Assessments - 4, GPA: 3.5
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Replace any loose terminal or damaged wiring. Securely reconnect terminals. 9. For loose motor brush leads and terminals. See page 12. 9. Tighten terminal screws. Replace brushes if leads are damaged. See page 12. 10.For worn motor brushes which must be 1/4 in. (6 mm) minimum. See page 12. 10. Replace brushes. See page 12. 11. For broken or missing motor brush caps. 11. Replace brushcap if broken. Realign spring with brush. See page 12. 12.Motor brushes for binding in brush holders. See page 12. 12.Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement. 13.Low stall pressure. 13. Do either or both: a. Turn pressure control knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position. b. Try a new transducer. 14.Motor armature for shorts by using an armature tester (growler) or perform spin test. See page 12. 14.Replace motor. See page 25. 10 309063 Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK If check is OK, go to next check WHAT TO DO When check is not OK refer to this column Motor runs and pump strokes 1. Paint supply. 1. Refill and reprime pump. 2. Intake strainer clogged. 2. Remove and clean, then reinstall. 3. Suction tube or fittings loose. 3. Tighten; use thread sealant or sealing tape on threads if necessary. 4. To see if intake valve ball and piston ball are seating properly. See page 26. 4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 26. Strain paint before using to remove particles that could clog pump. 5. Leaking around throat packing nut which may indicate worn or damaged packings. See page 26. 5. Replace packings, page 26. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup. 6. Pump rod damage. 6. Repair pump, page 26. 7. Capacitor failure. Visually inspect capacitor near terminals. Ensure that orange safety relief plug is intact. 7. Replace capacitor. Motor runs but pump does not stroke 1. Displacement pump pin (9a) (damaged or missing), page 26. 1. Replace pump pin if missing. Be sure retainer spring (9b) is fully in groove all around connecting rod, page 26. 2. Connecting rod assembly (9) for damage, page 24. 2. Replace connecting rod assembly, page 24. 3. Gears or drive housing, page 24. 3. Inspect drive housing assembly and gears for damage and replace if necessary, page 24. Motor is hot and runs intermittently 1. Be sure ambient temperature where sprayer is located is not more than 115 _F(46 _C) and sprayer is not located in direct sun. 1. Move sprayer to shaded, cooler area if possible. 2. Motor has burned windings indicated by removing positive (red) brush and seeing burned adjacent commutator bars. 2. Replace motor. See page 25, Motor Replacement. 3. Tightness of pump packing nut. Overtightening tightens packings on rod, restricts pump action and damages packings. 3. Loosen packing nut. Check for leaking around throat. Replace pump packings if necessary. See pump manual 309060. 309063 11 12 309063 Spin Test Setup Electric Shock Hazard; page 6. To check armature, motor winding and brush electrical continuity: 1. Relieve pressure; page 6. 2. Remove drive housing; page 24. 3. Fig. 7. Remove pressure control cover (39). Disconnect red and black motor leads from control board. 4. Fig. 8. Remove motor shroud (74). Armature Short Circuit Test Quickly turn motor fan by hand. If no electrical shorts, motor coasts two or three revolutions before complete stop. If motor does not spin freely, armature is shorted. Replace motor; page 25. Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) 1. Connect red and black motor leads together with test lead. Turn motor fan by hand at about two revolutions per second. 2. If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair as needed; page 12. 3. If still uneven or no resistance, replace motor; page 25. 9578A Fig. 7 F G 39 Motor Brush Replacement Motor Brush Removal Replace brushes worn to less than 1/4 in. (6 mm). Check both sides. See Parts List 309064 for correct brush kit for your series of sprayer. 1. Read General Repair Information; page 7. 2. Relieve pressure; page 6. 3. Fig. 8. Remove four screws (18) and motor shroud (74). 4. Pry off two brush caps (A). Tag locations of red (+) and black (--) motor leads. Cut tie wrap. 5. Fig. 5. Remove screw (C) and discard brush (B) for motor with capacitor attached. Remove brush leads from control box for motor without capacitor attached. (Continued on page 13) TI0053 A 74 Fig. 8 18 Motor Brush Replacement 6. Fig. 9. Insert brush (B). Push cap (A) into place over brush. Orient each cap with the 2 projections on either side of the brush lead. You will hear a “snap” when cap is securely in place. CAUTION When installing brushe...