Graco DutyMax 24M054 Assembly instructions

Repair
DutyMax™Hydraulic Sprayers 3A2247A
EN
-For professional use only -
- Not approved for use in European explosive atmosphere locations -
Models: 24M054 (EH200DI), 24M055 (GH200DI), 24M056 (EH300DI), 24M057 (GH300DI)
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
See page 3 for model information.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
3A2246
311845
3A2248
308491 - Blue Texture Gun
309495 - Inline Texture Gun
ti18188a

23A2247A
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Repair Information . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric Motor Starter . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Motor Rebuild . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic Oil/Filter Change . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32

Models
3A2247A 3
Models
Electric Motor Kit Options
24M054 ✔✔
24M055 ✔✔
24M056 ✔✔
24M057 ✔✔
GH200DI GH300DI EH200DI
240 VAC
50 Hz
1 Phase
EH300DI
CSA
400VAC
50 Hz
3 Phase
BLUE GUN
1/4 in. x 3 ft WHIP
3/8 in. x 50 ft HOSE
INLINE GUN
3/8 in. x 12 in. WHIP
1/2 in. x 50 ft HOSE
Kit Number Sprayer Model Description
24M666 EH200DI Gas Conversion Kit
24M667 EH300DI Gas Conversion Kit
24M668 GH200DI Electric Conversion Kit
24M669 GH300DI Electric Conversion Kit

Models
43A2247A
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 on 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.
DANGER
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Improper contact with high voltage equipment will cause death or
serious injury.
• Turn off and disconnect power cord before servicing equipment.
• This equipment must be grounded. Connect only to grounded power source.
• Use only 3-wire extension cords for 240V and single phase models.
• Use only 5-wire extension cords for 400 AC and three phase models.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.

Models
3A2247A 5
WARNING
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:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and
can ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are
antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 Graco 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.
• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
• This system is capable of producing 3300 psi. Use Graco replacement parts or accessories that are
rated a minimum of 3300 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.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Models
63A2247A
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 and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-
turer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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 prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or flu-
ids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
SUCTION HAZARD
Powerful suction could cause serious injury.
• Never place hands near the pump fluid inlet when pump is operating or pressurized.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death.
• Do not operate in an enclosed area.
WARNING

Models
3A2247A 7
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.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye
injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not lim-
ited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

General Repair Information
83A2247A
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts are not normally provided with replacement
assemblies.
• Test repair after problem is corrected.
• If sprayer does not operate properly, review repair
procedure to verify procedure was done correctly. If
necessary, see Troubleshooting, page 10, for
other possible solutions.
• Install belt guard before operation of sprayer and
replace if damaged. Belt guard reduces risk of
pinching and loss of fingers; see preceding warning.
• Install hydraulic motor shield before operation and
replace if damaged. Hydraulic motor shield reduces
risk of pinching and loss of fingers; see preceding
warning.
Grounding
Ground sprayer with grounding clamp to earth ground
for safe sprayer operation.
SAE O-Ring Installation
1. Unscrew lock nut to touch fitting.
2. Lubricate o-ring (A).
3. Screw in fitting hand tight.
4. Unscrew fitting until oriented properly.
5. Tighten lock nut to indicated torque. (Make sure
washer is seated properly without pinching o-ring).
D
A
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Improper
contact with high voltage equipment will cause death or
serious injury.
• Turn off and disconnect power cord before
servicing equipment.
• This equipment must be grounded. Connect only to
grounded power source.
• Use only 3-wire extension cords for 240V and
single phase models.
• Use only 5-wire extension cords for 400 AC and
three phase models.
• Ensure ground prongs are intact on power and
extension cords.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
To reduce risk of serious injury, do not touch moving
parts with fingers or tools while testing repair. Shut
off sprayer when repairing. Install all covers,
gaskets, screws and washers before operating
sprayer.
6250
A
ti5414a
ti5415a
ti5416a
ti5417a
DANGER

