Magnum 232735 Use and care manual

309226M
Repair and Parts
Airless Sprayers
US Patent No. 1184US3
- For portable spray applications of architectural paints and coatings - (Specifications, page 3.)
Use water-based or mineral spirit-type material only.
Do not use materials having flash points lower than
70°F (21°C). For information about your material
request MSDS from distributor or retailer.
Important Safety Instructions
Read all warnings and instructions in this manual. Save
these instructions. See page 3 for model and series
information, including dispense rate, recommended hose
length, guns, and maximum working pressure.
ti4309a
ti6878a
ti6877a
ti6879a
MAGNUM XR5
MODEL 232740
MAGNUM dx
MODEL 232735
MAGNUM XR7
MODEL 232745
MAGNUM XR9
MODEL 232750
Related Manuals - 309225 Operation
EN

2309226M
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding and Electric Requirements . . . . . . . . . . . . . 6
Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 10
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Repair Information . . . . . . . . . . . . . . . . . . . . . . . 11
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Advanced Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 15
General Problem: Motor Does Not Operate . . . . . . . . 15
General Problem: Circuit Breaker is Tripping . . . . . . . 17
General Problem: Erratic Motor Operation . . . . . . . . . 18
General Problem: Low or Fluctuating Output . . . . . . . 19
General Problem: No Output . . . . . . . . . . . . . . . . . . . 21
General Problem: Excessive Pressure Build Up . . . . . 21
List of Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 25
Pump Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
dx Sprayer Model 232735 . . . . . . . . . . . . . . . . . . . . . . 26
XR5 Sprayer Model 232740 . . . . . . . . . . . . . . . . . . . . 28
XR7 Sprayer Model 232745 . . . . . . . . . . . . . . . . . . . . 32
XR9 Sprayer Model 232750 . . . . . . . . . . . . . . . . . . . . 36
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 40

Models
309226M 3
Models
Specifications
This equipment is not intended for use with flammable or combustible materials used in places such as cabinet shops
or other “factory”, or fixed locations. If you intend to use this equipment in this type of application, you must comply
with NFPA 33 and OSHA requirements for the use of flammable and combustible materials.
Model Name,
Model No. Series
Dispense Rate
gpm (lpm)
Hose
Length and
Diameter Gun Model
Maximum Working
Pressure
PSI MPa bar
Magnum dx
232735
B 0.24 gpm
(0.91 lpm)
25 ft (7.6 m)
3/16 in. SG1™- EF 2800 19 193
Magnum XR5
232740
E 0.27 gpm
(1.02 lpm)
25 ft (7.6 m)
1/4 in. SG1™- EF 3000 21 207
Magnum XR7
232745
D 0.34 gpm
(2.17 lpm)
50 ft (15.2 m)
1/4 in. SG2™3000 21 207
Magnum XR9
232750
D 0.38 gpm
(1.44 lpm)
50 ft (15.2 m)
1/4 in. SG3™3000 21 207

Warnings
4309226M
Warnings
The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the
manual, refer back to these pages for a description of the specific hazard.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• When flammable liquid is used in or near the sprayer or for flushing or cleaning, keep sprayer at least
20 feet (6 m) away from explosive vapors.
• Do not clean with materials having flash points lower than 70°F (21°C). Use water-based materials
or mineral spirits type material only. For complete information about your material, request the
MSDS from the fluid distributor or retailer.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in work area. See Grounding instructions.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
SKim
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
309226M 5
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces can become very hot during operation. To avoid severe burns, do not touch hot
equipment. Wait until equipment has cooled completely.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
WARNING

