309713G Ultimate NOVA 395, Ultimate Super NOVA 495/595 .

TroubleshootingRelieve pressure; page 5.MOTOR WON’T OPERATETYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkBasic Fluid PressureProblems1. Pressure control knob setting. Motor will not run 1. Slowly increase pressure setting to see if moif at minimum setting (fully counterclockwise).tor starts.Basic MechanicalProblemsWHAT TO DOWhen check is not OK refer to this column2. Spray tip or fluid filter may be clogged.2. Relieve pressure and clear clog or clean filter; refer to separate gun or tip instructionmanual.1. Pump (41) for frozen or hardened paint.1. Thaw sprayer if water or water-based painthas frozen in sprayer. Place sprayer in warmarea to thaw. Do not start sprayer untilthawed completely. If paint hardened (dried)in sprayer, replace pump packings. Seepage 21 (Displacement Pump Replacement).2. Displacement pump connecting rod pin (9a). 2. Push pin into place and secure with spring rePin must be completely pushed into connectingtainer.rod (9) and retaining spring (9b) must be firmlyin groove of pump pin. See Fig. 11.3. Motor (54). Remove drive housing assembly 3. Replace motor (54) if fan won’t turn. See(42). See page 19. Try to rotate fan by hand.page 20.Basic Electrical Problems1. Motor control board. Board shuts down and dis- 1. See Motor Control Board Diagnostics,plays error code.page16.2. Electrical supply:Meter must read 85--130 Vac.2. Reset building circuit breaker; replace building fuse. Try another outlet.3. Extension cord. Check extension cord continu- 3. Replace extension cord.ity with volt meter.4. Sprayer power supply cord (56). Inspect for 4. Replace power supply cord.damage such as broken insulation or wires.3097137

TroubleshootingMOTOR WON’T OPERATE (Continued)TYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkBasic Electrical Problems(continued)1. That motor leads are securely fastened and 1. Replace loose terminals; crimp to leads. Beproperly mated.sure terminals are firmly connected.WHAT TO DOWhen check is not OK refer to this columnClean circuit board terminals. Securely reconnect leads.2. For loose motor brush lead connections and ter- 2. Tighten terminal screws. Replace brushes ifminals. See page 13.leads are damaged. See page13.3. Brush length which must be 1/2 in. minimum. 3. Replace brushes. See page13.See page 13.NOTE: Brushes do not wear at the same rate onboth sides of motor. Check both brushes.4. For broken or misaligned motor brush springs. 4. Replace spring if broken. Realign spring withRolled portion of spring must rest squarely onbrush. See page 13.top of brush. See page 13.5. Motor brushes may be binding in brush holders. 5. Clean brush holders. Remove carbon withSee page 13.small cleaning brush. Align brush leads withslot in brush holder to assure free verticalbrush movement.6. Motor armature commutator for burn spots, 6. Remove motor and have motor shop resurgouges and extreme roughness.face commutator if possible. See page 20.See page 13.7. Motor armature for shorts using armature tester 7. Replace motor. See page 20.(growler) or perform spin test. See page 12.Refer to wiring diagram, Fig. 1. Power supply cord (56). Connect volt meter be- 1. Replace power supply cord.tween TP1 (neutral) and L2.8, to identify test points (TP).Plug in sprayer. Meter must read 85--130 Vac.Unplug sprayer.2. ON/OFF switch (58). Connect volt meter be- 2. Replace ON/OFF switch. See page 15.tween L1 and L2 terminal on ON/OFF switch.Plug in sprayer and turn ON.Meter must read 85--130 Vac3. All terminals for damage or loose fit.83097133. Replace damaged terminals and reconnectsecurely.

