Page 1
A
ALLPRO
A
P
S
/O
ANUAL
Page 2
2
Manifold Filter Parts List
Upper & Lower Seats
Fluid Pump
20
21
Lo-Boy Machine Parts List
22
Hi-Boy Machine Parts List
23
24
Electrical System Drawing - 5/6 Series
28
TABLE OF CONTENTS
LP Series Speci cations
2
Flushing
How to Flush
Pressure Relief Procedure
Daily Maintenance
Electric Motor Maintenance
Field Troubleshooting
Packing Replacement
Electrical Board Calibration
25
Electrical Troubleshooting - 5/6 Series
27
Replacement of Electrical Components
29
www.airlessco.com email: techsupport@airlessco.com
©
2006, All rights reserved.
Page 3
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.
Page 4
2
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
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
Page 5
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
Page 6
4
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.
2.
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.
3.
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.
4.
Never use high pressure in the cleaning process.
USE MINIMUM PRESSURE.
5.
Do not smoke in spraying/cleaning area.
5 - 6
6 - 8
8 - 10
25
400
8
6
6
30086
6
6
250
8
8
6
20088
8
50
50066
4
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
Page 7
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
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
4. Changing from oil-base to
water-base paint.
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
Page 8
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
2
empty metal pail to ll the pump and hoses.
3.
Place the suction tube into the pail.
4.
Turn the Prime/Pressure Relief (PR) Valve to the
5.
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
6.
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.
7.
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.
8.
Release the trigger and engage the gun safety
latch.
9.
Whenever you shut off the sprayer, follow the
"PRESSURE RELIEF PROCEDURE".
HOW TO FLUSH (continued)
Page 9
Remove the plastic cap plug from the outlet tee
and screw a conductive or grounded 3000 psi
airless spray hose onto uid outlet.
b.
Connect an airless spray gun to the other end of
the hose.
c.
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
4. Grounding
2. Fill the packing nut/wet cup with
2. Fill the packing nut/wet cup with
As per "Flushing Procedure" in this manual.
safety warning section of this manual.
SETTING UP
Page 10
2. Prepare the material
2. Prepare the material
Prepare the material according to the material
manufacturer's recommendations.
b.
Place the suction tube into the material
container.
Prime/PR Valve must be "OPEN" in the priming
position.
b.
When you have ensured that the gun safety latch is
engaged, attach tip and safety guard.
c.
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.
f.
Turn Pressure Control Knob to the desired spray
pressure. Optional LCD displays pressure.
g.
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!
STARTING UPSTARTING UP
Page 11
4. Adjusting the pressure
4. Adjusting the pressure
Turn the Pressure Control Knob Clockwise to
increase pressure and counterclockwise to decrease
pres sure.
b.
Always use the lowest pressure necessary to
completely atomize the material.
c.
If more coverage is needed, use a larger tip rather
than increasing the pressure.
Check the spray pattern. The tip size and angle
determines the pattern width and ow rate.
Always point the gun toward the ground
Whenever you stop spraying, even for a short break,
follow the "Pressure Relief Procedure".
b.
Clean the tip & gun as recommended it the spray 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". Use a
compatible solvent to ush, then ll the pump and hoses
with an oil based solvent such as mineral spirits.
For long term shutdown or storage, refer to the
STARTING UP
Avoiding Tip Clogs
Avoiding Tip Clogs
There is an easy way to keep the outside of the
tip clean from material build up:
lock the gun and submerge it into a small bucket
Page 12
To avoid possible serious body injury, always follow this procedure whenever the sprayer
spraying, or when you are instructed to relieve the pressure.
Engage the gun safety latch. Refer to the separate
instruction manual provided with your gun on its
4.
Turn Prime/Pressure Relief Valve (PR Valve) to the
open
open
body when in open position. In the closed position there is
only a very slight gap.
.
2.
Turn the unit off & unplug it from the electrical outlet.
3.
Disengage the gun safety latch and trigger the gun
to relieve residual uid pressure.
Hold metal part of the gun in
5.
Re-engage gun safety latch and
close Prime/Pressure Relief Valve.
splashing into the bucket while relieving pressure during Step 4.
Service Center.
PRESSURE RELIEF PROCEDURE
Keep the displacement pump packing nut/wet cup lubricated with Airlessco TSO (Throat Seal Oil) at all times. The
TSO helps protect the rod and the packings.
2.
Inspect the packing nut daily. Your pump has a patented Triple Life Packing System.
