AIRLESS PAINT SPRAYER SERVICE/OPERATION MANUAL AIRLESSCO SL6500 001-818 APR08 1
TABLE OF CONTENTS Product Diagrams & Parts Lists Introduction Description & Specifications................................. 1 Fluid Pump ...................…................................... Safety Warnings .................................................. 2 Paint System ................................………........... Manifold Filter Assembly .......……...…............... Prime Valve ........................................................ Getting Started Setting Up.........................................
INTRODUCTION The SL6500 sprayer is the choice of the high volume contractors that need a machine that can pump extremely heavy materials like wallboard mud and waterproofing coatings. It's most popular application is spraying a skim coat of wallboard mud to give a Level 5 finish using the supplied size 627 REV-TIP. Utilizing the proven SL pump platform in conjuction with an oversized bottom mounted foot valve, it delivers unprecedented suction. The SL6500 is powered by a Honda commercial gas engine.
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 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.
WARNINGS - Continued KEEP CLEAR OF MOVING PARTS TOXIC FLUID HAZARD 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. Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are using.
WARNINGS - Continued AVOID COMPONENT RUPTURE PREVENT STATIC SPARKED FIRE/ EXPLOSIONS 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. ALWAYS be sure all equipment and objects being sprayed are properly grounded. Always ground sprayer, paint bucket and object being sprayed.
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. NOTE: The first 50' of hose should always be 3/8". 2. Fill the Packing Nut/Wet Cup Fill the Packing Nut/Wet Cup 1/3 full with Airlessco Throat Seal Oil (TSO). Fig 1 below.
FLUSHING - Read Prior to Using Your Sprayer 1. New sprayer Your unit was factory tested in an anti-freeze 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.
HOW TO FLUSH FIG. 2 FIG. 4 REMOVE SPRAY TIP Choke Lever FIG. 3 PRESSURE CONTROL KNOB PRIME VALVE Open (Priming & Pressure Relief) Closed (Pressure) High Pressure Low Pressure 1. Be sure the gun safety latch is engaged and there is no spray tip in the gun. Refer to Fig. 2. Refer to your separate instruction manual provided with your gun on its safety features and how to engage safety latch. 2. Pour enough clean, compatible solvent into a large, empty metal pail to fill the pump and hoses. 3.
STARTING UP 1. Learn the controls Pressure Control Knob - used to adjust pressure only. Turn clockwise to increase pressure and counterclockwise to decrease pressure. (See Fig. 6) Prime & Pressure Relief Valve - Turn to OPEN position (see Fig. 7) to prime the pump. Turn to the CLOSED position to spray. FOLLOW "PRESSURE RELIEF PROCEDURES" ON PAGE 6 WHENEVER YOU: - are instructed to relieve pressure - stop spraying - checking or servicing any of the system equipment. - or installing or cleaning the spray tip.
STARTING UP - continued 4. Prime the Pump a. Allow pump to operate until paint comes from gun. b. Release the trigger and engage the gun safety latch. c. Turn Prime Valve OPEN to the prime position ensuring the pressure is released from the system. d. Turn Pressure Control Knob to minimum pressure. e. Install spray tip onto gun. f. Close the prime valve to the pressure position. g. Turn the pressure control knob to desired spray pressure. h.
Pressure Relief Procedure 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 or changing the tips, 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.
AIRLESS SPRAY GUN OPERATION FIG. 8 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) * The gun safety latch should always be set when the gun is not being triggered. MAJOR COMPONENTS OF SPRAY GUN FIG. 9 AND REVERSIBLE SPRAY TIP ™ FIG. 10 Reversible Spray Tip Gun Safety Latch or lock Handle Trigger SPRAY TIP ASSEMBLY 1.
AIRLESS SPRAY 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 Use smaller spray angle tip.
REV-TIP™ SIZE SELECTION CHART Spray tip selection is based on paint viscosity, paint type, your pumps output capabilities, and job needs. Going to larger spray tip sizes is dependent on how many gallons of paint per minute can be sprayed by your pump Do not use a tip larger than the maximum pump flow rate or capacity the sprayer can accommodate. Pump flow rate is measured in gallons per min. (GPM), or where appropriate, liters per min. (LPM).
