Graco Inc. 309674M Paint Sprayer User Manual
Contents
1. 1 For sprayers with digital display see Digital Display Messages 2 Remove screws 12 and cover 50 3 Turn ON OFF switch ON 4 Observe LED operation and reference following table DISPLAY LED BLINKS SPRAYER OPERATION INDICATES WHAT TO DO No Display Never blinks Sprayer stops Power is not Loss of power Check power source Relieve pressure applied Sprayer must be pres before repair or disassembly surized psi bar MPa Once Sprayer is pressurized Power is Normal operation Do nothing applied Pressure varies with tip size and pressure control set ting E 02 Two times Sprayer may continue to run Run away pressure Pres Replace motor control board or pressure repeatedly Power is applied sure greater than 4500 psi transducer 310 bar 31 MPa or dam aged pressure transducer E 03 Three times Sprayer shuts down and LED Pressure transducer is Check transducer connection Open drain repeatedly continues to blink three times faulty or missing valve Substitute new transducer for trans repeatedly ducer in sprayer If sprayer runs replace transducer E 04 Four times Sprayer shuts down and LED Line voltage is too high Check for voltage supply problems repeatedly continues to blink four times repeatedly Power is applied E 05 Five times Sprayer does not start or stops Motor fault Check for locked rotor shorted wiring or repeatedly and LED continues to blink five disconnected motor2. 3 Disconnect transducer lead from motor control board 49 4 cs transducer grommet 20 out of control box 5 Remove pressure control transducer 38 and o ring 3 from filter housing Installation 1 Install o ring 3 and pressure transducer 38 in fil ter housing 15 Torque to 30 35 ft lb 2 Thread transducer lead plastic connector through transducer grommet 20 and slide grommet into slot in control box housing 48 Install filter housing 15 with screws 47 4 Connect transducer lead J7 or J11 to motor control board 49 5 Install cover 50 with screws 12 SmartControl The SmartControl contains stored data to assist with troubleshooting and maintenance To view this stored data on the digital display WAS 1 Relieve pressure page 7 2 Plug in sprayer 1 Relieve pressure page 7 2 Remove screws 12 from cover 50 3 Disconnect potentiometer lead from motor control board 49 4 Remove potentiometer knob 11 nut 87a and pressure adjust potentiometer 37 Installation 1 Install pressure adjust potentiometer 37 and nut 37a a Turn potentiometer fully clockwise b Install knob 11 at full clockwise position 2 Connect potentiometer lead J8 or J12 to motor control board 49 See wiring diagram pages 22 23 and 24 for your sprayer model 3 Install cover 50 with screws 12 3 Hold down display button and turn sprayer ON 4
3. 23 On Off Switch Replacement UltraMax II Ultimate MX Il and ST Max Il 490 495 595 models ON OFF Switch Power Cord Board Kit NAS Removal 1 Relieve pressure page 7 2 Remove four screws 12 and control box cover 50 Power Cord 3 Remove green ground screw 19 and disconnect ground choke coil and black leads 4 Slide black power cord strain relief a out of slot in control box 48 to remove it On Off Switch 5 Remove switchboard mounting screw 6 6 Using a 5 8 in deep socket wrench remove ON OFF switch toggle boot 58 7 Slide switch 30 through opening in control box housing 24 8 Disconnect black lead between control boards 9 Remove switch board from box Installation 1 Reconnectblack lead between control and switch boards 2 Slide ON OFF switch 30 through opening in con trol box housing and position switch board 3 Place toggle boot 58 over ON OFF switch Using a 5 8 in deep socket wrench tighten securely 4 Install switchboard mounting screws 6 5 Slide power cord strain relief a into opening in con trol box 48 6 Reattach black and white power cord leads to con trol and switch boards 7 Reattach ground choke coil to ground screw 19 Replace and tighten green ground screw 8 Install pressure control cover 50 with four screws 12 ti7433a 309674M On Off Switch Replacement Wiring Diagram P
4. 2 x White 22 309674M On Off Switch Replacement 110 240 VAC Ultra Nova and ST Max 395 495 595 models AN Removal 1 Relieve pressure page 7 2 Remove four screws 12 and pressure control cover 50 3 Remove display connector B from plug C 4 Disconnect four wires A from ON OFF switch 58 ti2478b ON OFF Switch TP2 TP1 Brown To Power Plug Red 5 Remove toggle boot 30 and locking ring Remove ON OFF switch 58 Installation 1 Install new ON OFF switch 58 Install locking ring and toggle boot 30 2 Connect four wires A to ON OFF switch 58 3 Install display connector B to plug C 4 Install pressure control cover 50 with four screws 12 CAUTION 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 all loose wires so none lay in contact with inductor coil of filter board Potentiometer Black From Motor 309674M white x me Inductor Coil Cu E P Black E E Transducer Filter Board O R A J7 hy SSS O L2 L1 ti2478b 2 x White
