Lemmer DC1600 Owner'S Manual Download Page 18

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MAINTENANCE & SERVICE (DC-7700)

NOTE: Clean and refill the gear box cavity up to the rear face of
each gear with wheel bearing grease.
11) Install the motor into the gearbox housing. Make sure the housing

gasket is positioned properly.

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

electrical schematic).

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

Secure the electronic cover with the three electronic cover screws.

15) Slip the baffle assembly up and around the motor. Secure the baffle

assembly with the tie wrap.

16) Slide the motor shroud over the motor.
17) Secure the motor shroud with the four motor shroud screws.

REPLACING THE TRANSDUCER

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

motor shroud.

3) At the electronic control assembly, disconnect the black wire coming

from the transducer.

4) Pull the grommet out of the mounting plate and slide it up the shaft

of the transducer until it is clear of the mounting plate.

5) Using a wrench, loosen and remove the transducer from the filter

housing. Carefully thread the transducer wire out through the
mounting plate.

6) Slide the grommet off of the old transducer and onto the new

transducer.

7) Thread the new transducer wire through the mounting plate and up

to the electronic control assembly.

8) Thread the new transducer into the filter housing and tighten

securely with a wrench.

NOTE: Make sure the o-ring on the transducer is in place before
threading the transducer into the filter housing.
9) Push the grommet into the mounting plate.
10) Connect the transducer wire to the electronic control assembly (refer

to the electrical schematic in this section of manual).

11) Slide the motor shroud over the motor.
12) Secure the motor shroud with the four motor shroud screws.

Use the following procedures to service the valves and repack the
fluid section.
REPACKING THE FLUID SECTION (KIT # L045-890)
Use the following procedures to repack the fluid section. For best results
use all parts supplied in this kit. Parts included are shown with "•".
1. Loosen and remove the four front cover screws. Remove the front

cover.

2. Position the crankshaft/slider assembly at the bottom, dead-center

of its stroke so that the connecting pin and retaining ring are visible
below the slider assembly. This is done by turning the sprayer on
and off in short bursts until the connecting pin is visible below the
slider housing.

3. Perform the “Pressure Relief Procedure” in the Owner’s Manual and

unplug the unit.

WARNING, Before proceeding, follow the Pressure Relief Proce-
dure outlined in the Owner’s Manual. Additionally, follow all other
warnings to reduce the risk of an injection injury, injury from
moving parts or electric shock. Always unplug the sprayer before
servicing!
4. Remove the return hose from the clamp on the siphon tube.
5. Unscrew the siphon tube/suction set from the inlet valve.
6. Loosen and remove the high-pressure hose from the nipple on the

back of the cylinder of the fluid section.

7. Slide the retaining ring up on the slider

assembly to expose the connecting pin.

8. Push the connecting pin back through

the slider assembly and piston. The
connecting pin will fall into a recessed
area of the gear box housing where it
can be retrieved.

9. Using a wrench, turn the jam nut

counterclockwise to loosen it from the
gear box housing.

10. Turn the fluid section counterclockwise to

remove it from the gear box housing.

11. Place the fluid section cylinder upright in

a vise by clamping on the wrench flats.

NOTE: Do not over-tighten the vise.
Damage to the cylinder may occur.
12. Loosen and remove the inlet valve