Operation/Repair/Parts
MP 400/300
Mustang 4800
332882A
Airless Paint Sprayer
For portable application of architectural paints and coatings. For professional use only.
Not approved for use in European explosive atmosphere locations.
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual and in gun manual. Save all
instructions.
See page 3 for model information.
Related Manuals
Gun Manual
312363 - English
312364 - Spanish
312365 - French
EN
Hi-Boy Model
ti22317a
ti22320a
Stand Model
Contents
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Prime and Flush Storage Fluid . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clearing Clogs . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Pressure . . . . . . . . . . . . . . . . . . . 13
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . 14
Electric Motor Maintenance . . . . . . . . . . . . . . . 14
Servicing the Fluid Pump . . . . . . . . . . . . . . . . . 14
Fluid Pump Disconnect . . . . . . . . . . . . . . . . . . . 14
Servicing the Inlet Valve - Hi-Boy . . . . . . . . . . . 16
Servicing the Inlet Valve - Stand . . . . . . . . . . . . 16
Packing Replacement Procedures . . . . . . . . . . 16
Gear and Pump Assembly . . . . . . . . . . . . . . . . 18
Replacement of Electrical Components . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manifold Filter (868014) . . . . . . . . . . . . . . . . . . 22
Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stand Frame Parts Diagram . . . . . . . . . . . . . . . 23
Hi-Boy Parts Diagram . . . . . . . . . . . . . . . . . . . . 24
Control Parts Diagram . . . . . . . . . . . . . . . . . . . 25
Motor and Drive Parts Diagram . . . . . . . . . . . . 26
Drive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Packing Replacement . . . . . . . . . . . . . . . . . . . . 28
Suction Assemblies . . . . . . . . . . . . . . . . . . . . . . 29
Electrical System . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Airlessco Standard Warranty . . . . . . . . . . . . . . . . 32
2 332882A
Models
Models
Model Model No. Series Hi-Boy Stand 120V 240V Euro 220V CN 220V LA 220V AP 230V ANZ
MP300 868058 A x x
868050 A x x
868051 A x x
868054 A x x
MP400
Mustang
4800
868055 A x x
868056 A x x
868057 A x x
868060 A x x
868052 A x x
868053 A x x
332882A 3
Warnings
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 warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
WARNINGWARNINGWARNING
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 or 230V circuit and has a grounding plug similar to the plugs
illustrated in the figure below.
120V US 230V
• 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 grounding plug and a grounding 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.
4 332882A
Warnings
WARNING
WARNINGWARNINGWARNING
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 Graco conductive or
grounded high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge. Do not use
pail liners unless they are antistatic or conductive.
• 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.
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.
332882A 5
Warnings
WARNING
WARNINGWARNINGWARNING
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
• Do not aim the 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, page 10 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, page 10 for turning off the unit.
• 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.
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, page 10 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 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.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
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.
6 332882A
Warnings
WARNING
WARNINGWARNINGWARNING
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 10 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.
CALIFORNIA PROPOSITION 65
This product contains a chemical known to the State of California to cause cancer, birth defects or other
reproductive harm. Wash hands after handling.
332882A 7
Component Identification
Component Identification
E
D
B
C
A Power switch Turns sprayer ON and OFF
B Pressure Control Knob Adjusts pressure. Turn clockwise to increase pressure and
counterclockwise to decrease pressure.
C Prime Valve Primes pump.
D Prime Valve Open Position Valve is in open position when handle is in the vertical position.
E Prime Valve Closed Position Valve is in closed position when handle is in the horizontal posi-
tion.
A
ti22321a
8 332882A
Operation
Grounding
Operation
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts
grounding continuity.
TIC
Do not modify the plug provided; if it does not fit the
outlet, have the proper outlet installed by a qualified
electrician.
Extension Cords: Use an extension cord with an
undamaged ground contact. If an extension cord is nec-
essary, use a 3-wire, 12 AWG (2.5 mm
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
2
) minimum.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
The plug must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
332882A 9
Operation
Pails
Solvent and oil/based fluids: follow local code. Use
only conductive metal pails, placed on a grounded surface such as concrete.
Do not place pail on a nonconductive surface such as
paper or cardboard which interrupts grounding
continuity.
Grounding a metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to a true
earth ground such as a water pipe.
ti5851a
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Engage the gun trigger lock. Refer to the separate
instruction manual provided with gun for safety features and how to engage the trigger lock.
2. Turn the unit off.
3. Disengage the gun trigger lock and trigger the gun
to relieve residual fluid pressure.
