Repair

309674P
Electric Airless Sprayers EN

- For the application of architectural paints and coatings. For professional use
only. -
Important Safety Instructions. Read all warnings and instructions
in this manual. Save these instructions. See page 2 for model
information.

3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure

ti7374a

ti2399

UltraTM 395/495/595
Ultimate NovaTM 395 UltraMax IITM 490/495/595
Super NovaTM 495/595 Ultimate MX IITM 490/495/595
ST MaxTM 395/495/595 ST Max IITM 490/495/595
 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
Super Nova 595 826052 826046
120
Ultra Max II 490 249911 249913 249914
Ultimate MX II 490 825028 825029 825036
Ultra Max II 495 249915 249916 249917
Ultimate MX II 495 825037 825038 825039
Ultra Max II 595 249918 249919
Ultimate MX II 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 II 490 Hopper 253011
ST Max II 490 249926 253012 253013
ST Max II 495 249928 253014 249978
ST Max II 595 253015 249930
ST Max 395 223963
ST Max 495 233957 233975
230 ST Max 595 244436
Europe ST Max II 490 249927
ST Max II 495 249929 249979
ST Max II 595 249931
ST Max 395 223972
ST Max 495 233973 233975
ST Max 595 244436
110 UK
ST Max II 490 249935
ST Max II 495 249936 249980
ST Max II 595 249937
Ultra 395 234180
Ultra 495 234183 234181 234182
Ultra 595 248660 244439
230 Asia
Ultra Max II 490 249932
Ultra Max II 495 249933 253104 253105
Ultra Max II 595 253107 249934
100 Ultra 495 234186 233974
Japan UltraMax II 495 249938 253106

2 309674P
 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.

WARNING
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 flushing 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

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.

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.

309674P 3
 Warnings

WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. Read Technical Data in all equipment manuals.
• 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.
• 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 injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• 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:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection

4 309674P
 Component Identification

Component Identification
Model 233960 shown
4 5
3

 9
8

6
B

FN Component
1 ON/OFF switch
2 Prime tube
3 Siphon tube
4 Pressure control
5 Filter
6 Trigger lock
7 Pump
8 Fluid outlet
9 Prime/Spray valve
10 Service Tag (below sprayer frame)

309674P 5
 Installation

Installation

Grounding and Electric Power Requirements

Requirements • 100-120V units require 100-120VAC, 50/60 Hz,

15A, 1 phase
The sprayer must be grounded. Grounding reduces the
risk of static and electric shock by providing an escape • 230V units require 230VAC, 50/60 Hz, 7.5A, 1
wire for the electrical current due to static build up or in phase
the event of a short circuit.
• 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
The sprayer power cord includes a grounding wire with 3-wire, 12 AWG (2.5 mm2) minimum.
an appropriate grounding contact.
NOTE: 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.

The plug must be plugged into an outlet that is properly Do not place the pail on a nonconductive surface, such
installed and grounded in accordance with all local as paper or cardboard, which interrupts grounding conti-
codes and ordinances. Do not use an adapter. 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

TIC
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
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.

6 309674P
 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. - ti2

ti2599a

FLUSH
1. Turn power switch OFF and unplug power cord. \ ti2614a

3. Engage gun trigger lock if unit is being shut down or

left unattended.

NOTE: Leave Spray - Prime/Drain valve in the

ti2718a
PRIME/DRAIN position until you are ready to spray
again.

ti2707a 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.

309674P 7
 General Repair Information

General Repair Information

Flammable materials spilled on hot, bare motor could To reduce risk of serious injury, including electric shock:
cause fire or explosion. To reduce risk of burns, fire or
explosion, do not operate sprayer with cover removed. • Do not touch moving or electric parts with fingers or
tools while testing repair.
NOTICE
• Unplug sprayer when power is not required for test-
To reduce risk of pressure control malfunction:
ing.
• Use needle nose pliers to disconnect wire. Never
• Install all covers, gaskets, screws and washers
pull on wire, pull on connector.
before you operate sprayer.
• Mate wire connectors properly. Center flat blade
of insulated male connector in female connector. NOTICE
• Do not run sprayer dry for more than 30 seconds.
• Route wires carefully to avoid interference with Doing so could damage pump packings.
other connections or pressure control. Do not
pinch wires between cover and control box. • Protect the internal drive parts of this sprayer from
water. Openings in the cover allow for air cooling of
• Keep all screws, nuts, washers, gaskets, and electri- the mechanical parts and electronics inside. If
cal fittings removed during repair procedures. These water gets in these openings, the sprayer could
parts usually are not provided with replacement kits. malfunction or be permanently damaged.

