LP SERIES

AIRLESS PAINT SPRAYER

OPERATION MANUAL AND PARTS LIST

Models LP 2400, LP 2500

LP 2600 Hi-Boy and LP 2600 Lo-Boy

WARNING !!

HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!

The high pressure spray can cause extremely serious injury.

OBSERVE ALL WARNINGS!

Before operating this unit, read and follow all safety warnings and instructions related to the usage of this equipment. READ, LEARN and FOLLOW the Pressure Relief Procedure on Page 6 of this manual.

All Service Procedures to be performed by Authorized Airlessco

Service Center ONLY.

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

AIRLESSCO BY DUROTECH CO.

P.O. Box 8006, Moorpark, CA. 93020-8006, Ship to: 5397 Commerce Ave., Moorpark, CA 93021

Tel: 805-523-0211 Fax: 805-523-1063

SUBJECT TO CHANGE WITHOUT NOTICE.

FORM NO. 001-428, May 99

U.S. PATENT NO. 4775303. OTHER US & FOREIGN PATENTS APPLIED FOR.

TABLE OF CONTENTS

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

Flushing ................................................................. 1

How to Flush .......................................................... 2

Setting Up .............................................................. 3

Starting Up ............................................................. 3, 4

Warnings- Read prior to using sprayer .................... 4, 5, 6, 7

PRESSURE RELIEF PROCEDURE ......................... 6

Airlessco 007 Spray Gun Components ...................... 8

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

Spray Technique .................................................... 10, 11

Airlessco 007X and 007XL Parts Lists ..................... 12, 13

Airless Spray Gun Troubleshooting .......................... 14

Regular Maintenance .............................................. 15

Electric Motor Maintenance ..................................... 15

Troubleshooting ...................................................... 16

Troubleshooting- Machine Does not Start ................. 17

Pressure Control Assembly .................................... 18

Electrical System .................................................... 19

Replacement of Electrical Components ......................20

Servicing the Fluid Pump .......................................... 21

Gear and Pump Assembly ....................................... 22

Servicing Piston Rod, Upper Check Valve ................ 22

Servicing Lower Suction V alve ................................ 23

V-Packing Replacement .......................................... 24

Fluid Pump ............................................................. 25

2400 / 2500 Complete Machine Parts List ................ 26

2600 Lo-Boy Complete Machine Parts List ............... 27

2600 Hi-Boy Frame ................................................ 28

Suction Assemblies ................................................ 29

INTRODUCTION

AIRLESSCO'S DC POWERED LP SERIES

The LP Series are compact, lightweight, airless paint sprayers built to meet the

needs of the beginning and the experienced painting contractor.

Pressure

Output

Tip Size

Motor

Weight

LP2400

3000 psi

0.4 gpm

1 gun up to 0.019

DC TEFC .5 hp

38 lbs.

Specifications

LP2500

3000 psi

0.5 gpm

1 gun up to 0.021

DC. TEFC. .75 hp

41 lbs.

LP2600 (Hi-Boy & Lo-Boy)

3000 psi

0.6 gpm

1 gun up to 0.023

DC. TEFC. .75 hp

65 lbs.

WARNING

Prior to starting, read, understand and observe all safety

precautions and warnings on cover & pages 4, 5, 6, 7 and all

labels and tags on the machine

Learn how to relieve pressure by following Pressure Relief

Procedure on page 6 before operating this machine.

FLUSHING Read prior to using your sprayer

1. New Sprayer

Your Airlessco unit was factory tested in an anti-freeze 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.

5. Storage

Always relieve pressure (See pressure relief procedure on page 6) prior to storage or when machine is unattended.

Oil-base Paint:

Flush with mineral spirits. Ensure that there is no pressure in the unit, then close the prime/pressure relief valve.

Water-base Paint:

Flush with water, then mineral spirits. For longer term storage use a 50/50 mixture of mineral spirits and motor oil. Always ensure that there is no pressure in the unit, and close the prime/pressure relief valve for storage.

WARNING - NEVER LEAVE PUMP UNATTENDED

WHILE UNDER PRESSURE!

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.

6. Start up after Storage

Before using water-base paint,

flush with soapy water and than a clean water flush.

When using oil-base paint,

flush out the mineral spirits with the material to be sprayed.

1

2

HOW TO FLUSH

FIGURE 1

Prime/Pressure Relief Valve

(Prime/PR Valve)

Used to relieve pressure from gun, hose & tip and to prime the 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 gap between handle & body.

When closed the system is pressurized.

Handle as a loaded firearm!

PRIME/PRESSURE (PR) RELIEF VALVE (FIG. 1)

is used to prime pump and to relieve pressure from gun, hose and tip.

1.

Be sure the gun safety latch is engaged and there is no spray tip in the gun. Refer to separate gun instruction manual on how to lock the safety latch and the gun's safety features. Refer to Figure 4 and Page 8 for Airlessco 007 Gun.

REMOVE SPRAY TIP.

FIGURE 2

PRESSURE CONTROL KNOB. (FIG. 2)

is used to adjust pressure. Turn clockwise (CW) to increase pressure and counterclockwise (CCW) to decrease pressure.

FIGURE 3

ON

TOGGLE

SWITCH

OFF

SAFETY TIP

GUARD

ENGAGE GUN

SAFETY

LATCH.

FIGURE 4

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.

4.

Turn the Prime/Pressure Relief (PR) Valve to the

"OPEN" , priming position. Refer to Fig. 1.

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. 5.

FIGURE 5

MAINTAIN FIRM

METAL TO METAL

CONTACT BETWEEN

GUN AND CONTAINER

5.

Point the gun into the metal pail and hold a metal

part of the gun firmly against the pail. Refer to Fig. 5.

6.

Disengage the gun safety latch and squeeze the gun trigger. Turn the ON-OFF Toggle Switch

to the "ON" position (Fig. 3) and turn Pressure

Control Knob (Fig. 2) clockwise to increase pressure just enough to start the pump.

7.

Turn the Prime/PR Valve to the PRESSURE -

"CLOSED" position. This will allow solvent to be flushed through the pump, hoses and gun. Allow the unit to operate until clean solvent comes from the gun.

8.

Release the trigger and engage the gun safety latch.

9.

If you are going to start spraying, place the 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 and force the solvent from the pump and hose. Engage the gun safety latch until you are ready to spray.

10.

If you are going to store the sprayer, remove the suction tube from the solvent pail, holding a metal part of the gun firmly against the metal pail and force the solvent from the pump and hose. Engage the gun safety latch. Refer to "Storage"

Procedure on Page 1.