Hold metal part of the gun in contact with grounded
metal pail. Use minimum pressure.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of spray gun firmly
to side of a grounded metal pail. Then trigger gun.
ti5310b
ti15989a
4. Re-engage gun trigger lock and turn Prime Valve to
the open (priming) position.
Closed
(Pressure)
Open
(Priming)
ti17403a
NOTE: The valve handle can move both clockwise and
counter clockwise and can face different directions.
NOTE: 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.
10 332882A
Operation
Setup
To reduce the risk of static sparking, fire or explosion
which can result in serious bodily injury and property
damage. Always ground the sprayer and system components and the object being sprayed.
• Ensure proper electrical service and amperage
and that the outlet is properly grounded.
Connect the hose and gun
1. Remove the plastic cap plug from the outlet and
screw a conductive or grounded 3000 psi spray
hose onto fluid outlet.
2. Connect an airless spray gun to the other end of the
hose. Do not install spray tip.
Fill the Packing Nut/Wet Cup
1. Remove guard and cap.
2. Fill the Packing Nut/Wet Cup with 5 drops of Throat
Seal Oil (TSO) or Packing Seal Fluid.
Oil- or Water-based Materials
• When changing from water-based material to oil
based material, flush with soapy water and then
mineral spirits.
• When changing from oil based material to water
base material, flush with mineral spirits, followed by
soapy water, then a clean water flush.
• When flushing with solvents, ground pail and gun.
• Flush before changing colors, before fluid can dry in
the equipment, at the end of the day, before storing,
and before repairing equipment.
Flushing
• To reduce the risk of static sparking, which can
cause fire or explosion, always hold a metal part of
the gun firmly against the metal pail when flushing.
This also reduces splashing.
• To reduce risk of injection, always remove the
spray tip before flushing to avoid.
1. Make sure the gun trigger lock is engaged and there
is no spray tip in the gun. Refer to the separate
instruction manual provided with gun for safety features and how to engage the trigger lock.
ti16049a
Flush the Sprayer
1. Flush the sprayer. See Flushing Procedure on
page 11.
Prime and Flush Storage Fluid
NOTICE
The equipment was tested with lightweight oil,
which is left in the fluid passages to protect parts.
To avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using
the equipment for the first time.
Before beginning a new spraying project you need to
prime the sprayer and flush the storage fluid out of the
sprayer.
332882A 11
2. Pour enough clean, compatible solvent into a large,
empty metal pail to fill the pump and hoses.
3. Place the suction tube into the pail or place the pail
under the pump.
ti16028a
Operation
4. Turn Pressure Control Knob to low.
ti22322a
5. Open the prime valve to the open (priming) position.
This will allow an easy start.
Closed
(Pressure)
Open
(Priming)
ti17403a
6. Turn the power ON/OFF switch to ON.
7. Point the gun into the metal pail and hold a metal
part of the gun firmly against the pail. Maintain firm
metal to metal contact between gun and container.
ti15989a
13. Whenever shutting down the sprayer, follow Pres-
sure Relief Procedure, page 10.
NOTICE
To prevent damage and freezing during storage,
never leave water in the fluid pump
Startup
1. Prepare the material according to the material manufacturer’s recommendations.
2. Place the suction tube into the material container.
3. Start the sprayer.
a. Prime Valve must be in the open (priming)
position.
b. After ensuring the gun trigger lock is engaged,
attach tip and safety guard.
c. Turn the power ON/OFF switch to the “ON”
position.
d. Turn the Pressure Control Knob clockwise to
prime the pump.
e. After the pump is primed, turn the Prime Valve
to the “CLOSED” position.
f. Turn Pressure Control Knob to the desired
spray pressure.
g. Disengage the gun trigger lock to begin spray-
ing.
4. To stop the unit in an emergency, turn the engine
off. then relieve the fluid pressure in the pump and
hose. See Pressure Relief Procedure, page 10.
8. Disengage the gun trigger lock and squeeze the
trigger. At the same time, slowly turn the pressure
control knob clockwise, just enough to move liquid
at low pressure.
9. Allow the pump to operate until clean solvent comes
from the gun.
10. Release the trigger and engage the gun trigger lock.
11. If you are going to start spraying, place the pump or
suction tube into the supply container. Release the
gun trigger lock and trigger the gun into another
empty, metal container, holding a metal part of the
gun firmly against the metal pail, forcing the solvent
from the pump and hose. When paint starts coming
from gun, turn pressure control knob to minimum
pressure, place prime valve in prime (open) position
and engage the gun trigger lock.
12. If you are going to store the sprayer see Storage,
page 13. Engage the gun trigger lock.
