AIRLESSCO 910E Service manual

AIRLESSCO PAINT SPRAYER

SERVICE MANUAL

AIRLESSCO 8-10-11 SERIES

ALLPRO 910E & 1110E

IMPORTANT WARNING !!

HANDLE THIS UNIT AS YOU WOULD A LOADED FIRE ARM!

High pressure spray can cause extremely serious injury.

OBSERVE ALL WARN INGS!

Before operating this unit, read and follow all safety warnings and in struc tions related to the usage of this equipment. READ, LEARN, and FOLLOW the

Pressure Relief Pro ce dure on Page 6 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.

Manufactured by: AIRLESSCO BY DUROTECH CO.

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

Moorpark, CA 93021Tel: 805-523-0211 Fax: 805-523-1063

SUBJECT TO CHANGE WITHOUT NOTICE.

Copyright © 2003, Airlessco by Durotech. All rights reserved. Form No. 001- 493 JUN 2003

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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 - 7

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

Airlessco 007 Spray GunTip & Base...................... 8

Spray Technique .................................................... 9 -10

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

Airlessco 007 Spray Gun ....................................... 12 -13

Spray Tip Selection ................................................. 14

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

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

Field Troubleshooting .............................................. 16

Servicing the Fluid Pump ........................................ 17

Servicing Inlet and Outlet Valves ............................ 18

V-Packing Replacement ........................................ 19 - 20

Manifold Filter Parts List ........................................ 21

Paint System........................................................... 21

Machine Parts List ................................................. 22 - 23

Replacement of Belt/Belt Adjustment .................... 24

Suction Assemblies ................................................ 24

Pressure Control Assembly Calibrations ............. 25 - 26

Electrical System ..................................................... 27

Troubleshooting- Machine does not run ................ 28

Replacement of Electrical Components ............... 29 - 30

Supplemental 230 Volt Part List ............................. 30

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INTRODUCTION

This airless paint sprayer is a time-tested, slow-stroking pump built to give many years of reliable service. The design and quality of manufacture has been contractor proven to meet the demanding needs of the professonal painting contractor.

8 SERIES

AIRLESSCO

SL810

10/11 SERIES SL1100

SPECIFICATIONS

ALLPRO

810E .8

GPM PRESSURE MAX. TIP SIZE

3000 .029 (1 gun) - .019 (2 guns)

1000E 1.0 3000 .032 (1 gun) - .021 (2 guns)

WARNING

Prior to starting, read, understand and observe all safety precautions & warnings on pages 4, 5, 6 & 7, and all labels and tags on the machine.

FLUSHING - Read prior to using your sprayer

1. New Sprayer

Your new unit was factory tested in oil, which was left in the pump. Before using oil-base paint, flush with mineral spririts 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.

3. Changing From Water-base to Oil-base

Flush with soapy water, then mineral spirits.

4. Changing From Oil-base to Water-base

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

WARNING: NEVER LEAVE PUMP UNATTENDED

WHILE UNDER PRESSURE !

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.

1

HOW TO FLUSH

FIG. 1

REMOVE

SPRAY

TIP

ENGAGE GUN

SAFETY LATCH

(LOCK GUN) as per gun instruction manual.

FIG. 2

FIG. 3

metal pail

Pressure Control Knob: used to adjust pressure only. Turn clockwise to increase pressure and counterclockwise to decrease pressure.

On/Off Switch

Thermal Overload Switch

2

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!

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

1

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 the pressure control knob to low pressure.

Refer to Fig. 2.

5. Open the prime valve to the open- priming position.

This will allow an easy start. Refer to Fig. 2.

6. Turn the motor 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. 3.

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.

8. Disengage the gun safety latch and squeeze the gun trigger. At the same time, slowly turn the pressure control knob clockwise, just enough to start the pump.

Refer to Fig. 2.

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

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

11. 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 prime the pump.

12. 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, force the solvent from the pump and hose, Engage the gun safety latch.

Refer to "Storage" procedure on page 1.

13. Whenever you shut off the sprayer follow the Pres-

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SETTING UP

1. Connect the Hose and Gun a. Remove the plastic cap plug from the outlet connector 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.

2. Fill the Packing Nut/Wet Cup

1/3 full with

Throat Seal Oil (TSO) supplied. (Fig. 4)

FIG. 4

3. Check the Electrical Service

Be sure the electrical service is 120 V, 60 HZ AC 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.

SETTING UP AND STARTING -

1. Learn the Controls

FIG. 5

Read Safety Warnings on page

4, 5, 6 and 7 before starting.

Pressure Control Knob

-used to adjust pressure only. Turn clockwise to increase pressure and counterclockwise to decrease pressure.

On/Off Switch

Thermal Overload Switch

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.

2. Prepare the Material according to the material

manufacturer's recommendations.

Prime/Pressure Relief Valve- used both to relieve pressure from gun/ hose/ tip, and to prime the pump when in the open position (a wider gap shows between the valve handle and cam body.)

