Lemmer DC1500 User manual

1
DC-7800
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
DC1500, DC3100, DC3200,
DC5550, DC7800
CALGARY • TORONTO • MONTRÉAL
DC-5550
DC-1500
DC-3200
DC-3100
Latex & Oil
Base only.

2
TABLE OF CONTENTS
SAFETY PRECAUTIONS ...................................................................... 3 & 4
TECHNICAL SPECIFICATIONS ...................................................................5
PUMP COMPONENTS .................................................................................6
ELECTRONIC CONTROLS ..........................................................................7
SETTING UP OF UNIT .................................................................................7
TIP SELECTION & MAINTENANCE...................................................... 8 & 9
HOWTO SELECT TIP SIZE AND 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 ................................................................................12
EXTENSION CORD ......................................................................12
CLEANING INSTRUCTIONS......................................................................13
MAINTENANCE & SERVICE, DC-2000 / 3100 / 4600 & 7700 ........... 14 - 18
TROUBLESHOOTING ................................................................................19
OTHER QUALITY LEMMER PRODUCTS..................................................20
ACCESSORIES FOR LEMMER AIRLESS EQUIPMENT...........................21
L-60 PARTS ....................................................................................... 22 & 23
DC-3100 & DC-4600 PARTS ............................................................. 24 & 25
DC-5550 PARTS................................................................................ 26 & 27
DC-7700 PARTS................................................................................ 28 & 29
DC-1500 PARTS.........................................................................................30
NOTES .......................................................................................................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 professional 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 spraying 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.
These Lemmer sprayers are powerful and versatile enough to be used
with a variety of accessories (extra lenghts of hose, extensions,
pressure feed rollers, etc. as shown later in this manual) to make them
even more versatile systems. Ask your supplier about the recommended
accessories for your particular job.
PUMP TYPE:
The Lemmer DC units use a double acting piston pump, with stationary
packings (DC1500 is single action, do not use with solvents stronger
than varsol). 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.
PRODUCT SPECIFICATIONS
ADVANTAGES OF THESE SYSTEMS ARE:
• Pump stops working when you do. Minimizes wear.
• 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 - minimal fan fluctuations.
• Compact paint pump - quick cleaning, less parts to wear.
TECHNICAL SPECIFICATIONS
DC-1500 DC-5300 DC-5550 DC-7800
Weight: 15.5 lbs (7 kg) w/ght 40 lbs (16 kg) 74 lbs 87 lbs
Capacity, volume @ 2000 psi: .25 gpm .48 gpm .55 gpm 1.0 gpm
Maximum tip size, 1 gun: .015 (.015 installed) .023 (.021 installed) .025 (.023 installed) .031 (.029 installed)
Maximum tip size, 2 gun: .015 (.013 installed) .017 (.015 installed) .021 (.019 installed)
Motor: 1/2 hp ac 7/8 hp dc industrial TE 7/8 hp dc industrial 2.3 hp PMDC industrial
Power requirements, 110V: 9.0A,115VAC,60HZ 10.5A,115VAC,60HZ 12A,115VAC,60HZ 12.7A,115VAC,60HZ
Spraying pressure: 0 - 2800 psi 0 - 3000 psi 0 - 3000 psi 0 - 3300 psi
Maximum hose length: 100 feet (30.5meters) 300 feet (91meters) 300 feet (91meters) 300 feet (91meters)
Maximum power cord: 100 feet (14-16 guage) 300 feet (14-16 guage) 300 feet (12-14 guage) 300 feet (12-14 guage)
Paint inlet: spl metric swivel swivel
Paint outlet: 1/4" npt(m) 1/4" npt(m) 1/4" npt(m) 1/4" npt(m)
Wetted parts: Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon Al,SS,Tc,Tef,Nylon,Zin,Nic,PTFE,Ace,Lea Al,SS,Tc,Tef,Nylon,Zin,Nic,PTFE,Ace,Lea Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon,Chrome,Zinc
Capability: All conventional coatings, ie: latex, stain, lacquer (not DC1500), varnish, ink, primer, preservatives and many other architectural coatings,
and with the DC-7800 also heavier coatings such as block filler 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-1500/5550/7800 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
for example). 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 anodized 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-1600/3100/5300/
5500/7700):
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.
SPEED REDUCER, DC-1600/3100/5300/
5500/7700:
Consists of a two stage gear reduction in
permanent grease for long life. All
bearings are also permanently greased. It
converts the high speed output of motor
into very high torque to drive the pump.
MOTOR (DC-1600/3100/5300/5500):
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-7700):
This unit has the most technologically advanced motor available today.
In addition to being very compact and lightweight, it also has no brushes
or commutator, and it has high torque combined with low amp draw.
PRESSURE CONTROL BOX (DC-1600/3100/5300/7700):
A rugged membrane transducer transmits a paint pressure 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-5500 & DC-7700):
A tough solid state pressure transducer combined with a state of the art
variable speed electronic control provides consistant spray pressure for
both the DC5500 & DC7700 sprayers. The DC7700 also features run
dry protection and allowing faster priming once fluid fills the pump. The
safety fuse is easy to access from the outside of the motor shell. This
motor does not require any service.
(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
L65 & L-50
DC-3100 components.
paint pump
motor
speed reducer
prime
valve
suction system
airless hose
Pressure control
heavy duty gun
reversible tip
on / off
switch
For model
L-26
DC-1500 components.
(Latex & Oil Base only)
reversible tip
spray gun
prime valve
airless hose paint pump
suction system
on / off switch
suction screen
2 to 3
drops
oil daily
DC-5300 components.
paint pump
motor
speed reducer
prime
valve
suction system
airless hose
Pressure control
heavy duty gun
reversible tip
on / off switch
2 to 3
drops
oil daily

