SERVICE /OPERATION MANUAL HSS 9000 Hydraulic Airless Paint Sprayer Form No.
TABLE OF CONTENTS INTRODUCTION ................................................................................................... 1 SAFETY WARNINGS ............................................................................................ 2 GAS ENGINE PRECAUTIONS ............................................................................. 5 FLUSHING ............................................................................................................ 7 HOW TO FLUSH.................................
INTRODUCTION Your new Airlessco 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.
SAFETY WARNINGS HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. Handle as you would a loaded firearm. 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. Cleaning agents, coatings, paints or adhesives may contain halogenated hydrocarbon solvents. DON'T TAKE CHANCES! Consult your material suppliers to be sure.
SAFETY WARNINGS ALWAYS INSPECT SPRAYING AREA HOSES • Keep the spraying area free from obstructions. • Tighten all of the 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. • Make sure the spraying area has good ventilation to safely remove vapors and mists. • NEVER keep flammable material in spraying area.
SAFETY WARNINGS 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 fingers 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.
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.
GAS ENGINE PRECAUTIONS (continued) • 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.
FLUSHING 1. New Sprayer 5. Storage Your sprayer was factory tested in an oil solution which was left in the pump. Before using oil-base paint, flush with mineral spirits only. Before using water-base paint flush with mineral spirits, followed by soapy water, then a clean water flush. Always relieve pressure (See pressure relief procedure on page 11) prior to storage or when machine is unattended. 2. Changing Colors Flush with a compatible solvent such as mineral spirits or water. 3.
HOW TO FLUSH 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 FIGURE 2 REMOVE SPRAY TIP. ENGAGE GUN SAFETY LATCH. 2. Pour enough clean, compatible solvent into a large, empty metal pail to fill the pump and hoses. 3. Place the suction tube into the pail. 4. Turn the Prime Valve (Figure 6) to the "OPEN" priming position. 5.
SETTING UP 1. Connect the hose and gun. a. Remove the plastic cap plug from the outlet fitting 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.
SETTING UP (continued) 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.
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. FIGURE 6 2. Turn the unit off & unplug it from the electrical outlet. 3.
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) FIGURE 7 * 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.
SPRAYING TROUBLESHOOTING CHART Problem Cause Correction Coarse Spray, Spotty Pattern Pressure setting low Irratic spray gun/hand motion Increase pressure setting Use a steady, parallel pass Excessive Overspray (Fogging) Pressure setting high Paint over thinned/reduced/cut Reduce pressure setting Use less thinner/water/reducer Spray Pattern Excessively Wide Incorrect fan width selection Select narrower fan width tip* Spray Pattern Excessively Narrow Incorrect fan width selection Select wider fa
REV-TIP SELECTION CHART ™ 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. REV-TIP for Painting 561-XXX TM SPRAY PAINTING TIP - ORIFICE SIZE (Inches) Fan Width (12” from surface) .007 .009 .011 .013 (mm) in.
FIELD TROUBLESHOOTING PROBLEM Unit doesn't prime Unit primes but has no or poor pressure Unit does not maintain good spraying pressure Unit does not run CAUSE Airleak due to: • Loose Suction Nut • Worn O-Rings • Leak in Siphon Assy SOLUTION • Tighten Suction Nut • Service Suction Assy • Replace Siphon Assy Stuck or Fouled Balls Service outlet valve suction assembly Pressure set too low Turn up pressure Filter(s) are clogged Clean or replace gun filter, inlet filter and/or manifold filter
SERVICING THE FLUID PUMP Disassembly of the Fluid Pump - Figure 19 Fluid Pump Removal - Refer to Figure 12 1. Follow the Pressure Relief Procedure page 11. 2. Flush the material you are spraying out of the machine. 3. Remove the Front Cover (119-099). 4. Slip Retaining Ring (116-106) down to expose the Piston Pin. 5. Push Piston Pin (119-025) out of the piston pin hole. 6. Loosen Jamb Nut (187-088) until the Fluid Pump can unthread from the Yoke (186-078). 1.
SERVICING THE FLUID PUMP Fluid Pump Reinstallation - Refer to Figure 12 1. With the Retaining Ring loosly in place around the pump piston, thread the Fluid Pump in to the Yoke (186-078) until the top edge of the Outlet Housing (187-086) is one thread above the inside edge of the Yoke threaded bore. 2. Tighten the Jamb Nut (187-088) until it stops against the bottom edge of the Yoke. 3. Line up the Displacement Rod pin hole with the Hydraulic Piston pin hole; insert the Piston Pin. 4.
SERVICING INLET VALVE ASSEMBLY Disassembly of Inlet Valve - Figure 14 1. Relieve pressure following Pressure Relief steps on page 11. FIGURE 14 1 2. Remove Inlet Valve Housing (187-084). 6 2 3 7 4 5 8 3. Remove Ball Guide (187-087), O-Rings and Inlet Ball (187-092). Remove Inlet Seat (187-086). 7. Clean and inspect parts for wear or damage, replace parts as necessary. PTFE O-Ring (106-008) and Viton O-Ring (106-013) will always be replaced in this procedure. Re-assembly of Inlet Valve - Figure 14 1.
OPTIONAL SUCTION ASSEMBLIES FIGURE 17 2 4 1 5 4 3 6 5 Gal. Latex Suction Assembly 119-108 FIGURE 17 PARTS LIST ITEM # 1 2 3 4 5 6 PART # 6 5 4 3 2 1 ITEM NO. DESCRIPTION 100-668 189-587 100-664 250-116 301-514 141-008 Suction Elbow Suction Nut 1" ID Suction Hose Clamp 5 Gal Suction Tube Filter Basket 141-008 301-514 250-116 100-664 189-587 100-668 PART NUMBER THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO DUROTECH CO.
