Graco AIRLESSCO SP400 Hi Boy Operating instructions

3A1181B
ENG
Repair
Electric Airless Sprayers
For portable spray application of architectural paints and coatings. For professional use
only.
Not approved to European explosive atmosphere requirements.
Models
24F562(SP400 Hi Boy)
24F564 (Mustang 4700 Hi Boy)
24F561 (SP400 Stand)
24F563 (Mustang 4700 Stand)
3300 psi (22.7MPa, 227 bar) Maximum Working Pressure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
3A1180
312363 312365 312364
English Français Español
312362
ti11608a
ti16088a
SP400 Stand Model 24F561
Mustang 4700 Stand Model 24F563
SP400 HiBoy Model 24F562
Mustang 4700 HiBoy Model 24F564

Warnings
23A1181B
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, 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.
WARNINGWARNINGWARNING
WARNING
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 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.

Warnings
3A1181B 3
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.
WARNINGWARNINGWARNING
WARNING

Warnings
43A1181B
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.
SKIN INJECTION HAZARD
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 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 for turning off the unit.
• 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.
• 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.
WARNINGWARNINGWARNING
WARNING

Warnings
3A1181B 5
WARNINGWARNINGWARNING
WARNING
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 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.
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 7 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.

Installation
63A1181B
Installation
Grounding and Electric
Requirements
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
The sprayers require:
110-120V Units: 100-130 VAC, 50/60 Hz, 11A, 1 phase,
circuit with a grounding receptacle.
Never use an outlet that is not grounded or an
adapter.
Do not use the sprayer if the electrical cord has a dam-
aged ground contact. Only use an extension cord with
an undamaged ground contact.
Recommended extension cords:
• 110-120V: 3-wire, 12 AWG (2.5 mm2) minimum.
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent and Oil-based fluids: follow local code. Use
only conductive metal pails placed on a grounded sur-
face such as concrete. Do not place the pail on a non-
conductive surface such as paper or cardboard, which
interrupts grounding continuity.
Grounding the metal pail: connect a ground wire to the
pail by clamping one end to pail and other end to ground
such as a water pipe.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
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Pressure Relief Procedure
3A1181B 7
Pressure Relief Procedure
Follow this Pressure Relief Procedure whenever you
are instructed to relieve pressure, stop spraying, check
or service equipment or install or clean spray tip.
1. Turn OFF power and turn pressure control to lowest
pressure setting.
2. Hold gun against side of grounded metal flushing
pail. Trigger gun to relieve pressure.
3. Turn prime valve down.
If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure gradually,
then loosen completely. Clear hose or tip obstruction.
4. Engage trigger safety lock on gun if unit is being
shut down or left unattended.
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a
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General Repair Information
83A1181B
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Trouble-
shooting, page 9.
• Overspray may build up in the air passages.
Remove any overspray and residue from air pas-
sages and openings in the enclosures whenever
you service sprayer.
• Do not operate the sprayer without the motor shroud
in place. Replace if damaged. Motor shroud directs
cooling air around motor to prevent overheating and
insulates the control board from accidental electric
shock.
Flammable materials spilled on hot, bare, motor
could cause fire or explosion. To reduce risk of burns,
fire or explosion, do not operate sprayer with cover
removed.
To reduce risk of serious injury, including electric
shock:
• Do not touch moving or electric 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
• Do not run sprayer dry for more than 30
seconds. Doing so could damage pump
packings.
• Protect the internal drive parts of this sprayer
from water. Openings in the cover allow for air
cooling of the mechanical parts and
electronics inside. If water gets in these
openings, the sprayer could malfunction or be
permanently damaged.
• Prevent pump corrosion and damage from
freezing. Never leave water or water-base
paint in sprayer when its not in use in cold
weather. Freezing fluids can seriously damage
sprayer. Store sprayer with Pump Armor to
protect sprayer during storage.

Troubleshooting
3A1181B 9
Troubleshooting
Problem Cause Solution
Basic Fluid Pressure 1. Pressure control knob setting.
Motor will not run if set at mini-
mum (fully counter-clockwise).
Slowly increase pressure setting to
see if motor starts.
2. Spray tip or fluid filter may be
clogged.
Relieve pressure, page 7. Then
clear clog or clean gun filter. Refer
to gun instruction manual, 312363.
Basic Mechanical 1. Pump frozen or hardened paint Thaw sprayer if water or
water-based paint has frozen in
sprayer. Place sprayer in warm area
to thaw. Do not start sprayer until
thawed completely. If paint hard-
ened (dried) in sprayer, replace
pump packings. See Displace-
ment Pump Replacement, page
13.
2. Displacement pump connecting
rod pin. Pin must be completely
pushed into connecting rod and
retaining spring must be firmly in
groove or pump pin.
Push pin into place and secure with
spring retainer. See Displacement
Pump Replacement, page 13.
3. Motor. Remove drive housing
assembly. See Drive Housing
Replacement, page 15. Try to
rotate fan by hand.
Replace motor if fan won’t turn. See
Motor Replacement, page 27.