Pressure Relief Procedure
3A2247A 9
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Set pump valve OFF.
2. Turn gas engine or electric motor OFF.
3. Unplug power cord.
4. Turn pressure to lowest setting. Trigger gun into
pail to relieve pressure.
5. Turn prime valve down.
If after following these steps you suspect the spray tip or
hose is still clogged or that pressure has not been fully
relieved, very slowly loosen tip guard retaining nut or
hose end coupling to relieve pressure gradually. Then
loosen completely.
Maintenance
NOTE: For detailed engine maintenance and specifica-
tions, see separate Honda owner’s engine manual (sup-
plied).
DAILY: Check hydraulic oil level and fill as necessary.
DAILY: Check gas engine oil level and fill as necessary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper operation.
DAILY: Check that displacement pump is tight.
DAILY: Check level of Throat Seal Liquid (TSL) in dis-
placement pump packing nut. Fill nut, if necessary. Keep
TSL in nut to help prevent fluid buildup on piston rod and
premature wear of packings and pump corrosion.
W E E K LY /DA I LY: Remove any debris or media from
hydraulic rod.
AFTER EACH 100 HOURS OF OPERATION: Change
engine oil (see Honda engine owner’s manual for correct
oil viscosity).
SEMI-ANNUALLY:
Check belt wear, replace if necessary.
YEARLY OR 2000 HOURS: Replace belt.
Replace hydraulic oil and filter with Graco hydraulic oil
169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter)
and filter 116909.
SPARK PLUG: Use only BPRGES or W20EPR-U
(NIPPONDENSO) plugs. Gap plug to 0.028 - 0.031 in
(0.7 - 0.8 mm). Use spark plug wrench when installing or
removing plug.
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.
ti9686a
OI
I
O
OFF
ON
Electric Models
Single Phase
Electric Models
Three Phase
Gas Models
ti7529a
ti18812a
TIA
ti5266b

Troubleshooting
10 3A2247A
Troubleshooting
PROBLEM CAUSE SOLUTION
Gas engine pulls hard (won't start) Hydraulic pressure is too high Turn hydraulic pressure knob counter clockwise
to lowest setting.
Gas engine does not start Switch OFF, low oil, no gasoline Consult engine manual, supplied.
Gas engine doesn't work properly Faulty engine Consult engine manual, supplied.
Elevation Consult engine manual, supplied.
Electric motor does not start or
starts slowly
No power Check power source; check circuit breakers
and/or fuses. Reset/replace as required.
Cord not connected to power source Connect plug to receptacle (grounded with
properly sized circuit breaker and/or fuses).
Switch OFF 1 phase motors: Turn on/off switch to ON.
3 phase motors: Push ON switch.
Incorrect power source Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
NOTE: If using the EH300DI (24M056) sprayer,
the generator must be sized for 15 kW
output minimum.
Incorrect amp setting on motor starter (3
phase motor only)
Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
Over current switch has tripped Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
Hydraulic pressure is too high Turn hydraulic pressure knob counter clockwise
to lowest setting.
Electric motor does not work
properly
Incorrect power source Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
Low voltage to motor Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
3 phase motors: A phase of three phase
power has open circuit
Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.
Faulty motor Have a certified electrician or authorized Graco
Repair Center evaluate and repair.
See Technical Data, page 30.