Packing life will be extended a
minimum of three times if the following "Packing Adjustment" procedure is followed:
not any tighter. Overtightening will damage the packings and reduce the packing life.
DAILY MAINTENANCE
Page 13
SPRAY GUN OPERATION
Tip Guard
Trig ger
Attach spray gun to airless unit and tighten t tings se cure ly.
or trigger lock)
The gun safety latch should always be set when the gun is
not being triggered.
Read all warnings and safety precautions sup plied with the
Be sure pressure relief procedure is followed before
2.
Lock gun safety latch.
3.
Insert REV-TIP™ cylinder into the REV-GUARD™
4.
5.
Insert O-Ring gasket on metal seat so it ts in the grooves.
Finger tighten REV-GUARD™ retaining nut onto the gun.
7.
Turn guard in the desired position.
8.
O-Ring Gasket
Reverse to
Guard Housing Assembly
TO REMOVE CLOGS FROM SPRAY TIP
Lock gun safety latch.
2.
Turn REV-TIP™ handle 180 de grees.
3.
Disengage trigger lock & trigger gun into pail.
4.
If the REV-TIP™ handle appears locked (resists
turning), loosen the retaining nut. The handle will
now turn easily.
5.
Engage gun safety latch & return handle to the
Immediately after the work is nished, ush the gun out with
a solvent. Brush pins with solvent and oil them lightly so
they will not collect dried paint.
To clean the lter, use a brush dipped in an appropri-
ate solvent. Change or clean lters at least once a day.
four hours of operation.
Gun Safety
Gun Safety
hose by following the "Pressure Relief Procedure." Secure
gun with the safety latch, take off guard, take out the tip,
use a needle or sharp pointed instrument to clean the tip.
The tungsten carbide is brittle and can chip.)
Part # 561-026
Part # 561-029
Part # 561-XXX
G Thread 7/8" 561-002
F Thread 11/16" 561-001
Page 14
Problem Cause Correction
Tip worn beyond use
Thin or Spotty Coverage (Holidays)
Thin Coverage in Center of Pattern
Tip size larger than pump specs
Tip ori ce partialy clogged
Tip damaged
surface
Valve seat and/or ball in gun head
damaged or worn
assembly
Tip Clogs Continually
Thouroughly strain paint before use
Thouroughly strain paint before use
*See “Tip Selection Guide” in this
Page 15
During use, especially with latex paint, high pres sure will
cause the ori ce to grow larger. This de stroys the pattern.
Replace tips before they become excessively worn. Worn
tips waste paint, cause overspray, make cut ting-in dif cult,
and decreases sprayer per formance.
Two tips having the same tip size, but different pat tern widths
will deliver the same amount of paint over a dif fer ent area
width makes it easy to spray in tight places
Thickness of the paint coat per stroke is de ter mined by spray
tip "fan width", rate of the spray gun move ment, and distance
to surface.
SPRAY TIP SELECTION
SPRAY TIP REPLACEMENT
SPRAY TIP SELECTION
minute can be sprayed through the tip. Do not use a tip
larger than the max i mum pump ow rate or capacity the
in gallons per minute (GPM).
and job needs. For light viscosities (thin paints), use a
larger tip size.
(water @ 2000psi, 138 bar)
(latex paint @ 2000psi,
*Pump will support tip worn to next larger size.
Water Flow Rate
2.15
2.54
2.96
3.90
4.98
6.17
6.81
Paint Flow Rate
(gal./min.)
2.20
2.50
3.33
4.24
5.26
5.83
Pump Minimum
2.0
2.2
Output
2.3
2.8
3.3
3.8
5.7
8.2
4-6
209
211
213
215
217
219
221
223
225
229
6-8
307
309
311
313
315
317
319
321
323
325
327
335
8-10
203-254
409
411
413
415
419
423
425
427
431
254-305
511
513
515
517
519
521
523
525
527
531
535
305-356
611
613
615
617
619
621
623
625
627
631
635
639
641
356-406
406-457
815
819
821
831
20-24
508-610
W23
W25
C = Coarse
Wood
Stain, Sealer
Wood
Vinyl, Acrylic, Latex
vinyl,oil-base
alkyd
Ceiling
Structural Steel
.
029
Orifice Size
Inches
4-6
212
214
6-8
312
314
8-10
203-254
Double Orifice
design for lower pressure airless
spraying when you need finer atomization for a smoother
finish on interior trim, cabinetry, shutters, and doors.
