Graco 395/490/495/595 manual

334530A EN Operation, Parts Electric Airless Sprayers For professional use only. Not approved for use in explosive atmosphere s or hazardous locations. For portable airless spray ing of architectural paints and coat ings. 395/490/495/595 Mo dels: 3300 psi (228 bar, 22.8 MPa) Maximum Wo rking Pressure See page 3 for additional model info rmation. Im[...]

Contents 2 334530A Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Ident ification . . . . . . . . . . . . . . [...]

Models 334530A 3 Models VAC Model Stand Lo-Boy Hi-Boy 120 USA Ultra MAX II 490 PC Pro 17C327 17C 328 17C332 Ultimate MX II 490 PC Pro 826199 826200 826201 Ultra MAX II 495 PC Pro 17C333 17C 334 17C335 Ultimate MX II 495 PC Pro 826202 826203 826204 Ultra MAX II 595 PC Pro 17C336 17C 337 Ultimate MX II 595 PC Pro 826205 826206 120 Japan/Taiwan Ultra [...]

Warnings 4 334530A Warnings The following warnings are for the setup, us e, groundin g, maintenance, an d repair of this equipment. The exclamation point symbol alerts you to a general warning a nd the hazard symbols refer to procedure-specifi c risks. W hen these symbols appea r in the body of this manual or on wa rning labels, refe r back to thes[...]

Warnings 334530A 5 W ARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fume s, in work area can ignite or explode. To help prevent fire and explosion: • Do not spray flammable or combustible mat erials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipmen t. • Paint or solvent fl[...]

Warnings 6 334530A W ARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Always wear appropriate gloves, eye protecti o n, and a respirator or mask when painting. • Do not operate or spray near children. Keep children away fr om equipment at all times. • Do not overreach or stand on an unstable s upport. Keep effective [...]

Warnings 334530A 7 W ARNING PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in t he work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: • Protective eyewear, and hearing protection. • Respirators, pr[...]

Component Identification 8 334530A Component Identification Stand Models W U K S M N V P R A B D ti24942a J G F L H F A ON/OFF Switch B Pressure Control D Prime Valve F Tip Guard G Spray Tip HG u n J Airless Hose K Power Cord L Trigger Lock M Drain Tube N F luid Intake PP u m p R F luid Outlet S Power Cord Wrap UF i l t e r V Finger Guard / TSL Fil[...]

Component Identification 334530A 9 Lo-Boy Models D U K M N V P R B ti24943a J G F L H F A W A ON/OFF Switch B Pressure Control D Prime Valve F Tip Guard G Spray Tip HG u n J Airless Hose K Power Cord L Trigger Lock M Drain Tube N F luid Intake PP u m p R F luid Outlet UF i l t e r V Finger Guard / TSL Fil l Point W Display Model/Serial Tag (N ot sh[...]

Component Identification 10 334530A Hi-Boy Models K M N U T T S V P B ti24944a J G F L H F A D R W[...]

Component Identification 334530A 11 Hi-Boy Models A ON/OFF Switch B Pressure Control D Prime Valve F Tip Guard G Spray Tip HG u n J Airless Hose K Power Cord L Trigger Lock M Drain Tube N F luid Intake PP u m p R F luid Outlet S Hanger TF i l t e r U Finger Guard / TSL Fill Point V Pail Hook W Display Model/Serial Tag (N ot shown, located on bottom[...]

Grounding 12 334530A Grounding This sprayer includes a ground wi re with an appropriate ground contact. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installe d by a qualified el[...]

Pressure Relief Procedure 334530A 13 Pressure Relief Procedure Follow the Pr essure Relief Procedure when ever you see this symbol. 1. Turn ON/OFF switch to OFF position. Wait 7 seconds for power to dissipate. 2. Engage trigger lock. 3. Remove tip guard. 4. Turn pressure control to lowest setting. Disengage trigger lock. This equipment stays pressu[...]

Pressure Relief Procedure 14 334530A 5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. 6. Engage trigger lock. 7. Put drain tube in pail. Turn prime valve down. Leave prime valve in down (drain) position until you are ready to spray again. 8. If you suspect the spray tip or hose is clogged or that[...]

