Graco 334530D Operation And Parts Manual

334530D

EN

Operation, Parts

Electric Airless
Sprayers

For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
For portable airless spraying of architectural paints and coat ings.

490/495/595/395EU Models:

3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure

See page 3 for additional model information.

Important Safety Instructions

Read all warnings and instructions in this manual and relate d manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.

Related Manuals

Gun – 311861 (Contractor/FTx) 312830 (SG3) Pump – 334599

ti24941a

Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.

Contents

2 334530D

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Stand Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lo-Boy Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hi-Boy Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Spray Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Clear Tip Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

490/495/395EU Stand Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

490/495/395EU Stand Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

490/495/595 Lo-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

490/495/595 Lo-Boy Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

490/495/595/395EU Hi-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

490/495/595/395EU Hi-Boy Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Accessories and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Control Box Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

110/120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Models

334530D 3

Models

VAC Model

Stand

Lo-Boy

Hi-Boy

120

USA

Ultra MAX II

490 PC Pro

17C327 17C328 17C332

Ultimate MX II

490 PC Pro

826199 826200 826201

Ultra MAX II

495 PC Pro

17C333 17C334 17C335

Ultimate MX II

495 PC Pro

826202 826203 826204

Ultra MAX II

595 PC Pro

17C336 17C337

Ultimate MX II

595 PC Pro

826205 826206

100

Japan/Taiwan

Ultra MAX II

490 PC Pro

17C393

Ultra MAX II

495 PC Pro

17C399

230

CEE 7/7

ST MAX II 395 PC Pro 17C369 17C372
ST MAX II 495 PC Pro 17C373 17C376
ST MAX II 595 PC Pro 17C381

230 Europe

Multi

ST MAX II 495 PC Pro 17C374 17C377
ST MAX II 595 PC Pro 17C382

110

UK

ST MAX II 495 PC Pro 17C375 17C378
ST MAX II 595 PC Pro 17C383

230

Asia/ANZ

Ultra MAX II

490 PC Pro

17C395

Ultra MAX II

495 PC Pro

17C398 17C401 17C402

Ultra MAX II

595 PC Pro

17C404 17C403

230

China

Ultra MAX II 490 PC 17C394

110474

Certified to

CAN/CSA

C22.2 No. 68

Conforms to

UL 1450

Warnings

4 334530D

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 on 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 manua l
where applicable.

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 below.

• Only connect the product to an outlet having the same configuration as the plug.

• Do not use an adapter with this product.

Extension Cords:

•

Use only a 3-wire extension cord that has a 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 (2.5mm

2

) 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.

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120V US 230V

230V ANZ

Warnings

334530D 5

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.

• Do not spray flammable or combustible liquids in a confined area.

• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area.

• Sprayer generates sparks. Keep pump assembly in a well ventilated area at least 20 feet

(6.1 m) from the spray area when spraying, flushing, cleaning, or servicing. Do not spray
pump assembly.

• Do not smoke in the spray area or spray where sparks or flame is present.

• 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.

Warnings

6 334530D

SKIN INJECTION HAZ ARD

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 Graco nozzle tips.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs

while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving
the pressure before removing the nozzle tip to clean.

• Equipment maintains pressure after power is shut off. Do not leave the equipment

energized or under pressure while unattended. Follow the Pressure Relief Procedure

when the equipment is unattended or not in use, and before servicing, cleaning, or
removing parts.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3300 psi. Use Graco replacement parts or accessories

that are rated a minimum of 3300 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 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.

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.

• Connect only to 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.

• Wait five minutes after disconnecting power codr before servicing large capacitor units.

Warnings

334530D 7

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.

• Do not use chlorine bleach.

• Many other fluids may contain chemicals that can react with aluminum. Contact your

material supplier for compatibility.

MOVING PARTS HAZARD

Moving parts can pinch, cut, or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing

equipment, follow the Pressure Relief Procedure 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

Wear appropriate protective equipment when in the 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, 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.

Component Identification

8 334530D

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
HGun

J Airless Hose
K Power Cord

L Trigger Lock
M Drain Tube

N Fluid Intake
PPump
R Fluid Outlet
S Power Cord Wrap
UFilter
V Finger Guard / TSL Fill Point

W Display

Model/Serial Tag (Not shown, located
on bottom of unit.)

Component Identification

334530D 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
HGun

J Airless Hose
K Power Cord

L Trigger Lock

M Drain Tube

N Fluid Intake
PPump
R Fluid Outlet
UFilter
V Finger Guard / TSL Fill Point

W Display

Model/Serial Tag (Not shown, located
on bottom of unit.)

Component Identification

10 334530D

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

334530D 11

Hi-Boy Models

A ON/OFF Switch
B Pressure Control
D Prime Valve

F Tip Guard
G Spray Tip
HGun

J Airless Hose
K Power Cord

L Trigger Lock
M Drain Tube
N Flu id Intake
PPump

R Fluid Outlet
S Hanger

TFilter
U Finger Guard / TSL Fill Point
V Pail Hook

W Display

Model/Serial Tag (Not shown, located
on bottom of unit.)

Grounding

12 334530D

Grounding

This sprayer includes a ground wire 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 installed
by a qualified electrician.

Power Requirements

• 100-120V units require 100-120 VAC,

50/60 Hz, 12 or 15A, 1 phase.

• 230V units require 230 VAC, 50/60 HZ, 7

or 9A, 1 phase.

Extension Cords

Use an extension cord with an undamaged
ground contact. If an extension cord is
necessary, use a 3-wire, 12 AWG (2.5 mm2)
minimum.

NOTE: Smaller gauge or longer extension
cords may reduce sprayer performance.

