Operation, Parts
ti24941a
Electric Airless
334530A
Sprayers
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
For portable airless spraying of architectural paints and coatings.
395/490/495/595 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 related manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals
311861 (Contractor/FTx)
312830 (SG3)
334599
EN
Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.
Contents
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spray Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clear Tip Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
395/490/495 Stand Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
395/490/495 Stand Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
395/490/495/595 Lo-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
395/490/495/595 Lo-Boy Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
395/490/495/595 Hi-Boy Sprayers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
395/490/495/595 Hi-Boy Sprayers Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Accessories and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control Box Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
120V, US/Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
110V, UK / 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 334530A
Models
Models
Hi-Boy
110474
Certified to
CAN/CSA
C22.2 No. 68
Conforms to
UL 1450
VAC Model
120
USA
120
Japan/Taiwan
230
CEE 7/7
230 Europe
Multi
110
UK
230
Asia/ANZ
230
China
ST MAX II 395 PC Pro
ST MAX II 495 PC Pro
ST MAX II 595 PC Pro
ST MAX II 495 PC Pro
ST MAX II 595 PC Pro
ST MAX II 495 PC Pro
ST MAX II 595 PC Pro
Ultra MAX II 490 PC
Ultra MAX II
490 PC Pro
Ultimate MX II
490 PC Pro
Ultra MAX II
495 PC Pro
Ultimate MX II
495 PC Pro
Ultra MAX II
595 PC Pro
Ultimate MX II
595 PC Pro
Ultra MAX II
490 PC Pro
Ultra MAX II
495 PC Pro
Ultra MAX II
490 PC Pro
Ultra MAX II
495 PC Pro
Ultra MAX II
595 PC Pro
Stand
Lo-Boy
17C327 17C328 17C332
826199 826200 826201
17C333 17C334 17C335
826202 826203 826204
17C336 17C337
826205 826206
17C393
17C399
17C369 17C372
17C373 17C376
17C381
17C374 17C377
17C382
17C375 17C378
17C383
17C395
17C398 17C401 17C402
17C404 17C403
17C394
334530A 3
Warnings
WARNING
ti24583a
120V US 230V
110V UK
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 manual
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.
4 334530A
Warnings
WARNING
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.
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 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.
334530A 5
Warnings
WARNING
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.
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.
6 334530A
Warnings
WARNING
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.
334530A 7
Component Identification
W
U
K
S
M
N
V
P
R
A
B
D
ti24942a
J
G
F
L
H
F
Component Identification
Stand 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 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.)
8 334530A
Lo-Boy Models
D
U
K
M
N
V
P
R
B
ti24943a
J
G
F
L
H
F
A
W
Component Identification
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.)
334530A 9
Component Identification
K
M
N
U
T
T
S
V
P
B
ti24944a
J
G
F
L
H
F
A
D
R
W
Hi-Boy Models
10 334530A
Hi-Boy Models
Component Identification
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 Hanger
TFilter
U Finger Guard / TSL Fill Point
V Pail Hook
W Display
Model/Serial Tag (Not shown, located
on bottom of unit.)
334530A 11
Grounding
ti24584a
Grounding
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.
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
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.
• 100-120V units require 100-120 VAC,
50/60 Hz, 15A, 1 phase.
• 230V units require 230 VAC, 50/60 HZ,
7A, 1 phase.
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.
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.
12 334530A
ti24585a
Pressure Relief Procedure
ti24586a
ti24953a
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, 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.
1. Turn ON/OFF switch to OFF position.
Wait 7 seconds for power to dissipate.
3. Remove tip guard.
ti24592a
4. Turn pressure control to lowest setting.
Disengage trigger lock.
2. Engage trigger lock.
ti24931a
334530A 13
Pressure Relief Procedure
ti24607a
ti24612a
5. Hold a metal part of the gun firmly to a
grounded metal pail. Trigger the gun to
relieve pressure.
ti24585a
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 pressure has not been
fully relieved:
a. VERY SLOWLY loosen tip guard
retaining nut or hose end coupling to
relieve pressure gradually.
b. Loosen 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 by hand or if dropped
or bumped.