Setup 334530A 15 Setup When unpacking sprayer for th e first time or after long term storage p erform setup procedure. When first setup is perfo rmed remove shipping plug from fluid outlet. 1. Connect Graco airless ho se to fluid outlet. Use wrenches to tighten se curely. 2. Connect other end of hose to gun. 3. Use wrenches to tighten securely. 4. [...]

Setup 16 334530A 5. Remove tip guard. 6. When unpacking sprayer for the first time remove p ackaging materials from inlet strainer. After long term storage check inlet strainer for clogs and debris. 7. Fill throat packing nut with T SL to prevent premature pa cking wear. Do this daily or each ti me you spray. a. Place the TSL bo ttle nozzle into th[...]

Setup 334530A 17 8. Make certain ON/OFF switch is OFF . 9. Plug power suppl y cord into a p roperly grounded electrical outle t. 10. Turn prime valve dow n. 11. Place fluid intake with drain tube in grounded metal pail partially filled with flushing fluid. See Grounding , page 12. 12. Turn pressure control to OFF. 13. Turn ON/OFF switch to ON posit[...]

Setup 18 334530A 22. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun and flush until clean. 23. Turn ON/OFF switch to OFF position. 24. Engage trigger lock. 25. Sprayer is now ready to startup and spray.[...]

Startup 334530A 19 Startup 1. Perform Pressure Relief Procedure , page 13. 2. Turn pressure control to lowest pressure. 3. Turn ON/OFF switch to ON position. 4. Place fluid intake in paint pail. Place drain tube in waste pail. 5. Turn pressure control to Fast Flush to start motor. Allow paint to circu late through drain tube for 15 seconds. 6. Turn[...]

Startup 20 334530A 8. Move gun to paint pail and trigger for 20 seconds. Release trigger and allow sprayer to build p ressure. Engage trigger lock. 9. Inspect for leaks. If leaks o ccur, perform Pressure Relief Procedur e , page 13, then tighten all fittings and repeat Startup procedure . If there are no leak s continue with the next step. 10. Scre[...]

Operation 334530A 21 Operation Spray Tip Installation 1. Pe rform Pressure Relief Procedure , page 13. 2. Use spray tip (A) to insert OneSeal ™ (B) into tip guard (C). 2. Insert Spray Tip. 3. Screw assembly onto gun. Tighten. Spray 1. Spray test pattern. Adjust pressure to eliminate heavy edges. ti24653a C B A ti24664a ti24652a ti24669a[...]

Operation 22 334530A 2. Use smaller tip size if pressure adjustment cannot e liminate heavy edges. 3. Hold gun perpendicular, 10-12 in. (25-30 cm) from surface. Spray back and forth; overlap by 50%. 4. Trigger gun after moving. Release trigger before stopping. For ad ditional spraying information, see sep arate gun manual. Clear Tip Clog 1. Release[...]

Operation 334530A 23 Digital Display Most models are equipped with a digita l display. This section explains how to use this feature. Pressure Display 1. Pe rform Pressure Relief Procedure , page 13. 2. Plug sprayer into grounded o utlet. Turn ON/OFF switch to ON position. 3. The pressure is displayed. Dashes indicate pr essure is less than 200 psi[...]

Operation 24 334530A 2. To enter Stored Data Mode, press and hold display button and turn ON/OFF switch to ON position. 3. Sprayer model number is displayed followed by Data Point 1 w hich is the unit power on time in hours. 4. Press display bu tton again to display Data Point 2. Motor run time in hours is displayed. 5. Press display button again t[...]

Operation 334530A 25 Cleanup 1. Perform Pressure Relief Procedure , page 13. 2. Remove tip guard and Spray Tip. For additional information, se e separate gun manual. Fast Flush Drain Tube 3. Remove fluid intake and drain tube from paint, wipe excess paint off outside. 4. Place fluid intake in flushing fluid. Use water for water base paint and miner[...]

Operation 26 334530A 5. To flush drain tube and pump turn prime valve down. 6. Turn pressure control to Fast Flush operate until the pump runs steady and flushing fluid appears in the waste pai l. Fast Flush Hose and Gun 7. To flush airless hose and spray gun, turn prime valve horizontal. 8. Hold gun against waste pail. Disenga ge trigger lock. Tri[...]

