Wagner SprayTech 3500 User's Manual
Contents
1. VA SERVICE OPERATI MANUAL Form No 001 683 FEB2305 Table of Contents INTRODUCTION Spray amp Stripe Specifications Safety Warnings 2 GETTING STARTED Hovv to Flush 7 Flushing 8 Setting Up 9 Pressure Relief Procedure 10 Daily Maintenance 10 Starting Up 11 Striping Operation 12 Striping Tip Guide 13 REPAIRS MAINTENANCE INSTRUCTIONS Spray Gun Operation 14 Spray Gun Troubleshooting 15 Field Troubleshooting 16 Servicing the Fluid Pump 17 Servicing the Piston Rod 18 Servicing the Suction Assembly 18 Packing Replacement 19 Inspection amp Replacement of Control Valve Ball amp Seat 21 PRODUCT DIAGRAMS amp PARTS LISTS Gearbox Assembly 22 Gun Assembly 23 Gun Mount Assembly 23 Bypass Valve Assembly 24 Suction Assembly 25 Frame Assembly 26 Manufactured by AIRLESSCO BY DUROTECH CO P O Box 8006 Moorpark CA 93020 8006 Ship to 5397 Commerce Ave Moorpark CA 93021 Tel 805 523 0211 Fax 805 523 1063 www airlessco com email techsupport airlessco com SUBJECT TO CHANGE WITHOUT NOTICE Copyright 2005 All rights reserved Introduction INTRODUCTION a Model 3000 Specifications The heart of the Spray amp Stripe series Part 305 229 is the time tested and contractor proven Max Pressure 0 2500 PSI 170 Bar Airlessco LP piston paint pump Designed Max Output 62 GPM 2 35 Litres min for spraying 1700 gallons per year this Max Tip 1 gun 0 027 inch 12. x 50 Hose ie 116 103 Cable Retainer Spring f Pall oo 120 115 008 Silver Gun vvlo Tip 56331757 Hi WU seagizst i LY E i l F ki caii arte NM H03 f Part Number Nua 100 342 321 x 1 25 LG Screw i 116 100 Compression Spring 119 049 HexScrew 25 20UNC 2A x 1 88 LG IN 205 085 fo Sem 331 103 Flat Washer 1 4 23 Bypass Valve Assembly Part No 305 264 Un 115 031 se 977 115017 LI A4 115 016 7 f 305 194 ro eucKker 115 016 Control Valve Seat Ass y 1 15 017 Bal 1 115 024 Unloader Vave 1 E O1 a 305 194 PR Regulator Housing 1 1 1 1 1 1 1 1 24 Suction Assembly Part No 331 290 F _ 391 228 106 020 331 035 ta A 141 015 tao C _ 331 217 341 034 Part Number 106 020 Teflon O Ring 141 015 Hose Clamp some models only 331 034 Suction Nut 331 035 Suction Elbow 331 217 Suction Filter 25 Frame Assembly Part No 305 213 TOP VIEW BACK VIEW 301 533 Paint Bucket Lid SIDE VIEW UNDERNEATH VIEW nates NT H VEHI EH Part Number Part Number 100 317 J Nut 5 16 18 Centerlock 301 165 100 320 Wing Screw 3 8 301 170 Axel 22 5 8 113 031 Spacer 5 8 x 1 00 305 051M 119 026 Screw Hex Hd 305 105 136 131 Chain Sash 136 133 Key Ring 305 108 Clamp Plate 100 370 Screw Hex Cap 301 547 Screw HXHD
3. 5 Remove the retaining ring 331 062 from the 331 065 through the connecting rod amp piston Slip connecting rod 331 038 and slide the sleeve 331 the sleeve up over the connecting rod pin and insert 117 down revealing the connecting rod pin 331 065 the retaining ring into the groove on the connecting rod 6 Remove the suction tube assembly from the fluid 3 Push the two bolts 100 318 through the tube spacers pump 331 209 by Pere ne the suction nut 331 074 amp screw them into the cover assembly 331 331 034 with the packing adjustment tool 234 Using a 1 2 wrench tighten the two bolts evenly 7 Using a 1 2 wrench unscrew the two bolts 100 318 alternating between them until you reach 20 ft lbs from the cover assembly 331 234 The fluid pump 331 209 will be hanging loosely at this point 4 Reassemble lower suction valve assembly by placing l l the suction seat 331 409 O ring 106 011 suction 8 Remove the connecting rod pin 331 065 out of ball 331 030 amp suction ball guide 331 029 in the the connecting rod 331 038 allowing the removal suction nut 331 034 amp screw onto fluid pump body of the fluid pump 331 209 from the machine 5 Start the machine and operate slowly to check the piston rod for binding Adjust the two bolts holding the fluid pump body to the cover assembly if necessary This will eliminate any binding Cover Assembly FIGURE 1 33124 6 Tighten th
4. 2000psi 138 bar Ipm Paint Flow Rate gpm latex paint 2000psi 138 bar 1 36 spec gr lpm Pump Minimum gpm Output lpm Pump will support tip worn to next larger size REV TIP for Striping REV GUARD P N 562 xxxST Super Compact Includes Rev Tip Metal Seal P N 561 001 amp O Ring Seal 11 16 16 F Thread Fits Airlessco and some ASM Wagner and Campbell Hausfeld Sample 1 2 Fan Width P N 561 002 560 215 7 8 14 G Thread REV TIP Orifice Size Fits some Graco Wagner Titan Airlessco Striping Tips should not be used for regular spraying Striping tips are designed for a single pass application while spray tips are designed for the 1 3 overlap technique used for spray painting Spray Tip Replacement During use high pressure will cause the orifice to grow larger This destroys the flat spray pattern or will leave tailing or two heavy lines on the outside of the pattern When this ocurs replace the spray tip or excessive paint will be wasted REGULAR PAINTING SPRAY TIP STRIPING TIP LIGHT HEAVY LIGHT UNIFORM PATTERN 13 Spray Gun Operation 14 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 t
5. 3 Remove the connecting rod shield 331 111 the following order with the inverted side down mw l l Polyethylene leather polyethylene leather polyethylene 4 Move the piston rod 331 093 to its lowest position by 3 Take the female adaptor 331 305 which is inverted on both cycling pump slowly l pA sides i amp place it on top of your assembled lower packings 5 Remove the retaining ring 331 062 from the connecting l o rod 331 038 and slide the sleeve 331 117 down 4 Follow step 2 above with your packings inverted side up Sissi revealing the connecting rod pin 331 065 5 Take the second lower male gland and place it on top of your 6 Remove the suction tube assembly from the fluid pump assembled packings with the rounded side down 331 209 by unscrewing the suction nut 331 034 with the 6 Take assembled glands amp packings 13 pieces amp slide on to the packing adjustment tool lower half of the piston 7 Using a 1 2 wrench unscrew the two bolts 100 318 from 7 Take the spacer 331 018 amp slide over the top of the piston it the cover assembly 331 234 The fluid pump 331 209 doesn t matter which direction it sits falling onto lower packings will be hanging loosely at this point 8 Take three Belleville Springs 331 025 amp slide over the top of 8 Remove the connecting rod pin 331 065 out of the the piston in the following order connecting rod 331 038 allowing the rem