11.

Whenever you shut off the sprayer, follow the

"PRESSURE RELIEF PROCEDURE" on Page 6.

SETTING UP

1. Connect the hose and gun.

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

b. Connect an airless spray gun to the other end of the hose.

c. Do not use steel braided airless hose. Use nylon braided airless hose only.

NOTE:

Do not use thread sealer on swivel unions as they are made to self-seal. Use thread seal on tapered male threads only.

2.

Fill the Packing Nut/Wet Cup 1/3 full with Throat Seal Oil (TSO) supplied.

FIGURE 6

3.

Check the Electrical Service.

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

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 on Page 6.

5. Flush the sprayer

as per "Flushing - New

Sprayer" on page 1 and "How to Flush on page 2.

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.

FIGURE 7

Prime/Pressure Relief Valve

(Prime/PR Valve)

Used to relieve pressure from gun, hose & tip and to prime the 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 gap between handle & body.

When closed the system is pressurized.

Handle as a loaded firearm!

FIGURE 8

ON OFF

TOGGLE

SWITCH

FIGURE 9

PRESSURE CONTROL KNOB

is used to adjust pressure. Turn clockwise (CW) to increase pressure and counterclockwise (CCW) to decrease pressure.

2. Prepare the Material a.

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

b.

Place the suction tube into the material container.

3. Starting the Sprayer (See Fig. 7,8 & 9) 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 ON-OFF Toggle Switch to the

"ON" position.

WARNING

- To stop the unit in an emergency, turn motor off. Then relieve the fluid pressure in the pump and hose as instructed in the

"Pressure Relief" Procedure on Page 6.

d.

Turn Pressure Control Knob CW to prime pump.

e.

After the pump is primed, turn Prime/PR Valve to the PRESSURE, "Closed" position.

f.

Turn Pressure Control Knob to the desired spray pressure.

g.

Disengage the gun safety latch and you are ready to spray.

WARNING -

If you spray into the paint bucket, always use the lowest spray pressure and maintain firm metal to metal contact between gun and container. See Page 2 , Fig. 5.

3

4

STARTING UP continued

4. Adjusting the Pressure a.

Turn the Pressure Control Knob CW to increase pressure and CCW to decrease pressure.

b.

Always use the lowest pressure necessary to completely atomize the material being sprayed.

CAUTION - 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. Cleaning a Clogged Tip.

WARNING

- Follow the "Pressure Relief

Procedure" on page 6 .

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 selfcleaning tip.

WARNING

- Clogged standard (flat) tip - clean only after the tip is removed from the gun and pressure has been relieved.

FOLLOW THE PRESSURE RELIEF

PROCEDURE WARNING ON PAGE 6.

6. When Shutting off the Sprayer a

. Whenever you stop spraying, even for a short break, follow the "Pressure Relief Procedure Warning" on page 6.

b.

Clean the tip & gun as recommended on page 13.

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" pages 1 and 2. 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 page 1.

WARNING

- Be sure to relieve pressure in

the pump after filling with mineral spirits.

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.

WARNINGS

DO NOT USE halogenated solvents in this sytem. The prime valve 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.

Note:

United States Government safety standards have been adopted under the Occupational

Safety & Health Act. These standards, particularly the General Standards, Part 1910 & Construction

Standards, Part 1926 should be consulted.

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

WARNINGS continued

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. Handle as you would a

loaded firearm. Follow PRESSURE RELIEF PROCEDURE on page 6. Observe all 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.

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.

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 at anyone or 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 these materials 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, this is not an air spray sprayer.

ALWAYS follow the

PRESSURE RELIEF PROCE-

DURE

, as shown on page 6, before cleaning or removing the spray tip or servicing any system equipment.

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

Tighten all fluid connections before each use.

ALWAYS INSPECT SPRAYING AREA

Keep spraying area free from obstructions.

Make sure area has good ventilation to safely remove vapors and mists.

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 RE

-

LIEF PROCEDURE

as outlined on page 6.

MEDICAL TREATMENT

If any fluid appears to penetrate your skin, get

EMER-

GENCY 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.

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.

GENERAL PRECAUTIONS

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 PRES-

SURE IN THE SYSTEM. FOLLOW PRESSURE RELIEF

PROCEDURES ON PAGE 6.

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

and then remove 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.

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.

5

WARNINGS continued

PRESSURE RELIEF PROCEDURE

.

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 and whenever you stop spraying or when you are instructed to relieve the pressure.

1. Engage gun

Safety Latch.

Lock

4. Turn Prime/Pressure Relief 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.

2. Turn motor off and unplug from electrical outlet.

Note: When in closed position there is only a very slight gap.

Note: The valve handle can move both CCW and CW and can face different directions.

3. Disengage gun safety latch and trigger gun to relieve residual fluid pressure. Hold metal part of the gun in contact with grounded metal pail.

Use minimum pressure.

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 gun safety latch and take your unit to an authorized Airlessco Service Center.

6

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.

Use only hose having 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 an injection injury or other serious bodily injury or property 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.

GROUNDING

Ground the sprayer & 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. For detailed instructions on how to ground, check your local electrical code.

ALWAYS ensure switch is in OFF position before plugging unit in.

Always ground all of these components.

1. Sprayer: plug the power supply cord, or extension cord, each equipped with an undamaged three-prong plug, into a properly grounded outlet. DO NOT USE AN

ADAPTER.

Use only a 3 wire extension cord that has a 3 blade grounding plug, and a 3 slot receptacle that will accept the plug on the product. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. (Note: The table on the top of the next page shows the correct size to use depending on cord length and name plate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

2. Air Hoses; use only grounded hoses.

3. Fluid hose: use only grounded hoses.

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

5. Object being sprayed; according to your local code.

6. All solvent pails used when flushing.

Once each week, check electrical resistance of hose

(when using multiple hose assemblies, check overall resistance.) Overall (end to end) 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.

WARNINGS continued

AMPERAGE

RATING

RANGE

5 - 6

6 - 8

8 - 10

10 - 12

UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD

VOLTAGE

25 50 100

LENGTH OF CORD IN FEET

150 200 250 300

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

6

6

8

6

Always follow recommended pressure and operating instructions.

400

6

4

8

6

500

4

4

6

6

ALWAYS use approved high pressure fittings and replacement parts.

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

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 motor, 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 6.

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 PROCE-

DURE 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.

