Graco ultra max ii Operating instructions

311365H
ENG
Ultra
®
Max II/Ultimate Mx II
- For Portable Airless Spraying of Architectural Coatings and Paints. For professional use only.
Not for use in explosive atmospheres.-
3300 psi (22.8 MPa, 227 bar) Maximum Working Pressure
See page 3 for model information, including maximum working pressure and approvals.
Korean patent 10-0579681
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this
manual. Save these instructions.
MARK V
ti13461a
ti13460a
1095/1595 HI
ti13459a
695/795 LOW
695/795 HI
ti13450a
Repair

Table of Contents
2 311365H
Table of Contents
Table of Contents ...........................2
Models ....................................3
Warnings ..................................5
Component Identification and Function ...........8
General Repair Information ....................9
Pressure Relief Procedure .................9
Grounding ................................10
Troubleshooting ............................11
Mechanical/Fluid Flow ...................11
Electrical ..............................13
Pressure Control Board ......................20
100 - 120 Vac North American and
Japan/Taiwan Motor Control Board .........20
240 Vac Motor Control Board ..............23
240 Vac Filter Board .....................25
110 Vac U.K. Motor Control Board ..........26
110 Vac U.K. Filter Board .................28
Pressure Adjust Potentiometer .............30
Pressure Control Transducer ..............31
Notes ....................................33
Drive and Bearing Housing Replacement ........34
Disassembly ...........................34
Assembly .............................34
Motor Replacement .........................36
Removal ..............................36
Installation .............................36
Displacement Pump Replacement for 695/795 ....38
Removal ..............................38
Installation .............................39
Displacement Pump Replacement
1095/1595/Mark V ..........................40
Removal ..............................40
Installation .............................41
Wiring Diagram ............................43
Wiring Diagram ............................44
Wiring Diagram ............................45
Wiring Diagram ............................46
Notes ....................................47
Graco Standard Warranty ....................48

Models
311365H 3
Models
Vac Model Type Lo-Boy Hi-Boy
120
North America
695 Standard 255130 249642
Premium 255131 249644
795 Standard 255132 249646
Premium 255133 249648
1095 Standard 249651
Premium 249653
1595 Standard 253060
Premium 253059
Mark V 249904
120
North America
1595 Standard 249658**
Premium 249659**
Mark V 249903**
Ultimate Mx II
695 Standard 826093 826067
Premium 826094 826069
795 Standard 826071
Premium 826072
1095 Standard 826073
Premium 826074
1595 Standard 826082
Premium 826081
Ultimate Mx II 1595 Standard 826075
Premium 826076
240
Europe
695 255134 249663
795 249666
256165
1095 249667
Mark V 249905
256166
240
Europe Multi-cord
695 255135 249668
795 249671
1095 249672
Mark V* 249907
110
UK
695 249673
795 249674
1095 249675
Mark V 249906
240
Asia
695 255138 249681
795 249683
1095 249684
*Also for Asia and Australia;
**Not ETL Approved
All models not available in all
countries.

Models
4 311365H
240
Australia
695 255139 249685
795 255140 249687
1095 249688
100
Japan & Taiwan
695 255136 249676
795 255137 249678
1095 249680
Vac Model Type Lo-Boy Hi-Boy

Warnings
311365H 5
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.
WARNING
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 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
6 311365H
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
311365H 7
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 and Function
8 311365H
Component Identification and Function
English
1 Premium Digital Display
2 ON/OFF switch
3 Pressure control
4 Prime / Spray valve
5 Filter
6AutoClean2™
7 Siphon tube
8 Pump
9Bearing Housing / ProConnect™
10 Fluid Outlet
11 Drain tube
12 Trigger Lock
13 Model/serial tag
14 WatchDog™Switch (not Mark V)
1.
2.
3.
4.
5. 6. 7. 8.
9.
10.
11.
12.
13.14.
ti13451a