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) Connect high pressure airless paint hose to pump outlet. Tighten to
approximately 20 ft. lbs.
4) Attach the tip assembly to the spray gun.
5) 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.
6) 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 disengage, 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.
PUMP COMPONENTS
motor
pail hook
suction pipe
speed reducer
paint pump
suction screen
pressure control
& on / off switch
High pressure filter
Figure 1e. - DC-7800 components.
Figure 1d. - DC-5500 components.
paint
pump
motor
pressure
control
speed reducer
prime
valve
suction
system
on / off
switch
2 to 3 drops
oil daily

8
TIP SELECTION
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 refer-
ence.
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.
.021 Maximum tip on DC-3100 not req’d
.025 Maximum tip on DC-4600 not req’d
.031 Maximum tip on DC-7700 not req’d
.045 Maximum tip on HP-9500 not req’d
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 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 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, wearing it out
quickly.
Order Number Orifice Fan Fan Flow Tip
Zip Tip BB Tip at 1' Angle Ltr/min mark
L043-091 0.009 2" 10 DEG. 0.26 109
L043-092 L038-092 0.009 4" 20 DEG. 0.26 209
L043-093 L038-093 0.009 6" 30 DEG. 0.26 309
L043-094 L038-094 0.009 8" 40 DEG. 0.26 409
L043-095 L038-095* 0.009 10" 50 DEG. 0.26 509
L043-096 L038-096* 0.009 12" 60 DEG. 0.26 609
L043-111 L038-111 0.011 2" 10 DEG. 0.4 111
L043-112 L038-112 0.011 4" 20 DEG. 0.4 211
L043-113 L038-113 0.011 6" 30 DEG. 0.4 311
L043-114 L038-114 0.011 8" 40 DEG. 0.4 411
L043-115 L038-115 0.011 10" 50 DEG. 0.4 511
L043-116 L038-116 0.011 12" 60 DEG. 0.4 611
L043-117 0.011 14" 70 DEG. 0.4 711
L043-131 L038-131 0.013 2" 10 DEG. 0.6 113
L043-132 L038-132 0.013 4" 20 DEG. 0.6 213
L043-133 L038-133 0.013 6" 30 DEG. 0.6 313
L043-134 L038-134 0.013 8" 40 DEG. 0.6 413
L043-135 L038-135 0.013 10" 50 DEG. 0.6 513
L043-136 L038-136 0.013 12" 60 DEG. 0.6 613
L043-137 0.013 14" 70 DEG. 0.6 713
L043-138 0.013 16" 80 DEG. 0.6 813
L043-151 0.015 2" 10 DEG. 0.8 115
L043-152 L038-152 0.015 4" 20 DEG. 0.8 215
L043-153 L038-153 0.015 6" 30 DEG. 0.8 315
L043-154 L038-154 0.015 8" 40 DEG. 0.8 415
L043-155 L038-155 0.015 10" 50 DEG. 0.8 515
L043-156 L038-156 0.015 12" 60 DEG. 0.8 615
L043-157 0.015 14" 70 DEG. 0.8 715
L043-171 0.017 2" 10 DEG. 1 117
L043-172 L038-172 0.017 4" 20 DEG. 1 217
L043-173 L038-173 0.017 6" 30 DEG. 1 317
L043-174 L038-174 0.017 8" 40 DEG. 1 417
L043-175 L038-175 0.017 10" 50 DEG. 1 517
L043-176 L038-176 0.017 12" 60 DEG. 1 617
L043-177 0.017 14" 70 DEG. 1 717
L043-178 0.017 16" 80 DEG. 1 817
L043-192 0.019 4" 20 DEG. 1.3 219
L043-193 L038-193 0.019 6" 30 DEG. 1.3 319
L043-194 L038-194 0.019 8" 40 DEG. 1.3 419
L043-195 L038-195 0.019 10" 50 DEG. 1.3 519
L043-196 L038-196 0.019 12" 60 DEG. 1.3 619
L043-197 0.019 14" 70 DEG. 1.3 719
L043-198 0.019 16" 80 DEG. 1.3 819
L043-213 L038-213 0.021 6" 30 DEG. 1.6 321
L043-214 L038-214 0.021 8" 40 DEG. 1.6 421
L043-215 L038-215 0.021 10" 50 DEG. 1.6 521
L043-216 L038-216 0.021 12" 60 DEG. 1.6 621
L043-217 0.021 14" 70 DEG. 1.6 721
L043-218 0.021 16" 80 DEG. 1.6 821
L043-219 0.021 18" 90 DEG. 1.6 921
L043-234 L038-234 0.023 8" 40 DEG. 1.9 423
L043-235 L038-235 0.023 10" 50 DEG. 1.9 523
L043-236 0.023 12" 60 DEG. 1.9 623
L043-237 0.023 14" 70 DEG. 1.9 723
L043-238 0.023 16" 80 DEG. 1.9 823
L043-239 0.023 18" 90 DEG. 1.9 923
L043-254 0.025 8" 40 DEG. 2.3 425
L043-255 L038-255 0.025 10" 50 DEG. 2.3 525
L043-256 0.025 12" 60 DEG. 2.3 625
L043-257 0.025 14" 70 DEG. 2.3 725
L043-258 0.025 16" 80 DEG. 2.3 825
L043-259 0.025 18" 90 DEG. 2.3 925
L043-274 0.027 8" 40 DEG. 2.7 427
L043-275 L038-275 0.027 10" 50 DEG. 2.7 527
L043-276 0.027 12" 60 DEG. 2.7 627
L043-277 0.027 14" 70 DEG. 2.7 727
L043-278 0.027 16" 80 DEG. 2.7 827
L043-279 0.027 18" 90 DEG. 2.7 927
L043-294 0.029 8" 40 DEG. 3.1 429
L043-295 L038-295 0.029 10" 50 DEG. 3.1 529
L043-296 0.029 12" 60 DEG. 3.1 629
L043-297 0.029 14" 70 DEG. 3.1 729
L043-298 0.029 16" 80 DEG. 3.1 829
L043-299 0.029 18" 90 DEG. 3.1 929
L043-313 0.031 6" 30 DEG. 3.5 331
L043-314 0.031 8" 40 DEG. 3.5 431
L043-315 L038-315 0.031 10" 50 DEG. 3.5 531
L043-316 0.031 12" 60 DEG. 3.5 631
L043-317 0.031 14" 70 DEG. 3.5 731
L043-318 0.031 16" 80 DEG. 3.5 831
N/A L038-355 0.035 10" 50 DEG. 3.8 535
* LTD - Limited supply, special order when stocks are low.
Maximum volume discount allowed is 5+.
Tip Selection