PREVENT STATIC SPARKING FIRE/EXPLOSIONS

ALWAYS be sure all equipment & objects being sprayed are properly grounded. Always ground sprayer, paint bucket and object being sprayed. See grounding on page 6 for 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 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 process.

ALWAYS follow the PRESSURE RELIEF PROCE-

DURE on page 6.

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 degrees F. Some of these are: acetone, benzene, ether, gasoline, naptha. Consult your supplier to be sure.

NEVER SMOKE in the spraying/cleaning area.

WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS AND THINNERS

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 & spraying object. See GROUNDING on pg. 6. 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.

7

AIRLESSCO 007 SPRAY GUN

SPRAY GUN

Attach spray gun to whip hose and tighten fittings securely. Set the gun safety latch.(Also may be called gun safety lock) * Refer to Fig. A.

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

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

GUN SAFETY

LATCH

IN LOCKED

POSITION

FIG. A

MAJOR COMPONENTS OF SPRAY GUN

AND REVERSIBLE SPRAY TIP

Gun Safety

Latch

(or Lock)

Reversible

Spray Tip

Tip Guard

Handle

(filter inside)

Trigger

Guard

O-RING

GASKET

METAL

SEAT

GUN

SAFETY

LATCH

RELEASED

REV-TIP

REV

GUARD

8

SPRAY TIP ASSEMBLY

1. Be sure the pressure relief procedure is followed before assembling tip and housing to the gun.

2. Insert Rev-Tip cylinder into REV-GUARD (guard housing assembly).

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

4. Insert the O ring gasket onto the metal seat so that it fits into the grooves.

5. Finger tighten the REV-GUARD retaining nut onto the gun.

6. Turn guard in the desired position.

7. Completely tighten the retaining nut.

O-Ring Gasket

Retaining Nut

Metal Seat

REV-GUARD

Guard Housing Assembly

Rev-Tip

Cylinder

TO REMOVE CLOGS

FROM SPRAY TIP

1. Turn Rev-Tip handle 180 degrees.

2. Disengage gun safety latch and trigger gun into pail.

3. Engage gun safety latch and return handle to spraying position.

Reverse to

Unplug

Spray Position Shown

SPRAY TIP SELECTION

Spray tip selection is based on paint viscosity, paint type, and job needs. For light viscosities (thin paints), use a smaller tip; for heavier viscosities (thicker paints), use a larger tip size.

Spray tip size is based on how many gallons of paint per minute can be sprayed through the tip. Do not use a tip larger than the maximum pump flow rate or capacity the sprayer can accommodate. Pump flow rate is measured in gallons per minute (GPM).

TIP SELECTION CHART

REV -TIPS (P.N. 560-XXX)

FLAT TIPS (P.N. 570-XXX)

FULL RANGE OF TIP SIZES

Tip Identification: All tips have a 6 digit part number. The first 3 digits identifies it as a Rev-Tip (560) or a Flat

Tip (570). The 4th digit is the fan width - the number is half the fan width, ie. 5 means a 10” fan when it is held

12” from the surface. The 5th and 6th digit is for the orifice size and is measured in thousands of an inch,

ie: 17 = 0.017 inch- the higher the number, the larger the tip.

For sizes not shown, call factory for availability.

Fan Width

Orifice Size (Inch) in.

(mm)

.011

.013

.015

.017

.019

.021

.023

.025

.027

.031

.035

4-6

6-8

8-10

10-12

12-14

14-16

16-18

(102-152)

(152-203)

(203-254)

(254-305)

(305-356)

(356-406)

(406-457)

Water Flow Rate (gpm)

Tip Flow Rate -water (lpm)

(Water @ 2000 psi, 138 bar)

Paint Flow Rate (gpm)

Tip Flow Rate -water (lpm)

(latex paint @ 2000 psi, 138 bar/1.36 spec.)

Pump Minimum -pa (gpm)

Output* Rate -water (lpm)

*Pump will support tip worn to next larger size.

Gun Filter

C

= Coarse - 60 mesh

F

= Fine - 100 mesh

W o o d

Interior

W o o d

Exterior

Masonry

Lacquer, Varnish

Stain, Sealer

Enamel

Exterior Stain

Vinyl, Acrylic,Latex

Vinyl, Oil Base Alkyd

Latex, Acrylic

Block Filler

Elastomer

Ceiling

Hi Build, Mil White

Structural Steel

Heavy Coatings

211

311

411

511

.12

.49

.10

.38

.25

1.0

F

213

313

413

513

613

.18

.69

.15

.57

.25

1.0

F

215

315

415

515

615

715

815

.24

.91

.21

.79

.33

1.25

F,C

217

317

417

517

617

717

.31

1.17

.27

1.02

.40

1.5

C

219

319

419

519

619

819

.38

1.47

.33

1.25

.50

1.9

C

1.79

.40

1.51

.

321

421

521

621

721

821

.47

60

2.3

C

Consult your paint manufacturer for application recommendation.

323

423

523

623

.57

2.15

.49

1.85

.75

2.8

C

325

425

525

625

327

427

527

627

431

531

631

535

635

.67

2.54

.58

2.20

.88

3.3

.77

2.96

.66

2.50

1.0

3.8

831

1.03

3.90

.88

3.33

1.25

4.7

REMOVE FILTER

1.31

4.98

1.12

4.24

1.5

5.7

PATTERN WIDTH

Thickness of the paint coat per stroke is determined by spray tip "fan width", rate of the spray gun movement, and distance to surface.

SPRAY TIP SELECTION

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.

SPRAY TIP REPLACEMENT

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.

9

SPRAY TECHNIQUE

Good Spray Gun Technique is at the core of any spray paint operation. Operator skill and efficiency is as important as good equipment and good paint. Good spray technique is a skill that can be quickly learned by following these simple instructions.

If you are not familiar with spraying techniques, we recommend that you study this section of your manual and practice the proper technique on pieces of cardboard or a suitable surface.

Equal spray distance

Equal amount of paint

CORRECT DISTANCE

CORRECT GUN ANGLE

Equal amount of paint

Equal spray distance

RIGHT

RIGHT

WRONG

Shorter spray distance

Excessive paint spray

TILTED GUN ANGLE causes uneven paint coating

WRONG

TILTED GUN

WRONG

Hold the spray gun 12 - 15 inches away from the work surface and keep it perpendicular (straight) to the surface. Move the spray gun parallel to the work and at a right angle to the surface.

Keep even distance to surface.

