Lemmer DC-3000 User manual

1
WARNING..Read all instructions carefully before assembling components and operating sprayer. Incorrect procedure
could result in damage to the unit, severe personal injury and/or property damage. When spraying flammable materials,
sprayer must be placed at least 20 feet from target in a well-ventilated area. Vapours can be ignited by static discharge or
electrical sparks and result in severe personal injury. LEMMER airless sprayers generate high fluid pressure. Improper
use could result in an injection injury.
OWNER'S MANUAL
DC-3000, DC-4000
VANCOUVER • KELOWNA • CALGARY • EDMONTON • WINNIPEG • TORONTO • MONTRÉAL
DC-4000
cart
DC-3000
DC-4000
stand

2
TABLE OF CONTENTS
SAFETY PRECAUTIONS ...................................................................... 3 & 4
TECHNICAL SPECIFICATIONS ...................................................................5
PUMP COMPONENTS .................................................................................6
SETTING UP OF UNIT .................................................................................7
ELECTRONIC CONTROLS ..........................................................................7
TIP SELECTION & MAINTENANCE...................................................... 8 & 9
HOW TO SELECT TIP SIZEAND PROPER FILTER .................................10
STARTUP PROCEDURE:
UNIT PRIMING AND FLUSHING .................................................. 11
PRIMING UNIT IN PAINT ..............................................................11
TO TURN UNIT OFF ..................................................................... 11
HINTS FOR AIRLESS SPRAYING:
PAINTING AND TIP SELECTION .................................................12
SPRAY PAINTING METHOD ........................................................12
HELPFUL HINTS FOR TROUBLE FREE PAINTING:
SPRAYER......................................................................................12
PAINT ............................................................................................12
SPRAY TIPS..................................................................................12
FILTERS ........................................................................................12
PAINT HOSE .................................................................................12
ELECTRICAL ................................................................................13
EXTENSION CORD ......................................................................13
CLEANING INSTRUCTIONS............................................................. 14 & 15
MAINTENANCE & SERVICE.............................................................. 16 - 20
TROUBLESHOOTING ................................................................................21
OTHER QUALITY LEMMER PRODUCTS..................................................22
ACCESSORIES FOR LEMMER AIRLESS EQUIPMENT...........................23
L-65 PARTS ....................................................................................... 24 & 25
DC-3000 PARTS................................................................................ 26 & 27
DC-4000 PARTS................................................................................ 28 & 29
DC-7000 PARTS................................................................................ 30 & 31
DISTRIBUTION CENTRES ACROSS CANADA.........................................32
LEMMER WARRANTY ...............................................................................32

3
SAFETY PRECAUTIONS
WARNING
1) Injection hazard: Airless Painting Equipment can
cause serious injury if the spray penetrates the
skin. Do not point the gun at anyone or any part of
the body. The tip guard provides some protection
against accidental injection injuries, but is mostly a
warning device. Never put your hand, fingers or
body over the spray tip. Gloves and clothing do not
necessarily offer any protection either. Keep the
gun trigger safety lever in locked postion when not
spraying. Always have the tip guard in place while
spraying.
In case of penetration seek medical aid immediately!
Note to physician: Injection into skin is a serious
traumatic injury. It is important to treat the injury
surgically as soon as possible. Do not delay treat-
ment to research toxicity. Toxicity is a concern with
some exotic coatings injected into the bloodstream.
Consultation with a plastic surgeon or reconstructive
hand surgeon may be advisable. Be prepared to tell
the doctor what fluid was injected.
2) This system is capable of producing 3200 PSI. To
avoid rupture and injury, do not operate this pump with
components rated less than 3200 PSI working pressure
(including but not limited to spray guns, hose and hose
connections).
3) Do not spray paints or other inflammable fluids
indoors which have a flash point below 21 degree C, 70
degree F. Keep spray area well ventilated. Before
spraying, turn off all pilot lights and open flames.
4) Wear a respirator which is approved for the product
being sprayed.
5) Do not use halogenated hydrocarbon solvents in this
system; it contains aluminium parts and may explode.
Cleaning agents, coatings, paints, and adhesives may
contain halogenated hydrocarbon solvents. Don't take
chances, consult your material supplier to be sure. (ex:
methylene chloride and 1,1,1 - Trichlorethane)
6) Caution: When a flammable liquid is sprayed there may
be danger of fire or explosion especially in a closed
area.
7) Caution: Arcing parts. Keep the pump at least 20 feet
away from explosive vapors.
8) Caution: Static electricity can be developed by airless
spraying. Ground unit and object to be sprayed. On
electric units, unit power cord must be connected to a
grounded outlet. Use only three wire extension cords.
Static explosion can occur with ungrounded unit.
9) Flush system with spray tip removed. Always use
lowest pressure possible.
10) Always follow safety precautions and warnings printed
on paint container.
11) Only use spray guns and hoses supplied by Lemmer.
User assumes all risk and liability when using spray guns
or hoses not complying with minimum specification and
safety devices of Lemmer Spray Systems Ltd.
12) Inspect hoses before each use. Never use a damaged
hose. High pressure in hoses with wear, leaks or splits
may cause the hose to rupture and cause serious
personal injury. Never try to stop or deflect leaks with any
part of your body.
13) Use extreme caution when cleaning spray tip guard.
DO NOT try to wipe off build up around the spray tip
before following shut down procedure. Follow the Shut
down Procedure, then follow the spray tip manufacturer’s
instructions for removing and cleaning the spray tip.
14) Never attempt to change spray tip or leave the unit
unattended without first shutting off pump, releasing fluid
pressure, and locking the trigger safety lock.
15) Use extreme caution when changing spray tip. Follow
the Shut down Procedure, then follow the spray tip
manufacturer’s instructions for changing the spray tip.
ATTENTION
1) Risque d’injection de peinture: Le matériel de
pulvérisation sans air peut entraîner de graves blessures
s’il y a pénétration de la peau par la peinture. Ne jamais
pointer le pistolet vers une personne ou vers soi-même.
La garde de la buse limite le risque de blessures
accidentelles par injection mais constitue principalement
un élément de mise-en-garde. Ne jamais mettre la main,
les doigts ou toutes parties du corps contre la buse. Le
port de gants et de vêtements n'est pas nécessairement
une forme de protection non plus.Laisser le cran de sureté
du pistolet en position fermée quand il nést pas utilisé.
Toujours avoir la garde en place pour peindre.
En cas d’accident, demander immédiatement des soins médicaux.
Note au médicin: La pénétration de peinture dans la peau peut causer
de graves blessures. Il est important de traîter la blessure à la
chirurgie aussitôt possible. Ne pas retarder le traitement pour
rechercher la toxicité. La toxicité peut avoir de graves conséquences
quand certains enduits exotiques son injectés directement dans le
systéme sanguin. Une consultation avec un chirurgien spécialisant en
reconstruction de mains serait conseillable. Soyez prêts à décrire au
médecin quel liquide a été injecté.
2) Ce matériel peut produire une pression de 3200 lbf/po2. Afin d’éviter
des ruptures et des blessures, ne pas utiliser cette pompe avec des
éléments dont la pression nominale de service est inférieure à 3200 lbf/po2
(y compris les pulvérisateurs, tuyaux flexibles et raccords).
3) Ne jamais pulvériser à l’interieur un produit inflammable qui a un point
éclair inférieur à 21 degrés C,70 degrés F. L’endroit où vous peinturez doit
toujours être bien aéré. Avant de pulvériser s’assurer qu’il n’y a aucune
flamme ou pilot (veilleuse) de fournaise en marche dans l’appartement.
4) Servez-vous d’un masque respiratoire qui est certifié pour le produit que
vous pulvérisez.
5) Ne pas utiliser de solvants contenant des hydrocarbures halogénés
avec ce matériel. Il contient des particules d'aluminium et peut exploser. Les
agents de nettoyage, enduits, peintures et, adhésifs, peuvent contenir des
solvants contenant des hydrocarbures halogénés. Soyez prudents;
consultez votre fournisseur pour les informations nécessaires. (ex:
méthylène chloride and 1,1,1 - Trichloréthane)
6) Attention: La pulvérisaton d'un liquide inflammable peut entraîner un
risque d'incendie ou d'explosion, surtout dans les espaces fermés.
7) Attention: Étincelles électriques. Ne pas placer la pompe à moins de 6
mètres des vapeurs explosives.
8) Attention: La pression du produit que l’on pulvérise peut produire une
charge électrostatique. Mettre le matériel et l'objet à pulvériser à la terre.
Sur les modèles électriques, le cordon électrique doit être attaché à une
prise de courrant reliée à terre. Le cordon de rallonge doit être à 3 fils. Des
décharges d'électricité statique peuvent se produire si le matériel n'est pas
mis à la terre.
9) Retirer l'embout de pulvérisation avant de rincer le matériel tout en
utilisant une pression aussi basse que possible.
10) Toujours prendre les précautions nécessaires et observer toutes les
consignes de sécurité figurant sur le pot de peinture.
11) N'utiliser que les pulvérisateurs et les tuyaux flexibles fournis par
Lemmer. Les personnes qui utilisent des pulvérisateurs et des tuyaux
flexibles non conformes aux standards d'utilisation et de sécurité minimum
du fabricant de la pompe le font à leurs propres risques et seront les seuls
responsables.
12) Examiner soigneusement le tuyau avant de s'en servir. Il ne faut jamais
utiliser un tuyau endommagé ou avec des fentes. Un tuyau à haute pression
qui n'est pas en bon état représente un serieux danger de blessure à la
personne en cas de crevaison soudaine. Il ne faut jamais essayer d'arrêter
des fuites de liquide avec n'importe quelle partie de votre corps.
13) Il est nécessaire d'exercer beaucoup de précaution pendant le
nettoyage de la protection de la buse. Ne jamais essayer d'enlever la
peinture qui aurait pu s'accumuler sur la buse avant d'avoir suivi les
consignes de sécurité concernant le nettoyage et le remplacement de la
buse.
14) Ne jamais essayer de changer la buse ou laisser l'appareil sans surveillance
avant d'arrêter le moteur, couper la pression et verrouiller la gâchette du
pistolet.
15) Le remplacement d'une buse doit être fait avec beaucoup de
précaution. Référez-vous au PROCÉDÉ D'ENTRETIEN.
HIGH PRESSURE!
INJECTION HAZARD!

