teste de placas graco.pdf

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Rev. N 10/11 /07

Electrical and Mechanical Repair Tips

WARNINGThis manual should only be used

by a qualified Service Technician.

For Contractor Sprayers

-

-

Black

Red

Yel

Yel

3.00

First choice whenquality counts.


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Table of Contents

Basic meter terminology and testing procedures...............................................................................................5-11

Error Code Chart .............................................................................................................................................12-28

Brushless type motor test Ultra-Max IIs ........................................................................................................ 20,21

Brush type motor test............................................................................................................................................ 22

Electric Sprayers

241989 Control board (190ES,SPX, 295ST):

Motor will not start ............................................................................................................................. 31,32

Motor Test ............................................................................................................................................... 22

Motor will not shut off............................................................................................................................ 29

245892 Control board (190ES, SP, SPX, ST, STX):


Motor Test ............................................................................................................................................... 22


253118 Control Board (190ES, Models 232900F, 232901E, 233797E, 233815E)


Motor Test ............................................................................................................................................... 22 Motor will not shut off............................................................................................................................ 29

249052 C (390 , Performance 390, Nova 390 ):

Motor will not run .............................................................................................................................. 37,38

Motor test ............................................................................................................................................ .....22


235707, 235008 Control Board (390ST, 390STS, 395ST, 450ST, 455ST, Duron 390, 395, 495, Nova SP,

SPX):

Motor will not run ................................................................................................................................... 40

Motor test ................................................................................................................................................ 41


241990 Control Board (395/455/495ST Pro, Performance Pro 395/495, NOVA Pro & Super):


Motor test ................................................................................................................................................ 22


246379 Control Board (Ultra 395/495/595, Ultimate Nova 395/SuperNova 495/595, Performance Max

395/495/595, ST Max 395/495/595):


Motor test ................................................................................................................................................ 22


287909 Control Board (490II, 495II, 595II):


Motor test ........................................................................................................................................... 20,21

Motor will not shut off............................................................................................................................ 29237659 Control Board (Ultra 600,Ultimate 600,Ultra Plus 600,Ultimate Plus 600):


Motor test ................................................................................................................................................ 22

Motor will not shut off ............................................................................................................... 29240168 Control Board (695,795,1095):


Motor test ................................................................................................................................................ 22



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244237 Control Board (695,795,1095):


Motor test ................................................................................................................................................ 22


287247,287941 Control Board (695II, 795II, 1095II, 1595II, MarkIV, MarkV):


Motor test ........................................................................................................................................... 20,21


244232 Control Board (1595 Mark V):


Motor test ................................................................................................................................................ 22


239750,239751 Control board located under sprayer (1500,1595, Mark V):

Motor will not run ......................................................................................................................... 59,60,61

Motor test ................................................................................................................................................ 22


236563 Control Board, Retrofit Kit 236974 (1000,900,750 and 500, 590,700 updated control boxes)


Motor test ................................................................................................................................................ 22


Electr ic Motor Kit for Convert ible Sprayers

236528 Control Board (GM 5000):


236528 Control Board (GMAX 5900):


Motor runs, no AC output to sprayer control board. .......................................................................... 69,70

246129 & 246125 Control Board (GH 200/230/300 Convertible Sprayer):

Motor will not run ................................................................................................................................... 71

GasPoweredSprayers

238672 Control Box (GM3000):

Fluid Pump will not run...................................................................................................................... 72,73

Fluid Pump will not shut off.................................................................................................................... 74

287486 Control Board (GMAX Sprayers 3400):


Fluid Pump will not stop pumping .......................................................................................................... 30

239056, Retrofit Kit 239693, 239266, 236974 (GM Sprayers 3500,3012,5000,7000):



220974, 221033, 222369 Pressure Control With Bourdon Tube (GM Sprayers 3500,5000):



241093 Control Board (Non-Display), (3900,5900,7900):

Fluid Pump will not run................................................................................................................. 83,84,85


245394 Control Board (Display), (3900,5900,7900):




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287516 Control Board: GMax II Sprayers (Display and Non-Display), (3900,5900,7900):



237373 Control Board, Retrofit Kit 237669 (GM 10,00, GMax 10,000)



HydraMax Sprayers:

Operational Overview ............................................................................................................................. 93

Piston rod stuck in the up position........................................................................................................... 94

Piston rod stuck in the down position...................................................................................................... 95

Control Board Off.................................................................................................................................... 96

LineStripers

238672 Control Board (GM3000 LineLazer):



287486 Control Board (LineLazer 3400):


Fluid Pump will not stop pumping .......................................................................................................... 30220974, 221033, 222369 Pressure Control With Bourdon Tube (GM LineLazer 3500,5000):



241543 Updated Control Board (GM LineLazer 3500,5000)

Fluid Pump will not run................................................................................................................ 97,98,99

Fluid Pump will not shut off.................................................................................................................. 30

241093 Control Board LineLazer (3900II, 5900II)

Fluid Pump will not run................................................................................................................. 83,84,85


245512 Control Board(LineLazer 3900III, 5900III):

Fluid Pump will not run.................................................................................................................. 100.101

Fluid Pump will not stop pumping .......................................................................................................... 30287689 Control Board(LineLazer 3900IV, 5900IV):

Fluid Pump will not run.................................................................................................................. 102,103


Engine Generator Test ........................................................................................................................... 104

Sensor Test ............................................................................................................................................ 105

Light Kit Troubleshooting..................................................................................................................... 106

4


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BASIC ELECTRICAL TERMINOLOGYIn any discussion of electricity, there are three basic terms you will need to understand.

CURRENT

VOLTAGE

RESISTANCE

CURRENT:

Current is the movement of the electrical charge.Current Flows through the wires from the power source to the load.

Current is measured in AMPERES (AMPS, A or I). See Figure 1.

NOTE: Meter is only clamped around one wire.

VOLTAGE:

Voltage is the force that causes current to flow in a circuit.

Voltage is measured in VOLTS (V or E). See Figure 2.

FIGURE 1

FIGURE 2

ON/OFF

Switch

Ref 58

PowerPlug

Red (+)

White

Black

Green

Black ()

Black

from Motor

ON/OFF

Switch

Ref 58

Power

Plug

Potentiometer Ref 37

Red (+)

White

Black

Green

Black ()

Black

120 AC

V

Motor

5


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BASIC ELECTRICAL TERMINOLOGY

RESISTANCE:

Resistance is anything that causes an opposition to the flow of current in a circuit.Resistance is used to control the amount of voltage and/or amperage in a circuit.

Resistance is measured in OHMS - . See Figure 3.A common component check would be motor and clutch field windings.

FIGURE 3

-

-

Black

Red

Yel

Yel

Known Value

-

Known Value

+

-

6


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CONTINUITY TESTING

Checking continuity is one of the most common tests in electrical troubleshooting. Continuity is the ability of a wire or electrical component to

conduct current. When you use a continuity tester, you connect a circuit (the continuity tester) that you know works, to a wire or a component that

may or may not work. The continuity tester will tell you if the wire or component is capable of conducting current.

