Titan 0533630W User manual

Edition 9 / 2015 0533 845C
Ausgabe
D F
GB
Operating manual
Betriebsanleitung............p. 22
Mode d’emploi.................p. 44
Air Powered Airless Sprayer
Mit Druckluft betriebenes Airless-Spritzgerät
Pulvérisateur sans air pneumatique
PowrCoat 630
Model:
0533630C
Model:
0533630W

2 PowrCoat
GB
Warning!
Attention: Danger of injury by injection!
Airless units develop extremely high spraying pressures.
Be safety conscious!
1
2
3
Never put your ngers, hands or any other parts of the body into
the spray jet!
Never point the spray gun at yourself, other persons or animals.
Never use the spray gun without safety guard.
Do not treat a spraying injury as a harmless cut. In case of injury
to the skin through coating materials or solvents, consult a doctor
immediately for quick and expert treatment. Inform the doctor
about the coating material or solvent used.
The operating instructions state that the following points must
always be observed before starting up:
1. Faulty units must not be used.
2. Secure Titan spray gun using the safety catch on the trigger.
3. Ensure that the unit is properly grounded / earthed.
4. Check allowable operating pressure of high-pressure hose and spray
gun.
5. Check all connections for leaks.
The instructions regarding regular cleaning and maintenance of
the unit must be strictly observed.
Before any work is done on the unit or for every break in work the
following rules must be observed:
1. Release the pressure from spray gun and hose.
2. Secure the Titan spray gun using the safety catch on the trigger.
3. Switch o unit.
Original Operating Manual

PowrCoat 1
GB
Contents
Contents
Page
1. Safety regulations for Airless spraying...................................... 2
1.1 Explanation of symbols used.............................................................. 2
1.2 Compressor safety .................................................................................. 3
1.3 Setting up on uneven surfaces........................................................... 4
1.4 Freezing Parts ........................................................................................... 4
2. General view of application............................................................. 5
2.1 Application ................................................................................................ 5
2.2 Coating materials .................................................................................... 5
3. Description of unit................................................................................ 5
3.1 Airless process.......................................................................................... 5
3.2 Functioning of the unit ......................................................................... 5
3.3 System diagram....................................................................................... 6
3.4 Technical data for PowrCoat units.................................................... 7
4. Operation.................................................................................................. 7
4.1 Setup............................................................................................................ 7
4.2 Automatic lubricator.............................................................................. 8
4.3 Preparing a new sprayer.....................................................................10
4.4 Preparing to spray.................................................................................10
4.5 Spraying....................................................................................................11
4.6 Pressure relief procedure ...................................................................11
5. Cleanup....................................................................................................12
5.1 Special cleanup instructions for use with
ammable solvents ..............................................................................12
5.2 Cleaning the sprayer............................................................................12
5.3 Cleaning the air lter............................................................................13
Page
6. Maintenance..........................................................................................13
6.1 Daily maintenance................................................................................13
6.2 Maintaining the lter assembly........................................................14
6.3 Maintaining the air motor..................................................................15
6.4 Maintaining the uid pump ..............................................................15
7. Troubleshooting .................................................................................15
7.1 Spray gun .................................................................................................15
7.2 Air motor ..................................................................................................15
7.3 Spray patterns ........................................................................................16
7.4 Fluid pump ..............................................................................................17
8. Servicing..................................................................................................18
8.1 Servicing the air motor........................................................................18
8.2 Servicing the pump assembly ..........................................................20
Accessories and spare parts ........................................................................66
Spare parts list for the main assembly.................................................. 66/67
Spare parts list for the motor / pump assembly ............................... 68/69
Spare parts list for the upper housing assembly .............................. 70/71
Spare parts list for the air motor ............................................................ 72/73
Spare parts list for the uid pump assembly ..................................... 74/75
Spare parts list for automatic lter, regulator, lubricator
assembly.......................................................................................................... 76/77
Spare parts list for the high-pressure lter ......................................... 78/79
Spare parts list for the cart assembly .................................................... 80/81
Warranty ...............................................................................................................81

2 PowrCoat
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Safety precautions
1. Safety regulations for Airless spraying
1.1 Explanation of symbols used
This manual contains information that must be read and understood
before using the equipment. When you come to an area that has one
of the following symbols, pay particular attention and make certain
to heed the safeguard.
This symbol indicates a potential hazard that
may cause serious injury or loss of life. Important
safety information will follow.
At
tention
This symbol indicates a potential hazard to you
or to the equipment. Important information that
tells how to prevent damage to the equipment or
how to avoid causes of minor injuries will follow.
Danger of skin injection
Danger of fire from solvent and paint fumes
Danger of explosion from solvent, paint fumes
and incompatible materials
Danger of injury from inhalation of harmful
vapors
i
Notes give important information which should
be given special attention.
HAZARD: INJECTION INJURY
A high pressure stream produced by this equipment
can pierce the skin and underlying tissues, leading to
serious injury and possible amputation.
Do not treat a spraying injury as a harmless cut. In
case of injury to the skin through coating materials
or solvents, consult a doctor immediately for quick
and expert treatment. Inform the doctor about the
coating material or solvent used.
PREVENTION:
•NEVERaimthegunatanypartofthebody.•NEVERallowanypartofthebodytotouchtheuidstream.DONOTallowbodytotouchaleakintheuidhose.•NEVERputyourhandinfrontofthegun.Gloveswillnotprovide protection against an injection injury.
•ALWAYSlocktheguntrigger,shuttheuidpumpoand release all pressure before servicing, cleaning the tip
guard, changing tips, or leaving unattended. Pressure will
not be released by turning o the compressor. The PRIME/
SPRAYvalveorpressurebleedvalvemustbeturnedtotheirappropriate positions to relieve system pressure.
•ALWAYSkeeptipguardinplacewhilespraying.Thetipguardprovides some protection but is mainly a warning device.
•ALWAYSremovethespraytipbeforeushingorcleaningthesystem.
•NEVERuseaspraygunwithoutaworkingtriggerlockandtrigger guard in place.
•Allaccessoriesmustberatedatorabovethemaximumoperating pressure range of the sprayer. This includes spray
tips, guns, extensions, and hose.
HAZARD : HIGH PRESSURE HOSE
The paint hose can develop leaks from wear, kinking
and abuse. A leak can inject material into the skin.
Inspect the hose before each use.
PREVENTION:
•Avoidsharpbendingorkinkingofthehigh-pressurehose.Thesmallest bending radius amounts to about 20 cm.
•Donotdriveoverthehigh-pressurehose.Protectagainstsharp objects and edges.
•Replaceanydamagedhigh-pressurehoseimmediately.•Neverrepairdefectivehigh-pressurehosesyourself!•Electrostaticchargingofspraygunsandthehigh-pressurehose is discharged through the high-pressure hose. For this
reason the electric resistance between the connections of the
high-pressure hose must be equal to or lower than 1M.
•Forreasonsoffunction,safetyanddurabilityuseonlyoriginalTitan high-pressure hoses.
•Beforeeachuse,checkallhosesforcuts,leaks,abrasionor bulging of cover. Check for damage or movement of
couplings. Immediately replace the hose if any of these
conditionsexist.Neverrepairapainthose.Replaceitwithanother earthed high-pressure hose.
•Makesurepowercord,airhoseandsprayhosesareroutedinsuch a manner to minimize slip, trip and fall hazard.

