Problem
|
Cause
|
Solution
|
| Engine
won’t start |
1. Engine switch
is OFF |
Turn engine
switch ON |
| 2. Engine is out
of gas |
Refill gas
tank. |
| 3. Engine oil
level is low |
Try to start
engine. Replenish oil, if necessary.
See Honda Engines Owner’s Manual. |
| 4. Spark plug
cable is disconnected or damaged |
Connect spark
plug cable or replace spark plug |
| 5. Cold engine |
Use choke |
| 6. Fuel shutoff
lever is OFF |
Move lever
to ON position |
| 7. Oil is seeping
into combustion chamber |
Remove spark
plug. Pull starter rope 3 or 4 times.
Clean or replace spark plug. Try
to start engine. Keep sprayer upright
to avoid oil seepage. |
| Engine
operates, but displacement pump
does not operate. |
Pressure control
switch is OFF. |
Turn pressure
control switch ON. |
| Pressure setting
is too low. |
Turn pressure
adjusting knob clockwise to increase
pressure. |
| Fluid filter is
dirty. |
Clean filter. |
| Tip or tip filter
is clogged. |
Clean tip or
tip filter. See gun instruction
manual. |
| Displacement pump
piston rod is stuck due to dried
paint. |
Repair pump. |
| Connecting rod
is worn or damaged. |
Replace connecting
rod. See page 8. |
| Drive housing
is worn or damaged. |
Replace drive
housing. |
| Electrical power
is not energizing field. |
Check wiring
connections. Reference control board
diagnostics. With pressure control
switch ON and pressure turned to
MAXIMUM, use a test light to check
for power between clutch terminals
on control board.
Remove black clutch wires from control
board and measure resistance across
wires. At 70 F, the resistance
must be between 1.2 0.2Ω (LL 3900);
1.7 0.2Ω (LL 5900); if not, replace
pinion housing.
Have pressure control checked by
and authorized Graco dealer. |
| Clutch is worn,
damaged, or incorrectly positioned. |
Replace clutch. |
| Pinion assembly
is worn or damaged. |
Repair or replace
pinion assembly, see pg 10. |
| Pump
output is low on upstroke |
Hose inlet screen
is clogged. |
Clean inlet
screen. |
| Piston ball is
not seating. |
Service piston
ball. |
| Piston packings
are worn or damaged. |
Replace packings. |
| O-ring in displacement
pump is worn or damaged. |
Replace o-ring. |
| Pump
output is low on down stroke or on
both strokes |
Hose strainer
is clogged. |
Clean strainer
screen. |
| Piston packings
are worn or damaged. |
Replace packings. |
| Intake valve ball
is not seating properly. |
Clean intake
valve. |
| Engine speed is
too low. |
Increase throttle
setting. |
| Clutch is worn
or damaged. |
Replace clutch |
| Paint
leaks into wetcup. |
Wetcup is loose. |
Tighten wetcup
just enough to stop leakage. |
| Throat packings
are worn or damaged. |
Replace packings. |
| Displacement rod
is worn or damaged. |
Replace rod. |
| Fluid
delivery is low. |
Inlet screen is
clogged. |
Clean inlet
screen. |
| Pressure setting
is too low. |
Increase pressure. |
Engine speed is
too low.
|
Increase throttle
setting. |
| Fluid filter,
tip filter or tip is clogged or
dirty. |
Clean filter. |
Large pressure
drop in hose with heavy
materials. |
Use larger
diameter hose and/or reduce overall
length of hose. Use of more than
100 ft of 1/4 in. hose significantly
reduces performance of sprayer.
Use 3/8 in. hose for optimum performance |
| Fluid
is spitting from gun. |
Air in pump or
hose. |
Check and tighten
all fluid connections. Reprime pump. |
| Tip is partially
clogged. |
Clear Tip |
| Fluid supply is
low or empty. |
Refill fluid
supply. Prime pump. Check fluid
supply often to prevent running
pump dry. |
| Pump
is difficult to prime. |
Air in pump or
hose. |
Check and tighten
all fluid connections. Reduce engine
speed and cycle pump as slowly as
possible during priming. |
| Intake valve is
leaking. |
Clean intake
valve. Be sure ball seat is not
nicked or worn and that ball seats
well. Reassemble valve. |
| Pump packings
are worn. |
Replace pump
packings |
| Paint is too thick. |
Thin the paint
according to the supplier’s recommendations. |
| Engine speed is
too high. |
Decrease throttle
setting before priming pump. |
| Clutch squeaks
each time clutch engages. |
Small irregularities
of new clutch surfaces grind together
and cause noise |
Clutch surfaces
need to wear into each other. Noise
will dissipate after a day of run
time. |
| High
engine speed at no load. |
Misadjusted throttle
setting. |
Reset throttle
to 3600–3800 engine rpm at no load. |
| Worn engine governor. |
Replace or
service engine governor. |
| Low
stall or run pressure shown on display. |
New pump or new
packings. |
Pump break-in
period takes up to 100 gallons
of material. |
| Faulty transducer. |
Replace transducer. |
| Excessive
paint leakage into throat packing
nut. |
Throat packing
nut is loose |
Remove throat
packing nut spacer. Tighten throat
packing nut just enough to stop
leakage. |
| Throat packings
are worn or damaged. |
Replace packings. |
| Displacement rod
is worn or damaged. |
Replace rod.