6. grounding is obtained through connection to a properly grounded fluid hose and pump e Object being sprayed according to your local code e All solvent pails used when flushing should only be metal pails which are conductive Once each week check electrical resistance of hose when using multiple hose assemblies check overall resistance of un pressurized hose must not exceed 29 megohms max for any coupled length or combination of hose lengths If hose exceeds these limits replace it immediately Never exceed 300 Ft 150 m overall combined hose length to assure electrical continuity AVOID COMPONENT RUPTURE This sprayer operates at 2500 psi 170 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 e NEVER leave a pressurized sprayer unattended to avoid accidental operation of it which could result in serious bodily injury e ALWAYS follow the PRESSURE RELIEF PROCEDURE whenever you stop spraying and before adjusting removing or repairing any part of the sprayer e NEVER alter or modify any part of the equipment to avoid possible component rupture which could result in serious bodily injury and property damage e NEVER use weak damaged or non conductive paint hoses Do not allow kinking or crushing of hoses or allow it to vibrate against rough sharp or hot surfaces Befor
7. 117 amp the retaining ring 331 062 over the piston rod Loctite No 242 blue on the threads amp torque to 20 ft lbs 2 Push piston rod up into the connecting rod 331 038 amp align the holes Insert the connecting rod pin 331 065 through the connecting rod amp piston Slip the sleeve up over the connecting rod pin amp insert retaining ring into the groove on the connecting rod ball outlet seat and O ring 19 Packing Replacement Procedures FIGURE 5 3 76 20 Push the two bolts 100 318 through the tube spacers 331 074 amp 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 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 amp screw onto the fluid pump body Start the machine amp operate slowly to check the piston rod for binding Adjust the bolts holding the fluid pump body to the cover assembly if necessary This will eliminate any binding Tighten packing nut clockwise until resistance is felt against the Belleville Springs then go 3 4 of a turn more Put five drops of Airlessco Throat Seal Oil into the packing nut Run the machine at full pressure for several minutes Release the pressure by following the Pressure Relief Procedure amp readjust the packing nut p
8. 305 262 Bucket Base 113 032 Axel 13 305 058 Rubber Grip 140 029 Washer Flat 5 16 305 270 Striper Frame 143 028 Washer Flat 5 8 2 305 271 Spacer 5 8 x 3 00 143 029 Set Collar i Fiat 305 286 Cable Guide Plate 26 SEAL LOCATING HANDLE Tip handle simplifies installing amp aligning the seal EASIEST ASSEMBLY Fewer parts Less complicated takes only seconds INTERCHANGEABLE Can be used with most tip guards HIGHEST QUALITY CARBIDE Micro ground for extra long life consistent tip size amp pattern SIRINGER HOLE LU Each tip individually tested PRODUCT FEATURE Reps ku P R Aerodynamic Non Drip Guard Finger Tight Nut Seal Orientation Slot Tip Handle Hole for Stringer No Seal Blow By When Tip is Not in Centered Position 1 Seal Orientation Tool on Tip Handle Tips Fit Graco Bases Seal Installer on Tip 7 8 amp 11 16 Gun Thread Working Pressure Rating a I pe e E ga EH 1 Uncontrolled Spray Back Tovvard User 3 No Spitting 2 No Pattern Distortion From Pin Copyright 2004 Airlessco by Durotech Co All rights reserved Product specifications subject to change witout notice ht nut no tools m More compact size to use in tight areas Order 561 002 REV GUARD with with 7 8 14 G Thread 561 001 REV GUARD with 11 16 16 F Thread Simple to Use Fast to Finish Connect adapter to any F or G thread airl
9. plug e Disconnect battery at negative terminal only engines with electric start WHEN TESTING FOR SPARK e Use approved spark plug tester e Do not check for spark with spark plug removal FIGURE 1 FIGURE 3 Honda Engine LOCK TRIGGER TO REMOVE SPRAY TIP FIGURE 2 CONTROL VALVE Fuel Valve Throttle Lever FIGURE 4 Maintain firm metal to metal contact between gun and container Tje Hinke k Prai Lala SM i Fl I ai WARNING iks e eee Shi oe bi oi betoi e A i T i To reduce the risk of static sparking which can cause fire or explosion always hold a metal part of the gun firmly against the metal pail when flushing This also reduces splashing Refer to Fig 4 t IE TH nE Ci 1 Be sure the gun safety latch is engaged and there is no spray tip in the gun Refer to Fig 1 Refer to your separate instruction manual provided vvith your gun on its safety features and how to engage safety latch 11 Disengage the gun safety latch and squeeze the gun trigger Turn the control valve clockwise just enough to move liquid at low pressure 2 Pour enough clean compatible solvent or water when using water base paint into a large empty metal pail to fill the pump and hoses 12 Allow the pump to operate until clean solvent comes 3 Place the suction tube into the pail from the gun 4 Turn the control valve to the prime position or fully 13 Release the trigger and engage
10. stain or paint without needing to dilute the material FOLLOW PRESSURE RELIEF PROCEDURES ON PAGE 10 WHENEVER YOU are instructed to relieve pressure stop spraying checking or servicing any of the system equipment install or clean the spray tip WARNING To stop the unit in an emergency or before performing any service or maintenance procedure follow the Pressure Relief Procedure on page 10 to relieve the fluid pressure HANDLE THE SPRAY SYSTEM AS YOU WOULD A LOADED FIREARM 2 Prepare the Material a Prepare the material according to the manufacturer s material recommendations b Place the suction tube into the material container 3 Starting the Sprayer see Figure above a Pressure Control Knob must be in the low pressure position b Control Valve must be open to the priming position or fully counterclockwise c Follow the procedure under How to Flush Steps 6 through 12 d Install spray tip onto gun e If so equipped turn engine switch to ON position then pull starter rope vigorously until engine starts Turn Control Valve clockwise to the desired spray pressure required to properly atomize your material Sprayer is limited to a maximum of 2500 psi Disengage the gun safety lock and you are ready to start spraying 5 Adjusting the Pressure a Turn the Control Valve clockwise to increase pressure and counterclockwise to decrease pre