Learn and follow Pressure Relief Procedure on page 6 of this manual. When in closed position (very slight gap) the system is pressurized and ready to spray.

3. Place the suction tube into the material container.

4. Starting the Sprayer (See Fig. 5 above) a. Prime Valve must be open - priming position.

b. Pressure control knob must be in Low Pressure

position.

c. Turn the motor ON/OFF switch to ON.

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.

CAUTION: Do not turn motor on without fluid pump having enough fluid so that it can be primed. Running fluid pump dry will decrease life of pumps packings.

5. Prime the pump.

a. Be sure gun safety latch is engaged.

b. After the pump is primed, close the prime valve by

turning it all the way to "closed" position.

c. Turn the pressure control knob to desired spray pres d. Disengage the gun safety lock and you are ready to sure.

start spraying.

WARNING: If you spray into the paint bucket, always use lowest spray pressure and maintain firm metal to metal contact between gun and container. See Fig.3. page 2.

CONTINUED NEXT PAGE

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SETTING UP AND STARTING

4

6. Adjusting the Pressure a. Turn the pressure control knob clockwise to increase and counterclockwise to decrease pressure.

b. Always use the lowest pressure necessary to com-

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

Everytime you stop spraying for even a minute, lock the gun and submerge the gun into a small bucket of thinner compatible with the material sprayed. Thinner will dissolve the build up of paint on the outside of tip, tip guard and gun much more effectively if the paint did not have time to dry out completely.

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.

7. Cleaning a Clogged Tip

WARNING: 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 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.

a. Follow the Pressure Relief Procedure on page 6.

b. Clean the front of the tip frequently (with toothbrush only) during the day to keep material from building up and clogging the tip.

c. To clean and clear a tip if it clogs, refer to the separate instruction manual received with your gun or nozzle.

WARNING: Clogged standard (flat) tip - clean only after the tip is removed from the gun.

Follow the Pressure Relief Procedure on Page

6.

8. 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 and gun as recommended by your separate gun instruction manual.

c. Flush the sprayer at the end of each work day if the material you are spraying is waterbased, or if it could harden in the sprayer overnight. See "Flushing" page 1 & 2. Use a compatible solvent to flush, then fill the pump and hoses with an oil-based solvent

WARNING: Be sure to relieve pressure in the pump after filling with mineral spirits.

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

LCD - LIQUID CRYSTAL DISPLAY

If your sprayer is equipped with an optional LCD Readout, the system pressure will be displayed.

WARNINGS

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. Handle as you would a loaded firearm. Learn and follow the PRESSURE RELIEF PROCEDURE

ON PAGE 6. Observe all warnings. This sprayer is for professional use only.

DO NOT USE halogenated solvents in this sytem. 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.

Important: United States Government safety standards have been adopted under the Occupational

Safety & Health Act. These standards, particularly the General Standards, Part 1910 & and Construction Standards, Part 1926 should be consulted.

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

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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 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, this is not an air spray sprayer.

ALWAYS follow the PRESSURE RELIEF PROCEDURE, 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.

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.

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.

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.

jury 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 manufac-

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

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WARNINGS

PRESSURE RELIEF PROCEDURE

To avoid possible serious bodily injury, including injection, always follow this procedure whenever the sprayer is shut off, when checking or servicing 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. Refer to separate instruction manual provided with your gun on its safety features and how to engage safety latch.

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 po-

sition.

2. Turn unit off and unplug from electrical outlet.

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.

Note: When in closed position there is only a very slight gap. The valve handle can move both CCW & CW and can face different direc tions.

5. Re-engage gun safety latch.

Lock

*For overnight or long term storage close

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.

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.

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

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

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.

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WARNINGS

UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD

VOLTAGE

25 50 100 150 200 250 300

AMPERAGE

RATING

RANGE

5 - 6

6 - 8

8 - 10

10 - 12

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

400

6

4

8

6

500

4

4

6

6

Always follow recommended pressure and operating instructions.

KEEP CLEAR OF MOVING PARTS

Keep clear of moving parts when starting or operating the sprayer. Do not put your iginfers 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 PROCE-

DURE 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 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.

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.

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AIRLESSCO 007 SPRAY GUN

SPRAY GUN

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) * 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.

FIG. A

GUN SAFETY

LATCH

IN LOCKED

POSITION

MAJOR COMPONENTS OF SPRAY GUN

AND REVERSIBLE SPRAY TIP

Gun Safety

Latch

(or

Reversible

Spray Tip

Tip Guard

Trigger

Guard

Handle

(filter inside)

O-RING

GASKET

AL

MET-

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. Install the o-ring gasket onto the back of the

metal seat.

3. Insert the nose of the tip handle into the slot on

the o-ring side of the metal seat.

4. Insert the metal seat onto the guard housing. Use

the nose of the tip handle to position the seat. (The

tip will be installed later)

5. Start the guard-housing nut onto the gun.

6. Insert the tip into the guard.

7. Turn the guard to the desired position and tighten

the nut sufficiently to keep the guard in position

(fingertight). Over-tightening

O-Ring Gasket

will make it hard to turn

the tip handle.

