Graco ti13498a Operating instructions

IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this manual.
Save these instructions.
313558E rev.a
Ultra
®
Platinum Sprayers
- For Portable Airless Spraying of Architectural Coatings and Paints -
Repair
ti13498a
695/795
ti13630a
1095/MARK V

Table of Contents
2
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . . . 7
General Repair Information . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
240 Vac and 110 Vac Motor Control Board . . . . . . 19
240 Vac Filter Board . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Adjust Potentiometer . . . . . . . . . . . . . . . 22
Pressure Control Transducer . . . . . . . . . . . . . . . . . 24
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive and Bearing Housing Replacement . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Displacement Pump Replacement for 695/795 . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Displacement Pump Replacement 1095/Mark V . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Smart Control-E Board Replacement . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AutoClean Reed Switch Replacement . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
E-Control Battery Replacement . . . . . . . . . . . . . . . . . 40
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . 42

Models
3
Models
Vac Model Hi-Boy
240 Europe
695 257034
795 257037
1095 257040
Mark V 257043
240 Europe
Multi-Cord
695 257035
795 257038
1095 257041
Mark V 257044
110 UK
695 257036
795 257039
1095 257042
Mark V 257045

Warnings
4
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 symbol refers to procedure-specific risks. Refer back to
these warnings. Additional, product-specific warnings may be found throughout the body of this manual where appli-
cable.
Grounding Instructions
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.
WARNING
GROUNDING
• 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 qual-
ified electrician.
• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illus-
trated in the figure 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 3-blade grounding plug and a 3-slot 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
(2.5 mm2) 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.
ti9164a

Warnings
5
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as
cigarettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity
creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray sys-
tem, 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.
• 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.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep
pump assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• 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.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
SKIN INJECTION HAZARD
• 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.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure for turning off the unit.
• 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.
• 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.
WARNING

Warnings
6
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.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1, 1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
WARNING

Component Identification
7
Component Identification
1.
2.
3.
4.
5. 6. 7. 8.
9.
10.
11.
12.
13.14.
ti13668a
English
1 Premium Digital Display
2 ON/OFF Switch
3 Pressure Control / E-Control
4 Prime / Spray Valve
5 Filter
6AutoClean2™
7 Siphon Tube
8Pump
9Bearing Housing / ProConnect™
10 Fluid Outlet
11 Drain Tube
12 Trigger Lock
13 Model/Serial Tag
14 WatchDog™Switch (not Mark V)

General Repair Information
8
General Repair Information
Pressure Relief Procedure
System pressure must be manually relieved to prevent
system from starting or spraying accidentally. Fluid un-
der high pressure can be injected through skin and
cause serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pressure Re-
lief Procedure whenever you:
• are instructed to relieve pressure
• stop spraying
• check or service any system equipment
• install or clean spray tip
1. Turn pressure control knob to zero.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Hold metal part of gun firmly to grounded metal pail.
Trigger gun to relieve pressure.
5. Lock gun safety latch.
6. Open prime valve. Leave prime valve open until
ready to spray again.
If suspected that spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following steps above, VERY SLOWLY loosen
tip guard retaining nut or hose end coupling to re-
lieve pressure gradually, then loosen completely.
Then clear tip or hose obstruction.
1. Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts are not normally provided with replacement
assemblies.
To reduce risk of serious injury, including electric shock,
do not touch moving or electrical parts with fingers or
tools while testing repair. Shut off and unplug sprayer
when inspection is complete. Install all covers, guards,
gaskets, screws, washers and shroud before operating
sprayer.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review repair
procedure to verify procedure was done correctly. If
necessary, see Troubleshooting, page 10, for other
possible solutions.
NOTICE
To reduce risk of pressure control malfunction:
• Use needle-nose pliers to disconnect wire. Never
pull on wire, pull on connector.
• Mate wire connectors properly. Center flat blade of
insulated male connector in female connector.
• Route wires carefully to avoid interference with
other connections of pressure control. Do not
pinch wires between cover and control box.

