LP800G

SERVICE/OPERATION

MANUAL

Form No. 001-686 JUNE1005

Table of Contents

INTRODUCTION

LP 800G Specifi cations

Safety Warnings

1

2

GETTING STARTED

Flushing

Setting Up

Pressure Relief Procedure

Daily Maintenance

Starting Up

REPAIRS/MAINTENANCE

INSTRUCTIONS

Spray Gun Operation

Spray Gun Troubleshooting

Field Troubleshooting

Servicing the Fluid Pump

12

13

14

15

Servicing the Piston Rod 16

Servicing the Suction Assembly 16

17 Packing Replacement

Electrical Control Board

Replacement

Pressure Calibration on the Electrical Control Board

Clutch Replacement

Troubleshooting Clutch Does

Not Engage

19

19

20

21

7

8

9

9

10

PRODUCT DIAGRAMS &

PARTS LISTS

Gearbox Assembly

Suction Assembly

Frame Assembly

Complete Sprayer Assembly

22

23

24

25

Manufactured by: AIRLESSCO BY DUROTECH CO.

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

Moorpark, CA 93021 Tel: 805-523-0211 Fax: 805-523-1063 www.airlessco.com email: [email protected]

SUBJECT TO CHANGE WITHOUT NOTICE.

Copyright © 2004, All rights reserved.

Introduction

Part Number BARE Model #331-827

Part Number COMPLETE Model #331-829

INTRODUCTION

The LP800G is a mobile airless sprayer designed for the needs of painting professionals. Built on a compact, well-balanced triple chrome plated frame, the 800G combines dependable Honda OHV 4-cycle engine, and the proven durability of our LP paint pump.

No need to run a generator or search around the job site to fi nd a working electrical outlet, or string together multiple extension cords when spraying with the 800G. Just hook your 5-gallon bucket over the carrying clip, and roll along on fl atproof tires right to the job.

The 800G comes standard with an easy-clean high capacity fi lter. It’s available complete with the Airlessco ProLight Convertible 4/2-fi nger contractor spray gun with swivel, and

50’ of high pressure airless hose.

LP800G SPECIFICATIONS

MAXIMUM TIP SIZE .029”

OUTPUT GAL./MIN.

@ Pressure (2000 psi) .8

@ Free Flow .83

RATING WITH LATEX PAINT

Annual Gallonage 2,500

MATERIAL APPLICATIONS Oil Base Coatings, Sealer, Varnish,

Water Base Coatings, Solid Stain

PRESSURE CONTROLS Electronic

Min. for Light Materials 250 psi

Max. Working Pressure 3000 psi

ENGINE HP/TYPE 4.0 Honda OHV with oil alert

IMPORTANT WARNING !!

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 instructions

related to the usage of this equipment. READ, LEARN, and FOLLOW the

Pressure Relief Procedure on

Page 9

and understand all warnings on pages

2 thru 6.

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

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

1

2

Safety Warnings

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are using. Store & dispose of hazardous fluids according to manufacturer, local, state & national guidelines. ALWAYS wear protective eye wear, gloves, clothing and respirator as recommended by fluid manufacturer.

ALWAYS INSPECT SPRAYING AREA

• ALWAYS keep spraying area free from obstructions.

• ALWAYS 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 the spray unit.

SPRAY GUN SAFETY

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

• NEVER remove or modify any part of the gun.

• ALWAYS REMOVE SPRAY TIP when cleaning. Flush unit with 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 gun. A plugged line contains fluid under pressure. If the tip or

line is plugged, follow the PRESSURE RELIEF PROCEDURE as outlined on page 9.

TIP GUARD

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

SPRAY TIP SAFETY

Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately.

• ALWAYS follow the PRESSURE RELIEF PROCEDURE 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.

KEEP CLEAR OF MOVING PARTS

Keep clear of moving parts when starting or operating the sprayer. Do not put your fingers into any openings to avoid amputation by moving parts or burns from hot parts.

Precaution is the best insurance against an accident.

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

Before adjusting or servicing any mechanical part of the sprayer, follow the PRESSURE RELIEF PROCEDURE, and remove the ignition cable from the spark plug to prevent accidental starting of the sprayer.

