AIRLESSCO LP 400 Use and care manual

For application of architectural paints and coatings. For professional use only. Not
approved for use in European explosive atmosphere locations.
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
For model information, see page 2.
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
Gun Manual
312363 - English
312364 - Spanish
312365 - French
Operation/Repair/Parts
LP 400/500/600/700
Mustang 5100/8100
Airless Paint Sprayer
3A1185H
EN

Models
2 3A1185H
Models
Vac HiBoy Stand LoBoy
120V
North America
24F568 LP500 - Series B
24F571 LP600 - Series B
24F581 Mustang 5100 - Series B
24F583 Mustang 8100 - Series B
24F567 LP500 - Series C
24F579 Mustang 5100 - Series C
24F569 LP500 - Series C
24F570 LP600 - Series C
240V
Europe
16M373 LP500 - Series A
16M374 LP600 - Series A
16M375 LP700 - Series A
16M371 LP400 - Series A
16M372 LP500 - Series A
110V
UK
16M380 LP500 - Series A
16M381 LP600 - Series A
16M382 LP700 - Series A
16M378 LP400 - Series A
16M379 LP500 - Series A
230V
Australia
16M393 LP600 - Series A 16M389 LP400 - Series B
16M390 LP500 - Series B
16M391 LP500 - Series B
16M392 LP600 - Series B
230V Asia 17M002 LP600 - Series A 17M000 LP400 - Series A
17M001 LP500 - Series A
230V CN 17M005 LP600 - Series A 17M003 LP400 - Series A
17M004 LP500 - Series A
ti16111a ti16113a
ti16112a

Warnings
3A1185H 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
ARNINGARNINGARNING
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GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that
is properly installed and grounded in accordance with all local codes and ordinances.
! Improper installation of the grounding plug is able to result in a risk of electric shock.
! When repair or replacement of the cord or plug is required, do not connect the grounding wire to either
flat blade terminal.
! The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
! Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
! Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a
qualified electrician.
! This product is for use on a nominal 120V or 230V circuit and has a grounding plug similar to the plug
illustrated in the figure below.
! Only connect the product to an outlet having the same configuration as the plug.
! Do not use an adapter with this product.
Extension Cords:
! Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that
accepts the plug on the product.
! Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG
(2.5 mm2) minimum to carry the current that the product draws.
! An undersized cord results in a drop in line voltage and loss of power and overheating.
120V US 230V

Warnings
4 3A1185H
ARNINGARNINGARNING
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FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as
cigarettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity
creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray
system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall
be properly grounded to protect against static discharge and sparks. Use Airlessco conductive or
grounded high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump
assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets
(MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents
manufacturer•s safety instructions.
• Fire extinguisher equipment shall be present and working.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
ELECTRIC SHOCK HAZARD
This equipment must be grounded.Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.

Warnings
3A1185H 5
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
! Do not aim the gun at, or spray any person or animal.
! Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with
any part of the body.
! Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
! Use Airlessco nozzle tips.
! Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure, page 8 for turning off the unit and relieving the
pressure before removing the nozzle tip to clean.
! Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure, page 8 for turning off the unit.
! Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
! This system is capable of producing 3000 psi. Use Airlessco replacement parts or accessories that are
rated a minimum of 3000 psi.
! Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
! Verify that all connections are secure before operating the unit.
! Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
! Always wear appropriate gloves, eye protection, and a respirator or mask when painting.
! Do not operate or spray near children. Keep children away from equipment at all times.
! Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
! Stay alert and watch what you are doing.
! Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure, page 8 for turning off the unit.
! Do not operate the unit when fatigued or under the influence of drugs or alcohol.
! Do not kink or over-bend the hose.
! Do not expose the hose to temperatures or to pressures in excess of those specified by Airlessco.
! Do not use the hose as a strength member to pull or lift the equipment.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
! Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
! Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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Warnings
6 3A1185H
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure, page 8 and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause
cancer, birth defects or other reproductive harm.
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Component Identification
3A1185H 7
Component Identification
A
B
C
D
E
ti17301a
A Power switch Turns sprayer ON and OFF
B Pressure Control Knob Adjusts pressure. Turn clockwise to increase pressure and
counterclockwise to decrease pressure.
C Prime/Pressure Relief Valve Primes pump and relieves pressure from gun, hose and tip.
D Prime/Pressure Relief Valve Open
Position
Relieves pressure from gun, hose and tip and primes the unit
when in the open position. Valve is in open position when there
is a wider gap between valve handle and cam body.
Refer to Pressure Relief Procedure page 8.
E Prime/Pressure Relief Valve Closed
Position
Pressurizes system when closed. Valve is in closed position
when there is a slight gap between valve handle and cam body.

