Magnum Magnum XR Series, Service Instructions Manual

Page 1: ...ay tip and tip guard 2800 psi 19 MPa 193 bar Maximum Working Pressure MAGNUM XR7 Model 232745 Series A 0 31 gpm 1 17 lpm sprayer on heavy duty cart 50 ft 15 2 m hose and SG2 metal spray gun with rever...

Page 2: ...List of Kits 15 Motor Diagnostics 16 Control Board Diagnostics 16 Control Board Kit 17 Motor Kit 18 Pump Service Packing Module Kit 20 Pressure Control Switch Kit 22 Inlet Valve Kit 23 Outlet Valve K...

Page 3: ...ing such solvents in pressurized aluminum equipment such as this sprayer and spray gun Such use could result in a chemical reaction with the possibility of explosion WARNING OFF FLUID INJECTION HAZARD...

Page 4: ...C H F G D A N B M MAGNUM XR5 L J P K MAGNUM XR7 MAGNUM XR9 W W X X Y E W OFF ON 9558A 9559A 9560A K K 4 309044 Component Identification and Function...

Page 5: ...t screen Prevents debris from entering pump M Paint hose For transporting high pressure fluid from pump to spray gun N Cord wrap bracket For stowing electrical cord MAGNUM XR5 only P Airless spray gun...

Page 6: ...tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loos en the tip guard retaining nut or hose end coupling to relieve pressure...

Page 7: ...ure and replace if damaged Enclosures direct cooling air around the motor to prevent overheating They also reduce the risk of burns fire or explosion Read the following WARNING WARNING ELECTRIC SHOCK...

Page 8: ...heck valves See Pump Service on page 23 Suction tube is leaking Tighten suction tube connection K Inspect for other cracks or vacuum leaks Spray gun stopped spraying Spray tip is plugged Unplug spray...

Page 9: ...a 120V AC 60 Hz 1500 Watt generator page 3 Damage can occur if cause is not corrected Sprayer was operated at high pressure with very small tip which causes frequent motor starts and excessive heat bu...

Page 10: ...Replace motor if shaft will not turn See Motor Kit on page 18 Yoke is broken because pump is locked up by dried paint or worn packings Repair as necessary See Gear Yoke Kit on page 27 Basic Electrica...

Page 11: ...unplug in line connection of white electrical cord wire Plug in electrical cord and test voltage between black and white electrical cord wires Meter must read 85 to130V AC Replace electrical cord if...

Page 12: ...tch B and unplug in line connection of white electrical cord wire Plug in electrical cord and test voltage between black and white electrical cord wires Meter must read 85 to130V AC Replace electrical...

Page 13: ...e or overheated Be sure terminals are centered and firmly connected Inspect wiring insulation and terminals for signs of overheating and replace any loose terminals or damaged wiring Securely reconnec...

Page 14: ...minals or damaged wiring Securely reconnect terminals Pressure control switch leads are pinched between pump and drive housing or between front cover and drive housing Make sure pressure control harne...

Page 15: ...st of Kits Kit Number Kit Description 235014 Spray Prime Drain Valve 243082 Inlet Strainer for inlet of suction tube 243090 XR Pump Repair pump packing module 243093 XR Pump Inlet Valve Module 243094...

Page 16: ...ions per second 2 If there is uneven resistance or no resistance replace motor See Motor Kit on page 18 Control Board Diagnostics See Service Drawing on page 18 Check for a damaged control board or pr...

Page 17: ...pull on the leads from the electrical cord and the Power switch B 3 Disconnect motor harness and electrical cord and Power switch leads from control board 4 Remove screw that mounts control board and...

Page 18: ...r and drive housing For best cover alignment tighten lower two cover screws first then top two Torque screws to 70 to 80 in lb 8 to 9 NSm Installation Notes For yoke installation eccentric bearing on...

Page 19: ...tor leads are routed through the arches and slots of the fan shield 12 Remove stand XR5 or cart XR7 or XR9 legs from drive housing Installation D Read all Installation Notes in service drawing on faci...