9
ZIP TIP & BIG BARREL INFORMATION
Pos. Order # Description
1)L043-001 Zip Tip housing (Lemmer)
L043-002 Zip Tip housing (Graco)
L043-003 Zip Tip housing (Binks)
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
3
2
1
4
Pos. Order # Description
1)L038-001 BB Tip housing (Lemmer)
L038-002 BB Tip housing (Graco)
2)L038-007 Metal seal
3)L038-006 Gasket (standard)
L038-008 Lacquer Gasket (optional)
4)L038-*** Tip - see chart
3
2
14
Zip Tip
Big Barrel
Big Barrel Tip Features:
Fast Tip Size Changes - no tools required.
Versatility - Interchangeable with G big barrel tips.
Long Seal Life - withstands harsh solvents - won't swell or leak even in
severe abrasives - replaces in minutes.
Replacement Seal - is included with each new tip.
Venturi-Guard - less paint accumulation - helps protect against accidental
injection and prevents tip from slipping out of position.
Diffuser - safer unclogging in clean-out position.
Zip Tip Features:
Fast Tip Size Changes - no tools required.
Long Seal Life - withstands harsh solvents - won't swell or leak even with
small tips - 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 position.
How to Operate Parts Lists
To operate:
When tip plugs rotate the tip handle 180˚. Trigger the gun and line pressure
will purge clog.
Clean Position
Spray Position
To change tips:
Rotate tip 90˚.
Remove from housing.
Install new tip.
Rotate 90˚ to spray position.
To change seal assembly:
Relieve line pressure and set gun safety.
Remove tip housing from gun.
Remove tip from housing.
Press seal assembly with gasket out of housing. (On the Zip Tip type you can
use the tip as a tool for pressing).
Install tip into housing.
Lubricate and insert new seal ass'y through back of housing (press firmly to
insure seal is tight against tip shaft).
Insert gasket. Install unit on gun. Tighten gun nut.

10
HOW TO SELECT TIP SIZE AND PROPER FILTER
(BASIC INFORMATION)
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
DC-1500 .015 .015
DC-2000 .019
DC-5550 .025 .023 (2X.017)
DC-7800 .031 .029 (2X.021)
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 DC-
3100 is the spray ma-
chine. The maximum
tip is a .019 for a DC-
3100.Drawalinealong
the.019tipsasshown
below. Everything
above the line is
sprayablewiththeDC-
3100.Nowjustchoose
the fan width. For
fences a 6” width will
givealotofcontrol, 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:
k
k
k
i
i
i
ok for DC-3000
k

11
STARTUP PROCEDURE
Whenever the pump is to be used, it must be prepared 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-1500, DC-3100, DC-7700: 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). The DC-
5300 & 5500 turns 360˚ with horizontal always in the prime position.
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.
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). 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.
14) The motor will run when the gun is open. Motor on-off cycles is in
relation to both the size of the tip, and the pressure you have set.
Test spray pattern per chart below, and adjust pressure 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.
DC-5300
DC-5500
DC-7700
prime valve
prime valve
DC-1500
(Latex & Oil Base only)
prime valve
prime valve

12
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 recommendations.
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 in manual.
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 IN FRONT OF
MANUAL!
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-1600, DC-3100 & DC-
5500, DC-7700 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) 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.
Figure 10. - Proper way to trigger spray gun.
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 perpendicular 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).
HINTS FOR AIRLESS SPRAYING

13
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.
Warning: Special cleanup instructions for use with flammable
solvents:
• Always flush spray gun preferably outside and at least one hose
length from spray pump.
• If collecting flushed solvents in a one gallon metal container,
place it into an empty five gallon container, then flush solvents.
• Area must be free of flammable vapors.
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.
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).
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.
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.
lacquer 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
REPLACED IMMEDIATELY.
WARNING: DO NOT CLEAN THE SPRAY GUN UNLESS THE
PRESSURE HAS BEEN RELEASED FROM THE SYSTEM. SEE
FRONT OF MANUAL FOR FURTHER PRECAUTIONS.
Warning!