Operation 334530A 27 11. With prime valve horizontal. Trig ger gun into flushing pail to purge fluid from hose. 12. Engage trigger lock. 13. Turn pressure control knob to OF F and turn ON/OFF switch to OFF position. Disconnect power to sprayer. 14. Remove filter from gun and sprayer if installed. Clean and i nspect. Install filter. See separate gun[...]

Maintenance 28 334530A Maintenance Routine maintenance is important to ensure prop er operat ion of your sprayer. Maintenance includes performing ro utine actions wh ich keep your sprayer in operati on and prevents troubl e in the future. Activity Interval Inspect/clean sprayer filter, fluid inlet straine r, and gun filter. Daily or each time you s[...]

Troubleshooting 334530A 29 Troubleshooting Mechanical/Fluid Flow 1. Follow Pressure Relief Procedure , page 13, before checkin g or repairing. 2. Check all possible pro blems and causes before disassembling the unit. Problem What to Check If check is OK, go to next check What to Do When check is not OK, refer to this column For units with display: [...]

Troubleshooting 30 334530A Pump output is low Pump rod damag e. R epair pump. See pu mp manual. Low stall pressure. Turn pressu re knob fully clockwise. Make sure pr essure control knob is properly install ed to allow full clockwise position. If problem persists, re place pressure tran sducer. Piston packi ngs are worn or damaged. Replace packings.[...]

Troubleshooting 334530A 31 Fluid is spitting fr om gun Air in pump or hose. Check an d tighten all flu id connections. Cycle pump as slowly as possible during primin g. Spray tip is partial ly clogged. Clear tip. See Clear Tip Clog , page 22. Fluid supply is low or empty. Re fill fluid supply. Prime pump. See pump manual. Ch eck fluid supply often [...]

Troubleshooting 32 334530A Electrical Symptom: Sprayer does not run, stops running, or will not shut off. Perform Pressure Relief Procedure , page 13. 1. Plug sprayer in to correct voltage, grounded outlet. 2. Turn the ON/OFF switch OFF wait 30 seconds and then turn power back ON again (this ensures sprayer is in normal run mode). 3. Turn pressure [...]

Troubleshooting 334530A 33 Problem What to Check How to check Sprayer does not r un at all AND Display is blank OR Control board stat us light never lights See flow chart, page 38. Sprayer does no t shut off AND Displays Code 02 message OR Control board stat us light blinks 2 times repeated ly Control board. Replace control bo ard. Sprayer does not[...]

Troubleshooting 34 334530A Sprayer does not r un at all AND Displays Code 03 message OR Control board stat us light blinks 3 times repeated ly Check transduce r or transducer connections (contr ol board is not detecting a pressu re signal). Turn ON/OFF switch OFF and disconnect power to sprayer. Check transduce r and connection s to control board. [...]

Troubleshooting 334530A 35 5.Perfor m Spin Test: Te st at large 4-pin motor f ield connector . Disconnect fluid p ump from sprayer. Test motor by placin g a jumper ac ross pins 1 & 2. Rotate motor fan at about 2 revolution s per second. A cogging r es is ta nc e t o motion should b e felt at the fan. The motor sho uld be replaced if no resistan[...]

Troubleshooting 36 334530A 6.Perform Field Short Test: Te st at large 4-pin mot or field connector . There should not be cont inuity from pin 4, the grou nd wire, and any of the remaining 3 pins. If motor field connector tests f ail, replace mo tor. 7.Check Motor Thermal Switch: Unplug thermal wires . Set meter to ohms. Meter sh ould read 100k ohms[...]

Troubleshooting 334530A 37 Sprayer does not r un at all AND Displays Code 06 message OR Control board stat us light blinks 6 times repeated ly Motor is hot or there is a fault in the motor thermal device. Allow sprayer to cool. If sprayer runs when cool, correct cause of overheating. Keep sprayer in cooler location with goo d ventilation. Ma ke sur[...]

Troubleshooting 38 334530A Sprayer Will Not Run (See following page for steps) Remov e Control box co ver . T ur n spra yer ON. Observe control board status light on control board (see page 27). No Light Once Light on continuously Flashing Normal Operation Control board Commanding motor to run See Step 1. Do you hav e over 100 V AC (220 V AC f or 2[...]