REGULAR MAINTENANCE 1. Always stop the pump at the bottom of its stroke when you take a break or at the end of the day. This helps keep material from drying on the rod, damaging the packings. 2. Keep the displacement pump packing nut/wet cup 1/3 full of Airlessco Throat Seal Oil at all times. The TSO helps protect the packings and rod. 3. Lubricate Connecting Rod Pin every 3 months. 4. Inspect the packing nut daily. Your paint pump has Airlessco's patented "Triple Life Packing System".
FIELD TROUBLESHOOTING PROBLEM CAUSE SOLUTION There is spitting from the gun. The fluid supply is low or empty. Refill the supply container. Air entrapped in the fluid pump or hose. Check for loose connections on the siphon assembly, tighten, then reprime pump. The packing nut/wet cup is loose. The upper packings are worn or damaged. Worn Piston Rod. Tighten just enough to stop leakage. Replace the packings. See pages 18-20. The engine operates, but the paint pump doesn't cycle.
SERVICING FLUID PUMP Note: Check everything in the Troubleshooting Chart before disassembling the sprayer. FLUID PUMP DISCONNECT Refer to Fig. 30 1. Flush out the material you are spraying, if possible. 2. Follow the Pressure Relief Procedure on Page 10. Stop the pump in the middle of down stroke. 3. Remove the suction assembly, fluid hose and gun hose from the fluid pump. 4. Remove 2 retaining rings and slip the coupling assembly cover down and remove both coupling halfs.
SERVICING INLET & OUTLET VALVES SERVICING INLET VALVE Refer to Fig. 18 & 30 Part No. Table for Figures 18 thru 21 is located on page 20. 1. Using a lightweight hammer, loosen then screw the suction nut (187084) off of the cylinder (187-095). See Fig. 21 2. Remove the inlet seat (187-036), O-ring (106-008), inlet ball (187-092) and inlet retainer (187-075) with O-ring (106-013). See Fig. 18 3. Clean all parts and inspect them for wear or damage, replacing parts as needed.
V-PACKING REPLACEMENT FIG. 20 V-PACKING REPLACEMENT KIT (301-443) Part No. Table for Figures 18 thru 21 is located on page 20. Refer to Figures 20 & 21 Repack Kit contains all leather & plastic V-packings, O-Rings, balls and dual side adapter. 1 GLAND KIT (187-064) 2 3 4 5 Refer to Figures 20 & 21 Gland Kit contains four metal male glands. MAJOR REPAIR KIT (301-444) Refer to Figures 20 & 21 Major Repair Kit contains all components of the Repack Kit (301-443) plus the bare piston (187-330).
V-PACKING REPLACEMENT (Continued) V-PACKING REPLACEMENT (Continued) 4. Disassemble and discard old packings. Clean all parts that will be reused for reassembly. If the piston (187-330) is worn and needs to be replaced, hold it using the special block and pin in a vice. Then unscrew the piston extension using a wrench on the flats. NOTE: The piston extension is a non-wear part and should be reused. NOTE: Save all four metal glands for reuse and reassembly. 5.
V-PACKING REPLACEMENT (Continued) FIG. 21 1 2 2 16 3 4 25 23 26 27 17 5 28 6 7 8 9 10 11 12 13 14 15 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 29 24 19 30 20 21 31 22 PARTS LIST FIGURES 18-21 PART NO. DESCRIPTION ITEM NO. PART NO.
PAINT SYSTEM ASSEMBLY FIG. 22 9 10 11 12 13 8 14 7 6 9 5 5 16 15 4 3 1 17 2 PARTS LIST FIGURE 22 ITEM NO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 ProLight Gun (Optional) Hose 50' x 1/4" (Optional) Nipple 3/8"M x 1/4"M Hose 50' x 3/8" Nipple 3/8"M Plug 1/4" Manifold Filter Assembly Hose 3/8" Elbow 3/8"M 120-504 100-011 100-109 100-023 169-010 100-028 111-200-99 301-309 167-016 ITEM NO. PART NO.