4
SAFETY PRECAUTIONS
16) Il ne faut jamais essayer de déplacer l'appareil en tirant sur le
tuyau. Il faut aussi éviter tout tortillement du tuyau.
17) Les enfants et le personnes n'ayant aucune
expérience avec ce genre de pulvérisateur doivent êtres
gardés à l'écart de l'appareil et du chantier de travail.
18) Quand on décharge des liquides inflammables il
faut utiliser des pots conducteurs en métal. Quand on
relâche la pression avec le pistolet, une partie métallique
du pistolet doit être en contact avec le pot en métal muni
de mise à la terre.
19) La protection de la gâchette réduit le risque
d'activement involontaire si on laisse tomber le pistolet ou s'il est
frappé par accident. Ne jamais utiliser le pistolet sans la
protection de gâchette.
20) Procédé à suivre avant tout travail d'entretien ou de
nettoyage.
1) Bloquer la gâchette avec le levier de verrouillage.
2) Placer l'interrupteur MARCHE-ARRÊT en position ARRÊT.
3) Débrancher le cordon électrique.
4) Ouvrir la vanne de mise à l'air libre pour relâcher la pression.
Gardez-la ouverte jusqu'au moment où vous êtes prêts à utiliser
l'appareil.
5) Enlever la buse.
6) Débloquer le levier de verrouillage de la gâchette.
7) Relâcher le reste de la pression en déchargeant avec le
pistolet dans un pot en métal. Quand on relâche la pression, une
partie métallique du pistolet doit être en contact avec le pot en
métal muni de mise à la terre. (Il n'est pas nécessaire d'utiliser un
pot avec mise à la terre pour des produits non inflammables,
comme par exemple le latex).
8) Ramener le levier de verrouillage en position bloquée.
Avertissement
Cet appariel est équipé d'un disjoncteur à Protection thermique.
En cas de surcharge, le disjoncteur automatique coupe le moteur
de la source d'alimentation.
• Toujours déconnecter le moteur de la source d’alimentation avant de
travailler sur l’appareil.
• Lorsque le disjoncteur coupe le moteur de la source d’alimentation
relâcher la pression en plaçant le clapet d’amorçage en position
“amorçage”.
• Placer l’interrupteur MARCHE-ARRÊT en position ARRÊT.
Attention: La cause de la surcharge doit être eliminée avant de
remettre le moteur en marche.
Données électriques.
Si l'on utilise un cordon de rallonge, veillez à ce qu'il soit à 3 fils (avec
mise à la terre) et avec certification CSA. Le calibre des fils doit être
suffisant pour l'ampérage qui est nécessaire pour que l'appareil
fonctionne. Voir le tableau ci-dessous indiquant les calibres minimuns
requis selon les différentes longueurs de la rallonge.
Il est important de garder le moteur propre et à l'abri de l'humidité.
L'isolation créée par la peinture sèche pourrait le surchauffer et
l'endommager.
Ne jamais enlever la broche de la mise à la terre car elle est essentielle
pour la slûreté du travail.
16) Do not pull on hoses to move equipment, DO NOT kink or bend
the hose sharply.
17) Keep children or anyone not familiar with airless spray
systems away from equipment and work area.
18) Conductive metal containers must be used when
flushing flammable fluids through the system. Always
flush at low pressure with spray tip removed. A metal part
of the spray gun must be held firmly against the grounded
metal pail when flushing or relieving pressure from the
gun.
19) Trigger guard helps reduce the risk of accidentally
triggering the gun if dropped or bumped. Do not use a spray gun
without a trigger guard.
20) Shut Down Procedure
Always follow Shut Down Procedure before starting any
troubleshooting, servicing or cleaning.
1) Engage the trigger safety lock in the locked position. Test the
trigger safety lock to ensure the lock is working properly.
2) Turn the On/Off switch to the Off position.
3) Unplug the electrical cord on the sprayer.
4) Open the prime valve to relieve pressure. Leave open until
ready to spray or test or clean.
5) Remove the spray tip.
6) Disengage the trigger safety lock.
7) Trigger the gun into a metal pail to relieve any remaining
pressure. A metal part of the spray gun should be held firmly
against the grounded metal pail when relieving the pressure from
the gun. (A grounded metal pail is not required for non-flammables
such as latex.)
8) Reset the trigger safety lock to locked position.
Warning
This unit is provided with a thermally protected Reset. If an
overload occurs, the thermally protected automatic reset discon-
nects the motor from the power supply.
• Always disconnect motor from power supply before working on
equipment.
• When thermally protected reset disconnects the motor from the
power supply, relieve pressure by turning priming valve to “prime”.
• Turn ON-OFF switch to OFF.
Caution: The cause of the overload should be corrected before
restarting.
Important: Read and understand these special safety precautions
before operating the unit.
Electrical requirements
If an extension cord is used, make sure it is a 3 conductor type (has
grounding wire) and is CSA approved.Also make sure that its wire size
(AWG) is thick enough to carry the amperage your machine requires.
The chart below will show the minimum recommended AWG for specific
lengths. See next page for pump specifications.
Remember; keep the motor clean and dry. Paint acts as an insulator
and will cause overheating and/or motor damage.
Do not remove or bend grounding pin under any circumstances, it is
essential for safe operation.
Cord Motor Amperage Rating
Length 0-5 67891011121314151617181920
25 ft 16 16 16 16 16 16 14 14 14 12 12 12 12 12 12 12
50 ft 16 16 16 16 16 16 14 14 14 12 12 12 12 12 12 12
75 ft 16 16 16 16 16 16 14 14 14 12 12 12 12 12 12 12
100 ft 16 16 16 14 14 14 14 14 12 12 12 12 12 12 12 12
125 ft 16 16 14 14 14 12 12 12 12 12 12 12 12 12 12 12
150 ft 16 14 14 14 12 12 12 12 12 12 12 12 12 12 12 12
Minimum recommended AWG

5
INTRODUCTION:
We appreciate your decision to purchase a Lemmer high
quality professional paint spraying system and believe
you will find it to be the best sprayer you ever owned.
Your Lemmer airless paint machine is capable of spray-
ing a wide variety of latex, oil-based and alkyd paints, as
well as stains, preservatives and other architectural
coatings. The material you are spraying will have a direct
effect on the amount of pressure required for the optimum
pattern and coverage to be obtained. We recommend
that before actually beginning your job, you carefully read
this manual and practice with the sprayer until you feel
comfortable using it.
The Lemmer DC-3000 & DC-4000 sprayers are powerful
and versatile enough to be used with a variety of acces-
sories (extra lenghts of hose, extensions, pressure feed
rollers, etc. as shown on page 23) to make them even
more versatile systems. Ask your supplier about the
recommended accessories for your particular job.
PRODUCT SPECIFICATIONS
PUMP TYPE:
The DC-3000 & DC-4000 units use a double acting piston
pump, with stationary packings and the DC-4000 has a
hard chromed piston. This gives good service life and is a
simple to maintain system. The valves are stainless steel
balls with tungsten carbide seats, giving very good
reliability.
Industrial grade DC motors are used in conjunction with
reliable pressure control sytems.
The DC-4000 uses an innovative electronic control which
varies the speed of the pump in accordance with your
need for pressure and material flow, with a minimum of
fluctuation in spray. This system allows tips as small as
.009" to be used for lacquer, yet perform well with large
tips in heavy bodied products.
ADVANTAGES OF THESE SYSTEMS ARE:
•Pump stops working when you do. Minimizes wear.
•Motor operates only as fast as the job requires again
reducing wear (DC-4000 only).
•Accurate spray pattern with minimal overspray.
•Minimal or no thinning of paint products.
•Pumps straight out of original paint container.
•Variable pressure from 0 to 3000 PSI.
•Various nozzles are available for slow to fast spraying.
•Light weight, compact and portable.
•Quiet running and low power consumption.
•Steady spraying pressure - no fan fluctuations.
•Compact paint pump - quick cleaning, less parts to wear.
TECHNICAL SPECIFICATIONS
DC-3000 DC-4000
Weight: 31 lbs (14 kg) 77 lbs (35 kg)
Capacity, volume @ 2000 psi: .47 gpm .57 gpm
Maximum tip size, 1 gun: .021 (.019 installed) .025 (.023 installed)
Maximum tip size, 2 gun: .015 (.013 installed) .017 (.015 installed)
Motor: 3/4 hp dc industrial 3/4 hp dc industrial
Power requirements, 110V: 6.5A,115VAC,60HZ 12A,115VAC,60HZ (North America)
220V: 6A,220VAC,50HZ (Europe)
Spraying pressure: 0 - 3000 psi 0 - 3000 psi
Maximum hose length: 300 feet (91meters) 300 feet (91meters)
Maximum power cord: 300 feet (14-16 guage) 300 feet (12-14 guage)
Paint inlet: metric 1/2" npt(f)
Paint outlet: 1/4" npt(m) 1/4" npt(m)
Gear oil capacity: 200 ml. EP 90w
Wetted parts: Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon,Chrome,Zinc
Capability: All conventional coatings, ie: latex, stain, lacquer, varnish, ink, primer, preservatives and many other
architectural coatings with the DC-4000 such as block fillers and some elastomerics and glues.
IMPORTANT NOTICES:
Due to the nature of operation of this unit, even though the motor cuts off, or appears to have cut off, it may re-
start at any time. Even once the switch has been turned off, there will likely be pressure remaining in the
system. Do not service the unit unless it has been turned off, unplugged and the pressure has been relieved.
Pressure is relieved by turning the prime knob counter clockwise and double checking by triggering the gun.
DO NOT USE STEEL BRAID paint spray hose! The DC-3000 & DC-4000 can only be used with fibre braid hose.