PowrCoat 3
GB
Safety precautions
HAZARD: EXPLOSION OR FIRE
Flammable vapors, such as solvent and paint vapors,
in work area can ignite or explode.
PREVENTION:
•Useequipmentonlyinwellventilatedarea.Keepagoodsupply of fresh air moving through the area to keep the air
within the spray area free from accumulation of ammable
vapors.Keeppumpassemblyinwellventilatedarea.Donotspray pump assembly.
•Eliminateallignitionsources,suchaspilotlights,cigarettes,portable electric lamps and plastic drop cloths (potential static
arc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitches on or o when ammable vapors are present.
•Groundequipmentandconductiveobjectsinworkarea.Make sure the grounding cable is connected from the
grounding lug to a true earth ground.
•Useonlygroundedhoses.•Holdspraygunrmlytothesideofagroundedpailwhentriggering into pail.
•Ifthereisstaticsparkingorifyoufeelashock,stop operation
immediately.
•Knowthecontentsofthepaintandsolventsbeingsprayed.Read all Material Safety Data Sheets (MSDS) and container
labels provided with the paints and solvents. Follow the paint
and solvent manufacturer’s safety instructions.
•Donotuseapaintorsolventcontaininghalogenatedhydrocarbons. Such as chlorine, bleach mildewcide,
methylene chloride and trichloroethane. They are not
compatible with aluminum. Contact the coating supplier
about compatibility of material with aluminum.
•Keepareextinguisherinworkarea.HAZARD: HAZARDOUS VAPORS
Paints, solvents, and other materials can be harmful
if inhaled or come in contact with body. Vapors can
cause severe nausea, fainting, or poisoning.
PREVENTION:
•Wearrespiratoryprotectionwhenspraying.Readallinstructions supplied with the mask to be sure it will provide
the necessary protection.
•Alllocalregulationsregardingprotectionagainsthazardousvapors must be observed.
•Wearprotectiveeyewear.•Protectiveclothing,glovesandpossiblyskinprotectioncreamare necessary for the protection of the skin. Observe the
regulations of the manufacturer concerning coating materials,
solvents and cleaning agents in preparation, processing and
cleaning units.
HAZARD: GENERAL
This product can cause severe injury or property
damage.
PREVENTION:
•Followallappropriatelocal,state,andnationalcodesgoverning ventilation, re prevention, and operation.
•Pullingthetriggercausesarecoilforcetothehandthatisholding the spray gun. The recoil force of the spray gun is
particularly powerful when the tip has been removed and
a high pressure has been set on the airless pump. When
cleaning without a spray tip, set the pressure control knob to
the lowest pressure.
•Useonlymanufacturerauthorizedparts.Userassumesallrisks and liabilities when using parts that do not meet the
minimum specications and safety devices of the pump
manufacturer.
•ALWAYSfollowthematerialmanufacturer’sinstructionsforsafe handling of paint and solvents.
•Cleanupallmaterialandsolventspillsimmediatelytopreventslip hazard.
•Wearearprotection.Thisunitcanproducenoiselevelsabove85dB(A).•Neverleavethisequipmentunattended.Keepawayfromchildren or anyone not familiar with the operation of airless
equipment.
•Deviceweighsinexcessof36kg.Three-personliftisrequired.•Donotsprayonwindydays.•Thedeviceandallrelatedliquids(i.e.hydraulicoil)mustbedisposed of in an environmentally friendly way.
1.2 Compressor Safety
PowrCoat units are Air-Powered (powered by an air compressor).
Follow all safety precautions given by the compressor manufacturer
regarding electrical and general safety.
Locatethecompressoroutsidetheimmediatesprayingareatoavoidclogged air intake of the compressor with overspray.
If lacquer or other flammable materials are to be
sprayed, ALWAYS locate the compressor outside the
immediate spraying area. Failure to do so may cause
an explosion.

