Asahi Sunac SP1636 User manual

SP1636
Operation and Maintenance Manual
SP1636/28(S)
This manual contains important information on warnings and cautions. Read the manual
thoroughly before starting to operate the equipment, and follow the instructions.
A
lways keep the manual handy until such time as the equipment is no longer being used.
If your manual is lost or worn badly, do not hesitate to contact our agency which is closes
t
to you, or the Asahi Sunac Corporation, directly, and ask us to send you a new one.
LIGHT BEAR
for pneumatic airless coating equipment

Dear Valued Customer:
Thank you for buying our PneumaticAirless Painting Equipment, Model <SP1636/28/(S)>
LIGHT BEAR.
Please read this manual carefully before starting to operate the equipment. Please pay
particular attention to major specifications, warnings and precautions, including prohibited
items. Use the equipment appropriately and with care, following the instructions. We hope
that by doing so you derive benefit from use of the product over a long period of time.
The gun is geared to industrial painting. It is for use only by those who are familiar with its
workings and have undergone proper training; persons without such knowledge should not be
allowed to operate the equipment.
Should you have any questions with regard to the manual, please give us the “Model Name”
and “Serial Number” of your equipment, so that we may be able to help you with your
questions. You can reach us at any of the addresses, phone numbers and fax numbers
shown on the back cover.
Thank you,
Asahi Sunac Corporation
Thank you for buying our product.
Contents
1 For Your Safety.............................................................................1
2 Specifications, Dimensions and System Configurations ..............8
3 Setting Up for Operation...............................................................9
General Set-up Precautions....................................................9
Unpacking and Connections....................................................9
4 Operation....................................................................................10
Operation...............................................................................10
Shutdown and Equipment Care.............................................10
Color change and additive addition precautions ...................12
5 Maintenance ...............................................................................12
6 Tear Down Inspection and Parts Replacement Procedure.........13
7 Troubleshooting..........................................................................15
8 Performance Tips........................................................................16
9 Component Names.....................................................................17
10 Maintenance Log........................................................................25
11 Warranty .....................................................................................25

1
Please carefully read this manual and get acquainted with the equipment.
Please observe the operating procedures in the manual. Failure to do so may result in personal injury
and/or damage to property.
This manual covers only minimum safety precautions, and it does not suggest or imply that no other
precautions are required. Of course, each enterprise must observe its own rules as well as the laws and
regulations of the country or region in which it operates, in addition to the safety precautions in the manual.
Again, shown on the pages that follow are basic and minimum safety precautions for use of our products.
As shown below, safety precautions are classified into three categories based on the severity of
hazards involved.
WARNING Alerts a hazardous situation which may result in personal injury, with
instructions on how to avoid it.
CAUTION Alerts a hazardous situation which may result in damage or breakage to
equipment, with instructions on how to avoid it.
NOTICE Indicates important methods and practical information.
※A hazardous situation included in the CAUTION category could also cause a serious accident depending
on how matters develop. All the precautions in the manual convey significant information that you should
observe such precautions in order to ensure your own safety and prevent the equipment from failure.
Equipment misuse hazard
Never use hazardous materials, such as acidic or corrosive materials, or halogenated hydrocarbon
solvents with this equipment.
Should you have any questions with regard to the use of the equipment or materials to be used, please
feel free to contact us.
1
WARNING
For Your Safety

