AIRLESSCO LP690 Instruction manual

®

A

IRLESS

P

AINT

S

PRAYER

S

ERVICE

/O

PERATION

M

ANUAL

AIRLESSCO

LP500 - LP540 - LP690

ALLPRO

510E - 710E - 810E

001-492 SEPT 08

2

TABLE OF CONTENTS

SECTION

Introduction........................................................................ 1

Warnings ........................................................................... 2

Flushing............................................................................. 5

How to Flush...................................................................... 5

Setting Up.......................................................................... 6

Starting Up ........................................................................ 6

Pressure Relief Procedure ................................................ 8

Daily Maintainance ............................................................ 8

Airless Spray Gun Operation ............................................ 9

Airless Spray Gun ............................................................10

Airless Spray Gun Troubleshooting..................................11

Tip Selection Guide..........................................................12

Electric Motor Maintenance..............................................13

Motor Brushes..................................................................13

Field Troubleshooting .......................................................14

Manifold Filter...................................................................14

Servicing the Fluid Pump .................................................15

Servicing the Outlet Valve................................................16

Servicing the Inlet Valve...................................................16

Packing Replacement Procedures...................................17

Gear and Pump Assembly ...............................................19

Carry Frame Models ....................................................... 20

Lo-Boy Models .................................................................21

Hi-Boy Models................................................................. 22

Suction Assemblies......................................................... 23

Pressure Control Assembly Calibration .......................... 24

Electrical System............................................................. 25

Replacement of Electrical Components .......................... 26

Troubleshooting- Machine Does Not Start ...................... 27

Notes ............................................................................... 28

Airlessco Accessories ..................................................... 30

FIGURES

1. Spray Gun Tip .............................................................. 5

2. Pressure Control knob ................................................. 5

3. Flushing........................................................................ 5

4. Flushing ........................................................................ 5

5 Throat Seal Oil ............................................................. 6

6. Pressure Adjustment Controls...................................... 6

7. Gun Safety Latch.......................................................... 9

8. Gun Components ......................................................... 9

9. Spray Tip ...................................................................... 9

10. Spray Tip Assembly..................................................... 9

11. Airless Spray Gun.......................................................10

12. Motor Brushes ............................................................13

13. Manifold Filter .............................................................14

14. Fluid Pump..................................................................15

15. Outlet Valve ................................................................16

16. Inlet Valves .................................................................16

17. V-Packings..................................................................17

18. V-Packings .................................................................18

19. Gearbox Assy.............................................................19

20. Sleeve Bearing Replacement.....................................19

21. Carry Frame Assy...................................................... 20

22. Lo-Boy Frame Assy....................................................21

23. Hi-Boy Frame Assy ................................................... 22

24. Lo-Boy and Carry Suction Assy ................................ 23

25. Hi-Boy Suction Assy.................................................. 23

26. Electrical System....................................................... 25

27. LCD............................................................................ 26

1

2

INTRODUCTION

CARRY FRAME HI-BOY FRAME Your new Airlessco or ALLPRO airless paint sprayer is designed to meet the demands of the professional painting contractor as well as the homeowner. The famous

Airlessco slow-stroking stainless steel piston pump delivers extra long life for the piston, packings, valve seats and balls. The patented Triple-Life packing system is externally adjustable, extending packing life and reducing repacking costs. Its large high-torque electric motor runs slower reducing heat. The motor is fan cooled and totally enclosed to reduce brush wear and to prevent the ignition of paint fumes in the motor.

LO-BOY FRAME

LP500

510E

Max Pressure 3000 PSI

Output (FreeFlow) 0.60 GPM

Output (At Pressure) 0.50 GPM

Tip Size (1 Gun) 0.023 in.

Motor DC TEFC

0.6 HP

LP540

710E

3000 PSI

0.75 GPM

0.57 GPM

0.027 in.

DC TEFC

0.9 HP

LP690

810E

3000 PSI

0.85 GPM

0.62 GPM

0.029 in.

DC TEFC

0.9 HP

WARNING

HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY

SERIOUS INJURY. OBSERVE ALL WARNINGS!

MANUAL NOTATIONS

WARNING - Alerts user to avoid or correct conditions that could cause bodily injury.

CAUTION - Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.

IMPORTANT - Alerts users to steps or procedures that are essential to proper equipment repair and maintenance.

NOTE - Identifies essential procedures or extra information.

BEFORE OPERATING THIS UNIT, READ AND FOLLOW

ALL SAFETY WARNINGS AND INSTRUCTIONS RELATED

TO THE USAGE OF THIS EQUIPMENT ON PAGES 2, 3 & 4.

READ, LEARN, AND FOLLOW THE PRESSURE RELIEF

PROCEDURE ON PAGE 8 OF THIS MANUAL.

All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.

NO MODIFICATIONS or alterations of any AIRLESSCO Equipment or part is allowed.

1

WARNINGS

MEDICAL ALERT - Airless Spray Wounds

If any fluid appears to penetrate your skin, get EMERGENCY

MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE

CUT. Tell the doctor exactly what fluid was injected. Have him read the following "NOTE TO PHYSICIAN".

NOTE TO PHYSICIAN: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. DO NOT DELAY treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

2

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. OBSERVE ALL

WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY.

INJECTION HAZARD

FLUIDS UNDER HIGH PRESSURE FROM SPRAY OR

LEAKS CAN PENETRATE THE SKIN AND CAUSE

EXTREMELY SERIOUS INJURY, INCLUDING THE

NEED FOR AMPUTATION.

NEVER point the spray gun towards anyone or at any part of the body.

NEVER put hand or fingers over the spray tip. Do not use rag or other materials over your fingers. Paint will penetrate through material and into the hand.

NEVER try to stop or deflect leaks with your hand or body.

ALWAYS have gun tip guard in place when spraying.

ALWAYS lock gun trigger when you stop spraying.

ALWAYS remove tip from the gun to clean it.

NEVER try to "blow back" paint, it’s not an air sprayer.

ALWAYS follow the PRESSURE RELIEF PROCEDURE, as shown on page 8, before cleaning or removing the spray tip or servicing any system equipment.

Be sure equipment safety devices are operating properly before each use.

ALWAYS tighten all fluid connections before each use.

MEDICAL TREATMENT

If any fluid appears to penetrate your skin, get

EMERGENCY CARE AT ONCE.

DO NOT TREAT AS A SIMPLE CUT.

• Go to an emergency room immediately.

• Tell the doctor you suspect an injection injury.

• Tell him what kind of material you were spraying with and have him read NOTE TO PHYSICIAN above.

GENERAL PRECAUTION

NEVER alter equipment in any manner.

NEVER smoke while in spraying area.

NEVER spray highly flammable materials.

NEVER use around children.

NEVER allow another person to use sprayer unless he is thoroughly instructed on its' safe use and given this operators manual to read.

ALWAYS wear a spray mask, gloves and protective eye wear while spraying.

ALWAYS ensure fire extinquishing equipment is readily available and properly maintained.

NEVER LEAVE SPRAYER UNATTENDED WITH

PRESSURE IN THE SYSTEM. FOLLOW PRESSURE

RELIEF PROCEDURES ON PAGE 8.

ALWAYS INSPECT SPRAYING AREA

Keep spraying area free from obstructions.

Make sure area has good ventilation to safely remove vapors. NEVER keep flammable material in spraying area.

NEVER spray in vicinity of open flame or other sources of ignition. Spraying area must be at least 20 ft. away from spray unit.

SPRAY GUN SAFETY

ALWAYS set safety lock on the gun in "LOCKED" position when not in use and before servicing or cleaning.

DO NOT remove or modify any part of gun.

ALWAYS remove spray tip when cleaning.

Flush unit with LOWEST POSSIBLE PRESSURE.

CHECK operation of all gun safety devices before each use. Be very careful when removing the spray tip or hose from gun. A plugged line contains fluid under pressure. If the tip or line is plugged, follow the PRESSURE RELIEF

PROCEDURE as outlined on page 8.

TIP GUARD

TIP GUARD

ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the injection hazard and helps prevent accidentally placing your fingers or any part of your body close to the spray tip.

SPRAY TIP SAFETY

USE EXTREME CAUTION when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately.

ALWAYS follow the PRESSURE RELIEF PROCEDURE before removing the spray tip to clean it.

NEVER wipe off build up around the spray tip.

ALWAYS remove tip & tip guard to clean AFTER pump is turned off and the pressure is relieved by following the

PRESSURE RELIEF PROCEDURE.

WARNINGS CONTINUED ON NEXT PAGE.........

3

2

WARNINGS - CONTINUED

HOSES

Tighten all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling and result in an injection injury or serious bodily injury.

GROUNDING

Ground the sprayer and other components in the system to reduce the risk of static sparking, fire or explosion which can result in serious bodily injury and property damage.