6
PUMP COMPONENTS
SPRAY GUN:
The spray gun is designed
specifically for airless spraying.
Since there is no compressed air
to atomize the paint, atomization
is accomplished by forcing the
paint at a very high pressure
(3200 psi) through a very small
hole (.017" diameter). Because
of this high pressure, the spray tip
and gun valve are made of
tungsten carbide for maximum
wear resistance. The gun body is
made of forged alloy and ano-
dized for chemical resistance.
As a safety feature, the spray gun
can be locked with the trigger
safety lever when you are not
spraying. Be sure to read all
warnings concerning the high
pressures of airless spraying on
page 3 & 4.
PISTON PUMP (DC-3000 & DC-4000):
Uses two sets of packings and two check valves in
conjunction with an abrasion resistant piston. This forms
a double acting pump; ie pumps on both up and down
stroke. Both sets of packings are stationary, eliminating
costly cylinder wear.
CENTRAL BODY (DC-4000):
Is a meeting point of pump and speed reducer. Helps
turn rotating motion of motor and reduce into an even up
and down motion to drive pump.
SPEED REDUCER(DC-3000):
Consists of a two stage gear reduction in permanent
grease for long life. All bearings are alsopermanently
greased. Converts the high speed output of motor into
very high torque to drive pump.
SPEED REDUCER (DC-4000):
Consists of a single stage gear reduction in an oil bath for
long life. All major bearings are also lubricated by this oil.
Converts the high speed output of motor into very high
torque to drive pump.
MOTOR (DC-3000):
Is an industrial grade high speed unit. Its permanent
magnet DC type construction withstands construction site
power fluctuations. The higher rpm of this motor results in
a compact and lightweight design.
MOTOR (DC-4000):
Is an industrial grade high quality unit. Due to the perma-
nent magnet DC type construction, the motor will run at
different speeds, depending on how much voltage it is
sent by pressure control box. This allows for highly
accurate control of pressure.
Motor also features long life brushes, which are readily
accessible from the outside.
PRESSURE CONTROL BOX (DC-3000):
A rugged membrane transducer transmits a paint pres-
sure signal to an electronic relay which then powers the
motor. This on-off design has a pressure fluctuation of
about 200 psi.
PRESSURE CONTROL BOX (DC-4000):
It balances input from the pressure control box with a
signal from the sensor. On the basis of these two inputs,
and electronic decision is made regarding how much
voltage, if any, is required by the motor to maintain an
even pressure. The more pressure set by operator, or
pressure drop from a large tip, the more voltage is sent to
motor to speed up the pump. When the gun is released,
the pressure rises and the motor is turned off.
The advantages of this system will become most obvious
if you try smaller tips (.011/.013) at lower pressures for
lacquering or other fine work.
A safety circuit is also incorporated which will turn the
pump off if it runs out of paint at spraying pressures.
(above approx. 1000 psi) If the unit drops from spraying
pressure to below approx. 500 psi, for more than 25
seconds continuously the safety will turn the pump off.
This is to reduce the typical packing damage from “dry”
running. At pressures below approx. 1000 psi, the safety
will not engage, making the unit fully compatible with all
types of pressure rollers. It also prevents interference of
the safety with typical cleaning procedures.
(trigger shown in horizontal
locked position)
locked
unlocked
Important
To engage trigger
safety lock, turn
lever tab to horizon-
tal position. Test
regularily for proper
functioning while
system is shut
down.
For models
L45 & L-50
Figure 1b. - DC-4000 components.
motor
pail hook
suction pipe return hose
control box
speed reducer
grease fitting
central body
paint pump
brush cap
suction screen
Figure 1a. - DC-3000 components.
paint pump
prime valve
motor
pressure control
control box
speed reducer
prime valve
suction
system

7
SETTING UP OF UNIT
TOOLS NEEDED:
2 x 8" or larger crescent wrench
PROCEDURE:
1) Remove all system components from the box for
assembly.
2) Remove protective cap from outlet connection of
pump.
3) Install handle and tool box. (DC-4000 only).
4) Connect high pressure airless paint hose to pump
outlet. Tighten to approximately 20 ft. lbs.
5) Attach the tip assembly to the spray gun.
6) Connect the paint hose to the swivel connection of
the spray gun. Tighten 20 ft lbs. Ensure the gun
handle is securely hand tightened to the gun.
7) Double check all connections, the unit is now ready.
Note: The pump contains a preservative oil when you
receive it, that may drip from the various connections
when the protective caps are removed.
WARNING: INJECTION HAZARD POSSIBLE. DO NOT
SPRAY WITHOUT TIP IN PLACE. ALWAYS ENGAGE
TRIGGER LOCK BEFORE REMOVING, REPLACING
OR CLEANING TIP. NEVER TRY TO CLEAN THE TIP
WITH YOUR FINGERS.
To disengage your trigger lock: Your spray gun is
shipped from the factory with the trigger lock in the
engaged position (horizontal on the L-65). To disen-
gage, turn the trigger lock down until it is in a vertical
position. To engage the trigger lock, turn it back to a
horizontal position.
trigger lock.
Figure 2. - L-65 gun components.
gun handle
with filter
inside.
hand tight
only!
tip.
tip housing.
trigger guard
for safety. do
not remove!
high pressure
swivel, 1/4"npt.
ELECTRONIC CONTROLS (DC-4000):
OFF: The first 10-20 degrees of pressure knob rotation
do not activate unit.
PRIME ZONE: The next approx. 20 degrees of rotation
will turn the motor on at a constant slow speed, when the
prime valve is in the open (prime) position. This is the
best speed for priming and cleaning the unit. It also works
well for power rolling. The safety cutout is not activated in
this zone. Maximum pressure in the prime zone is about
1000 psi.
SPRAYING ZONE: As the pressure knob is turned past
the prime zone (with prime valve open) the motor will
suddenly change from a constant low speed to full speed.
When the prime valve is closed, this will give fully adjust-
able pressure from about 900 psi to approximately 3000
psi.
The safety circuit is activated throughout the spray zone.
Safety turns motor off if the pressure drops from spraying
pressure to less than 500 psi for more than 25 seconds
(continuous). If the pump were to run out of paint, the gun
would have to be held open to ensure that the pressure
drop is enough to activate safety. This is to prevent
accidental triggering of safety with large tips, air bubbles
in paint etc. Indicator light will go off if safety has been
activated. Safety is re-set by turning power OFF for 3-5
seconds.
Figure 4. - DC-4000 control box components.
circuit
breaker
prime
valve
to prime,
turn ccw
on/off
pressure
control
"spray"
"prime"
"off"
sensor assembly paint out (hose
connection)
indicator light
Figure 3. - DC-4000 system components.
foot valve
paint pump
oil drain
connecting bolt
packing nut
gear oil fill plug

