AIRLESS PAINT SPRAYER SERVICE/OPERATION MANUAL AIRLESSCO LP460 - LP540 - LP690 ALLPRO 510E - 710E - 810E Form No.
TABLE OF CONTENTS Product Diagrams & Parts Lists Introduction LP Series Specifications Safety Warnings 1 2 Getting Started Flushing How to Flush Setting Up Starting Up Pressure Relief Procedure Daily Maintenance 5 5 7 8 10 10 Repairs/Maintenance Instructions Spray Gun Operation Spray Gun Troubleshooting Spray Tip Selection Electric Motor Maintenance Field Troubleshooting Servicing the Fluid Pump Servicing Piston Rod, Outlet Valve Servicing Suction Assembly Packing Replacement Electrical Board Calibrati
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 UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD AMPERAGE RATING RANGE 5-6 6-8 8 - 10 10 - 12 VOLTAGE 120 120 120 120 LENGTH OF CORD IN FEET 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.
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 10) 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 (continued) 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 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/Pressure Relief (PR) Valve to the "OPEN" , priming position. Refer to Figure 1. 5.
SETTING UP 1. Connect the hose and gun. a. Remove the plastic cap plug from the outlet tee 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.
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. FIGURE 7 When in CLOSED position, there is only a very slight gap between handle & body. When closed the system is pressurized. Handle as a loaded firearm! 3. Starting the sprayer (See Figure 7, 8 & 9) 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.
STARTING UP 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. 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) * 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.
AIRLESS SPRAY GUN TROUBLESHOOTING DEFECTS CAUSE CORRECTION Coarse spray Low pressure Increase the pressure Excessive fogging (overspray) High pressure Material too thin Reduce pressure for satisfactory pattern Use less thinner Pattern too wide Spray angle too large Use smaller spray angle tip Pattern too narrow Spray angle too small Use larger spray angle tip.
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 IDENTIFICATION: Rev-Tip for Painting P.N. 560-xxx Rev-Tip for Striping P.N. 562-xxxST TM 1st 3-digits identifies it as a REV-TIP for airless paint spraying (P.N. 560-xxx) or a REV-TIP for airless line striping (P.N. 562-xxxST).
ELECTRIC MOTOR MAINTENANCE 1. LUBRICATION - This motor is supplied with prelubricated ball bearings, lubricated for life of bearing. 2. MOTOR BRUSHES - These 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 inspections. Standard Leeson brushes for this motor have an initial length of 3/4".
FIELD TROUBLESHOOTING PROBLEM Unit doesn't prime CAUSE Airleak due to: • Loose Suction Nut • Worn O-Rings • Hole in Suction Hose Unit primes but has no or poor pressure Unit does not maintain good spraying pressure Unit does not run SOLUTION • Tighten Suction Nut • Replace O-Ring (106-011) on suction seat, & O-Ring (106-020) below suction seat • Replace Suction Hose (331-290) Stuck or Fouled Balls Service outlet valve suction assembly Pressure set too low Turn up pressure Filter(s) are clog
SERVICING THE FLUID PUMP NOTE: Check everything in the Troublshooting Chart before disassembling the Fluid Pump. Fluid Pump Reinstallation Refer to Figure 11 & 14 Follow the Pressure Relief Procedure page 11. 1. Loosen the packing nut and ensure that the piston rod Flush the material you are spraying out of the machine. (331-093) is in its upper position in the fluid pump Remove the connecting rod shield (331-111). body (331-209).
GEAR AND PUMP ASSEMBLY - Do not operate FIGURE 12 machine without cover guard in place.
Servicing the Piston Rod - Outlet Valve DISASSEMBLY OF THE OUTLET VALVE REFER TO FIGURE 13 1. Disconnect the Fluid Pump. 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 (331-314) 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.
Packing Replacement Procedures Replacement Instructions: Fluid Pump Removal - Refer to Figure 11 1. Follow the Pressure Relief Procedure above. 2. Flush 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 or by rotating the motor fan. 5. Disconnect the sensor (331-294-99) by holding it in place with a 7/8” wrench & unscrewing the swivel connector (100-003) with an 11/16” wrench.
Packing Replacement Procedures (Continued) 3. Push the two bolts (100-318) through the tube spacers (331-074) & screw 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 seat (331-409) O-ring (106-011), suction ball (331-030) and suction ball guide (331-029) in the suction nut (331-034) & screw onto the fluid pump body. 5.
CARRY FRAME MODELS FIGURE 17 Part Number 100-003 100-180 100-312 100-318 106-500 111-037 115-019 117-044 117-090 119-048 301-191 301-405 331-048 331-068 331-074 Description Part Number Swivel 331-111 Prime P/R Valve 331-143 Screw (4) 331-212 Screw (2) 331-213 Sensor Seal 331-215 Screw (4) 331-234 Hose Connector (1/4 NPSXNPT) 331-248 Knob 331-294-99 Fan Cover Screws (3) 331-315-99 Screw (4) 331-316 Fan Retaining Clip 331-321 Blank Plate for LCD Panel 331-337 Rubber Boot (2) 331-398 .