14 334530A
Setup
ti24616a
ti24633a
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.
Setup
2. Connect other end of hose to gun.
3. Use wrenches to tighten securely.
4. Engage trigger lock.
ti24931a
334530A 15
Setup
ti24638a
ti24639a
5. Remove tip guard.
ti24592a
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.
16 334530A
Setup
ti24586a
ti24651a
ti24608a
ti24640a
8. Make certain ON/OFF switch is OFF.
9. Plug power supply cord into a properly
grounded electrical outlet.
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.
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.
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.
334530A 17
Setup
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.
18 334530A
Startup
ti24953a
ti24644a
ti24954a
15 s
ti24646a
1 m
1. Perform Pressure Relief Procedure,
page 13.
2. Turn pressure control to lowest
pressure.
3. Turn ON/OFF switch to ON position.
Startup
7. Hold gun against grounded metal waste
pail. Trigger gun until paint appears.
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.
ti24647a
334530A 19
Startup
ti24649a
20 s
8. Move gun to paint pail and trigger for 20
seconds. Release trigger and allow
sprayer to build pressure. Engage
trigger lock.
10. Screw tip assembly onto gun and
tighten. See Spray Tip Installation,
page 21. For gun assembly instructions,
see separate gun manual.
ti24652a
High-pressure spray is able to inject
toxins into the body and cause serious
bodily injury. Do not stop leaks with hand
or rag.
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.
20 334530A
Operation
ti24653a
C
B
A
ti24664a
ti24669a
Operation
Spray Tip Installation
1. Perform Pressure Relief
Procedure, page 13.
2. Use spray tip (A) to insert
OneSeal
2. Insert Spray Tip.
™
(B) into tip guard (C).
3. Screw assembly onto gun. Tighten.
ti24652a
Spray
1. Spray test pattern. Adjust pressure to
eliminate heavy edges.
334530A 21
Operation
ti24673a
ti24676a
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%.
4. Trigger gun after moving. Release
trigger before stopping. For additional
spraying information, see separate gun
manual.
ti24674a
2. Engage trigger lock. Return Spray Tip to
original position. Disengage trigger lock
and continue spraying.
Clear Tip Clog
1. Release trigger. Engage trigger lock.
Rotate Spray Tip. Disengage trigger
lock. Trigger gun at waste area to clear
clog.
22 334530A
Operation
ti24651a
ti24644a
ti2888a
ti24586a
Digital Display
Most models are equipped with a digital
display. This section explains how to use this
feature.
Pressure Display
1. Perform Pressure Relief
Procedure, page 13.
2. Plug sprayer into grounded outlet. Turn
ON/OFF switch to ON position.
4. Press and hold display button to change
pressure units (psi, bar, or MPa).
Stored Data Display
1. Turn ON/OFF switch to OFF position.
3. The pressure is displayed. Dashes
indicate pressure is less than 200 psi (14
bar, 1.4 MPa).
ti2786a
334530A 23
Operation
ti24644a
ti2824a
ti24586a
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 which is the unit
power on time in hours.
5. Press display button again to display
Data Point 3. This will be the last error
code.
6. To erase last error code, press and hold
display button.
7. Press display button again to display
Data Point 4. The software revision is
displayed.
8. Press display button again to return to
Data Point 1.
9. Turn ON/OFF switch to OFF position to
exit Stored Data.
4. Press display button again to display
Data Point 2. Motor
run time in hours is
displayed.
24 334530A
Cleanup
ti24710a
1. Perform Pressure Relief Procedure,
page 13.
2. Remove tip guard and Spray Tip. For
additional information, see separate gun
manual.
Operation
ti24709a
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
Fast Flush Drain Tube
3. Remove fluid intake and drain tube from
paint, wipe excess paint off outside.
334530A 25
Operation
5. To flush drain tube and pump turn prime
valve down.
ti24713a
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.
ti24991a
9. Stop triggering gun.
10. Raise fluid intake above flushing fluid.
ti24714a
26 334530A
11. With prime valve horizontal. Trigger gun
ti24649a
20 s
ti24992a
ti24718a
ti24719a
ti24720a
into flushing pail to purge fluid from hose.
