AIRLESSCO 3500 User manual

SERVICE/OPERATION
MANUAL
Form No. 001-683 APR0705

Table of Contents
INTRODUCTION
Spray & Stripe Specications 1
Safety Warnings 2
GETTING STARTED
How 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 & Replacement of
Control Valve, Ball & Seat 21
PRODUCT DIAGRAMS & PARTS LISTS
Gearbox Assembly 22
Gun Assembly 23
Gun Mount Assembly 23
Bypass Valve Assembly 24
Suction Assembly 25
Frame Assembly 26
Swivel Wheel Assembly 27
Manufactured by: AIRLESSCO BY DUROTECH CO.
P.O. Box 8006, Moorpark, CA. 93020-8006, Ship to: 5397 Commerce Ave.,
Moorpark, CA 93021 Tel: [phone] Fax: [phone]
www.airlessco.com email: [email protected]
SUBJECT TO CHANGE WITHOUT NOTICE.
Copyright © 2005, All rights reserved.

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.
IMPORTANT WARNING !!
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!!
High pressure spray can cause extremely serious injury.
OBSERVE ALL WARNINGS!
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.
Introduction
1
INTRODUCTION Model 3500 Specications:
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
Part #305-245
Spray & Stripe 3500 shown has
the optional Front Swivel Wheel
with RADIUS MEMORY™
The heart of the Spray & Stripe series
is the time tested and contractor proven
Airlessco “LP” piston paint pump. Designed
for spraying 1700 gallons per year, this
pump is used daily by thousands of painting
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 trafc lines or athletic elds. 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.
A quick release of the spray gun from its
mount lets you paint using stencils, or utilize
the 50' of supplied hose and the spray gun to
paint with exterior latex & enamel paints.
Flexibility makes the Spray & Stripe popular
with cities, school districts, and sports
programs for parking lot or athletic eld
striping, and for use as a mobile airless
spraying station. It’s perfect for painting
fences, buildings, & covering grafti.
Part #305-240
Spray & Stripe 3500 shown has
the Fixed Swivel Wheel.

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 ngers 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.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE and then remove the spray tip to clean it.
• NEVER wipe off build up around the spray tip.
• ALWAYS remove tip & 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 ngers 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.
ALWAYS INSPECT SPRAYING AREA
• ALWAYS keep spraying area free from obstructions.
• ALWAYS make sure area has good ventilation to safely remove vapors and mists.
• NEVER keep ammable material in spraying area.
• NEVER spray in vicinity of open ame or other sources of ignition.
SPRAY GUN SAFETY
• ALWAYS set safety lock on the gun in "LOCKED" position when not in use and before servicing or cleaning.
• NEVER remove or modify any part of the gun.
• ALWAYS REMOVE SPRAY TIP when cleaning. Flush unit with LOWEST POSSIBLE PRESSURE.
• ALWAYS 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 uid under pressure. If the tip or
line is plugged, follow the PRESSURE RELIEF PROCEDURE as outlined on page 10.
Safety Warnings
Keep all labels on the unit clean and readable. Replacement labels are available from the manufacturer.
LABELING
Hazardous uid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know
the hazards of the uid you are using. Store & dispose of hazardous uids according to manufacturer, local, state & national
guidelines. ALWAYS wear protective eye wear, gloves, clothing and respirator as recommended by uid manufacturer.
TOXIC FLUID HAZARD
2

Safety Warnings
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 ngers over the spray tip. Do not use a rag or any other material over your ngers. Paint will
penetrate through material and into the hand.
• NEVER try to stop or deect leaks with your hand or body.
• NEVER try to "blow back" paint, this is not an air spray sprayer.
• ALWAYS have gun tip guard in place when spraying.
• ALWAYS lock gun trigger when you stop spraying.
• 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.
• ALWAYS Be sure equipment safety devices are operating properly before each use.
• ALWAYS tighten all uid connections before each use.
MEDICAL TREATMENT
If any uid 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.
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
OBSERVE ALL WARNINGS.
MEDICAL ALERT - Airless Spray Wounds NOTE TO PHYSICIAN:
If any uid 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 uid 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.
INJECTION HAZARD
GENERAL PRECAUTIONS
• NEVER alter equipment in any manner. • NEVER smoke while in spraying area.
• NEVER spray highly ammable materials. • NEVER use around children.
• NEVER allow another person to use sprayer unless they are thoroughly instructed on safety use and
given this operators manual to read.
• ALWAYS wear a spray mask, gloves and protective eye wear while spraying.
• ALWAYS ensure re extinquishing equipment is readily available and properly maintained.
NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM.
FOLLOW PRESSURE RELIEF PROCEDURES ON PAGE 10.
3

