Graco 16E778 User manual

3A0978A
Instructions
Gear/Drive Kit for Magnum X5, X7,
LTS 15, LTS 17 (Series B)
This manual contains kit installation instructions only
Kit: 16E778, 16E835
Pressure Relief Procedure
Important Safety Instructions
For detailed sprayer information and warnings,
see Operation manual 312001, 313034.
To help prevent injection injuries, follow this procedure
when you stop spraying and before you service or clean
the sprayer, remove parts, or repair leaks.
1. Turn Power switch OFF. Unplug sprayer.
2. Turn Spray/Prime valve to PRIME to relieve pressure. Turn
pressure control knob left (counterclockwise) to minimize
pressure.
3. Trigger gun.
4. Put trigger safety in safety ON position.
NOTE: Leave Spray/Prime valve in PRIME
position until you are ready to spray again.
If you suspect that the spray tip or hose is completely clogged or
that pressure has not been fully relieved after following the steps
above, VERY SLOWLY loosen the tip guard retaining nut or hose
end coupling to relieve pressure gradually. Then loosen it com-
pletely. Clear the tip or hose obstruction. ti15766a
ti11868a
ENG

23A0978A
Disassembly
1. Unplug electrical cord (A) and perform Pressure
Relief Procedure (see page 1, or Operation manu-
als 312001 or 313034).
2. Remove suction hose and drain tubes from pump.
3. Remove front cover screws (B) (T-30 Torx).
4. Remove side shroud screws (C) (T-20 Torx), and
remove left shroud (D). X7 and LTS 17 Only:
Remove underside shroud screw (E).
5. Loosen screw (F) retaining the green ground wire to
the back of the drive assembly and remove the
ground wire.
6. Disconnect all leads from control board (G), then
remove the power cord.
7. Remove right shroud (H) and front cover (J).
8. Remove fan cover (K) by gently prying adjacent to
the narrow retention bars with a flat blade screw-
driver to lift them up and over the retention hooks.
NOTE: Prying on the bars themselves can fracture
them.
9. Loosen two motor screws (T-20) then pull the motor
from the pump/drive assembly. NOTE: Bare careful
not to damage the cooling fan.
10. Remove gear cover (L). Remove the two screws (M)
at the bottom of the pump/drive assembly then
remove the pump/drive assembly.
11. Place the pump/drive assembly in a vise, with the
jaws clamping on the flat sides at the bottom of the
pump.
12. If the bearing on the motor shaft remains in the drive
assembly, remove it from the drive and replace it on
the motor.
13. Remove the remaining two screws (M) holding the
drive to the pump, then rotate the drive bracket
approximately 90°.
14. Pull the drive assembly and pump piston from the
pump. If necessary, tap on the shorter leg of the
drive with a plastic hammer to separate the parts.
Assembly
1. Apply a thin coat of oil to the pump piston and place
it partially into the pump. Apply some oil to the small
bronze bushing in the pump.
2. Verify the stud on the new drive assembly is still
pre-greased. If that lubricant has been lost, apply a
small amount of chassis grease to the drive pocket
in the piston.
3. Rotate the drive gear to bring the stud towards the
pump, then insert the stud into the piston pocket.
Align the drive shaft with the pump bushing, then
push the drive into the pump, rotating the gear to
draw the drive inward. Press the drive and pump
fully together (if necessary) by tapping on the bot-
tom of the drive with a plastic hammer to seat the
piston in the pump.
4. Insert the two screws (M) at the top of the drive.
Tighten to 80-90 in-lb.
5. Assemble the motor to the drive with its thermal
overload switch on the pressure control side of the
sprayer. Tighten the screws to 26-32 in-lb. NOTE:
The gear is internally lubricated; no grease is nec-
essary.
6. Route the motor leads through the ports in fan cover
(K), then snap the cover onto the motor.
7. Place the pump/drive/motor assembly on the
sprayer frame, then install the two screws (M) at the
bottom of the drive. Tighten to 80-90 in-lb. Replace
gear cover (L).
8. Route the pressure control harness through setting
indicator (N) then install the indicator around the
pressure control and snap together. Pass the har-
ness through the front cover (J), aligning the indica-
tor with the opening in the front cover as they are
positioned loosely on the pump.
9. Assemble right shroud (H) to the front cover with
two screws (B) and tighten to 26-32 in-lb.
Icons only table sample
ELECTRIC SHOCK HAZARD MOVING PARTS HAZARD
To reduce risk of serious injury, including electric
shock, do not touch moving or electrical parts with
fingers or tools while testing repair. Unplug sprayer
when power is not required for testing. Install all covers,
gaskets, screws, and washers before you operate
sprayer.
NOTICE
Prying between the pump and drive can damage the
drive and lead to failure of equipment.

3A0978A 3
10. Route the power cord and motor leads between the
motor and right shroud (H). Then connect all leads
to the control board (G). Press the strain relief on
power cord (A) into the recess in the right shroud
(H).
11. Align the hole at the bottom of right shroud (H) with
the holes in the pump and sprayer frame. Verify that
no electrical leads are pinched between the shroud
and motor, then install one side screw (C). Tighten
to 20-25 in-lb. X7 and LTS 17 Only: Install under-
side shroud screw (E) and tighten to 25-35 in-lb.
12. Install left shroud (D) to shroud (H) and the front
cover. Verify that no electrical leads are pinched
between the shroud halves then install side shroud
screws (C) (T-20). Tighten to 20-25 in-lb. Install
screws (B) through the front cover and tighten to
26-32 in-lb.
13. Replace the suction and drain hoses on the pump,
and secure with their clamps.
K
E
L
H
G
J
B
N
D
C
A
M
ti15767a

All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 3A0984
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
08/2010
Wiring Diagram
WIRING DIAGRAM
WHITE
BOARD WIRE
AUTO PRIME
POWERCORD
BLACK WIRE
POWERCORD
WHITE WIRE
10A FUSE
POWERCORD
GREEN WIRE
CHASSIS
GROUND
ON/OFF
SWITCH
PRESSURE
SWITCH
ti15763a