Continuity testers are available at almost any hardware store.

A volt-ohmmeter or VOM can also be used to check continuity. This meter can be purchased at most electrical or electronic supply stores.

To test a component for continuity:

1 Check the tester by connecting the leads.

* If using a test light the light should turn on.

* If using a digital volt-ohmmeter, the screen should show 00 if OL appears the meter needs to be repaired.

SWITCH TESTING-ROCKER

Common test procedure for a SPST Switch:

0.000

7


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WIRE CONTINUITY TESTING

Continuity testing will NOT find wire fragmentation!!

Example:

120 Vac input static voltage and drops to 119Vac load voltage.

A good piece of wire will carry line and load voltage.

Damaged / Fragmented Wire Damaged / Fragmented Wire

Pinched Wire

120 Vac input static voltage and drops to 76Vac load voltage.

Other causes:

Poor stripping of outer insulation.

Poor crimp.

A defective piece of wire may carry line voltage but will NOT carry load voltage

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GROUND TESTING

Every corded electric sprayer that comes into your shop for repair should be tested as described below, to make sure that it is properly grounded.

Pull the machines plug out of the wall outlet and connect one lead from a DC continuity test light or a VOM to the (round) ground terminal on the

plug.

NOTE:

If the ground terminal is broken off of the plug, install a new plug.

Touch the test light (or VOM) leads to several bare metal surfaces on the body of the machine. If the light (or meter) indicates continuity, the machine

is properly grounded. If the light (or meter) doesnt indicate continuity trace through the ground (green) wiring on the machine to determine where

the break is.

Improper installation or alteration of grounding plug could results in risk of electric shock, fire or explosion that could cause serious injury or death.

The other function of the grounding plug is to protect the control board from static build up. If the plug is missing this could cause permanent damage

to the control board.

9


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CAPACITOR TESTING:

A capacitor is an electrical component that stores electricity. Capacitors are usually used to help start a motor or make a motor run more efficiently.

The following instructions can be used to test any capacitor.

WARNING!A CAPACITOR CAN SHOCK YOU EVEN WHEN A MACHINE IS UNPLUGGED. NEVER TOUCH CAPACITOR TERMINALS WITH

YOUR FINGERS. ALWAYS USE TOOLS WITH INSULATED HANDLES. NEVER DISCHARGE A CAPACITOR NEAR FLAMMABLE

LIQUIDS OR VAPORS.

1 Visually inspect the capacitor for leaks, mechanically damage or loose terminals. Replace it if any of these problems exist.

2 Unplug the machine and remove the capacitor(s).

If capacitor(s) are attached to the control board the test can not be performed.

3 SEE ABOVE WARNING Using a screwdriver with

insulated handles, hold so that the blade contacts the

capacitor terminals as shown in Fig. A. This will

discharge the capacitor.

4 Put a volt-Ohm meter on the R X 100 scale.

5 While watching the meter, connect the 2 leads to the 2 terminals on the capacitor.

If the capacitor is good, the meter needle will go to the right (toward 0 resistance) (Fig. 1), then to the left (toward - maximum resistance)

If the meter needle goes all the way to the right and stays there, the capacitor is defective.(Fig.2)

If the meter needle stays all the way to the left (doesn't move at all when connected to the capacitor), the capacitor is defective.(Fig. 3)

FIG. A

Capacitor

GOOD BAD BAD

10


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RECTIFIER

(See Fig. 1) Now we come to the most popular application of the diode: rectifcation. Simply rectifcation is the conversion of alternating

current (AC) to direct current (DC). This almost always involves the use of some device that only allows one-way flow of electrons.

As we have seen, this is exactly what a diode does.

RECTIFIER TESTING:

The following instructions can be used to test any bridge rectifer.Use a DC continuity test light or a VOM (on the R x 100 scale) for all tests.

Disconnect all wires from the rectifer.

AC

AC

+-

FIG. 1

1 Connect test leads as shown in Figure A. If the meter beeps, the rectifer is

defective. If the meter does not beep, go to the next step.

2 Connect test leads as shown in Figure B. If the meter does not beep, the

rectifer is defective. If the meter beeps, go to the next step.

3 Connect test leads as shown in Figure C. If the meter beeps, the rectifer is

defective. If the meter does not beep, go to the next step.

4 Connect test leads as shown in Figure D. If the meter does not beep, the

rectifer is defective. If the meter beeps, go to the next step.

5 Connect test leads as shown in Figure E. If the meter beeps, the rectifer isdefective. If the meter does not beep, go to the next step.

6 Connect test leads as shown in Figure F. If the meter does not beep, the rectifer is defective. If the meter beeps, go to the next step.

7 Connect test leads as shown in Figure G. If the meter beeps, the rectifer is defective. If the meter does not beep, go to the next step.

8 Connect test leads as shown in Figure H. If the meter does not beep, the rectifer is defective. If the meter beeps, the recti fer is good.

0.000OL OL 0.000

0.000OL OL 0.000

FIG. A FIG. B FIG. C FIG. D

FIG. E FIG. F FIG. G FIG. H

DC DC

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Instruction for checking the ERORR CODES:

1. Relieve pressure leave prime valve open and power switch OFF.

2. If sprayer has no display, remove the control box cover to view the control board LED status light.

3. Plug sprayer into correct AC power, grounded outlet.

4. Turn pressure control knob clockwise turn.5. Turn Power switch ON.

6. View digital display. If digital display is not available, view the control board LED status light

instead.

The Codes below ar e for several different models.

DIGITAL

DISPLAY

CONTROL BOARD

STATUS LIGHT.INDICATION

GO TO

PAGE

Digital_Display

_BlankNever Lights No power to microprocessor on control board. 13

- - - -

PSI icon not

blinking

Blinks once and stops Power to board is ok, No RUN command to motor.

14

- - - -

PSI iconblinking

Constant on Control is commanding motor to run. 15

Unreadable 1 Blink every 3 seconds

Board is trying to start up. Unplug transducer, pot

and display. If still blinking replace board. If itstops blinking one of the 3 parts are faulty.

Reconnect the parts one at time to find the faulty

part.

Displays high

pressure Improper pressure signal from transducer 16

E=02 Blinks 2 x repeatedly High pressure signal from transducer 17

E=03 Blinks 3 x repeatedly Transducer failure or connection error 18

E=04 Blinks 4 x repeatedly Excessive Wall voltage 19

E=05 Blinks 5 x repeatedly High current or motor is not turning. 20-22E=06 Blinks 6 x repeatedly

Motor is too hot or motor/thermal device

connection may be bad.23

E=07 Blinks 7 x repeatedly Exceeded 2000 psi during timed flush cycle. 24

E=08 Blinks 8 x repeatedly Low wall voltage 24

E=09 Blinks 9 x repeatedly Motor sensor failure 25

E=10 Blinks 10 x repeatedly High control board temperature 26

E=11 Blinks 11 x repeatedly Excessive motor speed 26

E=12 Blinks 12 x repeatedly High Current 27

E=13 Blinks 13 x repeatedly Model not selected 27

EMPTY Watchdog mode is activated. Sprayer will stop

running when pressure drops sharply28

Cal

Older Ultra-Maxs

Unplug the display, If sprayer operates Replace the

Display. If the sprayer does not operate replace thecontrol board.

