3A1181B - Electric Airless Sprayers, Repair, English

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Repair3A1181BElectric Airless SprayersENGFor portable spray application of architectural paints and coatings. For professional useonly.Not approved to European explosive atmosphere requirements.Models24F562(SP400 Hi Boy)24F564 (Mustang 4700 Hi Boy)24F561 (SP400 Stand)24F563 (Mustang 4700 Stand)SP400 Stand Model 24F561Mustang 4700 Stand Model 24F5633300 psi (22.7MPa, 227 bar) Maximum Working PressureImportant Safety InstructionsRead all warnings and instructions in thismanual. Save these instructions.ti11608aRelated ManualsSP400 HiBoy Model 24F562Mustang 4700 HiBoy Model 24F5643A1180312363English312365312364Français Español312362ti16088a

WarningsWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Whenthese symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols andwarnings not covered in this section may appear throughout the body of this manual where applicable.WARNINGWARNINGGROUNDINGThis product must be grounded. In the event of an electrical short circuit, grounding reduces the risk ofelectric shock by providing an escape wire for the electric current. This product is equipped with a cordhaving a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet thatis properly installed and grounded in accordance with all local codes and ordinances. Improper installation of the grounding plug is able to result in a risk of electric shock. When repair or replacement of the cord or plug is required, do not connect the grounding wire to eitherflat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is thegrounding wire. Check with a qualified electrician or serviceman when the grounding instructions are not completelyunderstood, 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 aqualified electrician. This product is for use on a nominal 120V circuit and has a grounding plug similar to the plugillustrated in the figure below. Only connect the product to an outlet having the same configuration as the plug. Do not use an adapter with this product.Extension Cords: Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle thataccepts the plug on the product. Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG(2.5 mm2) minimum to carry the current that the product draws. An undersized cord results in a drop in line voltage and loss of power and overheating.23A1181B

WarningsWARNINGWARNINGFIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help preventfire and explosion: Do not spray flammable or combustible materials near an open flame or sources of ignition such ascigarettes, motors, and electrical equipment. Paint or solvent flowing through the equipment is able to result in static electricity. Static electricitycreates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spraysystem, including the pump, hose assembly, spray gun, and objects in and around the spray area shallbe properly grounded to protect against static discharge and sparks. Use Airlessco conductive orgrounded high-pressure airless paint sprayer hoses. Verify that all containers and collection systems are grounded to prevent static discharge. Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter. Do not use a paint or a solvent containing halogenated hydrocarbons. Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pumpassembly in a well ventilated area. Do not spray pump assembly. Do not smoke in the spray area. Do not operate light switches, engines, or similar spark producing products in the spray area. Keep area clean and free of paint or solvent containers, rags, and other flammable materials. Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets(MSDS) and container labels provided with the paints and solvents. Follow the paint and solventsmanufacturer’s safety instructions. Fire extinguisher equipment shall be present and working. Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing orcleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.3A1181B3

WarningsWARNINGWARNINGELECTRIC SHOCK HAZARDThis equipment must be grounded. Improper grounding, setup, or usage of the system can cause electricshock. Turn off and disconnect power cord before servicing equipment. Use only grounded electrical outlets. Use only 3-wire extension cords. Ensure ground prongs are intact on power and extension cords. Do not expose to rain. Store indoors.SKIN INJECTION HAZARDDo not aim the gun at, or spray any person or animal. Keep hands and other body parts away from the discharge. For example, do not try to stop leaks withany part of the body. Always use the nozzle tip guard. Do not spray without nozzle tip guard in place. Use Airlessco nozzle tips. Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs whilespraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressurebefore removing the nozzle tip to clean. Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turnoff the unit and follow the Pressure Relief Procedure for turning off the unit. High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the eventthat injection occurs, get immediate surgical treatment. Check hoses and parts for signs of damage. Replace any damaged hoses or parts. This system is capable of producing 3000 psi. Use Airlessco replacement parts or accessories that arerated a minimum of 3000 psi. Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly. Verify that all connections are secure before operating the unit. Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.43A1181B