Grounding
9
Grounding
Improper installation or alteration of grounding plug re-
sults in risk of electric shock, fire or explosion that could
cause serious injury or death.
1. Ultra Max II 695, 795 and 1095 100-200 Vac models
require a 50/60 Hz, 15A circuit with a grounding
receptacle. Ultra Max II 1595/Mark V 120 Vac mod-
els require a 50/60 Hz 20A circuit with a grounding
receptacle; 220-240 Vac models require a 50/60 Hz,
10A circuit with a grounding receptacle.
2. Do not alter ground prong or use adapter.
3. 120 Vac: A 12 AWG, 3 wires with grounding prong,
300 ft (90 m) extension cord may be used. 220-240
Vac: You may use a 3-wire, 1.0 mm (12 AWG) (mini-
mum) extension cord up to 90 m long. Long lengths
reduce sprayer performance.
ti2810a

Troubleshooting
10
Troubleshooting
Mechanical/Fluid Flow
Relieve pressure; page 8.
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column
E=XX is displayed 1. Fault condition exists 1. Determine fault correction from table,
page 12.
False tripping of WatchDog
system. EMPTY is dis-
played. Pump does not run.
1. Operating conditions out of
WatchDog parameters. Pump
output is low, see below.
1. Turn pressure down. Refer to operation
manual for adjusting. Operate without
WatchDog active; see operation manual.
Pump output is low 1. Spray tip worn 1. Follow Pressure Relief procedure Warn-
ing, then replace tip. See your separate
gun or tip manual.
2. Spray tip clogged 2. Relieve pressure. Check and clean spray
tip.
3. Paint supply 3. Refill and reprime pump.
4. Intake strainer clogged 4. Remove and clean, then reinstall
5. Intake valve ball and piston ball
are not seating properly
5. Remove intake valve and clean. Check
balls and seats for nicks; replace if neces-
sary; see pump manual 310643 or
310894. Strain paint before using to
remove particles that could clog pump.
6. Suction hose connections 6. Tighten any loose connections. Check for
missing or damaged seals.
7. Fluid filter, tip filter, or tip is
clogged or dirty.
7. Clean filter; see operation manual.
8. Prime valve leaking 8. Relieve pressure. Repair prime valve.
9. Verify pump does not continue to
stroke when gun trigger is
released. (Prime valve not leak-
ing.)
9. Service pump; see pump manual 310643
or 310894.
10. Leaking around throat packing
nut which may indicate worn or
damaged packings.
10. Replace packings; see pump manual. Also
check piston valve seat for hardened paint
or nicks and replace if necessary. Tighten
packing nut/wet-cup.
11. Pump rod damage 11. Repair pump. See pump manual 310643
or 310894.
12. Low stall pressure 12. Turn pressure knob fully clockwise. Make
sure pressure control knob is properly
installed to allow full clockwise position. If
problem persists, replace pressure trans-
ducer.
13. Piston packings are worn or
damaged
13. Replace packings; see pump manual
310643 or 310894.