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 non-conductive surface
such as paper or cardboard which interrupts
grounding continuity.

Always ground a metal pail: connect a
ground wire to the pail. Clamp one end to the
pail and the other end to a true earth ground
such as a water pipe.

To maintain ground continuity when
sprayer is flushed or pressure is relieved:

hold metal part of spray gun firmly to the side
of a grounded metal pail then trigger the gun.

The equipment must be grounded to
reduce the risk of static sparking and
electric shock. An electric or static spark
can cause fumes to ignite or explode. An
improper ground can cause electric shock.
A good ground provides an escape wire for
the electric current.

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Pressure Relief Procedure

334530D 13

Pressure Relief Procedure

Follow the Pressure Relief
Procedure whenever you see this
symbol.

1. Turn ON/OFF switch to the OFF
position. Wait 7 seconds for power to
dissipate.

2. Engage the trigger lock.

3. Turn pressure control to the lowest
setting. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a
grounded metal pail. Trigger the gun to
relieve pressure.

5. Engage the trigger lock.

This equipment stays pressurized until
pressure is manually relieved. To help
prevent serious injury from pressurized
fluid, such as skin injection, splashed fluid
and moving parts, follow the Pressure
Relief Procedure whenever sprayer is
stopped and before sprayer is cleaned or
checked, and before equipment is
serviced.

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ti24931a

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Pressure Relief Procedure

14 334530D

6. Turn the prime valve down. Put drain
tube in a pail. Leave prime valve in the
down (drain) position until you are ready
to spray again.

7. If you suspect the spray tip or hose is
clogged or that pressure has not been
fully relieved:

a. VERY SLOWLY loosen the tip

guard retaining nut or the hose end
coupling to relieve pressure
gradually.

b. Loosen the nut or coupling

completely.

c. Clear hose or tip obstruction.

Trigger Lock

Always engage the trigger lock when sprayer
is stopped to prevent the gun from being
triggered accidentally b y hand or if dropped
or bumped.

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Setup

334530D 15

Setup

When unpacking sprayer for the first time or
after long term storage perform setup
procedure. When first setup is performed
remove shipping plug from fluid outlet.

1. Connect Graco airless hose to fluid
outlet. Use wrenches to tighten securely.

2. Connect other end of hose to gun.

3. Use wrenches to tighten securely.

4. Engage trigger lock.

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Setup

16 334530D

5. Remove tip guard.

6. When unpacking sprayer for the first
time remove packaging materials from
inlet strainer. After long term storage
check inlet strainer for clogs and debris.

7. Fill throat packing nut with TSL to
prevent premature packing wear. Do this
daily or each time you spray.

a. Place the TSL bottle nozzle into the

top center opening in the grill at the
front of the sprayer.

b. Squeeze bottle to dispense enough

TSL to fill the space between the
pump rod and packing nut seal.

8. Make certain ON/OFF switch is OFF.

9. Plug power supply cord into a properly
grounded electrical outlet.

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Setup

334530D 17

10. Turn prime valve down.

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 position.

14. Turn prime valve horizontal. Disengage
trigger lock.

15. Turn pressure control to Prime/Slow.

16. Hold a metal part of the gun firmly to a
grounded metal pail. Trigger gun and
flush for one minute.

17. Turn ON/OFF switch to OFF position.

18. Engage trigger lock.

19. After flushing storage fluid out of the
sprayer empty pail. Replace fluid intake
with drain tube in grounded metal pail
partially filled with flushing fluid. Use
water to flush water-based paint or
mineral spirits to flush oil-based paint.

20. Turn ON/OFF switch to ON position.

21. Turn prime valve horizontal. Disengage
trigger lock.

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.

NOTE: New sprayers are shipped with
storage fluid that must be flushed out with
mineral spirits prior to using the sprayer.

Check flushing fluid for compatibility with
material that is to be sprayed. A secondary
flush with a compatible fluid may be
necessary. Water for latex paint or mineral
spirits for oil-based paint.

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Startup

18 334530D

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 circulate
through drain tube for 15 seconds.

6. Turn prime valve horizontal. Disengage
trigger lock.

7. Hold gun against grounded metal waste
pail. Trigger gun until paint appears.

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15 s

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1 m

Startup

334530D 19

8. Move gun to paint pail and trigger for 20
seconds. Release trigger and allow
sprayer to build pressure. Engage
trigger lock.

9. Inspect for leaks. If leaks occur, perform
Pressure Relief Procedure, page 13,
then tighten all fittings and repeat
Startup procedure. If there are no leaks
continue with the next step.

10. Screw tip assembly onto gun and
tighten. See Spray Tip Installation,
page 20. For gun assembly instructions,
see separate gun manual.

ti24649a

20 s

High-pressure spray is able to inject toxins
into the body and cause serious bodily
injury. Do not stop leaks with hand or rag.

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Operation

20 334530D

Operation

Spray Tip Installation

1. Perform 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.

2. Use smaller tip size if pressure
adjustment cannot eliminate heavy
edges.

3. Hold gun perpendicular, 10-12 in. (25-30
cm) from surface. Spray back and forth;
overlap by 50%.

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C

B

A

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Operation

334530D 21

4. Trigger gun after moving. Release
trigger before stopping. For additional
spraying information, see separate gun
manual.

Clear Tip Clog

1. Release trigger. Engage trigger lock.
Rotate Spray Tip. Disengage trigger
lock. Trigger gun at waste area to clear
clog.

2. Engage trigger lock. Return Spray Tip to
original position. Disengage trigger lock
and continue spraying.

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Operation

22 334530D

Digital Display

Most models are equipped with a digital
display. This section explains how to use this
feature.