12. Engage trigger lock.
Operation
15. If flushing with water, flush again with
mineral spirits or Pump Armor to leave a
protective coating to prevent freezing or
corrosion.
13. Turn pressure control knob to OFF and
turn ON/OFF switch to OFF position.
Disconnect power to sprayer.
16. Wipe sprayer, hose and gun with a rag
soaked in water or mineral spirits.
14. Remove filter from gun and sprayer if
installed. Clean and inspect. Install filter.
See separate gun manual.
334530A 27
Maintenance
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.
Inspect motor shield vents for blockage.
Fill TSL by adding through TSL fill point. Daily or each time you spray
Inspect motor brushes for wear. Brushes must be 1/2 in.
(13mm) minimum length. NOTE: Brushes do not wear at
the same rate on both sides of motor. Check both brushes.
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.
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.
Daily or each time you spray
Daily or each time you spray
Every 1000 gallons (3785 liters)
Every 1000 gallons (3785 liters)
As necessary based on usage
28 334530A
Troubleshooting
Mechanical/Fluid Flow
Troubleshooting
1. Follow Pressure Relief Procedure,
page 13, before checking or repairing.
What to Check
If check is OK, go to next
Problem
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.
Pump output is low Spray tip worn. Follow Pressure Relief Procedure,
Fault condition exists. Determine fault correction from
Spray tip clogged. Relieve pressure. Check and clean
Paint supply. Refill and reprime pump.
Intake strainer clogged. Remove and clean, then reinstall.
Intake valve ball and piston ball are
not seating properly.
Fluid filter or tip filter is clogged or
dirty.
Prime valve leaking. Follow Pressure Relief Procedure,
Verify pump does not continue to
stroke when gun trigger is released.
(Prime valve not leaking.)
Leaking around throat packing nut
which may indicate worn or damaged
packings.
2. Check all possible problems and causes
before disassembling the unit.
What to Do
When check is not OK,
check
refer to this column
Electrical, page 32.
page 13, then replace tip. See
separate gun or tip manual.
spray tip.
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.
Clean filter.
page 13, then repair prime valve.
Service pump. See pump manual.
Replace packings. See pump manual.
Also check piston valve seat for
hardened paint or nicks and replace if
necessary. Tighten packing
nut/wet-cup.
334530A 29
Troubleshooting
What to Check
If check is OK, go to next
Problem
Pump output is low Pump rod damage. Repair pump. See pump manual.
Low stall pressure. Turn pressure knob fully clockwise.
Piston packings are worn or
damaged.
O-ring in pump is worn or damaged. Replace o-ring. See pump manual.
Intake valve ball is packed with
material.
Large pressure drop in hose with
heavy materials.
Check extension cord for correct size. See Extension Cords, page 12.
Loose motor brushes and terminals. Tighten terminal screws. Replace
Worn motor brushes. (Brushes must
be 1/2 in. [13mm] minimum length.)
Broken and misaligned motor brush
springs. Rolled portion of spring must
rest squarely on top of brush.
Motor brushes are binding in brush
holders.
Motor runs but pump does not stroke Connecting rod assembly damaged.
Excessive paint leakage into throat
packing nut
See pump manual.
Gears or drive housing damaged. Inspect drive housing assembly and
Throat packing nut is loose. Remove throat packing nut spacer.
Throat packings are worn or
damaged.
Displacement rod is worn or
damaged.
check
Make sure pressure control knob is
properly installed to allow full
clockwise position. If problem
persists, replace pressure transducer.
Replace packings. See pump manual.
Clean intake valve. See pump
manual.
Reduce overall length of hose.
brushes if leads are damaged.
Replace brushes.
Replace spring if broken. Realign
spring with brush.
Clean brush holders, remove carbon
dust with a small cleaning brush.
Align brush lead with slot in brush
holder to assure free vertical brush
movement.
Replace connecting rod assembly.
See pump manual.
gears for damage and replace if
necessary.
Tighten throat packing nut just
enough to stop leakage.
Replace packings. See pump manual.
Replace rod. See pump manual.