Troubleshooting
10 3A1181B
Basic Electrical
See wiring diagram, page 28
1. Electric supply. ON/OFF switch in
OFF position. Meter must read
100-130 Vac; 210-260 Vac.
Turn ON/OFF switch to ON position.
Reset building circuit breaker,
replace building fuses. Try another
outlet.
2. Extension cord. Check extension
cord continuity with volt meter.
Replace extension cord.
3. Sprayer power supply cord.
Inspect for damage such as bro-
ken insulation or wires.
Replace power supply cord. See
Power Cord Replacement, page
26.
4. Fuse. Check replaceable fuse on
control board (next to ON/OFF
switch).
Replace fuse after completing
motor inspection. See Fuse
Replacement, page 21.
5. Motor leads are securely fas-
tened and properly connected to
control board.
Replace loose terminals; crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.
6. Motor thermal switch. Yellow
motor leads must have continuity
through thermal switch.
Replace motor. See Motor
Replacement, page 27.
7. Brush cap missing or loose brush
lead connections.
Install brush cap or replace brushes
if leads are damaged. See Motor
Brush Replacement, page 18.
8. Brush length which must be
greater than 1/4 in. (6 mm).
NOTE: Brushes do not wear at
the same rate on both sides of
motor. Check both brushes.
Replace brushes. See Motor
Brush Replacement, page 18.
9. Motor armature commutator for
burn spots, gouges and extreme
roughness.
Remove motor and have motor
shop resurface commutator if possi-
ble. See Motor Replacement,
page 27.
10. Motor armature for shorts using
armature tester (growler) or per-
form Spin Test,page 16.
Replace motor. See Motor
Replacement, page 27.
11. Pressure control not plugged in
to control board.
Insert pressure control connector
into control board.
Problem Cause Solution

Troubleshooting
3A1181B 11
Low Output 1. Worn spray tip. Relieve pressure, page 7. Replace
tip. Refer to gun instruction manual,
312363.
2. Verify pump does not continue to
stroke when gun trigger is
released.
Service pump. See Displacement
Pump Replacement, page 13.
3. Prime valve leaking. Relieve pressure, page 7. Then
repair prime valve. See Drain Valve
Replacement, page 24.
4. Suction tube connections. Tighten any loose connections.
Check o-ring on suction tube.
5. Electric supply with volt meter.
Meter must read 100-130 Vac;
210-260 Vac. Low voltages
reduce sprayer performance.
Reset building circuit breaker;
replace building fuse. Repair electri-
cal outlet or try another outlet.
6. Extension cord size and length. Replace with a correct, grounded
extension cord. See Grounding
and Electric Requirements, page
6.
7. Leads from motor to circuit board
for damaged or loose wire con-
nectors. Inspect wiring insulation
and terminals for signs of over-
heating.
Be sure male terminal pins are cen-
tered and firmly connected to
female terminals. Replace any
loose terminals or damaged wiring.
Securely reconnect terminals.
8. Worn motor brushes which must
be greater than 1/4 in. (6 mm).
Replace brushes. See Motor
Brush Replacement, page 18.
9. Motor brushes binding in brush
holders.
Clean brush holders. Remove car-
bon dust by using compressed air to
blow out brush dust.
10. Low stall pressure. Turn pressure
control knob fully clockwise.
Replace pressure control assem-
bly. See Pressure Control Assem-
bly Replacement, page 22.
11. Motor armature for shorts by
using an armature tester
(growler) or perform Spin Test,
page 16.
Replace motor. See Motor
Replacement, page 27.
Problem Cause Solution

Troubleshooting
12 3A1181B
Motor runs and pump strokes 1. Prime Valve Open. Close prime valve.
2. Paint supply. Refill and reprime pump.
3. Intake strainer clogged. Remove and clean, then reinstall.
4. Suction tube leaking air. Tighten nut. Check o-ring on tube.
5. Intake valve ball and piston ball
are seating properly.
See Pump Manual 312362. Strain
paint before using to remove parti-
cles that could clog pump.
6. Leaking around throat packing
nut which may indicate worn or
damaged packings.
See Pump Manual 312362.
7. Pump rod damaged. See Pump Manual 312362.
Motor runs but pump does not
stroke
1. Displacement pump pin dam-
aged or missing.
Replace pump pin if missing. Be
sure retaining spring is fully in
groove all around connecting rod.
See Displacement Pump
Replacement, page 13.
2. Connecting rod assembly for
damage.
Replace connecting rod assembly.
See Displacement Pump
Replacement, page 13.
3. Gears or drive housing. Inspect drive housing assembly and
gears for damage and replace if
necessary. See Drive Housing
Replacement, page 15.
Motor is hot and runs intermittently 1. Be sure ambient temperature
where sprayer is located is not
more than 115°F (46°C) and
sprayer is not located in direct
sun.
Move sprayer to shaded, cooler
area if possible.
2. Motor has burned windings indi-
cated by removing positive (red)
brush and seeing burned adja-
cent commutator bars.
Replace motor. See Motor
Replacement, page 27.
3. Tightness of pump packing nut.
Overtightening tightens packings
on rod, restricts pump action and
damages packings.
Loosen packing nut. Check for leak-
ing around throat. Replace pump
packings if necessary. See Pump
Manual 312362.
Problem Cause Solution