8
TIP SELECTION
FAN FAN FLOW TIP
PART NO. ORIFICE AT 1' ANGLE LTR/MIN MARKING
L043-091 .009 2" 10 DEG. 0.26 109
L043-092 .009 4" 20 DEG. 0.26 209
L043-093 .009 6" 30 DEG. 0.26 309
L043-094 .009 8" 40 DEG. 0.26 409
L043-095 .009 10" 50 DEG. 0.26 509
L043-096 .009 12" 60 DEG. 0.26 609
L043-111 .011 2" 10 DEG. 0.40 111
L043-112 .011 4" 20 DEG. 0.40 211
L043-113 .011 6" 30 DEG. 0.40 311
L043-114 .011 8" 40 DEG. 0.40 411
L043-115 .011 10" 50 DEG. 0.40 511
L043-116 .011 12" 60 DEG. 0.40 611
L043-117 .011 14" 70 DEG. 0.40 711
L043-131 .013 2" 10 DEG. 0.60 113
L043-132 .013 4" 20 DEG. 0.60 213
L043-133 .013 6" 30 DEG. 0.60 313
L043-134 .013 8" 40 DEG. 0.60 413
L043-135 .013 10" 50 DEG. 0.60 513
L043-136 .013 12" 60 DEG. 0.60 613
L043-137 .013 14" 70 DEG. 0.60 713
L043-138 .013 16" 80 DEG. 0.60 813
L043-151 .015 2" 10 DEG. 0.80 115
L043-152 .015 4" 20 DEG. 0.80 215
L043-153 .015 6" 30 DEG. 0.80 315
L043-154 .015 8" 40 DEG. 0.80 415
L043-155 .015 10" 50 DEG. 0.80 515
L043-156 .015 12" 60 DEG. 0.80 615
L043-157 .015 14" 70 DEG. 0.80 715
L043-171 .017 2" 10 DEG. 1.0 117
L043-172 .017 4" 20 DEG. 1.0 217
L043-173 .017 6" 30 DEG. 1.0 317
L043-174 .017 8" 40 DEG. 1.0 417
L043-175 .017 10" 50 DEG. 1.0 517
L043-176 .017 12" 60 DEG. 1.0 617
L043-177 .017 14" 70 DEG. 1.0 717
L043-178 .017 16" 80 DEG. 1.0 817
L043-192 .019 4" 20 DEG. 1.3 219
L043-193 .019 6" 30 DEG. 1.3 319
L043-194 .019 8" 40 DEG. 1.3 419
L043-195 .019 10" 50 DEG. 1.3 519
L043-196 .019 12" 60 DEG. 1.3 619
L043-197 .019 14" 70 DEG. 1.3 719
L043-198 .019 16" 80 DEG. 1.3 819
L043-213 .021 6" 30 DEG. 1.6 321
L043-214 .021 8" 40 DEG. 1.6 421
L043-215 .021 10" 50 DEG. 1.6 521
L043-216 .021 12" 60 DEG. 1.6 621
L043-217 .021 14" 70 DEG. 1.6 721
L043-218 .021 16" 80 DEG. 1.6 821
L043-219 .021 18" 90 DEG. 1.6 921
L043-234 .023 8" 40 DEG. 1.9 423
L043-235 .023 10" 50 DEG. 1.9 523
L043-236 .023 12" 60 DEG. 1.9 623
L043-237 .023 14" 70 DEG. 1.9 723
L043-238 .023 16" 80 DEG. 1.9 823
L043-239 .023 18" 90 DEG. 1.9 923
L043-254 .025 8" 40 DEG. 2.3 425
L043-255 .025 10" 50 DEG. 2.3 525
L043-256 .025 12" 60 DEG. 2.3 625
L043-257 .025 14" 70 DEG. 2.3 725
L043-258 .025 16" 80 DEG. 2.3 825
L043-259 .025 18" 90 DEG. 2.3 925
L043-274 .027 8" 40 DEG. 2.7 427
L043-275 .027 10" 50 DEG. 2.7 527
L043-276 .027 12" 60 DEG. 2.7 627
L043-277 .027 14" 70 DEG. 2.7 727
L043-278 .027 16" 80 DEG. 2.7 827
L043-279 .027 18" 90 DEG. 2.7 927
L043-294 .029 8" 40 DEG. 3.1 429
L043-295 .029 10" 50 DEG. 3.1 529
L043-296 .029 12" 60 DEG. 3.1 629
L043-297 .029 14" 70 DEG. 3.1 729
L043-298 .029 16" 80 DEG. 3.1 829
L043-299 .029 18" 90 DEG. 3.1 929
L043-313 .031 6" 30 DEG. 3.5 331
L043-314 .031 8" 40 DEG. 3.5 431
L043-315 .031 10" 50 DEG. 3.5 531
L043-316 .031 12" 60 DEG. 3.5 631
L043-317 .031 14" 70 DEG. 3.5 731
L043-318 .031 16" 80 DEG. 3.5 831
TIP SELECTION:
A standard size .017 tip will give good performance in
latex or oil base materials of moderate viscosities.
The following chart gives a basic idea of what tips the
Lemmer sprayers can handle performance wise and what
tip is appropriate for which material. Gun filter sizing is
also included in the chart for handy reference.
For a much more detailed look at tip sizes, please consult
the detailed tip chart on page 10.
Tip size Paint type Filter size
.011 Lacquers, industrial enamel, red
very thin paints.
.013 Oil stains, pigmented lacquers, yellow
red oxide primer.
.015 Normal application of latex, oil base, yellow
stains and , solid color oil stains.
.017 Fast application of latex paints white
and stains, oil base paints.
.019 Heavier body latex paints. white
.021 Fast application of heavier latex white
paint, smooth block filter when
properly thinned.
.023 Maximum tip on DC-4000/L-1. not req’d
.027 Maximum tip on L-5,000. not req’d
.033 Maximum tip on L-7,500. not req’d
.043 Maximum tip on L-10,000. not req’d
The maximum tip for a pump is the largest tip that will
deliver a proper pressure for spraying without overwork-
ing or overloading. When a tip is used for some period of
time, it can wear beyond the maximum for the pump,
which will cause low pressure and poor spray pattern.
Stains and thick latex products often cause the most rapid
wear of the tip, while clear lacquers and varnishes cause
the least wear. Thus tip life can vary from as little as 50
gallons to as much as 200 or more, depending on the
product being sprayed and the pressure used.
Filters for the gun are picked not because of the type of
paint being used, but to protect a given size of tip. You
pick the tip for the type of paint and job being done and
then choose the filter to protect that tip. The chart on
page 10 gives much more detail about tip and filter
choices.
THE TWO MOST IMPORTANT THINGS TO REMEM-
BER ABOUT TIPS.....
1) Low pressure means longer life, for tips and the
pump. Less overspray too!
2) Worn tips waste paint and overwork the pump,
wearing it out quickly.

9
TO CHANGE ZIP TIPS:
1) Rotate zip-tip 90˚.
2) Remove from housing.
3) Install new zip tip.
4) Rotate 90˚ to spray position.
Figure 7. - Removing tip seal.
TO CHANGE SEAL ASSEMBLY:
1) Relieve line pressure and set gun safety.
2) Remove zip tip housing from gun.
3) Remove zip tip from housing.
4) Insert zip tip cylinder into front of housing and press
seal assembly out of housing.
5) Install zip tip (4) through slot in guard and into body.
6) Insert seal ass'y (2) through gun nut to seat seal
around zip tip cylinder (press firmly to insure seal is
tight against cylinder).
7) Insert tip/gun washer (3) over spring (in gun nut).
Install unit on gun. Tighten gun nut.
IMPORTANT: The seal ass'y (2) is a wear part that
must be replaced periodically. If leaking occurs,
replace the seal ass'y immediately before it damages
the tip (4).
ZIP TIP INFORMATION
FEATURES:
Fast Tip Size Changes - no tools required.
Long Seal Life - withstands harsh solvents - won't swell
or leak - replaces in minutes.
Tip Rotates Easily - even under “high pressure” clog-up.
Venturi-Guard - less paint accumulation - helps protect
against accidental injection and prevents tip from slipping
out of position.
Patented Diffuser - safer unclogging in clean-out posi-
tion.
TO OPERATE:
When tip clogs, turn zip-tip handle 180˚ to "cleanout
position". Trigger gun and line pressure will purge clog.
DO NOT spray or empty the hose in "clean out"
position, this will cause extreme wear and premature
failure. Always remove the tip when cleaning out the
hose.
TO CLEAN PLUGGED TIP:
1) Rotate the tip to the “Clean” position.
2) Pull trigger and spray. This should clear the tip of any
blockage.
3) Rotate the tip back to the “Spray” position and con-
tinue spraying.
4) If the clogging continues, clean or replace the gun
filter and see the section in this manual on instruc-
tions for straining and thinning paint.
Clean Position Spray Position
Figure 6. - Tip unclogging.
CAUTION: DO NOT USE A NEEDLE OR SHARP OB-
JECT TO CLEAN THE TIP. TUNGSTEN CARBIDE IS
BRITTLE AND CAN BE CHIPPED.
3
2
1
4
Figure 5. - Zip tip
Pos. Part nos. Description
1 L043-001 Zip Tip housing with guard
L043-007 Zip Tip guard (not shown separately)
2 L043-005 Zip Tip seal kit (includes gasket #3)
L043-006 Spring, 3/pkg (not shown separately)
3 L043-008 Nylon gasket
L043-009 Tube of 8x nylon gaskets
4 L043-*** Zip Tip - see chart on opposite page