Troubleshooting
11
Pump output is low 14. O-ring in pump is worn or dam-
aged
14. Replace o-ring; see pump manual 310643
or 310894.
15. Intake valve ball is packed with
material
15. Clean intake valve; see pump manual
310643 or 310894.
16. Pressure setting is too low 16. Increase pressure; see pump manual
310643 or 310894.
17. Large pressure drop in hose with
heavy materials
17. Use larger diameter hose and/or reduce
overall length of hose. Use of more than
100 ft of 1/4 in. hose significantly reduces
performance of sprayer. Use 3/8 in. hose
for optimum performance (50 ft minimum).
Motor runs but pump does
not stroke
1. Displacement pump pin (32)
damaged or missing; see pump
manual 310643 or 310894.
1. Replace pump pin if missing. Be sure
retainer spring (31) is fully in groove all
around connecting rod; see pump manual
310643 or 310894.
2. Connecting rod assembly (43)
damaged; see pump manual
310643 or 310894.
2. Replace connecting rod assembly; see
pump manual 310643 or 310894.
3. Gears or drive housing damaged,
page 27.
3. Inspect drive housing assembly and gears
for damage and replace if necessary; see
pump manual 310643 or 310894.
Excessive paint leakage into
throat packing nut
1. Throat packing nut is loose 1. Remove throat packing nut spacer.
Tighten throat packing nut just enough to
stop leakage.
2. Throat packings are worn or
damaged
2. Replace packings; see pump manual
310643 or 310894.
3. Displacement rod is worn or
damaged
3. Replace rod; see pump manual 310643 or
310894.
Fluid is spitting from gun 1. Air in pump or hose 1. Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
2. Tip is partially clogged 2. Clear tip; see tip guard manual 309640.
3. Fluid supply is low or empty 3. Refill fluid supply. Prime pump; see pump
manual 310643 or 310894. Check fluid
supply often to prevent running pump dry.
Pump is difficult to prime 1. Air in pump or hose 1. Check and tighten all fluid connections.
Reduce engine speed and cycle pump as
slowly as possible during priming.
2. Intake valve is leaking 2. Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well.
Reassemble valve.
3. Pump packings are worn 3. Replace pump packings; see pump man-
ual 310643 or 310894.
4. Paint is too thick 4. Thin the paint according to the supplier’s
recommendations.
No display, sprayer operates 1. Display is damaged or has bad
connection
1. Check connections. Replace display.
TYPE OF PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK, refer to this column

Troubleshooting
12
Electrical
Symptom: Sprayer does not run or stops running.
Relieve pressure; page 8.
• Plug sprayer into correct voltage, grounded outlet
• Set power switch OFF for 30 seconds and then ON
again. This ensures sprayer is in normal run mode.
• Turn pressure control knob clockwise 1/2 turn
• View digital display
WARNING
To avoid electrical shock or moving parts hazards when
covers are removed for troubleshooting, wait 30 seconds
after unplugging power cord for stored electricity to dissi-
pate. Keep clear of electrical and moving parts during
troubleshooting procedures.
If no digital display is available, use control
board status light to troubleshoot prob-
lems: Turn ON/OFF switch OFF, remove
control cover and then turn power back
ON. Observe status light. Blinking LED to-
tal count equals digital error code i.e., two
blinks equals E=02.
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK
Sprayer does not run at all See flow chart, page 18.
Digital display is blank
Control board status light never
lights
Sprayer does not run at all Check transducer or transducer
connections
1. Make sure there is no pressure in the system (see
Pressure Relief, page 8). Check fluid path for clogs,
such as clogged filter.
2. Use airless paint spray hose with no metal braid
1/4 in. x 50 ft minimum. Smaller hose or metal braid
hose may result in high-pressure spikes.
3. Set sprayer to OFF and disconnect power to sprayer.
4. Check transducer and connections to control board.
5. Disconnect transducer from control board socket.
Check that transducer and control board contacts
are clean and secure.
6. Reconnect transducer to control board socket.
Connect power, set sprayer ON and control knob
1/2 turn clockwise. If sprayer does not run properly,
set sprayer to OFF and go to next step.
7. Install new transducer. Connect power, set sprayer
ON and control knob 1/2 turn clockwise. Replace
control board if sprayer does not run properly.
Digital display shows E=02
Control board status light blinks
2 times repeatedly

Troubleshooting
13
Sprayer does not run at all Check transducer or transducer
connections (control board is not
detecting a pressure signal).
1. Set sprayer to OFF and disconnect power to sprayer.
2. Check transducer and connections to control board.
3. Disconnect transducer from control board socket.
Check to see if transducer and control board
contacts are clean and secure.
4. Reconnect transducer to control board socket.
Connect power, set sprayer ON and control knob
to 1/2 turn clockwise. If sprayer does not run,
set sprayer to OFF and go to next step.
5. Connect a confirmed working transducer to control
board socket.
6. Set sprayer ON and control knob to 1/2 turn
clockwise. If sprayer runs, install new transducer.
Replace control board if sprayer does not run.
7. Check transducer resistance with ohmmeter (less
than 9k ohm between red and black wires and 3-6k
ohm between green and yellow wires).
Digital display shows E=03
Control board status light blinks
3 times repeatedly
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK

