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Table Of Contents

3A3951C

Repair Kit Instructions

Repair Kits for

Magnum ProX & GX Sprayers

Use these instructions when repairing the ProX or GX sprayers.

Contents

IMPORTANT SAFETY INSTRUCTIONS

Read all warnings and instructions in the repair kit instructions and in the Owners/Operation manual for the

sprayer.

Section Description Kit #

1 Drive

Front Cover Replacement page 3 17J866

Motor Replacement page 4 17F756, 17F757, 17F758, 17K285,

17K684, 17L083

Fan Replacement page 4 16X980, 287770

Gear & Yoke Replacement page 5 17J863, 17J864, 17J869

2 Control Control Board Replacement page 7 17J867, 17J885

3 Pump

Pressure Control Replacement page 9 17J881, 17J927

Prime/Spray Valve and Knob Replacement page 10 17J925

Pump Outlet Valve Replacement page 11 17J880

Pump Inlet Valve Replacement page 12 17J876, 17J877, 17J924

PushPrime Button Replacement page 12 17J878

Refer to the illustrations in this document and your

Owners/Operation manual for additional parts

information, wiring diagrams, and any additional

assembly torques that you may need.

Pressure Relief Procedure

Before 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

lock when sprayer is stopped to prevent the gun

from being triggered accidentally.

3. Turn pressure control to lowest setting.

4. Put drain tube into a pail and place Prime/Spray

valve in PRIME position (drain) to relieve pressure.

5. Hold the gun firmly to a pail. Point gun into pail. Dis-

engage the trigger lock and trigger the gun to

relieve pressure.

6. Engage the trigger lock.

7. If you suspect the spray tip or hose is clogged or

that pressure has not been fully relieved:

a. VERY SLOWLY loosen the spray tip guard

retaining nut or the hose end coupling to relieve

pressure gradually.

b. Loosen the nut or coupling completely.

c. Clear airless hose or spray tip obstruction.

CALIFORNIA PROPOSITION 65

This product contains a chemical known to the State of

California to cause cancer, birth defects or other repro-

ductive harm. Wash hands after handling.

SKIN INJECTION HAZARD: This sprayer builds up

an internal pressure of 3000 psi (20.7 MPa, 207

bar) during use. This equipment stays pressurized

until pressure is manually relieved. Follow this

Pressure Relief Procedure whenever you stop

spraying and before cleaning, checking, servicing,

or transporting equipment to prevent serious injury.

Summary of content (14 pages)