WarningsWARNINGWARNINGEQUIPMENT MISUSE HAZARDMisuse can cause death or serious injury. Always wear appropriate gloves, eye protection, and a respirator or mask when painting. Do not operate or spray near children. Keep children away from equipment at all times. Do not overreach or stand on an unstable support. Keep effective footing and balance at all times. Stay alert and watch what you are doing. Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turnoff the unit and follow the Pressure Relief Procedure for turning off the unit. Do not operate the unit when fatigued or under the influence of drugs or alcohol. Do not kink or over-bend the hose. Do not expose the hose to temperatures or to pressures in excess of those specified by Airlessco. Do not use the hose as a strength member to pull or lift the equipment.PRESSURIZED ALUMINUM PARTS HAZARDUse of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemicalreaction and equipment rupture. Failure to follow this warning can result in death, serious injury, orproperty damage. Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents orfluids containing such solvents. Many other fluids may contain chemicals that can react with aluminum. Contact your material supplierfor compatibility.MOVING PARTS HAZARDMoving parts can pinch, cut or amputate fingers and other body parts. Keep clear of moving parts. Do not operate equipment with protective guards or covers removed. Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,follow the Pressure Relief Procedure, page 7 and disconnect all power sources.TOXIC FLUID OR FUMES HAZARDToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, orswallowed. Read MSDSs to know the specific hazards of the fluids you are using. Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.PERSONAL PROTECTIVE EQUIPMENTYou must wear appropriate protective equipment when operating, servicing, or when in the operating areaof the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation oftoxic fumes, and burns. This equipment includes but is not limited to: Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.3A1181B5

InstallationInstallationGrounding and ElectricRequirementsRecommended extension cords: 110-120V: 3-wire, 12 AWG (2.5 mm2) minimum.NOTE: Smaller gauge or longer extension cords mayreduce sprayer performance.The sprayer cord includes a grounding wire with anappropriate grounding contact.The sprayers require:110-120V Units: 100-130 VAC, 50/60 Hz, 11A, 1 phase,circuit with a grounding receptacle.Never use an outlet that is not grounded or anadapter.Spray gun: ground through connection to a properlygrounded fluid hose and pump.Fluid supply container: follow local code.Solvent and Oil-based fluids: follow local code. Useonly conductive metal pails placed on a grounded surface such as concrete. Do not place the pail on a nonconductive surface such as paper or cardboard, whichinterrupts grounding continuity.Grounding the metal pail: connect a ground wire to thepail by clamping one end to pail and other end to groundsuch as a water pipe.To maintain grounding continuity when flushing orrelieving pressure: hold metal part of the spray gunfirmly to the side of a grounded metal pail, then triggerthe gun.ti5573aDo not use the sprayer if the electrical cord has a damaged ground contact. Only use an extension cord withan undamaged ground contact.ti11558ati4297a63A1181B

Pressure Relief ProcedurePressure Relief ProcedureFollow this Pressure Relief Procedure whenever youare instructed to relieve pressure, stop spraying, checkor service equipment or install or clean spray tip.3. Turn prime valve down.1. Turn OFF power and turn pressure control to lowestpressure setting.2. Hold gun against side of grounded metal flushingpail. Trigger gun to relieve pressure.ti8326aIf you suspect the spray tip or hose is clogged or thatpressure has not been fully relieved after following thesteps above, VERY SLOWLY loosen tip guard retainingnut or hose end coupling to relieve pressure gradually,then loosen completely. Clear hose or tip obstruction.4. Engage trigger safety lock on gun if unit is beingshut down or left unattended.ati83243A1181Bti10307a7