MANIFOLD FILTER - PN 111-200-99 FIG. 23 1 2 3 4 5 10 6 7 9 8 ITEM NO. 1 2 3 4 5 6 7 8 9 10 22 PARTS LIST FIGURE 24 PART NO.
PRIME VALVE FIG. 24 1 2 3 4 5 6 7 14 8 9 10 11 12 13 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PARTS LIST FIGURE 24 PART NO.
REPLACEMENT OF ELECTRICAL CONTROL BOARD 1. Remove electrical cover. 2. Disconnect sensor lead from Electrical Board. 3. Disconnect two clutch leads on Electrical Board from leads on clutch. 4. Using a 1/16" allen, loosen set screw in Pressure Control Knob and remove knob. 5. Using a 1/2" nutdriver or 1/2" deep socket, remove nut from pressure control shaft. This will allow removal of electrical control board from frame. 6. Replace Electrical Board Assembly in reverse order.
CLUTCH REPLACEMENT REMOVING CLUTCH Refer to Figures 25-31 1. Remove the gear box cover (Fig 30, item 1) by disconnecting the fluid hose to the manifold filter and by unscrewing the four allen head bolts (Fig 30, item 35). 2. Disconnect the fluid pump as described on page 16. 3. Pull off the spacer tubes (Fig 30, item 29) and drop the sleeve bearing down and off. Slide the connecting rod off the gear box. 4. Remove the top cover (Fig 30, item 2) by unscrewing the 6 mounting screws.
CLUTCH REPLACEMENT (Continued) 12. Slide cog belt over engine pulley. BELT TENSIONING 13. Slightly loosen the two horizontal screws (Fig 30, items 19-22) that connect the top and bottom supports (Fig 30, items 24 & 25). 14. Evenly tighten set screws (Fig 26, item 6) until flush with tip of block tensioner (Fig 26, item 7) . Check tension on cog belt by pressing hard with thumb. Proper tensioning should allow for approximately 1/8". If belt is too loose, tighten set screws further. 15.
CLUTCH ASSEMBLY FIG. 27 10 9 8 3 1 2 7 Gearbox 4 6 5 FIG. 28 PARTS LIST FIGURES 27 & 28 ITEM NO. PART NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 112-041 112-054 301-412 301-413 301-264 301-037 100-333 301-274 136-068 301-316 Screw-Differential Coupling Nut Assy Spacer Spacer-Removable Clutch-Replacement Bearing (2) Retaining Ring (2) Spacer (2) Spring Rubber Edge ENGINE ASSEMBLY FIG. 29 1 2 3 4 5 6 7 8 9 ITEM NO. PARTS LIST FIGURE 29 PART NO.
POWER UNIT ASSEMBLY FIG. 30 1 2 3 See Fig. 25 8 7 9 10 See Fig. 22 11 4 6 5 32 31 30 38 37 36 35 3 39 29 34 26 27 28 33 18 14 15 16,17 13 See Fig. 27 19,20 25 24 See Fig. 30 19,20,21,22 20,21,22,23 See Fig. 21 28 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 * PART NO. 301-320 301-531 301-135 301-337 301-047 301-333 301-208 305-045 305-064 305-012 301-160 305-046 136-091 305-067 100-345 305-047 140-044 301-231 111-044 188-160 PARTS LIST FIGURE 30 DESCRIPTION ITEM NO.
FRAME ASSEMBLY FIG. 31 1 2 3 ITEM NO. 4,5,6 1 2 3 4 5 6 7 8 9 7 8,9 PARTS LIST FIGURE 31 PART NO. DESCRIPTION 301-201 301-202 301-165 136-126 140-029 100-317 331-048 113-030 143-029 Frame Bracket-Motor Wheel (2) Screw (4) Washer (12) Nut (4) Rubber Boot (2) Spacer (2) Set Collar (2) SUCTION ASSEMBLIES (Optional) FIG. 32 1 ITEM NO. PARTS LIST FIGURE 32 PART NO. DESCRIPTION 1 * * 141-008 119-108 119-087 Inlet Filter Suction Assy- 5 Gallons Suction Assy- 55 Gallons For Bypass Assembly See Fig.
AIRLESS ATOMIZER KIT (120-117) Operator must thorougly clean the atomizer and component parts after each use.