Operation Main Menu

A short press of the display button moves to
the next display. Press and hold display
button for five seconds to change units or
reset data.

1. Perform Pressure Relief Procedure,
page 13.

2. Plug sprayer into grounded outlet. Turn
ON/OFF switch to ON position.

3. Pressure display appears. Dashes
appear when pressure is less than 200
psi (14 bar, 1.4 MPa).

4. Short press display button to move to
Job Gallons (or Liters x 10).

NOTE: JOB displays briefly, then the
number of gallons sprayed above 1000
psi (70 bar, 7MPa).

5. Press and hold display button to reset to
zero, or short press button to move to
Lifetime Gallons (or Liters x10).

NOTE: LIFE displays briefly, then the
number of gallons sprayed above 1000
psi (70 bar, 7MPa).

6. To change pressure units (psi, bar, or
MPa), press and hold display button for
eight seconds until desired units appear.
Selection of bar or MPa changes gallons
to Liters x10.

ti24651a

ti24644a

ti2786a

ti7486b

ti7487b

Operation

334530D 23

Stored Data Display

1. Perform Pressure Relief Procedure,
page 13.

2. Press display button and turn ON/OFF
switch to ON position.

3. S/N displays for one second, then the
serial number. Short press display
button and the total motor run hours is
displayed.

4. Short press display button and the last
error code is displayed: e.g., E=07. See
Electrical, page 31 for trouble shooting
information.

5. Press and hold display button to clear
error code to zero. Short press to move
to software REV.

6. Turn ON/OFF switch to OFF position to
exit Stored Data.

ti24644a

ti7489b

ti7490b

ti7491b

ti24586a

Operation

24 334530D

Cleanup

1. Perform Pressure Relief Procedure,
page 13.

2. Remove tip guard and Spray Tip. For
additional information, see 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 mineral
spirits for oil-based paint. Place drain
tube in waste pail.

ti24592a

ti24709a

ti24710a

Operation

334530D 25

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 pail.

Fast Flush Hose and Gun

7. To flush airless hose and spray gun, turn
prime valve horizontal.

8. Hold gun against waste pail. Disengage
trigger lock. Trigger gun and turn
pressure control to Fast Flush operate
until the pump runs steady and flushing
fluid appears.

9. Stop triggering gun.

10. Raise fluid intake above flushing fluid.

ti24713a

ti24991a

ti24714a

Operation

26 334530D

11. With prime valve horizontal. Trigger gun
into flushing pail to purge fluid from hose.

12. Engage trigger lock.

13. Turn pressure control knob to OFF and
turn ON/OFF switch to OFF position.
Disconnect power to sprayer.

14. Remove filter from gun and sprayer if
installed. Clean and inspect. Install filter.
See separate gun manual.

15. If flushing with water, flush again with
mineral spirits or Pump Armor to leave a
protective coating to prevent freezing or
corrosion.

16. Wipe sprayer, hose and gun with a rag
soaked in water or mineral spirits.

ti24649a

20 s

ti24992a

ti24718a

ti24719a

ti24720a

Maintenance

334530D 27

Maintenance

Routine maintenance is important to ensure proper operation of your sprayer. Maintenance
includes performing routine actions which keep your sprayer in operation and prevents trouble
in the future.

Activity Interval

Inspect/clean sprayer filter, fluid inlet strainer, and gun
filter.

Daily or each time you spray

Inspect motor shield vents for blockage.

Daily or each time you spray
Fill TSL by adding through TSL fill point. Daily or each time you spray
Check sprayer stall.

With sprayer gun NOT triggered, sprayer motor should stall
and not restart until gun is triggered again.

If sprayer starts again with gun NOT triggered, inspect
pump for internal/external leaks and check prime valve for
leaks.

Every 1000 gallons (3785 liters)

Throat packing adjustment
When pump packing begins to leak after extended use,

tighten packing nut down until leakage stops or lessens.
This allows approximately 100 gallons of additional
operation before a repacking is required. Packing nut can
be tightened without 0-ring removal.

As necessary based on usage

Troubleshooting

28 334530D

Troubleshooting

Mechanical/Fluid Flow

1. Follow Pressure Relief Procedure,
page 13, before checking or repairing.

2. Check all possible problems and causes
before disassembling the unit.

Problem

What to Check

If che

ck is OK, go to next

check

What to Do

When check is not OK,

refer to this column

For units with display:

E=0X is displayed.

For units with no display: Control
board status light is blinking or the
light is off and there is power to the
sprayer.

Fault condition exists. Determine fault correction from

Electrical, page 31.

Pump output is low Spray tip worn. Follow Pressure Relief Procedure,

page 13, then replace tip. See
separate gun or tip manual.

Spray tip clogged. Relieve pressure. Check and clean

spray tip.

Paint supply. Refill and reprime pump.

Intake strainer clogged. Remove and clean, then reinstall.

Intake valve ball and piston ball are
not seating properly.

Remove intake valve and clean.
Check balls and seats for nicks;
replace if necessary. See pump
manual. Strain paint before using to
remove particles that could clog
pump.

Fluid filter or tip filter is clogged or
dirty.

Clean filter.

Prime valve leaking. Follow Pressure Relief Procedure,

page 13, then repair prime valve.

Verify pump does not continue to
stroke when gun trigger is released.
(Prime valve not leaking.)

Service pump. See pump manual.

Leaking around throat packing nut
which may indicate worn or damaged
packings.

Replace packings. See pump manual.
Also check piston valve seat for
hardened paint or nicks and replace if
necessary. Tighten packing
nut/wet-cup.

Troubleshooting

334530D 29

Pump output is low Pump rod damage. Repair pump. See pump manual.

