AIRLESSCO Prolight Contractor Series User manual

ProLight
Contractor Series
Convertible Spray Gun
Convertible Spray Gun
Convertible Spray Gun
Form No. 001-627 Aug04
™

IMPORTANT!
To avoid possible serious body injury, always follow 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.
1. Engage gun safety latch. 4. On Airlessco Model Paint Sprayers turn
Prime/Pressure Relief Valve (PR Valve) to
the open (priming) position to relieve residual
uid pressure. (PR Valves on sprayers made by other
manufacturers may operate differently.)
There will be a wider gap between valve handle and
cam body when in open position. In the closed
position there is only a very slight gap.
Note: The valve handle can move both clockwise
and counter clockwise and can face different
directions.
2. Turn unit off and unplug from electrical outlet.
3. Disengage gun safety latch and trigger gun to
relieve residual uid pressure.
Hold metal part of the gun in
contact with grounded metal pail.
USE MINIMUM PRESSURE !
5. Re-engage gun safety latch and
close Prime/Pressure Relief Valve.
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.
PRESSURE RELIEF PROCEDURE
1
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]
SUBJECT TO CHANGE WITHOUT NOTICE.
Copyright © 2004, Airlessco by Durotech. All rights reserved.
WARNINGS - READ FIRST BEFORE USING PRODUCT
High pressure spray can cause extremely serious injuries such as amputation.
Handle the spray gun as you would a loaded rearm!! Read and understand all instruction manuals, tags,
warnings, users guides & labels supplied with the spray gun, airless pump, hoses, spray tips & any other
attachments before operating equipment.
Learn & follow “Pressure Relief Procedure” of the equipment in use. Never attempt to change or clean the
spray tip or service unit & gun without rst releasing pressure. If “Pressure Relief Procedure” is not known,
contact pump manufacturer for instruction.
Never leave pressure in the system while not in use.
Airlessco spray guns are designed for use with Airlessco spray tips only.
If any other attachments are used, the spray gun is considered to be modied and safe operation is now
limited to the safety of the attachment.
For safe renting of airless equipment, use rental instructions, warnings and forms supplied by airless
pump manufacturer
Be sure that all safety devices are operating properly before each use.

WARNINGS - READ FIRST BEFORE USING PRODUCT
Reversible
Spray Tip
Tip Guard
Trigger
Guard
MAJOR COMPONENTS OF SPRAY
GUN AND REVERSIBLE SPRAY 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
PROLIGHT GUN OPERATION
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.
Handle
(lter inside)
Gun Safety
Latch or lock
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.)
2
™
™
Press up here and pull
gently to remove guard

SPRAY TECHNIQUE
Good spray gun technique is at the core of any
spray paint operation. Operator skill and efciency
is as important as good equipment and good paint.
Good spray technique is a skill that can be quickly
learned by following these simple instructions.
If you are not familiar with spraying techniques,
we recommend that you study this section of your
manual and practice the proper technique on pieces
of cardboard or a suitable surface.
Hold the spray gun 12 - 15 inches away from the work surface and keep it perpendicular (straight) to the
surface. Move the spray gun parallel to the work and at a right angle to the surface.
RIGHT
Move the gun at a steady rate in order to apply
a good coverage. The wet coat should be just
under the thickness at which a run or sag will
occur. Slow gun movement or gun held too
close will result in an overly wet or thick coat
coverage that is likely to run or sag.
Do not wave the spray gun. This waving is called
arching. Instead, hold the spray gun at a 12 to 15
inch distance perpendicular from the work.
The closer the spray gun is held to the work, the
thicker the paint is deposited and the faster the gun
must be moved to prevent sags and runs. Holding the
gun too far from the work will cause excessive fog,
overspray, and a thin and grainy coat.
Keep parallel to surface.
WRONGRIGHT
WRONG
3

SPRAY TECHNIQUE
4
It is important to “trigger” the gun after the gun movement
(arm movement) has started and release trigger (shut
gun off) before gun movement ends. Gun movement is
always longer than actual paint (spray) stroke. In that
manner, even blending and uniform paint coat thickness
is achieved over the entire surface. When the gun is in
motion as the trigger is pulled, it deposits an even amount
of paint.
Overlap the previous pass by 1/3 the width of the spray
pattern. Aim at the bottom of the previous pass.
Spray with uniform strokes from left to right and from right to
left, holding same stroke speed, distance, lapping and triggering
as uniform as possible.
Adjust pressure control knob so that the paint is completely atomize from the spray gun. Insufcient pressure will result in
“tailing.” Too much pressure will result in excess fog and over-spray, excessive tip wear & increased sprayer wear & tear.
• Always use the lowest pressure possible to obtain
desirable results.
• Test spray pattern on a piece of cardboard or other surface.
• “Inside” and “outside” corners can be sprayer.
• Aim the spray gun toward the center of the corner. The
spray pattern is divided in half, and the edges of the spray
pattern on both walls are the same.

