Magnum XR Series Service Instructions Manual page 21

When repairing or cleaning the pump, never submerge the pump in water or allow fluid to enter the pressure control.
When the pump packings wear, paint begins to leak down the outside of the pump. Replace the pump packings at
the first sign of leaking, or additional damage could occur. Install the pump repair kit as follows:
Disassembly
See Electric Shock Hazard on
page 7.
See Pressure Relief
Procedure on page 6.
1. Unplug electrical cord, and relieve pressure.
2. Remove the four cover screws and front cover.
3. Remove yoke and guide rods.
4. Disconnect pressure control harness from control
board connector at back of drive housing. Using
fingernail or tip of small, flat-blade screwdriv-
er, press tab on right side of connector to
release.
5. Remove pump from drive housing.
6. Place pump on workbench or in vise.
7. Remove any dried paint from around existing
packing module.
8. Unscrew pump packing module from top of pump,
remove packing spring and any fragments from
recess in pump, and clean out all residue.
Pump Service
XR Pump Repair Kit 243090 (Packing Module)
CAUTION
Installation
D Read all Installation Notes in service drawing on
facing page.
D To prevent misalignment, assemble sprayer tipped
onto back of enclosure.
1. Position new rod in new packing module so top of
rod is 1.5 in. (38 mm) from top of packing nut.
Take care that the packings or male adapter do
not fall out of the packing module.
2. Place new packing spring into recess in pump,
guide pump rod through spring and into pump, and
tighten pump packing module until E-clip is against
top of pump. Torque packing nut to 120 to 150 in-lb
(14 to 17 NSm). Remove pump from vise.
3. Route pressure control harness through retention
clip, and connect to control board connector at
back of drive housing (connect with tab to the
right).
4. Install pump on mounting pins. Make sure the
plastic washers are between the drive housing
and the pump.
5. Install yoke with rod cap in slot of yoke, as shown
in Rod/Yoke Detail on facing page.
6. Check final assembly against Drive Train Detail
on facing page.
7. Install front cover and cover screws.
8. To break in new parts, prime system with water or
solvent, then run sprayer with Spray/Prime–Drain
valve in PRIME position for 1 to 2 minutes.
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