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.
• NEVER leave a pressurized sprayer unattended to avoid accidental operation of it which could result in serious
bodily injury.
• ALWAYS follow 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, 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. Before each use, check hoses for damage and wear and ensure
all uid 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 ttings with your hand or any part of the body. Turn off the
unit and release pressure by following PRESSURE RELIEF PROCEDURE on page 10.
• ALWAYS use approved high pressure ttings and replacement parts.
• ALWAYS ensure re extinquishing equipment is readily available and properly maintained.
Safety Warnings
GROUNDING
Ground the sprayer and other components in the system to reduce the risk of static sparking, re or
explosion which can result in serious bodily injury and property damage.
Always ground all of these components:
• Fluid Hose: use only grounded hoses.
• Spray gun or dispensing valve: grounding is obtained through connection to a properly
grounded uid hose and pump.
• Object being sprayed: according to your local code.
• All solvent pails used when ushing 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.
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.
4

WHEN ADDING FUEL
• Turn engine OFF and let engine cool at least 2
minutes before removing gas cap.
• Fill fuel tank outdoors or in well ventilated area.
• Do not overll fuel tank. Fill tank to
approximately1 inches below top of neck to
allow for fuel expansion.
• Keep gasoline away from sparks, open ames,
pilot lights, heat and other ignition sources.
• Check fuel lines, tank, cap and ttings frequently
for cracks or leaks. Replace if necessary.
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 re, 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 & solvent manufacturers safety warnings and precautions.
Use only conductive uid hoses for airless applications. Be sure gun is grounded through hose connections. Check
ground continuity in hose & 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.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR PAINT THINNERS:
1. When spraying with ammable liquids, unit must be located a minimum of 25 feet away from spraying area
in a well ventilated area. Ventilation must be sufcient 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
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.
FLUSHING
Reduce risk of injection injury, static sparking or splashing by following the specic cleaning procedure on page 7.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 10.
• ALWAYS remove the spray tip before ushing. Hold a metal part of the gun rmly to the side of a metal pail and
use the lowest possible uid pressure during ushing.
• NEVER use cleaning solvents with ash points below 140º F. Some of these are: acetone, benzene, ether,
gasoline and naphtha. Consult your supplier to be sure.
• NEVER smoke in the spraying/cleaning area.
Safety Warnings
WHEN STARTING ENGINE
• Make sure spark plug, mufer, fuel cap and air cleaner
are in place.
• Do not crank engine with spark plug removed.
• If fuel spills, wait until it evaporates before starting
engine.
• If engine oods, set choke to OPEN/RUN
position, place throttle in FAST and crank until
engine starts.
WHEN OPERATING EQUIPMENT
• Do not tip engine or equipment at angle which
causes gasoline to spill.
5
Gasoline & its vapors are extremely
ammable & explosive.
Fire or explosion can cause severe burns or death.