Low stall pressure. Turn pressure knob fully clockwise.

Make sure pressure control knob is
properly installed to allow full
clockwise position. If problem
persists, replace pressure transducer.

Piston packings are worn or
damaged.

Replace packings. See pump manual.

O-ring in pump is worn or damaged. Replace o-ring. See pump manual.

Intake valve ball is packed with
material.

Clean intake valve. See pump
manual.

Large pressure drop in hose with
heavy materials.

Reduce overall length of hose.

Check extension cord for correct size. See Extension Cords, page 12.

Motor runs but pump does not stroke Connecting rod assembly damaged.

See pump manual.

Replace connecting rod assembly.
See pump manual.

Gears or drive housing damaged. Inspect drive housing assembly and

gears for damage and replace if
necessary.

Excessive paint leakage into throat
packing nut

Throat packing nut is loose. Remove throat packing nut spacer.

Tighten throat packing nut just
enough to stop leakage.

Throat packings are worn or
damaged.

Replace packings. See pump manual.

Displacement rod is worn or
damaged.

Replace rod. See pump manual.

Fluid is spitting from gun Air in pump or hose. Check and tighten all fluid

connections. Cycle pump as slowly as
possible during priming.

Spray tip is partially clogged. Clear tip. See Clear Tip Clog, page

21.

Fluid supply is low or empty. Refill fluid supply. Prime pump. See

pump manual. Check fluid supply
often to prevent running pump dry.

Problem

What to Check

If check is OK, go to next

check

What to Do

When check is not OK,

refer to this column

Troubleshooting

30 334530D

Pump is difficult to prime Air in pump or hose. Check and tighten all fluid

connections. Cycle pump as slowly as
possible during priming.

Intake valve is leaking. Clean intake valve. Be sure ball seat

is not nicked or worn and that ball
seats well. Reassemble valve.

Pump packings are worn. Replace pump packings. See pump

manual.

Paint is too thick. Thin the paint according to supplier

recommendations.

Sprayer operates for 5 to 10 minutes
then stops

Pump packing nut too tight. When
pump packing nut is too tight the
packings on the pump rod restrict
pump action and overloads the motor.

Loosen pump packing nut. Check for
leaks around throat. If necessary,
replace pump packings. See Pump
manual.

Problem

What to Check

If check is OK, go to next

check

What to Do

When check is not OK,

refer to this column

Troubleshooting

334530D 31

Electrical

Symptom: Sprayer does not run, stops
running, or will not shut off.

Perform Pressure Relief Proce dure, page

13.

1. Plug sprayer into 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 control knob clockwise
1/2 turn.

4. View digital display or remove control
box cover to view control board status
light. To determine which code (or any
other code besides voltage supply) refer
to the control board status light. Turn the
ON/OFF switch OFF, remove the control
cover then turn power back ON. Observe
the status light. Blinking LED total count
equals the error code (for example: two
blinks equals CODE 02).Press display
button to restart code messages.

Error Code Messages

Keep clear of electrical and moving parts
during troubleshooting procedures. To
avoid electrical shock hazards when
covers are removed for troubleshooting,
wait 7 seconds after disconnecting power
cord for stored electricity to dissipate.

CODE MESSAGE ACTION

02 HIGH PRESSURE

DETECTED - RELIEVE
PRESSURE

Check for clogs. Use only Graco spray hoses,
use a minimum of 50ft/15m.

03 PRESSURE TRANSDUCER

NOT DETECTED

Check transducer connection.

05 MOTOR NOT SPINNING Check for mechanical failure and check motor

connections. Material may be too thick, thin
material.

06 MOTOR OVERHEATED Turn sprayer OFF. Check motor connections.

Check shroud vents for blockage. Sprayer
may take up to an hour to cool.

Troubleshooting

32 334530D

Problem What to Check How to check

Sprayer does not run at all

AND

Display is blank

OR

Control board status light never lights

See flow chart,

page 37.

Sprayer does not shut off

AND

Displays Code 02 message

OR

Control board status light blinks 2
times repeatedly

Control board. Replace control board.

Sprayer does not run at all

AND

Displays Code 02 message

OR

Control board status light blinks 2
times repeatedly

Check transducer or transducer
connections

Make sure there is no pressure in the
system (see Pressure Relief
Procedure, page 13). Check fluid
path for clogs, such as clogged filter.

Use airless paint spray hose with no
metal braid. A small hose or metal
braid hose may result in
high-pressure spikes.

Turn ON/OFF switch OFF and
disconnect power to sprayer.

Check transducer and connections to
control board.

Disconnect transducer from control
board socket. Check that transducer
and control board contacts are clean
and secure.

Reconnect transducer to control
board socket. Connect power, turn
ON/OFF switch ON and control knob
1/2 turn clockwise. If sprayer does not
run properly, turn ON/OFF switch
OFF and go to next step.

Install new transducer. Connect
power, turn ON/OFF switch ON and
control knob 1/2 turn clockwise.
Replace control board if sprayer does
not run properly.

Troubleshooting

334530D 33

Sprayer does not run at all

AND

Displays Code 03 message

OR

Control board status light blinks 3
times repeatedly

Check transducer or transducer
connections (control board is not
detecting a pressure signal).

Turn ON/OFF switch OFF and
disconnect power to sprayer.

Check transducer and connections to
control board.

Disconnect transducer from control
board socket. Check to see if
transducer and control board contacts
are clean and secure.

Reconnect transducer to control
board socket. Connect power, turn
ON/OFF switch ON and control knob
to 1/2 turn clockwise. If sprayer does
not run, turn ON/OFF switch OFF and
go to next step.

Connect a confirmed working
transducer to control board socket.

