Service Manual
Contents
1. 5 To replace the diaphragm remove the connecting rod G from the backing plate by removing the retaining screw Replace the diaphragm and reassemble See Figure 16 6 The valve assembly H is removed using a locally produced special tool See drawing for measurements The valve unscrews counter clockwise 7 Once the valve assembly is removed the valve plates and o rings can be replaced See Figure 18 8 The pump housing L is separated from the pressure cylinder J by pulling it off The o ring can then be replaced 9 When reassembling the pump housing to the pressure cylinder be sure the square tab on the pump housing K is aligned in the notch see arrows L on the pump cylinder See Figure 20 Be careful not to pinch or nick the o ring 10 Screw the valve assembly into the cylinder Be sure that the two 2 square holes the threaded portion of the valve assembly are aligned with the holes in the pressure cylinder Look through the inlet screen to check alignment 11 Re install the diaphragm and the flange with the twelve 12 screws Push assembly into tank Tighten the large clamp and re install other parts THE PRESSURE CYLINDER 1 With the large clamp at the bottom of the tank removed the pressure cylinder will push out through the bottom of the tank See Figure 21 2 Once the pump cylinder is removed the large o ring A can be replaced See Figure 21 Note The new o ring should be s2. fitted sides See Figure 6 7 To replace the valve plates and o rings on the pump cylinder remove the outer o rings the top valve plate and replace The lower valve plate inside the cylinder is replaced by pulling out the retaining pin Use pliers See Figure 7 Replace the valve plate and then push the holding pin back into place 8 The pump cylinder screws into the pressure cylinder A little grease on the o ring makes reassembly easier Screw cylinder in tight and be sure that the notch on pump cylinder A is lined up with catch on pressure cylinder B See Figures 9 amp 10 9 Apply a non water soluble grease petroleum jelly works well arround the outside edge of the Viton collar before installing the piston into the pump cylinder See figure 12 Re connect the lever to the pump rod THE DIAPHRAGM PUMP 1 Loosen the stop plate A and remove the two 2 allen head screws B that hold the connecting pieces to the pump rod See Figure 13 2 Remove the pump rod C and the hose D Next loosen the clamp at the base of the sprayer E See Figure 13 3 Push the pressure cylinder approximately 1 out of the bottom of the tank Then turn the pump assembly 1 2 turn See Figure 14 Push pressure cylinder from sprayer 4 Next remove the 12 torx screws that hold the flange in place The flange and diaphragm can then be removed See Figure 15 Note Pressure cylinder is shown removed from tank
3. Leaks from shut off valve Leaks from hose Pressure release valve sticks Air leak Air coming out between the two halves of the pump support CAUSE Dirty cylinder wall O ring on piston swollen Not cleaned properly No lube on piston cylinder Check valve not sealing or missing Damaged o ring in relief valve Worn or damaged o ring on piston Tank cap not tight No lube on piston cylinder Worn or damaged o ring in shut off valve Worn or damaged o rings on bottom of cylinder Damaged or missing gasket Screw cap not tight Worn Damaged or Loose fittings Worn Damaged or Loose fittings Lack of lubrication or contaminated release valve assembly Tank cap not tight Gasket twisted Tank lip damaged SOLUTION Remove piston clean and replace Replace o ring Lubricate with heavy grease Check amp replace if necessary Replace o ring Replace o ring Tighten cap Lubricate piston o ring and cylinder Rebuild shut off valve Replace o ring and valve cone Replace gasket Pressurize unit tighten caps until leaks stop Tighten fittings and replace worn parts Tighten fittings and replace worn parts Clean and lubricate pressure release valve Tighten tank cap Straighten gasket Repair or replace tank HANDHELD SPRAYERS 1 If the sprayer will not hold pressure fill the sorayer to the neck with water Replace the cap and pump up sprayer Note USE CAUTION Filling the spra
4. M Difficulty In moving Pump lever Insufficient resistance during repeated pumping and no pressure High resistance after just a few pumping strokes pressure lasts only briefly During Spraying upward pumping becomes more amp more difficult and tank walls may indent inwards When handle is pulled up it wants to move itself forcibly back down Leaks inside cylinder 425 Leaks outside cylinder 425 Leaks on diaphragm pump 475 Leaks from end of spray Wand CAUSE Dirty bushing Dirty cylinder walls 425 Collar swollen 425 from long term exposure Lack of lubrication 425 Damaged dirty valve plates Damaged o ring at valve seat Collar or piston 425 worn Sealing in pressure regulator is leaking Little or no air cushion in pressure cylinder Wrong formula tank cap No vent hole Vent hole clogged Lower valve plate sticks Intake channels clogged Screen at base of pressure cylinder clogged Damaged dirty collar or piston Damaged o ring on cylinder Damaged o ring on pressure cylinder Damaged diaphragm Damaged o ring on diaphragm housing Damaged o ring on pressure cylinder Worn or damaged shut off valve SOLUTION Remove pump lever clean amp grease bushings Remove piston clean replace piston amp collar Replace collar and maintain according to instructions Lubricate viton collar Clean or replace valve plates or cylinder Replace o ring Replace collar or piston Che