12 332882A
Operation
Clearing Clogs
1. Release trigger. Engage trigger lock. Rotate Spray
Tip. Disengage trigger lock. Trigger gun at waste
area to clear clog.
ti10166a
2. Engage trigger lock. Return Spray Tip to original
position. Disengage trigger lock and continue
spraying.
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Shutdown
1. Relieve Pressure, page 10.
2. Clean the tip and gun as recommended in the separate Gun Manual supplied with the gun.
3. If spraying water-based material or a material that
could harden in the sprayer overnight, flush the
sprayer after use. See Flushing, page 11.
Storage
Short Term
1. Flush sprayer with compatible solvent before storing, then fill the pump and hoses with an oil based
solvent such as mineral spirits.
• For oil base paint: flush with mineral spirits
• For water-base paint: flush with water, then min-
eral spirits and leave the pump, hose and gun
filled with mineral spirits.
Long Term
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Adjusting the Pressure
To reduce the risk of injection, never hold your hand,
body, fingers or hand in a rag in front of the spray tip
when cleaning or checking for a cleared tip. Always
point the gun toward the ground or into a waste container when checking to see if the tip is cleared or
when using a self cleaning tip.
When adjusting the pressure, turn the Pressure Control
Knob clockwise to increase pressure and counterclockwise to decrease pressure. Always use the lowest pressure necessary to completely atomize the material. If
more coverage is needed, use a larger tip rather than
increasing the pressure.
NOTE: Operating the sprayer at higher pressure than
needed wastes material, causes early tip wear, and
shortens sprayer life.
For longer storage, use Graco Pump Armor or mineral
spirits. Shut off sprayer, Relieve Pressure, page 10,
and make sure prime valve is left open.
Start Up After Storage
Before using water-base paint, flush sprayer with soapy
water and then a clean water flush. When using oil-base
paint, flush out the mineral spirits with the material to be
sprayed.
NOTE: Always store unit indoors.
NOTE: Check the spray pattern. The tip size and angle
determines the pattern width and flow rate.
332882A 13
Maintenance
Maintenance
Daily Maintenance
1. Keep the displacement pump packing nut/wet cup
lubricated with Throat Seal Oil (TSO) or Packing
Seal Fluid at all times. The oil or fluid help protect
the rod and packings.
2. Inspect the packing nut daily. If seepage of paint
into the packing nut and/or movement of the piston
upward is found (while not spraying), the packing
nut should be tightened just enough to stop leakage.
Overtightening will damage the packings and
reduce the packing life.
Electric Motor Maintenance
Lubrication
The motor is supplied with pre-lubricated ball bearings,
lubricated for the life of the bearing.
Motor Brushes
Motor brushes need periodic inspection and replacement as wear indicates. Standard brushes have an initial length of 1” and should be replaced when they are
worn to a length of 1/2”. Brush wear is greatly influenced
by individual application and it is recommended that
brush wear be checked at early intervals of operation in
order to determine future required inspection.
To change the brushes:
1. Disconnect power from the unit.
2. Remove the cover over the motor, if applicable.
3. Open the two covers at the rear of the motor.
4. Disconnect the brush wire.
5. Pull out the wire.
6. Push the brush retainer clip in and withdraw.
7. Remove the worn brushes.
8. Install new brushes in the reverse order.
9. To increase brush life, new brushes (Part # 331780)
need to have a run in period. After changing
brushes, set the machine for spraying. With a
bucket of Pump Conditioner and water, a 50’ 1/4”
airless hose, airless gun and tip on unit, open the
prime valve and power on. The pump will now
prime. With pump running in the prime mode, turn
the pressure control knob to high pressure. (The
pump has to cycle fast with no pressure in the
pump). Run the pump for 20 minutes and the
brushes will be run in.
Brush Kit
331780
ti16051a
Servicing the Fluid Pump
Fluid Pump Disconnect
1. Relieve Pressure, page 10.
2. Flush the material you are spraying out of the
machine.
3. Remove the connecting rod shield(12).
4. Move the piston rod (10) to its lowest position by
cycling pump slowly.
5. Turn off the motor and disconnect power from unit.
6. Remove the retaining ring (4) from the connecting
rod (2) and slide the sleeve (3) down revealing the
connecting rod pin (1).
7. Remove the suction tube assembly from the fluid
pump (9) by unscrewing the suction nut (7) with the
packing adjustment tool. (865008).
8. Using a 1/2” wrench, unscrew the two bolts (8) from
the cover assembly (14). The fluid pump (9) will be
hanging loosely at this point.
9. Remove the connecting rod pin (1) out of the connecting rod (2), allowing the removal of the fluid
pump (9) from the machine.
