1. Backpack Sprayers

1.1. Operator's Manual
1.2. Service Bulletins
1.3. Getting Started
Getting started using your new Solo backback sprayer is easy. Click to go to any section of instructions.
1.3.1. Removing Nozzle
Unscrew the nozzle cap (1) from the nozzle body (3). This is bestaccomplished while the retaining nut (2) is fastened tightly tothe elbow (5). Next, unscrew the retaining nut (2). Push thenozzle body (3) out of the retaining nut (2). The filter withgasket (4) will come out with the body. To reinstall the nozzle,reverse the above instructions.
1.3.2. Assembly Instruction for Wand

1.  Insert wand into shut-off valve as shown.
2.  Tighten the screw cap clockwise onto the shut-off valve.

 

1.3.3. Pump Lever Installation
 
All hardware necessary for pump lever installation is included with the sprayer. The pump lever (C) should be installed as follows: place lever handle (C) onto the shaft (A). Align bolt holes and install the two bolts (E) and washers (F); then tighten. To install pump lever on the opposite side, remove the stop plate (D) and washer, install the pump lever as above. The stop plate (D) should be mounted on the inner bolt hole with the closed end of the stop plate pointing downward on the opposite side of the pump shaft.
1.3.4. Fold Away Pump Handle
1. Remove bolt and nut (A) from pump rod (B).

 

 

 

 

2. Slide handle assembly over the pump rod and align the holes so that the rear (elbow) portion of the handle points up and slightly forward and away from the Solo logo. Reinstall bolt and locknut. Pump handle can be installed on the opposite side of the sprayer for right hand pumping. (Stop plate will need to be relocated to the left side.)

 

3. The handle can be rotated to either down (pumping) or up (storage) positions. Note: The handle swings away from the sprayer, then up or down as desired. The spray wand attaches to the clamps on the handle assembly for storage (does not apply to the brass wand).

1.3.5. Shoulder Strap Installation
The top of the shoulder straps are pre-attached to the sprayer by means of a buckle. The lower end of the straps are attached by fastening the strap hooks to the metal frame between where frame exits the plastic tank and makes a bend.
1.3.6. Regulating Pressure
The Solo backpack sprayer is equipped with a built-in regulator to control output pressure. This regulator is operator adjustable. Make adjustments prior to filling tank. To adjust the regulator, remove the tank cap and the filter basket. Look inside the spray tank; you will see the top of the regulator. There are 4 fingers on the regulator knob. The finger farthest to the right is #1; to the left is #4. They are numbered 1, 2, 3, 4. 1 = 15 psi, 2 = 30 psi, 3 = 45 psi, 4 = 60 psi. The higher the pressure, the more chemical applied from the sprayer in a given amount of time, but the droplets will be smaller with more drift. If the spray pressure must be changed, excess pressure in the pressure cylinder must be released back into the tank through the spray tube. To adjust, push down on the knob and rotate to align the desired number with the alignment pin. If a spray pressure exceeding 60 psi (4 bar) is required, first release the excess pressure and then replace the adjustment piece with the optional plug (#4200215). The plug should only be used on piston pump sprayers.

Please note: the maximum pressure the models 425, 435 are capable of is 90 psi and the 474, 475, 476 and 485 models is 60 psi. For operating the 425, 435 at higher than 60 psi, the pressure control valve must be removed and replaced with an optional plug (#4200215) (see item B).

 

1.3.7. Filling
Mix the spray formula and the proper volume of water in a separate container. Pour the mix through the filter basket in the tank opening. This keeps debris from entering sprayer. Note: To fill the sprayer to its full 4 gallon capacity, set the pressure control valve to the 3 or 4 setting. (See Above: "Regulating the Pressure.") Add 2 or 3 gallons of spray formula mix. Pumpthe sprayer handle to prime the pump and fill the pressurecylinder. The volume of liquid in formula mix tank will appear todecrease as the pressure cylinder is filled. Liquid will flow through the top of the pressure regulator when the cylinder iscompletely full. Add the remaining formula mix to the tank.Remember that it's not necessary to completely fill the sprayer tank each time. Mix only the amount needed to get the job done.

Always read and follow manufacturer's instructions printed on the product label. This cansave money and help prevent crop and environmental damage.

1.3.8. Operating Features

Nozzles - Your Solo sprayer is standard with nozzle arrangements to provide a variety of spray patterns. 
  