What to Do
When check is not OK,
refer to this column
30 334530A
Troubleshooting
What to Check
If check is OK, go to next
Problem
Fluid is spitting from gun Air in pump or hose. Check and tighten all fluid
Spray tip is partially clogged. Clear tip. See Clear Tip Clog, page
Fluid supply is low or empty. Refill fluid supply. Prime pump. See
Pump is difficult to prime Air in pump or hose. Check and tighten all fluid
Intake valve is leaking. Clean intake valve. Be sure ball seat
Pump packings are worn. Replace pump packings. See pump
Paint is too thick. Thin the paint according to supplier
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.
check
connections. Cycle pump as slowly as
possible during priming.
22.
pump manual. Check fluid supply
often to prevent running pump dry.
connections. Cycle pump as slowly as
possible during priming.
is not nicked or worn and that ball
seats well. Reassemble valve.
manual.
recommendations.
Loosen pump packing nut. Check for
leaks around throat. If necessary,
replace pump packings. See Pump
manual.
What to Do
When check is not OK,
refer to this column
334530A 31
Troubleshooting
Electrical
Symptom: Sprayer does not run, stops
running, or will not shut off.
Perform Pressure Relief Procedure, 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.
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.
Error Code Messages
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
05 MOTOR NOT SPINNING Check for mechanical failure and check motor
06 MOTOR OVERHEATED Turn sprayer OFF. Check motor connections.
32 334530A
Check transducer connection.
connections. Material may be too thick, thin
material.
Check shroud vents for blockage. Sprayer
may take up to an hour to cool.
Troubleshooting
Problem What to Check How to check
Sprayer does not run at all
AND
Display is blank
OR
Control board status light never lights
Sprayer does not shut off
AND
Displays Code 02 message
OR
Control board status light blinks 2
times repeatedly
Sprayer does not run at all
AND
Displays Code 02 message
OR
Control board status light blinks 2
times repeatedly
See flow chart,
Control board. Replace control board.
Check transducer or transducer
connections
page 38.
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.
334530A 33
Troubleshooting
Problem What to Check How to check
Sprayer does not run at all
AND
Displays Code 03 message
OR
Control board status light blinks 3
times repeatedly
Sprayer does not run at all
AND
Displays Code 05 message
OR
Control board status light blinks 5
times repeatedly
Check transducer or transducer
connections (control board is not
detecting a pressure signal).
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.
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).
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.
34 334530A
Troubleshooting
GRN BLU R BLK
GRN BLU R BLK
STEP 2:
STEP 3:
STEP 1:
GRN BLU R BLK
Problem What to Check How to check
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.
334530A 35
Troubleshooting
1-3 ohms
Problem What to Check How to check
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.
36 334530A
Troubleshooting
Problem What to Check How to check
Sprayer does not run at all
AND
Displays Code 06 message
OR
Control board status light blinks 6
times repeatedly
Basic electrical problems Motor leads are securely fastened
Motor is hot or there is a fault in the
motor thermal device.
and properly mated
For loose motor brush lead
connections and terminals.
Brushes must be 1/2 in. [13mm]
minimum length. NOTE: Brushes do
not wear at the same rate on both
sides of motor. Check both brushes.
Broken or misaligned motor brush
springs. Rolled portion of spring must
rest squarely on top of brush.
Motor brushes may be binding in
brush holders.
Motor armature commutator for burn
spots, gouges or extreme roughness.
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.
Replace loose terminals; crimp to
leads. Be sure terminal are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.
Tighten terminal screws. Replace
brushes if leads are damaged.
Replace brushes.
Replace spring if broken. Realign
spring with brush.
Clean brush holders. Remove carbon
with small cleaning brush. Align brush
leads with slot in brush holder to
assure free vertical brush movement.
Remove motor and have motor shop
resurface commutator if possible.
334530A 37
Troubleshooting
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
Sprayer Will Not Run
(See following page for steps)
38 334530A
Troubleshooting
Step 1:
Plug Power cord in and turn switch ON.
Connect probes to ontrol board. Turn
meter to AC Volts.