14 332882A
Fluid Pump Reinstall
1. Loosen the packing nut and ensure that the piston
rod (10) is in its upper position in the fluid pump
body, snap cap onto packing nut and slip the sleeve
(3) and the retaining ring (4) over the piston rod
(10).
2. Push the piston rod (10) up into the connecting rod
(2) and align the holes. Insert the connecting rod pin
(1) through the connecting rod (2) and piston. Slip
the sleeve (3) up over the connecting rod pin (1) and
insert the retaining ring (4) into the groove on the
connecting rod (2).
Maintenance
14
2
1
3. Push the two bolts (8) through the tube spacers (11)
and screw them into the cover assembly. Using a
1/2” wrench, tighten the two bolts (8) evenly (alternating between them) to 20 ft-lbs (27.1 N•m).
4. For Hi-Boy: Reassemble lower suction valve
assembly by placing the suction seat, O-ring, suction ball and suction ball guide in the suction nut (7)
and screw onto fluid pump body.
For Stand: Reassemble lower suction valve assembly by placing the o-ring, PTFE-ring on stop of ball
cage, o-ring on bottom of ball cage in the suction nut
(7) and screw onto fluid pump body.
5. Reconnect the pressure control knob and fitting to
the fluid pump body.
6. Start the machine and operate slowly to check the
piston rod (10) for binding. Adjust the two bolts (8),
holding the fluid pump body to the cover assembly,
if necessary. This will eliminate any binding.
7. Tighten packing nut clockwise until resistance is felt
against the Belleville Springs, go 3/4 of a turn more.
Put five drops of Throat Seal Oil or Packing Seal
Fluid in the packing nut.
12
3
4
5
9
10
11
7
8
ti22323a
8. Run the machine at full pressure for several minutes. Release the pressure by following the Pres-
sure Relief Procedure, page 10, and readjust the
packing nut per step 7 above.
9. Install the connection rod shield (12).
332882A 15
Maintenance
Servicing the Inlet Valve - Hi-Boy
1. Relieve Pressure, page 10. Disconnect power from
unit.
2. Un-thread and remove suction nut from the fluid
pump body (8).
3. Remove suction seat assembly (12).
4. Clean all parts and inspect them for wear or damage, replacing parts as needed.
5. Clean inside of the fluid pump body (8).
6. Reassemble lower suction valve assembly by placing the suction seat assembly (12) in the suction nut
(13) and screw onto fluid pump body (8).
Stand Model
8
159
160
157
158
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9
10
11
12
13
Servicing the Inlet Valve - Stand
Packing Replacement Procedures
Disassembly of the Fluid Pump
1. Disconnect the Fluid Pump, page 14.
2. Unscrew and remove the packing nut, with wet cup
cap.
3. Push the piston rod down through the packings and
out of the pump.
4. Push the packing removal tool up through the pump
and remove from the top, bringing packings, spacer
and springs along with it, leaving fluid body empty.
Make sure all old packings and glands have been
removed from fluid pump.
5. Clean inside of fluid body.
6. Disassemble all parts and clean for reassembly.
Discard any old packings.
7. Lubricate leather packing in lightweight oil for 10
minutes prior to reassembly.
Reassembly of the Fluid Pump
1. Place lower male gland (1) down on the flat side.
2. Take three of the lower polyethylene packings (2)
and two of the leather packings (23) and place onto
the male gland (1), with the inverted side down, in
the following order:
• Polyethylene
• Leather
• Polyethylene
• Leather
• Polyethylene
1. Relieve Pressure, page 10. Disconnect power from
unit.
2. Un-thread and remove suction nut from the fluid
pump body (8).
3. Remove O-ring (158), suction seat assembly (157),
O-ring (159) and backup ring (160).
4. Clean all parts and inside fluid body (8).
5. Reassemble inlet valve with O-ring (159), backup
ring (160) and O-ring (158).
6. Tighten suction nut using packing adjustment tool
(865008).
16 332882A
3. Take the female adaptor (3), which is inverted on
both sides, and place it on top of your assembled
lower packings.
4. Follow step 2 with your packings inverted side up.
5. Take the second lower male gland (1) and place it
on top of your assembled packings with rounded
side down.
6. Take assembled glands and packings (13 pieces)
and slide onto the lower half of the piston (14).
7. Take the spacer (15) and slide over the top of the
piston (14).
Maintenance
8. Take three spring washers (16) and slide over the
top of the piston (14) in the following order:
• First spring - curve facing up
• Second spring - curve facing down
• Third spring - curve facing up
9. Take the upper male gland (17) and place it
rounded side up.