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Safety precautions
1.3 Setting up on uneven surfaces
The front side of the unit must point downwards to prevent sliding
away.
1.4 Freezing Parts
The temperature of some components of the unit can drop below 32º
F (0º C) during usage, and may show a build-up of frost. Refer to the
diagram below for the area of the pump most likely to reach freezing
temperatures. Avoid touching any components in this area during
usage.
Operating Temperature
This equipment will operate correctly in its intended ambient, at a
minimum between +50ºF (+10°C) and +104ºF (+40°C).
Relative Humidity
The equipment will operate correctly within an environment
at50%RH,+104ºF(+40°C).HigherRHmaybeallowedatlowertemperatures.
Measures shall be taken by the Purchaser to avoid the harmful eects
of occasional condensation.
Altitude
This equipment will operate correctly up to 2100 m above mean sea
level.
Transportation and Storage
This equipment will withstand, or has been protected against,
transportation and storage temperatures of -13ºF (-25°C) to 131ºF
(+55°C) and for short periods up to 158ºF (+70°C).
It has been packaged to prevent damage from the eects of normal
humidity, vibration and shock.

3. Description of unit
3.1 Air Powered / Airless
An Airless piston pump takes in coating material by suction. The
pneumatic piston pump is powered by compressed air provided by
an outside air compressor (Air-Powered).
Cycling of the piston pump moves the material through the pump
and down the uid hose to the spray gun. Pressed through the
tip at very high pressure, the coating material is atomized into ne
particles.
This method of spraying has the advantages of nest atomization,
cloudless operation and a smooth, bubble-free surface. As well as
these, the advantages of the speed of work and convenience must be
mentioned.
3.2 Functioning of the unit
The following section contains a brief description of the technical
construction for better understanding of the function.
TITANPowrCoatarehigh-pressuresprayingunitsdrivenbyairpowerprovided by an air compressor.
An air compressor connected by an air hose drives the air motor (1)
which then moves the piston up and down in the material feed pump
(2), drawing up spray material via the siphon hose (3).
The air regulator (4) controls the air pressure being allowed into
the system, and is directly proportionate to the uid pressure being
produced.
Example: PowrCoat 630 = 30:1
100 PSI reading at air gauge (5) = 3000 PSI at pump outlet
The inlet valve is opened automatically by the upwards movement
of the piston. The outlet valve is opened when the piston moves
downward.
Coating material ows under high pressure through the high-
pressure hose to the spray gun. When the coating material exits from
the tip it atomises.
3
4
1
5
2
PowrCoat 5
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Generalviewofapplication2. General view of application
2.1 Application
This spray system can be used for ne-nish as well as small
protective coatings applications.
Examples of objects to be sprayed
Metal nishing, concrete, wood nishing, cabinetry, exterior nishing.
2.2 Coating materials
Processible coating materials
Stains, latex, oil, acrylic, urethane and epoxy.
i
Pay attention to the spray quality of the coating
materials to be processed.
NoothermaterialsshouldbeusedforsprayingwithoutTitan’sapproval.
Filtering
In spite of the high-pressure lter, ltering of the coating material
is to be recommended in general. Follow manufacturer's
recommendations regarding paint straining and mixing.
Stir coating material before commencement of work.
iMake sure when stirring with motor-driven agitators
that no air bubbles are stirred in. Air bubbles disturb
when spraying and can, in fact, lead to interruption
of operation.
Viscosity
This sprayer is not for high viscosity coatings or coatings that require
very high pressures for application. Recommended are light to
medium viscosity coatings with a manufacturer recommended
atomization pressure of 3000 PSI (207 bar) or less.
Two-component coating material
The appropriate processing time must be adhered to exactly. Within
this time rinse through and clean the unit meticulously with the
appropriate cleaning agents. This is acceptable for all coatings with a
pot life of 45 minutes or greater.

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Description of unit
3.3 System diagram
1 Cart assembly (cart models only)
2 Air motor
3 Air pressure gauge
4 Air lter / moisture separator
5 Moisture drip tube
6 Fluid pump
7 Pressure bleed valve
8 Siphon tube
9 Air regulator
10Ventedshutovalve11 Automatic lubricator adjustment
12 Air hose connection 13Groundingcable14 Filter assembly
15OilcupforPistonLube™16Gunhoseconnection17Bleedhose8
1
2
3
5
6
7
4
9
10
11
12
13
15
16
14
17
13
15

PowrCoat 7
GB
Description of unit Operation
PowrCoat 630
Model Number
Cart 0533630C
Wall 0533630W
Pressure Ratio
30:1
Max. operating pressure
3480 PSI (240 bar)
Max. air inlet pressure
116 PSI (8 bar)
Cycle rate per gallon / liter
63 / 16
Volume per double stroke
60.8 cc (3.71 in)
Max. volume ow @ Cycles per minute (CPM)
60 CPM 0.96 gal (3.63 l)/min
90 CPM 1.45 gal (5.49 l)/min
Fluid inlet / outlet
Inlet 3/4”NPT(F)Outlet 3/8"NPT(F)Hose connection 1/4”NPSM(M)Approximate air requirement (SCFM) per gallon of output @ 116 PSI
(8.0 bar) air pressure
25 SCFM (0.71 m/min)
Air inlet 3/8”NPT(M)Max. sound pressure level 98dB*Weight
Cart 90 lbs (41 kg)
Wall 64 lbs (29 kg)
Max. viscosity
50.000 mPa·s
Dimensions L x W x H
Cart 19.75" x 18.5" x 40" (50.16 cm x 47 cm x 101.6 cm)
Wall 14.5" x 12" x 34.5" (36.8 cm x 30.5 cm x 87.6 cm)
Max. temperature of pre-heated coating material
140º F (60º C)
Filter insert (standard equipment)
60 mesh, 97 cm (15 In)
*Placeofmeasurement:1mdistancefromunitand1.60mabove reverberant oor, 120 bar (12 MPa) operating pressure.
3.4 Technical data for PowrCoat units 4. Operation
This equipment produces a uid stream at extremely
high pressure. Read and understand the warnings
in the Safety Precautions section at the front of this
manual before operating this equipment.
4.1 Setup
1. Make sure the siphon hose (g. 5, 1) is connected to the uid
section (2) and the bleed hose (3) is connected to the bleed
valve (4).
2. Thread the suction tube lter (5) onto the metal suction tube.
3
1
25
4
3.Lockthegunbyippingthetriggerlockintolockposition(see spray gun manual).
4.Usingawrench,attachaminimumof50’of1/4”nylonairlessspray hose to the material outlet tting (g. 6, item 1) on the
pump. Tighten securely.
1
Make sure all airless hoses and spray guns are
electrically grounded and rated for at least 3500 PSI
(24 MPa) uid pressure.