TM
REV-TIP
for Painting 561-XXX
SPRAY PAINTING TIP - ORIFICE SIZE
NEW
WIDE PATTERN
►
)
(
Inches
NEW!
REV-TIP
Page 16
ELECTRIC MOTOR MAINTENANCE
This motor is supplied with prelubricated ball bearings, lubricated for life of bearing.
2.
-
These need periodic inspection and replacement as wear indicates. Brushes for the Leeson motor
Motor (LP400/460) PN 331-778 have an initial length of 13/16" and must be replaced when worn to 1/4".
3.
TO CHANGE THE BRUSHES,
follow the procedures below:
Unplug the machine.
b.
Remove brush access plates at the rear of the motor.
c.
Loosen the screw holding the brush terminal and remove the brush lead.
Push the brush retainer clip in and remove.
Remove the worn brushes (one on each side of motor).
f.
Install new brushes in reverse order and replace plates.
properly.
46 *7
* LP690 & 810E come equipped with ttings
MANIFOLD FILTER - PN 111-200-99
FIGURE 10 PARTS LIST
ITEM # PART # DESCRIPTION
Page 17
FIELD TROUBLESHOOTING
Airleak due to:
below suction seat
assembly
Pressure set too low
Turn up pressure
Filter(s) are clogged
Clean or replace gun lter, inlet
lter and/or manifold lter
Outlet Valve fouled/worn
Prime/Pressure Relief valve
Clean or replace primve valve
bypassing
Packings and/or piston worn
Tighten packing nut
Repack unit
Blown spray tip
Replace spray tip
Packings and/or piston worn
Repack unit
Upper Seat worn
Replace upper seat
Blown fuse
Replace fuse
(pn. 331-256) - 4 Series
20A SlowBlow
(pn. 331-328) - 5&6 Series
Electrical failure
4 Series & 5-6 Series
Page 18
SERVICING THE FLUID PUMP
331-209
331-236
Fluid Pump Removal - Refer to Figure 11
1. Follow the Pressure Relief Procedure page 10.
2. Flush the material you are spraying out of the machine.
3. Remove the connecting rod shield (331-11
4. Move the piston rod (331-093) to its lowest position by
cycling pump slowly or by rotating the motor fan.
5. Disconnect the sensor (331-294-99) by holding it in
place with a 7/8” wrench and unscrewing the swivel
connector (100-003) with an 11/16” wrench.
DO NOT TURN THE SENSOR.
6. Remove the retaining ring (331-062) from the
connecting rod (331-038) and slide the sleeve (331-117)
down revealing the connecting rod pin (331-065).
7. Remove the suction tube assembly from the uid pump
by unscrewing the suction nut (331-034) with
the packing adjustment tool.
8. Using a 1/2” wrench unscrew the two bolts (100-318)
from the cover assembly 331-234). The uid pump
(331-209) will be hanging loosely at this point.
9. Remove the connecting rod pin (331-065) out of the
connecting rod (331-038), allowing the removal of the
uid pump (331-209) from the machine.
1).
Fluid Pump Reinstallation -
Refer to Figure 11 & 14
1. Loosen the packing nut and ensure that the piston rod
(331-093) is in its upper position in the uid pump
body. Slip the sleeve (331-117) & the
retaining ring (331-062) over the piston rod.
2. Push the piston rod up into the connecting rod (331-
038) & align the holes. Insert the connecting rod pin
(331-065) through the connecting rod & piston. Slip
the sleeve over the connecting rod pin and insert the
retaining ring into the groove on the connecting rod.
3. Push the two bolts (100-318) through the tube spacers
(331-074) & screw them into the cover assembly (331-
234). Using a 1/2” wrench, tighten the two bolts evenly
(alternating between them) until you reach 20 ft-lbs.
4. Reassemble the lower suction valve assembly by
placing the suction seat assembly: O-ring (106-011),
suction ball (331-030) and suction ball guide (331-029)
in the suction nut (331-034) and screw onto the uid
pump body.
5. Reconnect the sensor (331-294-99) to the uid pump
body. Hold the sensor with a 7/8” wrench while
tightening the swivel connector (100-003) with an
11/16” wrench.
DO NOT TURN THE SENSOR.
6. Start the machine and operate slowly to check the
piston rod for binding. Adjust the two bolts, holding the
uid pump body to the cover assembly, if necessary.
This will eliminate any binding.
