Campbell Hausfeld AL2810 User Manual

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Operating Instructions and Parts Manual

AL2810

 

 

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

BUILT TO LAST

Airless Paint

Systems

Thank you for purchasing a Campbell Hausfeld product. If you have any technical questions about this product, please call 1-800-626-4401.

For Parts and Accessories: 1-800-626-4401

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

© 2002 Campbell Hausfeld/Scott Fetzer

For parts, product & service information

IN422500AV 12/02

visit www.chpower.com

! WARNING
! DANGER
! WARNING

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Fluid Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

General Safety Information . . . . . . . . . . . . . . . . . . . . . . .

2

Outlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

How to Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

12

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Oil and Lubrication Procedure . . . . . . . . . . . . . . . . .

13

Spray Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

V-PackingReplacement . . . . . . . . . . . . . . . . . . . . . . .

13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . .

14

Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Parts Diagrams and Parts Lists . . . . . . . . . . . . . . . . . . . .

18

Spray Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

 

 

Replacement of Electrical Control Board . . . . . . . . . .

8

 

 

Pressure Calibration on Electrical Board . . . . . . . . . . .

9

 

 

Description

Airless paint sprayers are capable of spraying a wide variety of latex, oilbased, and alkyd paints, as well as stains, preservatives and other nonabrasive finishes.

These sprayers are also powerful and versatile enough to be used with a variety of options (roller attachment, extra lengths of hose, etc.) to make it an even more efficient tool.

NOTE: Guns pictured in illustrations may be different than the one included with your unit.

Specifications

Max. Pressure . . . . . . . . . . . . . 3000 psi

Output. . . . . . . . . . . . . . . . . . . 1.5 GPM

Tip size . . . . . . . . . . . 1 gun up to 0.041

2 guns up to 0.028

Engine . . . . . . . . . . . . . . . 5.5HP Honda

Weight . . . . . . . . . . . . . . . . . . . 160 lbs.

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates an imminently

hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates a potentially

hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates a ! CAUTION potentially

hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates NOTICE important

information, that if not followed, MAY cause damage to equipment.

Unpacking

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service.

Do not operate unit if damaged

during shipping, handling or use. Damage may result in bursting and cause injury or property damage.

General Safety

Information

1.Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

2.Always wear a mask or respirator and eye protection when painting. Be certain mask or respirator will provide necessary protection against inhalation of harmful vapors.

3.Keep visitors away and NEVER allow children or pets in the work area.

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2

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

General Safety

● This system is capable of producing

 

 

 

 

 

 

 

 

PRESSURE RELIEF PROCEDURE

 

3000 psi. Use only Campbell

 

Information (Cont.)

 

 

Before servicing or resting unit,

 

Hausfeld replacement parts rated

 

4. Do not smoke or eat when spraying

 

at 3000 psi or higher.

 

relieve pressure from system by

paint, insecticides, or other

● Never spray without tip guard.

 

following this procedure:

flammable substances.

1.

Engage gun trigger lock.

● Ensure trigger lock is functioning

5. Always work in a clean

2.

Turn off engine.

 

properly.

 

 

 

 

environment. To avoid injury and

 

 

 

 

 

 

 

 

 

 

 

 

● Always engage trigger lock when

3.

Disengage

 

 

 

 

 

 

damage to the workpiece, do not

 

 

 

 

 

gun trigger

 

 

 

 

not spraying.

 

 

 

 

 

 

 

 

 

aim the spray gun at any dust or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

lock and

 

 

 

● Do not remove spray tip while

 

 

 

 

 

debris.

 

 

 

 

 

 

 

trigger gun

 

 

 

 

 

 

 

 

 

 

cleaning pump.

 

 

 

 

 

 

 

 

 

6. When spraying and cleaning,

 

 

 

 

 

 

 

to relieve

 

 

 

● Never leave equipment pressurized

 

 

 

 

 

always follow the instructions and

 

 

residual fluid

 

 

 

 

 

 

 

 

safety precautions provided by the

 

while unattended.

 

 

pressure. Hold metal part of gun

material manufacturer (Refer to

● Do not clean spray tip while it is

 

 

in contact with grounded metal

MSDS).

 

attached to the spray gun. Remove

 

 

pail.