Use only hose that has a spring guard. The spring guard helps protect the hose from kinks or other damage which could result in hose rupture and cause an injection injury.

NEVER use a damaged hose, which can result in hose failure or rupture and cause in injection injury or other serious bodily injury or bodily damage. Before each use, check entire hose for cuts, leaks, abrasion or bulging of cover, or damage or movement of couplings. If any of these conditions exist, replace the hose immediately.

Never use tape or any device to try to mend the hose as it cannot contain the high pressure fluid. NEVER ATTEMPT

TO RECOUPLE THE HOSE. High pressure hose is not recoupleable.

Help prevent damage to the hose by handling and routing it carefully. Do not move the sprayer by pulling it with the hose.

LABELING

Keep all labels on the unit clean and readable.

Replacement labels are available from manufacturer.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed.

Know the hazards of the fluid you are using. Store & dispose of hazardous fluids according to manufacturer, local, state & national guidelines.

ALWAYS wear protective eyewear, gloves, clothing and respirator as recommended by fluid manufacturer.

ALWAYS GROUND ALL OF THESE COMPONENTS:

1. Sprayer: Connect a ground wire and clamp (supplied) to a true earth ground.

2. Fluid Hose: use only grounded hoses.

3. Spray gun or dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.

4. Object being sprayed: according to your local code.

5. All solvent pails used when flushing should only be metal pails which are conductive.

Once each week, check electrical resistance of hose (when using multiple hose assemblies, check overall resistance of unpressurized hose must not exceed 29 megohms (max) for any coupled length or combination of hose lengths. If hose exceeds these limits, replace it immediately.

Never exceed 500 Ft. (150 m.) overall combined hose length to assure electrical continuity.

KEEP CLEAR OF MOVING PARTS

Keep clear of moving parts when starting or operating the sprayer. Do not put your fingers into any openings to avoid amputation by moving parts or burns on hot parts.Precaution is the best insurance against an accident.

When starting the engine, maintain a safe distance from moving parts of the equipment.

Before adjusting or servicing any mechanical part of the sprayer, follow the PRESSURE RELIEF

PROCEDURE on page 8, and remove the ignition cable from the spark plug to prevent accidental starting of sprayer.

AMPERAGE

RATING

RANGE

5-6

6-8

8-10

10-12

UL RECOMENDATION FOR MINIMUM GAUGE EXTENSION CORD

VOLTAGE LENGTH OF CORD IN FEET

25 50 100 150 200 250 300 400

120

120

120

120

18

18

18

16

16

16

14

14

12

12

12

10

12

10

10

8

10

10

8

8

10

8

8

6

8

6

6

6

8

6

6

4

500

6

6

4

4

WARNINGS CONTINUED ON NEXT PAGE.........

3

WARNINGS - CONTINUED

AVOID COMPONENT RUPTURE

This sprayer operates at 3000 psi (205 bar). ALWAYS be sure that all components and accessories have a maximum working pressure of at least 3000 psi to avoid rupture which can result in serious bodily injury including injection and property damage.

NEVER leave a pressurized sprayer unattended to avoid accidental operation of it which could result in serious bodily injury.

ALWAYS follow the PRESSURE RELIEF PROCEDURE whenever you stop spraying and before adjusting, removing or repairing any part of the sprayer.

NEVER alter or modify any part of the equipment to avoid possible component rupture which could result in serious bodily injury and property damage.

NEVER use weak or damaged or non-conductive paint hose. Do not allow kinking or crushing of hoses or allow it to vibrate against rough or sharp or hot surfaces. Before each use, check hoses for damage and wear and ensure all fluid connections are secure.

REPLACE any damaged hose. NEVER use tape or any device to mend the hose.

NEVER attempt to stop any leakage in the line or fittings with your hand or any part of the body. Turn off the unit and release pressure by following PRESSURE RELIEF

PROCEDURE.

ALWAYS use approved high pressure fittings and replacement parts.

ALWAYS ensure fire extinquishing equipment is readily available and properly maintained.

WARNING: Do not use halogenated solvents in this system.

The prime valve, 2 gun manifold and most airless guns have aluminum parts and may explode. Cleaning agents, coatings, paints or adhesives may contain halogenated hydrocarbon solvents. DON"T TAKE CHANCES! Consult your material suppliers to be sure. Some of the most common of these solvents are: Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether, Ethylbromide, Ethylchloride,

Tethrachloethane. Alternate valves and guns are available if you need to use these solvents.

PREVENT STATIC SPARKED FIRE/ EXPLOSIONS

ALWAYS be sure all equipment and objects being sprayed are properly grounded.

ALWAYS ground sprayer, paint bucket and object being sprayed. See "grounding" on page 3 for detailed grounding information. Vapors created when spraying can be ignited by sparks. To reduce the risk of fire, always locate the sprayer at least 20 feet (6 m.) away from the spray area.

DO NOT plug in or unplug any electrical cords in the spray area, which can create sparks, when there is any chance of igniting vapors still in the air. Follow the coating & solvent manufacturers safety warnings and precautions.

Use only conductive fluid hoses for airless applications. Be sure gun is grounded through hose connections. Check ground continuity in hose & equipment. Overall (end to end) resistance of unpressurized hose must not exceed 29 megohms for any coupled length or combination of hose length. Use only high pressure airless hoses with static wire approved for 3000 psi.

FLUSHING

Reduce the risk of injection injury, static sparking or splashing by following the specific cleaning procedure on page 5.

ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 8.

ALWAYS remove the spray tip before flushing. Hold a metal part of the gun firmly to the side of a metal pail and use the lowest possible fluid pressure during flushing.

NEVER use cleaning solvents with flash points below 140 degress F. Some of these are: acetone, benzene, ether, gasoline, naphtha. Consult your supplier to be sure.

NEVER SMOKE IN THE SPRAYING/CLEANING AREA.

IMPORTANT: United States Government safety standards have been adopted under the Occupational Safety & Health

Act. These standards, particularly the General Standards,

Part 1910, & the Construction Standards, part 1926 should be consulted.

WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR THINNERS:

4

1. When spraying with flammable liquids, the unit must be located a minimum of 25 feet away from the spraying area in a well ventilated area. Ventilation must be sufficient enough to prevent the accumulation of vapors.

2. To eliminate electrostatic discharge, ground the spray unit, paint bucket and spraying object. Use only high pressure airless hoses approved for 3000 psi which is conductive.

3. Remove spray tip before cleaning gun and hose. Make contact of gun with bucket and spray without the tip in a well ventilated area, into the grounded steel bucket.

4. Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.

5. Do not smoke in spraying/cleaning area.

5

4

FLUSHING

1. NEW SPRAYER

Your unit was factory tested in an oil solution which was left in the pump. Before using oil-base paint, flush with mineral spirits only.

Before using water-base paint flush with mineral spirits, followed by soapy water, then a clean water flush.

2. CHANGING COLORS

Flush with a compatible solvent such as mineral spirits or water.

3. CHANGING FROM WATER-BASE TO

OIL-BASE PAINT

Flush with soapy water, then mineral spirits.

4. CHANGING FROM OIL-BASE TO

WATER-BASE PAINT

Flush with mineral spirits, followed by soapy water, then a clean water flush.

HOW TO FLUSH

FIG. 1 FIG. 2

REMOVE SPRAY TIP PRESSURE CONTROL KNOB

FIG. 3

CLOSED

(Pressure)

5. STORAGE

Oil-base paint: Flush with mineral spirits.

Water-base paint: Flush with water, then mineral spirits and leave the pump, hose and gun filled with mineral spirits.

For longer storage, use mixture of mineral spirits and motor oil (half & half). Shut off the sprayer, follow PRESSURE

RELIEF PROCEDURE on page 8 to relieve pressure and make sure prime valve is left open.

6. START UP AFTER STORAGE

Before using water-base paint, flush with soapy water and then a clean water flush.

When using oil-base paint, flush out the mineral spirits with the material to be sprayed.

PRIME VALVE

OPEN

(Priming & Pressure Relief

FIG. 4

MAINTAIN FIRM METAL TO METAL CONTACT

BETWEEN GUN AND CONTAINER

HIGH PRESSURE

Flushing Procedure

1. Be sure the gun safety latch is engaged and there is no spray tip in the gun. Refer to Fig. 1. Refer to your separate instruction manual provided with your gun on its safety features and how to engage safety latch.

2. Pour enough clean, compatible solvent into a large, empty metal pail to fill the pump and hoses.

3. Place the suction tube into the pail or place the pail under the pump.

4. Turn pressure control knob to low. Refer to Fig. 2.

5. Open the prime valve to the open - "Priming Position".

This will allow an easy start. Refer to Fig. 3.

6. Turn the engine ON/OFF switch to ON.

7. Point the gun into the metal pail and hold a metal part of the gun firmly against the pail Refer to fig.4.

8. Disengage the gun safety latch and squeeze the trigger.

At the same time, slowly turn the pressure control knob clockwise just enough to move liquid at low pressure.