5. Service Manual 425 435 475 485 456 457 9 425 300 CONTENTS OPERATING DISCRIPTION Specifications Page Backpack Sprayers 425 435 475 485 Technical Data 2 During the upward stroke of the handle on either Operating Description the piston or diaphragm liquid is drawn from the 425 435 475 485 2 formula tank through the intake channel into the Operating Description space above the pump The lower valve plate opens intake channel while the upper valve plate closes the 456 457 2 transfer ports During subsequent upward stroke of Backpack Sprayer piston or diaphragm the previously siphoned liquid Trouble Shooting Guide 3 is forced through the four transfer ports and into the Piston Pump 4 pressure cylinder During this compression phase the Diabh p 5 upper valve plate opens the transfer ports and the iaphragm Pump lower valve plate closes sealing the intake channel Pressure cylinder 8 The transfer ports cannot be sealed by the lower Handheld Sprayer valve plate Trouble Shooting Guide 9 Handheld Sprayer 10 Through repetition of these piston or diaphragm shutoff valve 12 strokes the air present in the pressure cylinder is OPERATING DESCRIPTION Compression Sprayer 456 457 During the upward stroke the o ring on the plunger moves to the fluted side of the o ring groove and allows air to be drawn past the o ring and into the pump cylinder On the downward stroke the o ring presses against the solid side of the o ring
6. The large gasket at the top of the cylinder will hold the cylinder in the red cap Turning the cylinder counter clockwise while holding the red cap and pulling may help separate the two See Figure 32 7 To replace the o ring on the plug A remove the plug by prying it out with a screwdiver Replace the o ring and lubricate Reassemble by pushing the plug in until it is flush with bottom of the pump piston The outer o ring can be replaced if damaged or worn Lubricate it before it is reassembled into the cylinder See Figures 33 and 34 8 To replace the pump piston remove the cylinder supports by pushing them out of the red cap Once the pump piston is repaced the cylinder support is snapped back into place See Figure 35 9 When reassembling the pump cylinder to the pump piston make sure that gasket A does not get twisted This will cause the sprayer to leak Note The cylinder is shown removed from the tank cap for clarity To ease the assembly drop the cylinder into the neck of the sprayer tank and then screw the cap assembly on See Figure 36 10 The o ring at the connection between the hose and the shut off valve is replaced by first removing the shut off valve The o ring will then snap off and the new one can be pushed on See Figure 37 THE SHUT OFF VALVE 1 Complete shut off valve See Figure 38 2 To remove valve core you must first take off the handle To do this remove the retaining pin C by squee
7. ck seal and valve seat Remove PVC hose drain pressure cylinder reconnect hose preventive measure release pressure after each use Replace with vented cap Clean vent hole Replace valve plate Clean channels amp tank Clean intake screen with a small brush and detergent Clean or replace collar and possibly cylinder if worn Replace o ring Replace o ring Replace diaphragm Replace o ring Replace o ring Inspect and rebuild shut off valve PISTON PUMP 1 Loosen the stop plate A Remove the bolt and nut in the protective cap and pull protective cap off C Remove the two 2 allen head bolts D from the lever The piston can then be pulled from the cylinder E See figure 1 Also loosen the clamp F and remove the hose 2 Remove the pump cylinder by turning it counter clockwise from the bottom of the pressure cylinder See figure 2 3 Check the inside of the pump cylinder and the piston for vertical scratches If the cylinder is scratched replace it 4 To disconnect the piston from the connecting rod pry the two 2 halves of the connecting rod apart with a flathead screwdriver See Figure 4 5 With a new piston line up the connecting rod on the posts inside the piston and on the lever Snap the connecting rods together See Figure 5 6 To replace the Viton collar push it off with the top of the piston with your thumb The new one is simply pushed over the piston crown into the form