14
MAINTENANCE (DC-2000, DC-3100 & DC-7700)
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 L-65 section for overhaul details.
SPRAY TIP:
The spray tip is one of the most important elements in producing a
quality spray job. It requires periodic replacement (every 50-200 gallons)
to maintain performance and to prevent overworking the pump (see Tip
Selection section for details).
LOWER PACKINGS:
No regular service required.
The lower packings of these units are stationary, so that the only metal
wearing parts are the valves and the piston. Costly replacement of the
pump cylinder is eliminated. The lower packings are self adjusting, 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. On the DC-7700 the lower packings can be re-thightened
after every 2000 gallons of paint has been sprayed. Simply rotate the
inlet valve housing 1/8 of a turn clockwise to adjust the spring tension on
the packings.
UPPER PACKINGS:
Lubricate daily with 2 to 3 drops of L034-125 oil. Oiling location is shown
on pages 6 & 7. 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 reasonable effort. Packings should
be replaced.
CHECK VALVES:
These pumps have two valves, the footvalve at the paint inlet, and the
shaft valve in the bottom 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 wooden block will usually suffice. Should this not work,
the following pages will show you how to remove and clean the
footvalve and check the shaft valve.
Wiring diagram, DC-2000
SERVICE (DC-3100)
Wiring diagram, DC-3100
MAINTENANCE
Before proceeding, follow the Pressure Relief Procedure outlined
previously in this manual. Additionally, follow all other warnings to
reduce the risk of an injection injury, injury from moving parts or
electric shock. Always unplug the sprayer before servicing!
GENERAL REPAIR AND SERVICE NOTES
1) Before repairing any part of the sprayer, read the instructions
carefully, including all warnings. Never pull on a wire to disconnect
it. Pulling on a wire could loosen the connector from the wire.
2) Test your repair before regular operation of the sprayer to be sure
that the problem is corrected. If the sprayer does not operate
properly, review the repair procedure to determine if everything was
done correctly. Refer to the Troubleshooting section to help identify
other possible problems.
3) Make sure that the service area is well ventilated in case solvents
are used during cleaning. Always wear protective eyewear while
servicing. Additional protective equipment may be required depend-
ing on the type of cleaning solvent. Always contact the supplier of
solvents for recommendations.
4) If you have any further questions concerning your LEMMER Airless
Sprayer, call one of our locations listed in the back of this manual.
REPLACING THE PRIME/SPRAY VALVE
Perform the following procedure using PRIME/SPRAY valve replace-
ment kit P/N L045-862.
1) Drive the groove pin out of the valve handle.
2) Remove the valve handle and the cam base.
3) Using a wrench, loosen and remove the valve housing assembly
from the pump manifold.
4) Make sure the gasket is in place and thread the new valve housing
assembly into the pump manifold. Tighten securely with a wrench.
5) Place the cam base over the valve housing assembly.
Lubricate the cam base with grease and line up the cam with the pump
manifold using the dowel pin.
6) Line up the hole on the valve stem with the hole in the valve handle.
7) Insert the groove pin into the valve handle and through the valve
stem to secure the valve handle in position.
Wiring diagram, DC-3100N

15
SERVICE (DC-3100)
REPLACING THE PUMP FILTER
1) Loosen and remove the filter housing.
2) Pull the filter from the pump manifold.
NOTE: If the filter breaks off in the pump manifold, use a small
wood screw to remove.
3) Inspect the filter seal. Based on inspection, clean or replace the
seal.
4) Push the new or cleaned filter into the pump manifold.
5) Slide the filter housing over the filter and thread it into the pump
manifold until secure.
REPLACING THE MOTOR ASSEMBLY
1) Perform the Pressure Relief Procedure and unplug the sprayer.
2) Remove the four motor cover screws. Remove the motor cover.
3) Remove the four heat sink assembly screws. Pull the heat sink
assembly away from the gear box housing.
4) Disconnect the five wires from the relay that is mounted on the
inside of the heat sink assembly.
5) Remove the three relay mounting screws from the heat sink
assembly. Remove the relay.
6) Using the three relay mounting screws, install the new relay onto the
heat sink assembly. Tighten the screws securely.
7) Connect the five wires to the new relay (refer to the electrical
schematic in this manual).
8) Using the four heat sink assembly screws, install the heat sink
assembly onto the gear box housing. Tighten the screws securely.
9) Disconnect the black and red wires coming from the gear box
housing. Disconnect the black and red wires from the capacitors.
Disconnect the black and red wires from the motor.
10) Loosen and remove the four motor mounting screws.
11) Pull the motor out of the gear box housing.
NOTE: If the motor will not dislodge from the pump housing:
• Remove the front cover plate.
• Using a rubber mallet, carefully tap on the front of the motor
crankshaft that extends through the slider assembly.
12) With the motor removed, inspect the gears in the gear box housing
for damage or excessive wear. Replace the gears, if necessary.
13) Install the new motor into the gear box housing.
NOTE: Rotate the motor fan manually until the armature gear
engages with the mating gear in the gear box housing.
14) Secure the motor with the four motor mounting screws.
15) Push the new capacitors into their clip on the new motor.
16) Reconnect the wires (refer to the electrical schematic in this
manual).
17) Slide the motor cover over the motor. Secure the motor cover with
the four motor cover screws.
REPLACING THE MOTOR BRUSHES
Perform this procedure using Motor Brush Kit P/N L045-472.
1) Perform the Pressure Relief Procedure and unplug the sprayer.
2) Loosen and remove the four motor cover screws. Remove the motor
cover.
3) Loosen and remove the two fan shroud screws. Remove the fan
shroud.
4) Using a small screwdriver, pry off the two plastic brush covers.
5) Disconnect the black and red wires from the motor brushes.
Remove the motor brushes.
6) Install the new motor brushes and snap on the plastic brush covers.
7) Reconnect the black and red wires from the motor brushes (refer to
the electrical schematic in this manual).
8) Position the fan shroud over the motor fan. Secure the fan shroud
with the two fan shroud screws.
9) Slide the motor cover over the motor. Secure the motor cover with
the four motor cover screws.
REPLACING THE GEARS
1) Perform the Pressure Relief Procedure and unplug the sprayer.
2) Loosen and remove the four motor cover screws. Remove the motor
cover.
3) Disconnect the black and red wires coming from the gear box
housing.
4) Loosen and remove the four motor mounting screws.
5) Pull the motor out of the gear box housing.
NOTE: If the motor will not dislodge from the pump housing:
• Remove the front cover plate.
• Using a rubber mallet, carefully tap on the front of the motor
crankshaft that extends through the slider assembly.
6) Inspect the armature gear on the end of the motor for damage or
excessive wear. If this gear is completely worn out, replace the
entire motor.
7) Remove and inspect the 2nd stage gear for damage or excessive
wear. Replace if necessary.
8) Remove and inspect the crankshaft/gear assembly for damage or
excessive wear. Replace if necessary.
9) Reassemble the pump by reversing the above steps. During
reassembly, make sure the thrust washer is in place.
NOTE: Refill the gear box with five ounces of Lubriplate (P/N L045-
479).
REPLACING THE TRANSDUCER
1) Loosen and remove the four front cover screws. Remove the front
cover.
2) Stop the sprayer at the bottom of its stroke so that the piston is in its
lowest position.
3) Perform the Pressure Relief Procedure and unplug the sprayer.
Warning: before proceeding, follow the Pressure Relief Procedure
outlined previously in this manual. Additionally, follow all other
warnings to reduce the risk of an injection injury, injury from
moving parts or electric shock. Always unplug the sprayer before
servicing!
4) Tilt the sprayer back for easy access to the fluid section.