Displacement Pump Replacement
3A1181B 13
Displacement Pump Replacement
See manual 312362 for pump repair instructions.
Removal
1. Relieve pressure, page 7. Unplug sprayer from
outlet.
2. Loosen two screws (11) and remove pail hanger
(10).
3. Loosen nut (37) and remove suction tube (39).
Loosen nut (B) and remove coupled hose (42).
4. Cycle pump until pin (31) is in position to be
removed.
5. Disconnect power cord from outlet.
6. Push up retaining spring (C). Push out pump pin
(31).
7. Loosen pump jam nut (34). Unscrew and remove
pump (33).
11
10
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42B
37
39 ti9139a
C
31
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34
33
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Displacement Pump Replacement
14 3A1181B
Installation
1. Extend pump piston rod fully. Apply grease to top of
pump rod (D). Install jam nut (34) on pump threads.
2. Install pump rod (D) into connecting rod (30).
3. Install pump pin (31). Verify retainer spring (30a) is
in groove over pump pin.
4. Push pump (33) up until pump threads engage.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet (E) to back.
7. Screw jam nut (34) up onto pump until nut stops.
Tighten jam nut by hand, then tap 1/8 to 1/4 turn
with a 20 oz (maximum) hammer to approximately
75 ft-lb (102 N•m).
8. Install suction tube (39) and coupled hose (42).
Tighten nuts (37) and (B).
9. Fill packing nut with ASM Packing Seal®until fluid
flows onto top of seal. Install pail hanger (10) with
screws (11).
If pump pin works loose, parts could break off due to
force of pumping action. Parts could project through
air and result in serious injury or property damage.
NOTICE
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
D
34
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30
30
30a
31
33
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ti
E
34
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42
B
37
39 ti9139a
10
11
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Drive Housing Replacement
3A1181B 15
Drive Housing Replacement
Removal
1. Relieve pressure, page 7.
2. Remove pump (33). Displacement Pump Replace-
ment, page 13.
3. Disconnect power cord from outlet.
4. Remove two screws (11) and cover (32).
5. Remove screw (13) and four screws (4).
6. Pull drive housing (29) out of motor front endbell.
7. Remove gear cluster (27) and (26) and thrust bear-
ing (28) from drive housing.
Installation
1. Apply a liberal coat of grease to gears and needle
bearing surfaces. Install thrust bearing (28) and
gears (26) and (27) in motor front endbell.
2. Push drive housing (29) into motor front endbell.
Insert gear crank (27) through hole in connecting
rod (30).
3. Install four screws (4) and screw (13).
4. Install cover (32) with two screws (11).
5. Install pump (33). Displacement Pump Replace-
ment, page 13.
NOTICE
Do not drop gear cluster (27) and (26) when remov-
ing drive housing (29). Gear cluster may stay
engaged in motor front endbell or drive housing.
13
32
26
11
27
28
4
29
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Needle
Bearing Surfaces
27
26
28
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13
11
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32
4
30
27