2
Injection Hazard
<<General Safety Precautions>>
●This is a high-pressure painting equipment and an extreme care should be exercised to prevent
serious personal injury.
This pump generates very high pressure to feed paint fluid to the airless spray gun.
High-pressure spray or ruptured component pieces from point-blank range can inject fluid or
fragments into your body, causing skin injury from which no small amount of toxic substances might
enter into the body.
Should that happen, get a proper medical treatment by a specialist, immediately.
If you don’t, you may suffer from a life-long disability or you may get amputated.
Fluid splashed in the eyes or on the skin can also cause serious injury.
<<Emergency Medical Treatment: A Must>>
If a high-pressure fluid splashes on your skin or into the eyes, go immediately to a
specialist and tell him/her exactly what type of paint fluid you were using in order to obtain
proper medical treatment.
●Don’t point the gun at anyone or at any part of your body.
Stay away from the trajectory of spray jet from the nozzle.
●Don’t put your hand or fingers over the spray nozzle.
●Don’t attempt to use the painting equipment -- until you are fully acquainted with its operation.
●Be extra vigilant when operating an air-spray painting equipment.
<<Spray Gun Safety Mechanisms>
●The spray gun is equipped with safety mechanisms. Use them properly.
●Each time you use a spray gun, check to see, in advance, if all the safety mechanisms operate
properly.
●Do not alter or modify or remove any part of the gun: the gun may behave unexpectedly and
personal injury may result.
□Trigger Lock
●When not spraying, always lock the trigger safety lock in order to disable trigger.
If you forget to lock the trigger, it may be pulled accidentally.
□Chip Guard
●When spraying, always put the chip guard on the gun.
The chip guard alerts injection hazard, reducing occurrences as a result.
The guard, however, cannot prevent hand or part of body from getting close to the nozzle
accidentally.
□Trigger Guard
●Don’t spray with the trigger guard removed. This guard prevents the trigger from being pulled
accidentally when the gun is dropped or hit by something.
WARNING

3
<<Nozzle Safety Precautions>>
●Don’t put your hand or fingers or anything over the spray nozzle.
●Be extra careful when cleaning or replacing the nozzle.
If the nozzle gets clogged while spraying, immediately lock the trigger safety lock and relieve the
fluid pressure in accordance with the “Pressure Relief Procedure,” and then take off the nozzle for
cleaning.
It is dangerous to wipe sticky paint off the nozzle with some residual pressure still remaining or
without locking the trigger safety lock.
When relieving pressure, follow the procedure below:
<<Pressure Relief Procedure>>
To reduce the risks of injury from injection, splashing fluid on the skin or in the eyes, etc.,
relieve the pressure following this “Pressure Relief Procedure” whenever you:
Inspect the pump or gun, Remove or mount the nozzle for cleaning or replacement, Stop
spraying.
The step-by-step procedure:
①Lock the trigger.
②Shut off air supply by turning the pressure control dial counter-clockwise, bringing down the
pressure all the way.
③Relive the ball cock, bring down the system pressure to zero, unlock the trigger and pull it
for double-checking.
④Lock the trigger again.
●When the nozzle or hose is clogged or when it is suspected that some pressure still remains
after going through the “Pressure Relief Procedure,” slowly loosen the chip guard mounting
nut or the connector at hose end, gradually releasing the pressure until it is completely
relieved. Then inspect the nozzle and hose.
WARNING

4
Equipment Misuse Hazard
<<General Safety Precautions>>
●Misuse, such as use of too much pressure, unauthorized component modification, improper paints
or solvents, use of worn or broken part, may result in a serious accident like pump breakage,
unexpected fluid injection, fluid splashed in the eyes or on the skin that possibly causes personal
injury, or even fire or explosion.
●Don’t alter or modify pump parts without our authorization or approval, for such a change may result
in equipment failure or malfunction.
●Inspect the whole system periodically. Repair or replace parts as required.
●When conducting spray operation, always wear eye protection, protective clothing, and breathing
protection recommended by the paint/solvent manufacturer.
Depending on the kind of pint fluid used and the ventilation performance, additional personal
protective equipment may be required. Please check it out with the paint/solvent manufacturer.
<<Equipment Interior Pressure>>
●Confirm the maximum fluid working pressure and maximum air input pressure of the pump.
Be careful not to exceed these maximum pressures when operating the pump.
Also, make sure that all component parts used for the equipment, such as hoses, connectors,
swivels, are compatible with the maximum pressures.
Should you find them not, set the pump at a pressure that does not exceed the lowest maximum
operating pressure of all parts and accessories used with the equipment.
●Each time you use the equipment, retighten all the joints before use.
<<Paint/Solvent Compatibility>>
Check the compatibility of the paint and solvent with the “material of the pump parts they come into
contact with” against the parts material specifications provided by the pump manufacturer -- before you
introduce the fluid (paint/solvent) into the pump.
<<Hose Safety Precautions>>
●High-pressure fluid in the hose can be very dangerous: it could cause injury to the operator or
damage to the equipment, spewing out of cracks, damage, wear in the hose, triggered by misuse or
spontaneously.
●Please handle hose carefully.
To move a hose from one place to another, don’t pull, but carry.
Don’t use paint or solvent that is not compatible with the interior and exterior materials of the hose.
●Check the hose for bending or squeezing, for if there is it may cause a local
Concentration of pressure, causing possible fluid leak.
●Don’t leave hose in an environment where temperature may go up to 80C or higher or where it may
go down to - 40C or lower.
●Securely retighten hose connectors and joints before use.
●Never use a broken hose.
Check the hose throughout its length for cut, fluid leak, wear, blister, scratches, and loose fittings.
Should you find anything wrong, stop using the hose right there and then, and replace.
WARNING

