Service manual

ManualsBrandsAIRLESSCO ManualsPaint Sprayer910E

Manufactured by: AIRLESSCO BY DUROTECH CO.

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

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

SUBJECT TO CHANGE WITHOUT NOTICE.

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

HANDLE THIS UNIT AS YOU WOULD A LOADED FIRE ARM!

High pressure spray can cause extremely serious injury.

OBSERVE ALL WARN INGS!

IMPORTANT WARNING !!

Before operating this unit, read and follow all safety warnings and in struc tions

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

Pressure Relief Pro ce dure on Page 6 of this manual.

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

AIRLESSCO PAINT SPRAYER

SERVICE MANUAL

AIRLESSCO 8-10-11 SERIES

ALLPRO 910E & 1110E

Summary of content (32 pages)

PAGE 1
AIRLESSCO PAINT SPRAYER SERVICE MANUAL AIRLESSCO 8-10-11 SERIES ALLPRO 910E & 1110E 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 6 of this manual.
PAGE 2
TABLE OF CONTENTS 4 Introduction ............................................................ 1 Flushing ................................................................. 1 How to Flush .......................................................... 2 Setting Up .............................................................. 3 Starting Up ............................................................. 3-4 Warnings- Read prior to using sprayer .............. 4-7 PRESSURE RELIEF PROCEDURE ..............
PAGE 3
INTRODUCTION This airless paint sprayer is a time-tested, slow-stroking pump built to give many years of reliable service. The design and quality of manufacture has been contractor proven to meet the demanding needs of the professonal painting contractor. SPECIFICATIONS AIRLESSCO ALLPRO GPM PRESSURE MAX. TIP SIZE 8 SERIES SL810 810E .8 3000 .029 (1 gun) - .019 (2 guns) 10/11 SERIES SL1100 1000E 1.0 3000 .032 (1 gun) - .
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HOW TO FLUSH FIG. 1 REMOVE SPRAY TIP FIG. 3 ENGAGE GUN SAFETY LATCH (LOCK GUN) as per gun instruction manual. metal pail FIG. 2 Pressure Control Knob: used to adjust pressure only. Turn clockwise to increase pressure and counterclockwise to decrease pressure. On/Off Switch Thermal Overload Switch Prime/Pressure Relief Valve (Prime/PR Valve) Used to relieve pressure from gun/hose/tip and to prime the unit when in OPEN position.
PAGE 5
SETTING UP 1. Connect the Hose and Gun 3. Check the Electrical Service a. Remove the plastic cap plug from the outlet connector and screw a conductive or grounded 3000 psi spray hose onto fluid outlet. Be sure the electrical service is 120 V, 60 HZ AC 15 amp minimum and that the outlet you use is properly grounded. b. Connect an airless spray gun to the other end of the hose. 4. Grounding 2. Fill the Packing Nut/Wet Cup 1/3 full with Throat Seal Oil (TSO) supplied. (Fig. 4) FIG.
PAGE 6
SETTING UP AND STARTING 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 comCAUTION: 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.
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WARNINGS MEDICAL ALERT - Airless Spray Wounds If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. 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.
PAGE 8
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. 2. Turn unit off and unplug from electrical outlet.
PAGE 9
WARNINGS UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD AMPERAGE RATING RANGE 5-6 6-8 8 - 10 10 - 12 VOLTAGE 120 120 120 120 25 50 100 150 200 250 300 400 500 18 18 18 16 16 16 14 14 12 12 12 10 12 10 10 8 10 10 8 8 10 8 8 6 8 6 6 6 8 6 6 4 6 6 4 4 Always follow recommended pressure and operating instructions. KEEP CLEAR OF MOVING PARTS Keep clear of moving parts when starting or operating the sprayer.
PAGE 10
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. GUN SAFETY LATCH IN LOCKED POSITION GUN SAFETY LATCH * 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.
PAGE 11
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.
PAGE 12
SPRAY TECHNIQUE TOTAL SPRAYGUN MOVEMENT - arm movement - full sweep TRIGGER POINT TRIGGER POINT e t Strok al Pain tu The Ac oke aint Str tual P The Ac It is important to "trigger" the gun after gun movement (arm movement) has started and release trigger (shut gun off) before gun movement ends. Gun movement is always longer than actual paint (spray) stroke. In that manner, even blending and uniform paint coat thickness is achieved over the entire surface.
PAGE 13