LABELING

Keep all labels on the unit clean and readable. Replacement labels are available from the manufacturer.

Safety Warnings

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.

OBSERVE ALL WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY.

INJECTION HAZARD

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

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

• NEVER put hands or fingers over the spray tip. Do not use a rag or any other material over your fingers. Paint will

penetrate through material and into the hand.

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

• NEVER try to "blow back" paint, this is not an air spray sprayer.

• 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.

• ALWAYS follow the PRESSURE RELIEF PROCEDURE, as shown on page 9, before cleaning or removing the

spray tip or servicing any system equipment.

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

• ALWAYS tighten all fluid connections before each use.

MEDICAL TREATMENT

If any fluid appears to penetrate your skin, get EMERGENCY CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT.

* Go to an emergency room immediately.

* Tell the doctor you suspect an injection injury.

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

MEDICAL ALERT - Airless Spray Wounds

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL CARE AT ONCE. DO

NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Have him read the following "NOTE TO PHYSICIAN".

NOTE TO PHYSICIAN:

Injection in the skin is a traumatic injury.

It is important to treat the injury surgically as soon as possible. DO NOT DELAY treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

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 they are thoroughly instructed on safety use and

given this operators manual to read.

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

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

NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM. FOLLOW PRESSURE RELIEF

PROCEDURES ON PAGE 9.

3

4

Safety Warnings

GROUNDING

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

Always ground all of these components:

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

• Fluid Hose: use only grounded hoses.

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

• Object being sprayed: according to your local code.

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

Once each week, check electrical resistance of hose (when using multiple hose assemblies, check overall resistance of un-pressurized 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.

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, damaged or non-conductive paint hoses. Do not allow kinking or crushing of hoses or allow

it to vibrate against rough, 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 on page 9.

• ALWAYS use approved high pressure fittings and replacement parts.

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

Do not use halogenated solvents in this system. The prime valve, 2 gun manifold and most airless guns have aluminum parts and may explode. Cleaning agents, coatings, paints or adhesives may contain halogenated hydrocarbon solvents. DON'T TAKE CHANCES!

Consult your material suppliers to be sure. Some of the most common of these solvents are:

Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether, Ethylbromide,

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

Safety Warnings

FLUSHING

Reduce risk of injection injury, static sparking or splashing by following the specific cleaning procedure on page 8.

• ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 9.

• 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 140º F. Some of these are: acetone, benzene, ether,

gasoline and naphtha. Consult your supplier to be sure.

• NEVER smoke in the spraying/cleaning area.

PREVENT STATIC SPARKING FIRE/ EXPLOSIONS

ALWAYS be sure all equipment and objects being sprayed are properly grounded. Always ground sprayer, paint bucket and object being sprayed. See "grounding" on page 4 for detailed grounding information.

Vapors created when spraying can be ignited by sparks. To reduce the risk of fire, always locate the sprayer at least 20 feet (6 m.) away from the spray area. Do not plug in or unplug any electrical cords in the spray area, this 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 un-pressurized 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.

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

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

Construction Standards, part 1926 should be consulted.

WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR PAINT THINNERS:

1. When spraying with flammable liquids, unit must be located a minimum of 25 feet away from spraying area

in a well ventilated area. Ventilation must be sufficient enough to prevent the accumulation of vapors.

2. To eliminate electrostatic discharge, ground the spray unit, paint bucket and spraying object. Use only high

pressure airless hoses approved for 3000 psi which is conductive.

3. Remove spray tip before cleaning gun and hose. Make contact of gun with bucket and spray without the tip in

a well ventilated area, into the grounded steel bucket.

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

5. Do not smoke in spraying/cleaning area.

GAS ENGINE PRECAUTIONS

Gasoline & its vapors are extremely flammable & explosive.Fire or explosion can cause severe burns or death.

WHEN ADDING FUEL

• Turn engine OFF and let engine cool at least 2

minutes before removing gas cap.

• Fill fuel tank outdoors or in well ventilated area.

• Do not overfill fuel tank. Fill tank to approximately

11⁄2 inches below top of neck to allow for fuel

expansion.