 

 

 

 

 

 

 

 

 

spray tip from gun to clean tip

 

4. Re-engagegun trigger lock.

 

! WARNING

 

 

guard.

 

 

 

 

5.

Turn

 

 

 

 

● Ensure tightness of high pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GASOLINE ENGINE PRECAUTIONS:

 

 

Prime/Pressure

 

 

 

connections.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Relief Valve to

 

 

● Locate unit 25 feet away from

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

● Do not use pliers to tighten or

 

 

open (priming)

 

 

spray area in well-ventilatedarea.

 

 

 

 

 

loosen high pressure connections.

 

 

position to

 

 

● NEVER operate in closed building

 

 

 

 

 

● Motor is equipped with an automatic

 

 

relieve fluid

 

 

unless exhaust is piped outside.

 

 

 

 

 

 

pressure.

 

 

 

thermal overload. Motor will restart

 

 

 

 

● NEVER allow hose to lay against

 

 

 

 

 

 

 

 

 

 

 

OPEN POSITION

 

 

without warning, after cooling.

6.

Leave

 

engine mufflers or hot parts.

 

 

 

 

 

 

 

Never aim or

 

 

Prime/Pressure

 

 

● NEVER refill fuel tank while engine

 

! WARNING

 

 

 

 

 

 

 

spray at yourself

 

 

Relief Valve OPEN until you are

 

 

 

 

 

is hot or running.

or anyone else or serious injury could

 

 

ready to spray again.

 

 

 

 

 

 

occur.

 

 

 

 

 

NOTE: If spray tip or hose is clogged,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

! WARNING

 

 

 

! WARNING

 

 

 

follow Step 1 to 5 above. Expect

SKIN INJECTION HAZARD:

 

 

 

 

 

paint splashing into the pail while

FIRE OR EXPLOSION HAZARD:

 

 

relieving pressure during Step 5. If

● High pressure spray

 

 

 

 

 

 

 

● Do not use solvents with flash

 

 

 

you suspect that pressure has not

can inject toxins

 

 

 

 

 

 

 

 

points less than 70°F (21°C) to clean

 

 

 

 

been relieved after following the

into blood stream.

 

 

 

 

 

 

 

 

 

this equipment (examples of

 

 

 

 

above procedure, engage gun trigger

If injection occurs,

 

 

 

 

 

 

 

 

 

acceptable cleaning solvents are

 

 

 

 

lock and take your unit to an

 

 

 

 

 

seek emergency medical treatment.

 

 

 

water, mineral spirits, lacquer

 

 

 

authorized Campbell Hausfeld

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thinner, Xylene and high flash

 

 

 

 

 

 

 

 

 

Service Center.

 

 

! WARNING

 

 

 

 

 

 

 

 

 

 

 

 

 

napha. A partial example list of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Use a face mask/respirator

 

 

 

 

 

 

 

 

 

 

 

 

unacceptable cleaning solvents are

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and protective clothing

 

 

 

 

 

 

 

 

 

 

 

 

low flash napha, mek, acetone,

electrical arcs that will ignite a

when spraying. Always

 

 

 

 

 

alcohol and toluene).

flammable gas or vapor. Never store

spray in a well ventilated

 

 

 

 

 

area to prevent health and fire

 

 

 

 

 

 

 

 

flammable liquids or gases in the

hazards. Refer to Material Safety Data

 

! WARNING

 

 

 

 

 

vicinity of the unit.

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not spray acids,

Sheets (MSDS) of spray material for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not spray flammable

 

 

 

 

! WARNING

 

 

details.

 

 

 

 

corrosive materials,

materials in vicinity of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

toxic chemicals, fertilizers or pesticides.

● Never try to stop leaks with any

open flame or near

 

 

 

 

 

 

 

 

Using these materials could result in

 

 

 

 

 

 

ignition sources. Motors, electrical

part of your body.

equipment and controls can cause

death or serious injury.

 

 

 

 

 

 

 

 

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3

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

General Safety

Information (Cont.)

Paints and solvents containing HALOGENATED HYDROCARBONS can react explosively with aluminum. Do not use halogenated hydrocarbons with this equipment. Consult the paint or solvent product label or Material Safety Data Sheets (MSDS) to help determine if it contains halogenated hydrocarbons.

Do not use fuels to clean this equipment.