Item Application Part #
Flat spray nozzle Row treatment 4074263
Jet stream nozzle Spot & longer range 4074755
Jet stream nozzle and Swirl plate = Hollow Cone Shrubs and bushes 4074755
4074756
Plastic adjustable nozzle Spot, shrubs & bushes 4900527
1.3.9. Sprayer Tip Assembly
1. Flat spray nozzle
2. Filter
3. Jet cap
4. Swirl plate
5. Nozzle cap
6. Nozzle body
7. Brass adj. nozzle*
8. Nozzle retaining nut













  Flatspray    

Hollowcone
 spray

Brass
adjustable
nozzle

Jetstream

Plastic
adjustable nozzle



* Brass adjustable nozzle is not a standard item on all sprayers.
Spray tips should be assembled as above for desired spray pattern
1.3.10. Spraying

Prime the pump with rapid pump strokes. When you feel very firm resistance, the pressure chamber is filling with liquid. With repeated piston strokes, the air in the pressure chamber is slowly compressed. By pressing the hand lever, the valve opens, and liquid is forced through the nozzle. The shut-off valve has a retaining clip which keeps the valve in the "OPEN" position for continuous operation. Pump using the end of the pump handle, as it is less fatiguing. The volume of liquid delivered varies with the working pressure which should be as high as needed to ensure an adequate spray pattern for each individual application.

NOTE: Should the pressure drop very quickly, drain the tank completely and pump without liquid. By this procedure, the air chamber is refilled with the required volume of air. It is advisable to pump the tank completely empty from time to time.

1.3.11. Wettable Powders
Wettable powders are abrasive by nature and will cause wear to the Viton® collar, piston pump and cylinder of the model 425, 435 sprayer. The Solo models 474, 475, 476 and 485 sprayers with a diaphragm pump are generally resistant to abrasive materials and are recommended for this purpose. Note: If you use a wettable powder in your 425, 435 sprayer, be sure it is thoroughly mixed in the formula solution. Immediately after use, be sure to remove the piston, clean and lubricate the Viton® collar with Solo Superior Grease or petroleum jelly. Thorough flushing of sprayer will extend the useful life of its working parts. If you use wettable powders in the piston pump sprayer be sure to inspect regularly for seepage around the piston and repair accordingly.
1.3.12. Cleaning

  • After spraying, clean the tank thoroughly. If some spray liquid is left inside, drain tank completely.

  • Pumping causes air to be taken in and the remaining liquid to be discharged. Pump until liquid and air are coming out through the nozzle.

  • Refill tank with a few quarts of clean water and pump the water out as explained above (if necessary, repeat this procedure several times).

  • If the shut-off valve is removed, the pump can be flushed quickly. Improper spray distribution is the result of a clogged nozzle, which is easily removed and cleaned.

  • Soap and water may also be used to clean tank.

  • Do not use aggressive cleaning agents or abrasives.

  • Follow the recommendations of the chemical manufacturer for disposal of waste water and chemicals.

  • Activated charcoal in liquid or other form may be used to absorb chemicals in tanks or spills.

 

NOTE: When cleaning the sprayer after working with hormone weedkillers, follow the instructions of the herbicide producers. Neutralize with activated charcoal. (Example: add 0.35 oz./1 g. of activated charcoal to 1.7 pint/1 liter of water and leave this detergent in the tank and the lines approximately 24 hours.) This is very important if other chemicals should be sprayed as the residues of the herbicide may damage susceptible plants. Cleaning after application of products containing carbolineum, if they are not water soluble, should be done with a 5% soda lye having a temperature of 104°F (40°C). Rinse with plenty of clean water.

1.3.13. Maintenance and Storage Tips
 

To protect the piston, cylinder and Viton® collar, a fine mesh, stainless steel screen is located on the pressure cylinder inlet.

If you find that your sprayer will not empty the formula tank, check for a clogged inlet screen (2). The inlet screen is located at the bottom of the pressure cylinder on the side that faces your back.

One indication that it needs cleaning is that when you let go of the pump handle, it "springs" to the down position. The screen can be cleaned with a small bristle brush or a discarded toothbrush. See diagram for location of screen.

1. Pressure Cylinder
2. Inlet Screen
3. Cylinder Support
4. Pressure Control
    Valve

  • After operation, the sprayer should be stored away from direct sunlight to prevent UV damage.
  • After removing the pump or when mounting a new
    Viton® collar, treat both the collar and the piston with
    water-resistant grease.*
  • Before winter, drain all liquid in tank, lines and air
    chamber. (See "Cleaning.") Leave shut-off valve locked in the "open" position.
  • For service, call on your nearest Solo dealer.
    Always insist on original Solo spare parts.
  • Regularly inspect hose, wand, pump, tank and shut-off valve for wear, damage or leaks. Repair promptly.