Troubleshooting
14
Sprayer does not run at all Control is commanding motor to run
but motor shaft does not rotate.
Possibly locked rotor condition, an
open connection exists between
motor and control, there is a
problem with motor or control board,
or motor amp draw is excessive.
1. Remove pump and try to run sprayer. If motor runs,
check for locked or frozen pump or drive train.
If sprayer does not run, continue to step 2.
2. Set sprayer to 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.
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.
Digital display shows E=05
Control board status light blinks
5 times repeatedly
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK
Green Blue Red Black
Green Blue Red Black
Green Blue Red Black
STEP 1:
STEP 2:
STEP 3:

Troubleshooting
15
Sprayer does not run at all 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.
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 the
proper resistance for each model (see table below).
Digital display shows E=05
Control board status light blinks
5 times repeatedly
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK
Resistance Table:
695 0 ohms
795 2k ohms
1095 3.9k ohms
MARK V 3.9k ohms
-
ti13140a

Troubleshooting
16
Sprayer does not run at all 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, follow
Step 1.
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.
3. 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 the
proper resistance for each model (see table below).
4. 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.
Digital display shows E=06
Control board status light blinks
6 times repeatedly
Sprayer does not run at all Check the connections. Control
is not receiving a motor position
sensor signal
1. Turn power OFF.
2. Disconnect motor position sensor and inspect for
damage at connectors.
3. Reconnect sensor.
4. Turn power ON. If error continues, replace motor.
Digital display shows E=09
Control board status light blinks
9 times repeatedly
Sprayer does not run at all Check to see if control board is over
heating.
1. Make sure motor air intake is not blocked.
2. Make sure fan has not failed.
3. Make sure control board is properly connected
to back plate and that conductive thermal paste
is used on power components.
4. Replace control board.
5. Replace motor.
Digital display shows E=10
Control board status light blinks
10 times repeatedly
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK
Resistance Table:
695 0 ohms
795 2k ohms
1095 3.9k ohms
MARK V 3.9k ohms
-
ti13140a

Troubleshooting
17
Sprayer Will Not Shut Off
1. Relieve Pressure, page 8. Leave prime valve open
and power switch OFF.
2. Remove control box cover so the control board
status light can be viewed if available.
Troubleshooting Procedure
Plumb pressure gauge into paint
hose, plug sprayer in, and turn power
switch ON. Does sprayer reach or
exceed its maximum pressure?
Unplug the transducer from control
board. Does motor stop running?
Bad transducer. Replace and test
with a new one.
Replace the control board.
Mechanical problem: See the proper
fluid pump manual for the sprayer for
further trouble shooting procedures.
NO
NO
YES
YES

Troubleshooting
18
Sprayer Will Not Run
(See following page for steps)
Remove control box cover. Turn
sprayer ON. Observe control
board status light on control
board (see page 12).
No light
Once Normal operation
Light on
Continuously
Control board
commanding
motor to run
Flashing See Error Code
section for further
troubleshooting
Connect a test
transducer to the
board. Does the
motor run?
Replace
potentiometer.
Pressure switch.
See Step 3. Is the
proper reading
present through the
thermal switch
wires?.
Replace the
ON/OFF switch.
See step 4. Does
the motor run?
See Step 1. Do
you have over
100 AC volts?
See Step 2. Do
you have over
100 AC volts?
Repair or
replace
power cord.
If motor is hot, let cool and
retest. If Step 4 still shows
incorrect resistance, replace
motor. The motor has
a defective thermal device.
Replace the
transducer
Replace the
control board.
YES
YES
YES
NO
NO
NO
NO
YES
YES
NO

