Teste de Placas Graco PDF

Electrical and Mechanical Repair Tips
For Contractor Sprayers

First choice when
quality counts.
Rev. N 10/11 /07
3.00
WARNING
This manual should only be used
by a qualified Service Technician.
Black
Red
Yel
Yel
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
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
237659 Control Board (Ultra 600,Ultimate 600,Ultra Plus 600,Ultimate Plus 600):
Motor test ................................................................................................................................................ 22
Motor will not shut off ............................................................................................................... 29
240168 Control Board (695,795,1095):

Motor test ................................................................................................................................................ 22
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
Electric Motor Kit for Convertible 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
Gas Powered Sprayers
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):
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
Line Stripers
238672 Control Board (GM3000 LineLazer):
287486 Control Board (LineLazer 3400):
220974, 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
287689 Control Board (LineLazer 3900IV, 5900IV):
Fluid Pump will not run.................................................................................................................. 102,103
Engine Generator Test ........................................................................................................................... 104
Sensor Test ............................................................................................................................................ 105
Light Kit Troubleshooting ..................................................................................................................... 106
BASIC ELECTRICAL TERMINOLOGY
In 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.
FIGURE 1
ON/OFF
Switch
Ref 58
Power
Plug
Black
Black
White
Green
Red (+)
Black ()
from Motor
VOLTAGE:
Voltage is the force that causes current to flow in a circuit.
Voltage is measured in VOLTS (V or E). See Figure 2.
ON/OFF
Switch
Ref 58
120 AC
V
FIGURE 2
Potentiometer Ref 37
Power
Plug
Black
Black
Green
White
Red (+)
Motor
Black ()
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
Known Value
Black
Red
Yel
Yel
Known Value
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.
0.000
SWITCH TESTING-ROCKER
Common test procedure for a SPST Switch:
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
GROUND TESTING
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.
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.
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.
Unplug the machine and remove the capacitor(s).

If capacitor(s) are attached to the control board the test can not be performed.
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.
FIG. A
Put a volt-Ohm meter on the R X 100 scale.
Capacitor
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)
GOOD
BAD
BAD
10
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:
FIG. 1
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.
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.
AC
+ DC
- DC
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.
Connect test leads as shown in Figure C. If the meter beeps, the rectifer is
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.
Connect test leads as shown in Figure E. If the meter beeps, the rectifer is
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.
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.
Connect test leads as shown in Figure H. If the meter does not beep, the rectifer is defective. If the meter beeps, the rectifer is good.
OL
OL
0.000
FIG. A
OL
FIG. B
0.000
FIG. C
OL
0.000
FIG. E
AC
FIG. F
FIG. D
0.000
FIG. G
FIG. H
11
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 are for several different models.

DIGITAL
DISPLAY
Digital_Display
_Blank
---PSI icon not
blinking
---PSI icon
blinking
CONTROL BOARD
STATUS LIGHT.
Unreadable
1 Blink every 3 seconds
Never Lights
Blinks once and stops
Constant on
Displays high
pressure
INDICATION
No power to microprocessor on control board.
Power to board is ok, No RUN command to motor.
Control is commanding motor to run.
17
E=03
E=04
E=05
Blinks 3 x repeatedly
E=06
E=07
E=08
E=09
E=10
E=11
E=12
E=13
Transducer failure or connection error

Excessive Wall voltage
High current or motor is not turning.
Motor is too hot or motor/thermal device
connection may be bad.
Exceeded 2000 psi during timed flush cycle.
Low wall voltage
Motor sensor failure
High control board temperature
Excessive motor speed
High Current
Model not selected
Watchdog mode is activated. Sprayer will stop
running when pressure drops sharply
Unplug the display, If sprayer operates Replace the
Display. If the sprayer does not operate replace the
control board.
Set switches on back of digital display to the
appropriate settings.
Perform appropriate motor tests, if motor tests ok,
replace control board.
Digital Display Switches

not set.
Motor Hums
Constant on
15
16
High pressure signal from transducer
8888
14
Improper pressure signal from transducer

Cal
Older UltraMaxs
13
Board is trying to start up. Unplug transducer, pot

and display. If still blinking replace board. If it
stops blinking one of the 3 parts are faulty.
Reconnect the parts one at time to find the faulty
part.
E=02
EMPTY
GO TO
PAGE
18
19
20-22
23
24
24
25
26
26
27
27
28
12
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 and
wiring 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.
13
Symptoms:
____
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.

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 & connections to control board. Set sprayer to OFF.
Disconnect potentiometer from control board socket. Check that potentiometer and control board contacts are
clean 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 potentiometer
if sprayer runs. Replace control board if sprayer does not run. But first,
verify transducer and connections are ok. See next page.
Check transducer & connections to control board. Set sprayer to OFF and disconnect 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.
14
Symptoms:
Digital Display shows dashes and Psi icon is blinking
Control board status light blinks and stays on constant.
E5 error code brushless unit
____

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 board
contacts 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 (brush
type) 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 not present, check brushes. If ok, replace
motor. If voltage present, go to next step.
5. Reconnect motor connector to control board socket. Connect power, set sprayer ON and control knob to
turn clockwise. If sprayer does not run, replace control board.
15
Symptoms:
Digital Display shows a pressure reading

and Psi icon on
Control board status light off.
E2 error code Brushless unit (possible)
XXXX
Psi

Improper pressure signal to control board, with no pressure in sprayer. The transducer or connections is likely
the problem.
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.
Set sprayer ON and control knob to turn clockwise. Install new
transducer if sprayer runs. Replace control board if sprayer does
not run.
16
Symptoms:
Digital Display shows E=02
Control board status light blinks 2x repeatedly.
E=02

The control board is detecting an excessive pressure. The transducer or connections is likely the problem.
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.
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.
17
Symptoms:
E=03

The control board is not detecting a pressure signal.
The pressure transducer or connections are likely the problem.
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.
18
Symptoms:
E=04

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.
19
Symptoms:
E=05

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 or
the motor amp draw is excessive.
Ultamax lls: Brushless motors test when the motor is runnning 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 pump
or 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 and
control board contacts are clean and secure. If tests ok go to step 4.
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.
5. Spin Test: Test at the large 4-pin motor field connector. Disconnect the fluid pump from the
sprayer. Test motor by placing a jumper across pins 1 & 2. Rotate the motor fan at about 2revolutions/second. A cogging resistance to motion should be felt at the fan. The motor needs
replacing if no resistance is felt. Repeat for pin combinations 1 & 3 and 2 & 3. Pin 4, the green
ground wire, is not used in this test. If it tests good go to step 5 Resolver test
Spin Test
GRN BLU RED BLK
Step 1
4 3 2 1
GRN BLU RED BLK
GRN BLU RED BLK
Step 2
4 3 2 1
Step 3
4 3 2 1
20
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 to
the 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 connector
to make sure they are not causing a bad connection. Squeeze the socket back to size if one appears
too large. If it tests good go to step 6.
Resolver Test
Step 2
Step 1
1
4
44 ohms
2
5
1
3
Step 3
2
5
3
6
2
5
3
6
167 ohms
167 ohms
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.
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
21
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 pump
or 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 and
control 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 fan
and check for a voltage to register on the meter. If voltage not present, check brushes. If ok, replace
motor. If voltage present, go to next step.
6. Reconnect motor connector(s) to control board socket(s). Connect power, set sprayer ON and
control knob to turn clockwise. If motor does not run, replace control board.
OR
Use CAUTION not to distort the connectors when inserting the meter probes.
Step 3
Step 2
Step 1
Spin the motor while checking.

If a open is found replace the motor.
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.
Red
Checking the motors thermal protection.

Meter should read continuity or Ohms
depending on the motor.
Note: motor should be cooled down.
Yellow
Red
Black
Yellow
Black
Red
Yellow
1-3 ohms
Black
BEEP
- +
9 volt
battery
Step 4
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.
OL
Red
Ground
Yellow
Black
22
Symptoms:
E=06

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 and disconnect power to
sprayer.
2. Disconnect motor / temp connector from control board socket. Check that transducer and control board
3. Measuring the resistance of the thermal device. NOTE: A low resistance reading would be indicating to
the control board that the motor is hot. The resistance for most motors with yellow sensor 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.
23
Symptoms:
E=07

Pressure exceeded 2000 psi while using the flush timer (AutoClean Timer)
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.
Symptoms:
E=08

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.
24
Symptoms:
E=09

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 control
board 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.
25
Symptoms:
E=10

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 is
used on the power components.
3. Replace control board.
4. Replace motor.
Symptoms:
E=11

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.
26
Symptoms:
E=12

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.
Symptoms:
E=13

Model select resistors on control board not properly selected.
Resistors on control board must be properly clipped to identify model type, see replacement control board
instruction manual.
27
Symptoms:
Digital Display shows EMPTY
EMPTY

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.
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.
28
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?
NO
Mechanical problem: See the proper

fluid pump manual for the sprayer for
further trouble shooting procedures.
YES
Is light on at the control

board? If the board has no
light the answer is yes.
NO
Replace the control board.

Shorted Board.
YES
Unplug the transducer from control

board, does motor stop running?
NO
YES
Bad transducer, replace

and test with a new one.
29
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?
NO

YES
Disconnect the clutch wires from

the control board. Does the pump
stop running?
NO
Mechanical problem in the clutch pinion

assembly. (Clutch may be to close to the rotor).
YES
With the clutch wires plugged in.
Do you have 10-18 DC Volts
at the clutch test points?
Check for a short from the

2 clutch wires to the frame.
If shorted repair or replace
the faulty wire.
NO
YES
Unplug the transducer from control

the board, does the pump stop.
NO
YES
Bad transducer, replace

and test with a new one.
30
190ES,SPX,295ST
Control Board 241989
(Capacitor on Motor)
Motor will not start:

See pages 32 for the steps and illustrations.
Remove the control box cover.