9. Allow the pump to operate until clean solvent comes from the gun.

WARNING: To reduce the risk of static sparking, which can cause fire or explosion, always hold a metal part of the gun firmly against the metal pail when flushing. This also reduces splashing. Refer to Fig 4.

10. Release the trigger and engage the gun safety latch.

11. If you are going to start spraying, place the pump or suction tube into the supply container. Release the

gun safety latch and trigger the gun into another empty, metal container, holding a metal part of the gun firmly against the metal pail (Fig. 4), forcing the solvent from the pump and hose. When paint starts coming from gun, turn pressure control knob to minimum pressure, place prime valve in prime (open) position and engage the gun safety latch.

12. If you are going to store the sprayer, remove the suction tube or pump from the solvent pail force the solvent from the pump and hose. Engage the gun safety latch and refer to the "Storage" Procedure above. Step 5.

13. Whenever you shut off the sprayer follow PRESSURE

RELIEF PROCEDURE warning on page 8.

5

SETTING UP

1. CONNECT THE HOSE AND GUN

a. Remove the plastic cap plug from the outlet and screw a conductive or grounded 3000 psi spray hose onto fluid outlet.

b. Connect an airless spray gun to the other end of the hose, but do not install the spray tip yet!

NOTE: Do not use thread sealer on swivel unions as they are made to self seal.

2. FILL THE PACKING NUT/WET CUP

FIG. 5

Fill the Packing Nut/Wet

Cup with 5 drops of

Airlessco Throat Seal

Oil (TSO).

3. ELECTRICAL SERVICE

Be sure the electrical service is 120 VAC, 15 amp minimum, and that the outlet you use is properly grounded.

NOTE: FOR GENERATOR POWER, A MINIMUM

OF 7000 WATT GENERATOR WITH VOLTAGE

REGULATION MUST BE USED.

4. GROUNDING

WARNING: To reduce the risk of static sparking, fire or explosion which can result in serious bodily injury and property damage, always ground the sprayer and system components and the object being sprayed, as instructed in the safety warning section of this manual.

5. FLUSH THE SPRAYER

Follow “Flushing Procedure” on page 5 of this manual.

STARTING UP

1. LEARN THE FUNCTIONS OF THE

CONTROLS.

PRIME/PRESSURE (PR) RELIEF VALVE is used to prime pump and to relieve pressure from gun, hose and tip.

Prime/Pressure Relief Valve

PRESSURE CONTROL KNOB is used to adjust pressure. Turn clockwise (CW) to increase pressure and counterclockwise

(CCW) to decrease pressure.

FIG. 6

PRIME/PRESSURE RELIEF

VALVE (PRIME/PR VALVE):

Used to relieve pressure from gun/hose/tip and to primethe unit when in OPEN position. (It is in open position when there is a wider gap between valve handle and cam body). Learn and follow the PRESSURE RELIEF PROCE-

DURE on page 8 of this manual.

When in closed position (very slight gap) the system is pressurized and ready to spray.

(Prime/PR Valve) Used to relieve pressure from gun, hose & tip and to primethe unit when in OPEN position. (It is in open position when there is a wider gap between valve handle and cam body.)

When in CLOSED position,there is only a very slight gapbetween handle & body. When closed the system ispressurized. Handle as a loaded firearm!

PRESSURE CONTROL KNOB: used to adjust pressure only.

Turn clockwise to increase pressure and counterclockwise to decrease pressure.

6

When you turn the valve handle and the gap between the valve handle and the cam body becomes wider - this means the valve is in the open position. It is in the closed position when the gap becomes very small.

ON/OFF SWITCH FUSE

7

6

STARTING UP

2. PREPARE THE MATERIAL

a. Prepare the material according to the material manufacturer's recommendations.

b. Place the suction tube into the material container.

WARNING

To stop the unit in an emergency, turn the engine off. Then relieve the fluid pressure in the pump and hose as instructed in the PRESSURE RELIEF PROCEDURE.

3. STARTING THE SPRAYER

a. Prime/PR Valve must be "OPEN" in the priming

position.

b. When you have ensured that the gun safety latch is engaged, attach tip and safety guard.

c. Turn the engine ON/OFF switch to the "ON" position. d. Turn Pressure Control Knob clockwise to prime the pump.

e. After the pump is primed, turn Prime/PR Valve to the

"Closed" position.

f. Turn Pressure Control Knob to the desired spray pressure. g. Disengage the gun safety latch and you are ready to spray.

4. ADJUSTING THE PRESSURE

a. Turn the Pressure Control Knob Clockwise to increase pressure and counterclockwise to decrease pressure.

b. Always use the lowest pressure necessary to completely atomize the material.

NOTE: OPERATING THE SPRAYER AT HIGHER

PRESSURE THAN NEEDED, WASTES MATERIAL,

CAUSES EARLY TIP WEAR, AND SHORTENS

SPRAYER LIFE.

c. If more coverage is needed, use a larger tip rather than increasing the pressure.

d. Check the spray pattern. The tip size and angle determines the pattern width and flow rate.

5. WHEN SHUTTING OFF THE SPRAYER

a. Whenever you stop spraying, even for a short break, follow the PRESSURE RELIEF PROCEDURE. b. Clean the tip & gun as recommended in the seperate

Gun Manual supplied with the gun.

c. Flush the sprayer at the end of each work day, if the

material you are spraying is water-based, or if it could harden in the sprayer overnight. See "Flushing". Use a compatible solvent to flush, then fill the pump and hoses with an oil based solvent such as mineral spirits.

d. For long term shutdown or storage, refer to the

"Flushing" section of this manual.

WARNING

Be sure to relieve pressure in the pump after filling with

Airlessco Pump Conditioner.

AVOIDING TIP CLOGS

There is an easy way to keep the outside of the tip clean from material build up:

Every time you stop spraying, for even a minute, lock the gun and submerge it into a small bucket of thinner suitable for the material sprayed.

Thinner will dissolve the buildup of paint on the outside of tip, tip guard and gun much more effectively if the paint doesn't have time to dry out completely.

WARNING

FOLLOW THE "PRESSURE RELIEF PROCEDURE".

To reduce the risk of injection, never hold your hand, body, fingers or hand in a rag in front of the spray tip when cleaning or checking for a cleared tip. Always point the gun toward the ground or into a waste container when checking to see if the tip is cleared or when using a self-cleaning tip.

WARNING

When you spray into the paint bucket, always use the lowest spray pressure and maintain firm metal to metal contact between gun and container.

7

8

PRESSURE RELIEF PROCEDURE

!

IMPORTANT!

TO AVOID POSSIBLE SERIOUS BODY INJURY, ALWAYS FOLLOW THIS PROCEDURE WHENEVER THE

SPRAYER IS SHUT OFF, WHEN CHECKING IT, WHEN INSTALLING, CHANGING OR CLEANING TIPS,

WHENEVER YOU STOP SPRAYING, OR WHEN YOU ARE INSTRUCTED TO RELIEVE THE PRESSURE.

1. Engage the gun safety latch. Refer to the separate instruction manual provided with your gun on its safety features and how to engage safety latch.

2. Turn the unit off.

3. Disengage the gun safety latch and trigger the gun to relieve residual fluid pressure.

HOLD METAL PART OF THE GUN IN CONTACT WITH

GROUNDED METAL PAIL. USE MINIMUM PRESSURE !

4. Turn Prime/Pressure Relief Valve (PR

Valve) to the open (priming) position to relieve residual fluid pressure.

THERE WILL BE A WIDER GAP BETWEEN VALVE

HANDLE AND CAM BODY WHEN IN OPEN POSITION.

IN THE CLOSED POSITION THERE IS ONLY A VERY

SLIGHT GAP.

NOTE: THE VALVE HANDLE CAN MOVE BOTH

CLOCKWISE AND COUNTER CLOCKWISE AND CAN

FACE DIFFERENT DIRECTIONS.

5. Re-engage gun safety latch and close

Prime/Pressure Relief Valve.

If the SPRAY TIP OR HOSE IS CLOGGED, follow Step

1 through 5 above. Expect paint splashing into the bucket while relieving pressure during Step 4.

If you suspect that pressure hasn't been relieved due to damaged Prime/Pressure Relief Valve or other reason, engage the gun safety latch and take your unit to an authorized Airlessco Service Center.

DAILY MAINTENANCE

1. Keep the displacement pump packing nut/wet cup lubricated with Airlessco TSO (Throat Seal Oil) at all times. The

TSO helps protect the rod and the packings.

