AIRLESSCO Sure Stripe 3650 User manual

001-822 SEPT 08
AIRLESS PAINT LINE STRIPER
Gun Assembly ............................................... 22
Gun Holder Assembly.................................... 22
Paint System ................................................. 23
Suction Assembly .......................................... 24
loating Gun Assembly ................................. 25
Replacement of Electrical Control Board ...... 26
Pressure Calibration on the Control Board.... 26
Clutch Troubleshooting.................................. 27
Notes ............................................................. 28
Striping Accessories ...................................... 29
1 illing the Packing Nut/Wet Cup................ 5
2. Spray Tip ................................................... 6
3. Prime Valve ............................................... 6
4. Pressure Control Knob .............................. 6
5. Choke, uel Throttle .................................. 6
6. Static Discharge ........................................ 6
7. Gun Safety Latch..................................... 10
8. Major Gun Components .......................... 10
9. Spray Tip ................................................. 10
10. Spray Tip Assembly................................. 10
11. Airless Spray Gun Assembly.....................11
12. luid Pump .............................................. 14
13. Outlet Valve ............................................. 15
14. Inlet Valve ................................................ 15
15. Packing.................................................... 16
16. Packing Cutaway..................................... 17
17. Gearbox Assembly .................................. 18
18. Clutch Assy.............................................. 19
19. rame Assembly...................................... 20
20. Swivel Wheel Assembly .......................... 21
21. Gun Assembly ......................................... 22
22. Gun Holder Assembly.............................. 22
23. Paint System ........................................... 23
24. Suction Assembly .................................... 24
25. loating Gun Assembly ........................... 25
26. Control Board .......................................... 26
SECTIONINTRODUCTIONSS3650 Specifications
Part Number: 305401
Max. Tip Size: .027
Max. Output: .7 gpm (2.65 lpm)
Max. Working Pressure: 3000 psi (270 bar)
Max. Hose Length: 100 ft (30 m)
Unit Weight: 166 lbs (75 kg)
Engine: Honda GX 120 cc (4.0 hp) with Oil Alert

HANDLE THIS UNIT ASYOU WOULDALOADED FIREARM!
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUSINJURY. OBSERVE ALL
WARNINGS!
MANUAL NOTATIONS
WARNING - Alerts user to avoid or correct conditions that could cause bodily injury.
CAUTION - Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.
IMPORTANT - Alerts users to steps or procedures that are essential to proper equipment repair and maintenance.
NOTE - Identifies essential procedures or extra information.
BEFORE OPERATING THIS UNIT, READAND FOLLOWALL SAFETY WARNINGSAND INSTRUCTIONSRELATED TO THE
USAGE OF THIS EQUIPMENT ON PAGES2, 3 & 4. READ, LEARN, AND FOLLOW THE PRESSURE RELIEF PROCEDURE ON
PAGE 8 OF THIS MANUAL.
SS3650
SS4050
S Model D
S Plus
The Sure Stripe 3650 and Sure Stripe 4050, as well as their respective ield Stripe versions, the ield Stripe
Model D and ield Stripe Plus (+) have been designed to produce profesional results at very reasonable prices.
Using our proven LP airless piston-powered paint pump, with triple life externally adjustable packing system and
quality, clutch based, electronic pressure control system, the Sure Strip and ield Stripe stripers can be relied
upon to get the job done for years to come.
ield Stripe units are equipped with a wheeled gun arm to ensure consistant lines on athletic fields.
All four units can also be used as mobile airless paint sprayers.
2 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. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.
FLUIDSUNDER HIGH PRESSURE FROM SPRAY OR LEAKSCAN PENETRATE THE SKIN AND CAUSE EXTREMELY
SERIOUS INJURY, INCLUDING THE NEED FOR AMPUTATION.
NEVER point the spray gun towards anyone or at any part of the body.
NEVER put hand or fingers over the spray tip. Do not use rag or other materials over your fingers. Paint will
penetrate through material and into the hand.
NEVER try to stop or deflect leaks with your hand or body.
ALWAYShave gun tip guard in place when spraying.
ALWAYSlock gun trigger when you stop spraying.
ALWAYSremove tip from the gun to clean it.