General Repair Information
311365H 9
General Repair Information
Pressure Relief Procedure
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.
NOTE: If suspected that spray tip or hose is com-
pletely clogged, or that pressure has not been fully
relieved after following steps above, VERY SLOW-
LY loosen tip guard retaining nut or hose end cou-
pling to relieve pressure gradually, then loosen
completely. Then clear tip or hose obstruction.
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair
procedures. These parts are not normally
provided with replacement assemblies.
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 11, for other possible solutions.
System pressure must be manually relieved to pre-
vent system from starting or spraying accidentally.
Fluid under high pressure can be injected through
skin and cause serious injury. To reduce risk of in-
jury from injection, splashing fluid, or moving parts,
follow Pressure Relief Procedure whenever you:
• are instructed to relieve pressure
• stop spraying
• check or service any system equipment
• install or clean spray tip
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.
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 un-
plug sprayer when inspection is complete. Install all
covers, guards, gaskets, screws, washers and
shroud before operating sprayer.

Grounding
10 311365H
Grounding
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 models 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) (minimum) extension cord up to
90 m long. Long lengths reduce sprayer
performance.
Improper installation or alteration of grounding
plug results in risk of electric shock, fire or
explosion that could cause serious injury or
death.
ti2810a

Troubleshooting
311365H 11
Troubleshooting
Mechanical/Fluid Flow
Relieve pressure; page 9.
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 13.
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
12 311365H
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 34.
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
311365H 13
Electrical
Symptom: Sprayer does not run or stops running.
• 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.
Relieve pressure; page 9.
TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK
Sprayer does not run at all See flow chart, page 19.
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 9). 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
14 311365H
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
311365H 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.
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 combinations1&3and2&3.Pin4
(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
16 311365H
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
-
100k ohm
ti13140a

Troubleshooting
311365H 17
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
-
100k ohm
ti13140a

Troubleshooting
18 311365H
Sprayer Will Not Shut Off
1. Relieve Pressure, page 9. 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 ex-
ceed 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
311365H 19
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 13).
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 pres-
ent through the ther-
mal 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 re-
test. If Step 4 still shows incor-
rect 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

Pressure Control Board
20 311365H
Pressure Control Board
100 - 120 Vac North American and Japan/Taiwan Motor Control Board
Removal
1. Remove four screws (38) and cover (96).
2. Disconnect display connector (A) from motor
control board.
3. Remove bottom two screws (39) and allow
control panel (68) to hang down freely.
4. Disconnect control board power lead(s) (D)
from ON/OFF switch (33) and motor control
board (52).
5. Disconnect potentiometer connector (C) from
motor control board.
6. Disconnect WatchDog (49) switch connector
(X) from motor control board.
7. Disconnect 15/20A switch (178) (1595 model
only).
8. Disconnect transducer connector (E) from
motor control board.
9. Disconnect motor connectors (F, G, and H)
from motor control board.
10. Remove motor shroud. Disconnect and remove
wiring from baffle.
11. Remove nut and screw (88) and disconnect
ground wire (87). Disconnect coil connector
(Y). Remove coil (81).
12. Remove top two screws (39) and control box
(61).
13. Remove six screws (27), two screws (102) and
control board.
Installation
1. Use Acetone or equivalent solvent to
thoroughly remove thermal paste from the
pockets of the Powerbar.
2. Apply thermal compound:
a. For 2 capacitor boards and 6 capacitor
boards with the Powerbar shown in Figure 1
below, apply a small amount of thermal
compound 15U114 or 110009 (5) to shaded
component areas on rear of motor control
board (52).
b. For 6 capacitor boards with the Powerbar
shown in Figure 2 below, apply a small
amount of thermal compound 15U114 or
110009 (5) into both pockets of the Power-
bar (69) and scrape across the pocket with
the provided scraper so an even layer is
remaining in the pocket.
Relieve pressure; page 9. Wait 5 minutes before
servicing.
NOTICE
To reduce risk of motor control board failure, do
not overtighten screws (102) which can damage
the electric components.
ti17334a
Figure 1
5
52
ti14693a
5
69
Figure 2