Retaining Nut

Metal Seat

Nose of tip handle

REV-GUARD

Guard Housing Assembly

Rev-Tip

Cylinder gun

1. Lock gun safety latch.

2. Turn Rev-Tip handle 180 degrees.

3. Disengage trigger lock and trigger

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 and return

Spray Position Shown

9

8

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.

WRONG

RIGHT

RIGHT 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

RIGHT

WRONG

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.

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.

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.

9

SPRAY TECHNIQUE

TOTAL SPRAYGUN MOVEMENT - arm movement - full sweep

TRIGGER

POINT

TRIGGER POINT

The Actual Paint Stroke

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.

FOR EVEN PAINT COAT OVERLAP HALF

THE WIDTH OF EACH PAINT STROKE.

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

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.

10

Always use the lowest pressure possible to obtain desirable results.

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

INSIDE CORNER OUTSIDE CORNER

"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.

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10

AIRLESS SPRAY GUN TROUBLESHOOTING

DEFECTS CAUSE CORRECTION

Coarse spray

Excessive fogging

(overspray)

Pattern too wide

Pattern too narrow

Too much material

Too little material

Low pressure

High pressure

Material too thin

Spray angle too large

Increase the pressure.

Reduce the pressure to satisfactory pattern distribution.

Use less thinner.

Use smaller spray angle tip.

Spray angle too small

Nozzle too large

Material too thin

Pressure too high

Nozzle too small

Material too thick

Worn tip

Wrong 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 distribution in center of pattern

"horns".

Thick skin on work

Coating fails to close & smooth over

Material too viscous

Application too heavy

Material too viscous

Spray pattern irreg- ular, deflected

Orifice clogged.

Tip damaged

Solvent balance Craters or pock

"long" sol marks, bubbles on work

Clogged screens Extraneous material in paint.

Coarse pigments

Poorly milled pigments

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

Thin cautiously.

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

Thin cautiously.

Clean carefully.

Replace with new tip.

Use 1 to 3% "short" solvents remainder

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

Clean screen

Use coarse screen if orifice size allows.

Try different thinner in fresh batch of paint.

TEST THE PATTERN

Good, full pattern.

Spotty pattern

Increase Pressure.

11

AIRLESSCO 007X & XL SPRAY GUNS

2 3 4 5

6 8 10 11 12 13

14 15

7 9 9a

27

1

16

18

20

21

22

25

17

19

26

23

24

Item No.

1

9a

10

11

12

13

14

8

9

6

7

4

5

2

3

561-001

561-002

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

Part No.

Rev-Guard ("F" thread)

Rev-Guard ("G" thread)

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 Teflon (2)

Trigger Pin

Washer (2)

Gun Head

Description

22

23

24

25

26

27

19

20

21

15

16

17

18

Retainer Pin (2)

Retainer

Item No.

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

032-012

Part No. De-

Nut

Washer

Safety Latch or Trigger Lock

Wave Washer

Retaining Ring

Seal

Filter-Complete-Coarse

Filter-Complete-Fine

Spring

Handle Complete 007X

Connector

Trigger

Handle with Swivel 007XL

F/G Thread Adapter

12 13

12

AIRLESSCO 007X & 007XL SPRAY GUN

REPLACING THE VALVE SPRING UNIT (9)

KIT#3-007

3 Tip Washers

Seat (7)

1 Valve

TRIGGER

LOCK

UNLOCK

LOCK

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.

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)

KIT #2-007

3 Tip Washers 1 Valve Seat (7)

1 Valve Ball Holder (8) 2 Seals-Teflon (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 the off the valve seat. Failure to lift

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 Teflon 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.

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.

13

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)

For sizes not shown, call factory for availability.

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.

Fan Width Orifice Size (Inch) in.

(mm) .009

.011

.013

.015

.017

.019

.021

.023

.025

.027

.029/.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)

209

309

409

.08

.30

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

.06

.26

.25

1.0

F

Wood

Interior

Wood

Exterior

Masonry

Ceiling

Lacquer, Varnish

Stain, Sealer

Enamel

Exterior Stain

Vinyl, Acrylic,Latex

Vinyl, Oil Base Alkyd

Latex, Acrylic

Block Filler

Elastomer

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

321

421

521

621

721

821

.47

1.79

.40

1.51

.

60

2.3

C

223

323

423

523

623

.57

2.15

.49

1.85

.75

2.8

C

Consult your paint manufacturer for application recommendation.

14

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.

225

325

425

525

625

.67

2.54

.58

2.20

.88

3.3

.77

2.96

.66

2.50

1.0

3.8

227

327

427

527

627

229

431

531

631

831

1.03

3.90

.88

3.33

1.25

4.7

REMOVE FILTER

535

635

1.31

4.98

1.12

4.24

1.5

5.7

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.

15

14

2.

3.

1.