Troubleshooting
19
240 Vac and 110 Vac Motor Control Board
Removal
Relieve pressure; page 8. Wait 5 minutes before servic-
ing.
1. Remove Motor Shroud:
a. Remove bolts from motor shroud.
b. Remove pressure tube from sprayer.
c. Remove bottom screw from toolbox.
d. Loosen (but do not remove) four nuts on shelf.
Carefully slide shelf forward.
e. Remove shroud.
f. Slide shelf back and tighten four nuts on shelf.
2. Remove all four screws (38) and cover (96).
3. Disconnect display connector (A) from motor control
board (52).
4. Remove bottom two screws (39). disconnect poten-
tiometer connector (C) from motor control board
(52). Disconnect power cord connectors (D) and fil-
ter board connectors (J) from ON/OFF switch (33)
and remove control panel (68).
5. Disconnect WatchDog switch connector (X) and
reed switch connector (L) from motor control board.
6. Disconnect motor control board power connectors
(K) from filter board (146).
7. Remove top two screws (39) and control box (61).
8. Disconnect transducer connector (E) from motor
control board.
9. Disconnect motor connectors (F, G and H).
10. Remove six screws (27), two screws (102) and con-
trol board.
Installation
1. Apply a small amount of thermal compound 15U114
or 110009 (5) to shaded areas on rear of motor con-
trol board (52).
2. Install motor control board (52) with six screws (27).
Install and tighten two screws (102).
3. Connect motor connectors (F, G and H) and install
into baffle.
4. Connect transducer connector (E) to motor control
board.
5. Connect motor control board power connectors (K)
to filter board (146).
6. Install control box (61) with top two screws (39).
7. Connect filter board power connectors (J) and
power cord connectors (D) to ON/OFF switch (33).
8. Connect potentiometer connector (C) to motor con-
trol board.
9. Connect WatchDog switch (X) and reed switch con-
nector (L) to motor control board.
10. Install control panel (68) with two screws (39).
11. Connect display connector (A) to motor control
board (52).
12. Install cover (96) with four screws (38)
13. Install Motor Shroud.
a. Loosen (but do not remove) four nuts on shelf
and slide shelf forward.
b. Replace shroud.
c. Slide shelf back and tighten four nuts on shelf.
d. Replace bottom screw from toolbox and tighten.
e. Replace pressure tube from sprayer.
f. Replace bolts from motor shroud.
NOTICE
To reduce risk of motor control board failure, do not
overtighten screws (102) which can damage the elec-
tric components.

Troubleshooting
20
240 Vac Filter Board
Relieve pressure; page 8.
Removal
1. Remove four screws (38) and cover (96).
2. Disconnect display connector (A) from motor control
board (52).
3. Remove bottom two screws (39). disconnect poten-
tiometer connector (C) from motor control board
(52). Disconnect power cord connectors (D) and fil-
ter board connectors (J) from ON/OFF switch (33)
and remove control panel (68).
4. Disconnect WatchDog switch connector (X) and
reed switch connector (L) from motor control board.
5. Disconnect motor control board power connectors
(K) from filter board (146).
6. Remove four screws (163) from filter board (146).
Installation
1. Install filter board (146) with four screws (163).
2. Connect motor control board power connectors (K)
to filter board (146).
3. Connect filter board power connectors (J) to top two
terminals of ON/OFF switch (33) and power cord
connectors (D) to bottom two terminals of ON/OFF
switch.
4. Connect potentiometer connector (C) to motor con-
trol board (52).
5. Connect WatchDog switch (X) and reed switch con-
nector (L) to motor control board.
6. Install control panel (68) with two screws (39).
7. Connect display connector (A) to motor control
board (52).
8. Install cover (96) with four screws (38).
AA
240 Vac 5
52
96
38
39
115
33 J
A163
146
61 K
82
C
C
E80
A
20
67
E
52
26
34
82
68
X
39
ti13672a
F
G
H
L