8888Digital Display Switches

not set.

Set switches on back of digital display to the

appropriate settings.

Motor Hums Constant onPerform appropriate motor tests, if motor tests ok,

replace control board.

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Symptoms: Sprayer does not run at all

Digital Display is blank

Control board status light never lights

What does this mean?No power to the control board or display or control board is likely the problem.

Troubleshooting Procedure:

1. Set sprayer to OFF. Unplug digital display. Set sprayer to ON. If sprayer runs, replace display. If not, go to

next step.

2. Set sprayer ON and check for A.C. voltage at the control board. If no voltage, check power source andwiring back to power cord.

3. Set sprayer to OFF and disconnect power to sprayer.Check continuity from power cord plug (through

power switch) to control board.

4. If power cord, switch, EMI filter and wiring continuity is ok, replace control board.

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Digital Display shows dashes and Psi icon is not blinking

Control board status light blinks once when switch is turned on but then stays off.

What does this mean?Power to board is ok but there is no RUN command to the motor. Either the potentiometer or control board is

likely the problem.


Check potentiometer & connectionsto control board. Set sprayer to OFF.

Disconnect potentiometer from control board socket. Check that potentiometer and control board contacts areclean and secure.

Reconnect potentiometer to control board socket. Set sprayer ON

and control knob to turn clockwise. If sprayer does not run, set

sprayer to OFF and go to next step.

Connect a known good potentiometer to control board socket and set sprayer ON and control knob to turn

clockwise. If ok, replace pot. Replace control board if sprayer still does not run. But first, verify transducer

and connections are ok. See next page.

OR

Short center pin of socket to each outer pin. Install new potentiometerif sprayer runs. Replace control board if sprayer does not run. But first,

verify transducer and connections are ok. See next page.

Check transducer & connectionsto control board. Set sprayer to OFF anddisconnect power to sprayer.

Disconnect transducer from control board socket. Check that transducer and control board contacts are

clean and secure.

Reconnect transducer to control board socket. Connect power, set sprayer ON and control knob to turn

clockwise. If sprayer does not run, set sprayer to OFF and go to next step.

Connect a known good transducer to control board socket.

Set sprayer ON and control knob to turn clockwise. Install new transducer if sprayer runs. Replace control

board if sprayer does not run.

_ _ _

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Digital Display shows dashes and Psi icon is blinking

Control board status light blinks and stays on constant.

E5 error code brushless unit

What does this mean?There is power to control board, the potentiometer and transducer are ok and the control is commanding the

motor to run. Either the motor, motor connections, capacitor connections (brush type motor) or control board is

likely the problem.


1. Check motor and connections to control board. Also check

capacitor connections to control board for brush style motor.

2. Set sprayer to OFF and disconnect power to sprayer.

3. Disconnect motor connector from control board socket. Check that motor connector and control boardcontacts are clean and secure.

Check that connections at capacitor are secure. CAUTION

CAPACITOR MAY STILL HAVE A CHARGE ON IT!

4. Check motor. Remove pump pin and connect a D.C. voltmeter across two motor wires red & black (brushtype) red, black, blue (brushless type) Spin motor fan and check for a voltage to register on meter. Repeat

for all motor wire combinations brushless type only. If voltage notpresent, check brushes. If ok, replace

motor. If voltage present, go to next step.

5. Reconnect motor connector to control board socket. Connectpower, set sprayer ON and control knob to

turn clockwise. If sprayer does not run, replace control board.

_ _ _

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Digital Display shows a pressure reading

and Psi icon on

Control board status light off.

E2 error code Brushless unit (possible)

What does this mean?Improper pressure signal to control board, with no pressure in sprayer. The transducer or connections is likely

the problem.


1. Set sprayer to OFF anddisconnect power to sprayer.

2. Check transducer & connectionsto control board.

3. Disconnect transducer from control board socket. Check that transducer and control board

contacts are clean and secure.

4. Reconnect transducer to control board socket. Connect power; set sprayer ON and control knob to turn

clockwise. If sprayer does not run, set sprayer to OFF and go to next step.

5. Connect a known good transducer to control board socket.

Set sprayer ON and control knob to turn clockwise. Install newtransducer if sprayer runs. Replace control board if sprayer does

not run.

XXXX Psi

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Digital Display shows E=02

Control board status light blinks 2x repeatedly.

What does this mean?The control board is detecting an excessive pressure. The transducer or connections is likely the problem.

Troubleshooting Procedure:1. Make sure there is no pressure in the system (see pressure relief procedure). Check fluid path for clogs,

such as clogged filter.

2. If running Auto Clean, open prime valve and trigger gun.

3. Use airless paint spray hose with no metal braid. in. x 50 ft minimum. Smaller hose or metal braid hose

may result in high-pressure spikes.

4. Set sprayer to OFF anddisconnect power to sprayer.

5. Check transducer & connectionsto control board.

6. Disconnect transducer from control board socket. Check that transducer and control board contacts are

clean and secure.

7. Reconnect transducer to control board socket. Connect power, set sprayer ON and control knob to turn

clockwise. If sprayer does not run properly, set sprayer to OFF and go to next step.

8. Replace transducer. Connect power, set sprayer ON and control

knob to turn clockwise. Install new transducer if sprayer runs

properly. Replace control board if sprayer does not run properly.

E=02

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What does this mean?The control board is not detecting a pressure signal.

The pressure transducer or connections are likely the problem.


1. Set sprayer to OFF and disconnect power to sprayer.

2. Check transducer & connections to control board.

3. Disconnect transducer from control board socket. Check that transducer and control board


4. Reconnect transducer to control board socket. Connect power, set sprayer ON and control knob

to turn clockwise. If sprayer does not run, set sprayer to OFF and go to next step.

5. Connect a known good transducer to control board socket.

6. Set sprayer ON and control knob to turn clockwise. Install new

7. transducer if sprayer runs. Replace control board if sprayer does not run.

8. You can also check transducer resistance with an ohmmeter;

Between red & black wires less then 9 k ohm and 3-6 k ohm between green & yellow

wires.

E=03

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What does this mean?Voltage applied to the sprayer is too high.


1. Make sure the sprayer is plugged into the proper AC power source. Less than 138 volts for 120V

sprayers and less than 260V for 230V sprayers.

E=04

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What does this mean?The control is commanding the motor to run but the motor shaft does not rotate. Possibly locked rotor condition,an open connection exists between the motor and control, there is a problem with the motor or control board orthe motor amp draw is excessive.

Ultamax lls: Brushless motors test when the motor isrunnning at the start of the test. For all others go to step 1.

With the prime valve open and pressure relieved, start and stop the motor 15 times using the set point pot(Pressure Switch). If the motor restarts each time at no load Motor is probably bad (Resolver in the motor)replace the motor. If the motor will not restart every time then the board is at fault (running on 2 phase) replace

the circuit board.