• Keep gasoline away from sparks, open flames, pilot

lights, heat and other ignition sources.

• Check fuel lines, tank, cap and fittings frequently for cracks

or leaks. Replace if necessary.

WHEN STARTING ENGINE

• Make sure spark plug, muffler, fuel cap and air cleaner are in place.

• Do not crank engine with spark plug removed.

(continued on next page)

5

Safety Warnings

• If fuel spills, wait until it evaporates before starting

engine.

• If engine floods, set choke to OPEN/RUN

position, place throttle in FAST and crank until

engine starts.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which

causes gasoline to spill.

• Do not choke carburetor to stop engine.

WHEN TRANSPORTING EQUIPMENT

• Transport with fuel tank EMPTY or with fuel shut-off

valve OFF.

WHEN STORING GASOLINE OR EQUIPMENT

WITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters and

other appliances that have pilot lights or other ignition

source. They can ignite gasoline vapors.

Engines give off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

• Start and run engine outdoors.

• Do not start or run engine in enclosed area, even if doors or

windows are open.

Starting engine creates sparking.

Sparking can ignite nearby flammable gases.

Explosion and fire could result.

• If there is natural or LP gas leakage in area, do not

start engine.

• Do not use pressurized starting fluids because vapors

are flammable.

Running engines produce heat. Engine parts, especially mufflers, become extremely hot.

Severe thermal burns can occur on contact.

Combustible debris, such as leaves, grass, brush, etc. can catch fire.

• Allow muffler, engine cylinder and fins to cool before touching.

• Remove accumulated combustibles from muffler area and

cylinder area.

• Install and maintain in working order a spark arrester

before using equipment on forest covered, grass covered

and brush covered unimproved land. The state of California

requires this (Section 4442 of the California Public Resources

Code). Other states may have similar laws. Federal laws apply

on federal land.

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

• When starting engine, pull cord slowly until resistance is

felt, then pull rapidly.

• Remove all external equipment/engine loads before starting

engine.

• Direct coupled equipment components such as, but not

limited to, blades, impellers, pulleys, sprockets, etc. must

be securely attached.

Unintentional sparking can result in fire or electric shock.

Unintentional start up can result in entanglement, traumatic amputation, or lacerations.

BEFORE PERFORMING ADJUSTMENTS OR REPAIRS

• Disconnect spark plug wire and keep it away from

spark plug.

• Disconnect battery at negative terminal (only

engines with electric start).

WHEN TESTING FOR SPARK

• Use approved spark plug tester.

• Do not check for spark with spark plug removal.

6

Rotating parts can contact or entangle hands, feet, hair, clothing or accessories.

Traumatic amputation or severe laceration can result.

• Operate equipment with guards in place.

• Keep hands and feet away from rotating parts.

• Tie up long hair and remove jewelry.

• Do not wear loose fitting clothing, dangling drawstrings or

items that could become caught.

Flushing

Read prior to using your sprayer

1. New Sprayer

Your Airlessco unit was factory tested in an antifreeze solution which was left in the pump.

Before using oil-base paint, flush with mineral spirits only. Before using water-base paint

flush with soapy water, then do a clean water flush.

2. Changing Colors

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

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

Flush with soapy water, then mineral spirits.

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

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

5. Storage

Oil-base paint: Flush with mineral spirits.

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

filled with mineral spirits. For longer storage, use mixture of mineral spirits and motor oil

(half & half). Shut off the sprayer, follow Pressure Relief Procedure on page 9 to relieve

pressure and make sure prime valve is left OPEN.

6. Start up after storage

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

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

7

8

Setting Up

1. Connect the hose and gun.

a. Remove the plastic cap plug from the hose connector

and screw a conductive or grounded 3000 psi airless

spray hose onto fluid outlet.

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

the hose.

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

braided airless hose only.

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

Use thread seal on tapered male threads only.

2. Fill the packing nut/wet cup with

5 drops of Airlessco Throat Seal

Oil (TSO).

3. Grounding

WARNING

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

4. Flush the sprayer

As per "Flushing Procedure" in this manual.

