sprayer unit simply as “the pump.” There are two general types
of pumps offered in the airless sprayer market: diaphragm and piston. The
following section describes the advantages and disadvantages of each type of
pump for airless applications. All Graco airless sprayers use piston pumps.
Piston vs. Diaphragm

Advantages Disadvantages
Piston • Pumps higher-viscosity • Higher initial purchase price,
Pump coatings with ease but less expensive to maintain
• Provides higher pressure at • Some pressure fluctuations,
common tip sizes noticeable at low
• Better atomization pressure settings
• Allows the use of
longer hoses
• Better withstands hard use
• Lower maintenance costs
• Easy to repair
• Primes easier
• Runs only on demand
Diaphragm • Good, tight pressure control • Runs continuously
Pump across a full range of • Higher maintenance costs
pressures • Difficult to prime
• High free-flow rates, • Cavitates easily—air is
good for high-volume introduced into the system
transfer of fluids for texture possibly causing erratic
applications, water, and flow or spitting. This usually
so forth is because the pump isn’t
• Lower initial purchase price strong enough to move the
coating material.
• Poor performance with
higher viscosity fluids as
mentioned above
• Must be kept clean (small
moving parts)
• Requires constant
maintenance
• Hydraulic oil leakage
• Frequent diaphragm failure

How a Piston Pump Works
Upstroke
Downstroke
The double action displacement pump is a reciprocating pump with two ball
checks (inlet and outlet ball checks) that control the flow of fluid through the
fluid section. The displacement rod connects the pump’s internal components
to the drive system. The rod moves up and down with the action of the drive
system and motor. Fluid is loaded on the upstroke and displaced on both the
upstroke and downstroke. Displacing fluid on both the up and down strokes
ensures an even flow of fluid to the hose and gun.

How a Diaphragm Pump Works
Pulsing Hydraulic Pressure
Paint flows out Plastic Diaphragm

to hose and gun
Inlet Valve
Outlet Valve Ball

Paint is drawn in
A diaphragm pump uses the sprayer’s

motor to create pulsing hydraulic
Independent research indicates pressure (a hydraulic system using oil)
that professional contractors prefer to drive the pump. During the upstroke
or intake stroke, the diaphragm is
piston pumps because they . . .
pulled up, creating a partial vacuum
- Last longer within the paint chamber. The vacuum
- Perform on-the-job better pulls the inlet valve open and the outlet
- Are more durable than valve is pushed closed by the spring
diaphragm pumps and paint pressure in the hose. Paint is
- Require less maintenance then drawn into the paint chamber.
On the down-stroke or pressure stroke,
the inlet valve is closed and the outlet
valve is forced open as paint is discharged to the sprayer hose. Diaphragm
pumps have a relatively small displacement volume. The pump must run fast
(about 1725 cycles per minute) to deliver a steady flow of coating material.

Displacement
Pump Rod
(piston)
Adjustable Packing
Nut & Wet Cup
Throat Packings
(upper)
Cylinder/Sleeve Fluid Outlet
Piston Outlet Ball

(upper)
Piston Packings
(lower)
Inlet Ball (lower)
Fluid Inlet

The general purpose of the packings is to create a seal and direct fluid flow.
There are two sets of packings, throat and piston:
Throat packings seal the displacement rod to the top of the pump
cylinder. As the throat packings wear, there may be leakage into the
wet cup. Leakage indicates that the packing nut must be tightened or that
the throat packings, or other parts, should be replaced or serviced.
Piston packings create a seal inside the cylinder as the rod moves up and
down (like a doctors syringe).
• On the upstroke fluid is drawn into the pump because a vacuum is
created as the rod goes up. As the rod goes up, fluid is pushed out to
the hose. The lower ball lifts and allows fluid to be drawn into the pump,
filling the cylinder. The upper ball seals the opening to the lower section.
• On the downstroke the lower ball seals, the upper ball opens and the
rod moving down displaces (the volume of the rod takes up space) fluid
and forces fluid out to the hose.
This process allows fluid to be pumped to the hose on both the up stroke
and down stroke, for more consistent pressure and fan pattern from the
spray gun.
The wet cup is a reservoir that holds Throat Seal Liquid (TSL ) and
™
extends the life of the throat packings by preventing paint from drying on
the displacement rod. Graco’s TSL is clear in color and specially formulated
so it will not impact the finish of oil or water-based coatings, even if it is
accidentally dripped into the coating material. Do not substitute oil for TSL
When the throat packings no longer seal properly Graco TSL

there will be fluid/paint leaking at the wet cup. Specially
formulated to
A little leakage might be ok; many contractors will extend the life of
throat packings
tighten the packing nut. This allows them time to and other
finish the job prior to servicing the packings. components.
The Power Of One.