Troubleshooting Procedure ULTRA-MAX II(Brushless Type Motors)

1. Remove the pump pin and try to run the sprayer. If the motor runs check for locked or frozen pumpor drive train. If sprayer does not run, go to next step.

2. Set sprayer to OFF and disconnect power to sprayer .

3. Disconnect motor connector(s) from control board socket(s). Check that motor connector andcontrol board contacts are clean and secure. If tests ok go to step 4.

5. Spin Test: Test at the large 4-pin motor field connector. Disconnect the fluid pump from thesprayer. Test motor by placing a jumper across pins 1 & 2. Rotate the motor fan at about 2-revolutions/second. A cogging resistance to motion should be felt at the fan. The motor needsreplacing if no resistance is felt. Repeat for pin combinations 1 & 3 and 2 & 3. Pin 4, the greenground wire, is not used in this test. If it tests good go to step 5 Resolver test

E=05

Spin Test

4. Set sprayer to OFF spin the motor fan 1/4 turn. Restart sprayer. If sprayer runs, replace control board.If not, go to step 5.

Step 1

4 3 2 1 4 3 2 1

Step 3

4 3 2 1

Step 2

GRN BLU RED BLK GRN BLU RED BLK GRN BLU RED BLK

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Resolver Test

NOTE: 490II, 495II and 595II Brushless motors will not have a resolver plug.

5. Resolver Test: Test the 6-pin Resolver connector on the end of the cable that connects the motor tothe circuit board. Use a volt-ohm meter to test resistance. Should read 44 ohms across pins 1 & 4,167 ohms across pins 2 & 5, and 167 ohms across pins 3 & 6. Inspect the 6 sockets in the connectorto make sure they are not causing a bad connection. Squeeze the socket back to size if one appearstoo large. If it tests good go to step 6.

6. Field Short Test: Test at the large 4-pin motor field connector. There should not be continuity from

pin 4, the ground wire, to any of the remaining 3 pins. If it tests good replace the Control Board.

12

345

644 ohms

Step 1

12

345

6167 ohms

Step 2

12

345

6

167 ohms

Step 3

7. Checking the motor thermistor: Unplug the Black wires. Set meter to Ohms.

Meter should read 100K(+ or -)10%. Note: motor should be cooled down.

-

100k ohm

+

-

To Motor

Black

Control

Board

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Troubleshooting Procedure for Brush Type Motors:

1. Remove the pump pin and try to run the sprayer.If the motor runs check for locked or frozen pumpor drive train. If sprayer does not run, go to next step.

2. Set sprayer to OFF and disconnect power to sprayer .

3. Disconnect motor connector(s) from control board socket(s). Check that motor connector andcontrol board contacts are clean and secure. If ok go to Step 4.

4. See capacitor test page. CAUTION - CAPACITOR MAY STILL HAVE ACHARGE! If it test ok go to step 5.

5. Check motor. Connect a D.C. voltmeter across two motorwires red & black spin the motor fanand check for a voltage to register on the meter. If voltage not present, check brushes. If ok, replacemotor. If voltage present, go to next step.

6. Reconnect motor connector(s) to control board socket(s). Connect power, set sprayer ON andcontrol knob to turn clockwise. If motor does not run, replace control board.

OR

+-9 volt

battery

Step 1

-

BEEP

Step 2

+-

-

-

1-3 ohms

Step 3

-

OL

+

Step 4

Ground

-

Checking the motor wires for a short.

Put the (-) meter lead on the motor case.

Move the (+) meter lead to each wire.

Meter should read open on all the wires.

Perform a spin test by connecting

a 9 volt battery or larger to the

motor leads. Motor leads may vary

in style and size. Locate the 2 wires

going to the carbon brushes normally

Red and Black.

Spin the motor while checking.

If a open is found replace the motor.

Checking the motors thermal protection.

Meter should read continuity or Ohms

depending on the motor.

Note: motor should be cooled down.

Black

RedYellow

Black

RedYellow

Black

RedYellow

Black

RedYellow

Use CAUTION not to distort the connectors when inserting the meter probes.

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What does this mean?Motor is too hot or motor/thermal device connections are likely the problem.


Quick test for Ultra Max ll's Only:

Note: This test is only for the BRUSHLESS MODELS. For all others go to step 1.

Motor must be cooled down for the test. Unplug thermistor wires from the control board, turn the sprayer on,

if motor starts the thermistor switch is bad, replace the motor. If motor still does not start or error code is still

present replace the control board. Step 3 should also be performed if a VOM is available to confirm that the

thermistor is shorted.

1. Check thermal sensor and connections to control board. Set sprayer to OFF anddisconnect power to

sprayer.

2. Disconnect motor / temp connector from control board socket. Check that transducer and control board


3. Measuringthe resistance of thethermal device. NOTE: A low resistance reading would be indicating to

the control board that the motor is hot. The resistance for most motors with yellowsensor wires will be

about 100 k ohm.If the reading is not correct,replace motor. Motors with a thermal switch you will test

for continuity.If open replace the motor.

4. Reconnect motor / temp connector to control board socket. Connect power, set sprayer ON and control

knob to turn clockwise. If sprayer does not run, replace control board.

5. If connections are all OK, allow sprayer to cool. If sprayer runs when cool, correct cause of overheating.

Keep sprayer in cooler location with good ventilation. Make sure motor air intake is not blocked.

6. If the sprayer still does not run after cooling off, replace the motor.

E=06

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What does this mean?Pressure exceeded 2000 psi while using the flush timer (AutoClean Timer)

Troubleshooting Procedure:1. This error only occurs when using the flush timer. Do not use the flush timer mode when spraying.

2. When using the flush timer for AutoClean , make sure that the gun trigger, prime valve and AutoClean

valve are all open before starting the motor.




What does this mean?Voltage applied to the sprayer is too low.


Make sure the sprayer is plugged into the proper AC power. More then 90 volts for 120V sprayers and at least

200 volts for 230V sprayers) Check the voltage at the control board. If below 90 or 200 volts repair or replace

cord or switch. If voltage at the boards is above 90 or 200 replace the control board.

E=07

E=08

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What does this mean?The control is not receiving a motor position sensor signal. The resolver or connections is likely the problem.

(Ultra Max II motors only)


1. Set sprayer to OFF.

2. Disconnect motor and resolver connectors from control board sockets. Check that connector and controlboard contacts are clean and secure.

3. Check the resolver connections and resistance. Take three resistance readings at the resolver connector,

between the two rows. The readings should be about: 44 ohms and 167 ohms twice. If any reading is

open, replace motor.

4. Make sure the connector sockets are not (or do not get) spread out or damaged. This may cause the

motor not to run. If any of the sockets are out of shape or enlarged, the sockets can be pinched tighter

for a better contact.

5. Reconnect motor connectors to control board sockets. Set sprayer ON and control knob to turn

clockwise. If motor does not run, replace control board.

E=09

25


26/107




What does this mean?Control board power module high operating temperature. The module

is likely too hot or motor running too hot.