7. Tighten the packing nut counter clockwise until
resistance is felt against the Belleville Springs, then go
3/4 of a turn more. Put ve drops of Airlessco Throat
Seal Oil into the packing nut.
8. Run the machine at full pressure for several minutes.
Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield (331-111) so that the
small hole is in the upper right hand corner.
Page 19
GEAR AND PUMP ASSEMBLY
Do not operate
Servicing Gear Box Assembly
Servicing Gear Box Assembly
Remove uid pump as per "Fluid Pump Disconnect"
procedures.
2.
Remove frame from the gearbox by loosening the four
mounting screws.
3.
Refer to Figure 12. Separate cover assembly from box
by removing bolts from front of cover & back of box &
4.
Lay unit on its back and disassemble gearbox.
5.
Inspect bearings, Crosshead Assembly, Gearcrank & sleeve
bearing inside cover assembly for wear/damage. Replace
worn/damaged parts.
If gear grease needs replacing, replace with gear grease
7.
Part No. 105-331 BLUE XS™ ADVANCED RTV
8.
Reassemble in reverse order.
Can be ordered separately, but is included
with Motor Ass'y (Part No. 331-490, 331-068)
331-038
331-040
331-046
331-047
331-061
331-062
331-065
331-074
Tube Spacer (2)
331-088
331-111
331-117
331-209
331-234
331-236
331-406
331-407
331-408
331-061
Sleeve Bearing
331-103
Washers (2)
331-197
Screws (2)
prior to inserting into cover assembly.
2
FIGURE 10 PARTS LIST
ITEM # PART # DESCRIPTION
Page 20
Servicing the Piston Rod - Outlet Valve
331-196
331-195
Disconnect the Fluid Pump.
-Low Boy/Carry
331-292-Hi Boy
Suction Nut
331-034
2. Place piston holder (331-195) in a vise. Slide piston into
the holder & lock in place with a 3/8” dowel (331-196).
3. Use a 1/4” allen wrench to unscrew the outlet seat retainer
(331-314) from the piston.
4. Remove the outlet seat (331-026), O-ring (331-100) and
outlet ball (331-027).
5. Inspect outlet ball & seat for wear. Replace as necessary.
6. While piston is still locked in the holder, install parts
back into the piston in the following order:
ball, outlet seat and O-ring
Before reinstalling the outlet seat retainer, apply two drops of
Loctite No. 242 (blue) on the threads & torque to 20 ft-lbs.
* Available in LP tool kit PN 188-397
Servicing the Suction Assembly
Refer to Figure 14
1. Unthread and remove suction nut from the
2. Remove suction seat (331-409), O-ring (106-011), suction ball
(331-030) and suction retainer (331-029).
3. Clean all parts and inspect them for wear or damage, replacing
parts as needed.
4. Clean inside of the
5. Reassemble lower suction valve assembly by placing the
suction seat (331-409), O-ring (106-011), suction ball (331-030)
& suction ball guide (331-029) in the suction nut (331-034) &
screw onto uid pump body.
uid pump body.
uid pump body.
Page 21
of the leather packings (331-306) & place onto the male gland in
the following order with the inverted side down :
Follow step 2 above with your packings inverted side up.
Take the upper male gland (331-022) & place it rounded side up.
Take three upper polyethylene packings (331-023) & two leather
packings (331-307) & assemble with inverted side down ,
Unscrew & remove the packing nut (331-037).
2.
Push the piston rod (331-708) down through the packings
& out of the pump.
3.
Now push the packing removal tool (187-249) up through
the pump & remove from the top bringing packings, spacer
& springs along with it, leaving fluid body (331-011) empty.
Clean inside of fluid body (331-011).
5.
Disassemble all parts & clean for reassembly. Discard any
old packings.
6.
Lubricate leather packing in lightweight oil for 10 minutes
prior to reassembly.
Disassembly of the Outlet Vavle - Figure 13
Packing Replacement Procedures
Fluid Pump Removal - Refer to Figure 11
1. Follow the Pressure Relief Procedure above.
2. Flush material you are spraying out of the machine.
3. Remove the connecting rod shield (331-11
4. Move the piston rod (331-093) to its lowest position by
cycling pump slowly or by rotating the motor fan.
5. Disconnect the sensor (331-294-99) by holding it in place
with a 7/8” wrench & unscrewing the swivel connector
(100-003) with an 11/16” wrench.
DO NOT TURN THE SENSOR.
6. Remove the retaining ring (331-062) from the connecting
rod (331-038) and slide the sleeve (331-117) down
revealing the rod pin (331-065).