The ability to quickly change a pump on the job site can be the difference
between a productive day spraying and one spent waiting on costly repairs.
Graco has the only quick, easy, on-the-job pump replacement solution on
the market today. With the Express and Endurance Pumps, Graco has
revolutionized the industry for every small and midsize sprayer built from 2004
through current. Clearly, the BETTER WAY to finish the job!

Endurance Pump ™
Endurance Pump is the most rugged and reliable pump on the market today.
This field proven design with long lasting V-Max Blue packing, Chromex rod and
MaxLife pump coating delivers superior reliability and life for today’s coatings.
Endurance Vortex Pumps

The Longest Lasting Pumps Ever Built
Graco Endurance Vortex pumps are built with a patent-pending
Helical Design that delivers high-velocity flow to rotate pump rod while
spraying – creating a 360° wear surface for the longest pump life.
Available in Two Configurations:
Endurance Vortex Endurance Vortex

MaxLife Pump MaxLife Extreme Pump
(ProContractor Series Sprayers) (IronMan Series Sprayers)
• 6X
longer between repacks • Abrasion-resistant
composite for extreme
jobsite conditions
• Extends
pump rod life by 3X
– delivering the lowest cost of ownership
Pump Wear Parts

Wear parts are components in the fluid section that are designed to wear with use.
Wear parts will need replacement or service during the life of the pump. Throat and
piston packings are made to wear with use. This saves wear on the expensive hard
parts of the fluid section (displacement
rod, cylinders and sleeves). Replacing Got Wear?
the packings right away when needed
will save you time and money. Replacing Changing the packings at the first sign
packings in a service center takes little of wear will prolong the life of the pump
time, and the costs associated with by preventing wear of the hard parts.
repairs are much less than if the hard
The throat and piston packings and balls
parts need replacing. The following parts
should be checked periodically for wear: and seats are included in the packing
kits available for each Graco sprayer.
• Displacement Rod
• Cylinder or Sleeve
• Throat and Piston Packings
• Balls (inlet & outlet) and Seats
ProConnect ™
Graco’s exclusive ProConnect system allows quick

removal or installation of your pump lower, with no tools
required. The pump can easily be switched
out in minutes right on the job site.
ProConnect prevents down time and avoids
expensive labor when repair is needed.

Beyond the Basics . . . Only on a Graco
Pressure Controls
The purpose of the pressure control is to regulate the spraying pressure.
There are two types of pressure controls: Mechanical and Electronic.
Mechanical—a pressure control uses a micro switch to turn the motor on and
off to maintain the desired pressure setting. The fluid pump runs until it reaches
the set pressure—at this point the micro switch is activated and the motor shuts
off. When the pressure decreases to a certain point, the micro switch closes and
starts the motor, and the pump begins to run. The difference between when the
motor turns off and on is known as deadband.
Electronic—the fluid pressure is sensed electronically and the signal is sent
to a circuit board and compared to the signal received by the pressure control
knob. The deadband on an electronic pressure control is typically around 50
psi; thus, the pump begins to run when the pressure drops to 50 psi. However,
recent advances in Graco electronic controls have virtually eliminated deadband.
Electronic pressure controls regulate the pressure in a manner that is constant
and accurate, perfect for painting contractors who spray coatings at low
pressures or who need to maintain constant spraying pressures.
SmartControl ™
Graco’s exclusive SmartControl, advanced microprocessor control delivers:

• A consistent spray fan at all spraying pressures.
• Zero deadband (no pulsating, steady consistent pressure) at lower spraying
pressure, ideal for fine finish spraying.
• Automatically adjusts motor (pump) speed to best match the demand
eliminating constant stopping and starting. In lower flow conditions the
pump speed operates in slow stroking mode.
BlueLink
Job & Sprayer Management System
BlueLink combines the power of a mobile app with Bluetooth-enabled Graco sprayers
to connect the people and equipment that drive a painting business. Painters on the
jobsite can sync to a Bluetooth-enabled Graco sprayer when within 25 feet of the sprayer.
Once connected, BlueLink provides the critical, real-time jobsite and sprayer information
painting contractors need to help streamline their business — including real-time jobsite
access, instant maintenance alerts, on-demand productivity reports and much more!
Track Every Sprayer
- Know exact locations & hourly productivity
- Make fewer trips to jobsites
Know Your Job Progress
- On-demand productivity facts & reporting from anywhere
- Ensure you’re on-time with needed materials
Maximize Spray Time
- Set preventative maintenance schedules and receive alerts
- Ensure your sprayer is ready for every job
BlueLink is perfect to help streamline existing operations for any company size. Owners and
painters can also get faster service and support with quick access to Graco product information
and nearby distributors. BlueLink is available in 9 languages and there are no monthly fees.
To learn more, visit www.graco.com/BlueLink.