REGULAR MAINTENANCE

Always stop the pump at the bottom of its' stroke when you take a break at the end of the day.

This helps keep material from drying on the rod and damaging the packings.

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

Inspect the packing nut daily. It should be tight enough to stop leakage, but no tighter. Overtightening will damage the packings.

OIL AND LUBRICATION INSTRUCTIONS

FIG. 6

Bleed (Weep) Hole

Sealed Bearing

1 oz. SAE 30 W oil - semiannually

Fill Plug - unit has grease in gearbox from factory and will not require changing.

(Grease - PN 301-178)

Oil Impregnated sleeve

Dip in hot 10 W oil when removed

ELECTRIC MOTOR MAINTENANCE

1. LUBRICATION

- This motor is supplied with pre-lubricated 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 Leeson brushes have an initial length of 1 and 1/4". When the brushes are worn to a length of 5/8" they should be replaced.

TO CHANGE THE BRUSHES:

1. Unplug the machine.

2. Remove the cover over the motor.

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

4. Loosen the screw under the brush.

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 No. 301-146 for 110V service, Part No. 301-147 for 220 - 240 V service) need to have a run in period. After changing brushes, set the machine for spraying. With a bucket of Coro-

Chek 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). Now run the pump for 20 minutes.

15

FIELD TROUBLESHOOTING

PROBLEM

Unit doesn't prime.

CAUSE

Airleak due to:

1. Loose Suction Nut

2. Worn O-Rings

Stuck or Fouled Balls

Prime/Pressure Relief valve not opening.

SOLUTION

1. Tighten Suction Nut

2. Replace O-Rings (106-018 & 106-

017) on inlet valve.

Service inlet and outlet valves.

See pg 19

Clean or replace Prime Valve (100-180).

Unit primes, but has no or poor pressure.

Pressure set too low.

Filter(s) are clogged.

Outlet Valve fouled or worn.

Prime/Pressure Relief valve bypassing.

Packings and/or piston

worn.

Turn up pressure.

Clean or replace gun filter, inlet filter and/or manifold filter.

Service OutletValve. See pg 19


1. Tighten Packing Nut. See pg 21

2. Repack unit. See pg 20-21

Unit does not maintain good spraying pressure.

Blown spray tip.

Packings and/or piston

worn.

Outlet seat & ball

worn.

Unit does not run.

Replace Spray Tip.

Repack unit.

Replace Piston.

Replace Outlet seat and ball.

See electrical troubleshooting on page 29.

16 17

16


1. Tighten Packing Nut. See pg 21

2. Repack unit. See pg 20-21

Replace Spray Tip.

Repack unit.

Replace Piston.

Replace Outlet seat and ball.

See electrical troubleshooting on page 29.

SERVICING FLUID PUMP

Note: Check everything in the Troubleshooting Chart before disassembling the sprayer.

FLUID PUMP DISCONNECT

1.

2.

3.

4.

5.

6.

Flush out the material you are spraying, if possible.

Follow the Pressure Relief Procedure on Page 6. Stop the pump in the middle of down stroke.

Remove the suction tube and fluid hose (if so equipped) from the fluid pump.

Remove 2 retaining rings and slip the sleeve of the coupling down and remove both coupling halfs.

This will disconnect fluid pump from the connecting rod.

Unscrew the two tie rod locknuts.

Pull the pump off the tie rods.

FLUID PUMP REINSTALL

1.

2.

3.

4.

5.

Loosen the packing nut and extend piston rod to fully up position. Slip sleeve (189-047) over the piston rod.

Make sure that spacer tubes (301-048) are in place.

Connect connecting rod with fluid pump by installing coupling halfs (189-046). Slide sleeve over coupling halfs. Secure with retaining ring (189-048).

Secure the fluid pump housing to the tie rods (100-328) and screw locknuts with washers on loosely.

Tighten the tie rod locknuts evenly to 30 ft. lb.

8.

9.

NOTE: After all the rod locknuts are tight, the alignment of both rods should allow easy assembly and disassembly of the coupling. If any binding, loosen and retighten all the rod locknuts to improve the alignment.

Misalignment causes premature wear of seal and packings.

6.

7.

Tighten the packing nut clockwise until resistance against the packings can be felt. Turn it 1 full turn more.

Start the pump and operate it slowly (at low engine speed) to check the piston rod for binding. Adjust tie rod lock nuts if necessary to eliminate binding.

Prime the unit and run at maximum pressure for several minutes, then release the pressure and repeat step 6.

Fill the wet cup (packing nut) about 1/3 full of TSO (Throat Seal Oil)

17

18

SERVICING INLET & OUTLET VALVES

INLET VALVE (SEE FIG. 7 & 9)

1. Using the rod collar tool (189-211), screw the suction nut

(187-018), containing intake seat support (187-017), off

of the fluid body (187-313).

2. Remove the inlet seat (187-065), O-ring (106-017), inlet

ball (187-020) and ball cage (187-016) with O-ring (106-018).

