AIRLESSCO SP200 - Manual (Page 22)

Advanced Troubleshooting
22 3A0997F
Pump cycles, but output is low
or surging. Leads from motor or pressure
switch to control board are
damaged, loose, pinched, or
overheated. Be sure terminals are centered and firmly con-
nected. 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 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 26.
Motor brush springs are bro-
ken. If springs are broken, replace motor using Motor
Kit, page 26.
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 Con-
trol Switch Kit, page 26.
Control board is damaged.
CAUTION: Do not perform
control board diagnostics until
you have determined the
armature is good. A damaged
armature can burn out a good
control board.
See Control Board Diagnostics, page 25. If
damaged, replace control board using Control
Board Kit, page 26.
Motor runs and pump cycles,
but pressure does not build
up. Intake valve or outlet valve is
not seating properly. Remove and clean inlet valves and outlet valves.
Replace if necessary. See List of Kits, page 26.
Pump packings are worn or
damaged. Check for leaking around pump.
SP300, Mustang 3100: Replace pump pack-
ings. See List of Kits, page 26.
SP200, Mustang 2400: Replace complete
pump. See List of Kits, page 26.
General Problem: Excessive Pressure Build Up
Prime/Spray Valve actuates
automatically, relieving pres-
sure through drain tube. Pressure control switch has
pinched wires. Replace pressure control switch using Pressure
Control Switch Kit, page 26.
Water or paint entered pres-
sure control switch or shorted
control board. Use Pressure Control Switch Kit, to replace
switch. See List of Kits, page 26.
Control board failed. See Control Board Diagnostics, page 25.
Replace damaged control board using Control
Board Kit, page 26.