Troubleshooting
Troubleshooting
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
To reduce the risk of an injury, follow the Pressure
Relief Procedure on page 15 when you stop spray-
ing and whenever you are instructed to relieve the pressure.
Spray Pattern Troubleshooting
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Fluttering or spitting spray.
Cause Solution
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Clean or replace nozzle, page 30.
Improper spray pattern.
Streaks.
Air in fluid supply.
Damaged nozzle or air cap.
Check fluid source. Refill.
Replace, page 30.
Fluid buildup on air cap or nozzle.
Fan air pressure too high.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Clean. See page 20.
Decrease.
Increase viscosity.
Increase.
Increase.
Fluid too thick.
Too much fluid.
Did not apply 50% overlap.
Dirty or damaged air cap.
Reduce viscosity.
Decrease flow.
Overlap strokes 50%.
Clean or replace, page 30.
313227A 25
Troubleshooting
Gun Operation Troubleshooting
Problem Cause Solution
Excessive spray fog.
“Orange Peel” finish.
Fluid leaks from the fluid packing area
Air leaks from the air cap
Fluid leakage from the front of the gun
Atomizing air pressure too high.
Fluid too thin.
Atomizing air pressure too low.
Poorly mixed or filtered fluid.
Fluid too thick.
Worn packings or rod.
Worn piston stem o-rings (16e, 16f).
Replace; see page 34.
Worn or damaged packing rod (8).
Decrease air pressure as low as possible.
Increase viscosity.
Increase air pressure; use lowest air pressure necessary.
Remix or refilter fluid.
Reduce viscosity.
Replace packings or rod; see pages
32 or 33.
Replace; see page 32
Gun does not spray
Dirty air cap
Air leaks from manifold
Worn fluid seat.
Loose fluid nozzle (4).
Damaged nozzle o-ring (4b).
Low fluid supply.
Damaged air cap (3).
Dirty or clogged fluid nozzle (4).
Damaged fluid nozzle (4).
Replace fluid nozzle (4) and/or elec-
trode needle (7); see pages 30 to 31.
Tighten; see page 30.
Replace; see page 30.
Add fluid if necessary.
Replace; see page 30.
Clean; see page 30.
Replace; see page 30.
Piston (16) not actuating.
Check cylinder air. Check piston
u-cup (16d); see page 34.
Actuator arm (29) is out of position.
Check actuator arm and nuts. See
page 35.
Misaligned air cap (3) and fluid nozzle (4).
Damaged nozzle orifice.
Fluid is coming on before the air.
Manifold is not tight.
Fluid leaks at the quick-disconnect.
Manifold is not tight.
Fluid hose o-rings are worn or missing.
Clean fluid buildup off air cap and
fluid nozzle seat; see page 20.
Replace nozzle (4); see page 30.
Check actuator arm and nuts. See
page 35.
Tighten manifold screws (106).
Tighten manifold screws (106).
Inspect or replace o-rings.
26 313227A
Troubleshooting
Electrical Troubleshooting
Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.
Problem Cause Solution
Poor wrap.
Turbine air is not turned on.
(In general, a Pro Xs Waterborne gun will have less wrap than a Pro Xs solventborne gun.)
Booth exhaust velocity is too high.
Atomizing air pressure too high.
Turn on.
Reduce velocity to within code limits.
Decrease.
Fluid pressure too high.
Decrease.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Faulty gun resistance.
Resistance must be 1 megohm or less. Clean workpiece hangers.
See Test Total Gun Resistance on page 22.
Low fluid resistivity.
Fluid leaks from the packing (8d) and causes a short.
Check fluid resistivity, page 14.
Clean the packing rod cavity.
Replace the packing rod. See page
33.
Faulty turbine alternator.
The KV switch is stuck on low.
Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine
alternator. See page 39.
Check the switch actuation; replace if needed.
No voltage or low voltage reading on the gun ES display module
No power.
Damaged fiber optic cable or connection.
Turbine air is not turned on.
Poor wrap.
Replace power supply. See page 38.
Check; replace damaged parts.
Turn on.
See causes and solutions under Poor
Wrap, above.
Operator gets mild shock.
Operator not grounded or is near ungrounded object.
Gun not grounded.
See Grounding on page 12.
Operator gets shock from workpiece. Workpiece not grounded.
See Check Electrical Grounding on
page 13 and Test Total Gun Resis-
tance on page 22.
Resistance must be 1 megohm or less. Clean workpiece hangers.
313227A 27
