SprayTECH 1150 User manual

Diaphragm Pumps
1150
Piston Pumps
EP2105
EP2205
EP2300
EP2300se
EP2400
EP2510
GP2605
GP2905
HVLP
CS5100
CS8100
CS9100
Maxum II Gun
Diaphragm Pumps
1150
Piston Pumps
EP2105
EP2205
EP2300
EP2300se
EP2400
EP2510
GP2605
GP2905
HVLP
CS5100
CS8100
CS9100
Maxum II Gun

1
EP2300 Piston Pump
1297 © 1997 Wagner Spray Tech. All rights reserved. Form No. 0294724E
Model Numbers:
0294006 Cart Mount
0294036 Low Boy
SprayTECH
1770 Fernbrook Lane
Minneapolis, MN 55447
Owner's Manual

2
GROUNDING INSTRUCTIONS
Thisproductmustbegrounded.Intheeventofanelectrical
shortcircuit,groundingreducesthe riskofelectricshockby
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
pluggedintoanoutletthatisproperlyinstalledandgrounded
in accordance with all local codes and ordinances.
Ifrepairorreplacementofthecordorplug isnecessary,do
not connect the green 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 and must be connected to grounding pin.
Check with a qualified electrician or serviceman if the
groundinginstructions arenot completelyunderstood, orif
indoubtastowhethertheproduct isproperlygrounded.Do
not modify the plug provided; if it will not fit the outlet, have
the proper outlet installed by a qualified electrician.
Thisproductisforuseonanominal120voltcircuit,andhas
agrounding plugthat lookslike plugillustrated in sketch A.
Atemporaryadapterwhichlooksliketheadapterillustrated
in sketch B and C, may be used to connect this plug to a 2
polereceptacleasshowninsketchBifaproperlygrounded
outlet is not available. The temporary adapter should be
usedonlyuntilaproperlygroundedoutlet(sketchA)canbe
installed by a qualified electrician. The green colored rigid
ear lug, or the like extending from the adapter must be
connected to a permanent ground such as a properly
grounded outlet box cover. Whenever the adapter is used,
it must be held in place by a metal, screw.
(A)
(B)
(C)
WARNING
Improper installation of the
grounding plug can result in a
risk of electrical shock.
IMPORTANT
EXTENSION CORD SELECTION
If an extension cord is used, make sure it is of the three-conductor type with NEMA connectors so a continuous grounding circuit is
providedfrom toolto powercircuit receptacle.Also, besurethat theconductor sizeis largeenough toprevent excessivevoltagedrop
which will cause loss of power. A table of recommended extension cord sizes will be found below.
For nameplate ampere ratings which are between those given, use the extension cord recommended for the NEXT higher ampere
rating.
If an extension cord is to be used outdoors it must be marked with the suffixi W-A following the cord type designation. For example
— SJTW-A to indicate it is acceptable for outdoor use.
RECOMMENDED EXTENSION CORD SIZES FROM SERVICE ENTRANCE TO PUMP MOTOR.
NAMEPLATE AMPERE RATING
Cord
Lgth. 0 to 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
25Ft. 18 18 18 18 18 18 16 16 16 14 14 14 14 14 12 12
50Ft. 18 18 18 18 18 18 16 16 16 14 14 14 14 14 12 12I
25Ft. 18 18 18 18 18 18 16 16 16 14 14 14 14 14 12 12
100Ft. 18 18 18 16 16 16 16 16 14 14 14 14 14 14 12 12
125Ft. 18 18 16 16 16 14 14 14 14 14 14 12 12 12 12 12
150Ft. 18 16 16 16 14 14 14 14 14 12 12 12 12 12 12 12

3
CONTENTS
Safety Warnings......................................................... 4-6
Specifications.................................................................7
Initial Set-up...................................................................7
Purging & Priming..........................................................8
Operation....................................................................... 9
Setting the Pressure...................................................... 9
Using the Spray Gun....................................................10
Pressure Relief Procedure...........................................10
Prime the Sprayer with Paint....................................... 10
Spraying Technique.....................................................11
SAFETY PRECAUTIONS
This manual contains information which must be read and understood before using the equipment. When you come to an
area which has one of the following symbols, pay particular attention and make certain to heed the safeguard.
WARNING
Important safety information indicates a hazard which may cause serious injury or loss of life.
CAUTION
Important information that tells how to prevent damage to equipment or how to avoid causes of minor injuries.
Note: Gives important information which should be given special attention.
Clean-up.......................................................................12
Maintenance.................................................................13
Daily Maintenance......................................................13
Repacking the Fluid Section.......................................14
Motor Brush Replacement..........................................16
Trouble Shooting...........................................................17
Parts List...............................................................19 - 29
Accessories..................................................................30
Warranty........................................................Back Cover