11. thin Pressure too high Tip size too small Material too thick Worn tip Wrong tip Material too viscous Application too heavy Material too viscous Orifice clogged Tip damaged Solvent balance Contamination or dust Extraneous material in paint Coarse pigments Poorly milled pigments paint pigments glocculate cover screen Incompatible paint mixture amp thinners CORRECTION Increase the pressure Reduce pressure for satisfactory pattern Use less thinner Use smaller spray angle tip Use larger spray angle tip If coverage is OK try tip in same nozzle group Use next smaller tip Reduce pressure Use next larger tip Change for new tip Use tip with a smaller spray angle Thin material Reduce pressure and or use smaller tip Thin material Clean carefully Replace with new tip Use 1 3 short solvents remainder long solvents This is most likely to happen with material of low viscosity lacquers etc Clean surface to be sprayed Clean screen Use coarse screen 1f orifice size allows Use coarser screen larger orifice tips Obain ball milled paint If thinner was added test to see if a drop on top of paint mixes or flattens out on on the surface If not try different thinner in fresh batch of paint Spotty Pattern Increase Pressure 15 Field Troubleshooting PROBLEM Unit doesn t prime Unit primes but has no or poor pressure Unit does not maintain good spr
12. with multipurpose grease 10 Screw control seat into valve body and torque to 85 ft lbs 11 Place TC guide into control seat with notched side up 12 Drop control ball into TC guide 13 Screw control valve with ring seal into pump head Torque to 15 ft lbs 14 If anew control valve ball or seat is installed complete the Pressure Calibration Procedure A repair kit with the control ball and seat is available as KIT 3 3100 Pressure Control Calibration DO NOT USE THIS PROCEDURE WITHOUT A TEST GAUGE Install a gun flexible airless hose and Airlessco part 111 045 glycerin filled test gauge onto unit Prime unit Turn the control valve knob fully clockwise maximum pressure setting Read the gauge it should be approximently 2500 PSI nak Q N If maximum pressure is incorrect remove the black plastic cap from the control valve knob Insert a 3 16 allen wrench into the control valve knob set screw turn clockwise to increase pressure and counter clockwise to decrease pressure Replace black plastic cap 6 NEVER set the maximum pressure above 2500 PSI 21 Gear Box Assembly Part No 305 196 50 0 wai et tia a n m LT fa iri ka a aa KIT E i i do a i Ps ja pa 1 u g 2 RSS LI om si ea Kr 1 358 Wa ana J EF 2 IEHL NotShown aa 331 038 Crosshead Ass y 22 Spray Gun Assembly Part No 305 280 TI Part Number pan TI 100 011 Airless 1 4
13. arking fire or explosion which can result in serious bodily b Connect an airless spray gun to the other end of the hose injury and property damage always ground the sprayer and system components and the object being sprayed as instructed in the safety warning section of this manual 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 A small steel chain grounding strap 1s installed at Use thread seal on tapered male threads only the factory to prevent static build up 2 Remove the snap on cover plate over the piston 4 Flush the sprayer As per Flushing Procedure in this manual 3 Fill the packing nut wet cup with 5 drops of Airlessco Throat Seal Oil TSO and then reinstall snap on piston cover plate_ Failure to lubricate the piston properly with throat seal oil can cause premature wear and damage to piston and packings 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 instruction N Sot en GUN y manual provided with your gun on its POSITION safety features and how to engage safety latch 2 Turn eng
14. ay 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 10 and understand all warnings on pages 2 thru 6 All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY NO MODIFICATIONS or alterations of any Airlessco Equipment or part is allowed Safety VVarnings TOXIC FLUID HAZARD 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 Store amp dispose of hazardous fluids according to manufacturer local state amp national guidelines ALWAYS wear protective eye wear gloves clothing and respirator as recommended by fluid manufacturer ALWAYS INSPECT SPRAYING AREA e ALWAYS keep spraying area free from obstructions e ALWAYS make sure area has good ventilation to safely remove vapors and mists e NEVER keep flammable material in spraying area e NEVER spray in vicinity of open flame or other sources of ignition SPRAY GUN SAFETY e ALWAYS set safety lock on the gun in LOCKED position when not in use and before servicing or cleaning e NEVER remove or modify any part of the gun e ALWAYS REMOVE SPRAY TIP when cleaning Flush unit with LOWEST POSSIBLE PRESSURE e ALWAYS check operation of all gun safety device
15. aying pressure 16 CAUSE Airleak due to e Loose Suction Nut e Worn O Rings e Hole in Suction Hose Stuck or Fouled Balls Pressure set too low Filter s are clogged Outlet Valve fouled worn Prime Pressure Relief valve bypassing Packings and or piston worn Blown spray tip Packings and or piston worn Upper Seat worn SOLUTION e Tighten Suction Nut e Replace O Ring 106 011 on suction seat amp O Ring 106 020 below suction seat e Replace Suction Hose 331 290 Service outlet valve suction assembly Turn up pressure Clean or replace gun filter inlet filter and or manifold filter Service outlet valve Clean or replace primve valve e Tighten packing nut e Repack unit Replace spray tip Repack unit Replace upper seat Servicing the Fluid Pump Fluid Pump Disconnect Fluid Pump Reinstall Refer to Figure 1 amp 4 1 Loosen the packing nut and ensure that the piston rod 331 093 is in its upper position in the fluid pump body Refer to Figure 1 1 Follow the Pressure Relief Procedure on page 10 2 Flush the material you are spraying out of the machine 331 011 Slip the sleeve 331 117 amp the retaining 3 Remove the connecting rod shield 331 111 ring 331 062 over the piston rod 4 Move the piston rod 331 093 to its lowest position 2 Push the piston rod up into the connecting rod 331 by cycling pump slowly 038 amp align the holes Insert the connecting rod pin