Beyond the Basics . . . Only on a Graco
FastFlush ™
The Graco exclusive FastFlush mode greatly reduces cleaning time by increasing the
pump speed up to 50% during low pressure cleaning. This creates a high turbulent
flow through the pump, hose and gun helping to break loose residual paint or coating
in less time. The FastFlush mode is activated with the Prime valve.
WatchDog ™
The WatchDog system automatically shuts the sprayer off when the paint supply
bucket is empty to prevent damage of running the pump dry. This system is available
on select Graco sprayers.
QuikReel
The QuikReel is designed to get the paint crew on and off the job faster by not
wrestling with long and cumbersome coils of hose. The integrated reel allows
easy pull-out and recoil of up to 300 feet of hose without kinking or twisting. The
EasyGlide hose guide ensures the rig doesn’t tip over and allows pulling from nearly
any direction. With the integrated position lock and tuck away crank handle, hose
management has never been easier. The QuikReel is
available on select Graco sprayers.
Genuine Graco Parts

Great design is in the details. At Graco, our engineering
gracopartsbook.com team designs and specifies every part with a careful
eye toward the parts with which it interacts, resulting in
superior unified systems that deliver peak performance.
Only genuine Graco parts are tested and re-tested to deliver the quality, performance,
long life and durability that our customers have come to trust and respect.
Graco Parts Book

The fast and easy way to look up common Graco parts. Hold the knowledge of our
experts in the palm of your hand and protect your investment with quality Graco parts
Accessories
Tip Extensions
Tip extensions are a simple and economical
way to extend spray reach and are available
in lengths from 10 to 30 inches.
Pole Guns
Pole guns are a real time and muscle saver
when spraying high or recessed areas. Graco’s Pole
Gun shuts fluid flow off at the tip for a crisp spray pattern
with no spitting or delays. The Pole Gun is rated at 3600 psi
(248 bar, 24.8 MPa) and is available in 3- and 6-foot lengths.

Beyond the Basics . . . Accessories
Airless Spray Hose

Airless spray hoses are available in different lengths, diameters, and pressure
ratings. Selecting the proper hose is critical for maintaining optimal spraying
pressure at the gun.
The length and diameter of hose you use affects the pressure drop
of fluid to the spray gun. A longer hose has a greater pressure
drop. A smaller hose diameter has greater pressure drop.
For ease of use, Graco hoses are more flexible and durable.
Hose length, diameter and the resulting pressure drop should be
considered when selecting the size of airless sprayer to purchase.
If using two different diameter hoses coupled together, attach the larger
diameter hose to the pump and the smaller hose to the gun to minimize
pressure drop.
Pressure Rollers
Pressure rolling is ideal when spraying is not possible. Simply pull the gun
trigger when you need more paint and keep on rolling. No more climbing up
and down ladders and stopping to dip the roller in a messy tray. Reach to the
top without a ladder with fixed or telescoping extensions.
JetRoller ™
ROLL YOUR PROJECT IN HALF THE TIME! Lightweight and portable,

the JetRoller consists of a spray roller, a spray extension and a hand roller
in one complete kit. It combines the speed and coverage advantages
of airless spraying with the classic technique and familiarity of rolling.
The JetRoller is the perfect solution for Contractor’s looking for a flexible
lightweight tool that is specifically designed to speed up paint rolling projects
while virtually eliminating overspray. It fits existing airless sprayers and is a
versatile, time-saving tool for any professional painter.