Turn the sprayer on. Observe
the control boards light(s).
No light
Once
Normal operation.
Control board
Light on
continuously commanding
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO
Repair or replace
the power Cord.
YES
YES
See step 3.
Is there over
100 DC volts?
Replace the
power switch.
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
NO
YES
If motor is hot let

cool and retest, if
step 4 still shows an
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
See step 5.
Does the
motor run?
No
Connect a test
transducer to
the board.
Does the
motor run
No
YES
Replace
Potentiometer.
Pressure Switch
Yes
Replace
Control
Board.
Replace the
transducer.
31
190ES,SPX,295ST
110-120 AC
V
(Capacitor on Motor)
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.
Control
Board
L2
Black
L1
M+
White
L2
TO2 TO1
Black
Ground
Black
L1
White
Grn
M-
Yellow
J10
Black
Red
Potentiometer
Red
Step 5
Cord plugged in.
Switch ON.
Potentionmeter
disconnected.
Control
Board
J12
Black
cit
pa
Ca
or
Potentiometer
Step 3
BEEP
J10
Step 4
J12
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
100 + DC Cord plugged in.

V
M+
Switch ON.
Black
Pressure Switch
Turned to high.
Meter on DC volts.
White
- M-
Yellow
TO2 TO1
L1
Control
Board
Control
Board
32
190ES,DTX,SP,SPX,ST,STX
Control Board 245892 (Capacitor on PC board)
No light
Once
See step 1.
Do you have
over 100 AC
volts?
Normal operation.
Control board
Light on
motor to run.
Flashing
NO
Is the fuse
good.
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 doesn t open
replace the motor.
NO
YES
See Error Code

section for further
troubleshooting.
See step 2.
Do you have
over 100 AC
volts?
YES
Repair or replace the

power Cord.
NO
YES
Replace the
power switch.
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
NO
YES
See motor
test section.
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See step 5.
Does the motor run?
No
Connect a test
transducer to
the board.
Does the
motor run
No
YES
Replace Potentiometer.
P ressure Switch
Yes
Replace the
Control
Board
Replace the
transducer.
33
190ES,DTX,SP,SPX,ST,STX
Control Board 245892 (Capacitor on PC board)
100 + DC
Step 2
Cord plugged in.
Switch ON.
Wires connected
to ON/Off Switch.
F1
Control FUSE
Board
M+ M-
T02
T01
110-120 AC
Step 3
Cord plugged in.
Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Yellow
Black
Red
Black
Motor
White
N
Ground
F1
D7
FUSE
Black
M+ M-
110-120 AC
V
Step 1
Cord plugged in.

Switch ON.
Wires connected.
Reference F1 on the
Control board for
proper meter location.
White
N
Black
Control Board
Pressure
Transducer
Black
Red
Yellow
BEEP
Motor
Step 4
Step 5
Cord plugged in.
Switch ON.
Potentionmeter
disconnected.
Checking the motor

thermistor switch .
Unplug the 2 yellow
Meter should read
Control
Board T02
F1
J8
Control
Board
FUSE
J7
T01
White
Green
T02
T01
J8
J7
Potentiometer
Yellow
34

190ES
232900,F;232901,E;233797,E;233815,E
Remove the motor

cover. See step 1. Do
you have over 100 AC
volts?
NO
Is the fuse
good.
NO
YES
See step 2.
Do you have
over 100 AC
volts?
YES
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 open
replace the motor.

power Cord.
NO
YES
Replace the
power switch.
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there continuity
through the
thermistor wires?
If motor is hot let cool and

retest, if step 4 still shows an
open replace motor. The
motor has a defective
thermistor switch.
NO
YES
YES
See motor test section.
See step 5.
Does the motor run?
NO
Replace
control board.
YES
Replace pressure
control switch.
35

190ES
232900,F;232901,E;233797,E;233815,E
Step 1
110-120 AC
Step 2
110-120 AC
Cord plugged in.

Switch ON.
Wires connected.
Reference F1 on the
Control board for
proper meter location.
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
Fuse
White
F1
Black
Black
Step 5
Control
Board
Pressure
switch
Ground
Cord plugged in.

Switch ON.
Pressure switch unplugged.
White
Fuse
Green
N
White
F1
J1
Black
Black
Black
Red
J1
Insulated Jumper wire

stripped on the ends
Yellow
White
Yellow
Motor
BEEP
Step 4
100 + DC
Control
Board
Fuse
Step 3
Cord plugged in.
Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Fuse
Control
Board
F1
Checking the motor

thermistor switch .
Unplug the motor.
Meter should read
Red
Black
F1
Yellow
Yellow
36
249052 Control Board

Motor will not run
See step 1.
Do you have
over 100 AC
volts?
NO
Repair or replace
the power Cord.
NO
Replace the
control board.
Faulty switch.
YES
See step 2.
Do you have
over 100 AC
volts?
YES
See step 3. Do
you have over
100 AC volts?
NO
If the fuse is
blown check
the motor for
a short before
replacing the
control board.
YES
See step 4.
Is there over
100 DC volts?
NO
See step 5.
Is there
continuity
through the
thermistor
wires?
NO
YES
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
See step 6.
Does the
motor run?
No
Replace Control Board.
YES
Replace
Pressure Switch
37
249052 Control Board Trouble Shooting
Step 1
110-120 AC
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
Step 2
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
Step 3
Cord plugged in.
Switch ON.
Wires connected
to control board.
Meter on AC Volts
J4
J3
F1
F1
Control
Board
To
Power Cord
Control
Board
On/Off
Switch
FUSE
J4
Yellow
Pressure
Switch
Control
Board
J4
Motor
Red
Blk
J1
F1
FUSE
J4
On/Off
Switch
J3
Grnd.
Step 6
BEEP
Control
Board
J1
Red
Blk
Step 5
Checking 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.
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Red
Yellow
Blk
Yellow
Insulated Jumper wire

stripped on the ends
Step 4
100 + DC
Motor plugged in.

Cord plugged in.
Switch ON.
Pressure switch
unplugged.
On/Off
Switch
FUSE
Control
Board
38

Motor Will Not Shut Off
With a pressure gauge plumbed into the paint gun
hose, turn the power switch on, does the gauge read
the sprayers maximum pressure and continue to
build pressure?
No
Mechanical problem: Sprayer cannot build to

proper pressure. See the proper fluid pump
manual for further troubleshooting procedures.
Yes
See Fig.1 Unplug the pressure control's (A) plug

from the control board. Does the motor stop?
No
Yes
Replace the pressure control.
Fig. 1
Pressure Control
A
39
235707, 235008 Control Board

See pages 41 for the steps.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 3.
Is there
continuity
through the
thermistor
switch.
Check all the wiring

connection to the 2
small motor wires, if
ok replace motor. Faulty
thermistor switch.
NO
YES
See step 2.
Do you have
over 100 AC
volts?
YES

power Cord.
NO
YES
Replace the
power switch.
See step 4.
Is there over
100 DC volts?
YES
See motor
test section.
NO
See step 5.
Does the motor run?
No
No
Replace
Pressure Switch
YES
See step 6.
Does the presure
switch test ok?
YES
Check the pressure transducer for

hardened paint or damaged or
worn components. Clean or replace.
40
235707, 235008 Control Board Trouble Shooting
Cord plugged in.

Switch ON.
Wires connected.
Step 2
110-120 AC
Black
Black
Checking the motor

thermistor switch .
Unplug the 2 red wires.
Meter should read
Cord plugged in.

Switch ON.
Wires connected.
Step 3
BEEP
Motor
White
Black
L
M-
Red
Thermistor
Switch (NC)
Red
Step 1
110-120 AC
White
Black
L
Ground
Blk
M-
Wht/Blk
Motor
White
Red
Black
Thermistor
Switch (NC)
Red
Wht/Blk
Blk
White
White
Black
L
Pressure Control
Switch
M+
M-
Motor Start Board
J5
Step 6
BEEP
Step 4
100 + DC
Step 5
Cord plugged in.
Switch ON.
Pressure Switch
unplugged.
Control
Board
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Control
Board
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.
J5
Wht/Blk
Blk
+M
-M
Motor Start Board

41

Motor Will Not Shut Off
With a pressure gauge plumbed into the paint gun
hose, turn the power switchon, does the gauge read
the sprayers maximum pressure and continue to
build pressure?
No
Mechanical problem: Sprayer cannot build to

proper pressure. See the proper fluid pump
manual for further troubleshooting procedures.
Yes
Unplug the pressure transducer switch plug

from the control board. Does the motor stop?
No
Yes
Remove pressure control and check the

micro switch operation with a 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.
Replace the Pressure

Control Assembly .
NO
Yes
MOTOR
Check the pressure transducer for

hardened paint or damaged or worn
components. Clean or replace
On/Off Switch
B
To Pressure
Transducer
E
42

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


No light
Go to step 1.
Normal operation.
Once
Go to step 1.
Control board
Light on
commanding
continuously motor to run.
Go to Step 1.
See Error Code
Flashing
section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
Repair or replace
the power Cord.
NO
YES
YES
See step 3.
Is there over
100 DC volts?
Replace the
power switch.
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
NO
YES
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
See step 5.
Does the
motor run?
No
Connect a test
transducer to
the board.
Does the
motor run?
No
YES
Replace
Potentiometer.
Pressure Switch
Yes
Replace
Control
Board.
Replace the
transducer.
43

(395/455/495ST Pro, Performance Pro 395/495, NOVA Pro & Super)
110-120 AC
V
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.
Control
Board
L2
Black
L1
M+
White
L2
TO2 TO1
Black
Ground
Black
L1
White
Grn
Yellow
M-
J10
J12
Potentiometer
Black
Step 5
Red
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
Control
Board
Potentiometer
Step 3
Step 4
J10
J12
Checking the motor

thermistor switch .
Unplug the 2 yellow
Meter should read
L2
BEEP
M+
Switch ON.
Black
Pressure Switch
Turned to high.
Meter on DC volts.
White
- M-
Yellow
TO2 TO1
L1
100 + DC Cord plugged in.

