AIRLESSCO 510E, LP460 Service & Operation Manual

A

IRLESS

P

AINT PRAYER

S

ERVICE

/O

PERATION

M

ANUAL

A

IRLESSCO

LP460 - LP540 - LP690

ALLPRO

510E - 710E - 810E

Form No. 001-492 JUNE 2006

TABLE OF CONTENTS

Introduction

LP Series Specifi cations

Safety Warnings

1

2

Getting Started

Flushing

How to Flush

Setting Up

Starting Up

Pressure Relief Procedure

Daily Maintenance

Repairs/Maintenance Instructions

Spray Gun Operation

Spray Gun Troubleshooting

Spray Tip Selection

Electric Motor Maintenance

Field Troubleshooting

Servicing the Fluid Pump

Servicing Piston Rod,

Outlet Valve

Servicing Suction Assembly

Packing Replacement

Electrical Board Calibration

Electrical Troubleshooting - 5/6 Series

Replacement of Electrical Components

11

12

13

14

15

16

18

18

19

25

27

29

7

8

5

5

10

10

Product Diagrams & Parts Lists

Manifold Filter Parts List

Gear & Pump Assembly

Upper & Lower Seats

Fluid Pump

Carry Frame Machine Parts List

Lo-Boy Machine Parts List

Hi-Boy Machine Parts List

Suction Assemblies

Electrical System Drawing - 5/6 Series

21

22

23

24

28

14

17

18

20

Quick Reference Guide

Single Sheet of Instructions for Operation

& Cleaning of an Airless Paint Sprayer 30

2

Manufactured by: AIRLESSCO BY DUROTECH CO.

Ship to: 5397 N Commerce Ave.,

Moorpark, CA 93021Tel: 800-223-8213 Fax: 805-523-1063 www.airlessco.com email: [email protected]

SUBJECT TO CHANGE WITHOUT NOTICE.

Copyright © 2006, All rights reserved.

INTRODUCTION

Your new Airlessco or ALLPRO airless paint sprayer is designed to meet the demands of the professional painting contractor as well as the homeowner.

The famous Airlessco slow-stroking stainless steel piston pump delivers extra long life for the piston, packings, valve seats and balls. The patented

Triple-Life packing system is externally adjustable, extending packing life and reducing repacking costs. Its large high-torque electric motor runs slower reducing heat. The motor is fan cooled and totally enclosed to reduce brush wear and to prevent the ignition of paint fumes in the motor.

LP460/510E

Max. Pressure

Output (FreeFlow)

Output (At Pressure)

Tip Size

3000 psi

0.5 gpm

0.46 gpm

1 gun up to 0.021

Motor- Output

Weight

DC TEFC .6 hp

38 lbs

LP540/610E

3000 psi

0.7 gpm

0.54 gpm

1 gun up to 0.023

DC TEFC .8 hp

41 lbs.

LP690/810E

3000 psi

0.8 gpm

0.6 gpm

1 gun up to 0.026

DC. TEFC. .8 hp

65 lbs.

LO-BOY FRAME

HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!

High pressure spray can cause extremely serious injury.

OBSERVE ALL WARNINGS!

Before operating this unit, read and follow all safety warnings and in struc tions related to the usage of this equipment on pages 2, 3 & 4. READ, LEARN, and

FOLLOW the Pressure Relief Pro ce dure on Page 10 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.

MANUAL NOTATIONS

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

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

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

NOTE - Identifi es essential procedures or extra information.

1

2

SAFETY WARNINGS

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.

Handle as you would a loaded fi rearm.

Follow the PRESSURE RELIEF PROCEDURE .

DO NOT USE HALOGENATED SOLVENTS IN THIS SYSTEM.

The prime valve, and most airless guns have aluminum parts and may explode. Clean ing 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.

MEDICAL ALERT

-

Airless Spray Wounds

If any fl uid appears to penetrate your skin, get

EMERGENCY MEDICAL CARE AT ONCE.

DO NOT TREAT AS A SIMPLE CUT .

Tell the doctor exactly what fl uid was injected .

NOTE TO PHYSICIAN : Injection in the skin is a trau mat ic injury.

It is important to treat the injury sur gi cal ly as soon as possible. DO NOT DELAY treat ment to research toxicity. Toxicity is a concern with some ex ot ic coatings injected directly into the blood stream. Con sul ta tion with a plastic surgeon or re con struc tive hand sur geon may be advisable.

INJECTION HAZARD

• Fluids under high pressure from spray or leaks can penetrate the skin and cause ex treme ly serious injury, including the need for amputation.

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

• NEVER put your hand or fi ngers over the spray tip. Do not use a rag or any other materials over your fi ngers.

Paint will penetrate through these materials & into the hand.

• NEVER try to stop or defl ect leaks with your hand or body.

ALWAYS have the tip guard in place when spraying.

• ALWAYS lock the 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 system equipment.

PRESSURE RELIEF PRO CE DURE before cleaning or re mov ing the spray tip or servicing any

• Be sure the equipment safety devices are operating prop er ly before each use.

• Tighten all of the fl uid connections before each use.

MEDICAL TREATMENT \\\\

• If any fl uid appears to penetrate your skin, get EMER GEN CY

CARE AT ONCE! DON'T TREAT AS A SIM PLE CUT.

• Go to an emergency room immediately.

• Tell the doctor you suspect an injection injury.

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

GENERAL PRECAUTIONS

• NEVER alter equipment in any manner.

• NEVER smoke while in spraying area.

• NEVER spray highly fl ammable 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 fi re extinquishing equipment is readily available and properly maintained .

NEVER LEAVE SPRAYER UNATTENDED

WITH PRES SURE IN THE SYSTEM.

FOLLOW PRES SURE RELIEF

PROCEDURES.

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.

SAFETY WARNINGS

ALWAYS INSPECT SPRAYING AREA

• Keep the spraying area free from obstructions.

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

• NEVER keep fl ammable material in spraying area.

• NEVER spray in vicinity of open fl ame or other sources of ignition.

• The spraying area must be at least 20 ft. away from spray unit.

SPRAY GUN SAFETY

• ALWAYS set gun safety lock in the "LOCKED" po si tion when not in use & before servicing or cleaning.

• NEVER remove or modify any part of the gun.

• ALWAYS REMOVE THE SPRAY TIP when cleaning.

Flush unit at the LOWEST POSSIBLE PRESSURE.

• ALWAYS check operation of all gun safety devices before each use.

• Be very careful when removing the spray tip or hose from the gun. A plugged line will con tain fl uid un der pressure. If the tip or line is plugged, follow the

PRES SURE RELIEF PRO CE DURE .

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 fi n gers or any part of your body close to the spray tip.

SPRAY TIP SAFETY

• Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately. ALWAYS follow the PRESSURE RELIEF PROCEDURE and then remove the spray tip to clean it.

• NEVER wipe off build up around the spray tip.

TOXIC FLUID HAZARD

• ALWAYS remove tip guard & tip to clean AFTER pump is turned off and the pressure is relieved by fol low ing the PRESSURE RELIEF PROCEDURE.

• Hazardous fl uid or toxic fumes can cause serious in ju ry or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fl uid you are us ing.