• Test repairs after problems are corrected. • Prevent pump corrosion and damage from freezing.
Never leave water or water-base paint in sprayer
• If sprayer does not operate properly, review repair when its not in use in cold weather. Freezing fluids
procedure to verify you did it correctly. See Trouble- can seriously damage sprayer. Store sprayer with
shooting, page 9. Pump Armor to protect sprayer during storage.

• Install motor shroud before operation of sprayer and

replace if damaged. Motor shroud directs cooling air
around motor to prevent overheating. It can reduce
risk of burns, fire or explosion, or cut fingers.

8 309674P
 Troubleshooting

Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
Basic fluid pressure problems Pressure control knob setting. Motor Slowly increase pressure to see if
will not run if at minimum setting (fully motor starts.
counter-clockwise).
Spray tip or fluid filter may be Relieve pressure, page 7 and clear
clogged. clog, or clean filter; refer to separate
gun or tip instruction manual.
Basic Mechanical Problems Pump frozen or paint hardened in Thaw sprayer if water or water-based
pump. 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 Push pin into place and secure with
pin must be completely pushed into spring retainer.
connecting rod and retaining spring
must be firmly in groove of pump pin.
See page 15.
Motor. Remove drive housing assem- Replace motor if fan won’t turn. See
bly. See page 17. Try to rotate fan by page 19.
hand.
Motor control board. Board shuts See Motor Control Board Diagnos-
down and displays error code. tics, page 27.

309674P 9
 Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
Basic Electrical Problems Electric supply. Meter must read: Reset building circuit breaker.
Replace building fuse. Try another
• 210-255 VAC for 220-240V outlet.
models
• 85-130 VAC for 100-120V
models.
Extension cord. Check extension Replace extension cord.
cord continuity with volt meter.
Sprayer power supply cord. Inspect Replace power supply cord, page 24.
for damage such as insulation or
wires.
Motor leads are securely fastened Replace loose terminals; crimp to
and properly mated. leads. Be sure terminals are firmly
connected.

Clean circuit board terminals.

Securely reconnect leads.
Basic Electrical Problems - These Motor armature for shorts using Replace motor. See page 29.
problems only apply to Ultra, Nova armature tester (growler) or perform
and STMax 395/495/595 model spin test. See page 18.
sprayers with brush motors. They do For loose motor brush lead connec- Tighten terminal screws. Replace
not apply to UltraMax II, Ultimate tions and terminals. brushes if leads are damaged.
MX II and ST Max II 490/495/595
Brush length which must be 1/2 in. Replace brushes, page 20.
model sprayers.
minimum. NOTE: Brushes do not
wear at the same rate on both sides
of motor. Check both brushes.
Broken or misaligned motor brush Replace spring if broken. Realign
springs. Rolled portion of spring must spring with brush.
rest squarely on top of brush.
Motor brushes may be binding in Clean brush holders. Remove carbon
brush holders. with small cleaning brush. Align
brush leads with slot in brush holder
to assure free vertical brush move-
ment.
Motor armature commutator for burn Remove motor and have motor shop
spots, gouges or extreme roughness. resurface commutator if possible.
See page 29.

10 309674P
 Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
Note: for the following electric prob- Power supply cord. Connect volt Replace power supply cord, page 24.
lems, refer to wiring diagram, page meter between TP1 (neutral) and
22, 23, and 24 to identify Test Points TP2. Plug in sprayer. Meter must
(TP). read:

• 210-255 VAC for 220-240V

models
• 85-130 VAC for 100-120V
models.