NEVER try to "blow back" paint, it’s not an air sprayer.
ALWAYSfollow the PRESSURE RELIEF PROCEDURE, as shown on page 8, before cleaning or removing the spray
tip or servicing any system equipment.
Be sure equipment safety devices are operating properly before each use.
ALWAYStighten all fluid connections before each use.
If any fluid appears to penetrate your skin, get EMERGENCY CAREAT ONCE. DO NOT TREAT ASASIMPLE 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 above.
NEVER alter equipment in any manner.
NEVER smoke while in spraying area.
NEVER spray highly flammable materials.
NEVER use around children.
NEVER allow another person to use sprayer unless he is thoroughly instructed on its' safe use and given this
operators manual to read.
ALWAYSwear a spray mask, gloves and protective eye wear while spraying.
ALWAYSensure fire extinquishing equipment is readily available and properly maintained.
NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM. FOLLOW PRESSURE RELIEF
PROCEDURES ON PAGE 8.

Keep spraying area free from obstructions.
Make sure area has good ventilation to safely remove vapors. NEVER keep flammable material in spraying area.
NEVER spray in vicinity of open flame or other sources of ignition. Spraying area must be at least 20 ft. away
from spray unit.
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUSINJURY. OBSERVE ALL WARNINGS. THIS SPRAYER IS
FOR PROFESSIONAL USE ONLY.
ALWAYSset safety lock on the gun in "LOCKED" position when not in use and before servicing or cleaning.
DO NOT remove or modify any part of gun.
ALWAYSremove spray tip when cleaning.
lush unit with LOWEST POSSIBLE PRESSURE.
CHECK operation of all gun safety devices before each use. 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 8.TIP GUARD
ALWAYShave 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.
USE EXTREME CAUTION when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the
gun safety latch immediately.
ALWAYSfollow the PRESSURE RELIEF PROCEDURE before removing the spray tip to clean it.
NEVER wipe off build up around the spray tip.
ALWAYSremove tip & tip guard to clean AFTER pump is turned off and the pressure is relieved by following the
PRESSURE RELIEF PROCEDURE.
INJECTION H
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".
GENERAL PRECAUTION
MEDICAL TREATMENT
SPRAY TIP SAFETY
TIP GUARD
SPRAY GUN SAFETY
WARNINGS - CONTINUED
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 & dispose of hazardous fluids according to
manufacturer, local, state & national guidelines.
ALWAYSwear protective eyewear, gloves, clothing
and respirator as recommended by fluid manufacturer.
Keep all labels on the unit clean and readable. Replacement labels are available from manufacturer.
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.
NEVER use a damaged hose, which can result in hose failure or rupture and cause in injection injury or other
serious bodily injury or bodily damage. Before each use, check entire hose for cuts, leaks, abrasion or bulging of
cover, or damage or movement of couplings. If any of these conditions exist, replace the hose immediately.
Never use tape or any device to try to mend the hose as it cannot contain the high pressure fluid. NEVER
ATTEMPT TO RECOUPLE THE HOSE. High pressure hose is not recoupleable.
Help prevent damage to the hose by handling and routing it carefully. Do not move the sprayer by pulling it with
the hose.
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.
ALWAYSGROUND ALL OF THESE COMPONENTS:
1. Sprayer: Connect a ground wire and clamp (supplied) to a true earth ground.
2. luid Hose: use only grounded hoses.
3. Spray gun or dispensing valve: grounding is obtained through connection to a properly grounded fluid hose
and pump.
4. Object being sprayed: according to your local code.
5. 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 unpressurized 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 500 t. (150 m.) overall combined hose length to assure electrical continuity.
Keep clear of moving parts when starting or operating the sprayer. Do not put your fingers into any openings to
avoid amputation by moving parts or burns on hot parts.Precaution is the best insurance against an accident.
When starting the 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 on
page 8, and remove the ignition cable from the spark plug to prevent accidental starting of sprayer.
TOXIC FLUID HAZARD
WARNINGS CONTINUED ON NEXT PAGE.........
LABELING
HOSES
ALWAYS INSPECT SPRAYING AREA
GROUNDING
4 This sprayer operates at 3000 psi (205 bar). ALWAYSbe 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.
ALWAYSfollow the PRESSURE RELIEF PROCEDURE whenever you stop spraying and before adjusting, removing
or repairing any part of the sprayer.