110-120 AC
V
-
Powe r
Cord
Blue
Brown
Green
On/Off
Switch
110-120 AC
V
-
Powe r
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
334530A 39
Troubleshooting
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
Sprayer Will Not Shut Off
1. Perform Pressure Relief Procedure,
page 13. Leave prime valve open
(down) and turn ON/OFF switch OFF.
Troubleshooting Procedure
Troubleshooting Procedure
2. Remove control box cover so the
control board status light can be viewed
if available.
40 334530A
ti24731a
395/490/495 Stand Sprayers
1
2
59
67
54
54b
54a
47
47
23
12
71
68
53
65
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
63
334530A 41
ti24994a
395/490/495 Stand Sprayers
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
123
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)
42 334530A
395/490/495 Stand Sprayers
395/490/495 Stand Sprayers Parts List
Ref. Part Description
12 117501 SCREW, mach, hex
13 115099 WASHER, hose
14 117559 O-ring
22 17C541 COVER, front, painted
23 15G449 SHIELD, motor,
25 180131 BEARING, thrust
33 206994 FLUID, TSL (not
See page 50CARD, medical alert
34
39 241920 DEFLECTOR,
40 249194 GEAR, reducer
41 PUMP, displacement,
17C487 North America
17C488 Europe
17C489 Asia/ANZ/Japan
42 24W817 HOUSING, drive, PC,
43 24W640 ROD, connecting, PC
44 24X020 KIT, repair, crankshaft,
45 24W830 KIT, hose, cpld, PC,
46 See page 50HOSE, cpld, 1/4 in. x
47 117493 SCREW, mach, hex
52 See page 50LABEL, front,
53 See page 50LABEL, side
54* 24S022 MOTOR, kit includes
washer hd
painted
shown)
(not shown)
threaded
PC
includes
includes
include
50 ft (not shown)
washer hd
upper/lower
54a, 54b
12, 47, 70
25
s 132
Qty.
Ref. Part Description
54a 15D088 FAN, motor
4
54b 115477 SCREW, mach, torx,
1
55 246381 HOSE, drain, stand,
2
1
57 246385 STRAINER, 7/8-14 unf
1
59 15E823 FRAME, standmount
60 246386 KIT, hose suction,
1
1
61 See page 50GUN, spray (not
1
62 276888 CLIP, drain line
1
1
See page 50LABEL, danger
63
See page 50LABEL, warning
65
painted
include
s 39,62
includes 13, 14, 57, 62
shown)
1
66 116139 GRIP, handle
67 15G857 CAP, leg
68 287903 CUP, suction/drain
69 287072 HANDLE, sprayer,
1
70 17C483 COVER, pump rod
71 122667 SCREW, drill, hex
1
1
108 115523 GAUGE, pressure,
1
132 16H137 PACKING, O-ring
1
139 127914 SCREW, mach, slot,
9
* For motor brush kit order 287735
1
1
Replacement Danger and Warning labels,
tags, and cards are available at no cost.
includes 47, 66
washer head
fluid, not shown (on
select models)
hex
1
Qty.
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
3
334530A 43
395/490/495/595 Lo-Boy Sprayers
59
54
47
23
12
71
74
6668
69
150
83
53
54a
54b
ti24996a
82
63
65
See page 51.
2
1
1
2
395/490/495/595 Lo-Boy Sprayers
Ref. Torque
140-160 in-lb (15.8 - 18.1 N•m)
30-35 in-lb (3.4 - 4.0 N•m)
44 334530A
395/490/495/595 Lo-Boy Sprayers
45
43
41
132
13
60
60
14
57
55
39
62
40
25
44
47
42
22
52
12
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
334530A 45
395/490/495/595 Lo-Boy Sprayers
395/490/495/595 Lo-Boy Sprayers Parts List
Ref. Part Description
12 117501 SCREW, mach, hex
washer hd
13 115099 WASHER, hose
14 117559 O-ring
22 17C541 COVER, front, painted
23 15G449 SHIELD, motor,
25 180131 BEARING, thrust
33 206994 FLUID, TSL (not
See page 50CARD, medical alert
34
39 241920 DEFLECTOR,
40 249194 GEAR, reducer
41 PUMP, displacement,
17C487 North America
17C489 Asia, ANZ, Japan
42 24W817 HOUSING, drive, PC,
43 24W640 ROD, connecting, PC
44 KIT, repair, crankshaft,
24X020 Models 395/490/495
24X021 Model 595
45 24W830 KIT, hose, cpld, PC,
46 See page 50HOSE, cpld, 1/4 in. x
47 117493 SCREW, mach, hex
52 See page 50LABEL, front,
53 See page 50LABEL, side
54*
24S022 Models 395/490/495
painted
shown)
(not shown)
threaded
PC
includes
inclu
includes
50 ft (not shown)
washer hd
upper/lower
MOTOR, includes 54a,
54b
12, 47, 70
des 25
132
Qty.