Avoid excessive wear by:

1) Regular lubrication of Viton® collar, cylinder and piston with water resistant grease.*
2) Prompt and thorough cleaning and flushing of sprayer. Soap and water work well.

*Use Solo Superior Grease (#9850). Petroleum jelly may also be used.

1.4. General Information

 

Since its launch into the market in the 1960's, the Solo backpack sprayer has retained its pleasing appearance, efficiency, and ergonomic design. While little has changed in the sprayer's physical appearance, it has undergone many significant changes in functional efficiency, materials, and durability.

Often poorly imitated, the Solo backpack sprayer maintains its worldwide leadership role through adherence to quality and performance standards which are widely envied. Solo offers customers a wide choice of products and features.

425 (4 gal.) and 435 (5 gal.): piston pump generates higher pressure to atomize the formula. The droplets are smaller and hence suitable for pest control. Use a Solo 425 or 435 sprayer when treating shrubs, bushes, and trees with insecticide or liquid fertilizer.

475 474, 476 (4 gal.) and 485 (5 gal.): diaphragm pump generates lower pressure resulting in larger droplets with less spray drift but thorough coverage. The diaphragm pump is preferable for use with wettable powders whose abrasive nature may cause wear to piston pumps.

1.4.1. Unit Weight

HOW HEAVY IS THE UNIT?

When empty, models 425, 474, 475 and 476 weigh only 9.5 lbs. and models 435 and 485 weigh 11.5 lbs.

1.4.2. Pressure Limitations
CAN THE SPRAY TANK STAND THE PRESSURE?

Although quite strong, the spray tank itself is intended only as a container for the spray solution. Pressure is maintained in a separate pressure chamber. This chamber is injection molded and built to withstand normal operating pressure. Additionally, an internal pressure control valve has been fitted to the cylinder and has four pressure settings adjustable to specific spraying needs (see "Regulating the Pressure" page 2).

1.4.3. Spot Spraying
CAN I DO SPOT SPRAYING?

The shut-off valve on the Solo sprayer is well suited for spot spraying. It's almost effortless! The shut-off valve handle incorporates a clip which holds the trigger valve open for area spraying without tiring the operator's hand. A pressure gauge may be added with increments from 5 psi up to 90 psi.

1.4.4. Pumping
DOES THE UNIT REQUIRE CONSTANT PUMPING?

The well-designed lever action greatly reduces the pumping effort. The pressure cylinder within the tank has a hydraulic effect. Liquid from the pump compresses air in the pressure chamber which allows irregular pumping action, yet results in steady spray at the nozzle.

1.4.5. Chemical Compatability
CAN I USE WEEDKILLER AND INSECTICIDE IN THE SAME SPRAYER?

In theory you can, if the sprayer is thoroughly cleaned out with a bleach:water solution of 1:25. In practice, the use of both types of chemicals in the same unit is not recommended as the risk to the plants can be high. Use caution when handling any type of chemical and when cleaning your sprayer.

1.4.6. Sprayer Uses
POSSIBLE USES OF SPRAYER:

Plant feeding and protection - A variety of spray tips enables user to perform foliar feeding or apply fungicides and pesticides effectively.

Herbicides - May be applied to reduce pesky weeds and plants; however, avoid using same sprayer for plant feeding or protection without first thoroughly cleaning. (See "Cleaning".)

Indoor use - Sprayers may be used to apply detergents, vinegar, cleaning solutions, warm water up to 120°F (49°C) and other nontoxic household cleaning and maintenance liquids. Carpets, walls, glass, floors, ceilings and other surfaces can be treated. Do not use sprayer which has previously been used with herbicides, pesticides or other toxic chemicals.

Outdoor use - Window cleaner, detergent, general purpose cleaning solutions, certain wood preservatives, waxes, waterproofing, and diluted household bleach (maximum 1 part household bleach with 9 parts water solution) are among the many things Solo sprayers can apply. Avoid using sprayer for cleaning and other applications once it has been used for plant protection or herbicide spraying. If sprayer was used for herbicide or other spraying first, clean the sprayer as described on page 4 before using.