Store & dispose of hazardous fl uid according to manufacturer, local, state & national guidelines.

• ALWAYS wear protective eyewear, gloves, clothing and respirator as recommended by fl uid man u fac tur er.

HOSES

• Tighten all of the fl uid connections securely before each use. High pressure fl uid 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.

• Only use hoses with 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, abrasions, bulging of the 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 fl uid. NEVER

ATTEMPT TO RECOUPLE THE HOSE. A high pressure hose is not recoupleable.

GROUNDING

• Ground the sprayer & other components in the system to reduce the risk of static sparking, fi re 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 cor rect size to use depending on cord length and name plate ampere rating. If in doubt, use the next heavi er gauge.

The smaller the gauge num ber, the heavi er the cord.)

2. Fluid hose : use only grounded hoses.

3. Spray gun or dispensing valve : grounding is ob tained through connection to a properly grounded fl u id hose and pump.

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

5. All solvent pails used when fl ushing.

• 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 im me di ate ly.

• Never exceed 500 ft. (150 m) overall combined cord length to assure electrical continuity.

3

4

SAFETY WARNINGS

AMPERAGE

RATING

RANGE

UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD

VOLTAGE

25 50

LENGTH OF CORD IN FEET

100 150 200 250 300

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

• ALWAYS use approved high pressure fi ttings and re place ment parts.

• ALWAYS ensure fi re extinquishing equip ment is readi ly avail able and properly maintained.

KEEP CLEAR OF MOVING PARTS

Keep clear of moving parts when starting or operating the sprayer. Do not put your fi ngers into any openings to avoid amputation by moving parts or burns on hot parts. Pre cau tion is the best in sur ance against an accident. When starting the motor, maintain a safe distance from moving parts of the equipment. Before adjusting or ser vic ing any mechanical part of the sprayer, follow the PRESSURE RELIEF PROCEDURE.

AVOID COMPONENT RUPTURE

• This sprayer operates at 3000 psi (205 bar). Al ways be sure that all com po nents and ac ces so ries have a max imum work ing pres sure of at least 3000 psi to avoid rup ture which can result in serious bodily injury in clud ing in jec tion and prop er ty damage.

• NEVER leave a pressurized sprayer un at tend ed to avoid ac ci den tal operation of it, which could result in serious bodily in ju ry.

• ALWAYS follow the PRESSURE RE LIEF PRO CE DURE whenever you stop spraying and before ad just ing, re mov ing 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 bodi ly injury and property damage.

• NEVER use weak, damaged, or non-conductive paint hose. Do not allow kinking or crushing of hoses or al low it to vibrate against rough, sharp or hot surfaces.

Before each use, check your hoses for damage and wear and ensure all of the fl uid connections are secure.

• ALWAYS replace any damaged hose. NEVER use tape or any device to mend the hose.

• NEVER attempt to stop any leakage in the line or fi t tings with your hand or any part of the body. Turn off the unit and release pressure by following PRES SURE

RELIEF PROCEDURE.

•

•

PREVENT STATIC SPARKING FIRE/EXPLOSIONS

• ALWAYS be sure all of the equipment & objects being sprayed are properly grounded. Always ground sprayer, paint bucket and object being sprayed. See the ground ing section of this manual for grounding information.

• Vapors created when spraying can be ignited by sparks.

To reduce the risk of fi re, 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. Doing so can cause sparks which can ignite any vapors still in the air. Follow the coating & solvent man u fac tur ers safety warnings and precautions.

• Use only conductive fluid hoses for airless ap pli ca tions.

Be sure the gun is grounded through the hose con nec tions.

Check ground continuity in hose & equipment. Overall

(end to end) resistance of unpressurized hose must not exceed 29 megohms for any coupled length or com bi na tion 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 specifi c cleaning process.

ALWAYS follow the PRESSURE RELIEF PRO CE DURE.

• ALWAYS remove the spray tip before fl ushing. Hold the metal part of the gun fi rmly to the side of a metal pail

& use the lowest possible fl uid pressure during fl ush ing.

• NEVER use cleaning solvents with fl ash points below

140 degrees F. Some of these are: acetone, ben zene, 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 fl ammable liquids, the unit must be located a minimum of 25 feet away from the spraying area in a

well ventilated area. Ventilation must be suffi cient enough to prevent the accumulation of vapors.

2. To eliminate electrostatic discharge, ground the spray unit, paint bucket & spraying object. See GROUNDING. Use only

high pressure airless hoses approved for 3000 psi which is conductive.

3.

Remove the spray tip before fl ushing. Hold the metal part of the gun fi rmly to the side of a metal pail & use the lowest

possible fl uid pressure during fl ush ing.

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

5.

Do not smoke in spraying/cleaning area.

FLUSHING

Your sprayer was factory tested in an oil solution which was left in the pump. Before using oil-base paint, fl ush with mineral spirits only. Before using water-base paint fl ush with mineral spirits, followed by soapy water, then a clean water fl ush.

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

3. Changing from water-base to oil-base paint.

Flush with soapy water, then mineral spirits .

4. Changing from oil-base to water-base paint.

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

Always relieve pressure (See pressure relief procedure on page 10) 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.

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

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

NEVER leave pump unattended while under pressure!

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 po si tion when there is a wider gap between valve handle and cam body).

When valve is in the CLOSED position, there is only a very slight gap between handle & body.

When closed the system is pressurized .

Handle as a Loaded Firearm!

FIGURE 2

PRESSURE CONTROL KNOB. (FIG. 2)

Used to adjust pressure. Turn clockwise (CW) to increase pressure and coun ter clock wise (CCW) to decrease pressure.

FIGURE 3

ON

TOGGLE

SWITCH

OFF

Continued on next page............

5

6

HOW TO FLUSH (continued)

1. Be sure the gun safety latch is engaged and there

is no spray tip in the gun. Refer to page 14 on how

to lock the safety latch and the gun's safety features.

FIGURE 4

REMOVE SPRAY TIP.

ENGAGE GUN SAFETY

LATCH.

2 . Pour enough clean, compatible solvent into a large,

empty metal pail to fi ll 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 Figure 1.

5.

Point the gun into the metal pail and hold a metal

part of the gun fi rmly against the pail. Refer to Figure 5.

6. Disengage the gun safety latch and squeeze the

gun trigger. Turn the ON-OFF Toggle Switch to the

"ON" position (Figure 3) and turn Pressure Control

Knob (Figure 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

fl ushed 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.

Whenever you shut off the sprayer, follow the

"PRESSURE RELIEF PROCEDURE".

To reduce the risk of static sparking which can cause fi re or explosion, always hold a metal part of the gun fi rmly against the metal pail when fl ushing. This also reduces splashing.

FIGURE 5

MAINTAIN FIRM

METAL TO METAL

CONTACT BETWEEN

GUN AND CONTAINER

SETTING UP

a.

Remove the plastic cap plug from the outlet tee

and screw a conductive or grounded 3000 psi

airless spray hose onto fl uid 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 with

5 drops of Airlessco Throat Seal

Oil (TSO).

See (Figure 6).

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.

NOTE: *For Generator power, a minimum 7000 watt generator with voltage regulation must be used.