Ref. Part Description
4
1
2
1
1
1
1
1
1
287807 Model 595
54a 15D088 FAN, motor
54b 115477 SCREW, mach, torx,
55 246381 HOSE, drain, stand,
57 246385 STRAINER, 7/8-14 unf
59 246250 FRAME, cart, lo
60 246386 KIT, hose suction,
61 See page 50GUN, spray (not
62 276888 CLIP, drain line
See page 50LABEL, danger
63
painted
include
s 39,62
includes 13,
shown)
14, 57, 62,
1
1
1
1
1
1
1
8
1
1
See page 50LABEL, warning
65
66 15B999 CLIP, retaining
68 104811 CAP, hub
69 287488 HANDL E, assembly, lo
70 17C483 COVER, pump, rod
71 107310 PLUG, tubing
74 195766 WHEEL, semi
82 122667 SCREW, drill, hex
83 15B870 CUP, suction/drain
117 15G447 PLUG, shield painted
132 16H137 PACKING, O-ring
139 127914 SCREW, mach, slot,
150 109032 SCREW, pan hd
Replacement Danger and Warning labels,
tags, and cards are available at no cost.
cart
pneumatic
washer head
hex
1
* For motor brush kit order 287735
Qty.
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
2
1
1
1
3
4
46 334530A
395/490/495/595 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 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)
123
395/490/495/595 Hi-Boy Sprayers
334530A 47
395/490/495/595 Hi-Boy Sprayers
43
41
132
45
13
55
39
87
60
57
14
84
69
62
ti24997a
40
44
42
117
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)
123
4
48 334530A
395/490/495/595 Hi-Boy Sprayers
395/490/495/595 Hi-Boy Sprayers Parts List
Part Description
Part Description
Ref.
12 117501 SCREW, mach, hex
13 115099 WASHER, hose
14 103413 O-ring
22 17C541 COVER, front, painted
23 15G449 SHIELD, motor, painted
25 180131 BEARING, thrust
33 206994 FLUID, TSL (not
34 See page 50CARD, medical alert
39 241920 DEFLECTOR,
40 249194 GEAR, reducer
41 PUMP, displacement,
17C487 North America
17C488 Europe
17C489 Asia/ANZ/Japan
42 24W817 HOUSING, drive, PC,
43 24W640 ROD, connecting, PC
44 KIT, repair, crankshaft,
24X020 Models 395/490/495
24X021 Model 595
45 24W830 KIT, hose, cpld, PC,
46 See page 50HOSE, cpld, 1/4 in. x 50
47 117493 SCREW, mach, hex
52 See page 50LABEL, front,
53 See page 50LABEL, side
54* MOTOR, includes
24S022 395/490/495
287807 595
54a 15D088 FAN, motor
54b 115477 SCREW, mach, torx,
244240 HOSE, drain, includes
55
washer hd
shown)
(not shown)
threaded
PC
includes
inclu
include
ft (not shown)
washer hd
upper/lower
54b
painted
39
12, 47, 70
des 25
s 132
54a,
Qty.
Ref.