5. Release display button about 1 second after turning on sprayer Sprayer model number displays U395 U495 for a few seconds and then data point 1 is displayed 5 Push display button and next data point displays 6 Turn sprayer OFF and then ON to exit stored data mode Data Point Definition 1 Number of hours power switch has been ON with power applied Ultra Ultimate Nova Super Nova and ST Max 395 495 595 only e Serial Number of sprayer UltraMax II Ultimate Max Il and ST Max Il 490 495 595 only Number of hours motor has been running Last error code Press and hold display button to clear error code to E 00 Software revision 28 309674M Motor Replacement Ultra Nova and ST Max 395 495 595 Models Only CAUTION Do not drop gear cluster 44 and 40 when removing from drive housing 42 Gear cluster may stay engaged in motor front end bell or drive housing Removal NaN 1 Relieve pressure page 7 2 Remove pump 41 Displacement Pump Replace ment page 15 3 Remove drive housing 42 Drive Housing Replacement page 17 4 Remove screws 12 from cover 50 5 Disconnect all leads from board 49 Remove screws 6 and board A Liberally apply grease 309674M Motor Replacement 6 Remove screws 47 and control box 48 7 Remove screws 47 and manifold 15 8 Remove screws 47 and motor 54
6. are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 This manual contains English MM 309674 Graco Headquarters Minneapolis International Offices Belgium Kor
7. 249978 ST Max Il 595 253015 249930 ST Max 395 223963 ST Max 495 233957 233975 230 ST Max 595 244436 Europe ST Max Il 490 249927 ST Max Il 495 249929 249979 ST Max Il 595 249931 ST Max 395 223972 ST Max 495 233973 233975 ST Max 595 244436 110 UK ST Max Il 490 249935 ST Max Il 495 249936 249980 ST Max Il 595 249937 Ultra 395 234180 Ultra 495 234183 234181 234182 Ultra 595 248660 244439 230 Asia Ultra Max Il 490 249932 Ultra Max Il 495 249933 253104 253105 Ultra Max Il 595 253107 249934 100 Ultra 495 234186 233974 Japan UltraMax Il 495 249938 253106 309674M Warnings Warnings The following are general warnings related to the setup use grounding maintenance and repair of this equipment Additional more specific warnings may be found throughout the body of this manual where applicable Symbols appearing in the body of the manual refer to these general warnings When these symbols appear throughout the manual refer back to these pages for a description of the specific hazard DE I tit FAI 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 Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Sprayer generates sparks When flammable liquid is used in or near the sprayer or for flush
8. Repair or replace times repeatedly Power is failed parts applied E 06 Six times Sprayer stops and LED blinks six Motor is too hot or there isa Allow sprayer to cool If sprayer runs cor repeatedly times repeatedly Power is fault in motor thermal rectly when cool check motor fan function applied device and air flow Keep sprayer in cool location If sprayer does not run when cool and con tinues to blink six times replace motor Power is applied Pressure less than 200 psi Increase pressure if desired Drain valve 14 bar 1 4 MPa may be open EMPTY Sprayer stops Power is applied Empty paint pail Loss of Refill paint pail Check for leaks or clogged pressure pump inlet Repeat Startup procedure E 10 Blinks 10 Sprayer does not start or stops High control board temper Make sure motor air intake in not times repeat and LED continues to blink 10 ature blocked edly times repeatedly Power is Make sure control board is properly con applied nected to the back plate and that con ductive thermal paste is used on the power components Ultra Ultimate Nova Super Nova and ST Max 395 495 595 Ultra Max II Ultimate MX Il and ST Max Il 490 495 595 309674M 27 Pressure Control Transducer Removal Pressure Control Repair Pressure Adjust Potentiometer Removal NAV NAS 1 Relieve pressure page 7 2 Remove screws 12 and cover 50
9. from frame 59 Installation 1 Install new motor 54 on frame 59 with screws 47 2 Install manifold 15 with screws 47 3 Install control housing 48 with screws 47 4 Install board 49 with screws 6 Connect all leads to board See wiring diagrams on pages 22 23 and 24 for your sprayer model 5 Install drive housing 42 Drive Housing Replace ment page 17 6 Install pump 41 Displacement Pump Replace ment page 15 ti2569b 29 UltraMax II Ultimate II and ST Max Il 490 495 595 Models Only CAUTION Do not drop gear cluster 44 and 40 when removing from drive housing 42 Gear cluster may stay engaged in motor front end bell or drive housing Removal NAV Relieve pressure page 7 2 Remove four screws 12 and shroud 23 3 Remove two screws 12 and front cover 22 4 Remove pump 41 Displacement Pump Replace ment page 15 5 Remove drive housing 42 Drive Housing Replacement page 17 6 Disconnect motor leads 30 Motor Replacement 7 Remove screws 47 and manifold 15 8 Remove screws 47 and control box 48 9 Remove screws 47 and motor 54 from frame 59 Installation 1 Install new motor 54 on frame 59 with screws 47 2 Install control housing 48 with screws 47 3 Install manifold 15 with screws 47 4 Connect motor leads See wiring diagram on page 25 5 In