WARNING

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

As per "Flushing Procedure" in this manual.

7

8

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.

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 Figure 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.

d. Turn Pressure Control Knob clockwise to prime

the pump.

e.

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

the "Closed" position.

f. Turn Pressure Control Knob to the desired spray

pressure. Optional LCD displays pressure.

g. Disengage the gun safety latch and you are

ready to spray.

FIGURE 7

Prime/Pressure Relief Valve (Prime/PR Valve)

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

When in the CLOSED position, there is only a very slight gapbetween handle & body.

When closed the system is pressurized. Handle as a loaded fi rearm!

FIGURE 8

FIGURE 9

ON

TOGGLE

SWITCH

OFF

PRESSURE CONTROL KNOB is used to adjust pressure. Turn clockwise (CW) to increase pressure and coun ter clock wise (CCW) to decrease pressure .

STARTING UP

a. Turn the Pressure Control Knob Clockwise to

increase pressure and counterclockwise to decrease

pres sure.

b. Always use the lowest pressure necessary to

completely atomize the material.

Note: Operating the sprayer at higher pres sure 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 fl ow rate.

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

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

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

WARNING

Be sure to relieve pressure in the pump after fi lling with Airlessco Pump Conditioner.

WARNING

Follow the "Pressure Relief Procedure".

To reduce the risk of injection, never hold your hand, body, fi ngers or hand in a rag in front of the spray tip when cleaning or checking for a cleared tip.

Always point the gun toward the ground or into a waste container when checking to see if the tip is cleared or when using a self-cleaning tip.

WARNING

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

a.

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

b.

Clean the tip & gun as recommended it the spray gun instruction manual.

c.

Flush the sprayer at the end of each work day, if the material you are spraying is water-based, or if it could harden in the sprayer overnight. See "Flushing". Use a compatible solvent to fl ush, then fi ll the pump and hoses with an oil based solvent such as mineral spirits.

d.

For long term shutdown or storage, refer to the

"Flushing" section of this manual.

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

Pressure Relief Procedure.

9

PRESSURE RELIEF PROCEDURE

IMPORTANT!

To avoid possible serious body injury, always follow this procedure whenever the sprayer is shut off, when check ing it, when installing, changing or cleaning tips, whenever you stop spraying, or when you are instructed to relieve the pressure.

1.

Engage the gun safety latch. Refer to the separate

instruction manual provided with your gun on its

safety features and how to engage safety latch.

2.

Turn the unit off & unplug it from the electrical outlet.

3.

Disengage the gun safety latch and trigger the gun

to relieve residual fl uid pressure.

Hold metal part of the gun in

contact with grounded metal pail.

USE MINIMUM PRESSURE !

4. Turn Prime/Pressure Relief Valve (PR Valve) to the open

There will be a wider gap be tween valve handle and cam body when in open position. In the closed position there is

.

only a very slight gap.

NOTE: The valve handle can move both clockwise

& counter clockwise and can face different di rec tions.

5.

Re-engage gun safety latch and

close Prime/Pressure Relief Valve.

If the SPRAY TIP OR HOSE IS CLOGGED, follow Step 1 through 5 above. Expect paint splashing into the bucket while relieving pressure during Step 4.

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

Service Center.

DAILY MAINTENANCE

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

TSO helps protect the rod and the packings.

2.

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

If seepage of paint into the packing nut and/or movement of the piston upward is found

(while not spraying), the packing nut should be tightened enough to stop leakage only, but not any tighter. Overtightening will damage the packings and reduce the packing life.

SPRAY GUN OPERATION

SPRAY GUN

Attach spray gun to airless unit and tighten fi t tings se cure ly.

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

* The gun safety latch should always be set when the gun is

not being triggered.

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

MAJOR COMPONENTS OF SPRAY

GUN AND REVERSIBLE SPRAY TIP

Re vers ible

Spray Tip

Tip Guard

Gun Safety

Latch or lock

™

Trig ger

Guard

Handle

(fi lter inside)

SPRAY TIP ASSEMBLY

1. Be sure pressure relief procedure is followed before

assembling tip and housing to the gun.

2.

Lock gun safety latch.

3.

Insert REV-TIP™ cylinder into the REV-GUARD™

(guard housing assembly).

4.

Guide metal seat into REV-GUARD™ (guard housing

assembly) through retaining nut & turn until it seats

against the cylinder.

5.

Insert O-Ring gasket on metal seat so it fi ts in the grooves.

6.

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

7.

Turn guard in the desired position.

8.

Completely tighten the retaining nut.

TO REMOVE CLOGS FROM SPRAY TIP

1.

Lock gun safety latch.

2.

Turn REV-TIP™ handle 180 de grees.

3.

Disengage trigger lock & trigger gun into pail.

4.

If the REV-TIP™ handle appears locked (resists

turning), loosen the retaining nut. The handle will

now turn easily.

5. Engage gun safety latch & return handle to the

spray position.

REV-GUARD™

Guard Housing Assembly

G Thread 7/8" 561-002

F Thread 11/16" 561-001

Metal Seat

Part # 561-029

Spray Position Shown

Part # 561-XXX

CLEANING SPRAY GUN

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

CLEANING FILTER IN GUN HANDLE

To clean the fi lter, use a brush dipped in an appropriate solvent. Change or clean fi lters at least once a day.

Some types of latex may require a fi lter change after four hours of operation.

CLOGGED FLAT TIP

Should the spray tip become clogged, relieve pressure from hose by following the "Pressure Relief Procedure." Secure gun with the safety latch, take off guard, take out the tip, soak in appropriate solvent & clean with a brush. (Do not use a needle or sharp pointed instrument to clean the tip.

The tungsten carbide is brittle and can chip.)

Problem

Coarse Spray, Spotty Pattern

Excessive Overspray (Fogging)

Spray Pattern Excessively Wide

Spray Pattern Excessively Narrow

Cause

Pressure setting low

Irratic spray gun/hand motion

Pressure setting high

Paint over thinned/reduced/cut

Incorrect fan width selection

Incorrect fan width selection

Excessive Paint Delivery

Paint Film Runs/Sags

Large tip orifi ce for application

Paint over thinned/reduced/cut

Excessive pressure

Spray gun/hand speed slow

Tip worn beyond use Spray Pattern Rounded and Heavy:

Pump Does Not Keep Up

Spray Pattern Pulsates/Irratic:

Pump Does Not Keep Up

Pump worn or malfunctioning

Correction

Increase pressure setting

Use a steady, parallel pass

Reduce pressure setting

Use less thinner/water/reducer

Select narrower fan width tip*

Select wider fan width tip*

Select smaller tip orifi ce*

Use less thinner/water/reducer


Increase pass speed

Replace with new tip*

Service pump

Thin or Spotty Coverage (Holidays)

Thin Coverage in Center of Pattern

(Fingers)

Spray Pattern Irregular, Defl ected

Excess Paint Builds on Tip Guard

Drips, Spits From Tip

Tip Clogs Continually

Gun Filter Clogs Quickly

*See “Tip Selection Guide” in this manual

Small tip orifi ce

Spray gun/hand speed fast

Tip size larger than pump specs

Low pressure setting

Pump worn or malfunctioning

Tip orifi ce partialy clogged

Tip damaged

Spray gun excessively close to surface

Pressure setting high

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

Debris in paint

Gun fi lter missing

Coarse fi lter mesh

Debris in paint

Pump inlet strainer missing

Select larger tip orifi ce*

Decrease pass speed

Replace with correct tip for pump*

Increase pressure setting

Service pump

Clean tip carefully

Replace with new tip*

Hold gun further from surface sprayed


Service spray gun, replace valve assembly

Thouroughly strain paint before use

Insure gun fi lter is in handle

Use fi ne mesh fi lter in gun handle

Thouroughly strain paint before use

Do not operate without intlet strainer

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 vis cos i ties (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 max i mum pump fl ow rate or capacity the sprayer can ac com mo date. Pump fl ow rate is mea sured in gallons per minute (GPM).

