Airlessco LP540 User Manual

ALLPRO

ANUAL

Manifold Filter Parts List

Upper & Lower Seats

Fluid Pump

Lo-Boy Machine Parts List

Hi-Boy Machine Parts List

Electrical System Drawing - 5/6 Series

TABLE OF CONTENTS

LP Series Speci cations

Flushing

How to Flush

Pressure Relief Procedure

Daily Maintenance

Electric Motor Maintenance

Field Troubleshooting

Packing Replacement

Electrical Board Calibration

Electrical Troubleshooting - 5/6 Series

Replacement of Electrical Components

www.airlessco.com email: techsupport@airlessco.com

INTRODUCTION

Tip Size

Weight

41 lbs.

All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.

WARNING

- Alerts user to avoid or correct conditions that could cause bodily injury.

- Alerts user to avoid or correct conditions that could cause damage to or de struc tion of equipment.

- Alerts users to steps or procedures that are essential to proper equipment repair and maintenance.

- Identi es essential procedures or extra information.

Your new Airlessco or ALLPRO airless paint sprayer is designed to meet the

demands of the professional painting contractor as well as the homeowner.

The famous Airlessco slow-stroking stainless steel piston pump delivers

Triple-Life packing system is externally adjustable, extending packing life

reducing heat. The motor is fan cooled and totally enclosed to reduce brush

wear and to prevent the ignition of paint fumes in the motor.

65 lbs.

SAFETY WARNINGS

standards have been adopted under the

standards, particularly the General Standards,

should be consulted.

DO NOT USE HALOGENATED SOLVENTS IN THIS SYSTEM.

The prime valve, and most airless guns have aluminum parts and may explode. Clean ing agents, coatings, paints or adhesives

may contain halogenated hydrocarbon solvents. DON'T TAKE CHANCES! Consult your material suppliers to be sure. Some of

the most common of these solvents are: Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether,

Ethylbromide, Ethylchloride, Tethrachloethane. Alternate valves and guns are available if you need to use these solvents.

Airless Spray Wounds

If any  uid appears to penetrate your skin, get

EMERGENCY MEDICAL CARE AT ONCE.

DO NOT TREAT AS A

Tell the doctor exactly what  uid was injected

injury.

It is important to treat the injury sur gi cal ly as

toxicity.

Toxicity is a concern with some ex ot ic coatings injected

directly into the blood stream. Con sul ta tion with a plastic surgeon

or re con struc tive hand sur geon may be advisable.

NEVER

alter equipment in any manner.

NEVER

smoke while in spraying area.

NEVER

spray highly  ammable materials.

NEVER

use around children.

NEVER

allow another person to use sprayer unless

he is thoroughly instructed on its safe use and

given this operators manual to read.

ALWAYS

wear a spray mask, gloves and protective

eye wear while spraying.

ALWAYS

ensure  re extinquishing equipment is

readily available and properly maintained

Fluids under high pressure from spray or leaks can

penetrate the skin and cause ex treme ly serious injury,

including the need for amputation.

NEVER

point the spray gun at anyone or any part of

the body.

NEVER

put your hand or  ngers over the spray tip. Do

not use a rag or any other materials over your  ngers.

Paint will penetrate through these materials & into the hand.

NEVER

try to stop or de ect leaks with your hand or body.

ALWAYS

have the tip guard in place when spraying.

ALWAYS

lock the gun trigger when you stop spraying.

ALWAYS

remove tip from the gun to clean it.

NEVER

try to "blow back" paint, this is not an air spray

ALWAYS

follow the

PRESSURE RELIEF

PRO CE DURE

before cleaning or re mov ing the spray tip or servicing any

Be sure the equipment safety devices are operating prop er ly

before each use.

Tighten all of the  uid connections before each use.

If any  uid appears to penetrate your skin, get

EMER GEN CY

Go to an emergency room immediately.

Tell the doctor you suspect an injection injury.

Tell him what kind of material you were spraying with

and have him

read NOTE TO PHYSICIAN above.

