®
AIRLESS PAINT LINE STRIPER
SERVICE/OPERATION
MANUAL
SURE STRIPE
4550 & 6050
001-811 APR09
1
TABLE OF CONTENTS
SECTION FIGURE
Introduction...................................................... 1
Safety Warnings .............................................. 2
Setting Up........................................................ 5
Flushing........................................................... 5
How to Flush ................................................... 6
Starting Up ...................................................... 7
Pressure Relief Procedure .............................. 9
Line Striping Operation.................................. 10
Airless Spray Gun Operation..........................11
Airless Spray Gun ......................................... 12
Airless Spray Troubleshooting....................... 13
Rev Tips ........................................................ 14
Regular Maintanence .................................... 15
Field Troubleshooting.................................... 15
Servicing the Fluid Pump .............................. 16
Servicing the Inlet Valve ................................ 17
Servicing the Outlet Valve ............................. 17
Packing Replacement Procedures ................ 18
Paint System Assembly................................. 20
Prime Valve ................................................... 21
Manifold Filter................................................ 21
Replacement of Electrical Control Board ...... 22
Pressure Calibration on the Control Board.... 22
Clutch Troubleshooting.................................. 23
Clutch Replacement ...................................... 23
Clutch Assembly............................................ 25
Engine Assembly........................................... 25
Power Unit Assembly .................................... 26
First Gun Assembly ....................................... 27
Second Gun Assembly.................................. 27
Ball Valve....................................................... 27
Gun Holder Assembly.................................... 28
Swivel Wheel Assembly - 4550 ..................... 29
Frame Assembly - 4550 ................................ 30
Swivel Lock Assembly - 6050........................ 31
Swivel Wheel Assembly - 6050 ..................... 31
Frame Assembly - 6050 ................................ 32
Suction Assembly.......................................... 33
Striping Accessories...................................... 33
Airlessco Accessories.................................... 34
1 Filling the Packing Nut/Wet Cup................ 5
2. Spray Tip ................................................... 6
3. Prime Valve ............................................... 6
4. Pressure Control Knob .............................. 6
5. Choke, Fuel, Throttle................................. 6
6. Static Discharge ........................................ 6
7. Spray Gun ................................................11
8. Gun Safety Latch......................................11
9. Major Gun Components ...........................11
10. Spray Tip ..................................................11
11. Airless Spray Gun.................................... 12
12. Oil and Lubrication .................................. 14
13. Fluid Pump .............................................. 16
14. Fluid Pump Connection ........................... 16
15. Fluid Pump Connection ........................... 16
16.Fluid Pump Connection ............................ 16
17. Fluid Pump Connection ........................... 16
18. Fluid Pump Connection ........................... 16
19. Inlet Valve ................................................ 17
20. Outlet Valve ............................................. 17
21. V-Packing ................................................ 19
22. V-Packing Cutaway ................................. 19
23. Paint System ........................................... 20
24. Prime Valve ............................................. 21
25. Manifold Filter.......................................... 21
26. Control Board .......................................... 22
27. Belt Tensioning ........................................ 24
28. Clutch Assembly...................................... 25
29. Engine Assembly..................................... 25
30. Power Unit Assembly .............................. 26
31. First Gun Assembly ................................. 27
32. Second Gun Assembly............................ 27
33. Ball Valve................................................. 27
34. Gun Holder Assembly.............................. 28
35. Swivel Wheel Assembly - 4550 ............... 29
36. Frame Assembly - 4550 .......................... 30
37. Swivel Lock Assembly - 6050.................. 31
38. Swivel Wheel Assembly - 6050 ............... 31
39. Frame Assembly - 6050 .......................... 32
40. Suction Assembly.................................... 33
Airlessco
5397 N. Commerce Ave, Moorpark, CA 93021
www.airlessco.com • (805) 523-0211
2
INTRODUCTION
The Model 4550 & 6050 are gasoline powered, SL "Slow
Stroker" piston pump equipped, airless line stripers. They
have been designed to have the reliability and versatility
needed to meet the tough daily demands of professional
line striping contractors.
The SL pump delivers up to 1.7 gallon per minute output.
This allows both models to support dual spray guns with
very high volume spray tips. Both are as at home striping
a convenience store parking lot as they are lining a
professional football eld.