10
HOW TO SELECT TIP SIZE AND PROPER FILTER
(BASIC INFORMATION)
i
i
i
The two most important things to remember about tips.....
1) Low pressure means longer life, for tips and the pump. Less overspray too!
2) Worn tips waste paint and overwork the pump, causing premature pump wear. The maximum tip for a pump
is the largest tip that will deliver a proper pressure for spraying without overworking or overloading. When a
tip is used for some period of time, it can wear beyond the maximum size recommended for the pump, which
will cause low pressure and poor spray pattern.
• Stains and thick latex products often cause the most rapid wear of the tip, while clear lacquers and var-
nishes cause the least wear. Thus tip life can vary from as little as 50 gallons to as much as 200 or more,
depending on the product being sprayed and the pressure used.
• Filter screen mesh for the gun or pump are picked not because of the type of paint being used, but to protect
a given size of tip. Pick the tip for the type of paint and job being done and then choose the filter to protect
that tip.
Fan Size (measured at 1 foot)
Coating 2" 4" 6" 8" 10" 12"
Lacquer, varnish, furniture stain 1-09 R 2-09 R 3-09 R 4-11 R 5-11 R 6-11 R
(viscosity of 15 to 35 seconds, similar to vegetable oil)
Industrial enamels, stain, colored lacquer 1-09 R 2-11 R 3-11 R 4-13 R 5-13 R 6-15 Y
(viscosity of 25 to 50 seconds, similar to dish washing liquid)
Shop primer, solid stain, oil base, latex 1-11 R 2-13 Y 3-13 R 4-15 Y 5-15 Y 6-17 W
(viscosity of 40 to 100 seconds, similar to 10-30 motor oil)
Flat oil base, latex 1-13 Y 2-15 W 3-15 Y 4-17 W 5-17 W 6-19 W
(viscosity of 60 to 150 seconds, similar to 50 weight oil)
Thick latex, prepared blockfiller 1-15 W 2-17 W 3-17 W 4-19 W 5-19 W 6-21 *
(viscosity of 150 to 200 seconds, similar to gear oil)
Most block fillers 1-17 W 2-19 W 3-19 W 4-21 * 5-21 * 6-23 *
(viscosity of over 200 seconds, are not measurable with the Lemmer cup)
explanation of tip and filter sizing: eg:4-15 Y
4= half of fan width (8" @ 1 foot)
15 = orifice size in thousands of an inch (.015)
Y= Yellow 100 mesh filter.
(R = Red 180 mesh)
(Y = Yellow 100 mesh)
(W = White 50 mesh)
(*= *not recommended)
Tip volume at various pressures.
—Gallons per minute—
Results are based on water,
heavier viscosities will produce
less volume. This is especially
noticeable with large tips and
very heavy coatings.
TIP 500 1000 1500 2000
SIZE PSI PSI PSI PSI
.009 .039 .055 .067 .078
.011 .06 .08 .10 .12
.013 .09 .12 .15 .18
.015 .12 .16 .20 .23
.017 .16 .23 .27 .32
.019 .20 .27 .33 .39
.021 .24 .33 .41 .47
.023 .28 .40 .49 .57
.025 .33 .47 .58 .68
.027 .37 .52 .64 .76
.029 .47 .65 .79 .98
.031 .53 .75 .91 1.1
.035 .69 .9 1.0 1.2
.043 1.1 1.5 1.8 2.1
.053 1.5 2.2 2.9 3.4
.057 1.8 2.5 3.1 3.5
.063 2.2 3.1 3.9 4.4
.067 2.5 3.5 4.3 5.0
.073 2.9 4.1 5.1 5.9
.079 3.6 5.1 6.3 7.3
.085 3.9 5.5 6.7 7.8
.089 4.3 6.0 7.4 8.5
.099 5.3 7.5 9.2 10.6
Pump maximum tip size
Absolute To allow
Pump maximum for tip wear
L-1400 .015 .013
L-1500 .017 .015
DC-3000 .021 .019
DC-4000 .025 .023 (2X.015)
L-1 VN .025 .023 (2X.015)
Approximate wear values comparing tungsten tips and
paint type. (Paint is in gallons)
New tip size .015 .017 .019 .027
worn to worn to worn to worn to
Tip worn to .017 .019 .021 .029
Lacquer 400 - - -
Latex 75 150 250 -
Block filler - - 75 250
Road marking paint 2 20 50 200
Tipchartexample:La-
tex stain is being
sprayed onto a fence.
Thepaint is fairly thick
(like a very heavy mo-
tor oil) and the L-1500
is the spray machine.
The maximum tip is a
.015 for an L-1500.
Draw a line along the
.015 tips as shown
below. Everything
above the line is
sprayable with the L-
1500.Nowjustchoose
the fan width. For
fences a 6” width will
givealot of control, so
the intersecting best
choice would be a 3-
15tipwithayellowgun
filter.
Measure the paint’s viscosity as follows: (note, paints that
are intended to be rolled should be thinned for air or airless
spraying. A general rule of thumb is 5 to 15% for latex and
oils, 30% or more for fine finishes. (consult your paint
supplier for best results).
a) Submerge the Lemmer Viscosity cup in the paint.
b) Lift the cup out of the paint and begin timing.
c) Stop timing when the steady paint stream is first broken.
d) The time recorded is the paint’s viscosity.
Notes:
ok for L-1500
k
k

11
STARTUP PROCEDURE
Whenever the pump is to be used, it must be pre-
pared for the type of paint to be used. This requires the
unit to be flushed out with an appropriate solvent (water
for latex, mineral spirits for oil base, etc.). Incorrect
flushing can cause gumming of the valves and priming
problems.
PRIME VALVE OPERATION:
1. DC-3000: Valve turns continuously left or right.
PRIME position is when the valve is "pulled out" and
spray is when the valve is "seated in".
2. DC-4000: Valve turns left or right. PRIME position is
when the valve is turned counterclockwise (pulled
out) ,and spray is when the valve is turned clockwise
(seated in).
UNIT PRIMING AND FLUSHING:
1) Check that all hose, gun handle and tip connections
are tight.
2) Place trigger lock in “LOCK” position. Plug unit into
correct power source.
3) Place prime valve into open or “PRIME” position.
4) Turn pressure control to minimum. Turn ON unit. On
the DC-4000 green indicator light should be on but
motor not running. If motor runs, re-check that pres-
sure control is turned to minimum.
5) Place suction into container of correct solvent.
Slowly, turn up the pressure control into the prime
zone. Motor will begin to run, watch for flow from
return tube.
6) Let pump prime for 20-30 seconds. Close prime
valve. Unit will build up a low pressure and cut out.
NOTE: Always turn down pressure control before
changing position of the prime valve. This reduces
shock loading of the pump and possible damage.
7) Turn zip tip to halfway position and remove from gun
(see page 9). Turn up pressure about 1/6 turn. This
gives a good low pressure for flushing and cleaning.
8) Aim gun into empty metal pail, holding gun body
against pail edge to ground gun for safety. Open
trigger, and allow solvent to flow for one minute.
9) Release and lock trigger (read static safety on page
4). Turn pressure control to minimum and open prime
valve to release pressure.
10) Unit is now flushed out.
PRIMING UNIT IN PAINT:
Follow same procedure as steps 1-7 of “Priming and
Flushing”, but instead using paint. Then continue with the
remaining steps as outlined below.
11) Remove tip from gun. Unlock trigger. Aim gun into
solvent pail and hold trigger open until solvent flow
changes to paint. Release and lock trigger. Re-install
tip.
12) Turn up pressure approximately 1/2 to 3/4 turn from
minimum setting.
13) This about 2000 psi, which is a normal spraying
pressure for many medium thickness products. As the
pressure you have set is reached, the motor will slow
down and cut out. DC-4000 only: as the hose contin-
ues to absorb pressure, it may cut momentarily in a
few times, to top up the line pressure. This is the
unique “kicker” feature which reduces “buzzing”
associated with most other units. This feature helps to
increase motor, brush and pressure control life.
14) The motor will run when the gun is open. Motor speed
(on the DC-4000), or motor on-off cycles (on the DC-
3000), is in relation to both the size of the tip, and the
pressure you have set.
Test spray pattern per chart below, and adjust pres-
sure accordingly.
Figure 8. - Spray pattern examples.
NOTE
TO TURN UNIT OFF:
Always reduce pressure, turn prime valve to prime, trigger
gun to release pressure build up in hose, and turn motor
off.
prime
valve
DC-4000
DC-3000
prime
valve