10

RIGHT

Move the gun at a steady rate in order to apply a good coverage. The wet coat should be just under the thickness at which a run or sag will occur. Slow gun movement or gun held too close will result in an overly wet or thick wet or thick coat coverage that is likely to run or sag.

Do not wave the spray gun. This waving is called arching. Instead, hold the spray gun at a 12 to 15 inch distance perpendicular from the work.

WRONG

The closer the spray gun is held to the work, the thicker the paint is deposited and the faster the gun must be moved to prevent sags and runs. Holding the gun too far from the work will cause excessive fog, overspray, and a thin and grainy coat.

SPRAY TECHNIQUE

TOTAL SPRAYGUN MOVEMENT - arm movement - full sweep

TRIGGER

TRIGGER POINT

POINT

The Actual Paint Stroke

It is important to "trigger" the gun after gun movement

(arm movement) has started and release trigger (shut gun off) before gun movement ends. Gun movement is always longer than actual paint (spray) stroke. In that manner, even blending and uniform paint coat thickness is achieved over the entire surface. When the gun is in motion as the trigger is pulled, it deposits an even amount of paint.

Overlap the previous pass by half the width of the spray pattern. Aim at the bottom of the previous pass.

Spray with uniform strokes from left to right and from right to left, holding stroke speed, distance, lapping, and triggering as uniform as possible.

FOR EVEN PAINT COAT, OVERLAP

HALF THE WIDTH OF EACH PAINT

STROKE.

TAILING GOOD PATTERN FOG, OVERSPRAY

Adjust pressure control knob so that paint is completely atomized from the spray gun. Insufficient pressure will result in "tailing".

POOR PATTERN GOOD PATTERN

Too much pressure will result in excess fog and overspray, excessive tip wear, and increased sprayer wear and tear.

INSIDE CORNER OUTSIDE CORNER

Always use the lowest pressure possible to obtain desirable results.

Test the spray pattern on a piece of cardboard or other surface.

"Inside" and "outside" corners can be sprayed.

Aim the spray gun toward the center of the corner. The spray pattern is divided in half, and the edges of the spray pattern on both walls are the same.

11

AIRLESSCO 007X & 007XL SPRAY GUNS

6 8 10 11 12 13

2 3 4 5

14 15

7 9 9a

1

25

16

18

20

21

22

26

17

19

23

24

12

Item No. Part No.

Description

9

9a

10

11

12

13

14

7

8

5

6

3

4

1

2

561-001

560-xxx

561-025

561-026

120-023

120-005

120-035

120-037

120-011

120-033

120-022

120-046

120-002

120-045

120-020

Rev-Guard

Rev-Tip

Rev-Tip Seal-metal

Rev-Tip Seal-O-ring

Screw (3)

Guard

Valve Seat Complete

Valve Ball with Holder

Valve Spring Unit

Seals PTFE (2)

Trigger Pin

Washer (2)

Gun Head

Retainer Pin (2)

Retainer

Item No. Part No.

19

20

21

21

15

16

17

18

22

23

24

25

26

120-021

120-056

120-048

120-055

120-049

120-082

120-090CX

120-090FX

120-088

120-087

115-019

120-044

120-085

Description

Nut

Washer

Safety Latch or Lock

Wave Washer

Retaining Ring

Seal

Filter-Complete-Coarse

Filter-Complete-Fine

Spring

Handle Complete 007X

Connector

Trigger

Handle with Swivel 007XL

AIRLESSCO 007X & 007XL SPRAY GUN

Attach spray gun to hose and tighten fittings securely.

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

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

GUN SAFETY LATCH

IN LOCKED

POSITION

GUN

SAFETY

LATCH

(LOCK)

RELEASED

ADJUSTING SPRAY GUN

Hold gun with trigger locked (25) and push trigger against the lock (17). Then adjust nut (15) so that the retainer (14) will move freely back and forth approximately 1/32" to allow valve spring unit (9) to seat the valve ball (8).

IMPORTANT: Readjust nut (15) periodically for wear of valve seat (7) and valve ball (8); otherwise, leakage will occur.

TO REPLACE THE VALVE BALL HOLDER (8)

3 Tip Washers

KIT #2-007

1 Valve Seat (7)

1 Valve Ball Holder (8) 2 Seals- PTFE (9a)

Dismantling:

1. Unscrew Rev-Guard and remove spray tip and seal.

2. Unscrew valve seat (7) with 1/2" socket wrench.

*Caution*

When removing and replacing valve seat (7), hold

the trigger (25) in the open position so that the valve ball (8) is lifted off the valve seat. Failure to lift the ball off the seat will result in a scratched leaky valve.

3. Unscrew valve ball (8) together with the brass part of the assembly (9). Do not pull on the parts or the packing may get damaged.

4. Unscrew the valve ball (8) from the brass part of the assembly (9).

Reassembling

is done in reverse sequence.

Screw the new valve ball with holder (8) into the brass part (9).

*Caution*

Tighten valve ball and brass part on threaded end of the shaft by hand until you feel a positive stop.

Do not tighten with a wrench since this could result in breaking the shaft.

Note it is recommended that you change the valve seat (7) and valve ball (8) at the same time.

REPLACING THE VALVE SPRING UNIT (9)

3 Tip Washers

KIT#3-007

1 Valve Seat (7)

1 Valve Ball Holder (8) 1 Valve Spring Unit (9)

1. Repeat dismantling procedure as outlined above under Steps 1 through 3.

2. Unscrew nut (15), remove retainer (14) with retainer pins (13) and push shaft of the valve spring unit (9) out of the gun head (12).

3. Clean gun head (12) bore with solvent and small brush. Do not use any sharp objects to scrape away dried paint, as they would cause leakage around the seal.

Reassembling

is done in reverse sequence.

IMPORTANT: When reassembling, install valve spring unit (9) with spring loose.

Push firmly into gun head by hand. Install retainer pins (13), retainer (14) and nut (15) loosely onto valve spring unit (9). By hand turn front of valve spring unit clockwise, tightening the valve spring unit until you feel a positive stop. At that point, continue tightening the valve spring another 1/8 turn expanding the PTFE seals against body of gun.

*Caution*

Do not tighten beyond 1/8 turn as this can result in breaking the valve spring unit shaft. Continue reassembly and adjustment as described above.

CLEANING 007 SPRAY GUN

Immediately after the work is finished, flush the gun out with a solvent. Brush pins (13) with solvent and oil them lightly so they will not collect dried paint.