57 246385 STRAINER, 7/8-14 unf
4
59 17C485 FRAME, cart, hi
1
60 17C992 KIT, stinger tube,
1
1
61 See page 50GUN, spray (not shown)
1
1
62 276888 CLIP, drain line
1
63 See page 50LABEL, danger
1
65 See page 50LABEL, warning
1
67 109032 SCREW, pan hd
69 15E813 NUT, jam
1
70 17C483 COVER, pump rod
1
74 287489 HANDLE
75 108691 PLUG, tubing
81 106062 WHEEL
82 15B999 CLIP, retaining
1
83 104811 CAP, hub
84 15B652 WASHER, suction
1
87 17C281 TUBE, suction
1
105 17C990 HANGER, pail
107 111040 NUT, lock, insert, nylon
114 15D281 HANGER, stand (on
1
115 15C982 CAM, cart (on select
1
116 114531 SCREW, mch, hex (on
8
117 15G447 PLUG, tubing
122 118852 SCREW, thd forming
1
1
123 287184 TOOL BOX (on select
1
132 16H137 PACKING, O-ring
139 127914 SCREW, mach, slot,
1
Replacement Danger and Warning labels,
1
tags, and cards are available at no cost.
1
* For motor brush kit order 287735
includes
76, 84, 87
select models)
models)
select models)
(on select models, not
shown)
models, not shown)
hex
Qty.
1
1
13,14, 57, 69,
1
1
1
1
4
1
1
1
2
2
2
2
1
1
1
2
1
2
4
1
3
1
1
3
334530A 49
Accessories and Labels
Accessories and Labels
Ref. 52
Label,
Front,
Upper/
Lower
17C830/
17C831
17C830/
17C835
17C830/
17C839
17C827/
17C828
17C827/
17C833
17C827/
17C837/
17C864/
17C866
Ref. 53
Label,
Side
Ref. 61
Gun,
Spray
Ref. 63
Label,
Danger
Ref. 65
Label,
Warning
17C832 826085 15H085 # 195793 &
17C836 826085 15H085 # 195793 &
17C840 826085 15H085 # 195793 &
17C829 288420 15H085 # 195793 &
17C834 288420 15H085 # 195793 &
17C838 288420 15H085 # 195793 &
17C867 288438 - - -
16G596
Sprayer
Model
826199
826200
826201
826202
826203
826204
826205
826206
17C327
17C328
17C332
17C333
17C334
17C335
17C336
17C337
17C369
17C372
Ref. 34
Card,
Medical
Alert
Ref. 46
Hose, 1/4
in. x 50 ft
222385 # 826079
222385 # 826079
222385 # 826079
222385 # 240794
222385 # 240794
222385 # 240794
222385 # 240794
17C373
17C374
17C375
17C376
222385 # 240794
17C864/
17C868
17C869 288438 - - -
16G596
17C377
17C378
17C381
17C382
222385 # 240794
17C383
17C393 222385 # 240794
17C394
17C395
17A134
17A134
240794
240794
17C399 222385 # 240794
17C398
17C401
17A134
240794
17C402
17C403
17C404
17A134
240794
17C827/
17C837
17C827/
17C828
17C827/
17C857
17C827/
17C828
17C827/
17C833
17C827/
17C833
17C827/
17C837
17C838 288438 - - -
16G596
17C829 17C926 15H086 * 195792 @
17C858
288427/
288436
15H087 @ 195792 @
17C829 17C926 15H087 @ 195792 @
17C834
17C834
17C838
288427/
288436
288427/
288436
288427/
288436
15H086 * 195792 @
15H087 @ 195792 @
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.
50 334530A
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
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 - 16.9 N•m)
48-72 in-lb (5.4 - 8.1 N•m)
12567
8
1
Control Box
334530A 51
Control Box
Control Box Parts List
Ref. Part Description
2 117828 PACKING, o-ring
3 111457 PACKING, o-ring
4 111600 PIN, grooved
5 277364 GASKET, seat, valve
6 120405 SCREW, mach,
7 SCREW, slot, hex,
115498 230V and UK models
123850 120V US/Japan
11 116167 KNOB, potentiometer
12 117501 SCREW, mach, hex
15 MANIFOLD, fluid
15G455 Models without
15T811 Models with pressure
16 FILTER, fluid
246425
246384
246382
246383
17 287902 KIT, repair, filter cap
18 15B071 INSERT, filter
19 15G562 BUSHING, control box
20 15B120 GROMMET,
24 162453 NIPPLE, (1/4 npsm x
26 15E022 SEAT, valve
27 187625 HANDLE, valve, drain
30 BOARD, filter
287911 120V, GFI, US/Japan
287912 110V, UK
287913 230V
35 239914
36 224807 BASE, valve
Phillips, pan hd
wash hd
models
washer hd
pressure gauge
gauge
30 mesh
60 mesh, original
100 mesh
200 mesh
includes 18
transducer
1/4 npt)
VALVE, drain includes
5, 26
Qty.