2. Inspect the packing nut daily. Your pump has a patented Triple Life Packing System. Packing life will be extended a minimum of three times if the following "Packing Adjustment" procedure is followed:

IF SEEPAGE OF PAINT INTO THE PACKING NUT AND/OR MOVEMENT OF THE PISTON UPWARD IS FOUND

(WHILE NOT SPRAYING), THE PACKING NUT SHOULD BE TIGHTENED ENOUGH TO STOP LEAKAGE ONLY,

BUT NOT ANY TIGHTER. OVERTIGHTENING WILL DAMAGE THE PACKINGS AND REDUCE THE PACKING LIFE.

9

8

AIRLESS SPRAY GUN OPERATION

SPRAY

Attach spray gun to airless unit and tighten fittings securely.

Set the gun safety latch. (Also may be called gun safety lock, or trigger lock)

* The gun safety latch should always be set when the gun is not being triggered.

FIG. 7 GUN SAFETY LATCH

IN LOCKED POSITION

GUN SAFETY

LATCH

Read all warnings and safety precautions supplied with the spray gun and in product manual.

MAJOR COMPONENTS OF SPRAY GUN AND REVERSIBLE SPRAY TIP

FIG. 8

GUN SAFETY

LATCH OR LOCK

FIG. 9

O-RING GASKET

REVERSIBLE

SPRAY TIP

HANDLE

(FILTER INSIDE)

TIP GUARD

METAL SEAT

RELEASED

REV-TIP™

REV-GUARD™

TRIGGER GUARD

SPRAY TIP ASSEMBLY

1. Be sure PRESSURE RELIEF PROCEDURE is followed before assembling tip and housing to the gun.

2. Lock gun safety latch.

3. Insert REV-TIP™ cylinder into the

REV-GUARD™ (guard housing assembly).

4. Guide metal seat into REV-GUARD™ (guard housing assembly) through retaining nut & turn until it seats against the cylinder.

5. Insert O-Ring gasket on metal seat so it fits in the grooves.

6. Finger tighten REV-GUARD™ retaining nut on gun.

7. Turn guard in the desired position.

8. Completely tighten the retaining nut.

FIG. 10

RETAINING NUT O-RING GASKET

Part # 561-026

REV-GUARD™

GUARD HOUSING ASSEMBLY

G Thread 7/8" 561-002

F Thread 11/16" 561-001

REV-TIP™ CYLINDER

Part # 561-XXX

METAL SEAT

Part # 561-029

CLEANING SPRAY GUN

Immediately after the work is finished, flush the gun out with a solvent. Brush pins with solvent and oil them lightly so they will not collect dried paint.

CLEANING FILTER IN GUN HANDLE

To clean the filter, use a brush dipped in an appropriate solvent. Change or clean filters at least once a day. Some types of latex may require a filter change after four hours of operation.

TO REMOVE CLOGS FROM SPRAY TIP

1. Lock gun safety latch.

2. Turn REV-TIP™ handle 180 degrees.

3. Disengage trigger lock & trigger gun into pail.

4. If the REV-TIP™ handle appears locked (resists turning), loosen the retaining nut. The handle will now turn easily.

5. Engage gun safety latch & return handle to the spray position.

RETAINING NUT

REVERSE TO

UNPLUG

Spray Position Shown

CLOGGED FLAT TIP

Should the spray tip become clogged, relieve pressure from hose by following the PRESSURE RELIEF

PROCEDURE. Secure gun with the safety latch, take off guard, take out the tip, soak in appropriate solvent & clean with a brush. (Do not use a needle or sharp pointed instrument to clean the tip. The tungsten carbide is brittle and can chip.)

9

AIRLESS SPRAY GUN

FIG. 11

6 7

5

4

3*

1*

2*

8 9 10*

11

12

13

14

15

16

10

8

9

10*

11

12

13

14

15

16

PARTS LIST FIGURE 11

Item No.

Part No.

Description

17

18

19

20

*

3

4

1

2

5

6

7

120-530 Gun Seat Assembly

120-535 Gasket-Seat

120-520 Needle Assembly

120-529 Gun Seat Adapter

120-562 Trigger Guard

120-539

119-055

119-054

120-509

120-109

Pivot Trigger Pin (008 Gun)

Bolt (Prolight Gun)

Nut (Prolight Gun)

Gun Head (008 Gun)

Gun Head (Prolight Gun)

120-540 Actuator Pin (2)

120-536 Gun Plate

120-038 Nut

120-056 Plastic Washer

120-538 Gun Trigger Lock

120-055 Wave Washer

120-049 Retaining Ring

120-082 Handle Seal

120-090CX Gun Filter-Coarse

120-090FX Gun Filter-Fine

120-088 Spring

120-099

120-106

Gun Handle Assy (008 Gun)

Gun Handle Assy (Prolight Gun)

120-506 Gun Trigger (008 Gun)

120-542 Gun Trigger (Prolight Gun)

120-534 Gun Repair Kit

19

20

17

18

11

10

AIRLESS SPRAY GUN TROUBLESHOOTING

DEFECTS

Coarse spray

CAUSE

Low pressure Increase the pressure

CORRECTION

Excessive fogging

(overspray)

Patten too wide

High pressure

Material too thin

Spray angle too large

Reduce the pressure to satisfactory pattern distrabution

Use less thinner

Use smaller spray angle tip

Pattern too narrow too much material too little material thin distribution in center of pattern “horns”

Thick skin of work

Spray angle too small

Nozzle too large

Material too thin

Pressure too high

Nozzle too small

Worn tip

Wrong tip

Material too viscous

Application too heavy

Material too viscous

Use larger spray angle tip (if coverage is OK, try tip in same nozzle group)

Use smaller nozzle

Reduce pressure

Use next larger nozzle

Material too thick

Change to new tip

Use nozzle with narrow spray angle

Thin cautiously

Reduce pressure and/or use tip in next smaller nozzle group

Thin cautiously Coating fails to close & smooth over

Spray pattern irregular, deflected

Craters or pock marks, bubbles on work

Clogged screens

Orifice clogged

Tip damaged

Solvent balance

Extraneous material in paint

Course pigments

Poorly milled pigments

(paint pigments glocculate)

Clean carefully

Replace with new tip

Use 1 to 3% “short solvents remainder “long” solvents

(this is most likely to happen with material of low viscosity, lacquers, etc.)

Clean screen

Use coarse screen if orifice size allows.

Use courser screen, larger orifice tips. Obtain ball milled paint. If thinner has been added, test to see if a cover screen. Incompatible drop placed on top of paint mixes or flattens out on the paint mixture & thinners on the surface. If not, try different thinner in fresh batch of paint.

Hold gun further from surface sprayed Excess paint builds on tip guard

Drips, spits from tip

Tip clogs continually

Spray gun too close to surface

Pressure setting too high

Valve seat and/or ball in gun head damaged or worn

Debris in paint

Gun filter missing

Coarse filter mesh

TEST THE PATTERN

GOOD, FULL

Reduce pressure setting

Service spray gun, replace valve assembly

Thouroughly strain the paint before use

Do not operate without inlet strainer

SPOTTY PATTERN, INCREASE PRESSURE

11

TIP SELECTION GUIDE

12

Spray tip selection is based on paint viscosity, paint type, & job needs. For light viscosities (thin paints), use a smaller tip; heavier (thicker paints), use a larger tip size. Spray tip size is based on how many gallons of paint per minute can

REV-TIP TM for Painting

Fan Width (12” from surface) be sprayed through the tip. Do not use a tip larger than maximum pump flow rate or capacity the sprayer can accommodate. Pump flow rate is measured in gallons per minute (GPM).

SPRAY TIP - ORIFICE SIZE (INCHES)

in.

4-6

6-8

8-10

10-12

12-14

14-16

16-18

20-24

Gun Filter

Wood Interior mm

102-152

152-203

203-254

254-305

305-356

356-406

406-457

508-610

C=course-60 mesh

F=Fine-100 mesh

Lacquer, Varnish,

Stain, Sealer,

Enamel

Wood Exterior

Masonry

Exterior Stain,

Vinyl, Acrylic, Latex

Vinyl, Oil Base, Alkyd,

Latex, Acrylic,

Block Filler,

Elastomer

Ceiling

Structural Steel

Water Flow Rate

@ 2000psi, 138 bar

Paint Flow Rate latex paint @ 2000psi,

138 bar/1.36 spec. gr.

Hi Build, Mil White

Heaviy Coatings

(gpm)

(lpm)

(gpm)

(lpm)

Pump Minimum

Output*

*Pump will support tip worn to next larger size.

