® AIRLESS PAINT SPRAYER SERVICE/OPERATION MANUAL AIRLESSCO LP500 - LP540 - LP690 ALLPRO 510E - 710E - 810E 001-492 SEPT 08
TABLE OF CONTENTS SECTION Introduction........................................................................ 1 Warnings ........................................................................... 2 Flushing ............................................................................. 5 How to Flush...................................................................... 5 Setting Up.......................................................................... 6 Starting Up .......................................
INTRODUCTION CARRY FRAME HI-BOY FRAME Your new Airlessco or ALLPRO airless paint sprayer is designed to meet the demands of the professional painting contractor as well as the homeowner. The famous Airlessco slow-stroking stainless steel piston pump delivers extra long life for the piston, packings, valve seats and balls. The patented Triple-Life packing system is externally adjustable, extending packing life and reducing repacking costs. Its large high-torque electric motor runs slower reducing heat.
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. 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.
WARNINGS - CONTINUED HOSES GROUNDING 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 that has 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.
WARNINGS - CONTINUED 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.
FLUSHING 1. NEW SPRAYER 5. STORAGE Your unit 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. 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.
SETTING UP 1. CONNECT THE HOSE AND GUN a. Remove the plastic cap plug from the outlet and screw a conductive or grounded 3000 psi spray hose onto fluid outlet. b. Connect an airless spray gun to the other end of the hose, but do not install the spray tip yet! NOTE: Do not use thread sealer on swivel unions as they are made to self seal. 2. FILL THE PACKING NUT/WET CUP FIG. 5 Fill the Packing Nut/Wet Cup with 5 drops of Airlessco Throat Seal Oil (TSO). 3.
STARTING UP 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 engine ON/OFF switch to the "ON" position. d. Turn Pressure Control Knob clockwise to prime the pump. e.
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. 4.
AIRLESS SPRAY GUN OPERATION SPRAY 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) FIG. 7 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. RELEASED MAJOR COMPONENTS OF SPRAY GUN AND REVERSIBLE SPRAY TIP FIG.
AIRLESS SPRAY GUN FIG. 11 6 7 10* 9 8 5 4 11 1* 3* 2* 12 13 14 15 16 PARTS LIST FIGURE 11 Item No. Part No.
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 distrabution Use less thinner Patten too wide Spray angle too large Use smaller spray angle tip Pattern too narrow Spray angle too small Use larger spray angle tip (if coverage is OK, try tip in same nozzle group) too much material Nozzle too large Material too thin Pressure too hig
TIP SELECTION GUIDE Spray tip selection is based on paint viscosity, paint type, & job needs. For light viscosities (thin paints), use a smaller tip; heavier (thicker paints), use a larger tip size. Spray tip size is based on how many gallons of paint per minute can SPRAY TIP - ORIFICE SIZE (INCHES) REV-TIPTM for Painting Fan Width (12” from surface) in. mm 4-6 102-152 .007 6-8 152-203 8-10 203-254 10-12 254-305 12-14 305-356 be sprayed through the tip.
ELECTRIC MOTOR MAINTENANCE 1. LUBRICATION - This motor is supplied with prelubricated ball bearings, lubricated for the life of the bearing. 2. MOTOR BRUSHES - need periodic inspection and replacement as wear indicates. Brush wear is greatly influenced by individual application. It is recommended that brush wear be checked at early intervals of operation in order to determine future required inspection. Standard Durotech brushes have an initial length of 1".
FIELD TROUBLESHOOTING PROBLEM Unit doesn’t prime CAUSE SOLUTION Airleak due to: •Loose suction nut • Worn o-rings • Hole in suction hose Stuck or fouled balls Unit primes but has poor or no pressure Pressure set too low Filter(s) are clogged Outlet valve fouled/worn Prime/pressure relief valve bypassing Packings and/or piston worn • tighten suction nut • replace o-ring (106-018) on suction seat & o-ring (106-017) below suction seat • replace suction hose • service inlet and outlet valves • turn up pre
SERVICING THE FLUID PUMP FLUID PUMP REINSTALL FLUID PUMP DISCONNECT REFER TO FIGURE 14 1. Follow the Pressure Relief Procedure on page 8. 2. Flush the material you are spraying out of the machine. 3. Remove the connecting rod shield. 4. Move the piston rod to its lowest position by cycling pump slowly. 5. Turn off the motor. 6. Disconnect Sensor by holding it in place with a 7/8” wrench and unscrewing the swivel with a 11/16” wrench. 7.
SERVICING THE OUTLET VALVE DISASSEMBLY OF THE OUTLET VALVE FIG. 15 1. Disconnect the Fluid Pump following instructions on page 15. 2. Place piston holder in a vise. Slide piston into the holder & lock in place with a 3/8” dowel. 3. Use a 1/4” allen wrench to unscrew the outlet seat retainer from the piston. 4. Remove the outlet seat, O-ring and outlet ball. 5. Inspect outlet ball & seat for wear. Replace as necessary. Ensure seat is right side up. 6.