1.4.7. Calibrating The Sprayer
CALIBRATING THE SPRAYER

The output of the sprayer should be checked by collecting and measuring the spray liquid emitted during one minute. Maintain steady pumping on the pump handle while measuring. Having determined the output from the nozzle in gallons/minute, the rate per unit area treated can be calculated knowing the swath width and walking speed.

Gal./acre = (Gal./min. of nozzle) x 43560 Sq. ft./acre
(Sq. ft./min.)
Note: Gal./min. for standard nozzles

4074263 Flat Spray Nozzle 5 PSI = .22 Gal./min. nozzle
29 PSI = .33 Gal./min.
44 PSI = .40 Gal./min.
4074755 & 4074756 Hollow Cone Nozzle 15 PSI = .17
29 PSI = .24
44 PSI = .29
4900527 Plastic Adj. Nozzle 40 PSI = .4 straight stream
40 PSI = .2 hollow cone

Sq. ft. / min. = speed (ft./min.) x swath width (ft.)

1. Determine the nozzle's rated capacity. See page 6 for nozzle ratings. Get the capacity in gallons/minute at the desired pressure. Test the delivery of the nozzle. Spray for one minute and collect the spray.

Gal./min. = oz. collected/minute
128 oz. = 1 gal.


2. Compute the area covered in square feet per minute. Select a comfortable walking speed and figure how many feet per minute you walk. A convenient fast walk for some is 2.5 mph, but this may vary. One mile per hour equals 88 feet per minute. An easy way to calculate is to simply measure the distance you walk in one minute.

3. Compute the gallons per acre. The above information is used to compute the gallons of spray that will be applied per acre.

1.4.8. Nozzle Tip Specifications

 

Nozzle Tip Specifications
Description Order Number Spray Volume Pressure Angle Applications
1/min US gal
/min
atu
atm
psi
Flat spray nozzle 4074263* 0.88 
1.25
1.53 
.23
.33
.40 
1.0
2.0
3.0
15
29
44 
120°
120°
120° 

Area and row treatment

Flat spray nozzle - brass plastic with
stainless steel insert
0065210
0065132
0.46 
0.64 
0.78 
.12
.17
.21 
1.0
2.0
3.0
15
29
44 
80°
80°
80° 
Adjustable nozzle - brass - plastic 4900207**
4900527*
1.53
0.76 
.40
.20 
2.8
2.8
40
40  
Straight Stream 
Hollow Cone 

Tree Spraying (adjustable spraying pattern)

Full cone nozzle 0065212 30°-50°  Game repellants of high viscosity
Full cone nozzle 0065213
30°-50°  Game repellants of low viscosity
Full cone nozzle 0065214         Game repellants
Hollow cone nozzle
1 mm orifice
4900209 0.40
 0.55 

.10
.15  

1.0
2.0
15
29
  Shrubs, bushes

Hollow cone nozzle
1.4 mm orifice
4900252 0.64
0.91
1.11 

.17
.24
.29

1.0
2.0
3.0
15
29
44 
50°
65°
 65° 
Hollow cone nozzle
1.8 mm orifice
4900322* 0.88
1.2
 1.53 
.23
.33 
40 
1.0
2.0
3.0
15
29
44
55°
70°
72° 
No-drift nozzle
AN 0.5
4074383 0.23  .06  1.0  15  90°   Mainly for herbicides at low pressure

No-drift nozzle
AN 1.0
4074385 0.28 
0.38
0.46 

.07
.10
.12 

0.4
0.7
1.0
6
10
15 
100°
100°
100°
No-drift nozzle
AN 2.0
4074386 0.55 
0.76 
0.91 

.15
.20 
.24 

0.4
0.7
1.0
6
10
15 
100°
100°
100° 
No-drift nozzle
N 2.5
4074514 0.72
0.95
1.14 

.19 
.25
.30 

0.4
0.7
1.0
6
10
15 
110°
110°
110° 
No-drift nozzle
AN 5.0
4074513 1.80
1.90
2.28 

.48 
.50
.60 

0.4
0.7
1.0
6
10
15 
120°
120°
120°
Foam nozzle 4900397 0.76 
0.90 
1.01
1.10

.20
.23
.26
.29

3.0
4.0
5.0
6.0
45
60
75
90
The XAN 2 nozzle is suited for low drift and water saving application of herbicides which tend to foam

1.5. Service and Repair
Click on a link on the left for information about service and Repair.
1.5.1. Service & Repair Video
Click Here to view a Service and Repair Video  (Windows Media Player)
1.5.2. Pump Operation
 
How The Pumps Work

During the upward stroke of the handle on either the piston (1) or diaphragm (2), liquid is drawn from the formula tank (3) through the intake channel (4) into the space above the pump. The lower valve plate (5) opens the intake channel (4) while the upper valve plate (8) closes the transfer ports (6). During the subsequent upward strokes on piston or diaphragm, the previously siphoned liquid is forced through the four transfer ports (6) and into the pressure cylinder (7). During this compression phase, the upper valve plate (8) opens the transfer ports and the lower valve plate closes, sealing the intake channel (4). The transfer ports cannot be sealed by the lower valve plate.