(gpm)

(lpm)

.007 .009 .011 .013 .015

.017 .019 .021 .023 .025 .027

.029

.031 .035 .039

209 211 213 215 217 219 221 223 225 227 229

.041

307 309 311 313 315 317 319 321 323 325 327

409 411 413 415 417 419 421 423 425 427 431

335

511 513 515 517 519 521 523 525 527 531 535

613 615 617 619 621 623 625 627 631 635 639

715 717 721

641

739 741, 754

815 819 821 831

NEW WIDE TIPS: W21 W23 W25 W28 W29 W31

F F F F,C C C C C C REMOVE FILTER

•

•

•

•

•

.12

.49

.10

.38

.25

1.0

.18

.69

.15

.57

•

•

.25

1.0

•

•

.24

.91

.21

.79

•

•

.33

1.25

.31

1.17

.27

1.02

•

•

•

.40

1.5

•

•

•

.38

1.47

.33

1.25

.50

1.9

•

•

•

•

•

.47

1.79

.40

1.51

.60

2.3

•

•

•

•

.57

2.15

.49

1.85

.75

2.8

•

•

•

.67

2.54

.58

2.20

.88

3.3

•

•

•

.77

2.96

.66

2.50

1.0

3.8

•

•

•

1.03

3.90

.88

3.33

1.25

4.7

•

•

•

1.31

4.98

1.12

4.24

1.5

5.7

•

•

•

1.63

6.17

1.39

5.26

2.0

8.2

•

•

1.80

6.81

1.54

5.83

2.2

8.2

Thickness of the paint coat per stroke is determined by spray tip "fan width", rate of the spray gun movement, and distance to surface. Two tips having the same tip size, but different pattern widths will deliver the same amount of paint over a different area (wider or narrower strip).

A spray tip with a narrow pattern width makes it easy to spray in tight places.

During use, especially with latex paint, high pressure will cause the orifice to grow larger. This destroys the pattern.

Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make cutting-in difficult, and decreases sprayer performance.

FINE FINISH

REV-TIP TM

New double orifice design for lower pressure airless spraying when you need finer atomization for a smoother finish on interior trim, cabinetry, shutters, and doors

Fan Width

Inches (mm)

4-6

6-8

8-10

102-152

152-203

203-254

.012

Orifice Size

.014

212

312

412

214

314

414

13

12

ELECTRIC MOTOR MAINTENANCE

1. LUBRICATION - This motor is supplied with prelubricated ball bearings, lubricated for the life of the bearing.

2. MOTOR BRUSHES - need periodic inspection and replacement as wear indicates. Brush wear is greatly influenced by individual application. It is recommended that brush wear be checked at early intervals of operation in order to determine future required inspection. Standard Durotech brushes have an initial length of 1". When the brushes are worn to a length of

1/2" they should be replaced.

TO CHANGE THE BRUSHES:

1. Unplug the machine.

2. Remove the cover over the motor (if applicable.)

3. Open the two covers at the rear of the motor.

4. Disconnect the brush wire.

5. Pull out the wire.

6. Push the brush retainer clip in and withdraw.

7. Remove the worn brushes.

8. Install new brushes in the reverse order.

For long life, new brushes (Part # 331-778 for 110 volt, Part # 331-784 for 220 - 240 volts) need to have a run in period.

After changing brushes, set the machine for spraying. With a bucket of Pump Conditioner and water, a 50' 1/4" airless hose, airless gun and tip on unit, open the prime valve and switch on. The pump will now prime. With pump running in the prime mode, turn the pressure control knob to high pressure. (The pump has to cycle fast with no pressure in the pump).

Run the pump for 20 minutes and the brushes will be run in.

MOTOR BRUSHES

FIG. 12

Durotech (Current)

331-778

Durotech (Circa 2007)

331-784

Leeson (Circa 2006 and Prior)

331-131

13

14

FIELD TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Unit doesn’t prime

Unit primes but has poor or no pressure

Airleak due to:

•Loose suction nut

• Worn o-rings

• Hole in suction hose

Stuck or fouled balls

Pressure set too low

Filter(s) are clogged

Outlet valve fouled/worn

Prime/pressure relief valve bypassing

Packings and/or piston worn

• tighten suction nut

• replace o-ring (106-018) on suction seat & o-ring (106-017)

below suction seat

• replace suction hose

• service inlet and outlet valves

• turn up pressure

• clean or replace gun filter, inlet filter, and/or manifold filter

• service outlet valve

• clean or replace prime valve (100-180)

Unit does not maintain good spraying pressure

Unit does not run.

Blown spray tip

Packings and/or pistons worn

Upper seat worn

Blown Fuse

• tighten packing nut

• repack unit

• replace spray tip

• repack unit

• replace upper seat

• replace fuse

20A Slow Blow (331-328)

• see electrical troubleshooting

Electrical Faliure

MANIFOLD FILTER (111-200-99)

FIG. 13

1

2

3

4

5

6

7

8

9

10


Item No.

Part No.

Description

7

8

5

6

9

10

3

4

1

2

111-202 Base

301-356 Spring

106-007 O-Ring

111-204 Filter 60 Mesh

111-203 Support

111-201 Base

100159 Swivel

100-129 Plug 3/8” (2)

100-109 Nipple 3/8”M x 1/4”M

100-028 Plug 1/4”

15

14

SERVICING THE FLUID PUMP

FLUID PUMP DISCONNECT

REFER TO FIGURE 14

1. Follow the Pressure Relief Procedure on page 8.

2. Flush the material you are spraying out of the machine.

3. Remove the connecting rod shield.

4. Move the piston rod to its lowest position by cycling pump slowly.

5. Turn off the motor.

6. Disconnect Sensor by holding it in place with a 7/8” wrench and unscrewing the swivel with a 11/16” wrench.

7. Remove the retaining ring from the connecting rod and slide the sleeve down revealing the connecting rod pin.

8. Remove the suction tube assembly from the fluid pump by unscrewing the suction nut with the packing adjustment tool (189-211).

9. Using a 1/2” wrench unscrew the two bolts from the cover assembly. The fluid pump will be hanging loosely at this point.

10.Remove the connecting rod pin out of the connecting rod, allowing the removal of the fluid pump from the machine.

FIG. 14

13

FLUID PUMP REINSTALL

REFER TO FIGURES 14

. Loosen the packing nut and ensure that the piston rod

is in its upper position in the fluid pump body. Slip the sleeve & the retaining ring over the piston rod.

2. Push the piston rod up into the connecting rod & align the holes. Insert the connecting rod pin through the connecting rod & piston. Slip the sleeve up over the connecting rod pin and insert the retaining ring into the groove on the connecting rod.

3. Push the two bolts through the tube spacers & screw them into the cover assembly. Using a 1/2” wrench, tighten the two bolts evenly (alternating between them) until you reach 20 ft-lbs.

4. Reassemble lower suction valve assembly by placing the suction seat, O-ring, suction ball & suction ball guide in the suction nut & screw onto fluid pump body.

5. Reconnect the sensor to the fluid pump body. Hold sensor with a 7/8” wrench and tighten the swivel with a

11/16” wrench.

6. Start the machine and operate slowly to check the piston rod for binding. Adjust the two bolts, holding the fluid pump body to the cover assembly, if necessary. This will eliminate any binding.

7. Tighten packing nut clockwise until resistance is felt against the Belleville Springs, go 3/4 of a turn more. Put five drops of Airlessco Throat Seal Oil in the packing nut.

8. Run the machine at full pressure for several minutes.

Release the pressure by following the Pressure Relief

Procedure & readjust the packing nut per step 7 above.

9. Install the connecting rod shield so that the small hole is in the upper right hand corner.

12

1

11

10

9

8

2

3

4,5

6

7


Item No.

Part No.

Description

9

10

11

12

13

7

8

5

6

3

4

1

2

119-028 Connecting Rod Pin

331-117 Sleeve


115-019 Hose Connector

100-152 Swivel

331-034 Suction Nut

100-318 Bolts

331-209

331-236

Fluid Pump (Lo-Boy)

Fluid Pump (Hi-Boy)

331-093 Piston Rod

331-074 Tube Spacers

331-111 Connection Rod Shield

331-038 Connecting Rod

331-234 Cover Assembly

15

SERVICING THE OUTLET VALVE

FIG. 15

DISASSEMBLY OF THE OUTLET VALVE

1. Disconnect the Fluid Pump following instructions on page 15.

2. Place piston holder in a vise. Slide piston into the holder

& lock in place with a 3/8” dowel.

3. Use a 1/4” allen wrench to unscrew the outlet seat retainer from the piston.

4. Remove the outlet seat, O-ring and outlet ball.

5. Inspect outlet ball & seat for wear. Replace as necessary. Ensure seat is right side up.

6. While piston is still locked in the holder, install parts back into the piston in the following order:

3

1

2

BALL, OUTLET SEAT AND O-RING

Before reinstalling the outlet seat support, apply two drops of Loctite No. 242 (blue) on the threads & torque to

20 ft-lbs.

NOTE: Airlessco LP pump tool kit 188-197 is required for this task. Kit includes: Tightening Bar (189-211),

Packing Removal Tool (331-465), Piston Holder (331-

195), 3/8” dowel (331-196).