Unplug sprayer.
ON/OFF Switch. Connect volt meter Replace ON/OFF switch. See page
between L1 and L2 terminal on 22.
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.
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 Service pump. See page 15.
stroke when gun trigger is released.
Filter clogged. Relieve pressure, page 7. Check
and clean filter.
Prime valve leaking. Relieve pressure, page 7. Repair
prime valve.
Suction hose kinks and/or loose Correct kink and/or tighten any loose
connection. connections.
Electric supply with volt meter. Low Reset building circuit breaker;
voltages reduce sprayer replace building fuse. Repair
performance. Meter must read: electrical outlet or try another outlet.

• 210-255 VAC for 220-240V

models
• 85-130 VAC for 100-120V
models.
Extension cord size and length; must Replace with a correct, grounded,
be at least 12 gauge wire and no extension cord.
longer than 300 ft. Longer cord
lengths reduce sprayer performance.

309674P 11
 Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
Low Output Leads from motor to pressure control Be sure male terminal blades are
circuit board for damaged or loose centered and firmly connected to
wires or connectors. Inspect wiring female terminals. Replace any loose
insulation and terminals for signs of terminal or damaged wiring. Securely
overheating. 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 a new transducer.
These problems only apply to Ultra, Motor armature for shorts by using an Replace motor. See page 29.
Nova and STMax 395/495/595 armature tester (growler) or perform
model sprayers with brush motors. spin test. See page 18.
They do not apply to UltraMax II, Loose motor brushes and terminals. Tighten terminal screws. Replace
Ultimate MX II and ST Max II brushes if leads are damaged.
490/495/595 model sprayers.
Worn motor brushes. (Brushes must Replace brushes.
be 1/2 in. minimum.)
Broken and misaligned motor brush Replace spring if broken. Realign
springs. Rolled portion of spring must spring with brush.
rest squarely on top of brush.
Motor brushes are binding in brush Clean brush holders, remove carbon
holders. 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 tape on threads if necessary.
See if intake valve ball and piston ball Remove intake valve and clean.
are seating properly. See pump Check balls and seats for nicks,
manual. replace if necessary. Strain paint
before using to remove particles that
could clog pump. See pump manual.
Leaking around throat packing nut Replace packings. Also check piston
which may indicate worn or damaged valve seat for hardened paint or nicks
packings. See pump manual. and replace if necessary. Tighten
packing nut/wet-cup. See pump
manual.
Pump rod damage. Replace pump, page 15.

12 309674P
 Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
Motor runs but pump does not stroke Displacement pump pin damaged or Replace pump pin if missing. Be sure
missing. 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 Decrease pressure setting or
high pressure with small tips, which increase tip size.
causes low motor RPM and
excessive heat buildup.
Be sure ambient temperature where Move sprayer to shaded, cooler area
sprayer is located is not more than if possible.
90°F (32.22°C) and sprayer is not
located in direct sun.
Building circuit breaker opens as All electrical wiring for damaged Repair or replace any damaged
soon as sprayer switch is turned on insulation and all terminals for loose wiring or terminals. Securely
fit or damage. Also, wires between reconnect all wires.
CAUTION pressure control and motor. See
page 28.
Any short in any part of the motor
For missing inspection plate gasket, Correct faulty conditions.
power circuit will cause the control
see page 26, bent terminal forks or
circuit to inhibit sprayer operation.
other metal to metal contact points
Correctly diagnose and repair all
which case a short.
shorts before checking and replacing
control board. Motor control board by performing Replace with a new pressure control
control board diagnostics. See page board. See page 26.
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.
Building circuit breaker opens as Motor armature for shorts. Use an Replace motor. See page 29.
soon as sprayer switch is turned on armature tester (growler) or perform
spin test. See page15. Inspect
This problem only applies to Ultra, windings for burns.
Nova and STMax 395/495/595
model sprayers with brush motors.
They do not apply to UltraMax II,
Ultimate MX II and ST Max II
490/495/595 model sprayers.

Building circuit breaker opens as Basic Electric Problems, page 9 of Perform necessary procedures.
soon as sprayer is plugged into outlet Troubleshooting.
and sprayer is NOT turned on.