Through repetition of these piston or diaphragm strokes, the air in the pressure cylinder is being 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 until the required pressure is reached.

After opening the shut-off valve, continue to pump slowly and steadily in order to maintain a consistent rate of discharge.

 

Models 425, 435
Piston Pump

Models 474, 475, 476, 485
Diaphragm Pump

1.5.3. Troubleshooting
 
Backpack Sprayer Troubleshooting Guide

PROBLEM

CAUSE

SOLUTION
Difficulty in moving pump lever Dirty bushing


Dirty cylinder walls (425)


Collar swollen from long term exposure (425)

Lack of lubrication (425)
Remove pump lever, clean & grease bushings

Remove piston, clean/replace piston & collar

Replace collar and maintain according to instructions

Lubricate Viton® collar

Insufficient resistance during repeated pumping and no pressure Damaged/dirty valve plates

Damaged O-ring at valve seat

Collar or piston (425) worn

Seal in pressure regulator is leaking

Clean or replace valve plates or cylinder

Replace O-ring 

Replace collar or piston

Check seal and valve seat


High resistance after just a few pumping strokes, pressure lasts only briefly Little or no air cushion in pressure cylinder Remove PVC hose, drain pressure cylinder, Reconnect hose. Preventive measure - release pressure after each use

During spraying, upward pumping becomes more & more difficult and tank walls may indent upwards

 

When handle is pulled up it wants to move itself forcibly back down

Wrong formula tank cap (no vent hole)

Vent hole clogged

Lower valve plate sticks

Intake channels clogged

Inlet screen at base of pressure cylinder clogged

Replace with vented cap


Clean vent hole.

Replace valve plate

Clean channels & tank

Clean intake screen with a small brush and detergent

Leaks inside cylinder (425)
Leaks outside cylinder (425)




Leaks from diaphragm pump  (474, 475, 476, 485)





Leaks from end of spray wand
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
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 

 

Note: Always wear rubber gloves, safety goggles and appropriate protective clothing when repairing a sprayer. Work in well ventilated area. Prior to repair, flush unit with water by filling, then spraying the water into an appropriate container or area. Ensure that all pressure is released by locking the shut-off valve in the open position. Once a repair is completed, fill the unit with clean water, pressurize, and check for leaks. If the sprayer leaks, Do Not Use. Repair leaks and recheck.

1.5.4. Piston Pump Repair
 
Piston Pump Disassembly And Repair


1) Using a 13mm socket wrench remove the handle bolts, and set handle and bolts aside. Lay unit on its back with pump system facing you. See Figure 1. Loosen hose clamp (E) by unscrewing the bolt. Pull off sprayer hose. Caution: there may be liquid inside the hose and
pressure cylinder even if the tank is empty. Wear protective gloves. Next, remove the nut and bolt from protective cap, and remove cap (C). Loosen stop plate (A) but do not remove. Rotate the pump shaft to access the two lever bolts in the center (B). Using a 6mm Allen head wrench, remove them. Pull the piston (F) out of the piston cylinder (D)



Figure 1

2) To remove the piston cylinder assembly, turn the piston cylinder counter clockwise when viewing from the bottom. Figure 2. Caution: the piston cylinder has sharp edges.

 


Figure 2

3) Check the inside of the piston cylinder and the piston for vertical scratches. If the piston cylinder or piston are scratched, replace it. Figure 3.

 


Figure 3

4) To remove the connecting rods from the piston and lever, insert a flathead screwdriver between the two connecting rods and twist. Figure 4.

 


Figure 4

5) With the new piston, place the two connecting rods over the studs on the inside of the piston. Place the lever studs into the connecting rods and snap together with your fingers. Figure 5.

 


Figure 5

6) To replace the Viton ® collar, push it off of the top of the piston with your thumb. Figure 6. Install the new collar on the piston crown into the form fitted sides.