5
●When you fluid find leak, take no stopgap measures, such as covering the leak hole by hand or
adhesive tape. Such measures will only increase potential hazards.
●When you find fluid leak, replace the hose with a new one or contact our authorized repair shop.
●Use a hose that is compatible with our standard specifications.
●Our fluid hose standard specifications ensure a sufficient hose durability in an normal operating
environment. However, tension is applied to a hose for many hours, it deteriorates in a relatively
short time. When tension is applied frequently, it may not last longer than half a year. Under
normal operating conditions, replacement in a year would be recommended.
<<Moving Parts Hazard>>
●There is an air-motor piston rod in the air-motor cap. The piston rod moves up and down as air is
supplied to the air-motor. When operating the pump, be sure to put the air-motor cap on so that
your fingers may not be struck or caught in a pinch or shear point by the moving part, and that your
eardrum may not get injured by the deafening exhaust sound.
●There is a step at the piston rod connecting nut in between the air-motor and material cylinder,
which moves up and down as the pump operates. So don’t touch it when the pump is operating.
If you do so, you may get your fingers caught in a pinch point by the packing retainer.
●When checking or servicing the pump and component parts, bring the pressure down in advance in
accordance with the “Pressure Relief Procedure” on page 3 in order to prevent the pump from
behaving unexpectedly.
●With the pump running, don’t leave the painting equipment unattended.
Each time you stop spraying for a break or at the end of shift, shut off the air supply.
●Keep people away for the pump, children and adults who are not familiar with the airless painting
operation.
WARNING

6
Fire and Explosion Hazard
<<Source of Fire>>
As liquid flows through the pump and hose, static electricity is generated.
If each component of the painting equipment is not properly grounded, sparks may occur due to static
electricity. When there are vaporized solvent, sprayed paint particles, floating dust and other
flammables in the atmosphere near the painting equipment, these sparks can cause fire or explosion,
possibly causing serious injury to the operator and damage to the equipment.
●Provide fresh air ventilation in the spray area.
●Keep the spray area free of open flames, pilot lights, and other flammables.
●When using a pole gun, stay clear of electric wires.
●Ensure that equipment and conductive painting objects in the work area are properly grounded.
Take no chances: when these things are not properly grounded, fire or explosion can occur
triggered by electrostatic spark.
●If you feel any electric shock while using the painting equipment, stop spraying Immediately and
check the grounding of each component of the equipment.
Do not use the equipment until you identify and correct the problem.
●Keep a powerful fire extinguisher in the work area.
<<Grounding>>
To prevent hazards associated with static electricity, ground all the pumps, painting objects, painting
equipment and components that are used in the area. If they are not properly grounded, ground
properly, by all means, in accordance with the grounding procedure set forth by “Electrical Equipment
Technical Standard (Class D grounding or equivalent).”
The grounding procedure for each of the painting system components is as follows:
□Grounding Pump
●Connect a ring crimp terminal (that comes with equipment) to the pump grounding
terminal , the other clip to a Class D grounding object.
□Grounding Compressor
●Arrange grounding in accordance with the compressor manufacturer’s instructions.
□Gruonding Hose
●To ensure the grounding of a whole system, be sure to ground the hose. Especially when an
extension hose is used, check to see that it is ground properly.
●Once every week, inspect the hose in use for electrical resistance.
Class D grounding, our standard grounding, requires the resistance value to be 100or lower.
When the hose does not have a maximum resistance label on it, please check it out with the agency
from whom you bought the hose or the hose manufacturer directly.
Measure the electrical resistance of hose by connecting an ohmmeter to an appropriate location on
the hose. If the resistance measured exceeds the maximum value allowed, replace the hose with
a new one. Improper grounding of a hose puts the whole system in peril.
□Grounding Spray Gun
Aspray gun that is securely connected to the properly grounded hose and pump is considered to be
grounded properly.
□Grounding Painting Object
A contaminated hanger or grounding clip do not ensure proper grounding of a painting object.
Keep the hanger and clip clean to maintain proper grounding.
WARNING

