AIRLESSCO LP460 User manual

A
IRLESSCO
LP460 - LP540 - LP690
ALLPRO
510E - 710E - 810E
A
IRLESS
P
AINT
PAINT P
S
AINT SAINT
PRAYER
S
ERVICE
/O
ERVICE/OERVICE
PERATION
M
ANUAL
Form No. 001-492 JUNE 2006

2
Product Diagrams & Parts Lists
Manifold Filter Parts List
14
Gear & Pump Assembly
17
Upper & Lower Seats
18
Fluid Pump
20
Carry Frame Machine Parts List
21
Lo-Boy Machine Parts List
22
Hi-Boy Machine Parts List
23
Suction Assemblies
24
Electrical System Drawing - 5/6 Series
28
Quick Reference Guide
Single Sheet of Instructions for Operation
& Cleaning of an Airless Paint Sprayer
30
TABLE OF CONTENTS
Introduction
LP Series Speci cations
1
Safety Warnings
2
Getting Started
Flushing
5
How to Flush
5
Setting Up
7
Starting Up
8
Pressure Relief Procedure
10
Daily Maintenance
10
Repairs/Maintenance Instructions
Spray Gun Operation
11
Spray Gun Troubleshooting
12
Spray Tip Selection
13
Electric Motor Maintenance
14
Field Troubleshooting
15
Servicing the Fluid Pump
16
Servicing Piston Rod,
Outlet Valve
18
Servicing Suction Assembly
18
Packing Replacement
19
Electrical Board Calibration
25
Electrical Troubleshooting - 5/6 Series
27
Replacement of Electrical Components
29
Manufactured by: AIRLESSCO BY DUROTECH CO.
Ship to: 5397 N Commerce Ave.,
Moorpark, CA 93021Tel: [phone] Fax: [phone]
www.airlessco.com email: [email protected]
SUBJECT TO CHANGE WITHOUT NOTICE.
Copyright
©
2006, All rights reserved.

1
INTRODUCTION
Max. Pressure
3000 psi
3000 psi
3000 psi
Output (FreeFlow)
0.5 gpm
0.7 gpm
0.8 gpm
Output (At Pressure)
0.46 gpm
0.54 gpm
0.6 gpm
Tip Size
1 gun up to 0.021
1 gun up to 0.023
1 gun up to 0.026
Motor- Output
DC TEFC .6 hp
DC TEFC .8 hp
DC. TEFC. .8 hp
Weight
38 lbs
41 lbs.
65 lbs.
LP460/510E
LP540/610E
LP690/810E
NO MODIFICATIONS or alterations of any AIRLESSCO Equipment or part is allowed.
Before operating this unit, read and follow all safety warnings and in struc tions
related to the usage of this equipment on pages 2, 3 & 4. READ, LEARN, and
FOLLOW the Pressure Relief Pro ce dure on Page 10 of this manual.
All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.
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 de struc tion of equipment.
IMPORTANT
- Alerts users to steps or procedures that are essential to proper equipment repair and maintenance.
NOTE
- Identi es essential procedures or extra information.
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!
High pressure spray can cause extremely serious injury.
OBSERVE ALL WARNINGS!
CARRY FRAME MODEL
LO-BOY FRAME
HI-BOY FRAME
Your new Airlessco or ALLPRO airless paint sprayer is designed to meet the
demands of the professional painting contractor as well as the homeowner.
The famous Airlessco slow-stroking stainless steel piston pump delivers
extra long life for the piston, packings, valve seats and balls. The patented
Triple-Life packing system is externally adjustable, extending packing life
and reducing repacking costs. Its large high-torque electric motor runs slower
reducing heat. The motor is fan cooled and totally enclosed to reduce brush
wear and to prevent the ignition of paint fumes in the motor.
CARRY FRAME MODEL
65 lbs.
HI-BOY FRAME