AIRLESS SPRAY GUN TROUBLESHOOTING DEFECTS CAUSE CORRECTION Coarse spray Low pressure Increase the pressure. Excessive fogging (overspray) High pressure Material too thin Reduce the pressure to satisfactory pattern distribution. Use less thinner. Pattern too wide Spray angle too large Pattern too narrow Spray angle too small Too much material Nozzle too large Material too thin Pressure too high Use smaller spray angle tip.
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AIRLESSCO 007X & XL SPRAY GUNS 6 2 3 4 8 10 11 12 13 5 14 7 27 1 9 15 9a 16 17 18 20 21 19 26 22 25 23 24 Item No. 1 2 3 4 5 6 7 8 9 9a 10 11 12 13 14 12 Part No.
PAGE 15
AIRLESSCO 007X & 007XL SPRAY GUN REPLACING THE VALVE SPRING UNIT (9) KIT#3-007 3 Tip Washers 1 Valve Seat (7) TRIGGER LOCK LOCK UNLOCK ADJUSTING SPRAY GUN Hold gun with trigger locked (25) and push trigger against the lock (17). Then adjust nut (15) so that the retainer (14) will move freely back and forth approximately 1/32" to allow valve spring unit (9) to seat the valve ball (8). IMPORTANT: Readjust nut (15) periodically for wear of valve seat (7) and valve ball (8); otherwise, leakage will occur.
PAGE 16
SPRAY TIP SELECTION Spray tip selection is based on paint viscosity, paint type, and job needs. For light viscosities (thin paints), use a smaller tip; for heavier viscosities (thicker paints), use a larger tip size. TIP SELECTION CHART FULL RANGE OF TIP SIZES Tip Identification: All tips have a 6 digit part number. The first 3 digits identifies it as a Rev-Tip (560) or a Flat Tip (570). The 4th digit is the fan width - the number is half the fan width, ie.
PAGE 17
REGULAR MAINTENANCE 1. Always stop the pump at the bottom of its' stroke when you take a break at the end of the day. This helps keep material from drying on the rod and damaging the packings. 2. Keep the displacement pump packing nut/wet cup 1/3 full of TSO at all times. The TSO helps protect the packings and rod. 3. Inspect the packing nut daily. It should be tight enough to stop leakage, but no tighter. Overtightening will damage the packings. OIL AND LUBRICATION INSTRUCTIONS FIG.
PAGE 18
FIELD TROUBLESHOOTING PROBLEM Unit doesn't prime. CAUSE Airleak due to: 1. Loose Suction Nut 2. Worn O-Rings Stuck or Fouled Balls Prime/Pressure Relief valve not opening. Unit primes, but has no or poor pressure. Pressure set too low. Filter(s) are clogged. 16 Service inlet and outlet valves. See pg 19 Clean or replace Prime Valve (100-180). Turn up pressure. Clean or replace gun filter, inlet filter and/or manifold filter. Service OutletValve. See pg 19 Prime/Pressure Relief valve bypassing.
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SERVICING FLUID PUMP Note: Check everything in the Troubleshooting Chart before disassembling the sprayer. FLUID PUMP DISCONNECT 1. 2. 3. 4. 5. 6. Flush out the material you are spraying, if possible. Follow the Pressure Relief Procedure on Page 6. Stop the pump in the middle of down stroke. Remove the suction tube and fluid hose (if so equipped) from the fluid pump. Remove 2 retaining rings and slip the sleeve of the coupling down and remove both coupling halfs.
PAGE 20
SERVICING INLET & OUTLET VALVES INLET VALVE (SEE FIG. 7 & 9) 1. Using the rod collar tool (189-211), screw the suction nut (187-018), containing intake seat support (187-017), off of the fluid body (187-313). 2. Remove the inlet seat (187-065), O-ring (106-017), inlet ball (187-020) and ball cage (187-016) with O-ring (106-018). 3. Clean all parts and inspect them for wear or damage, replacing parts as needed. Old "O" rings should be replaced with new ones. NOTE: Inlet seat (187-065) is reversible. 4.
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V-PACKING REPLACEMENT V-PACKING REPLACEMENT KIT SEVERE DUTY- PART NO. 187-040 Contains: Leather & Plastic Packings, Teflon & Viton O-Rings, Balls & plastic dual sided female adaptor & Larger Male Glands. FIG. 8 GLAND KIT - PN 187-064 V-PACKING REPLACEMENT INSTRUCTIONS 1. Remove the fluid pump as per the "Fluid Pump Disconnect" instructions on page 17. 2. Unscrew and remove the inlet valve per instructions on page 18. 3. Unscrew & remove the packing nut (187-046).
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V-PACKING REPLACEMENT (Continued) FIG. 9 106-018 (optional) 187-046 187-047 187-315 106-013 106-012 187-026 187-037 187-030 187-020 187-065 187-029 187-059 See FIG. 10 187-330-99* 187-016 187-060 187-058 187-025 187-062* 187-029 187-059 106-021* 187-031 115-022 187-313 106-017 187-017 187-018 301-094 187-037 187-061 141-010 187-051* * INCLUDED WITH 187-330-99 PISTON ASSEMBLY REASSEMBLY 6. Lubricate leather packings in lightweight oil for 10 minutes prior to assembly. 7.