Operation
8 3A1185H
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage the gun trigger lock. Refer to the separate
instruction manual provided with gun for safety fea-
tures and how to engage the trigger lock.
2. Turn the unit off.
3. Disengage the gun trigger lock and trigger the gun
to relieve residual fluid pressure.
Hold metal part of the gun in contact with
grounded metal pail. Use minimum pressure.
4. Re-engage gun trigger lock and turn Prime/Pres-
sure Relief Valve (PR Valve) to the open (priming)
position to relieve residual pressure.
There will be a wider gap between valve handle
and cam body when in open position. In the
closed position there is only a very slight gap.
NOTE: The valve handle can move both clockwise and
counter clockwise and can face different directions.
If the spray tip or hose is clogged, follow Steps 1
through 4 above. Expect paint to splash into the
bucket while relieving pressure during Step 3.
NOTE: If you suspect that pressure hasn’t been relieved
due to damaged Prime/Pressure Relief Valve, or other
reason, slowly loosen the tip nut or hose coupling to
relieve pressure.
Setup
Connect the hose and gun
1. Remove the plastic cap plug from the outlet and
screw a conductive or grounded 3000 psi spray
hose onto fluid outlet.
2. Connect an airless spray gun to the other end of the
hose. Do not install spray tip.
NOTE: Do not use thread sealer on swivel unions as
they are made to self seal.
Fill the Packing Nut/Wet Cup
1. Remove guard and cap.
2. Fill the Packing Nut/Wet Cup with 5 drops of Air-
lessco Throat Seal Oil (TSO) or Packing Seal fluid.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
ti15989a
Closed
(Pressure)
Open
(Priming and Pressure Relief)
ti17403a
• To reduce the risk of static sparking, fire or
explosion which can result in serious bodily injury
and property damage. Always ground the sprayer
and system components and the object being
sprayed, as instructed in the safety warning
section of this manual.
• Ensure proper electrical service and amperage
and that the outlet is properly grounded.
• For generator power, a minimum 7000 watt
generator with a voltage regulation must be used.
ti16049a

