The Graco Ultra 500 Airless Paint Sprayer is a professional electric airless unit built for contractors who need consistent spray pressure, long operating life, and reliable mechanical performance. With a maximum working pressure of 2750 PSI, this sprayer was designed for residential repainting, maintenance crews, and light commercial work where durability matters more than entry-level convenience.
Unlike small homeowner sprayers, the Ultra 500 uses a DC motor and displacement pump system designed to maintain stable pressure under real jobsite conditions. This guide explains how the sprayer works, where it performs best, how to operate it safely, and how to maintain it for years of dependable service.
How the Graco Ultra 500 System Works
The Ultra 500 operates using a DC motor-driven piston pump. The motor speed adjusts based on pressure demand, ensuring steady output even when spraying at different tip sizes or hose lengths.
- DC Motor Drive: Maintains torque under load and handles voltage variation better than many AC systems.
- Displacement Pump: Balanced delivery on up and down strokes for smoother atomization.
- Pressure Control Assembly: Electronically regulates output for consistent spray patterns.
- Fluid Filtration System: Protects the spray tip from debris and reduces clogging.
- RAC Tip Guard: Allows quick tip reversal for clearing blockages without disassembly.
Best Applications for the Ultra 500
This sprayer is best matched to medium-duty contractor workloads. It bridges the gap between compact contractor units and large production sprayers.
- Interior residential repainting
- Exterior trim, siding, and fences
- Property maintenance and facility repainting
- Light commercial painting
- Latex paints and primers
It is not intended for very heavy elastomerics or continuous large-scale industrial coatings, which require higher output models.
Safe Startup Procedure
- Fill wet cup 1/3 full with Throat Seal Liquid (TSL).
- Attach grounded spray hose and gun.
- Plug into grounded 120V outlet.
- Set pressure control to minimum.
- Prime pump using suction tube in paint.
- Trigger gun into waste pail to purge air.
- Install tip guard and tip.
- Increase pressure gradually.
Daily Maintenance Tasks
- Keep wet cup filled with TSL to lubricate packings.
- Clean fluid filter after each use.
- Flush system thoroughly at end of day.
- Check hoses for wear and leaks.
- Lubricate drive housing every 100 hours.
Long-Term Maintenance & Service
Regular service prevents pump failure and extends equipment life.
- Replace pump packings when leakage begins.
- Inspect motor brushes periodically.
- Clean cooling fan and motor vents.
- Store with mineral spirits or pump protector.
Troubleshooting Common Issues
| Issue | Possible Cause | Fix |
|---|---|---|
| Motor won’t run | No power or pressure set too low | Check outlet, increase pressure |
| Low spray pressure | Worn tip or clogged filter | Replace tip, clean filter |
| Pressure surge | Air in system | Re-prime pump |
| Pump leakage | Worn packings | Install repair kit |
Replacement Parts Support
Keeping the Ultra 500 in peak condition requires quality components.
Cost of Ownership Considerations
Proper maintenance reduces downtime, extends pump life, and lowers total ownership cost. Contractors who flush daily and keep packings lubricated typically double pump lifespan compared to poorly maintained units.
Final Thoughts
The Graco Ultra 500 remains a reliable professional sprayer for contractors needing consistent results. With proper care and the right workload match, it delivers years of dependable service and excellent finish quality.