2
SAFETY WARNINGS
NOTE: United States Government safety
standards have been adopted under the
Occupational Safety & Health Act. These
standards, particularly the General Standards,
Part 1910 & Construction Standards, Part 1926
should be consulted.
DO NOT USE HALOGENATED SOLVENTS IN THIS SYSTEM.
The prime valve, and most airless guns have aluminum parts and may explode. Clean ing 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.
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
Handle as you would a loaded  rearm.
Follow the PRESSURE RELIEF PROCEDURE
.
Follow the PRESSURE RELIEF PROCEDURE.Follow the PRESSURE RELIEF PROCEDURE
MEDICAL ALERT
-
Airless Spray Wounds
Airless Spray Wounds
If any  uid appears to penetrate your skin, get
EMERGENCY MEDICAL CARE AT ONCE.
DO NOT TREAT AS A
SIMPLE CUT
.
Tell the doctor exactly what  uid was injected
.
NOTE TO PHYSICIAN
: Injection in the skin is a trau mat ic
injury.
It is important to treat the injury sur gi cal ly as
soon as possible. DO NOT DELAY treat ment to re
search
toxicity.
Toxicity is a concern with some ex ot ic coatings injected
directly into the blood stream. Con sul ta tion with a plastic surgeon
or re con struc tive hand sur geon may be advisable.
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
he is thoroughly instructed on its safe use and
given this operators manual to read.
•
ALWAYS
wear a spray mask, gloves and protective
ALWAYS wear a spray mask, gloves and protective ALWAYS
eye wear while spraying.
•
ALWAYS
ensure  re extinquishing equipment is
ALWAYS ensure  re extinquishing equipment isALWAYS
readily available and properly maintained
.
NEVER LEAVE SPRAYER UNATTENDED
WITH PRES SURE IN THE SYSTEM.
FOLLOW PRES SURE RELIEF
PROCEDURES.
•
Fluids under high pressure from spray or leaks can
penetrate the skin and cause ex treme ly serious injury,
including the need for amputation.
•
NEVER
point the spray gun at anyone or any part of
the body.
•
NEVER
put your hand or  ngers over the spray tip. Do
not use a rag or any other materials over your  ngers.
Paint will penetrate through these materials & into the hand.
•
NEVER
try to stop or de ect leaks with your hand or body.
•
ALWAYS
have the tip guard in place when spraying.
ALWAYS have the tip guard in place when spraying.ALWAYS
•
ALWAYS
lock the gun trigger when you stop spraying.
ALWAYS lock the gun trigger when you stop spraying.ALWAYS
•
ALWAYS
remove tip from the gun to clean it.
ALWAYS remove tip from the gun to clean it.ALWAYS
•
NEVER
try to "blow back" paint, this is not an air spray
sprayer.
•
ALWAYS
follow the
ALWAYS follow the ALWAYS
PRESSURE RELIEF
PRO CE DURE
before cleaning or re mov ing the spray tip or servicing any
system equipment.
•
Be sure the equipment safety devices are operating prop er ly
before each use.
•
Tighten all of the  uid connections before each use.
MEDICAL TREATMENT
\
\
\
\
•
If any  uid appears to penetrate your skin, get
EMER GEN CY
CARE AT ONCE! DON'T TREAT AS A SIM PLE 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.
INJECTION HAZARD