309674P 13
 Troubleshooting

What to Do
What to Check (When check is not OK, refer to this
Type of Problem (if check is OK, go to next) column)
ON/OFF switch. See page 22. Be Replace ON/OFF switch. See page
sure sprayer is unplugged! 22.
Disconnect wires from switch. Check
switch with ohmmeter. Reading must
be infinity with ON/OFF switch OFF,
and zero when switch is ON.
For damaged or pinched wires in Replace damaged parts. See page
pressure control. See page 26. 26.
Sprayer quits after sprayer operates Basic Electric Problems, page 9 of Perform necessary procedures.
for 5 to 10 minutes. Troubleshooting.
Electrical supply volt meter. Meter If voltage is too high, do not operate
must read: sprayer until corrected.

• 210-255 VAC for 220-240V

models
• 85-130 VAC for 100-120V
models.
Tightness of pump packing nut. Over Loosen packing nut. Check for
tightening tightens packings on rod, leaking around throat. Replace pump
restricts pump action, and overloads packings, if necessary. See pump
motor. manual.

14 309674P
 Displacement Pump Replacement

Displacement 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).

1. Relieve pressure, page 7.

2. (Style A) Loosen screws (12) and rotate cover (70). ti7389a

Note: Style A is shown in most illustrations. 32

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).
Style B
Style A

31

12
70 70
32
3. Remove suction tube (60) and hose (45). 7. Loosen pump jam nut (29). Unscrew and remove
pump (41).

29

45

12
41 TIA

60

309674P 15
 Displacement Pump Replacement

Installation 5. Screw in pump until threads are flush with top of

drive housing opening.

WARNING
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.

NOTICE 6. Align pump outlet to back.

If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.

1. Extend pump piston rod full. Apply grease to top of

pump rod at (A) or inside connecting rod (43). Install 29
jam nut (29) on pump threads.

ti7391a

7. Turn jam nut (29) counter-clockwise until it stops.

Tighten jam nut by hand, then tap 1/8 to 1/4 turn
A
with a 20 oz (maximum) hammer to approximately
75 ft-lb (102 N•m).

8. Install suction tube (60) and high pressure hose

(45). Tighten fittings.
.
ti7392a

2. Install pump rod (A) into connecting rod (43).

45
43

29 60
9. Fill packing nut with Graco TSL until fluid flows onto
TIA top of seal.

3. Install pump pin (32). Slide retainer spring (31)

down into groove over pump pin.

31 12
70
ti7393a

10. (Style A) Rotate cover (70). Tighten screws (12).

32
(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 309674P
 Drive Housing Replacement

Drive Housing Replacement

3. Remove screws (12) and pump rod cover (70).
NOTICE
Do not drop gear cluster (44) and (40) when removing 4. Remove pump (41), Displacement Pump Replace-
from drive housing (42). Gear cluster may stay ment, page 15
engaged in motor front end bell or drive housing.
5. Remove screws (12) from shroud (23).
Removal 6. Remove screws (12) from front cover (22).

7. Remove screws (47).

8. Pull drive housing (42) off motor (54).

9. Remove gear cluster (44) and (40) and thrust

1. Relieve pressure, page 7.
washer (25) from drive housing.
2. Disconnect power cord from outlet.









!




 

 



TIC






Installation 5. Push drive housing (42) on motor endbell as you

guide gear crank (44) through hole in connecting
1. Apply a heavy coat of grease to gears and needle rod (43).
bearing surfaces.
6. Install screws (47).
2. Install washers (8, 10) on back of gear (40). Install
gear in motor end bell. Using grease for retention, 7. Install cover (22) and screws (12).
place washer (10) over bearing inside housing (42).
8. Install shroud (23) and screws (12).
3. Install washers (1, 9) on back of gear (44). Install in
motor endbell. 9. Install pump (41); Displacement Pump Replace-
ment, page 15.
4. Install thrust washer (25) on gear (44).
10. Install pump rod cover (70) with screws (12).

309674P 17
 Motor Diagnostics

Motor Diagnostics

Spin Test

*Note: Motors used in the UltraMax II, Ultimate MX II and ST Max II 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. Remove 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)
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.

ti2572a

50

18 309674P
 Fan Replacement

Fan Replacement
Removal

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).