8. groove and blocks air from escaping past the o ring As the downward stroke continues air is compressed in the pump cylinder and is expelled past the check valve on the bottom of the cylinder and into the tank As more air is pumped into the tank the pressure is increased Pressure in excess of 45 PSI is released through the spring loaded pressure relief valve When the shut off valve is opened liquid is forced through a pick up tube in the spray tank From the pick up tube the liquid travels through the hose shut off valve and finally out the nozzle TECHNICAL DATA beeing slowly compressed by the forced in liquid A prerequisite for this condition is a closed shut off valve These pumping strokes can be carried out so long until the required pressure is reached After opening the shut off valve continue to pump slowly and steadily in order to achieve a consistent rate of discharge Weight Empty 9 5 Lbs 4 3 Kg 9 5Lbs 4 3 Kg 5 5 Lbs 2 5 Kg 6 5 Lbs 3 5 Kg Tank capacity 4 US Gal 15 L 4 US Gal 15 L 1 5 US Gal 5 0 L 2 US Gal7 5 L Pump system Piston Diaphragm Piston Piston Pressure Chamber 14USQ 1 3L 1 4USQ 1 3L N A N A Displacement Pump Cylinder 4 9 CU IN 4 9 CU IN 21 1 CU IN 21 1 CU IN Operating pressure 90 PSI 6 ATM 60 PSI 4 ATM 45 PSI 3 ATM 45 PSI 3 ATM Total Height 21 IN 21 IN 17 25 IN 23 IN Total Width 13 75 IN 13 75 IN 8 25 IN 8 25 IN Depth 8 25 IN 8 25 IN N A N A 2 BACKPACK SPRAYER TROUBLE SHOOTING GUIDE PROBLE
9. lid onto the pressure cylinder from the top to the recess It should not be streched over the flange at the bottom 3 Remove the adjustment cap by depressing and turning counter clockwise past the 1 setting See Figure 22 4 The adjustment piece is then removed by unscrewing it from the pressure cylinder Once the o rings are replaced apply a small amount of grease to them and reassemble See Figure 23 Note The adjustement piece has been painted white for clarity of the o rings in photo 5 The spring and the sealing piece on the adjustment cap can be removed by pulling them apart The new ones will just push together See Figure 24 6 If the inlet screen on the pressure cylinder is clogged it should be cleaned before reassembly See Figure 25 Note If the pump handle tends to spring to the down position when you lift up the inlet screen is clogged It can be cleaned while in the tank with a small hard bristle brush and detergent 7 When reassembling the pressure cylinder make sure the o ring stays in the recess Also make sure that the cut out on the pressure cylinder B lines up with the notch C on the tank Once it is completely assembled re install the clamp and tighten See Figure 26 HANDHELD SPRAYER TROUBLE SHOOTING GUIDE PROBLEM Difficulty in moving pump handle Low pressure amp resistance during pumping Leaks from end of spray wand Leaks from inside cylinder Leaks under cap
10. yer this full makes it very easy to pump up to the maximum pressure Approx 4 pumps The pressure relief valve is in the water and will therefore spray water when it releases You will be able to observe any leaks in the way of water beeing released See Figure 27 If you observe water on the outside of the sprayer check the damage at the site of the leak 2 If the leak is at a connection try to tighten the screw cap If that fails remove the screw cap and check the sealing surface to make sure that it is flat smooth and the seal or o ring is undamaged See Figure 28 3 When reassembling the connections especially the hose make sure that the o ring is seated before tightening the screw cap See figure 29 4 The pressure relief valve is removed by unscrewing it from the tank Once removed the lower housing pulls off to acess the o ring on the stem A When replacing this o ring make sure that it is seated in the recess on the stem Lubricate before reassembly See Figure 30 5 If the pump fails to offer resistance when pumping check the valve cone A on the bottom of the cylinder to make sure that it is present and sealing The valve cone is removed by pulling it out The o ring can then be replaced The valve cone is replaced by pinching the two 2 ears together and inserting into the hole in the bottom of the cylinder See Figure 31 6 The pump piston is removed from the cylinder by pulling the two apart
11. zing the notched end and pushing through the handle Pull on the pin head until pin clears the handle Slide the handle off the valve core See Figure 39 3 Once the handle is off the screw cap can be removed and the valve core C pushed out Replace worn parts Lubricate the o rings and reassemble in reverse order Note The valve core has been painted white for clarity See Figure 40 C SOLO Kleinmotoren GmbH P O Box 60 01 52 Telefon 49 7031 301 0 D 71050 Sindelfingen Telefax 49 7031 301 149 Germany Telex 7 265 892
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