4
• Maximum operating range of the gun - 3000 PSI fluid
pressure.
• NEVER aim the gun at any part of the body.
• NEVER allow any part of the body to come in contact
with the fluid stream. DO NOT come in contact with a
fluid stream created by a leak in the fluid hose.
• NEVER put hand in front of the gun. Gloves will not
provide protection against an injection injury.
• ALWAYS lock the gun trigger,shut fluid pump off and
releaseallpressurebefore servicing,cleaningtipguard,
changing tips, or leaving unattended. Simply turning off
the motor will not release pressure in the system. The
Prime Spray Valve must be turned to the position to
relieve the pressure. See Pressure Relief Procedure,
Page 10.
• ALWAYShavethetipguardinplacewhilespraying.The
tip guard provides some protection against injection
injuries but is mainly a warning device.
ALWAYS remove spray tip before flushing or cleaning
the system.
WARNING
PREVENTION
HAZARD
• NEVER use a spray gun which does not have a trigger
lock or trigger guard in place and in working order.
• All accessories must be rated at or above 3000 PSI
(Includes spray tips, guns, extensions, and hose).
Injection Injury - A high pressure stream of paint pro-
duced by this equipment can pierce the skin and
underlying tissues, leading to serious injury and pos-
sible amputation.
DONOTTREATASASIMPLECUT! Injection-
can lead to amputation. See a physician im-
mediately.
NOTE TO PHYSICIAN: Injection into the skin
is a traumatic injury. It is important to treat
the injury surgically as soon as possible. DO
NOT delay treatment to research toxicity.
Toxicity is a concern with some coatings
injected directly into the blood stream. Con-
sultation with a plastic surgeon or recon-
structive hand surgeon may be advisable.
•
• Painthosecandevelopleaks from wear,kinking,abuse
etc. A leak is capable of injecting material into the skin.
The paint hose should be inspected before each use.
• In case of skin injection, see physician immediately.

5
WARNING
HAZARD
Explosionorfire-Solventandpaintfumescanexplodeor
ignite causing property damage and or severe injury. • Exhaust and fresh air introduction must be provided to keeptheairwithinthesprayareafreefromaccumulation
of flammable vapors.
• Avoidallignitionsourcessuchasstaticelectricitysparks,
open flames such as pilot lights, hot objects such as
cigarettes,andsparks from connectinganddisconnect-
ing power cords and working light switches.
• Fire extinguishing equipment must be present and in
working order.
• Keep the pump away from spray area to avoid solvent
and paint fumes.
• High velocity flow of material through equipment may
develop static electricity. The equipment being used,
and objects in and around the spray area must be
properlygroundedtopreventstaticdischargeandsparks.
• Use only conductive or grounded high pressure fluid
hoses for airless applications. Be sure that gun is
grounded through hose connections.
• Follow the material and solvent manufacturer's safety
precautions and warnings.
• WHEN FLUSHING EQUIPMENT use lowest possible
pressure.
PREVENTION