7
□Grounding Fluid Container
When your fluid container is made of conductive metal, you can place it on the grounded floor or
table. When it is made of something else, you cannot.
□Grounding Cleaning Solvent Can
When the cleaning solvet is made of conductive metal, you can place it on the grounded floor or
table.
Don’t place it on a non-conductive sheet, such as a sheet of paper or corrugated fiberboard.
When you clean the pump or relieve the pressure, hold a metal part of the gun firmly to the side of a
grounded metal container and then pull the trigger.
<<Cleaning Safety Precautions>>
Before you get down to cleaning, check to see that the whole painting system and cleaning can are
properly grounded. (see “Grounding Cleaning Solvent Can.”)
●When cleaning the system, take off the nozzle in accordance with the procedure set forth in the
<<Nozzle Safety Precautions>> (on page 3), and bring the pressure down to a minimum level (that
is required for flushing with solvent).
●To prevent electrostatic spark, hold a metal part of the gun firmly to the side of a grounded cleaning
solvent can (made of metal), and trigger the gun for flushing.
<<Solvent Safety Precautions>>
Do not use halogenated hydrocarbon solvent.
Halogenated hydrocarbon solvent may explode when it comes into contact with the aluminum or plated
portion of pressure vessel (pump, heater, filter, valve, gun, etc.), possibly causing fatal or serious injury.
●Typical halogenated hydrocarbon solvents.
Chlorines Trichloroethylene, Tetrachloroethylene, Ethylene chloride
Bromines n-Propyl Bromide
Carbon-fluorines HCFC-225, HFC-43-10mee, HFE-449s1(HFE-7100)
(Shown above are typical examples and there are, of course, other kinds of halogenated hydrocarbon
solvents in the marketplace. Please check with your paint vendors or manufactures for further
details.)
●Spray-mist-filled atmosphere may cause respiration difficulty and/or intoxication.
Do not spray in an environment where ventilation is poor, such as indoors, in tunnel, inside the tank,
etc. When you spray, exercise care so that the operator, people and livestock near by may not be
affected.
The carbon alloy nozzle is precision-machined. To remove nozzle clogging,
don’t use a hard metal needle but use a soft wooden toothpick, etc. With a
toothpick push the stuffed material from the tip of the nozzle, then air blow.
A hard metal needle, if used, could damage the nozzle orifice beyond repair.
WARNING
NOTICE

8
●Dimensions
●Specifications
Model SP1636 SP1628
Name Light Bear
Pressure ratio 1：20 1：30
Fluid flow 3.2L/min
(Max. 10 L/min) 2.2L/min (Max. 6.8 L/min)
Maximum fluid working
pressure 10Mpa
(Air pressure at 0.5MPa) 15MPa (Air pressure at 0.5MPa)
Dimensions 500Ｌ×350Ｗ×900Ｈmm
Weight 33kg 32kg
Compressor requirements Continuous 1.5kW (2PS)
Intermittent 0.75kW (1PS)
●System Configurations
Pump
Suction filter
Suction hose
Air regulator
Air pressure gauge
Nozzle cleaner
Material filter
Special tool
Accumulator hose
Airless spray gun
※
Airless nozzle
Material hose
The items marked with ※do not come with the equipment as standard accessories.
Please choose suitable items from our painting equipment catalog that will best suit your applications.
505
350
919
2 Specifications, Dimensions and System Configurations

