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Magnum X5, Repair Manual

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Magnum X5 Repair Manual Download Page 15

Troubleshooting

3A1943B

15

Sprayer Wiring Problems

NOTE: Remove enclosure 
mounting screws and pull 
enclosure away from drive 
housing. Take care not to pull on 
leads from electrical cord and 
power switch.

Sprayer electrical cord damaged.

Unplug sprayer electrical cord. 

Disconnect black electrical cord wire from filter.

Unplug in-line connection white cord wire.

Plug in electrical cord.

Test voltage between black and white wires. Meter must 
read 220 to 240V AC.

Replace electrical cord if no voltage.

Sprayer power switch damaged.

1.

Unplug sprayer electrical cord.

2.

Disconnect black control board wire at power 
switch.

3.

Unplug in-line connection white cord wire.

4.

Plug in electrical cord.

5.

Turn power switch ON.

6.

Test voltage between open terminal of power 
switch and white electrical cord wire. Meter must 
read 220 to 240V AC.

7.

Replace power switch if no voltage.

Motor thermal overload cutoff 
switch.

Startup Hazard After Thermal 
Overload, page 6.

1.

Unplug sprayer electrical cord.

2.

Remove motor harness from control card.

3.

Check for continuity between yellow leads or motor 
harness. 

4.

If thermal relief switch is open (no continuity) allow 
motor to cool.

5.

If switch remains open after motor cools, replace 
motor using Motor Kit, page 16.

6.

If thermal relief switch closes after motor cools, find 
correct cause of overheating.

Terminals are damaged or loose.

Replace any damaged terminals. Make sure all terminal 
connections are tight.

Problem

Cause Solution

Summary of Contents for X5

Page 1: ... Magnum X7 16J751 Series A Maximum Working Pressure 207 bar 21 MPa 3000 PSI Includes 1 17 lpm 0 31 gpm cart mount sprayer SG3 gun Manual 312830 0 635 cm 1 4 in x 15 m 50 ft hose Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Repair Magnum X5 and X7 Airless Sprayers 3A1943B EN Use water based or mineral spirit type material only Do not use ma...

Page 2: ...this type of application you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials Model Name Series Dispense Rate gpm lpm Hose Length and Diameter Maximum Hose Length Gun Model Maximum Working Pressure PSI MPa bar Magnum X5 A 0 24 gpm 0 91 lpm 1 4 in x 25 ft 6 4 mm x 7 5 m 75 ft 23 m SG2 3000 21 207 Magnum X7 A 0 31 gpm 1 17 lpm 1 4 in x 50 ft 6 4 mm x ...

Page 3: ...the grounding plug is able to result in a risk of electric shock 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 qual ified electrician This product is for use on a nominal ...

Page 4: ...l 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 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 e...

Page 5: ...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 immedia...

Page 6: ...f electrical cord has damaged ground prong 3 Do not use an extension cord with damaged ground plug Recommended extension cords 15 m 49 2 ft 1 0 mm2 30 m 98 4 ft 1 5 mm2 50 m 164 0 ft 2 5 mm2 4 Smaller gauge or longer extension cords may reduce sprayer performance Thermal Overload Motor has a thermal overload switch to shut itself down if overheated If unit overheats allow approximately 45 minutes ...

Page 7: ...r switch C Pressure control knob D Pump fluid outlet fitting G Suction Tube H Prime tube with diffuser J Prime Spray valve control K Fluid inlet connection and inlet valve L Inlet screen M Paint hose P SG2 airless spray gun Q Tip guard R Reversible spray tip S Trigger safety lever T Gun fluid inlet fitting V Gun fluid filter in handle Z Pump Priming Button ...

Page 8: ... knob D Pump fluid outlet fitting G Suction Tube H Prime tube with diffuser J Prime Spray valve control K Fluid inlet connection and inlet valve L Inlet screen M Paint hose P SG3 airless spray gun Q Tip guard R Reversible spray tip S Trigger safety lever T Gun fluid inlet fitting U Smooth Glide swivel V Gun fluid filter in handle W Hose cord wrap bracket X Pail hanger Z Pump Priming Button ...