6
• Halogenated hydrocarbon solvents such as methylene
chloride and 1,1,1 - Trichlorethane are not compatible
withaluminumandmaycauseanexplosion.Ifunsure of
a material’s compatibility with aluminum, contact your
coating's supplier.
• Some spray guns and accessories cannot be used with
halogenated hydrocarbon solvents. Be certain of com-
patibility before use with halogenated hydrocarbon sol-
vents.
• TheSprayTechEP2300pumpisNOTcompatibleforuse
withhalogenatedhydrocarbonsolvents. TheSprayTech
G-05, G-09, and G-10 guns must not be used with
halogenated hydrocarbon solvents.
WARNING
PREVENTION
HAZARD
Explosion hazard incompatible materials - May cause
property damage or severe injury.
General - May cause property damage or severe injury.
Hazardous vapors - Paints, solvents, insecticides, and
other materials may be harmful if inhaled causing se-
vere nausea, fainting, or poisoning.
• Readallinstructionsandsafetyprecautionsbeforeoper-
ating.
• Comply with all appropriate local, state and national
codes governing ventilation, fire preventive, and opera-
tion.
• The United States Government Safety Standards have
been adopted under Occupational Safety and Health
Act. These standards, particularly the General Stan-
dards, Part 1910 and construction Standard, Part 1926,
should be consulted.
• This high- pressure airless pump is designed to be used
with authorized SprayTech parts only. When using this
pump with parts that do not comply with the minimum
specifications and safety devices of the pump manufac-
turer, the user assumes all risks and liabilities.
• Before each use, check all hoses for cuts, leaks, abra-
sion or bulging of cover or damage or movement of
couplings. If any of these conditions exist, replace the
hose immediately. Never repair a paint hose. Replace it
with another grounded hose.
• Allhoses,swivels,guns,andaccessories used withthis
unit must be pressure rated at or above 3000 PSI.
• Usearespiratorormaskwheneverthereisachancethat
vapors may be inhaled. Read all instructions with the
mask to assure that it will provide the necessary protec-
tion against the inhalation of harmful vapors.

7
SPECIFICATIONS
MODEL EP2300
1. GPM----------------------------------------------------------2/3
2. Maximum pressure-------------------------------3000 PSI
3. Motor - electric ------------------------------------------1 HP
4. Amperage-------------------------------------------8.5 Amps
5. Cycle------------------------------------124 cycles per min.
6. Maximum Tip Size @2000 psi---------------------- .023"
(Latex paint)
1. Attach handle to cart using bolts and knobs provided.
Insert bolt through square hole in handle and then
through hole in cart leg. Secure with knob. Repeat
other side.
2. Remove protector cap on outlet fitting and install air-
lesshose.DONOTINSTALLSPRAYTIP(S)INGUN(S)
AT THIS POINT.
INITIAL SET-UP
The SprayTech EP2300 Piston Pump unit is fully assembled upon delivery. Follow these
simple steps for set-up: CART MOUNT/LOW BOY
LOWBOY
1. Remove the plug from the inlet elbow on the fluid
section.
2. Attach the suction set fitting into the inlet elbow on the
fluid section.
3. Attach the return line to the tube fitting at the dump
valve.
4. Remove protector cap on outlet fitting and install air-
less hose. DO NOT INSTALL SPRAY TIP(S) IN
GUN(S) AT THIS POINT.
SprayTech EP2300 Low Boy Piston Pump
Figure 1. SprayTech EP2300 Cart Mounted Piston Pump
7. Max. Hose Length @ 2000 PSI-----------------100 feet
8. Weight:
LowBoy--------------------------------------------------63 lbs.
Cart Mount--------------------------------------------- 64 lbs.
9. Dimensions:
Cart Mount -------------------------------30"Lx39''Hx21''W
LowBoy------------------------------------28L x 21H x 21W
(38H with Handle)
Figure 2. Install Siphon Tube

8
4. Set Prime/Spray Ball Valve to the Prime position.
Figure 5. Set Prime/Spray Ball Valve to Prime
5. Turn the ON-OFF switch to the ON position.
6. Graduallyincreasepressure byturningPressure Con-
trol Knob clockwise.
7. Watchforfluidtostartcomingthroughreturntube. Use
minimum pressure necessary to keep fluid flowing.
8. Whentestfluidispurged,soapywaterwillflowthrough
the return. Turn pressure down to minimum and
replace soapy water bucket with clear water.
9. Increase pressure again and let unit run until water
running through the return line is clear.
10. Decrease pressure. Replace clean water container
with bucket of latex paint.
11. Increasepressureslowlyuntilpaintcomesthroughthe
return tube. Place return hose back into operating
position above paint bucket. Keep recirculating until
the paint coming through the return tube is free of air
bubbles.
12.Decrease pressureto minimum setting(counter-clock-
wise). The unit is now ready to use. (See “Operating
the Sprayer, page 9.)
PURGING AND PRIMING
This unit is shipped with test fluid in the fluid section to
prevent corrosion during shipment and storage.
Forsprayingwithsolvent-basedpaint,thoroughflushingof
this material is not necessary.
If you are going to spray with LATEX paint, this fluid must
be thoroughly cleaned out of the system.
KEEP SPRAY GUN LOCKED AND IN THE OFF POSI-
TON DURING ALL THESE STEPS.
Purging System for Latex Paint
1. Place a bucket of soapy water under the paint suction
tube. Also, have a waste container handy to catch the
purged fluid.
2. Place paint return hose into the waste container.
Figure4. Turn Pressure ControlKnob Counter-Clockwise to
Reduce Pressure
Figure 3. Place return hose so purged fluid goes into
waste container.
WARNING
If a metal container is used, ground
the gun by holding it against the
edge of the container while flushing (As shown below).
Failureto dosomayleadtostaticelectricdischarge,which
may cause a fire.