Troubleshooting 334530A 39 Step 1: Plug P ower cord in a nd turn switch ON. Connect probes to ontrol bo a rd. T urn meter to A C V olts. 110-120 AC V - Po w e r Cord Blue Brown Green On/Off Switch 110-120 AC V - Po w e r Cord Bl a ck Blue Green - + Y ellow Thermistor Wires to motor - Step 3: Check motor therm a l switch. Unplug yello w wires. Meter[...]

Troubleshooting 40 334530A Sprayer Will Not Shut Off 1. Perform Pressure Relief Procedure , page 13. Leave prime valve open (down) and turn ON/OF F switch OFF . 2. Remove control box cover so the control board status light can be viewed if available. Troubleshooting Procedure T r oubleshooting Procedure Plumb pressure gauge into paint hose, plug sp[...]

395/490/495 Stand Sprayers 334530A 41 395/490/495 Stand Sprayers 1 2 59 67 54 54b 54a 47 47 23 12 71 68 53 63 65 ti24994a Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) 1 2 1 2 See page 51.[...]

395/490/495 Stand Sprayers 42 334530A 40 44 25 42 47 69 66 43 41 22 52 12 70 13 60 14 57 62 55 39 45 132 ti24993a 1 4 2 3 Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) Hammer tight 25-30 ft-lb (33.9 - 40.7 N•m) 1 2 3 4[...]

395/490/495 Stand Sprayers 334530A 43 395/490/495 Stand Sprayers Parts List Ref. Part Description Qty. 12 117501 SCREW, mach, hex washer hd 4 13 115099 WASHER, hose 1 14 117559 O-ring 2 22 17C541 COVER, front, painted 1 23 15G449 SHIELD, motor, painted 1 25 180131 BEARIN G, thrust 1 33 206994 FLUID, TSL (not shown) 1 34  See page 50 CARD, medica[...]

395/490/495/595 Lo-Boy Sprayers 44 334530A 395/490/495/595 Lo-Boy Sprayers 59 54 47 23 12 71 74 66 6 8 69 150 8 3 53 54 a 54b ti24996 a 8 2 63 65 See page 51. 2 1 Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) 1 2[...]

395/490/495/595 Lo-Boy Sprayers 334530A 45 45 43 41 132 13 60 60 14 57 55 39 62 40 25 44 47 42 22 52 12 70 11 7 ti24995a 1 2 3 4 Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) Hammer tight 25-30 ft-lb (33.9 - 40.7 N•m) 1 2 3 4[...]

395/490/495/595 Lo-Boy Sprayers 46 334530A 395/490/495/595 Lo-Boy Sprayers Parts List Ref. Part Description Qty. 12 117501 SCREW, mach, hex washer hd 4 13 115099 WASHER, hose 1 14 117559 O-ring 2 22 17C541 COVER, front, painted 1 23 15G449 SHIELD, motor, painted 1 25 180131 BEARING, thrust 1 33 206994 FLUID, TSL (not shown) 1 34  See page 50 CAR[...]

395/490/495/595 Hi-Boy Sprayers 334530A 47 395/490/495/595 Hi-Boy Sprayers 54 54a 54b 23 63 65 12 74 59 11 5 11 4 11 6 47 75 81 82 83 67 ti24998a 53 1 2 3 See page 51. Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) 23-27 in-lb (2.6 - 3.1 N•m) 1 2 3[...]

395/490/495/595 Hi-Boy Sprayers 48 334530A 43 41 132 45 13 55 39 87 60 57 14 84 69 62 ti24997a 40 44 42 11 7 25 47 22 52 12 70 105 107 2 3 1 4 Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) Hammer tight 25-30 ft-lb (33.8 - 40.6 N•m) 1 2 3 4[...]

395/490/495/595 Hi-Boy Sprayers 334530A 49 395/490/495/595 Hi-Boy Sprayers Parts List Ref. Part Description Qty. 12 117501 SCREW, mach, hex washer hd 4 13 115099 WASHER, hose 1 14 103413 O-ring 1 22 17C541 COVER, front, painted 1 23 15G449 SHIELD, motor, painted 1 25 180131 BEARIN G, thrust 1 33 206994 FLUID, TSL (not shown) 1 34  See page 50 CA[...]