10. more than 90 F 32 22 C and sprayer is not located in direct sun Move sprayer to shaded cooler area if possible Building circuit breaker opens as soon as sprayer switch is turned on CAUTION Any short in any part of the motor power circuit will cause the control circuit to inhibit sprayer operation Correctly diagnose and repair all shorts before checking and replacing control board All electrical wiring for damaged insulation and all terminals for loose fit or damage Also wires between pressure control and motor See page 28 Repair or replace any damaged wiring or terminals Securely reconnect all wires For missing inspection plate gasket see page 26 bent terminal forks or other metal to metal contact points which case a short Correct faulty conditions Motor control board by performing control board diagnostics See page 14 If diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn out a good board Replace with a new pressure control board See page 26 Building circuit breaker opens as soon as sprayer switch is turned on This problem only applies to Ultra Nova and STMax 395 495 595 model sprayers with brush motors They do not apply to UltraMax Il Ultimate MX Il and ST Max Il 490 495 595 model sprayers Motor armature for shorts Use an armature tester gr
11. or be permanently damaged Prevent pump corrosion and damage from freezing Never leave water or water base paint in sprayer when its not in use in cold weather Freezing fluids can seriously damage sprayer Store sprayer with Pump Armor to protect sprayer during storage 309674M Troubleshooting z IN AIA Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column Basic fluid pressure problems Basic Mechanical Problems 309674M Pressure control knob setting Motor will not run if at minimum setting fully counter clockwise Slowly increase pressure to see if motor starts Spray tip or fluid filter may be clogged Pump frozen or paint hardened in pump Relieve pressure page 7 and clear clog or clean filter refer to separate gun or tip instruction manual Thaw sprayer if water or water based paint has frozen in sprayer Place sprayer in warm area to thaw Do not start sprayer until thawed completely If paint hardened dried in sprayer replace pump packings See page 15 Displacement Pump Replace ment Displacement pump connecting rod pin must be completely pushed into connecting rod and retaining spring must be firmly in groove of pump pin See page 15 Motor Remove drive housing assem bly See page 17 Try to rotate fan by hand Push pin into place and secure
12. with spring retainer Replace motor if fan won t turn See page 19 Motor control board Board shuts down and displays error code See Motor Control Board Diagnos tics page 27 Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column Basic Electrical Problems Electric supply Meter must read e 210 255 VAC for 220 240V models e 85 130 VAC for 100 120V models Reset building circuit breaker Replace building fuse Try another outlet Extension cord Check extension cord continuity with volt meter Replace extension cord Sprayer power supply cord Inspect for damage such as insulation or wires Replace power supply cord page 24 Motor leads are securely fastened and properly mated Replace loose terminals crimp to leads Be sure terminals are firmly connected Clean circuit board terminals Securely reconnect leads Basic Electrical Problems These problems only apply to Ultra Nova and STMax 395 495 595 model sprayers with brush motors They do not apply to UltraMax II Ultimate MX Il and ST Max II 490 495 595 model sprayers Motor armature for shorts using armature tester growler or perform spin test See page 18 Replace motor See page 29 For loose motor brush lead connec tions and terminals Tighten terminal screws Replace brushes if leads are
13. 31 69 31 21 53 3 26 66 0 20 5 52 1 Hi Boy 66 30 57 26 66 30 57 26 72 33 72 33 Handle down 21 53 3 20 5 52 1 29 5 74 9 Handle Up 39 5 100 3 309674M 31 Graco Standard Warranty Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is
14. QUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component Read Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts Read Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer e Check equipment daily Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or overbend hoses or use hoses to pull equipment Comply with all applicable safety regulations Keep children and animals away from work area Do not operate the unit when fatigued or under the influence of drugs or alcohol PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride and or other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemi cal reaction and equipment rupture and result in death serious injury and or property damage TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious inj
15. Repair N GRACO Electric Airless Sprayers 309674M For the application of architectural paints and coatings in this manual Save these instructions See page 2 for model Important Safety Instructions Read all warnings and instructions information 3300 psi 227 bar 22 7 MPa Maximum Working Pressure Korean patent 10 0579681 Ultra 395 495 595 Umate Neva ok UltraMax II 490 495 595 Super Nova 495 595 Ultimate MX II 490 495 595 ST Max 395 495 595 ST Max II 490 495 595 PROVEN QUALITY LEADING TECHNOLOGY WTERTE Graco Inc P O Box 1441 Minneapolis MN 55440 1441 ID O C PE Copyright 2002 Graco Inc is registered to l S EN ISO 9001 c le US ow STES 0 Models Models VAC Model Ultra 395 233960 233961 233962 Ultimate Nova 395 826014 Ultra 495 233966 233967 233968 Super Nova 495 826017 826018 826019 Ultra 595 234490 234435 120 Super Nova 595 826052 826046 Ultra Max Il 490 249911 249913 249914 Ultimate MX Il 490 825028 825029 825036 Ultra Max Il 495 249915 249916 249917 Ultimate MX Il 495 825037 825038 825039 Ultra Max Il 595 249918 249919 Ultimate MX Il 595 825046 825045 ST Max 395 Hopper 233955 ST Max 395 234176 258662 ST Max 495 233956 233970 233971 ST Max 595 248661 244437 230 CEE ST Max Il 490 Hopper 253011 ST Max Il 490 249926 253012 253013 ST Max Il 495 249928 253014
16. conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc
17. cover 22 Remove screws 47 Pull drive housing 42 off motor 54 Remove gear cluster 44 and 40 and thrust washer 25 from drive housing 7 SS Co A l DK J WE A A NE 4 Sar 12 47 Push drive housing 42 on motor endbell as you guide gear crank 44 through hole in connecting rod 43 Install screws 47 Install cover 22 and screws 12 Install shroud 23 and screws 12 Install pump 41 Displacement Pump Replace ment page 15 10 Install pump rod cover 70 with screws 12 17 Motor Diagnostics Motor Diagnostics Spin Test Note Motors used in the UltraMax II Ultimate MX Il and ST Max Il 490 495 595 model sprayers are brushless The following brush information and instructions apply to Ultra Nova and ST Max 395 495 595 model sprayers only Check for electrical continuity in motor armature windings and brush as follows If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 1 2 in 12 7 mm or if the motor shaft cannot turn replace the motor page 29 Armature Brushes and Motor Wiring Open Circuit Setup Test Continuity 1 Relieve pressure page 7 1 Connect red and black motor leads together with test lead 2 Unplug electric cord 2 Turn motor fan by hand about two revolutions per 3 Remove drive housing Drive Housing Replace second ment page 17 3 If there is an uneven resistance or no resistance 4 Rem
18. damaged Brush length which must be 1 2 in minimum NOTE Brushes do not wear at the same rate on both sides of motor Check both brushes Replace brushes page 20 Broken or misaligned motor brush springs Rolled portion of spring must rest squarely on top of brush Motor brushes may be binding in brush holders Replace spring if broken Realign spring with brush Clean brush holders Remove carbon with small cleaning brush Align brush leads with slot in brush holder to assure free vertical brush move ment Motor armature commutator for burn spots gouges or extreme roughness Remove motor and have motor shop resurface commutator if possible See page 29 10 309674M Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column Note for the following electric prob lems refer to wiring diagram page 22 23 and 24 to identify Test Points TP Power supply cord Connect volt meter between TP1 neutral and TP2 Plug in sprayer Meter must read e 210 255 VAC for 220 240V models e 85 130 VAC for 100 120V models Unplug sprayer Replace power supply cord page 24 ON OFF Switch Connect volt meter between L1 and L2 terminal on ON OFF switch Plug in sprayer and turn ON Meter must read e 210 255 VAC for 220 240V models e 85 130 VAC for 100 120V models Replace ON OFF sw
19. ea China Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com 12 2002 Rev 9 2007 32 309674M