Beyond the Basics . . . Maintenance
Scan to watch the videos online
Start Up &
Clean Up
Start Up Clean Up
graco.com/BasicsOfAirless-Chapter6 graco.com/BasicsOfAirless-Chapter7
Maintaining Airless Equipment

Check your operators manual for the complete maintenance
requirements of your specific Graco equipment.
Equipment Inspection
Check the following components and tighten, clean or replace, as needed:
• Inlet Screen • Gun Body
• Manifold Filter • Tip Guard and Tip
• Gun Filter • Trigger Safety
• Tip Filter • Trigger Guard
• Hose Connections • Power Cord
• Inlet Suction Tube
General Maintenance
• Use the appropriate size filters for the material being sprayed
(see the Correct Filter Reduces Tip Clogs chart).
The Correct Filter Reduces Tip Clogs

Mesh Size 200 100 60 30
Materials Stains, Varnish, Lacquers, Latex, Enamels Heavy Latex,
Polyurethane Enamels (Latex) Block-fillers,
Solvent Based (Solvent), Elastomerics
Solvent Based
Paints
Use With .007 - .013 inch .013 - .015 inch .015 - .029 inch .031+ inch
Tip Sizes
• Check filters daily, if clogged more than 20%, replace. If punctured,

replace immediately.
• Visually check hoses every time you spray for internal build-up, cracks,
kinks, holes, blisters, abrasions, and damage to the hose cover.
• Use two wrenches when tightening all hose connections.
• Ensure good air-flow path into motor, wipe shroud clean after each use.

Beyond the Basics . . . Maintenance
• Do not cover the pump with a rag or plastic while spraying, allow good
airflow to keep the sprayer cool.
• Don’t pressure wash the unit.
• Keep wet cup/brass packing nut tightened. Fill cup with TSL every
time you spray to reduce paint adhesion on the rod. Do not use oil as a
substitute for TSL.
• If raw paint appears on the pump rod, tighten packing nut 1/8 turn or
until weeping stops. Over tightening can overwork pump and reduce
performance.
• When pump packings wear, paint will begin to leak down the outside
of the pump. Replace pump packings at the first sign of leaking or
additional damage could occur to the expensive pump hard parts.
• Clear tips with a couple short bursts of water or solvent with the
tip in the “reverse” position.
• Clean tips with a soft brush. Store tips for short periods in
a sealed container of water or solvent.
• Replace tips if fan pattern has collapsed or pump can not maintain
enough pressure for a good pattern.
• In cold climates, don’t allow water or paint to freeze in internal parts or
the hoses. Expansion as water freezes can cause severe damage.
• HVLP – Check and clean or replace air intake filters.
• Gas Units – Check oil level. Change oil as indicated in owners manual.
• Bring your sprayer in annually for a general service check at an
authorized Graco repair center.
• Do a dirty rinse and a clean rinse, another rinse with clean water or
thinner, with a minimum of five gallons of rinse fluid.
• Store your system with the pump rod in the down location. Less
exposure to air will reduce corrosion.
• Short term storage (overnight), water is OK, thinner is better.
• Longer term storage, thinner is OK, Pump Armor is better.
• Do not store the unit under pressure.
• To prevent fluid from running out of the sprayer
during storage, fasten a plastic bag over suction tube.

Beyond the Basics . . . Safety
Safety
Safety is a shared responsibility. It is up to everyone to ensure a safe working

environment.
• Graco, as a manufacturer, is responsible for providing reliable products
as well as safety information.
• The sales team, as representatives of Graco, should demonstrate and
point out safety devices and procedures when demonstrating airless
spray equipment.
• Distributors and their employees are responsible for training their
staff about airless spray equipment and should always follow safety
procedures.
• Airless spray equipment users should read all warnings and should
follow all safety precautions and procedures.
An effective way to become familiar with safety considerations and procedures
is to review the Instruction Manuals that are included with Graco products.
The manuals use icons to represent the different types of hazards, such as fire
and explosion, toxicity, injection, and others. The icons indicate the location of
safety information located throughout the instruction manuals and operating
instructions.
Potential Hazards (and their icons)

The potential hazards that may occur when using Graco products are:
Fire and Explosions—can only occur if there is an ignition source combined

with flammable vapors and air in the workspace. Ignition sources that can
potentially lead to a fire or explosion are:
• Electrical switches or motors
• Open flames
• Static electricity

