Operation, Parts Electric Airless Sprayers 334530A EN 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.
Contents Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Stand Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models Models Hi-Boy Stand VAC Lo-Boy Model Ultra MAX II 490 PC Pro Ultimate MX II 490 PC Pro Ultra MAX II 110474 495 PC Pro 120 Certified to USA Ultimate MX II CAN/CSA 495 PC Pro C22.2 No.
Warnings 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.
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.
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.
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.
Component Identification Component Identification Stand Models M B U A K V W S D R P N G J F F L H ti24942a A B D F G H J K L 8 ON/OFF Switch Pressure Control Prime Valve Tip Guard Spray Tip Gun Airless Hose Power Cord Trigger Lock M N P R S U V W Drain Tube Fluid Intake Pump Fluid Outlet Power Cord Wrap Filter Finger Guard / TSL Fill Point Display Model/Serial Tag (Not shown, located on bottom of unit.
Component Identification Lo-Boy Models B M A K V W U D R P N G J F F L H ti24943a A B D F G H J K L ON/OFF Switch Pressure Control Prime Valve Tip Guard Spray Tip Gun Airless Hose Power Cord Trigger Lock 334530A M N P R U V W Drain Tube Fluid Intake Pump Fluid Outlet Filter Finger Guard / TSL Fill Point Display Model/Serial Tag (Not shown, located on bottom of unit.
Component Identification Hi-Boy Models S A B T U K V W P D R M N G J F F L H ti24944a 10 334530A
Component Identification Hi-Boy Models A B D F G H J K L M N ON/OFF Switch Pressure Control Prime Valve Tip Guard Spray Tip Gun Airless Hose Power Cord Trigger Lock Drain Tube Fluid Intake 334530A P R S T U V W Pump Fluid Outlet Hanger Filter Finger Guard / TSL Fill Point Pail Hook Display Model/Serial Tag (Not shown, located on bottom of unit.
Grounding 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.
Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. 3. Remove tip guard. 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.
Pressure Relief Procedure 5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. 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. c. Loosen nut or coupling completely. Clear hose or tip obstruction.
Setup Setup 2. Connect other end of hose to gun. 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. ti24633a 3. Use wrenches to tighten securely. 4. Engage trigger lock.
Setup 5. Remove tip guard. ti24638a 7. 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. 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.
Setup 8. Make certain ON/OFF switch is OFF. 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. ti24586a 9. Plug power supply cord into a properly grounded electrical outlet. Check flushing fluid for compatibility with material that is to be sprayed. A secondary flush with a compatible fluid may be necessary.
Setup 22. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun and flush until clean. 18 23. Turn ON/OFF switch to OFF position. 24. Engage trigger lock. 25. Sprayer is now ready to startup and spray.
Startup Startup 1. Perform Pressure Relief Procedure, page 13. 2. Turn pressure control to lowest pressure. ti24953a 3. Turn ON/OFF switch to ON position. ti24646a 7. Hold gun against grounded metal waste pail. Trigger gun until paint appears. ti24644a 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. 15 s ti24954a 6. Turn prime valve horizontal.
Startup 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. 20 s ti24649a 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. 20 Inspect for leaks.
Operation Operation Spray Tip Installation 3. Screw assembly onto gun. Tighten. 1. Perform Pressure Relief Procedure, page 13. 2. Use spray tip (A) to insert OneSeal™ (B) into tip guard (C). C B A ti24653a 2. Insert Spray Tip. ti24652a Spray 1. Spray test pattern. Adjust pressure to eliminate heavy edges.
Operation 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%. ti24674a 2. ti24673a 4. Engage trigger lock. Return Spray Tip to original position. Disengage trigger lock and continue spraying. 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.
Operation Digital Display 4. Press and hold display button to change pressure units (psi, bar, or MPa). 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. ti2888a Stored Data Display ti24651a 1. Turn ON/OFF switch to OFF position. ti24644a ti24586a 3. The pressure is displayed.