3
SAFETY WARNINGS
ALWAYS INSPECT SPRAYING AREA
•
Keep the spraying area free from obstructions.
•
Make sure the spraying 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.
•
The spraying area must be at least 20 ft. away from
spray unit.
SPRAY GUN SAFETY
•
ALWAYS
set gun safety lock in the "LOCKED"
po si tion when not in use & before servicing or cleaning.
•
NEVER
remove or modify any part of the gun.
•
ALWAYS
REMOVE THE SPRAY TIP when cleaning.
Flush unit at the 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 the gun. A plugged line will con tain  uid un der
pressure. If the tip or line is plugged, follow the
PRES SURE RE
LIEF PRO CE DURE
.
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  n gers 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, en-
gage the gun safety latch immediately. ALWAYS
follow the
PRES
SURE RELIEF PROCEDURE
and then remove the spray tip to clean it.
•
NEVER
wipe off build up around the spray tip.
TOXIC FLUID HAZARD
•
ALWAYS
remove tip guard & tip to clean AFTER
pump is turned off and the pressure is relieved by
fol low ing the
PRESSURE RELIEF PROCEDURE.
•
Hazardous  uid or toxic fumes can cause serious in ju ry
or death if splashed in eyes or on skin, inhaled or
swallowed. Know the hazards of the  uid you are us ing.
Store & dispose of hazardous  uid according to
manufacturer, local, state & national guidelines.
•
ALWAYS
wear protective eyewear, gloves,
clothing and respirator as recommended by  uid
man u fac tur er.
HOSES
•
Tighten all of the  uid connections securely before each
use. High pressure  uid 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.
•
Only use hoses with 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 an injection injury or other
serious bodily injury or property damage. Before each use,
check entire hose for cuts, leaks, abrasions, bulging of the
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  uid. NEVER
ATTEMPT TO RECOUPLE THE HOSE. A high pressure
hose is not recoupleable.
GROUNDING
•
Ground the spr
ayer & 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.
For detailed instructions on how to ground, check your
local electrical code.
•
ALWAYS
ensure switch is in OFF position before
plugging unit in.
Always Ground All of These Components:
1. Sprayer
: plug the power supply cord, or extension cord,
each equipped with an undamaged three-prong plug, into a
properly grounded outlet. DO NOT USE AN ADAPTER.
Use only a 3 wire extension cord that has a 3 blade
grounding plug, and a 3 slot receptacle that will accept
the plug on the product. Make sure your extension cord is
in good condition. When using an extension cord, be sure to
use one heavy enough to carry the current your product will
draw. (
Note
: The table on the top of the next page shows
the cor rect size to use depending on cord length and name
plate ampere rating. If in doubt, use the next heavi er gauge.
The smaller the gauge num ber, the heavi er the cord.)
2. Fluid hose
: use only grounded hoses.
3. Spray gun or dispensing valve
: grounding is ob tained
through connection to a properly grounded  u id hose and
pump.
4. Object being sprayed
: according to your local code.
5. All solvent pails
used when  ushing.
•
Once each week, check electrical resistance of hose (when
using multiple hose assemblies, check overall resistance.)
Overall (end to end) 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 im me di ate ly.
• Never exceed 500 ft. (150 m) overall combined cord
length to assure electrical continuity.