Keep spraying area well ventilated. Keep doors and windows open.

Remove all ignition sources (i.e. Static electricity, pilot lights, cigarettes and electrical arcing).

Airless spraying can cause static electricity. Always ground the pump and spraying surface.

Do not use solvents containing halogenated hydrocarbons.

Keep hose away

! CAUTION from sharp objects. Bursting hoses may cause injury. Examine hoses regularly and replace if damaged.

Check hoses for weak or worn condition before each use, making certain that all connections are secure.

Pre-Operation

FLUSHING

1.NEW SPRAYER: Your sprayer was factory tested in an oil solution which was left in the pump. Before using oilbased paint, flush with mineral spirits only.Before usingwater-basedpaint flush with mineral spirits, followed by soapy water, then a clean water flush.

2.CHANGING COLORS: Flush with a compatible solvent such as mineral spirits or water.

3.CHANGING FROM WATER-BASED TO OIL-BASED PAINT: Flush with soapy water, then mineral spirits.

4.CHANGING FROM OIL-BASED TO WATER-BASED PAINT: Flush with mineral spirits, followed by soapy water, then a clean water flush.

5.STORAGE: Always relieve pressure (See pressure relief procedure on page 3) prior to storage or when machine is unattended. Follow the

storage procedure based on the kind of paint you used:

Oil-basedpaint: Flush with mineral spirits.

Water-basedpaint: Flush with water, then mineral spirits. Leave the pump, hose and gun filled with mineral spirits.

For longer term storage use a 50/50 mixture of mineral spirits and motor oil. Always ensure that there is no pressure in the unit, and close the prime/pressure relief valve for storage.

Never leave pump ! WARNING unattended while it

is under pressure!

6.START UP AFTER STORAGE: Before usingwater-basepaint, flush with soapy water and then a clean water flush. Before usingoil-basedpaint, flush out the mineral spirits with the material to be sprayed.

HOW TO FLUSH

IMPORTANT COMPONENTS

Prime/Pressure Relief Valve (Prime/PR Valve, Figure 1). Used to relieve pressure from gun, hose and tip and to prime the unit when in OPEN position.

Pressure Control Knob (Figure 2). Used to adjust pressure. Turn clockwise to increase pressure and counterclockwise to decrease it.

Choke Lever, Fuel Valve, and

CLOSED POSITION (Pressure)

OPEN POSITION

(Prime and Pressure Relief)

Figure 1 - Prime/Pressure Relief Valve

High

Pressure

Low Pressure

Figure 2 - Pressure Control Knob

Throttle

Lever

Choke Lever

Fuel Valve

 

Figure 3 - Choke Lever, Fuel Valve,

and Throttle Lever

Throttle Lever (Figure 3).

PROCEDURE

1.Be sure the gun safety lock is engaged and there is no spray tip in the gun.

2.Pour enough clean, compatible solvent into a large,

empty metal pail to fill the pump and hoses.

3.Place the suction tube into the pail or place the pail under the pump.

4.Turn the pressure control knob to low pressure. Refer to Fig. 2.

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4

! WARNING

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Pre-Operation(Cont.)

5.Open the prime valve to the open - "Priming Position". This will allow for an easy start. Refer to Figure 1 on page 4.

6.Turn the engine ON/OFF switch to ON.

7.Move the choke toward the closed position as per Figure 3.

8.Move the throttle lever slightly to the left as per Figure 3.

9.Turn the fuel valve ON as per Figure 3. Pull the start rope. Pull the engine over against compression stroke and then let the rope rewind slowly into the starter. Pull firmly and rapidly to start the engine. Do NOT drop the rope. Hold onto the handle while rewinding, or the rope may rewind improperly and jam the assembly. If the engine does not start, open the choke a little more. If the engine floods, open the choke all the way and continue cranking.

10.After the engine is warm, gradually close the choke lever, increase the RPM of engine slightly by moving throttle to the left. Close the prime valve. Refer to Figure 1.

11.Point the gun into the metal pail and hold a metal part of the gun firmly against the pail Refer to Figure 4.

Figure 4 - Spray Gun Against Metal

Container

12.Disengage the gun trigger lock and squeeze the gun trigger. At the same time, slowly turn the pressure control knob clockwise just enough

to move liquid at low pressure.