1

4

5

6

7

16

SERVICING THE INLET VALVE

1. Un-thread and remove suction nut from the fluid pump body.

2. Remove suction seat, O-ring, suction ball and suction retainer.

3. Clean all parts and inspect them for wear or damage, replacing parts as needed.

4. Clean inside of the fluid pump body.

5. Reassemble lower suction valve assembly by placing the suction seat, O-ring, suction ball & suction ball guide in the suction nut & screw onto fluid pump body.

FIG. 16

8

9

10

11

12

13

PARTS LIST FIGURE 15 & 16

Item No.

Part No.

Description

5

6

7

8

3

4

1

2

9

10

11

12

13

331-708 Piston

331-195 Piston Holder

331-196 Dowel Pin

331-027 Outlet Ball

331-100 O-Ring

331-026 Outlet Seat

331-314 Outlet Seat Retainer

331-011 Fluid Pump Body

331-029 Suction Ball Guide

331-030 Suction Ball

106-011 O-Ring

331-409

331-292

Suction Seat (Lo-Boy)

Suction Seat (Hi-Boy)

331-034 Suction Nut

17

16

PACKING REPLACEMENT PROCEDURES

DISASSEMBLY OF THE FLUID PUMP

REFER TO FIGURE 17 & 18

1. Disconect the Fluid Pump as instructed on page 15.

2. Unscrew & remove the packing nut.

3. Push the piston rod down through the packings & out of the pump.

4. Now push the packing removal tool up throughthe pump

& remove from the top bringing packings, spacer & springs along with it, leaving fluid body empty.

*Make sure all old packings & glands have been removed from fluid pump.

5. Clean inside of fluid body.

6. Disassemble all parts & clean for reassembly. Discard any old packings.

7. Lubricate leather packing in lightweight oil for 10 minutes prior to reassembly.

13. Take the packing holder & replace the white O-ring & the black O-ring with new ones from the packing kit.

14. Slide the packing holder over the top of the upper packings so they fit inside.

15. Lubricate inside of the fluid pump body & the outside of the packings with a light weight oil.

16. Slide assembly into fluid pump body.

TO KEEP PACKINGS SECURED IN CORRECT

POSITION, HOLD THE PUMP BODY UPSIDE DOWN

& PUSH THE COMPLETED ASSEMBLY UPWARDS

INTO THE PUMP BODY. ONCE PLACED INSIDE, TILT

PUMP BODY BACK UP TO KEEP ALL PIECES IN.

17. Tighten packing nut onto the top of the fluid pump body & tighten until you feel slight resistance against the

Belleville Springs. Using the Packing Adjustment Tool, tighten another 3/4 of a turn.

!8. Reinstall Fluid Pump as instructed on page 15.

REASSEMBLY

REFER TO FIGURE 17

1. Take lower male gland & place it down on the flat side.

2. Take three of the lower polyethylene packings & two of the leather packings & place onto the male gland inthe following order with the inverted side down

POLYETHYLENE, LEATHER, POLYETHYLENE,

LEATHER, POLYETHYLENE.

3. Take the female adaptor, which is inverted on both sides

, & place it on top of your assembled lower packings.

4. Follow step 2 with your packings inverted side up.

5. Take the second lower male gland and place it on top of your assembled packings with the rounded side down.

6. Take assembled glands & packings (13 pieces) & slide onto the lower half of the piston.

7. Take the spacer & slide over the top of the piston

(itdoesn’t matter which direction it sits, falling onto lower packings.

8. Take three Belleville Springs & slide over the top of the piston in the following order:

• First spring, curve facing down

• Second spring, curve facing up

• Third spring, curve facing down

( (

9. Take the upper male gland & place it rounded side up.

10. Take three upper polyethylene packings & two leather packings & assemble with inverted side down, on to the male gland in the following order: polyethylene, leather, polyethylene, leather, polyethylene.

11. Take upper female gland & place on top of assembled upper packings with the inverted side down.

12. Take assembled upper glands & packings (7 pieces) & slide on over the top of the piston, making sure inverted sides are down.

FIG. 17

21

20

19

18

17

16

15

14

13

11

12

10

PARTS LIST ON FOLLOWING PAGE

25

24

22

23

1

2

3

2

1

4

5

6

7

8

9

17

PACKING REPLACEMENT PROCEDURES

20 FIG. 18

19*

14

18*

25*

24*

21

4

22*

17*

16*

2*

3*

1*

15* 13*

11

12*

5

23*

1*

18

PARTS LIST FIGURE 17 & 18

Item No.

Part No.

Description

9

10

11

12*

13*

5

6*

7*

8

1*

2*

3*

4

331-014 Male Gland

331-016 Packing Polyethylene

331-308 Female Adaptor

331-011 Fluid Pump Body

331-029 Suction Ball Guide

331-030 Suction Ball

106-011 O-Ring

331-409

331-292

Suction Seat (Carry & Lo-Boy)

Suction Seat (Hi-Boy)

331-034 Suction Nut

331-314 Outlet Seat Retainer

331-026 Outlet Seat

331-100 O-Ring

331-027 Outlet Ball

7*

6*

PARTS LIST FIGURE 17 & 18 CONT.

Item No.

Part No.

Description

21

22*

23*

24*

25*

*

14

15*

16*

17*

18*

19*

20

331-708 Piston

331-018 Spacer

331-025 Belleville Springs

331-022 Male Gland

331-023 Packing Polyethylene

331-021 Female Gland

331-019 Packing Holder

331-037 Packing Nut

331-307 Packing Leather

331-306 Packing Leather

106-009 White O-Ring

106-010 Black O-Ring

331-210 Packing Kit

19

18

GEAR AND PUMP ASSEMBLY

FIG 19

13

14 15 16 17

1

2

WARNING

DO NOT OPERATE

WITHOUT COVER

GUARD IN PLACE

1

3

2

12

10

11

9

7

8

4

5

6

SERVICING GEAR BOX ASSEMBLY

1. Remove fluid pump as per "Fluid Pump Disconnect" procedures on page 15.

2. Remove frame from the gearbox by loosening the four mounting screws.

3. Refer to Figure 19. Separate cover assembly from box by removing bolts from front of cover & back of box & shoulder bolts from front of cover & back of box.

4. Lay unit on its back and disassemble gearbox.

5. Inspect bearings, Crosshead Assembly, Gearcrank & sleeve bearing inside cover assembly for wear/damage.

Replace worn/damaged parts.

6. If gear grease needs replacing, replace with gear grease

(Part No. 331-132).

7. Clean mating surfaces of cover and box thoroughly.

Use Part No. 105-331 BLUE XS™ ADVANCED RTV

SILICONE INSTANT GASKET.

8. Reassemble in reverse order.

MOTOR

13

14

15

16

9

10

11

12

7

8


Item No.

Part No.

Description

3

4

1

2

5

6

17

100-381 Bolt (2)

100-380 Shoulder Bolt (2)


331-117 Sleeve

331-062 Retaining Spring

331-209

331-236

Pump Assy (Carry and Lo-Boy)

Pump Assy (Hi-Boy)

115-019 Hose Connector (1/4NPSXNPT)

119-028 Pin

331-061 Sleeve Bearing

100-318 Bolt (2)

331-074 Tube Spacer

331-111 Shield

331-234 Cover

331-046 Bearing

331-038 Crosshead Assy

331-406

331-407

331-593

331-590

Gear Crank (510E)

Gear Crank (LP 500)

Gear Crank (LP 540/710E)

Gear Crank (LP 690/810E)

331-047 Bearing

*NOTE: Can be ordered separately, but is included with

Motor Ass'y.

GEARBOX SLEEVE BEARING

REPLACEMENT

FIG 20

1

2

3


Item No.

Part No.

Description

1

2

3

331-061 Sleeve Bearing

331-103 Washer (2)

331-197 Screw (2)

NOTE: WHEN REPLACING ITEM (1), COVER OUTSIDE

OF SLEEVE WITH CLEAR SILICONE PRIOR TO

INSERTING INTO COVER ASSEMBLY

19

CARRY FRAME MODELS

FIG. 21

19 20

18

17

16

15

14

20


Item No.

Part No.

Description

5

6

7

8

9

10

3

4

1

2

331-785 Fan

331-786 Fan Cover

117-090 Fan Cover Screws (3)

117-044 Knob

331-321 Terminal Box

331-787 Bolt (.6HP)

111-037 Heatsink Screw (4)

100-382 Screw (2)

106-500 Sensor Seal

331-294-99 Sensor

13 12 11 10 9

PARTS LIST FIGURE 21 CONT

Item No.

Part No.