4
SAFETY WARNINGS
KEEP CLEAR OF MOVING PARTS
Always Follow Recommended Pressure
and Operating
Instructions
•
ALWAYS
use approved high pressure  ttings and
re place ment parts.
•
ALWAYS
ensure  re extinquishing equip ment is readi ly
avail able and properly maintained.
FLUSHING
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS AND THINNERS
1.
When spraying with  ammable liquids, the unit must be located a minimum of 25 feet away from the 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 & spraying object. See GROUNDING. Use only
high pressure airless hoses approved for 3000 psi which is conductive.
3.
Remove the spray tip before  ushing. Hold the metal part of the gun  rmly to the side of a metal pail & use the lowest
possible  uid pressure during  ush ing.
4.
Never use high pressure in the cleaning process.
USE MINIMUM PRESSURE.
5.
Do not smoke in spraying/cleaning area.
5 - 6
6 - 8
8 - 10
10 - 12
120
120
120
120
25
18
18
18
16
400
8
6
6
4
300
8
6
6
6
250
10
8
8
6
200
10
10
8
8
150
12
10
10
8
100
12
12
12
10
50
16
16
14
14
500
6
6
4
4
UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD
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 on hot parts. Pre cau tion
is the best in sur ance against an accident. When starting the
motor, maintain a safe distance from moving parts of the equip-
ment. Before adjusting or ser vic ing any mechanical part of the
sprayer, follow the PRESSURE RELIEF PROCEDURE.
AVOID COMPONENT RUPTURE
•
This sprayer operates at 3000 psi (205 bar). Al ways be
sure that all com po nents and ac ces so ries have a max imum
work ing pres sure of at least 3000 psi to avoid rup ture
which can result in serious bodily injury in clud ing
in jec tion and prop er ty damage.
•
NEVER
leave a pressurized sprayer un at tend ed to avoid
ac ci den tal operation of it, which could result in serious
bodily in ju ry.
•
ALWAYS
follow the PRESSURE RE LIEF PRO CE DURE
whenever you stop spraying and before ad just ing,
re mov ing 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 bodi ly injury and property damage.
•
NEVER
use weak, damaged, or non-conductive paint
hose. Do not allow kinking or crushing of hoses or
al low it to vibrate against rough, sharp or hot surfaces.
Before each use, check your hoses for damage and wear
and ensure all of the  uid connections are secure.
•
ALWAYS
replace any damaged hose.
NEVER
use tape
or any device to mend the hose.
•
NEVER
attempt to stop any leakage in the line or
 t tings with your hand or any part of the body. Turn off
the unit and release pressure by following PRES SURE
RELIEF PROCEDURE.
PREVENT STATIC SPARKING FIRE/EXPLOSIONS
•
ALWAYS
be sure all of the equipment & objects being
sprayed are properly grounded. Always ground sprayer,
paint bucket and object being sprayed. See the ground ing
section of this manual for grounding information.
•
Reduce the risk of injection injury, static sparking or
splashing by following the speci c cleaning process.
•
ALWAYS
follow the PRESSURE RELIEF PRO CE DURE.
•
ALWAYS
remove the spray tip before  ushing. Hold
the metal part of the gun  rmly to the side of a metal pail
& use the lowest possible  uid pressure during  ush ing.
•
NEVER
use cleaning solvents with  ash points below
140 degrees F. Some of these are: acetone, ben zene,
ether, gasoline, naptha. Consult your supplier to be sure.
•
NEVER
SMOKE in the spraying/cleaning area.
•
Use only conductive fluid hoses for airless ap pli ca tions.
Be sure the gun is grounded through the hose con nec tions.
Check ground continuity in hose & equipment. Overall
(end to end) resistance of unpressurized hose must not
exceed 29 megohms for any coupled length or com bi na tion
of hose length. Use only high pressure airless hoses with
static wire approved for 3000 psi.
•
Vapors created when spraying can be ignited by sparks.
To reduce the risk of  re, always locate the sprayer at
least 20 feet (6 m.) away from spray area. Do not plug in
or unplug any electrical cords in the spray area. Doing so
can cause sparks which can ignite any vapors still in the
air. Follow the coating & solvent man u fac tur ers safety
warnings and precautions.
VOLTAGE
LENGTH OF CORD IN FEET
AMPERAGE
RATING
RANGE

5
1. New Sprayer
1. New Sprayer
Your sprayer was factory tested in an oil solution which
was left in the pump.
Before using oil-base paint,
 ush
with mineral spirits only.
Before using water-base paint
 ush with mineral spirits, followed by soapy water, then a
clean water  ush.
2. Changing Colors
2. Changing Colors
Flush with a compatible solvent such as mineral spirits or
water.
3. Changing from water-base to
3. Changing from water-base to
oil-base paint.
oil-base paint.
Flush with soapy water, then mineral spirits
.
4. Changing from oil-base to
4. Changing from oil-base to
water-base paint.
water-base paint.
Flush with mineral spirits, followed by soapy water, then a
clean water  ush
.
NEVER leave pump unattended
while under pressure!
FLUSHING
5. Storage
5. Storage
Always relieve pressure (See pressure relief
procedure on page 10) prior to storage or when
machine is unattended.
Oil-base Paint:
Flush with mineral spirits. Ensure that
there is no pressure in the unit, then close the prime/
pressure relief valve.
Water-base Paint:
Flush with water, then mineral spirits.
For longer term storage use a 50/50 mixture of mineral
spirits and motor oil. Always ensure that there is no pres-
sure in the unit, and close the prime/pressure relief valve
for storage.
6. Start-up after storage
6. Start-up after storage
Before using water-base paint,
 ush with soapy
water and then a clean water  ush.
When using oil-base paint,
 ush out the mineral
spirits with the material to be sprayed.
FIGURE 1
Prime/Pressure Relief Valve
(Prime/PR Valve)
Used to relieve pressure from gun, hose & tip and to prime
the unit when in OPEN position.
(It is in open po si tion
when there is a wider gap
between valve handle and
cam body).
When valve is in the CLOSED
position, there is only a very
slight gap between handle & body.
When closed the system is
pressurized
.
Handle as a Loaded Firearm!
FIGURE 2
PRESSURE CONTROL KNOB. (FIG. 2)
Used to adjust pressure. Turn clockwise (CW) to increase
pressure and coun ter clock wise (CCW) to decrease pres-
sure.
TOGGLE
SWITCH
ON
OFF
FIGURE 3
HOW TO FLUSH
Continued on next page............