Operation
3A1185H 9
Flush the Sprayer
1. Flush the sprayer. See Flushing Procedure on
page 9.
Prime and Flush Storage Fluid
Before beginning a new spraying project you need to
prime the sprayer and flush the storage fluid out of the
sprayer.
Oil- or Water-based Materials
! When changing from water-based material to oil
based material, flush with soapy water and then
mineral spirits.
! When changing from oil based material to water
base material, flush with mineral spirits, followed by
soapy water, then a clean water flush.
! When flushing with solvents, ground pail and gun.
! Flush before changing colors, before fluid can dry in
the equipment, at the end of the day, before storing,
and before repairing equipment.
Flushing
1. Make sure the gun trigger lock is engaged and there
is no spray tip in the gun. Refer to the separate
instruction manual provided with gun for safety fea-
tures and how to engage the trigger lock.
2. Pour enough clean, compatible solvent into a large,
empty metal pail to fill the pump and hoses.
3. Place the suction tube into the pail or place the pail
under the pump.
4. Turn Pressure Control Knob to low.
5. Open the prime/pressure relief valve to the open -
"Priming Position#. This will allow an easy start.
6. Turn the engine ON/OFF switch to ON.
7. Point the gun into the metal pail and hold a metal
part of the gun firmly against the pail. Maintain firm
metal to metal contact between gun and container.
8. Disengage the gun trigger lock and squeeze the
trigger. At the same time, slowly turn the pressure
NOTICE
The equipment was tested with lightweight oil,
which is left in the fluid passages to protect parts.
To avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using
the equipment for the first time.
! To reduce the risk of static sparking, which can
cause fire or explosion, always hold a metal part of
the gun firmly against the metal pail when flushing.
This also reduces splashing.
! Always remove the spray tip before flushing.
ti16028a
ti16048a
High Pressure
ti17403a
Closed
(Pressure)
Open
(Priming and Pressure Relief)
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Operation
10 3A1185H
control knob clockwise, just enough to move liquid
at low pressure.
9. Allow the pump to operate until clean solvent comes
from the gun.
10. Release the trigger and engage the gun trigger lock.
11. If you are going to start spraying, place the pump or
suction tube into the supply container. Release the
gun trigger lock and trigger the gun into another
empty, metal container, holding a metal part of the
gun firmly against the metal pail, forcing the solvent
from the pump and hose. When paint starts coming
from gun, turn pressure control knob to minimum
pressure, place prime/pressure relief valve in prime
(open) position and engage the gun trigger lock.
12. If you are going to store the sprayer, remove the
suction tube or pump from the solvent pail, force the
solvent from the pump and hose. Engage the gun
trigger lock. See Storage, page 11.
13. Whenever shutting down the sprayer, follow Pres-
sure Relief Procedure, page 8.
Startup
1. Prepare the material according to the material man-
ufacturer’s recommendations.
2. Place the suction tube into the material container.
3. Start the sprayer.
a. Prime/PR Valve must be "OPEN# in the prim-
ing position.
b. After ensuring the gun trigger lock is engaged,
attach tip and safety guard.
c. Turn the engine ON/OFF switch to the "ON#
position.
d. Turn the Pressure Control Knob clockwise to
prime the pump.
e. After the pump is primed, turn the Prime/PR
Valve to the "CLOSED# position.
f. Turn Pressure Control Knob to the desired
spray pressure.
g. Disengage the gun trigger lock to begin spray-
ing.
Adjusting the Pressure
When adjusting the pressure, turn the Pressure Control
Knob clockwise to increase pressure and counterclock-
wise to decrease pressure. Always use the lowest pres-
sure necessary to completely atomize the material. If
more coverage is needed, use a larger tip rather than
increasing the pressure.
NOTE: Operating the sprayer at higher pressure than
needed wastes material, causes early tip wear, and
shortens sprayer life.
NOTE: Check the spray pattern. The tip size and angle
determines the pattern width and flow rate.
NOTICE
To prevent damage and freezing during storage,
never leave water in the fluid pump
$ To reduce the risk of injection, never hold your
hand, body, fingers or hand in a rag in front of the
spray tip when cleaning or checking for a cleared
tip. Always point the gun toward the ground or into
a waste container when checking to see if the tip is
cleared or when using a self cleaning tip.
$ When you spray into the paint bucket, always use
the lowest spray pressure and maintain firm metal
to metal contact between the gun and container.
$ To stop the unit in an emergency, turn the engine
off. Then relieve the fluid pressure in the pump and
hose. See Pressure Relief Procedure, page 8

