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Advanced Troubleshooting
312667K 23
General Problem: Low or Fluctuating Output
Specific Problem Cause Solution
Pump cycles, but output is low or
surging.
See Basic Troubleshooting,
page 13.
Worn or obstructed inlet and
outlet valves.
Check for worn pump valves as follows:
Prime sprayer with paint. Turn the Prime/Spray valve
to SPRAY position. Turn pressure control fully
clockwise.
Trigger spray gun briefly.
When spray gun trigger is released pump should
cycle momentarily and stop.
If pump continues to cycle, pump valves may be
worn or obstructed.
For replacement inlet and outlet valve kits, see List
of Kits, page 28.
Prime/Spray valve is leaking out
drain line when Prime/Spray
valve is in SPRAY position.
Check Prime/Spray valve for debris trapped on seat
and for worn parts. Torque to 130 - 180 in-lb
(15.8 - 18.1 N•m). Replace if parts are worn using
Prime/Spray Valve Kit, page 28.
Voltage from electrical outlet is
too low. Low voltages reduce
sprayer performance.
Check voltage of outlet. Meter must read 85 to 130V
AC.
Extension cord is too long or not
heavy enough gauge.
Replace extension cord.
See Grounding and Electrical Requirements,
page 10.
Leads from motor or pressure
switch to control board are
damaged, loose, pinched, or
overheated.
Be sure terminals are centered and firmly
connected. Inspect for pinched wiring and wiring
insulation and terminals for signs of overheating.
Replace any loose terminals or damaged wiring.
Securely reconnect terminals.
Motor brushes are worn. Check length of BOTH brushes (brushes do not
wear evenly on both sides of the motor). Brush
length must be 0.25 in. (6.4mm). If brushes are worn
replace motor using Motor Kit, page 28.
Motor brush springs are broken. If springs are broken, replace motor using Motor Kit,
page 28.
Motor brushes are binding in
brush holders.
Clean brush holders. Remove carbon dust with
small cleaning brush.
Motor stops before sprayer
reaches correct pressure (stall
pressure is too low).
Replace pressure control using Pressure Control
Switch Kit, page 28.
Control board is damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A damaged
armature can burn out a good
control board.
See Control Board Diagnostics, page 27. If
damaged, replace control board using Control
Board Kit, page 28.