Installation
6309226M
Installation
Grounding and Electric
Requirements
The sprayer must be grounded. Grounding reduces the
risk of static and electric shock by providing an escape
wire for the electrical current due to static build up or in
the event of a short circuit.
The sprayer requires a 120V AC, 60 Hz, 15A circuit
with a grounding receptacle. Never use an outlet that is
not grounded or an adapter.
Do not use the sprayer if the electrical cord has a dam-
aged ground prong.
Only use an extension cord with an undamaged
3-prong plug. Recommended extension cords for use
with this sprayer:
• 25 ft (7.6 m) 18 AWG
• 50 ft (15.2 m) 16 AWG
• 100 ft (30.5 m) 14 AWG
• 150 ft (45.7 m) 12 AWG
Spray gun:ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container:follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface such as concrete. Do not place the pail on a
nonconductive surface, such as paper or cardboard,
which interrupts grounding continuity.
Grounding the metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to ground
such as a water pipe.
Maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
Thermal Overload
Motor has a thermal overload switch to shut itself down
if overheated.
Smaller gauge or longer extension cords may
reduce sprayer performance.
To reduce risk of injury from motor starting
unexpectedly when it cools, always turn power
switch OFF if motor shuts down.

Installation
309226M 7
Notes

Component Identification
8309226M
Component Identification
AElectric motor (inside enclosures) Provides mechanical power to pump.
B Power switch Manually turns ON and OFF electric power to motor (I is ON
and 0 is OFF.
C Pressure control knob Manually increases (turn clockwise) and decreases (turn
counter-clockwise) fluid pressure in pump, hose, and spray
gun.
D Pump fluid outlet fitting Threaded connection for paint hose.
EInstaClean™fluid filter (XR models only) • Filters fluid coming out of pump to reduce tip plugging
and improve finish.
• Self cleans only during pressure relief.
FPower-Piston™pump (behind Easy
Access door)
Pumps and pressurizes fluid and delivers it to paint hose.
Easy Access door permits quick removal of outlet valve.
G Suction tube Draws fluid from paint pail into pump.
H Prime tube (with diffuser) Drains fluid in system during priming and pressure relief.
J Spray- Prime/Drain valve control • In SPRAY position (pointing forward) directs pressurized
fluid to paint hose.
• In PRIME/DRAIN position (pointing down) directs fluid to
drain tube.
• Automatically relieves system pressure in overpressure
situations.
K Fluid inlet connection and inlet valve Suction tube connection to pump and inlet valve.
L Inlet screen Prevents debris from entering pump.
M Paint hose Transports high-pressure fluid from pump to spray gun.
N Cord wrap bracket Stows electrical cord (XR5 model only).
P Airless spray gun Dispenses pumped fluid.
Q Tip guard Reduces risk of fluid injection injury.
R Reversible spray tip • Atomizes fluid being sprayed, forms spray pattern and
controls fluid flow according to hole size.
• Reverses for unclogging plugged tips without disassem-
bly.
S Trigger safety lever Prevents accidental triggering of spray gun.
T Gun fluid inlet fitting Threaded connection for paint hose.
USmooth Glide™swivel (SG3 spray gun
only)
Allows spray gun to swivel without twisting paint hose.
V Gun fluid filter (in handle) Filters fluid entering spray gun to reduce tip clogs and
improve finish.
W Hose/cord wrap bracket Stows paint hose and electrical cord (XR7 and XR9 models
only).
X Pail hanger For transporting pail by its handle (XR7 and XR9 models
only).
Y Power Flush attachment (included) Connects garden hose to suction tube for power flushing
water-base fluids.

Component Identification
309226M 9
TIA
Connect cart handles on XR7 and XR9 as follow:
1. Position handle on frame as shown and align
bolt holes in handle with bolt holes in frame.
2. Run bolts through holes with heads pointing
toward each other, and hand tighten wingnuts.
NOTE: For space-saving configuration, loosen,
(but do not remove) wingnuts.
Fold handle forward over sprayer shroud.
Sprayers
#
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'
$
!
.
"
,
*
+
%
-
0
TIA
W
X
K
W
W
K
X
Magnum XR7
Magnum XR9
Magnum dx
Magnum XR5
K
D
B
Spray Guns
Q
R
S
T
Q
R
S
U
T
9562A
V
V
9561A