16. d to service GUN SAFETY LATCH GUN IN LOCKED SAFETY POSITION x a LATCH RELEASED REWTIP TO REMOVE CLOGS FROM SPRAY TIP 1 Lock gun safety latch 2 Turn REV TIP handle 180 degrees 3 Disengage trigger lock and trigger gun into the pail 4 Ifthe REV TIP handle appears locked resists turning loosen the retaining nut The handle will now turn easily 5 Engage gun safety latch and return handle to the spray position Retaining Nut N Reverse to Unplug Spray Position Shown CLOGGED FLAT TIP Should the spray tip become clogged relieve pressure from hose by following the Pressure Re lief Procedure Secure gun with the safety latch take off guard take out the tip soak in appropriate solvent amp clean with a brush Do not use a needle or sharp pointed instrument to clean the tip The tungsten carbide is brittle and can chip Spray Gun Troubleshooting DEFECTS Coarse spray Excessive fogging overspray Pattern too wide Pattern too narrow Too much material Too little material Thin distribution in center of pattern horns Thick skin on work Coating fails to close amp smooth over Spray pattern irregular deflected Craters or pock marks Bubbles on work Clogged screens TEST THE PATTERN Good full CAUSE Low pressure High pressure Material too thin Spray angle too large Spray angle too small Tip size too large Material too
17. e each use check hoses for damage and wear and ensure all fluid connections are secure e REPLACE any damaged hose NEVER use tape or any device to mend the hose e NEVER attempt to stop any leakage in the line or fittings with your hand or any part of the body Turn off the unit and release pressure by following PRESSURE RELIEF PROCEDURE on page 10 e ALWAYS use approved high pressure fittings and replacement parts e ALWAYS ensure fire extinquishing equipment is readily available and properly maintained WARNING Do not use halogenated solvents in this system The prime valve 2 gun manifold 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 Some of the most common of these solvents are Carbontetrachloride Chlorobenzene Dichloroethane Dichloroethyl Ether Ethylbromide Ethylchloride Tethrachloethane Alternate valves and guns are available if you need to use these solvents Safety VVarnings FLUSHING Reduce risk of injection injury static sparking or splashing by follovving the specific cleaning procedure on page 7 e ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 10 e ALWAYS remove the spray tip before flushing Hold a metal part of the gun firmly to the side of a metal pail and use the lowest possible fluid pressure during flushing e NEVER
18. e packing nut clockwise until resistance is felt against the Belleville Springs then go 3 4 of a turn om more Put five drops of Airlessco Throat Seal Oil into the m r r Rod packing nut 7 i Connecting Rod Pin Tinie HE n 331 055 7 Run the machine at full pressure for several minutes Rodin t i Release the pressure by following the Pressure Relief 381 111 Seya Procedure amp readjust the packing nut per step 6 above a it 481 117 TNTE 8 Install the connecting rod shield 331 111 so that the e Th small hole is in the upper right hand corner Pision Rod Retaining Ring 331 093 E 331 052 Fluid Pump TT Shhil Connecti 331 209 100 005 Sch n Nil 181 134 Botts 100 318 17 Servicing the Piston Rod Outlet Valve DISASSEMBLY OF THE OUTLET VALVE REFER TO FIGURE 3 1 Disconnect the Fluid Pump follovving instructions on page 17 2 Place piston holder 331 195 in a vise Slide piston into the holder amp lock in place with a 3 8 dowel 331 196 3 Use a 1 4 allen wrench to unscrew the outlet seat retainer 331 026 from the piston 4 Remove the outlet seat 331 026 O ring 331 100 and outlet ball 331 027 5 Inspect outlet ball amp seat for wear Replace as necessary 6 While piston is still locked in the holder install parts back into the piston in the following order ball outlet seat and O ring Before reinstalling the outlet seat support apply two drops of Loctite No 242 blue on the th
19. e unit clean and readable Replacement labels are available from the manufacturer Safety VVarnings HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY OBSERVE ALL VVARNINGS 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 hands or fingers over the spray tip Do not use a rag or any other material over your fingers Paint will penetrate through material and into the hand NEVER try to stop or deflect leaks with your hand or body e NEVER try to blow back paint this is not an air spray sprayer e ALWAYS have gun tip guard in place when spraying e ALWAYS lock gun trigger when you stop spraying e ALWAYS remove tip from the gun to clean it ALWAYS follow the PRESSURE RELIEF PROCEDURE as shown on page 10 before cleaning or removing the spray tip or servicing any system equipment e ALWAYS Be sure equipment safety devices are operating properly before each use e ALWAYS tighten all fluid connections before each use MEDICAL TREATMENT If any fluid appears to penetrate your skin get EMERGENCY CARE AT ONCE DO NOT TREAT AS A SIMPLE CUT Go to an emergency room immediately Tell the doctor you suspect an injection injury Tell him what kind of material you were spraying with and have him read NOTE TO PHYSICIAN MEDICAL ALERT Airle
20. er step 6 above Install the connecting rod safety shield Fig 1 Part 331 111 so that the small hole is in the upper right hand corner FIGURE 6 Pacung Holder 331 019 Female Gland g 331021 31 023 Black 106 070 White O ring 106 009 Packing Leathar 391 307 Male Gland ala 7 ae a3 1 016 Female Adaptor qa 1 308 Fading e Leathe 331 306 Mala Gland 241 014 d1 025 shoh Pision 21 08 tani Packing t307 Padung E ade Gland Inspection amp Replacement of Control Valve Ball amp Seat 1 Use a wrench to unscrew the control valve with ring seal 2 Make sure that the control valve knob turns freely and that its stem is not worn unevenly mushroomed or otherwise damaged Remove TC guide verify that it is unbroken clean and notch side is up Remove control ball Inspect for any cuts scratches chips rust or other damage Use a 7 16 allen wrench to unscrew the control seat from the valve body Clean seat and inspect bevel edge for damage Also ensure that the gasket on the underside of the seat is intact 6 Ifno obvious damage to the control ball and seat place ball into seat and fill with water If water leaks out between ball and seat they must be replaced 7 Replace control valve ball seat and or TC guide as necessary 8 Clean and inspect valve body opening where the control seat was installed 9 Grease valve body opening
