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 counter-clockwise 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 counter-clockwise 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. |
| |
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 |