Figure 6

 

7) Remove the valve plate and O-rings from the outside of the piston cylinder. Install the new valve plate and the two O-rings, making sure the O-rings seat in the grooves. Finally, inside the piston cylinder you will find a second valve plate. Using needle nose pliers, pull out the red or orange pin and remove the valve plate. Figure 7. Install a new valve plate and firmly reseat the retaining pin using needle nose pliers. Figure 8.

 


Figure 7


Figure 8

 

8) Next, assemble the piston cylinder. First grease the O-ring on the piston cylinder, being careful not to get any on the valve plate, and then place the piston cylinder into the pressure cylinder. Screw the piston cylinder clockwise until it is tight and the bottom O-ring is no longer seen. Figure 9. When properly seated the notch on the piston cylinder (G) will line up with the catch on the pressure cylinder (H). Figure 10.

 


Figure 9


Figure 10

 

9) Apply a light coat of grease to the inside of the piston cylinder wall and on the Viton® collar, and then re-install the piston into the piston cylinder. Figure 11. Insert the piston at a slight angle with the leading edge of the Viton® collar placed over the slot in the piston cylinder. Install the 6mm Allen head bolts through lever base into shaft.

 


Figure 11

10) Replace the protective cap and tighten the nut and bolt. Reinstall the handle. Re-tighten the stop plate, making sure the bolt goes through the rear hole. Replace the hose and black hose clamp making sure it is firmly secured.


Figure 12

1.5.5. Diaphragm Pump Repair
DiaphragmPumpDisassembly and Repair

1) Loosen the stop plate (A) and remove the two Allen headscrews(B) that hold the connecting pieces to the pump rod. Figure 13.



Figure 13

 

2) Remove the pump rod (C) and the hose (D). Next, loosen the clamp at the base of the sprayer (E). Figure 14.


Figure 14

 

3) Push the pressure cylinder approximately 1" out of the bottom of the tank.Then turn the pump assembly 180°.

 

4) Next, remove the12 torx screws that hold the flange in place. The flange and diaphragm can then be removed. Figure 15. Note: For clarity of this information the pressure cylinder is shown removed from the tank.

 


Figure 15

 

5) To replace the diaphragm, remove the connecting rod retaining screw (G) from the plunger and lever (F). Replace the diaphragm and reassemble.See Figure 16.

 


Figure 16

 

6) The valve assembly (H) is removed using a locally made tool. See tool drawing for measurements to make tool. Remove valve plate retaining pin and insert tool into slots. See Figure 17. Use a screwdriver to rotate tool counter-clockwise.

 


Figure 17

(Tool can be ordered from Solo - #4400222-T  $1.95)

 

7) Once the valve assembly is removed, the valve plates and O-rings can be replaced.
Remove the lower valve plate by pulling out the red retaining pin. Figure18.

 


Figure 18

 

8) The pump housing (I) is separated from the pressure cylinder (J) by pulling it off. Figure 19. The O-ring can then be replaced.


Figure 19

 

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 pressure cylinder in Figure 20. Be careful not to pinch or nick the O-ring.


Figure 20

 

10) Screw the valve assembly into the cylinder. Be sure that the two square holes on the threaded portion of the valve assembly are aligned with the holes in the pressure cylinder. If the pressure cylinder was removed, look through the inlet screen to check alignment. If the pressure cylinder was not removed, the four holes of the valve assembly must be centered on and facing the hose nipple.

 

11) Reinstall the diaphragm and the flange with the twelve screws. Note: The rib with"Solo" on the lever should be facing and in line with the hose nipple. Tighten the large clamp and reinstall other parts.
1.5.6. Pressure Cylinder Repair
 
Diaphragm Pump Disassembly and Repair

1) Loosen the stop plate (A) and remove the two Allen head screws (B) that hold the connecting pieces to the pump rod. Figure 13.



Figure 13

 

2) Remove the pump rod (C) and the hose (D). Next, loosen the clamp at the base of the sprayer (E). Figure 14.


Figure 14

 

3) Push the pressure cylinder approximately 1" out of the bottom of the tank. Then turn the pump assembly 180°.

 

4) Next, remove the 12 torx screws that hold the flange in place. The flange and diaphragm can then be removed. Figure 15. Note: For clarity of this information the pressure cylinder is shown removed from the tank.

 


Figure 15

 

5) To replace the diaphragm, remove the connecting rod retaining screw (G) from the plunger and lever (F). Replace the diaphragm and reassemble. See Figure 16.