21. ess spray gun amp to a garden hose Lock trigger epe turn on water flow to VatnrIusSIT Pd int int 0 UIE original Spray Gun amp Hose Spray Packs Part No 002 013 Spray Pack includes 120 504 ProLight Convertible 4 2 Finger Gun 100 011 50 x 114 Hi Flex Airless Hose Part No 002 025 Spray Pack includes 120 502 ProLight 502 Flat Handle Gun 100 011 50 x 1 4 HI Flex Airless Hose Part No 002 015 Spray Pack includes 120 554 008 Silver 4 Finger Gun 100 011 50 x 1 4 Hi Flex Airless Hose See Airlessco REV TIP Brochure Form 001 449 for current listings of available tip sizes including W wide and FINE FINISH tips for Spraying amp Striping tips Should be used on piston pumps drying on the piston amp causing packing wear 010 001 Display of 48 1 oz bottles 010 009 1 quart bottle 010 019 1 Gallon bottle PAINT STRAINERS Prefilter your paint using strainer ps One dozen per pack 100 064 Used to cover suction filter 100 065 5 Gallon strainer HOSE COVER 4 mil clear poly protects your airless hose from paint and abrasion damage Comes in 1000 roll with perforations each 50 100 219 Hose Cover Roll 100 426 Case of 6 Rolls Strong yet flexible suitable for airless equipment up to 3300 PSI Part No 100 012 3 16 Whip Hose 4 Ft 100 011 1 4 Hose 50 Ft 100 023 3 8 Hose 50 Ft 100 037 1 2 Hose 50 Ft 100 010 1 4 Hose Connector 100 009 3 8 Ho
22. he spray gun and in product manual MAJOR COMPONENTS OF SPRAY GUN amp REVERSIBLE REV TIP Reversible Spray Tip Tip Guard Gun Safety Latch or Lock Trigger Guard filter inside Press up here amp pull gently to remove trigger guard SPRAY TIP ASSEMBLY 1 Be sure the pressure relief procedure is followed before assembling tip and housing to the gun 2 Insert REV TIP cylinder into the REV GUARD guard housing assembly 3 Guide the metal seat into REV GUARD guard housing assembly through the retaining nut and turn until it seats against the cylinder 4 Insert the O Ring gasket onto the metal seat so that it fits into the grooves 5 Finger tighten REV GUARD retaining nut onto the gun 6 Turn guard in the desired position 7 Completely tighten the retaining nut ey WA Sh ie MA so S O Ring Gasket REV GUARD KA gi I TA pe NS Metal Seat j LANA 57 Guard Housing Assembly ZA d MA YA WA REV TIP Cylinder CLEANING SPRAY GUN Immediately after the work is finished flush the gun out with a solvent Brush pins with solvent and oil them lightly so they will not collect dried paint CLEANING FILTER IN GUN HANDLE To clean the filter use a brush dipped in an appropri ate solvent Change or clean filters at least once a day Some types of latex may require a filter change after four hours of operation Gun Handle Unscrew from gun hea
23. ine off using OFF switch on the engine 3 Disengage safety latch amp trigger gun to relieve residual fluid pressure Hold metal part of the gun in contact with grounded metal pail 4 Re engage gun safety latch 5 Turn Control Valve Prime Pressure Relief Valve as shown open priming to relieve fluid pressure Daily Maintenance 10 1 Keep the displacement pump packing nut wet cup lubricated with Airlessco TSO Throat Seal Oil at all times The TSO helps protect the rod and the packings Inspect the packing nut daily Your pump has a patented Triple Life Packing System Packing life will be extended a minimum of three times if the following Packing Adjustment procedure is followed If seepage of paint into the packing nut and or movement of the piston upward is found while not spraying the packing nut should be tightened enough to stop leakage only but not any tighter Overtightening will damage the packings and reduce the packing life Tighten suction nut daily 1 Learn how to operate the control valve The control valve sets the prime or pressure position as vvell as the spraying pressure When the valve is fully counter clockwise the unit is in the prime position As the control valve is turned clockvvise the unit s output pressure to the gun is gradually increased until the control valve is fully clockwise and the unit is at it s maximum output pressure of 2500 psi This will fully atomize any
24. n Nut F Thread 11 16 16
25. ng with flammable liquids unit must be located a minimum of 25 feet away from spraying area in a well ventilated area Ventilation must be sufficient enough to prevent the accumulation of vapors 2 To eliminate electrostatic discharge ground the spray unit paint bucket and spraying object Use only high pressure airless hoses approved for 3000 psi which is conductive 3 Remove spray tip before cleaning gun and hose Make contact of gun with bucket and spray without the tip in a well ventilated area into the grounded steel bucket 4 Never use high pressure in the cleaning process USE MINIMUM PRESSURE 5 Do not smoke in spraying cleaning area GAS ENGINE PRECAUTIONS WHEN ADDING FUEL Turn engine OFF and let engine cool at least 2 minutes before removing gas cap WARNING Gasoline amp its vapors are extremely flammable amp explosive Fire or explosion can cause severe burns or death WHEN STARTING ENGINE e Make sure spark plug muffler fuel cap and air cleaner Do not overfill fuel tank Fill tank to are in place approximately inches below top of neck to allow for fuel expansion Fill fuel tank outdoors or in well ventilated area e Do not crank engine with spark plug removed e If fuel spills wait until it evaporates before starting engine e If engine floods set choke to OPEN RUN position place throttle in FAST and crank until engine starts WHEN OPERATING EQUIPMENT e Do not tip engine or e