V
Control
Board
Control
Board
44
Ultra 395/495/595, Ultimate Nova 395/SuperNova 495/595

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

No light
Once
Normal operation.
Control board
Light on
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO

power Cord.
YES
YES
See step 3.
Is there over
100 DC volts?
Replace the
power switch.
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
NO
YES
See motor
test section.
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See step 5.
Does the
motor run?
NO
Connect a test
transducer to
the board.
Does the
motor run
YES
Yes
Pressure Switch
No
Replace the
Control
Board
Replace the
transducer.
45
Ultra 395/495/595, Ultimate Nova 395/SuperNova 495/595

Performance Max 395/495/595, ST Max 395/495/595
Step 1
110-120 AC
110-120 AC
Cord plugged in.

Switch ON.
Wires connected.
Step 2
Step 3
100 + DC
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Control
Board
Motor
Control
Board +
Yellow Thermistor
Wires to motor
Black
+
Black
White
N
White
Black L
J8
L
Control
Board
C15
J7
J11
Step 4
BEEP
Control
Board
Step 5
J8
Checking the motor

thermistor switch .
Unplug the J11 2 yellow
wires from control board.
Meter should read
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
Power
Cord
Yellow Thermistor
Wires to motor
46

(490ll, 495II,595ll)
Motor will not Run:
the control boards Green light.
No light
Once
Normal operation.
Light on
continuously
Control board
commanding
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
See step 2.
Do you have
over 100 AC
volts?
NO
NO
See step 3.
Is there over
100 AC volts?
NO
Repair or
replace
power
Cord.
YES
YES
YES
See step 4.
Is there
100K Ohms
through the
thermistor
wires?
Replace the
power switch board.
Replace the
power switch board.
NO
If motor is hot let

cool and retest, if
step 4 still shows low
resistance replace motor.
The motor has a
defective thermistor .
YES
See step 5.
Does the motor run?
No
Connect a test
transducer to
the board.
Does the
motor run?
No
YES
Yes
Replace the
Control
Board
Pressure Switch
Replace the
transducer.
47

(490ll, 495II,595ll)
Step 1
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
L1
Ground
L1B
L1
L1 Black
Ground
White
Black
L1B
L2B
L2B
On/Off
Switch
Board
Power
Cord
Power
Cord
Step 3
Cord plugged in.
Switch ON.
Wires connected
to control board.
Meter on AC Volts
L1 Black
White
Black
110-120 AC
L1
Ground
White
Black
On/Off
Switch
Board
Step 2
Cord plugged in.
Switch ON.
Wires connected
to control board.
Meter on AC Volts
L1 Black
On/Off
Switch
Board
110-120 AC
L1B
L2B
Power
Cord
Motor
Step 4
Yellow
n
ee
Gr Blue d
Re ck
100k ohm
Bla
Potentiometer
Yellow
Checking the motor

thermistor .
Unplug the yellow wires.
Meter should read 100K
Note: motor should be
cooled down.
L1 Black
To Motor
Yellow
L1
Transducer
Ground
On/Off
Switch
Board
D21
White
Black
L1B
Yellow
L2B
Step 5
Green
White
Control
Board
J12
Cord plugged in.

Switch ON.
Potentiometer
disconnected.
Control
Board
D21

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

See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO
Repair or replace
the power Cord.
YES
YES
See step 3.
Is there over
100 DC volts?
Replace the
power switch.
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
NO
YES
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
See step 5.
Does the
motor run?
No
Connect a test
transducer to
the board.
Does the
motor run?
No
Replace Control
Board.
YES
Replace
Potentiometer.
Pressure Switch
Yes
Replace the
transducer.
49

Ultra 600,Ultimate 600,Ultra Plus 600,Ultimate Plus 600
110-120 AC
V
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter set to AC Volts.
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
On/Off
Switch
Step 3
100 + DC
Control
Board
Motor
Black to L
Red
Blk/Wht
Black to power cord
Motor
M+
On/Off
Switch
Control TS
Board
TS
Red
Blk/Wht
Black
Black
Blk
M-
White
M+
N
L
Blk
M-
TS
TS
Transducer
Potentiometer
Step 4
Step 5
BEEP
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
Checking the motor

thermistor switch .
Meter should read
Motor
Control
Board
Red
Blk/Wht
Potentiometer
Blk
M-
M+
TS
Control
Board
Black
Step 2
White
Step 1
TS
50

(695,795,1095)
Motor will not Run:

the control boards Red light.
No light
Once
Normal operation.
Light on
continuously
Jumper not
not cut.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO

power Cord.
YES
Replace the
power switch.
YES
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there
100K Ohms
through the
thermistor
wires?
NO
If motor is hot let

cool and retest, if
The motor has a
YES
See motor
test section.
YES
See step 5.
Does the motor run?
No
Connect a test
transducer to
the board.
Does the
motor run
No
YES
Yes
Replace the
Control
Board
Pressure Switch
Replace the
transducer.
51

(695,795,1095)
110-120 AC
V
Step 1
Cord plugged in.
Switch ON.
Wires connected
to control board.
L1
M+
L1
L2
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
BLACK
M-
Control
Board
M+
Step 3
100 + DC
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
BLACK
M-
Step 2
110-120 AC
Control
Board
BLACK
L2
- M-
WHITE
WHITE
M+
L1
BLACK
Pressure
Transducer
Control
Board
L2
WHITE
ON/OFF
Switch
1095 Only
VIOLET
J4
Ground
YELLOW
M-
Power Supply
Cord
GREEN
WHITE
Step 5
Control
Board
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
Potentiometer
M+
L1 L2
from Motor
RED (+)
BLACK()
Step 4
100k ohm
J12
Checking the motor thermistor .

Unplug the yellow wires.
Meter should read 100K
Note: motor should be cooled down.
Control
Board
J4
Potentiometer
YELLOW
BLACK
52

(695,795,1095)
Motor will not run:
the control boards Red light.
No light
Once
Normal operation.
Light on
continuously
Control board
commanding
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
Repair or
replace the
power Cord.
NO
YES
YES
Replace the
power switch.
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Do you have
open through
the thermistor
wires?
NO
YES
See motor
test section.
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See step 5.
Does the motor run?
NO
Connect a test
transducer to
the board.
Does the
motor run
YES
Yes
Pressure Switch
No
Replace the
Control
Board
Replace the
transducer.
53

(695,795,1095)
100 + DC
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
White
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
L1
Black
Control
Board
ON/OFF
Switch
White
Black
L2
White
L2
Step 2
Control
Board
++
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
J7
Red
Blk
Yel
Yel
110-120 AC
Step 3
Step 1
L1
Black
Red LED
Green
D11
J9
J12 J10
Red
Blk
Yel
Yel
J7
Display
Pressure
Transducer
Motor
Potentiometer
Step 5
Control
Board
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
BEEP
J12
Checking the motor

thermistor switch .
Meter should read
Control
Board
J7
Red
Blk
Yel
Yel
Potentiometer
Step 4
54
Control Board 287941 (With GFI Filter Coil)

(695ll, 795II,1095ll,1595ll)
Motor will not Run:
the control boards Green light.
No light
Once
Normal operation.
Light on
continuously
Control board
commanding
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
See step 2.
Do you have
over 100 AC
volts?
NO
NO

power Cord.
YES
YES
See step 3.
Is there
100K Ohms
through the
thermistor
wires?
Replace the
On/Off Switch.
NO
If motor is hot let

cool and retest, if
The motor has a
YES
See step 4.
Does the motor run?
No
Connect a test
transducer to
the board.
Does the
motor run?
No
YES
Yes
Replace the
Control
Board
Pressure Switch
Replace the
transducer.
55
Control Board 287247,287941 (With GFI Filter Coil)

(695ll, 795II,1095ll,1595ll,MarkIV,MarkV)
Cord plugged in.

Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
110-120 AC
V
Step 2
Cord plugged in.
Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
Step 3
100k ohm
Checking the motor

thermistor .
Unplug the yellow
wires. Meter should
read 100K. Note: motor
+
110-120 AC
Step 1
To Motor
BLACK
BLACK
WHITE
BLACK
Control
Board
Power Cord
On/Off
Switch
BLACK
Power Cord
Motor
On/Off
Switch
WHITE
Control
Board
GFI Filter Coil

on 287941
updated 287247
On/Off
Switch
Black
To Optional
Display
Blk
Control
Board
Step 4
Cord plugged in.
Switch ON.
Potentiometer
disconnected.
Neutral
BLACK
Control
Board
WHITE
Black
Transducer
Power Cord
Potentiometer
Switch
15 amp closed
20 amp open
287941 Only
Watch Dog Switch
On/ Open
Off /Closed
56

(1595, MarkV)
Motor will not run:

the control boards RED light.
No light
Once
Normal operation.
Light on
continuously
Control board
commanding
motor to run.
Flashing
See Error Code

section for further
troubleshooting.
See step 1.
Do you have
over 100 AC
volts?
NO
YES
See step 4.
Is there over
100 DC volts?
NO
See step 2.
Do you have
over 100 AC
volts?
See step 3.
Do you have NO
over 100 AC
volts?
NO
YES
YES
Replace the
Filter.
Replace the
power switch.
See step 5.
Is there
continuity
through the
thermistor
wires?
NO
YES
See motor
test section.
Repair or
replace the
power Cord.
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See step 6.
Does the
motor run?
No
YES
(Pressure Switch)
Connect a test
transducer to
the board.
Does the
motor run
No
Replace
Control
Board
Yes
Replace the
transducer.
57