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Operation
5.Filltheoilcup1/2fullwithPistonLube(P/N314-480).Thisextends packing life.
Attention
Piston Lube prevents increased wear and tear to the
packings.
6.Verifythattheaircompressormeetsthepowerrequirementsnecessary to eectively power the sprayer. See “Technical
Data”, section 3.4 to determine air requirements.
7. Prior to connecting the compressor to the unit, perform the
following in order to prevent accidental startup:
a. Close the shuto valve (g 7, item 1). The gure shows the
handle in the closed position.
b. Turn the air regulator (2) fully counterclockwise to its lowest
pressure setting.
c. Open the bleed valve (3) by turning it fully counterclockwise.
The bleed valve handle should be pointing down.
1
3
2
8. Remove the red plug from the air hose tting (Fig. 8, item 1).
Attach the air hose and tighten wrench tight. All units are
equippedwitha3/8”NPT(M)nipple.1
Proper earthing (grounding) is important. The
passage of some materials through the nylon uid
hose will build up a static electric charge, which if
discharged, could ignite solvent vapors present and
create an explosion.
9. Make sure the sprayer is earthed (grounded). All sprayers are
equipped with a earthing (grounding) cable (1). Clip the end
of the grounding cable to a true earth ground.
1
10. Strain all paints with a nylon strainer to ensure trouble free
operation and freedom from frequent cleaning of the inlet
screen and gun lter.
11. Make sure the spray area is well ventilated to prevent
hazardous operation with volatile solvents or exhaust fumes.
If lacquer or other flammable materials are to be
sprayed, ALWAYS locate the compressor outside the
immediate spraying area. Failure to do so may cause
an explosion.
12.Locatethecompressoroutsidetheimmediatesprayingareato avoid clogged air intake of the compressor with overspray.

PowrCoat 9
GB
Operation
4.2 Automatic Lubricator
The automatic lubricator (Fig. 10, item 1) provides lubrication to the
air that is being delivered to the system. Check the level through the
openings (2) in the side of the air motor shroud.
After relling the reservoir, the automatic lubricator will need
adjusting. Turn the adjusting screw (1) clockwise to increase the
AirCare™injectionrateandcounterclockwisetodecreaseit.1
2
Check the injection rate by observing the ow through the openings
in the side of the air motor shroud.
•Theproperowrateis1dropofAirCare™perminute.•Inhumidweatherwhenicingmayoccur,increasetheinjection rate.
•Theinjectionratecomespre-setto1drop/30sec.4.3 Preparing a New Sprayer
If this unit is new, it is shipped with test uid in the uid section to
prevent corrosion during shipment and storage. This uid must be
thoroughly cleaned out of the system with cleaning agent before you
begin spraying.
Attention
Always keep the trigger lock on the spray gun in the
locked position while preparing the system.
1. Place the siphon tube into a container of mineral spirits.
2. Place a metal container under the bleed hose.
3. Close the shuto valve (g. 11, item 1). The gure shows the
handle in the closed position.
4. Turn on the air compressor.
5. Turn the air regulator (2) fully counterclockwise to its lowest
pressure setting.
6. Open the bleed valve (3) by turning it fully counterclockwise.
The bleed valve handle should be pointing down.
1
3
2
7. Open the shuto valve (1). The handle should now be in line
with the valve.
8. Turn the air regulator (2) clockwise to increase pressure until
the sprayer cycles evenly and solvent ows freely from the
bleed hose.
9. Allow the sprayer to run for 15–30 seconds to ush the test
uid out through the bleed hose and into the waste container.
10. Turn o the sprayer.
a. Turn the air regulator fully counterclockwise to its lowest
pressure setting.
b. Close the shuto valve.