 


Figure 16

 

6) The valve assembly (H) is removed using a locally made tool. See tool drawing for
measurements to make tool. Remove valve plate retaining pin and insert tool into slots. See Figure 17. Use a screwdriver to rotate tool counter-clockwise.

 


Figure 17

7) Once the valve assembly is removed, the valve plates and O-rings can be replaced.
Remove the lower valve plate by pulling out the red retaining pin. Figure 18.

 


Figure 18

 

8) The pump housing (I) is separated from the pressure cylinder (J) by pulling it off. Figure 19. The O-ring can then be replaced.


Figure 19

 

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 pressure cylinder in Figure 20. Be careful not to pinch or nick the O-ring.

 


Figure 20

 

10) Screw the valve assembly into the cylinder. Be sure that the two square holes on the threaded portion of the valve assembly are aligned with the holes in the pressure cylinder. If the pressure cylinder was removed, look through the inlet screen to check alignment. If the pressure cylinder was not removed, the four holes of the valve assembly must be centered on and facing the hose nipple.

11) Reinstall the diaphragm and the flange with the twelve screws. Note: The rib with "Solo" on the lever should be facing and in line with the hose nipple. Tighten the large clamp and reinstall other parts.
1.5.7. Shut-Off Valve Repair
 
Shut-Off Valve Disassembly & Repair

1).Complete shut-off valve. Figure 27.

 


Figure 27
2) Remove the retaining pin (A). Rest the split end of the retaining pin on a hard surface (such as a table) and push. Once the retaining pin pops up, remove it. Now slide the handle off the valve body. Figure 28.

 


Figure 28
3) With the handle off, remove the screw cap, spring, and valve body. Replace worn parts. Lubricate the O-rings and reassemble in reverse order. Note: The valve body (B) depicted is white for clarity. Figure 29. Next, place the handle groove into the slotted part of the valve body, making sure that the locking clip is positioned correctly. Insert the retaining pin. Push down on the handle and release repeatedly so the grease distributes evenly.  


Figure 29

1.5.8. Wand Repair Kit
 
Wand Repair Kit 0610411-K

The backpack and handheld sprayers use the same shut-off valve, wand and elbow nozzle assemblies, and repair kit. If the sprayer is equipped with a plastic adjustable nozzle, unscrew the nozzle cap first. Remove the nut, nozzle, nozzle O-ring, filter, filter O-ring, and elbow from the wand. Remove the O-ring from the elbow, and discard. Reassemble using the nut, nozzle, new nozzle O-ring, filter, new filter O-ring, elbow and new elbow O-ring in that order. Reassemble the retaining nut to the elbow. Metal screen filters with rubber-like gasket do not require an O-ring on either side.

Remove the wand from the shut-off valve assembly. Remove the O-ring from the wand and replace with new O-ring. Set the wand aside.

1) Disconnect the shut-off valve from the hose. Remove the retaining pin. Press the split end of the pin on a hard surface (such as a table) and push. Once the retaining pin pops up, remove by pulling out. Now slide the handle off the valve body. With the handle off, remove the screw cap, spring, and valve body. Replace worn parts. Lubricate the O-rings and reassemble in reverse order. Note: The valve body (c) depicted is white for clarity. Figure 29, page 10. Next, place the handle groove into the slotted part of the valve body, making sure that the locking clip is positioned correctly. Insert the retaining pin. Push down on the handle and release repeatedly so the grease distributes evenly.

2) On the older backpack sprayers without a metal washer between the clamp and screw cap, the clamp is to be replaced with the newer version in the repair kit. Remove the old clamp, O-ring, screw cap, and cut off approximately one inch of the hose. Install the new screw cap and metal washer over the hose. Wearing gloves to protect your hands from the heat, place the end of the hose in boiling water for fifteen seconds. Partially insert the longer end of the clamp into the hose and push against a flat surface. Finally put the O-ring onto the clamp. Pull the screw cap and metal washer up to the shut-off valve and screw tight.

3) Reinstall the wand to the shut-off valve. Finally, reinstall the elbow to the wand.

4)Test with water before using.

1.5.9. Wand Tip Assembly Video
Click Here to view the wand tip assembly video (Windows Media Player)
1.6. Spare Parts Lists
 
1.6.1. 425, 475, 435, 485, 474, 476 Illustrated Backback Sprayer Parts List

Special Parts& Accessories 
(Not shownin parts list)
Click on order number to order desired part.