(1595, MarkV)
Step 1
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
Step 2
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to filter.
Meter on AC Volts.
Black
L
Filter
Black
Black
15 amp closed
20 amp open
Black
White
Display
Filter
White N
Green
Black
Black
J4
Violet
Step 4
D7
Violet
100 + DC
J3
J2
D1
J1
Capacitor
(+)
Orange
Grey
Black(-)
Red
(+)
Transducer
J1
Motor
Yellow
J12
Org
Blk
Step 5
Cord plugged in.
Switch ON.
Potentiometer
disconnected.
Control
Board
Potentiometer
Control
Board
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
SWA SWB
Step 6
On/Off
Switch
Switch
On/Off
Switch
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
Meter on AC Volts.
White N
Control
Board
Step 3
110-120 AC
Red
D1
Yel
Grey
Yel
Checking the motor

thermistor switch .
Meter should read
Meter on Continuity test.
BEEP
Control
Board
Potentiometer
J1
Org
Blk
Red
D1
Yel
Grey
Yel
58
Control Board 239750, 239751

1500,1595, MarkV Board Under Machine
Motor will not run:
See pages 60 ,61 for the steps.
See step 1.Do you have

over 100 AC volts?
NO
Repair or
replace the
power Cord.
NO
Repair or
replace wire
harness from
AC power Inlet.
NO
Replace the
power switch.
YES

over 100 AC volts?
YES

over 100 AC volts?
YES
See step 4.Is there continuity

through the conductor wires?
NO
Replace Control
board cover with
potted conductor.
YES
See step 5.
Is there over
100 DC volts?
NO
YES
See step 7.
Is there over
100 DC volts?
YES
See motor
test section.
See step 6.
Is there
continuity
through the
thermistor
wires?
NO
See step 8.
Is there
continuity
through the
thermistor
wires?
NO
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
NO
Repair or
replace wire
harness from
control board.
YES
See step 9.
Does the
motor run?
Repair or replace wire

harness from control board.
No
YES
(Pressure Switch)
Connect a test transducer

to the board. Does the
motor run?
Yes
Replace the
transducer.
No
Replace
Control
Board
59
1500,1595, MarkV, Board Under Machine

239750, 239751
Step 1
110-120 AC
110-120 AC
Cord plugged into

AC Power Inlet.
Meter set to AC.
Step 2
Cord plugged in.
Switch ON.
Wires connected
to control board.
AC Power
Inlet
L
E
Step 3
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
On/Off
Switch
+
L2 Wht
Control
Board
Blk Wht
L1
Blk
Yellow
Blk
Step 4
Blk/Wht
Testing
Testing the
the conductor.
conductor.
Meter
Meter on
on Continuity.
Continuity.
Meter
Meter should
should read
read
continuity.
continuity.
BEEP
Potted
Inductor
AC Power
Inlet
Blk
Yellow
Blk/Wht
Wht
M+ M-
Wht
Blk
I1
Blk
Red
Red
On/Off
Switch
L2
Wht
Blk
L1
Red
I2
I1
Potentionmeter
J3
J5 J4
TS TS
J6
15/20 Amp Switch
Red
Ground
I2
Control
Board
Transducer
Orange
Step 5
BEEP
Step 6
100 + DC
Testing the motor thermal device.

Meter on Continuity.
Meter should read continuity.
TS TS
Blk
Blk/Wht
Control
Board
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Ground
M- Control
Board
M+
60
1500,1595, MarkV, Board Under Machine

239750, 239751
100 + DC
V
Step 9
Step 8
Step 7
Cord plugged in.
Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Testing the motor

thermal device.
Meter should
read continuity.
BEEP
Cord plugged in.

Switch ON.
Pressure Switch
unplugged.
Control
Board
J3
+
-
Yellow
Blk/Wht
Blk
Yellow
Blk/Wht
Blk
Yellow
Blk
Blk/Wht
L
E
Potted
Inductor
AC Power
Inlet
Blk
Yellow
Blk/Wht
Wht
Blk
M+ M-
Wht
I1
Blk
Red
Red
On/Off
Switch
L2
Wht
Blk
L1
I2
Potentionmeter
J3
J5 J4
TS TS
J6
15/20 Amp Switch
Ground
Transducer
Orange
61
(1000,900,750 and 500, 590,700 with updated control boxes)

Control Board 236563, Retrofit Kit 236974
Motor will not run:
Remove the
control box
cover.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?

power Cord.
NO
YES
Replace the
power switch.
YES
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
NO
YES
See motor
test section.
YES
See step 5.
Does the motor run?
NO
Replace
control board.
YES
Pressure Switch
62

110-120 AC
V
Step 1
Step 2
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Cord plugged in.

Switch ON.
Wires connected
to ON/Off Switch.
TS
Red
Control
Board L1
L2
L2
TS
White
Red
M+
MBlack
Blk/White
Black to power cord

(+)
White
On/Off
Switch
Black
to L1
Cord plugged in.

Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
Control
Board
Step 3
100 + DC
Blk/White
(-)
Motor
Black
Control Board
TS
L2
TS
M+
Red
Potentiometer
Ground
L1
White
Red
(+)
Cord plugged in.

Switch ON.
Potentionmeter
disconnected.
Blk/White
Black
Ground
(-)
Motor
Black
Step 4
BEEP
Checking the motor

thermistor switch .
Meter should read
Control
Board
TS
L2
TS
White
M+
Blk/White
Potentiometer
+
MBlack
Red
Control
Board
Black
M-
Blk/White
Step 5
On/Off
Switch
Black
Built in
Transducer
(+)
Blk/White
Motor
(-)
Black
63

Motor Will not Shut Off:

hose turn the power switch on, does the gauge
read the sprayers maximum pressure and
NO

YES
Is the fluid tube plugged ?
NO
YES
Clean and retest. Does the

motor shut off?
NO
Fluid Tube
64
Convertible Motor Kit for GM5000

Motor will not run.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO
Repair or
replace the
power Cord.
YES
Replace the
power switch.
YES
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
YES
NO
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
Replace
Motor control board
65
Convertible Motor Kit GM5000

Motor will not run.
Step 2
Step 1
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
110-120 AC
V
110-120 AC
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
Black to
power cord
Black
L2
L1
White
Black
White
L2
L1
Motor Control Board
Motor Control Board
Ground
Black
White
Motor Control Board
Black
L1
+M -M
L2
White
TS TS
Step 4
BEEP
Checking the motor

thermistor switch .
Meter should read
+M
-M
Motor
Control
Board
TS
TS
Motor
Step 3
100 + DC
V
Motor
Cord plugged in.

Switch ON.
Meter on DC volts.
+M
-M
Motor
Control
Board
TS TS
Blk
Blk/Wht
Yellow
Motor
Red
66
Convertible Motor Kit for GMax 5900, GMaxll 5900

Motor will not run.
See step 1.
Do you have
over 100 AC
volts?
NO
See step 2.
Do you have
over 100 AC
volts?
NO
Repair or
replace the
power Cord.
YES
Replace the
power switch.
YES
See step 3.
Is there over
100 DC volts?
NO
See step 4.
Is there
continuity
through the
thermistor
wires?
YES
NO
If motor is hot let

cool and retest, if
open replace motor.
The motor has a
defective
thermistor switch.
YES
See motor
test section.
Replace
Motor control board
67

Motor will not run.
Step 2
Step 1
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
110-120 AC
V
White
Black
Black
Motor Control Board
Ground
Black
Black
L2
L1
Black to
power cord
Black
Cord plugged in.

Switch ON.
Wires connected
to control board.
Meter on AC Volts
Transformer
110-120 AC
Motor Control Board
Jack
Power Cord
White to Barrel
Black to Tips
AC power to
control board.
Black
White
L2
L1
White
Motor Control Board
Black
Step 4
BEEP
Checking the motor

thermistor switch .
Meter should read
+M
-M
Motor
Control
Board
TS
TS
L1
+M -M
L2
White
TS TS
Step 3
100 + DC
V
Motor
Cord plugged in.

Switch ON.
Meter on DC volts.
+M
-M
Motor
Control
Board
TS TS
Motor
Yellow
Motor
Yellow
68

Motor runs, no AC output to sprayer control board.
See step 1.
Do you have
over 10-20 AC
volts?
YES
See step 2.
NO
Is there
continuity
NO
YES
Replace
See stepthe
3.
See the sprayers
control board
troubleshooting in
this manual.
Repair or
replace the
power Cord.
Is there
continuity
NO
Repair or
replace the
power Cord.
YES
See step 4.
Do you have
over 100 AC
volts?
NO
Repair or
replace wire
splice(s) on the
power cord wires.
YES
See step 5.
Do you have
over 10-20 AC
NO
Replace
Transformer
YES
Replace
Cord Jack.
69

Motor runs, no AC output to sprayer control board.
Step 1
10-20 AC
Step 2
Cord plugged in.

Switch ON.
Transformer and
power cord wires
connected.
Meter on AC Volts
Jack
Power Cord
Checking the AC
power cord for a
open wire.
Meter should read
continuity.
BEEP
Power Cord
White to Barrel
Black to Tips
Step 3
BEEP
Black
Transformer
Ground
Ground
Black
Black
Black
Jack
Power Cord
AC power to
control board.
White
Black
L1
+M -M
White to Barrel
TS TS
Black
Black
Black
To Jack
Black to Tip
Step 4
Cord plugged in.