Operation
10 309226M
Operation
Pressure Relief Procedure
Follow Pressure Relief Procedure when you stop spray-
ing and before cleaning, checking, servicing, or trans-
porting equipment. Read warnings, page 4.
1. Turn power switch (B) OFF and unplug power cord.
2. Turn Spray- Prime/Drain valve (J) to PRIME/DRAIN
to relieve pressure.
3. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
4. Engage trigger lock. See Trigger Lock, page 10 or
your gun operation manual.
If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure gradually,
then loosen completely. Clear hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
PRIME
Leave Spray - Prime/Drain valve in the
PRIME/DRAIN position until you are ready to spray
again.
(SG2 and SG3)
(SG1-EF)
Trigger Locked Position

General Repair Information
309226M 11
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Basic
Troubleshooting, page 12 and Advanced Trouble-
shooting, page 15.
• Overspray may build up in the air passages.
Remove any overspray and residue from air pas-
sages and openings in the enclosures whenever
you service sprayer.
• Do not operate the sprayer without the cover in
place. Replace if damaged. Covers direct cooling air
around motor to prevent overheating.
To reduce risk of serious injury, including electric shock:
• Do not touch moving or electric pars with fingers or
tools while testing repair.
• Unplug sprayer when power is not required for test-
ing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
Flammable materials spilled on hot, bare, motor could
cause fire or explosion. To reduce risk of burns, fire
or explosion, do not operate sprayer with cover
removed.
CAUTION
• Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
• Protect the internal drive parts of this sprayer from
water. Openings in the cover allow for air cooling of
the mechanical parts and electronics inside. If
water gets in these openings, the sprayer could
malfunction or be permanently damaged.
• Prevent pump corrosion and damage from freezing.
Never leave water or water-base paint in sprayer
when its not in use in cold weather. Freezing fluids
can seriously damage sprayer. Store sprayer with
Pump Armor to protect sprayer during storage.

Basic Troubleshooting
12 309226M
Basic Troubleshooting
The following troubleshooting guidelines from the Operating Instructions are included here as a preemptive measure
against Advanced Troubleshooting, page 15. Refer to Component Identification, page 8 for reference letters
used in table.
Problem Cause Solution
Power switch is on and sprayer is
plugged in, but motor does not run,
and pump does not cycle.
Pressure is set at zero pressure. Turn Pressure Control Knob (C)
clockwise to increase pressure set-
ting.
Motor or control is damaged. See Motor Does Not Operate, page
15.
Electric outlet is not providing power. • Try a different outlet or plug in
something that you know is work-
ing to test outlet.
• Reset building circuit breaker or
replace fuse.
Extension cord is damaged. Replace extension cord. See
Grounding and Electric Require-
ments, page 6.
Sprayer electric cord is damaged. Check for broken insulation or wires.
Replace electric cord if damaged.
Paint is frozen or hardened in pump. See Motor Does Not Operate, page
15.
Pump does not prime. Spray-Prime/Drain Valve (J) is in
SPRAY position.
Turn Spray-Prime/Drain Valve to
PRIME/DRAIN position (pointing
down).
Inlet screen (L) is clogged or suction
tube (G) is not immersed.
Clean debris off inlet screen and
make sure suction tube is at bottom
of paint pail.
Balls in check valve are stuck or
check valves are damaged.
Clean or replace check valves. See
Pump Service, page 25. Do not
store check valves in water.
Suction tube is leaking. Tighten suction tube connection (K).
Inspect for cracks or vacuum leaks.
Spray gun stopped spraying. Spray tip is clogged. Unclog spray tip. See Operation Man-
ual, 309225.