Troubleshooting
3A2247A 11
Gas engine / electric motor operates
but displacement pump does not
operate
Hydraulic pump valve is OFF Set hydraulic pump valve ON.
Pressure setting too low Increase pressure, page Operation manual.
Displacement pump outlet filter (if used)
is dirty or clogged
Clean the filter.
Tip or tip filter (if used) is clogged Remove tip and/or filter and clean.
Hydraulic fluid too low Shut off sprayer. Add fluid*.
Belt is off pulley, worn or broken Replace. See Repair manual.
Hydraulic pump worn or damaged Bring sprayer to Graco distributor for repair.
Dried paint seized paint pump rod Service pump. See manual 311845.
Hydraulic motor not shifting Set pump valve OFF. Turn pressure down. Turn
engine OFF. Pry rod up or down until hydraulic
motor shifts. See Repair manual.
For 3 Phase electric motor only: Red
phase sequence light is ON, indicating
motor rotating in the wrong direction
Remove plug from receptacle and rotate plug
phase screw. See Operation manual.
Displacement pump operates, but
output is low on upstroke
Piston ball check not seating properly Service piston ball check. See manual 311845.
Piston packings worn or damaged Replace packings. See manual 311845.
Displacement pump operates but
output is low on downstroke and/or
on both strokes
Piston packings worn or damaged Tighten packing nut or replace packings.
See manual 311845.
Intake valve ball check not seating
properly
Service intake valve ball check. See manual
311845.
Displacement pump air leak
Paint leaks and runs over side of
wetcup
Loosen wet-cup Tighten wet-cup enough to stop leakage.
Throat packings worn or damaged Replace packings. See manual 311845.
Excessive leakage around hydraulic
motor piston rod wiper
Piston rod seal worn or damaged Replace these parts. See Repair manual.
Fluid delivery is low Pressure setting too low Increase pressure, see Operation manual.
Displacement pump outlet filter (if used)
is dirty or clogged
Clean filter.
Hydraulic motor is worn or damaged Bring sprayer to Graco distributor for repair.
Large pressure drop in fluid hose Use larger diameter or shorter hose.
Sprayer overheats Paint build up on hydraulic components Clean hydraulic components.
Oil level is low Fill with oil. See Operation manual.
Inlet to hydraulic pump pulley/cooling fan
is obstructed
Remove obstructions.
Inlet to 3 phase electric motor cooling fan
is obstructed.
Remove obstructions.
Spitting from gun Air in fluid pump or hose Check for loose connections on siphon
assembly, tighten, then reprime pump.
Fluid supply is low or empty Refill supply container.
Excessive hydraulic pump noise Low hydraulic fluid level Turn sprayer OFF. Add fluid*.
Air in hydraulic lines Bleed lines. See Repair manual.
*Check hydraulic fluid level often. Do not allow it to become too low. Use only Graco approved hydraulic fluid.
PROBLEM CAUSE SOLUTION

Hydraulic Pump
12 3A2247A
Hydraulic Pump
Removal
Let hydraulic system cool before beginning service.
1. Relieve pressure, page 9.
2. Place drip pan or rags under sprayer to catch
hydraulic oil that leaks out during repair.
3. Remove drain plug (202) and oil filter (227) and
allow hydraulic oil to drain.
4. Remove screw (172), nut (173) and belt guard
(117).
5. Raise electric motor (or gas engine) and remove
belt (44).
6. Remove two set screws (197) and fan pulley (96).
7. Remove case drain tube (225).
8. Remove elbow (221).
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.
ti18348a
227
202
ti18349a
173
117
172
ti18350a
44
ti18351a
197
96
197
ti18352a
225
ti18353a
221

Hydraulic Pump
3A2247A 13
9. Remove hose (276) from elbow (226). Remove
elbow (226) from hydraulic pump (220).
10. Remove hydraulic hose (288) from reservoir cover
(209).
11. Remove eight screws (212) reservoir cover (209) fil-
ter assembly (206) and gasket (203).
12. Remove four screws (277) and hydraulic pump
(220) from reservoir cover (209).
Installation
1. Install hydraulic pump (220) to reservoir cover (209)
with four screws (277) (ensure o-rings 210 and 211
are in place); torque 90 - 110 in-lb (10 - 12 N•m).
2. Install gasket (203) filter assembly (206) and
reservoir cover (209) with eight screws (212).
Torque 110 - 120 in-lb (12 - 14 N•m).
3. Install hydraulic hose (288) to reservoir cover (209).
4. Install elbow (226) in hydraulic pump (220). Install
hose (276) in elbow (226). Torque to 15 ft-lb (20.3
N•m).
5. Install elbow (221); torque to 15 ft-lb (20.3 N•m).
6. Install case drain tube (225); torque to 15 ft-lb (20.3
N•m).
7. Install fan pulley (96) with two set screws (197).
8. Raise electric motor (or gas engine) and install belt
(44).
9. Install belt guard (117) with screw (172) and nut
(173).
10. Install drain plug (202). Install oil filter (227); tighten
3/4 turn after gasket contacts base. Fill hydraulic
pump with Graco hydraulic oil, page 6, through
elbow (221) port until full. Fill reservoir with remain-
ing hydraulic oil.
11. Start up and allow pump to operate at low pressure
for approximately 5 minutes to purge all air.
12. Check oil hydraulic oil and top off, if required.
ti18354a
220
226
276
ti18355a
209
288
ti18356a
212 209
206
203
ti18357a
209
220
277