Switch ON.
Wires partially
connected to splice.
Meter on AC Volts
To Transformer
Power
Cord
110-120 AC
Step 5
Cord plugged in.
Switch ON.
Wires connected Transformer
to splice.
Meter on AC Volts
White to Barrel
AC power to
control board.
Motor
Power Cord
White
L2
Checking the AC
power cord for a
open wire.
Meter should read
continuity.
Black to Tips
Motor Control Board
10-20 AC
Black to Tip
AC power to
control board.
AC power to
control board.
Transformer
White to Barrel
White
Motor Control Board
Black
L1
L2
White
70
Operational overview of the 200/230GH Electric Motor

(246129 & 246125)
The main switch has 3 different functions:
1. Turns the electric motor ON/OFF.
2. Provides circuit breaker protection
3. Provides thermal overload protection for the motor.
Overview of Thermal Protection:
When the motor goes into thermal overload, the thermal switch will
close and send voltage to the ON/Off switch. When this occurs the
coil in the On/Off switch will energize and pull the switch to the off
position, opening the circuit to the black rectifier wire shutting down
the electric motor.
Switch
287145
BLK
BLK
WHT
Rectifier (NA)
Yel
AC
GRN
WHT
AC
Yel
BLK
RED
Yel
Yel
Thermal Switch
Motor
246149
71
238672 Pressure Control, Gm3000, LineLazer 3000

Pump will not run.
Remove the control
box cover.
Go to step 1. Do
you have the
proper engine
voltage?
Check the red wire

from the engine to
the control board for
proper connection, if
ok repair or replace
engine generator.
No
YES
Go to step 3.
Do you have 12-20 AC volts?
Replace the
power switch.
No
YES
Go to step 3.
Is the continutiy throughthe pressure switch?
No
Replace the pressure

control switch.
YES
Go to step 4.
No
Repair or Replace the

red wire from the
On/Off switch.
No
Clean or Replace
the transducer.
No
Replace the Rectifer
No
Replace the Triac.
YES
Go to step 5.
YES
Go to step 6.
YES
Go to step 7.
Do you have 10-12 DC volts?
YES
Repair or replace the clutch/pinion assemble.

Mechanical Problem
72
238672 Pressure Control Box

Gm3000, LineLazer3000
Step 1
12 -20 AC
Engine running.
Wires connected
to Switch.
Ground
Ground
Green
On/Off
Switch
Red
Red To Pressure
Control Switch
To Engine
Pressure
Control
Switch
Red To Pressure
Control Switch
To Engine
Step 4
On/Off
Switch
Pressure
Control
Switch
White
Red
White to Pressure
Control
Green
(+)
Red From Engine
Triac
(-)
Rectifier
Red to Pressure
Control
White to Clutch
Black to Clutch
Step 7
Step 6
12 -20 AC
V
Green
Red
White to Clutch
Black to Clutch
Engine running.
Wires connected to
rectifer. Pressure switch
set to max.
12 -20 AC
V
Step 5
Engine running.
Wires connected
to Triac. Pressure switch
set to max.
Ground
(-)
White to Pressure
Control switch
Red Green
(+)
(+)
Ground
Triac
(-)
Engine running.
Wires connected to
rectifer. Pressure
Switch set to max.
Meter set to DC Volts.
Engine running.
Wires connected to Triac .
Pressure Switch connected.
Pressure switch set to max.
Ground
Red
Red
12 -20 AC
Triac
10-12 DC
Pressure Control
Switch test.
Unplug the pressure
control wires.
Meter set to continuity.
Pressure control turned
to high.
Green
On/Off
Switch
Red
238672
Pressure Control Box
Red
BEEP
Engine running.
Wires connected
to Switch.
Rectifier
White to Clutch
Black to Clutch
Rectifier
12 -20 AC
Step 3
Step 2
Red to Pressure
Control
Ground
73
238672 Pressure Control, Gm3000, LineLazer 3000

Pump will not stop pumping.

NO

YES
See step 1.
Is the Pressure Contol Switch open?
No
Remove the Pressure Control

Switch from the pump manifold
and retest. Is the Pressure Control
Switch still closed?
No
Clean or Replace
the transducer.
YES
YES

clutch assemble.
Mechanical Problem clutch
is stuck on the rotor
Replace the pressure

control switch.
Step 1
OL
Pressure Control Switch test.

Engine OFF.
Pressure relieved.
Pressure control turned to low(OFF).
Unplug the pressure control wires.
Meter set to continuity.
Pressure
Control
Switch
74
Gmax 3400 / LineLazar 3400

Remove the control
board cover.
Go to step 1.
Does the switch
test ok?
Replace the
Switch.
No
Yes
Go to step 2. Do
you have the
proper engine
voltage?
Check the wiring

from J3& J4 for
engine generator.
No
Yes
Go to step 3. Is the
proper voltage
present?
No
Go to step 5.
Does the clutch
engage?
No
Connect a test
transducer to
the board.
Does the
clutch
engage?
No
Yes
Replace the
Control
Board
Yes
Yes
Go to step 4.
Is the proper
Ohms
present?
Replace the
potentiometer.
No
Replace the
transducer.
If low restance is present in step 4,

the problem is a shorted field.
Replace pinion. If a open is present,
check wiring connections going to
the pinion if no open in the wiring
replace the pinion housing.
Yes

clutch/pinion assemble.
Mechanical Problem
75
Gmax 3400 / LineLazar 3400

Step 2
Engine OFF.
Switch
unplugged.
Meter set
continutity.
18-20 AC
Step 1
BEEP
Engine ON.
Meter set AC Volts.
Wires connected to
control board.
Control
Board
J3
On/Off
Switch
J4
Ground
Clutch A
Clutch B
Engine
Pinion Housing
J4
J3
Control
Board
Step 3
10-12 DC
J1
J2
On/Off
Switch
Transducer
Step 5
Potentiometer
Step 4
Control
Board
Engine OFF
Clutch wires
unplugged.
Meter set to Ohms.
1-3 ohms
Clutch B
J6
J1
Clutch A
Engine ON.
Switch ON.
Potentiometer unplugged.
Engine ON.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
J5
Control
Board
J2
Clutch B
Clutch A
Control
Board
To Pinion Housing
Clutch Field
76
Control Board 239056, Retrofit Kit 239693, 239266, 236974

(GM 3500,3012,5000,7000)
Pump will not run
Remove the control
board cover.
Go to step 1. Do
you have the
proper engine
voltage?
See step 2.
Do you have
12-20 AC
volts?
No
NO
Check the red wire

from the engine to
engine generator.
YES
Replace the
power switch.
Yes
proper voltage
present?
No
Go to step 5.
Does the clutch
engage?
NO
Replace
control board.
Yes
Yes
Go to step 4.
Is the proper
Ohms
present?
Replace the
potentiometer.
No

Yes

clutch or field assembly.
Mechanical Problem
77

(GM 3500,3012,5000,7000)
12 -20 AC
V
Step 1
Engine running.
Wires connected
to control board.
12-20 AC
Switch ON.
Wires connected
to ON/Off Switch.
Control
Board
Red from board
Red
from
engine
Engine running.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
On/Off
Switch
Power
Control
Board
10-12 DC
Engine running.
Ground
Step 3
Step 2
White to field
J6
J5
Clutch
Black to field
On/Off
Switch
Ground
Control Board
Red
from
engine
Power
Built in
Transducer
Red from board
Red from engine

White to field
Potentiometer
J5
J6
Black to field
Clutch
Step 4
Step 5
Potentiometer
Control
Board
Engine OFF
Clutch wires
unplugged.
Meter set to Ohms.
1-3 ohms
Engine running.
Switch ON.
Potentionmeter
disconnected.
Control
Board
J5
J6
Clutch
White to field
Black to field
78

(GM 3500,3012,5000,7000)
Pump Will not Shut Off:


NO
YES
NO
YES

motor shut off?
NO
Ground
Control Board
Power
Built in
Transducer
J5
J6
Clutch
Fluid Tube
79
220974, 221033, 222369 Pressure Control

With Bourdon Tube Gm3500,5000, LineLazer 3500, 5000
Pump will not run.
Fig. A
Remove the control box cover. Locate the adjustable

pressure control switch. Start the engine and push
down on the switch tab. See Fig. A Dose the pump start?
YES
No
Switch
Tab
Switch
-
Check the bourdon tube for warping. If warped,

control board must be replaced. If ok, follow pressure
adjustment procedures in the appropriate manual.
Tube
NC
NO
C
Tube
Go to step 1.
No
YES
Go to step 2.
No
Check the red wire from the engine

to the control board for proper
connection,if ok repair or replace
engine generator.
Replace the
power switch.
YES
Go to step 3.
Do you have continuity?
No
Replace the adjustable
pressure switch .
YES
Go to step 4.
No
Repair or Replace the white wire from

the adjustable pressure switch.
No
Repair or Replace the red wire from

the adjustable pressure switch.
No
Replace the Triac.
YES
Go to step 5.
YES
Go to step 6.
YES
Go to step 7.
Do you have 10-12 DC volts?
No
Replace the Rectifier
YES
Repair or replace the clutch/pinion assemble.

Mechanical Problem
80
220974, 221033, 222369 Pressure Control

With Bourdon Tube Gm3500,5000, LineLazer 3500, 5000
Step 1
12 -20 AC
V
Step 2
12 -20 AC
Engine running.
Wires connected
to Switch.
Ground
On/Off
Switch
Ground
Red
NC
NO
Red
To Engine
Red
To Pressure
Control Switch
To Pressure
Control Switch
Red
To Engine
Switch
Tab
Switch
Tube
Red
Red
Engine OFF.
Meter should read continuity.
Prussure Switch must
be closed (tab pushed down.)
On/Off
Switch
Step 3
BEEP
Engine running.
Switch ON.
Wires connected
to Switch.
Tube
White to triac
Red
to triac
Red to On/Off
Switch
Rectifier
On/Off
Switch
Step 4
12 -20 AC
Engine running.
Wires connected to Triac.
Pressure switch closed.
Triac
Adjustable
Pressure Switch
White to Pressure
Control switch
Triac
Red to
Pressure
Control
Ground
Red to rectifier
Step 6
Step 7
Red
Red
White to Clutch
Black to Clutch
12 -20 AC
V
Engine running.
Wires connected to
rectifer. Pressure switch
set to max.
Step 5
12 -20 AC
V
Engine running.
Wires connected to Triac .
Pressure switch closed.
White to Pressure
Control
Ground
Red Red
(-)
(+)
(+)
(-)
10-12 DC
Engine running.
Wires connected to
rectifer. Pressure
Switch set to max.
Rectifier
White to Clutch
Black to Clutch
Rectifier
Ground
Red to rectifier
Triac
Red to
Pressure
Control
PENDING
RELEASE
82
GMAX 3900,5900 and 7900