4. Pull off fan (77).

12

23

125

126

TIA

309674P 19
 Motor Brush Replacement

Motor Brush Replacement

Note: Motors used in the UltraMax II, Ultimate MX II and ST Max II 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 different 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 1 Included in Brush Repair Kit

D
Replace brushes worn to less than 1/2 in. Brushes wear 2 Minimum 0.5 in. (12.5 mm) G
differently on each side of motor, check both sides.
2
Brush Repair Kit 287735 is available.
C
1 B
1. Read General Repair Information, page 8.

F
2. Relieve pressure, page 7. ti7384a
E
Style A
3. Remove motor shroud and two inspection covers
(A).
5. Pull brush lead (E) off terminal (F). Remove brush
Style A (G).

1 Motor lead; do not disconnect D

2 Minimum 0.5 in. (12.5 mm)
3 Included in Brush Repair Kit
C E
ti7383a

2
A Style B ti7387a

3 B G
ti7386a
Style B

6. Inspect commutator for excessive pitting, burning, or

gouging. A black color on commutator is normal.
4. Push clip spring (B) to release hook (C) from brush Have commutator resurfaced by a motor repair shop
holder (D). Pull out spring clip (B). if brushes wear too fast.

20 309674P
 Motor Brush Replacement

Motor Brush Installation

NOTICE
When installing brushes, follow all steps carefully to
avoid damaging parts.

Style A Style B
G
D

D
B B
ti7385a

ti7388a G
F E F
E

1. Install new brush (G) with lead into brush holder (D). c. Turn sprayer ON. Slowly increase pressure until
motor is at full speed.
2. Slide brush lead (E) onto terminal (F).

3. Install spring clip (B). Push down to set hook (C) into
brush holder (D). NOTICE
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.

a. Operate sprayer 1 hour with no load.

b. With sprayer OFF, turn pressure control knob
fully counter-clockwise to minimum pressure.
b. Install pump. Displacement Pump Replace-
Plug in sprayer.
ment, page 15.

309674P 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).

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).

11
37a

30

A 19
37

20
58 47
49
6

D
E
50 38

12
Wiring Diagram ti2509b

Domestic

Black

ON/OFF
Switch Black TP1/L1 L2 J8

Power Plug TP2

Black

White
Potentiometer
Green

Red (+) J7

Black (-)

ti2471
from Motor

2 x White

22 309674P
 On/Off Switch Replacement

110/240 VAC Ultra, Nova, and ST Max 395/495/595 models

5. Remove toggle boot (30) and locking ring. Remove
ON/OFF switch (58).

Installation
Removal 1. Install new ON/OFF switch (58). Install locking ring
and toggle boot (30).
1. Relieve pressure, page 7.
2. Connect four wires (A) to ON/OFF switch (58).
2. Remove four screws (12) and pressure control cover
(50). 3. Install display connector (B) to plug (C).
3. Remove display connector (B) from plug (C). 4. Install pressure control cover (50) with four screws
(12).
4. Disconnect four wires (A) from ON/OFF switch (58).


A




 



!

#


$ %


"
TIB

"LACK
 /./&&
3WITCH
"LUE J8
0OTENTIOMETER

40 40
4O0OWER "ROWN )NDUCTOR#OIL
0LUG "LUE
"LACK
4RANSDUCER
'REEN &ILTER"OARD
"ROWN J7
2ED

"LACK
WHITE

TIB
&ROM-OTOR , ,
X7HITE

$IGITAL$ISPLAY

309674P 23
 On/Off Switch Replacement

UltraMax II, Ultimate MX II and ST Max II 490/495/595 models

ON/OFF Switch/Power Cord Board Kit

8. Disconnect black lead between control boards.

9. Remove switch board from box.

Installation
Removal
1. Reconnect black lead between control and switch
1. Relieve pressure, page 7. boards.
2. Remove four screws (12) and control box cover (50). 2. Slide ON/OFF switch (30) through opening in con-
trol box housing and position switch board.
Power Cord
3. Remove green ground screw (19) and disconnect 3. Place toggle boot (58) over ON/OFF switch. Using a
ground choke coil and black leads. 5/8 in. deep socket wrench, tighten securely.