20. f ON OFF Switch Power Cord Board Kit removal instructions page 24 3 Remove screw 127 from bottom of control box and screws 6 holding motor control board 49 to back of control box 48 Remove motor shroud 23 and screws 12 Disconnect motor and thermistor connections 210 211 Disconnect pressure transducer lead J11 Disconnect potentiometer lead J12 from board o Non A Remove grommet 5 from back of control box Slide motor leads through opening in back of control box 48 9 Remove motor control board 49 from control box 48 Installation 1 Feed motorleads through back of control box 48 2 Replace grommet 5 in control box 48 3 Position motor control board 49 in control box Secure control board with screws 6 and 127 4 Connect potentiometer and transducer leads to con trol board 5 Connect motor and thermistor leads 210 211 6 Do steps 1 8 of ON OFF Switch Power Cord Board Kit installation instructions page 24 7 Replace shroud 23 with four screws 12 309674M Motor Control Board Diagnostics INA NOTE e Keep a new transducer on hand to use for test e No display does not mean the sprayer is not pres surized Before repair relieve pressure page 7 Pressure Control Repair CAUTION Do not allow sprayer to develop fluid pressure without transducer installed Leave drain valve open if test transducer is used
21. f the spray gun firmly to the side of a grounded metal pail then trigger the gun 309674M Operation Operation Pressure Relief Procedure 2 Turn pressure to lowest setting Hold gun to side of grounded metal flushing bucket Trigger gun to To reduce risk of injury from injection follow this proce relieve pressure turn prime valve down dure whenever you are instructed to relieve pressure stop spraying service equipment or install or clean spray tip Read warnings page 3 MaN 1 Turn power switch OFF and unplug power cord 3 Engage gun trigger lock if unit is being shut down or a kl left unattended Leave Spray Prime Drain valve in the t2718a PRIME DRAIN position until you are ready to spray again If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction 309674M 7 General Repair Information General Repair Information EN A ARA W NA v Flammable materials spilled on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed CAUTION To reduce risk of pressure control malfunction Use needle
22. ferent motor manufacturers Style A motor has brush caps held on with screws Style B has brush caps that snap onto the motor Determine which style motor you are servicing and refer to the appropriate illustration in the following instructions Motor Brush Removal Replace brushes worn to less than 1 2 in Brushes wear differently on each side of motor check both sides Brush Repair Kit 287735 is available 1 Read General Repair Information page 8 NAV 2 Relieve pressure page 7 3 Remove motor shroud and two inspection covers A 4 Push clip spring B to release hook C from brush holder D Pull out spring clip B 20 A Included in Brush Repair Kit A Minimum 0 5 in 12 5 mm i AB ti7384a E Pd Style A 5 Pull brush lead E off terminal F Remove brush G A Motor lead do not disconnect D ZA Minimum 0 5 in 12 5 mm AX Included in Brush Repair Kit 6 Inspect commutator for excessive pitting burning or gouging A black color on commutator is normal Have commutator resurfaced by a motor repair shop if brushes wear too fast 309674M Motor Brush Replacement Motor Brush Installation CAUTION When installing brushes follow all steps carefully to avoid damaging parts Style B a ms F G 1 Install new brush G with lead into brush holder D c Turn sprayer ON Slowly increase pressure until m
23. ing or cleaning keep sprayer at least 20 feet 6 m away from explosive vapors Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground equipment and conductive objects in work area Read Grounding instructions If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a fire extinguisher in the work area ELECTRIC SHOCK HAZARD AN 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 oe SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 309674M Warnings E
24. itch See page 22 All terminals for damage or loose fit Replace damaged terminals and reconnect securely Low Output For worn spray tip Relieve pressure page 7 Then replace tip See your separate gun manual for additional instruction Verify pump does not continue to stroke when gun trigger is released Service pump See page 15 Filter clogged Prime valve leaking Relieve pressure page 7 Check and clean filter Relieve pressure page 7 Repair prime valve Suction hose kinks and or loose connection Correct kink and or tighten any loose connections Electric supply with volt meter Low voltages reduce sprayer performance Meter must read e 210 255 VAC for 220 240V models e 85 130 VAC for 100 120V models Reset building circuit breaker replace building fuse Repair electrical outlet or try another outlet Extension cord size and length must be at least 12 gauge wire and no longer than 300 ft Longer cord lengths reduce sprayer performance Replace with a correct grounded extension cord 309674M 11 Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column Low Output Leads from motor to pressure control circuit board for damaged or loose wires or connectors Inspect wiring insulation and terminals for signs of overheating Be sure male terminal b