16
SERVICE (DC-3100)
5) Slide the retaining ring up on the slider assembly to expose the
connecting pin.
6) Push the connecting pin forward through the slider assembly and
piston. The connecting pin will fall into a recessed area of the gear
box housing where it can be retrieved.
7) Using 3/8" a hex wrench, loosen and remove the two pump manifold
mounting screws.
8) Pull the pump manifold down off of the gear box housing.
9) Using a wrench, remove the transducer assembly from the pump
manifold.
10) Thread the new transducer assembly into the pump manifold.
Tighten securely with a wrench.
11) Reassemble the pump by reversing steps 1-8.
Make sure the transducer is aligned properly with the hole in the
pump manifold during reassembly. Improper alignment may cause
damage to the transducer o-ring.
SERVICING THE FLUID SECTION
Use the following procedures to service the valves and repack the fluid
section. Perform the following steps before performing any mainte-
nance on the fluid section.
1) Loosen and remove the four front cover screws. Remove the front
cover.
2) Position the slider assembly at the bottom, dead-center of its stroke
so that the connecting pin and retaining ring are visible below the
slider assembly. This is done by turning the sprayer on and off in
short bursts until the connecting pin is visible below the slider
housing.
3) Perform the Pressure Relief Procedure and unplug the sprayer.
Warning: before proceeding, follow the Pressure Relief Procedure
outlined previously in this manual. Additionally, follow all other
warnings to reduce the risk of an injection injury, injury from
moving parts or electric shock. Always unplug the sprayer before
servicing!
4) For Upright Cart units, remove the return hose from the hose clip on
the siphon tube. Unscrew the siphon tube from the inlet valve
housing.
5) For Low Boy cart units, remove the retaining ring from the bottom of
the inlet valve housing using a snap ring pliers. Remove the return
hose clamp and pull the return hose from its fitting on the pump
manifold. Remove the suction set assembly.
6) Loosen and remove the high-pressure hose from the outlet fitting on
pump manifold.
SERVICING THE VALVES
The design of the fluid section allows access
to the inlet valve and seat as well as the outlet
valve and seat without completely disassem-
bling the fluid section. It is possible that the
valves may not seat properly because of
debris stuck in the foot valve seat or outlet
valve seat. Use the following instructions to
clean the valves and reverse or replace the
seats.
1) Using a wrench, loosen and remove the
inlet valve housing from the pump
manifold.
2) Clean out any debris in the inlet valve
housing and examine the valve housing
and seat. If the seat is damaged, reverse
or replace the seat.
3) Using a 5/16" hex wrench, loosen and remove the outlet valve
retainer from the piston rod.
NOTE: Always service the outlet valve with
the piston rod attached to the pump. This
will prevent the piston rod from rotating
during disassembly of the outlet valve.
4) Clean out any debris and examine the
valve housing and seat. If the seat is
damaged, reverse or replace the seat.
5) Remove, clean, and inspect the outlet
valve cage and outlet valve ball. Replace
if they are worn or damaged.
6) Reassemble the valves by reversing the steps above. (Note: Seal
only req'd on DC3100N or units with metal outlet valve cage.)
REPACKING THE FLUID SECTION
1) Remove the inlet valve assembly
using the steps in the "Servicing the
Valves" procedure above.
NOTE: The outlet valve does not
need to be disassembled from the
piston rod for this procedure.
2) Slide the retaining ring up on the
slider assembly to expose the
connecting pin. (Step 2 & 3 not req'd
on DC3100N with slotted piston.)
3) Push the connecting pin forward
through the slider assembly and
piston. The connecting pin will fall
into a recessed area of the gear box
housing where it can be retrieved.
4) Using 3/8" a hex wrench, loosen
and remove the two pump manifold
mounting screws.
5) Pull the pump manifold down off of
the gear box housing.
6) Slide the piston rod out through the
bottom of the pump manifold.
7) Loosen and remove the retainer nut
and piston guide from the pump
manifold.
8) Remove the upper and lower
packings from the pump manifold.
9) Clean the pump manifold and install the new upper and lower packings.
Refer to the illustration below for proper packing orientation.
10) Inspect the piston rod for wear and replace if necessary.
11) Insert the piston guide into the retainer nut. Thread the retainer nut
into the pump manifold until it is hand tight.