PAGE 1
Repair Kit Instructions Repair Kits for Magnum ProX & GX Sprayers 3A3951C EN Use these instructions when repairing the ProX or GX sprayers. IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in the repair kit instructions and in the Owners/Operation manual for the sprayer.
PAGE 2
Drive Drive Drive Assembly Drawing Ref. Torque 1 140-160 in-lb (16 - 18 N•m) 2 30-35 in-lb (3.5 - 4.0 N•m) 3 110-120 in-lb (12 - 14 N•m) 2 9 24 17 13 14 8 1 10a 12 1 54b 6 3 18 2 1a 2 15a 10c 16 2 15 5 10 3 12 7 3 22 3 9 10b 2 10a Ref. 1 1a 2 3 5 6 7 Description Motor Fan Gear and yoke Power cord Yoke Handle screw Pump Motor shield 8 9 Machine screw 10-24 x 0.5 in. 10 Front cover 10a Easy access cover 2 ti28539a Ref.
PAGE 3
Drive Front Cover Replacement See Drive Assembly Drawing page 2 and your Owners/Operation manual for illustrations. 12 10a Disassembly 1. Perform Pressure Relief Procedure, on page 1. 2. Unplug sprayer. 10 Remove Motor Shield 3. Remove two machine screws (9) and motor shield (8). 9 10c 2 8 ti28536a 4. Disconnect cable (10c) from control board (15). 15 ti28538a 9. Pull cable (10c) through drive housing. Assembly 1. Locate new front cover (10). 10c 2.
PAGE 4
Drive Motor Replacement 7. Install gear and yoke (2). See Gear & Yoke Replacement page 5. See Drive Assembly Drawing page 2 and your Owners/Operation manual for illustrations. 8. Install front cover see Front Cover Replacement page 3 assembly procedure. NOTE: On hopper units you may need to remove the hopper before replacing the motor. Direct immersion and hopper units are easier to disassemble if the sprayer is placed on the side.
PAGE 5
Drive e. Position the push nut and socket at the end of the motor shaft. Use a small or light (8 oz./225g) hammer to drive the push nut (54b) onto the shaft. e. Place a push nut (54b) on a 3/8” or 10mm socket. f. Position the push nut and socket at the end of the motor shaft. Use a small or light (8 oz./225g) hammer to drive the push nut onto the shaft compressing the wave washer. 6. Slide motor shield (8) over the motor. 7. Secure the motor shield (8) using the two machine screws (12) removed earlier.
PAGE 6
Drive 8. Remove yoke (D) with the two yoke guide rods (C) from the drive housing. 9. Remove gear (A) from drive housing. D C Assembly 1. Use applicator brush to spread entire contents of grease tube (included in kit) into gear teeth. Grease must be worked into roots of gear teeth to ensure long life. 2. Carefully position new gear (A) in drive housing. Make certain motor drive gear meshes with new gear (A). E 3. Install yoke (D) with slot (E) facing out for pump piston as shown. A 4.
PAGE 7
Control Control Control Board Replacement 2. Reconnect the power cord connector(s) to the correct leads on the control board (15). Refer to your Owners/Operation manual for wiring diagrams. 3. Connect appropriate control board (15) lead(s) to the ON/OFF switch (17). Note color and location of all wires connected to the control board before you start the control board replacement. Removal 1. Perform Pressure Relief Procedure, on page 1. 2. Unplug sprayer. 3. Remove Motor Shield page 3. 4.
PAGE 8
Pump Pump Pump Assembly Drawing Ref. Torque Ref. 1 140-160 in-lb (16 - 18 N•m) 2 270-330 in-lb (30 - 37 N•m) Torque Ref. 3 30-35 in-lb (3.4 - 4.0 N•m) 4 220-250 in-lb (25 - 28 N•m) 5 Torque 320-380 in-lb (36 - 43 N•m) 2 16 21 5 3 29 4 8 11 9 10 1 30 5 15 42 28 1 28c 28b 2 3 12 4 6a 6 13 4 14 5 7a 7 4 ti27488a1 Ref. 1 2 3 4 5 6 6a 7 7a 8 9 10 8 Description Pump housing Ball guide Compression spring Ball 0.
PAGE 9
Pump Pressure Control Replacement Assembly Disassembly 1. Examine pressure control (28) to verify that O-ring (28c) is on the pressure control (28). If O-ring is not installed on pressure control, install O-ring. 1. Perform Pressure Relief Procedure, on page 1. 2. Unplug sprayer. Open Easy Access Door 3. Pull tabs on sides of the easy access door pump towards you while pushing the entire door away from the inlet end of the pump. 4. Now lift the door so that it swivels out of the way. 1 2.
PAGE 10
Pump 7. Slide pump assembly onto the mounting pins. Prime/Spray Valve and Knob Replacement Disassembly 1. Perform Pressure Relief Procedure, on page 1. 2. Unplug sprayer. 3. Turn knob (A) up to SPRAY position. 4. Remove pin (B) with pin punch and hammer. B ti27036a 8. Move pump displacement rod up or down until cap is level with the opening in the yoke. A ti11873a 5. Remove knob (A) and base (C). ti27037a Close Easy Access Door 9.
PAGE 11
Pump Assembly 7. Apply sealant (provided in kit) to valve threads. Install valve stem assembly in pump manifold and torque. See Pump Assembly Drawing page 8 for torque. 13. Install pin (B) through hole in knob (A). Tap pin through knob with hammer. End of pin will be flush with top of hole in knob when correctly installed. 8. Install base (C) on valve, aligning pin (E) on base (C) with hole (F) on pump housing (1). B A C F ti26455a GX Models Only E ti11876b 9.
PAGE 12
Pump Pump Inlet Valve Replacement Disassembly 1. Perform Pressure Relief Procedure, on page 1. 2. Unplug sprayer. 3. Remove suction tube. Hopper may need to be removed on models with a hopper. 4. Remove inlet valve fitting (6) from pump housing (1) and discard. Make certain inlet ball (4), spring (3), and ball guide (2) are removed from pump housing (1). d. Install ball (4) into ball guide (2). 2. Make certain O-ring (6a) is installed on inlet valve housing (6). 3.
PAGE 13
Pump Pump Packing O-ring Replacement Remove pump packing assembly (25) and replace O-ring (21) with new one. 1. Remove pump housing (1) from sprayer. See Pressure Control Replacement, on page 9 for pump removal. 2. Insert hex end of pump into hex tool in the sprayer frame and turn counter-clockwise to loosen assembly. Location of the hex varies depending on the sprayer. ti26954a 6. Insert hex end of pump into hex tool in the sprayer frame and torque. See Pump Assembly Drawing page 8 for torque. 7.
PAGE 14
Graco Information Graco Information For the latest information about Graco products, visit www.graco.com TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor. 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. Original instructions.