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Advanced Troubleshooting 
12
309477F
Basic electrical problems
Motor overheated
Allow motor to cool for 30 minutes. Retry.
Electrical outlet is damaged
Reset building circuit breaker or replace building 
fuse. Try another outlet.
Check electric supply with volt meter. Meter must 
read 200-260V 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 6.4mm (0.25 in). If brushes are 
worn replace motor using Motor Kit, page 18.
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 18.
Motor armature shorting
Check for shorts using armature tester (growler) 
or perform spin test, Motor Diagnostic, page 19. 
If shorts are evident, replace motor using Motor 
Kit
, page 18.
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 19. 
Replace control board if damaged using Control 
Board Kit
, page 18.
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 200-260 V 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 200-260 V AC.
7. Replace power switch if no voltage.
Specific Problem
Cause
Solution