NEVER alter or modify any part of the equipment to avoid possible component rupture which could result in
serious bodily injury and property damage.
NEVER use weak or damaged or non-conductive paint hose. Do not allow kinking or crushing of hoses or allow it
to vibrate against rough or sharp or hot surfaces. Before each use, check hoses for damage and wear and
ensure all fluid connections are secure.
REPLACE any damaged hose. NEVER use tape or any device to mend the hose.
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.
ALWAYSuse approved high pressure fittings and replacement parts.
ALWAYSensure fire extinquishing equipment is readily available and properly maintained.
Place unit 25 feet away from spraying in ventilated area.
NEVER operate in buildings unless exhaust is piped outside.
NEVER allow hose to lay against engine mufflers or hot parts.
NEVER refill fuel tank while engine is hot or is running.
IMPORTANT: United States Government safety standards have been adopted under the Occupational Safety & Health Act.
These standards, particularly the General Standards, Part 1910, & the Construction Standards, part 1926 should be
consulted.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR THINNERS:
1. When spraying with flammable liquids, the unit must be located a minimum of 25 feet away from the 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.

Reduce the risk of injection injury, static sparking or splashing by following the specific cleaning procedure on
page 6 and 8.
ALWAYSfollow the PRESSURE RELIEF PROCEDURE on page 8.
ALWAYSremove 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.
NEVER use cleaning solvents with flash points below 140 degress . Some of these are: acetone, benzene,
ether, gasoline, naphtha. Consult your supplier to be sure.
NEVER SMOKE IN THE SPRAYING/CLEANINGAREA.
ALWAYSbe sure all equipment and objects being sprayed are properly grounded. ALWAYSground sprayer, paint
bucket and object being sprayed. See "grounding" on page 3 for detailed grounding information.
Vapors created when spraying can be ignited by sparks. To reduce the risk of fire, always locate the sprayer at
least 20 feet (6 m.) away from the spray area. DO NOT plug in or unplug any electrical cords in the spray area,
which can create sparks, when there is any chance of igniting vapors still in the air. ollow the coating & 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 & equipment. Overall (end to end) resistance of unpressurized 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.
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.
AVOID COMPONENT RUPTURE
PREVENT STATIC SPARKED FIRE/ EXPLOSIONS
GAS ENGINE PRECAUTIONS
WARNINGS - CONTINUED
FLUSHING
5
SETTING UP
1. CONNECT THE HOSE AND GUN
2. FILL THE PACKING NUT/WET CUP
3. CHECK THE ENGINE OIL LEVEL
4. FILL THE FUEL TANK
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 6' whip hose should always be 3/8".
ill the Packing Nut/Wet Cup 1/3 full with Airlessco Throat Seal Oil (TSO). FIG 1 BELOW.
a. Unscrew the oil fill plug. The dipstick is attached to the plug.
b. Without threading the plug into place, check to be sure the oil is up to the top mark on the dipstick.
c. If oil is needed, refer to engine manual.
WARNING: uel spilled on a hot surface can cause a fire or explosion and cause serious bodily injury and property damage.
Always shut off the engine and let it cool before filling the tank, and carefully follow steps a - c below being sure not to spill
any fuel.
a. Close the fuel shutoff valve.
b. Use only clean, fresh, well-known brands of unleaded regular grade gasoline.

c. Remove the fuel cap and fill tank. Be sure the air vent in the fill cap is not plugged so fuel can flow to the
carburetor, then replace the cap.
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.
lush with a compatible solvent such as mineral spirits or water.
lush with soapy water, then mineral spirits.
lush with mineral spirits, followed by soapy water, then a clean water flush.
3. CHANGING FROM WATER-BASETO OIL-BASEPAINT
4. CHANGING FROM OIL-BASETO WATER-BASEPAINT
Oil-base paint: lush with mineral spirits.
Water-base paint: lush with water, then mineral spirits and leave the pump, hose and gun filled with mineral
spirits.
or longer storage, use mixture of mineral spirits and motor oil (half & half). Shut off the sprayer, follow
PRESSURE RELIEF PROCEDURE on page 8 to relieve pressure and make sure prime valve is left open.