10. Take three upper polyethylene packings (18) and
two leather packings (22) and assemble with
inverted side down, on to the male gland (17) in the
following order:
• Polyethylene
• Leather
• Polyethylene
• Leather
• Polyethylene
11. Take upper female gland (19) and place on top of
assembled upper packings with the inverted side
down.
12. Take assembled upper glands and packings (7
pieces) and slide on over the top of the piston (14),
making sure inverted sides are down.
13. Take the packing holder (20) and replace the white
O-ring (24) and the black O-ring (25) with new ones
from the packing kit.
14. Slide the packing holder (20) over the top fo the
upper packings so they fit inside.
15. Lubricate inside of the fluid pump body (4) and the
outside of the packings with a light weight oil.
16. Slide assembly into fluid pump body.
NOTE: To keep packings secured in correct position,
hold the pump body upside down and push the completed assembly upwards into the pump body. Once
placed inside, tilt pump body back up to keep all pieces
in.
18. Reinstall Fluid Pump, page 15.
26
21
20
25
23232323
24
19
18
18
18
22
22
17
16
16
16
15
5
6
7
14
13
8
9
11
12
10
1
2
22
3
222
1
4
ti16115b
Stand model
159
160
157
158
17. Tighten packing nut (21) onto the top of the fluid
pump body and tighten until you feel slight resistance against the Belleville Springs (16). Using the
Packing Adjustment Tool, tighten another 3/4 of a
turn.
332882A 17
Maintenance
Gear and Pump Assembly
Servicing Gear box Assembly
1. Remove fluid pump. See Fluid Pump Disconnect,
page 14.
2. Remove frame from the gearbox by loosening the
four mounting screws.
3. Separate cover assembly (13) from box by removing bolts (1) from front of cover and back of box and
shoulder bolts (2) from front of cover and back of
box.
4. Lay unit on its back and disassemble gearbox.
5. Inspect bearings (14, 17), Crosshead Assembly
(15), Gearcrank (16) and sleeve bearing inside the
Crosshead assembly (15) for wear/damage.
Replace worn/damaged parts.
6. If gear grease needs replacing, replace with gear
grease (Part No. 114819).
7. Clean mating surfaces of cover and box thoroughly.
Apply Loctite
®
518 on half the bottom surface of end
bell.
8. Reassemble in reverse order.
1
2
17
16
13
2
1
12
14
10
11
15
8
4
5
6
ti22326a
18 332882A
Maintenance
Replacement of Electrical Components
To avoid electric shock, always unplug the electrical
cord before servicing the machine.
NOTE: Anytime the pressure control assembly, sensor,
or both are replaced, perform the calibrations.
Pressure Control Assembly (Electrical
Control Board)
1. Unplug machine’s power cord.
2. Remove two screws from terminal box.
3. Disconnect all leads from pressure control assembly.
4. Reassemble in reverse order.
NOTE: Ensure ground lead (A) is connected to control
board mounting screw nearest to On-Off Toggle Switch
(B).
B
A
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.
ti22483a
On-Off Toggle Switch
1. Lower the pressure control assembly as described
above.
2. Disconnect the two wires on the toggle switch.
3. Use a 9/16” wrench to loosen the nut on the toggle
switch shaft.
4. Reassemble in reverse order.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.
332882A 19
Troubleshooting
Troubleshooting
Problem Cause Solution
Unit doesn’t prime Air leak due to loose suction
nut
Air leak due to worn o-rings For Hi-Boy: Replace o-ring (108526) on suc-
Air leak due to hole in suction
hose
Stuck or fouled balls Service inlet and outlet valves.
Unit primes but has poor or no
pressure
Unit does not maintain good
spraying pressure
Pressure set too low Turn up pressure.
Filter(s) are clogged Clean or replace gun filter, inlet filter, and/or
Outlet valve fouled/worn. Service outlet valve.
Prime valve bypassing Clean or replace prime valve (866428).
Packings and/or piston worn Tighten packing nut, repack unit.
Worn spray tip Replace spray tip.
Packings and/or pistons worn Repack unit.
Tighten suction nut.
tion seat and o-ring (867370) below suction
seat.
For Stand: Replace o-ring (120777) on suction seat and o-ring (121370) below suction
seat.
Replace suction hose.
manifold filter.
Upper seat worn Replace upper seat.
Unit does not run Blown fuse Replace fuse:
120V models: 12.5A time delay fuse
220V - 240V models: 8A time delay fuse
20 332882A
Troubleshooting
Problem Cause Solution
Machine does not start Control Settings Make sure machine is plugged into the wall.
Verify the on-off switch is in the ON position
and the pressure control knob is turned all the
way to the right (clockwise for maximum pressure).
Pressure Control Assembly
(Board)
If the power indicating light is still out after
checking the control settings and power
source, replace the pressure control assembly.