General Repair InformationGeneral Repair InformationNOTICEFlammable materials spilled on hot, bare, motorcould cause fire or explosion. To reduce risk of burns,fire or explosion, do not operate sprayer with coverremoved.To reduce risk of serious injury, including electricshock: Do not touch moving or electric parts with fingersor tools while testing repair. Unplug sprayer when power is not required fortesting. Install all covers, gaskets, screws and washersbefore you operate sprayer. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. Theseparts usually are not provided with replacement kits. Test repairs after problems are corrected. If sprayer does not operate properly, review repairprocedure to verify you did it correctly. See Troubleshooting, page 9. Overspray may build up in the air passages.Remove any overspray and residue from air passages and openings in the enclosures wheneveryou service sprayer. Do not operate the sprayer without the motor shroudin place. Replace if damaged. Motor shroud directscooling air around motor to prevent overheating andinsulates the control board from accidental electricshock.8 Do not run sprayer dry for more than 30seconds. Doing so could damage pumppackings. Protect the internal drive parts of this sprayerfrom water. Openings in the cover allow for aircooling of the mechanical parts andelectronics inside. If water gets in theseopenings, the sprayer could malfunction or bepermanently damaged. Prevent pump corrosion and damage fromfreezing. Never leave water or water-basepaint in sprayer when its not in use in coldweather. Freezing fluids can seriously damagesprayer. Store sprayer with Pump Armor toprotect sprayer during storage.3A1181B

TroubleshootingTroubleshootingProblemBasic Fluid PressureBasic Mechanical3A1181BCauseSolution1. Pressure control knob setting.Motor will not run if set at minimum (fully counter-clockwise).Slowly increase pressure setting tosee if motor starts.2. Spray tip or fluid filter may beclogged.Relieve pressure, page 7. Thenclear clog or clean gun filter. Referto gun instruction manual, 312363.1. Pump frozen or hardened paintThaw sprayer if water orwater-based paint has frozen insprayer. Place sprayer in warm areato thaw. Do not start sprayer untilthawed completely. If paint hardened (dried) in sprayer, replacepump packings. See Displacement Pump Replacement, page13.2. Displacement pump connectingrod pin. Pin must be completelypushed into connecting rod andretaining spring must be firmly ingroove or pump pin.Push pin into place and secure withspring retainer. See DisplacementPump Replacement, page 13.3. Motor. Remove drive housingassembly. See Drive HousingReplacement, page 15. Try torotate fan by hand.Replace motor if fan won’t turn. SeeMotor Replacement, page 27.9

TroubleshootingProblemBasic ElectricalSee wiring diagram, page 28CauseSolution1. Electric supply. ON/OFF switch inOFF position. Meter must read100-130 Vac; 210-260 Vac.Turn ON/OFF switch to ON position.Reset building circuit breaker,replace building fuses. Try anotheroutlet.2. Extension cord. Check extensioncord continuity with volt meter.Replace extension cord.3. Sprayer power supply cord.Inspect for damage such as broken insulation or wires.Replace power supply cord. SeePower Cord Replacement, page26.4. Fuse. Check replaceable fuse oncontrol board (next to ON/OFFswitch).Replace fuse after completingmotor inspection. See FuseReplacement, page 21.5. Motor leads are securely fastened and properly connected tocontrol board.Replace loose terminals; crimp toleads. Be sure terminals are firmlyconnected.Clean circuit board terminals.Securely reconnect leads.6. Motor thermal switch. Yellowmotor leads must have continuitythrough thermal switch.Replace motor. See MotorReplacement, page 27.7. Brush cap missing or loose brushlead connections.Install brush cap or replace brushesif leads are damaged. See MotorBrush Replacement, page 18.8. Brush length which must begreater than 1/4 in. (6 mm).Replace brushes. See MotorBrush Replacement, page 18.NOTE: Brushes do not wear atthe same rate on both sides ofmotor. Check both brushes.109. Motor armature commutator forburn spots, gouges and extremeroughness.Remove motor and have motorshop resurface commutator if possible. See Motor Replacement,page 27.10. Motor armature for shorts usingarmature tester (growler) or perform Spin Test, page 16.Replace motor. See MotorReplacement, page 27.11. Pressure control not plugged into control board.Insert pressure control connectorinto control board.3A1181B