The compact frame of the 4550 gives you big pump power
with minimal space requirements, while the 6050 offers the
ease of use of a dual swivel front wheel.
You will appreciate convenient design features like
spray guns that can quickly be moved to any corner of
the machine. Handlebar releasable swivel wheels have
turnbuckle based RADIUS MEMORY™ for consistently
smooth arcs & circles.
Like all Airlessco stripers and sprayers, they are Build to
Last....Built to Perform.
SS4550 SS6050
Part No. 1 Gun Unit 305-403 305-305
Part No. 2 Gun Unit 305-404 305-307
Max Pressure 3300 PSI 3300 PSI
Output 1.50 GPM 1.70 GPM
Tip Size (1 Gun) 0.035 in. 0.041 in.
Tip Size (2 Gun) 0.029 in. 0.029 in.
Motor
Weight 215 lbs 242 lbs
Honda GX160 Honda GX160
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!
WARNING
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY
SERIOUS INJURY. OBSERVE ALL WARNINGS!
MANUAL NOTATIONS
WARNING - Alerts user to avoid or correct conditions that
could cause bodily injury.
CAUTION - Alerts user to avoid or correct conditions that
could cause damage to or destruction of equipment.
IMPORTANT - Alerts users to steps or procedures that are
essential to proper equipment repair and maintenance.
NOTE - Identies essential procedures or extra information.
All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.
NO MODIFICATIONS or alterations of any AIRLESSCO Equipment or part is allowed.
BEFORE OPERATING THIS UNIT, READ AND FOLLOW
ALL SAFETY WARNINGS AND INSTRUCTIONS RELATED
TO THE USAGE OF THIS EQUIPMENT ON PAGES 2, 3 & 4.
READ, LEARN, AND FOLLOW THE PRESSURE RELIEF
PROCEDURE ON PAGE 9 OF THIS MANUAL.
1
3
WARNINGS
MEDICAL ALERT - Airless Spray Wounds
If any uid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
CUT. Tell the doctor exactly what uid was injected. Have
him read the following "NOTE TO PHYSICIAN".
WARNING
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. OBSERVE ALL
WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY.
INJECTION HAZARD
FLUIDS UNDER HIGH PRESSURE FROM SPRAY OR
LEAKS CAN PENETRATE THE SKIN AND CAUSE
EXTREMELY SERIOUS INJURY, INCLUDING THE
NEED FOR AMPUTATION.
NEVER point the spray gun towards anyone or at any part
of the body.
NEVER put hand or ngers over the spray tip. Do not use
rag or other materials over your ngers. Paint will penetrate
through material and into the hand.
NEVER try to stop or deect leaks with your hand or body.
ALWAYS have gun tip guard in place when spraying.
ALWAYS lock gun trigger when you stop spraying.
ALWAYS remove tip from the gun to clean it.
NEVER try to "blow back" paint, it’s not an air sprayer.
ALWAYS follow the PRESSURE RELIEF PROCEDURE,
as shown on page 9, before cleaning or removing the spray
tip or servicing any system equipment.
Be sure equipment safety devices are operating properly
before each use.
ALWAYS tighten all uid connections before each use.
MEDICAL TREATMENT
If any uid appears to penetrate your skin, get
EMERGENCY CARE AT ONCE.
DO NOT TREAT AS A SIMPLE CUT.
• 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.
GENERAL PRECAUTION
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.
NEVER LEAVE SPRAYER UNATTENDED WITH
PRESSURE IN THE SYSTEM. FOLLOW PRESSURE
RELIEF PROCEDURES ON PAGE 9.
2
NOTE TO PHYSICIAN: Injection in the skin is a traumatic
injury. It is important to treat the injury surgically as soon as
possible. DO NOT DELAY treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
ALWAYS INSPECT SPRAYING AREA
Keep spraying area free from obstructions.
Make sure area has good ventilation to safely remove
vapors. NEVER keep ammable material in spraying area.
NEVER spray in vicinity of open ame or other sources of
ignition. Spraying area must be at least 20 ft. away from
spray unit.
SPRAY GUN SAFETY
ALWAYS set safety lock on the gun in "LOCKED" position
when not in use and before servicing or cleaning.
DO NOT remove or modify any part of gun.
ALWAYS remove spray tip when cleaning.
Flush unit with LOWEST POSSIBLE PRESSURE.