Motor Remove the motor brush covers and turn the
machine ON. Set the pressure control at maximum pressure and check for DC voltage
across both brush terminals. It should read
greater than 80 volts DC.
If you have DC voltage, turn the machine off
and unplug it from the wall. Check to make
sure the brushes are making good contact
with the armature. Replace the brushes if they
are less than 1/2” long. If the brushes are
good, replace the motor.
332882A 21
Parts
Parts
Manifold Filter (868014)
Model 868057
5
6
7
9
44
1
Ref. Part Description Qty.
2
3
1 867145 COVER 1
2 301356 SPRING 1
3 867377 O-RING 1
4 867214 FILTER 60 MESH 1
4
5 867647 SUPPORT 1
6 867077 BASE 1
7 867420 PLUG 1
9 867309 NIPPLE 3/8” NPT x 1/4” NPT 1
10 557391 PLUG 1/4” NPT 1
44‡ FITTING 1
46‡ GAUGE, pressure 1
‡ Not included in Manifold Kit 868014, See page 27.
Inlet Valve
Stand Model
159
160
157
158
46
10
8
9
10
11
12
13
ti16056b
ti22327a
Ref. Part Description Qty.
8 331011 FLUID PUMP BODY 1
9 331029 SUCTION BALL GUIDE 1
10 331030 SUCTION BALL 1
11 108526 O-RING 1
12 331292 SUCTION SEAT (HI-BOY) 1
13 331034 SUCTION NUT 1
157 ‡ SUCTION SEAT ASSEMBLY (Stand) 1
158 ‡O-RING 1
159 ‡O-RING 1
160 ‡ RING, BACKUP 1
Included in O-Ring Kit 16W484.
‡ Included in Kit 331051.
22 332882A
Stand Frame Parts Diagram
Parts
2
1
Ref. Part Description Qty.
1 331101 FRAME, CARRY 1
2 16F551 FASTENER,THREAD,EXTERNAL 4
42 331048 RUBBER BOOT 2
42
42
63
53
ti22328a
Ref. Part Description Qty.
53 HSE1450 HOSE CPLD 1/4” x 50 ft. (MP400,
Mustang 4800)
245449 HOSE, 1/4” x 25 ft., (MP300) 1
63 289316 GUN, 500,2 FINGER,ASM 1
1
332882A 23
Parts
Hi-Boy Parts Diagram
2
3
1
78
77
7
Ref.Part Description Qty.
2 331273 FRAME 1
3 16F551 FASTENER,THREAD, EXTERNAL 4
4 866356 SPACER 2
5 867736 WHEEL,10” X 3.5” 2
6 143029 COLLAR, SCREW, SET 2
4
5
6
ti17483a
Ref.Part Description Qty.
7 331048 RUBBER BOOT 2
77 HSE1450 HOSE CPLD, 1/4” X 50’ 1
78 289316 GUN, 500, 2 FINGER,ASM 1
24 332882A
Control Parts Diagram
Parts
220/230V Models
34
37
27
28
26
25
33
29
38
39
28
30
31
32
36
120V Models
35
34
Ref. Part Description Qty.
25 867243 GASKET, seal 1
26 868000 BOX, terminal, weldment 1
27 868013 SEAL, rubber 1
28 331342 SCREW, 10-24 X 0.50 6
29 116969 NUT, lock 2
30 331185 STRAIN RELIEF 2
31 301083 SWITCH, toggle 1
32 301150 BOOT, rubber, black 1
33 15V909 SCREW, M8 X12 2
34 868018 CONTROL, board, 120V 1
868019 CONTROL, board, 230V
(220V-240V models)
35 868007 CONNECTOR, 120V 1
36 868008 CONNECTOR, 120V 1
37 868009 CONNECTOR, 230V (220V-240V
models)
38 868010 GASKET, terminal box 1
39 868004 COVER, terminal box 1
ti17482a
ti22429a
1
1
332882A 25
Parts
Motor and Drive Parts Diagram
35a
ti17481a
8
9
6
7
52
5
4
3
35e
35b
35c
25
35d
26
66
57
57
5858
56
51
13
45
44
46
4
43
5
69
44
12
11
24
10
15
22
20
16
17
18
3333
Stand Model
30
30
28
41
159
160
157
158
23
19
40
See page 29
ti22329a
26 332882A
Drive Parts
Parts
Ref. Part Description Qty.