Description

15

16

17

18

11

12

13

14

19

20

100-003 Swivel

100-180 Prime Valve

331-048 Rubber Boot (2)

100-318 Bolt (2)

115-019 Hose Connector (1/4”)

331-074 Tube Spacer (2)

331-111 Shield

331-234 Cover

331-401 Frame

119-048 Screw (4)

8

4

5

6

7

1, 2, 3

21

20

LO-BOY MODELS

FIG. 22 28 29 30

26 27

25

31 32 33

1, 2, 3

4

5

6

7

24

23

22

21

20

8

19 18 17 16 15 14 13 12 11 10


Item No.

Part No.

Description

13

14

15

16

17

9

10

11

12

7

8

5

6

1

2

3

4

331-785 Fan

331-786 Fan Cover

117-090 Fan Cover Screws (3)

117-129 Screw (2)

119-033 Nut (2)

331-477 Cup Support

331-476 Cup Assembly

143-029 Collar (2)

113-019 10” Wheel (2)

305-039 Spacer (2)

331-337 Rubber Edge (2) (690)

117-044 Knob

111-037 Heatsink Screws (4)


331-048 Rubber Boot (2)

106-500 Sensor Seal

331-294-99 Sensor


Item No.

Part No.

Description

30

31

32

33

26

27

28

39

22

23

24

25

18

19

20

21

100-003 Swivel

100-180 Prime Valve

100-318 Bolts (2)



331-111 Shield

331-234 Cover

331-174 Handle

119-032 Screw (2)

331-176 Bushing (2)

331-365 Frame Assy

119-048 Screw (4)

331-788 Bolt (.9HP)

331-222 Pin (2)

331-175 Spacer (2)

331-795 Motor Cover

9

21

HI-BOY MODELS

FIG. 23

22

24, 25, 26

23 20 21

19

18

1

2

3

4

5

17

16

15

14

11

12

13

6

22


Item No.

Part No.

Description

7

8

5

6

3

4

1

2

9

10

11

12

13

331-795 Motor Cover

331-788 Bolt (.9HP)

331-337 Rubber Edge (690)

117-044 Knob


111-037 Heatsink Screws

143-029 Collar (2)

113-019 10” Wheel (2)

113-030 Spacer (2)

331-048 Rubber Boot

106-500 Sensor Seal

331-294-99 Sensor

100-003 Swivel

7

9

10

8


Item No.

Part No.

Description

18

19

20

21

14

15

16

17

22

23

24

25

26

100-180 Prime Valve


100-318 Bolt (2)


331-111 Shield

331-336 Pail Hook

331-234 Cover

100-373 Screw (2)

331-273 Frame

119-048 Screw (4)

331-785 Fan

331-786 Fan Cover

331-090 Fan Cover Screw

23

22

SUCTION ASSEMBLIES

LO-BOY AND CARRY CHASSIS (331-238)

FIG. 24

HI-BOY CHASSIS (331-284)

FIG. 25

1

10

7

9

1

6

2 8

5

3

4


Item No.

Part No.

Description

3

4

1

2

5

6

7

8

9

10

331-290 Suction Hose Assy

331-217 Inlet Strainer

331-035 Suction Elbow

331-034 Suction Nut

106-020 PTFE O-Ring

331-231 Bypass Hose Assy

331-425 Bypass Hose

331-090R Fitting

111-016 Nylon Tie

331-135 Spring Clip

7


Item No.

Part No.

Description

3

4

1

2

5

6

7

331-090R Fitting

331-034 Suction Nut

331-292 Suction Seat Assy

301-348 Bypass Hose Assy

116-103 Spring Clip

331-400 Inlet Tube

141-008 Inlet Strainer

2

3

4

5

6

23

PRESSURE CONTOL ASS'Y CALIBRATION

24

NOTE: ANYTIME A SENSOR OR PRESSURE CONTROL ASSEMBLY (BOARD) OR BOTH ARE REPLACED, THE

FOLLOWING CALIBRATIONS MUST BE PERFORMED.

NOTE: PRESSURE CONTROL ASSEMBLIES (BOARDS) ARE NOW BEING EQUIPPED WITH A GREEN

GROUNDING WIRE ATTACHED. CONTECT THE GROUNDING WIRE TO TERMINAL BOX USING THE SAME

SCREW THAT HOLDS THE GROUNDING WIRE FROM THE POWER CORD.

1. ZERO CALIBRATION

1. Place prime/pressure relief valve in the prime (open) position.

2. Set the pressure control knob to the minimum setting

(CCW).

3. Remove the screws and lower the pressure control assembly.

4. Remove any jumper on the "P-ZR" terminal. Note: This

Jumper is no longer used.

5. Turn machine "ON" and ensure it is not cycling.

6. If the yellow light on the electrical board is ON and you have "0000" on the LCD display, the Zero Calibration is complete no further adjustment is necessary. If the light is ON and there are numbers on the display, use an insulated screwdriver to turn the "ZERO" trimpot counter-clockwise until the light goes out. Then turn it clockwise until the yellow light comes on, continue to turn the trimpot and the numbers will reduce untill the LCD shows "0000." The Zero Calibration is now complete. If you adjust beyond "0000" the numbers will start to increase.

3. LCD DISPLAY CALIBRATION

IF SO EQUIPED

1. Complete the "ZERO CALIBRATION" and "PRESSURE

CALIBRATION" procedures prior to commencing this calibration.

2. Turn pressure control knob up until system pressure is above 2500 psi (as indicated on glycerin filled pressure gauge) and the machine is not cycling.

3. Use an insulated screwdriver to adjust the LCD Set trimpot. Turn trimpot CCW until it clicks, then adjust to match pressure against pressure gauge reading.

4. Move the pressure control knob to different settings and trigger the gun several times to ensure that the

LCD continues to match the pressure gauge reading.

4. PHASE LIMIT CALIBRATION

If the digital display shows "- - -" and no yellow light, you should turn the Zero trimpot clockwise until the

yellow light is on, continue turning until "0000" is shown.

The goal is to see "0000" on the digital display, this is when you have Zero Calibration (Relying on the

yellow light is no longer used.)

2. PRESSURE CALIBRATION

1. Complete the ZERO calibration, as per "ZERO

CALIBRATION" prior to commencing this calibration.

2. Attach a 50', 1/4" airless hose, airless gun with 0.017 tip and a 5000 psi glycerin filled pressure gauge to pump.

3. Place the suction tube into a bucket of Coro-chek and water.

4. Turn prime/pressure relief valve to the prime (open) position.

5. Turn pressure control knob clockwise until machine starts to prime.

6. Place the prime/pressure relief valve in the pressure

(closed) position.

7. While watching pressure gauge, slowly adjust the pressure trimpot (clockwise to increase and counter clockwise to decrease) until the maximum static pressure is 3000 psi, with the pressure control knob fully clockwise. Trigger the gun several times to ensure pressure returns to 3000 psi .

FORMERLY KNOWN AS THE LOW VOLTAGE OR

MASTER VOLTAGE CALIBRATION

1. Attach a 50', 1/4" airless hose, airless gun with .017 tip and a 5000 psi glycerin filled pressure gauge to the pump.

2. Place the suction tube into a bucket of anti-freeze and water.

3. Turn pump on and turn up pressure control until the machine starts to prime.

4. Place the prime/pressure relief valve in the pressure

(closed) position.

5. Pressurize pump to 600 psi.

6. Trigger the gun several times noting the deadband (the amount of pressure drop before the pump rebuilds to set pressure).

7. If deadband is greater than 100 psi, adjust the phase limit trimpot so that the deadband is less than 100 psi and the pressure increase after the gun trigger is released is less than 200 psi. These pressures are guidelines and may vary slightly from pump to pump.

8. Reattach pressure control assembly to unit.

25

24

ELECTRICAL SYSTEM

FIG. 26 6

4

5

7

1

2


Item No.

Part No.

Description

1

2

3

4

5

6

7

8

331-168

301-101

Electrical Cord 110V

Electrical Cord 230V

331-185 Strain Relief

331-138 Screw

331-311 Toggle Switch

331-328

331-165

Fuse 20A Slow Blow 110V

Fuse 12A Slow Blow 230V

331-312 Fuse Holder

331-490

331-492

331-491

331-493

0.6HP Motor 110V

(LP500/510E)

0.6HP Motor 230V

0.9HP Motor 110V

(LP540/LP670/710E/810E)

0.9HP Motor 230V

331-315-99

331-396-99

Pressure Control Assy 110V

Pressure Control Assy 230V

9

10

11

12

13

14

15

117-207 Jumper

331-294-99 Sensor

331-297 Potentiometer

331-184 Spacer

117-044 Knob

331-377

331-397

117-452

LCD Display (PSI)

LCD Display (BAR)

Ground Wire

GREEN

BLACK

3

A2 A1

B

L

K

B

K

&

W

T

R

E

D

R

E

D

BLACK

L1

L2

INHIBIT

SWITCH

POT

S1 S2

ON-SL

P-ZR

LCD ZERO

PRESSURE

LCD SET

PHASE LIMIT

SENSOR DISPLAY

15

POWER

RED

LIGHT

ZERO

YELLOW

LIGHT

11

12

13

10

9

8

14

25

REPLACEMENT OF ELECTRICAL COMPONENTS

26

WARNING: ALWAYS UNPLUG THE ELECTRICAL CORD BEFORE SERVICING MACHINE!