Ref. Part Description
37 256219 POTENTIOMETER,
1
1
38 243222 TRANSDUCER,
1
1
5
47 117493 SCREW, mach, hex
1
48 BOX, control board
24W893 120V, 490/495
1
6
24W894 120V, 595 models,
1
24W895 230V
24W896 110V, UK
49 17D154 LABEL, control,
1
50 COVER, control
277229 Models without display
24W892 DIGITAL, display
51 LABEL, control
1
1
1
1
2
1
1
1
17C964 Models without display
17C875 Models with display
56
253367 US, 490/495 models
253371 US, 595 models
253378 Japan
253373
242001
253369
253370
58 195428
90 195551 RETAINER, plug,
1
91 CORD SET, adapter
1
253368 UK
242005
adj, pressure with nut
pressure control,
includes 3
washer hd
includes 6, 7, 11, 19,
30, 37, 49, 58, 127,
128, 129
models, US/Japan
includes 19
US/Japan includes 19
w/FastFlush
includes 51, 106, 107
CORD, power
Multicord, Asia/ANZ
Europe
CEE 7/7
Multicord, Europe
BOOT, toggle
adapter
Multicord models
CEE 7/7 models
Australia
Qty.
1
1
4
1
1
1
1
1
1
2
1
1
52 334530A
Control Box
Ref. Part Description
287121
92 244285
106 15G861 LABEL, smart control
107 15G588 LABEL, digital tracking
108 115523 GAUGE, pressure,
127 120165
128 120406 SCREW, mach, hex
129 158674 O-RING, packing
KIT, ProGuard+, 230V models only
(not shown)
24W090 CEE 7/7
24W755
Italy, Denmark,
Sweden
ADPTER, Japan
display
system
fluid (on select models)
SCREW, mach,
Phillips, pan hd
washer hd
Multicord, IEC-320
Qty.
1
1
1
1
1
1
1
1
334530A 53
Wiring Diagrams
ti7380b
On/O Switch
Black
Green
To P ower
Plug
Pressure
Transducer
J12
J11
Wiring Diagrams
120V, US/Japan
MOTOR
Potentiometer
54 334530A
110V, UK / 230V
MOTOR
ti7454b
On/O Switch
Blue
Black
Blue
Green
Brown
To P ower
Plug
Potentiometer
Pressure
Transducer
J12
J11
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.
Wiring Diagrams
334530A 55
Technical Specifications
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
395/490/495 620 per gallon 164 per liter
595 540 per gallon 143 per liter
Generator Minimum
395/490 3500 W
495 3750 W
595 4000 W
Power Requirements
395/490 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. 57.1 cm
Hi-Boy 29 in. (Handle down)
38 in. (Handle up)
Length
Stand 16.25 in. 41.3 cm
Lo-Boy 26.5 in. 67.3 cm
Hi-Boy 23.25 in. 59.1 cm
Width
Stand 13.5 in. 34.3 cm
Lo-Boy 20 in. 50.8 cm
Hi-Boy 20.75 in. 52.7 cm
73.4 cm (Handle down)
96.5 cm (Handle up)
56 334530A
Technical Specifications
395/490/495/595
US Metric
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
Sound power
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.
90 dBa
100 dBa
334530A 57
Graco Standard Warranty
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, Graco 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 component parts.
Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco
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 warranty, 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.
58 334530A
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.
All written and visual data contained in this document reflects the latest product information available at
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 334530
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.
the time of publication.
Graco Headquarters: Minneapolis
www.graco.com
Revision A, November 2014
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