3MOTOR
331491 1HP, 120V (120V models) 1
331492 0.5 HP, 220V (220V-240V models) 1
3a 331785 FAN (not shown) 1
3b 331786 FAN COVER (not shown) 1
3c 331787 BOLT (not shown) 1
4 866338 SCREW, SHOULDER 2
5 107445 SCREW, CAP 2
6 331047 BEARING,BALL 1
7 GEAR,CRANK
331406 .21 ASSY (120V models; MP300) 1
331407 .26 ASSY (MP400 220V-240V mod-
els)
9 331038 YOKE,CROSSHEAD ASSY 1
10 866082 PIN,CROSS PIN .375 1
11 331062 SPRING,RET. SPRING 1
12 331117 SLEEVE 1
13 868016 COVER - GUARD 1
15 866482 PUMP,PAINT,ASSY 1
16 331029 RETAINER,PUMP 1
17 331030 BALL .500 1
18 108526 PACKING,O-RING 1
23 867539 SCREW,5/16-18 X 3.75 HX HD 2
24 331074 SPACER 2.691 LONG 2
25 867243 GASKET,SEAL 1
26 868000 BOX,TERMINAL BOX WELDMENT 1
28 331342 SCREW,MACH,PANHEAD 4
30 331185 STRAIN RELIEF 2
31 116969 NUT. LOCK (not shown) 2
33 15V909 SCREW,M8X12 2
35 866477 COVER,FRONT,ASSEMBLY
(Includes 35a, 35b, 35c)
35a 331046 BEARING 1
35b 331061 SLEEVE BEARING 1
Ref. Part Description Qty.
35c 331103 WASHER 2
35d 331197 SCREW 2
35e 331234 COVER, BARE 1
43 POWER CORD (see page 30)
44 111763 FITTING, HI-BOY 1
162453 FITTING, STAND 1
867309 FITTING (model 868057) 1
867309 FITTING (model 868058) 2
45 867660 FITTING, tee, (MP300) 1
46 868015 GAUGE, pressure (Models 868057,
868058)
51 866428 PRESSURE RELIEF VALVE KIT 1
1
52 342524 LABEL- PRIME/SPRAY 1
54 15B516 LABEL, warning (120V models;
model 868054)
15H087 LABEL, warning (models 868055,
868056, 868060)
55 195793 LABEL, warning (120V models;
model 868054)
195792 LABEL, warning (models 868055,
868056, 868060)
16G596 LABEL, warning (models 868057,
868058)
56 331336 HOOK, pail (HI-BOY models) 1
58 113783 SCREW, MACH, PNH 2
66 16X134 LABEL, AIRLESSCO, MP400 1
16X135 LABEL, AIRLESSCO, MP300 1
16X527 LABEL, ALLPRO, Mustang 4800 1
1
Additional warning labels are available at no cost.
1
1
1
1
1
1
332882A 27
Parts
Packing Replacement
Ref. Part Description Qty.
1* 331014 MALE GLAND 2
2* 331016 PACKING POLYETHYLENE 6
3* 331308 FEMALE ADAPTOR 1
4 331011 FLUID PUMP BODY 1
5 331029 SUCTION BALL GUIDE 1
8 331292 SUCTION SEAT (HI-BOY) 1
331051 SUCTION SEAT (LO-BOY) 1
9 331034 SUCTION NUT 1
10+ 331314 OUTLET SEAT RETAINER 1
11+ 331026 OUTLET SEAT 1
12+* 111457 O-RING 1
13+* 331027 OUTLET BALL 1
14+ PISTON 1
15* 331018 SPACER 1
16* 331025 WASHER, SPRING 3
17* 331022 MALE GLAND 1
18* 331023 PACKING POLYETHYLENE 3
19* 331021 FEMALE GLAND 1
20 331019 PACKING HOLDER 1
21 331037 PACKING NUT 1
22* 331307 PACKING LEATHER 2
23* 331306 PACKING LEATHER 4
24* 107313 WHITE O-RING 1
25* 108771 BLACK O-RING 1
26 180656 PLUG, BUTTON 1
157** SEAT,SUCTION SEAT 1
158** PACKING, O-RING 1
159** PACKING, O-RING 1
160** RING, BACKUP 1
* 331210 PACKING KIT
+ 331093 PISTON ASSEMBLY
** Included in 331051
26
21
20
25
24
19
18
18
18
17
16
16
15
14
13
11
12
10
16
22
22
23232323
1
2
22
3
222
1
4
Stand model
5
6
159
160
7
157
8
9
ti16115b
158
28 332882A
Gearbox Sleeve Bearing Replacement
1 2
3
ti16059a
Suction Assemblies
Parts
Ref. Part Description Qty.
1 331061 SLEEVE BEARING 1
2 331103 WASHER 2
3 331197 SCREW 2
NOTE: When replacing item (1), cover outside of
sleeve with 6 drops of Loctite 246 prior to inserting into
cover assembly.
