Graco Ultra Max II 490

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. 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. 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. 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

1. Pump rod damage. Repair pump. See pump manual.
2. Low stall pressure. Turn pressure knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position. If problem persists, replace pressure transducer.
3. Piston packings are worn or damaged. Replace packings. See pump manual.
4. O-ring in pump is worn or damaged. Replace o-ring. See pump manual.
5. Intake valve ball is packed with material. Clean intake valve. See pump manual.
6. Large pressure drop in hose with heavy materials. Reduce overall length of hose.
7. Check extension cord for correct size. See Extension Cords , page 11.

From 334530 rev H, page 28

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

From 334530 rev H, page 28

1. Throat packing nut is loose. Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.
2. Throat packings are worn or damaged. Replace packings. See pump manual.
3. Displacement rod is worn or damaged. Replace rod. See pump manual.

From 334530 rev H, page 28

1. Air in pump or hose. Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.
2. Spray tip is partially clogged. Clear tip. See Clear Tip Clog , page 20.
3. Fluid supply is low or empty. Refill fluid supply. Prime pump. See pump manual. Check fluid supply often to prevent running pump dry.

From 334530 rev H, page 28

1. Air in pump or hose. Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.
2. Intake valve is leaking. Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.
3. Pump packings are worn. Replace pump packings. See pump manual.
4. Paint is too thick. Thin the paint according to supplier recommendations.

From 334530 rev H, page 29

1. Pump packing nut too tight. When pump packing nut is too tight the packings on the pump rod restrict pump action and overloads the motor. Loosen pump packing nut. Check for leaks around throat. If necessary, replace pump packings. See Pump manual.

From 334530 rev H, page 29

View digital display or remove control box cover to view control board status light. To determine which code (or any other code besides voltage supply) refer to the control board status light. Turn the ON/OFF switch OFF , remove the control cover then turn power back ON . Observe the status light. Blinking LED total count equals the error code (for example: two blinks equals CODE 02).Press display button to restart code messages.

From 334530 rev H, page 30

Remove control box cover to view control board status light. To determine which code (or any other code besides voltage supply) refer to the control board status light. Turn the ON/OFF switch OFF , remove the control cover then turn power back ON . Observe the status light. Blinking LED total count equals the error code (for example: two blinks equals CODE 02).

From 3A6491, page 30

1. Fault condition exists. Determine fault correction from Electrical , page 30.

From 334530 rev H

1. Spray tip worn. Follow Pressure Relief Procedure , page 12, then replace tip. See separate gun or tip manual.
2. Spray tip clogged. Relieve pressure. Check and clean spray tip.
3. Paint supply. Refill and reprime pump.
4. Intake strainer clogged. Remove and clean, then reinstall.
5. Intake valve ball and piston ball are not seating properly. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary. See pump manual. Strain paint before using to remove particles that could clog pump.
6. Fluid filter or tip filter is clogged or dirty. Clean filter.
7. Prime valve leaking. Follow Pressure Relief Procedure , page 12, then repair prime valve.
8. Verify pump does not continue to stroke when gun trigger is released. (Prime valve not leaking.) Service pump. See pump manual.
9. Leaking around throat packing nut which may indicate worn or damaged packings. Replace packings. See pump manual. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

From 334530 rev H