Maintenance
3A1185H 11
Shutdown
1. Relieve Pressure, page 8.
2. Clean the tip and gun as recommended in the sepa-
rate Gun Manual supplied with the gun.
3. If spraying water-based material or a material that
could harden in the sprayer overnight, flush the
sprayer after use. See Flushing, page 9.
Storage
Short Term
1. Flush sprayer with compatible solvent before stor-
ing, then fill the pump and hoses with an oil based
solvent such as mineral spirits.
! For oil base paint: flush with mineral spirits
! For water-base paint: flush with water, then min-
eral spirits and leave the pump, hose and gun
filled with mineral spirits.
Long Term
For longer storage, use Graco Pump Armor or mineral
spirits. Shut off sprayer, Relieve Pressure, page 8, and
make sure prime/pressure relief valve is left open.
Start Up After Storage
Before using water-base paint, flush sprayer with soapy
water and then a clean water flush. When using oil-base
paint, flush out the mineral spirits with the material to be
sprayed.
NOTE: Always store unit indoors.
Maintenance
Daily Maintenance
1. Keep the displacement pump packing nut/wet cup
lubricated with Airlessco TSO (Throat Seal Oil) at all
times. The TSO helps protect the rod and packings.
2. Inspect the packing nut daily. If seepage of paint
into the packing nut and/or movement of the piston
upward is found (while not spraying), the packing
nut should be tightened just enough to stop leakage.
Overtightening will damage the packings and
reduce the packing life.
Electric Motor Maintenance
Lubrication
The motor is supplied with pre-lubricated ball bearings,
lubricated for the life of the bearing.
Motor Brushes
Motor brushes need periodic inspection and replace-
ment as wear indicates. Standard brushes have an ini-
tial length of 1" and should be replaced when they are
worn to a length of 1/2". Brush wear is greatly influenced
by individual application and it is recommended that
brush wear be checked at early intervals of operation in
order to determine future required inspection.
To change the brushes:
1. Unplug the machine.
2. Remove the cover over the motor, if applicable.
3. Open the two covers at the rear of the motor.
4. Disconnect the brush wire.
5. Pull out the wire.
6. Push the brush retainer clip in and withdraw.
7. Remove the worn brushes.
8. Install new brushes in the reverse order.
To increase brush life, new brushes (Part #331780)
need to have a run in period. After changing brushes,
set the machine for spraying. With a bucket of Pump
Conditioner and water, a 50$ 1/4" airless hose, airless
gun and tip on unit, open the prime/pressure relief valve
and switch on. The pump will now prime. With pump
running in the prime mode, turn the pressure control
knob to high pressure. (The pump has to cycle fast with
no pressure in the pump). Run the pump for 20 minutes
and the brushes will be run in.
Brush Kit
331780
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Maintenance
12 3A1185H
Servicing the Fluid Pump
Fluid Pump Disconnect
1. Relieve Pressure, page 8.
2. Flush the material you are spraying out of the
machine.
3. Remove the connecting rod shield (12).
4. Move the piston rod (10) to its lowest position by
cycling pump slowly.
5. Turn off the motor and disconnect power from unit.
6. Disconnect fluid tube (17) from pump body.
7. Remove the retaining ring (4) from the connecting
rod (2) and slide the sleeve (3) down revealing the
connecting rod pin (1).
8. Remove the suction tube assembly from the fluid
pump (9) by unscrewing the suction nut (7) with the
packing adjustment tool. (865008).
9. Using a 1/2! wrench, unscrew the two bolts (8) from
the cover assembly (14). The fluid pump (9) will be
hanging loosely at this point.
10. Remove the connecting rod pin (1) out of the con-
necting rod (2), allowing the removal of the fluid
pump (9) from the machine.
Fluid Pump Reinstall
1. Loosen the packing nut and ensure that the piston
rod (10) is in its upper position in the fluid pump
body, snap cap onto packing nut and slip the sleeve
(3) and the retaining ring (4) over the piston rod
(10).
2. Push the piston rod (10) up into the connecting rod
(2) and align the holes. Insert the connecting rod pin
(1) through the connecting rod (2) and piston. Slip
the sleeve (3) up over the connecting rod pin (1) and
insert the retaining ring (4) into the groove on the
connecting rod (2).
3. Push the two bolts (8) through the tube spacers (11)
and screw them into the cover assembly. Using a
1/2! wrench, tighten the two bolts (8) evenly (alter-
nating between them) until you reach 20 ft-lbs
(27.12 N.m).
4. Reassemble lower suction valve assembly by plac-
ing the suction seat, O-ring, suction ball and suction
ball guide in the suction nut (7) and screw onto fluid
pump body.
5. Reconnect the Fluid Tube (17) to the fluid pump
body.
6. Start the machine and operate slowly to check the
piston rod (10) for binding. Adjust the two bolts (8),
holding the fluid pump body to the cover assembly,
if necessary. This will eliminate any binding.
7. Tighten packing nut clockwise until resistance is felt
against the Belleville Springs, go 3/4 of a turn more.
Put five drops of Airlessco Throat Seal Oil in the
packing nut.
8. Run the machine at full pressure for several min-
utes. Release the pressure by following the Pres-
sure Relief Procedure, page 8, and readjust the
packing nut per step 7 above.
9. Install the connection rod shield (12) so the small
hole is in the upper right hand corner.
1
2
3
4
5
7
8
9
10
14
ti16053b
11
12
17

