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Advanced Troubleshooting
309477F 15
General Problem: Low or Fluctuating Output
Specific Problem Cause Solution
Pump cycles, but output is low
or surging
See Basic Troubleshooting,
page 9.
Worn or obstructed pump
valves
Check for worn pump valves as follows:
1. Prime sprayer with paint.
2. Trigger spray gun momentarily.
3. When spray gun trigger is released pump
should cycle momentarily and stop.
4. If pump continues to cycle, pump valves
may be worn or obstructed.
5. Pump Service, page 20.
Prime/Spray valve is leaking Check Prime/Spray valve for debris trapped on
seat and for worn parts. Torque to 21 N•m (185
in-lb). Replace if parts are worn using
Prime/Spray Drain Valve Kit, page 18.
Voltage from electrical outlet is
too low. Low voltages reduce
sprayer performance.
Check voltage of outlet. Meter must read 200-260
V AC.
Reset building circuit breaker or replace building
fuse.
Repair electrical outlet or try another outlet.
Extension cord is too long or
not heavy enough gauge
Replace extension cord.
Grounding and Electrical Requirements, page
7.
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 to not
wear evenly on both sides of the motor). Brush
length must be 6.4mm (0.25 in). If brushes are
worn replace motor using Motor Kit, page 18.
Motor brush springs are broken If springs are broken replace motor using Motor
Kit, page 18.
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 18.
Motor armature shorted Check for shorts using armature tester (growler)
or perform spin test, Motor Diagnostics, page
19. If shorts are evident, replace motor using
Motor Kit, page 18.