CHECK operation of all gun safety devices before each
use. Be very careful when removing the spray tip or hose
from gun. A plugged line contains uid under pressure. If
the tip or line is plugged, follow the PRESSURE RELIEF
PROCEDURE as outlined on page 9.TIP GUARD
TIP GUARD
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 ngers
or any part of your body close to the spray tip.
SPRAY TIP SAFETY
USE EXTREME CAUTION when cleaning or changing
spray tips. If the spray tip clogs while spraying, engage the
gun safety latch immediately.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
before removing the spray tip to clean it.
NEVER wipe off build up around the spray tip.
ALWAYS remove tip & tip guard to clean AFTER pump
is turned off and the pressure is relieved by following the
PRESSURE RELIEF PROCEDURE.
WARNINGS CONTINUED ON NEXT PAGE.........
WARNINGS - CONTINUED
ALWAYS INSPECT SPRAYING AREA
Keep clear of moving parts when starting or operating
the sprayer. Do not put your ngers into any openings
to avoid amputation by moving parts or burns on hot
parts.Precaution is the best insurance against an
accident.
When starting the engine, maintain a safe distance
from moving parts of the equipment.
Before adjusting or servicing any mechanical part
of the sprayer, follow the PRESSURE RELIEF
PROCEDURE on page 9, and remove the ignition
cable from the spark plug to prevent accidental
starting of sprayer.
HOSES
Tighten all 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.
Use only hose that has 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.
GROUNDING
Ground the sprayer and 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.
ALWAYS GROUND ALL OF THESE COMPONENTS:
1. Sprayer: Connect a ground wire and clamp (supplied) to
a true earth ground.
2. Fluid Hose: use only grounded hoses.
3. Spray gun or dispensing valve: grounding is obtained
through connection to a properly grounded uid hose
and pump.
4. Object being sprayed: according to your local code.
5. All solvent pails used when ushing should only be
metal pails which are conductive.
Once each week, check electrical resistance of hose (when
using multiple hose assemblies, check overall 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 immediately.
Never exceed 500 Ft. (150 m.) overall combined hose
length to assure electrical continuity.
KEEP CLEAR OF MOVING PARTS
NEVER use a damaged hose, which can result in hose
failure or rupture and cause in injection injury or other
serious bodily injury or bodily damage. Before each use,
check entire hose for cuts, leaks, abrasion or bulging of
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. High pressure hose is not
recoupleable.
Help prevent damage to the hose by handling and routing
it carefully. Do not move the sprayer by pulling it with the
hose.
LABELING
Keep all labels on the unit clean and readable.
Replacement labels are available from manufacturer.
TOXIC FLUID HAZARD
Hazardous uid or toxic fumes can cause serious injury or
death if splashed in eyes or on skin, inhaled or swallowed.
Know the hazards of the uid you are using. Store &
dispose of hazardous uids according to manufacturer,
local, state & national guidelines.
ALWAYS wear protective eyewear, gloves, clothing
and respirator as recommended by uid manufacturer.
Keep clear of moving parts when starting or operating
the sprayer. Do not put your ngers into any openings to
avoid amputation by moving parts or burns on hot parts.
Precaution is the best insurance against an accident.
When starting the engine, maintain a safe distance from
moving parts of the equipment.
Before adjusting or servicing any mechanical part of the
sprayer, follow the PRESSURE RELIEF PROCEDURE on
page 9, and remove the ignition cable from the spark plug
to prevent accidental starting of sprayer.
WARNINGS CONTINUED ON NEXT PAGE.........
3
5
WARNINGS - CONTINUED
AVOID COMPONENT RUPTURE
This sprayer operates at 3000 psi (205 bar). ALWAYS be
sure that all components and accessories have a maximum
working pressure of at least 3000 psi to avoid rupture
which can result in serious bodily injury including injection
and property damage.
NEVER leave a pressurized sprayer unattended to avoid
accidental operation of it which could result in serious
bodily injury.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
whenever you stop spraying and before adjusting,
removing 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 serious
bodily injury and property damage.
NEVER use weak or damaged or non-conductive paint
hose. Do not allow kinking or crushing of hoses or allow it
to vibrate against rough or sharp or hot surfaces. Before
each use, check hoses for damage and wear and ensure
all uid connections are secure.