1. Make sure the motor air intake is not blocked

2. Make sure control board is properly connected to the back plate and that conductive thermal paste isused on the power components.

3. Replace control board.

4. Replace motor.




What does this mean?Excessive motor speed. The control is sensing abrupt motor speed change. The sprayer drive or motor resolver

is likely the problem.



1. Check for damaged gears or disconnected pump.

2. Run sprayer at low pressure to check for normal operation.

3. Replace drive or motor as needed.

E=10

E=11

26


27/107




What does this mean?The control board is detecting an excessive amp draw. The motor circuit is possibly shorting out, a locked rotor

condition exists or the control boards has a problem. (Ultra Max II motors only)


1. Set sprayer to OFF.

2. Disconnect motor connector from control board socket. Check that motor connector and control board


3. With the motor unplugged turn the control knob fully counter clockwise. Set sprayer ON. If E=12 does

not display, control board is ok. If E=12 is displayed, control board is faulty, before replacing the board

check for possible short circuits in motor wiring.

4. Reconnect motor connector to control board socket.

5. Set sprayer to OFF. Remove the pump pin and try to run the sprayer. If the motor runs check for locked

or frozen pump or drive train. If display shows E=12 (or control board status light blinks 12x

Repeatedly) replace motor.




What does this mean?Model select resistors on control board not properly selected.(Ultra Max II motors only)

Troubleshooting Procedure:Resistors on control board must be properly clipped to identify model type, see replacement control board

instruction manual.

E=12

E=13

27


28/107


Digital Display shows EMPTY

What does this mean?

Watchdog mode is activated. Sprayer will stop running when pressure drops sharply. This prevents pump

runaway when out of paint, clogged inlet strainer, severe leak.

Troubleshooting Procedure:Watchdog mode can be deactivated (See sprayer instruction manual)

To restart the sprayer after a Watchdog trip, turn pressure control to zero and back up or turn power off/ then on.

EMPTY

28


29/107

Electric Motor will not shut off:

1. Relieve pressure, leave prime valve open and power switch OFF.2. Remove the control box cover so the control board status light can be viewed if available.


With a pressure gauge plumbed into the paint hose,

plug the sprayer in. Turn the power switch on, does

the gauge read the sprayersmaximum pressure and

continues to build pressure?

Mechanical problem: See the properfluid pump manual for the sprayer for

further trouble shooting procedures.

Is light on at the control

board? If the board has no

light the answer is yes.

Replace the control board.

Unplug the transducer from controlboard, does motor stop running?

Bad transducer, replaceand test with a new one.


YES

YES

YES

Shorted Board.

NO

NO

NO

29


30/107

Gas Sprayers (Fluid Pump)runs all the time:

1. Relieve pressure, leave prime valve open, power switch OFF.

2. Remove the control box cover.


With a pressure gauge plumbed into the paint

hose, start the engine. Turn the pump switch on,

does the gauge read the sprayers maximum

pressure and continues to build pressure?

Mechanical problem: See the properfluid pump manual for the sprayer forfurther trouble shooting procedures.

Unplug the transducer from controlthe board, does the pump stop.

Bad transducer, replaceand test with a new one.


NO

NO

YES

YES

YES

With the clutch wires plugged in.

Do you have 10-18 DC Volts

at the clutch test points?

NODisconnect the clutch wires from

the control board. Does the pump

stop running?

Mechanical problem in the clutch pinion

assembly. (Clutch may be to close to the rotor).

YES

NO

Check for a short from the

2 clutch wires to the frame.

If shorted repair or replace

the faulty wire.

30


31/107

NO

Remove the control box cover.

Turn the sprayer on. Observe

the control boards light(s).

Replace the

power switch.

If motor is hot let

cool and retest, if

step 4 still shows an

open replace motor.

The motor has a

defective

thermistor switch.

See pages 32for the steps and illustrations.

NO

See step 4.

Is there

continuity

through the

thermistor

wires?

See step 5.Does the

motor run?

See motor

test section.

Motor will not start:

See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES

Repair or replace

the power Cord.

NO

Replace

Potentiometer.Pressure Switch

190ES,SPX,295ST

Control Board 241989 (Capacitor on Motor)

Connect a test

transducer to

the board.

Does themotor run

Replace the

transducer.

Replace

Control

Board.Yes

No No

See Error Code

section for further

troubleshooting.

Once Normal operation.

Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

31


32/107

Capacit

or

190ES,SPX,295ST

Control Board 241989

L2M+TO2 TO1

L1

M-

J12J10

Black

Black

White

Ground

Grn

RedRed Black

Black

Yellow

L2

L1

Black

White

Control

Board

Step 1

Cord plugged in.

Switch ON.

Wires connected

to control board.

110-120 AC

V

-

+

-

Step 2

Cord plugged in.

Switch ON.

Wires connected

to ON/Off Switch.

+

-

M+

M-

White

Yellow

Black

Control

Board

100 + DC

V

Step 3

Cord plugged in.

Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

-

Potentiometer

110-120 AC

V

-

J12

J10

Step 5

Potentiometer

Cord plugged in.

Switch ON.Potentionmeter

disconnected.

Control

Board

-

BEEP

Checking the motor

thermistor switch .

Unplug the 2 yellow

wires from TO2 and TO1

Meter should read

continuity. Note: motor

should be cooled down.

L2

TO2TO1

L1

-

Step 4

Control

Board

(Capacitor on Motor)

32


33/107

NO

Replace Potentiometer.

Pressure Switch

Replace the

power switch.

If moto r is hot letcool and retest, if


open replace moto r.

The motor has a

defective

thermistor switch.

See pages34for the steps and illustrations.

NO

See step 4 .Is there

continuity

through the

thermistor

wires?

See step 5 .

Does the moto r run?

See motor

test section.

190ES,DTX,SP,SPX,ST,STX

(Capacitor on PC board)Control Board 245892


See step 2.

Do you haveover 100 AC

volts?

See step 1.

Do you have

over 100 AC

volts?

NO

YES

See step 3 .

Is there over

100 DC volts?

YES

YES

Repair or repl ace the

power Cord.

NO

Check the motor for a short

before replacing fuse. See

moto r test section.If motor

tests ok install a new fuse

with the motor

unplugged.Turn sprayer on,

if the fuse doesn t open

replace the motor.

Is the fuse

good.

YES

NO

YES

YES

Connect a test

transducer to

the board.

Does the

motor run

Replace the

transducer.

Replace the

Control

Board

Yes

No No

Remove the control box cover.Turn the sprayer on. Observe


See Error Code

section for further

troubleshooting.


Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

33


34/107

Pressure

Transducer

Motor

Yellow

Ground

Black

Black

White

White

Green

FUSE

J8J7

NL

M+ M-

T01

T02

D7

Red Black

F1

Step 1110-120 AC

V

-

White

FUSE

NL

F1

Black

Control Board

-

+

Cord plugged in.

Switch ON.

Wires connected.

Reference F1 on the

Control board for

proper meter location.