INJECTION HAZARD

GENERAL PRECAUTIONS

SAFETY WARNINGS

Keep the spraying area free from obstructions.

Make sure the spraying area has good ventilation

to safely remove vapors and mists.

NEVER

keep  ammable material in spraying area.

NEVER

The spraying area must be at least 20 ft. away from

ALWAYS

po si tion when not in use & before servicing or cleaning.

NEVER

remove or modify any part of the gun.

ALWAYS

REMOVE THE SPRAY TIP when cleaning.

Flush unit at the LOWEST POSSIBLE PRESSURE.

ALWAYS

check operation of all gun safety devices

before each use.

Be very careful when removing the spray tip or hose

from the gun. A plugged line will con tain  uid un der

pressure. If the tip or line is plugged, follow the

PRES SURE RE

LIEF PRO CE DURE

ALWAYS

have the tip guard in place on the spray

gun while spraying. The tip guard alerts you to the

injection hazard and helps prevent accidentally

placing your  n gers or any part of your body close

to the spray tip.

Use extreme caution when cleaning or changing

gage the gun safety latch immediately. ALWAYS

follow the

PRES

and then remove the spray tip to clean it.

NEVER

wipe off build up around the spray tip.

ALWAYS

remove tip guard & tip to clean AFTER

pump is turned off and the pressure is relieved by

fol low ing the

PRESSURE RELIEF PROCEDURE.

Hazardous  uid or toxic fumes can cause serious in ju ry

or death if splashed in eyes or on skin, inhaled or

manufacturer, local, state & national guidelines.

ALWAYS

wear protective eyewear, gloves,

clothing and respirator as recommended by  uid

man u fac tur er.

Tighten all of the  uid connections securely before each

use. High pressure  uid can dislodge a loose coupling or

allow high pressure spray to be emitted from the coupling

and result in an injection injury or serious bodily injury.

Only use hoses with a spring guard. The spring guard

helps protect the hose from kinks or other damage which

could result in hose rupture and cause an injection injury.

NEVER

use a damaged hose, which can result in hose

failure or rupture and cause an injection injury or other

check entire hose for cuts, leaks, abrasions, bulging of the

cover, or damage or movement of couplings. If any of

these conditions exist, replace the hose immediately.

NEVER

use tape or any device to try to mend the hose as

it cannot contain the high pressure  uid. NEVER

ATTEMPT TO RECOUPLE THE HOSE. A high pressure

hose is not recoupleable.

Ground the spr

ayer & other components in the system to

reduce the risk of static sparking,  re or explosion which

can result in serious bodily injury and property damage.

For detailed instructions on how to ground, check your

local electrical code.

ALWAYS

ensure switch is in OFF position before

plugging unit in.

Always Ground All of These Components:

each equipped with an undamaged three-prong plug, into a

properly grounded outlet. DO NOT USE AN ADAPTER.

Use only a 3 wire extension cord that has a 3 blade

grounding plug, and a 3 slot receptacle that will accept

the plug on the product. Make sure your extension cord is

in good condition. When using an extension cord, be sure to

use one heavy enough to carry the current your product will

draw. (

Note

the cor rect size to use depending on cord length and name

plate ampere rating. If in doubt, use the next heavi er gauge.

The smaller the gauge num ber, the heavi er the cord.)

2. Fluid hose

3. Spray gun or dispensing valve

through connection to a properly grounded  u id hose and

pump.

4. Object being sprayed

5. All solvent pails

used when  ushing.

Once each week, check electrical resistance of hose (when

using multiple hose assemblies, check overall resistance.)

Overall (end to end) resistance of unpressurized hose must

not exceed 29 megohms (max.) for any coupled length or

combination of hose lengths. If hose exceeds these limits,

replace it im me di ate ly.

length to assure electrical continuity.