REPLACE any damaged hose. NEVER use tape or any
device to mend the hose.
NEVER attempt to stop any leakage in the line or ttings
with your hand or any part of the body. Turn off the unit
and release pressure by following PRESSURE RELIEF
PROCEDURE.
ALWAYS use approved high pressure ttings and
replacement parts.
ALWAYS ensure re extinquishing equipment is readily
available and properly maintained.
IMPORTANT: United States Government safety standards
have been adopted under the Occupational Safety & Health
Act. These standards, particularly the General Standards,
Part 1910, & the Construction Standards, part 1926 should
be consulted.
WARNING
Do not use halogenated solvents in this system. The prime
valve, 2 gun manifold and most airless guns have aluminum
parts and may explode. Cleaning 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.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR THINNERS:
1. 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 sufcient enough to prevent the accumulation of vapors.
2. To eliminate electrostatic discharge, ground the spray unit, paint bucket and spraying object. Use only high
pressure airless hoses approved for 3000 psi which is conductive.
3. Remove spray tip before cleaning gun and hose. Make contact of gun with bucket and spray without the tip in a well
ventilated area, into the grounded steel bucket.
4. Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.
5. Do not smoke in spraying/cleaning area.
4
PREVENT STATIC SPARKED FIRE/ EXPLOSIONS
ALWAYS be sure all equipment and objects being sprayed
are properly grounded. ALWAYS ground sprayer, paint
bucket and object being sprayed. See "grounding" on page
3 for detailed grounding information.
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 the spray area. DO NOT plug in
or unplug any electrical cords in the spray area, which can
create sparks, when there is any chance of igniting vapors
still in the air. Follow the coating & solvent manufacturers
safety warnings and precautions.
Use only conductive uid hoses for airless applications. Be
sure gun is grounded through hose connections. Check
ground continuity in hose & equipment. Overall (end to
end) resistance of unpressurized hose must not exceed 29
megohms for any coupled length or combination of hose
length. Use only high pressure airless hoses with static
wire approved for 3000 psi.
FLUSHING
Reduce the risk of injection injury, static sparking or
splashing by following the specic cleaning procedure on
page 6 and 9.
ALWAYS follow the PRESSURE RELIEF PROCEDURE
on page 9.
ALWAYS remove the spray tip before ushing. Hold a
metal part of the gun rmly to the side of a metal pail and
use the lowest possible uid pressure during ushing.
NEVER use cleaning solvents with ash points below 140
degress F. Some of these are: acetone, benzene, ether,
gasoline, naphtha. Consult your supplier to be sure.
NEVER SMOKE IN THE SPRAYING/CLEANING AREA.
NEVER leave water in uid pump, to prevent freezing
during storage.
GAS ENGINE PRECAUTIONS
Place unit 25 feet away from spraying in ventilated area.
NEVER operate in buildings unless exhaust is piped outside.
NEVER allow hose to lay against engine mufers or hot parts.
NEVER rell fuel tank while engine is hot or is running.
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
uid 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 rst 50’ of hose should always be 3/8".
2. FILL THE PACKING NUT/WET CUP
Fill the Packing Nut/Wet Cup 1/3 full with Airlessco Throat
Seal Oil (TSO). FIG 1 BELOW.
FIG. 1
3. CHECK THE ENGINE OIL LEVEL
a. Unscrew the oil ll 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
WARNING: Fuel spilled on a hot surface can cause a re or
explosion and cause serious bodily injury and property damage. Always shut off the engine and let it cool before lling
the tank, and carefully follow steps a - c below being sure not
to spill any fuel.
a. Close the fuel shutoff valve.
b. Use only clean, fresh, well-known brands of unleaded
regular grade gasoline.
c. Remove the fuel cap and ll tank. Be sure the air vent
in the ll cap is not plugged so fuel can ow to the
carburetor, then replace the cap.
FLUSHING
1. NEW SPRAYER 5. STORAGE
Your unit was factory tested in an anti-freeze 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.
3. CHANGING FROM WATER-BASE TO
OIL-BASE PAINT
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.
Oil-base paint: Flush with mineral spirits.
Water-base paint: Flush with water, then mineral spirits and
leave the pump, hose and gun lled with mineral spirits.
For longer storage, use mixture of mineral spirits and motor
oil (half & half). Shut off the sprayer, follow PRESSURE
RELIEF PROCEDURE on page 9 to relieve pressure and
make sure prime valve is left open.