AIRLESS 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 Nozzle too large Use next smaller nozzle.
Material too thin
Pressure too high Reduce pressure.
Too little material Nozzle too small Use next larger nozzle.
Material too thick
Thin distribution in Worn tip Change for new tip.
center of pattern Wrong tip Use nozzle with a narrow spray angle.
"horns"
Thick skin on work Material too viscous Thin cautiously.
Application too heavy Reduce pressure and/or use tip in next
larger nozzle group.
Coating fails to Material too viscous Thin cautiously.
close & smooth over
Spray pattern irregular, Orice clogged Clean carefully.
deected Tip damaged Replace with new tip.
Craters or pock Solvent balance Use 1 to 3% "short" solvents remainder "long"
marks, bubbles solvents. (Most likely to happen with material of
on work low viscosity, lacquers etc.).
Clogged screens Debris in paint Clean screen.
Coarse paint pigments Use coarse gun lter screen.
Incompatible paint Use coarser screen for larger orice tips.
mixture & thinners. If thinner was added, test to see if a drop
on top of paint mixes or attens out on
the surface. If not, try different thinner in
fresh batch of paint.
TEST THE PATTERN
5

GUN DISMANTLING AND REASSEMBLY
6
IMPORTANT NOTE: Whenever working on Airless Equipment, be sure to follow the Pressure Relief
Procedure found in your manual. If the gun is attached to a sprayer, engage the gun trigger lock
(which may be called the gun safety latch). The gun trigger lock should always be set when the gun is
not being triggered.
REPLACING THE VALVE SPRING UNIT
Dismantling:
1. Unscrew the REV-GUARD™ and remove the spray tip & seal.
2. Pulling the trigger, unscrew the Valve Seat using a 5/8” socket wrench.
3. Unscrew the retainer nut, remove the retainer and retainer pins then push the shaft of the valve spring
unit out of the gun head.
4. Clean the Gun Head bore with solvent and a small brush. Do not use any sharp objects to scrape away
dried paint; doing so may cause damage to the gun head, causing a leak around the seal.
Reassembling:
1. Apply grease to the O-Ring then push valve spring unit rmly into gun head by hand.
2. Reinstall the retainer pins, retainer, and the retainer nut on valve spring unit, tighten the nut until one
thread is showing out of the back of the nut.
3. Pull the trigger and install the valve seat by hand until you feel a positive stop.
4. With the trigger locked, and using a feeler gauge (feeler gauge must be placed between the retainer
and gun body), tighten the retainer nut so that you have .020” spacing between retainer and gun body.
5. Unlock and depress the trigger, then torque the valve seat to 30 ft. pounds.

119-050 Screw
119-053 Nut
120-049 Retaining Ring
120-055 Wave Washer
120-056 Plastic Washer
120-082 Handle Seal
120-088 Handle Spring
120-090CX Course Filter
120-090FX Fine Filter
120-106 Handle Assembly
120-109 Gun Head
120-506 4 Finger Gun Trigger
120-529 Gun Seat Adapter
120-534 Gun Repair Kit
120-536 Gun Plate
120-537 Trigger Guard
120-538 Gun Trigger Lock
120-539 Pivot Trigger Pin
120-540 Actuator Pin (2)
120-542 2 Finger Gun Trigger
GUN DIAGRAM AND PARTS LIST
Part # Description
7
120-542
* Included in Handle Assembly:
Handle, Spring, Swivel

QUICK REFERENCE & SAFETY WARNINGS
High pressure spray can cause extremely serious injuries such as amputation.
Handle the spray gun as you would a loaded rearm!! Read and understand all instruction manuals, tags,
warnings, users guides & labels supplied with the spray gun, airless pump, hoses, spray tips & any other
attachments before operating equipment.
Learn & follow “Pressure Relief Procedure” of the equipment in use. Never attempt to change or clean the
spray tip or service unit & gun without rst releasing pressure. If “Pressure Relief Procedure” is not known,
contact pump manufacturer for instruction.
Never leave pressure in the system while not in use.
Airlessco spray guns are designed for use with Airlessco spray tips only.
If any other attachments are used, the spray gun is considered to be modied and safe operation is now
limited to the safety of the attachment.
For safe renting of airless equipment, use rental instructions, warnings and forms supplied by airless
pump manufacturer
Be sure that all safety devices are operating properly before each use.
MAJOR COMPONENTS OF SPRAY GUN
AND REVERSIBLE SPRAY TIP
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 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 the REV-GUARD™ retaining nut
onto the gun.
6. Turn guard in the desired position.
7. Completely tighten the retaining nut.
Reverse to
Unplug
TO REMOVE CLOGS FROM SPRAY TIP
Spray Position Shown
1. Lock gun trigger.
2. Turn REV-TIP™ handle 180 degrees.
3. Disengage trigger lock and 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 trigger lock and return handle to the spray position.
SPRAY GUN
Attach spray gun to airless hose &
tighten ttings securely.
The trigger lock should
always be set (locked)
when the gun is not
being triggered.
Cut along line and keep handy for Quick Reference
8
TRIGGER
LOCK
e
d
UNLOCK
LOCK
Reversible
Spray Tip
Tip Guard
(REV-GUARD™)
Trigger
Guard
Handle
(lter inside)
Trigger
Lock
#
#
RETAINING
NUT
Warnings Continued on Reverse