9
Foranewunit,followpurgingandprimingstepsabove. For
units already in service, also purge water or solvent from
the system as described above, depending on the type of
paint being used.
After pump is primed and ready to spray, it may also be
necessary to purge the hoses of water or solvent.
1. SetPressureControlKnobtominimumsetting(counter-
clockwise).
2. Set Prime/Spray Ball Valve to Spray .
3. Be sure spray gun still has no tip installed.
4. Unlock spray gun.
5. Increase pressure by turning Pressure Control Knob
clockwise.
6. Trigger gun into waste container until solvent or water
is purged from the hose.
7. Decrease pressure by turning Pressure Control Knob
counter-clockwise.
8. Set Prime/Spray Ball Valve to Prime, and trigger gun
to be sure no pressure is left in the hose.
9. Lock gun off.
10. Install spray tip appropriate for the material being
sprayed. (Thethickerthepaint,thelargerthespraytip
required.)
11. Re-set Prime/Spray Ball valve to Spray.
12. Increase pressure to maximum setting (turn Pressure
Control Knob clockwise).
13. Release gun lock.
14. Triggerguntotestspraypattern. Sprayagainstascrap
piece of pasteboard or other test surface.
15. See Setting the Pressure, below.
Setting the Pressure
Thebestpressuresettingwillvarywiththetypeofpaintand
thesizeandtypeofnozzle. Thethickerthepaint,thehigher
the pressure needed.
To find the optimum pressure setting, start with the Pres-
sure Control Knob turned fully clockwise (maximum pres-
sure). Graduallydecreasethepressurebyturningtheknob
counter-clockwisetotheminimumlevelnecessarytomain-
tain the desired spray pattern and atomization.
Untilyouaresatisfiedwiththespraypattern,sprayonatest
surface rather than on the surface to be painted.
Purging System for Solvent-Based
Paint
If you are going to spray solvent-based paint, all you need
todoispurgethefluid. Thoroughcleaningisnotnecessary
as it is with latex paint.
NOTE: KEEP SPRAY GUN LOCKED OFF DURING
ALL THESE STEPS.
1. Put full paint bucket into position.
2. Place return hose over waste container. (See Figure
3.) Attach paint hose without tip and put into waste
container.
3. SetPressureControlKnobfullcounter-clockwise(mini-
mum pressure). (See Figure 4.)
4. SetPrime/SprayBall ValveonPrime . (See Figure5.)
5. Turn the ON-OFF switch to the ON position.
6. Turn Pressure Control Knob clockwise to increase
pressure until fluid starts to come through return tube
into waste container.
7. Whenpaintstartstoflowthroughreturntube,decrease
pressuretominimumsettingandplacereturntubeover
paint bucket.
8. Continuerecirculatinguntilpaintflowingthroughreturn
tube is free of bubbles.
9. Install spray tip.
10. You are now ready to spray.
OPERATION
Before starting spraying every day, squirt upper packing
lubricant(PartNo.9992504)intoslotsinpackingnutcover.
Do not apply so much that it overflows and drips into the
paint. Thislubricantkeepsthepistonsealspliant,minimiz-
ing paint by-pass and piston wear. If unit is operated
severalhours aday,repeat lubricationafter about4hours.
Figure 6. Oil Upper Pump Packings