To prevent fire and explosion:
• Install and use proper ventilation
• Remove or extinguish all ignition sources, such as pilot lights,
cigarettes, arcing motors, and others
• Ground all people, objects and spraying equipment in the spray area to
prevent electrostatic discharge
• Use appropriate flushing procedures: use water, mineral spirits or
lacquer thinner—never use gasoline!
• Use only grounded outlets, extension cords, and fluid hoses designed
for high-pressure spraying that are in good condition—do not modify or
remove electrical cords.
Skin Injection—spray equipment users and doctors often underestimate

the seriousness of a skin injection injury and the medical complications that
could result. The injury might look like “just a cut” but should be considered a
serious injury! The factors in the work environment that contribute to the risk of
accidental skin injection are:
• A high-pressure fluid stream directed toward skin or clothing
• Removal of protective devices from equipment (gun safety, trigger
guard, and tip guard)
• Unintended release of fluid pressure
• Failure to use a spray gun trigger safety
To prevent skin injection:
• Stay clear of high-pressure fluid streams and sprays
• Never remove protective devices, such as spray gun tip guards
• Use proper pressure-relief procedures
• Use proper flushing practices described in instruction manual
• Never try to stop leaks with your hands or body
• Always use the spray gun trigger safety when not spraying
• Don’t feel for leaks with your hands or a rag

Over-pressurization and Unintended Pressure Release—pressure-related

injuries occur when equipment is over-pressurized and a component of the
airless sprayer ruptures. Component ruptures are most often caused by:
• Exceeding the safe working pressure of a component
• Continued use of worn or damaged equipment
• Operator does not follow pressure-relief procedures
• Using replacement parts that are not genuine Graco parts
• Connections are not tight
• Connections are incompatible
• Connections or components are inappropriate for the pressure rating
When equipment components rupture or an unexpected pressure release
occurs, injuries are most often caused by spray in the face or eyes, a whipping
hose, or projectiles.
To prevent pressure-related injuries
• Do not exceed the Working Pressure Ratings (WPR) of components,
paying special attention to high-pressure equipment
• Use pressure-relief devices like pressure relief valves on sprayers
• Limit the air or hydraulic pressure to the motor so that the fluid
pressure produced by the pump is less than the working pressure of
all system components
• Do not repair permanently coupled hoses
• Use only genuine Graco service parts
• Do not modify Graco (or any other) parts
• Properly align spray tips to prevent back-spray
• Do not use low-pressure fittings on high-pressure equipment
• Use proper pressure-relief procedures
• Do not use damaged or worn equipment
• Check for proper connections and make sure they are tight before
pressurizing the system

Injury from Moving Parts—injury from moving parts most often occurs after:
• Unintended contact with moving components (for example, air motor
and pump displacement rods)
• Removal of equipment guards
• Failure to completely relieve fluid and air pressure when servicing
equipment
To prevent injury from moving parts:
• Follow procedures for relieving fluid pressure whenever you stop
equipment for service or repair
• Never operate equipment with guards or other protective devices
removed
• Check regularly to ensure that safety devices are operating properly
• Properly use bleed type shutoff valves
Toxicity—is a potential risk when:

• Fumes from coating materials, fluids, or gas engine exhaust fumes are
present in the work environment
• Toxic fluid makes contact with skin, nose, mouth, or eyes
To prevent toxicity:
• Use recommended Personal Protection Equipment (PPE) to avoid
contact with hazardous materials
• Read and follow directions on all coating material labels and material
safety data sheets (MSDS)
• Follow the recommendations of fluid manufacturers
• Never operate gas engines indoors

Electric Shock—the factors in the work environment that may potentially lead
to electric shock are:
• Contact with electrically live or charged parts
• Improper grounding of equipment and other objects in the spray area
To prevent electric shock:
• Properly ground all objects in the system, including operators
• Follow the procedures in instruction manuals to avoid shocks from
electrostatically charged components
• Never operate electric equipment when it is wet or when the
surrounding area is wet
• Use only grounded outlets, extension cords, and fluid hoses designed
for high-pressure spraying that are in good condition
• Do not modify or remove electrical cords.
The instruction manual for each Graco

product identifies preventive actions
that pertain to that equipment. Always
consult the product safety information
in the manual to learn about the safe
use of each Graco product.

Beyond the Basics . . . Accident & Near Miss Reporting
All Graco employees and distributors must report accidents and near-miss
accidents to Graco toll free at 1-800-543-0339. Prepare for the possibility of an
accident by having the Graco Accident Reporting Wallet Card on hand at all
times. To order the Graco Accident Reporting Wallet card, call customer
service, toll free at 1-800-690-2894 and order part number 301‑283.
Important!
An injection occurs when high-pressure fluid pierces the
skin. The injury might look like “just a cut” but should
be considered a serious injury!
Any injury caused by high-pressure fluid can be serious. If you or
someone else becomes injured – even slightly:
• Go immediately to an emergency room
• Notify the doctor that the injury is a “fluid injection injury”
• Be sure to tell the doctor the type of material that was injected
Visit us at www.graco.com
For product information or to request a demonstration,
contact your local distributor or call 800-690-2894.

