Lemmer DC1600 Owner'S Manual Download Page 17

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SERVICE (DC-3100)

REPLACING THE MOTOR ASSEMBLY (WITH ELECTRONIC
CONTROL)
WARNING: Electrostatic discharge (ESD) potential could cause
damage to electronic control. B sure you are grounded when
working on electronic control with electronic cover removed.

1) Perform the Pressure Relief Procedure and unplug the unit.
2) Loosen and remove the four motor shroud screws. Remove the

motor shroud.

3) Release the tie wrap on the top of the baffle assembly and slip the

baffle assembly down off of the motor.

4) Loosen and remove the three electronic cover screws. Lift the

electronic cover off of the electronic control assembly on the motor.

5) At the electronic control assembly:

Disconnect the white wire coming from the power cord and the

white wire coming from the relay.

Disconnect the three wires coming from the potentiometer.

6) Loosen and remove the three motor mounting screws.
7) Pull the motor out of the gearbox housing.
8) With the motor removed, inspect the gears in the gearbox housing

for damage or excessive wear. Replace the gears, if necessary.

9) Install the new motor into the gearbox housing. Make sure the

housing gasket is positioned properly.

10) Secure the motor with the three motor mounting screws.
11) Reconnect the wires to the electronic control assembly (refer to the

electrical schematic in this section of manual).

12) Position the electronic cover over the electronic control assembly.

Secure the electronic cover with the three electronic cover screws.

CAUTION: Use only Lemmer electronic cover screws to secure the
electronic cover (see parts list). Use of any other screws may
damage the electronic control assembly.
13) Slip the baffle assembly up and around the motor. Secure the baffle

assembly with the tie wrap.

14) Slide the motor shroud over the motor.
15) Secure the motor shroud with the four motor shroud screws. Motor

Shroud Electronic Cover Electronic Cover Screw - Gearbox v
Housing Motor Mounting Screw Electronic Control Assembly Motor
Motor Shroud Screws

REPLACING THE GEARS

1) Perform the Pressure Relief Procedure and unplug the unit.
2) Loosen and remove the four motor shroud screws. Remove the

motor shroud.

3) Release the tie wrap on the top of the baffle assembly and slip the

baffle assembly down off of the motor.

4) Loosen and remove the three electronic cover screws. Lift the

electronic cover off of the electronic control assembly on the motor.

5) At the electronic control assembly:

Disconnect the white wire coming from the power cord and the

white wire coming from the relay.

Disconnect the three wires coming from the potentiometer.

6) Loosen and remove the three motor mounting screws.
7) Pull the motor out of the gearbox housing.
8) Inspect the armature gear on the end of the motor for damage or

excessive wear. If this gear is completely worn out, replace the
motor.

9) Remove and inspect the 1 st stage gear and 2nd stage gear

assemblies for damage or excessive wear. Replace, if necessary.

10) Remove and inspect the front gear box assembly for damage or

excessive wear. If damaged or worn, replace the front gear box
assembly.

MAINTENANCE & SERVICE (DC-7700)

Motor Shroud

Motor Shroud
Screws

Electronic Cover

Cover Screw

Gasket

Motor

Electronic Control Assembly

Motor Mounting Screws

Motor Fan

Baffle
Assembly

Front End Bell
Assembly

Armature Gear

1st Stage Gear

Front Gear
Box Assembly

Housing
Gasket

2nd Stage Gear

12) Slide the piston guide tool (included in the repacking kit) over the top

of the piston rod and insert the piston rod through the bottom of the
pump manifold. Using a rubber mallet, tap the bottom of the piston
rod lightly until the piston rod is in position in the pump manifold.

NOTE: Coat the piston guide tool and the piston rod with grease
before inserting them into the pump manifold.
13) Using a wrench, tighten the retainer nut securely.
14) Position the pump block underneath the pump housing and push up

until it rests against the pump housing. When the connecting pin
hole on the piston rod lines up with the hole in the slider assembly,
insert the connecting pin.

15) Slide the retaining ring down over the connecting pin.(not DC3100N)
Make sure the transducer is aligned properly with the hole in the
pump manifold during reassembly. Improper alignment may cause
damage to the transducer gasket.
16) Thread the pump manifold mounting screws through the pump

manifold and into the gear box housing. Tighten securely.

17) Reassemble the inlet valve assembly into the pump manifold.

18) For Upright Cart units, thread the siphon tube into the inlet valve and

tighten securely. Make sure to wrap the threads on the down tube
with Teflon tape before assembly. Replace the return hose into the
hose clip on the siphon tube.

19) For Low Boy cart units, insert the elbow on the suction set assembly

into the bottom of the inlet valve housing. Push the retaining ring up
into the groove inside the inlet valve housing to secure the suction
set assembly in position. Push the return hose onto the return hose
fitting on the pump manifold and secure in position with the return
hose clamp.

20) Place the front cover on the gear box housing and secure in position

using the four front cover screws.

21) Turn on the sprayer by following the procedure in the "Startup

Procedure" section of this manual and check for leaks.

NOTE: Repacking kit P/N L045-470 is available. For best results use
all parts supplied in this kit.