15
SERVICE (DC-3100)
REPLACING THE PUMP FILTER
1) Loosen and remove the filter housing.
2) Pull the filter from the pump manifold.
NOTE: If the filter breaks off in the pump manifold, use a small
wood screw to remove.
3) Inspect the filter seal. Based on inspection, clean or replace the
seal.
4) Push the new or cleaned filter into the pump manifold.
5) Slide the filter housing over the filter and thread it into the pump
manifold until secure.
REPLACING THE MOTOR ASSEMBLY
1) Perform the Pressure Relief Procedure and unplug the sprayer.
2) Remove the four motor cover screws. Remove the motor cover.
3) Remove the four heat sink assembly screws. Pull the heat sink
assembly away from the gear box housing.
4) Disconnect the five wires from the relay that is mounted on the
inside of the heat sink assembly.
5) Remove the three relay mounting screws from the heat sink
assembly. Remove the relay.
6) Using the three relay mounting screws, install the new relay onto the
heat sink assembly. Tighten the screws securely.
7) Connect the five wires to the new relay (refer to the electrical
schematic in this manual).
8) Using the four heat sink assembly screws, install the heat sink
assembly onto the gear box housing. Tighten the screws securely.
9) Disconnect the black and red wires coming from the gear box
housing. Disconnect the black and red wires from the capacitors.
Disconnect the black and red wires from the motor.
10) Loosen and remove the four motor mounting screws.
11) Pull the motor out of the gear box housing.
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.
12) With the motor removed, inspect the gears in the gear box housing
for damage or excessive wear. Replace the gears, if necessary.
13) Install the new motor into the gear box housing.
NOTE: Rotate the motor fan manually until the armature gear
engages with the mating gear in the gear box housing.
14) Secure the motor with the four motor mounting screws.
15) Push the new capacitors into their clip on the new motor.
16) Reconnect the wires (refer to the electrical schematic in this
manual).
17) Slide the motor cover over the motor. Secure the motor cover with
the four motor cover screws.
REPLACING THE MOTOR BRUSHES
Perform this procedure using Motor Brush Kit P/N L045-472.
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 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.
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.
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 washer is in place.
NOTE: Refill the gear box with five ounces of Lubriplate (P/N L045-
479).
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.
Warning: 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.
Содержание DC1600
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