Basic Troubleshooting
309226M 13
Pump cycles but does not build up
pressure.
Pump is not primed. Prime pump.
Inlet screen (L) is clogged or suction
tube (G) is not immersed.
Clean debris off inlet screen and
make sure suction tube is at bottom
of paint pail.
Paint pail is empty. Refill paint pail. Reprime sprayer.
Suction tube is leaking. Tighten suction tube connection (K).
Inspect for cracks or vacuum leaks.
Pump check valves are dirty or dam-
aged. (Usually only one valve).
Clean or replace check valves. See
Pump Service on page 25.
Spray-Prime/Drain Valve (J) is worn
or obstructed with debris.
Check Spray-Prime/Drain valve for
debris trapped on seat or worn parts.
Torque to 185 in-lbs (21 N•m).
Replace if parts are worn.
Pump cycles, but paint only dribbles
or spurts when spray gun is trig-
gered.
Pressure is set too low. Slowly turn Pressure Control Knob
(C) clockwise to increase pressure
setting and verify if sprayer pressure
increases.
Spray tip is clogged. Unclog spray tip. See Operation Man-
ual 309225.
InstaClean fluid filter is clogged (XR
models only).
Clean or replace InstaClean fluid fil-
ter (E).
Spray gun fluid filter is clogged or
installed backward.
Clean or replace gun fluid filter (V).
Spray pattern is inconsistent or is
leaving stripes.
Pressure is set too low. Turn Pressure Control Knob (C)
clockwise, to increase pressure.
Spray tip is worn beyond capability of
sprayer.
Replace spray tip.
Pressure is set at maximum but
cannot achieve a good spray pattern.
Spray tip is too large for sprayer. Select smaller spray tip.
Spray tip is worn beyond capability of
sprayer.
Replace spray tip.
Extension cord is too long or not
heavy enough gauge.
Replace extension cord. Grounding
and Electrical Requirements, page
6.
Spray gun fluid filter is clogged. Clean or replace spray gun fluid filter.
InstaClean fluid filter is clogged (XR
models only).
Clean or replace InstaClean fluid
filter.
Inlet screen is clogged. Clean debris off inlet screen.
Pump valves are worn. See Low or Fluctuating Output,
page 19.
Problem Cause Solution

Basic Troubleshooting
14 309226M
Motor is hot and runs intermittently.
This is NOT a thermal overload con-
dition. Motor automatically shuts off
due to excessive heat. Damage can
occur if cause is not corrected.
Startup Hazard After Thermal
Overload, page 6.
Vent holes in enclosure are plugged
or sprayer is covered.
Keep vent holes clear of obstructions
and overspray and keep sprayer
open to air.
Extension cord is too long or not a
heavy enough gauge.
Replace extension cord. See
Grounding and Electrical
Requirements, page 6.
Unregulated electrical generator
being used has excessive voltage.
Use electrical generator with a proper
voltage regulator. Sprayer requires
120VAC, 60 Hz, 1500-Watt
generator.
Sprayer was operated at high
pressure with very small tip which
causes frequent motor starts and
excessive heat build up.
Decrease pressure setting or
increase tip size.
Building circuit breaker opens after
sprayer operates for 5 to 10 minutes.
Too many appliances are plugged in
on same circuit.
Free up circuit (unplug things), or use
a less busy circuit.
Sprayer electrical cord is damaged. Check broken insulation or wires.
Replace electrical cord if damaged.
Fan pattern varies dramatically while
spraying.
OR
Sprayer does not turn on promptly
when resuming spraying.
Pressure control switch is worn and
causing excessive pressure variation.
Replace pressure control knob using
Pressure Control Switch Kit, page
22.
Cannot trigger spray gun. Spray gun trigger safety is unlocked. Rotate trigger safety lever to lock
SAFETY, page 10.
Spray comes out of spray gun in two
thick streams.
Reversible spray tip is in UNCLOG
position.
Rotate arrow-shaped handle on
spray tip so it points forward in
SPRAY position.
Paint is coming out of pressure
control switch.
Pressure control switch is worn. Replace pressure control using
Pressure Control Switch Kit, page
22.
Spray-Prime/Drain valve actuates
automatically relieving pressure
through drain tube.
System is over pressurizing. See Excessive Pressure Build Up,
page 21.
Paint leaks down outside of pump. Pump packings are worn. Replace pump packings. See Pump
Service, page 25.
Problem Cause Solution