TroubleshootingProblemLow Output3A1181BCauseSolution1. Worn spray tip.Relieve pressure, page 7. Replacetip. Refer to gun instruction madrainSCREW, drill, hex washer headHANDLE, includes 4, 2CAP, tubingLABEL, frontModel 24F561Model 24F563LABEL, sideModel 24F561Model 24F563119277249042FUSE, replacementKIT, brush, motor, replacement16F57316F73470‡ DescriptionQty2111211111111114111111 Replacement Danger and Warning labels, tags, andcards are available at no cost.† Other filters available: 245528, 100 mesh; 245526, 200mesh.3A1181B31

Parts (Stand) Models 24F561, 24F563Parts (Stand) Models 24F561, 24F5635655547222531721 522320 19254835181111 444a44b44714347514546195019ti10331a323A1181B

Parts (Stand) Models 24F561, 24F563Parts List (Stand) Models 24F561, 24F563Ref4111718‡192021222325 35434444a44bPart117493117501DescriptionSCREW, mach, hex washer hdSCREW, machine, hex washerhead249005 CONTROL, pressure, includes 21,23, 03255483 CONTROL BOARD15B119 CORD115498 SCREW, mch, slot, hex, wash hd15E794 CAP, wire, control, pressure15F399 LABEL, control115756 BUSHING189930 LABEL, caution162453 FITTING, (1/4 npsm x 1/4 npt)15J745 MANIFOLD, filter235014 VALVE, drain, includes 44a, 44b111699 GASKET, seat15E022 SEAT, 50515253†54555671 72 E28815E28919570715K359195833BASE, valveHANDLE, valve, drainPIN, groovedLABEL, instructionDEFLECTOR, barbedFITTINGO-RINGFILTER, fluid, 60 meshINSERT, filterCAP, filterLABEL, identificationLABEL, warningLABEL, warning‡ 119277249042FUSE, replacementKIT, brush, motor, replacementQty1111111111111 Replacement Danger and Warning labels, tags, andcards are available at no cost.† Other filters available: 245528, 100 mesh; 245526,200 mesh.3A1181B33

Parts (Hi-Boy) Models 24F562, 24F564Parts (Hi-Boy) Models 24F562, 24F564412272928327057b46957a57 2611227411830421063141 40353438937533391614136156364646834ti10336b3A1181B

Parts List (Hi-Boy) Models 24F562, 24F564Parts List (Hi-Boy) Models 24F562, J812117501DescriptionFRAME, cart, hiHANDLE, cartSCREW, mach, hex washer hdSCREW, mach, pnhSLEEVE, cartPIN, spring straightBUTTON, snapWASHERHANGER, pailSCREW, mach, slot hex wash hdKIT, shield, motor(includes 4, 70, 71, 72)255434Models 24F562255435Model 24F564HSE1450 HOSE, cpld, 1/4 in. x 50 ftGUN, spray289316Model 24F564289283Model 24F563249194GEAR, assembly, combination249195GEAR, crankshaft; includes 28180131BEARING, thrust255487HOUSING, drive; includes 4, 10,11287053ROD, connecting; includes 30a,31196750SPRING, retaining196762PIN, straight276883COVER, front255475PUMP, displacement; includes 35Manual 3123623A1181BQty Ref111042222171111111111111134353637383940414257 9915M671255485DescriptionNUT, jam, pumpFITTING, (1/4 npsm x 1/4 npt)STRAINER, 3/4-16 unfNUT, jamWASHER, suctionTUBE, suction, intakeO-RINGWASHER, garden hoseHOSE, cpldMOTOR, electric(includes 57a, 57b)57a 249043FAN, motor57b 119653RING, retaining63119451WHEEL, semi pneumatic64119452CAP, hub6815C871CAP, leg69LABEL, front, brand16F573Models 24F56216F734Models 24F56470LABEL, side, brand16F599Models 24F56216F927Model 24F56478245651FLUID, TSL, 8 oz (not shown) Warning labels are available free of charge 249042 KIT, brush, motorQty121111111112221111135