13.Allow the pump to operate until clean solvent comes from the gun.

14.Release the trigger and engage the gun trigger lock.

15.If you are going to start spraying, place the pump or suction tube into the supply container. Release the gun safety latch and trigger the gun into another empty, metal container, holding a metal part of the gun firmly against the metal pail (Figure 4) and force the solvent from the pump and hose. When paint starts coming from gun, turn pressure control knob to minimum pressure, place prime valve in prime (open) position and engage the gun trigger lock.

16.If you are going to store the sprayer, remove the suction tube or pump from the solvent pail force the solvent from the pump and hose. Engage the gun safety

latch and refer to the "Storage" Procedure on page 4, Step 5.

17.Whenever you shut off the sprayer follow the Pressure Relief Procedure warning on page 3.

SETTING UP

1. Connect the hose and gun.

a.Remove the plastic cap plug from the outlet and screw a conductive or grounded 3000 psi spray hose onto fluid outlet.

b.Connect an airless spray gun to the other end of the hose, but do not install the spray tip yet!

NOTE: Do not use thread sealer on swivel unions as they are made to self seal.

NOTE: The first 50' of hose should always be 3/8".

2. Fill the Packing Nut/Wet Cup 1/3 full with Throat Seal Oil (TSO) supplied. See Figure 5.

Figure 5 - Applying throat seal oil

3.Check the engine oil level.

a.Unscrew the oil fill plug. The dipstick is attached to the plug.

b.Without threading the plug into place, check to be sure the oil is up to the top mark on the dipstick.

c.If oil is needed, refer to engine manual.

4.Fill the fuel tank.

Fuel spilled on a hot surface can cause a

fire or explosion and cause serious bodily injury and property damage. Always shut off engine and let it cool before filling the tank, and carefully follow steps a to c below, making sure you do not spill any fuel.

a.Close the fuel shutoff valve.

b.Use only clean, fresh, wellknown brands of unleaded regular grade gasoline.

c.Remove the fuel cap and fill tank. Be sure the air vent in the fill cap is not plugged so fuel can flow to the carburetor, then replace the cap.

SPRAY TIP SELECTION

See Tip Selection Chart on Page 6.

Spray tip selection is based on paint viscosity, paint type, and job needs. For light viscosity (thin paints), use a smaller tip. For heavier viscosities (thicker paints), use a larger tip size.

Spray tip size is based on how many gallons of paint per minute can be sprayed through the tip. Do not use a tip larger than the maximum pump

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5

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Pre-Operation(Cont.)

flow rate or capacity the sprayer can accommodate. Pump flow rate is measured in gallons per minute (GPM).

PATTERN WIDTH

Thickness of the paint coat is determined by spray tip “fan width,” rate of the spray gun movement, and distance to surface.

SPRAY TIP SELECTION

Two tips having the same tip size, but different pattern widths, will deliver the same amount of paint over a different area (wider or narrower strip).

A spray tip with a narrow pattern width makes it easy to spray in tight places.

SPRAY TIP REPLACEMENT

During use, especially with latex paint, high pressure will cause the orifice to grow larger. This destroys the pattern.

Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make cutting-indifficult, and decrease sprayer performance.

Tip Selection Chart

 

QuadraflowTM Tip

for painting

 

 

 

 

Orifice Size (inches)

 

 

 

 

 

 

 

 

(12" from surface)

 

 

 

 

 

 

.029

 

 

 

 

 

Fan Width (in.)

(mm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.009

.011

.013

.015

.017

.019

.021

.023

.025

.027

.031

 

.035

 

 

 

4-6

102-152

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6-8

152-203

AL3116

AL3117

AL3119

AL3122

AL3125

 

 

 

 

 

 

 

 

 

 

 

8-10

203-254

 

AL2211

AL2213

 

AL3126

 

AL3131

 

 

 

 

 

 

 

 

 

10-12

254-305

 

AL3118

AL3120

AL2215

AL2217

AL3130

AL3132

AL3135

AL3137

 

AL3139

 

 

 

 

 

12-14

305-356

 

 

AL3121

AL3124

AL3127

AL2219

AL2221

AL3136

AL3138

 

AL3140

 

 

 

 

 

14-16

356-406

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16-18

406-457

 

 

 

 

 

 

AL3134

 

 