WHEN TRANSPORTING EQUIPMENT
• Transport with fuel tank EMPTY or with fuel shut-off
valve OFF.
WHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
• Store away from furnaces, stoves, water heaters and
other appliances that have pilot lights or other ignition
source. They can ignite gasoline vapors.
Starting engine creates sparking.
Sparking can ignite nearby ammable gases.
Explosion and re could result.
• If there is natural or LP gas leakage in area, do not
start engine.
• Do not use pressurized starting uids because vapors
are ammable.
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 is
felt, then pull rapidly.
• 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.
Rotating parts can contact or entangle hands, feet,
hair, clothing or accessories.
Traumatic amputation or severe laceration 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 tting clothing, dangling drawstrings or
items that could become caught.
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.
Safety Warnings
Running engines produce heat. Engine parts,
especially mufers, become extremely hot.
Severe thermal burns can occur on contact.
Combustible debris, such as leaves, grass, brush,
etc. can catch re.
• Allow mufer, engine cylinder and ns to cool before
touching.
• Remove accumulated combustibles from mufer 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.
Unintentional sparking can result in re
or electric shock.
Unintentional start up can result in entanglement,
traumatic amputation, or lacerations.
BEFORE PERFORMING ADJUSTMENTS OR
REPAIRS
• Disconnect spark plug wire and keep it away from
spark plug.
• Disconnect battery at negative terminal (only
engines with electric start).
WHEN TESTING FOR SPARK
• Use approved spark plug tester.
• Do not check for spark with spark plug removal.
6

How to Flush
FIGURE 1
LOCK TRIGGER TO
REMOVE SPRAY TIP
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 with your gun
on its safety features and how to engage safety latch.
2. Pour enough clean, compatible solvent (or water when
using water-base paint) into a large, empty metal pail to
ll the pump and hoses.
3. Place the suction tube into the pail
4. Turn the control valve to the prime position or fully
counterclockwise. Refer to Fig. 2.
5. Turn the engine ON/OFF switch to ON.
6. Move the choke to the closed position. Refer to Fig 3.
7. Move the throttle lever slightly to the FAST position.
Refer to Fig 3.
8. Turn the fuel valve ON (Honda only). Pull the start rope.
Pull the engine over against compression stroke and then
let the rope rewind slowly into the starter. Pull rmly and
rapidly to start the engine. Do NOT drop the rope. Hold
onto the handle while rewinding, or the rope may rewind
improperly and jam the assembly. If the engine does not
start, open the choke half way. If the engine oods, open
the choke all the way and continue cranking.
9. After the engine is warm, gradually open the choke
lever, increase the RPM of engine by squeezing the
throttle control trigger on the handlebars.
10. Point the gun into the metal pail and hold a metal part of
the gun rmly against the pail Refer to Fig. 4.
11. Disengage the gun safety latch and squeeze the gun trigger.
Turn the control valve clockwise just enough to move liquid
at low pressure.
12. Allow the pump to operate until clean solvent comes from
the gun.
13. Release the trigger and engage the gun safety latch.
14. 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 rmly against the metal
pail (Fig. 4) and force the solvent from the pump and hose.
When paint starts coming from the gun, turn control valve
to prime or fully counter clockwise position and engage
the gun safety latch.
15 . 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 8.
16 . Whenever you shut off the sprayer follow the Pressure
Relief Procedure warning on page 10.
To reduce the risk of static sparking, which can
cause re or explosion, always hold a metal
part of the gun rmly against the metal pail
when ushing. This also reduces splashing.
Refer to Fig.4.
Maintain rm metal
to metal contact
between gun and container.
CONTROL VALVE
FIGURE 4
FIGURE 2
7
FIGURE 3 - Honda Engine

1. New Sprayer
Your Airlessco unit was factory tested in an antifreeze solution which was left in the pump.
Before using oil-base paint, ush with mineral spirits only. Before using water-base paint
ush with soapy water, then do a clean water ush.
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 ush.
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
lled with mineral spirits. For longer storage, use mixture of mineral spirits and motor oil
(half & half). Shut off the sprayer, follow Pressure Relief Procedure on page 10
Flushing
Read prior to using your sprayer
8

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 uid outlet.
b. Connect an airless spray gun to the other end of
the hose.
c. Do not use steel braided airless hose. Use nylon
braided airless hose only.
NOTE: Do not use thread sealer on swivel
unions as they are made to self-seal.
Use thread seal on tapered male threads only.
3. Grounding
A small steel chain grounding strap is installed at
the factory to prevent static build-up.
4. Flush the sprayer
As per "Flushing Procedure" in this manual.
2. Remove the snap-on cover plate
over the piston.
WARNING
To reduce the risk of static sparking, re or
explosion which can result in serious bodily
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.
9
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
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.
2. 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.
3. Tighten suction nut daily.
Daily Maintenance
10
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
manual provided with your gun on its
safety features and how to engage safety latch.
2. Turn engine off using OFF switch on the engine.
3. Disengage safety latch & trigger gun to relieve
residual uid 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 uid pressure.