LL3900II,LL5900II
Control Board 241093 Non- Display
See pages 84, 85 for the steps.
NOTE: The red light will not light when the clutch is engaged.
Remove the control box
cover. With the engine at
med throttle, power switch
on , pressure potentiometer
turned up. Observe the
control boards Red light.
No light
Once
Normal operation.
Flashing
See Error Code

section for further
troubleshooting.
RED Light on
continuously
with pot. off
after a
replacemnet
board was
installed.
Go to step 1.
Is the proper
voltage
present?
No
Go to step 2.
Is the proper
voltage
present?
No
Go to step 7.
Is the proper
voltage
present?
Go to step 6.
Is the proper
No
voltage
present?
Yes
Yes
Model not
selected
Replace the
on/off
switch.
Yes
Go to step 3.
Is the proper
DC voltage
present?
No
Go to step 5.
Does the
clutch engage?
No

clutch engage?
Yes
Yes
Go to step 4. Is
the proper
Ohms present?
Yes
Mechanical
Problem with
the clutch/pinion
assemble.
Check the wiring

from engine
for proper
connection, if
ok repair or
replace engine
generator.
Check the round 5

pin plug for damage
to pin 3. Repair
pin 3 or replace the
pinion assembly.
No
Replace the
Control Board
Yes
Replace the
potentiometer.
Yes
Replace the
control box
harness.
No
Replace the
transducer.
No
Go to step 8.
Is the proper
Ohms present?
No
Check the 5 pin round

plug for damage to
terminals 1 & 2 repair
or replace the pinion
assembly.
Yes
Replace the
control box
harness.
83
GMAX 3900,5900 and 7900

LL3900II, LL5900II
Step 2
Step 1
Engine Running
Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
10-20 AC
V
Step 3
Engine Running
Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
10-20 AC
V
10-20 DC
V
Engine Running.
Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
J1
J1
Control
Board
On/Off
Switch
To 5 pin
round plug
J2
Control
Board
J3 J4
Clutch
To 5 pin
round plug
To 5 pin
round plug
J3 J4
Clutch
ON/Off
Switch
J1
J2
On/Off
Switch
Control
Board
J10
Potentiometer
Control
Board
Pressure
J2
J9
transducer
Temp
J6
J5
Step 5
Step 4
1-3 ohms
Engine ON
Switch ON
Pot. unplugged.
Engine OFF.
Meter set
to Ohms.
J10
To 5 pin
round plug
Control
Board
J3 J4
Clutch
Control
Board
84
GMAX 3900,5900 and 7900

LL3900II, LL5900II
Use CAUTION not to distort the pins when inserting the meter probe.
Step 7
Step 6
10-20 AC
V
Engine Running
Switch ON.
5 pin round plug
unpluugged.
Meter on AC Volts.
10-20 AC
V
Vio
Blk
Ground
Engine Running
Switch ON.
Red wire from engine
unpluugged.
Meter on AC Volts.
Red
Ground
Red
Red Wire
To Engine
Control Box
Red
Control Box
Bottom
View
Bottom
View
1-3 ohms
Step 8
Engine OFF.
5 pin round plug
unpluugged.
Meter set
to Ohms.
+
Vio
Blk
2
Ground
Red
Red
Control Box
Bottom
View
85
245394 Control Board LineLazer GMAX 3900,5900 and 7900

Pump will not run.
NOTE:
The display must be used for reading errors.
The RED light on this control board will only
indicate clutch engaged and 1 blink at start up.
Are there any

errors shown
on the display
board?
No

Once
Yes
See Error
Chart.
Go to step 1.
Do you have
the proper
engine
voltage?
No light
Normal operation.
Control board
Light on
clutch to engage.
Go to step
2. Do you
have the
proper
engine
voltage?
No
Yes
Yes
Go to step 3.
Does the switch
test ok? IF not
Replace the Switch.
Yes
Go to step 5.
Is the proper
voltage
present?
See Pinion Housing

Plug Fig A. Check
the pin (Engine
power) for damage.
Repair pin or
replace pinion
housing
No
Yes
Go to step
6. Is the
proper
Ohms
present?
No
Yes
If 00 is present in step
6, the problem is a
shorted field. Replace
pinion. If a open is
present See Pinion
Housing Plug Fig. B.
Check the pins (Clutch
Coil) for damage.
Repair pins or replace
pinion housing.
Go to step 4.
Does the clutch
engage?
No
Connect a test
transducer to
the board.
Does the
clutch
engage?
Yes
Yes
Replace the
potentiometer.

clutch/pinion assemble
Mechanical Problem.
OL
No
Check the
wiring to the
engine, if ok
repair or
replace engine
generator.
Fig. A
Checking the gallon sensor for a short.
Put the (-) meter lead on a frame ground.
Move the (+) meter lead to each of the
pins on the 2 pin plug.
No
Faulty Control
Board. See Fig. A
before replacing
Control Board.
Replace the
transducer.
Fig. B
Engine
Power
Gallon
Counting
Sensor
Clutch
Coil
Thermistor
Ground
Gallon
Counting
Sensor
86
GMAX 3900,5900 and 7900

Step 1
12 -20 AC
12 -20 AC
Engine running.
Red engine wire plugged
into pionion harness.
Step 2
Engine running.
Red engine wire unplugged
from pionion harness.
TP 1
TP 1
+
Control
Board
Control
Board
Generator
Generator
Engine
Ground
Engine To Engine
Generator
Ground
Step 3
BEEP
Engine OFF.
Switch
unplugged.
Meter set to
continutity.
Display Board
Pinion
Housing
Start up: 1 blink

Clutch engaged: Constant on
Drive
Housing
To Engine
Generator
Red LED
Transducer
Potentiometer
Clutch Test Points
To Engine
Generator
Pot. unplugged.
Engine ON.
Switch ON.
10-12 DC
Step 6
1-3 ohms
Step 4
TP 1
Generator
Engine OFF.
Meter set to
Ohms.
J6
TP 1
Generator
Clutch Test
Points
Control
Board
Generator
TP 1
Control
Board
Engine running.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
Step 5
Control
Board
Clutch Test
Points
87
GMAX II 3900,5900 and 7900

cover. Turn the sprayer on.
Observe the control boards
GREEN and RED LEDs.
No light
Once
Normal operation.
RED Light on
continuously
Control board
commanding
motor to run.
Go to step 1.
Does the
switch test ok?
No
Replace the
Switch.
No
GREEN Light
Watch Dog
on continuously enabled
See Error Code
section for further
troubleshooting.
Flashing
RED Light on
continuously
with pot. off
after a
replacemnet
board was
installed.
Yes
Yes
Model not
selected
proper voltage
present?
Yes
Go to step 4.
Is the proper
Ohms
present?
No
Yes
No
Go to step 2. Do
you have the
proper engine
voltage?
No
Check the wiring

from J1& J2 for
engine generator.
Yes
If O0 is present in
step 4, the problem
is a shorted field.
Replace pinion.
If a open is present,
check wiring
connections going
to the pinion.
Go to step 5.
Does the clutch
engage?
No
Connect a test
transducer to
the board.
Does the
clutch
engage?
Yes
Yes
Replace the
potentiometer.
No
Replace
the
Control
Board
Replace the
transducer.

Mechanical Problem
88
GMAX II 3900,5900 and 7900

BEEP
Step 1
12 -20 AC
Engine OFF.
Meter set
to continuity.
Step 2
Step 3
10-12 DC Engine running.
Engine ON.
Meter set
to AC Volts.
Wires connected
to control board.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
J1
Control
Board
Clutch
Field
Engine
Generator
J2
Pump
ON/OFF
Switch
CONTROL
BOARD
To Clutch
Field
Clutch Test Points

Pinon Drive
Assy. Housing
J3 J4
Step 4
1-3 ohms
Step 5
Engine ON
Switch ON
Clutch
Field
Control
Board
Engine OFF
Clutch wires
unplugged.
Meter set
to Ohms.
Control
Board
Clutch Test
Points
89

(GM 10,000, GMax 10,00)
Pump will not run
Remove the control
board cover.
Go to step 1. Do
you have the
proper engine
voltage?
See step 2.
Do you have
12-20 AC
volts?
No
NO
Check the red wire

from the engine to
engine generator.
YES
Replace the
power switch.
Yes
proper voltage
present?
No
Go to step 5.
Does the clutch
engage?
NO
Replace
control board.
Yes
Yes
Go to step 4.
Is the proper
Ohms
present?
Replace the
potentiometer.
No

Yes

Mechanical Problem
90

(GM 10,000, GMax 10,00)
12 -20 AC
V
Step 1
Engine running.
Wires connected
to control board.
12-20 AC
Switch ON.
Wires connected
to ON/Off Switch.
Control
Board
Red from board
Red
from
engine
Engine running.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
On/Off
Switch
Power
Control
Board
10-12 DC
Engine running.
Ground
Step 3
Step 2
White to field
J6
J5
Clutch
Black to field
On/Off
Switch
Ground
Control Board
Red
from
engine
Power
Built in
Transducer
Red from board
Red from engine

White to field
Potentiometer
J5
J6
Black to field
Clutch
Step 4
Step 5
Potentiometer
Control
Board
Engine OFF
Clutch wires
unplugged.
Meter set to Ohms.
1-3 ohms
Engine running.
Switch ON.
Potentionmeter
disconnected.
Control
Board
J5
J6
Clutch
White to field
Black to field
91

(GM 10,000, GMax 10,00)
Pump Will not Shut Off:


NO
YES
NO
YES

motor shut off?
NO
Ground
Control Board
Power
Built in
Transducer
J5
J6
Clutch
Fluid Tube
92
Operational Overview of the 225/300/350 Hydra Max