Before using water-base paint, flush with soapy water and then a clean water flush.
When using oil-base paint, flush out the mineral spirits with the material to be sprayed.
1. NEW SPRAYER
5. STORAGE
6. START UP AFTERSTORAGE
FLUSHING
2. CHANGING COLORS
5. FLUSH THE SPRAYER
a. lush sprayer per instructions below.
6 WARNING: 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 ig 6.
1. Be sure the gun safety latch is engaged and there is no spray tip in the gun. Refer to ig. 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. Place the suction tube into the pail or place the pail under the pump.
4. Turn pressure control knob to low. Refer to ig. 4.
5. Open the prime valve to the open - "Priming Position". This will allow an easy start. Refer to ig. 3.
6. Turn the engine ON/O switch to ON.
7. Move the choke toward the closed position as per ig.5.
8. Move the throttle lever slightly to the left as per ig.5.
9. Turn the fuel valve ON as per ig. 5. Pull the start rope. Pull the engine over against compression stroke and
then let the rope rewind slowly into the starter. Pull firmly and rapidly to start the engine. Do NOT drop the rope.
Hold on to the handle while rewinding, or the rope may rewind improperly and jam the assembly. If the engine
does not start, open the choke a little more. If the engine floods, open the choke all the way and continue
cranking.
10. After the engine is warm, gradually close the choke, raise the RPM of engine slightly by moving throttle to the
left. Close the prime valve. Refer to ig. 3
11. Point the gun into the metal pail and hold a metal part of the gun firmly against the pail Refer to fig. 6.
12. Disengage the gun safety latch and squeeze the gun trigger. At the same time, slowly turn the pressure
control knob clockwise just enough to move liquid at low pressure.
13. Allow the pump to operate until clean solvent comes from the gun.
14. Release the trigger and engage the gun safety latch.
15. If you are going to start spraying, place the pump or suction tube into the supply container. Release the gun
safety latch and trigger the gun into another empty, metal container, holding a metal part of the gun firmly against
the metal pail ( ig. 6), forcing the solvent from the pump and hose. When paint starts coming from gun, turn
pressure control knob to minimum pressure, place prime valve in prime (open) position and engage the gun
safety latch.
16. If you are going to store the sprayer, remove the 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 page 5. Step 5.
17. Whenever you shut off the sprayer follow the
PRESSURE RELIEF PROCEDURE warning on page 8.
HOW TO FLUSH
REMOVE SPRAY TIP. ENGAGE GUN SAFETY LATCH.
STARTING UP
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 SPRAYERAT HIGHER PRESSURE THAN NEEDED, WASTESMATERIAL, CAUSESEARLY
TIP WEAR, AND SHORTENS SPRAYER LIFE.
PRESSURE CONTROL KNOB is used to adjust pressure. Turn clockwise (CW) to increase pressure and
counterclockwise (CCW) to decrease pressure.
PRIME/PRESSURE (PR) RELIEF VALVE is used to prime pump and to relieve pressure from gun, hose and tip.
1. LEARN THE FUNCTIONS OF THE CONTROLS.
2. PREPARETHE 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 primingposition.
b. When you have ensured that the gun safety latch is engaged, attach tip and safety guard.
c. Turn the engine ON/O switch to the "ON" position. Pull rope vigorously until engine starts.
d. Turn Pressure Control Knob clockwise to prime the pump.
e. After the pump is primed, turn Prime/PR Valve to the "Closed" position.
f. Turn Pressure Control Knob to the desired spray pressure.
g. Disengage the gun safety latch and you are ready to spray.
4. ADJUSTING THE PRESSURE
FOLLOW THE "PRESSURE RELIEF PROCEDURE".
To reduce the risk of injection, never hold your hand, body, fingers or hand in a rag in front of the spray tip when cleaning or
checking for a cleared tip. Always point the gun toward the ground or into a waste container when checking to see if the tip is
cleared or when using a self-cleaning tip.
When you spray into the paint bucket, always use the lowest spray pressure and maintain firm metal to metal contact
between gun and container.
