3A3655AEN

Repair

Replacement Kits for Magnum ElectricAirless SprayersUsed to replace parts in Magnum Electric Sprayers

Kits:

Pressure Relief ProcedureBefore servicing the sprayer, pump pressure must be relieved.

1. Turn ON/OFF switch to the OFF position.

2. Engage the trigger lock. Always engage the trigger lockwhen sprayer is stopped to prevent the gun from beingtriggered accidentally.

3. Turn pressure control to lowest setting.

4. Put drain tube into a pail and place Prime/Spray valve inPRIME position (drain) to relieve pressure.

5. Hold the gun firmly to a pail. Point gun into pail. Disen-gage the trigger lock and trigger the gun to relieve pres-sure.

6. Engage the trigger lock.

7. If you suspect the spray tip or hose is clogged or thatpressure has not been fully relieved:

a. VERY SLOWLY loosen the tip guard retaining nut orthe hose end coupling to relieve pressure gradually.

b. Loosen the nut or coupling completely.

c. Clear airless hose or spray tip obstruction.

Important Safety InstructionsRead all instructions in this Kit Manual and in theOwners Manual for the sprayer.

Section Description Kit #

1 Pressure Relief Pressure Relief Procedure, page 1

2 Disassembly Enclosure Disassembly, page 3

3 Replacement

PushPrime Replacement, page 3 17L086

Control Board Replacement, page 4 17L104

Motor Replacement, page 4 17L282

Pump Assembly Replacement, page 5 17L079

3 Assembly Enclosure Assembly, page 6

4 Verification Assembly Verification, page 6

SKIN INJECTION HAZARDThe sprayer builds up an internal pressure of 3000 psi (20.7MPa, 207 bar) during use. This sprayer stays pressurizeduntil pressure is manually relieved. To help prevent seriousinjury from pressurized fluid, such as skin injection, follow thePressure Relief Procedure whenever sprayer is stoppedand before sprayer is cleaned or checked, and before equip-ment is serviced or transported.

Repair

2 3A3655A

Assembly Drawing

1

2

4

1a

18

1b

318

4848a

10b

105

5a5b

22

9

12

10b

13

13a

10d

1616a

10c

6

22a

ti28518a

Ref Description1 Pump

1a Piston1b Pad, foam2 Drive4 Screw, drive5 Motor

5a Fan Cover5b Motor Screw6 Frame8 Pressure Control9 Left Shroud

10 Right Shroud10b Screw, shroud

Ref Description10c Clip, shroud (X7/LTS 17 only)10d Screw, underside shroud (X7/LTS 17 only)12 Switch, ON/OFF13 Control Board Assembly

13a Screw, control board16 Front Cover

16a Screw, front cover18 Gear Cover22 Power Cord

22a Screw, ground31 Indicator, pressure control48 PushPrime

48a Button, PushPrime

Replacement Procedures

3A3655A 3

Enclosure Disassembly

1. Unplug power cord (22) and perform PressureRelief Procedure, page 1, or see Owners manual3A3208 or 3A3529.

2. Remove front cover screws (16a) (T-30 Torx).

3. X7 and LTS 17 only: Remove underside shroudscrew (10d).

4. Remove side shroud screws (10b) (T-20 Torx), andremove right shroud (10).

5. Disconnect all wire leads and connectors fromcontrol board (13).

6. Remove left shroud (9) and front cover (16).

Replacement Procedures1. Proceed to the appropriate page for the replace-

ment kit instructions, as follows:

PushPrime Replacement, page 3

Control Board Replacement, page 4

Motor Replacement, page 4

Pump Assembly Replacement, page 5

2. Refer to the illustrations in the Assembly Drawing,page 2, and in the Owners manual for additionalparts information, wiring diagrams, and any addi-tional assembly torques.

PushPrime Replacement

To replace the PushPrime, first disassemble theenclosure. See Enclosure Disassembly, page 3.

1. Using a 1/16" hex driver, remove button (48a) byloosening set screw.

2. Using a 13mm deep socket, remove PushPrimemodule (48).

3. Install replacement PushPrime module (48). Torqueto 200-220 in-lb.

4. Install button (48a) by lightly tightening set screw.

5. Perform Enclosure Assembly, page 6

ELECTRICAL SHOCK HAZARDMOVING PARTS HAZARDTo reduce risk of serious injury, do not touch electricalor moving parts with fingers or tools while testingrepair. Unplug sprayer when power is not required fortesting. Install all covers, gaskets, screws and washersbefore you operate sprayer.

Replacement Procedures

4 3A3655A

Control Board Replacement

To replace the control board, first disassemble theenclosure. See Enclosure Disassembly, page 3.

1. Remove control board mounting screw (13a) andcontrol board (13) from left side shroud (9).

2. If needed, assemble replacement control board intobracket.

3. Install control board assembly (13) to left sideshroud (9) with mounting screw (13a). Torque to12-16 in-lb.

4. Perform Enclosure Assembly, page 6.

Motor Replacement

To replace the motor, you must first disassemble theenclosure. See Enclosure Disassembly, page 3.

1. Disconnect motor leads from control board (13) andpower cord (22).

2. Remove fan cover (5a) by gently prying adjacent toits narrow retention bars with a flat blade screw-driver. NOTE: Prying on the bars themselves cancause damage.

3. Remove 2 motor screws (5b) (T-20 Torx). Pull motor(5) from the pump/drive assembly. Be careful not todamage the cooling fan.