REV-TIP

TM for Painting 561-XXX

Fan Width (12” from surface)

SPRAY PAINTING TIP - ORIFICE SIZE

in.

(mm) .007 .009 .011 .013

(Inches)

.

029

4-6 102-152 209 211 213

6-8 152-203 307 309 311 313

8-10 203-254 409 411 413

10-12 254-305 511 513

12-14 305-356

515

611 613

14-16 356-406 715

16-18 406-457 815

20-24 508-610

Gun Filter C = Coarse

F= Fine

NEW

WIDE PATTERN REV-TIP

►

335

831

739 741

Wood

Interior

Lacquer, Varnish

Stain, Sealer

Enamel

•

•

• •

Wood Exterior Stain

Exterior

Vinyl, Acrylic, Latex

•

• •

Masonry vinyl,oil-base alkyd

Latex, Acrylic

Block Filler

Elastomer

Ceiling Hi Build, Mil White

Structural Steel

Heavy Coatings

•

•

•

•

• •

•

•

• • • • •

Water Flow Rate

(water @ 2000psi, 138 bar)

(gal./min.)

(liters/min.)

.12 .18 .24 .31 .38 .47 .57 .67 .77 1.03 1.31 1.63 1.80

.49 .69 .91 1.17 1.47 1.79 2.15 2.54 2.96 3.90 4.98 6.17 6.81

Paint Flow Rate

138 bar/1.36 spec. gr.)

(gal./min.) .10 .15 .21 .27 .33 .40 .49 .58 .66 .88 1.12 1.39 1.54

(liters/min.) .38 .57 .79 1.02 1.25 1.51 1.85 2.20 2.50 3.33 4.24 5.26 5.83

Pump Minimum (gal./min.) .25 .25 .33 .40 .50 .60 .75 .88 1.0 1.25 1.5 2.0

2.2

Output* (liters/min.) 1.0 1.0 1.25 1.5 1.9 2.3 2.8 3.3 3.8 4.7 5.7 7.5

8.2

*Pump will support tip worn to next larger size.

Protected By U.S. Patent No. 6,264,115 Other U.S. & Foreign Patents Applied For.

PATTERN WIDTH

Thickness of the paint coat per stroke is de ter mined by spray tip "fan width", rate of the spray gun move ment, and distance to surface.

W!

Fine Finish

Part # 571-xxx

REV-TIP

TM

NEW Double Orifice design for lower pressure airless spraying when you need finer atomization for a smoother finish on interior trim, cabinetry, shutters, and doors.

SPRAY TIP SELECTION

Two tips having the same tip size, but different pat tern widths will deliver the same amount of paint over a dif fer ent 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 pres sure will cause the orifi ce to grow larger. This de stroys the pattern.

Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make cut ting-in diffi cult, and decreases sprayer per formance.

4-6 102-152 212 214

6-8 152-203 312 314

8-10 203-254 412 414

ELECTRIC MOTOR MAINTENANCE

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

2. MOTOR BRUSHES - These need periodic inspection and replacement as wear indicates. Brushes for the Leeson motor

(LP540/690) PN 331-131 have an initial length of 3/4" and must be replaced when worn to 3/8." Brushes for the Airlessco DC

Motor (LP400/460) PN 331-778 have an initial length of 13/16" and must be replaced when worn to 1/4".

3. TO CHANGE THE BRUSHES, follow the procedures below: a.

Unplug the machine.

b.

Remove brush access plates at the rear of the motor.

c.

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

d.

Push the brush retainer clip in and remove.

e.

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

f. Install new brushes in reverse order and replace plates.

NOTE: For longer life, new brushes need to have a "run in" period. After installing a new brushes, set up the machine for spraying. Use a bucket of water and Airlessco Pump Conditioner mixture, a 50 foot x 1/4" airless hose, airless gun with 0.017 tip on Gun. Turn the Prime/PR Control Valve to the Prime position and turn the unit on. Turn the Pressure Control Knob to maximum pressure (fully CW position) and let the pump cycle at high speed in the prime position for 20 minutes. This will allow the brushes to "run in" properly.

14

MANIFOLD FILTER - PN 111-200-99

*7

8

5

6

9

10

3

4

1

2

FIGURE 10 PARTS LIST

ITEM # PART # DESCRIPTION

111-200-99 Filter Ass'y

111-202

301-356

106-007

111-204

111-203

111-201

100-159

100-129

100-028

100-109

Base

Spring

O-Ring

Filter 60 Mesh

Support

Base

Swivel

Plug 3/8" (2)

Plug 1/4"

Nipple 3/8 x 1/4

* LP690 & 810E come equipped with fi ttings

100-201 and 169-010

FIGURE 10

FIELD TROUBLESHOOTING

PROBLEM CAUSE

Unit doesn't prime Airleak due to:

• Loose Suction Nut

• Worn O-Rings

• Hole in Suction Hose

Stuck or Fouled Balls

SOLUTION

• Tighten Suction Nut

• Replace O-Ring (106-011) on

suction seat, & O-Ring (106-020)

below suction seat

• Replace Suction Hose (331-290)

Service outlet valve suction assembly

Pressure set too low

Filter(s) are clogged

Outlet Valve fouled/worn

Prime/Pressure Relief valve

bypassing

Packings and/or piston worn

Turn up pressure

Clean or replace gun fi lter, inlet

fi lter and/or manifold fi lter

Service outlet valve

Clean or replace primve valve

• Tighten packing nut

• Repack unit

Unit does not run

Blown spray tip

Packings and/or piston worn

Upper Seat worn

Blown fuse

Electrical failure

Replace spray tip

Repack unit

Replace upper seat

Replace fuse

• 15A SlowBlow (pn. 331-256) - 4 Series

• 20A SlowBlow (pn. 331-328) - 5&6 Series

See electrical troubleshooting -

4 Series & 5-6 Series

15

SERVICING THE FLUID PUMP

NOTE: Check everything in the Troublshooting Chart before disassembling the Fluid Pump.

Fluid Pump Removal - Refer to Figure 11

1.

Follow the Pressure Relief Procedure page 10.

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

3.

Remove the connecting rod shield (331-111).

4. Move the piston rod (331-093) to its lowest position by

cycling pump slowly or by rotating the motor fan.

5.

Disconnect the sensor (331-294-99) by holding it in

place with a 7/8” wrench and unscrewing the swivel

connector (100-003) with an 11/16” wrench.

