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309226
Advanced Troubleshooting
General Problem: Output is Low or Fluctuating
SPECIFIC PROBLEM
CAUSE
SOLUTION
Motor brushes are worn.
NOTE:
Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
Check length of brushes. Brush length must
be 0.25 in. (6.4 mm) minimum. If brushes
are worn, replace motor using
Motor Kit
245080 for DX models or 243236 for XR
models.
Motor brush springs are broken.
If springs are broken, replace motor using
Motor Kit
245080 for DX models or 243236
for XR models.
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 knob using
Pressure Control Switch Kit
244266 for DX
models or 244267 for XR models.
General Problem: Output is Low or Fluctuating
SPECIFIC PROBLEM
CAUSE
SOLUTION
Motor armature is shorting.
Check for shorts using armature tester
(growler), or perform spin test (see
Motor
Diagnostics
on page 19). If shorts are
evident, replace motor using
Motor Kit
245080 for DX models or 243236 for XR
models.
Control board is damaged.
CAUTION:
Do not perform control board
diagnostics until you have determined that the
armature is good. A bad motor armature can burn
out a good control board.
See
Control Board Diagnostics
on page
19, and if damaged, replace control board
using
Control Board Kit
245079 for DX
models, 243228 for XR5 and XR7 models, or
243229 for XR9 models.
General Problem: Output is Low or Fluctuating (continued)
SPECIFIC PROBLEM
CAUSE
SOLUTION
Motor runs and pump
cycles, but pressure does
not build up.
Intake valve ball or outlet valve ball is not
seating properly.
Remove and clean valves, and check balls and
seats for nicks; replace if necessary. Strain paint
before spraying to remove particles that could clog
pump.
See
Pump Service
on page 20.
Pump packings are worn or damaged.
Check for leaking around throat packing nut.
Replace pump packings if there are leaks.
See
Pump Service
on page 20.
Spray–Prime/Drain valve is leaking.
Check Spray–Prime/Drain valve for debris trapped
on seat and for worn parts. Torque to 185 in-lb
(21 N
S
m). If parts are worn, replace valve using
Spray–Prime/Drain Valve Kit
235014.