4. Slide black power cord strain relief (a) out of slot in 4. Install switchboard mounting screws (6).
control box (48) to remove it.
5. Slide power cord strain relief (a) into opening in con-
trol box (48).
On/Off Switch
5. Remove switchboard mounting screw (6) 6. Reattach black and white power cord leads to con-
trol and switch boards.
6. Using a 5/8 in. deep socket wrench, remove
ON/OFF switch toggle boot (58). 7. Reattach ground choke coil to ground screw (19).
Replace and tighten green ground screw.
7. Slide switch (30) through opening in control box
housing. 8. Install pressure control cover (50) with four screws
(12).

11

37 58
37a

a 5
49 48
20 38
6
12
15

127 6
30 3
TIA
50 19 47

24 309674P
 On/Off Switch Replacement

Wiring Diagram

MOTOR

210

211
Potentiometer
Ref 37

ON/OFF Switch
Ref 30
Black
J12 Pressure Transducer
Ground J11 Ref 38

Power Plug
Ref 56

Black

Green

White

Black ti7380a

309674P 25
 Pressure Control Repair

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
1. Relieve pressure, page 7.
Removal
2. Do steps 2- 9 of 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).

1. Relieve pressure, page 7, and unplug sprayer. 4. Remove motor shroud (23) and screws (12).

2. Remove screws (12) and cover (50). 5. Disconnect motor and thermistor connections (210, 211).

3. Disconnect all leads to motor control board (49). 6. Disconnect pressure transducer lead (J11).

4. Remove screws (6) and circuit board (49). 7. Disconnect potentiometer lead (J12) from board.

Installation 8. Remove grommet (5) from back of control box. Slide

motor leads through opening in back of control box (48).
1. Remove old thermal paste or thermal pad from control
9. Remove motor control board (49) from control box (48).
box.
Installation
2. Install motor control board (49) with screws (6).
1. Feed motor leads through back of control box (48).
3. Connect all leads to motor control board (49). See wir-
ing diagram for your sprayer on pages 22, 23, and 24. 2. Replace grommet (5) in control box (48).
4. Bundle and tie all loose wires so none touch induc- 3. Position motor control board (49) in control box.
tor coil (does not apply to 120V model sprayers). Secure control board with screws (6 and 127).
5. Install cover (50) with screws (12). 4. Connect potentiometer and transducer leads to con-
trol board.
Motor Control Board Kit 5. Connect motor and thermistor leads (210, 211).
UltraMax II, Ultimate MX II, ST Max II 490/495/595
Models.
6. Do steps 1-8 of ON/OFF Switch/Power Cord Board
Refer to your sprayer wiring diagram, pages 24 and 25. Kit installation instructions, page 24.
7. Replace shroud (23) with four screws (12).

26 309674P
 Pressure Control Repair

Motor Control Board Diagnostics

NOTICE
Do not allow sprayer to develop fluid pressure without
transducer installed. Leave drain valve open if test
transducer is used.
NOTE:
• Keep a new transducer on hand to use for test.
1. For sprayers with digital display, see Digital Display
• No display does not mean the sprayer is not pres-
Messages.
surized. Before repair, relieve pressure, page 7.
2. Remove screws (12) and cover (50).
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:

LED
DISPLAY 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 motor. 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 is a 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 II and ST Max II 490/495/595.

309674P 27
 Pressure Control Repair

Pressure Control Transducer Pressure Adjust Potentiometer

Removal Removal

1. Relieve pressure, page 7. 1. Relieve pressure, page 7.

2. Remove screws (12) and cover (50). 2. Remove screws (12) from cover (50).
3. Disconnect transducer lead from motor control 3. Disconnect potentiometer lead from motor control
board (49).
board (49).
4. Slide transducer grommet (20) out of control box
(48). 4. Remove potentiometer knob (11), nut (37a) and
pressure adjust potentiometer (37).
5. Remove pressure control transducer (38) and o-ring
(3) from filter housing.
Installation
Installation 1. Install pressure adjust potentiometer (37) and nut (37a).
1. Install o-ring (3) and pressure transducer (38) in fil-
ter housing (15). Torque to 30-35 ft-lb. a. Turn potentiometer fully clockwise.