Maintenance
3A1185H 13
Servicing the Inlet Valve- Hi-Boy
1. Un-thread and remove suction nut from the fluid
pump body (8).
2. Remove suction seat (12), O-ring (11), suction ball
(10), and ball guide (9).
3. Clean all parts and inspect them for wear or dam-
age, replacing parts as needed.
4. Clean inside of the fluid pump body (8).
5. Reassemble lower suction valve assembly by plac-
ing the suction seat (12), O-ring (11), suction ball
(10) and suction ball guide (9) in the suction nut (13)
and screw onto fluid pump body (8).
Servicing the Inlet Valve- Lo-Boy
1. Un-thread and remove suction nut from the fluid
pump body (8).
2. Remove O-ring (158), suction seat assembly (157),
O-ring (159) and backup (160).
3. Clean all parts and inside fluid body (8).
4. Reassemble inlet valve with O-ring (159), backup
ring (160) and O-ring (158).
5. Tighten suction nut using packing adjustment tool
(865008).
Packing Replacement
Procedures
Disassembly of the Fluid Pump
1. Disconnect the Fluid Pump, page 12.
2. Unscrew and remove the packing nut, with wet cup
cap.
3. Push the piston rod down through the packings and
out of the pump.
4. Now push the packing removal tool up through the
pump and remove from the top bringing packings,
spacer and springs along with it, leaving fluid body
empty.
Make sure all old packings and glands have been
removed from fluid pump.
5. Clean inside of fluid body.
6. Disassemble all parts and clean for reassembly.
Discard any old packings.
7. Lubricate leather packing in lightweight oil for 10
minutes prior to reassembly.
Reassembly of the Fluid Pump
1. Place lower male gland(1) down on the flat side.
2. Take three of the lower polyethylene packings (2)
and two of the leather packings (23) and place onto
the male gland (1), with the inverted side down, in
the following order:
! Polyethylene
! Leather
! Polyethylene
! Leather
! Polyethylene
3. Take the female adaptor (3), which is inverted on
both sides, and place it on top of your assembled
lower packings.
4. Follow step 2 with your packings inverted side up.
5. Take the second lower male gland (1) and place it
on top of your assembled packings with rounded
side down.
6. Take assembled glands and packings (13 pieces)
and slide onto the lower half of the piston (14).
7. Take the spacer (15) and slide over the top of the
piston (14).
8. Take three spring washers (16) and slide over the
top of the piston (14) in the following order:
! First spring - curve facing up
! Second spring - curve facing down
! Third spring - curve facing up
9. Take the upper male gland (17) and place it
rounded side up.
9
10
11
12
13
159
160
157
15
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Maintenance
14 3A1185H
10. Take three upper polyethylene packings (18) and
two leather packings (22) and assemble with
inverted side down, on to the male gland (17) in the
following order:
• Polyethylene
• Leather
• Polyethylene
• Leather
• Polyethylene
11. Take upper female gland (19) and place on top of
assembled upper packings with the inverted side
down.
12. Take assembled upper glands and packings (7
pieces) and slide on over the top of the piston (14),
making sure inverted sides are down.
13. Take the packing holder (20) and replace the white
O-ring (24) and the black O-ring (25) with new ones
from the packing kit.
14. Slide the packing holder (20) over the top fo the
upper packings so they fit inside.
15. Lubricate inside of the fluid pump body (4) and the
outside of the packings with a light weight oil.
16. Slide assembly into fluid pump body.
NOTE: To keep packings secured in correct position,
hold the pump body upside down and push the com-
pleted assembly upwards into the pump body. Once
placed inside, tilt pump body back up to keep all pieces
in.
17. Tighten packing nut (21) onto the top of the fluid
pump body and tighten until you feel slight resis-
tance against the Belleville Springs (16). Using the
Packing Adjustment Tool, tighten another 3/4 of a
turn.
18. Reinstall Fluid Pump, page 12.
2
3
4
22
222
59
60
57
58
9
8
7
6
5
23232323
4
5
3
2
0
666
7
888 2222
9
24
25
20
2
26
ti16056b