ALWAYS INSPECT SPRAYING AREA

SPRAY GUN SAFETY

HOSES

GROUNDING

TIP GUARD

SPRAY TIP SAFETY

TOXIC FLUID HAZARD

SAFETY WARNINGS

Always Follow Recommended Pressure

ALWAYS

use approved high pressure  ttings and

re place ment parts.

ALWAYS

ensure  re extinquishing equip ment is readi ly

avail able and properly maintained.

When spraying with  ammable liquids, the unit must be located a minimum of 25 feet away from the spraying area in a

well ventilated area. Ventilation must be suf cient enough to prevent the accumulation of vapors.

To eliminate electrostatic discharge, ground the spray unit, paint bucket & spraying object. See GROUNDING. Use only

high pressure airless hoses approved for 3000 psi which is conductive.

Remove the spray tip before  ushing. Hold the metal part of the gun  rmly to the side of a metal pail & use the lowest

possible  uid pressure during  ush ing.

Never use high pressure in the cleaning process.

USE MINIMUM PRESSURE.

Do not smoke in spraying/cleaning area.

5 - 6

6 - 8

8 - 10

400

30086

250

20088

50066

Keep clear of moving parts when starting or operating the

amputation by moving parts or burns on hot parts. Pre cau tion

is the best in sur ance against an accident. When starting the

motor, maintain a safe distance from moving parts of the equip-

ment. Before adjusting or ser vic ing any mechanical part of the

This sprayer operates at 3000 psi (205 bar). Al ways be

work ing pres sure of at least 3000 psi to avoid rup ture

which can result in serious bodily injury in clud ing

in jec tion and prop er ty damage.

NEVER

leave a pressurized sprayer un at tend ed to avoid

ac ci den tal operation of it, which could result in serious

bodily in ju ry.

ALWAYS

follow the PRESSURE RE LIEF PRO CE DURE

whenever you stop spraying and before ad just ing,

re mov ing or repairing any part of the sprayer.

NEVER

alter or modify any part of the equipment to

avoid possible component rupture which could result in

NEVER

use weak, damaged, or non-conductive paint

hose. Do not allow kinking or crushing of hoses or

al low it to vibrate against rough, sharp or hot surfaces.

Before each use, check your hoses for damage and wear

and ensure all of the  uid connections are secure.

ALWAYS

replace any damaged hose.

NEVER

use tape

or any device to mend the hose.

NEVER

attempt to stop any leakage in the line or

 t tings with your hand or any part of the body. Turn off

the unit and release pressure by following PRES SURE

RELIEF PROCEDURE.

ALWAYS

be sure all of the equipment & objects being

paint bucket and object being sprayed. See the ground ing

Reduce the risk of injection injury, static sparking or

ALWAYS

follow the PRESSURE RELIEF PRO CE DURE.

ALWAYS

remove the spray tip before  ushing. Hold

the metal part of the gun  rmly to the side of a metal pail

& use the lowest possible  uid pressure during  ush ing.

NEVER

use cleaning solvents with  ash points below

ether, gasoline, naptha. Consult your supplier to be sure.

NEVER

Use only conductive fluid hoses for airless ap pli ca tions.

Be sure the gun is grounded through the hose con nec tions.

Check ground continuity in hose & equipment. Overall

exceed 29 megohms for any coupled length or com bi na tion

of hose length. Use only high pressure airless hoses with

Vapors created when spraying can be ignited by sparks.

To reduce the risk of  re, always locate the sprayer at

least 20 feet (6 m.) away from spray area. Do not plug in

or unplug any electrical cords in the spray area. Doing so

can cause sparks which can ignite any vapors still in the

air. Follow the coating & solvent man u fac tur ers safety

warnings and precautions.

VOLTAGE

AMPERAGE

KEEP CLEAR OF MOVING PARTS

AVOID COMPONENT RUPTURE

PREVENT STATIC SPARKING FIRE/EXPLOSIONS

FLUSHING

WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS AND THINNERS

Your sprayer was factory tested in an oil solution which

was left in the pump.

Before using oil-base paint,

 ush

with mineral spirits only.