25. lades are centered and firmly connected to female terminals Replace any loose terminal or damaged wiring Securely reconnect terminals Low stall pressure Do either or both a Turn pressure control knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise position b Try anew transducer These problems only apply to Ultra Nova and STMax 395 495 595 model sprayers with brush motors They do not apply to UltraMax Il Ultimate MX Il and ST Max Il 490 495 595 model sprayers Motor armature for shorts by using an armature tester growler or perform spin test See page 18 Replace motor See page 29 Loose motor brushes and terminals Tighten terminal screws Replace brushes if leads are damaged Worn motor brushes Brushes must be 1 2 in minimum Replace brushes Broken and misaligned motor brush springs Rolled portion of spring must rest squarely on top of brush Replace spring if broken Realign spring with brush Motor brushes are binding in brush holders Clean brush holders remove carbon dust with small cleaning brush Align brush lead with slot in brush holder to assure free vertical brush movement Motor runs and pump strokes Low paint supply Refill and reprime pump Intake strainer clogged Remove and clean then reinstall Suction tube or fittings loose Tighten use thread sealant or sealing ta
26. mately 75 ft Ib 102 Nem 8 Install suction tube 60 and high pressure hose 45 Tighten fittings 2 9 Fill packing nut with Graco TSL until fluid flows onto SV ti7390a top of seal 3 Install pump pin 32 Slide retainer spring 31 down into groove over pump pin E 70oT SA ti7393a 10 Style A Rotate cover 70 Tighten screws 12 Style B Replace cover 70 over screws Push 4 Push pump 41 up until pump threads engage cover down into place Tighten screws 12 16 309674M Drive Housing Replacement CAUTION Do not drop gear cluster 44 and 40 when removing from drive housing 42 Gear cluster may stay engaged in motor front end bell or drive housing Removal MAN 1 Relieve pressure page 7 2 Disconnect power cord from outlet Installation 1 Apply a heavy coat of grease to gears and needle bearing surfaces 2 Install washers 8 10 on back of gear 40 Install gear in motor end bell Using grease for retention place washer 10 over bearing inside housing 42 motor endbell 4 Install thrust washer 25 on gear 44 309674M Install washers 1 9 on back of gear 44 Install in Drive Housing Replacement Remove screws 12 and pump rod cover 70 Remove pump 41 Displacement Pump Replace ment page 15 Remove screws 12 from shroud 23 Remove screws 12 from front
27. 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 or pressure control Do not pinch wires between cover and control box Keep all screws nuts washers gaskets and electri cal fittings removed during repair procedures These parts usually are not provided with replacement kits Test repairs after problems are corrected If sprayer does not operate properly review repair procedure to verify you did it correctly See Trouble shooting page 9 Install motor shroud before operation of sprayer and replace if damaged Motor shroud directs cooling air around motor to prevent overheating lt can reduce risk of burns fire or explosion or cut fingers To reduce risk of serious injury including electric shock Do not touch moving or electric parts with fingers or tools while testing repair Unplug sprayer when power is not required for test ing Install all covers gaskets screws and washers before you operate sprayer CAUTION Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings Protect the internal drive parts of this sprayer from water Openings in the cover allow for air cooling of the mechanical parts and electronics inside If water gets in these openings the sprayer could malfunction
28. otentiometer Ref 37 ON OFF Switch Ref 30 P E Black 2 Pressure Transducer J11 Ref 38 Power Plug O Ref 56 Black A ti7380a 309674M 25 Pressure Control Repair Motor Control Board Ultra Nova and ST Max 395 495 595 Models Refer to wiring diagram for your sprayer shown on pages 22 and 23 Removal NAV Relieve pressure page 7 and unplug sprayer 2 Remove screws 12 and cover 50 3 Disconnect all leads to motor control board 49 4 Remove screws 6 and circuit board 49 Installation 1 Remove old thermal paste from control box Remove cover from thermal pad on new motor control board 2 Install motor control board 49 with screws 6 3 Connect all leads to motor control board 49 See wir ing diagram for your sprayer on pages 22 23 and 24 4 Bundle and tie all loose wires so none touch induc tor coil does not apply to 120V model sprayers 5 Install cover 50 with screws 12 26 Pressure Control Repair Motor Control Board Kit UltraMax II Ultimate MX II ST Max Il 490 495 595 Models Refer to your sprayer wiring diagram pages 24 and 25 NaN Removal 1 Relieve pressure page 7 2 Do steps 2 9 o
