Starting Up. AIRLESSCO 910E

SETTING UP AND STARTING

4

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

b. Always use the lowest pressure necessary to com-

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

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

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

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

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

7. Cleaning a Clogged Tip

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

a. Follow the Pressure Relief Procedure on page 6.

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

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

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

Follow the Pressure Relief Procedure on Page

6.

8. When shutting off the sprayer a. Whenever you stop spraying, even for a short break, follow the Pressure Relief Procedure Warning on page 6.

b. Clean the tip and gun as recommended by your separate gun instruction manual.

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

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

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

LCD - LIQUID CRYSTAL DISPLAY

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

WARNINGS

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

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

DO NOT USE halogenated solvents in this sytem. The prime valve, 2 gun manifold and most airless guns have aluminum parts and may explode. Cleaning agents, coatings, paints or adhesives may contain halogenated hydrocarbon solvents. DON'T TAKE

CHANCES! Consult your material suppliers to be sure.

Some of the most common of these solvents are:

Carbontetrachloride, Chlorobenzene, Dichloroethane,

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

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

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

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

5

4

WARNINGS

MEDICAL ALERT - Airless Spray Wounds

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL CARE AT ONCE.

DO NOT TREAT AS A SIMPLE CUT.

Tell the doctor exactly what fluid was injected.

NOTE TO PHYSICIAN: Injection in the skin is a traumatic injury.

It is important to treat the injury surgically as soon as possible. DO NOT DELAY treatment

to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream.

Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

INJECTION HAZARD

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

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

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

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

ALWAYS have gun tip guard in place when spraying.

ALWAYS lock gun trigger when you stop spraying.

ALWAYS remove tip from the gun to clean it.

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

ALWAYS follow the PRESSURE RELIEF PROCEDURE, as shown on page 6, before cleaning or removing the spray tip or servicing any system equipment.

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

Tighten all fluid connections before each use.

MEDICAL TREATMENT

If any fluid appears to penetrate your skin, get

EMERGENCY CARE AT ONCE. DO NOT TREAT AS

A SIMPLE CUT.

* Go to an emergency room immediately.

* Tell the doctor you suspect an injection injury.

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

ALWAYS INSPECT SPRAYING AREA

Keep spraying area free from obstructions.

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

NEVER keep flammable material in spraying area.

NEVER spray in vicinity of open flame or other sources of ignition.

Spraying area must be at least 20 ft. away from spray unit.

SPRAY GUN SAFETY

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

DO NOT remove or modify any part of gun.

ALWAYS REMOVE SPRAY TIP when cleaning. Flush unit with LOWEST POSSIBLE PRESSURE.

CHECK operation of all gun safety devices before each use.

Be very careful when removing the spray tip or hose from gun. A plugged line contains fluid under pressure.

If the tip or line is plugged, follow the PRESSURE RE-

LIEF PROCEDURE as outlined on page 6.

TIP GUARD

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

GENERAL PRECAUTIONS

NEVER alter equipment in any manner.

NEVER smoke while in spraying area.

NEVER spray highly flammable materials.

NEVER use around children.

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

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

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

NEVER LEAVE SPRAYER UNATTENDED WITH PRES-

SURE IN THE SYSTEM. FOLLOW PRESSURE RELIEF

PROCEDURES ON PAGE 6.

SPRAY TIP SAFETY

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

PRESSURE RELIEF PROCEDURE and then remove the spray tip to clean it.

NEVER wipe off build up around the spray tip.

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

jury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are using.

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

ALWAYS wear protective eyewear, gloves, clothing and respirator as recommended by fluid manufac-

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

5

6

WARNINGS

PRESSURE RELIEF PROCEDURE

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

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

4. Turn Prime/pressure relief valve

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

There will be a wider gap between valve handle and cam body when in open po-

sition.

2. Turn unit off and unplug from electrical outlet.

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

Use minimum pressure.

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

5. Re-engage gun safety latch.

Lock

*For overnight or long term storage close

If the SPRAY TIP OR HOSE IS CLOGGED, follow Step 1 through 5 above. Expect paint splashing into the bucket while relieving pressure during Step 4. If you suspect that pressure hasn't been relieved due to damaged prime/pressure relief valve or other reason, engage gun safety latch and take your unit to an authorized Airlessco Service Center.

HOSES

Tighten all fluid connections securely before each use.

High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling and result in an injection injury or serious bodily injury.

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

NEVER use a damaged hose, which can result in hose failure or rupture and cause an injection injury or other serious bodily injury or property damage. Before each use, check entire hose for cuts, leaks abrasion or bulging of cover, or damage or movement of couplings. If any of these conditions exist, replace the hose immediately. Never use tape or any device to try to mend the hose as it cannot contain the high pressure fluid. NEVER ATTEMPT TO RECOUPLE THE HOSE.