NOTE: ANYTIME THE PRESSURE CONTROL ASSEMBLY, SENSOR, OR BOTH ARE REPLACED,

PERFORM THE CALIBRATIONS.

PRESSURE CONTROL ASSEMBLY

(ELECTRICAL CONTROL BOARD)

1. Unplug machine's power cord.

2. Remove four screws heatsink housing.

3. Disconnect all leads from pressure control assembly.


SENSOR

1. Remove the four screws, heatsink, and lower the pressure control assembly.

2. Disconnect swivel from sensor by holding sensor with

7/8” wrench and loosening swivel with 11/16” wrench.

3. Disconnect sensor lead from the board. Carefully pull sensor lead out of the terminal box and remove sensor.


LIQUID CRYSTAL DISPLAY (LCD)

1. Lower pressure control assembly as described above.

2. Unscrew the four nuts (6/32") and remove LCD Display assembly.

3. If unable to loosen the four nuts, hold them and unscrew

the four screws. Then remove the LCD Display

Assembly. If the display is removed in this

manner, the mylar label must be replaced.

4. Reassemble in reverse order, while making sure

that the four spacers and the four

washers are in place.

Tighten the four nuts handtight and seal with blue loctite.

DO NOT overtighten the nuts as this will damage the display.

FIGURE 27

7 1 2

POTENTIOMETER


2. Disconnect potentiometer lead from pressure control assembly.

3. Use a 1/16" allen wrench, loosen set screw in the potentiometer knob and remove knob and spacer.

5. Using a 1/2" wrench or deep socket, remove the nut from the potentiometer shaft assembly.

5. Pull entire potentiometer assembly out of terminal box.

6. Replace in reverse order.

6

3

4

ON-OFF TOGGLE SWITCH

1. Lower the pressure control assembly as described above.

2. Disconnect the two wires on the toggle switch

3. Use a 9/16" wrench to loosen the nut on the toggle switch shaft.


5

FUSE HOLDER


2. Disconnect the two wires on the holder.

3. Remove holder cover and fuse.

4. Use 11/16" wrench to remove the nut from the holder shaft.



Item No.

Part No.

Description

3

4

1

2

5

6

7

100-362 Screw (4)

101-270 Mylar Label - Clear

331-360 Window

117-281 Spacer (4)

117-126 Nut (4)

331-377

331-397

331-304-99

331-355-99

LCD Display (PSI)

LCD Display (BAR)

LCD Display Kit (PSI)

LCD Display Kit (BAR)

120-046 Washer (4)

27

26

TROUBLESHOOTING - MACHINE DOES NOT START

Control Settings

Fuse

Power Source

Power Source

Cause Steps

STEP 1: After making sure that the machine is plugged into the wall, verify that the on-off switch is in the ON position and that the pressure control knob is turned all the way to the right (clockwise for maximum pressure).

STEP 2: Using your multi-meter, test the fuse for continuity or replace with a new fuse. If the fuse reads good, move on to step three.

STEP 3: Using a Phillips Head screwdriver, remove the four screws holding the pressure control assembly. Locate the red light on the board indicating that there is power (it will be red.) If the light is OFF proceed to step four. If the light is ON go to step six.

STEP 4: Locate the L1 and L2 terminals on the board, and then using your multi-meter check to make sure you have 110 volts AC across the two terminals

(the cord wires will still be attached). If there is no voltage at these leads, there is no power getting to the machine. Check your power source (outlet, circuit fuse, extension cord, and power cord). If you have AC voltage at the L1 and L2 terminals, go to step 5.

Thermal Overload STEP 5: Disconnect the two red motor leads (S1 & S2) and test for continuity between them. No continuity means that the thermal coupler has opened due to excessive motor heat. If the motor is still hot to the touch, allow it to cool and then retest. If the motor is cool and there is not continuity on the red leads, contact Airlessco Technical Support to repair/replace the thermal coupler.

Continuity shows that the motor's thermal coupler has not tripped. Proceed to step six.

Pressure Control Assembly (Board) STEP 6: If everything checks out in steps one through five and the power indicating light is still out, replace the pressure control assembly.

Motor STEP 7: Remove the motor brush covers and turn the machine on. Set the potentiometer (POT) at maximum pressure and check for DC voltage across both brush terminals. You should read greater than 80 volts DC. IF YOU DO

NOT HAVE DC VOLTAGE GO TO STEP EIGHT. If you have DC voltage, turn the machine off and unplug it from the wall. Check to make sure that the brushes are making good contact with the armature. Replace the brushes if they are less than 1/2" long. If the brushes are good, replace the motor.

Sensor

Pressure Control Knob

(Potentiometer)

STEP 8: Plug another sensor into the board and perform the zero calibration procedure. If the machine starts to run, the sensor was bad. If there is no replacement sensor available, use a multi-meter to test the resistance across the red and black wires of the sensor (be sure to test at the plug). You should read 1.5 - 3.5k ohms. A faulty sensor usually reads no continuity (open). If the sensor passes all the tests move to step nine.

STEP 9: Plug another potentiometer (POT) into the control board. If the machine starts, the old POT is bad. When a replacement POT is not available, remove the POT lead (with the machine turned off) from the control board and test the resistance between the red and black wires (be sure to test at the plug).

The resistance should read between 8-12k ohms if it is outside of this range replace the POT.

Pressure Control Assembly (Board) STEP 10: If you have DC voltage at the motor brushes and all of the components check out fine in steps eight and nine, replace the pressure control assembly.

27

28

NOTES

29

28

NOTES

29

CCESSORIES

Quick Flush

™

■ The only clean water flushing system

■ Cuts sprayer clean-up time in half!

■ Connects to standard garden hose

to backflush sprayer through gun

■ Includes "F" and "G" adapters to

work with all brands of gun

STAY CLEAN

™

Spray protectant for machine to prevent paint from sticking to it. Keeps your sprayer looking new for years!

114-030 20 oz. can

Case quantity: 12 cans

Part # 170-005

PAINT HOPPER

For use on small jobs where paint is kept in smaller than 5 gallon containers.

Threads onto pick-up tube of carry or

LoBoy framed Airlessco sprayers.

331-775 6 Liter Paint Hopper

PUMP CONDITIONER

Should be used on piston pumps between uses to prevent paint from drying on the piston & causing packing wear.

010-001 Display of 48 - 1 oz. bottles

010-009 1 quart bottle

010-019 1 Gallon bottle

Case quantity: 12 on quarts, 4 on gallons

THROAT SEAL OIL

Used in the wet cup of a piston pump to prevent paint from drying on the piston & causing damage to the upper packing. Use with all piston pumps.

188-187 6 oz. Bottle

188-392 1 qt. Bottle

XTEND-A-POLE SYSTEM

Standard Tip Extension

Swivel Extension

PAINT STRAINERS

Pre-filter your paint using strainer bags. One dozen per pack.

100-064 Used to cover suction filter

100-065 5 Gallon strainer

HOSE COVER

4 mil poly protects your airless hose from paint and abrasion damage. Comes in 1000' roll with perforations each 50'.

100-219 Hose Cover Roll

100-426 Case of 6 Rolls

HIGH PRESSURE AIRLESS HOSE

Strong yet flexible, for airless sprayers up to 3300 PSI

Part No: Hose Description

100-012 3/16” Whip Hose, 4 Ft.

100-040 1/4” Whip Hose, 3 Ft.

100-204 1/4” Whip Hose, 5 Ft.

100-199 3/8” Whip Hose, 6 Ft.

100-011 1/4” Hose, 50 Ft.

100-023 3/8” Hose, 50 Ft.

100-037 1/2” Hose, 50 Ft.

100-010 1/4" Hose Connector

100-009 3/8" Hose Connector

For a complete listing of all available accessories see the Airlessco Accessories Catalog, Part # 001-357.

Bare Pole

STANDARD TIP EXTENSION, “G” Thread

032-170

032-171

032-172

032-173

6” Long

12” Long

18” Long

24” Long

SWIVEL EXTENSION, “G” Thread

032-184 36” Long

BARE POLE

Add Tip Extension or Swivel Extension to create desired length

032-053

032-054

24” Long

36” Long

SWIVEL “G” THREAD

032-035-55 7/8" x 14 Swivel

ADAPTERS

90° Pole to Gun Adapter

032-042

Gun Nut “F” Thread 11/16-16

032-010

Gun Nut “G” Thread 7/8-14

032-011

"F to G" Gun adapter to attach

Graco

®

tips to Airlessco guns.

032-012

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