PACKING REPLACEMENT PROCEDURES DISASSEMBLY OF THE FLUID PUMP REFER TO FIGURE 17 & 18 1. Disconect the Fluid Pump as instructed on page 15. 2. Unscrew & remove the packing nut. 3. Push the piston rod down through the packings & out of the pump. 4. Now push the packing removal tool up throughthe pump & remove from the top bringing packings, spacer & springs along with it, leaving fluid body empty. *Make sure all old packings & glands have been removed from fluid pump. 5. Clean inside of fluid body. 6.
PACKING REPLACEMENT PROCEDURES 20 FIG. 18 14 19* 18* 21 25* 24* 4 22* 17* 16* 1* 15* 13* 11 2* 12* 3* 5 23* 1* PARTS LIST FIGURE 17 & 18 18 6* 7* Description PARTS LIST FIGURE 17 & 18 CONT. Item No. Part No.
GEAR AND PUMP ASSEMBLY FIG 19 1 14 13 15 16 17 WARNING 2 DO NOT OPERATE WITHOUT COVER GUARD IN PLACE 1 3 2 4 11 8 9 12 5 6 7 10 SERVICING GEAR BOX ASSEMBLY 1. Remove fluid pump as per "Fluid Pump Disconnect" procedures on page 15. 2. Remove frame from the gearbox by loosening the four mounting screws. 3. Refer to Figure 19. Separate cover assembly from box by removing bolts from front of cover & back of box & shoulder bolts from front of cover & back of box. 4.
CARRY FRAME MODELS FIG. 21 19 20 1, 2, 3 18 4 17 16 5 15 14 6 7 13 12 11 PARTS LIST FIGURE 21 Item No. Description 9 8 PARTS LIST FIGURE 21 CONT Item No. Part No. Description 1 331-785 Fan 11 100-003 Swivel 2 331-786 Fan Cover 12 100-180 Prime Valve 3 117-090 Fan Cover Screws (3) 13 331-048 Rubber Boot (2) 4 117-044 Knob 14 100-318 Bolt (2) 5 331-321 Terminal Box 15 115-019 Hose Connector (1/4”) 6 331-787 Bolt (.
LO-BOY MODELS FIG. 22 26 28 29 30 31 32 33 27 1, 2, 3 4 25 5 6 7 24 23 8 22 21 20 19 18 17 16 15 14 13 12 11 10 PARTS LIST FIGURE 22 Item No. Part No. 1 331-785 2 Description 9 PARTS LIST FIGURE 22 CONT Item No. Part No.
HI-BOY MODELS FIG. 23 24, 25, 26 20 21 22 23 1 2 19 3 18 4 5 17 16 11 15 6 12 14 7 13 9 8 10 PARTS LIST FIGURE 23 Item No. Part No. 1 331-795 2 3 Item No. Part No. Motor Cover 14 100-180 Prime Valve 331-788 Bolt (.
SUCTION ASSEMBLIES LO-BOY AND CARRY CHASSIS (331-238) HI-BOY CHASSIS (331-284) FIG. 24 FIG. 25 1 7 2 9 3 10 4 1 5 5 4 6 6 3 2 8 7 PARTS LIST FIGURE 25 PARTS LIST FIGURE 24 Item No. Part No.
PRESSURE CONTOL ASS'Y CALIBRATION NOTE: ANYTIME A SENSOR OR PRESSURE CONTROL ASSEMBLY (BOARD) OR BOTH ARE REPLACED, THE FOLLOWING CALIBRATIONS MUST BE PERFORMED. NOTE: PRESSURE CONTROL ASSEMBLIES (BOARDS) ARE NOW BEING EQUIPPED WITH A GREEN GROUNDING WIRE ATTACHED. CONTECT THE GROUNDING WIRE TO TERMINAL BOX USING THE SAME SCREW THAT HOLDS THE GROUNDING WIRE FROM THE POWER CORD. 1. ZERO CALIBRATION 1. Place prime/pressure relief valve in the prime (open) position. 2.
ELECTRICAL SYSTEM FIG. 26 6 7 4 GREEN R E D L1 AC 9 K A2 A1 BL 2 B B R L K E K & D W T BLACK WHITE/BLUE BLACK/BROWN 5 8 L2 3 S1 S2 1 INHIBIT SWITCH LCD ZERO PRESSURE ON-SL POT P-ZR LCD SET PHASE LIMIT SENSOR DISPLAY PARTS LIST FIGURE 26 Item No. Part No.
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 four screws heatsink housing. 3. Disconnect all leads from pressure control assembly. 4. Reassemble in reverse order. SENSOR 1. Remove the four screws, heatsink, and lower the pressure control assembly. 2.
TROUBLESHOOTING - MACHINE DOES NOT START Cause Steps Control Settings STEP 1: After making sure that the machine is plugged into the wall, verify that the on-off switch is in the ON position and that the pressure control knob is turned all the way to the right (clockwise for maximum pressure). Fuse STEP 2: Using your multi-meter, test the fuse for continuity or replace with a new fuse. If the fuse reads good, move on to step three.
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ACCESSORIES AIRLESSCO Quick Flush STAY CLEAN™ ™ Spray protectant for machine to prevent paint from sticking to it. Keeps your sprayer looking new for years! ■ The only clean water flushing system ■ Cuts sprayer clean-up time in half! ■ Connects to standard garden hose to backflush sprayer through gun 114-030 ■ Includes "F" and "G" adapters to work with all brands of gun 20 oz.