Pressure Relief Procedure

IMPORTANT!

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

1. Engage the gun safety latch. Refer to the

separate instruction manual provided with

your gun on its safety features and how to

engage safety latch.

2. Turn the unit off.

3. Disengage the gun safety latch and trigger

the gun to relieve residual fluid pressure.

Hold metal part of the gun in

4. Turn Prime/Pressure Relief Valve (PR Valve)

to the open (priming) position to relieve

residual fluid pressure.

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

.

Note: The valve handle can move both clockwise and counter clockwise and can face different directions.

5. Re-engage gun safety latch and

close Prime/Pressure Relief Valve.

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

If you suspect that pressure hasn't been relieved due to damaged Prime/Pressure

Relief Valve or other reason, engage the gun safety latch and take your unit to an authorized Airlessco Service Center.

Daily Maintenance

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

TSO helps protect the rod and the packings.

2. Inspect the packing nut daily. Your pump has a patented Triple Life Packing System. Packing life will be extended a

minimum of three times if the following "Packing Adjustment" procedure is followed:

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

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

3. Inspect suction nut daily. Suction nut must be tight at all times.

9

10

Starting Up

1. Learn the Functions

of the Controls.

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

Prime/Pressure Relief Valve (Prime/PR Valve) the unit when in OPEN position. (It is in open position when there is a wider gap between valve handle and cam body) there is only a very slight gap between handle & body.

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

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

2. Prepare the Material

a. Prepare the material according to the material

manufacturer's recommendations.

b. Place the suction tube into the material

container.

3. Starting the Sprayer

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 Engine Switch to the "ON"

position.

d. Turn Pressure Control Knob clockwise to prime

the pump.

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

the "Closed" position.

f. Turn Pressure Control Knob to the desired spray

pressure.

g. Disengage the gun safety latch and you are

ready to spray.

4. Adjusting the Pressure

a. Turn the Pressure Control Knob Clockwise to

increase pressure and counterclockwise to decrease

pressure.

b. Always use the lowest pressure necessary to

completely atomize the material.

Note: Operating the sprayer at higher pressure than needed, wastes material, causes early tip wear, and shortens sprayer life.

c. If more coverage is needed, use a larger tip rather

than increasing the pressure.

d. Check the spray pattern. The tip size and angle

determines the pattern width and flow rate.

Starting Up

Follow the "Pressure Relief Procedure".

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

Avoiding Tip Clogs

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

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

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

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

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

Pressure Relief Procedure.

Be sure to relieve pressure in the pump after filling with Airlessco

Pump Conditioner.

5. When Shutting off the Sprayer

a. Whenever you stop spraying, even for a short break,

follow the "Pressure Relief Procedure".

b. Clean the tip & gun as recommended in the seperate

Gun Manual supplied with the gun/

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

material you are spraying is water-based, or if it could

harden in the sprayer overnight. See "Flushing". Use a

compatible solvent to flush, then fill the pump and hoses

with an oil based solvent such as mineral spirits.

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

"Flushing" section of this manual.

11

Spray Gun Operation

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)

* 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.

MAJOR COMPONENTS OF SPRAY

GUN AND REVERSIBLE SPRAY TIP

™

Tip Guard

Trigger

Guard

Press up here and pull gently to remove guard

Retaining Nut

REV-GUARD™

Guard Housing Assembly

Handle handle to access.)

SPRAY TIP ASSEMBLY

1. Be sure the pressure relief procedure is followed

before assembling tip and housing to the gun.

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

(guard housing assembly).

3. Guide the metal seat into REV-GUARD™ (guard

housing assembly) through the retaining nut and turn

until it seats against the cylinder.

4. Insert the O-Ring gasket onto the metal seat so that it

fits into the grooves.

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

6. Turn guard in the desired position.

7. Completely tighten the retaining nut.

TO REMOVE CLOGS FROM SPRAY TIP

1. Lock gun safety latch.

2. Turn REV-TIP™ handle 180 degrees.

3. Disengage trigger lock and trigger gun into

the 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 handle to

the spray position.

