Asahi Sunac SUPER BEAR SP2544 User manual

Operation and Maintenance Manual
High Performance Plunger Type Airless Pump
SUPER BEAR
SP2544/54/78
(
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 closest to
you, or the Asahi Sunac Corporation, directly, and ask us to send you a new one.

Dear Valued Customer:
Thank you for buying our High Performance Plunger Type Airless Pump, Model
SP2544/54/78(S) SUPER 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 ...........7
3 Setting Up for Operation............................................................8
General Set-up Precautions.................................................8
Unpacking and Connections.................................................9
4 Operation.................................................................................10
Operation............................................................................10
Shutdown and Equipment Care.......................................... 11
Color change and additive addition precautions ................12
5 Maintenance ............................................................................ 13
6 Tear Down Inspection and Parts Replacement Procedure......14
7 Troubleshooting.......................................................................16
8 Performance Tips..................................................................... 18
9 Exploded Diagram and Names of Parts .................................. 19
10 Maintenance Log.....................................................................28
11 Warranty ..................................................................................29

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.
Use of the equipment in a manner contrary to the instructions in this manual constitutes improper use,
possibly causing equipment failure, injury to the operator or damage to the equipment, etc.
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, ensure, 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.
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, an 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.
WARNING

4
<<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.
●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.
●Don’t use a repaired joint to fix fluid leak.
●If a fluid leak is present, always replace the hose with a new one. Use a hose compatible with
our standard specifications. Excessive pressure build-up is likely to occur in a hose shorter
than 20 meters.
●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

5
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, ensure 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

6
□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, ensure 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

7
●Dimensions
●Specifications
Model SP2578 SP2554 SP2544
Name SUPER BEAR
Fluid flow 1:20 1:45 1:65
Maximum fluid
working pressure 8L/min
(Max. 30 L/min) 6L/min (Max. 20 L/min) 4L/min (Max. 14 L/min)
Dimensions 720L x 600W x 1280H (mm)
Weight 115 kg 108 kg 105 kg
Compressor
requirements Continuous 5.5kW (7.5PS) Intermittent 3.7kW (5PS)
●System Configurations
Pump
Suction filter
Suction hose
Air regulator
Air combination (Air filter and Lubricator (Oiler) )
Air pressure gauge
Material filter
Accumulator hose (Optional item)
Duster gun (Optional item)
Special tool
Airless spray gun ※
Nozzle ※
Material hose ※
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.
2 Specifications, Dimensions and System Configurations

8
①General Set-up Precautions
(1)This airless spray equipment uses compressed air as the power source of the fluid pressure pump.
Use a compressor with a capacity of 3.7kW (5PS) 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 the air compressor is installed in a place far removed from the pump.
The maximum compressed air pressure supplied to the pump is 0.5 MPa.
Use a 3/4B hose or larger
(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 symptom of failure, take corrective actions in accordance with the “Tear
Down Inspection and Parts Replacement” (pages 14 and 15) and “Troubleshooting” (pages 16 and
17).
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.
3 Setting Up for Operation
CAUTION
WARNING

9
②Unpacking and Connections
(See pages 20 through 27 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 joint at the air regulator inlet.
Equipment setup is now complete.
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 10 liters of solvent (cleaning thinner).
Fill an empty can (fluid container) with solvent (cleaning thinner). Put the suction pipe into the can
and ensure 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:
SP2578 (with ratio of 1:20) is 20 times the compressed air pressure,
SP2554 (with ratio of 1:45) is 45 times the compressed air pressure,
SP2544 (with ratio of 1:65) is 65 times the compressed air pressure.
Therefore, when the ratio is:
1:20, fluid pressure will be 4MPa ~ 10MPa,
1:45, fluid pressure will be 9MPa ~ 22.5MPa,
1:65. fluid pressure will be 13MPa ~ 32.5MPa or more, causing the pump to stop.
The fluid pressure can be 20, 45, or 65 times the operating air pressure,
requiring extra care when operating the pump. Especially when the ratio is
1:65, the maximum compressed air pressure is only 0.5MPa, the resultant fluid
pressure is so great that you have to be careful about safety and about
equipment pressure resistance and durability. Use the minimum pressure that
is required.
4 Operation
NOTICE
WARNING
CAUTION

11
(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 painting equipment or 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.
②Shutdown and Equipment Care
(1)After completion of painting operation, perform one of the two treatments.
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).
Leave the equipment filled with solvent until you use the equipment again.
Do so each time you shutdown the equipment.
(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.
WARNING
NOTICE
CAUTION
WARNING
WARNING

12
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.”
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.
WARNING
WARNING

13
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.
5 Maintenance
WARNING
WARNING
WARNING

14
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.
※For the index number in parentheses ( ), see page 22.
When you apply grease to the cylinder interior or replace perishable parts, follow the procedure shown below.
(See the exploded diagram for the index number referred to in the following instructions.)
Before you take parts apart, always drain all paint fluid in the system and shutdown compressed air supply.
①Remove the air hose joint and the
nipple (28) mounted on the cap
(4), then remove the cap (4) itself.
Now you can replenish oil in the
valve.
②Loosen the spring housing (16) with a spanner, Unscrew the four hexagon socket head cap
screws in the pusher holder (9), Lift the pusher holder (9) up, Remove the roller (19), pin (20)
and other parts.
If you find wear on the roller (19) and pin (20), replace them with new ones.
③Remove the hexagon socket head
cap screws from the two valve
bodies (10), Remove the lock nut
(24) with a spanner, putting it on
the spool (23), Remove the cam
(12).
④Remove mounting the bolts that put
the cylinder (1) and stand (2)
together,
Lift the cylinder (1) up,
The piston (3) will be exposed.
⑤Inspect the O-ring (37) on the
piston (3).
If you find damage or wear, replace
the O-ring with a new one.
Clean the cylinder (1) interior and
then apply grease.
⑥Remove the nut disconnecting the
air motor and material cylinder.
Lift the piston (3) up.
⑦Disconnect the piston (3), rod (25)
and adaptor (8) from one another,
Pull out the rod (25) and spring
(27).
⑧Inspect the spring (27).
When valve-shifting response is
slow due to spring fatigue, replace
the spring (27) with a new one.
Reassemble in the reverse order.
① Air Motor
WARNING
6 Tear Down Inspection and Parts Replacement Procedure