To stop the unit in an emergency, turn the engine off. Then relieve the fluid pressure in the pump and hose as instructed in
the Pressure Relief Procedure.
a. Whenever you stop spraying, even for a short break, follow the "Pressure Relief Procedure".
b. Clean the tip & gun as recommended in the seperate Gun Manual supplied with the gun.
c. lush the sprayer at the end of each work day, if the
material you are spraying is water-based, or if it could harden in the sprayer overnight. See " lushing". Use a
compatible solvent to flush, then fill the pump and hoses with an oil based solvent such as mineral spirits.
d. or long term shutdown or storage, refer to the " lushing" section of this manual.
5. WHEN SHUTTING OFF THE SPRAYER
Be sure to relieve pressure in the pump after filling with Airlessco Pump Conditioner.
AVOIDING TIP CLOGS
There is an easy way to keep the outside of the tip clean from material build up:
Every time you stop spraying, for even a minute, lock the gun and submerge it into a small bucket of thinner suitable for the
material sprayed.
Thinner will dissolve the buildup of paint on the outside of tip, tip guard and gun much more effectively if the paint doesn't
have time to dry out completely.
(Prime/PR Valve) Used to relieve pressure from gun, hose & tip and to primethe unit when in OPEN position. (It is
in open positionwhen there is a wider gap between valve handle and cam body.)
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!
c. If more coverage is needed, use a larger tip rather than increasing the pressure.
d. Check the spray pattern. The tip size and angle determines the pattern width and flow rate.
8 PRESSURERELIEFPROCEDURE
5. Re-engage gun safety latch and close Prime/Pressure Relief Valve.
TO AVOID POSSIBLE SERIOUSBODY INJURY, ALWAYSFOLLOW 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.
IMPORTANT!
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.
3. Disengage the gun safety latch and trigger the gun to relieve residual fluid pressure.
HOLD METAL PART OF THE GUN IN CONTACT WITH GROUNDED METAL PAIL. USE MINIMUM PRESSURE !
4. Turn Prime/Pressure Relief Valve (PR Valve) to the open (priming) position to relieve residual fluid pressure.
THERE WILL BEAWIDER GAPBETWEEN VALVE HANDLE AND CAM BODY WHEN IN OPEN POSITION. IN THE
CLOSED POSITION THERE IS ONLYAVERY SLIGHT GAP.
NOTE: THE VALVE HANDLE CAN MOVE BOTH CLOCKWISE AND COUNTER CLOCKWISEAND CAN FACE
DIFFERENT DIRECTIONS.
If the SPRAY TIP OR HOSE IS CLOGGED, follow Step 1 through 5 above. Expect paint splashing into the bucket
while relieving pressure during Step 4.
If you suspect that pressure hasn't been relieved due to damaged Prime/Pressure Relief Valve or other reason,
engage the gun safety latch and take your unit to an authorized Airlessco Service Center.
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". Packing
life will be extended a minimum of 3 times if the proper packing tightening procedure is followed!
DAILY MAINTENANCE
PACKING TIGHTENING PROCEDURE:
Inspect the packing nut daily!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 to the life of other piston pumps.
9
STRAIGHT LINES
a. Stripers are factory aligned, but if necessary, loosen the two bolts (fig. 20, item 19) on the swivel wheel
assembly, just enough to be able to move the wheel by hand. Align wheel and re-tighten bolts.
b. Place the turnbuckle over the two mounting nubs on the frame.
c. Pressurize the unit with water and Airlessco's Pump Conditioner and spray out several lines with the swivel
assembly in the locked position. Use the turnbuckle to fine tune the alignment of the wheels, until the stripes are
straight.
d. Tighten the jam nuts on the turnbuckle to affix theturnbuckle length for future reference.
e. Tighten the ratchet handles.
CURVESAND ARCS
Basically the same as above, except the swivel wheel assembly is set at angle. The swivel assembly can be
adjusted to 30 degrees either side of straight ahead. If you have arcs that you paint regularly, purchase
additional turnbuckles (136-231) and keep them set to those arc sizes.