DO NOT TURN THE SENSOR.

6. Remove the retaining ring (331-062) from the

connecting rod (331-038) and slide the sleeve (331-117)

down revealing the connecting rod pin (331-065).

7. Remove the suction tube assembly from the fl uid pump

by unscrewing the suction nut (331-034) with the packing adjustment tool.

8.

Using a 1/2” wrench unscrew the two bolts (100-318)

from the cover assembly 331-234). The fl uid pump

(331-209) will be hanging loosely at this point.

9.

Remove the connecting rod pin (331-065) out of the

connecting rod (331-038), allowing the removal of the

fl uid pump (331-209) from the machine.

FIGURE 11

Fluid Pump Reinstallation -

Refer to Figure 11 & 14

1.

Loosen the packing nut and ensure that the piston rod

(331-093) is in its upper position in the fl uid pump

body. Slip the sleeve (331-117) & the retaining ring (331-062) over the piston rod.

2.

Push the piston rod up into the connecting rod (331-

038) & align the holes. Insert the connecting rod pin

(331-065) through the connecting rod & piston. Slip

the sleeve over the connecting rod pin and insert the

retaining ring into the groove on the connecting rod.

3.

Push the two bolts (100-318) through the tube spacers

(331-074) & screw them into the cover assembly (331-

234). Using a 1/2” wrench, tighten the two bolts evenly

(alternating between them) until you reach 20 ft-lbs.

4.

Reassemble the lower suction valve assembly by

placing the suction seat assembly: O-ring (106-011),

suction ball (331-030) and suction ball guide (331-029)

in the suction nut (331-034) and screw onto the fl uid

pump body.

5.

Reconnect the sensor (331-294-99) to the fl uid pump

body. Hold the sensor with a 7/8” wrench while

tightening the swivel connector (100-003) with an

11/16” wrench.


6.

Start the machine and operate slowly to check the

piston rod for binding. Adjust the two bolts, holding the

fl uid pump body to the cover assembly, if necessary.

This will eliminate any binding.

7.

Tighten the packing nut counter clockwise until resistance is felt against the Belleville Springs, then go

3/4 of a turn more. Put fi ve drops of Airlessco Throat

Seal Oil into the packing nut.

8.

Run the machine at full pressure for several minutes.

Release the pressure by following the Pressure Relief

Procedure & readjust the packing nut per step 7 above.

9.

Install the connecting rod shield (331-111) so that the small hole is in the upper right hand corner.

Fluid Pump

331-209

Low Boy/Carry

331-236

Hi Boy

16

GEAR AND PUMP ASSEMBLY

FIGURE 12

-

Do not operate machine without cover guard in place.

Part Number Description

100-318 Bolt (2)

100-380

100-381

115-019

Shoulder Bolt (2)

Bolt (2)

Hose Connector (1/4 NPSXNPT)

331-088

331-111

331-117

331-209

331-234

331-236

331-406

331-407

331-408

331-038

331-040

331-046

331-047

331-061

331-062

331-065

331-074

Crosshead Assembly

Gearbox Casting *

Bearing

Bearing

Sleeve Bearing

Retaining Spring

Pin

Tube Spacer (2)

Retaining Ring

Cover Guard

Sleeve

Pump Ass’y - Carry/LoBoy

Cover

Pump Ass’y - HiBoy

Gear Crank (4 Series)



*NOTE: Can be ordered separately, but is included with Motor Ass'y (Part No. 331-490, 331-068)

GEARBOX SLEEVE

BEARING REPLACEMENT

1.

Remove fl uid pump as per "Fluid Pump Disconnect" procedures.

2.

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

3. Refer to Figure 12. Separate cover assembly from box by removing bolts from front of cover & back of box & shoulder bolts from front of cover & back of box.

4.

Lay unit on its back and disassemble gearbox.

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

6.

If gear grease needs replacing, replace with gear grease

(Part No. 331-132).

7. Clean mating surfaces of cover and box thoroughly. Use

Part No. 105-331 BLUE XS™ ADVANCED RTV

SILICONE INSTANT GASKET.

8. Reassemble in reverse order.

2

1

3

NOTE: When replacing item (1), cover outside of sleeve with clear sil i cone prior to inserting into cover assembly.



1 331-061 Sleeve Bearing

2 331-103 Washers (2)

331-197

17

18

Servicing the Piston Rod - Outlet Valve

DISASSEMBLY OF THE OUTLET VALVE

REFER TO FIGURE 13

1.

Disconnect the Fluid Pump.

2.

Place piston holder (331-195) in a vise. Slide piston into

the holder & lock in place with a 3/8” dowel (331-196).

3.

Use a 1/4” allen wrench to unscrew the outlet seat retainer

(331-314) from the piston.

4.

Remove the outlet seat (331-026), O-ring (331-100) and

outlet ball (331-027).

5.

Inspect outlet ball & seat for wear. Replace as necessary.

6.

While piston is still locked in the holder, install parts

back into the piston in the following order: ball, outlet seat and O-ring

Before reinstalling the outlet seat retainer, apply two drops of

Loctite No. 242 (blue) on the threads & torque to 20 ft-lbs.

* Available in LP tool kit PN 188-397

* 331-196

Piston

* 331-195

Figure 13

Servicing the Suction Assembly

Refer to Figure 14

1. Unthread and remove suction nut from the fl uid pump body.

2.

Remove suction seat (331-409), O-ring (106-011), suction ball

(331-030) and suction retainer (331-029).

3.

Clean all parts and inspect them for wear or damage, replacing

parts as needed.

4.

Clean inside of the fl uid pump body.

5.

Reassemble lower suction valve assembly by placing the

suction seat (331-409), O-ring (106-011), suction ball (331-030)

& suction ball guide (331-029) in the suction nut (331-034) &

screw onto fl uid pump body.

Figure 14

-Low Boy/Carry

331-292-Hi Boy

Suction Nut

331-034

Packing Replacement Procedures

Replacement Instructions:

Fluid Pump Removal - Refer to Figure 11

1.

Follow the Pressure Relief Procedure above.

REASSEMBLY - Figure 15 & 16

1.

Take lower male gland (331-014) & place it down on

the fl at side.

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

3.

Remove the connecting rod shield (331-111).

4. Move the piston rod (331-093) to its lowest position by

cycling pump slowly or by rotating the motor fan.

5.

Disconnect the sensor (331-294-99) by holding it in place

with a 7/8” wrench & unscrewing the swivel connector

(100-003) with an 11/16” wrench.


2. Take three of the lower polyethylene packings (331-016) & two

of the leather packings (331-306) & place onto the male gland in

the following order with the inverted side down :

polyethylene, leather, polyethylene, leather, polyethylene.

3.

Take the female adaptor (331-305), which is inverted on both

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

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

5.

Take the second lower male gland and place it on top of your

assembled packings with the rounded side down.

6. Remove the retaining ring (331-062) from the connecting

rod (331-038) and slide the sleeve (331-117) down

revealing the rod pin (331-065).

6. Take assembled glands & packings (13 pieces) & slide on to the

lower half of the piston.