Parts List (Hi-Boy) Models 24F562, 24F564Parts (Hi-Boy) Models 24F562, 24F5645655192054227217532321 5235 48444 4571472518114351466749191950193A1181ue toforce of pumping action. Parts could project throughair and result in serious injury or property damage.ti6111aNOTICEIf the pump jam nut loosens during operation, thethreads of the drive housing will be damaged.6. Align pump outlet (E) to back.341. Extend pump piston rod fully. Apply grease to top ofpump rod (D). Install jam nut (34) on pump threads.E30Dtiti9145a347. Screw jam nut (34) up onto pump until nut stops.Tighten jam nut by hand, then tap 1/8 to 1/4 turnwith a 20 oz (maximum) hammer to approximately75 ft-lb (102 N m).ti9143a8. Install suction tube (39) and coupled hose (42).Tighten nuts (37) and (B).2. Install pump rod (D) into connecting rod (30).3. Install pump pin (31). Verify retainer spring (30a) isin groove over pump pin.30a30B 42373139ti9139a9. Fill packing nut with ASM Packing Seal until fluidflows onto top of seal. Install pail hanger (10) withscrews (11).33ti9144a114. Push pump (33) up until pump threads engage.10ti9040a143A1181B

Drive Housing ReplacementDrive Housing ReplacementRemovalInstallation1. Relieve pressure, page 7.1. Apply a liberal coat of grease to gears and needlebearing surfaces. Install thrust bearing (28) andgears (26) and (27) in motor front endbell.2. Remove pump (33). Displacement Pump Replacement, page 13.3. Disconnect power cord from outlet.27NeedleBearing Surfaces28272926133228426ti9147a11ti9148a2. Push drive housing (29) into motor front endbell.Insert gear crank (27) through hole in connectingrod (30).4. Remove two screws (11) and cover (32).5. Remove screw (13) and four screws (4).27306. Pull drive housing (29) out of motor front endbell.137. Remove gear cluster (27) and (26) and thrust bearing (28) from drive housing.NOTICEDo not drop gear cluster (27) and (26) when removing drive housing (29). Gear cluster may stayengaged in motor front endbell or drive housing.32114ti9149a3. Install four screws (4) and screw (13).4. Install cover (32) with two screws (11).5. Install pump (33). Displacement Pump Replacement, page 13.3A1181B15

Spin TestSpin TestSee Wiring Diagrams, page 28.2. If uneven or no resistance, check for missing brushcaps, broken brush springs, brush leads, and wornbrushes. Repair as needed, page 18.3. If still uneven or no resistance, replace motor, page27.4To check armature, motor winding and brush electricalcontinuity:1. Relieve Pressure, page 7. Disconnect power cordfrom outlet.2. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).123. Remove two screws (4) and shroud (12).4. Remove drive housing (29) (see page 15).5. Disconnect motor connector (H).HArmature Short Circuit TestQuickly turn motor fan by hand. If motor coasts two orthree revolutions before complete stop, there are noelectrical shorts. If motor does not spin freely, armatureis shorted. Replace motor, page 27.Armature, Brushes, and Motor Wiring OpenCircuit Test (Continuity)1. Connect red and black motor leads with test lead.Turn motor fan by hand at about two revolutions persecond.16ti5638a4. Reattach motor connector (H).5. Replace drive housing (see page 15).6. Replace shroud (12) and two screws (4).7. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).3A1181B