TroubleshootingLOW OR FLUCTUATING OUTPUTTYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkWHAT TO DOWhen check is not OK refer to this columnLow Output1. For worn spray tip.1. Follow Pressure Relief Procedure Warning, then replace tip. See your separategun or tip manual.2. Verify pump does not continue to stroke when 2. Service pump. See page 21.gun trigger is released.3. Filter clogged.3. Relieve pressure. Check and clean filter.4. Prime valve leaking.4. Relieve pressure. Repair prime valve.5. Suction hose connections.5. Tighten any loose connections.6. Electrical supply with volt meter.Meter must read 85--130 Vac.Low voltages reduce sprayer performance.6. Reset building circuit breaker; replacebuilding fuse. Repair electrical outlet or tryanother outlet.7. Extension cord size and length; must be at least 7. Replace with a correct, grounded exten12 gauge wire and no longer than 300 ft. Longersion cord.cord lengths reduce sprayer performance.8. Leads from motor to pressure control circuit 8. Be sure male terminal blades are centeredboard (49) for damaged or loose wires or conand firmly connected to female terminals.nectors. Inspect wiring insulation and terminalsReplace any loose terminal or damagedfor signs of overheating.wiring. Securely reconnect terminals.9. For loose motor brush leads and terminals. See 9. Tighten terminal screws. Replace brushespage 13.if leads are damaged. See page 13.10.For worn motor brushes which must be 1/2 in. 10. Replace brushes. See page 13.minimum. See page 13.11. For broken and misaligned motor brush 11. Replace spring if broken. Realign springsprings. Rolled portion of spring must restwith brush. See page13.squarely on top of brush.12.Motor brushes for binding in brush holders. See 12.Clean brush holders, remove carbon dustpage 13.with small cleaning brush. Align brush leadwith slot in brush holder to assure free vertical brush movement.13.Low stall pressure.13. Do either or both:a. Turn pressure control knob fullyclockwise. Make sure pressurecontrol knob is properly installed toallow full clockwise position.b.Try a new transducer.14.Motor armature for shorts by using an armature 14.Replace motor. See page 20.tester (growler) or perform spin test. Seepage 12.3097139

TroubleshootingLOW OR FLUCTUATING OUTPUTTYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkWHAT TO DOWhen check is not OK refer to this columnMotor runs and pump strokes1. Paint supply.1. Refill and reprime pump.2. Intake strainer clogged.2. Remove and clean, then reinstall.3. Suction tube or fittings loose.3. Tighten; use thread sealant or sealing tapeon threads if necessary.4. To see if intake valve ball and piston ball are 4. Remove intake valve and clean. Checkseating properly. See page 21.balls and seats for nicks; replace if necessary, page 21. Strain paint before using toremove particles that could clog pump.5. Leaking around throat packing nut which may 5. Replace packings, page 21. Also checkindicate worn or damaged packings. Seepiston valve seat for hardened paint orpage 21.nicks and replace if necessary. Tightenpacking nut/wet-cup.6. Pump rod damage.6. Repair pump, page 21.Motor runs but pump does not 1. Displacement pump pin (32) (damaged or 1. Replace pump pin if missing. Be sure remissing), page 21.tainer spring (31) is fully in groove allstrokearound connecting rod, page 21.2. Connecting rod assembly (43) for damage, 2. Replace connecting rod assembly,page 19.page 19.3. Gears or drive housing, page 19.103097133. Inspect drive housing assembly and gearsfor damage and replace if necessary,page 19.

TroubleshootingMOTOR IS HOT AND RUNS INTERMITTENTLYTYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkWHAT TO DOWhen check is not OK refer to this columnMotor is hot and runs intermit- 1. Determine if sprayer was operated at high 1. Decrease pressure setting or increase tippressure with small tips, which causes lowsize.tently.motor RPM and excessive heat build up.2. Be sure ambient temperature where sprayer 2. Move sprayer to shaded, cooler area if possible.is located is no more than 90 F and sprayeris not located in direct sun.ELECTRICAL SHORTTYPE OF PROBLEMWHAT TO CHECKIf check is OK, go to next checkWHAT TO DOWhen check is not OK refer to this columnBuilding circuit breaker opens 1. All electrical wiring for damaged insulation, and 1. Repair or replace any damaged wiring orall terminals for loose fit or damage. Also wiresterminals. Securely reconnect all wires.as soon as sprayer switch isbetween pressure control and motor. See pageturned on.20.CAUTIONAny short in any part of themotor power circuit will causethe control circuit to inhibitsprayer operation. Correctlydiagnose and repair all shortsbefore checking and replacing control board.2. For missing inspection plate gasket (see page 2. Correct faulty conditions.20), bent terminal forks or other metal to metalcontact points which could cause a short.3. Motor armature for shorts. Use an armature 3. Replace motor. See page 20.tester (growler) or perform spin test. See page12. Inspect windings for burns.4. Motor control board (49) by performing motor 4. Replace with a new pressure control boardcontrol board diagnostics on page 16. If diag(35). See page 18.nostics indicate, substitute with a good board.CAUTION: Do not perform this check until motor armature is determined to be good. A badmotor armature can burn out a good board.1. Basic Electrical Problems on page 7.Building circuit breaker opensas soon as sprayer is pluggedinto outlet and sprayer is NOTturned on.1. Perform necessary procedures.2. ON/OFF switch (58) See page 15. Be sure 2. Replace ON/OFF switch. See page 15.sprayer is unplugged! Disconnect wires fromswitch. Check switch with ohmmeter. Readingmust be infinity with ON/OFF switch OFF, andzero with switch ON.3. For damaged or pinched wires in pressure con- 3. Replace damaged parts. See page 18.trol. See page 18.Sprayer quits after sprayer op- 1. Basic Electrical Problems on page 7.erates for 5 to 10 minutes.2. Electrical supply with volt meter.Meter must read 85--130 Vac.1. Perform necessary procedures.2. If voltage is too high, do not operatesprayer until corrected.3. Tightness of pump packing nut. Over tightening 3. Loosen packing nut. Check for leakingtightens packings on rod, restricts pump action,around throat. Replace pump packings, ifand damages packings.necessary. See page 21.30971311