110-120 AC

V

-

-

+

Step 2

Cord plugged in.

Switch ON.

Wires connected

to ON/Off Switch.

Control

Board

100 + DC

V

Step 3Cord plugged in.

Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

Motor

Yellow

FUSE

M+ M-

T01

T02

RedBlack

F1

-

J8

Step 5

Potentiometer

Cord plugged in.

Switch ON.

Potentionmeter

disconnected.

Control

Board

Yellow

J7

T01

T02

-

BEEP

Checking the motor

thermistor switch .

Unplug the 2 yellow


Meter should read



-

Step 4

Control

Board

190ES,DTX,SP,SPX,ST,STX

(Capacitor on PC board)Control Board 245892

34


35/107

Remove the motor

cover. See step 1. Do

you have over 100 AC

volts?

Replace pressure

control switch.

If motor is hot let cool and

retest, if step 4 still shows an

open replace motor. The

motor has a defective

thermistor switch.

Replace

control board.

See pages 36 for the steps and illustrations.

NO

YES

See step 3.

Is there over

100 DC volts?

See step 4.

Is there continuity

through the

thermistor wires?

See step 5.

Does the motor run?

NO

See motor test section.

YES

NO

Replace the

power switch.

See step 2.

Do you have

over 100 AC

volts?

NO

YES

Repair or replace the

power Cord.

Check the motor for a short

before replacing fuse. See

motor test section.If motor

tests ok install a new fuse

with the motor

unplugged.Turn sprayer on,

if the fuse doesnt openreplace the motor.

Is the fuse

good.

YES

NO

YES

NO

190ES 232900,F;232901,E;233797,E;233815,E



YES

35


36/107

Motor

L

Black

J1

N

WhiteF1

Fuse

BlackWhite

Ground

Green

Black

Black

Yellow

Red

Yellow

White

Black

-

+

100 + DC

V

Step 3

Cord plugged in.Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

F1

Fuse

Red Black

-

J1

Step 5 Cord plugged in.

Switch ON.

Pressure switch unplugged.

Control

Board

Insulated Jumper wire

stripped on the ends

Pressure

switch

Control

Board

Checking the motor

thermistor switch .

Unplug the motor.

Meter should read



F1

Fuse

Control

Board

-

BEEP

Yellow Yellow

-

Step 4


Switch ON.

Wires connected.

Reference F1 on the

Control board for

proper meter location.

NWhite

F1

Fuse

-

+

110-120 AC

V

-

110-120 AC

V

-

Step 2Cord plugged in.Switch ON.

Wires connected

to ON/Off Switch.

190ES 232900,F;232901,E;233797,E;233815,E


36


37/107

NO

Replace the

control board.Faulty switch.

If motor is hot let

cool and retest, if


open replace motor.

The motor has a

defective

thermistor switch.

See pages38 for the steps and illustrations.

NO

See step 5.

Is there

continuity

through the

thermistor

wires?

See step 6.

Does themotor run?

See motor

test section.

See step 2.


volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 4.

Is there over

100 DC volts?

YES

YES

Repair or replace

the power Cord.

NO

Replace

Pressure Switch

Replace Control Board.No

249052 Control Board

Motor will not run

See step 3. Do

you have over

100 AC volts?

If the fuse is

blown check

the motor for

a short before

replacing the

control board.

NO

YES

37


38/107

On/Off

Switch

Pressure

Switch

Motor

FUSE

F1

Grnd.

249052 Control Board Trouble Shooting

J1

J3J4

BlkRed

Yellow

J3J4

Control

Board

To

Power Cord

Step 1

Cord plugged in.

Switch ON.Wires connected

to control board.

Meter on AC Volts

110-120 AC

V

-

-

On/Off

Switch

FUSE

F1

J4

Control

Board

Step 2

Cord plugged in.


to control board.

Meter on AC Volts

110-120 AC

V

-

-

+

On/Off

Switch

FUSE

F1

J4

Control

Board

Step 3

Cord plugged in.


to control board.

Meter on AC Volts

110-120 AC

V

-

-

+

Blk

Red

Yellow

Control

Board

100 + DC

V


Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts

-

-

-

BEEPChecking the motor

thermistor switch .

Unplug the motor

wires from control

board.

Carefully insert the

meter probes into the

2 yellow wires.

Meter should read

continuity.

Note: motor should be

cooled down.

+

Yellow

-

Step 5

J1

Step 6

Motor plugged in. Cord plugged in.

Switch ON.

Pressure switch

unplugged.

Control

Board

Insulated Jumper wire

stripped on the ends

+

Red

Blk38


39/107


Motor Will Not Shut Off

With a pressure gauge plumbed into the paint gun

hose, turn the power switch on, does the gauge readthe sprayers maximum pressure and continue to

build pressure?

Mechanical problem: Sprayer cannot build to

proper pressure. See the proper fluid pumpmanual for further troubleshooting procedures.

See Fig.1 Unplug the pressure control's (A)plugfrom the control board. Does the motor stop?

No

No

Yes

Yes

Replace the pressure control.


A

Fig. 1

Pressure Control

39


40/107

NO

Replace the

power switch.

NO

See step 3.

Is there

continuity

through the

thermistor

switch.

See step 5.

Does the motor run?

See motor

test section.

See step 2.


volts?YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

See step 4.

Is there over

100 DC volts?

YES

Repair or replace thepower Cord.

See pages 41for the steps.

235707, 235008 Control Board

Check all the wiring

connection to the 2

small motor wires, if

ok replace motor. Faulty

thermistor switch.

NO

YES

Replace Control Board.No

See step 6.

Does the presure

switch test ok?

YES

Replace

Pressure Switch

Check the pressure transducer for

hardened paint or damaged or

worn components. Clean or replace.

YES

No

40


41/107

Black

-ML

Black

N

White

110-120 AC

V

-

Cord plugged in.

Switch ON.

Wires connected.

-

+

Step 1

Motor

Wht/Blk

RedRed

Blk

ThermistorSwitch (NC)

-


thermistor switch .Unplug the 2 red wires.

Meter should read



Step 3

+-

+M-M

Motor Start Board

BlkWht/Blk

Control

Board

100 + DC

V


Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts

-

+

-

Black

-ML

Black

N

White

110-120 AC

V

-


Wires connected.

-

+

Step 2

J5Control

Board

Step 5

Black

+M-M

Motor

Motor Start Board

L

Wht/Blk

Black

Ground

White Red WhiteRed

N

Blk White

Thermistor

Switch (NC)

Pressure Control

Switch

J5

1

Cord plugged in.

Switch ON.

Pressure Switch

unplugged.

Remove pressure control and check the

micro switch operation with ohmmeter:

(1) With pressure knob at the lowest setting

and stem pushed into the control, readings

should be: white & black = 1 ohm max.

white & red = open. (2) With pressure knob

at the highest setting, readings should be:

white & black = open; white & red =

1 ohm max. If any of the above tests are not

correct it's a NO.