Starting Up
1. Learn how to operate the control valve.
The control valve sets the prime or pressure position as well as the
spraying pressure. When the valve is fully counter-clockwise the unit
is in the prime position. As the control valve is turned clockwise,
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 stain or paint
without needing to dilute the material.
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 uid pressure.
g. Disengage gun safety latch & squeeze gun trigger. Turn
control valve clockwise just enough to move liquid at low
pressure.
h. Allow the pump to operate until clean solvent comes from
the gun.
i. Install spray tip onto gun.
j. If so equipped, turn engine switch to ON position, then
pull starter rope vigorously until engine starts.
k. Turn Control Valve clockwise to the desired spray
pressure required to properly atomize your material
(Sprayer is limited to a maximum of 2500 psi).
l . Disengage the gun safety lock and you are ready to
start spraying.
If you spray into the paint bucket,
always use the lowest spray pressure
and maintain rm metal to metal
contact between gun and container.
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!
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.
5. Adjusting the Pressure
a. Turn the Control Valve clockwise to increase pressure and
counter clockwise to decrease pressure.
b. Always use the lowest pressure and engine RPM necessary
to completely automize the material.
c. If wider 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 ow 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.
11
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
Refer to Figure above for steps a -c
a. Pressure Control Knob must be in the low pressure position.
b. Control Valve must be open to the priming position or fully
counterclockwise.
Refer to Fig 3 Page 7 for steps c - h.
c. Move the choke to the closed position.
d. Move the throttle lever slightly to the FAST position.
e. Turn fuel valve ON (Honda only). Pull the start rope. Pull
engine over against compression stroke & let the rope rewind
slowly into the starter. Pull rmly & rapidly to start engine.
Do NOT drop the rope. Hold onto handle while rewinding
or the rope may rewind improperly & jam the assembly. If
the engine does not start, open the choke half way. If engine
oods, open the choke all the way & continue cranking.
f. After the engine is warm, gradually open the choke lever,
increase the RPM of engine by squeezing the throttle control
trigger on the handlebars.

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 or truck.
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 on the base of the
gun trigger, where the cable connects to the gun
trigger assembly.
b. Loose the locking nut & 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 insufcient.
3. 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, “W” 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 Operation
12
1. Setting the Swivel Wheel
Refer to gure below
a. Release Swivel Wheel Trigger to adjust the
wheel to desired angle.
b. To set the angle for constant arch loosen the jam
nuts on the Turnbuckle. Place Turnbuckle onto
the mounting nub located on the striper frame.
Adjust the turnbuckle until it ts over the mounting
nub located on the wheel frame. Tighten jam nuts
on the turnbuckle to afx the length.
Note: If you have archs that you paint regularly,
purchase additional Turnbuckles (P.N. 136-163) and
keep them set to those arc sizes for easy use.
Mounting Nubs
Turnbuckle
Wheel Release