Maintenance
3A1185H 15
Gear and Pump Assembly
Servicing Gear box Assembly
1. Remove fluid pump. See Fluid Pump Disconnect,
page 12.
2. Remove frame from the gearbox by loosening the
four mounting screws.
3. Separate cover assembly (13) from box by remov-
ing bolts (1) from front of cover and back of box and
shoulder bolts (2) from front of cover and back of
box.
4. Lay unit on its back and disassemble gearbox.
5. Inspect bearings (14, 17), Crosshead Assembly
(15), Gearcrank (16) and sleeve bearing (10) inside
cover assembly (15) for wear/damage. Replace
worn/damaged parts.
6. If gear grease needs replacing, replace with gear
grease (Part No. 114819).
7. Clean mating surfaces of cover and box thoroughly.
Apply Loctite®518 on half the bottom surface of end
bell.
8. Reassemble in reverse order.
Replacement of Electrical
Components
NOTE: Anytime the pressure control assembly, sensor,
or both are replaced, perform the calibrations.
Pressure Control Assembly (Electrical
Control Board)
1. Unplug machine’s power cord.
2. Remove six screws heatsink housing.
3. Disconnect all leads from pressure control assem-
bly.
4. Reassemble in reverse order.
Sensor
1. Remove the four screws, heatsink, and lower the
pressure control assembly.
2. Disconnect sensor lead from the board.
3. Unscrew sensor by holding sensor with 3/4" wrench.
4. Reassemble in reverse order.
Potentiometer
1. Lower pressure control assembly as described
above.
2. Disconnect potentiometer lead from pressure con-
trol assembly.
3. Use a 1/16" allen wrench, loosen set screw in the
poteniometer knob and remove knob and spacer.
4. Using a 1/2" wrench or deep socket, remove the nut
from the potentiometer shaft assembly.
ti22326a
1
12
2
13 15
11
14
17
1
16
2
6
4
5
8
10
Always unplug the electrical cord before servicing the
machine.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.

Maintenance
16 3A1185H
5. Pull entire potentiometer assembly out of the termi-
nal box.
6. Replace in reverse order.
On-Off Toggle Switch
1. Lower the pressure control assembly as described
above.
2. Disconnect the two wires on the toggle switch.
3. Use a 9/16” wrench to loosen the nut on the toggle
switch shaft.
4. Reassemble in reverse order.
Liquid Crystal Display (LCD)
1. Lower pressure control assembly as described
above.
2. Unscrew the two nuts (M3) and remove LCD Dis-
play assembly.
3. If unable to loosen the two nuts, hold them and
unscrew the two screws. Then remove the LCD Dis-
play Assembly.
4. Reassemble in reverse order, while making sure
that the two spacers and the two washers are in
place. Tighten the two nuts handtight and seal with
blue loctite. Do not overtighten the nuts as this will
damage the display.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.
NOTICE
Unit will not operate if wires are disconnected or
pinched. Upon reassembly, ensure all wires are
connected and not pinched.

Troubleshooting
3A1185H 17
Troubleshooting
Problem Cause Solution
Unit doesn’t prime Airleak due to loose suction nut Tighten suction nut.
Airleak due to worn o-rings Replace o-ring (108526) on suction seat and
o-ring (867370) below suction seat.
Airleak due to hole in suction
hose
Replace suction hose.
Stuck or fouled balls Service inlet and outlet valves.
Unit primes but has poor or no
pressure
Pressure set too low Turn up pressure.
Filter(s) are clogged Clean or replace gun filter, inlet filter, and/or
manifold filter.
Outlet valve fouled/worn. Service outlet valve.
Prime/pressure relief valve
bypassing
Clean or replace prime/pressure relief valve
(866428).
Packings and/or piston worn Tighten packing nut, repack unit.
Unit does not maintain good
spraying pressure
Blown spray tip Replace spray tip.
Packings and/or pistons worn Repack unit.
Upper seat worn Replace upper seat.
Unit does not run Blown fuse Replace fuse 20A Slow Blow (331328).
Machine does not start Control Settings Make sure machine is plugged into the wall.
Verify the on-off switch is in the ON position
and the pressure control knob is turned all the
way to the right (clockwise for maximum pres-
sure).
Pressure Control Assembly
(Board)
If the power indicating light is still out after
checking the control settings and power
source, replace the pressure control assem-
bly.

Troubleshooting
18 3A1185H
Motor Remove the motor brush covers and turn the
machine ON. Set the potentiometer (POT) at
maximum pressure and check for DC voltage
across both brush terminals. It should read
greater than 80 volts DC.
If you have DC voltage, turn the machine off
and unplug it from the wall. Check to make
sure the brushes are making good contact
with the armature. Replace the brushes if they
are less than 1/2” long. If the brushes are
good, replace the motor.
If you do not have DC voltage, see Sensor.
Sensor Plug another sensor board into the board and
perform the zero calibration procedure. If the
machine starts to run, the sensor is bad. If
there is no replacement sensor available, use
a multi-meter to test the resistance across the
red and black wires of the sensor (be sure to
test the plug). You should read 1.5 - 3.5k
ohms. A faulty sensor usually reads no conti-
nuity (open).
If the sensor passes all the tests, see Pres-
sure Control Knob (Potentiometer).
Pressure Control Knob (Poten-
tiometer)
Plug another potentiometer (POT) into the
control board. If the machine starts, the old
POT is bad.
When a replacement POT is not available,
remove the POT lead (with the machine
turned off) from the control board and test the
resistance between the red and black wires
(be sure to test at the plug). The resistance
should read between 8-12k ohms. If it is out-
side of this range replace the POT.
If there is DC voltage at the motor brushes
and the sensor and pressure control knob are
functioning, replace the pressure control
assembly.
Problem Cause Solution