Turn ON/OFF switch ON and control
knob to 1/2 turn clockwise. If sprayer
runs, install new transducer. Replace
control board if sprayer does not run.

Check transducer resistance with an
ohmmeter (less than 9k ohm between
red and black wires and 3-6k ohm
between green and yellow wires).

Sprayer does not run at all

AND

Displays Code 05 message

OR

Control board status light blinks 5
times repeatedly

Control is commanding motor to run
but motor shaft does not rotate.
Possibly locked rotor condition, an
open connection exists between
motor and control, there is a problem
with motor or control board, or motor
amp draw is excessive.

1.Remove pump and try to run
sprayer. If motor runs, check for
locked or frozen pump or drive train.
If sprayer does not run, continue to
step 2.

2.Turn ON/OFF switch OFF and
disconnect power to sprayer.

3.Disconnect motor connector(s) from
control board socket(s). Check that
motor connector and control board
contacts are clean and secure. If
contacts are clean and secure,
continue to step 4.

4.Set sprayer to OFF and spin motor
fan 1/2 turn. Restart sprayer. If
sprayer runs replace control board.
If sprayer does not run, continue to
step 5.

Problem What to Check How to check

Troubleshooting

34 334530D

5.Perform Spin Test: Test at large
4-pin motor field connector.
Disconnect fluid pump from
sprayer. Test motor by placing a
jumper across pins 1 & 2. Rotate
motor fan at about 2 revolutions per
second. A cogging resistance to
motion should be felt at the fan.
The motor should be replaced if no
resistance is felt. Repeat for pin
combinations 1 & 3 and 2 & 3. Pin 4
(the green wire) is not used in this
test. If all spin test is positive,
continue to step 6.

Problem What to Check How to check

GRN BLU R BLK

GRN BLU R BLK

STEP 2:

STEP 3:

STEP 1:

GRN BLU R BLK

Troubleshooting

334530D 35

6.Perform Field Short Test: Test at
large 4-pin motor field connector.
There should not be continuity from
pin 4, the ground wire, and any of
the remaining 3 pins. If motor field
connector tests fail, replace motor.

7.Check Motor Thermal Switch:
Unplug thermal wires. Set meter to
ohms. Meter should read 100k
ohms.

8.Reconnect motor connector(s) to
control board socket(s). Connect
power, turn ON/OFF switch ON and
control knob to 1/2 turn clockwise. If
motor does not run, replace control
board.

Problem What to Check How to check

-

1-3 ohms

Troubleshooting

36 334530D

Sprayer does not run at all

AND

Displays Code 06 message

OR

Control board status light blinks 6
times repeatedly

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 good ventilation. Make
sure motor air intake is not blocked. If
sprayer still does not run, replace
motor.

NOTE: Motor must be cooled down
for the test.

1. Check thermal device
connector (yellow wires)
at control board.

2. Disconnect thermal device
connector from control board
socket. Make sure contacts are
clean and secure. Measure
resistance of the thermal
device. If reading is not correct,
replace motor.

Check Motor Thermal Switch:
Unplug thermal wires. Set meter to
ohms. Meter should read 100k ohms.

3. Reconnect thermal device
connector to control board
socket. Connect power, turn
sprayer ON and control knob 1/2
turn clockwise. If sprayer does
not run, replace control board.

Basic electrical problems Motor leads are securely fastened

and properly mated

Replace loose terminals; crimp to
leads. Be sure terminal are firmly
connected.

Clean circuit board terminals.
Securely reconnect leads.

Motor armature commutator for burn
spots, gouges or extreme roughness.

Remove motor and have motor shop
resurface commutator if possible.

Problem What to Check How to check

Troubleshooting

334530D 37

Sprayer Will Not Run

(See following page for steps)

Remove Control box cover.
Turn sprayer 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

have over 100 VAC

(220 VAC for 230v units)?

NO

See Code section for
further troubleshooting

Sprayer Will Not Run

(see following pages for steps)

See Step 2. Do you

have over 100 VAC

(220 VAC for 230v units)?

Repair or

replace

power cord.

See Step 3. Is there

Continuity through the

thermal switch wires?

See Step 4.

Does the motor run?

Replace the

potentiometer.

Replace

the transducer

Replace

the control board

If motor is hot, let cool and retest. If Step 3 still

shows no continuity, replace motor. The motor

has a defective thermal device.

Connect a test transducer to the board.

Does the motor run?

Replace

the On/Off

switch.

NO

NO

NO

NO

YES

YES

YES

YES YES

ti24726a

Troubleshooting

38 334530D

Step 1:

Plug Power cord in and turn switch ON.
Connect probes to ontrol board. Turn
meter to AC Volts.

110-120 AC

V

-

Power
Cord

Blue

Brown

Green

On/Off
Switch

110-120 AC

V

-

Power
Cord

Black

Blue

Green

-

+

Yellow Thermistor
Wires to motor

-

Step 3:

Check motor thermal switch. Unplug
yellow wires. Meter should read
100 ohms. NOTE: Motor should be
cool during reading.

Step 2:

Plug Power cord in and turn switch
ON. Connect probes to control board.
Turn meter to AC Volts

Control Board

Step 4:

Disconnect potentiometer.
Plug power cord in and
turn switch ON.

ti24084a

To Potentiometer

100 ohms

Troubleshooting

334530D 39

Sprayer Will Not Shut Off

1. Perform Pressure Relief Procedure,
page 13. Leave prime valve open
(down) and turn ON/OFF switch OFF.

2. Remove control box cover so the
control board status light can be viewed
if available.

Troubleshooting Procedure

Troubleshooting Procedure

Plumb pressure gauge into paint hose,

plug sprayer in, and turn power switch ON.