Fan ReplacementFan ReplacementRemovalInstallation1. Slide new fan (57a) in place on back of motor. Besure blades of fan face motor as shown.2. Install spring clip (57b).1. Relieve Pressure, page 7. Disconnect power cordfrom outlet.3. Replace shroud (12) and two screws (4).2. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).4. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).3. Remove two screws (4) and shroud (12).4. Remove spring clip (57b) on back of motor.5. Pull off fan (57a).57b57a412ti16089a3A1181B17

Motor Brush ReplacementMotor Brush ReplacementSee Wiring Diagram, page 28.RemovalReplace brushes worn to less than 1/4 in. (6 mm).Brushes wear differently on each side of motor, checkboth sides.the brush lead. You will hear a snap when cap issecurely in place.3. Strip approximately 1/4 inch (6 mm) of insulationfrom end of each yellow wire (C) from motor.4. Insert stripped end into end of a butt splice (E) onnew brush assembly.5. Crimp ends of butt splice (E) around each wire. Pullgently on each wire to be sure wire does not pull outof butt splice.1. Relieve pressure, page 7. Disconnect power cordfrom outlet.2. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).6. Wrap new tie wrap around motor and wires only.Trim off excess. Be sure pressure hose is not caughtin tie wrap.7. Connect motor connector (D) to control board (18).303. Remove two screws (4) and shroud (12) (see illustration on page 17).4. Disconnect motor connector (D) from control board(18).D295. Cut tie wrap (F).6. Locate two yellow wires (C). Cut each yellow wire atthe center.AE7. Pry off two brush caps (A). Remove brushes (B)from motor.8. Discard old brush assembly.9. Rotate fan by hand and blow compressed air intotop brush holder to remove brush dust.NOTE: Place end of a shop vacuum hose over lowerbrush holder. Turn on shop vacuum when you blow compressed air into top brush holder.33A RedCDB-Blackti5637bInstallationNOTE: Use all new parts included in brush kit. Do notreuse old parts if new replacement parts are provided.1. Install new brushes (B) in motor with wires facingtoward front of motor. Install positive (red) brushlead in top of motor and negative (black) brush leadin side of motor.2. Push each cap (A) into place over brush. Orienteach cap with the two projections on either side of188. Replace shroud (12) and two screws (4) (see illustration, page 17).9. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).3A1181B

Control Board ReplacementControl Board ReplacementSee Wiring Diagram, page 28.Removal1. Relieve pressure, page 7. Disconnect power cordfrom outlet.2. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).3. Remove two screws (4) and shroud (12) (see illustration, page 17).7. Pull control board out slightly and then slide controlboard back and off of frame.NOTE: Make sure power cord is free and not wrappedaround cord wrap.8. Remove grommet and wires from strain relief.NOTE: Ground wire remains attached to sprayer withgrounding screw.4. Disconnect pressure control assembly connector(A) from control board (18).18StrainReliefD18Grommetti6122aA120VC9. Remove two power cord (C) connectors from controlboard.ti16079a5. Disconnect motor connector (D) from control board(18).D6. Remove three screws (11) securing control board tohousing (two are located on the front and one on theback next to the power cord).18A120VCti16079a11ti11554a3A1181B19

Control Board ReplacementInstallation3. Slide control board into place on side of motor frontendbell.1. Push grommet and power cord wires into strainrelief in control board (18).StrainRelief18Grommetti6122a112. Connect power cord connectors to terminals indicated on control board (18).18ti11553a4. Replace three screws (11). Torque to 30-35 in-lb(3.4-3.9 N.m).D18DA120VCti16079aANOTE: Route power cord (19) between coupled hose(42) to filter manifold and sprayer frame.42Cti16079a5. Connect motor connector (D) and pressure controlassembly connector (A).6. Install shroud (12) with two screws (4) (see page17).7. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).19Bottom View of Sprayer20ti11555a3A1181B