Operation 2. To enter Stored Data Mode, press and hold display button and turn ON/OFF switch to ON position. 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. ti2824a ti24644a 3. 4.
Operation Cleanup 1. Perform Pressure Relief Procedure, page 13. 2. Remove tip guard and Spray Tip. For additional information, see separate gun manual. 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.
Operation 5. To flush drain tube and pump turn prime valve down. 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. 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. ti24991a 9. Stop triggering gun. 10. Raise fluid intake above flushing fluid.
Operation 11. With prime valve horizontal. Trigger gun into flushing pail to purge fluid from hose. 12. Engage trigger lock. ti24718a 20 s 15. If flushing with water, flush again with mineral spirits or Pump Armor to leave a protective coating to prevent freezing or corrosion. ti24649a 13. Turn pressure control knob to OFF and turn ON/OFF switch to OFF position. Disconnect power to sprayer. ti24719a 16. Wipe sprayer, hose and gun with a rag soaked in water or mineral spirits. ti24992a 14.
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. Daily or each time you spray Inspect motor shield vents for blockage. Fill TSL by adding through TSL fill point. Inspect motor brushes for wear. Brushes must be 1/2 in. (13mm) minimum length.
Troubleshooting Troubleshooting Mechanical/Fluid Flow 1. Follow Pressure Relief Procedure, page 13, before checking or repairing. Problem 2. Check all possible problems and causes before disassembling the unit. What to Check If check is OK, go to next check What to Do When check is not OK, refer to this column For units with display: 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.
Troubleshooting Problem Pump output is low What to Check If check is OK, go to next check What to Do When check is not OK, refer to this column 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.
Troubleshooting Problem Fluid is spitting from gun Pump is difficult to prime Sprayer operates for 5 to 10 minutes then stops 334530A What to Check If check is OK, go to next check What to Do When check is not OK, refer to this column 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 22. Fluid supply is low or empty. Refill fluid supply. Prime pump. See pump manual.
Troubleshooting Electrical 4. 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. View digital display or remove control box cover to view control board status light.
Troubleshooting Problem What to Check How to check Sprayer does not run at all See flow chart, page 38. 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 Control board. Replace control board.
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 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.
Troubleshooting 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.
Troubleshooting 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. 1-3 ohms - 8.Reconnect motor connector(s) to control board socket(s).
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 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.
Troubleshooting Sprayer Will Not Run (See following page for steps) Sprayer Will Not Run (see following pages for steps) Remove Control box cover. Turn sprayer ON. Observe control board status light on control board (see page 27). See Step 1. Do you have over 100 VAC (220 VAC for 230v units)? No Light Once Normal Operation YES Control board Light on continuously Commanding motor to run Flashing See Code section for further troubleshooting See Step 3.
Troubleshooting Step 1: Step 2: Plug Power cord in and turn switch ON. Connect probes to ontrol board. Turn meter to AC Volts. Plug Power cord in and turn switch ON. Connect probes to control board. Turn meter to AC Volts 110-120 AC 110-120 AC V V - - On/Off Switch Blue Brown Power Cord Green Power Cord Green Black Blue Step 3: Step 4: Check motor thermal switch. Unplug yellow wires. Meter should read 100 ohms. NOTE: Motor should be cool during reading. Disconnect potentiometer.
Troubleshooting 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.
395/490/495 Stand Sprayers 395/490/495 Stand Sprayers Ref. Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 63 2 23 2 12 53 65 54 54a 54b 68 71 59 47 1 47 67 1 See page 51.
395/490/495 Stand Sprayers Ref. Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 3 Hammer tight 4 25-30 ft-lb (33.9 - 40.
395/490/495 Stand Sprayers 395/490/495 Stand Sprayers Parts List Ref.
395/490/495/595 Lo-Boy Sprayers 395/490/495/595 Lo-Boy Sprayers Ref. 63 2 12 Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 23 53 65 54a 54 54b See page 51.