7. Remove the suction tube assembly from the fl uid pump

(331-708) by unscrewing the suction nut (331-034) with the

packing adjustment tool.

8.

Using a 1/2” wrench unscrew the two bolts (100-318) from

the cover assembly 331-234). The fl uid pump (331-209)

will be hanging loosely at this point.

7. Take the spacer (331-018) & slide over the top of the piston (it

doesn’t matter which direction it sits), falling onto lower packings.

8.

Take three Belleville Springs (331-025) & slide over the top of

the piston in the following order:

* First spring, curve facing down

* Second spring, curve facing up

* Third spring, curve facing down

( (

9.

Remove the connecting rod pin (331-065) out of the

connecting rod (331-038), allowing the removal of the fl uid

pump (331-209) from the machine.

Disassembly of the Fluid Pump - Figure 15

1.

Unscrew & remove the packing nut (331-037).

9.

Take the upper male gland (331-022) & place it rounded side up.

10. Take three upper polyethylene packings (331-023) & two leather packings (331-307) & assemble with inverted side down ,

on to the male gland in the following order: polyethylene, leather, polyethylene, leather, polyethylene.

2.

Push the piston rod (331-708) down through the packings

& out of the pump.

11.

Take upper female gland (331-021) & place on top of the assembled

upper packings with the inverted side down.

3.

Now push the packing removal tool (187-249) up through

the pump & remove from the top bringing packings, spacer

& springs along with it, leaving fluid body (331-011) empty.

12.

Take assembled upper glands & packings (7 pieces) & slide on

over the top of the piston, making sure inverted sides are down.

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

4 . Clean inside of fluid body (331-011).

13.

Take the packing holder (331-019) & replace the white O-ring

(106-009) & the black O-ring (106-010) with new ones from the

packing kit.

5.

Disassemble all parts & clean for reassembly. Discard any

old packings.

6.

Lubricate leather packing in lightweight oil for 10 minutes

prior to reassembly.

14.

Slide the packing holder over the top of the upper packings

so they fi t inside.

15.

Lubricate inside of the fl uid pump body & the outside of the

packings with a light weight oil.

16.

Slide completed assembly into fl uid pump body (331-011).

Disassembly of the Outlet Vavle - Figure 13

1.

Place piston holder (331-195) in a vise. Slide piston into

the holder & lock in place with a 3/8” dowel.

* To keep packings secured in correct position, hold the pump body upside down & push the completed assembly upwards into the pump body. Once placed inside, tilt pump body back up to keep all pieces in.

2.

Use a 1/4” allen wrench to unscrew the outlet seat retainer

(331-026) from the piston.

3.

Remove the outlet seat (331-026), O-ring (331-100) and

outlet ball (331-027).

4.

Inspect outlet ball & seat for wear. Replace as necessary.

17.

Tighten packing nut (331-037) onto the top of the fl uid pump

body & tighten until you feel slight resistance against the

Belleville Springs (331-025). Using the Packing Adjustment Tool

(189-211), tighten another 3/4 of a turn.

5.

While piston is still locked in the holder, install parts back into the piston in the following order: ball, outlet seat and O-ring

Fluid Pump Reinstallation - Figure 11 & 14

1.

Loosen packing nut & ensure that the piston rod (331-093) is in

its upper position in the fl uid pump body (331-209). Slip the

sleeve (331-117) & the retaining ring (331-062) over the piston rod.

Before reinstalling the outlet seat support, apply two drops of Loctite

No. 242 (blue) on the threads & torque to 20 ft-lbs.

2.

Push piston rod up into the connecting rod (331-038) & align the

holes. Insert the connecting rod pin (331-065) through the

connecting rod & piston. Slip the sleeve up over the connecting

rod pin & insert retaining ring into the groove on the connecting rod.

19

20

Packing Replacement Procedures ( Continued)

FIGURE 15

3.

Push the two bolts (100-318) through the tube spacers

(331-074) & screw into the cover assembly (331-234).

Using a 1/2” wrench, tighten the two bolts evenly

(alternating between them) until you reach 20 ft-lbs.

4.

Reassemble lower suction valve assembly by placing

the suction seat (331-409) O-ring (106-011), suction

ball (331-030) and suction ball guide (331-029) in the

suction nut (331-034) & screw onto the fl uid pump body.

*

5.

Reconnect the sensor (331-294-99) to the fl uid pump

body. Hold sensor with a 7/8” wrench while tightening

the swivel connector (100-003) with an 11/16” wrench.


*

6.

Start the machine & operate slowly to check the piston

rod for binding. Adjust the bolts, holding the fl uid

pump body to the cover assembly, if necessary. This

will eliminate any binding.

*

*

7.

Tighten packing nut counter clockwise until resistance

is felt against the Belleville Springs, then go 3/4 of a

turn more. Put fi ve drops of Airlessco Throat Seal Oil

into the packing nut.

8.

Run the machine at full pressure for several minutes.

Release the pressure by following the Pressure Relief

Procedure & readjust the packing nut per step 7 above.

9.

Install the connecting rod shield (331-111) so that the

small hole is in the upper right hand corner.

†

*

† *

† *

†

†

* Viton O-Ring

106-010

* PTFE O-Ring

106-010

Swivel

Connector

100-003

*

*

*

*

*

*

*

FIGURE 16

* Included in Packing Kit

PN #331-210

† Included in Piston Replacement

PN #331-093

331-093

Assy

Low Boy/Carry

331-292 Hi Boy

Suction Nut

331-034

CARRY FRAME MODELS

FIGURE 17

Part Number

100-003

100-180

100-312

100-318

106-500

111-037

115-019

117-044

117-090

119-048

301-191

301-405

331-048

331-068

331-074

Description

Swivel

Prime P/R Valve

Screw (4)

Bolt (2)

Sensor Seal

Heatsink Screw (4)

Hose Connector (1/4 NPSXNPT)

Knob

Fan Cover Screws (3)

Screw (4)

Fan Retaining Clip

Blank Plate for LCD Panel

Rubber Boot (2)

.8 HPDC Motor (5/6 Series)

Tube Spacer (2)

Part Number

331-111

331-143

331-212

331-213

331-215

331-234

331-248

Shield

Frame

Fan

Fan Cover

Description

Screw (LP 5/6 Only)

Cover

Cover (690 Models)

331-294-99 Sensor

331-315-99 Press. Ass’y

331-490 .6 Airlessco DC Motor (4 Series)

331-321

331-337

331-398

331-131

331-778

Terminal Box

Rubber Edge (2) (690 Only)

Brush Spring (2) (5/6 Series)

Motor Brush (2) (5/6 Series)

Motor Brush (2) (4 Series)

21

LO-BOY MODELS

FIGURE 18

119-032

331-068, 331-490, 331-069, 331-426

331-476

331-074

100-318

331-315-99,

331-396-99,

301-405

22

Part Number

100-003

331-476

100-180

100-318

100-377

106-500

111-037

113-019

113-030

115-019

117-044

117-090

117-129

119-032

119-033

143-029

301-191

331-048

331-068

331-069

331-426

Description

Swivel

Cup Assembly

Prime Valve

Bolts (2)

Screw (4)

Sensor Seal

Heatsink Screws (4)