Spin TestSetupArmature, Brushes, and Motor Wiring OpenCircuit Test (Continuity)Electric Shock Hazard; page 5.To check armature, motor winding and brush electricalcontinuity:1.Relieve pressure; page 5.1. Connect red and black motor leads with test lead.Turn motor fan by hand at about two revolutionsper second.2. If uneven or no resistance, check for: broken brushsprings, brush leads, motor leads; loose brushterminal screws, motor lead terminals; wornbrushes. Repair as needed; page 13.3. If still uneven or no resistance, replace motor;page 20.2. Remove drive housing; page 19.3. Fig. 4. Remove pressure control cover (50). Disconnect connector (F).50F4. Fig. 5. Remove motor shroud (23) and inspectioncovers (A).Armature Short Circuit TestQuickly turn motor fan by hand. If no electrical shorts,motor coasts two or three revolutions before completestop. If motor does not spin freely, armature isshorted. Replace motor; page 20.12309713Fig. 4ti2572a

Motor Brush ReplacementThe 395/495/595 sprayer’s motors are supplied by two different motor manufacturers. Style A motor has brushcaps held on with screws. Style B has brush caps that snap onto the motor. Determine which style motor you areservicing and refer to the appropriate illustration in the following instructions.Motor Brush Removal2.Replace brushes worn to less than 1/2 in. Brusheswear differently on each side of motor, check bothsides. Brush Repair Kit 287735 is available.Relieve pressure; page 5.3. Fig. 5. Remove motor shroud and two inspectioncovers (A).1. Read General Repair Information; page 5.AAti2571aStyle AAStyle BFig. 54. Fig. 6. Push in spring clip (A) to release hook (B)from brush holder (C). Pull out spring clip (A).1Included in Brush Repair Kit2Minimum 0.5” (12.5 mm)CF5. Fig. 6. Pull brush lead (D) off of terminal (E).Remove brush (F).1Motor lead; do not disconnect2Minimum 0.5” (12.5 mm)3Included in Brush Repair Kit21FBA22C1ti4194aB DEEti2542Style A3A DStyle Bti4195aFig. 66. Inspect commutator for excessive pitting, burningor gouging. A black color on commutator is normal.Have commutator resurfaced by a motor repairshop if brushes wear too fast.30971313

Motor Brush ReplacementMotor Brush InstallationCAUTIONWhen installing brushes, follow all steps carefully toavoid damaging parts.FCBAACFDti4194aEDStyle AFig. 71. Fig. 7. Install new brush (F) with lead into brushholder (C).c.EStyle B1ti4195aTurn sprayer ON. Slowly increase pressureuntil motor is at full speed.2. Fig. 7. Slide brush lead (D) onto terminal (E).3. Fig. 7. Install spring clip (A). Push down to sethook (B) into brush holder (C).4. Repeat for other side.5. Test brushes.a. Remove pump (41); Displacement PumpReplacement, page 21.b. With sprayer OFF, turn pressure control knobfully counterclockwise to minimum pressure.Plug in sprayer.14309713CAUTIONDo not run sprayer dry for more than 30 secondswhile checking brushes to avoid damaging displacement pump packings.6. Install brush inspection covers and gaskets.7. Break in brushes.a. Operate sprayer 1 hour with no load.b. Install pump (41); Displacement Pump Replacement, page 21.

On/Off Switch ReplacementRemovalInstallation1.Relieve pressure; page 5.2. Fig. 8. Remove four screws (12) and pressurecontrol cover (50).1. Install new ON/OFF switch (58). Install locking ringand toggle boot (30).2. Connect two wires (A) to ON/OFF switch.3. Disconnect two wires (A) from ON/OFFswitch (58).4. Remove toggle boot (30) and locking ring. RemoveON/OFF switch (58).3. Install pressure control cover (50) with fourscrews tchRef 58PowerPlugRef 56BlackBlackTP1Potentiometer Ref 37L2 L1BlackWhiteBlackPressureTransducerRef 38GreenRed ( )Black (--)from MotorFig. 82 x Whiteti2471a30971315