 

 

 

 

 

 

 

Gun Filter

2 types (part #)

 

l---------AL086101AJ------ll--------------AL086100AJ---------------l

REMOVE FILTER

 

 

 

 

 

Lacquer, Varnish

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wood Interior

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stain, Sealer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Enamel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wood Exterior

Exterior Stain

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vinyl, Acrylic, Latex

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vinyl, Oil Base Alkyd

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Masonry

Latex, Acrylic

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Block Filler

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Elastomer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ceiling

Hi Build, Mil White

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Structural Steel

Heavy Coatings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Water Flow Rate

(gpm)

.12

.18

.24

.31

.38

.47

.57

.67

.77

1.03

 

1.31

 

 

 

(water @ 2000psi,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(lpm)

.49

.69

.91

1.17

1.47

1.79

2.15

2.54

2.96

3.90

 

4.98

 

 

 

138 bar)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Paint Flow Rate

(gpm)

.10

.15

.21

.27

.33

.40

.49

.58

.66

.88

 

1.12

 

 

 

(latex paint @ 2000psi, 138

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(lpm)

.38

.57

.79

1.02

1.25

1.51

1.85

2.20

2.50

3.33

 

4.24

 

 

 

bar/1.36 spec. gr.)

 

 

 

 

Pump Minimum

(gpm)

.25

.25

.33

.40

.50

.60

.75

.88

1.00

1.25

 

1.50

 

 

 

Output*

(lpm)

1.00

1.00

1.25

1.50

1.90

2.30

2.80

3.30

3.80

4.70

 

5.70

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*pump will support tip worn to next larger size.

Consult your paint manufacturer for application recommendation

Table 1 - Tip Selection Chart

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6

! WARNING
! WARNING
! WARNING

Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Operation

STARTING UP

1.Learn the functions of the controls (see “How to Spray / Important Components” for more information).

2.Prepare the Material

a.Prepare the material according to material manufacturer's recommendations.

b.Place the pump or suction tube into the material container.

3.Start the sprayer.

a.Prime/PR Valve must be open in the priming position.

b.Pressure Control Knob must be in low pressure position.

c.Follow procedure under “How to Flush,” page 5, Steps 6 to 12.

To stop the unit in an emergency or

before performing any service or maintenance procedure follow the Pressure Relief Procedure on page 3 to relieve the fluid pressure.

4.Prime the pump.

a.Allow pump to operate until paint comes from gun.

b.Release the trigger and engage the gun safety latch.

c.Turn Prime Valve OPEN to the prime position ensuring the pressure is released from the system.

d.Turn Pressure Control Knob to minimum pressure.

e.Install spray tip onto gun.

f.Close the prime valve to the pressure position.

g.Turn the pressure control knob to desired spray pressure.

h.Disengage the gun safety lock and you are ready to start spraying.

If you spray paint into the paint

bucket, always use the lowest spray pressure and maintain firm metal-to-metal contact between gun and container.

5.Adjust pressure.

a.Turn the Pressure Control Knob clockwise to increase pressure and counterclockwise to decrease pressure.

b.Always use the lowest pressure necessary to completely atomize the material.

NOTICE

Operating the

sprayer at higher

 

pressure than needed wastes material, causes early tip wear and reduces the life of the spray equipment.

c.If more coverage is needed, use

alarger tip rather than increasing the pressure.

d.Check the spray tip. The tip size and angle determine the pattern width and flow rate.

6.Reduce clutch wear.

a.The first 50 feet of airless spray hose should be 3/8", the larger diameter works as a pulsation damper and saves unnecessary cycling of the clutch. A minimum of 100 feet of hose should be used.

b.Adjust the Engine Speed and Pump Pressure. First set the throttle lever to the maximum RPM setting (fully left). Trigger the gun onto a test paper to check the spray pattern and atomization. Adjust the Pressure Control Knob until you get a good pattern. Reduce RPM of engine to support pressure without overworking engines.

7.Clean tip if clogged. If tip is becoming worn, replace it. Worn tips waste paint, cause overspray, make cutting-indifficult, and decrease sprayer performance.

IMPORTANT: Always follow the

Pressure Relief Procedure on page 3 before servicing unit.