Striping Tip Guide
STRIPING TIPREGULAR PAINTING SPRAY TIP
UNIFORM PATTERN
LIGHTHEAVY
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.
STRIPING TIP - ORIFICE SIZE (Inches)
in (mm) .009 .011 .013 .015 .017 .019 .021 .023 .025 .027 .031 .035
1-2 25-51 113ST 115ST 117ST 119ST
2-4 51-102 215ST 217ST 219ST 221ST
4-6 102-152 315ST 317ST 319ST 321ST
6-8 152-203
Striping Paint
Oil Base Oil Base Latex Latex Latex Latex LatexLatex
Rev-Tip
TM
for Striping
Fan Width (6” from surface)
REV-GUARD
TM
Super Compact
P.N. 561-001
11/16-16 “F” Thread. Fits:
Airlessco, and some ASM,
Wagner, and Campbell Hausfeld.
P.N. 561-002
7/8-14 “G” Thread.
Fits some: Graco, Wagner,
Titan, Airlessco.
560-215
REV-TIPTM Orifice Size
1/2 Fan Width
Sample:
REV-TIP
TM
for Striping
P.N. 562-xxxST
Includes Rev-Tip
TM
, Metal Seal
& O-Ring Seal.
(water @ 2000psi, 138 bar)
(latex paint @ 2000psi,
138 bar/1.36 spec. gr.)
*Pump will support tip worn to next larger size.
Water Flow Rate (gpm) .12 .18 .24 .31 .38 .47 .57 .67 .77 1.03 1.31 1.63 1.80
(lpm) .49 .69 .91 1.17 1.47 1.79 2.15 2.54 2.96 3.90 4.98 6.17 6.81
Paint Flow Rate (gpm) .10 .15 .21 .27 .33 .40 .49 .58 .66 .88 1.12 1.39 1.54
(lpm) .38 .57 .79 1.02 1.25 1.51 1.85 2.20 2.50 3.33 4.24 5.26 5.83
Pump Minimum (gpm) .25 .25 .33 .40 .50 .60 .75 .88 1.0 1.25 1.5 2.0 2.2
Output* (lpm) 1.0 1.0 1.25 1.5 1.9 2.3 2.8 3.3 3.8 4.7 5.7 7.5 8.2
LIGHT
13

Spray Gun Operation
Reversible
Spray Tip
Tip Guard
Trigger Guard
MAJOR COMPONENTS OF SPRAY GUN &
REVERSIBLE REV-TIP™
SPRAY GUN
Attach spray gun to airless unit and tighten ttings 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.
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
ts 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.
O-Ring Gasket
Metal Seat
REV-TIP™ Cylinder
Retaining Nut
Spray Position Shown
Reverse to
Unplug
REV-GUARD™
Guard Housing Assembly
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. If the 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
CLEANING SPRAY GUN
CLEANING FILTER IN GUN HANDLE
Immediately after the work is nished, ush the gun out
with a solvent. Brush pins with solvent and oil them
lightly so they will not collect dried paint.
To clean the lter, use a brush dipped in an appropri-
ate solvent. Change or clean lters at least once a day.
Some types of latex may require a lter change after
four hours of operation.
Gun Handle. Unscrew
from gun head to service
lter inside.
Gun Safety
Latch or Lock
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 & 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.)
™
14
Press up here & pull gently
to remove trigger guard

Spray Gun Troubleshooting
DEFECTS CAUSE CORRECTION
Coarse spray Low pressure Increase the pressure
Excessive fogging High pressure Reduce pressure for satisfactory pattern
(overspray) Material too thin Use less thinner
Pattern too wide Spray angle too large Use smaller spray angle tip
Pattern too narrow Spray angle too small Use larger spray angle tip. (If coverage is OK,
try tip in same nozzle group)
Too much material Tip size too large Use next smaller tip
Material too thin
Pressure too high Reduce pressure
Too little material Tip size too small Use next larger tip
Material too thick
Thin distribution in Worn tip Change for new tip
center of pattern Wrong tip Use tip with a smaller spray angle
"horns"
Thick skin on work Material too viscous Thin material
Application too heavy Reduce pressure and/or use smaller tip
Coating fails to Material too viscous Thin material
close & smooth over
Spray pattern irregular, Orice clogged Clean carefully
deected Tip damaged Replace with new tip
Craters or pock marks Solvent balance Use 1-3% "short" solvents remainder "long"
solvents. (This is most likely to happen with
material of low viscosity, lacquers etc.)
Bubbles on work Contamination or dust Clean surface to be sprayed
Clogged screens Extraneous material Clean screen
in paint.
Coarse pigments Use coarse screen if orice size allows
Poorly milled pigments Use coarser screen, larger orice tips. Obain ball
(paint pigments glocculate milled paint. If thinner was added, test to see if a
cover screen. Incompatible drop on top of
paint mixes or attens out on
paint mixture & thinners. on the surface. If not, try different thinner
in fresh batch of paint.
TEST THE PATTERN
15