|
| Excessive leakage
around hydraulic motor piston rod
wiper. |
Piston rod seal
worn or damaged. |
Replace these
parts. |
| Distance
counter not operating properly. |
Trigger sensor
not set correctly. |
See "Spray
icon does not show on display when
fluid is sprayed". |
| Bad wiring connections. |
Check connector,
and reconnect |
| Distance sensor
not spaced correctly from gear. |
Adjust space
between sensor and gear to .050
-/+ .020 in. |
| Distance sensor
and gear not aligned. |
Remove tire,
and press in or pull out gear to
align sensor and gear. |
| Gear teeth missing
or damaged. |
Replace distance
gear/wheel. |
| Wire cracked or
broken. |
Replace sensor. |
| Mils
not calculating. |
Distance sensor. |
See "Distance
counter not operating properly". |
| Trigger sensor. |
See "Spray
icon does not show on display when
fluid is sprayed". |
| Gallon counter. |
See "Gallon
counter not working". |
| Bad or damaged
control board. |
Replace control
board. |
| Fluid spray starts
after spray icon is shown on display. |
Interrupter is
improperly positioned. |
Turn screw
counterclockwise until spray icon
synchronizes with fluid spray |
| Fluid spray starts
before spray icon is shown on display. |
Interrupter (164)
is improperly positioned. |
Turn screw
clockwise until spray icon is synchronized
with fluid spray |
| Spray
icon does not show on display when
fluid is sprayed. |
Loose connector. |
Check that
5-pin connector and reed switch
are properly connected |
| Interrupter is
improperly positioned. |
Turn screw
counterclockwise until spray icon
synchronizes with fluid spray. |
| Reed switch assembly
is damaged. |
Replace reed
switch assembly |
| Magnet on assembly
is missing. |
Replace reed
switch assembly |
| A connector on
wiring harness or on reed switch
(18) is damaged. |
Disconnect
reed switch and 5-pin connector
from back of control board.
Check continuity between pin 1 on
2-pin connector and pin 1 on 5-pin
connector. Check continuity between
pin 2 on 2-pin connector and pin
4 on 5-pin connector. If there is
no continuity in either case, replace
wiring harness.
If there is continuity in both cases
replace reed switch assembly |
| Cut or sliced
wire. |
Replace wiring
harness. |
| Control board
is damaged. |
Replace control
board. |
| Display is damaged. |
Replace display. |
| Spray
icon is always shown on display. |
Interrupter (164)
is improperly positioned. |
Turn screw
clockwise until spray icon is synchronized
with fluid spray. |
| Reed switch assembly
(18) is damaged. |
Replace reed
switch assembly |
| Pressure control
knob does not rotate. |
Knob is jammed. |
Pull back cover
where remote cable connects to hydraulic
pump and turn counter clockwise
(ccw) until free. |
| Pressure control
knob rotates freely with no pressure
change. |
Remote cable broken
or disconnected. |
Replace or
reconnect cable. |
| Engine bounces
when striping. |
Spring is broken,
loose or missing. |
Replace or
reconnect spring. |
| No
dots or poor dots with ghosting |
No
dots. |
Check that
solenoid power cord is plugged in.
|
| Check
Remote button. Verify Remote button
operation by changing angle in ANGLE
CALC display |
| Solenoid cartridge
bar is too far away from aerosol
marking can spray tip. Do Auto-Layout
Can Actuator Adjustment. |
| Poor dots or dots
with ghosting. |
Solenoid cartridge
bar is too close to aerosol marking
can spray tip. Do Auto-Layout Can
Actuator Adjustment. |
| Engine speed to
slow |
Engine speed
must be greater than 2600 rpm. |
| Aerosol can malfunctioning |
Check that
can sprays. Replace if not. |
| Solenoid
module malfunctioning |
Replace
solenoid module |
