Advanced Troubleshooting - Magnum XR Series Service Instructions Manual

See Electric Shock Hazard on
page 7.
NOTE: See Basic Troubleshooting on page 8 for the problems that are more easily remedied.
SPECIFIC PROBLEM
Power switch is on and
sprayer is plugged in, but sprayer is plugged in but
pump does not cycle.
Basic Mechanical
Problems
Basic Electrical Problems
10 309044

Advanced Troubleshooting

General Problem: Motor Does Not Operate
CAUSE
See Basic Troubleshooting page 8.
Paint is frozen or hardened in pump.
Motor is damaged.
Yoke is broken, because pump is locked up by
dried paint or worn packings.
Motor is overheated.
Electrical outlet is damaged.
Control board leads are improperly fastened or
improperly mated.
Motor brushes are worn.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
Motor armature commutator is damaged.
See Pressure Relief
Procedure on page 6.
SOLUTION
Unplug sprayer from electrical outlet.
NOTE: If frozen, do not try to start sprayer
until completely thawed, or damage to motor,
control board, and/or drivetrain may occur.
Make sure power switch (B) is OFF. Place
sprayer in warm area for several hours, then
plug in and turn on. Slowly increase pressure
setting to see if motor starts.
If paint hardened in sprayer, replace pump
packings and remove all residue from valves.
See Pump Service on page 20.
Remove gear, and try to rotate motor shaft by
hand. See Motor Diagnostics on page 16.
Replace motor if shaft will not turn.
See Motor Kit on page 18.
Repair as necessary.
See Gear/Yoke Kit on page 27.
Allow to cool for 30 minutes. Retry.
Reset building circuit breaker or replace
building 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.
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.
Check length of brushes. Brush length must
be 0.25 in. (6.4 mm) minimum. Replace motor
if brushes are worn.
See Motor Kit on page 18.
Check for burn spots, gouges and extreme
roughness. Have motor shop resurface
commutator if possible, or replace motor.
See Motor Kit on page 18.