10
1. Engage the gun safety latch.
2. Shut off the motor and turn the pressure control knob
counterclockwise as far as possible.
3. Turn the prime/spray ball valve to prime, having a pail
ready to catch the drainage or return to the paint
container via the return hose.
4. Disengage the gun safety latch.
5. Hold metal part of the gun firmly to the side of a metal
pail to avoid a build up of static electricity, and trigger
thegunintothemetalcontainertorelievethepressure.
6. Engage the gun safety latch.
7. Leavetheprime/sprayballvalveonprime,untilyouare
ready to operate the sprayer again.
WARNING
the unit down for any purpose, including servicing or
adjusting any part of the spray system, changing or
cleaning spray tips, or preparing for clean-up.
Be sure to follow the Pressure
Relief Procedure when shutting
Using the Spray Gun
NOTE: FOLLOW THE INSTRUCTIONS THAT CAME
WITH YOUR GUN.
PRESSURERELIEFPROCEDURE
Prime the Sprayer with Paint
1. Turn the prime/spray ball valve to prime.
2. Put the suction tube into the paint container.
3. Turnthepressurecontrolknobcounterclockwiseasfar
as possible to the lowest pressure setting.
4. Start motor. Slowly increase pressure by turning the
pressure control knob clockwise until pump begins to
function. Whenpaintbeginstoflowthroughreturntube
decrease pressure by turning the pressure control
knob counterclockwise and then turn the prime/spray
ball valve to the spray position.
5. Disengage the gun safety latch.
6. Hold a metal part of the gun firmly against and aimed
intoa metalwastecontainer. Trigger thegun andhold
it open while slowly increasing the pressure setting by
turning the pressure control knob clockwise until the
sprayer starts. Keep the gun triggered until all the air
is forced out of the system and paint is flowing freely.
Release the trigger and engage the safety latch.
7. Check all fluid connections for leaks. If any are found,
follow the pressure relief procedure before tightening
the connection.

11
Spraying Technique
You can learn to spray paint as easily as you can learn to
paint with a brush or roller. You can get a professional
lookingjobinasafemannerbyfollowingthespraypainting
tips below.
1. Heed all WARNINGS and CAUTIONS that are listed
onpages 3thru 6at thefront ofthis manual. Taketime out
now to reread them.
2. Avoid sharp bending and kinking of the paint hose. All
painthoses shouldbekeptclearoftrafficandsharpcutting
edges or objects.
3. Use the lowest pressure possible when spraying. Too
much pressure shortens equipment life. It also causes
faster than normal wear on the spray tip.
4. Determine the best spraying distance (distance from
spray tip on the spray gun to the work). If the spray gun is
held too close to the work, you will have paint buildup that
will cause sags and runs. If the spray gun is held too far
from the work, "fogging" will result.
Thecorrectdistanceshouldbeabout10to12inches. Keep
this distance for the entire length of the stroke. Of course,
the shape of some work surfaces will not permit this.
However, the same spraying distance should be kept
whenever possible.
5. Do not move the spray gun by flexing your wrist. The
result of this is shown in Figure 7. Rather, move the spray
gun with a smooth stroke of the entire arm and shoulder.
Maintain the same arm speed all the way through the
stroke. The result of this is shown in Figure 8.
Work
Heavy
Coat
Wrong
Way to Spray
Light
Coat Light Coat
Figure 7. - Result of flexing wrist while spraying.
Approximatley
10 to 12 Inches
Even Coat on Work Throughout
Right
Way To Spray Steady Arm
Figure 8. - Result of smooth arm stroke and steady, even
speed while spraying.
6. Keepthespraygunperpendiculartotheworkasshown
in Figure 9.
Figure 9. - Right and wrong ways to hold spray gun toward
work.
Wrong Way
Right Way
Approximately
10 to 12 inches
NOTE:
WHEN SPRAYING BLOCK FILLER, MASTICS OR
HIGH SOLID COATING LEAVE OUT GUN FILTER
AND HIGH PRESSURE FILTER SCREENS.