29. otor is at full speed 2 Slide brush lead E onto terminal F 3 Install spring clip B Push down to set hook C into C caution Oj brush holder D CAUTION Do not run sprayer dry for more than 30 seconds 4 Repeat for other side while checking brushes to avoid damaging displace ment pump packings 5 Test brushes 6 Install brush inspection covers A and gaskets a Remove pump Displacement Pump Replace ment page 15 7 Break in brushes b With sprayer OFF turn pressure control knob a Operate sprayer 1 hour with no load fully counter clockwise to minimum pressure b Install pump Displacement Pump Replace Plug in sprayer sian p PECE ment page 15 309674M 21 On Off Switch Replacement On Off Switch Replacement 100 120 VAC Ultra and ST 395 495 595 models Removal 4 Remove toggle boot 30 and locking ring Remove ON OFF switch 58 A A N Installation 1 Install new ON OFF switch 58 Install locking ring and toggle boot 30 1 Relieve pressure page 7 2 Connect two wires A to ON OFF switch 58 2 Remove four screws 12 and pressure control cover 50 3 Install pressure control cover 50 with four screws 12 3 Disconnect two wires A from ON OFF switch 58 ti2509b CL p ON OFF LL Switch TP2 Power Plug SN Potentiometer from Motor
30. ove pressure control cover 50 Disconnect check for broken brush springs brush leads loose connector F brush terminal screws worn brushes or motor lead terminals Repair as needed page 20 5 Remove four screws 12 and motor shroud 23 l and inspection covers 4 If still uneven or no resistance replace motor using Motor Kit page 29 Armature Short Circuit Test Quickly turn motor fan by hand If not shorted motor will coast two or three revolutions before complete stop If motor does not spin freely armature is shorted Replace motor page 29 18 309674M Fan Replacement Fan Replacement Removal 4 Pull off fan 77 A A AN Installation 1 Slide new fan 125 in place on back of motor Be 1 Relieve pressure page 7 Disconnect power cord sure blades of fan face motor as shown from outlet 2 Tighten screw 126 2 Remove four screws 12 and shroud 23 3 Replace shroud 23 and four screws 12 3 Loosen tensioning screw 126 on fan 125 eN a he 7 AA on i bb VIA 2 4 ti7423a 309674M 19 Motor Brush Replacement Motor Brush Replacement Note Motors used in the UltraMax II Ultimate MX Il and ST Max Il 490 495 595 model sprayers are brushless The following brush information and instructions apply to Ultra Nova and ST Max 395 495 595 model sprayers only The Utlra Nova and ST Max 395 495 595 sprayer s motors are supplied by two dif
31. owler or perform spin test See page14 Inspect windings for burns Replace motor See page 29 Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on Basic Electric Problems page 9 of Troubleshooting Perform necessary procedures 309674M 13 Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column ON OFF switch See page 22 Be sure sprayer is unplugged Disconnect wires from switch Check switch with ohmmeter Reading must be infinity with ON OFF switch OFF and zero when switch is ON Replace ON OFF switch See page 22 For damaged or pinched wires in pressure control See page 26 Replace damaged parts See page 26 Sprayer quits after sprayer operates for 5 to 10 minutes Basic Electric Problems page 9 of Troubleshooting Perform necessary procedures Electrical supply volt meter Meter must read e 210 255 VAC for 220 240V models e 85 130 VAC for 100 120V models If voltage is too high do not operate sprayer until corrected Tightness of pump packing nut Over tightening tightens packings on rod restricts pump action and overloads motor Loosen packing nut Check for leaking around throat Replace pump packings if necessary See pump manual 14 309674M Displacement Pump Replacement Di
32. pe on threads if necessary See if intake valve ball and piston ball are seating properly See pump manual Remove intake valve and clean Check balls and seats for nicks replace if necessary Strain paint before using to remove particles that could clog pump See pump manual Leaking around throat packing nut which may indicate worn or damaged packings See pump manual Replace packings Also check piston valve seat for hardened paint or nicks and replace if necessary Tighten packing nut wet cup See pump manual Pump rod damage Replace pump page 15 12 309674M Troubleshooting Type of Problem What to Check if check is OK go to next What to Do When check is not OK refer to this column Motor runs but pump does not stroke Displacement pump pin damaged or missing Replace pump pin if missing Be sure retainer spring is fully in groove all around connecting rod page 15 Connecting rod assembly damaged Replace connecting rod assembly See pump manual Gears or drive housing page 17 Inspect drive housing assembly and gears for damage and replace if necessary page 17 Motor is hot and runs intermittently Determine if sprayer was operated at high pressure with small tips which causes low motor RPM and excessive heat buildup Decrease pressure setting or increase tip size Be sure ambient temperature where sprayer is located is not