Does sprayer reach or exceed

its maximum pressure?

Mechanical problem:

See the proper fluid pump

manual for the sprayer for

further troubleshooting procedures.

Is the control board status light on?

NO

Replace the control board.

NO

Replace the control board.

NO

YES

YES

Unplug the transducer from control board.

Does motor stop running?

Bad transducer.

Replace and test with a new one.

YES

ti24731a

490/495/395EU Stand Sprayers

40 334530D

490/495/395EU 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 50.

490/495/395EU Stand Sprayers

334530D 41

40

44

25

42

47

69

66

43

41

22

52

139

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)

123

4

490/495/395EU Stand Sprayers

42 334530D

490/495/395EU 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 BEARING, thrust

1

33 206994 FLUID, TSL (not

shown)

1

34

See page 49CARD, medical alert

(not shown)

1

39 241920 DEFLECTOR,

threaded

1

40 249194 GEAR, reducer

1

41 PUMP, displacement,

PC

1

17C487 North America
17C488 Asia/ANZ/Japan
17C489 Europe

42 24W817 HOUSING, drive, PC,

includes 12, 47, 70

1

43 24W640 ROD, connecting, PC

1

44 24X020 KIT, repair, crankshaft,

includes

25

1

45 24W830 KIT, hose, cpld, PC,

include

s 132

1

46 See page 49HOSE, cpld, 1/4 in. x

50 ft (not shown)

1

47 117493 SCREW, mach, hex

washer hd

9

52 See page 49LABEL, front,

upper/lower

1

53 See page 49LABEL, side

1

54 MOTOR, includes 54a,

54b

1

24S022 490/495/395EU
287807 595

54a 15D088 FAN, motor

1

54b 115477 SCREW, mach, torx,

painted

1

55 246381 HOSE, drain, stand,

include

s 39,62

1

57 246385 STRAINER, 7/8-14 unf

1

59 15E823 FRAME, standmount

1

60 246386 KIT, hose suction,

includes 13, 14, 57, 62

61 See page 49GUN, spray (not

shown)

1

62 276888 CLIP, drain line

1

63

See page 49LABEL, danger

1

65

See page 49LABEL, warning

1

66 116139 GRIP, handle

1

67 15G857 CAP, leg

4

68 287903 CUP, suction/drain

1

69 287072 HANDLE, sprayer,

includes 47, 66

1

70 17C483 COVER, pump rod

1

71 122667 SCREW, drill, hex

washer head

1

108 115523 GAUGE, pressure,

fluid, not shown (on
select models)

1

132 16H137 PACKING, O-ring

1

139 127914 SCREW, mach, slot,

hex

3

206994 FLUID, TSL, 8 oz. (not shown)

1

Replacement Danger and Warning labels,
tags, and cards are available at no cost.

Ref. Part Description

Qty.

490/495/595 Lo-Boy Sprayers

334530D 43

490/495/595 Lo-Boy Sprayers

59

54

47

23

12

71

74

6668

69

150

83

53

54a

54b

ti24996a

82

63

65

See page 50.

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

490/495/595 Lo-Boy Sprayers

44 334530D

45

43

41

132

13

60

60

14

57

55

39

62

40

25

44

47

42

22

52

139

70

117

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)

123

4

490/495/595 Lo-Boy Sprayers

334530D 45

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 49CARD, medical alert

(not shown)

1

39 241920 DEFLECTOR,

threaded

1

40 249194 GEAR, reducer

1

41 PUMP, displacement,

PC

1

17C487 North America
17C488 Asia, ANZ, Japan

42 24W817 HOUSING, drive, PC,

includes 12, 47, 70

1

43 24W640 ROD, connecting, PC

1

44 KIT, repair, crankshaft,

inclu

des 25

1

24X020 Models

490/495/395EU

24X021 M odel 595

45 24W830 KIT, hose, cpld, PC,

includes

132

1

46 See page 49HOSE, cpld, 1/4 in. x

50 ft (not shown)

1

47 117493 SCREW, mach, hex

washer hd

8

52 See page 49LABEL, front,

upper/lower

1

53 See page 49LABEL, side

1

54

MOTOR, includes 54a,

54b

1

24S022 Models 490/495
287807 Model 595

54a 15D088 FAN, motor

1

54b 115477 SCREW, mach, torx,

painted

1

55 246381 HOSE, drain, stand,

include

s 39,62

1

57 246385 STRAINER, 7/8-14 unf

1

59 246250 FRAME, cart, lo

1

60 246386 KIT, hose suction,

includes 13,

14, 57, 62,

61 See page 49GUN, spray (not

shown)

1

62 276888 CLIP, drain line

1

63

See page 49LABEL, danger

1

65

See page 49LABEL, warning

1

66 15B999 CLIP, retaini ng

2

68 104811 CAP, hub

2

69 287488 HANDLE, assembly, lo

cart

1

70 17C483 COVER, pump, rod

1

71 107310 PLUG, tubing

2

74 195766 WHEEL, semi

pneumatic

2

82 122667 SCREW, drill, hex

washer head

2

83 15B870 CUP, suction /drain

1

117 15 G447 PLUG, shield painted

1

132 16 H137 PACKING, O-ring

1

139 127914 SCREW, mach, slot,

hex

3

150 109032 SCREW, pan hd

4

206994 FLUID, TSL, 8 oz. (not shown)

1

Replacement Danger and Warning labels,
tags, and cards are available at no cost.

Ref. Part Description

Qty.

490/495/595/395EU Hi-Boy Sprayers

46 334530D

490/495/595/395EU Hi-Boy Sprayers

54

54a

54b

23

63

65

12

74

59

115

114

116

47

75

81

82

83

67

ti24998a

53

1

2

3

See page 50.