12
Figure 11. - Result of flexing wrist while spraying.
3) Start moving the gun before triggering. To get
smooth overlap and prevent initial paint buildup, start
your stroke movement before pulling the trigger. At
the end of the stroke release the trigger before
stopping. NOTE: To assure uniform paint coverage,
overlap each stroke by 40% - 50%.
4) Intermittent use. If you are spraying and decide to
stop for several minutes, lock the spray gun trigger
and submerge the tip in a container of the appropriate
solvent. This will prevent paint from hardening in the
tiny spray opening and clogging the tip. Be sure to
release the pressure by opening prime valve and
turning the pump off.
WARNING: DO NOT BEGIN SPRAYING BEFORE
READING THIS SECTION AND ALL PREVIOUS
SAFETY INFORMATION.
PAINTING AND TIP SELECTION:
Correct adjustment of pressure and proper tip selection
are crucial to the best spray pattern....
1) In any situation, the lowest pressure that gives an
adequate spray pattern is the best pressure to use. It
will give maximum pump and tip life and produce
minimum overspray.
2) Typically, thicker materials require larger tips and
higher pressures than thinner paints do. Some very
thick paints may require slight thinning (5-10%)
depending upon pump and tip size and application.
Generally, thinning is performed when a good spray
pattern cannot be obtained with an appropriate tip
size at maximum pressure. (see figure 8).
SPRAY PAINTING METHOD:
1) Keep the gun perpendicular to the surface. Always
hold the gun perpendicular to the surface with the tip
approximately 12" from the surface. If held at an
angle (up and down or side to side) paint will build up
unevenly and leave the work splotchy. (See figure 9).
Figure 9. - Right and wrong way to hold spray gun.
2) Move with a smooth arm stroke. Move the gun at a
steady even pace while keeping the gun perpendicu-
lar to the surface. (See figure 10) Do not move the
gun by flexing your wrist. Fanning the gun will cause
excessive overspray and uneven coverage. (See
figure 11).
Figure 10. - Proper way to trigger spray gun.
HINTS FOR AIRLESS SPRAYING

13
SPRAYER:
1) Flush before each use with a solvent that is correct
for the paint you will be spraying. ie: Water for latex
paints.
2) Clean unit well after each use. A clean unit works
better and lasts longer.
3) Flush with mineral spirits when storing the unit for
more than 3 or 4 days.
PAINT:
1) Prepare paint according to manufactuer’s recom-
mendations.
2) Remove all skins on paint.
3) Stir paint thoroughly.
4) Strain paint through a fine mesh strainer bag to avoid
clogging of pump and filters. (see accessories page).
SPRAY TIPS:
1) Use minimum pressure that gives a good spray
pattern to reduce tip and pump wear and cut down
overspray.
2) Replace tips before they become too worn. Worn tips
waste paint and overwork the sprayer.
FILTERS:
1) Clean the filters after each use of sprayer.
2) Use correct filter for the tip size and paint type. See
chart page 10.
3) Push down on filter after inserting it into the gun
handle to test if the filter spring is at the bottom. Make
sure the filter is inserted with the double lip going into
the gun first.
HELPFUL HINTS FOR TROUBLE FREE PAINTING
PAINT HOSE:
1) INSPECT THE HOSE PERIODICALLY. DO NOT
USE KINKED, WORN OR DAMAGED HOSE. SEE
WARNINGS ON PAGES 3 & 4!
2) Use only hose that is designed for the high pressures
of airless units. Minimum working pressure of 3000
PSI. Be sure it is grounded, static dissipating type
hose.
3) Protect both the paint hose and the electric cord from
vehicle traffic and sharp cutting edges or objects.
4) For best performance, maximum hose length is about
300 ft. of 1/4". This maximum will largely depend on
tip size and thickness of paint.
5) DO NOT USE STEEL BRAID hose! The DC-3000 &
DC-4000 can only be used with fibre braid hose.
ELECTRICAL:
1) Always ensure the unit is plugged into a grounded
outlet providing 115 volt, 15 amp (minimum), 60 cycle
service.
2) Start unit with pressure control turned to minimum
setting with prime valve open and pressure relieved.
3) Indicator light will show if power is connected and
switch is ON. (DC-4000 only).
4) If circuit breaker has tripped, determine the cause of
overload before re-setting.
EXTENSION CORD:
1) Use only three wire, grounded type extension cord,
CSA approved.
2) Use correct wire size of extension cord for correct
operation. See chart on page 4.

14
Figure 13. Clean pump with suitable solvent .
5) Turn pressure control to minimum and close prime
valve.
6) Unlock trigger, and with spray tip still removed and
pressure in prime zone, aim gun into paint pail and
hold trigger open until paint flow stops and solvent
flow just begins. Release trigger. Aim gun into solvent
pail/hopper and circulate solvent for about two
minutes. To reduce splashing, direct the fluid stream
along inside of bucket at a side angle and well above
the fluid level (or submerge the tip in the solvent).
Release trigger. Point spray gun into an empty waste
bucket and spray at least 1 gallon of fluid into it. (see
figure 14).
CLEANING INSTRUCTIONS
As with all spray equipment, your sprayer must be
cleaned properly or it will not operate properly.
Clogged valves and filters are the most common
causes of problems. If followed, these guidelines will
insure trouble free performance from your sprayer.
CAUTION: Clean with water if latex is used. Clean
with paint thinners for oil based paints. Both water
and paint thinner will be refered to as "solvent" from
here on in.
CLEAN-UP:
To get the best use and longest life from your sprayer, it
is very important to clean it out properly. The procedure is
simple and is very similar to the flushing procedure
performed earlier. Cleaning and flushing would also be
required when changing color, or type of paint, ie: latex
changing to oil base.
1) Lock gun trigger, turn pressure control to minimum,
open prime valve to release all system pressure.
2) Turn zip tip to halfway position and remove from
gun. (if so equipped).
3) While unit is running in prime zone, with prime valve
open, tilt unit back (or lift suction system out of pail)
and allow it 10-15 seconds to pump out paint.
Figure 12. Pump fluid out.
4) Place suction tube in proper solvent. Clean outside of
metal suction tube.

15
Figure 14. Pump until clean solvent appears.
Warning: conductive metal containers must be used
when flushing flammable fluids through the system.
Always flush at low pressure with spray tip removed.
A metal part of the spray gun must be held firmly
against the grounded metal pail when flushing or
relieving pressure from the gun.
7) Pump solvent out by lifting both suction and return
hose out of the solvent. Turn pressure control to
minimum and open prime valve to release system
pressure. Lock trigger and cleanspray tip before re-
installing on gun.
Figure 15. Fluid is pumped out.
8) Follow above steps 1-7 using clean solvent to
completely flush unit.
9) If changing paint types, ie: latex (water base) to oil
base, you would have to flush unit with clean mineral
spirits using above steps 1-7. This would prepare the
pump for the oil base paint. Water would have to be
used as a last flush if changing from oil base paints to
latex.
CLEANING INSTRUCTIONS
10) Ensure pressure control is turned to minimum and
all pressure is released. Open prime valve. Turn
pump OFF.
11) Unthread gun handle from gun body to access gun
filter. Remove filter and brush clean with appropriate
solvent. Inspect filter for pinholes, plugging, or other
damage. Replace if required. Re-install with “double
lip” end pointing up into gun. Lightly grease handle
threads (petroleum jelly, auto grease) and re-install
firm hand tight. Brush exterior of gun clean.
12) Remove intake screen on metal suction tube and
brush clean, re-install.
13) Storing unit for more than 3 days. If unit was
cleaned with an oily paint thinner such as varsol, the
unit is now ready for storage (after step 14). If unit
was cleaned with water or a strong thinner (ie. lac-
quer thinner) pump varsol (or mineral spirits) through
the entire system by repeating step 8. If varsol is not
available, drain all the solvent out of the hose, gun,
and pump. (Tungsten carbide parts in the valves
will corrode if left in water for long periods of
time).
14) Coil up electrical cord and spray hose, inspecting
both for signs of damage. Suggested minimum coil
size for 1/4" paint hose is 18 inches.
DO NOT COIL PAINT HOSE TOO TIGHTLY. THIS MAY
CAUSE KINKS, WHICH WEAKEN THE HOSE. A
PAINT HOSE WITH KINKS OR OTHER DAMAGE
SHOULD BE CONSIDERED UNSAFE AND BE RE-
PLACED IMMEDIATELY.
WARNING: DO NOT CLEAN THE SPRAY GUN UN-
LESS THE PRESSURE HAS BEEN RELEASED FROM
THE SYSTEM. SEE PAGES 3 & 4 FOR FURTHER
PRECAUTIONS.
Warning!