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

replacing parts as needed. Old "O" rings should be replaced

with new ones.

NOTE: Inlet seat (187-065) is reversible.

PISTON

FIG. 7

PACKING NUT/

WET CUP 4. Clean inside of fluid body (187-313).

5. Reassemble the valve and screw it onto the fluid body if

no further service is needed.

UPPER

PACK-

ING

PISTON, OUTLET VALVE

(SEE FIG. 7 & 9)

1. Stop piston rod in middle of it's stroke. Remove retaining

rings (189-048).

2. Slip the sleeve (189-047) off the coupling halves (189-046)

and remove both coupling halves. This will disconnect piston

rod from connecting rod and gearbox assembly.

3. Screw the suction nut (187-018) off the pump and remove

inlet valve assembly.

4. Using the rod collar tool, loosen the packing nut (CCW) and

push the piston down and out of the fluid body.

5. Place piston holder (187-248) in a vise. Slide the piston

into the holder and lock in place with a 1/4" pin (187-250).

6. Clean all parts and inspect them carefully for wear or

damage. Inspect the outside of the piston rod for scoring or

wear. Replace these parts if needed. A worn piston rod will

cause premature wear of packings.

7. Using a 3/8" allen wrench to unscrew the outlet seat support

(187-051) from the piston (187-330).

8. Remove the outlet seat (187-061), O-ring (106-021), outlet ball

(115-022) and ball cage (187-062).

9. Inspect the outlet ball and seat for wear. Replace as required.

FLUID

OUTLET

DISTANCE

TUBE

LOWER

PACKING

WIPER

PACKING

OUTLET

VALVE

NOTE: Inlet seat (187-061) is reversible.

10. Install parts back into piston rod as per Fig. 9, page 20.

Place two drops of loctite No. 242 (blue) on threads of the

outlet seat support before assembling and torque to 20 ft-lbs.

INLET

VALVE

SUCTION

NUT

FLUID

INLET

19

18

V-PACKING REPLACEMENT

V-PACKING REPLACEMENT KIT

SEVERE DUTY- PART NO. 187-040

Contains: Leather & Plastic Packings,

Teflon & Viton O-Rings, Balls & plastic dual sided female adaptor

& Larger Male Glands.

GLAND KIT - PN 187-064

V-PACKING REPLACEMENT

INSTRUCTIONS

1. Remove the fluid pump as per the "Fluid Pump

Disconnect" instructions on page 17.

2. Unscrew and remove the inlet valve per

instructions on page 18.

3. Unscrew & remove the packing nut (187-046).

Push the piston rod down through the packings

and out of the pump. Utilizing packing removal

tool (187-249) the complete packing set can be

removed quickly and easily. Another method

is to wrap some masking tape around the

bottom of the piston. Now push the piston back

through the pump and remove through the top.

The packings and glands will be removed with

the piston rod, leaving the fluid body (187-313)

empty.

4. Disassemble and clean all parts for reassem-

bly. Discard old packings and lower glands.

Save upper glands (187-026 & 187-025) for

reuse.

5. Remove the outlet seat support, outlet seat,

outlet ball, O-ring and ball cage as previously described on page 18.

187-030

187-031

187-029

FIG. 8

187-026

187-060

187-025

187-315

187-059

187-058

187-037

19

V-PACKING REPLACEMENT (Continued)

FIG. 9

187-046

187-047

106-013

106-012

187-026

187-030

187-025

187-031

187-330-99*

187-060

187-062*

106-021*

115-022

187-061

187-051*

187-315

187-037

187-029 187-059 187-313

106-018

(optional)

187-016

187-020

187-065

106-017

187-017

187-058

187-029

187-018

187-059

301-094

187-037

141-010

* INCLUDED WITH 187-330-99 PISTON ASSEMBLY

REASSEMBLY

20

6. Lubricate leather packings in lightweight oil for 10

minutes prior to assembly.

7. Remove masking tape from piston. (if used)

8. Reassemble all parts onto piston in the following

order: (See Fig. 8)

a. Start with lower male gland (187-037)

b. Five V-Packings (187-029 &187-059). "V"

inverted.

c. Female adaptor (187-058)

d. Five V-Packings (187-029 & 187-059). "V" up.

e. Upper Male gland (187-037)

f. Slide on distance tube (187-315)

g. Three Belleville Springs (187-031) starting

with the first spring facing down ( ) and

next facing up ( ) and the third facing down

( ).

h. Slide on upper male gland (187-025) with

bevel facing up.

i. Five V-Packings (187-030 & 187-060). "V"

inverted.

j. Female Gland (187-026)

k. Slide on the V-Packing holder (187-047)

and O-rings (106-013 & 106-012) over upper packings.

9. Lubricate inside of cylinder & outside of packings,

then slide complete assembly into the fluid body

(187-313). Thread packing nut (187-046) into

cylinder & tighten (handtight).

10. Install the lower check valve and tighten the lower

check valve nut (187-018).

11. Connect the pump to the machine as per fluid

pump reinstall procedure on page 17.