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)

123

490/495/595/395EU Hi-Boy Sprayers

334530D 47

43

41

132

45

13

55

39

60

57

14

84

69

76

62

ti24997a

40

44

42

117

25

47

22

52

139

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)

123

4

490/495/595/395EU Hi-Boy Sprayers

48 334530D

490/495/595/395EU 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 BEARING, thrust 1
33 206994 FLUID, TSL (not

shown)

1

34 See page 49CARD, medical alert

(not shown)

1

39 241920 DEFLECTOR,

threaded

1

40 249194 GEAR, reducer 1
41 PUMP, displacement,

PC

1

17C487 North America
17C488 Asia/ANZ/Japan
17C489 Europe

42 24W817 HOUSING, drive, PC,

includes

12, 47, 70

1

43 24W640 ROD, connecting, PC 1
44 KIT, repair, crankshaft,

includes 25

1

24X020 Models 395EU/490/495
24X021 Model 595

45 24W830 KIT, hose, cpld, PC,

includes 132

1

46 See page 49HOSE, cpld, 1/4 in. x 50

ft (not shown)

1

47 117493 SCREW, mach, hex

washer hd

8

52 See page 49LABEL, front,

upper/lower

1
53 See page 49LABEL, side 1
54 MOTOR, includes 54a,

54b

1

24S022 490/495/395EU

287807 595
54a 15D088 FAN, motor 1
54b 115477 SCREW, mach, torx,

painted

1

55 244240 HOSE, drain, includes

39

1

57 246385 STRAINER, 7/8-14 unf 1

59 17C485 FRAME, cart, hi 1
60 17C992 KIT, stinger tube,

includes

13,14, 57, 69,

76, 84

61 See page 49GUN, spray (not shown) 1
62 276888 CLIP, drain line 1

63 See page 49LABEL, danger 1
65 See page 49LABEL, warning 1
67 109032 SCREW, pan hd 4

69 15E813 NUT, jam 1
70 17C483 COVER, pump rod 1
74 287489 HANDLE 1
75 108691 PLUG, tubing 2
76 TUBE, suction 1
81 106062 WHEEL 2
82 15B999 CLIP, retaining 2
83 104811 CAP, hub 2
84 15B652 WASHER, suction 1
105 17C990 HANGER, pail 1
107 111040 NUT, lock, insert, nylon 2
114 15D281 HANGER, stand (on

select models)

1

115 15C982 CAM, cart (on select

models)

2

116 114531 SCREW, mch, hex (on

select models)

4

117 15G447 PLUG, tubing 1
122 118852 SCREW, thd forming

(on select models, not
shown)

3

123 287253 KIT, tool box includes

122 (on select models,
not shown)

1

132 16H137 PACKING, O-ring 1
139 127914 SCREW, mach, slot,

hex

3

206994 FLUID, TSL, 8 oz. (not shown)

1

Replacement Danger and Warning labels,
tags, and cards are available at no cost.

Ref.

Part Description

Qty.

Accessories and Labels

334530D 49

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 # 826079

17C830/

17C831

17C832 826085 15H085 # 195793 &

826202
826203
826204

222385 # 826079

17C830/

17C833

17C836 826085 15H085 # 195793 &

826205
826206

222385 # 826079

17C830/

17C837

17C840 826085 15H085 # 195793 &

17C327
17C328
17C332

222385 # 240794

17C827/

17C828

17C829 288420 15H085 # 195793 &

17C333
17C334
17C335

222385 # 240794

17C827/

17C833

17C834 288420 15H085 # 195793 &

17C336
17C337

222385 # 240794

17C827/
17C837/

17C838 288420 15H085 # 195793 &

17C369
17C372

222385 # 240794

17C864/

17C866

17C867 288438 - - -

16G596



17C373
17C374
17C375
17C376
17C377
17C378

222385 # 240794

17C864/

17C868

17C869 288438 - - -

16G596 

17C381
17C382
17C383

222385 # 240794

17C827/

17C837

17C838 288438 - - -

16G596 

17C393

17A134 

240794

17C827/

17C828

17C829 17C926 15H086 * 195792 @

17C394

17A134



240794

17C827/

17C857

17C858

288427/

288436

15H087 @ 195792 @

17C395

17A134 

240794

17C827/

17C828

17C829 17C926 15H087 @ 195792 @

17C399

17A134 

240794

17C827/

17C833

17C834

288427/

288436

15H086 * 195792 @

17C398
17C401
17C402

17A134



240794

17C827/

17C833

17C834

288427/

288436

15H087 @ 195792 @

17C403
17C404

17A134 

240794

17C827/

17C837

17C838

288427/

288436

15H087 @ 195792 @

288526 – Kit, accessory, hopper
# – English, Spanish, French @ – Asia/ANZ

 – English, Chinese, Korean  – Europe

& – North America * – Japan

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Control Box

50 334530D

Control Box

15 24

108

24

30

3

92

91

90

27

36

106

107

51

50

11

37

129

17

2

18

12

113

47

48

49

58

19

20

38

6

128

7

37

127

56

56

47

4

16

35

5

26

ti24999a

6

5

1

5

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 - 16.9 N•m)

12567

1

Control Box

334530D 51

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 115498 SCREW, slot, hex, wash

hd

1

11 116167 KNOB, potentiometer

1

12 117501 SCREW, mach, hex

washer hd

6

15 MANIFOLD, fluid

1

15G455 Models without pressure

gauge

15T811 Models with prs gauge

16 FILTER, fluid

1

246425 30 mesh
246384 60 mesh, original
246382 100 mesh
246383 200 mesh

17 287902 KIT, repair, filter cap

includes 18

1

18 15B071 INSERT, filter

1

19 15G562 BUSHING, control box

1

20 15B120 GROMMET, transducer

1

24 162453 NIPPLE, (1/4 npsm x 1/4

npt)