395/490/495/595 Lo-Boy Sprayers Ref. Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 3 Hammer tight 4 25-30 ft-lb (33.9 - 40.
395/490/495/595 Lo-Boy Sprayers 395/490/495/595 Lo-Boy Sprayers Parts List Ref. Part 12 117501 13 14 22 23 115099 117559 17C541 15G449 25 33 180131 206994 34 See page 50 39 241920 40 41 42 43 44 45 46 47 52 53 249194 17C487 17C489 24W817 24W640 24X020 24X021 24W830 See page 50 117493 See page 50 See page 50 54* 24S022 46 Description Qty.
395/490/495/595 Hi-Boy Sprayers 395/490/495/595 Hi-Boy Sprayers Ref. 2 12 74 Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 3 23-27 in-lb (2.6 - 3.1 N•m) 63 23 53 65 54a See page 51.
395/490/495/595 Hi-Boy Sprayers Ref. 40 44 Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 3 Hammer tight 4 25-30 ft-lb (33.8 - 40.
395/490/495/595 Hi-Boy Sprayers 395/490/495/595 Hi-Boy Sprayers Parts List Ref.
Accessories and Labels Accessories and Labels Sprayer Model 826199 826200 826201 826202 826203 826204 826205 826206 17C327 17C328 17C332 17C333 17C334 17C335 17C336 17C337 17C369 17C372 17C373 17C374 17C375 17C376 17C377 17C378 17C381 17C382 17C383 17C393 Ref. 34 Card, Medical Alert Ref. 46 Hose, 1/4 in. x 50 ft 222385 # 826079 222385 # Ref. 52 Label, Front, Upper/ Lower Ref. 53 Label, Side Ref. 61 Gun, Spray Ref. 63 Ref.
Control Box Control Box Ref. Torque 1 140-160 in-lb (15.8 - 18.1 N•m) 2 30-35 in-lb (3.4 - 4.0 N•m) 5 20-25 in-lb (2.3 - 2.8 N•m) 6 37-43 ft-lb (50.2 - 58.3 N•m) 7 130-150 in-lb (14.7 - 16.9 N•m) 8 48-72 in-lb (5.4 - 8.
Control Box Control Box Parts List Ref.
Control Box Ref. Part Description Qty.
Wiring Diagrams Wiring Diagrams 120V, US/Japan MOTOR Potentiometer On/Off Switch J12 J11 Pressure Transducer Black To Power Plug Green ti7380b 54 334530A
Wiring Diagrams 110V, UK / 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.
Technical Specifications Technical Specifications 395/490/495/595 Sprayer Maximum fluid working pressure Maximum Delivery 395/490 495 595 Maximum Tip Size 395/490 495 595 Fluid Outlet npsm Cycles 395/490/495 595 Generator Minimum 395/490 495 595 Power Requirements 395/490 1Ø, 50/60 Hz 495 1Ø, 50/60 Hz 595 1Ø, 50/60 Hz Dimensions Height Stand Lo-Boy Hi-Boy Length Stand Lo-Boy Hi-Boy Width Stand Lo-Boy Hi-Boy 56 US Metric 3300 psi 228 bar, 22.8 MPa 0.54 gpm 0.60 gpm 0.68 gpm 2.0 lpm 2.3 lpm 2.6 lpm 0.
Technical Specifications 395/490/495/595 Weight Stand 395 490 / 495 Lo-Boy 395 490 / 495 595 Hi-Boy 395 490 / 495 595 US Metric 45.1 lb. 34 lb. 20.5 kg 15 kg 63 lb. 59.1 lb. 70 lb. 29 kg 26.8 kg 31.8 kg 66 lb. 66.1 lb. 73 lb. 30 kg 30 kg 33 kg Noise** (dBa) @ 70 psi (0.48 MPa, 4.
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.
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 the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English.