26. nutes packing kit prior to reassembly 14 Slide the packing holder over the top of the upper packings so they fit inside Disassembly of the Outlet Valve Figure 3 15 Lubricate inside of the fluid pump body amp the outside of the 1 Place piston holder 331 195 in a vise Slide piston into the packings with a light weight oil holder amp lock in place with a 3 8 dowel 16 Slide completed assembly into fluid pump body 331 011 2 Usea 1 4 allen wrench to unscrew the outlet seat retainer To keep packings secured in correct position hold the pump body 331 026 from the piston upside down amp push the completed assembly upwards into the pump 3 Remove the outlet seat 331 026 O ring 331 100 and body Once placed inside tilt pump body back up to keep all pieces in outlet ball 331 027 17 Tighten packing nut 331 037 onto the top of the fluid pump body amp tighten until you feel slight resistance against the 4 Inspect outlet ball amp seat for wear Replace as necessary Belleville Springs 331 025 Using the Packing Adjustment Tool 5 While piston is still locked in the holder install parts back into 189 211 tighten another 3 4 of a turn the piston in the following order Fluid Pump Reinstallation Figure 1 8 4 1 Loosen packing nut amp ensure that the piston rod 331 093 is in its upper position in the fluid pump body 331 011 Slip the Before reinstalling the outlet seat support apply two drops of sleeve 331
27. on the base of the gun trigger where the cable connects to the gun trigger assembly b Loose the locking nut amp move the adjusting screw until the slack has been removed from the cable c Tighten locking nut and retest gun triggers for proper function Note There is an additional cable adjustment where the cable attaches to the gun holder assembly Use only if the gun trigger adjustment is insufficient 5 Miscellaneous Operations CURBS To paint at a 90 degree angle to spray the sides of curbs install a part 032 028 swivel between gun head and tip guard and aim guard sideways towards the curb WIDE STRIPES Install wider fan striping tips and raise the gun height to achieve the desired width line STENCILS Install standard spray tip on the outer gun Rotate gun to remove from the gun holder and use the gun to spray within your stencils Use of an extension pole will make this job a lot easier on the operators back and is highly reccomended STANDARD PAINTING Install the appropriate size and type of paint spraying tip standard paint spray VV wide pattern or Fine Finish Remove gun and spray just as you do for stencils Additional paint hose may be required depending on the distance between the job and the equipment Striping Tip Guide Rev Tip for Striping STRIPING TIP ORIFICE SIZE nches os 015 017 019 02 i7sT 9st lerssr Water Flow Rate gpm water
28. ottle control trigger on the handlebars Pressure Relief Procedure warning on page 10 10 Point the gun into the metal pail and hold a metal part of the gun firmly against the pail Refer to fig 4 Read prior to using your sprayer 1 New Sprayer Your Airlessco unit was factory tested in an antifreeze solution which was left in the pump Before using oil base paint flush with mineral spirits only Before using water base paint flush with soapy water then do 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 Changing from Oil Base to Water Base Paint Flush with mineral spirits followed by soapy water then do a clean water flush 5 Storage Oil base paint Flush with mineral spirits Water base paint Flush with water then mineral spirits and leave the pump hose and gun filled with mineral spirits For longer storage use mixture of mineral spirits and motor oil half amp half Shut off the sprayer follow Pressure Relief Procedure on page 10 Setting Up to Stripe or Spray 1 Connect the hose and gun a If the hose is not already installed on the striper remove the plastic cap plug from the outlet tee at the spray pump and screw a conductive or grounded 3000 psi airless spray hose onto fluid outlet 3 Grounding WARNIN G i To reduce the risk of static sp
29. oval of the fluid First spring curve facing down AA pump 331 209 from the machine Second spring curve facing up WA Third spring curve facing down ZN 9 Take the upper male gland 331 022 amp place it rounded side up 10 Take three upper polyethylene packings 331 023 amp two leather Disassembly of the Fluid Pump Figure 6 1 Unscrew amp remove the packing nut 331 037 2 Push the piston rod 331 708 down through the packings packings 331 307 amp assemble with inverted side down w amp out of the pump on to the male gland in the following order 3 Now push the packing removal tool 331 465 up through polyethylene leather polyethylene leather polyethylene the pump amp EEN from the top bringing packings spacer 11 Take upper female gland 331 021 amp place on top of the assembled amp springs along with it leaving fluid body 331 011 empty upper packings with the inverted side down PP Make sure all old packings amp glands have been removed from fluid pump 12 Take assembled upper glands amp packings 7 pieces amp slide on 4 Clean inside of fluid body 331 011 over the top of the piston making sure inverted sides are down 5 Disassemble all parts amp clean for reassembly Discard any 13 Take the packing holder 331 019 amp replace the white O ring old packings 106 009 amp the black O ring 106 010 with new ones from the 6 Lubricate leather packing in lightweight oil for 10 mi
30. quipment at angle which causes gasoline to spill Keep gasoline away from sparks open flames pilot lights heat and other ignition sources Check fuel lines tank cap and fittings frequently for cracks or leaks Replace if necessary Safety VVarnings VVHEN TRANSPORTING EQUIPMENT e Transport with fuel tank EMPTY or with fuel shut off valve OFF WHEN STORING GASOLINE OR EQUIPMENT WITH FUEL IN TANK e Store away from furnaces stoves water heaters and other appliances that have pilot lights or other ignition source They can ignite gasoline vapors WARNING Starting engine creates sparking Sparking can ignite nearby flammable gases Explosion and fire could result e If there is natural or LP gas leakage in area do not start engine e Do not use pressurized starting fluids because vapors are flammable WARNING Rapid retraction of starter cord kickback will pull hand and arm toward engine faster than you can let go Broken bones fractures bruises or sprains could result When starting engine pull cord slowly until resistance 1s felt then pull rapidly e Remove all external equipment engine loads before starting engine Direct coupled equipment components such as but not limited to blades impellors pulleys sprockets etc must be securely attached WARNING Rotating parts can contact or entangle hands feet hair clothing or accessories Traumatic amputation or severe lacera