11. Close the bleed valve by turning it fully clockwise. The bleed
valve handle should be horizontal.
12. Open the shuto valve (1). The handle should now be in line
with the valve. The system is now under pressure.
13. Turn the air regulator clockwise to increase pressure until the
sprayer cycles evenly. The air regulator gauge should read
between 60-80 PSI (4 - 5.5 bar).
iThe air regulator can be locked into place by pushing
down on the knob. Unlock the regulator by pulling
the knob out.
14.Unlockthegunbyturningtheguntriggerlocktotheunlocked position.
Ground / Earth the gun by holding it against the
edge of the metal container while ushing. Failure
to do so may lead to a static electric discharge, which
may cause a re.
15. Trigger the gun into the metal waste container until the old
solvent is gone and fresh solvent is coming out of the gun.
16.Lockthegunbyturningtheguntriggerlocktothelockedposition.
POSSIBLE INJECTION HAZARD
Refer to your spray gun manual for information
regarding the locking mechanism and how to
properly lock the spray gun.
17. Set down the gun and increase the pressure by turning the air
regulator slowly clockwise to a maximum of 116 PSI (8.0 bar).
DO NOT exceed an air regulator gauge reading of
116 PSI (8.0 bar).
18. Check the entire system for leaks. If leaks occur, turn the
sprayer o and follow the “Pressure Relief Procedure” in this
manual before tightening any ttings or hoses.
19. Follow the “Pressure Relief Procedure” (section 4.6) in this
manual before changing from solvent to paint.
Be sure to follow the Pressure Relief Procedure when
shutting the unit down for any purpose, including
servicing or adjusting any part of the spray system,
changing or cleaning spray tips, or preparing for
cleanup.
4.4 Preparing to Spray
Beforespraying,itisimportanttomakesurethattheuidinthesystem is compatible with the paint that is going to be used.
iIncompatible uids and paint may cause the valves
to become stuck closed, which would require
disassembly and cleaning of the sprayer’s uid
section.
Attention
Always keep the trigger lock on the spray gun in the
locked position while preparing the system.
1. Place the siphon tube into a container of the appropriate
solvent for the material being sprayed.
iIf you are spraying a water-based latex, ush with
warm, clean water. If you are using any other
material, check with the material manufacturer for a
compatible solvent.
2. Place a metal container under the bleed hose.
3. Close the shuto valve (g. 12, item 1). The gure shows the
handle in the closed position.
4. Turn on the air compressor.
5. Turn the air regulator (2) fully counterclockwise to its lowest
pressure setting.
6. Open the bleed valve (3) by turning it fully counterclockwise.
The bleed valve handle should be pointing down.
1
3
2
7. Open the shuto valve (1). The handle should now be in line
with the valve.
8. Turn the air regulator (2) clockwise to increase pressure until
the sprayer cycles evenly and solvent ows freely from the
bleed hose.
9. Allow the sprayer to run for 15–30 seconds to ush the test
uid out through the bleed hose and into the waste container.
10. Turn o the sprayer.
a. Turn the air regulator fully counterclockwise to its lowest
pressure setting.
b. Close the shuto valve.
iMake sure that the spray gun does not have a tip or
tip guard installed.
10 PowrCoat
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Operation

21. Once the correct air pressure has been established, lock the air
regulator by pushing down on the knob.
iUsing a higher pressure than required will only
wear out tips. Use the guidelines in establishing the
lowest pressures for proper atomization.
Consult the materials manufacturer for guidelines in
establishing the correct uid pressure.
4.6 Pressure Relief Procedure
Be sure to follow the Pressure Relief Procedure when
shutting the unit down for any purpose, including
servicing or adjusting any part of the spray system,
changing or cleaning spray nozzles, or preparing for
cleanup.
1.Lockthespraygunbyturningtheguntriggerlocktothelocked position.
2. Close the shuto valve.
3. Open the bleed valve by turning it fully counterclockwise.
4.Unlockthegunbyturningtheguntriggerlocktotheunlocked position.
5.Holdthemetalpartofthegunrmlytothesideofametalwaste container to earth the gun and avoid a build up of static
electricity.
6. Trigger the gun to remove any pressure that may still be in the
hose.
7.Lockthegunbyturningtheguntriggerlocktothelockedposition.
4.5 Spraying
1. Place the siphon hose into a container of paint.
2. Place the bleed hose into a metal waste container.
3. Close the shuto valve (g. 12, item 1). The gure shows the
handle in the closed position.
4. Turn on the air compressor.
5. Turn the air regulator (2) fully counterclockwise to its lowest
pressure setting.
6. Open the bleed valve (3) by turning it fully counterclockwise.
The bleed valve handle should be pointing down.
7. Open the shuto valve (g. 12, item 1). The handle should
now be in line with the valve.
8. Turn the air regulator (2) clockwise to increase pressure until
the sprayer cycles evenly and material ows freely from the
bleed hose.
9. Turn o the sprayer.
a. Turn the air regulator fully counterclockwise to its lowest
pressure setting.
b. Close the shuto valve.
10. Remove the bleed hose from the waste container and place it
into the container of material.
11. Close the bleed valve by turning it fully clockwise.
12. Open the shuto valve. The handle should now be in line
with the valve.
13. Turn the air regulator clockwise to increase pressure until the
sprayer cycles evenly. The air regulator gauge should read
between 60-80 PSI (4 - 5.5 bar).
14.Unlockthegunbyturningtheguntriggerlocktotheunlocked position.
Earth (ground) the gun by holding it against the
edge of the metal container while flushing. Failure
to do so may lead to a static electric discharge, which
may cause a fire.
15. Trigger the gun into the metal waste container until all air and
solvent is ushed from the spray hose and paint is owing
freely from the gun.
16.Lockthegunbyturningtheguntriggerlocktothelockedposition.
17. Close the shuto valve (g 12, item 1). The gure shows the
handle in the closed position.
18. Attach tip guard and tip to the gun as instructed by the tip
guard or tip manuals.
POSSIBLE INJECTION HAZARD. Do not spray
without the tip guard in place. Never trigger the
gun unless the tip is in either the spray or the unclog
position. Always engage the gun trigger lock before
removing, replacing or cleaning tip.
19. Open the shuto valve. The handle should now be in line
with the valve.
20. Increase the pressure by turning the air regulator slowly
clockwise and test the spray pattern on a piece of cardboard.
Adjust the regulator until the spray from the gun is completely
atomized.Verifypressurereadingattheairgauge.•Paintpressureisdirectlyproportionaltotheamountofairpressure.
•Example:PowrCoat630=30:1100 PSI (6.9 bar) reading at air gauge = 3000 PSI (207 bar) at
pump outlet
DO NOT exceed an air regulator gauge reading of
116 PSI (8.0 bar).
PowrCoat 11
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Operation