TO REMOVE CLOGS- REVERSIBLE TIP

1. Turn Rev-Tip handle 180 degrees.

2. Disengage gun safety latch & trigger gun into pail.

3. Engage gun safety latch and return handle to spraying position.

Reverse to

Unplug

Spray Position Shown

CLOGGED FLAT TIP -

Should the spray tip become clogged, relieve pressure from hoses by following the "Pressure Relief

Procedure" in Machine Manual, secure the gun with safety lock (17), 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.)

CLEANING FILTER

To clean the filter, use a brush dipped in as 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.

13

14

AIRLESS SPRAY GUN TROUBLESHOOTING

DEFECTS

Coarse spray

Excessive fogging

(overspray)

Pattern too wide

Pattern too narrow

Too much material

Too little material

Thin distribution in center of pattern

"horns".

Thick skin on work

CAUSE

Low pressure

High pressure

Material too thin

Spray angle too large

Spray angle too small

Nozzle too small

Material too thin

Pressure too high

Nozzle too small

Material too thick

Worn tip

Wrong tip

Material too viscous

Application too heavy

Material too viscous

CORRECTION

Increase the pressure.

Reduce the pressure to satisfactory pattern distribution.

Use less thinner.

Use smaller spray angle tip.

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

Use next smaller nozzle.

Reduce pressure.

Use next larger nozzle.

Change for new tip.

Use nozzle with a narrow spray angle.

Thin cautiously.

Reduce pressure and/or use tip in next larger 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.

Coarse pigments

Poorly milled pigments

(paint pigments glocculate cover screen. Incompatible paint mixture & thinners.

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 coarser screen, larger orifice tips. Obain ball milled paint. If thinner has been added, test to see if a drop placed on top of paint mixes or flattens out on the on the surface. If not, try different thinner in fresh batch of paint.

TEST THE PATTERN

Good, full Spotty Pattern

Increase Pressure.

REGULAR MAINTENANCE

1.

Keep the displacement pump packing nut/wet cup 1/3 full of TSO (Throat Seal Oil) at all times. The TSO helps protect the packings and rod.

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 Tightening"

procedure is followed:

Inspect the packing nut daily. 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.

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 inspections. Standard Leeson brushes for this motor have an initial length of

3/4". When the brushes are worn to a length of 3/8", they should be replaced.

3. TO CHANGE BRUSHES

, follow the procedures below: a) Unplug the machine.

b) c)

Open the two covers at the rear of the motor.

Loosen the screw holding the brush terminal and remove the brush lead.

d) e) f)

Push the brush retainer clip (PN 331-398) in and remove.

Remove the worn brushes (one on each side of motor).

Install new brushes in reverse order and replace covers.

NOTE: For longer life

, new brushes (Part No. 331-131) need to have a run in period. After changing brushes, set up the machine for spraying. Use a bucket of water and Coro-Chek mixture, a 50' x 1/4" airless hose, airless gun with a .017 tip on unit, turn the Prime/PR Control Valve to the Prime position and turn the unit on. Turn the ON/

OFF Pressure Control Knob to maximum pressure (fully CW position) and let the pump cycle at high speed and zero pressure for 20 minutes. This will allow the brushes to "run in" properly, giving a longer life.

15

16

TROUBLESHOOTING

PROBLEM CAUSE

There is spitting from the gun.

The fluid supply is low or empty.

Air entrapped in the fluid pump or hose.

Paint leaks into the wet cup.

The motor operates, but the paint pump doesn't.

The motor and displacement pump operates, but paint pressure is too low or none.

The displacement pump operates but the output is too low.

The wet cup is loose.

The throat packings are worn or damaged.

Piston Rod is Worn.

The pressure setting is too low.

The pump is seized by dried paint.

The pressure setting is too low.

The tip or gun filter is clogged.

Tip is worn.

The fluid displacement pump filter is clogged.

There is a large pressure drop in the fluid hose.

The lower or upper check valve is not seating.

The packings are worn or damaged.

The Prime/PR Valve is bypassing.

SOLUTION

Refill the supply container.

Check for loose connections on the siphon assembly, tighten, then reprime pump.

Tighten just enough to stop leakage.

Replace the packings. See page 24 & 25

Replace Piston. See page 23

Increase the pressure.

Service the pump. See page 23, 24, 25

Increase the pressure.

Remove the tip and/or filter and clean them.

Replace Tip.

Clean the filter.

Use a larger diameter hose.

Service the lower & upper check valves. See pages 23.

Replace the packings.

See page 24, 25.

Replace the Prime/PR Valve.

TROUBLESHOOTING- Machine does not start.

CAUSE

Control Settings

Power Source

Fuse

Thermal Overload

Pressure Control Assembly

(Board)

Sensor

Pressure Control

Knob (Potentiometer)

Motor

Pressure

Calibration

Pressure Control Assembly

(Board)

SOLUTION

STEP 1:

Ensure that the ON-Off toggle switch is in the "ON" position and that the

Pressure Control Knob is fully CW (maximum pressure). Also check that the unit is plugged in.

STEP 2:

Lower the pressure control assembly and check if the green power light on the board is lit. If the light is "OFF", proceed to

Step 3. If the light is "ON", go to Step 7.

STEP 3:

Use a multimeter to check for 110 volts VAC across the L1 and L2 terminals on the board. If there is no voltage at these leads, there is no power to the unit. Check power source (outlet, breakers, extension cord and power cord).

STEP 4:

If the machine has power and the green light is "OFF", test the fuse for continuity or replace with a new fuse.

STEP 5:

If the fuse is okay, disconnect the two red motor leads (S1 & S2) and test for continuity between the two leads. Continuity shows that the motor's thermal coupler has not tripped. No continuity means that the thermal coupler has opened due to excessive motor heat. If the motor is still hot to touch, allow to cool and retest. If the motor is cool and there is no continuity on the red leads, contact your local Leeson repair facility to repair/ replace the thermal coupler.

STEP 6:

If all checks out fine in Steps 1 through 5 and the green light is still out, the pressure control assembly is defective and must be replaced.

STEP 7:

If the green light is "ON", the power source, fuse and thermal coupler are okay. Plug another sensor into the board. If the unit starts, the sensor was faulty and must be replaced. When a replacement sensor is not available, use a multimeter to test the resistance between the BLACK and RED wires on the sensor lead. The resistance should be approximately 1.5-3.5 kohms.

A faulty sensor usually reads zero resistance (open).

STEP 8:

With the machine still "OFF", remove the potentiometer lead from the board and read the resistance between the red and black wires. This must be 8 - 12 kohms. If outside this range, replace the potentiometer.