12. Tighten the packing nut (clockwise) until resis-

tance is felt against the belleville springs.

13.

Now turn it 1 turn clockwise.

14. Run unit to maximum pressure for 10 minutes,

relieve pressure, and repeat packing nut

adjustment.

21

20

106-018

(optional)

187-065

106-017

8

MANIFOLD FILTER - PN 111-200-99

FIG. 10

FIGURE 10 PARTS LIST

ITEM PART NO. DESCRIPTION

7

1

2

3

4

5

6

9

10

*

7

8

5

6

3

4

1

2

111-202

301-356

106-007

111-204

111-203

111-201

100-101

100-129

100-028

100-109

111-200

Base*

Spring*

O-Ring*

Filter

Support*

Base*

Swivel

Plug 3/8" (2)

Plug 1/4"

Nipple 3/8 x 1/4

Filter

8

10

9

PAINT SYSTEM - PN 301-454

5

FIG. 11

8

9 6

7

15

10

12

11

13

14

3

4

1

7

8

5

6

9

3

4

1

2

2

ITEM NO. PART NO.

100-109

301-308

301-318-99

111-037

331-294-99

100-028

100-180

331-424

111-200

DESCRIPTION

Nipple 1/4

Hose (2)

Pressure Control Ass'y

Screw (8)

Sensor

Plug 1/4

Prime/Pres. Relief Valve

Bypass Hose

Manifold Filter

10

11

12

13

14

15 not

FIG. 11 PARTS LIST

ITEM NO. PART NO DESCRIP-

169-013

100-109

100-160

100-312

331-103

167-016

100-050

Elbow

Nipple (2)

Plug

Screw (2)

Washer (2)

Elbow

Reducer (1)

21

COMPLETE SPRAYER

FIG. 12

22

5

4

3

6

20

1

2

12

14 15 13

36 38

20 26 27 28

31 29 30

32

49,57,58

7

43

8

9

11

8

16

17

23

24

22

10

19 18

21

45

44

25

37

33

39,40,41,55,56

34, 42

35

46

47

51

54

52, 53

Optional Suction Assy.

48 49, 50

23

22

COMPLETE SPRAYER PARTS LIST

ITEM NO. PART NO. DESCRIPTION

5

6

7

3

4

1

2

34

111-037

301-135

100-332

301-139

301-337

301-048

100-328

140-035

140-051

301-173

136-033A

301-099

140-051

301-233

115-041

112-029

301-189

301-092

301-105

100-360

100-312

301-320

301-333

301-291

189-048

189-046

301-047

189-047

301-193

111-044

100-349

113-023

301-321

301-205

301-206

301-414

301-415

301-318 99

12

13

14

15

8

9

10

11

16

17

18

19

20

21

22

23

28

29

30

31

24

25

26

27

32

33

Shield- Front

Shield- Rear

Hook

Screw (2)

Screw (4)

Cover

Connecting Rod Ass'y

(10/11 Series)

Connecting Rod Ass'y

(8 Series)

Retaining Ring (2)

Coupling Set

Sleeve Bearing

Coupling Cover

Tensioner Ass'y

Screw (2)

Washer (2)

Lock Washer, (2)

Screw (4)

Grommet (6)

Retaining Ring

Woodruff Key

Screw (2)

Spacer - Tube (2)

Stud (2)

Washer, Lock (2)

Nut (2)

Bracket - Return Tube

Screw (3)

Screw (3)

Nut (3)

Sheave

Set Screw (4)

Key

Cover

Frame w/ filter bracket

Frame w/o filter bracket

Frame Assly w/ filter mount

Frame Assly. w/o filter mount


50

51

52

53

46

47

48

49

54

55

42

43

44

45

38

39

40

41


35

36

37

56

57

58

100-028

301-190

301-191

117-052

101-060

301-046

301-237

301-231

189-427

143-029

167-014

140-029

113-056

301-134

301-517-99

301-543-99

141-010

301-106A

301-023A

301-089

113-022

113-023

111-037

301-204-99

301-203-99

301-316

Screw (8)

Gearbox 1"

(10/11 Series)

Gearbox 3/4"

(8 Series)

Rubber Edge (1.17')

(makes two)

Plug 1/4 NPT

Fan

Retaining Clip, Fan

Screws (3)

Label High Voltage

Rod End

Pulley, Cog

Cog Belt

Solid Wheel (2)

Set Collar (2)

Spacer (no longer used)

Washers (no longer used)

Axle

Stopper (2)

Suction Ass'y 16" (5 gal)

Suction Ass'y 36" (55 gal)

Inlet Strainer

1 1/4 HPDC Motor

(10/11 Series)

1 HPDC Motor

(8 Series)

Fan Cover

Nut (4)

Washer, Lock (4)

LABEL KITS

PART NO.