Before using water-base paint

 ush with mineral spirits, followed by soapy water, then a

clean water  ush.

2. Changing Colors

Flush with a compatible solvent such as mineral spirits or

water.

Flush with soapy water, then mineral spirits

4. Changing from oil-base to

water-base paint.

Flush with mineral spirits, followed by soapy water, then a

clean water  ush

FLUSHING

Always relieve pressure (See pressure relief

procedure on page 10) prior to storage or when

machine is unattended.

Flush with mineral spirits. Ensure that

there is no pressure in the unit, then close the prime/

pressure relief valve.

Water-base Paint:

Flush with water, then mineral spirits.

For longer term storage use a 50/50 mixture of mineral

for storage.

Before using water-base paint,

 ush with soapy

water and then a clean water  ush.

When using oil-base paint,

 ush out the mineral

(Prime/PR Valve)

Used to relieve pressure from gun, hose & tip and to prime

the unit when in OPEN position.

when there is a wider gap

between valve handle and

cam body).

When valve is in the CLOSED

position, there is only a very

When closed the system is

pressurized

Used to adjust pressure. Turn clockwise (CW) to increase

pressure and coun ter clock wise (CCW) to decrease pres-

TOGGLE

SWITCH

HOW TO FLUSH

Be sure the gun safety latch is engaged and there

is no spray tip in the gun. Refer to page 14 on how

to lock the safety latch and the gun's safety features.

FIGURE 4

empty metal pail to  ll the pump and hoses.

Place the suction tube into the pail.

Turn the Prime/Pressure Relief (PR) Valve to the

Point the gun into the metal pail and hold a metal

part of the gun  rmly against the pail. Refer to Figure 5.

METAL TO METAL

Disengage the gun safety latch and squeeze the

gun trigger. Turn the ON-OFF Toggle Switch to the

Knob (Figure 2) clockwise to increase pressure just

enough to start the pump.

Turn the Prime/PR Valve to the PRESSURE

 ushed through the pump, hoses and gun. Allow the

unit to operate until clean solvent comes from the gun.

Release the trigger and engage the gun safety

latch.

Whenever you shut off the sprayer, follow the

"PRESSURE RELIEF PROCEDURE".

HOW TO FLUSH (continued)

Remove the plastic cap plug from the outlet tee

and screw a conductive or grounded 3000 psi

airless spray hose onto  uid outlet.

Connect an airless spray gun to the other end of

the hose.

Do not use steel braided airless hose. Use nylon

braided airless hose only.

Be sure the electrical service is 120 VAC, 15 amp

minimum, and that the outlet you use is properly

grounded.

generator with voltage regulation must be used.

4. Grounding

2. Fill the packing nut/wet cup with

As per "Flushing Procedure" in this manual.

safety warning section of this manual.

SETTING UP

2. Prepare the material

Prepare the material according to the material

manufacturer's recommendations.

Place the suction tube into the material

container.

Prime/PR Valve must be "OPEN" in the priming

position.

When you have ensured that the gun safety latch is

engaged, attach tip and safety guard.

Turn the ON-OFF Toggle Switch to the

"ON" position.

Turn Pressure Control Knob clockwise to prime

the pump.

After the pump is primed, turn Prime/PR Valve to

the "Closed" position.

Turn Pressure Control Knob to the desired spray

pressure. Optional LCD displays pressure.

Disengage the gun safety latch and you are

ready to spray.

is used to adjust

pressure. Turn clockwise (CW) to increase pressure and

coun ter clock wise (CCW) to decrease pressure

TOGGLE

SWITCH

is used to

prime pump and to relieve pressure from gun, hose and tip.

Prime/Pressure Relief Valve

(Prime/PR Valve)

Used to relieve pressure from gun, hose & tip and to prime

the unit when in the OPEN position. (It is in open position

when there is a wider gap

between valve handle and

cam body)

When in the CLOSED

position, there is only a very

When closed the system is

pressurized. Handle as a loaded  rearm!

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