Hydra Max with the pump switch OFF and gas engine running:
See Figure 1: With the power switch off the directional valve will be de-energized forcing
hydraulic oil into the bottom of the hydraulic motor. When oil enterers the bottom the
hydraulic motor, the hydraulic motor rod willbe forced upwards.Once the hydraulic motor
rod is at the top of the motor, the hydraulic pressure regulator will go into bypass.
Hydra Max with the pump switch ON and gas engine running:
See Figure 2: With the pump switch on, the control board senses a closed circuit through J9.
This will allow the board to start using the magnetic sensor circuit to cycle the hydraulic
motor. The board will then turn ON the Red LED and supply power through the red wire to
the closed pump On/Off switch and then to the directional valve coil. This will energize the
directional valve coil forcing hydraulicoil into the top of the hydraulic motor. When oil
enterers the top of the hydraulic motor, the hydraulic motor rod will be forced down. When
the hydraulic motor rod and piston magnet passes by the lower magnetic sensor it will then
close the lower magnetic sensor circuit.
See Figure 3: The board will sense the closed circuit and turn OFF the Red LED and deenergize the directional valve. This will change the direction of hydraulic oil to the bottom of
the pump forcing the rod up. When the rod and piston magnet passes by the upper sensor it
will close the upper magnetic sensor circuit.
Using the Secondary Menu for Diagnosing the Sensors and Valve: To enter this menu
requires that you start the engine, hold down the DTS button and turn on the pump switch. See
Operational Manual 309378 for complete instructions if needed.
Diagnostics UP:
(Up) will display to indicate no current is present at electronic valve. Pump should move to up
position, and gal LED light should light to indicates a complete circuit to upper proximity
sensor.
Diagnostics dn:
(dn) will display to indicate current is present at electronic valve. Pump should move to the
down position, and liter LED should light to indicates a completed circuit to lower proximity
sensor.
Figure 1
J1
Engine
18-20 VAC
J2
J4
Blk
Grn
Blue
Yel
Blk
Wht
The Red LED Light will be off

when the board is not sending
voltage to the directional valve.
(Up Stroke)
Blue Yel Wht
Control Board
244981
Red Blk Grn

Wht
Blk
Blk
Grn
Red
LED
J9
J5
Transducer
243222
OIL FLOW
Blk
Red
Reservoir
Blk
Pump On/Off Switch

116270
Blk
Red
Pressure
Regulator
Direction Valve
244985
2
Pump
Valve shown in the

de-energizes state.
(OFF)
Blue
Black W/Green Shrink Wrap
Blk
Blu
Grn
Blk
Blk
Brn
Wht
Blk
Main Harness Plug

1
3 to 4 Up Stroke
3 to 2 Down Stroke
Neg. input
Brn
+5 output
+5 input
Magnetic Sensor
See Manual for PN
Blue
+5 output
Black
Brn
Piston
Magnet
225
197287
300/350
196653
Troubleshooting Tests with Piston Rod Stuck in the UP position.

1.Check the following before performing any tests. Proper engine voltage at pins J1 and J2. Pump On/Off
switch shows continuity. Hydraulic pump is putting out the proper pressure. Fluid pump is properly
installed on the hydraulic motor manifold housing (Threads must be flush.) Piston valve is tight on the fluid
pumprod.
2.With the motor running, pump On/Off switch turned on. Unplug the sensor harness and jump pins 3 and
2 of the main harness plug. This should move the piston rod down. If the piston rod goes down the
probable cause is the magnetic sensor kit. Their is a slight chance the piston magnet is damaged replace
if needed.
3. If the piston rod does not move down, check the harness for openwires from the 4 and 2 pin plugs to
the control board 6 pin plug. NOTE:Wire colors will change. If a open wire is found repair or replace
harness.
4.Reconnect all plugs and test for 12VDC at the directional valve coil, if voltage is present the possible
cause is a sticky or faulty directional valve. Repair or replace as needed. If no voltage replace the control
board.
Figure 2
J1
Engine
18-20 VAC
J2
J4
Blk
Grn
Blue
Yel
Blk
Wht
Blue Yel Wht
The Red LED Light will be on

when the board IS sending
(Down Stroke)
Control Board
244981
Red Blk Grn

Wht
Blk
Blk
Grn
Red
LED
J9
J5
Transducer
243222
OIL FLOW
Blk
Red
Reservoir
Blk
Pump On/Off Switch

116270
Blk
Red
Pressure
Regulator
Direction Valve
244985
2
Pump
Valve shown in the

energized state.
(ON)
Blue
Blk
Blue
Grn
Blk
Blk
Brn
Wht
Blk
Main Harness Plug

1
Neg. input
3 to 4 Up Stroke
3 to 2 Down Stroke
Brn
+5 output
+5 input
Magnetic Sensor
See Manual for PN
Blue
+5 output
Black
Brn
Piston
Magnet
225
197287
300/350
196653
Troubleshooting Tests with Piston Rod Stuck in the DOWN position:

1.Check the following before performing any tests. Proper engine voltage at pins J1 and J2. Pump On/Off
switch shows continuity. Hydraulic pump is putting out the proper pressure. Fluid pump is properly installed
on the hydraulic motor manifold housing(Threads must be flush.) Piston valve is tight on the fluid pump rod.
2.With the motor running, pump On/O ff switch turned on. Unplug the sensor harness and jump pins 3 and 4
of the main harness plug. This should move the piston rod up. If the piston rod goes up the probable cause is
the magnetic sensor kit. Their is a slight chancethe piston magnet is damaged replace if needed.
3. If the piston rod does not move up, check the main harness for open wires at the 4 and 3 pin plugs to the
control board 6 pin plug. NOTE: Wire colors will change. If a open wire is found repair or replace harness.
4.Reconnect all plugs and test for 12VDC at the directional valve coil, if voltage is present, replace control
board, if no voltage, the possible cause is a sticky or faulty directional valve. Repair or replace as needed.
Figure 3
The Red LED Light will be off
when the board is not sending
(Up Stroke)
J1
Engine
18-20 VAC
J2
J4
Blk
Grn
Blue
Yel
Blk
Wht
Blue Yel Wht
Control Board
244981
Red Blk Grn

Wht
Blk
Blk
Grn
Red
LED
J9
J5
Transducer
243222
OIL FLOW
Blk
Red
Reservoir
Blk
Pump On/Off Switch

116270
Pressure
Regulator
Direction Valve
244985
2
Blk
Red
Pump
Valve shown in the

de-energizes state.
(OFF)
Blue
Blk
Blu
Grn
Blk
Blk
Brn
Wht
Blk
Main Harness Plug

1
3 to 4 Up Stroke
3 to 2 Down Stroke
Neg. input
Brn
+5 output
+5 input
Magnetic Sensor
See Manual for PN
Blue
+5 output
Piston
Magnet
197287
Black
Brn
96
Line Lazer 3500,5000 with updated control board

241543
See pages 98, 99 for the steps.
No light
Once
Normal operation.
Flashing
See Error Code

section for further
troubleshooting.
RED Light on
continuously
with pot. off
after a
replacemnet
board was
installed.
Go to step 1.
Is the proper
voltage
present?
No
Go to step 2.
Is the proper
voltage
present?
No
Go to step 6.
Is the proper
voltage
present?
Yes
Yes
Model not
selected
Go to step 3.
Is the proper
DC voltage
present?
No
Go to step 5.
Does the
clutch engage?
Replace the
control box
harness.
Replace the
on/off
switch.
Yes
No

clutch engage?
Yes
Yes
Go to step 4. Is
the proper
Ohms present?
Yes
Mechanical
Problem with
the clutch/pinion
assemble.
Check the wiring

from engine
for proper
connection, if
ok, repair or
replace engine
generator.
No
Replace the
Control Board
Yes
Replace the
potentiometer.
No
Replace the
transducer.
No
Go to step 7.
Is the proper
Ohms present?
No
If (00) is present in step 7, the problem is a

shorted clutch field. Replace the field.
If a open (OL) is present Check the black and white
clutch field wires for damage. If ok replace
the clutch field.
Yes
Replace the
control box
harness.
97

241543
Step 2
Step 1
Engine Running
Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
10-20 AC
V
Step 3
Engine Running
Switch ON.
Wires connected
to control board
and On-Off switch.
Meter on AC Volts.
10-20 AC
V
10-20 DC
V
Engine Running.
Switch ON.
Pressure Switch
Turned to high.
Meter on DC volts.
J1
J1
Control
Board
J2
To Clutch Field
Control
Board
J3 J4
Clutch
To Engine
To Engine
Control
Board
J3 J4
Clutch
ON/Off
Switch
J1
J10
Step 4
1-3 ohms
Engine OFF.
Meter set
to Ohms.
Potentiometer
Control
Board
Pressure
J2
Red (+)
From Engine
On/Off
Switch
J2
On/Off
Switch
J9
transducer
Temp
J6
J5
Step 5
Engine ON
Switch ON
Pot. unplugged.
J10
To Clutch Field
Control
Board
J3 J4
Clutch
Control
Board
98

241543 Non- Display
To Control Board
10-20 AC
V
Engine Running
Switch ON.
Red wire from engine
unpluugged.
Meter on AC Volts.
Frame
Ground
Step 6
To Clutch Field
+
To Engine
To Control Board
Step 7
Engine OFF.
White and Black
wires unplugged.
Meter set
to Ohms.
1-3 ohms
Frame
Ground
To Clutch Field
To Engine
99
245512 Control Board LineLazer 3900III, 5900III

Pump will not run.
NOTE:
The display must be used for reading errors.
The RED light on this control board will only
indicate clutch engaged and 1 blink at start up.
Are there any

errors shown
on the display
board?
No

No light
Once
Yes
See Error
Chart.
Go to step 1.
Do you have
the proper
engine
voltage?
Normal operation.
Control board
Light on
clutch to engage.
Go to step
2. Do you
have the
proper
engine
voltage?
No
Yes
Yes
See Pinion Housing

Plug Fig B. Check
the pin (Engine
power) for damage.
Repair pin or
replace pinion
housing
No
Yes
Go to step
6. Is the
proper
Ohms
present?
No
Yes
No
Yes
Go to step 3.
Does the switch
test ok? IF not
Replace the Switch.
Go to step 5.
Is the proper
voltage
present?
Check the
wiring to the
engine, if ok
repair or
replace engine
generator.
Go to step 4.
Does the clutch
engage?
If 00 is present in step
6, the problem is a
shorted field. Replace
pinion. If a open is
present See Pinion
Housing Plug Fig. B.
Check the pins (Clutch
Coil) for damage.
Repair pins or replace
pinion housing.
No
Connect a test
transducer to
the board.
Does the
clutch
engage?
Faulty Control
Board. See Fig. A
before replacing
Control Board.
Yes
Yes
Replace the
potentiometer.

clutch/pinion assemble
Mechanical Problem.
No
Replace the
transducer.
Fig. A
OL
Checking the sensor wires for a short.