7. Remove the suction tube assembly from the uid pump
(331-708) by unscrewing the suction nut (331-034) with the
packing adjustment tool.
8. Using a 1/2” wrench unscrew the two bolts (100-318) from
the cover assembly 331-234). The uid pump (331-209)
will be hanging loosely at this point.
9. Remove the connecting rod pin (331-065) out of the
connecting rod (331-038), allowing the removal of the uid
pump (331-209) from the machine.
1. Place piston holder (331-195) in a vise. Slide piston into
the holder & lock in place with a 3/8” dowel.
2. Use a 1/4” allen wrench to unscrew the outlet seat retainer
(331-026) from the piston.
3. Remove the outlet seat (331-026), O-ring (331-100) and
outlet ball (331-027).
4. Inspect outlet ball & seat for wear. Replace as necessary
5. While piston is still locked in the holder, install parts back
into the piston in the following order:
ball, outlet seat and O-ring
Be
fore reinstalling the outlet seat support, apply two drops of Loctite
No. 242 (blue) on the threads & torque to 20 ft-lbs.
1).
.
REASSEMBLY - Figure 15 & 16
1. Take lower male gland (331-014) & place it down on
the at side.
2. Take three of the lower polyethylene packings (331-016) & two
polyethylene, leather, polyethylene, leather, polyethylene.
3. Take the female adaptor (331-305), which is inverted on both
sides, & place it on top of your assembled lower packings.
4.
5. Take the second lower male gland and place it on top of your
assembled packings with the rounded side down.
6. Take assembled glands & packings (13 pieces) & slide on to the
lower half of the piston.
7. Take the spacer (331-018) & slide over the top of the piston (it
doesn’t matter which direction it sits), falling onto lower packings.
8. Take three Belleville Springs (331-025) & slide over the top of
the piston in the following order:
* First spring, curve facing down
* Second spring, curve facing up
* Third spring, curve facing down
9.
10.
on to the male gland in the following order:
polyethylene, leather, polyethylene, leather, polyethylene.
11. Take upper female gland (331-021) & place on top of the assembled
upper packings with the inverted side down.
12. Take assembled upper glands & packings (7 pieces) & slide on
over the top of the piston, making sure inverted sides are down.
13. Take the packing holder (331-019) & replace the white O-ring
(106-009) & the black O-ring (106-010) with new ones from the
packing kit.
14. Slide the packing holder over the top of the upper packings
so they t inside.
15. Lubricate inside of the uid pump body & the outside of the
packings with a light weight oil.
16. Slide completed assembly into uid pump body (331-011).
*
To keep packings secured in correct position, hold the pump body
upside down & push the completed assembly upwards into the pump
body. Once placed inside, tilt pump body back up to keep all pieces in.
17. Tighten packing nut (331-037) onto the top of the uid pump
body & tighten until you feel slight resistance against the
Belleville Springs (331-025). Using the Packing Adjustment Tool
(189-211), tighten another 3/4 of a turn.
Fluid Pump Reinstallation - Figure 11 & 14
1. Loosen packing nut & ensure that the piston rod (331-093) is in
its upper position in the uid pump body (331-209). Slip the
sleeve (331-117) & the retaining ring (331-062) over the piston rod.
2. Push piston rod up into the connecting rod (331-038) & align the
holes. Insert the connecting rod pin (331-065) through the
connecting rod & piston. Slip the sleeve up over the connecting
rod pin & insert retaining ring into the groove on the connecting rod.
(
(
(
Page 22
Packing Replacement Procedures (Continued)
3. Push the two bolts (100-318) through the tube spacers
(331-074) & screw into the cover assembly (331-234).
Using a 1/2” wrench, tighten the two bolts evenly
(alternating between them) until you reach 20 ft-lbs.
4. Reassemble lower suction valve assembly by placing
the suction seat (331-409) O-ring (106-011), suction
ball (331-030) and suction ball guide (331-029) in the
suction nut (331-034) & screw onto the fl uid pump body.
5. Reconnect the sensor (331-294-99) to the fl uid pump
body. Hold sensor with a 7/8” wrench while tightening
the swivel connector (100-003) with an 11/16” wrench.
DO NOT TURN THE SENSOR.
6. Start the machine & operate slowly to check the piston
rod for binding. Adjust the bolts, holding the fl uid
pump body to the cover assembly, if necessary. This
will eliminate any binding.