16
MAINTENANCE & SERVICE (DC-3000 & DC-4000)
SPRAY GUN:
The filter should be cleaned or replaced after each use to
minimize tip clogging problems. If the gun valve becomes
worn and begins to leak, it should be replaced. See page
25 for overhaul details.
SPRAY TIP:
The spray tip is one of the most important elements in
producing a quality spray job. It requires periodic re-
placement (every 50-200 gallons) to maintain perform-
ance and to prevent overworking the pump (see page 8
for details).
CHANGING GEAR OIL (DC-4000):
1) Turn unit off, ensure prime valve is open, and all
pressure is relieved. Unplug from electrical outlet.
2) Remove oil drain plug from underside of speed
reducer.
3) Remove oil fill/vent cap from top of speed reducer.
4. Allow old oil to drain. Replace drain plug.
5) Fill unit with 200 ml of EP 90 gear oil, part no. L034-
124. Do not overfill!
6) Replace vent cap. Unit is now ready for use.
Repeat each 500 hr or at each packing replacement.
GREASE CENTRAL BODY (DC-4000):
1) Turn unit off, ensure prime valve is open, and all
pressure is relieved.
2) Using a grease gun with normal automotive grease,
pump 2-5 strokes into nipple on front of central body.
Some guns may require removal of pail hook using
5mm allen key.
3) Repeat every 100-200 hour and at each packing
change.
CLEAN COOLING FAN (DC-4000):
1) Turn unit off, ensure prime valve is open, and all
pressure is relieved. Unplug from electrical outlet.
2) Remove the 3 x screw from fan cover.
3) Scrape fan, back of motor and inside of cover clean.
Clean exterior of motor with wire brush or scraping.
4) Replace cover and screws.
This is to be done “on condition” ie; if fan and motor look
dirty, it is time for cleaning. A clean fan and motor run
cooler and last longer!
BRUSH INSPECTION AND REPLACEMENT (DC-4000):
NOTE: Check every 500 hr or at packing replace-
ment. Failure to replace worn brushes will reduce
unit performance and drastically shorten motor life.
1) Turn unit off, ensure prime valve is open, and all
pressure is relieved. Unplug from electrical outlet.
2) Remove brush caps from side of motor and remove
brushes. Keep note of which side of motor and which
side up brushes are.
3) Measure length of rectangular part of brush. If 15mm
or longer, brush is in near new condition. If 13-15mm,
replacement should be seriously considered. If 13mm
or shorter, brushes MUST be replaced or motor
damage may occur.
4) Blow out motor through brush holes with compressed
air.
5) Install brushes. If re-using old brushes, put back on
same side of motor, same way up as before to reduce
break-in time.
6) Install brush caps. DO NOT OVERTIGHTEN, AS
BRUSH CAPS ARE BAKELITE AND WILL BREAK!
7) Put unit in solvent, open prime valve, and run unit at
low priming speed for approximately 5 minutes to
break in brushes.
LOWER PACKINGS:
No regular service required.
The lower packings of this unit are stationary, so that the
only wearing part is the piston. Costly replacing of the
pump cylinder is eliminated. The packings are self adjust-
ing, and will generally outlast the upper packings. Both
sets are included in the packing kit, and should be
changed together for best reliability and performance.
UPPER PACKINGS:
Lubricate daily with L034-125 oil.
The upper packings are adjusted manually, by turning the
brass packing nut to the left, ie; clockwise as viewed from
the top. Keep guard in place during operation.
IMPORTANT NOTE: The packings should never be
over tightened, as this greatly reduces packing and
piston life. Never tighten packings with pressure in
unit, as a false indication of adjustment will result. A
bit of gummy buildup around the packing nut is
normal and should be periodically removed with a
brush and solvent. This allows lubricant oil to reach
packings.
NOTE: Do not adjust packing while unit is running.
Fingers, tools, etc. can be trapped between plunger
and packing nut. Loss of finger or serious injury
could result.
TO TIGHTEN UPPER PACKINGS:
1) Turn unit off, ensure prime valve is open, and all
pressure is relieved. Unplug from electrical outlet.
2) Remove all buildup from around packing nut.
3) Using a hammer and srewdriver, turn packing nut
clockwise a maximum of 1/8 turn. Packings should be
only tightened just enough to stop leakage. See
notice above. Gentle tightening is normally sufficient.
4) Lubricate packings using L034-125 oil.
5) Replace safety shield over packing area.
NOTE: When no further adjustment of packings is
possible, the nut will be difficult to turn with reason-
able effort. Packings should be replaced.
CHECK VALVES:
These pumps has two valves, the footvalve at the paint inlet,
and the shaft valve in the center of the piston. Both are of
stainless steel ball, tungsten seat construction. This means that
inexpensive, easily replaced balls are the normal wear point. If
the unit will not draw up paint, the footvalve may be stuck.
Simply tapping on the side of the footvalve with a wrench will
usually suffice. Should this not work, the following steps will
show you how to remove and clean the footvalve and check
the shaft valve. For shaftvalve disassembly, please see steps
1-12, 16, 17 of packing instructions for the DC-4000.

17
MAINTENANCE & SERVICE (DC-3000)
REMOVAL OF FLUID PUMP:
1) Turn unit off, ensure that prime valve is open, and all
pressure is relieved. Unplug unit from electrical outlet.
2) Unscrew the suction system, fluid connection hose, and
the return hose. (make note of return hose fitting position
before loosening).
3) Remove the front cover and pull the retaining clip from the
yoke and pin. Push the pin out of the piston and yoke. (use
the short end of a hex wrench if necessary).
4) Loosen the locknut at the top of the fluid section and
unscrew the pump.
REMOVAL OF PUMP PACKINGS:
Note: It is recommended to replace the packings
once they have been removed to prevent possible
future damage to the piston.
5) Hold the foot valve in a vise (contacting on the wrench
flats) and unscrew the fluid section. Unscrew the packing
nut from the fluid section.
Note: Do not allow the piston to fall or get damaged
in any way. Its finish must be perfectly smooth.
6) Push the piston out through the lower end of the fluid
section. Tap the top of the piston with a rubber mallet
if necessary.
7) Remove the upper and lower spacers from the fluid
section.
Note: When removing the packings, be careful not to
scrape or gouge the inside surface of the cylinder
with the screwdriver.
8) Push the packings out of the cylinder with a screw-
driver by pushing from the inside out (push from the
opposite end).
INSTALLING NEW PUMP PACKINGS:
9) Apply a light coat of oil to the packings. Install both
packings with the "v" edge with the spring faces into
the cylinder, the flat side facing outwards.
Installing lower packings
10) Lower packing; Insert it edge-first into the lower end
of the fluid section. Turn the packing inside the cylin-
der so that the springs of the packing face into the
cylinder. To do this, hold the lower edge of the pack-
ing in place while pressing the upper edge further into
the cylinder. Push the packing as far into the cylinder
as it will go. Insert the lower spacer.
11) Upper packing; Place it into the upper end of the
fluid section. Position the packing so that it is level and
the springs of the packing face into the cylinder.
Thread the packing nut into the cylinder to push the
packing farther into the cylinder, then remove the
packing nut. Insert the upper spacer and push it as
far into the cylinder as it will go. Screw the packing
nut into the cylinder and torque to 25 - 30 ft/lbs.
Piston
Yoke
Pin
Retaining clip
Torx screw
Front cover plate
Locknut
Packing nut
Upper spacer
Upper packing
Oulet
fitting
Cylinder
Lower packing
Lower spacer
S.V. ball guide
S.V. ball
S.V. seat
S.V. hex nut
O-ring
F.V. ball stop
F.V. ball guide
F.V. ball
F.V. seat
Seat seal
F.V. housing
Suction system
complete
main pump
housing

18
14) Install a new shaft valve ball.
15) Inspect the shaft valve seat for wear. If one side of
the seat is still new, install it with the good side facing
towards the ball.
Note: Do not put piston into a vise. Putting the piston
into a vise may cause damage.
16) Apply blue locktite to the shaft valve hex nut threads
and thread into shaft. Torque to 12 ft/lbs.
17) Apply a light coat of oil to the piston and insert it,
small end first, into the lower end of the fluid section
until it seats. Tap the bottom of the piston gently with
a rubber mallet if necessary.
FOOT VALVE MAINTAINENCE:
18) Remove the o-ring from the foot valve housing.
19) Cover the top of the foot valve housing and turn it
upside down to remove the ball stop, ball guide, ball,
seat, and seat seal.
20) Install a new seat seal into the housing. Do not reuse
the old seal.
21) Inspect the foot valve seat for wear. If one side of the
seat is still new, install it with the good side facing
towards the ball.
22) Install a new foot valve ball, ball guide, stop plate,
and a new o-ring (do not reuse the old o-ring).
23) Hold the foot valve in a vise (contacting on the
wrench flats) and screw the fluid section into the foot
valve. Torque to 85 - 90 ft/lbs.
INSTALLATION OF FLUID PUMP:
24) Turn the locknut on the fluid section until it reaches the
bottom of the threads. Thread the fluid section into the
main pump housing. Rotate the fluid pump to align
the hole in the piston shaft with the holes in the yoke.
25) Insert the pin through the yoke and piston. Snap the
retaining clip around the pin and yoke.
26) Screw the fluid section into the main pump housing as
far as it will go, then unscrew it slightly so that the
outlet hose fitting will align with the connection hose.
27) Firmly tighten the locknut at the top of the fluid section
against the main pump housing. Tighten the return
line fitting back to its original position.
28) Fill the packing nut with packing lubricating oil.
29) Install the front cover, connection hose, and the
suction system.
Piston
Yoke
Pin
Retaining clip
Torx screw
Front cover plate
Locknut
Packing nut
Upper spacer
Upper packing
Oulet
fitting
Cylinder
Lower packing
Lower spacer
S.V. ball guide
S.V. ball
S.V. seat
S.V. hex nut
O-ring
F.V. ball stop
F.V. ball guide
F.V. ball
F.V. seat
Seat seal
F.V. housing
Suction system
complete
MAINTENANCE & SERVICE (DC-3000)
main pump
housing
PISTON MAINTAINENCE:
12) Turn the piston upside down and use a hex wrench to
remove the shaft valve hex nut from the lower end of
the piston.
13) Cover the open end of the piston and turn the piston
right-side up again to remove the shaft valve ball and
seat. Inspect the piston for wear. Install a new ball
guide, do not reuse the old ball guide as it is also
the seat seal . Use the head of a long nail or screw to
seat the ball guide past the threads inside the piston. Wiring diagram, DC-3000