Page 9: ...aning checking servicing or transporting equipment 1 Turn OFF power switch 2 Place prime tube in waste pail 3 Turn Prime Spray valve to PRIME 4 Turn pressure control knob left minimum pressure 5 Trigger gun into bucket to relieve pressure in hose Pressure Control Knob Settings To select function align symbol on pressure control knob with setting indicator on sprayer Trigger Locked Trigger Unlocked...

Page 10: ...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 test ing Install all covers gaskets screws and washers before you operate sprayer NOTICE Do not run sprayer dry for more than 30 se...

Page 11: ...ve clogged Clean replace drain tube as necessary Return sprayer to Graco MAGNUM authorized service center if drain valve is clogged Power switch is on and sprayer is plugged in but pump does not cycle Pressure set at minimum Turn pressure control knob right to increase pressure Electrical outlet is not providing power Try a different outlet OR test outlet by plugging something in that you know is ...

Page 12: ...n and begin spraying Pump cycles but paint only dribbles or spurts when trigger is pulled Pressure is set too low Turn pressure control knob right to increase pressure Spray tip clogged Clean tip See Gun stops spraying section of Troubleshooting table Spray tip too large or worn Replace tip Gun filter clogged Clean or replace gun filter Fluid filter is clogged Clean or replace fluid filter Pump ch...

Page 13: ...pressure setting or increase tip size Move sprayer to cooler location Building circuit breaker opens after sprayer operates for 5 10 minutes OR Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is turned on Too many appliances plugged in on same circuit Unplug some appliances or use a less busy circuit Extension cord is damaged too long or not a heavy enough gaug...

Page 14: ...rness connection on front side of drive housing Clean control board terminals Securely reconnect leads Motor brushes are worn Check length of BOTH brushes brushes do not wear evenly on both sides of the motor Brush length must be 0 25 in 6 4mm If brushes are worn replace motor using Motor Kit page 16 Motor armature commutator damaged Check for burn spots gouges and extreme roughness Replace motor ...

Page 15: ... in line connection white cord wire 4 Plug in electrical cord 5 Turn power switch ON 6 Test voltage between open terminal of power switch and white electrical cord wire Meter must read 220 to 240V AC 7 Replace power switch if no voltage Motor thermal overload cutoff switch Startup Hazard After Thermal Overload page 6 1 Unplug sprayer electrical cord 2 Remove motor harness from control card 3 Check...

Page 16: ... Stand 257568 X7 Left Leg when viewed from front 257569 X7 Right Leg when viewed from front 16G226 X5 and X7 Power Cord CEE 16J789 X5 and X7 Power Cord Australia 246286 X5 and X7 Pressure Control 3000 psi 16F291 X5 and X7 Pump Inlet 16F292 X5 and X7 Pump Outlet 16F047 X5 and X7 Pump 243011 X5 SG2 Gun 243012 X7 SG3 Gun 197607 X5 Suction Tube 16E847 X7 Suction Tube 235014 X5 and X7 Drain Valve 16G22...

Page 17: ...dark brown and burnt odor Replace motor if burning has occurred Inspect commutator and brushes for wear and arcing If commutator surface is pitted and uneven in color replace motor If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 1 4 in 6 4 mm or if the motor shaft cannot turn replace the motor using Motor Kit page 16 Setup 1 Relieve pressure page 9 2 Unplug electri...

Page 18: ...ting 9 Plug electrical cord into receptacle 10 Turn power switch ON If motor runs replace pressure switch Pressure Control Switch Kit page 16 If motor does not run replace control board repeat test Control Board Kit page 16 Pump Diagnostics When pump packings wear paint begins to leak down outside of pump Replace pump packings at the first sign of leaking or additional damage to drive train could ...

Page 19: ...Notes 3A1943B 19 Notes ...

Page 20: ...Parts 20 3A1943B Parts Magnum X5 Model 16J750 5 9 72 72c 72a 72b 1 1a 1b 1d 1c 1e 2 74 4 55 7 8 31 16 17 30 18 1f 73 36 37 67 66 38 66 70 1 72 72c 72a 72b ti17725a ...