12
7. The spray gun should be triggered (turned off and on)
on each stroke. This will save paint and avoid paint
buildupattheendofthestroke. However,donottrigger
during the middle of a stroke. This will result in an
uneven spray and splotchy work. See Figure 10 for
proper triggering on a left-to-right stroke. Reverse for
a right-to-left stroke.
8. Move the spray gun at a rate of speed that is comfort-
able for you. If you have to move your arm too fast in
order to prevent excessive paint buildup, either (1)
lowerthepressurebyturningthepressurecontrolknob
counterclockwise, or (2) use a spray tip with a smaller
hole. If you have to move your arm too slow in order to
get a good coating, either (1) raise the pressure by
turningthe pressurecontrol knobclockwise, or(2) use
aspraytipwithalargerorfice. Youshouldalwayskeep
the spray gun moving when making a stroke. Slowing
down in one place will cause sags or runs.
CLEAN-UP
1. Turn power switch to OFF.
2. Bleed off any pressure remaining in the pump by
opening the dump valve.
3. Remove gun tip and clean with solution compatible
with material applied.
4. Removepaintcontainerfromitspositiondirectlybelow
siphon hose and paint strainer. Replace with a con-
tainer of solvent compatible with material being ap-
plied.
5. Turn the pressure control knob counter-clockwise to
the lowest pressure setting.
6. Turn power switch to ON.
7. Triggerspraygun(s)intocontainertoflushpump,hose
and gun(s) clean.
8. Turn power switch to OFF.
9. Bleed off solvent.
10. Unplug unit and store in a clean dry area.
Forlong-termstorage,besuretoflushunitwithappropriate
oil before storing.
Thepump,hoseandgunshouldbe
cleanedthoroughly after dailyuse.
CAUTION
Failuretodosopermitsmaterialtocake,seriouslyaffecting
the performance of the unit.
Figure 10. - Proper way to trigger spray gun.
9. Overlap each stroke by about 40% to 50%. The
overlap will assure a paint coating that is uniform
across the work. One way to get good overlap is to
point the spray gun at the edge of the last stroke.
Start
Stroke Pull
Trigger
End
Stroke
Release
Trigger
Even Steady
Stroke
Approximatley
10 to 12 Inches Work
WARNING
When cleaning the pump, hose
andgun with mineral spirits orany
other solvent, ALWAYS spray at minimum pressure with
thegunnozzletipremoved. Staticelectricitybuild-upmay
result in a fire or explosion in the presence of flammable
vapors.
After daily use, paint should be flushed from the unit with
solvent compatible with the material applied, and then re-
flushed with mineral spirits.

13
MAINTENANCE
Routineoperatormaintenanceonthisunit is minimal.Only
three daily procedures are required: (1) lubricating the
upperpackings,(2)cleaningthehighpressurefilterscreen,
and (3) cleaning the intake screen.
Daily Maintenance
1. Squirtupperpackinglubricantintoslotsinupperpump
housing. Do not over-lubricate, as this will result in oil
dripping into the paint. Oil approximately every four
hours of operation.
Figure 13. Clean paint intake screen daily, or more often if
needed.
Figure11. Squirtupperpackinglubricantintouppercylinder
housing every four hours.
2. Clean high pressure filter, as needed. Remove filter
housing. (Filter canister is threaded into base with
right-hand threads.) Take out filter element and wash
thoroughly. Scrub gently with a fiber-bristle brush if
necessary (DO NOT use a wire brush). If spraying
block fillers, mastics, etc. leave filter element out.
Figure 12. Remove and clean High-Pressure Filter at
least daily, more often if needed.
3. Inspect paint intake screen (at bottom of paint suction
tube)and washifnecessary. (Screenisthreadedonto
suction tube. Remove by turning counter-clockwise.)
Siphon tube
Screen
Teflon tape
Filter
Housing
Filter
Support
O-Ring Filter
Element

14
Refer to Figure 14 (left).
1. Loosen and remove siphon tube assembly by turning
counterclockwise.
2. Remove front cover.
3. Remove packing nut cover.
4. Run the unit in short intervals until the connecting pin
is in front of the recessed area of the housing.
5. Disconnect the power cord from the electrical supply.
6. Remove the retainer clip on the yoke.
7. Remove the connecting pin by pushing it through the
yoke and piston rod.
8. Loosen and remove fluid hose.
9. Loosen large locknut (7) on upper end of fluid section.
10. Unscrewentirefluidsectionassemblybyturningcoun-
terclockwise.
11. Using wrench flats on inlet valve holder (28), position
fluid section vertically into vise. Tighten vise.
12. Locate wrench flats on cylinder (8). Turn cylinder
counterclockwisewithlargeadjustablewrenchuntilitis
removed from the inlet valve holder (28).
13. Remove and inspect upper O-Ring (22) in inlet valve
holder. If damaged, replace when re-installing.
14. Remove inlet valve holder (28) from vise. Tap out ball
stop disc (23), ball cage (25) and ball (24).
Ifany parts aredifficult to disassemble, soak in
lacquer thinner until paint softens.
15. Remove lower ball seat (26). Inspect the ball and ball
seat for damage. If seat is worn or damaged it can be
flipped to the unused side. Ball must be replaced if
damaged or if the seat is flipped.
Figure 14 - Fluid Section
WARNING
ALWAYS follow the Pressure
Relief Procedure (page 10)
beforestartinganytroubleshooting,servicing,orcleaning.
Repacking the Fluid Section
A small amount of paint by-passing the piston and coming
out of the slots in the upper piston housing is normal, but if
itbecomesexcessive,orifpaintpressuredrops,thepiston
packings need to be replaced.
CAUTION
Donotrunmotorwithfluidsection
removed.
Inlet and Outlet Valve carbide seats are reversible.
Ifonesidebecomes wornor damaged,fliptheseat
to the un-used side.
NOTE:
Continued on next page.
*2
*4
7
8
*14
#26
#18 *#17
*IncludedinPackingKit
P/N 0294905.
# Included in Valve Kit
P/N 0294689.
*#27
*#24
*#22
16 15
*12
*13
*11
10
*9
*6
*5
*3
1
20 21
23
25
28
*#19
©1994, rev. 1995 Wagner Spray Tech Corporation. All rights reserved.