Retaining Nut

O-Ring Gasket

Metal Seat

Spray Position Shown

REV-TIP™ Cylinder

CLEANING SPRAY GUN

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

12

CLEANING FILTER IN GUN HANDLE

To clean the filter, use a brush dipped in an appropriate solvent. Change or clean filters at least once a day.

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

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.)

Spray Gun Troubleshooting

DEFECTS CAUSE CORRECTION

Coarse spray

Excessive fogging

(overspray)

Pattern too wide

Pattern too narrow

Too much material

Too little material

Thin distribution in

center of pattern

"horns"

Thick skin on work

Low pressure

High pressure

Material too thin

Spray angle too large

Spray angle too small

Tip size too large

Material too thin

Pressure too high

Tip size too small

Material too thick

Worn tip

Wrong tip

Material too viscous

Application too heavy

Coating fails to

close & smooth over

Material too viscous

Spray pattern irregular, Orifice clogged

deflected Tip damaged

Craters or pock marks

Bubbles on work

Solvent balance

Contamination or dust

Clogged screens Extraneous material in paint.

Coarse pigments

TEST THE PATTERN

Poorly milled pigments

(paint pigments glocculate cover screen. Incompatible

paint mixture & thinners.

Increase the pressure

Reduce pressure for satisfactory pattern

Use less thinner

Use smaller spray angle tip

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

Use next smaller tip

Reduce pressure

Use next larger tip

Change for new tip

Use tip with a smaller spray angle

Thin material

Reduce pressure and/or use smaller tip

Thin material

Clean carefully

Replace with new tip

Use 1-3% "short" solvents remainder "long" solvents. (This is most likely to happen with material of low viscosity, lacquers etc.)

Clean surface to be sprayed

Clean screen

Use coarse screen if orifice size allows

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

13

Field Troubleshooting

PROBLEM

Unit doesn't prime

CAUSE

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.

• Replace Suction Hose (331-290)

Service outlet valve suction

assembly

Unit primes but has no or poor pressure

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 filter, inlet

filter and/or manifold filter

Service outlet valve

Clean or replace prime valve

Tighten packing nut

Repack unit

Blown spray tip

Packings and/or piston worn

Upper Seat worn

Replace spray tip

Repack unit

Replace upper seat

14

Servicing the Fluid Pump

Fluid Pump Disconnect Fluid Pump Reinstall

Refer to Figure 1

1. Follow the Pressure Relief Procedure on page 9.

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.

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

in place with a wrench and unscrewing the swivel

connector (100-152) with an 11/16” wrench and the

hose connector (115-019) with a 9/16” 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 fluid

pump body (331-011) 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 fluid pump

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 fluid pump from the machine.

FIGURE 1

Refer to Figure 1 & 4

1. Loosen the packing nut and ensure that the piston rod

assembly (331-093) is in its upper position in the fluid

pump body (331-011). 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 up 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 lower suction valve assembly by placing

the suction tube assembly (331-284), O-ring (106-011),

suction ball (331-030) & suction ball guide (331-029) in

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

5. Reconnect the sensor (331-294-99) to the fluid pump

body. Hold the sensor with a wrench while tightening hose connector (115-019) with a 9/16” wrench and then the swivel connector (100-003) with an 11/16” wrench.

DO NOT TURN THE SENSOR.

6. Start the machine and operate slowly to check the piston

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

pump body to the cover assembly, if necessary. This

will eliminate any binding.

7. Tighten the packing nut clockwise until resistance is

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

more. Put five 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.

15

16

Servicing the Piston Rod - Outlet Valve

Piston

FIGURE 3

DISASSEMBLY OF THE OUTLET VALVE

REFER TO FIGURE 3

1. Disconnect the Fluid Pump following instructions on page 17 .

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

(331-026) 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 support, apply two drops of

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

331-196

331-195

NOTE: Airlessco LP Pump Tool Kit (Part Number 188-197) is suggested for this task. Kit includes: Packing Tightening Tool (189-211); Packing

Removal Tool (331-153); Piston Holder (331-195); 3/8” Dowel (331-196).