-

BEEP

Step 6

+

-

235707, 235008 Control Board Trouble Shooting

41


42/107


Motor Will Not Shut Off

Yes

Yes

NOReplace the PressureControl Assembly .

Remove pressure control and check themicro switch operation with a ohmmeter:

(1) With pressure knob at the lowest setting andstem pushed into the control, readings should be:

white & black = 1 ohm max. white & red = open.

No Replace the control board.Unplug the pressure transducer switch plug

from the control board. Does the motor stop?

With a pressure gauge plumbed into the paint gunhose, turn the power switchon, does the gauge readthe sprayers maximum pressure andcontinue to

build pressure?

No

Yes

Mechanical problem: Sprayer cannot build toproper pressure. See the proper fluid pump

manual for further troubleshooting procedures.

Check the pressure transducer for

hardened paint or damaged or worncomponents. Clean or replace

MOTOR

On/Off Switch

To Pressure

Transducer

E

A

B

CD

42


43/107

NO




Replace the

power switch.

If motor is hot let

cool and retest, if


open replace motor.

The motor has a

defective

thermistor switch.


NO

See step 4.

Is there

continuity

through the

thermistor

wires?

See step 5.Does the

motor run?

See motor

test section.


See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES

Repair or replace

the power Cord.

NO

Replace



(395/455/495ST Pro, Performance Pro 395/495, NOVA Pro & Super)

Connect a test

transducer to

the board.

Does themotor run?

Replace the

transducer.

Replace

Control

Board.

Yes

No No

See Error Code

section for further

troubleshooting.

OnceNormal operation.

Go to step 1.

Light on

continuously

Control board

commanding

motor to run.

Go to Step 1.

Flashing

No light Go to step 1.

43


44/107

L2M+TO2 TO1

L1

M-

J12J10

Black

Black

White

Ground

Grn

Red

Black

Yellow

L2

L1

Black

White

Control

Board

Step 1

Cord plugged in.

Switch ON.

Wires connected

to control board.

110-120 AC

V

-

+

-

Step 2

Cord plugged in.

Switch ON.

Wires connected

to ON/Off Switch.

+

-

M+

M-

White

Yellow

Black

Control

Board

100 + DC

V

Step 3

Cord plugged in.

Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

-

Potentiometer

110-120 AC

V

-

J12

J10

Step 5

Potentiometer

Cord plugged in.

Switch ON.Potentionmeter

disconnected.

Control

Board

Checking the motor

thermistor switch .

Unplug the 2 yellow


Meter should read



L2

TO2TO1

L1

-

Step 4

Control

Board


(395/455/495ST Pro, Performance Pro 395/495, NOVA Pro & Super)

-

BEEP

44


45/107

NO

Replace the

power switch.

If motor is hot let

cool and retest, if


open replace motor.

The motor has adefective

thermistor switch.

NO

See step 4.

Is there

continuity

through the

thermistorwires?

See step 5. Does the

motor run?

See motor

test section.

See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES


power Cord.

NO


Pressure Switch


Ultra 395/495/595, Ultimate Nova 395/SuperNova 495/595

Performance Max 395/495/595, ST Max 395/495/595


Connect a testtransducer to

the board.

Does the

motor run

Replace the

transducer.

Replace theControl

BoardYes

NoNO




See Error Code

section for further

troubleshooting.


Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

45


46/107

Black

110-120 AC

V

-

-

+

Step 2

Cord plugged in.

Switch ON.

Wires connected

to ON/Off Switch.

Black

Control

Board

100 + DC

V

Cord plugged in.

Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

-

Motor

-


thermistor switch .

Unplug the J11 2 yellow

wires from control board.

Meter should read



+

Yellow Thermistor

Wires to motor

-

J11

J8

J7

N

L

Cord plugged in.

Switch ON.

Potentionmeter

disconnected.

J8

ControlBoard

Step 3

Step 4

Step 5

C15

White

110-120 AC

V

-

Cord plugged in.

Switch ON.

Wires connected.

+

N

L

White

Black

-

+

Power

Cord

Step 1

Yellow Thermistor

Wires to motor

Ultra 395/495/595, Ultimate Nova 395/SuperNova 495/595

Performance Max 395/495/595, ST Max 395/495/595


Control

Board

ControlBoard

46


47/107

Replace the

power switch board.

If motor is hot let

cool and retest, if

step 4 still shows low

resistance replace motor.

The motor has a

defective thermistor .

NO

See step 4.

Is there

100K Ohms

through the

thermistor

wires?

See step 5.

Does the motor run?

See step 2.

Do you have

over 100 AC

volts?

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

YES

Repair or

replace

power

Cord.

NO


Pressure Switch


(490ll, 495II,595ll)

Motor will not Run:


Connect a test

transducer to

the board.

Does the

motor run?

Replace the

transducer.

Replace the

Control

BoardYes

No No

See step 3.

Is there over

100 AC volts?

Replace the

power switch board.YES

NO



the control boards Green light.

See Error Code

section for further

troubleshooting.


Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

YES

47


48/107

Ground

Motor

L1

L1

D21

L2BL1B

Yellow

Yellow

Green

Blue

Red

Blac

k

WhiteBlack

Black

White

Green

Step 1


Wires connected

to control board.

Meter on AC Volts

110-120 AC

V

-

+

Ground

L1

L1

L2BL1B

WhiteBlack

Black

Power

Cord

-

Step 2


Wires connected

to control board.

Meter on AC Volts

110-120 AC

V

-

+

Ground

L1

L1

L2BL1B

WhiteBlack

Black

Power

Cord

-

Step 3


Wires connected

to control board.

Meter on AC Volts

110-120 AC

V

-

+

Ground

L1

L1

L2BL1B

WhiteBlack

Black

Power

Cord

-

Control

Board

Step 4

-

D21

Yellow

Yellow

To Motor

-

J12

Potentiometer

Cord plugged in.

Switch ON.

Potentiometer

disconnected.Control

Board

Step 5


(490ll, 495II,595ll)

Checking the motor

thermistor .

Unplug the yellow wires.

Meter should read 100K

Note: motor should be

cooled down.-

100k ohm

Transducer

On/OffSwitch

Board

On/OffSwitch

Board

On/Off

Switch

Board

On/Off

Switch

Board


49/107

NO

Replace the

power switch.

If motor is hot let

cool and retest, if


open replace motor.

The motor has a

defectivethermistor switch.


NO

See step 4.

Is there

continuity

through the

thermistor

wires?

See step 5.Does the

motor run?

See motor

test section.


See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES

Repair or replace

the power Cord.

NO

Replace


Connect a test

transducer to

the board.

Does the

motor run?

Replace thetransducer.

Replace Control

Board.

Yes

No No


Ultra 600,Ultimate 600,Ultra Plus 600,Ultimate Plus 600

49


50/107

Potentiometer

BlackBlack

N

L

White

M+ M-

Blk

Blk/Wht

Motor

Transducer

On/Off

Switch Red

TS

TS


Ultra 600,Ultimate 600,Ultra Plus 600,Ultimate Plus 600


Switch ON.

Wires connected

to control board.

Meter set to AC Volts.