19
MAINTENANCE & SERVICE (DC-4000)
REMOVAL AND CLEANING OF FOOTVALVE:
1) Turn unit off, ensure that prime valve is open, and all
pressure is relieved. Unplug unit from electrical outlet.
2) Tilt unit back on handle.
3) Using a large crescent wrench, unscrew footvalve com-
plete with suction tube. The seal for the footvalve is part of
the pump cylinder and cannot fall out.
4) Remove retaining clip and ball.
5) While footvalve is removed, you can look up inside pump
to see hole in center of shaft where shaft ball is.
6) If hole is obstructed or plugged, use a small screwdriver (or
piece of wire) and compressed air to free up ball. Be sure
to cover end of return line with a rag so paint/solvent in
pump is not blown into your face!
7) Should this not be sufficient, see steps 1-12, 16 and 17 of
the DC-4000 packing instructions. Once o.k. proceed to
next step.
8) Clean all parts including intake screen and pipe.
9) If ball is very pitted or scored, it must be replaced. Inspect
seat inside of footvalve body. If it is damaged the footvalve
housing must be replaced.
10) Lightly oil ball and put into footvalve housing. Replace
retaining clip.
11) Lubricate nose and threads of footvalve with grease.
Thread into unit and tighten 15-20 ft/lb. Unit is now ready to
test in solvent etc.
PRESSURE CONTROL BOX:
The pressure control box for the DC-4000 is a precision unit,
designed to require no regular service or adjustment.
The following instructions are intended to guide you through
removal and re-installation of the control box.
CONTROL BOX REMOVAL AND REPLACEMENT:
1) Shut down unit, open prime valve to release pressure, and
trigger gun to be sure pressure is out of system.
2) Unplug cord from electrical outlet and wrap around handle
of unit.
3) Disconnect paint hose, inlet and return hoses from sensor.
4) Using 3mm allen key, remove 4 x bolts from behind control
box. Box will come free with about 6-8".
5) There are four wires to disconnect. Disconnect the two
from the power cord (the lower pair) first. These go to the
switch.
6) The second pair of wires go the the bridge rectifier from the
motor (upper pair). Disconnect these.
7) Control box is now free from pump and can be serviced.
Should service extend beyond changing of switch or
breaker, control box should be sent to nearest Lemmer
service center.
NOTE: Electrical shock warning. Some components of the
control box operate at full 120 volt 15 amp current. Do not
attempt to adjust the control box yourself. Excessive and
unsafe pressures may be attained by unauthorized tam-
pering.
8) Connect motor wires (upper black/white pair) to bridge
rectifier. The black goes to the positive (notched corner)
and the white to negative (opposite corner). See diagram.
9) Connect power wires (lower pair of black/white). Black
connects to terminal of switch in line with breaker. White
wire connects to terminal in line with wire to bridge rectifier.
10) Double check all connections. Mixup of power and motor
wires will result in complete destruction of triac and bridge
as a minimum.
11) Lift box into place, while gently tucking in extra length of
wires. Install and tighten the allen screws.
12) Connect return line, and paint inlet/outlet lines to sensor.
Torque 20 ft/lbs.
13) Place suction in solvent, open prime valve and turn
pressure to minimum. Ensure switch is OFF.
14) Plug in unit. Turn on and check for indicator light. Prime
and test.
on/off
switch
white
black
circuit
breaker triac
bridge
black
white motor
purple
blue
circuit
board
J8
J7
J1
J2
orange
yellow
sensor
potentiometer
(pressure control)
IMPORTANT:
the motor wire polarity
determines direction of
rotation. The wires must be
connected as shown to
result in a clockwise
rotation as viewed from the
fan cover.
CAUTION: connect the purple
and blue wires (J7 & J8)
exactly as shown. Incorrect
connection will result in
erratic motor operation, or
no operation at all.
CAUTION: connect the orange
and yellow wires (J1 & J2)
exactly as shown. Incorrect
connection will result in
erratic motor operation, or
no operation at all.
Figure 16. Wiring
diagram, DC-4000

20
upper packings:
male support
poly
leather
poly
leather
poly
female support
MAINTENANCE & SERVICE (DC-4000)
DC-4000 PACKING (L050-625 KIT) INSTRUCTIONS:
1. Flush unit thorougly with appropriate solvent.
2. Turn pressure control to minimum so that unit stops. Look
in opening of central body to observe position of connect-
ing screw.
3. If necessary, turn control to prime and down again (briefly)
so that motor runs in short bursts. When motor stops with
connecting bolt at bottom of its travel, turn unit OFF.
4. Relieve pressure via prime valve, and unplug unit from
electric outlet. Tilt unit back on handle and allow solvent to
drain.
5. Using a 5mm allen key, remove pail hook.
6. Using the same wrench, remove connecting screw from
plunger. (newer models
use a 4mm allen key).
7. Disconnect fluid hose
from pump section.
8. Using a pipe wrench,
and holding the
footvalve with another
wrench, remove
suction pipe and screw.
9. Using a large crescent
or pipe wrench, loosen
locknut pos. # 1. Pump
will unscrew by hand.
10. Place pump assy in
vice, using flat areas on
cylinder, with footvalve
facing up. DO NOT
OVERTIGHTEN!
Remove footvalve.
11. Place pump opposite
way in vice. Using
pliers etc, remove
packing nut pos. # 2.
12. While holding hand
under pump to catch
piston, gently tap on top
of piston pos. #6.
Packing spacer, pos. #
14 may also fall out at
this time.
13. Gently, using screw-
driver, pry out upper
packings and spacers
pos. # 3.
14. Remove pump cylinder
#4 from vice. Using fingers (or screwdriver and due care)
remove spacer, lower packings and wave washer pos. #
14, 13, 12.
15. Remove retaining clip pos. # 15, and ball pos. # 16 from
footvalve body. Ball seat is pressed into housing and is not
replacable.
16. Place wrench flats of tip of piston in vice, and using 10mm
allen wrench, take out shaft valve nut and seat pos.# 11,
10. Take piston from vice and remove shaft ball and
copper seal pos. 8, 9.
17. Thoroughly clean and dry all parts (except old packings).
18. Inspect upper and lower chrome areas of piston. Some
scratching is normal. If very extreme scratches or areas
missing hard chrome exist, the piston will have to be
replaced. A distinct darker, duller color in some areas may
indicate wear through the hard chrome.
19. Although new balls are supplied with kit, old ball condition
is a good indicator of seat wear. If the old balls are chewed
up or visibly smaller, take care to inspect shaft and
footvalve seats for wear.
20. Place new upper packings in oil (L034-125) to soak for 5-
10 minutes.
21. Put piston in vice using flats. Install new ball and copper
seal. Use a little bit of grease to hold seat in shaft valve nut.
Put one or two drops of blue or red locktite on threads.
Install by hand into shaft, then use wrench to tighten 40-45
ft/lb. Remove from vice.
22. Lightly grease inside of lower pump cylinder. Install wave
washer(s) and male packing spacer with flat end towards
washer. Lightly grease each packing and install with lips as
per diagram. Install female space V end first and push in
tightly by hand.
23. Turn pump cylinder over and lightly grease upper packing
bore. Install metal spacerflat end down. Install 1 x plastic
packing V end first, then in turn 1 x leather, 1 x plastic, 1 x
leather, 1 x plastic. Now put in thick plastic spacer V end
down. Lightly grease packing nut inside and on threads.
Install gently hand tight.
24. Lightly grease piston surfaces. Insert 10 mm allen wrench
for a holding tool, and push piston up through cylinder until
it stops.
25. Place pump cylinder open end up in vice. Install brass
spacer.
26. Lightly oil new footvalve ball, and place in body. Install
retaining clip. Lightly grease nose of valve and threads and
install approx. 20 ft./lb in pump cylinder.
27. Use teflon tape on threads of suction pipe. Hold footvalve
with wrench and install tube 10-15 ft/lbs.
28. Ensure large locknut pos. # 1 is bottomed out on threads.
Now grease threads of pump cylinder. Thread cylinder
assy. into central body until pin hole in top of piston just
lines up with pin hole in plunger.
29. Place one or two drops red or blue locktite on connecting
pin threads. Install pin and tighten 10 ft/lb.
30. Thread pump assembly onto unit until it bottoms out. Now
back pump up just enough that the paint outlet is in the
correct position. Securely tighten the locknut. (60-70 ft/lb)
31. Install paint hose to pump assembly, tighten 20 ft/lb. Place
a container of solvent under pump intake and set unit
upright.
32. Gently tighten packing nut until there is a slight resistance.
DO NOT OVERTIGHTEN OR PACKING/PISTON LIFE
WILL BE GREATLY REDUCED. Tighten just enough to
prevent leakage. Lubricate with L034-120/125 oil.
33. Prime and pressure unit checking for leaks. DO NOT
TIGHTEN PACKINGS WITH UNIT RUNNING. FIN-
GERS OR TOOLS CAN BE TRAPPED BETWEEN
PACKING NUT AND PLUNGER, RISKING LOSS OF
fFINGER(S) OR SEVERE PERSONAL INJURY.
1
2
3
4
6
7
8
9
10
11
12
17
14
16
lower packings:
male support
teflon
teflon
teflon
teflon
female support
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5
13
15