31. reads amp torque to 20 ft lbs FIGURE 3 aaa 1 Piston 331 195 331 196 NOTE Airlessco LP pump tool kit 188 197 is suggested for this task Kit includes Packing Tightening Bar 189 211 Packing Removal Tool 331 153 Piston Holder 331 195 3 8 dowel 331 196 servicing the Suction Assembly 18 REFER TO FIGURE 4 1 Un thread and remove suction nut from the fluid pump body 2 Remove suction seat 331 409 O ring 106 011 suction ball 331 030 and suction retainer 331 029 3 Clean all parts and inspect them for wear or damage replacing parts as needed 4 Clean inside of the fluid pump body 5 Reassemble lower suction valve assembly by placing the suction seat 331 409 O ring 106 011 suction ball 331 030 amp suction ball guide 331 029 in the suction nut 331 034 amp FIGURE 4 gore 341 011 Fe Supe 331 029 Wa T pen Suction Ball pe x 1 030 a Dini ao 106 111 s Suction Seal 331 400 Suction Mut 1004 Packing Replacement Procedures Replacement Instructions REASSEMBLY Figure 5 amp 6 1 Take lower male gland 331 014 amp place it down on Fluid Pump Removal Refer to Figure 1 the flat side aiiim 1 Follow the Pressure Relief Procedure on page 9 2 Take three of the lower polyethylene packings 331 016 amp two 2 Flush material you are spraying out of the machine of the leather packings 331 306 amp place onto the male gland in
32. s before each use e Be very careful when removing the spray tip or hose from gun A plugged line contains fluid under pressure If the tip or line is plugged follow the PRESSURE RELIEF PROCEDURE as outlined on page 10 TIP GUARD ALWAYS have the tip guard in place on the spray gun while spraying The tip guard alerts you to the injection hazard and helps prevent accidentally placing your fingers or any part of your body close to the spray tip SPRAY TIP SAFETY Use extreme caution when cleaning or changing spray tips If the spray tip clogs while spraying engage the gun safety latch immediately e ALWAYS follow the PRESSURE RELIEF PROCEDURE and then remove the spray tip to clean it e NEVER wipe off build up around the spray tip e ALWAYS remove tip amp tip guard to clean AFTER pump is turned off and the pressure is relieved by following the PRESSURE RELIEF PROCEDURE 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 from hot parts Precaution is the best insurance against an accident When starting the engine maintain a safe distance from moving parts of the equipment Before adjusting or servicing any mechanical part of the sprayer follow the PRESSURE RELIEF PROCEDURE and remove the ignition cable from the spark plug to prevent accidental starting of the sprayer LABELING Keep all labels on th
33. se Connector SPRAY TIP ADAPTER 032 012 F to G gun adapter to attach Graco tips to Airlessco 007 Spray Guns Flat Tip Washers 120 008 Flat Tip Washer 120 090 Flat Tip Washers 25 Pack 120 090CX Coarse 120 090FX Fine 120 088 Filter Spring F AIRLESSCO Y E al R 0 For a complete listing of all available accessories see the Airlessco Accessories Catalog Part 001 357 PUMP CONDITIONER between uses to prevent paint from Case order quantity 12 on quarts 4 on gallons HIGH PRESSURE HOSE STAY CLEAN Spray protectant for your machine to prevent paint from sticking to it 114 030 20 oz can THROAT SEAL OIL Used in the wet cup of a piston pump to prevent paint from drying on the piston amp causing damage to the upper packing Use with all piston pumps 188 187 6 oz Bottle 188 392 1 qt Bottle XTEND A POLE SYSTEM Tip Extensions Complete with Patented SPRAY CLEAN REV GUARD EA WAA AA VERI je njer Bare Pole TIP EXTENSIONS G THREAD 032 170 6 Long 032 171 12 Long 032 172 18 Long 032 173 24 Long SWIVEL EXTENSION G THREAD 032 184 36 Long EXTENSIONS BARE POLES Add Tip Extension or Swivel Extension to create desired length 032 053 24 Long 032 054 36 Long D SWIVEL G THREAD 032 035 7 8 14 Swivel ADAPTERS 90 Pole to Gun Adapter 032 042 032 010 Gun Nut G Thread 032 011 eS Gu
34. ss Spray Wounds NOTE TO PHYSICIAN If any fluid appears to penetrate your skin get Injection in the skin is a traumatic injury EMERGENCY MEDICAL CARE AT ONCE DO It is important to treat the injury surgically NOT TREAT AS A SIMPLE CUT Tell the doctor as soon as possible DO NOT DELAY treatment exactly what fluid was injected Have him read to research toxicity Toxicity is a concern with the following NOTE TO PHYSICIAN some exotic coatings injected directly into the bloodstream Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable GENERAL PRECAUTIONS e NEVER alter equipment in any manner e NEVER smoke while in spraying area e NEVER spray highly flammable materials e NEVER use around children e NEVER allow another person to use sprayer unless they are thoroughly instructed on safety use and given this operators manual to read e ALWAYS wear a spray mask gloves and protective eye wear while spraying e ALWAYS ensure fire extinquishing equipment is readily available and properly maintained NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM FOLLOW PRESSURE RELIEF PROCEDURES ON PAGE 10 Safety VVarnings Ground the sprayer and other components in the system to reduce the risk of static sparking fire or explosion which can result in serious bodily injury and property damage Always ground all of these components e Fluid Hose use only grounded hoses e Spray gun or dispensing valve
