Graco Ultra Max II 795

1. 1. Check digital display for error codes on spray- ers with digital displays or motor control board inside SmartControl for blinking LED on spray- ers without digital displays 1. If an error code (E=0X) is displayed or LED is blinking, go to page 18 for error code diag- nostics. If not continue.
2. 2. Make sure digital display is connected. If noth- ing is displayed, check power cord, power switch and all power connections for continuity. Check building circuit power. 2. Tighten any loose power connections. Re- place power switch, power cord or extension cords if damaged. Reset circuit breaker if tripped.
3. 3. Check pressure control knob setting. Motor will not run if pressure control knob is at minimum setting. 3. Increase pressure setting
4. 4. With drain valve open and pressure control knob set to maximum, check if there is a light blinking next to either psi , bar , or MPa a. If light is blinking, control board is commanding motor to run and prob- lem is most likely motor or motor wiring. b. If light is not blinking, control board, control board wiring, potentiometer or transducer is most likely cause. 4. Based on results of this test, investigate for possible wiring, motor, control, transducer or potentiometer problems in the following steps

From 309251 rev E, page 5

1. 1. Connections at control board and brushes 1. Repair any loose connections
2. 2. Brushes worn. Length must be 1/2 in. minimum. Check both sides. 2. Replace brushes. Page 9.
3. 3. Broken or misaligned brush springs 3. Realign or replace springs
4. 4. Brushes or springs binding in brush holder 4. Clean brush holder and align brush leads for free movement
5. 5. Check for armature short using an armature tester (growler) or perform spin test. Page 9. 5. Replace motor
6. 6. Check motor armature commutator for burn spots or other damage 6. Remove motor and have motor shop resur- face commutator if possible. Page 22.

From 309251 rev E, page 6

1. 1. Loose control board wiring 1. Repair any loose connections
2. 2. Damaged control board 2. Replace control board

From 309251 rev E, page 6

1. 1. Potentiometer damaged 1. Replace potentiometer
2. 2. Pressure transducer damaged 2. Replace pressure transducer

From 309251 rev E, page 6

1. 1. Current limit exceeded 1. Switch to another circuit with less load. If sprayer has a 15/20A or 10/12A switch, change to lower value.
2. 2. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page 22. 2. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.
3. 3. For missing inspection plate gasket (see page 22), bent terminals or other metal to metal con- tact points which could cause a short. 3. Correct faulty conditions.
4. 4. Motor armature for shorts. Use an armature tester (growler) or perform spin test. See page 9. Inspect windings for burns. 4. Replace motor. See page 22.

From 309251 rev E, page 8

1. 5. Motor control board (35) by performing motor control board diagnostics on page 16. If diag- nostics indicate, substitute with a good board. CAUTION: Do not perform this check until mo- tor armature is determined to be good. A bad motor armature can burn out a good board. 5. Replace with a new pressure control board (35). See page 16.

From 309251 rev E, page 8

1. Switches on back of display are set incorrectly. Set the four switches psi, bar, MPa and liters/gallons to proper settings for your sprayer. Fig. 13, page 16.

From 309251 rev E, page 8

1. Pump throat packings are worn. Tighten packing nut/wet cup. If leakage continues, replace packings; see pump manual. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.
2. Intake valve ball is packed with material Clean intake valve; see pump manual.
3. Pressure setting is too low Turn Pressure Control Knob clockwise to increase pressure.
4. Material is too thick for asmall diameter Hose,orHose is too long. Use larger diameter Hose and/or reduce overall length of Hose.
5. Amp switch is on low setting. (10A or 15A setting) Switch to 16A or 20A setting.

From 3A6342 rev G, page 37

1. Tip is partially clogged Refer to Clear Spray Tip Clog , page 25.
2. Material supply low, orairwas not properly purged during priming. Refill fluid supply. Refer to FillPump(Prime Pump) , page 21. Then Fill Spray Gun and Hose , page 21. Check fluid supply often to prevent running pump dry.

From 3A6342 rev G, page 37

1. Intake valve is stuck to seat. Removefootvalve.Cleanandinspectintake valve.
2. Suction tube o-ring on foot valve is damaged or missing. Replace Suction Tube o-ring.
3. Air in pump Refer to FillPump (PrimePump) , page 21. Then Fill Spray Gun and Hose , page 21.
4. Intake valve is leaking Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.
5. Pump packings are worn Replace pump packings; see pump manual.

From 3A6342 rev G, page 37

1. Pressure Control Knob is set too low Increase pressure by turning Pressure Control Knob clockwise.
2. Spray tip clogged Refer to Clear Spray Tip Clog , page 25.

From 3A6342 rev G, page 37

1. Displacement pump pin damaged or missing; see pump manual. Replace pump pin if missing. Be sure retainer spring is fully in groove all around connecting rod; see pump manual.
2. Connecting rod assembly damaged; see pump manual. Replace connecting rod assembly; see pump manual.
3. Gears or drive housing damaged. Inspect drive housing assembly and gears for damage and replace if necessary; see pump manual.