33. splacement Pump Replacement See manual 309053 for pump repair instructions 4 Cycle motor until pump pin 32 is in position to be removed Removal 1 Flush pump 13 MaN 1 Relieve pressure page 7 2 Style A Loosen screws 12 and rotate cover 70 Note Style A is shown in most illustrations 5 Disconnect power cord from outlet Style B Loosen screws 12 Push cover 70 up and pull off sprayer 6 Using a flat screwdriver push retaining spring 31 up Push out pump pin 32 3 Remove suction tube 60 and hose 45 7 Loosen pump jam nut 29 Unscrew and remove pump 41 f ti7390a a 309674M 15 Displacement Pump Replacement Installation If pump pin works loose parts could break off due to force of pumping action Parts could project through air and result in serious injury or property damage 5 Screw in pump until threads are flush with top of drive housing opening CAUTION If the pump jam nut loosens during operation the threads of the drive housing will be damaged 6 Align pump outlet to back 1 Extend pump piston rod full Apply grease to top of pump rod at A or inside connecting rod 43 Install jam nut 29 on pump threads yy X 9 fee Ye a i ti7391a Turn jam nut 29 counter clockwise until it stops Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approxi
34. stall drive housing 42 Drive Housing Replace ment page 17 6 Install pump 41 Displacement Pump Replace ment page 15 7 Replace front cover 22 and screws 12 Tighten screws securely 8 Replace shroud 23 and screws 12 Tighten screws securely ti7434a 309674M Technical Data Technical Data Max Fluid 100 120V 220 240 V Generator Motor HP Cycles Delivery Max Tip Outlet Model A Hz A Hz Minimum W W Gal I gpm lpm Size npsm 395 1 11 50 60 1 7 50 60 3000 3 4 560 700 185 0 50 1 9 0 023 1 4 in 490 1 12 50 60 1 6 50 60 3500 7 10 510 620 165 0 54 2 0 0 023 1 4 in 495 1 13 50 60 1 7 50 60 3750 3 4 560 620 165 0 60 2 3 0 025 1 4 in 595 1 15 50 60 1 7 50 60 4000 9 10 671 540 143 0 68 2 6 0 027 1 4 in Basic Sprayer Wetted Parts zinc plated carbon steel nylon stainless steel PTFE acetal chrome plating leather UHMWPE aluminum tungsten carbide Noise Level Sound power Sound pressure Measured 3 feet 1 meter from equipment Dimensions Weight Ib k Model eight Ib kg Height in Length in Width in Ultra 395 UltraMax Il Ultra 495 UltraMax Il Ultra 595 UltraMax Il cm cm cm 490 495 595 Stand 43 20 34 19 43 20 34 19 N A N A 21 53 3 15 38 1 14 35 6 Lo Boy 63 29 54 25 63 29 54 25 69
35. tact e gt Te au G The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Do not use an adapter ti3001 c Do not use the sprayer if the electrical cord has a dam aged ground prong Do not modify plug If it will not fit in outlet have a grounded outlet installed by a qualified electrician Installation Power Requirements e 100 120V units require 100 120VAC 50 60 Hz 15A 1 phase e 230V units require 230VAC 50 60 Hz 7 5A 1 phase e Never use an outlet that is not grounded or an adapter Only use an extension cord with an undamaged ground contact If an extension cord is necessary use a 3 wire 12 AWG 2 5 mm minimum Smaller gauge or longer extension cords may reduce sprayer performance Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent and oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts grounding conti nuity Grounding the metal pail connect a ground wire to the pail by clamping one end to pail and other end to ground such as a water pipe Maintain grounding continuity when flushing or relieving pressure hold metal part o
36. ury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 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 e Protective eye wear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 309674M Component Identification Model 233960 shown SERIAL PART NO n Z Component ON OFF switch Prime tube Siphon tube Pressure control Filter Trigger lock Pump Fluid outlet o CO N Di oY SI Wi N Prime Spray valve Service Tag below sprayer frame 309674M Component Identification 2890b Installation Grounding and Electric Requirements The sprayer must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit ANTA The sprayer power cord includes a grounding wire with an appropriate grounding con
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