Replacing the Motor Brushes
Perform this procedure using Motor Brush Kit P/N 0508645.
1. Perform the Pressure Relief Procedure and unplug the
sprayer.
2. Loosen and remove the four motor cover screws.
Remove the motor cover.
3. Loosen and remove the two fan shroud screws. Remove
the fan shroud.
4. Using a small screwdriver, pry off the two plastic brush
covers.
5. Disconnect the black and red wires from the motor
brushes. Remove the motor brushes.
6. Install the new motor brushes and snap on the plastic
brush covers.
7. Reconnect the black and red wires from the motor
brushes (refer to the electrical schematic in the Parts List
section of this manual).
8. Position the fan shroud over the motor fan. Secure the
fan shroud with the two fan shroud screws.
9. Slide the motor cover over the motor. Secure the motor
cover with the four motor cover screws.
Replacing the Gears
1. Perform the Pressure Relief Procedure and unplug the
sprayer.
2. Loosen and remove the four motor cover screws.
Remove the motor cover.
3. Disconnect the black and red wires coming from the gear
box housing.
4. Loosen and remove the four motor mounting screws.
5. Pull the motor out of the gear box housing.
6. Inspect the armature gear on the end of the motor for
damage or excessive wear. If this gear is completely
worn out, replace the entire motor.
7. Remove and inspect the 2nd stage gear for damage or
excessive wear. Replace if necessary.
8. Remove and inspect the crankshaft/gear assembly for
damage or excessive wear. Replace if necessary.
9. Reassemble the pump by reversing the above steps.
During reassembly, make sure the thrust washers is in
place.
Front Cover
Gear Box Housing
Front Cover Screw
2nd Stage Gear
Thrust Washer
Motor Mounting
Screw
Crankshaft/Gear
Assembly
Armature Gear
Motor
Motor Cover
Motor Cover Screw
NOTE: Refill the gear box with five ounces of
Lubriplate (P/N 9870307).
NOTE: If the motor will not dislodge from the pump
housing:
• Remove the front cover plate.
• Using a rubber mallet, carefully tap on the
front of the motor crankshaft that extends
through the slider assembly.
Replacing the Transducer
1. Loosen and remove the four front cover screws. Remove
the front cover.
2. Stop the sprayer at the bottom of its stroke so that the
piston is in its lowest position.
3. Perform the Pressure Relief Procedure and unplug the
sprayer.
Before proceeding, follow the Pressure Relief Procedure
outlined previously in this 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. Tilt the sprayer back for easy access to the fluid section.
5. Slide the retaining ring up on the slider assembly to
expose the connecting pin.
6. Push the connecting pin forward 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.
7. Using 3/8” a hex wrench, loosen and remove the two
pump manifold mounting screws.
8. Pull the pump manifold down off of the gear box housing.
9. Using a wrench, remove the transducer assembly from
the pump manifold.
10. Thread the new transducer assembly into the pump
manifold. Tighten securely with a wrench.
11. Reassemble the pump by reversing steps 1–8.
Make sure the transducer is aligned properly with the hole
in the pump manifold during reassembly. Improper
alignment may cause damage to the transducer o-ring.
Gear Box
Housing
Slider
Assembly
Pump
Manifold
Pump
Manifold
Mounting
Screw
Front
Cover
Front
Cover
Screw
Transducer
Assembly
Connecting Pin
Retaining Ring
CAUTION
WARNING
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