Accessories and Labels 50 334530A Accessories and Labels Sprayer Model Ref. 34 Card, Medical Alert  Ref. 46 Hose, 1/4 in. x 50 ft Ref. 52 Label, Front, Upper/ Lower Ref. 53 Label, Side Ref. 61 Gun, Spray Ref. 63 Label, Danger  Ref. 65 Label, Warning  826199 826200 826201 222385 # 82 6079 17C8 30/ 17C831 17C832 826085 15H08 5 # 195793 &[...]

Control Box 334530A 51 Control Box 15 24 10 8 24 30 3 92 91 90 27 36 106 107 51 50 11 37 129 17 2 1 8 12 113 47 4 8 49 5 8 19 20 3 8 6 12 8 7 37 127 56 56 47 4 16 35 5 26 ti24999 a 8 6 5 1 2 7 Ref. Torque 140-160 in-lb (15.8 - 18.1 N•m) 30-35 in-lb (3.4 - 4.0 N•m) 20-25 in-lb (2.3 - 2.8 N•m) 37-43 ft-lb (50.2 - 58.3 N•m) 130-150 in-lb (14.7[...]

Control Box 52 334530A Control Box Parts List Ref. Part Description Qty. 2 117828 PACKING, o-ring 1 3 111457 PACKING, o-ring 1 4 111600 PIN, grooved 1 5 277364 GASKET, seat, valve 1 6 120405 SCREW , mach, Phillips, pan hd 5 7 SCREW, slot, hex, wash hd 1 115498 230V and UK models 123850 120V US/Japan models 11 116167 KNOB, potentiometer 1 12 117501 [...]

Control Box 334530A 53 287121 Italy, Denmark, Sweden 92 244285 ADPTER, Japan 1 106 15G861 LABEL, s mart control display 1 107 15G588 LABEL, digital tracking system 1 108 115523 GAUGE, pressure, fluid (on select models) 1 127 120165 SCREW, mach, Phillips, pan hd 1 128 120406 SCREW, mach, hex washer hd 1 129 158674 O-RING, packing 1 KIT, ProGuard+, 2[...]

Wiring Diagrams 54 334530A Wiring Diagrams 120V, US/Japan M OTO R ti73 8 0b On/O Switch Black Green To P o w e r Plug Pot entiometer Pressur e T ransducer J12 J11[...]

Wiring Diagrams 334530A 55 110V, UK / 230V NOTICE Heat from inductor coi l of filter board may destroy wire insula tion that co mes in contact with it. Exposed wires could cause shorts and comp onent damage. Bundle and tie loose w ires so none la y in contact with inductor coil on the filter board. M OTO R ti7454b On/O Switch Blue Black Blue Gre[...]

Technical Specifications 56 334530A Technical Specifications 395/490/495/595 US Metric Sprayer Maximum fluid working pressure 3300 psi 228 bar, 22.8 MPa Maximum Delivery 395/490 0.54 gpm 2.0 lpm 495 0.60 gpm 2.3 lpm 595 0.68 gpm 2.6 lpm Maximum Tip Size 395/490 0.023 0.023 495 0.025 0.025 595 0.027 0.027 Fluid Outlet npsm 1/4 in. 6.3 mm Cycles 395/[...]

Technical Specifications 334530A 57 Weight Stand 395 45.1 lb. 20.5 kg 490 / 495 34 lb. 15 kg Lo-Boy 395 63 lb. 29 kg 490 / 495 59.1 lb. 26.8 kg 595 70 lb. 31.8 kg Hi-Boy 395 66 lb. 30 kg 490 / 495 66.1 lb. 30 kg 595 73 lb. 33 kg Noise** (dBa) @ 70 psi (0 .48 MPa, 4 .8 bar) Sound pressure 90 dBa Sound power 100 dBa Materials of Construction Wetted m[...]

Graco Standard Warranty 58 334530A Graco Standard Warranty Graco warrants all equipment referenced in this docu men t which is manufactured by Graco and bearing its name to be free from defects in mater ial and work manship on the date of sale to the original pur chaser for use. With the exception of any special, extended, or limited warranty publi[...]

All written and visual data containe d in this document reflects the latest p roduc t information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 334530 Graco Headquarters: Minneapoli s International Offices: Belgium, China, Japan, Kor[...]