High pressure hose is not recoupleable.

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

GROUNDING

Ground the sprayer & other components in the system to reduce the risk of static sparking, fire or explosion which can result in serious bodily injury and property damage. For detailed instructions on how to ground, check your local electrical code.

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

Always ground all of these components.

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

AN ADAPTER.

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

2. Air Hoses; use only grounded hoses.

3. Fluid hose: use only grounded hoses.

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

5. Object being sprayed; according to your local

6. All solvent pails used when flushing.

Once each week, check electrical resistance of hose

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

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

7

6

WARNINGS

UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD

VOLTAGE

25 50 100 150 200 250 300

AMPERAGE

RATING

RANGE

5 - 6

6 - 8

8 - 10

10 - 12

120

120

120

120

18

18

18

16

16

16

14

14

12

12

12

10

12

10

10

8

10

10

8

8

10

8

8

6

6

6

8

6

400

6

4

8

6

500

4

4

6

6

Always follow recommended pressure and operating instructions.

KEEP CLEAR OF MOVING PARTS

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

Precaution is the best insurance against an accident. When starting the motor, maintain a safe distance from moving parts of the equipment.

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

DURE on page 6.

AVOID COMPONENT RUPTURE

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

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

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

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

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

Before each use, check hoses for damage and wear and ensure all fluid connections are secure.

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

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

RELIEF PROCEDURE,

ALWAYS use approved high pressure fittings and replacement parts.

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

PREVENT STATIC SPARKING FIRE/EXPLOSIONS

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

Vapors created when spraying can be ignited by sparks.

To reduce the risk of fire, always locate the sprayer at least 20 feet (6 m.) away from spray area. Do not plug in or unplug any electrical cords in the spray area, which can create sparks, when there is any chance of igniting vapors still in the air. Follow the coating & solvent manufacturers safety warnings and precautions.

Use only conductive fluid hoses for airless applications.

Be sure gun is grounded through hose connections. check ground continuity in hose & equipment. Overall

(end to end) resistance of unpressurized hose must not exceed 29 megohms for any coupled length or combination of hose length. Use only high pressure airless hoses with static wire approved for 3000 psi.

FLUSHING

Reduce the risk of injection injury, static sparking or splashing by following the specific cleaning process.

ALWAYS follow the PRESSURE RELIEF PROCE-

DURE on page 6.

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

NEVER use cleaning solvents with flash points below

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

NEVER SMOKE in the spraying/cleaning area.

WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS AND THINNERS

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

2. To eliminate electrostatic discharge, ground the spray unit, paint bucket & spraying object. See GROUNDING on pg. 6. Use only high pressure airless hoses approved for 3000 psi which is conductive.

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

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

5. Do not smoke in spraying/cleaning area.

7

AIRLESSCO 007 SPRAY GUN

SPRAY GUN

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

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

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

FIG. A

GUN SAFETY

LATCH

IN LOCKED

POSITION

MAJOR COMPONENTS OF SPRAY GUN

AND REVERSIBLE SPRAY TIP

Gun Safety

Latch

(or

Reversible

Spray Tip

Tip Guard

Trigger

Guard

Handle

(filter inside)

O-RING

GASKET

AL

MET-

GUN

SAFETY

LATCH

RELEASED

REV-TIP

REV

GUARD

8

SPRAY TIP ASSEMBLY

1. Be sure the pressure relief procedure is followed

before assembling tip and housing to the gun.

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

metal seat.

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

the o-ring side of the metal seat.

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

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

tip will be installed later)

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

6. Insert the tip into the guard.

7. Turn the guard to the desired position and tighten

the nut sufficiently to keep the guard in position

(fingertight). Over-tightening

O-Ring Gasket

will make it hard to turn

the tip handle.

Retaining Nut

Metal Seat

Nose of tip handle

REV-GUARD

Guard Housing Assembly

Rev-Tip

Cylinder gun

1. Lock gun safety latch.

2. Turn Rev-Tip handle 180 degrees.

3. Disengage trigger lock and trigger

into pail.

4. If the Rev-Tip handle appears locked

(resists turning), loosen the retaining nut.

The handle will now turn easily.

5. Engage gun safety latch and return

Spray Position Shown

9

8

SPRAY TECHNIQUE

Good Spray Gun Technique is at the core of any spray paint operation. Operator skill and efficiency is as important as good equipment and good paint.

Good spray technique is a skill that can be quickly learned by following these simple instructions.

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

WRONG

RIGHT

RIGHT WRONG

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

KEEP EVEN DISTANCE TO SURFACE

RIGHT

WRONG

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

The closer the spray gun is held to the work, the thicker the paint is deposited and the faster the gun must be moved to prevent sags and runs.

Holding the gun too far from the work will cause excessive fog, overspray, and a thin and grainy coat.

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

9