LINE STRIPING OPERATION
There is a hole in each corner of the striper frame, in which the gun arm can be mounted. In a standard set up,
the gun arm would be mounted in the right hand near the single wheel. This allows for an easier visual check for
straight line striping and for basic arc striping.
a. Ensure that a striping tip is in the gun.
b. Pick a tip size for the desired line width. EXAMPLE: a 317ST tip for a four inch line.
c. Place gun into the gun holder, so that the top of the taper on the gun handle is flush with the edge of the gun
holder.
d. Set gun height for the desired line width. Adjust height by loosening the small black handle on the gun holder
assembly and slide the gun arm to the correct height. Now tighten the handle. This will require some
experimentation to find the correct height. It is suggested that tape, or some other method is used to mark the
height of commonly used settings.
e. Attach the swivel heads to the gun if painting curbs or wide stripes.
f. Angle the guns slightly forward. This allows the spray pressure from the guns to help blow dirt and debris out of
the path of the new stripes.
Once the handle and gun arm assembly is set up to the preferred position, pressurize the unit and trigger the
gun to ensure that it activates and releases correctly. If not, adjust the cable tension as follows:
a. Locate the adjustment knobs on the base of the gun trigger, where the cable connects to the gun trigger
assembly.
b. Loose the locking nut and 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 ANADDITIONALCABLEADJUSTMENT WHERE THE CABLEATTACHESTO THE GUN HOLDER
ASSEMBLY. USE ONLY IF THE GUN TRIGGER ADJUSTMENT IS INSUFFICIENT.
a. CURBS: Adjust gun to desired height and turn swivel head towards curb.
b. WIDE STRIPES: Install wider fan striping tips and raise the gun height to achieve the desired width line.
c. STENCILS: Install standard spray tip on the outer gun. Remove this gun from the gun holder and spray out the
stencils. A second gun and hose can be attatched and bolted with a ball valve for stencils.
d. STANDARD PAINTING: Same as stencils, but use additional paint hose as required.
4. CABLETENSION ADJUSTMENT
6. MISCELLANEOUS OPPERATIONS
3. SETTING UP THE GUNS
1. CHOOSETHE GUN ARM POSITION
5. ALIGN SWIVELWHEELASSEMBLY
Choose the handlebar position. The handlebars can be adjusted by loosening the bolts (fig. 19, item 10) and
rotating each handlebar to desired heights, then tightening the bolts. Rotating the handlebars all the way forward
allows for easy storage of the unit.
2. CHOOSETHE HANDLEBAR POSITIONS
10 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.
Read all warnings and safety precautions supplied with the spray gun and in product manual.
MAJOR COMPONENTS OF SPRAY GUN AND REVERSIBLESPRAY TIP
1. Be sure pressure relief procedure is followed before assembling tip and housing to the gun.
2. Lock gun safety latch.
3. Insert REV-TIP™ cylinder into the REV-GUARD™ (guard housing assembly).
4. Guide metal seat into REV-GUARD™ (guard housing assembly) through retaining nut & turn until it seats
against the cylinder.
5. Insert O-Ring gasket on metal seat so it fits in the grooves.
6. inger tighten REV-GUARD™ retaining nut onto the gun.
7. Turn guard in the desired position.
8. Completely tighten the retaining nut.
1. Lock gun safety latch.

2. Turn REV-TIP™ handle 180 degrees.
3. Disengage trigger lock & trigger gun into pail.
4. If the REV-TIP™ handle appears locked (resists turning), loosen the retaining nut. The handle will now turn
easily.
5. Engage gun safety latch & return handle to the spray position.
Spray Position Shown
REVERSE TO
UNPLUG
RETAINING NUT
CLOGGED FLAT TIP
Should the spray tip become clogged, relieve pressure from hose by following the "Pressure Relief Procedure."
Secure gun with the safety latch, take off guard, take out the tip, soak in appropriate solvent & 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.)
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.
To clean the filter, use a brush dipped in an appropriate solvent. Change or clean filters at least once a day.
Some types of latex may require a filter change after four hours of operation.
