Troubleshooting Guide

*FAULT*	CAUSE	REMEDY
LED on dashboard stays on	No air pressure	Air pressure should be over 110 psi.	see "Pump does not reach pressure"
	Broken mainline tubing	Repair line and de-aerate when new piece of line is used	link
	Broken meter (internal; not visibly broken, but grease pooling beneath it)	Replace with same size meter	link
	Grease container empty and air bubbles in main system.	Fill reservoir and remove air from system	link
	Pressure switch giving no signal (pump is reaching pressure)	Check for wire ruptures or replace pressure switch
	Broken solenoid valve	Test; clean, replace if necessary	link
	System not reaching pressure	Check Ecostar pump pressure using pressure guage; should be approx. 1000 psi
	Broken Pump	Test Grease Pump	link
LED on dashboard is not on	Temporary Electrical Fault	Test timer, fuse and light. Re-set timer	link
Pump does not reach pressure	No air pressure	Air pressure should be over 110 psi. Run truck longer to build pressure
	Broken solenoid valve	Test; replace if necessary	link
	Broken timer	Test timer, fuse. Re-set timer	link
	Grease container empty and air in the pump.	Fill reservoir and remove air from system	link
	Piston does not move upwards	Disassemble Cylinder tube (part 37) and check piston (part 31)	link
Pressure drops quickly	Leak in the mainline	Check for broken mainline (look for pools of grease); repair with 5/16" connector	link
	Broken meter (internal)	Look for over-greased parts; replace meter	link
	Piston failure (air coming from airline vent at back of pump)	Disassemble Cylinder tube (part 37) and check/replace piston (part 31)	link
	Piston tube/seal failure (grease coming from airline vent at back of pump)	Disassemble Cylinder tube (part 37) and check/replace piston tube (part 27)	link
Timer does not work	Poor or interrupted connection	Check connections
	Short-circuit	Check contacts
	Broken fuse	Replace fuse; check contacts	link
	Broken timer	Test; Replace timer	link
Solenoid valve does not work, or does not work properly	Poor or interrupted electrical circuit	Check circuit, check manual override without the timer and check connections	link
	Blocked/dirty or bad connection	Check circuit, check manual override without the timer and check connections	link
	Water in the air tank freezing in the solenoid	Drain the air tank; test solenoid; replace if necessary	link
All bearings dry	Grease container empty	Fill reservoir and remove air from system	link
	Broken fuse or wire	Check contacts; repair or renew as necessary	link
	Broken solenoid valve or air tubing fractured	Check clean or replace valve and repair tubing	link
	Broken timer	Test; Replace timer	link
	Mainline (5/16") broken.	Repair line and de-aerate when new piece of line is used	link
	Wrong grease used (too thick)	Clean the reservoir and pump the old grease out of the system (remove end plugs from the manifolds). Refill with EP00 or EP0 and remove air from the system	link
One or more bearings are dry	Broken secondary line (3/16")	Repair/fit new line.	link
	Air in the system	Bleed air from the system	link
	Broken meter (usually internal)	Replace meter	link
	Lubrication frequency too low	Adjust the timer	link
	Wrong output from meter	Replace meter with higher output meter	link
One or more bearings have an excess of grease	Broken meter (usually internal)	Replace meter	link
	Lubrication frequency too high	Adjust the timer	link
	Wrong output from meter	Replace meter with lower output meter	link