Stand Chassis
1
4
6
2
5
ti22330a
Hi-Boy Chassis (331284)
2
3
1
4
5
ti16061a
Ref. Part Description Qty.
1 331290 SUCTION HOSE ASSEMBLY 1
2 187651 INLET STRAINER 1
4* HOSE, 1/4 ID X 3/8 OD 40”
5* 244035 DEFLECTOR, BARBED 1
6* 114287 FITING, BARBED 1
Ref. Part Description Qty.
1 301348 BYPASS HOSE ASSEMBLY 1
2 331034 SUCTION NUT 1
3 331292 SUCTION SEAT ASSEMBLY 1
4 331400 INLET TUBE 1
5 187190 INLET STRAINER 1
* Sold in Kit 301349
332882A 29
Parts
r
Electrical System
120V
Power Plug
On/Off
Switch
Black
White
230V
7
1
1
Green
(Ground)
Pressure Control
Power Plug
Green
(Ground)
Brown
Blue
To Motor
Red
Board Kit 868018
ti22336a
3
On/Off
Switch
Black
Red
To Moto
White
7
Pressure Control
Ref. Part Description Qty. Ref. Part Description Qty.
1 POWER CORD 3 301083 POWER SWITCH 1
331163 120V models 1 7 868017 PRESSURE CONTROL 1
867427 Models 868056, 868060 1
301101 Models 868054, 868055,
868057, 868058
30 332882A
1
Board Kit 868019
ti22337a
Technical Data
Technical Data
MP400/300, Mustang 4800
US Metric
Sprayer
Power Requirements 120V AC, 60 hz, 10.5A, 1 phase
230V AC, 50/60 hz, 5A, 1 phase (MP400)
230V AC, 50/60 hz, 4A, 1 phase (MP300)
Generator required 3000w minimum
Maximum working pressure 3000 psi 20.7 MPa, 207 bar
Cycles per gallon (liter)*
120V Models/MP300 741 195
MP400 220V-240V models 599 158
Maximum delivery
MP400/ Mustang 4800 0.53 gpm 2.0 lpm
MP300 0.46 gpm 1.75 lpm
Maximum tip size
MP400/ Mustang 4800 0.021
MP300 0.019
Fluid outlet npsm 1/4 inch
Wetted parts zinc and nickel-plated carbon steel, nylon, stainless steel, PTFE, acetal,
leather, UHMWPE, aluminum, tungsten carbide
Dimensions
Stand
Length 15.5 in. 39.4 cm
Width 10.5 in. 26.7 cm
Height 14.9 in. 37.8 cm
Weight 42.1 lb. 19.1 kg
Hi-Boy
Length 20.7 in. 52.6 cm
Width 20.0 in. 50.8 cm
Height 33.8 in. 85.8 cm
Weight 57.8 lb 26.2 kg
Noise (dBa)
Sound power 88 dBa
Sound pressure 82 dBa
Notes
* Startup pressures and displacement per cycle may vary based on suction condition, discharge head, air pressure, and fluid
type.
Sound pressure measured at 3.3 feet (1 meter) from equipment.
Sound Power measured per ISO-3744.
332882A 31
Airlessco Standard Warranty
Airlessco Standard Warranty
Airlessco warrants all equipment referenced in this document which is manufactured by Airlessco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Airlessco, Airlessco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined
by Airlessco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Airlessco’s
written recommendations.
This warranty does not cover, and Airlessco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Airlessco component parts. Nor shall Airlessco be liable for malfunction, damage or wear caused by the incompatibility of Airlessco
equipment with structures, accessories, equipment or materials not supplied by Airlessco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Airlessco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Airlessco distributor for verification
of the claimed defect. If the claimed defect is verified, Airlessco will repair or replace free of charge any defective parts. The equipment will be
returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship,
repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Airlessco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
AIRLESSCO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY Airlessco. These items sold, but not manufactured by Airlessco (such as electric motors, switches, hose, etc.), are subject
to the warranty, if any, of their manufacturer. Airlessco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Airlessco be liable for indirect, incidental, special or consequential damages resulting from Airlessco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of
warranty, the negligence of Airlessco, or otherwise.
FOR AIRLESSCO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées
TO Place An Order Or For Service, contact your Airlessco distributor,
or call 1-800-223-8212 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publica
Airlessco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332882A
AIRLESSCO • 3501 N. 4TH AVENUE • SIOUX FALLS, SD 57104 • USA
Copyright 2013, Airlessco. All Airlessco Manufacturing locations are registered to ISO 9001.
Revision A - December 2013
tion.
32 332882A
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