Spin Test
16 3A1181B
Spin Test
See Wiring Diagrams, page 28.
To check armature, motor winding and brush electrical
continuity:
1. Relieve Pressure, page 7. Disconnect power cord
from outlet.
2. Hi-Boy Models Only - Disconnect high-pressure
hose at pump outlet (see page 13).
3. Remove two screws (4) and shroud (12).
4. Remove drive housing (29) (see page 15).
5. Disconnect motor connector (H).
Armature Short Circuit Test
Quickly turn motor fan by hand. If motor coasts two or
three revolutions before complete stop, there are no
electrical shorts. If motor does not spin freely, armature
is shorted. Replace motor, page 27.
Armature, Brushes, and Motor Wiring Open
Circuit Test (Continuity)
1. Connect red and black motor leads with test lead.
Turn motor fan by hand at about two revolutions per
second.
2. If uneven or no resistance, check for missing brush
caps, broken brush springs, brush leads, and worn
brushes. Repair as needed, page 18.
3. If still uneven or no resistance, replace motor, page
27.
4. Reattach motor connector (H).
5. Replace drive housing (see page 15).
6. Replace shroud (12) and two screws (4).
7. Hi-Boy Models Only - Connect high-pressure hose
at pump outlet (see page 14).
12
4
H
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Fan Replacement
3A1181B 17
Fan Replacement
Removal
1. Relieve Pressure, page 7. Disconnect power cord
from outlet.
2. Hi-Boy Models Only - Disconnect high-pressure
hose at pump outlet (see page 13).
3. Remove two screws (4) and shroud (12).
4. Remove spring clip (57b) on back of motor.
5. Pull off fan (57a).
Installation
1. Slide new fan (57a) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Install spring clip (57b).
3. Replace shroud (12) and two screws (4).
4. Hi-Boy Models Only - Connect high-pressure hose
at pump outlet (see page 14).
57b 57a
4
12
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Motor Brush Replacement
18 3A1181B
Motor Brush Replacement
See Wiring Diagram, page 28.
Removal
Replace brushes worn to less than 1/4 in. (6 mm).
Brushes wear differently on each side of motor, check
both sides.
1. Relieve pressure, page 7. Disconnect power cord
from outlet.
2. Hi-Boy Models Only - Disconnect high-pressure
hose at pump outlet (see page 13).
3. Remove two screws (4) and shroud (12) (see illus-
tration on page 17).
4. Disconnect motor connector (D) from control board
(18).
5. Cut tie wrap (F).
6. Locate two yellow wires (C). Cut each yellow wire at
the center.
7. Pry off two brush caps (A). Remove brushes (B)
from motor.
8. Discard old brush assembly.
9. Rotate fan by hand and blow compressed air into
top brush holder to remove brush dust.
NOTE: Place end of a shop vacuum hose over lower
brush holder. Turn on shop vacuum when you blow com-
pressed air into top brush holder.
Installation
NOTE: Use all new parts included in brush kit. Do not
reuse old parts if new replacement parts are provided.
1. Install new brushes (B) in motor with wires facing
toward front of motor. Install positive (red) brush
lead in top of motor and negative (black) brush lead
in side of motor.
2. Push each cap (A) into place over brush. Orient
each cap with the two projections on either side of
the brush lead. You will hear a snap when cap is
securely in place.
3. Strip approximately 1/4 inch (6 mm) of insulation
from end of each yellow wire (C) from motor.
4. Insert stripped end into end of a butt splice (E) on
new brush assembly.
5. Crimp ends of butt splice (E) around each wire. Pull
gently on each wire to be sure wire does not pull out
of butt splice.
6. Wrap new tie wrap around motor and wires only.
Trim off excess. Be sure pressure hose is not caught
in tie wrap.
7. Connect motor connector (D) to control board (18).
8. Replace shroud (12) and two screws (4) (see illus-
tration, page 17).
9. Hi-Boy Models Only - Connect high-pressure hose
at pump outlet (see page 14).
30
29
33
A
B
+
-
C
D
E
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D
A
Red
Black

Control Board Replacement
3A1181B 19
Control Board Replacement
See Wiring Diagram, page 28.
Removal
1. Relieve pressure, page 7. Disconnect power cord
from outlet.
2. Hi-Boy Models Only - Disconnect high-pressure
hose at pump outlet (see page 13).
3. Remove two screws (4) and shroud (12) (see illus-
tration, page 17).
4. Disconnect pressure control assembly connector
(A) from control board (18).
5. Disconnect motor connector (D) from control board
(18).
6. Remove three screws (11) securing control board to
housing (two are located on the front and one on the
back next to the power cord).
7. Pull control board out slightly and then slide control
board back and off of frame.
NOTE: Make sure power cord is free and not wrapped
around cord wrap.
8. Remove grommet and wires from strain relief.
NOTE: Ground wire remains attached to sprayer with
grounding screw.
9. Remove two power cord (C) connectors from control
board.
120V
A
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18 D
C
11
18
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18
Grommet
Strain
Relief
120V
A
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D
C

Control Board Replacement
20 3A1181B
Installation
1. Push grommet and power cord wires into strain
relief in control board (18).
2. Connect power cord connectors to terminals indi-
cated on control board (18).
NOTE: Route power cord (19) between coupled hose
(42) to filter manifold and sprayer frame.
3. Slide control board into place on side of motor front
endbell.
4. Replace three screws (11). Torque to 30-35 in-lb
(3.4-3.9 N.m).
5. Connect motor connector (D) and pressure control
assembly connector (A).
6. Install shroud (12) with two screws (4) (see page
17).
7. Hi-Boy Models Only - Connect high-pressure hose
at pump outlet (see page 14).
ti6122a
18
Grommet
Strain
Relief
120V
A
ti16079a
18 D
C
Bottom View of Sprayer
ti11555a
42
19
ti11553a
11
A
ti16079a
18 D
C