QUICK REFERENCE & SAFETY WARNINGS
INJECTION HAZARD
Fluid under high pressure from spray or leaks can
penetrate the skin & cause serious injury & the need for
amputation.
NEVER point the spray gun at anyone or any part of the body.
NEVER put hand or ngers over the spray tip. Do not use a
rag over your ngers, paint would penetrate through and
onto ngers.
NEVER try to stop leaks with your hand or body.
NEVER wipe off build up around spray tip.
ALWAYS remove the tip from the gun to clean it. After
following Pressure Relief Procedure!!
NEVER operate spray gun under pressure without spray tip.
NEVER try to “blow back” paint - this is not an air spray gun.
MEDICAL TREATMENT
If any uid appears to penetrate your skin, get EMERGENCY
CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell
doctor what uid was injected & have him call for treatment
instructions at NATIONAL POISON CENTER NETWORK
[phone].
SPRAY GUN SAFETY
ALWAYS SET SAFETY LOCK ON THE GUN IN
LOCKED POSITION WHEN NOT IN USE AND BEFORE
SERVICING & CLEANING.
DO NOT remove or modify any part of the gun.
Check operation of gun safety devices before each use.
TIP GUARD
NEVER operate gun without tip guard attached.
NEVER modify or alter tip guard.
NEVER use Airlessco tip guard on other attachments.
Airlessco’s tip guard is designed for use with standard spray
tips only. When using other than standard spray tips, consult
manufacturer of such attachment for recommended tip guard &
safety instructions.
SPRAY GUN SAFETY
NEVER work on gun when connected to hose.
Be very careful when removing hose or spray tip from gun.
A plugged line contains uid under pressure. If tip or line is
plugged, follow the Pressure Relief Procedure for the pump
you’re using.
SPRAY TIP SAFETY
Use extreme caution when cleaning or changing spray tips. If
spray tip clogs while spraying, engage the gun safety latch and
ALWAYS follow “PRESSURE RELIEF PROCEDURE” before
removing spray tip to clean it.
CLEANING
Refer to pump manufacturer’s recommendation for cleaning the
system. Release pressure from pump and hose, remove spray tip
and ush with lowest possible pressure.
GENERAL PRECAUTIONS
NEVER alter equipment in any manner.
NEVER use around children.
NEVER allow another person to use sprayer.
ALWAYS use face mask while spraying.
NEVER leave sprayer unattended with pressure in system.
FIRE EXPLOSION WARNING
SPRAYING VAPORS + STATIC SPARKING = FIRE/EXPLOSION
PREVENT FIRE AND EXPLOSION BY REDUCING STATIC SPARKING AND
ELIMINATING VAPORS BY FOLLOWING THESE WARNINGS
ALWAYS be sure all equipment, paint bucket and object being
sprayed are properly grounded. ALWAYS ground sprayer, gun,
paint bucket and object being sprayed. Be sure gun is grounded
through hose connection.
NEVER spray in closed area. Ventilation must be adequate to
remove vapors.
NEVER keep ammable materials in spray area.
NEVER spray highly ammable liquids.
ALWAYS use only high pressure conductive airless hoses with
static wire approved for 3000 psi. Never exceed 500 feet of hose.
NEVER SMOKE IN SPRAYING AREA.
ALWAYS ensure properly maintained re extinguishing
equipment is available.
NEVER spray in vicinity of open ame or other sources of
ignition such as water heaters and furnaces.
ALWAYS locate the sprayer and electrical outlets in use at
least 25 feet away from spray area in well ventilated area.
Do not plug in any electrical cords in spray area.
Follow the coating and solvent manufacture’s safety precautions
and warnings.
HALOGENATED HYDROCARBON WARNING:
NEVER use halogenated hydrocarbon (HHC) solvents or paints
that contain them in this system. Some of the most common of
these solvents are: Carbontetrachloride, Chlorobenzene,
Dichloroethane, Dichloroethyl Ether, Ethyl bromide,
Ethylchloride, Tetrachloethane.
FLUSHING AND CLEANING CAN CREATE STATIC SPARKING IF DONE IMPROPERLY!
NEVER spray solvents under pressure through spray tip.
Follow Pressure Relief Procedure and remove
spray tip for cleaning.
Use LOWEST POSSIBLE PRESSURE when
ushing and cleaning.
Hold gun rmly against a metal waste container to reduce spark
possibility.
NEVER use cleaning solvents with ash points below 140
degrees F. Some of these are: acetone, benzene, ether, gasoline,
naphtha. Consult your supplier to be sure.
9
Cut along line and keep handy for Quick Reference
#
#
NEVER OPERATE GUN WITHOUT TIP GUARD ATTACHED