Notes

How to Recognize Genuine Graco Parts
EVERY PART COUNTS ENGRAVED GRACO LOGO
Replacement parts are often purchased solely on the basis of price. The Graco logo is engraved on most of
However, the small amount of money saved will ultimately our piston rods, tubes, and sleeves.
put your performance and your business at risk..
HOLOGRAPHIC STICKER
Why Demand Genuine Graco Parts? A holographic sticker is always on the
packaging of a genuine Graco repair kit.
TIME AND MONEY SAFETY
Cheaper parts ultimately cost you more One non-Graco part can lead to GRACO QUALITY YOU CAN FEEL
time and money in extra repair costs, injury and downtime. Graco parts Genuine Graco parts are built tough
extra labor hours, etc. deliver best possible quality to and feel more robust than other
deliver safest experience. manufacturers’ parts.
PERFORMANCE AND RELIABILITY
Only genuine Graco parts deliver the WARRANTY
legendary Graco standard of performance Warranty conditions only remain
and the lowest downtime. valid with genuine Graco parts.
Defects or damage caused by
non-Graco parts are not covered.
gracopartsbook.com
The fast and easy way to look up
common Graco parts.
Every Graco purchase comes Scan to watch the videos

with A+ Customer Service.
The Basics of
Questions?
Call (844) 241-9499
Airless Spraying
graco.com/BasicsOfAirless
For more information visit graco.com

©2019 Graco Inc. 321132H 5/19 All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.
Trademarks are referenced herein for identification purposes only. All trademarks are the property of their respective owners. Product covered by issued and pending patents, see graco.com/patents

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THE BASICS

MADE IN THE USA WITH

1 The Basics - An Overview of Airless Sprayers

Contractor Equipment Division

The Basics - An Overview of Airless Sprayers 2

Graco works hard to meet the needs

3 The Basics - An Overview of Airless Sprayers

Virtually every coating contains four basic components:

The Basics - An Overview of Airless Sprayers 4

Typical Solids Content of Popular Coatings

Lacquers & Oil-based Acrylics Elastomerics Block Fillers

Enamels Interior Exterior Specialty

5 The Basics - An Overview of Airless Sprayers

Scan to watch the video online

Advantages of Airless Sprayers

The Basics - An Overview of Airless Sprayers 6

Airless Spray for Uniform Coverage

It is important to consider how much faster spraying is compared to other

7 The Basics - An Overview of Airless Sprayers

Scan to watch the video online

Did you know?

The Basics - An Overview of Airless Sprayers 8

The Basics . . . Atomized, evenly Air-Assisted Airless

Air-Assisted Airless tails

Low pressure spray with

• Controls the amount of fluid

easily under pressure D

9 The Basics - An Overview of Airless Sprayers

Scan to watch the video online

Airless Spray Tips

Did you know?

Breaking the Code

The Basics - An Overview of Airless Sprayers 10

11 The Basics - An Overview of Airless Sprayers

Rating Spray Tips

Many paint manufacturers

Hi-Boy–16W892 16W902 16W903 16W907

Maximum Tip Size 0.031 0.033 0.035 0.039

The Basics - An Overview of Airless Sprayers 12

Which tip puts out more paint,

13 The Basics - An Overview of Airless Sprayers

Effects of Tip Wear

Spray Pattern Width

12 in. Worn Worn Worn

Tips for extending the life of spray tips:

The Basics - An Overview of Airless Sprayers 14

Using a worn tip wastes paint and labor

Good Tip Worn Tip

15 The Basics - An Overview of Airless Sprayers

How Airless Sprayers are Rated by Manufacturers

Typical maximum airless Typical atomization pressures

hp—(horse power) a performance rating for the sprayer’s motor or engine.

The Basics - An Overview of Airless Sprayers 16

17 The Basics - An Overview of Airless Sprayers

Latex Paints Latex Paints

Gallons Up to 150 Up to 500 Up to 1000 Up to 500 Up to 1000 Up to 1000 Up to 150

Size of Application Up to 3 Gallons Up to 3 Gallons

.008 – .016 RAC X FF LP