Servicing the Suction Assembly

REFER TO FIGURE 4

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

2. Remove suction tube assembly (331-284), 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 tube assembly (331-284) by placing

the 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 4

Packing Replacement Procedures

Replacement Instructions:

F luid Pump Removal - Refer to Figure 1

1. Follow steps 1-9 on page 15 under Removal

procedures.

Disassembly of Fluid Pump - Figure 6

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

2. Push the piston rod (331-708) down through

the packings & out of the pump.

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 fl uid pump body (331-011) empty.

*Make sure all old packings & glands have been

removed from fl uid pump.

4. Clean inside of fl uid pump body (331-011).

5. Disassemble all parts & clean for reassembly.

Discard any old packings.

6. Lubricate leather packing in lightweight oil

for 10 minutes prior to reassembly.

Disassembly of Outlet Vavle - Figure 3

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

piston into the holder & lock in place with a

3/8” dowel.

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.

5. While piston is still locked in the holder, install

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

Before reinstalling the outlet seat support, apply

two drops of Loctite No. 242 (blue) on the

threads & torque to 20 ft-lbs.

REASSEMBLY - Figure 5 & 6

1. Take lower male gland (331-014) & place it

down on the fl at side.

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. Take assembled glands & packings (13 pieces)

& slide on to the lower half of the piston.

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. 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

11. Take upper female gland (331-021) & place on top

of assembled upper packings with inverted side down.

12. Take assembled upper glands & packings (7 pieces)

& slide on over the top of the piston, making sure

inverted sides are down.

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.

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).

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

17. Tighten packing nut (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.

Fluid Pump Reinstallation - Figure 1 & 4

1. Follow steps 1-9 on page 15 under Reinstallation

procedures.

17

Packing Replacement Procedures

FIGURE 5

18

FIGURE 6

Electrical Control Board Replacement

1. Remove electrical cover.

2. Disconnect sensor lead from Electrical Board.

3. Disconnect two clutch leads on Electrical Board

from leads on clutch.

4. Using a 1/16" allen, loosen set screw in Pressure

Control Knob and remove knob.

5. Using a 1/2" nutdriver or 1/2" deep socket, remove

nut from pressure control shaft. This will allow

removal of electrical control board from frame.

6. Replace Electrical Board Assembly in reverse order.

Adjust pressure as per procedure below, "Pressure

Calibration on the Electrical Control Board".

Pressure Calibration on the Electrical Control Board

1. Turn "Pressure Calibration" Trimpot adjustment on

electrical control board in the counter clockwise

direction at least 15 revolutions.

2. Connect 5000 psi glycerine pressure guage on output

of pump between fluid pump & airless hose to

monitor Fluid Pump Pressure.

3. Start engine and run at maximum RPM. Turn

Prime/Pressure Relief Valve to the open (Prime)

position. Turn Pressure Control Knob to maximum

position (fully clockwise).

4. Using an insulated screwdriver, adjust "Pressure

Calibration" Trimpot by turning clockwise until the

clutch engages. When the clutch engages the pump

will commence Priming. When pump is primed, turn

the Prime/Pressure Relief Valve to the Closed (Pres

sure) Position

The pump will begin to pressurize and the clutch will disengage at a low pressure. Continue turning the Trimpot clockwise to increase pressure to 3000 psi.

5. Trigger gun. The pressure should drop approximately

350-400 psi (when using a 3/8" hose), the clutch will

engage and build pressure to 3000 psi and disengage.

Trigger gun several times to ensure proper pressure

setting.

6. Turn Pressure Control Knob to minimum position. The

clutch should disengage and pump stop moving.

7. Secure leads with tie strap.

8. Replace cover on unit. Ensure the leads are not

pinched or damaged in the process of replacing covers.

* To replace just the control board, order part number 301-282-99.

19

20

Clutch Replacement

REMOVE CLUTCH AS FOLLOWS:

1. Remove clutch and electrical box cover.

2. Disconnect the power lead coming from the engine

to the electrical box and feed it through the back of

the electrical box.

3. Using a 1/2” wrench along with a 1/2” socket

remove the four bolts attaching the engine to the

frame.