Fan Belt
14 3A2247A
Fan Belt
Removal
1. Perform Pressure Relieve Procedure, page 9.
2. Loosen belt guard knob (55).
3. Rotate belt guard (117) up.
4. Lift electric motor or gas engine up to remove ten-
sion on belt (44).
5. Remove belt from pulley (43) and fan pulley (96).
Installation
1. Thread belt (44) around drive pulley (43) and fan
pulley (96).
2. Let electric motor (119) down to put tension on belt.
3. Rotate belt guard (117) down.
4. Tighten belt guard knob (55).
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 Proce-
dure when you stop spraying and before cleaning,
checking, or servicing the equipment.
ti18342a
117
44
119
43
55
96
Belt Table
Unit Part Number Description
24M054 116914 V-Belt AX42
24M055 119433 V-Belt AX41
24M056 125834 V-belt AX48
24M057 119432 V-Belt Ax44

Electric Motor Starter
3A2247A 15
Electric Motor Starter
Removal
3 Phase, 400 VAC, 50 Hz, Electric Motor Starter
1. Relieve pressure, page 9. Unplug power cord.
2. Remove Fan Belt, page 14.
3. Loosen electric motor nut (205). Swing motor
retainer bracket (204) out.
4. Remove motor assembly from sprayer.
D
A
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Improper
contact with high voltage equipment will cause death or
serious injury.
• Turn off and disconnect power cord before
servicing equipment.
• This equipment must be grounded. Connect only to
grounded power source.
• Use only 3-wire extension cords for 240V and
single phase models.
• Use only 5-wire extension cords for 400 AC and
three phase models.
• Ensure ground prongs are intact on power and
extension cords.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
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.
204
205
43
30
119
175
30
190
192 191
193
ti18617a
200
195
198
ti5384a
ti18749a
DANGER

Electric Motor Starter
16 3A2247A
5. Remove motor junction box cover (J).
6. Tilt motor junction box cover back and disconnect
three power leads (brown, black, and grey wires)
and the yellow and green ground wire (see Wiring
Diagram, page 29).
7. Remove cable strain relief fitting (S) from motor
junction cover and pull motor power leads and motor
ground wire from motor junction cover.
8. Remove six screws (200) from motor mounting
bracket (195).
9. Remove motor starter assembly (198).
Installation
3 Phase, 400 VAC, 50 Hz, Electric Motor Starter
1. Install motor starter (198) on motor starter bracket
(195).
2. Install six screws (200), into motor starter (198).
Torque screws to 20 in-lb (2.3 N•m).
3. Remove motor junction box cover (J).
4. Remove strain relief fitting (S) from motor junction
box cover (J).
5. Slide strain relief fitting (S) over motor cable power
leads.
6. Screw strain relief fitting (S) into motor junction box
cover (J).
ti18700a
S
J
204
205
43
30
119
175
30
190
192 191
193
ti18617a
200
198
195
ti18700a
S
J