6. START UP AFTER 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 spirits with
the material to be sprayed.
5
7
HOW TO FLUSH
1. Be sure the gun safety latch is engaged and there
is no spray tip in the gun. Refer to Fig. 2. Refer to your
separate instruction manual provided with your gun on its
safety features and how to engage safety latch.
2. Pour enough clean, compatible solvent into a large,
empty metal pail to ll the pump and hoses.
3. Place the suction tube into the pail or place the pail
under the pump.
4. Turn pressure control knob to low. Refer to Fig. 4.
5. Open the prime valve to the open - "Priming Position".
This will allow an easy start. Refer to Fig. 3.
6. Turn the engine ON/OFF switch to ON.
7. Move the choke toward the closed position as per Fig.5.
8. Move the throttle lever slightly to the left as per Fig.5.
9. Turn the fuel valve ON as per Fig. 5. Pull the start rope.
Pull the engine over against compression stroke and
then let the rope rewind slowly into the starter. Pull
rmly and rapidly to start the engine. Do NOT drop the
rope. Hold on to 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 oods, open the choke all the way and continue
cranking.
10. After the engine is warm, gradually close the choke,
raise the RPM of engine slightly by moving throttle to the
left. Close the prime valve. Refer to Fig. 3
11. Point the gun into the metal pail and hold a metal part of
the gun rmly against the pail Refer to g.6.
12. Disengage the gun safety latch 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 safety latch.
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 rmly
against the metal pail (Fig. 6), forcing 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
safety latch.
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 5. Step 5.
17. Whenever you shut off the sprayer follow the
PRESSURE RELIEF PROCEDURE warning on page 9.
FIG. 2
REMOVE SPRAY TIP. ENGAGE
GUN SAFETY LATCH.
FIG. 4
PRESSURE CONTROL KNOB
FIG. 5
CHOKE LEVER
FUEL VALVE
FIG. 6
MAINTAIN FIRM
METAL TO METAL
CONTACT BETWEEN GUN AND
CONTAINER
FIG. 3
PRIME VALVE
CLOSED
(Pressure)
OPEN
(Priming &
Pressure Relief
HIGH
PRESSURE
THROTTLE LEVER
WARNING: To reduce the risk of static sparking, which
can cause re or explosion, always hold a metal part of
the gun rmly against the metal pail when ushing. This
also reduces splashing. Refer to Fig 6.
6
STARTING UP
1. LEARN THE CONTROLS
PRESSURE CONTROL KNOB - used to adjust
pressure only. Turn clockwise to increase pressure and
counterclockwise to decrease pressure. (See Fig. 4)
PRIME & PRESSURE RELIEF VALVE - Turn to OPEN
position (see Fig. 3) to prime the pump. Turn to the
CLOSED position to spray.
FOLLOW "PRESSURE RELIEF PROCEDURES" ON
PAGE 9 WHENEVER YOU:
- are instructed to relieve pressure
- stop spraying
- checking or servicing any of the system equipment.
- or installing or cleaning the spray tip.
HANDLE SPRAY SYSTEM AS YOU WOULD A LOADED
FIREARM!
CAUTION: Do not start engine without uid pump having
enough uid so that it can be primed. Running uid pump dry
will decrease life of the pumps packings.
2. PREPARE THE MATERIAL
a. Prepare the material according to the material
manufacturer's recommendations.
b. Place pump or suction tube into material container.
3. STARTING THE SPRAYER
SEE FIGURE 3 & 6 ON PREVIOUS PAGE
a. Prime Valve must be open - priming position.
b. Pressure Control Knob must be in low pressure.
c. Follow the procedure under "How to Flush", page 6,
steps 6 through 12.
WARNING
If you spray into the paint bucket, always use the lowest spray
pressure and maintain rm metal to metal contact between
gun and container. See page 6, Fig 6.
5. ADJUSTING THE 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.
NOTE: Operating the sprayer at higher pressure than
needed, wastes material, causes early tip wear, and
shortens sprayer life.
c. If more coverage is needed, use a larger tip rather than
increasing the pressure.
d. Check the spray pattern. The tip size and angle
determines the pattern width and ow rate.
6. REDUCING CLUTCH WEAR
a. The rst 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 laboring engines.