Advanced Troubleshooting
309226M 15
Advanced Troubleshooting
See Basic Troubleshooting first, page 12 for problems that are more easily remedied.
General Problem: Motor Does Not Operate
Specific Problem Cause Solution
Power switch is on and sprayer
is plugged in; pump does not
cycle.
See Basic Troubleshooting,
page 12.
Basic mechanical problems. Paint is frozen or hardened in
pump.
Unplug sprayer from electrical outlet.
If paint is frozen in sprayer:
• Do NOT try to start sprayer until completely
thawed or you may damage the motor, control
board, and/or drivetrain.
1. Turn OFF power switch.
2. Place sprayer in warm area for several
hours.
3. Plug in and turn on sprayer.
4. Slowly increase pressure until motor starts.
If paint hardened in sprayer:
1. Replace pump packings.
2. Remove all residue from valves.
Pump Service, page 25.
Motor is damaged. Remove gear and try to rotate motor shaft by
hand. See Motor Diagnostics, page 24. If shaft
will not turn, replace motor using Motor Kit, page
22.
Yoke is broken because pump
is locked up due to dried paint
or worn packings (XR models
only).
Repair or replace using Gear/Yoke Kit, page 22.
Repair pump. See Pump Service, page 25.

Advanced Troubleshooting
16 309226M
Basic electrical problems. Motor overheated. Allow motor to cool for 30 minutes. Retry.
Electrical outlet is damaged. Reset building circuit breaker or replace fuse. Try
another outlet.
Check electric supply with volt meter. Meter must
read 85 to 130V AC. If voltage is too high, do not
plug sprayer in until outlet is corrected.
Control board leads are
improperly fastened or
improperly mated.
Replace any loose terminals. Make sure all leads
and harnesses are firmly connected.
Check pressure control harness connection on
front side of drive housing.
Clean control board terminals. Securely reconnect
leads.
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 22.
Motor armature commutator
damaged.
Check for burn spots, gouges and extreme
roughness. Have motor shop resurface
commutator if possible, or replace motor using
Motor Kit, page 22.
Fuse is blown. Replace fuse using Fuse Kit, page 22.
Motor armature shorting. Check for shorts using armature tester (growler)
or perform spin test, Motor Diagnostic, page 24.
If shorts are evident, replace motor using Motor
Kit, page 22.
Control board damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A bad
armature can burn out a good
control board.
See Control Board Diagnostics, page 25.
Replace control board if damaged using Control
Board Kit, page 22.
Sprayer Wiring Problems
NOTE: Remove enclosure
mounting screws and pull
enclosure away from drive
housing. Take care not to pull
on leads from electrical cord
and power switch.
Sprayer electrical cord
damaged.
1. Unplug sprayer electrical cord.
2. Disconnect black electrical cord wire at
power switch.
3. Unplug in-line connection white cord wire.
4. Plug in electrical cord.
5. Test voltage between black and white
wires. Meter must read 85 to 130V AC.
6. Replace electrical cord if no voltage.
Sprayer power switch
damaged.
1. Unplug sprayer electrical cord.
2. Disconnect black control board wire at
power switch.
3. Unplug in-line connection white cord wire.
4. Plug in electrical cord.
5. Turn power switch ON.
6. Test voltage between open terminal of
power switch and white electrical cord wire.
Meter must read 85 to 130V AC.
7. Replace power switch if no voltage.
Specific Problem Cause Solution

Advanced Troubleshooting
309226M 17
Sprayer Wiring Problems
(cont.)
Motor thermal overload cutoff
switch damaged.
Startup Hazard After Thermal
Overload, page 6.
1. Unplug sprayer electrical cord.
2. Remove motor harness from control card.
3. Check for continuity between yellow leads
or motor harness.
4. If thermal relief switch is open (no continu-
ity) allow motor to cool.
5. If switch remains open after motor cools,
replace motor using Motor Kit, page 22.
6. If thermal relief switch closes after motor
cools, find correct cause of overheating.
Terminals are damaged or
loose.
Replace any damaged terminals. Make sure all
terminal connections are tight.
Specific Problem Cause Solution
General Problem: Circuit Breaker is Tripping
Specific Problem Cause Solution
Building circuit breaker opens
as soon as sprayer is turned
on.
Sprayer electrical wiring is
pinched or insulation is
damaged.
Repair or replace any damaged wiring or
terminals. Securely reconnect wires.
Wires between pressure
control switch and control
board are pinched.
Motor armature is shorting. Check for shorts using armature tester (growler)
or perform spin test, Motor Diagnostics, page
24. If shorts are evident, replace motor using
Motor Kit, page 22.
Control board is damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A bad motor
armature can burn out a good
motor control board.
See Control Board Diagnostics, page 25.
Replace control board if damaged using Control
Board Kit, page 22.