OrderNo. Description
4900310N Conversionkit (from piston to diaphragm pump)
0610406-K Diaphragm,pump repair kit includes 8, 11-13, (2 ea.), 24, 25,66
0610407-K Pistonrepair kit includes 8, 10-13, 20 (2 ea.), 24, 25, 44
0610411-K Wandrepair kit includes7-10, 22, 26, 34, 49, 103 (see 13)
0610409-K Piston,rod & collar kit includes 41-44, 54
4400203 PumpAssembly (425,435) includes 1,8,11,12,13,20 (2 ea.),39,40,41,42,43,44,54
4400221 PumpAssembly (475,485) 1,8,11,12,20 (2 ea.), 39,61,63,64,(13 ea.),65,66,67,68,69,70,72 (2 ea.), 106

 

BackpackSprayer Parts List -Order
Part numbers correspond withimage above.
Click on order number to order desired part.

Pos.No. OrderNo. For 
Model
Description
2 0010165 Bolt
3 0012185 Bolt
4 0030131 Washer
6 0012185 Bolt
7 0610402-K Shut-off valve repair kit
8 0062258 gasket
10 0062115 O-ring
11 0062291 O-ring
12 0062139 O-ring
13 0062140 O-ring
14 0064234   Hose48" (item 34 incl.)
15 0066388 Hose clamp
16 0066394 Clamp
17 4043123 Stop Plate
18 4035111 Pump Shaft
20 4061257 Valve Plate
21 4200242 Red tank cap (item 48, 98 & 99incl.)
-- 4200305

Heavy Duty

Black tank cap (item 48, 98 &99 incl.)
22 4074148 Retainingnut
23 4074323 Valve body
24 4074350 Sealing piece
25 0070260 Compression spring
26 4074337 Retaining Nut
27 4074344 Control knob
28 4074410 Bushing
29 4074263 Flat spray jet
30 4074756 Swirl plate
31 4074283 Jet filter
32 4074755 Jet cap
33 4900527 Plastic adjustable nozzle (inc. a& b)
34 4074500 Clamp
35 4074527 Elbow
36 4200162

425,474,
475,476

Tank& frame assy., 4 gal
call for pricing 435,485 Tank &frame assy., 5 gal
37 4200106 Filter Basket
38 4300315 Carryings trap (item 73 incl.)
39 4400240 Pressure cylinder 
(item 10, 23-25, 27 incl.)
 39  4400240N Pressure cylinder (solid)
40 4073190 Cylinder assy. (item 12,13,20 inc.)
41 4074409 Connecting rod without stud
42 4074262 Lever
43 4073558 Piston
44 4400189 Viston®collar
45 4800170 Shut-offv alve assy.
46 480017325 Pump lever (item 75 incl.)
47 4900230 Spray tube 20"
48 4061345 Gasket
49 0031356 Washer
51 4074680 Protective cover
52 0010110 Bolt
53 0020101 Hex nut
54 4074408 Connecting rod with stud
55 4074412 Buckle
55-a4074425  Pin, backpack straps
584074996 Clip, wand retaining
60 4073411 Housing (diaphragm)
61 4073410 Flange
63 4400222 Valve assy. (item 12, 20 incl.)
64 0018275 Screw
65 4074256 Plunger
66 4074246 Diaphragm
67 4074255 Lever
68 4031130 Wrist pin
69 4074234 "R"connecting bracket
70 4074243 "L"connecting bracket
72 0010141 Bolt
73 4074837 Hook
75 4074392 Grip
97 4074295 Pin
98 4061464 Vent plate
99 4074123 Vent cap
100 4074329 Lock clip
101 4074336 Retaining nut
102 4074335 Lever
103 0062271 O-ring
106 0062324 O-ring
1 4200215 Plug (item8 incl.)
50 4900454 Fold away handle (item 58 incl.)
56 0020119 Nut
57 0012192 Bolt
58 4074996 Clip
59 0065210

Heavy Duty

Brassflay spray nozzle
 

4073725

 Carry Handle
76 4900430   Driftguard
80 4900477 Double spray nozzle
81 4900528 Extension wand 60" (1250 mm)
90 4900622

Heavy Duty

Pressure gauge w/connection parts
92 4900513 Extension tube 20" (500 mm)
94 4074338 Retaining nut
95 0062249 O-ring
-- 0610410-P Adj. spray nozzle assy.
-- 4900207 Adj. spray nozzle
-- 4300343 Shoulder saver harness
96 4900258N Elbow nozzle assy.
1.6.2. 416 Spare Parts List
1.7. 416 Backpack Battery Sprayer Spare Parts List