7. Tighten packing nut counter clockwise until resistance
is felt against the Belleville Springs, then go 3/4 of a
turn more. Put fi ve drops of Airlessco Throat Seal Oil
into the packing nut.
8. Run the machine at full pressure for several minutes.
Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield (331-111) so that the
small hole is in the upper right hand corner.
FIGURE 15
Viton O-Ring
*
106-010
PTFE O-Ring
*
*
106-010
*
*
*
*
*
*
*
†
†
*
†
*
Swivel
Connector
100-003
†
†
*
*
*
*
FIGURE 16
Included in Packing Kit
*
PN #331-210
† Included in Piston Replacement
PN #331-093
331-093
Low Boy/Carry
331-292 Hi Boy
Suction Nut
331-034
Assy
20
Page 23
21
CARRY FRAME MODELS
Tube Spacer (2)
Terminal Box
Page 24
22
LO-BOY MODELS
Wheel 10” (2)
Tube Spacer (2)
Terminal Box
331-074
331-315-99,
331-396-99,
331-068, 331-490, 331-069, 331-426
301-405
331-476
Page 25
23
HI-BOY MODELS
Wheel 10” (2)
Tube Spacer (2)
Terminal Box
331-490
FIGURE 19
Page 26
24
SUCTION ASSEMBLIES
- LoBoy & Carry Frames
- HiBoy Frame
4
6
2
(inc. strainer)
6
ITEM # PART # DESCRIPTION
O-Ring PTFE
FIGURE 21 PARTS LIST
ITEM # PART # DESCRIPTION
Page 27
25
the following calibrations must be per formed.
Place prime/pressure relief valve in the prime (open) position.
2.
3.
Remove the screws and lower the pressure control assembly.
4.
Ensure the jumper is on the "P-ZR" terminal.
Note:
pres ent ly in the unit, remove jumper from single terminal P-ZR and place on both terminals P-ZR. When Zero
5.
Turn machine "ON" and ensure it is not cycling.
If the yellow zero light on the electrical board is ON, use an insulated screwdriver to turn the "ZERO" trimpot
zero trimpot CW until "0000" is displayed.
7.
If the yellow light is OFF, turn the "Zero" trimpot clockwise, just until the light comes on and stop. Con rm
NOTE: If the yellow light remains constantly "ON", or "OFF" during this calibration, the sensor
is defective and should be replaced.
IMPORTANT:When calibration is complete, move jumper from both "PZ-R" terminals to single terminal
2. PRESSURE CALIBRATION
2.
Attach a 50', 1/4" airless hose, airless gun with 0.017 tip and a 5000 psi glycerin lled pressure gauge to the pump.
3.
Place the suction tube into a bucket of Coro-chek and water.
4.
Turn prime/pressure relief valve to the prime (open) position.
5.
Turn pressure control knob clockwise until machine starts to prime.
Place the prime/pressure relief valve in the pressure (closed) position.
7.
While watching pressure gauge, slowly adjust the pressure trimpot (clockwise to increase and counterclockwise
to decrease) until the maximum static pressure is 3000 psi, with the pressure control knob fully clockwise.
Trigger the gun several times to ensure pressure returns to 3000 psi.
this calibration.
2.
Turn pressure control knob up until system pressure is above 2500 psi (as indicated on glycerin lled pressure
gauge) and the ma chine is not cycling.
3.
Use an insulated screwdriver to adjust the Set trimpot. Turn trimpot CCW until it clicks, then adjust to match
pressure against pressure gauge reading.
4.
Move the pressure control knob to different settings and trigger the gun several times to ensure that the LCD
ELECTRICAL BOARD CALIBRATION
Page 28
26
ELECTRICAL BOARD CALIBRATION (CONTINUED)
4. PHASE LIMIT TRIMPOT CALIBRATION
Attach a 50', 1/4" airless hose, airless gun with .017 tip and a 5000 psi glycerin lled pressure gauge to the
pump.
2.
Place the suction tube into a bucket of Pump Conditioner and water.
3.
Turn pump ON and turn up pressure control until the machine starts to prime.
4.
Place the prime/pressure relief valve in the pressure (closed) position.
5.
Pressurize pump to 600 psi.
Trigger the gun several times noting the deadband (the amount of pressure drop before the pump rebuilds to
7.
If deadband is greater than 100 psi, adjust the low pressure voltage trimpot so that the deadband is less than
guidelines and may vary slightly from pump to pump.
8.