Advanced Troubleshooting
18 309226M
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.
NOTE: Remove enclosure
mounting screws and pull
enclosure away from drive
housing. Take care not to pull
on leads from electrical cord
and power switch.
Sprayer electrical cord is
damaged.
1. Unplug sprayer electrical cord.
2. Disconnect black electrical cord wire at
power switch.
3. Unplug in-line connection white cord wire.
4. Plug in electrical cord.
5. Test voltage between black and white
wires. Meter must read 85 to 130V AC.
6. Replace electrical cord if no voltage.
Sprayer power switch
damaged.
1. Unplug sprayer electrical cord.
2. Disconnect black control board wire at
power switch.
3. Check resistance of switch with ohmmeter.
4. Reading must be infinity with power switch
OFF.
5. Reading must be zero with power switch
ON.
6. Replace power switch if damaged.
Also see Basic Electrical Problems and Sprayer Wiring Problems, page 16.
Specific Problem Cause Solution
General Problem: Erratic Motor Operation
Specific Problem Cause Solution
Sprayer quits after running for
5 to 10 minutes
Electrical outlet is damaged Reset building circuit breaker or replace building
fuse.
Electrical outlet supplying
wrong voltage
Try another outlet. Check electric supply with volt
meter. Meter must read 85 to 130V AC. If voltage
is too high, do not use outlet until corrected.
Also see Basic Electrical Problems and Sprayer Wiring Problems, page 16.
Motor is overheating See Motor is Hot, page 14.
Motor is hot and runs
intermittently.
See Basic Troubleshooting, page 12.

Advanced Troubleshooting
309226M 19
General Problem: Low or Fluctuating Output
Specific Problem Cause Solution
Pump cycles, but output is low
or surging.
See Basic Troubleshooting,
page 12.
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 25.
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•m). Replace if parts are worn using
Prime/Spray Drain Valve Kit, page 22.
Voltage from electrical outlet is
too low. Low voltages reduce
sprayer performance.
Check voltage of outlet. Meter must read 85 to
130V 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
6.
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 0.25 in. (6.4mm). If brushes are
worn replace motor using Motor Kit, page 22.
Motor brush springs are
broken.
If springs are broken replace motor using Motor
Kit, page 22.
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 22.
Motor armature shorted. Check for shorts using armature tester (growler)
or perform spin test, Motor Diagnostics, page
24. If shorts are evident, replace motor using
Motor Kit, page 22.

Advanced Troubleshooting
20 309226M
Control board is damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A bad motor
can burn out a good control
board.
See Control Board Diagnostics, page 25. If
damaged replace control board using Control
Board Kit, page 22.
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. Pump Service, page 25.
Pump packings are worn or
damaged.
Check for leaking around throat packing nut.
Replace pump packings if there are leaks. Pump
Service, page 25.
Prime/Spray Valve leaking. Check Prime/Spray Valve for debris trapped on
seat and for worn parts. Torque to 185 in-lb (21
N•m). If parts are worn, replace valve using
Prime/Spray Drain Valve Kit, page 22.
Spray pattern has variations,
pressure fluctuates
excessively, or motor runs very
slowly.
Leads from motor or pressure
switch to control board are
damaged, loose or overheated
Be sure terminals are centered and firmly
connected. Inspect wiring insulation and terminals
for signs of overheating. Replace any loose
terminals or damaged wiring. Securely reconnect
terminals.
Pressure control switch leads
are pinched between pump
and drive housing or between
front cover and drive housing
(XR models only)
Make sure pressure control harness is routed
behind pump, through retention clip and
connected to control board connector on control
board (connect with tab to right).
Control board is damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A bad
armature can burn out a good
control board.
See Control Board Diagnostics, page 25. If
damaged, replace control board using Control
Board Kit, page 22.
Pressure control switch is
damaged or worn out.
Replace pressure control switch using Pressure
Control Switch Kit, page 22.
Specific Problem Cause Solution