WARNING
To stop the unit in an emergency or before performing
any service or maintenance procedure follow the PRES-
SURE RELIEF PROCEDURE on page 9 to relieve the uid
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.
CONTINUED ON NEXT PAGE.........
7
9
STARTING UP CONTINUED
7. CLEANING A CLOGGED TIP
a. Follow PRESSURE RELIEF PROCEDURE on page 9.
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.
IMPORTANT WARNING
Always follow the PRESSURE RELIEF PROCEDURE
on page 9 before perfoming any service or maintenance
procedure.
WARNING
Never hold your body, ngers, 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
self-cleaning tip.
8. WHEN SHUTTING OFF SPRAYER
a. 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.
d. For long term shutdown or storage, refer to the
"Flushing" section of this manual.
WARNING
Be sure to relieve pressure in the pump after lling with Airlessco Pump Conditioner.
THERE IS AN EASY WAY TO KEEP THE OUTSIDE OF THE
TIP CLEAN FROM MATERIAL BUILD-UP:
Every time you stop spraying, for even a minute, lock the gun
and submerge the gun into a small bucket of thinner comparable with the material sprayed. Thinner will dissolve the build
up of paint on the outside of tip, tip guard and gun much more
effectively than if the paint dries out completely.
WARNING
Clogged standard at tip - clean only after the tip is removed from the gun. Follow the PRESSUR E R ELIEF
PROCEDURE Warning on Page 9.
8
PRESSURE RELIEF PROCEDURE
!
TO AVOID POSSIBLE SERIOUS BODY INJURY, ALWAYS FOLLOW THIS PROCEDURE WHENEVER THE
SPRAYER IS SHUT OFF, WHEN CHECKING IT, WHEN INSTALLING, CHANGING OR CLEANING TIPS,
WHENEVER YOU STOP SPRAYING, OR WHEN YOU ARE INSTRUCTED TO RELIEVE THE PRESSURE.
1. Engage the gun safety latch. Refer to the separate
instruction manual provided with your gun on its safety
features and how to engage safety latch.
2. Turn the unit off.
3. Disengage the gun safety latch and trigger the gun to
relieve residual uid pressure.
HOLD METAL PART OF THE GUN IN CONTACT WITH
GROUNDED METAL PAIL. USE MINIMUM PRESSURE !
IMPORTANT!
4. Turn Prime/Pressure Relief Valve (PR Valve) to the open
(priming) position to relieve residual uid pressure.
5. Re-engage gun safety latch and close Prime/Pressure
Relief Valve.
If the SPRAY TIP OR HOSE IS CLOGGED, follow Step
1 through 5 above. Expect paint splashing into the bucket
while relieving pressure during Step 4.
If you suspect that pressure hasn't
been relieved due to damaged
Prime/Pressure Relief Valve or other
reason, engage the gun safety latch
and take your unit to an authorized
Airlessco Service Center.
C
N
E
P
O
L
O
S
E
DAILY MAINTENANCE
1. 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:
IF SEEPAGE OF PAINT INTO THE PACKING NUT AND/OR MOVEMENT OF THE PISTON UPWARD IS FOUND
(WHILE NOT SPRAYING), THE PACKING NUT SHOULD BE TIGHTENED ENOUGH TO STOP LEAKAGE ONLY,
BUT NOT ANY TIGHTER. OVERTIGHTENING WILL DAMAGE THE PACKINGS AND REDUCE THE PACKING LIFE.
9
11
LINE STRIPING OPERATION
1. CHOOSE THE GUN ARM POSITION 4. ALIGN SWIVEL WHEEL ASSEMBLY
There are 4 holes in the frame on the 4550 & 6050. In a
standard set up, the gun arm would be mounted in the right
hand near the single wheel. This allows for an easier visual
check for straight line striping and for basic arc striping.
2. SETTING UP THE GUNS
a. Ensure that striping tips are in the guns.
b. Pick a tip size for the desired line width.
EXAMPLE: a 317ST tip for a four inch line.
c. Place gun into the gun holder, so that the top of the
taper on the gun handle is ush with the edge of the
gun holder.
d. Set gun height for the desired line width. Adjust height
by loosening the small black handle on the gun holder
assembly and slide the gun arm to the correct height.