6
1.
Be sure the gun safety latch is engaged and there
is no spray tip in the gun. Refer to page 14 on how
to lock the safety latch and the gun's safety features.
FIGURE 4
2
. Pour enough clean, compatible solvent into a large,
empty metal pail to  ll the pump and hoses.
3.
Place the suction tube into the pail.
4.
Turn the Prime/Pressure Relief (PR) Valve to the
"OPEN" , priming position. Refer to Figure 1.
5.
Point the gun into the metal pail and hold a metal
part of the gun  rmly against the pail. Refer to Figure 5.
FIGURE 5
MAINTAIN FIRM
METAL TO METAL
CONTACT BETWEEN
GUN AND CONTAINER
6.
Disengage the gun safety latch and squeeze the
gun trigger. Turn the ON-OFF Toggle Switch to the
"ON" position (Figure 3) and turn Pressure Control
Knob (Figure 2) clockwise to increase pressure just
enough to start the pump.
7.
Turn the Prime/PR Valve to the PRESSURE
"CLOSED" position. This will allow solvent to be
 ushed through the pump, hoses and gun. Allow the
unit to operate until clean solvent comes from the gun.
8.
Release the trigger and engage the gun safety
latch.
9.
Whenever you shut off the sprayer, follow the
"PRESSURE RELIEF PROCEDURE".
REMOVE SPRAY TIP.
ENGAGE GUN SAFETY
ENGAGE GUN SAFETY
LATCH.
HOW TO FLUSH (continued)
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.

7
1. Connect the hose and gun.
1. Connect the hose and gun.
a.
Remove the plastic cap plug from the outlet tee
and screw a conductive or grounded 3000 psi
airless spray hose onto  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. Check the electrical service.
Be sure the electrical service is 120 VAC, 15 amp
minimum, and that the outlet you use is properly
grounded.
NOTE:
*For Generator power, a minimum 7000 watt
generator with voltage regulation must be used.
4. Grounding
4. Grounding
2. Fill the packing nut/wet cup with
2. Fill the packing nut/wet cup with
5 drops of Airlessco Throat Seal
5 drops of Airlessco Throat Seal
Oil (TSO).
Oil (TSO).
See (Figure 6).
5. Flush the sprayer
5. Flush the sprayer
As per "Flushing Procedure" in this manual.
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.
FIGURE 6
SETTING UP

8
1. Learn the functions of the controls.
2. Prepare the material
2. Prepare the 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
3. Starting the sprayer
(See Figure 7, 8 & 9)
(See Figure 7, 8 & 9)
a.
Prime/PR Valve must be "OPEN" in the priming
position.
b.
When you have ensured that the gun safety latch is
engaged, attach tip and safety guard.
c.
Turn the ON-OFF Toggle Switch to the
"ON" position.
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. Optional LCD displays pressure.
g.
Disengage the gun safety latch and you are
ready to spray.
FIGURE 7
FIGURE 9
PRESSURE CONTROL KNOB
is used to adjust
pressure. Turn clockwise (CW) to increase pressure and
coun ter clock wise (CCW) to decrease pressure
.
FIGURE 8
TOGGLE
SWITCH
ON
OFF
PRIME/PRESSURE (PR) RELIEF VALVE
is used to
prime pump and to relieve pressure from gun, hose and tip.
Prime/Pressure Relief Valve
(Prime/PR Valve)
Used to relieve pressure from gun, hose & tip and to prime
the unit when in the OPEN position. (It is in open position
when there is a wider gap
between valve handle and
cam body)
When in the CLOSED
position, there is only a very
slight gapbetween handle & body.
When closed the system is
pressurized. Handle as a loaded  rearm!
STARTING UPSTARTING UP