SPRAY TIP ASSEMBLY
CLEANING FILTER IN GUN HANDLE
TO REMOVE CLOGSFROM 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 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 high
Use smaller nozzle
Reduce pressure
Too little material
Nozzle too small
Use next larger nozzle
Material too thick
thin distribution in center of pattern “horns”
Worn tip
Wrong tip
Change to new tip
Use nozzle with narrow spray angle
Thick skin of work

Material too viscous
Application too heavy
Thin cautiously
Reduce pressure and/or use tip in next smaller nozzle group
Coating fails to close & smooth over
Material too viscous
Thin cautiously
Spray pattern irregular, deflected
Orifice clogged
Tip damaged
Clean carefully
Replace with new tip
Craters or pock marks, bubbles on work
Solvent balance
Use 1 to 3% “short solvents remainder “long” solvents
(this is most likely to happen with material of low viscosity, lacquers, etc.)
Clogged screens
Extraneous material in paint
Course pigments
Poorly milled pigments
(paint pigments glocculate)
Clean screen
Use coarse screen if orifice size allows.
Use courser screen, larger orifice tips. Obtain ball milled paint. If thinner has been added, test to see if a cover
screen. Incompatible drop placed on top of paint mixes or flattens out on the paint mixture & thinners on the
surface. If not, try different thinner in fresh batch of paint.
GOOD, FULL
SPOTTY PATTERN, INCREASE PRESSURE
TEST THE PATTERN
13
LINE STRIPING TIP CHART
NOTE: STRIPING TIPS SHOULD NOT BEUSED FOR REGULAR SPRAYING.
• 1st 3-digits identifies it as a REV-TIP™ for airless line striping (Part Number 562-xxxST).
• 4th digit is the fan width - the number is half the fan width, e.g., 2means a 4" line width.
• 5th and 6th digits are for the orifice size and is measured in thousandths of an inch, e.g., 17 = 0.017 inch.
The higher the number, the larger the tip.
During use, high pressure will cause the orifice to grow larger. This destroys the pattern or will leave tailing or
two heavy lines on the outside of the pattern. REPLACE SPRAY TIP FREQUENTLY!
REV-TIP™ for Striping, Part Number 562-xxxST
REV-TIP™ protected By U.S. Patent No. 6,264,115. Ot er U.S. & foreign patents applied for.
TIP REPLACEMENT
TIP IDENTIFICATION
REV-TIPTM FOR STRIPING 562-XXXST
FAN WIDTH (6” FROM SURFACE)
ORIFICE SIZE (INCHES)
INCHES
MILLIMETERS
.013
.015
.017

.019
.021
1-2
25-51
REVERSIBLESTRIPING TIP SIZE CHART
PROBLEM
CAUSE
SOLUTION
Unit doesn’t prime
Airleak due to:
•Loose suction nut
• Worn o-rings
•Hole in sucktion hose
Stuck or fouled balls
• tighten suction nut
• replace o-ring (106-011) on suction seat & o-ring (106-020)
below suction seat
• replace suction hose (331-290)
• service outlet valve suction assembly
Unit primes but has poor or no pressure
Pressure set too low
ilter(s) are clogged
Outlet valve fouled/worn
Prime/pressure relief valve bypassing
Packings and/or piston worn
• turn up pressure
• clean or replace gun filter, inlet filter, and/or manifold filter
• service outlet valve
• clean or replace prime valve
• tighten packing nut
• repack unit
Unit does not maintain good spraying pressure
Blown spray tip
Packings and/or pistons worn
Upper seat worn
• replace spray tip
• repack unit
• replace upper seat
FIELD TROUBLESHOOTING
14
THE FLUID PUMP
REFER TO FIGURE 12
1. ollow the Pressure Relief Procedure on page 8.
2. lush 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. Remove the retaining ring from the connecting rod and slide the sleeve down revealing the connecting rod pin.
8. Remove the suction tube assembly from the fluid pump by unscrewing the suction nut with the packing

adjustment tool (189-211).
9. Using a 1/2” wrench unscrew the two bolts from the cover assembly. The fluid pump will be hanging loosely at
this point.
10.Remove the connecting rod pin out of the connecting rod, allowing the removal of the fluid pump from the
machine.
1. Loosen the packing nut and ensure that the piston rod is in its upper position in the fluid pump body. Slip the
sleeve & the retaining ring over the piston rod.
