Low-Pressure Switch Hose Replacement (Kit #185608)

Applies to: DEWALT Variable-Flow Backpack Sprayer (applies to models using Kit #185608 for Low-Pressure Switch Hose Replacement)

What causes this: This procedural guide covers replacement of the low-pressure switch hose assembly on the DEWALT Variable-Flow Backpack using Kit #185608, which includes the hose assembly, pressure switch, electrical connector, and two hose clamps. Perform this repair when the sprayer fails to build pressure, the low-pressure switch malfunctions, or the hose between the pump and outlet is leaking internally.

How to fix it:

1. WARNING: Remove all chemicals from the sprayer and clean it before starting. Release all pressure before disassembly.
2. Set the Power Switch to OFF. Remove the battery. Squeeze the shut-off lever to release any remaining pressure in the hose.
3. Detach the harness from the bottom of the sprayer and flip the sprayer upside down.
4. Using a Phillips-head screwdriver, carefully remove the nine (9) screws from the Lower Shroud. Gently pull the Lower Shroud from the bottom of the sprayer.
5. Remove the two (2) front pump screws. The other two screws can remain in place. NOTICE: Carefully move the wires away from the hose clamps before removing screws to prevent wire damage.
6. Gently lift the pump to access the pump hose barb clamp. Remove the pump hose clamp screw on the pump hose barb and on the outlet barb.
7. Using a hair dryer on high heat or a heat gun on the LOWEST setting, lightly apply heat to the hose ends for a few seconds to soften. Gently work the hoses off the barbs.
8. Disconnect the pressure switch wire connector by pressing on the clip and gently pulling apart. Remove and discard the old low-pressure switch/hose assembly.
9. If the spring is separated from the new assembly, re-insert it into the end of the shorter hose.
10. Slide the new clamps onto the end of each hose. Match the orientation of the screws to the instruction photos so the clamps can be tightened after installation.
11. Position the new Low-Pressure Switch Hose Assembly between the Pump Hose Barb and the Outlet Hose Barb. Briefly warm each hose end before sliding onto the barbs.
12. Install the pump barb hose first (it is easier this way), then the outlet barb hose. Gently push each hose fully onto its barb.
13. Slide each clamp over its hose barb with the clamp screw facing upward. Support the clamp by hand and tighten the screw until fully closed.
14. Insert the pressure switch electrical connector onto the matching white connector. Gently tighten the two (2) pump screws down.
15. Leak test before closing: Fill the tank with 1/2 gallon of water (do not spill into the open Lower Shroud). Install the battery, purge air by opening the shut-off, then run the pump with the shut-off closed starting at low pressure and increasing. If leaking, tighten hose clamps and retest.
16. Once the leak test passes, align the Lower Shroud with the bottom of the sprayer and slide it into place. Tip the sprayer forward and reinstall the nine (9) shroud screws.
17. Re-install the harness. Repair complete.

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