110-120 AC

V

-

White

ControlBoard

NL

-

+

Black

Black to L

Black to power cord

Step 2


Wires connected

to ON/Off Switch.

110-120 AC

V

-Meter set to AC Volts.

On/Off

Switch+

-

M+ M-

Blk

Blk/Wht

Motor

Red

TS

TS

ControlBoard

100 + DC

V

Step 3

Cord plugged in.

Switch ON.Pressure Switch

Turned to high.

Meter on DC volts.

-

+ -

-

BEEP Checking the motor

thermistor switch .

Meter should read



Step 4

M+ M-

Blk

Blk/Wht

Motor

Red

TS

TS

ControlBoard

+

-

+

Potentiometer

Cord plugged in.

Switch ON.

Potentionmeter

disconnected.

Control

Board

Step 5

50


51/107

NO

Replace the

power switch.

If motor is hot let

cool and retest, if

step 4 still shows lowresistance replace motor.

The motor has a


NO

See step 4.

Is there

100K Ohmsthrough the

thermistor

wires?

See step 5.

Does the motor run?

See motor

test section.

See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES


power Cord.

NO


Pressure Switch

(695,795,1095)

Motor will not Run:



Connect a test

transducer to

the board.

Does the

motor run

Replace the

transducer.

Replace the

Control

BoardYes

No No

Jumper notnot cut.



the control boards Red light.

See Error Code

section for further

troubleshooting.


Light oncontinuously

Flashing

No light

51


52/107

BLACK

BLACK

WHITERED (+)

BLACK()

GREEN

VIOLET

PressureTransducer

ON/OFFSwitch

Power SupplyCord

Potentiometer

from Motor

Ground YELLOW

M-

L1 L2

M+

J4

Control

Board

Step 1

Cord plugged in.

Switch ON.

Wires connected

to control board.

110-120 AC

V

-

WHITE

M-

L1 L2

M+

BLACK

-

+

Step 2


Wires connected

to ON/Off Switch.

Control

Board

110-120 AC

V

-

WHITE

M-

L1 L2

M+

BLACK

-

+

100 + DC

V

Step 3

Cord plugged in.

Switch ON.Pressure Switch

Turned to high.

Meter on DC volts.

-

Control

Board

WHITE

M-

L1 L2

M+

BLACK+

-

J12

Potentiometer

Cord plugged in.

Switch ON.

Potentionmeter

disconnected.

Control

Board

Step 5

Control

Board

Checking the motor thermistor .

Unplug the yellow wires.

Meter should read 100K

Note: motor should be cooled down.

Step 4

YELLOW

J4

-

100k ohm

+

-

(695,795,1095)


1095 Only

52


53/107

NO

Replace the

power switch.

If motor is hot let

cool and retest, if


open replace motor.


thermistor switch.

NO

See step 4.

Do you have

open through

the thermistor

wires?

See step 5.

Does the motor run?

See motor

test section.

See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

See step 3.

Is there over

100 DC volts?

YES

YES

Repair or

replace the

power Cord.

NO


Pressure Switch

(695,795,1095)

Motor will not run:



Connect a test

transducer to

the board.

Does the

motor run

Replace the

transducer.

Replace the

Control

BoardYes

NoNO



the control boards Red light.

See Error Code

section for further

troubleshooting.


Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

53


54/107

-

Potentiometer

PressureTransducer

ON/OFF

Switch

Black

Display

Motor

Green

L2L1

D11

J7 J12 J10 J9

WhiteBlack

Red

Blk

Yel

Yel

White

Red LED

Control

Board

Step 1

Cord plugged in.

Switch ON.

Wires connected

to control board.

110-120 AC

V

-

+

- L2L1

WhiteBlack

+


Switch ON.

Wires connected

to ON/Off Switch.

110-120 AC

V

-

+-

Control

Board

100 + DC

V

Step 3

Cord plugged in.

Switch ON.

Pressure Switch

Turned to high.

Meter on DC volts.

-

J7

Red

Blk

Yel

Yel

+-

Control

Board

J7

Red

Blk

Yel

Yel

-

J12

Potentiometer

Cord plugged in.

Switch ON.

Potentionmeter

disconnected.

Control

Board

Step 5

(695,795,1095)


Checking the motor

thermistor switch .

Meter should read

continuity. Note: motorshould be cooled down.

Step 4BEEP

54


55/107

Replace the

On/Off Switch.

If motor is hot let

cool and retest, if

step 4 still shows low

resistance replace motor.

The motor has a


NO

See step 3.

Is there

100K Ohms

through the

thermistor

wires?

See step 4.

Does the motor run?

See step 2.

Do you have

over 100 AC

volts?

See step 1.

Do you have

over 100 AC

volts?

NO

YES

YES

YES


power Cord.

NO


Pressure Switch

Control Board 287941 (With GFI Filter Coil)

(695ll, 795II,1095ll,1595ll)

Motor will not Run:


Connect a test

transducer to

the board.

Does the

motor run?

Replace the

transducer.

Replace the

Control

BoardYes

No No

YES



the control boards Green light.

See Error Code

section for further

troubleshooting.


Light on

continuously

Control board

commanding

motor to run.

Flashing

No light

55


56/107

287941 Only

Watch Dog Switch

On/ Open

Off /Closed

Transducer

Potentiometer

On/Off

Switch

Motor

To Optional

Display

GFI Filter Coil

on 287941updated 287247

15 amp closed

20 amp open

Switch

Power Cord

Control Board 287247,287941 (With GFI Filter Coil)

(695ll, 795II,1095ll,1595ll,MarkIV,MarkV)

Control

Board

Step 1

Cord plugged in.

Switch ON.

Wires connected

to control board

and On-Off switch.

Meter on AC Volts.

110-120 AC

V

-

WHITEBLACK

On/Off

Switch WHITEBLACK

BLACK

+

-

Power Cord

Control

Board

Step 2

Cord plugged in.

Switch ON.

Wires connected

to control board

and On-Off switch.

Meter on AC Volts.

110-120 AC

V

-

On/Off

Switch WHITEBLACK

BLACK

+

-

Power Cord

Checking the motor

thermistor .

Unplug the yellow

wires. Meter should

read 100K. Note: motor

should be cooled dow

Step 3

-

100k ohm

+- To Motor

Blk

Step 4

Control Board

Cord plugged in.

Switch ON.

Potentiometer

disconnected.

ControlBoard

Neutral

Black

Black

56


57/107

NO

Replace the

Filter.

If motor is hot let

cool and retest, if


open replace motor.


thermistor switch.

NO

See step 5.

Is there

continuity

through the

thermistorwires?

See step 6.

Does the

motor run?

See motor

test section.

See step 2.

Do you have

over 100 AC

volts?

YES

See step 1.

Do you have

over 100 AC

volts?

YES

YES

See step 4.

Is there over

100 DC volts?

YES

YES

Repair or

replace thepower Cord

NO


(Pressure Switch)

(1595, MarkV)

Motor will not run:



Replace the

power switch.

NO

See step 3.

Do you have

ov

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