Wheel 10” (2)

Spacer (2)

Hose Connector (1/4” NPSXNPT)

Knob

Fan Cover Screws (3)

Screw (2)

Screw (2)

Nut (2)

Collar (2)

Fan Retaining Clip

Rubber Boot (2)

.8 HP DC Motor 110V (5/6 Series)


.6 HP DC Motor 230V (4 Series)

Part Number Description

331-074

331-111

331-171

331-174

331-175

331-176

331-212

331-213

331-215

331-222

Tube Spacer (2)

Shield

Frame

Handle

Spacer (2)

Bushing (2)

Fan

Fan Cover

Bolt (5/6 Series)

Pin (2)

331-234

331-248

Cover

Motor Cover (690 Only)

331-294-99 Sensor

331-315-99 Pressure Ass’y 110V

331-490 .6 Airlessco DC Motor (4 Series)

331-321

331-337

Terminal Box

Rubber Edge (2) (690 Only)


301-405 Blanking Plate, LCD Panel

331-477 Cup Support

HI-BOY MODELS

100-390

111-037

331-490

Part Number

100-003

100-180

100-318

100-390

106-500

111-037

113-019

113-031

117-044

117-090

119-048

143-029

115-019

301-191

301-405

331-048

331-068

Swivel

Prime Valve

Description

Bolt (2)

Screw (2)

Sensor Seal

Heatsink Screws

Wheel 10” (2)

Spacer (2)

Knob

Fan Cover Screw (3)

Screw (4)

Collar (2)

Hose Connector (1/4” NPSXNPT)

Fan Retaining Clip

Cover Plate for LCD Opening

Rubber Boot


Part Number

331-069

331-074

331-111

331-212

331-213

331-215

331-234

Description


Tube Spacer (2)

Shield

Fan

Fan Cover

Bolt (5/6 Series)

Cover

331-248

331-273

Motor Cover (690 Only)

Frame

331-294-99 Sensor


331-490

331-321

331-336

331-337

.6 Airlessco DC Motor (4 Series)

Terminal Box

Pail Hook

Rubber Edge (690 Only)


23

24

SUCTION ASSEMBLIES

FIGURE 20 - LoBoy & Carry Frames

PN 331-238 (Lo-Boy & Carry Chassis)

ITEM # PART #

1

2

DESCRIPTION

331-217 Inlet Strainer

331-135 Spring Clip

5

6

3

4

331-290 Suction Hose Ass’y

331-425 Bypass Hose

111-016 Nylon Tie

331-231 Bypass Hose Ass’y

(inc. strainer)

7

8

9

10

331-090R Fitting

331-035 Suction Elbow

331-034 Suction Nut

106-020 O-Ring PTFE

FIGURE 21 - HiBoy Frame

PN 331-284 (Hi-Boy Chassis)



5

6

7

3

4

1

2

331-034

331-292

301-348

116-103

331-400

141-008

331-090R

Suction Nut

Suction Seat Ass'y

Bypass Hose

Spring Clip

Inlet Tube

Inlet Strainer

Fitting

ELECTRICAL BOARD CALIBRATION

Note: Anytime a sensor, pressure control assembly (board) or both are replaced, the following calibrations must be per formed.

1. ZERO CALIBRATION

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

2.

Set the pressure control knob to the minimum setting (CCW).

3.

Remove the screws and lower the pressure control assembly.

4.

Ensure the jumper 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

pres ent ly 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 zero 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. If so

equipped, look at the LCD Display and if "0000" is showing the Zero Calibration is complete. If the display

shows more than "0000", turn the Zero Trimpot CCW until "0000" is showing. If "-- -- --" is showing, turn the

zero trimpot CW until "0000" is displayed.

7.

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

"0000" is displayed.

NOTE: If the yellow light remains constantly "ON", or "OFF" during this calibration, the sensor

is defective and should be replaced.

8. IMPORTANT:When calibration is complete, move jumper from both "PZ-R" terminals to single terminal

on P-ZR.

2. PRESSURE CALIBRATION

1. Complete the ZERO calibration, as per "ZERO CALIBRATION" prior to commencing this calibration.

2.

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

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

4.

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

5.

Turn pressure control knob clockwise until machine starts to prime.

6.

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

7. While watching pressure gauge, slowly adjust the pressure trimpot (clockwise to increase and counterclockwise

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 (LCD) 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 fi lled pressure

gauge) and the ma chine is not cycling.

3.

Use an insulated screwdriver to adjust the Set trimpot. Turn trimpot CCW until it clicks, then adjust to match

pressure against pressure gauge reading.

4.

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

continues to match the pressure gauge reading.

25

26

ELECTRICAL BOARD CALIBRATION

(CONTINUED)

4. PHASE LIMIT TRIMPOT 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 fi lled pressure gauge to the

pump.

2.

Place the suction tube into a bucket of Pump Conditioner 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 pres sures are

guidelines and may vary slightly from pump to pump.

8. Reattach Pressure Control Assembly being careful not to pinch wires.

Note: The 331-315-99 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 never have a jumper on it.

TROUBLESHOOTING - Machine does not start

CAUSE

Control Settings

Fuse

Power Source

Thermal Overload

Pressure Control Assembly

(Board)

Motor

Sensor

Pressure Control

Knob (Potentiometer)

Pressure Control Assembly

(Board)

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

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

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

STEP 4: Locate the L1 and L2 terminals on the board, and then using your multi-meter check to make sure you have 110 volts AC across the two terminals (the cord wires will still be attached). If there is no voltage at these leads, there is no power getting to the machine. Check your power source (outlet, circuit breaker, extension cord, and power cord). If you have AC voltage at the L1 and L2 terminals, go to step 5.

STEP 5: Disconnect the two red motor leads (S1 & S2) and test for continuity between them. No continuity means that the thermal coupler has opened due to excessive motor heat. If the motor is still hot to the touch, allow it to cool and then retest. If the motor is cool and there is not continuity on the red leads, contact your local Leeson repair facility to repair/replace the thermal coupler. Continuity shows that the motor's thermal coupler has not tripped. Proceed to step six.

STEP 6: If everything checks out in steps one through fi ve and the power indicating light is still out, replace the pressure control assembly.

STEP 7: Remove the motor brush covers and turn the machine on. Set the potentiometer (POT) at maximum pressure and check for DC voltage across both brush terminals.

You should read greater than 80 volts DC. IF YOU DO NOT HAVE DC VOLTAGE

GO TO STEP EIGHT. If you have DC voltage, turn the machine off and unplug it from the wall. Check to make sure that the brushes are making good contact with the armature. Replace the brushes if they are less than 3/8" long. If the brushes are good, replace the motor.

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

STEP 9: Plug another potentiometer (POT) into the control board. If the machine starts, the old POT is bad. When replacement POT is not available, remove the POT lead (with the machine turned off) from the control board and test the resistance between the red and black wires (be sure to test at the plug). The resistance should read between 8-12k ohms if it is outside of this range replace the POT.

STEP 10: If you do not have DC voltage at the motor brushes and all of the components check out fi ne in steps eight and nine, replace the pressure control assembly.