Troubleshooting
3A1185H 19
Pressure Control Repair
Motor Control Board Diagnostics
NOTE: Keep a new transducer on hand to use for test.
1. For sprayers with digital display, see Digital Dis-
play Messages, page 20
2. Remove four screws and cover.
3. Turn ON/OFF switch ON.
4. Observe LED operation and reference following
table:
Relieve pressure and unplug sprayer before
servicing control board. See Pressure Relief
Procedure, page 8.
NOTICE
Do not allow sprayer to develop fluid pressure with-
out transducer installed. Leave prime/pressure
relief valve open if test transducer is used.
LED
BLINKS SPRAYER OPERATION INDICATES WHAT TO DO
Once Sprayer runs Normal operation Do nothing
Two times
repeatedly
Sprayer shuts down and
LED continues to blink two
times repeatedly
Run away pressure. Pressure
greater than 4500 psi (310 bar,
31 MPa) or damaged pressure
transducer.
Replace motor control board or
pressure transducer.
Three times
repeatedly
Sprayer shuts down and
LED continues to blink four
times repeatedly.
Pressure transducer is faulty or
missing
Check transducer connection.
Open prime/pressure relief valve.
Substitute new transducer for
transducer in sprayer. If sprayer
runs, replace transducer.
Four times
repeatedly
Sprayer shuts down and
LED continues to blink four
times repeatedly.
Line voltage is too high Check for voltage supply prob-
lems
Five times
repeatedly
Sprayer does not start or
shuts down and LED con-
tinues to blink five times
repeatedly
Motor fault Check for locked rotor, shorted
wiring or disconnected motor.
Repair or replace failed parts.
Six times
repeatedly
Sprayer shuts down and
LED blinks six times
repeatedly
Motor is too hot or there is a
fault in the motor thermal
device
Allow sprayer to cool. If sprayer
runs correctly when cool, check
motor fan function and air flow.
Keep sprayer in cool location. If
sprayer does not run when cool
and continues to blink 6 times,
replace motor.
Eight times
repeatedly
Sprayer stops or does not
run
High input voltage Check power source for correct
voltage

Troubleshooting
20 3A1185H
Digital Display Messages (Series B)
No display does not mean that sprayer is not
pressurized. Relieve pressure before repair. See
Pressure Relief Procedure, page 8
DISPLAY SPRAYER OPERATION INDICATION ACTION
No Display Sprayer stops. Power is
not applied. Sprayer may
be pressurized.
Loss of power Check power source. Relieve
pressure before repair or disas-
sembly.
Sprayer is pressurized.
Power is applied. (Pres-
sure varies with tip size
and pressure control set-
ting.)
Normal operation Spray
Sprayer may continue to
run. Power is applied.
Pressure greater than 4500 psi
(310 bar, 31 MPa) or pressure
transducer faulty
Replace pressure control board or
pressure transducer
Sprayer stops. Power is
applied.
Pressure transducer faulty, bad
connection or broken wire.
Check transducer connection.
Open prime/pressure relief valve.
Substitute new transducer for
transducer in sprayer. If sprayer
runs, replace transducer.
Sprayer stops. Power is
applied.
Line voltage too high Check for voltage supply problem
Sprayer does not start or
stops. Power is applied.
Motor fault / High Current Check for locked rotor, shorted
wiring or disconnected motor,
frozen or stuck pump. Repair or
replace failed parts.
Sprayer stops. Power is
applied.
Motor is too hot Allow sprayer to cool. If sprayer
runs correctly when cool, check
motor fan function and air flow.
Keep sprayer in cool location. If
sprayer does not run when cool
and continues to blink 6 times,
replace motor.
Sprayer stops or does not
run.
Low input voltage Check power source for correct
voltage.
Power is applied. Pressure less than 200 psi (14
bar, 1.4 MPa)
Increase pressure if desired.
Prime/pressure relief valve may
be open.