4. Remove the engine from the frame and set it on

your work bench so the clutch face is facing you.

5. Disconnect two clutch leads from electrical board

leads. Carefully cut the small Zip-tie holding the

clutch wires to the gear housing.

INSTALL NEW CLUTCH AS FOLLOWS:

1. Apply Anti-seize lubricant to the pinion shaft

coming out of the gearbox.

2. Feed the black clutch wires into electrical box &

plug into matching wires from the control board.

3. Install the new zip-tie (comes with the clutch

replacement kit) to the wire mount, keeping the

wires from the path of the clutch.

4. Apply blue Lock-tite to the screws and reinstall into

the gearbox.

5. Mount clutch face to the clutch mount. Apply

blue Lock-tite to the three screws used for

mounting the clutch face.

6. Set the engine back on the frame and tighten the

nuts and bolts so that you still can move the

engine back and forth fairly easily.

7. Using a feeler gauge, slide the motor forward

until you reach a spacing of .010” between the

clutch face and the field. Once you reach this

point finish tightening the engine bolts, alternat-

ing to keep the air gap the same on all sides of

the clutch.

8. Replace the clutch cover and electrical box cover.

Troubleshooting - Clutch Does Not Engage

STEP 1: Ensure that the pressure control knob (POT) is in the maximum (CW) position.

STEP 2: Remove the clutch and electrical box covers.

STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose connections or damaged leads.

STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black).

Using a multimeter, with the engine at maximum RPM, pressure control knob in the maximum position and the prime valve open (priming) position, test the DC voltage across the boards leads

(blue). This voltage must be 13-14 VDC. If the readings are correct, the board, sensor and magneto are okay and the problem is the clutch assembly. If this is the case, proceed to Step 5. If the voltage is outside this range go to Step 7.

STEP 5: Check the spacing between the clutch field and plate. The gap should be .010” to .014”. If the gap is greater than .014” the gap is too wide. If this gap is too wide, replace the clutch assembly.

STEP 6: When the DC voltage from the board is not 13-14 VDC, disconnect the control board lead

(black) from the engine magneto lead (pink), located on the side of the engine. With the engine at maximum RPM (3600), pressure control knob in maximum (CW) position and prime valve open

(priming), read the AC voltage from the magneto lead to the sprayer frame. This reading should be

19-24 VAC. If outside this range, contact your local Honda repair facility for magneto replacement. If the magneto is producing the proper AC voltage, continue to Step 7.

STEP 7: Test the sensor by reading the resistance between the red and black wires. The resistance runs between 1.5-3K ohms. A defective sensor usually shows no resistance (open). If the reading is outside standards, replace the sensor. An alternative method to test the sensor, is to plug a new sensor into the board and see if the clutch will engage. Caution! When using this method, ensure prime/ pressure valve is in the prime position. This is important because the sensor plugged into the board is not measuring pressure in the fluid section.

STEP 8: When Steps 6 & 7 have been completed and the magneto and sensor check good, the electrical control board is the only item left, replace the board.

21

Gear Box Assembly

Part No. 331-467

22

Part Number Description

100-028 Plug, Pipe

100-109 FTG Nipple

100-129 Plug Pipe

Qty.

1

1

2

100-152 1/4” Swivel Connector 1

100-180 Prime Valve Assy 1

100-201 FTG Adapter

100-318 Screw

100-380 Screw

100-381 Screw

2

2

1

2

100-398 Retaining Ring

111-200 Filter Assy

112-068

115-019

Ball Bearing

1/4” Hose Connector

117-008 Ball Bearing

169-010 FTG Nipple

305-198 Pinion Shaft

305-287 End Bell

331-038 LP Crosshead Assy

331-046 Ball Bearing

331-047 Ball Bearing

331-061 Sleeve Bearing

331-062 Retaining Ring

331-074 Spacer

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Part Number

331-103

331-111

331-117

Description

Flat Washer

LP Front Shield

Sleeve

331-197

331-236

Screw

Fluid Pump Assy

331-294-99 Pressure Sensor

331-408 Crank Assy

331-537 LP Machined Cover

1

1

2

1

1

Qty.