15
※For the index number in parentheses ( ), see page 24.
Shown below are the replacement procedures for the booster V-packing (23) at the upper end of the piston
and the suction V-packing (23) at the lower end of the piston.
Suction V-packing Replacement Procedure
①Set the airless pump flat
horizontally,
Remove the cylinder (14) from the
pump housing (1) using a special
spanner.
②Put spanners on the check valve
body (8) and piston rod (6), and
Remove the check valve (8).
Check the packing retainer (5) for
wear or damage on the sliding
surface,
Replace it with a new one, if you
find wear or damage, and
Replace the V-packings (23) with a
new ones.
③When mounting, be careful so that
the direction in which the packing
retainer (5) and new V-packings
(23) each is installed is correct – if
you install them in a wrong manner,
they just don’t work the way they
should.
Reassemble in the reverse order.
Booster V-packing Replacement Procedure
Packing can be adjusted by retightening the packing retainer (2). To service set the pump flat horizontally.
①Remove the nut, disconnecting
the air motor and material cylinder.
Remove the stay mounting screw,
leaving the material cylinder alone.
②Remove the cylinder (14) from the pump housing (1),
Remove the check valve body (8),
Remove the suction packings.
⑤Assembly Precautions
1. Cylinder (14) clearance should be such
that it can be pushed in by hand.
When it’s too tight, do not use plain
washers (11) at 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.
2. To mount the packing retainer (2), 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.
③Loosen the packing retainer (2),
Pull out the piston rod (6), then
Remove the V-packings (23).
④Now put on a new V-packings (23).
At this point, be careful so that the
direction in which the packing
retainer (5) and new V-packings
(23) each is installed is correct – if
you install them in a wrong way,
they just don’t work the way they
should.
② Material Cylinder

16
※For part index numbers, see page 21.
Symptom Cause Remedy
1. No fluid pressure ①Air regulator not opened. ①Fully open.
②Defective pressure gauge (Contrary to
the meter reading, fluid pressure
builds up normally.)
②Replace it with a new one.
③Suction valve sticky due to solidified
paint left unremoved, which is
accounted for by poor cleaning.
post-shutdown cleaning.
③Flush thoroughly with thinner.
If hardened paint still remains after that,
disassemble pump and clean.
④Defective air regulator ④Take parts apart and clean the air regulator
or replace with a new one.
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 pump
housing replacement procedure.
④V-packing installed in reversed
direction
⑤Clogged suction filter not sucking
enough ⑤Clean suction filter.
⑥Swollen suction hose with fluid
passage (I.D.) that got too small ⑥Replace the suction hose with a new one.
3. Fluid flow drops ①Insufficient compressed air supply
capacity ①Replace compressor with one with larger capacity.
②Compressed air supply pump too
small in diameter ②Use larger hose in terms of diameter.
③Much compressed air consumed
elsewhere ③Provide a separate pipe line.
④Air regulator not operating properly or
setting pressure too low ④Readjust.
⑤Fluid level too low in the paint can ⑤Replenish fluid.
⑥Worn air cylinder valve or pump
packings ⑥Replace the worn parts in accordance with the Parts Replacement Procedure.
⑦Nozzle or filter getting clogged with
foreign materials ⑦Flush and clean each part.
⑧Worn spray nozzle ⑧If worn too fast, suspect nozzle compatibility
with fluid.
We have various kinds of spray nozzles for
you to choose from. Please contact us to
determine the spray nozzle that will best
serve your purpose.
Also, don’t use a pressure that is higher
than required: an excessive pressure will
make the service life of a hose shorter.
⑨Material filter is clogged. ⑨Clean the material filter.
7
Troubleshooting

17
Symptom Cause Remedy
4. Fluttering spray
and tails ①①through ③per 3 above, apply ①Check ①through ③per 3 above
②Fluid viscosity too high ②Adjust viscosity to proper level
③Clogged or contaminated nozzle ③Clean
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. Air motor fails to
run ①Worn or damaged roller pin ①Replace following the Part Replacement
Procedure
②Damage or burrs on the sliding
surfaces of cam (12), pusher holder
(9) and pusher (15)
②Replace following the Part Replacement
Procedure
③Spring (0109-027) fatigue ③Replace following the Part Replacement
Procedure
7. Pump operates,
but output low ①Clogged suction filter ①Remove and clean.
②Worn V-packings affecting suction
performance ②Replace packings with new ones
③Foreign materials between valve seat
and ball ③Remove and clean
V-packing Replacement Precautions
(1) Install V-packings in the correct direction with the convex side pointing in
the right direction.
(2) Cylinder ⑭clearance should be such that it can be pushed in by hand.
When it’s too tight, do not use plain washers ⑪at all or use only one
washer.
If the clearance is too tight, operation failure may occur.
If the clearance is too loose, suction failure may occur.
(3) To mount the packing retainer ②, tighten it by hand as far as you can.
Then tighten it further with a spanner for another 15~ 30.
If you tighten excessively, operation 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 filter ⑳on page 21, be sure to wear safety
gloves to avoid possible injury.
NOTICE
CAUTION

18
(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.
8 Performance Tips