NOTE: A bad POT will usually show no resistance (open).

STEP 10:

Remove the two black motor leads (A1 &A2) and test for continuity between them. Continuity is an indication that the motor is sound. The lack of continuity, points to a problem in the motor. If there is no continuity on these two leads, check the motor brushes. Ensure that the brushes are evenly worn and make solid contact with motor commutator. Replace the brushes if they are less than 3/8" long. If the brushes are okay, replace the motor.

STEP 11:

Calibrate the pressure control assembly in accordance with the instructions on page 18.

STEP 12:

If the unit fails to calibrate and all components in Steps 1-10 test okay, the pressure control assembly needs to be replaced.

17

18

PRESSURE CONTROL ASSEMBLY (PCA)

Note: Anytime a sensor, pressure control assembly (board) or both are replaced,

the following three calibrations must be performed.

1. ZERO CALIBRATION

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

2. Set the presssure control knob to the minimum setting (CCW).

3. Remove the screws (Fig. 17, Item 24) and lower the pressure control assembly. Ensure PCA is grounded.

4. Ensure the jumper (Fig. 10, Item 9) is on the "P-ZR" terminal. Note: This jumper comes with a new pressure control assembly (board) and is installed on the "P-ZR" terminals. If you are "Zero Calibrating" a pressure control assembly presently in the unit, remove Jumper from Single Terminal P-ZR and place on both terminals P-ZR. When Zero Calibration is complete replace jumper on a single terminal of P-ZR.

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

6. If the yellow light on the electrical board is ON, use an insulated screwdriver to turn the "ZERO" trimpot counter-clockwise until the light goes out. Then turn it clockwise until the light just comes back on.

7. If the yellow light is OFF, turn the "Zero" trimpot clockwise, just until the light comes on and stop.

NOTE: If the yellow light remains constantly "ON", or "OFF" during this calibration, the sensor is defective and should be replaced.

8. When calibration is complete, move jumper from both "PZ-R" terminals to single terminal on P-ZR.

2. PRESSURE CALIBRATION

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

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

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

4. Complete the ZERO calibration, as per "ZERO CALIBRATION".

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 .

3. LOW PRESSURE VOLTAGE TRIMPOT CALIBRATION

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

2. Place the suction tube into a bucket of antifreeze (or Coro-chek) 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 low pressure voltage 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.

ELECTRICAL SYSTEM

FIGURE 10

5

4

6

WHITE

2

BLK

BLK

7

BLK/WHITE

RED

RED

BLK

1

3

9

A1

L1

A2

BLK

L2

S1

S2

ZERO

PRESSURE

POT

P-ZR

SENSOR

POWER

LIGHT

ZERO

LIGHT

8

NOT USED

LOW PRESSURE

VOLTAGE

TRIMPOT

EMPTY

11

12

13

FIGURE 10 PARTS LIST

ITEM NO. PART NO.

DESCRIPTION

3

4

1

2

5

6

7

8

9

10

11

12

13

331-168C

331-185

331-138

331-311

331-165

331-328

331-312

331-070

331-068

331-315

117-207

331-294

331-297

331-184

117-044

Electrical Power Cord

Strain Relief

Screw

Toggle Switch

Fuse 12A Slow Blow (2400)

Fuse 20A Slow Blow (2500/2600)

Fuse Holder

1/2 HP DC Motor (2400)

3/4 HP DC Motor (2500/2600)

Pressure Control Ass'y

Jumper

Sensor

Potentiometer

Spacer

Knob

10

19

20

REPLACEMENT OF ELECTRICAL COMPONENTS

NOTE: Anytime the pressure control assembly, sensor or both are replaced, perform the three calibrations on page 18.

WARNING: Always unplug the electrical cord before servicing machine.

PRESSURE CONTROL ASSEMBLY (Electrical Control Board)

1. Unplug machine's power cord.

2. Remove four screws (Item 24, Fig. 17) from pressure control assembly.

3. Disconnect all leads from pressure control assembly. (Fig. 10).

4. Reassemble in reverse order.

SENSOR

1. Remove the screws (Fig. 17, Item 24) and lower the pressure control assembly.

2. Disconnect swivel (Item 17, Fig. 17) from sensor (Item 16, Fig. 17) 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.

4. Reassemble in reverse order.

POTENTIOMETER (Pressure Control Knob)

1. Lower pressure control assembly as described above.

2. Disconnect potentiometer lead from pressure control assembly.

3. Use a 1/16" allen wrench, loosen set screw in the potentiometer knob (Item 13, Fig. 10) and remove knob and

spacer. (Item 12, Fig. 10).

4. 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.

ON-OFF TOGGLE SWITCH

1. Lower the pressure control assembly as described above.

2. Disconnect the two wires on the switch.

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

4. Reassemble in reverse order.

FUSE HOLDER

1. Lower pressure control assembly as described above.

2. Disconnect the two wires on the switch.

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

4. Reassemble in reverse order.

SERVICING THE FLUID PUMP

NOTE: Check everything in the Troubleshooting

Chart before disassembling the Fluid Pump.

e. Reassemble the Lower Check Valve assembly by placing the Suction Seat Assembly, 0-ring, ball and retainer in the suction nut and screw nut onto pump body.

SEE FIG 12, Page 22.

FLUID PUMP DISCONNECT

f. Reconnect sensor assembly to fluid pump.

Hold sensor with 7/8" wrench while tightening swivel connector.

a. Flush out the material you are spraying, if possible.

b. Follow the "Pressure Relief Procedure" on page 6.

c. Remove the suction tube assembly from the paint pump by unscrewing the suction nut.

Disconnect sensor assembly by holding sensor with 7/8" wrench and unscrewing swivel connector with an 11/16" wrench.

g. Start the pump and operate slowly to check the Piston Rod for binding. Adjust screws holding pump assembly to cover assembly if necessary to eliminate binding.

h. Tighten the packing nut until resistance is felt against the belleville springs, then 1/2 turn more

CW (approximately three threads showing). Fill the wet cup of Packing Nut 1/3 full of Throat

Seal Oil (TSO).

d. Move the piston rod to its lowest stroke position by rotating the motor fan or by cycling rod to lowest position.

i. Run unit at full pressure, release pressure and repeat step h.

e. Unscrew the two screws (14) from cover assembly.

GEARBOX SLEEVE

BEARING REPLACEMENT

f. Remove retaining ring (12) down off crosshead assembly (3). Push pin (10) out of crosshead allowing removal of fluid pump from unit.