From 3A6342 rev G, page 37

1. Multiple electrical issues. See flow chart, page 46.

From 3A6342 rev G, page 39

1. Multiple electrical issues. See flow chart, page 48.

From 3A6342 rev G, page 39

1. Transducer or transducer connection issue. 1. Make sure there is no pressure in the system (see Pressure Relief Procedure , page 18). 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 clock - wise. 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

From 3A6342 rev G, page 39

1. Transducer connection issue (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 trans - ducer 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 clock - wise. If sprayer does not run, set sprayer to OFF and go to next step. 5. Connect a confirmed working trans - ducer to control board socket. 6. Set sprayer ONandcontrol 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 ohm - meter (less than 9k ohm between red and black wires and 3-6kohm between green and yellow wires).

From 3A6342 rev G, page 39

1. Control board detected voltage surges. Set sprayer to OFF and disconnect power to sprayer. Locate a good voltage supply to prevent damage to electronics.

From 3A6342 rev G, page 40

1. Control is commanding motor to run but motor shaft does not rotate. 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. Remove motor cover. 4. Disconnect motor connector(s) above motor. Check that connectors are clean. Reconnect connectors. Check that connectors are fully seated and secure. 5. 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. 6. Perform Spin Test: Test at large 4-pin motor field connector. Disconnect fluid pump from sprayer. Test motor by plac - ing a jumper across pins 1 & 2. Rotate motor fan at about 2 revolutions per sec - ond. Acogging resistance to motion should be felt at the fan. The motor should be replaced if no resistance is felt. Repeat for pin combinations 1 & 3 and 2 & 3. Pin 4 (the green wire) is not used in this test. If all spin test is posi - tive, continue to step 6. See connections on next page:

From 3A6342 rev G, page 40

1. Motor overheated NOTE: Motor must be cooled down for the test. 1. Keep sprayer in cooler location with good ventilation. Make sure motor air intake is not blocked. 2. Remove motor cover. Ensure fan is securely attached to motor shaft. 3. Check thermal switch connector (yel - low wires) above motor. 4. Disconnect thermal switch connector above motor. Make sure contacts are clean and secure. Measure resistance of the thermal switch. 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 unit (see table below). - ti13140a

From 3A6342 rev G, page 43

1. Incoming voltage too low for sprayer operation 1. Set sprayer to OFF and disconnect power to sprayer. 2. Remove other equipment that uses the same circuit. 3. Locate a good voltage supply to avoid damage to electronics.

From 3A6342 rev G, page 44

1. Control board is over heating. 1. Make sure motor air intake is not blocked. 2. Make sure fan is securely attached to motor shaft. 3. Replace control board. 4. Replace motor.

From 3A6342 rev G, page 44

1. Excessive current protection enabled Cycle power on and off.

From 3A6342 rev G, page 44

1. Motor not spinning (no current to motor) 1. Set sprayer to OFF and disconnect power to sprayer. 2. Remove motor cover. 3. Disconnect motor control and inspect for damage at connectors. 4. Reconnect motor control. 5. Turn power on. If code continues, replace control board.

From 3A6342 rev G, page 44

1. Spray tip worn. Replace tip. See separate gun or tip manual.
2. Spray tip clogged. Clear tip. See Clear Spray Tip Clog , page 26.
3. Paint supply. Refill and reprime pump.
4. Intake strainer clogged. Remove and clean, then reinstall. If problem persists, strain the paint.
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. Remove and clean, then reinstall.
7. Prime valve leaking. 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. Tighten packing nut/wet-cup. Replace packings. See pump manual. Also check piston valve seat for hardened paint or nicks and replace if necessary.

From 3B0070 rev C, page 37

1. Low stall pressure. Pressure setting is too low. Change spray mode to High Pressure. Turn pressure knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position. Perform Knob Calibration , page 32. If problem persists, replace pressure transducer.
2. Pump rod damage. Repair pump. See pump manual.
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. Use larger diameter hose.
7. Check extension cord for correct size. See Extension Cords , page 16.
8. Connecting rod assembly damaged. Replace connecting rod assembly.
9. Amp switch is on low setting. Switch to a 16A or 20A setting.

From 3B0070 rev C, page 38

1. Error code on the display. Determine fault correction from electrical, see page 39.
2. Motor cables damaged or loose connections. Reconnect or replace if necessary.
3. Potentiometer wire damaged or loose connections. Reconnect or replace if necessary.
4. Control board, see page 40. Replace power cord or control board.
5. Additional motor troubleshooting. See page 41.

From 3B0070 rev C, page 38

1. Connecting rod assembly damaged. Replace connecting rod assembly.

From 3B0070 rev C, page 38

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.
3. Displacement rod is worn or damaged. Replace rod.

From 3B0070 rev C, page 38

1. Air in pump or hose. Cycle pump as slowly as possible during priming. Purge paint through gun by following Startup , page 22.
2. Spray tip is partially clogged. Clear tip. See Clear Spray Tip Clog , page 26.
3. Fluid supply is low or empty. Refill fluid supply. Prime pump. Check fluid supply often to prevent running pump dry.

From 3B0070 rev C, page 38

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

From 3B0070 rev C, page 38

1. Leak in suction tube. Replace suction tube.
2. Debris stuck in inlet ball. Remove foot valve and clean with appropriate cleaning solution.

From 3B0070 rev C, page 38

Motor should spin freely with no binding or excessive cogging. If motor binds or requires excessive force to spin, replace motor. With multimeter, measure the resistance between the following phases: A to B B to C A to C Resistance values should be equal. If resistance values are significantly different from one another (>0.5 Ω), replace motor. Install pump. Install control board. Install top sprayer shroud.

From 3B0070 rev C, page 41