4. Assemble replacement motor (5) to the drive (2)with the black wire lead on the pressure control (8)side of the sprayer. Install 2 motor screws (5b) (T-20Torx). Torque to 26-32 in-lb.

5. Route the motor leads through the ports in the fancover (5a). Snap the cover onto the motor (5).

6. Perform Enclosure Assembly, page 6.

Replacement Procedures

3A3655A 5

Pump Assembly Replacement

To replace the pump assembly, first disassemble theenclosure. See Enclosure Disassembly, page 3.

1. Remove suction hose and drain tube from pump (1).

2. Loosen screw (22a) retaining the green ground wireto the back of the drive (2) and remove the groundwire.

3. Remove fan cover (5a) by gently prying adjacent toits narrow retention bars with a flat bladescrewdriver. NOTE: Prying on the bars themselvescan cause damage.

4. Remove 2 motor screws (5b) (T-20 Torx). Pull motor(5) from the pump/drive assembly. Be careful not todamage the cooling fan.

5. Remove gear cover (18). Remove the two screws(4) at the bottom of the pump/drive assembly thenremove the pump/drive assembly.

6. Place the pump/drive assembly in a vise with thejaws clamping on the flat sides at the bottom of thepump (1).

7. Open the latch at the bottom of the setting indicator(31), remove it from the pressure control (8).

8. Remove the two screws (4) holding the drive (2) tothe pump (1), then rotate the drive bracketapproximately 90°.

9. Pull the drive assembly (2) and pump piston (1a)from the pump (1). If necessary, tap on the shorterleg of the drive with a plastic hammer to separatethe parts. NOTE: Prying between the pump and thedrive can damage the drive and lead to failure ofequipment.

10. Verify that a small amount of grease has beenapplied to the drive pocket in the pump piston (1a) inthe replacement pump (1).

11. Rotate the drive gear to bring the stud towards thepump, then insert the stud into the piston pocket.Align the drive shaft with the pump bushing, thenpush the drive into the pump, rotating the gear todraw the drive inward. Press the drive and pumpfully together. If necessary, tap on the bottom of thedrive with a plastic hammer to seat the piston in thepump.

12. Install two screws (4) at the top of the drive (2).Torque to 80-90 in-lb.

13. Assemble motor (5) to the drive (2) with the blackwire lead on the pressure control (8) side of thesprayer. Install 2 motor screws (5b) (T-20 Torx).Torque to 26-32 in-lb.

14. Route the motor leads through the ports in the fancover (5a). Snap the cover onto the motor (5).

15. Replace foam pad (1b) on frame (6).

16. Place the pump/drive/motor assembly on thesprayer frame (6), then install the two screws (4) atthe bottom of the drive (2). Torque to 80-90 in-lb.

17. Reassemble gear cover (18).

18. Route the pressure control wire harness through thesetting indicator (31). Install the indicator around thepressure control (8), snap together. Pass the wireharness through the front cover (16), aligning theindicator with the opening in front cover as they arepositioned loosely on the pump.

19. Attach green ground wire to back of the driveassembly (2) using screw (22a). Torque to 25-35in-lb.

20. Replace the suction and drain hoses on the pump(1), and secure with their clamps

21. Perform Enclosure Assembly, page 6

Replacement Procedures

6 3A3655A

Enclosure Assembly1. Reassemble left shroud (9) and front cover (16).

2. Install power cord (22) into recess on left shroud (9).

3. Reconnect all wire leads and connectors, seeWiring Diagram, page 7.

4. After power cord connections are made, twist cordtwo or three times to group wires by removing slack.Then place cord grip in shroud location. Pay specialattention to ensure wires are free from the areasurrounding the motor rotor.

5. Reassemble right shroud (10). Verify no wire leadsare pinched between the shroud, motor andpump/drive assembly.

6. Install side shroud screws (10b) (T-20 Torx). Torqueto 20-25 in-lb.

7. X7 and LTS 17 only: Install underside shroudscrew (10d). Torque to 25-35 in-lb.

8. Install front cover screws (16a) (T-30 Torx). Torqueto 36-42 in-lb.

9. Perform Assembly Verification, page 6.

Assembly Verification

After assembly is complete, perform the following stepsto verify proper operation. If sprayer fails one of thesteps, repeat Enclosure Disassembly, page 3, andReplacement Procedures, page 3.

1. Visually inspect for gaps between enclosure halves.A gap larger than 1/32 in. (0.8 mm) may be causedby a pinched wire or an internal component notseated properly. If disassembly and inspectionindicates that no wire has been pinched and allinternal components are seated properly, carefullyreassemble and repeat verification steps.

2. Turn prime/spray valve to make sure it rotatesforward to the spray position and down to the primeposition.

3. Turn pressure control knob to verify it rotates.

4. Using water, verify sprayer primes and sprays.Follow instructions in sprayer Operation manual forproper setup, priming and spraying procedures. SeeOwners manual 3A3208 or 3A3529.

ELECTRICAL SHOCK HAZARDMOVING PARTS HAZARDTo reduce risk of serious injury, do not touch electricalor moving parts with fingers or tools while testingrepair. Unplug sprayer when power is not required fortesting. Install all covers, gaskets, screws and washersbefore you operate sprayer.

Replacement Procedures

3A3655A 7

Wiring Diagram

GREEN

ON/OFFSWITCH

WHITE

BLACK

PRESSURE SWITCH

WHITE

BLACK

MOTORti14050a

All written and visual data contained in this document reflects the latest product information available at the time of publication.Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

This manual contains English. MM 3A3655Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USACopyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.comRevision A, April 2016