12 PowrCoat
GB
Cleanup
5. Cleanup
Attention
The sprayer, hose, and gun should be cleaned
thoroughly after daily use. Failure to do so permits
material to build up, seriously aecting the
performance of the unit.
Always spray at minimum pressure with the gun
nozzle tip removed when using mineral spirits or
any other solvent to clean the sprayer, hose, or
gun. Static electricity buildup may result in a re or
explosion in the presence of ammable vapors.
5.1 Special cleanup instructions for use with
ammable solvents
•Alwaysushspraygunpreferablyoutsideandatleastonehose length from spray pump.
•Ifcollectingushedsolventsinaonegallonmetalcontainer,place it into an empty ve gallon container, then ush
solvents.
•Areamustbefreeofammablevapors.•Followallcleanupinstructions.5.2 Cleaning the sprayer
1. Follow the “Pressure Relief Procedure” found in the Operation
section of this manual, section 4.6.
2. Remove the gun tip and tip guard and clean with a brush
using the appropriate solvent.
3. Place the siphon tube into a container of the appropriate
solvent.
Attention
Use only compatible solvents when cleaning
out oil based enamels, lacquers, coal tar, and
epoxies. Check with the uid manufacturer for the
recommended solvent.
4. Place a metal container under the bleed hose.
5. Close the shuto valve (g. 13, item 1). The gure shows the
handle in the closed position.
6. Start the compressor.
7. Turn the air regulator (2) fully counterclockwise to its lowest
pressure setting.
8. Open the bleed valve (3) by turning it fully counterclockwise.
The bleed valve handle should be pointing down.
1
3
2
9. Open the shuto valve (g. 13, item 1). The handle should
now be in line with the valve.
10. Allow the solvent to circulate through the sprayer and ush
the material out of the bleed hose into the metal waste
container.
11. Close the shuto valve (g. 13, item 1). The gure shows the
handle in the closed position.
12. Close the bleed valve by turning it fully clockwise.
13. Open the shuto valve (g. 13, item 1). The handle should
now be in line with the valve.
Ground / Earth the gun by holding it against the
edge of the metal container while flushing. Failure
to do so may lead to a static electric discharge, which
may cause a fire.
14. Trigger the gun into the metal waste container until the paint
is ushed out of the hose and solvent is coming out of the
gun.
15. Continue to trigger the spray gun into the waste container
until the solvent coming out of the gun is clean.
i
For long-term or cold weather storage, pump
mineral sprits through the entire system.
16. Follow the “Pressure Relief Procedure” found in the Operation
section of this manual.
17. Store the sprayer in a clean, dry area.
Attention
Do not store the sprayer under pressure.

PowrCoat 13
GB
Cleanup Maintenance
5.3 Cleaning the air lter
The air lter blocks any debris or particles that might be present in
the supplied air from the air compressor. It is important that this lter
be checked after every use.
1. Follow the “Pressure Relief Procedure” found in the Operation
section of this manual, section 4.6.
2. Remove the top four screws that secure the front shroud. The
two screws at the bottom front do not need to be removed.
3. After the four top screws are removed, ip open the front
shroud.
4. Press the red lock release on the gray shroud (1) and turn 1/4
turncounterclockwisetoremove.BecarefulnottolosetheO-ring (2) that may fall out of the bowl. The clear tube may
slip o of the tting on the bottom of the housing. It can be
reinstalled later.
5.Unthreadthelterassemblyfromthesprayer.Becarefulnotto lose the cap (3), spring (4), lter (5) or stem (6).
6.Removeandinspectthelter(P/N0533557,5).Ifdirty,cleanwith warm, soapy water.
7. Prior to reassembly, tilt the sprayer on its back.
8. Make sure all parts of the lter are reassembled prior to
reinstallation (g. 14, items 3-6).
9. Thread the entire lter assembly back into its housing in the
sprayer.
10. Make sure the O-ring (2) is in place. With the bowl inside
the shroud, insert into place and turn clockwise until the two
parts lock into place. Make sure the red lock release is facing
towards the front of the sprayer.
11. Flip the front shroud back into place and secure with the four
top screws.
1
2
3
4
5
6
6. 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!
6.1 Daily Maintenance
Two daily procedures are required for routine operator maintenance
on this sprayer:
A.Lubricatingtheupperpackings.B.CleaningtheinletscreenA) Lubricating the Upper Packings
1. Clean out the paint that has seeped past the upper packings
into the packing oil reservoir (g. 15, item 1) above the uid
section.
2.Fillthepackingoilreservoir1/2fullwithPistonLube(P/N314-480) supplied by the factory. This will extend packing life.
1
i
Do not over-ll the reservoir so that it overows and
drips into the paint.
B) Cleaning the Inlet Screen
1. The inlet screen will clog and must be cleaned at least once a
day.
2.Loosenandremovetheinletscreen(1)fromthebottomofthe metal suction tube.
3. Clean thoroughly with the appropriate solvent.
1

