Graco 395, 490, 495, 595 User Manual

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

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

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

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

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

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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

) 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

ti24942a

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

ti24943a

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

ti24944a

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

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Pressure Relief Procedure

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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

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