Technical data

REPAIR SECTION INDEX
::
Procedure Page
The following tools are needed when repairing this
sprayer.
General Repair Notes.. .....................................
..2 1
Motor Brush Replacement
................................. ..22
Power Supply Cord Replacement
..........................
ON/OFF Switch Replacement.. ............................
$z
Bridge Rectifier Replacement
...............................
Circuit Breaker Replacement
................................ ;:
Circuit Board Replacement.. ...............................
.25
Pressure Control Replacement ............................
‘26
Stall Pressure Calibration ..................................
..2 7
Bearing Housing 8 Connecting Rod Replacement
.... .28
Drive Housing Replacement
................................. .
Motor Replacement..
....................................... ..36
Parts Drawing 8 List, Sprayer..
............................ .
Parts Drawing 8 List, Pressure Control
................... .
How To Order Replacement Parts.. ......................
.33
Phillips screwdriver
Small flatblade screwdriver
Needle nose pliers
Plastic mallet
Adjustable wrench
2” adjustable, open-end wrench
Torque wrench
l/4” hex key wrench
3116” hex key wrench
5/8” socket wrench
318” open end wrench
l/2” open end wrench
314” open end wrench
7/8” open end wrench
High quality motor oil
Bearing grease
NOTE: See separate manual 307-793 for displacement
pump repair.
For calibration procedure only:
3/8” ianition wrench
0.015”spray tip
High pressure, oil-filled test gauge, Part No. 820-455
5 gallon pail
Clean water
Mineral spirits
NEW 3ooo psi (210 bar) high pressure spray hose
GENERAL REPAIR NOTES “Y I; i “:- I ;‘,
Before repairing any part of the sprayer, read the follow-
ing general repair notes and the repair procedure. Be
sure you have the necessary tools and parts available.
1. When disconnecting wires in the pressure control
assembly, use needle nose pliers to separate mating
connectors.
When reconnecting the wires, be sure the flat blade
of the insulated male connector is centered in the
wrap-around blade of the female connector when
the connection is made.
wire could loosen the connector from the wire.
2. Route wires in the pressure control assembly
carefully through the legs of the U-shaped bourdon
tube, where appropriate, to avoid interfering with
the bourdon tube which moves as the pressure set-
ting changes and to avoid pinching the wires be-
tween the pressure control box and cover.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure control.
3. Keep all screws, nuts, washers, gaskets, and elec-
trical fittings removed during repair procedures.
These parts are not normally provided with replace-
ment assemblies.
4. Test your repair before regular operation of the
sprayer to be sure the problem is corrected.
If the sprayer does not operate properly, review the
repair procedure again to verify that everything was
done correctly. If necessary, refer to the
Troubleshooting Guide to help identify other possi-
ble problems and solutions.
WARNING
To avoid serious bodily injury, including electric
shock, DO NOT touch any moving parts or elec-
trical parts with your fingers or a tool while
inspecting the repair.
Shut off the sprayer and unplug it as soon as you
complete the inspection.
Reinstall all covers, gaskets, screws and washers
before operating the sprayer.
CAUTION
Do not run the sprayer dry for more than 36
seconds to avoid damaging the pump packings.
5. Reinstall the motor cover before regular operation
of the sprayer and replace it if it is damaged. The
cover directs cooling air around the motor to help
prevent overheating. It can also help prevent burns,
fire or explosion; see the WARNING, below.
WARNING
During operation, the motor becomes very hot
and could burn your skin if touched. Flammable
fluids and materials spilled on the hot, bare motor
could cause a fire or explosion. Always have the
motor cover in place during regular operation to
reduce the risk of burns. fire or exolosion.
820-047 21