Page 21: ...498 SCREW mach slot hex wash hd 1 16 16F629 COVER housing 1 17 120724 SCREW 4 18 15R605 LABEL Magnum X5 front 1 30 197607 TUBE suction set 1 31 15K530 LABEL control Magnum 1 36 195400 CLIP spring 2 37 195697 STRAINER 1 38 244035 DEFLECTOR barbed 1 55 24E510 COVER gear 1 66 115489 CLAMP drain tube 2 67 195084 TUBE drain 1 70 116295 CLAMP tube 1 72 16F291 HOUSING inlet includes 72a 72b 72c 1 72a 124...

Page 22: ...Parts 22 3A1943B Parts Magnum X5 Model 16J750 41 40 46 6 4 10 11 11 12 56 57 19 50 51 52 52 53 22a 10 102 39 115 121 122 123 125 22b 57 ti17681a 75 ...

Page 23: ...1 41 243011 GUN spray SG2 1 46 244168 FLUID pump armor 8 oz 1 47 179960 SIGN warning not shown 1 50 256992 HANDLE painted 1 51 116139 GRIP handle 1 52 122233 BOLT carriage 3 53 102040 NUT lock hex 3 56 16F567 BRACKET control board EMI filter 1 57 115492 SCREW mach slot hex wash hd 4 75 15J695 CAP tube 2 102 121423 RETAINER wire 1 115 195793 LABEL warning 1 121 245648 FILTER EMI 1 122 115632 CLAMP ...

Page 24: ...Parts 24 3A1943B Parts Magnum X7 Model 16J751 1 101 74 1 72 72c 72a 72b 9 2 5 4 63 7 8 31 16 17 1b 1d 1c 30 101 18 1f 1a 1e 68 66 67 66 38 37 36 70 73 72 72c 72a 72b ti17724a ...

Page 25: ...ash head 1 16 16F629 COVER housing 1 17 120724 SCREW 4 18 15R606 LABEL X7 front 1 30 16D951 TUBE suction 1 31 15K530 LABEL control Magnum 1 36 195400 CLIP spring 1 37 195697 STRAINER 1 38 244035 DEFLECTOR barbed 1 63 24E510 COVER gear 1 66 115489 CLAMP drain tube 2 67 195108 TUBE drain 1 68 16D907 HANGER pail 1 70 116295 CLAMP tube 1 72 16F291 HOUSING inlet includes 72a 72b 72c 1 72a 124249 BALL 1...

Page 26: ...Parts 26 3A1943B Parts Magnum X7 Model 16J751 39 10 20 55 51 22b 10 46 121 122 123 59 56 57 52 53 60 61 11 6 4 125 65 64 58 12 115 54 21 102 22a 11 65 40 41 ti17682a 75 75 ...

Page 27: ...1 15R602 AXLE cart 1 52 115095 WHEEL 9 in 2 53 112612 CAP hub 2 54 260212 SCREW hex washer hd thd form 4 55 120788 SCREW carriage 2 56 256993 HANDLE painted 1 57 115480 KNOB t handle 2 58 257326 RACK hose painted 1 59 120689 NUT hex acorn 5 16 18 nickel 2 60 121481 NUT u type tinnerman 1 61 120093 SCREW self drilling 1 64 16F567 BRACKET control board EMI filter 1 65 115492 SCREW mach slot hex wash...

Page 28: ... Diagram 28 3A1943B Wiring Diagram Magnum X5 16J750 Magnum X7 16J751 ti17683a POWER CORD GREENWIRE ON OFF SWITCH POWER CORD BROWNWIRE BLACK MOTOR LEAD BLACK MOTOR LEAD WIRING DIAGRAM POWER CORD BLUEWIRE 9 REF ...

Page 29: ...prayer weight only 6 1 kg 13 3 lb 10 6 kg 23 3 lb Dimensions Length 36 0 cm 14 5 in 49 5 cm 19 5 in Width 31 5 cm 12 4 in 38 9 cm 15 3 in Height 45 5 cm 17 9 in 94 0 cm 37 0 in Wetted parts sprayer Stainless steel brass ultra high molecular weight polyethylene UHMWPE leather carbide nylon aluminum PVC polypropylene fluroelastomer Inlet Screen on Suction Tube 450 micron 35 mesh Maximum material tem...

Page 30: ...nction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized G...

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