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MANIFOLD FILTER - PN 111-200-99 FIG. 10 FIGURE 10 PARTS LIST ITEM 1 2 3 1 2 3 4 5 6 7 8 9 10 * 4 5 6 7 8 PART NO. DESCRIPTION 111-202 301-356 106-007 111-204 111-203 111-201 100-101 100-129 100-028 100-109 111-200 Base* Spring* O-Ring* Filter Support* Base* Swivel Plug 3/8" (2) Plug 1/4" Nipple 3/8 x 1/4 Filter 8 10 9 PAINT SYSTEM - PN 301-454 5 FIG. 11 8 9 7 6 15 4 10 3 12 11 13 14 2 1 ITEM NO. 1 2 3 4 5 6 7 8 9 PART NO.
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COMPLETE SPRAYER FIG. 12 49,57,58 20 26 27 28 14 15 13 36 38 31 29 30 33 32 39,40,41,55,56 12 20 34, 42 7 6 35 43 5 8 22 8 10 9 11 4 3 16 17 45 44 37 19 18 21 25 1 23 24 2 46 47 48 54 52, 53 51 22 Optional Suction Assy.
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COMPLETE SPRAYER PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PART NO. 301-189 301-092 301-105 100-360 100-312 301-320 301-333 301-291 189-048 189-046 301-047 189-047 301-193 111-044 100-349 113-023 111-037 301-135 100-332 301-139 301-337 301-048 100-328 140-035 140-051 301-173 136-033A 301-099 140-051 301-233 115-041 112-029 301-321 301-205 301-206 301-414 301-415 301-318 99 DESCRIPTION ITEM NO.
PAGE 26
REPLACEMENT OF BELT/BELT ADJUSTMENT FIG. 13 NOTE: The Cog Belt System does not require alignment. When upper sheave is placed on motor shaft it is pushed on until a positive stop DEFLECTION is reached. The set screws (Fig. 12, Item 30) are then loctited. The lower pulley is placed on gearbox and held in place with keyway and snap ring (Fig. 12, Item 18) The flange on upper sheave holds the belt in alignment and the belt self aligns on lower pulley eliminating having to align.
PAGE 27
PRESSURE CONTOL ASS'Y CALIBRATION NOTE: Anytime a sensor, pressure control assembly or both are replaced, the these calibrations must be performed. 1. ZERO CALIBRATION 1. Place prime/pressure relief valve in the prime (open) position. 2. Set the pressure control knob to the minimum setting (CCW). 3. Detach the pressure control unit. 4. Place the jumper (PN 117-207) on both prongs of the "P-ZR" terminal. Note: This jumper comes with a new Pressure Control Assemblyand is installed on the "P-ZR" terminal.
PAGE 28
PRESSURE CONTROL ASS'Y CALIBRATION (cont.) 4. PHASE LIMIT CALIBRATION Formerly known as the Low Voltage or Master Voltage Calibration 1. Attach a 50', 1/4" airless hose, airless gun with .017 tip and a 5000 psi glycerin filled pressure gauge to the pump. 2. Place the suction tube into a bucket of anti-freeze (or Coro-Chek) and water. 3. Turn pump on and turn up pressure control until the machine starts to prime. 4. Place the prime/pressure relief valve in the pressure (closed) position. 5.
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ELECTRICAL SYSTEM FIG. 16 7 6 BLACK 5 8 4 B B R L K E K & D W T BLACK WHITE L1 K AC A2 A1 BL 2 R E D 9 L2 INHIBIT 3 S1 S2 1 LCD ZERO PRESSURE ON-SL POT POWER LIGHT ITEM NO. 1 2 3 4 5 7 8 9 10 11 12 13 14 15 PART NO.
PAGE 30
TROUBLESHOOTING - Machine does not start CAUSE Control Settings SOLUTION STEP 1: Ensure that the ON-Off toggle switch is in the "ON" position and that the Pressure Control Knob is fully CW (maximum pressure). Also check that the unit is plugged in. STEP 2: Lower the pressure control assembly and check if the red power light on the board is lit. If the light is "OFF", proceed to Step 3. If the light is "ON", go to Step 7.
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REPLACEMENT OF ELECTRICAL COMPONENTS WARNING: Always unplug the electrical cord before servicing machine. NOTE: Anytime the pressure control assembly, sensor or both are replaced, perform the calibrations. PRESSURE CONTROL ASSEMBLY (Electrical Control Board) 1. Unplug machine's power cord. 2. Remove eight screws (Fig. 12, Item 35 ) and lower the pressure control assembly. 3. Disconnect all leads from pressure control assembly. 4. Reassemble in reverse order. SENSOR 1. Remove the screws (Fig.
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REPLACEMENT OF ELECTRICAL COMPONENTS (Cont) LIQUID CRYSTAL DISPLAY (LCD) 1. Ensure that the power switch is OFF and that the machine is unplugged. 2. Detach the pressure control assembly (Fig. 12, Item 34) from the frame by unscrewing the eight screws (Fig. 12, Item 35). 3. Disconnect the LCD lead from the the pressure control assembly. 5. Separate the LCD assembly from the frame by undoing the four screws (Fig. 17 Item 6) 6. Disassemble Items 1-6 (Fig 17) 7. Remove and replace LCD Display (Fig.