17
SERVICE (DC-3100)
REPLACING THE MOTOR ASSEMBLY (WITH ELECTRONIC
CONTROL)
WARNING: Electrostatic discharge (ESD) potential could cause
damage to electronic control. B sure you are grounded when
working on electronic control with electronic cover removed.
1) Perform the Pressure Relief Procedure and unplug the unit.
2) Loosen and remove the four motor shroud screws. Remove the
motor shroud.
3) Release the tie wrap on the top of the baffle assembly and slip the
baffle assembly down off of the motor.
4) Loosen and remove the three electronic cover screws. Lift the
electronic cover off of the electronic control assembly on the motor.
5) At the electronic control assembly:
a) Disconnect the white wire coming from the power cord and the
white wire coming from the relay.
b) Disconnect the three wires coming from the potentiometer.
6) Loosen and remove the three motor mounting screws.
7) Pull the motor out of the gearbox housing.
8) With the motor removed, inspect the gears in the gearbox housing
for damage or excessive wear. Replace the gears, if necessary.
9) Install the new motor into the gearbox housing. Make sure the
housing gasket is positioned properly.
10) Secure the motor with the three motor mounting screws.
11) Reconnect the wires to the electronic control assembly (refer to the
electrical schematic in this section of manual).
12) Position the electronic cover over the electronic control assembly.
Secure the electronic cover with the three electronic cover screws.
CAUTION: Use only Lemmer electronic cover screws to secure the
electronic cover (see parts list). Use of any other screws may
damage the electronic control assembly.
13) Slip the baffle assembly up and around the motor. Secure the baffle
assembly with the tie wrap.
14) Slide the motor shroud over the motor.
15) Secure the motor shroud with the four motor shroud screws. Motor
Shroud Electronic Cover Electronic Cover Screw - Gearbox v
Housing Motor Mounting Screw Electronic Control Assembly Motor
Motor Shroud Screws
REPLACING THE GEARS
1) Perform the Pressure Relief Procedure and unplug the unit.
2) Loosen and remove the four motor shroud screws. Remove the
motor shroud.
3) Release the tie wrap on the top of the baffle assembly and slip the
baffle assembly down off of the motor.
4) Loosen and remove the three electronic cover screws. Lift the
electronic cover off of the electronic control assembly on the motor.
5) At the electronic control assembly:
a) Disconnect the white wire coming from the power cord and the
white wire coming from the relay.
b) Disconnect the three wires coming from the potentiometer.
6) Loosen and remove the three motor mounting screws.
7) Pull the motor out of the gearbox housing.
8) Inspect the armature gear on the end of the motor for damage or
excessive wear. If this gear is completely worn out, replace the
motor.
9) Remove and inspect the 1 st stage gear and 2nd stage gear
assemblies for damage or excessive wear. Replace, if necessary.
10) Remove and inspect the front gear box assembly for damage or
excessive wear. If damaged or worn, replace the front gear box
assembly.
MAINTENANCE & SERVICE (DC-7700)
Motor Shroud
Motor Shroud
Screws
Electronic Cover
Cover Screw
Gasket
Motor
Electronic Control Assembly
Motor Mounting Screws
Motor Fan
Baffle
Assembly
Front End Bell
Assembly
Armature Gear
1st Stage Gear
Front Gear
Box Assembly Housing
Gasket
2nd Stage Gear
12) Slide the piston guide tool (included in the repacking kit) over the top
of the piston rod and insert the piston rod through the bottom of the
pump manifold. Using a rubber mallet, tap the bottom of the piston
rod lightly until the piston rod is in position in the pump manifold.
NOTE: Coat the piston guide tool and the piston rod with grease
before inserting them into the pump manifold.
13) Using a wrench, tighten the retainer nut securely.
14) Position the pump block underneath the pump housing and push up
until it rests against the pump housing. When the connecting pin
hole on the piston rod lines up with the hole in the slider assembly,
insert the connecting pin.
15) Slide the retaining ring down over the connecting pin.(not DC3100N)
Make sure the transducer is aligned properly with the hole in the
pump manifold during reassembly. Improper alignment may cause
damage to the transducer gasket.
16) Thread the pump manifold mounting screws through the pump
manifold and into the gear box housing. Tighten securely.
17) Reassemble the inlet valve assembly into the pump manifold.
18) For Upright Cart units, thread the siphon tube into the inlet valve and
tighten securely. Make sure to wrap the threads on the down tube
with Teflon tape before assembly. Replace the return hose into the
hose clip on the siphon tube.
19) For Low Boy cart units, insert the elbow on the suction set assembly
into the bottom of the inlet valve housing. Push the retaining ring up
into the groove inside the inlet valve housing to secure the suction
set assembly in position. Push the return hose onto the return hose
fitting on the pump manifold and secure in position with the return
hose clamp.
20) Place the front cover on the gear box housing and secure in position
using the four front cover screws.
21) Turn on the sprayer by following the procedure in the "Startup
Procedure" section of this manual and check for leaks.
NOTE: Repacking kit P/N L045-470 is available. For best results use
all parts supplied in this kit.