PACKING REPLACEMENT PROCEDURES REASSEMBLY - Figure 19 1. Soak all Leather Packings (187-074) in oil for 5-10 minutes before assembly. 2. Install Scraper (187-083) open edge downwards, and metal Female Gland (187-072) open side up on Piston End (187078). 3. Install five UHMWPE Packings (187-075) and three Leather Packings (187-074) on Piston End, open side up, in this order from bottom: Plastic, Leather, Plastic, Leather, Plastic, Leather, Plastic, Plastic.
PAINT PUMP ASSEMBLY 2 FIGURE 19 29 7 5 25 3 19 24 20 21 20 21 26 2 20 22 21 20 20 21 22 20 21 23 6 1 20 21 8 20 27 19 9 10 11 15 4 12 17 16 18 30 13 14 *See Page 19 For Optional Suction Assemblies 21
MANIFOLD FILTER - PN 119-084 1 2 FIGURE 20 10 3 9 7 8 4 7 5 6 FIGURE 20 PARTS LIST ITEM # 1 2 3 4 5 22 PART # 111-202 301-256 111-204 100-005 111-201 DESCRIPTION Housing Bowl Spring 60 Mesh Filter 3/8 NPS-F X 3/8 NPT-M Swivel Housing Base ITEM # 6 7 8 9 10 PART # 100-028 100-129 169-010 106-007 111-203 DESCRIPTION 1/4 NPT-M Plug 3/8 NPT-M Plug 3/8 NPT-M X 3/8 NPT-M Nipple O-Ring, PTFE Filter Support
PRIME VALVE ASSEMBLY - 119-083 10 13 12 11 8 1 7 6 9 FIGURE 21 14 3 2 4 5 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ITEM NO. 115-068 117-046 115-063 115-072 115-303 115-071 115-064 115-065 115-067 115-074 115-012 115-069 115-029 115-073 PART NUMBER THIS DOCUMENT CONTAINS INFORMATIO PROPRIETARY TO DUROTECH CO. IT SHAL NOT BE REPRODUCED, USED OR DISCLOS TO ANYONE WITHOUT THE PRIOR WRITT PREMISSION OF DUROTECH CO.
HYDRAULIC PUMP AND RESERVOIR FIGURE 22 Note: Hydraulic Reservoir and Hydraulic System requires 3.5 Gallons of Pennzoil A.W. Hydraulic Oil #46 The minimum Oil Level must be approximately halfway up the Filler Tube, Never below.
HYDRAULIC INLET ASSEMBLY FIGURE 23 FIGURE 23 PARTS LIST ITEM # 1 2 3 PART # 189-570 189-562 189-561 DESCRIPTION ITEM # Hydraulic Pump O-Ring, Pump Pump Inlet Fitting 4 5 6 PART # DESCRIPTION 189-523 189-565 189-568 Threaded Nipple Strainer, Suction Inlet Connector HYDRAULIC MOTOR ASSEMBLY 3 2 1 2 2 FIGURE 24 4 6 3 FIGURE 24 PARTS LIST ITEM # 1 2 3 4 5 6 5 PART # 189-546 100-133 189-545 186-100 186-078 119-099 DESCRIPTION High Press. Hose 90 deg Elbow Hyd.
FRAME ASSEMBLY FIGURE 25 15 13 FIGURE 25 PARTS LIST ITEM # PART # 189-599 1 FIGURE XX2 PARTS LIST 189-576 301-165 3 189-558 4 119-077 5 100-655 6 140-051 7 100-656 8 189-530 9 189-452 10 189-450 11 189-451 12 119-079 13 136-233 14 26 DESCRIPTION Frame, Bare Pivot Tube Wheel Bumper, Stop Spacer Hex Bolt Nut Washer Handle Assembly Cover Guide Slide Axle Riv-Nut ITEM # 15 16 17 18 19 20 21 22 23 24 25 26 PART # 113-030 143-029 119-081 140-029 136-217 100-377 189-559 189-596 119-080 119-082 331-222 12
DIRECT IMMERSION ASSEMBLY FIGURE 26 FIGURE 26 PARTS LIST ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 PART # 189-554 189-571 189-580 189-606 189-548 140-035 100-307 188-118 100-390 100-344 189-545 189-546 DESCRIPTION Frame Assembly Hydraulic Assy Pump Shroud Paint Pump Assy Pressure Control Flat Washer Screw Nut Screw Flat Washer Hyd Press.
SIPHON UNIT ASSEMBLY FIGURE 27 FIGURE 27 PARTS LIST ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 28 PART # 189-554 189-571 140-035 100-307 188-118 100-344 189-545 189-546 111-014 119-083 119-084 188-125 140-051 100-655 DESCRIPTION Frame Assy Hydraulic Assembly Flat Washer Screw Nut Flat Washer Hyd Press.
MOTOR/ENGINE W/CARRY PLATE ASSEMBLY 1 2 FIGURE 28 4 1 3 2 5 7 6 FIGURE 28 PARTS LIST ITEM # 1 2 3 4 5 6 7 8 9 PART # 189-593 189-531 189-526 100-361 175-025 175-034 XXX-XXX 136-123 113-023 113-022 189-524 XXX-XXX 101-434 DESCRIPTION 2 1 ITEM NO. 175-025 189-627 PART NUMBER Lifting Handle/Plate Assembly THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO DUROTECH CO.
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