2. Thread transducer lead plastic connector through b. Install knob (11) at full clockwise position.
transducer grommet (20) and slide grommet into
slot in control box housing (48). 2. Connect potentiometer lead (J8 or J12) to motor
control board (49). See wiring diagram pages 22,
3. Install filter housing (15) with screws (47). 23, and 24 for your sprayer model.
4. Connect transducer lead (J7 or J11) to motor control 3. Install cover (50) with screws (12).
board (49).
5. Install cover (50) with screws (12).

SmartControl
The SmartControl contains stored data to assist with 3. Hold down display button and turn sprayer ON.
troubleshooting and maintenance. To view this stored
4. Release display button about 1 second after turning
data on the digital display: 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.
1. Relieve pressure, page 7. 6. Turn sprayer OFF and then ON to exit stored data mode.
2. Plug in sprayer.

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.)
• Serial Number of sprayer. (UltraMax II, Ultimate Max II and ST Max II 490/495/595 only.)
2 Number of hours motor has been running.
3 Last error code. Press and hold display button to clear error code to E=00
4 Software revision

28 309674P
 Motor Replacement

Motor Replacement
Ultra, Nova, and ST Max 395/495/595 6. Remove screws (47) and control box (48).
Models Only
7. Remove screws (47) and manifold (15).

NOTICE 8. Remove screws (47) and motor (54) from frame

Do not drop gear cluster (44) and (40) when removing (59).
from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing. Installation
1. Install new motor (54) on frame (59) with screws
Removal (47).

2. Install manifold (15) with screws (47).

3. Install control housing (48) with screws (47).

1. Relieve pressure, page 7. 4. Install board (49) with screws (6). Connect all leads
to board. See wiring diagrams on pages 22, 23, and
2. Remove pump (41); Displacement Pump Replace- 24 for your sprayer model.
ment, page 15
5. Install drive housing (42); Drive Housing Replace-
3. Remove drive housing (42); Drive Housing ment, page 17.
Replacement, page 17.
6. Install pump (41); Displacement Pump Replace-
4. Remove screws (12) from cover (50). ment, page 15.

5. Disconnect all leads from board (49). Remove

screws (6) and board.

54
48
1

49
6
44

40

12

50

47 1

47
47
59 ti2569b

15

1 Liberally apply grease

309674P 29
 Motor Replacement

UltraMax II, Ultimate II, and ST Max II 7. Remove screws (47) and manifold (15).
490/495/595 Models Only
8. Remove screws (47) and control box (48).

NOTICE 9. Remove screws (47) and motor (54) from frame

Do not drop gear cluster (44) and (40) when removing (59).
from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing. Installation
1. Install new motor (54) on frame (59) with screws
Removal (47).

2. Install control housing (48) with screws (47).

3. Install manifold (15) with screws (47).

1. Relieve pressure, page 7. 4. Connect motor leads. See wiring diagram on page
25.
2. Remove four screws (12) and shroud (23).
5. Install drive housing (42); Drive Housing Replace-
3. Remove two screws (12) and front cover (22) ment, page 17.

4. Remove pump (41); Displacement Pump Replace- 6. Install pump (41); Displacement Pump Replace-
ment, page 15 ment, page 15.

5. Remove drive housing (42); Drive Housing 7. Replace front cover (22) and screws (12). Tighten
Replacement, page 17. screws securely.

6. Disconnect motor leads. 8. Replace shroud (23) and screws (12). Tighten
screws securely.

12

23

48 54
22

12
49

12

47 59
50

ti7434a
47 15 47

30 309674P
 Technical Data

Technical Data
Max Fluid
100-120V 220-240 V Generator Motor HP Cycles/ Delivery Max Tip Outlet
Model Ø, A, Hz Ø, A, Hz Minimum W (W) Gal (l) 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 . . . . . . . . . . 100 dBa*
Sound pressure . . . . . . . . . 90 dBa*
*Measured 3 feet (1 meter) from equipment.

Dimensions

Weight lb (kg)
Height in. Length in. Width in.
Model Ultra 395 UltraMax II Ultra 495 UltraMax II Ultra 595 UltraMax II (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 (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)

309674P 31
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 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.), 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
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information
For the latest information about Graco products, visit www.graco.com.
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.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 309674

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2002, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised March 2013