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General Repair Information
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, when
instructed to relieve pressure, follow the
Pressure Relief Procedure on page 8.
Tool List
These service tools are required.
12” adjustable wrench: pump
1/4” Allen wrench: filter plug
3/8” Allen wrench: pump manifold
3/16” Allen wrench: gear housing, legs, handle
5/64” Allen wrench: pressure adjustment knob
Phillipsr screwdriver: junction box, front cover, motor
shield
3/8” socket wrench: motor mount
5/8” socket wrench: drain valve, on/off switch boot,
piston
5/8” open end wrench: outlet fittings
13/16” socket wrench: drain valve
1-1/4” socket wrench: pump inlet valve
1/2” open end wrench: pump rod
11/16” open end wrench: piston jam nut
15/16” open end wrench: flats of inlet tube
1-3/4” open end wrench: pump jam nut
5/64” drive pin: drain valve pin
3” needle nose pliers: wiring, on/off switch
Hammer & punch: packing nut
Torque wrenches: various fasteners
Pipe wrench: suction tube
CAUTION
To reduce the risk of a pressure transducer malfunc-
tion, properly mate connectors and never pull on a
wire to disconnect it.
1. When disconnecting wires, use needle nose
pliers to separate mating connectors.
2. When reconnecting wires, center flat blade of
male connector in blade of female connector.
3. Route wires carefully and avoid pinching any
wires between covers.
CAUTION
Improper wire routing can result in poor sprayer
performance or damage to the pressure transducer.
4. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures.
5. Test your repair before regular operation to be
sure problem is corrected.
6. If sprayer does not operate properly, verify that
everything was done correctly. Also refer to Trou-
bleshooting Guide, page 14, to help identify other
possible problems and solutions.
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury, in-
cluding electric shock, DO NOT touch
any moving parts or electrical parts with
your fingers or a tool while inspecting the sprayer.
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.
WARNING
FIRE HAZARD
During operation, the motor and drive
housing become very hot and could burn
your skin if touched. Flammable materi-
als spilled on the hot, bare motor could cause a fire
or explosion.