14 PowrCoat
GB
Maintenance
6.2 Maintaining the Filter Assembly
Clean the lter regularly. Dirty or clogged lters can greatly reduce
ltering ability and cause a number of system problems including
poor spray patterns, clogged spray tips, etc.
Cleaning (Fig. 17)
1. Follow the “Pressure Relief Procedure” found in the Operation
section of this manual (section 4.7).
2. Remove lter cap assembly (1).
3. Pull the lter element (2) with support (3) straight out of the
lter body (6).
4. Clean inside the lter body, lter element with support, and
lter cap assembly using the appropriate solvent.
iUse care in handling parts as dirt, debris, scratches,
or nicks may prevent o-rings or gaskets from sealing.
This lter element lters from the outside in. Be
sure to clean the lter element thoroughly. Soak in
solvent to loosen hardened paint or replace.
1
2
6
5
4
3
Inspection (Fig. 17)
Inspect all parts of the lter assembly before reassembly.
1. Inspect the support inside the lter element. If the support
has pressure cuts or scratches, replace the lter element.
2. Inspect the two PTFE gaskets (4, 5) for deformity, nicks, or
cuts. Replace, if needed.
Reassembly (Fig. 17)
After cleaning and inspecting all parts, reassemble the lter.
1. Place the lter element (2) with support (3) into the lter body
(6).
2. Place the thin PTFE gasket (5) onto the step at the top of the
lter body (6).
3. Place the PTFE O-ring (4) into the groove of the base of the
lter body threads (6).
4. Tighten the lter cap assembly (1) onto the lter body (6).
6.3 Air Motor Maintenance
Air motors require a normal maintenance and service inspection at
1500 hours service. Service procedure includes replacement of motor
service kit. It is suggested that one motor service kit be kept on hand
for normal maintenance and emergency repairs. Check the individual
model’s specications for correct part numbers.
6.4 Maintaining the Fluid Pump
If the sprayer is going to be out of service for an extended period of
time,itisrecommendedthatfollowingcleanup,LiquidShield™beintroduced as a preservative. Packings may tend to dry out from lack
of use. This is particularly true of the upper packing set for which
upperpackinglubricantPistonLube(P/N314-480)isrecommendedin normal usage.
If the sprayer has been out of service for an extended period of time,
it may be necessary to prime the pump with solvent. It is extremely
important that the threads on the siphon hose coupling are properly
sealed. Any air leakage will produce erratic operation of the sprayer
and may damage the system. The up and the down strokes should
be approximately equal in time (one should not be faster than the
other). A fast up or down stroke may indicate air in the system or
malfunctioning valve or seats (see the Troubleshooting section).

PowrCoat 15
GB
Troubleshooting
7. Troubleshooting
7.1 Spray Gun
Problem Cause Solution
A. Spitting gun 1. Air in system
2. Dirty gun
3.Needleassemblyoutofadjustment4.Brokenorchippedseat1. Inspect connections for air leaks.
2. Disassemble and clean.
3. Inspect and adjust.
4. Inspect and replace.
B.Gunwillnotshuto1. Worn or broken needle & seat
2.Needleassemblyoutofadjustment3. Dirty gun
1. Replace.
2. Adjust.
3. Clean.
C.Gundoesnotspray1.Nopaint2. Plugged lter or tip
3.Brokenneedleingun1. Check uid supply.
2. Clean.
3. Replace.
D. Insucient material supply. 1. Material pressure set too low.
2.Blockedspraygunlterorpumphighpressure lter.
3. Tip is blocked.
4. Tip is too small.
1. Increase the material pressure at pump.
2. Clean or replace the gun lter and/or pump high
pressure lter.
3. Clean the tip.
4. Select a larger tip.
E. Poor spraying pattern. 1. Tip is too large.
2. Material pressure at the pump is set too
low.
3. Material viscosity is too high.
4. Worn tip.
1. Select a smaller tip.
2. Increase the material pressure at the pump.
3. Dilute the material according to the material
manufacturer’s instructions.
4. Replace with a new tip.
7.2 Air Motor
Problem Cause Solution
A. Motor stops at top or bottom
of stroke - air does not exhaust
when gun is open.
1. Piston rod is loose where it connects to the
uid section.
2. Trip springs or valve spring broken.
3. Motor is frozen due to icing or lack of
lubrication.
1. Tighten connection.
2. Inspect and replace where neessary.
3.ChecktheAir-Care™uidlevelintheAutomaticLubricator.Iflow,addAir-Care™toreservoir.If condition persists, check air supply for
contamination.
B.Motorstops,blowsairfromexhaust when gun is open. 1. See above.
2. Air valve is in dead stall position.
3. O-rings were worn or damaged.
1. See above.
2. Remove one trip spring retainer, trip spring and ball.
Push spool valve up or down, lubricate, reassemble
and restart.
3. Install minor service kit and follow instructions in
Servicing section of manual.
If dust or dirt is found inside motor, check air supply for
contamination.

16 PowrCoat
GB
Troubleshooting
7.3 Spray Patterns
Problem Cause Solution
A. Tails 1. Inadequate uid delivery 1. Fluid not atomizing correctly:
Increase uid pressure. Change to smaller tip orice
size. Reduce uid viscosity. Reduce hose length.
Clean gun and lter(s). Reduce number of guns using
pump.
B.Hourglass1. Inadequate uid delivery 1. Same as above.
C. Distorted 1. Plugged or worn tip 1. Clean or replace tip.
D. Pattern expanding and
contracting (surge) 1. Suction leak 2. Pulsating uid delivery 1. Inspect for suction hose leak. 2. Change to a smaller tip orice size. Install pulsation
dampener in system or drain existing one. Reduce
number of guns using pump. Remove restrictions in
system; clean tip screen if lter is used.
E. Round pattern. 1. Worn tip
2. Fluid too heavy for tip 1. Replace tip. 2. Increase pressure. Thin material. Change nozzle tip.