FIGURE 11

1

FLUID PUMP REINSTALL:

2

a. Loosen packing nut and extend piston rod to its upper position in paint pump. Slip sleeve and retaining ring over piston rod.

b. Push piston rod up into crosshead assembly and align holes. Insert pin through crosshead assembly and piston. Insert retaining spring into groove on crosshead assembly.

c. Secure paint pump to cover assembly by two screws, up through tube spacers and screw into cover assembly.

d. Tighten screws evenly and alternating to 20 ft.

lbs.

3

Note: When replacing item (1), cover the outside of sleeve with clear silicone prior to inserting into cover assembly.

FIGURE 11 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

1

2

3

331-061

331-103

331-197

Sleeve Bearing

Washers (2)

Screws (2)

21

GEAR AND PUMP ASSEMBLY

FIGURE 12

Part No. 331-340 (2600 Hi)

Part No. 331-008 (2600 Lo)

Part No. 331-007 (2500)

Part No. 331-009 (2400)

2 3

4

5

7

8

1

9

8 7

10

6

12

18

17

15

13

16

14

22

WARNING -

Do not operate machine without cover guard in place.

9

10

12

13

7

8

5

6

FIGURE 12 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

1

2

3

4

14

15

16

17

18

331-041

331-341

331-046

331-038

331-039

331-039A

331-039B

331-047

331-040

100-381

100-380

331-088

331-065

331-062

331-209

331-236

100-318

331-074

331-111

331-061

331-219

Cover Ass'y

(2400,2500,2600 Lo)

Cover Ass'y

(2600 Hi)

Bearing

Crosshead Assembly

Gear Crank

(2500)

Gear Crank

(2400)

Gear Crank

(2600)

Bearing

Box

*

Bolt Soc Hd (2)

Shoulder Bolt (2)

Retaining Ring

Pin

Retaining Spring

Paint Pump Assembly-Lo-Boy

Paint Pump Assembly-Hi-Boy

Screw (2)

Tube Spacer (2)

Cover - guard

Sleeve Bearing

Gasket

SERVICING GEAR BOX

ASSEMBLY

1. Remove fluid pump as per "Fluid Pump Disconnect" procedures page 21.

2. On 2400 & 2500 remove handle (Fig. 17, Item 2)

by removing two screws (Fig. 17, Item 3). On the

2600, detach frame by removing the four screws (Fig. 18,

Item 7)

3. Refer to Fig. 12. Separate the cover assembly (1) from box (6) by removing bolts (7) from front of cover and back of box and shoulder bolts (8) from front of cover and back of box.

4. Lay unit on its back and disassemble gearbox.

5. Inspect bearings (2) and (5), Crosshead Assembly (3),

Gearcrank (4) and sleeve bearing (17) inside cover assembly for wear or damage. Replace worn or 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 and attach self stick gasket (18).

8. Reassemble in reverse order.

* Note Box (Item 6) can be ordered separately, but is included with Motor Ass'y (PN 331-070, 331-068)

SERVICING PISTON ROD, UPPER CHECK VALVE

SEE FIG. 13

1. Disconnect Fluid Pump as per page 21.

2. Place piston in block (PN 331-195) with the 3/8" dowel pin (PN 331-196) and hold in vise.

NOTE: DO NOT use smaller diameter pin to hold piston.

3. Place a 7/16" allen wrench into lower piston and unscrew lower piston from upper piston. Clean all parts and inspect them carefully for wear and damage. Inspect the surface of piston for wear or damage. Replace these parts if needed.

4. To reassemble the piston assembly, place in block using dowel pin and hold in vise. Install O-ring (4),

Seat (3) and Ball (2) and thread upper and lower pistons together. Slowly hand tighten piston then loosen piston and inspect that the O-ring (4) and seat (3) , are flush, then torque to 50 fts. Do not use locktite on threads, but apply light coat of grease or anti-seize compound to threads.

NOTE: The upper and lower piston must be purchased as an assembly (Item 1, Fig 13). This assembly will not have the ball, seat and O-ring inside.

FIGURE 13

1

FIGURE 13 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

1

2

3

4

331-093

331-027

331-026

331-100

Piston Ass'y

Ball

Seat

O-Ring-PTFE

2

3

4

SERVICING LOWER SUCTION VALVE

1. Unthread suction nut (Fig. 21, Item 2) and remove suction assembly from pump body.

2. Remove suction seat assembly,

O-ring, ball and retainer.

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

1

4. If lower seat need replacing, you must replace the suction seat assembly.

(PN 331-033A Lo-Boy, PN 331-292 Hi-Boy)

5. Clean inside of pump body.

6. If no further pump service is needed, reassemble the lower check valve assembly, by placing the suction seat assembly,

O-ring, ball and retainer in the suction nut and screw nut onto pump body. Tighten suction nut with rod tool (189-211).

FIGURE 14

3

4

2

5a

5b

FIGURE 14 PARTS LIST

ITEM PART DESCRIPTION

3

4

1

2

5a

5b

NO.

NO.

331-011

331-029

331-030

331-032T

331-033A

331-292

Pump Body

Retainer

Ball 1/2" Dia.

O-Ring - PTFE

Suction Seat Ass'y (Lo-Boy)

Suction Seat Ass'y (Hi-Boy)

23

24

V-PACKING REPLACEMENT

DISASSEMBLY

FIGURE 15

1.

Remove the Fluid Pump as per “Fluid Pump

Disconnect” instructions on page 18.

2.

Unscrew the packing nut and suction assembly.

Push piston rod out through bottom of pump body.

Remove the upper packings, belleville springs, tube spacer and lower packing set using packing removal tool (PN 331-153).

3.

Disassmble and clean all parts for reassembly.

Discard old packings, adaptors and O-Rings.

REASSEMBLY

4

5

2

3

6

8

1.

Lubricate piston rod with oil or grease.

2.

Soak leather packings in throat seal oil or other light-weight oil for 10-15 minutes.

3.

Reassemble all parts onto piston rod in following

order as per Fig.15 & 16: a. Start with lower male adaptor (15) b. Five V-Packings (16 & 17), “V” inverted.

c. Female adaptor (18).

d. FiveV-Packings (16& 17), “V” up.

e. Male Adaptor (15) f. Slide on tube spacer (10).

g. Three Belleville Springs (9) starting with the

first spring facing down ( ), second one

facing up ( ), and the third one facing

down ( ).

h. Upper male adaptor (8).

i. Five V-Packings, “V” inverted (6 & 7).

k. Place O-rings (3 & 4) onto seal holder (2) l. Lubricate outside diameter of V-packings with white lithium or multipurpose grease.

m. Slide seal holder (2) over Upper Packing

Set.

n. Lubricate threads on inside of pump body with white lithium or Multipurpose grease.