35. ssure WARNING If you spray into the paint bucket always use the lowest spray pressure and maintain firm metal to metal contact between gun and container Always use the lowest pressure and engine RPM necessary to completely automize the material If wider coverage is needed use a larger tip rather than increasing the pressure Check the spray pattern The tip size and angle determines the pattern width and flow rate e A trigger locking button is provided on the engine speed and spray gun actuation levers to prevent hand cramping and user fatigue during extended striping Sessions Operating the sprayer at higher engine RPM or higher pressure than needed wastes material causes early tip wear and shortens engine and sprayer pump life 11 Striping Operation 12 1 Choose handle location The choices are installing the handle opposite of the single wheel assembly standard set up or placing the handle directly over the single wheel assembly The handle location is really a matter of personal preference however having the handle away from the single wheel assembly allows for easier loading unloading from a van 2 Cable Tension Adjustment Once the handle and gun arm assemblies are set up to the preferred positions pressurize the unit and trigger each gun to ensure that they activate and release correctly If not adjust the cable tension as follows a Locate the adjustment knobs
36. the gun safety latch counterclockwise Refer to Fig 2 14 If you are going to start spraying place the pump or 5 Turn the engine ON OFF switch to ON suction tube into the supply container Release the 6 Move the choke to the closed position gun safety latch and trigger the gun into another N empty metal container holding a metal part of the 7 Move the throttle lever slightly to the FAST position gun firmly against the metal pail Fig 4 and force 8 Turn the fuel valve ON Honda only Pull the start rope the solvent from the pump and hose When paint Pull the engine over against compression stroke and then starts coming from the gun turn control valve to let the rope rewind slowly into the starter Pull firmly and prime or fully counter clockwise position and engage rapidly to start the engine Do NOT drop the rope Hold the gun safety latch onto the handle while rewinding or the rope may rewind 15 If you are going to store the sprayer remove the improperly and jam the assembly If the engine does not start open the choke half way If the engine floods open the choke all the way and continue cranking suction tube or pump from the solvent pail force the solvent from the pump and hose Engage the gun safety latch and refer to the Storage Procedure on 9 After the engine is warm gradually open the choke page 8 lever increase the RPM of engine by squeezing the 16 Whenever you shut off the sprayer follow the thr
37. tion can result Operate equipment with guards in place Keep hands and feet away from rotating parts Tie up long hair and remove jewelry Do not wear loose fitting clothing dangling drawstrings or items that could become caught VVARNING Engines give off carbon monoxide an odorless colorless poison gas Breathing carbon monoxide can cause nausea fainting or death Start and run engine outdoors Do not start or run engine in enclosed area even if doors or windows are open WARNING Running engines produce heat Engine parts especially mufflers become extremely hot Severe thermal burns can occur on contact Combustible debris such as leaves grass brush etc can catch fire e Allow muffler engine cylinder and fins to cool before touching e Remove accumulated combustibles from muffler area and cylinder area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered and brush covered unimproved land The state of California requires this Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal land WARNING Unintentional sparking can result in fire or electric shock Unintentional start up can result in entanglement traumatic amputation or lacerations BEFORE PERFORMING ADJUSTMENTS OR REPAIRS e Disconnect spark plug wire and keep it away from spark
38. use cleaning solvents with flash points below 140 F Some of these are acetone benzene ether gasoline and naphtha Consult your supplier to be sure e NEVER smoke in the spraying cleaning area PREVENT STATIC SPARKING FIRE EXPLOSIONS ALWAYS be sure all equipment and objects being sprayed are properly grounded Always ground sprayer paint bucket and object being sprayed See grounding on page 4 for detailed grounding information Vapors created when spraying can be ignited by sparks To reduce the risk of fire do not plug in or unplug any electrical cords in an enclosed spray area This can create sparks when there is any chance of igniting vapors still in the air Follow the coating amp solvent manufacturers safety warnings and precautions Use only conductive fluid hoses for airless applications Be sure gun is grounded through hose connections Check ground continuity in hose amp equipment Overall end to end resistance of un pressurized hose must not exceed 29 megohms for any coupled length or combination of hose length Use only high pressure airless hoses with static wire approved for 3000 psi Important United States Government safety standards have been adopted under the Occupational Safety amp Health Act These standards particularly the General Standards Part 1910 amp the Construction Standards part 1926 should be consulted WHEN SPRAYING amp CLEANING WITH FLAMMABLE PAINTS OR PAINT THINNERS 1 When sprayi
39. x 8 30cm line pump is used daily by thousands of painting Motor Output Briggs amp Stratton 3 5 hp professionals worldwide with a reputation for trouble free performance that s unmatched in the industry They re small compact easy to use and quick to clean Even changing colors is a breeze Stripe with water based paints made for traffic lines or athletic fields A professional quality spray gun is mounted on a multi position spray arm Their balance and light weight make them ideal for a one man operation Model 3500 Specifications Part 305 240 Fixed front wheel model 305 245 Front swivel wheel model Max Pressure 0 2500 PSI 170 Bar Max Output 0 62 GPM 2 35 Litres min Max Tip 1 gun 0 027 inch 1 x 12 30cm line Motor Output Honda 3 hp A quick release of the spray gun from its mount lets you paint using stencils or i utilize the 50 of supplied hose and the spray gun to paint with exterior latex and enamel paints e ss Flexibility makes the Spray amp Stripe popular with cities school districts and sports programs for parking lot or athletic field striping and for use as a mobile airless spraying station It s perfect for painting fences buildings and covering graffiti Part 305 245 j Spray 8 Stripe 3500 shovvn has the optional Front Swivel Wheel with RADIUS MEMORY TM AA IMPORTANT WARNING HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM High pressure spr
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