2

26 15E022 SEAT, valve

1

27 187625 HANDLE, valve, drain

1

30 BOARD, filter

1

287911 120V, GFI, US/Japan
287912 110V, UK
287913 230V

35 239914

VALVE, drain includes

5, 26

1

36 224807 BASE, valve

1

37 17D888 POTENTIOMETER, adj,

pressure with nut

1

38 243222 TRANSDUCER, prs

control, includes

3

1

47 117493 SCREW, mach, hex

washer hd

4

48 BOX, control board

includes 6, 7, 11, 19, 30,
37, 49, 58, 127, 128, 129

1

24W893 120V, 490/495 model s,

US/Japan includes 19

24W894 120V, 595 models,

US/Japan includes 19

24W895 230V
24W896 110V, UK

49 17D154 LABEL, control,

w/FastFlush

1

50 COVER, control

1

277229 Models without display
24W892 DIGITAL, display

includes 51, 106, 107

51 LABEL, control

1

17C964 Models without display
17C875 Models with display

56

CORD, power

1

253367 US, 490/495 models
253371 US, 595 models
253378 Japan
253373

Multicord, Asia/ANZ
253369 CEE 7/7
253370

Multicord, Europe

58 195428 BOOT, toggle

1

90 195551 RETAINER, plug,

adapter

Multicord models

2

CEE 7/7 models

1

91 CORD SET, adapter

1

253368 UK
242001 Europe
242005 Australia
287121

Italy, Denmark, Sweden

92 244285 ADPTER, Japan

1

106 15G861 LABEL, smart ctrl dspl

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+, 230V models only
(not shown)

1

24W090 CEE 7/7
24W755

Multicord, IEC-320

Ref. Part Description Qty.

Wiring Diagrams

52 334530D

Wiring Diagrams

110/120V

MOTOR

ti7380b

On/O Switch

Black

Green

To Po we r
Plug

Potentiometer

Pressure
Transducer

J12

J11

Wiring Diagrams

334530D 53

230V

NOTICE

Heat from inductor coil of filter board may
destroy wire insulation that comes in
contact with it. Exposed wires could cause
shorts and component damage. Bundle
and tie loose wires so none lay in contact
with inductor coil on the filter board.

MOTOR

ti7454b

On/O Switch

Blue

Black

Blue

Green

Brown

To P owe r
Plug

Potentiometer

Pressure
Transducer

J12

J11

Technical Specifications

54 334530D

Technical Specifications

490/495/595/395EU

US Metric
Sprayer
Maximum fluid working pressure 3300 psi 228 bar, 22.8 MPa
Maximum Delivery

395EU/490 0.54 gpm 2.0 lpm
495 0.60 gpm 2.3 lpm
595 0.70 gpm 2.6 lpm

Maximum Tip Size

395EU/490 0.023 0.023
495 0.025 0.025

595 0.027 0.027
Fluid Outlet npsm 1/4 in. 1/4 in.
Cycles

395EU/490/495 620 per gallon 164 per liter

595 540 per gallon 143 per liter
Generator Minimum

395EU/490 3500 W

495 3750 W

595 4000 W
Power Requirements

395EU/490 1Ø, 50/60 Hz 110–120V, 12 A / 220–240V, 7 A

495 1Ø, 50/60 Hz 110–120V, 15 A / 220–240V, 9 A

595 1Ø, 50/60 Hz 110–120V, 15 A / 220–240V, 9 A
Dimensions
Height

Stand 18.5 in. 47.0 cm

Lo-Boy 22.5 in. 57.2 cm

Hi-Boy 28.25 in. (Handle down)

38.25 in. (Handle up)

71.8 cm (Handle down)

97.2 cm (Handle up)

Length

Stand 16 in. 40.6 cm

Lo-Boy 26.5 in. 67.3 cm

Hi-Boy 23.25 in. 59.1 cm
Width

Stand 14 in. 35.6 cm

Lo-Boy 20 in. 50.6 cm

Hi-Boy 20.5 in. 52.1 cm

Technical Specifications

334530D 55

Weight

Stand

395EU 45.1 lb. 20.5 kg
490 / 495 34 lb. 15 kg

Lo-Boy

395EU 63 lb. 29 kg
490 / 495 59.1 lb. 26.8 kg
595 70 lb. 31.8 kg

Hi-Boy

395EU 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 materials on all models zinc- and nickel-plated carbon steel, nylon, stainless steel,

PTFE, Acetal, leather, UHMWPE, aluminum, tungsten
carbide, polyethylene, fluoroelastomer, urethane

Notes

* Startup pressures and displacement per cycle may vary based on suction condition,
discharge head, air pressure, and fluid type.

** Sound pressure measured 3 feet (1 meter) from equipment.
Sound power measured per ISO-3744.

490/495/595/395EU

US Metric

Graco Standard Warranty

56 334530D

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco 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 Graco, Gr aco will,
for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco 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-Graco compon ent parts.
Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Gr aco
equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper
design, manufacture, installation, operation or maintenance of structures, accessories, equipment or
materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an
authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco
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.

Graco’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.

GRACO 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 GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose,

etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with
reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from
Graco 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 warran ty, the negligence of Graco, or
otherwise.

FOR GRACO 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.

All written and visual data contained in this document reflects the latest product 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: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision D, June 2016

Graco Information

For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the

nearest distributor.