PowrCoat 17
GB
Troubleshooting
7.4 Fluid Pump
Problem Cause Solution
A. Pump delivers on upstroke only
or goes up slowly and down fast
(commonly called downstroke
dive). 1.Lowerfootvalveballisnotseatingduetotrash or wear. 2. Material to viscous to siphon.
3. Air leaking in on siphon side or damaged
siphon hose. Siphon may be too small for
heavy material.
4.Upperpackingnut(ifapplicable)islooseorupper packings are worn.
1. Remove foot valve assembly. Clean and inspect. Test
foot valve by lling with water. If ball fails to seal the
seat, replace ball.
2. Thin material - contact manufacturer for proper
thinning procedures.
3. Tighten all connections between pump and paint
container. If damaged, replace. Switch to bigger
siphon set.
4. If tightening upper packing nut does not correct,
change upper packings.
B.Pumpdeliversondownstrokeonly or goes up fast and down
slowly. 1.Upperballisnotseatingduetotrashorwear. 2.Lowerpackingsetisworn.1. Check upper seat and ball with water. If ball fails to
seal seat, replace.
2. Replace packing set is worn.
C. Pump moves up and down fast,
not delivering material. 1. Material container is empty or material is too thick to ow through the siphon hose.
2.Bottomballstucktofootvalveseat.3. Siphon hose is kinked or loose.
1. Rell with new material. If too thick, remove siphon
hose, immerse uid section in material, and start
pump to prime. Add thinner to material. Change to
bigger siphon set. Open bleed valve to remove air
and restart pump.
2. Remove foot valve. Clean ball and seat.
3. Straighten.
D. Pump moves up and down
slowly when spray gun is shut
o. 1.Looseconnections.Bleedvalveisopenpartiallyorbleedvalveisworn.Lowerpacking set is worn.
2.Upperand/orlowerballnotseating.1. Check all connections between pump and gun.
Tighten as necessary. If material is owing from
bleed hose, close bleed valve or replace if necessary.
Should none of above be evident, replace lower
packing.
2. Reset balls by cleaning.
E.Notenoughuidpressureatgun. 1. Spray tip is worn.
2. Compressor (air operated units only) too
small. Outlet lter or gun lter is clogged.
3.Lowvoltageand/orinadequateamperage.4.Hosesizeorlengthistoosmallortoolong.1. Replace.
2. Clean or replace lter. Recommend proper hose size
and/or air compressor size.
3. Check electrical service. Correct as required.
4. Increase hose size to minimize pressure drop through
hose and/or reduce hose lengths.
F. Pump chatters on up or down
stroke 1. Solvent has caused upper packing to swell, or packing is too tight. 1.Backoupperpackingnut1/4turn(ifapplicable)and restart pump. Repeat if necessary.

18 PowrCoat
GB
Servicing
8. Servicing
8.1 Servicing the Air Motor
The Air Motors require a normal mantenance inspection at 1500
hours of service on the non-circulating models.
ServiceprocedureincludesreplacementoftheMotorServiceKit(seenext page for part numbers). It is suggested that one Motor Service
Kitbekeptonhandfornormalmaintenanceandemergencyrepairs.SeenextpageforpartnumbersoftheMotorKit.Accessing the Air Motor (Fig. 19)
In order to be able to access the air motor, certain components must
be removed.
iThe piston rod in the uid pump should be in the
lowest-dead center position prior to performing
these steps. The shuto valve can be used to allow
the sprayer to run slowly.
1. Remove all external air and uid hoses from the sprayer.
2. Press the collar on the lower air hose tting (1) and remove
the air hose from the lower air hose tting only.
3.Underneaththefrontshroud,removetheclearairtube(2)that is connected to the air regulator reservoir.
4.Loosenthecylindercapnut(3)sothatitshandleisorientedside-to-side and is aligned with the gap in the top shroud (4).
5. Remove the lower screws (5) that secure the motor shroud
assembly (6) to the air motor. Once removed, carefully lift the
entire assembly o of the air motor.
3
6
4
2
5 (x6)
1
Disassembling the Air Motor (Fig. 21)
1. Remove the pin (1) that connects the air motor piston rod
(2)withtheuidpumpdisplacementrod(3).Usingawrench on the ats of the displacement rod (3), unthread the
displacement rod from the piston rod.
2.Removethelowerstanchionnuts(4).Gentlylowertheuidpump (5) away from the air motor.
3.Fullyloosenthecylindercapnut(6).Gentlypullupthecylindercapnuttoexposethetriprod(7).Usingapliers,gripthe hex nut (7) on the trip rod, and loosen and remove the
cylinder cap nut from the trip rod.
Attention
Be careful not to damage the outer surface of the
trip rod. A damaged trip rod will cause the air motor
to operate incorrectly.
4. Remove the screws (8) that hold the cylinder (9) and air motor
base(10)together.Becarefulnottolosetheshroudbracketsor washers that will be removed also. Pull o the cylinder.
Remove the o-ring (31) on top of the motor base.
Attention
When removing the cylinder, remove it straight up.
Avoid tilting. Tilting can damage the cylinder wall.
5. Pull the piston assembly (11) from the air motor base (10). The
piston rod (2) will remain attached within the piston.
6. Check the bearing down in the center of the air motor base. If
worn, replace the motor housing.
iIf the bearing is worn, the entire air motor base will
need to be replaced.
7. Place the ats of the piston rod (2) into a vise to secure the
entire piston rod assembly.
8.Usingascrewdriver,pushdownonthetriprodyoke(g.20,item 12) and snap the toggles (13) down.
PINCH HAZARD. Keep your fingers clear of the
toggle assemblies (13) when you are snapping the
toggles up or down.
9. Place the tip of a screwdriver between the piston lugs (14)
and below the toggle rocker (15) (place screwdriver at place
marked by asterisk, g. 20).
10. Push forward and up with the screwdriver to compress the
springs on the toggle assembly (13) up and away from the
piston lugs. Remove the springs (16) toggle arms (17), and
toggle pins (18).
iPlace your hand above the toggle assembly as you
perform this step. This will prevent parts from
popping out.
14
15
*
12
13
18
16
18
17
11. Straighten the lockwires (g. 21, item 19) and remove them
from the upper valve nuts (20). Remove the upper valve nuts.
12. Remove the hex nut from the trip rod (7). Remove the trip
rod yoke (12) and the actuator (21). Thread the hex nut (7)
back onto the trip rod to prevent it from sliding down into the
piston rod.
13. Remove the lower valve nuts (22) and remove the inlet valve
poppets (23). Make sure the spring clips (24) are not worn or
damaged, and that they properly guide the actuator (21).
11. Remove the exhaust valve poppets (25) by cutting them with a
side cutter. Remove them from the actuator.