18
MAINTENANCE & SERVICE (DC-7700)
NOTE: Clean and refill the gear box cavity up to the rear face of
each gear with wheel bearing grease.
11) Install the motor into the gearbox housing. Make sure the housing
gasket is positioned properly.
12) Secure the motor with the three motor mounting screws.
13) Reconnect the wires to the electronic control assembly (refer to the
electrical schematic).
14) Position the electronic cover over the electronic control assembly.
Secure the electronic cover with the three electronic cover screws.
15) Slip the baffle assembly up and around the motor. Secure the baffle
assembly with the tie wrap.
16) Slide the motor shroud over the motor.
17) Secure the motor shroud with the four motor shroud screws.
REPLACING THE TRANSDUCER
1) Perform the Pressure Relief Procedure and unplug the unit.
2) Loosen and remove the four motor shroud screws. Remove the
motor shroud.
3) At the electronic control assembly, disconnect the black wire coming
from the transducer.
4) Pull the grommet out of the mounting plate and slide it up the shaft
of the transducer until it is clear of the mounting plate.
5) Using a wrench, loosen and remove the transducer from the filter
housing. Carefully thread the transducer wire out through the
mounting plate.
6) Slide the grommet off of the old transducer and onto the new
transducer.
7) Thread the new transducer wire through the mounting plate and up
to the electronic control assembly.
8) Thread the new transducer into the filter housing and tighten
securely with a wrench.
NOTE: Make sure the o-ring on the transducer is in place before
threading the transducer into the filter housing.
9) Push the grommet into the mounting plate.
10) Connect the transducer wire to the electronic control assembly (refer
to the electrical schematic in this section of manual).
11) Slide the motor shroud over the motor.
12) Secure the motor shroud with the four motor shroud screws.
Use the following procedures to service the valves and repack the
fluid section.
REPACKING THE FLUID SECTION (KIT # L045-890)
Use the following procedures to repack the fluid section. For best results
use all parts supplied in this kit. Parts included are shown with "•".
1. Loosen and remove the four front cover screws. Remove the front
cover.
2. Position the crankshaft/slider assembly at the bottom, dead-center
of its stroke so that the connecting pin and retaining ring are visible
below the slider assembly. This is done by turning the sprayer on
and off in short bursts until the connecting pin is visible below the
slider housing.
3. Perform the “Pressure Relief Procedure” in the Owner’s Manual and
unplug the unit.
WARNING, Before proceeding, follow the Pressure Relief Proce-
dure outlined in the Owner’s Manual. Additionally, follow all other
warnings to reduce the risk of an injection injury, injury from
moving parts or electric shock. Always unplug the sprayer before
servicing!
4. Remove the return hose from the clamp on the siphon tube.
5. Unscrew the siphon tube/suction set from the inlet valve.
6. Loosen and remove the high-pressure hose from the nipple on the
back of the cylinder of the fluid section.
7. Slide the retaining ring up on the slider
assembly to expose the connecting pin.
8. Push the connecting pin back through
the slider assembly and piston. The
connecting pin will fall into a recessed
area of the gear box housing where it
can be retrieved.
9. Using a wrench, turn the jam nut
counterclockwise to loosen it from the
gear box housing.
10. Turn the fluid section counterclockwise to
remove it from the gear box housing.
11. Place the fluid section cylinder upright in
a vise by clamping on the wrench flats.
NOTE: Do not over-tighten the vise.
Damage to the cylinder may occur.
12. Loosen and remove the inlet valve
housing from the cylinder.
13. Remove the inlet valve cage, inletvalve
ball, inlet valve seat, and o-ring from the
inlet valve.
14. Clean out any debris in the inlet valve
housing and examine the housing and
the inlet valve seat. If the seat is
damaged, reverse or replace the seat.
NOTE: Inlet valve replacement parts can
be ordered separately.