4.

Hold pump body in one hand upside down and slide entire piston assembly with packings up into pump body. While inserting piston and packing assembly,

5.

Install packing nut, handtight only. Push piston rod up to its upper position.

6.

Connect the fluid pump onto Unit as per “Fluid

Pump Reinstall” Procedures on page 21.

10

15

16

15

7

9

11

17

18

FLUID PUMP -

PN. 331-209 (2400, 2500, 2600 Lo-Boy)

PN. 331-236 (2600 Hi-Boy)

FIGURE 16

1

15

2

11

16

3

4

5

18

6 7 12

13

14

8

9 11

10

16

15

17 19

17

23

24

20

21

22

ITEM NO.

1

2

3*

4*

5*

6*

7*

8*

9

10

11

12*

PART NO.

331-037

331-019

331-020V

331-020T

331-021

331-023

331-023L

331-022

331-025

331-018

331-093

331-027

FIGURE 15 & 16 PARTS LIST

DESCRIPTION

Packing Nut

Seal Holder

O-Ring Viton

O-Ring PTFE

Adapter Female

V-Packing-Plastic (3)

V-Packing-Leather (2)

Adapter Male

Belleville Springs (3)

Tube Spacer

Piston Assembly

Ball

ITEM NO.

13

14*

15*

16*

17*

18*

19

20

21*

22*

23

24

*

PART NO.

331-026

331-100

331-014

331-016

331-016L

331-015D

331-011

331-029

331-030

331-032T

331-033A

331-292

331-210

DESCRIPTION

Seat

O-Ring PTFE

Adapter Male(2)

V-Packing-Plastic (6)

V-Packing-Leather(4)

Adapter Female

Fluid Body

Retainer

Ball

O-Ring PTFE

Seat Lo-Boy

Seat Hi-Boy

Packing Kit

25

MACHINE ASSEMBLY 2400/2500

FIGURE 17

3

2

1

5

4

See Fig 12

Page 22

See Fig. 10

Page 19

6,7,8,9

10

11

12

See Fig 20

Page 29

21

See

Fig 16

Pg. 25

15

22

23

24

13

18

17

16

14

19 20

26

ITEM NO. PART NO. DESCRIPTION

1

2

3

4

7

8

5

6

9

10

11

12

331-216

331-215

331-079

100-377

101-107

101-108

101-005

331-212

331-213

117-090

331-070

331-068

117-044

331-344

101-069

Motor Screw (2400)

Motor Screw (2500)

Handle

Screw - Torque (T-27)

Label (2400)

Label (2500)

Label - Warning

Fan

Fan Cover

Screw (3)

Motor (2400)

Motor (2500)

Knob

Frame Ass'y

Label (2400, 2500)

FIGURE 17 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

13

14

15

16

17

18

19

20

21

22

23

24

331-315

331-151

114-009R

331-294

100-003

100-180

331-094

331-048

115-019

331-103

100-312

111-037

Pressure Control Ass'y

Seal

Washer, Nylon

Sensor

Swivel Connector

Prime/Pressure Relief Valve

Plug (4)

Rubber Boot (4)

Hose Connector

Washer (4)

Screw (4)

Screw (4)

MACHINE ASSEMBLY - 2600 LO-BOY

FIGURE 18

3 4

5

6

1

2

7

8,9,10,11

27, 28

See Fig 12

Page 22

12

13

25

See Fig. 20

Page 29

23

22

21

20

26

24

See Fig. 16

Page 25

16

17

18

19

15

14

ITEM NO. PART NO. DESCRIPTION

9

10

11

12

13

14

7

8

5

6

3

4

1

2

331-174

331-176

331-215

331-171

331-222

331-175

100-377

331-212

331-213

117-090

331-068

113-030

331-189

143-028

Handle

Bushing (2)

Motor Screw (2)

Frame

Roll Pin (2)

Spacer (2)

Screw-Torq. (T-27)

Fan

Fan Cover

Screw (3)

Motor

Spacer (2)

Wheel (2)

Washer (2)

FIGURE 18 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

23

24

25

26

27

28

19

20

21

22

15

16

17

18

143-032

331-048

111-037

100-312

331-103

331-151

114-009R

331-294

100-003

100-180

115-019

331-178

331-199US

101-134

Retaining Ring (2)

Rubber Boot (2)

Screw (4)

Screw (4)

Washer (4)

Seal

Washer

Sensor

Swivel Connector

Prime/Pressure Relief Valve

Hose Connector

Rubber Extrusion

Motor Cover

Label (2600)

27

28

LP2600 HI-BOY FRAME

FIGURE 19

3

4

1

2

5

6

FIGURE 19 PARTS LIST

ITEM PART NO. DESCRIPTION

331-273

331-289

113-017

143-028

143-032

331-048

Frame

Spacer (2)

Wheel (2)

Washer (2)

Retaining Ring (2)

Rubber Boot (2)

6

1

2

3

4

5

SUCTION ASSEMBLIES

SUCTION ASSEMBLY PARTS, MODELS 2400, 2500 & 2600 (Lo-Boy)

PART NO. 331-238

FIGURE 20

2

3

FIGURE 20 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

10

1

9

7

8

4

3

6

4

5

2

3

*

6

*

1

7

8

9

10

331-217

331-290

331-384

331-281

331-383

331-035

331-034

331-231

111-013

331-090

111-016

331-135

Inlet Strainer

Suction Hose Ass'y

Incl. Items 1,2,3,4,5,6

Suction Tube

Ferrule

Suction Hose

Suction Elbow

Suction Nut

Bypass Hose Ass'y

Incl. Items 7 & 8

Bypass Hose

Fitting

Nylon Tie

Spring Clip

5

SUCTION ASSEMBLY PARTS

FIGURE 21

1

2

3

FIGURE 21 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

1

2

3

331-036T

331-034

331-035

O-Ring, PTFE

Nut - Suction

Elbow- Modified

MODEL 2600 HI-BOY SUCTION ASSEMBLY, PART NO. 331-272

FIGURE 22

1

2

3

FIGURE 22 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

4

5

3

4

1

2

5

6

331-034

331-292

331-237

331-135

331-285

141-008

Suction Nut

Suction Seat Ass'y

Bypass Hose

Spring Clamp

Inlet Tube

Filter

6

29