Reattach Pressure Control Assembly being careful not to pinch wires.
which are the closest to the "S2" connection. Also on the Revision E is a
Page 29
27
TROUBLESHOOTING - Machine does not start
STEPS (SEE FIGURE 22)
STEPS (SEE FIGURE 22)
STEP 1:
After making sure that the machine is plugged into the wall, verify that the
on-off switch is in the ON position and that the pressure control knob is turned all the
way to the right (clockwise for maximum pressure).
STEP 2:
Using your multi-meter, test the fuse for continuity or replace with a new
fuse. If the fuse reads good, move on to step three.
STEP 4:
Locate the L1 and L2 terminals on the board, and then using your multi-me-
ter check to make sure you have 110 volts AC across the two terminals (the cord wires
will still be attached). If there is no voltage at these leads, there is no power getting
to the machine. Check your power source (outlet, circuit breaker, extension cord, and
power cord). If you have AC voltage at the L1 and L2 terminals, go to step 5.
STEP 3:
Using a Phillips Head screwdriver, remove the four screws holding the
pressure control assembly. Locate the light on the board indicating there is power (it
will be red or green). If light is OFF proceed to step four. If light is ON go to step six.
Thermal Overload
Sensor
STEP 5:
Disconnect the two red motor leads (S1 & S2) and test for continuity between
them. No continuity means that the thermal coupler has opened due to excessive motor
heat. If the motor is still hot to the touch, allow it to cool and then retest. If the motor
is cool and there is not continuity on the red leads, contact your local Leeson repair
facility to repair/replace the thermal coupler. Continuity shows that the motor's thermal
coupler has not tripped. Proceed to step six.
STEP 6:
If everything checks out in steps one through ve and the power indicating
light is still out, replace the pressure control assembly.
STEP 7:
Remove the motor brush covers and turn the machine on. Set the potentiome-
ter (POT) at maximum pressure and check for DC voltage across both brush terminals.
You should read greater than 80 volts DC. IF YOU DO NOT HAVE DC VOLTAGE
GO TO STEP EIGHT. If you have DC voltage, turn the machine off and unplug it from
the wall. Check to make sure that the brushes are making good contact with the arma-
ture. Replace the brushes if they are less than 3/8" long. If the brushes are good, replace
the motor.
STEP 8:
Plug another sensor into the board and perform the zero calibration proce-
dure. If the machine starts to run, the sensor was bad. If there is no replacement sensor
available, use a multi-meter to test the resistance across the red and black wires of the
usually reads no continuity (open). If the sensor passes all the tests move to step nine.
STEP 9:
Plug another potentiometer (POT) into the control board. If the machine
lead (with the machine turned off) from the control board and test the resistance be-
tween the red and black wires (be sure to test at the plug). The resistance should read
between 8-12k ohms if it is outside of this range replace the POT.
STEP 10:
If you do not have DC voltage at the motor brushes and all of the compo-
nents check out ne in steps eight and nine, replace the pressure control assembly.
Page 30
28
ELECTRICAL SYSTEM
FIGURE 22
Jumper
Toggle Switch
Page 31
29
Unplug machine's power cord.
2.
Remove four screws from heatsink housing.
3.
Disconnect all leads from pressure control assembly.
4.
Reassemble in reverse order.
Remove the 4 screws heat sink and lower the pressure control assembly.
2.
Disconnect swivel from sensor by holding sensor with 7/8" wrench and loos en ing swivel with 11/16" wrench.
3.
Disconnect sensor lead from the board. Carefully pull sensor lead out of the terminal box and remove sensor.
4.
Reassemble in reverse order.
Lower pressure control assembly as described above.
2.
Disconnect potentiometer lead from pressure control assembly.
3.
Use a 1/16" allen wrench, loosen set screw in the potentiometer knob (Fig. 22,) and remove knob and spacer.
4.
Using a 1/2" wrench or deep socket, remove the nut from the potentiometer shaft assembly.
5.
Pull entire potentiometer assembly out of terminal box.
6.
Replace in reverse order.
Lower pressure control assembly as described above.
2.
Unscrew the four nuts (6/32") (Fig. 23, Item 5) and remove
LCD Display assembly (Fig. 23, Item 6).
3.
If unable to loosen the four nuts, hold them and unscrew
the four screws (Fig. 23, Item 1). Then remove the
LCD Display Assembly. If the display is removed in this
manner, the mylar label (Fig. 23, Item 2) must be replaced.
4.
