Troubleshooting
WARNING
To reduce the risk of a serious injury, follow the
Pressure Relief Procedure on page 4 whenever
you are instructed to relieve the pressure.
Check everything in the charts before disassembling the sprayer.
1
The sprayer will not operate.
PROBLEM
WHAT TO CHECK
If check is OK, go to next check
WHAT TO DO
When check is not OK refer to this column
Check these basic fluid
pressure problems.
1.. Check the pressure setting. The motor will not
operate if the pressure is at the minimum set-
ting (fully counterclockwise).
1. Slowly increase the pressure setting to see
if the motor starts.
2. Check for a clogged spray tip. Refer to the
separate gun or tip instruction manual.
2. Relieve the pressure. Refer to the separate
gun or tip instruction manual for tip cleaning.
Check these basic
mechanical problems.
1. Check for frozen or hardened paint in the pump
(76) and/or the pressure control tube. Use a
screwdriver to manually rotate the fan at the
back of the motor. See page 22.
1. Thaw the pump. Plug in the sprayer and
turn on the sprayer. Slowly increase pres-
sure to see if the motor starts. If the motor
doesn’t start, see NOTE 1, below.
2. Check the pump’s connecting rod pin (43). The
pin must be completely pushed into the con-
necting rod (68), and the retaining spring (42)
must be firmly in groove of connecting rod. See
Fig. 29, page 36.
2. Push the pin into place and secure it with
the spring retainer.
3. Check for damage to the motor. Remove the
drive housing (67). See page 33. Try to manu-
ally rotate the fan.
3. Replace the motor (73) if the fan won’t turn.
See page 34 .
Check these basic elec-
trical problems.
1. Check the sprayer’s circuit breaker (309) but-
ton to be sure it has not popped up.
1. Depress the button to reset. If the circuit
breaker continues to open, see the section
“There is an electrical short.” on page 21.
2. Check the electrical supply with a volt meter.
The meter should read 105 to125 VAC.
2. Reset the building circuit breaker; replace
the building fuse. Try another outlet.
3. Check the extension cord for visible damage.
Check the outlet of the extensions cord with a
volt meter or a test lamp.
3. Replace the extension cord.
4. Check the power cord (311) for damage such
as broken insulation or wires.
4. Replace the power cord. See page 26.
5. Check the motor brush leads, the terminals
and the brush length. The brush length should
be at least 1/2 inch (12 mm). See page 25.
5. Tighten the terminal screws; replace the
brushes. See page 25.
NOTE 1: Thaw the sprayer in a warm area if water or water-based paint has frozen in it. Do not try to start the sprayer until it has
thawed completely. If the bourdon tube was not damaged by the freezing, the pump should operate. If the paint hardened or dried
in the sprayer, the pump packings or the bare pressure control must be replaced. See page 36 (pump) or page 29 (pressure con-
trol).
2
The motor will not operate.
Diagnosing the circuit
board indicator lamps.
The normal condition is
red lamp on, clear lamp
on
when the board is
telling the pump to run
1. Check the leads from the bridge (308) to the
motor to be sure the leads are securely fas-
tened and properly mated.
1. Replace any loose terminals. Crimp the
leads. Be sure male terminal blades are
straight and firmly connected to mating part.
telling the pump to run.
Follow the Pressure
Relief Procedure
Warning.
(Continued
on page 17.)
2. Check the G1 and G2 connections between
the circuit board (23) and the bridge (308) for
damage or loose terminals.
2. Clean circuit board male terminals. Replace
loose or damaged terminals. Securely re-
connect leads.
Summary of Contents for Ultra 1000
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