Field Troubleshooting
PROBLEM CAUSE SOLUTION
Unit doesn't prime Airleak due to:
• Loose Suction Nut • Tighten Suction Nut
• Worn O-Rings • Replace O-Ring (106-011) on
suction seat, & O-Ring (106-
020) below suction seat
• Hole in Suction Hose • Replace Suction Hose (331-290)
Stuck or Fouled Balls Service outlet valve suction
assembly
Unit primes but has no Pressure set too low Turn up pressure
or poor pressure
Filter(s) are clogged Clean or replace gun lter, inlet
lter and/or manifold lter
Outlet Valve fouled/worn Service outlet valve
Prime/Pressure Relief valve Clean or replace primve valve
bypassing
Packings and/or piston worn • Tighten packing nut
• Repack unit
Unit does not maintain Blown spray tip Replace spray tip
good spraying pressure
Packings and/or piston worn Repack unit
Upper Seat worn Replace upper seat
16

17
Refer to Figure 1
1. Follow the Pressure Relief Procedure on page 10.
2. Flush the material you are spraying out of the machine.
3. Remove the connecting rod shield (331-111).
4. Move the piston rod (331-093) to its lowest position
by cycling pump slowly.
5. Remove the retaining ring (331-062) from the
connecting rod (331-038) and slide the sleeve (331-
117) down revealing the connecting rod pin (331-065).
6. Remove the suction tube assembly from the uid
pump (331-209) by unscrewing the suction nut
(331-034) with the packing adjustment tool.
7. Using a 1/2” wrench unscrew the two bolts (100-318)
from the cover assembly (331-234). The uid pump
(331-209) will be hanging loosely at this point.
8. Remove the connecting rod pin (331-065) out of
the connecting rod (331-038), allowing the removal
of the uid pump (331-209) from the machine.
FIGURE 1
Servicing the Fluid Pump
Fluid Pump Disconnect Fluid Pump Reinstall
Refer to Figure 1 & 4
1. Loosen the packing nut and ensure that the piston rod
(331-093) is in its upper position in the uid pump body
(331-011). Slip the sleeve (331-117) & the retaining
ring (331-062) over the piston rod.
2. Push the piston rod up into the connecting rod (331-
038) & align the holes. Insert the connecting rod pin
(331-065) 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 (100-318) through the tube spacers
(331-074) & screw them into the cover assembly (331-
234). Using a 1/2” wrench, tighten the two bolts evenly
(alternating between them) until you reach 20 ft-lbs.
4. Reassemble lower suction valve assembly by placing
the suction seat (331-409), O-ring (106-011), suction
ball (331-030) & suction ball guide (331-029) in the
suction nut (331-034) & screw onto uid pump body.
5. Start the machine and operate slowly to check the piston
rod for binding. Adjust the two bolts, holding the uid
pump body to the cover assembly, if necessary. This
will eliminate any binding.
6. Tighten the packing nut clockwise until resistance is
felt against the Belleville Springs, then go 3/4 of a turn
more. Put ve drops of Airlessco Throat Seal Oil into the
packing nut.
7. Run the machine at full pressure for several minutes.
Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 6 above.
8. Install the connecting rod shield (331-111) so that the
small hole is in the upper right hand corner.
331-209

Servicing the Piston Rod - Outlet Valve
331-196
331-195
Piston
DISASSEMBLY OF THE OUTLET VALVE
REFER TO FIGURE 3
1. Disconnect the Fluid Pump following instructions on page 17 .
2. Place piston holder (331-195) in a vise. Slide piston into
the holder & lock in place with a 3/8” dowel (331-196).
3. Use a 1/4” allen wrench to unscrew the outlet seat retainer
(331-026) from the piston.
4. Remove the outlet seat (331-026), O-ring (331-100) and
outlet ball (331-027).
5. Inspect outlet ball & seat for wear. Replace as necessary.
6. 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.
Servicing the Suction Assembly
REFER TO FIGURE 4
1. Un-thread and remove suction nut from the uid 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 uid pump body.
5. Reassemble lower suction valve assembly by placing the
suction seat (331-409), O-ring (106-011), suction ball (331-030)
& suction ball guide (331-029) in the suction nut (331-034) &
FIGURE 3
FIGURE 4
18
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).