Never hold your hand, body, fingers,

or hand in a rag in front of the spray tip when cleaning or checking it for a cleared tip. Always point the gun toward the front or into a waste container when checking to see if the tip is cleared or when using a selfcleaning tip.

a.Follow the Pressure Relief Procedure on page 3.

b.Clean the front of the tip frequently (with toothbrush only) during the day to keep material from building up and clogging the tip.

c.To clean and clear a tip if it clogs, refer to the separate instruction manual received with your gun and nozzle.

NOTE: When pausing during a paint job, keep tip clean by locking the gun and submerging the tip in a small bucket of paint thinner. This will help reduce buildup and drying of paint in tip, tip guard, and gun.

NOTICE

Clean a clogged

standard flat tip

 

only after it has been removed from the gun. Follow the Pressure Relief Procedure on page 3.

8. When shutting off the sprayer, follow this procedure.

a.Whenever you stop spraying, even for a short break, follow the Pressure Relief Procedure on page 3.

b.Clean the tip and gun as recommended by your separate gun instruction manual.

c.Flush the sprayer at the end of each work day if the material you are spraying is water-based,or if it could harden in the sprayer overnight. See "Flushing" on page 4. Use a compatible solvent to flush, then fill the pump and hoses with an oil based sovent such as mineral spirits.

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Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Operation (Cont.)

d. For long term shutdown or storage, refer to page 4.

Be sure to relieve ! WARNING pressure in the

pump after filling with mineral spirits.

SPRAY TECHNIQUE

Good Spray Gun Technique is at the core of any spray paint operation. Operator skill and efficiency is as important as good equipment and good paint. Good spray technique is a skill that can be developed by following these simple instructions.

If you are not familiar with spraying techniques, study this section of your manual and practice the proper technique on pieces of cardboard or a suitable surface.

Hold the spray gun 12 - 15 inches away from the work surface and keep it perpendicular (straight) to the surface. Move the spray gun parallel to the work and at a right angle to the surface. (See Figure 6).

Move the gun at a steady rate in order to apply a good coverage. The wet coat should be just under the thickness at which a run or sag will occur. Slow gun movement or gun held too close will result in an overly wet or thick wet

or thick coat coverage that is likely to run or sag.

Do not wave the spray gun. This waving is called arching. Instead, hold the spray gun at a 12 to 15 inch distance perpendicular from the work. (See Figure 7.)

The closer the spray gun is held to the work, the thicker the paint is deposited and the faster the gun must be moved to prevent sags and runs. Holding the gun too far from the work will cause excessive fog, overspray, and a thin and grainy coat.

It is important to "trigger" the gun after gun movement (arm movement) has started and release trigger (shut gun off) before gun movement ends. Gun movement is always longer than actual paint (spray) stroke. In that manner, even blending and uniform paint coat thickness is achieved over the entire surface. When the gun is in motion as the trigger is pulled, it deposits an even amount of paint.

Overlap the previous pass by half the width of the spray pattern. Aim at the bottom of the previous pass.

Adjust Pressure Control Knob so that paint is completely atomized from the spray gun. Insufficient pressure will result in “tailing.” Too much pressure

12-15”

Gun is held perpendicular

 

Gun is held at an angle,

to work piece, fluid

 

fluid disperses unevenly

disperses evenly

 

 

 

 

 

 

RIGHT

WRONG

Figure 6 - How to hold spray gun when spraying

 

 

INCORRECT

Start Pull

ReleaseEnd

Trigger

Trigger

 

CORRECT

Figure 7 - Proper Spray Technique

will result in excess fog and overspray, excessive tip wear, and increased sprayer wear and tear.

Always use the lowest pressure possible to obtain desirable results. Test the spray pattern on a piece of cardboard or other surface.

To cover “inside” and “outside” corners (on walls or other objects), aim the spray gun toward the center of the corner. The spray pattern is divided in half, and the edges of the spray pattern on both walls are the same.

Electrical System

REPLACEMENT OF ELECTRICAL CONTROL BOARD

1.Remove electrical cover.

2.Disconnect sensor lead from electrical board.

3.Disconnect two clutch leads on electrical board from leads on clutch.

4.Using a 1/16” allen wrench, loosen set screw in Pressure Control Knob

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Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Electrical System (Cont.)

and remove knob.