9
①General Set-up Precautions
(1)This airless spray equipment uses compressed air for the fluid displacement pump.
Use a compressor with a capacity of 1.5kW (2PS) or larger.
(2)Supply dry compressed air.
Wet compressed air, if supplied, may cause pump failure, such as valve shifting
error, due to freezing or rusting. Watch water accumulation, etc. in the
compressor tank.
(3)Pressure drop occurs when a compressor is installed in a place far removed from the pump. The
maximum compressed air pressure supplied to the pump is 0.5 Mpa.
Determine the capacity of compressor taking the compressor-to-pump distance into account.
(4)Securely ground the grounding wire.
Connect a ring crimp terminal (that comes with the equipment) to the pump grounding
terminal , the other clip to a Class D grounding object.
Improper grounding may cause electric shock, fire or explosion.
(5)When you noticed any failure symptom, take corrective actions in accordance with the “Tear Down
Inspection and Parts Replacement” (pages 13 and 14) and “Troubleshooting” (pages 15 and 16).
If your problems still exist after you did all this, don’t try to do anything further but immediately
contact our agency near you orAsahi Sunac directly, giving us details about the problems. Please
rest assured; we’ll take care of them.
②Unpacking and Connections
(See pages 18 through 24 for part names.)
Being 100% inspected at the factory before shipment, the airless pump is ready for operation once
connections are made with a hose and gun. Upon unpacking, however, please check the contents
thoroughly for any damage that may have occurred in transit and for missing parts. If you find
anything wrong, please get in touch with our agency near you or us directly at Asahi Sunac.
(1)Upon unpacking you’ll find that the equipment, high-pressure hose, and spray gun are not
assembled yet. You’ll have to put them together in the manner as described below:
(2)Connect a ring crimp terminal (that comes with the equipment) to the pump grounding
terminal , the other clip to a Class D grounding object.
Improper grounding may cause electrical shock, fire or explosion.
(3)Connect the accumulator hose to the joint at the outlet of cylinder-shaped material filter.
And connect the fluid hose to the joint further down.
Ensure that the fluid hose is hooked up securely. A loosely connected hose
may provide injection and splash hazards, possibly causing personal injury or
accident.
(4)Mount the spray gun at the end of high-pressure fluid hose. At this point, do not put the nozzle on,
yet.
When you mount the spray gun, lock trigger. If you fail to lock the trigger, it
may be pulled accidentally and personal injury may result.
(5)Connect the air hose to the nipple at the air regulator inlet.
With this you have made all the connections that have to be made.
3 Setting Up for Operation
CAUTION
WARNING
WARNING
WARNING
WARNING

10
①Operation
▲Flushing the equipment before first use
Flush the equipment before first use. Check the fluid passage for leak at the same time. If there
is any leak, retighten using two (2) special spanner, putting one on the joint, the other on the base.
Remove foreign materials, as well.
Foreign materials, such as dust, contaminants, etc., may cause the nozzle to get
clogged, resulting in inconsistent spray pattern. Flush thoroughly.
Equipment Flushing Procedure
(1)Provide 3 liters of solvent (cleaning thinner).
Fill an empty can (fluid container) with solvent (cleaning thinner). Put the suction pipe into the can
and check to see that the suction filter is fully immersed in the solvent.
(2)Gradually open the air regulator (turn clockwise) and supply compressed air and then start
operation. Set the compressed air at about 0.1 MPa.
In order to prevent an air regulator from getting damage , unlock the handle of air
regulator before operate.
(3)Put the tip of spray gun into solvent and pull the trigger. Solvent circulates through the system,
purging air inside (which comes out in the form of bubbles).
This will clean the liquid passage through the system, hose and gun.
(4)Once passage cleaning is done, pull the suction pipe off the fluid can and run the pump idly to
completely remove residual solvent within the pump. And then close the air regulator (turn
counter-clockwise).
Now it’s ready for operation.
▲Starting and adjusting the pump
(5)Provide a paint fluid can.
(6)Repeat Step (1) through (3), with paint fluid.
(7)Adjust the air regulator to keep compressed air pressure at 0.2 to 0.5MPa.
The fluid pressure of:
SP1636 is 20 times the compressed air pressure,
SP1628 is 30 times the compressed air pressure.
Therefore, when the ratio is:
1:20, fluid pressure will be 4MPa ~ 10MPa,
1:30. fluid pressure will be 6MPa ~ 15MPa or more, causing the pump to stop.
The fluid pressure can be 20, 30 times the operating air pressure, calling for
extra care when operating the pump.
(8) Put the nozzle on the spray gun.
Ensure that spray gun’s trigger is locked. If you fail to do so, trigger could be
pulled accidentally, resulting in personal injury.
(9)Check to see that there is no leak from the joint between the painting equipment and hose.
If you find leak:
Bring the pressure down, Drain the fluid,
Then, locate the point of leakage, Retighten to fix the leak.
4 Operation
NOTICE
WARNING
WARNING
CAUTION