Fuse ReplacementFuse ReplacementIf the fuse is blown, check for:Removal Pinched or shorted wires1. Relieve pressure, page 7. Disconnect power cordfrom outlet. A defective motor (see Spin Test, page 16) A locked or frozen pumpCorrect defective condition before replacing fuse.2. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).3. Remove two screws (4) and shroud (12) (see illustration, page 17).4. Remove fuse from control board.Installation1. Install Fuse 119277 on control board.2. Install shroud (12) and two screws (4) (see illustration, page 17).3. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).Replaceable Fuseti9134b3A1181B21

Pressure Control Assembly ReplacementPressure Control Assembly ReplacementSee Wiring Diagram, page 28.Removal1. Relieve pressure, page 7. Disconnect power cordfrom outlet.7. Loosen and unscrew pressure control.172. Hi-Boy Models Only - Disconnect high-pressurehose at pump outlet (see page 13).3. Remove two screws (4) and shroud (12) (see illustration, page 17).4. Disconnect pressure switch connector (A) from control board (18). Pull bushing (23) from hole (K).ti9128aANOTICE18If you plan to reuse pressure control, be careful notto damage or tangle wires when unscrewing pressure control.ti9129aK238. Remove pressure control.5. Pull wires through hole (K).6. Turn pressure control knob (17) counter clockwiseas far as you can to access flats on either side ofpressure control.223A1181B

Pressure Control Assembly ReplacementInstallation3. Apply loctite to pressure control knob (B) threads.4. Screw pressure control threads (B) into manifoldand torque to 150 in-lb (17.0 N.m).NOTE: Be careful when tightening pressure controlknob that wires are not pinched between pressure control and fluid manifold.A5. Tuck wires into pressure control wire cap (21) androute wires toward cap opening. Feed wires throughhousing hole (K).186. Insert bushing (23) in hole (K).7. Connect pressure switch connector (A) to controlboard (18).ti9129aK23B 21o-ring8. Install shroud (12) and two screws (4) (see illustration, page 17).1. Inspect pressure control before installation to verifyo-ring is installed.9. Hi-Boy Models Only - Connect high-pressure hoseat pump outlet (see page 14).2. Align pressure control wire cap (21) on fluid manifold so opening faces toward motor.3A1181B23

Drain Valve ReplacementDrain Valve ReplacementRemovalInstallation1. Relieve pressure, page 7. Disconnect power cordfrom outlet.1. Install new seat gasket (44a) and valve seat (44b)on end of drain valve.2. Remove pin (47) from drain valve handle (46).2. Screw drain valve (44) into filter manifold (43).Torque to 120 to 130 in-lb.3. Pull drain valve handle and valve base (45) fromdrain valve (44).3. Push valve base (45) over drain valve (44) and thenvalve drain handle (46) over valve base.4. Unscrew drain valve from filter manifold (43).5. Remove valve seat (44b) and seat gasket (44a)from inside of filter manifold or end of drain valve.4. Install pin (47) in drain valve handle. If necessary,use a hammer to tap pin in place completely.444547434644a44bti16090a243A1181B

Drain Line ReplacementDrain Line ReplacementRemovalInstallation1. Cut drain line (49) from barbed fitting (51).1. Screw barbed fitting (51) into

Repair Electric Airless Sprayers . 24F563 (Mustang 4700 Stand) 3300 psi (22.7MPa, 227 bar) Maximum Working Pressure Related Manuals Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 3A1180 . grounded high-pressure airless paint sprayer hoses.

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Ref. manual 3A2954 24P016 240 VAC, 5400 watts, 22.5 amps 3A5422 King sprayers with XL 3400 or XL 6500 Air Motors - manual 3A5422 334645 King sprayers with XL 10000 Air Motor - manual 334645 3A5423 XL 3400, XL 6500 Motor Parts - manual 3A5423 334644 XL 10000 Motor Parts - manual 334644 311762 Xtreme Lower Parts & Repair Kits - manual 311762

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