2. Push the piston rod up into the connecting rod & align the holes. Insert the connecting rod pin through the
connecting rod & piston. Slip the sleeve up over the connecting rod pin and insert the retaining ring into the
groove on the connecting rod.
3. Push the two bolts through the tube spacers & screw them into the cover assembly. 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, O-ring, suction ball & suction ball guide
in the suction nut & screw onto fluid pump body.
5. Reconnect sensor to the fluid pump body. Hold sensor with a 7/8” wrench while tightening the swivel with a
11/16” wrench.
6. 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.
7. Tighten packing nut clockwise until resistance is felt against the Belleville Springs, go 3/4 of a turn more. Put
five drops of Airlessco Throat Seal Oil in the packing nut.
8. Run the machine at full pressure for several minutes. Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield so that the small hole is in the upper right hand corner.
FLUID PUMP DISCONNECT
FLUID PUMP REINS
1. Disconnect the luid Pump following instructions on page 14.
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. 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 threads & torque to
20 ft-lbs.
NOTE: Airlessco LP pump tool kit 188-197 is required for this task. Kit includes: Tightening Bar (189-211),
Packing Removal Tool (331-465), Piston Holder (331-195), 3/8” dowel (331-196).
SERVICING THE INLET ASSEMBLY
1. Un-thread and remove suction nut from the fluid pump body.
2. Remove suction seat, O-ring, suction ball and suction retainer.
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, O-ring, suction ball & suction ball guide
in the suction nut & screw onto fluid pump body.
DISASSEMBLY OF THE OUTLET VAL
13. Take the packing holder & replace the white O-ring & the black O-ring with new ones from the packing kit.
14. Slide the packing holder over the top of the upper packings so they fit inside.
15. Lubricate inside of the fluid pump body & the outside of the packings with a light weight oil.
16. Slide assembly into fluid pump body.
TO KEEP PACKINGSSECURED IN CORRECT POSITION, HOLD THE PUMP BODY UPSIDE DOWN & PUSH THE
COMPLETED ASSEMBLY UPWARDSINTO THE PUMP BODY. ONCE PLACED INSIDE, TILT PUMP BODY BACK UP
TO KEEP ALL PIECES IN.
17. Tighten packing nut onto the top of the fluid pump body & tighten until you feel slight resistance against the
Belleville Springs. Using the Packing Adjustment Tool, tighten another 3/4 of a turn.

!8. Reinstall luid Pump as instructed on page 14.
(
(
(
DISASSEMBLY OF THE FLUID PUMP
REFER TO FIGURE 15 & 16
1. Discon nect the luid Pump as instructed on page 14.
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. Disassemble all parts & clean for reassembly. Discard any old packings.
7. Lubricate leather packing in lightweight oil for 10 minutes prior to reassembly.
REASSEMBLY
PARTS LIST ON FOLLOWING PAGE
REFER TO FIGURE 15
1. Take lower male gland & place it down on the flat side.
2. Take three of the lower polyethylene packings & two of the leather packings & place onto the male gland inthe
following order with the inverted side downPOLYETHYLENE, LEATHER, POLYETHYLENE, LEATHER,
POLYETHYLENE.
3. Take the female adaptor, which is inverted on both sides , & place it on top of your assembled lower packings.
4. ollow step 2 with your packings inverted side up.
5. Take the second lower male gland and place it on top of your assembled packings with the rounded side
down.
6. Take assembled glands & packings (13 pieces) & slide onto the lower half of the piston.
7. Take the spacer & slide over the top of the piston (it doesn’t matter which direction it sits, falling onto lower
packings.
8. Take three Belleville Springs & slide over the top of the piston in the following order:
• irst spring, curve facing down
• Second spring, curve facing up
• Third spring, curve facing down
9. Take the upper male gland & place it rounded side up.
10. Take three upper polyethylene packings & two leather packings & assemble with inverted side down, on to
the male gland in the following order: polyethylene, leather, polyethylene, leather, polyethylene.
11. Take upper female gland & place on top of assembled upper packings with the inverted side down.
12. Take assembled upper glands & packings (7 pieces) & slide on over the top of the piston, making sure
inverted sides are down.
17
PACKING REPLACEMENT PROCEDURES
PARTS LIST FIGURE 15 &