LO-BOY MODELS FIGURE 18 22 Part Number 100-003 100-170 100-180 100-318 100-377 106-500 113-019 113-030 115-019 117-044 117-090 117-129 119-033 143-029 301-191 331-048 331-068 331-069 331-071 331-074 Description Swivel Cup Prime Valve Screw (2) Screw (4) Sensor Seal Wheel 10” (2) Spacer (2) Hose Connector (1/4” NPSXNPT) Knob Fan Cover Screws (3) Screw (2) Nut (2) Collar (2) Fan Retaining Clip Rubber Boot (2) .8 HP DC Motor 110V (5/6 Series) .75 HP DC Motor 230V (5/6 Series) .
HI-BOY MODELS FIGURE 19 Part Number 100-003 100-180 100-318 106-500 113-019 113-031 117-044 117-090 119-048 143-029 15-019 301-191 301-405 331-048 331-068 331-069 331-074 Description Part Number Swivel 331-111 Prime Valve 331-212 Screw (2) 331-213 Sensor Seal 331-215 Wheel 10” (2) 331-234 Spacer (2) 331-248 Knob 331-273 Fan Cover Screw (3) 331-294-99 Screw (4) 331-315-99 Collar (2) 331-316 Hose Connector (1/4” NPSXNPT) 331-321 Fan Retaining Clip 331-336 Cover Plate for LCD Opening 331-337 Rubber Boot 331
SUCTION ASSEMBLIES FIGURE 20 - LoBoy & Carry Part Number 106-020 111-016 331-034 331-035 331-090R 331-135 331-217 331-231 331-290 331-425 Description O-Ring PTFE Nylon Tie Suction Nut Suction Elbow Fitting Spring Clip Inlet Strainer Bypass Hose Ass’y Suction Hose Ass’y (Inc.
ELECTRICAL BOARD CALIBRATION (4 Series) Note: Anytime a sensor, pressure control assembly (board) or both are replaced, the following calibrations must be performed. 1. PRESSURE CALIBRATION 1. Attach a 50', 1/4" airless hose, airless gun with 0.017 tip and a 5000 psi glycerin filled pressure gauge to the pump. 2. Place the suction tube into a bucket of Airlessco Pump Conditioner and water. 3. Turn prime/pressure relief valve to the prime (open) position. 4.
TROUBLESHOOTING - Machine does not start (4 Series) CAUSE STEPS (SEE FIGURE 22) 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.
ELECTRICAL SYSTEM (4 Series) FIGURE 22 Part Number 117-044 331-138 331-168 331-184 331-185 331-256 331-294-99 331-297 331-311 331-312 331-316 331-488-99 Description Knob Screw Electrical Power Cord Spacer Strain Relief Fuse 15A Slow Blow Sensor Potentiometer Toggle Switch Fuse Holder .
ELECTRICAL BOARD CALIBRATION (5/6 Series) Note: Anytime a sensor, pressure control assembly (board) or both are replaced, the following calibrations must be performed. 1. ZERO CALIBRATION 1. 2. 3. 4. Place prime/pressure relief valve in the prime (open) position. Set the pressure control knob to the minimum setting (CCW). Remove the screws and lower the pressure control assembly. Ensure the jumper is on the "P-ZR" terminal.
ELECTRICAL BOARD CALIBRATION (CONTINUED) 4. PHASE LIMIT TRIMPOT 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 Pump Conditioner 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.
TROUBLESHOOTING - Machine does not start (5/6 Series) CAUSE STEPS (SEE FIGURE 23) 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.
ELECTRICAL SYSTEM (5 & 6 Series) FIGURE 23 Part Number 117-044 117-207 331-068 331-168 331-184 331-185 331-294-99 331-297 331-311 331-312 331-315-99 331-328 331-377 * Not Shown: * 331-304-99 Description Knob Jumper .
REPLACEMENT OF ELECTRICAL COMPONENTS 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 (Fig. 15, Item 20) from pressure control assembly. 3. Disconnect all leads from pressure control assembly. 4. Reassemble in reverse order. SENSOR 1. Remove the screws (Fig.
LP Series Electric Paint Sprayer Quick Reference Guide OPERATION Prime Pressure Relief Valve (Prime-PR Valve) Used to relieve pressure from gun, hose & tip and to prime the unit when in OPEN position. (It is in open position when there is a wider gap between handle and body). When in the CLOSED position, there is only a very slight gap between handle & body. When the relief valve is closed the system is pressurized. Handle as a loaded firearm! STEP 1A.
ACCESSORIES PUMP CONDITIONER Should be used on piston pumps between uses to prevent paint from drying on the piston & causing packing wear. AIRLESSCO to Spray protectant for your machine to prevent paint from sticking to it. 114-030 20 oz. can Display of 48 - 1 oz. bottles 1 quart bottle 1 Gallon bottle 010-001 010-009 010-019 Case order quantity: 12 on quarts, 4 on gallons PAINT STRAINERS Prefilter your paint using strainer bags. One dozen per pack.