1

1

1

Suction Assembly

Part No. 331-284

Part Number Description

111-051R Bypass Hose

116-103 Spring Clip

141-008

331-034

Suction Filter

Suction Nut

331-090R FTG Hose Barb

331-292 Suction Seat Assy

1

1

331-400 Inlet Tube 1

Qty.

17”

1

1

1

23

Frame Assembly

Part No. 331-447

24

Part Number Description

100-317 Centerlock Nut

113-019 10” Wheel

113-030

136-126

Spacer

HX HD Screw

140-029

143-029

305-269

331-048

331-436

Flat Washer

Set Collar

Engine Mount

Cap

LP800G Frame

1

2

8

2

1

Qty.

4

2

2

4

Complete Assembly

Part No. 331-827

Part Number

100-317

100-339

100-373

100-374

Description

Centerlock Nut

Screw

Screw

Screw

Qty.

100-635 Screw

101-006A Caution Label

101-024

101-157

Change Oil Label 1

Engine Speed Label 1

1

1

2

4

5

1

101-194

101-206

101-226

101-228

101-351

112-020

116-105

117-090

Gas Label

Packing Adj. Tag

Warning Label

Always/Never Label

LP800G Label

Key

Spring Clip

Screw

1

1

1

1

1

1

1

3

Part Number

136-123

140-029

140-042

140-047

175-029

305-268

305-278

305-279

305-282

331-138

331-284

331-336

331-342

331-447

331-467

331-495

Description

Screw

Flat Washer

Flat Washer

Flat Washer

Honda Engine

Engine Cover

Clutch

Clutch Adapter

Qty.

Elec. Control Board 1

Screw 4

Suction Assy

Bucket Hook

Screw

Frame Assy

1

1

1

1

Gearcase Assy

Bushing

1

1

1

1

1

1

2

4

4

8

25

CCESSORIES

PUMP CONDITIONER

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

010-001 Display of 48 - 1 oz. bottles

010-009 1 quart bottle

010-019 1 Gallon bottle

Case order quantity: 12 on quarts, 4 on gallons

PAINT STRAINERS

Prefilter your paint using strainer bags. One dozen per pack.

100-064 Used to cover suction filter

100-065 5 Gallon strainer

HOSE COVER

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

100-219 Hose Cover Roll

100-426 Case of 6 Rolls

HIGH PRESSURE HOSE

Strong yet flexible, suitable for airless equipment up to 3300 PSI

Part No:

100-012 3/16” Whip Hose, 4 Ft.

100-011 1/4” Hose, 50 Ft.

100-023 3/8” Hose, 50 Ft.

100-037 1/2” Hose, 50 Ft.

100-010 1/4" Hose Connector

100-009 3/8" Hose Connector

SPRAY TIP ADAPTER

032-012 "F to G" gun adapter to attach

Graco ® tips to Airlessco 007 Spray Guns.

Flat Tip Washers

120-008 Flat Tip Washer

120-090 Flat Tip Washers 25 Pack

GUN FILTERS

120-090CX Coarse

120-090FX Fine

120-088 Filter Spring

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

STAY CLEAN

™ to

Spray protectant for your machine to prevent paint from sticking to it.

114-030 20 oz. can

THROAT SEAL OIL

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

188-187 6 oz. Bottle

188-392 1 qt. Bottle

XTEND-A-POLE SYSTEM

Tip Extensions - Complete with

Patented SPRAY CLEAN REV-GUARD

Swivel Extension

Standard Tip Extension

Swivel Extension

Bare Pole

TIP EXTENSIONS, “G” THREAD

032-170

032-171

032-172

032-173

6” Long

12” Long

18” Long

24” Long

SWIVEL EXTENSION, “G” THREAD

032-184 36” Long

EXTENSIONS (BARE POLES)

Add Tip Extension or Swivel Extension to create desired length

032-053

032-054

24” Long

36” Long

SWIVEL “G” THREAD

032-035 7/8" - 14 Swivel

ADAPTERS

90° Pole to Gun Adapter

032-042

Gun Nut “F” Thread 11/16-16

032-010

Gun Nut “G” Thread

032-011