11
②Shutdown and Equipment Care
(1)Check the equipment and hose for leak from joints.
1. Interruption or overnight shutdown with resumption due in 24 hours
①Leave the equipment filled with fluid.
In this case, because air will be purged from the fluid passage keeping the fluid in the way as
if it were stored in a paint can, the fluid in the equipment will be kept free from solidification.
2. Long-term shutdown for a period beyond 24 hours
When you use a kind of paint that precipitates rapidly or one that is of high
viscosity, flush the equipment in accordance with “Equipment Flushing
Procedure” on page 11 when you shutdown the equipment.
②Completely remove fluid from the equipment and keep it empty.
Any fluid paint left inside the equipment, how little it may be, will solidify.
Flush thoroughly with solvent.
When you flush, keep the solvent pressure as low as possible (the minimum
pressure enough for flushing).
For a short-term equipment shut-down with resumption due in 24 hours, leave
the equipment filled with solvent until you use the equipment again.
Do so each time you shutdown the equipment. It doesn’t do any harm to the
equipment but keeps it in a good operating condition.
(2)Take the nozzle off the gun. Wipe the nozzle mounting surface on the gun with a solvent-soaked
rag. Then clean the nozzle (you may dip it into solvent for a while for cleaning).
(3)Set the airless nozzle in the reversed direction with the rear end facing the nozzle cleaner, then
loosen the nipple letting air jet out blowing out the materials that clogged the nozzle.
Please exercise extreme care when cleaning or replacing the nozzle. Bring the
pressure down following the “Pressure Relief Procedure” and then take the
nozzle off. It is quite dangerous to try to remove paint stuck in the nozzle
unless the pressure is completely removed, with the trigger locked.
Follow the procedure described below to relief pressure.
<<Pressure Relief Procedure>>
①Lock the trigger.
②Shut off air supply by turning the pressure control dial counter-clockwise, bringing
down the pressure all the way.
③Relive the ball cock, bring down the system pressure to zero.
Unlock the trigger and pull it for double-checking.
④Lock the trigger again.
●When the nozzle or hose is clogged or when it is suspected that some pressure still
remains after going through the “Pressure Relief Procedure,” slowly loosen the chip
guard mounting nut or the connector at hose end, gradually releasing the pressure
until it is completely relieved. Then inspect the nozzle and hose.
(4)Clean the material filter when the day’s work is done.
Before you take parts apart, always drain all paint fluid from the system and
relief the pump operating pressure down to zero.
(5)Operate the “three-way ball cock” when you have to bring down the pressure instantly, for safety
reasons. However, to relive the paint fluid pressure down to zero, open the “ball cock.”
NOTICE
CAUTION
CAUTION
WARNING
WARNING

12
When you shutdown the equipment for interruption or overnight stoppage,
always lock the spray gun trigger. If you fail to do so, it may be pulled
accidentally, and personal injury may result.
③Color change and additive addition precautions
(1)When you change paint fluids, thoroughly flush the can with solvent so that no paint residue may
be left unremoved. (Paint residue may cause the nozzle to get clogged.)
(2)When you add additives, do so through the filter.
(3)When you change paint colors, take the suction pipe out of the paint can, pull the trigger discharging
all paint from the system (this way you can save solvent), then flush it with solvent repeating
suction-circulation-discharge circles as many time as it takes to completely flush the fluid passage
from the inlet to outlet. After this, change paint colors.
Equipment Maintenance Guidelines
(1)When the pump V packing is worn, replace.
(Rule of thumb: Replace every six months under normal operation condition.)
(2)When paint is solidified and accumulated in the pump, take it apart and clean.
Before you take parts apart, always drain all paint fluid in the system and
completely relieve the pump operating pressure and wrap air pressure down to
zero.
(3)Flush the spray gun by shooting solvent. In addition, you need to clean the contacting surfaces
between the seat housing and nozzle by wiping with a thinner-soaked rag. When paint is solidified
in the gun, take it apart and clean.
Please exercise extreme care when cleaning or replacing the nozzle. Bring the
pressure down following the “Pressure Relief Procedure” and then take the
nozzle off. It is quite dangerous to try to remove paint stuck in the nozzle
unless the pressure is completely removed, with the trigger locked.
(4)Always keep the high-pressure fluid hose clean, free from paint residue and other contaminants.
Remove deposited paint, if any. Always keep the hose free from mechanical shock.
(e.g., don’t stomp on, don’t put things on, don’t run over with vehicle.)
Never use a broken hose. Check the hose throughout its length for cut, fluid
leak, wear, blister, scratches, and loose fitting. Should you find anything
wrong, stop using the hose right there and then, and replace.
WARNING
5 Maintenance
WARNING
WARNING
WARNING