301-430

301-435

301-431

301-436

UNIT

AIRLESSCO SL810

ALLPRO 810E (910E)

AIRLESSCO SL1100

ALLPRO 1000E (1110E)

23

REPLACEMENT OF BELT/BELT ADJUSTMENT

NOTE: The Cog Belt System does not require alignment. When upper sheave is placed on motor shaft it is pushed on until a positive stop is reached. The set screws (Fig. 12, Item 30)

FIG. 13

DEFLECTION are then loctited. The lower pulley is placed on gearbox and held in place with keyway and snap ring (Fig. 12, Item 18) The flange on upper sheave holds the belt in alignment and the belt self aligns on lower pulley eliminating having to align.

FORCE

REPLACEMENT OF BELT:

1. Remove cover (Fig. 12, Item 32 ) from unit.

BOLTS MUST BE LOOSE TO ADJUST BELT

2. Remove Tensioner Assembly (Fig 13). Then loosen screws (Fig. 12, Item 27). Move gearbox forward to

allow removal and replacement of belt.

3. Retighten screws into gearbox until they bottom out. (Fig. 12, Item 27) This will align gearbox correctly.

4. Replace tensioner with bolts and leave loose to allow adjusting belt tension.

5. Tighten belt as shown in Figure 13. When properly tightened the deflection play should be 1/4 inch when

pushing hard with thumb. (20 ft/lbs)

24

NOTE: When placing belt on pulleys and inserting the tensioner against belt, ensure cogs on belt are engaged into cogs on pulleys before tightening belts. Rotating upper pulley while holding the tensioner against the belt will allow proper engagement of cogs prior to tightening.

9

SUCTION ASSEMBLY - 5 GAL. - P.N. 301-090-99

FIG. 14



FLUID

PUMP

10

8

7

6

5

12

11 4

3

3

2

1

*

1

2

3

4

5

6

7

8

9

10

11

12

301-517

141-008

301-514

301-516

301-513A

100-165

188-377

100-128

100-012

Suction Hose Ass'y

(includes items 1-5)

Inlet Strainer

Suction Tube

Hose Clamps (2)

Hose

Elbow

Return Pipe

100-126

100-385

187-017

187-018

Elbow

Whip

Elbow **

Reducer**

Fitting

Suction Nut

** used on units equipped with either the 100-180 or 331-050 prime valves. The 301-090 suction ass'y also includes the

100-081A Elbow for units with the 138-001 marathon prime valve.

9

SUCTION ASSEMBLY - 55 GAL. - P.N. 301-543-99

FIG. 15



FLUID

PUMP

10

8

7

6

5

12

11

4

3

3

2

1

7

8

5

6

3

4

1

2

9

10

11

12

141-008

301-545

301-516

301-544

100-165

188-377

100-128

100-012

100-126

100-385

187-017

187-018

Inlet Strainer

Suction Tube

Hose Clamps (2)

Hose

Elbow

Return Pipe

Elbow

Whip

Elbow **

Reducer**

Fitting

Suction Nut

** used on units equipped with either the 100-180 or 331-050 prime valves. The 301-090 suction ass'y also includes the

100-081A Elbow for units with the 138-001 marathon prime valve.

25

24

PRESSURE CONTOL ASS'Y CALIBRATION

NOTE: Anytime a sensor, pressure control assembly or both are replaced,

the these calibrations must be performed.

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. Detach the pressure control unit.

4. Place the jumper (PN 117-207) on both prongs of the "P-ZR" terminal. Note: This jumper comes with a new

Pressure Control Assemblyand is installed on the "P-ZR" terminal. If you are "Zero Calibrating" a Pressure

Control Assembly presently in the unit, remove the jumper from one prong of the "P-ZR" terminal and place on both prongs of the "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 "LCD ZERO" trimpot

(P501) counter-clockwise until the light goes out. Then turn it clockwise until the light just comes back on.

At this point, the "Zero" Calibration is complete.

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

At this point "Zero" Calibration is complete.

NOTE: If your machine is equipt with the optional LCD, as a double check to confirm that the pump is at true zero the LCD should read "0000" when the yellow light just comes on.

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 prongs of the "P-ZR" terminal to single prong of the

"P-ZR" Terminal.

2. PRESSURE CALIBRATION

1. Attach a 50', 1/4" airless hose, airless gun with 0.017 tip and a 5000 psi 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 glycerine gauge (not the LCD) , slowly adjust the Pressure Trimpot (P502) (clock-

wise 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.

LIQUID CRYSTAL DISPLAY CALIBRATION -

(If so equipped)

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 (P503). 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.

5. Reattach Pressure Control Assembly.

25

26

PRESSURE CONTROL ASS'Y CALIBRATION (cont.)

4. PHASE LIMIT CALIBRATION

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 (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 150 psi, adjust the phase limit trimpot so that the deadband is less than 150

psi and the pressure increase after the gun trigger is released is less than 250 psi. These pressures are

guidelines and may vary slightly from pump to pump.

8. Reattach pressure control assembly to unit.

Note: The 301-318 Revision E pressure control assembly has a reddish brown terminal labelled "Inhibit Switch". At all times there should be a jumper on the two left terminals, which are the closest to the "S2" connection. Also on the Revision E is a terminal labelled

"ON-SL". This terminal should always have a jumper on it.