Page 20: ...ric bearing 5 5 5 5 5 Pump Service XR Pump Repair Kit 243090 Packing Module 6 Torque to 120 to 150 in lb 14 to 17 NSm 6 Drive Train Detail HINT A pump with slight leakage at the rod packings can be te...

Page 21: ...fragments from recess in pump and clean out all residue Installation D Read all Installation Notes in service drawing on facing page D To prevent misalignment assemble sprayer tipped onto back of enc...

Page 22: ...the pressure control switch may need to be replaced Replace the pressure control switch as follows Disassembly 1 Do Steps 1 through 6 above in Disassembly 2 Unscrew pressure control switch from pump I...

Page 23: ...of grease or oil to o ring and threads suction tube fitting o ring o ring pump 1 Torque to 400 to 450 in lb 45 to 51 NSm 3 3 pump Torque to 320 to 380 in lb 36 to 43 NSm 2 cover screw front cover For...

Page 24: ...b 45 to 51 NSm 8 Reassemble suction tube fitting to pump inlet valve XR Outlet Valve Replacement Kit 243094 Read all Installation Notes in service drawing on facing page 1 Flush sprayer thoroughly See...

Page 25: ...amage will occur when cover is tightened Always check position of guide rods before tightening cover 4 Apply light coat of grease 5 eccentric bearing 5 5 5 5 Pump Replacement Kit XR Pump Replacement K...

Page 26: ...Read all Installation Notes in service drawing on facing page D To prevent misalignment assemble sprayer tipped onto back of enclosure 1 Apply one or two drops of thread locking adhesive included in...

Page 27: ...do not have to remove the pump to remove the gear Installation D Read all Installation Notes in service drawing on facing page D For easier parts placement tip sprayer backwards during installation 1...

Page 28: ...because of trapped debris or because it needs to be retorqued to 185 in lb 21 N m The Spray Prime Drain valve may also be worn If worn replace as follows Disassembly See Pressure Relief Procedure on p...

Page 29: ...is 26 in 66 cm Electrical cord See Grounding and Electrical Requirementson page 6 for extension cord lengths 16 AWG 3 wire 6 ft 1 8 m 16 AWG 3 wire 6 ft 1 8 m 16 AWG 3 wire 10 ft 3 m Pump inlet fitti...

Page 30: ...30 309044 Parts Model 232740 XR5 Sprayer 54 58 1 65 76 74 81 72 69 68 67 65 70 52 73 51 62 66 52 61 47 46 71 13 75 90 93 36 20 2 19 18 40 88 48 114 114 127 17 25 63...

Page 31: ...e 10 54 243230 YOKE GEAR GUIDE repair kit 1 58 194507 DOWEL pin 5 16 2 61 115642 BUSHING strain relief 1 62 243237 COVER with label 1 Ref No Part No Description Qty 63 195110 CORD power 1 65 115478 SC...

Page 32: ...2 309044 Parts Model 232745 XR7 Sprayer 63 66 61 62 79 67 68 79 77 76 75 74 80 72 65 72 47 51 73 113 70 1 65 13 54 58 46 71 86 85 20 87 88 89 94 52 69 36 52 81 40 19 18 52 84 2 102 48 125 125 25 17 12...

Page 33: ...243237 COVER with label 1 63 115603 CORD SET 1 65 115478 SCREW torx slt pan hd 1 4 8 66 115499 SWITCH rocker 1 67 195433 SUPPORT right 1 Ref No Part No Description Qty 68 195434 SUPPORT left 1 69 195...

Page 34: ...309044 Parts Model 232750 XR9 Sprayer 67 68 77 76 75 74 79 72 71 112 69 65 72 73 112 70 71 63 66 61 62 47 51 1 13 54 58 46 85 20 86 87 88 52 36 52 80 40 19 18 84 52 2 65 78 78 93 83 48 124 124 101 17...

Page 35: ...43237 COVER with label 1 63 115604 CORD SET stow with grip 1 65 115478 SCREW torx slt 1 4 8 66 115499 SWITCH rocker 1 Ref No Part No Description Qty 67 195433 SUPPORT right 1 68 195434 SUPPORT left 1...

Page 36: ...OF ANY KIND WHETHER FROM BREACH OF THIS WARRANTY OR ANY OTHER REASON Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion ma...