13
Before you take parts apart, always drain all paint fluid in the system and
completely relieve the pump operating pressure and wrap air pressure down to
zero.
When you apply grease to the cylinder interior or replace perishable parts, follow the procedure shown below.
(See the exploded diagrams for the numbers referred to in the text.)
Before you take parts apart, always drain all paint fluid in the system and shutdown compressed air supply.
①Remove the cap (4) from the
cylinder (1) using a special
spanner that comes with the
equipment.
At that time, the trip rod (15)
comes off with the cap.
Disconnect the trip rod from
the cap with a spanner.
(If the trip rod is not lifted up
enough to provide a room for
a spanner to be manipulated,
life the cap. This will shift the
valve pushing the shift rod up
making access by a spanner
possible.)
②Remove four bolts.
③Carefully lift the cylinder and
take it out from the top.
The entire piston (3) and air
valve (16) will be exposed.
④When you replace the air
valves (12) and (16), do so
with the toggle shuttle (5) lifted.
(In this case, the spring (10)
will be pointing up diagonally.)
⑤Remove the wire (11) and nut
(18).
Carefully lift the toggle shuttle
(5) off.
⑥When you put them together
again, do so in the reversed
order.
When reassembling, carefully
mount the stay so that it may
move perpendicular to the hole
and adjust the nut (18) so that
a 3mm “clearance” may be
provided between the air valve
(12) and air hole.
If you find any damage to the
“O”-ring, replace.
6 Tear Down Inspection and Parts Replacement Procedure
① Air Motor
WARNING

14
(See page 21 for configurations and part names.)
Shown below are the replacement procedures for the booster “V packing” at the upper end of the
cylinder and the two suction “V packings” at the lower end of piston rod.
Packing can be adjusted by retightening the packing retainer (2).
Service the pump setting it flat horizontally.
[Booster V Packing Replacement Procedure]
①Remove the accumulator
hose.
Remove the nut for the stay
that connects the pump
housing (1).
②Loosen the nut (19)
disengaging the threaded
portion of the rod and piston
rod (6).
Disconnect the air motor from
the material cylinder.
③Remove the cylinder (14) from
the pump housing (1).
④Remove the packing from the
check valve (8).
Pull the pump housing off the
body.
⑤Put the packing retainer (2)
back in.
Pull off the piston rod (6).
Remove the V packings.
⑥Put in new V packings, one by
one.
(Install the packing gland and V
packings with the convex side
pointing up.)
Reassemble in the reverse order.
[Suction V Packing Replacement Procedure]
①Put a spanner on the two flat
faces at the upper part of
cylinder (14) and carefully
unscrew to remove.
Then take out the piston rod
(6) and V packings.
②Put a spanner on the piston
rod (6) and unscrew the check
valve (8) to remove it along
with V packings.
③Install new V packings, one by
one.
(Install the packing gland and V
packings with the convex side
pointing down.)
② Material Cylinder