Reassemble in reverse order, while making sure
that the four spacers (Fig. 23, Item 4) and the four
washers (Fig. 23, Item 7) are in place.
Tighten the four nuts handtight and seal with blue loctite.
DO NOT overtighten the nuts as this will damage the display.
Lower the pressure control assembly as described above.
2.
Disconnect the two wires on the switch.
3.
Use a 9/16" wrench to loosen the nut on the toggle switch shaft.
4.
Reassemble in reverse order.
Lower pressure control assembly as described above.
2.
Disconnect the two wires on the holder.
3.
Remove holder cover and fuse.
4.
Use 11/16" wrench to remove the nut from the holder shaft.
5.
Reassemble in reverse order.
REPLACEMENT OF ELECTRICAL COMPONENTS
4
6
Window
Washer (4)
ITEM # PART # DESCRIPTION
Always unplug the electrical cord before servicing machine.
FIGURE 24 PARTS LIST
Page 32
from gun and system!
Turn clockwise to increase
to decrease pressure.
STEP
Read safety rules! Read & understand all
warnings & safety rules before operating
equipment. Know how to lock the gun trigger
safety lock before operating the equipment.
Stir paint and if necessary strain paint using
a paint strainer bag to remove lumps.
STEP
Check gun/hose connections to make sure
they are tight.
cal outlet. Extension cord must be 3 wire, 12
gauge. Do not coil cord.
STEP
3A.
3B.
Turn the Prime-Pressure Relief Valve to
open position
open position
(wide gap between handle &
Turn toggle switch ON, and adjust to low
STEP
Wait about one minute until uid comes out
of the return tube (smaller diameter tube).
4B.
Turn the Prime-Pressure Relief Valve to
closed position.
closed position.
(slight gap between handle
and body)
CAUTION: THE UNIT IS NOW
STEP
Leave the Prime-Pressure Relief Valve
fully closed and very carefully unlock the guns
trigger safety lock.
5A.
Aim the gun 12” from test surface card-
Turn thepressure control knob clockwise to
enough to atomize the paint & give a full
5B.
Always keep the gun perpendicular to
the surface. Move the gun at a steady rate.
5C.
Overlap half the width of each paint stroke.
STEP
6A.
Release pressure when you stop spraying
& before servicing gun or machine or before
changing or cleaning gun tip by:
Lock the gun trigger safety.
2.
Turn toggle switch to OFF position and
3.
Release gun safety lock and trigger
gun to relieve residual pressure.
Turn Prime/PR Valve to open position.
5.
Relock gun safety latch.
6B.
Submerge gun in water (if using latex)
or thinner (oil-base) to prevent paint from
drying in the gun nozzle.
& tip and to prime the unit when in OPEN
When in the CLOSED position, there is
only a very slight gap between handle
& body. When the relief valve is
closed
the system is pressurized.
Handle as a
loaded rearm!
ON/OFF Toggle Switch
Turns the unit ON and OFF.
LP Series Electric Paint Sprayer
Always use low pressure in the cleaning process.
Always remove spray tip before cleaning–
AFTER
following the Pressure Relief Procedure!
TOOLS & EQUIPMENT NEEDED:
TOOLS & EQUIPMENT NEEDED:
Soft bristle brush, clean-up rags.
2.
8” crescent wrench for removing
gun tip & lter in gun handle.
3.
water if using latex, or mineral
spirits if using oil-based. (Second
STEP
gun and place in mineral spirits or water.
STEP
the bucket out through the return tube.
2B.
Wipe excess paint from suction tube.
2C.
of water or mineral spirits.
STEP
carefully.
3A.
Turn the Prime/PR Valve to the closed
IMPORTANT: Never use high
pressure for cleaning!
3B.
Trigger gun into paint bucket to allow
3C.
and trigger gun using VERY LOW
to metal contact for 3-4 minutes until
STEP
gun handle. Clean with water or mineral
spirits and soft brush and reassemble
suction and gun lter only.
STEP
5A.
with 1
gal. of water or prepared mineral spirits
and put suction tube into pail. Prime
Trigger gun to ll the hose & gun.
for storage. DO NOT DIS CHARGE. Turn
5B.
5C.
gun with spray tip and tip guard. After
you have disconnected sprayer from
electrical power, turn Prime/PR Valve to
the closed position for storage.
5.
Storage solution of Pump Conditioner
OR compatible paint thinner if using
oil-based paint.
Quick Reference Guide
OPERATION
CLEAN ING
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