Unplug the 5 pin cable from the board.
Move the (+) meter lead to each of the five
pins on the round plug. Perform the same
test on the gallon counting sensor
+
Trigger
Sensor
Trigger Sensor
Fig. B
Engine
Power
Clutch
Coil
Gallon
Counting
Sensor
Thermistor
Ground
Gallon
Counting
Sensor
Distance Sensor
Distance Sensor
100

LineLazer 3900III, 5900III
Step 1
12 -20 AC
12 -20 AC
Engine running.
Red engine wire plugged
into pionion harness.
Step 2
Engine running.
Red engine wire unplugged
from pionion harness.
TP 1
TP 1
+
Control
Board
Control
Board
Generator
Generator
Engine
Ground
Engine To Engine
Generator
Ground
Step 3
BEEP
Engine OFF.
Switch
unplugged.
Meter set to
continutity.
Display Board
Pinion
Housing
Start up: 1 blink

Clutch engaged: Constant on
Drive
Housing
To Engine
Generator
Red LED
Transducer
Potentiometer
Clutch Test Points
To Engine
Generator
Pot. unplugged.
Engine ON.
Switch ON.
10-12 DC
Step 6
1-3 ohms
Step 4
TP 1
Generator
Engine OFF.
Meter set to
Ohms.
J6
TP 1
Generator
Clutch Test
Points
Control
Board
Generator
TP 1
Control
Board
Engine running.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
Step 5
Control
Board
Clutch Test
Points
101
LineLazar IV 3900,5900
Pump will not run.
Are there
any error
codes?
No
Yes
Remove the control

board cover/display.
With the engine at
med throttle, power
switch on , pressure
potentiometer turned
high. Is the D12 LED
light on?
See Error
Chart.
Go to step 1. Do
you have the
proper engine
voltage?
No
No
See engine
generator test.
No

switch or wiring.
Yes
Go to step 2.
Does the switch
test ok?
Yes
Yes
proper voltage
present?
No
Go to step 6.
Does the
clutch engage?
Yes
No
Connect a test
transducer to
the board.
Does the
clutch
engage?
Yes
Yes
Replace the
potentiometer.
Go to step 4.
Is the proper
Ohms
present?
No
If OO is present in
step 4, the problem is
a shorted field.
Replace pinion.
If a open is present,
go to Step 5. Is the
proper Ohms Present
No
No
Faulty Control
Board. See sensor
test before replacing
Control Board.
Replace the
transducer.
Check wiring
connections going to
the pinion/field.
If ok replace the
pinion housing.
Yes
Yes
Mechanical Problem

wiring harness going
to the control board.
102
Engine ON.
Meter set
to AC Volts.
Wires connected
to control board.
Step 3
Step 2
BEEP
10-12 DC
Engine OFF.
Meter set
to continuity.
Control
Board
Clutch Test
Points
Clutch
Field
Pump
ON/OFF
Switch
J4 J3
CONTROL BOARD
J1 J2
Engine
Generator
Display
Board
Potentiometer
Transducer
Gallon
Counter
Light
Switch
J15
Distasnce
Sensor
Engine running.
Switch ON.
potentionmeter
turned to high.
Meter on DC volts.
12 -20 AC
Step 1
Trigger
Sensor
J5
J9
Pump
ON/OFF
Switch
J4 J3
CONTROL BOARD
J16
Drive
Housing
J1 J2
J11
Light
Board
Engine
Generator
J12
Pinion
Assy.
To Clutch
Field
Step 6
Junction
Box
Step 4
Clutch Test Points
1-3 ohms
Step 5
Engine ON.
Switch ON.
Potentiometer unplugged.
1-3 ohms
Control
Board
Engine OFF
Clutch wires
unplugged.
Meter set
to Ohms.
J5
Clutch
Field
Pinion
Assy.
To Clutch Field
+ +
- -
J9
Engine OFF
Clutch wires
unplugged.
Meter set
to Ohms.
Junction
Box
Control
Board
Control
Board
Clutch Test
Points
103
287689 Control Board LineLazer 3900IV, 5900IV

Engine Generator Test
See Step 1.
Do you have
the proper
Ac voltage?
See Step 2.
Do you have
the proper
Ac voltage?
No
See Step 3.
Do you have
the proper
Ac voltage?
No
YES
YES
YES
Open in wiring harness

or poor connections on
the plugs. Repair or replace
Replace
Light Board.
Replace
Control
Board.
Step 1
12 -20 AC
Engine running.
Wires connected.
12 -20 AC
V
No
Step 2
Engine running.
Wires connected.
ENGINE
5900
Ground
Wire
LIGHT
BOARD
To
Control
Board
ENGINE
GENERATOR
Engine
Generator
Engine
Ground
GROUND
3900
Ground
Wire
White/Red
LIGHT
BOARD
To Light
Red
Engine
Generator
Engine
Ground
Check the wiring from

engine for proper
connection, if ok repair or
replace engine generator.
To Control Board
To Control Board To Light
12 -20 AC
V
LIGHT
BOARD
Step 3
Engine running.
Wires connected.
ENGINE
J15
TO ENGINE
GENERATOR
5900
Ground
Wire
J4 J3
CONTROL BOARD
J11
J1 J2
TO ENGINE
GENERATOR
To Light Board
104
Sensor Test
Unplug the J16 and J12 plugs from the board. See Fig. A.
Move the (+) meter lead to each pin in the harness plugs.
(J12 plug contains 5 wires), (J16 contains 2 wires).
Meter should read open on all 7 wires.
OL
GUN TRIGGER
PICKUP
Fig. A.
DISTANCE
SENSOR
PUMP
STROKE
COUNTER
Ground
J16
PICKUP
GUN TRIGGER
J16
J12
CONTROL
BOARD
J12
J16
J12
DRIVE
HOUSING
PINION
HOUSING
TO CLUTCH
CONTROL
BOARD
CLUTCH TEST POINTS

JUNCTION
BOX
WHITE
JUNCTION
BOX
CLUTCH TEST POINTS
105
287689 Control Board LineLazer 3900IV, 5900IV

Light Kit Troubleshooting
Does the clutch engage?
See troubleshooting for

pump will not run.
No
YES
Unplug the J11

plug from the control board.
Does the light turn on?
See Fig. B Is there

3-5 DC Volts.
No
No
No
Replace
Light Board.
YES
YES
Replace Light.
See Fig. A
Does the switch test good?
Fig. B
Replace
Light Switch.
No
No
3-5 DC
V
YES
Engine running.
J11 unplugged from
control board.

ENGINE
TO ENGINE
GENERATOR
LIGHT
BOARD
5900
Ground
Wire
BEEP
Fig.A
3900
Ground
Wire
GROUND
Engine OFF.
Meter set
to continuity.
LIGHT
SWITCH
Switch Open
Light OFF
LIGHT
BOARD
Switch Open
Light OFF
J15
LIGHT
SWITCH
To Control Board
Red
White/Red
KIT
LIGHT
LED
J4 J3
CONTROL BOARD
J11
J1 J2
TO ENGINE
GENERATOR
106
Blank
107

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Electrical and Mechanical Repair Tips

For Contractor Sprayers

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

240168 Control Board (695,795,1095):

244237 Control Board (695,795,1095):

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

BASIC ELECTRICAL TERMINOLOGY

BASIC ELECTRICAL TERMINOLOGY

Check the tester by connecting the leads.

WIRE CONTINUITY TESTING

Damaged / Fragmented Wire

Damaged / Fragmented Wire

Unplug the machine and remove the capacitor(s).

SEE ABOVE WARNING Using a screwdriver with

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

The following instructions can be used to test any bridge rectifer.

Instruction for checking the ERORR CODES:

The Codes below are for several different models.

1 Blink every 3 seconds

Transducer failure or connection error

Digital Display Switches

High pressure signal from transducer

Improper pressure signal from transducer

Board is trying to start up. Unplug transducer, pot

Sprayer does not run at all

Digital Display is blank

Control board status light never lights

What does this mean?

Sprayer does not run at all

Digital Display shows dashes and Psi icon is not blinking

What does this mean?

Sprayer does not run at all

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?

Sprayer does not run at all

Digital Display shows a pressure reading

Control board status light off.

E2 error code Brushless unit (possible)

What does this mean?

Sprayer does not run at all

Digital Display shows E=02

Control board status light blinks 2x repeatedly.

What does this mean?

Replace transducer. Connect power, set sprayer ON and control

Sprayer does not run at all

Digital Display shows E=03

Control board status light blinks 3x repeatedly.

What does this mean?

Sprayer does not run at all

Digital Display shows E=04

Control board status light blinks 4x repeatedly.

What does this mean?

Sprayer does not run at all

Digital Display shows E=05

Control board status light blinks 5x repeatedly.

What does this mean?

Troubleshooting Procedure ULTRA-MAX II(Brushless Type Motors)