5.Using a 1/2” nut driver or 1/2” deep socket, remove nut from pressure control shaft. This will allow removal of electrical control board from frame.

6.Replace electrical board assembly in reverse order. Adjust pressure according to the procedure given in Pressure Calibration on Electrical Board section.

PRESSURE CALIBRATION ON ELECTRICAL BOARD

1.Turn "Pressure Calibration" Trimpot adjustment on electrical control board in the counter clockwise direction at least 15 revolutions.

2.Connect 5000 psi glycerine pressure

guage on output of pump between fluid pump and airless hose to monitor Fluid Pump Pressure.

3.Start engine and run at maximum RPM. Turn Prime/Pressure Relief Valve to the open (Prime) position. Turn Pressure Control Knob to maximum position (fully clockwise).

4.Using an insulated screwdriver, adjust "Pressure Calibration" Trimpot by turning clockwise until the clutch engages. When the clutch engages the pump will commence Priming. When pump is primed, turn the Prime/Pressure Relief Valve to the Closed (Pressure) position. The pump will begin to pressurize and the clutch will disengage at a low pressure. Continue turning the Trimpot

clockwise to increase pressure to 3000 psi.

5.Trigger gun. The pressure should drop approximately 350-400psi (when using a 3/8" hose), the clutch will engage and build pressure to 3000 psi and disengage. Trigger gun several times to ensure proper pressure setting.

6.Turn Pressure Control Knob to minimum position. The clutch should disengage and pump stop moving.

7.Secure leads with tie strap.

8.Replace cover on unit. Ensure the leads are not pinched or damaged in the process of replacing covers.

Figure 8 - Electrical Board/Pressure Calibration

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Operating Instructions and Parts Manual

AL2810

Airless Paint Systems

Service

FLUID PUMP

FLUID PUMP DISCONNECT

1.Flush out the material you are spraying, if possible.

2.Follow the Pressure Relief Procedure on page 3. Stop the pump in the middle of down stroke.

3.Remove the suction tube and fluid hose (if so equipped) from the fluid pump. Detach the hose from the front of the fluid pump.

4.Remove 2 retaining rings and slip the sleeve of the coupling down and remove both coupling halves. This will disconnect fluid pump from the connecting rod.

5.Unscrew the two tie rod locknuts.

6.Pull the pump down off the tie rods.

FLUID PUMP REINSTALL

1.Loosen packing nut and extend piston rod so that it is in the “fully up” position.

2.Make sure that spacer tubes (301048) are in place.

3.Connect connecting rod with fluid pump by installing coupling halves. Slide sleeve over coupling halves.

Secure with retaining rings.

4.Secure the fluid pump housing to the tie rods and screw nuts with lock washers on loosely.

5.Tighten the tie rod nuts evenly to 30 ft. lb.

6.Reconnect fluid hoses and suction tube (if so equipped).

NOTE: After all the rod locknuts are tight, the alignment of both rods should allow easy assembly and disassembly of the coupling. If there is any binding, loosen and retighten all the rod locknuts to improve the

Piston

Packing nut/ wet cup

Upper packing

Fluid outlet

Distance tube

Lower packing

Wiper packing

Outlet valve

Inlet valve

Suction nut

Fluid inlet

Figure 9 - Inlet Valve, Outlet Valve,

Piston Assembly

alignment. Misalignment causes premature wear of seal and packings.

7.Tighten the packing nut until there is resistance, then tighten it 1 full turn. Approximately 4 threads will show when new packings are installed. Fill the wet cup of the packing nut 1/3 full with Throat Seal Oil.

8.Start the pump and operate it

 

 

187-026

 

 

 

 

 

 

 

187-030

 

 

 

 

187-060

 

 

 

 

 

 

 

 

 

 

 

187-025

 

 

 

 

 

 

 

 

 

 

 

 

 

187-031

 

 

 

 

 

 

 

 

 

 

 

187-315

187-029

 

 

187-059

 

 

 

 

 

 

187-058

 

 

 

 

 

 

 

 

 

 

187-037

 

 

 

 

 

 

 

 

 

Figure 10 - Piston Assembly

slowly (at low engine speed and pressure setting ) to check the piston rod for binding.

Adjust tie rod lock nuts if necessary to eliminate binding.

9.Run at maximum pressure for several minutes, relieve pressure and repeat step 7.

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