27

ELECTRICAL SYSTEM

331-490

28

117-044

117-207

331-490

331-068

331-168

331-184

331-185

331-294-99 Sensor

331-297

331-311

331-312

Toggle Switch

Fuse Holder

331-315-99 Pressure Control Ass’y

331-328

331-256

331-377

Fuse 20A Slow Blow (5/6 Series)

Fuse 15A Slow Blow (4 Series)

LCD - Optional Display

REPLACEMENT OF ELECTRICAL COMPONENTS

Always unplug the electrical cord before servicing machine.

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

1.

Unplug machine's power cord.

2. Remove four screws from heatsink housing.

3.

Disconnect all leads from pressure control assembly.

4.

Reassemble in reverse order.

SENSOR

1.

Remove the 4 screws heat sink and lower the pressure control assembly.

2.

Disconnect swivel from sensor by holding sensor with 7/8" wrench and loos en ing 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.


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. 22,) and remove knob and spacer.

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.

1. Lower pressure control assembly as described above.

2.

Unscrew the four nuts (6/32") (Fig. 23, Item 5) and remove

LCD Display assembly (Fig. 23, Item 6).

3.

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

the four screws (Fig. 23, Item 1). Then remove the

LCD Display Assembly. If the display is removed in this

manner, the mylar label (Fig. 23, Item 2) must be replaced.

4.

Reassemble in reverse order, while making sure

that the four spacers (Fig. 23, Item 4) and the four

washers (Fig. 23, Item 7) are in place.

Tighten the four nuts handtight and seal with blue loctite.

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

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.


FUSE HOLDER

1.

Lower pressure control assembly as described above.

2.

Disconnect the two wires on the holder.

3.

Remove holder cover and fuse.

4.

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

5.


FIGURE 23

5

6

7

3

4

1

2

PN 331-304 (LCD UPGRADE KIT)



100-362

101-270

331-360

117-281

117-126

331-377

120-046

Screw (4)

Mylar Label - clear

Window

Spacer (4)

Nut (4)

Display Ass'y

Washer (4)

29

30

LP Series Electric Paint Sprayer

Quick Reference Guide

OPERATION

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 handle and body).

When in the CLOSED position, there is only a very slight gap between handle

& body. When the relief valve is closed the system is pressurized. Handle as a loaded fi rearm!

STEP

1A.

Read safety rules! Read & understand all warnings & safety rules before operating equipment. Know how to lock the gun trigger safety lock before operating the equipment.

1B.

Stir paint and if necessary strain paint using a paint strainer bag to remove lumps.

Pressure Control Knob

Used to adjust pressure only.

DOES NOT relieve pressure from gun and system!

Turn clockwise to increase pressure, counterclockwise to decrease pressure.

ON/OFF Toggle Switch

Turns the unit ON and OFF.

CLEAN ING

•

Always use low pressure in the cleaning process.

Always remove spray tip before cleaning– AFTER

•

following the Pressure Relief Procedure!

Use a metal bucket for cleaning and maintain fi rm metal to metal contact of gun to the bucket.

TOOLS & EQUIPMENT NEEDED:

1. Soft bristle brush, clean-up rags.

2. 8” crescent wrench for removing gun tip & fi lter in gun handle.

3. Prepared 5 gal. bucket of soapy water if using latex, or mineral spirits if using oil-based. (Second bucket will usually be required).

4. Empty bucket for wastes.

5. Storage solution of Pump Conditioner mixed with 1 gal. of water if using latex

OR compatible paint thinner if using oil-based paint.

1A.

IMPORTANT: Relieve pressure by following the Pressure Relief

Procedure, Step 6 of Operation, and be sure gun safety lock (latch) is in locked position.

1B.

Remove tip and tip guard from spray gun and place in mineral spirits or water.

2A.

Check gun/hose connections to make sure they are tight.

2B.

Lock gun trigger safety lock

(Airlessco gun shown)

Note: Plug into 3 pronged grounded electrical outlet. Extension cord must be 3 wire, 12 gauge. Do not coil cord.

3A.

Put pump suction tube into bucket of paint.

3B.

Turn the Prime-Pressure Relief Valve to open position (wide gap between handle & body).

Turn toggle switch ON, and adjust to low pressure on the pressure control knob. The unit will now self-prime.

4A.

Wait about one minute until fl uid comes out of the return tube (smaller diameter tube).

4B.

Turn the Prime-Pressure Relief Valve to closed position.

closed position. (slight gap between handle and body)

CAUTION: THE UNIT IS NOW

PRESSURIZED!

Note: Leave the Prime-Pressure Relief Valve fully closed and very carefully unlock the guns trigger safety lock.

5A.

Aim the gun 12” from test surface cardboard) and spray out the storage solution.

Turn thepressure control knob clockwise to increase pressure. Increase the pressure enough to atomize the paint & give a full pattern. Use the lowest pressure possible.

5B.

Always keep the gun perpendicular to the surface. Move the gun at a steady rate.

It is important to “trigger” the gun after gun movement has begun and release trigger before gun movement ends.

5C.

Overlap half the width of each paint stroke.

6A.

Release pressure when you stop spraying

& before servicing gun or machine or before changing or cleaning gun tip by:

1. Lock the gun trigger safety.

2. Turn toggle switch to OFF position and unplug from electrical outlet.

3. Release gun safety lock and trigger gun to relieve residual pressure.

4. Turn Prime/PR Valve to open position.

5. Relock gun safety latch.

6B.

Submerge gun in water (if using latex) or thinner (oil-base) to prevent paint from drying in the gun nozzle.

Note: Turn unit ON. Turn pressure control knob to low pressure.

2A.

Lift suction tube and return tube out of paint and hold over paint bucket. Any paint remaining in the unit will return into the bucket out through the return tube.

2B.

Wipe excess paint from suction tube.

2C.

Place suction tube into prepared bucket of water or mineral spirits.

Note: Release the gun trigger lock very carefully.

3A.

Turn the Prime/PR Valve to the closed position. Adjust the pressure control knob for minimum pressure.

IMPORTANT: Never use high pressure for cleaning!

3B.

Trigger gun into paint bucket to allow paint to run out of hose and gun.

3C.

Place gun over empty metal bucket and trigger gun using VERY LOW

PRESSURE & maintaining fi rm metal to metal contact for 3-4 minutes until it runs clean. (Second bucket may be required).

4A. IMPORTANT: Follow Pressure Relief

Procedure Step 6A of Operation!

4B.

Remove fi lters from suction tube and gun handle. Clean with water or mineral spirits and soft brush and reassemble suction and gun fi lter only. DO NOT reassemble gun tip and tip guard at this point.

5A.

Mix bottle of Pump Conditioner with 1 gal. of water or prepared mineral spirits and put suction tube into pail. Prime unit (Prime/PR Valve Open Position &

Pressure Control Knob in low position)

Trigger gun to fi ll the hose & gun.

LEAVE this mixture in the pump & hose for storage. DO NOT DIS CHARGE. Turn motor off while the suction tube remains in the bucket.

5B. Disconnect from power.

5C. Roll up hose and tape. Now reassemble gun with spray tip and tip guard. After you have disconnected sprayer from electrical power, turn Prime/PR Valve to the closed position for storage.

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