15
Repacking Fluid Section
Continued from Page 14
(Refer to Figure 14, Page 14)
16. Remove lower O-Ring (27) from inlet valve holder.
17. Place cylinder (8) in vise (on wrench flats) and
tighten.
18. Remove packing nut (1).
19. Gently hammer piston assembly down with rubber
mallet. Piston assembly will come out.
20. Remove lower packings (12, 13) and lower female
adapter (14) if they have not already fallen out.
21. Remove lower male adapter (11) and wave spring (9).
22. Remove upper packings (3, 4 ) and adapter (2, 5) and
wave spring (6).
23. Insert connecting pin through hole in piston rod (10).
Lock connecting pin in vise jaws so piston rod is
vertical. DONOT putpiston roditself invise. The vise
jaws will damage piston rod.
24. Remove jam nut (21).
25. Remove piston seat retainer (20) with 5/16'' allen
wrench.
26. Remove piston rod assembly from vise.
27. Remove washer (19), ball seat (18), ball (17), ball
cage(16) and ball stop disc (15) from lower end of
piston rod assembly.
28. Inspect ball, and ball seat for damage. If the seat is
wornor damaged it can beflipped tothe un-usedside.
Ballmustbereplacedifdamagedortheseatisflipped.
Washer must be replaced.
29. Holdpistonassemblyinviceusingsameprocedureas
step 23.
30. Insertupperballstopdisc(15),ballcage(16),ball(17),
ball seat (18), and washer (19) into piston assembly.
31. Put removable loctite on piston seat retainer (20).
Insertinto piston assemblyand tighten. Torque to250
in./lbs.
32. Put removable loctite on jam nut (21). Tighten onto
piston seat retainer. Torque to 200 in./lbs. Remove
piston assembly from vice.
33. Place cylinder in vice using wrench flats and tighten.
34. Soak new leather packings in linseed oil for 5 minutes.
Do not oversoak.
35. Insert wave spring (9) and lower male adapter (11) into
cylinder. Remove leather packings from oil. Install
leather packings (13) alternatively with UHMWPE
packings (12). Insert lower female adapter (14).
36. Insert piston assembly into bottom of cylinder (8). A
slight force may be required to push piston rod through
packings.
37. Place O-Ring (27), lower ball seat (26), ball cage (25),
ball (24) and lower ball stop disc (23) into inlet valve
holder (28).
38. Put anti-seize compound on lower threads of cylinder
(8). Put O-Ring (22) on cylinder. Loosen vise and tilt
cylinderassembly atabout a45 degreeangle. Tighten
vise again.
39. Tighten foot valve holder assembly onto cylinder with
anappropriateadjustablewrenchuntilcylinderbottoms
out in foot valve holder. Make sure to use wrench flats
onfootvalveholdertotightencompletely. Torqueto40
ft./lbs.
40. Soak remaining new leather packings in linseed oil for
5 minutes. Do not oversoak.
41. Insertwavespring(6),uppermaleadapter(5). Remove
leather packings from oil. Install leather packings (4)
alternativelywithUHMWPEpackings(3). Atool,Wagner
part #06009, may be required to compress packings
down. Insert female adapter (2).
42. Installpackingnut(1)andtightenuntilthenutbottoms
out in cylinder. Torque to 25 ft./lbs. Do not over-
tighten.
43. Install large locknut (7) onto upper cylinder (8) and
turn until nut bottoms out on threaded section of
cylinder.
44. Put anti-seize compound on upper cylinder threads.
45. Remove fluid section from vice and install into main
pump housing. Piston rod (10) will align itself inside
yoke.
46. Rotate fluid section slightly to align hole in yoke and
hole in piston assembly. Insert connecting pin.
Replace spring retainer.
47. Thread fluid section into pump housing completely,
then unscrew up to 3/4 turn to align outlet elbow with
fluid hose.
48. Rotate large locknut (7) clockwise until tight against
drive housing.
CAUTION
Do not over tighten or damage to
cylinder may occur.
CAUTION
Hold hand under piston rod (10).
Damage can occur if piston rod
falls to the floor. Lower packings may also fall out.