Pressure Control RepairMotor Control BoardInstallation1. Clean pad on rear of motor control board. Applysmall amount of thermal compound 073019 to pad.RemovalRefer to Fig. 8.1.Relieve pressure; page 5.2. Fig. 8. Install motor control board (49) with sixscrews (6).2. Remove four screws (12) and cover (50).3. Connect all leads to motor control board (49). SeeFig. 8.3. Disconnect all leads to motor control board (49).4. Bundle and tie all loose wires so none lay in contact with inductor coil (not 120 Vac sprayers).4. Remove six screws (6) and circuit board (49).5. Install cover (50) with four screws (12).Motor Control Board DiagnosticsNote: Keep a new transducer on hand to use for test.CAUTIONDo not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open iftest transducer is used.1. For sprayers with digital display, see Digital Display Messages, page 17.2. Remove four screws (12) and cover (50).See Fig. 8.3. Turn ON/OFF switch ON.4. Observe LED operation and reference followingtable:5.Relieve pressure and unplug sprayer before servicing control board; page 5.LEDBLINKSSPRAYER OPERATIONINDICATESWHAT TO DOOnceSprayer runsNormal operationDo nothingTwo timesrepeatedlySprayer shuts down and LED continues to Run away pressure. Pressure greater than 4500 psiblink two times repeatedly(310 bar, 31 MPa) or damaged pressure transducer.Replace motor control board orpressure transducer.Three timesrepeatedlySprayer shuts down and LED continues to Pressure transducer isfaulty or missingblink three times repeatedlyCheck transducer connection.Open drain valve. Substitutenew transducer for transducerin sprayer. If sprayer runs, replace transducer.Four timesrepeatedlySprayer shuts down and LED continues to Line voltage is too highblink four times repeatedlyCheck for voltage supply problemsFive timesrepeatedlySprayer does not start or shuts down andLED continues to blink five times repeatedlyMotor faultCheck for locked rotor, shortedwiring or disconnected motor.Repair or replace failed parts.Six timesrepeatedlySprayer shuts down and LED blinks sixtimes repeatedlyMotor is too hot or there is afault in the motor thermaldeviceAllow sprayer to cool. If sprayer runs correctly when cool,check motor fan function andair fow. Keep sprayer in coollocation. If sprayer does notrun when cool and continues toblink 6 times, replace motor.16309713

Pressure Control RepairDigital Display MessagesNo display does not mean that sprayer is not pressurized. Relieve pressure before repair; page 5.DISPLAYNo DisplaypsibarMPaSPRAYER OPERATIONINDICATIONSprayer stops. Power is not applied. Loss of powerSprayer may be pressurized.ACTIONCheck power source. Relieve pressure before repair or disassembly.Sprayer is pressurized. Power isapplied. (Pressure varies with tipsize and pressure control setting.)Normal operationSpraySprayer may continue to run.Power is applied.Pressure greater than4500 psi (310 bar, 31MPa) or pressure transducer faultyReplace pressure control board orpressure transducer.Sprayer stops. Power is applied.Pressure transducerfaulty, bad connectionor broken wire.Check transducer connection.Open drain valve. Substitute newtransducer for transducer in sprayer. If sprayer runs, replace transducer.Sprayer stops. Power is applied.Line voltage too highCheck for voltage supply problemSprayer does not start or stops.Power is applied.Motor faultCheck for locked rotor, shorted wiring or disconnected motor. Repairor replace failed parts.Sprayer stops. Power is applied.Motor it too hot.Allow sprayer to cool. If sprayerruns correctly when cool, checkmotor fan function and air fow.Keep sprayer in cool location. Ifsprayer does not run when cooland continues to blink 6 times, replace motor.Power is applied.Pressure less than 200psi (14 bar, 1.4 MPa)Increase pressure if desired. Drainvalve may be open.Sprayer stops. Power is applied.Empty paint pail. Lossof pressure.Refill paint pail. Check for leaks orclogged pump inlet. Repeat Startup procedure.30971317

Pressure Control RepairPressure Control TransducerPressure Adjust PotentiometerRemovalRefer to Fig. 8.RemovalRefer to Fig. 8.1.Relieve pressure; page 5.2.3.4.5.Remove four screws (12) and cover (50).Disconnect lead (E) from motor control board (49).Remove two screws (47) and filter housing (15).Thread transducer lead plastic connector downthrough transducer grommet (20).6. Remove pressure control transducer (38) andpacking o-ring (3) from filter housing.Installation1. Install packing o-ring (3) and pressure controltransducer (38) in filter housing (15). Torque to30--35 ft-lb.2. Thread transducer lead plastic connector upthrough transducer grommet (20).3. Install filter housing (15) with two screws (47).4. Connect

Sprayer NOVA 395 826014 826015 826016 Super NOVA 495 826017 826018 826019 Super NOVA 595 826052 826046 All models not available in all countries. Table of Contents Component Function and Identification 4. Grounding 6. Troubleshooting 7. General Repair Information 5.