Graco Ultra 395

1. Pressure control knob setting. Motor will not run if at minimum setting (fully counter-clockwise). Slowly increase pressure to see if motor starts.
2. Spray tip or fluid filter may be clogged. Relieve pressure , page 7 and clear clog, or clean filter; refer to separate gun or tip instruction manual.

From 309674 rev P, page 9

1. Pump frozen or paint hardened in pump. 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.
2. 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. Push pin into place and secure with spring retainer.
3. Motor. Remove drive housing assem- bly. See page 17. Try to rotate fan by hand. Replace motor if fan won't turn. See page 19.
4. Motor control board. Board shuts down and displays error code. See Motor Control Board Diagnos- tics , page 27.

From 309674 rev P, page 9

1. Electric supply. Meter must read: • 210-255 VAC for 220-240V models • 85-130 VAC for 100-120V models. Reset building circuit breaker. Replace building fuse. Try another outlet.
2. Extension cord. Check extension cord continuity with volt meter. Replace extension cord.
3. Sprayer power supply cord. Inspect for damage such as insulation or wires. Replace power supply cord, page 24.
4. 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.

From 309674 rev P, page 10

1. Motor armature for shorts using armature tester (growler) or perform spin test. See page 18. Replace motor. See page 29.
2. For loose motor brush lead connec- tions and terminals. Tighten terminal screws. Replace brushes if leads are damaged.
3. 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.
4. Broken or misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush. Replace spring if broken. Realign spring with brush.
5. Motor brushes may be binding in brush holders. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush move- ment.
6. Motor armature commutator for burn spots, gouges or extreme roughness. Remove motor and have motor shop resurface commutator if possible. See page 29.

From 309674 rev P, page 10

1. Power supply cord. Connect volt meter between TP1 (neutral) and TP2. Plug in sprayer. Meter must read: • 210-255 VAC for 220-240V models • 85-130 VAC for 100-120V models. Replace power supply cord, page 24.
2. ON/OFF Switch. Connect volt meter between L1 and L2 terminal on ON/OFF switch. Plug in sprayer and turn ON. Meter must read: • 210-255 VAC for 220-240V models • 85-130 VAC for 100-120V models. Replace ON/OFF switch. See page 22.
3. All terminals for damage or loose fit. Replace damaged terminals and reconnect securely.

From 309674 rev P, page 11

1. For worn spray tip. Relieve pressure, page 7. Then replace tip. See your separate gun manual for additional instruction.
2. Verify pump does not continue to stroke when gun trigger is released. Service pump. See page 15.
3. Filter clogged. Relieve pressure, page 7. Check and clean filter.
4. Prime valve leaking. Relieve pressure , page 7. Repair prime valve.
5. Suction hose kinks and/or loose connection. Correct kink and/or tighten any loose connections.
6. Electric supply with volt meter. Low voltages reduce sprayer performance. Meter must read: • 210-255 VAC for 220-240V models • 85-130 VAC for 100-120V models. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.
7. 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.

From 309674 rev P, page 11

1. 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 blades are centered and firmly connected to female terminals. Replace any loose terminal or damaged wiring. Securely reconnect terminals.
2. 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 a new transducer.

From 309674 rev P, page 12

1. Motor armature for shorts by using an armature tester (growler) or perform spin test. See page 18. Replace motor. See page 29.
2. Loose motor brushes and terminals. Tighten terminal screws. Replace brushes if leads are damaged.
3. Worn motor brushes. (Brushes must be 1/2 in. minimum.) Replace brushes.
4. 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.
5. 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.

From 309674 rev P, page 12

1. Low paint supply. Refill and reprime pump.
2. Intake strainer clogged. Remove and clean, then reinstall.
3. Suction tube or fittings loose. Tighten; use thread sealant or sealing tape on threads if necessary.
4. 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.
5. 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.
6. Pump rod damage. Replace pump, page 15.

From 309674 rev P, page 12

1. 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.
2. Connecting rod assembly damaged. Replace connecting rod assembly. See pump manual.
3. Gears or drive housing, page 17. Inspect drive housing assembly and gears for damage and replace if necessary, page 17.

From 309674 rev P, page 13

1. 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.
2. Be sure ambient temperature where sprayer is located is not more than 90°F (32.22°C) and sprayer is not located in direct sun. Move sprayer to shaded, cooler area if possible.

From 309674 rev P, page 13

1. 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.
2. 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.
3. Motor control board by performing control board diagnostics. See page 15. 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.

From 309674 rev P, page 13

1. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page15. Inspect windings for burns. Replace motor. See page 29.

From 309674 rev P, page 13

1. Basic Electric Problems, page 9 of Troubleshooting . Perform necessary procedures.

From 309674 rev P, page 13

1. Basic Electric Problems, page 9 of Troubleshooting . Perform necessary procedures.
2. Electrical supply volt meter. Meter must read: • 210-255 VAC for 220-240V models • 85-130 VAC for 100-120V models. If voltage is too high, do not operate sprayer until corrected.
3. 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.

From 309674 rev P, page 14