10
XTEND-A-POLE SYSTEM
Tip Extensions - Complete with
Patented SPRAY CLEAN REV-GUARD
TIP EXTENSIONS, “G” THREAD
032-170 6” Long
032-171 12” Long
032-172 18” Long
032-173 24” Long
SWIVEL EXTENSION, “G” THREAD
032-184 36” Long
EXTENSIONS (BARE POLES)
Add Tip Extension or Swivel Extension
to create desired length
032-053 24” Long
032-054 36” Long
Strong yet flexible, suitable for
Airless equipment up to 3300 PSI
Part No:
100-012 3/16” Whip Hose, 4 Ft.
100-011 1/4” Hose, 50 Ft.
100-023 3/8” Hose, 50 Ft.
100-037 1/2” Hose, 50 Ft.
100-010 1/4" Hose Connector
100-009 3/8" Hose Connector
For a complete listing of Airlessco Airless Accessories, see catalog # 001-357
.
HIGH PRESSURE AIRLESS HOSE
Standard Tip Extension
Swivel Extension
Bare Pole
For sizes not shown, call factory for availability.
SPRAY TIP - ORIFICE SIZE (Inches)
(water @ 2000psi, 138 bar)
(latex paint @ 2000psi,
138 bar/1.36 spec. gr.)
*Pump will support tip worn to next larger size.
TIP IDENTIFICATION:
1st 3-digits identifies it as a REV-TIPTM for airless paint spraying (P.N.
560-xxx) or a REV-TIP TM for airless line striping (P.N. 562-xxxST).
4th digit is the fan width - the number is half the fan width, e.g., 5 means
a 10” fan. Exception are the“W” prefix tips which indicate a wide spray
pattern.
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.
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
Rev-TipTM for Painting
Fan Width (12” from surface)
in. (mm) .009 .011 .013 .015 .017
.019 .021 .023 .025 .027 .031 .035
.039 .041
4-6 102-152 209 211 213 215 217
219 221 223 225 227 229
6-8 152-203 309 311 313 315 317
319 321 323 325 327 335
8-10 203-254 409 411 413 415 417
419 421 423 425 427 431
10-12 254-305 511 513 515 517
519 521 523 525 527 531 535
12-14 305-356 613 615 617
619 621 623 625 627 631 635
639
641
14-16 356-406 715 717
721
739
741
16-18 406-457 815
819 821
831
20-24 508-610
W21 W23 W25
Gun Filter C= Coarse - 60 mesh F F F,C C
C C C REMOVE FILTER
F= Fine - 100 mesh
Wood Lacquer, Varnish •
Interior Stain, Sealer • •
Enamel •
Wood Exterior Stain • •
Exterior Vinyl, Acrylic, Latex
• •
Masonry Vinyl, Oil Base Alkyd • •
Latex, Acrylic • •
• •
Block Filler
• • • • • • • •
Elastomer
• •
• • •
•
•
•
Ceiling Hi Build, Mil White
• •
Structural Steel Heavy Coatings
• •
• • •
•
•
•
.029
REV-TIPTM
For Paint Spraying
P.N. 560-xxx
Includes Rev-TipTM,
Metal Seal & O-Ring Seal.
560-517
REV-TIPTM Orifice Size
1/2 Fan Width
Sample:
REV-GUARDTM
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.
5 & 55 GAL. SIPHON
Optional for SL
Model Sprayers
301-090-99
5 Gal. Siphon Assembly
301-543-99
55 Gal. Siphon Assembly
REV-TIPTM
SPRAY TIP SIZE CHART
Part Number 560-xxx
For a complete listing of Airlessco Airless Accessories, see catalog # 001-357

IMPORTANT
READ, LEARN &
UNDERSTAND ALL
LABELS, INSTRUCTION
MANUALS & SAFETY
WARNINGS BEFORE
USING THIS PRODUCT.
ProLight
Contractor Series
Convertible 2 & 4 Finger
Part Number 120-504