Electric Motor Starter
3A2247A 17
7. Be sure gasket is in position on motor junction box
cover. Connect yellow and green ground wire to
motor junction box ground connection. Connect
power leads as follows:
• Brown wire to motor terminal U1
• Black wire to motor terminal V1
• Grey wire to motor terminal W1
See Wiring Diagram, page 29, for connection
locations. Torque power leads to 28 in-lb (3.2 N•m).
Torque ground lead to 28 in-lb (3.2 N•m).
8. Install motor junction box cover (J) to motor junction
box. Torque junction box cover to 28 in-lb (3.2 N•m).
9. Install motor assembly on sprayer.
10. Swing electric motor retainer bracket (204) in.
Tighten electric motor nut (205).
11. Install Fan Belt, page 14.
12. Check to make sure fan pulley and motor pulley are
in line. Also check to make sure fan pulley shaft and
motor pulley shaft are parallel. Adjust as required.
NOTICE
Make sure wires are completely inside motor junction
box and will not be pinched between motor junction
box and motor junction box cover. Wires will be dam-
aged and create an electrical hazard if pinched.
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Electric Motor
18 3A2247A
Electric Motor Removal
1 Phase, 240 VAC, 50 Hz Electric Motor
1. Relieve pressure, page 9. Unplug power cord.
2. Remove Fan Belt, page 14.
3. Loosen electric motor nut (205). Swing motor
retainer bracket (204) out.
4. Remove motor assembly from sprayer.
5. Remove four screws (30), nuts (174), handle (175),
bottom isolator plate (190) and motor mounting
plate (99) from electric motor.
6. Loosen set screws (133) and remove pulley (43)
from electric motor.
D
A
HIGH VOLTAGE ELECTRIC SHOCK HAZARD
This equipment uses high voltage power. Improper
contact with high voltage equipment will cause death
or serious injury.
• Turn off and disconnect power cord before
servicing equipment.
• This equipment must be grounded. Connect only
to grounded power source.
• Use only 3-wire extension cords for 240V and
single phase models.
• Use only 5-wire extension cords for 400 AC and
three phase models.
• Ensure ground prongs are intact on power and
extension cords.
• Do not expose to rain. Store indoors.
• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
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 Proce-
dure when you stop spraying and before cleaning,
checking, or servicing the equipment.
119
204 99
193
191
192
174
190
175
30
133
43
205
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DANGER

Electric Motor
3A2247A 19
3 Phase, 400 VAC, 50 Hz, Electric Motor
1. Relieve pressure, page 9. Unplug power cord.
2. Remove Fan Belt, page 14.
3. Loosen electric motor nut (205). Swing motor
retainer bracket (204) out.
4. Remove motor assembly from sprayer.
5. Remove motor junction box cover (J).
6. Tilt motor junction box cover back and disconnect
three power leads (brown, black, and grey wires)
and the yellow and green ground wire (see Wiring
Diagram, page 29).
7. Remove cable strain relief fitting (S) from motor
junction cover and pull motor power lead (3) and
motor ground wire from motor junction cover.
8. Remove four screws (30), nuts (174) and handle
(175) from motor mounting bracket (99).
9. Remove four screws (23), nuts (174), and electric
motor (119) from motor mounting bracket (99).
10. Loosen set screws (2) and remove pulley (43) from
electric motor.
204
205
43
30
119
175
30
190
192 191
193
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200
198
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S
J

Electric Motor
20 3A2247A
Installation
1 Phase, 240 VAC, 50 Hz Electric Motor
1. Install pulley (43) and set screws (133). Torque set
screws to 60 in-lb (6.8 N•m). Make sure pulley is
flush with end of electric motor shaft.
2. Install handle (175), bottom isolator plate (190) and
rocker plate (99) to electric motor (119) with four
screws (30) and nuts (174). Motor should be posi-
tioned all the way forward on rocker plate. Torque
screws (30) to 225 in-lb (25.4 N•m).
3. Install motor assembly on sprayer.
4. Swing electric motor retainer bracket (204) in.
Tighten electric motor nut (205).
5. Install Fan Belt, page 14.
6. Check to make sure fan pulley and motor pulley are
in line. Also check to make sure fan pulley shaft and
motor pulley shaft are parallel. Adjust as required.
119
204 99
193
191
192
174
190
175
30
133
43
205
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Parallel
In Line
Fan Pulley (43)
Fan Pulley Shaft
Motor Shaft
Motor Pulley (133)
(end of motor pulley should
be flush with end of motor shaft)
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