15
S
y
mptom Cause Remed
y
1. No fluid pressure ①Air regulator valve not opened. ①Fully open (turn clockwise).
②Defective pressure gauge ②Replace it with a new one.
③Poor cleaning: Pump valve stuck due
to hardened paint ③Flush thoroughly with thinner. If hardened paint still remains after that,
disassemble pump and clean.
2. Pressure does
not rise to
working
pressure
①Air in fluid passage ①Pull spray gun trigger for air bubble purging
through fluid circulation.
②Insufficient fluid supply ②Replenish fluid.
③Worn V packings ③, ④Replace V packings following V
Packing Replacement Procedure.
④V packing installed in reversed
direction
⑤Clogged suction filter not sucking
enough ⑤Clean suction filter (8).
3. Pump runs, but
amortizing
poorly
①Insufficient compressed air supply
capacity ①Replace compressor with one with larger capacity.
②Compressed air supply hose too small
in diameter ②Use larger hose in terms of diameter.
③Much compressed air consumed
elsewhere ③Provide a separate compressed air source for exclusive use.
④Air regulator not operating properly or
setting pressure too low ④Readjust.
⑤Insufficient fluid ⑤Replenish fluid.
⑥Clogged material filter ⑥Clean filter.
⑦Worn air motor valve or pump packing ⑦Replace perishable parts with new ones
following Parts Replacement Procedure.
⑧Nozzle of filter clogged with foreign
materials ⑧Flush and clean.
⑨Worn nozzle ⑨Replace nozzle with a new one.
(If worn too fast, suspect nozzle
compatibility with fluid. Also, if pressure too
high, nozzle service life gets shorter.)
4. Fluttering spray
and tails ①(1) through (9) per 3 above, apply ①Check (1) through (9) per 3 above.
②Fluid viscosity too high ②Adjust viscosity to proper level.
5. Pump does not
stop when stop
spraying
①No fluid ①Replenish fluid.
②Leak from fluid passage ②Bring fluid pressure down to zero and
retighten.
③Worn V packings ③Replace V packings with new ones.
6. Pump fails to
operate if
compressed air
introduced
①Seizure of rod and oiles metal ①Disassemble and clean rod and metal.
Replace oil seal with new one.
If damage is found to rod or metal replace.
②Packing retainer, (2) on page 24, too
tight ②Loosen packing retainer. The retighten it by hand until you can not
turn it any further.
Then turn it about another 15～30using
a spanner. That will be tight enough.
7. Air leak
(Sound is heard
when air leaks)
①Air valve is stuck in middle of stroke ①Remove cap and lift trip rod.
②Air valve is defective ②Replace
③Spring is defective ③Replace
8. Pump operates,
but output low ①Clogged suction filter ①Remove and clean.
If filter gets clogged all too soon, suspect
incompatibility. Contact us.
②Worn V packings affecting suction
performance ②Replace packings with new ones
③Foreign materials between valve seat
and ball ③Remove and clean
9. Fluid flow
suddenly stops
while spraying
Clogged nozzle Dip nozzle into thinner for a while to make
foreign materials softer. Then blow out with
compressed air from the opposite end.
7
Troubleshooting

16
V Packing Replacement Precautions
(1) Install V packings in the correct direction with the convex side pointing in
the right direction.
(2) Cylinder⑭clearance should be such that it can be pushed in by hand.
When it’s too tight, do not use plain washers⑪at all or use only one washer.
If the clearance is too tight, cylinder stroke may get sticky.
If the clearance is too loose, suction failure may occur.
(3) To mount the packing retainer②, tighten it by hand as far as you can.
Then tighten it further with a spanner for another 15~ 30.
If you tighten excessively, operational failure may occur.
If you tighten insufficiently, oil leak may occur.
Proper retightening at the end of service work helps packing to last longer.
When you replace the suction filter⑧on page 19, be sure to wear safety gloves
to avoid possible injury.
(1)Always pay attention to pressure
Don’t raise output pressure more than required.
Always lock the trigger of your gun – each time you stop spraying for a break or interruption.
When you found leak from joint,
Bring the pressure down,
Drain the fluid,
Locate the point of leakage,
Retighten.
Use the lowest pressure possible, when:
Flushing the fluid circulation passage in the system,
Circulating fluid.
(Air pressure at about 0.1MPa)
(2)Is the material hose OK?
Is there any sharp bending along the line?
Are hose fittings tight enough?
No hose damage?
No trace of any heavy object placed on the hose?
(3)When changing paints or adding additives …..
When you change paint fluid, thoroughly flush the can with solvent so that no paint residue may
be left unremoved. (Paint residue may cause the nozzle to get clogged.)
When you add additives, do so through the filter.
When you change paint colors, take the suction pipe out of the paint can, pull the trigger
discharging all paint from the system (this way you can save solvent), then flush it with solvent
repeating suction-circulation-discharge circles as many time as it takes to completely flush the
fluid passage from the inlet to outlet. After this, change paint color.
(Note) The specifications and configurations of this equipment are subject to change without
prior notice due to improvements being made continuously.
NOTICE
CAUTION
8 Performance Tips

17
Air regulator
Cart
Nozzle
Spray gun
High-pressure fluid hose
Material filter
Accumulator hose
Suction filter Suction hose
9 Component Names

18
SP1628
40344-7
SP1636
40344-6
SP1628S
40378-4
SP1636S
40378-5
Standard
specifications
SUS
specifications