Now tighten the handle. This will require some
experimentation to nd the correct height. It is suggested
that tape, or some other method is used to mark the
height of commonly used settings.
e. Set spacing between the two guns by loosening the
black handle on the gun arm. Slide to the desired width
and tighten.
f. Attach the swivel heads to the guns if painting curbs
or wide stripes.
g. Angle the guns slightly forward. This allows the spray
pressure from the guns to help blow dirt and debris out of
the path of the new stripes.
STRAIGHT LINES
a. SS6050: Loosen the two ratchet handles on the swivel
wheel assembly, just enough to be able to move the
assembly by hand. Lift the ratchet handle to move the
handle without turning the attached bolts, then press
down and turn handle counterclockwise to loosen.
SS4550: Stripers are factory aligned, but if necessary,
loosen the two bolts (g. 35, item 19) on the swivel
wheel assembly, just enough to be able to move the
wheel by hand. Align wheel and re-tighten bolts.
b. Place the turnbuckle over the two mounting nubs on the
frame.
c. Pressurize the unit with water and Airlessco's Pump
Conditioner and spray out several lines with the swivel
assembly in the locked position. Use the turnbuckle to
ne tune the alignment of the wheels, until the stripes
are straight.
IMPORTANT: Loosen ratchet handles prior to
any turnbuckle adjustment.
!
d. Tighten the jam nuts on the turnbuckle to afx the
turnbuckle length for future reference.
e. Tighten the ratchet handles (6050) or bolts (4550.)
CURVES AND ARCS
3. CABLE TENSION ADJUSTMENT
Once the handle and gun arm assemblies are set up to the
preferred positions, pressurize the unit and trigger each
gun to ensure that they activate and release correctly. If
not, adjust the cable tension as follows:
a. Locate the adjustment knobs on the base of the gun
trigger, where the cable connects to the gun trigger
assembly.
b. Loose the locking nut and move the adjusting screw until
the slack has been removed from the cable.
c. Tighten locking nut and retest gun triggers for proper
function.
NOTE: THERE IS AN ADDITIONAL CABLE
ADJUSTMENT WHERE THE CABLE ATTACHES TO
THE GUN HOLDER ASSEMBLY. USE ONLY IF THE
GUN TRIGGER ADJUSTMENT IS INSUFFICIENT.
Basically the same as above, except the swivel wheel
assembly is set at angle. The swivel assembly can be
adjusted to 30 degrees either side of straight ahead. If
you have arcs that you paint regularly, purchase additional
turnbuckles (PN. 136-231) and keep them set to those arc
sizes.
5. MISCELLANEOUS OPERATIONS
a. CURBS: Adjust gun to desired height and turn swivel
head towards curb.
b. WIDE STRIPES: Install wider fan striping tips and raise
the gun height to achieve the desired width line. Also
angle guns slightly towards each other to get an even
coat of paint.
c. STENCILS: Install standard spray tip on the outer gun.
Remove this gun from the gun holder and spray out the
stencils.
d. STANDARD PAINTING: Same as stencils, but use
additional paint hose as required.
10
AIRLESS SPRAY GUN OPERATION
SPRAY
Attach spray gun to airless unit and tighten ttings securely.
Set the gun safety latch. (Also may be called gun safety
FIG. 7
GUN SAFETY LATCH
IN LOCKED POSITION
lock, or trigger lock)
* The gun safety latch should always be set when the gun
is not being triggered.
Read all warnings and safety precautions supplied with the
spray gun and in product manual.
MAJOR COMPONENTS OF SPRAY GUN AND REVERSIBLE SPRAY TIP
FIG. 8 FIG. 9
REVERSIBLE
SPRAY TIP
TIP GUARD
TRIGGER GUARD
GUN SAFETY
LATCH OR LOCK
HANDLE
(FILTER INSIDE)
O-RING GASKET
METAL SEAT
SPRAY TIP ASSEMBLY CLEANING FILTER IN GUN HANDLE
1. Be sure pressure relief procedure is followed before
assembling tip and housing to the gun.
2. Lock gun safety latch.
3. Insert REV-TIP™ cylinder into the REV-GUARD™
(guard housing assembly).
4. Guide metal seat into REV-GUARD™ (guard housing
assembly) through retaining nut & turn until it seats
against the cylinder.
5. Insert O-Ring gasket on metal seat so it ts in the
grooves.