27

26

ELECTRICAL SYSTEM

FIG. 16

5

6

7

4 8

1

2

5

7

8

3

4

1

2

9

10

11

12

13

14

15

ITEM PART DESCRIPTION

NO. NO.

Electrical Cord

Strain Relief

Screw

Toggle Switch

331-168

331-185

331-138

301-083

301-518

117-035

301-106A

301-023A

301-318-99

117-207

331-294-99

331-297

331-184

117-044

35A Circuit Breaker

Rubber Boot

1 1/4 HPDC Motor (10&11 Series)

1 HPDC Motor (8 Series)


Jumper

Sensor

Potentiometer

Spacer

Knob

LCD (optional)

WHITE

3

BLACK

A2 A1

B

L

K

B

K

&

W

T

R

E

D

R

E

D

BLACK

L1

L2

INHIBIT

POT

S1 S2

ON-SL

P-ZR

LCD ZERO

PRESSURE

LCD SET

PHASE LIMIT

SENSOR DISPLAY

POWER

LIGHT

ZERO

LIGHT

9

15

27

28

TROUBLESHOOTING - Machine does not start

CAUSE SOLUTION

Control Settings 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 red 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.

Power Source

Thermal Overload

STEP 3: Use a multimeter to check for 110 volts VAC across the L1 and L2 terminals on the board. If no voltage at these leads, there is no power to the unit. Check power source (outlet, breakers, extension cord and power cord).

STEP 4: 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 thethermal 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 5: If all checks out fine in Steps 1 through 4 and the red light is still out, the pressure control assembly is defective and must be replaced.

Pressure Control

Assembly (Board)

Sensor

Pressure Control

Knob (Potentiometer)

STEP 7: 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).

Motor

STEP 6: If the red 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).

Pressure Calibration

STEP 8: 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 thatthe 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 9: Calibrate the pressure control assembly in accordance with the instructions on page 25-26.

Pressure Control

Assly. (Board)

STEP 10: If the unit fails to calibrate and all components in Steps 1-9 test okay, the pressure control assembly needs to be replaced.

29

28

REPLACEMENT OF ELECTRICAL COMPONENTS

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 eight screws (Fig. 12, Item 35 ) and lower the pressure control assembly.

3. Disconnect all leads from pressure control assembly.

4. Reassemble in reverse order.

SENSOR

1. Remove the screws (Fig. 12, Item 35 ) and lower the pressure control assembly.

2. Disconnect sensor lead from the board.

3. Unscrew sensor (Fig. 16 Item 11 ) from pressure control assembly using a 7/8" wrench.

4. Reassemble in reverse order. Use telfon tape on the sensor threads prior to reinstalling it into the

pressure control assembly.

POTENTIOMETER

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 (Fig. 12, Item 14 ) and

remove knob and spacer. (Fig. 12, Item 13 ).

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

5. Pull entire potentiometer assembly out of the frame.

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 toggle switch (Fig. 16, Item 4).

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


THERMAL CIRCUIT BREAKER

1. Lower pressure control assembly as described above.

2. Disconnect the two wires on the breaker (Fig. 16, Item 5).

3. Unscrew rubber boot (Fig. 16, Item 7) from breaker shaft.

3. Use 1/2" wrench to remove the bushing (Fig. 16, Item 6) from the breaker shaft.

4. Remove breaker from frame.

29

REPLACEMENT OF ELECTRICAL COMPONENTS (Cont)

LIQUID CRYSTAL DISPLAY (LCD)

1. Ensure that the power switch is OFF and that the machine is unplugged.

2. Detach the pressure control assembly (Fig. 12, Item 34) from the frame by unscrewing the eight

screws (Fig. 12, Item 35).

3. Disconnect the LCD lead from the the pressure control assembly.

5. Separate the LCD assembly from the frame by undoing the four screws (Fig. 17 Item 6)

6. Disassemble Items 1-6 (Fig 17)

7. Remove and replace LCD Display (Fig. 17 Item 3).


NOTE: Do not over tighten the screw and nuts (Fig 17, Item 1 & 6).

This can warp the LCD and damage it.

9. Perform "LCD Calibration Procedure". See page 25.

1

2

3 4 5

6

FIGURE 17

FIGURE 17 PARTS LIST

ITEM NO. PART NO. DESCRIPTION

*

*

5

6

3

4

1

2

117-126

120-046

331-377

117-281

331-360

100-362

Nut (4)

Plastic Washer (4)

Display Board Ass'y

Spacer (4)

Window

Screw (4)

Frame

30

SUPPLEMENTAL 230 VOLT PARTS LIST

MODEL MOTOR & PART NO. BOARD

8 SERIES 1 HP - P.N. 301-058A P.N. 301-364-99

10/11 SERIES 1.25 HP - P.N. 301-255A P.N. 301-364-99

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