19
TROUBLESHOOTING
Provided you have followed the instructions, the sprayer will operate efficiently and give trouble-free service.Should any unexpected problem arise
you can, in most cases, remedy the problem by following the chart below. If yo u find that you cannot correct the problem, then take the sprayer to
your nearest authorized service agency. Many of the “causes” listed are unlikely to happen. However, all are included in an attempt to cover every
possibility.
IT IS ABSOLUTELY ESSENTIAL FOR TROUBLE-FREE OPERATION THAT YOUR AIRLESS SPRAYER BE KEPT CLEAN AND FREE OF
RESIDUAL PAINT BUILD-UP ON THE INTERNAL PARTS. IT MUST BE CLEANED AND LUBRICATED AFTER EVERY USE.
Cause
1) Blown fuse or tripped circuit breaker on supply or
sprayer.
2) Power cord or extension cord not properly
connected.
1) Pressure control knob set too low.
2) Clogged spray tip or filters.
3) Frozen or hardened paint in pump.
4) Worn motor brushes.
1) Prime valve closed.
2) Pump inlet screen clogged.
3) Suction tube clogged or loose.
4) Stuck or clogged foot valve or shaft valve.
5) Clogged spray tip.
6) Packings dry or worn.
1) Worn spray tip.
2) Pressure control knob loose.
3) Unit not primed.
4) Fluid leakage.
5) Spray tip too large.
6) Worn prime vavle leaking back.
7) Worn of dirty foot valve, shaft valve, or lower
packings.
8) Clogged gun filter causes pump not to run after
unit is primed and trigger is pulled.
1) Upper packings worn.
2) Worn piston.
1) Spray tip too large or worn.
2) Pressure set too low.
3) Insufficient fluid delivery.
4) Paint too thick.
5) Gun filter plugged.
1) Worn ball or seat on gun.
2) Foreign matter or paint buildup between ball and
seat on gun.
3) Ball not in correct position.
1) Packing or tip is worn.
2) Gun not shutting off.
1) Worn valve ball on gun.
1) Spray tip or gun filter plugged.
1) Partially plugged spray tip or filter.
Problem
Ia Sprayer does not start
up.
Ib Sprayer does not start
up.
II Sprayer starts up but
does not draw up paint.
III Sprayer will not maintain
pressure or has low
output.
IV Upper end of fluid
section leaks.
V Poor spray pattern.
VI Spray gun won’t shut
off.
VII Spray tip leaks.
VIII Spray gun leaks.
IX Spray gun won’t spray.
X Low paint output from
spray gun.
Remedy
1) Check and replace fuse or reset circuit breaker. (deter-
mine cause if possible).
2) Check and repair if necessary.
1) Turn knob to higher setting.
2) Follow Pressure Shut Down Procedure. Remove and
clean spray tip and/or filter. Replace.
3) Remove and clean Fluid Section parts. Re-install.
4) Replace motor brushes.
1) Open prime valve. Keep valve open while pressure
control knob is in prime position. Close valve after unit is
primed.
2) Remove and clean inlet strainer.
3) Remove and clean suction tube, tighten.
4) Refer to maintenance section of manual.
5) Relieve pressure using the Pressure Shut Down
Procedure. Remove spray tip and replace.
6) Repack Fluid Section.
1) Follow Pressure Shut Down Procedure. Replace spray
tip.
2) Tighten pressure control knob set screw.
3) Follow priming procedure under Start-up section of
owner’s manual.
4) Check and tighten all high-pressure fittings.
5) Follow Pressure Shut Down Procedure. Replace spray
tip.
6) Replace valve.
7) Refer to re-pack section of manual
8) Follow Pressure Shut Down Procedure. Replace gun
filter.
1) Follow Pressure Shut Down Procedure. Tighten packing
takeup nut. If still leaking, replace packings.
2) Follow Pressure Shut Down Procedure. Replace
packings first. If still leaking, replace piston.
1) Use smaller spray tip size.
2) Increase pressure setting.
3) Follow instructions under "Unit will not maintain pressure
or has low output".
4) Reduce viscosity per manufacturer’s recommendations.
5) Follow pressure shut down procedure. Remove and
clean filter.
1) Replace ball or seat.
2) Disassemble gun and clean.
3) Adjust rear tension nut. If this doesn’t work examine ball
and replace if necessary.
1) Replace worn or damaged parts.
2) Clean or repair as required. Check gun filter.
1) Replace valve ball.
1) Clean spray tip. Clean or replace gun filter.
1) Clean or replace gun filter. Clean spray tip.

20
OTHER LEMMER PRODUCTS
LEMMER'S Full line of equipment comes with FIRST CLASS SERVICE in numerous
locations across CANADA, and a FULL ONE YEAR WARRANTY. For information on choosing the
right sprayer for your job, please contact your nearest LEMMER outlet.
May 2008
AIR GUNS & PRESSURE POTS
Conventional air spray guns for fine
finishing. Suitable for countless industrial
and automotive applications. Available in
suction, gravity, and pressure feed
versions. Each is available in many
different needle sizes.
LINEMARKERS
Designed to handle the abrasive nature
of road marking paint. The new DC-5500
LinePro is an all Stainless Steel piston
pump designed for the new water base
linestriping paints.
HVLP TURBINE & VENTURI UNITS
High Volume Low Pressure sprayers are
used for fine finishing where overspray
must be kept to a minimum. The finish
results are equal to or better than
conventional air spray. The turbine
systems are self contained and do not
require an outside air source. The
VENTURI spray gun only uses about 8
CFM of shop air. Applications vary from
automotive finishing to commercial multi-
color architectural coating.
ELECTROSTATIC UNITS
The electrostatic WRAP-A-ROUND
charge makes this the best method of
spraying metal with next to no overspray.
Solvent and waterborne versions are
available. The conversion kit will hook up
to most airless pumps and we carry a
completely self contained portable
system.
AUTOMATIC GUNS
Suitable for all heavy duty airless applica-
tions. Air actuated, universal rod mount-
ing, and standard 1/4" NPS hose connec-
tion.
ELECTRIC DIAPHRAGM
These sprayers are the same as above
piston pumps except in a lower cost
diaphragm design. The motor runs
continuous for the ultimate spraying
pressure control. Hopper models are
easiest to clean.
ELECTRIC PISTON PUMPS
Commercial airless sprayers for all sizes
of jobs and spraying a large variety of
paint types. These units are portable and
come in many different performance
categories. There are small units for
spraying a house or barn once a year,
and large units for spraying warehouses
on a continuous basis.
PAINTING SUNDRIES
Strainer bags, filters, pressure rollers etc.
A large variety of painting accessories to
help make a cleaner and more efficient
working environment.
AIRLESS ACCESSORIES
A very large assortment of hoses, guns,
tips, and filters, etc. These items are
universal to most airless spray equipment
on the market.
PNEUMATIC PISTON PUMPS
Being an air powered airless, these units
are generally used for industrial coatings.
Applications range from portable lacquer-
ing to plumbed-in automatic systems.
Also excellent for industry where operat-
ing conditions are very demanding.
TRANSFER PUMP
It can be used to transfer paint to remote
locations, or directly to high pressure
pumps. At a 1:1 ratio with up to 125 PSI
air pressure it can also supply numerous
air guns.
GAS POWERED AIRLESS
These units are ready for the biggest
outdoor jobs. Robust piston pump design
for long life and maximum performance.
RUSTPROOFING EQUIPMENT
Lemmer carries a wide range of pumps,
spray guns and accessories for the
automotive rustproofing industry.