16
NEVER OPERATE PUMP WITHOUT FRONT COVER IN
PLACE.
WARNING
Brushesshouldbeinspectedperiodicallytoinsureuninter-
ruptedservice.Their lifedependsonspeedaswellasload.
If one of the brushes measures less than 1/4'' or is worn
roughly or chipped, replace both motor brushes. It is also
recommendedthatbrushesbecheckedwhenpackingsare
replaced.
1. Disconnect power cord from electrical supply.
2. Remove the four (4) motor shroud mounting screws
and remove the motor shroud.
3. Unscrew and remove brush caps holding brushes in
place.
4. Remove brushes.
5. Replace with new brushes.
Brush Cap
Motor Brush
6. Replace brush caps.
7. Replace motor shroud and screws.
Figure 15. Remove Brush Cap and Motor Brush
Motor Brush Replacement

17
PROBLEM CAUSE REMEDY
Unit will not run Blown panel fuse or tripped Check and replace/reset
breaker
Unit not plugged in Plug in
Pressure control knob set too low Turn knob to higher pressure
Faulty or loose wiring Inspect/Take to SprayTech Authorized Service
Center
Worn motor brushes Check and replace brushes
Clogged Tip or Filters Clean tip and filters.
Faulty On/Off switch fuse Take to SprayTech Authorized Service Center
Unit will not prime Dried out piston packings Remove siphon tube and feel lower ball check to
be sure it is free to move off its seat. Place full
cup of paint thinner over end of fluid section and
turn on pump.
Pump inlet screen plugged Remove and clean.
Air in pump or hose Hold gun trigger in open position and run unit
about 10 seconds until air is purged
Check for siphon tube leak
Packings worn Replace packings. (See page 14)
Fluid is too viscous Prime pump with compatible solvent. Bring pump
up to pressure. Carefully remove pump from
solvent container and immerse inlet tube in heavy
material to be sprayed. With nozzle tip removed,
trigger gun until heavy material appears at gun.
Replace nozzle tip.
Siphon tube clogged Remove and clean
Siphon tube air leak Check connection and seal
Clogged tip Relieve pressure, remove tip and clean.
Unit will not build or Pressure adjusting knob not Adjust to increase pressure
maintain pressure properly set
Pump inlet strainer dirty Clean
Valve balls or seals worn or dirty Replace or clean
Air in pump or hose Hold gun trigger in open position and run about 10
seconds until air is purged
Packings worn Replace (See Page 14)
Worn spray tip Replace (Follow direction supplied with gun)
Internal leakage With gun trigger closed, allow unit to pump up to
pressure and shut off if pump momentarily starts.
Internal leak is indicated and fluid section rebuild
is necessary. (See Page14)
Fluid leak Check for external leaks including hydraulic
fittings attached to pressure control housing
Fluid too viscous Consult manufacturers recommendations on paint
container label
Spray tip too large Change tip
Fluid leakage at upper Upper packing worn Relieve pressure and tighten packing take up nut
end of fluid section or replace packings. (See Page 14)
Piston rod worn Replace. (See Page 14)
TROUBLESHOOTING

18
TROUBLESHOOTING CONTINUED
PROBLEM CAUSE REMEDY
Poor spray pattern Tip too large Change to smaller tip
Pressure adjustment wrong Adjust pressure control knob
Insufficient fluid delivery Clean all strainers and filters
Fluid too viscous Add solvent according to manufacturer's
recommendations
Unit lacks power Pressure adjustment low Increase pressure
Improper voltage supply Reconnect input voltage for 115 AC
Blow Fuses at Pump Excessive pressure Take to SprayTech Authorized Service
Circuit Breaker Center
Overtightened packings Repair/replace malfunctioning parts
gear box, linkage or motor
failures