6. Finger tighten REV-GUARD™ retaining nut onto the gun.
7. Turn guard in the desired position.
8. Completely tighten the retaining nut.
FIG. 10
To clean the lter, use a brush dipped in an appropriate
solvent. Change or clean lters at least once a day. Some
types of latex may require a lter change after four hours of
operation.
TO REMOVE CLOGS FROM SPRAY TIP
1. Lock gun safety latch.
2. Turn REV-TIP™ handle 180 degrees.
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
spray position.
RETAINING NUT
GUN SAFETY
LATCH
RELEASED
REV-TIP™
REV-GUARD™
RETAINING NUT
REV-GUARD™
GUARD HOUSING ASSEMBLY
G Thread 7/8" 561-002
F Thread 11/16" 561-001
REV-TIP™ CYLINDER
Part # 561-XXX
O-RING GASKET
Part # 561-026
METAL SEAT
Part # 561-029
CLEANING SPRAY GUN
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.
REVERSE TO
UNPLUG
Spray Position Shown
CLOGGED FLAT TIP
Should the spray tip become clogged, relieve pressure
from hose by following the "PRESSURE RELIEF
PROCEDURE." Secure gun with the safety latch, take
off guard, take out the tip, soak in appropriate solvent &
clean with a brush. (Do not use a needle or sharp pointed
instrument to clean the tip. The tungsten carbide is brittle
and can chip.)
11
AIRLESS SPRAY GUN
FIG. 11
1*
2*
3*
76
5
4
19
8
9
11
12
10*
13
14
15
16
PARTS LIST FIGURE 11
Item No. Part No. Description
1 120-530* Gun Seat Assembly
2 120-535* Gasket-Seat
3 120-520* Needle Assembly
4 120-529 Gun Seat Adapter
5 120-562 Trigger Guard
6 120-539 Pivot Trigger Pin
7 120-509 Gun Head
8 120-540 Actuator Pin (2)
9 120-536 Gun Plate
10 120-038* Nut
11 120-056 Plastic Washer
12 120-538 Gun Trigger Lock
13 120-055 Wave Washer
14 120-049 Retaining Ring
15 120-082 Handle Seal
16 120-090CX Gun Filter-Coarse
120-090FX Gun Filter-Fine
17 120-088 Spring
18 120-099 Gun Handle Assembly
19 120-506 Gun Trigger
* 120-534 Gun Repair Kit
17
18
12 13
AIRLESS SPRAY TROUBLESHOOTING
DEFECTS CAUSE CORRECTION
Coarse spray Low pressure Increase the pressure
Excessive fogging
(overspray)
Patten too wide Spray angle too large Use smaller spray angle tip
Pattern too narrow Spray angle too small use larger spray angle tip ( if coverage is OK, try tip in same
Too much material Nozzle too large
Too little material Nozzle too small use next larger nozzle
Thin distribution in center
of pattern “horns”
Thick skin on work Material too viscous
Coating fails to close &
smooth over
High pressure
Material too thin
Material too thin
Pressure too high
Worn tip
Wrong tip
Application too heavy
Material too viscous thin cautiously
Reduce the pressure to satisfactory pattern distrabution
Use less thinner
nozzle group)
use smaller nozzle
reduce pressure
material too thick
change to new tip
use nozzle with narrow spray angle
thin cautiously
reduce pressure and/or use tip in next smaller nozzle group
Spray pattern irregular,
deected
Craters or pock marks,
bubbles on work
Clogged screens Extraneous material in paint
Orice clogged
Tip damaged
Solvent balance use 1 to 3% “short solvents remainder “long” solvents
Course pigments
Poorly milled pigments
(paint pigments glocculate)
TEST THE PATTERN
SPOTTY PATTERN, INCREASE PRESSUREGOOD, FULL
clean carefully
replace with new tip
(this is most likely to happen with material of low viscosity,
lacquers, etc.)
Clean screen
Use coarse screen if orice size allows.
Use courser screen, larger orice tips. Obtain ball milled
paint. If thinner has been added, test to see if a cover
screen. Incompatible drop placed on top of paint mixes or
attens out on the paint mixture & thinners on the surface. If
not, try different thinner in fresh batch of paint.
13
15
LINE STRIPING TIP CHART
NOTE: STRIPING TIPS SHOULD NOT BE USED FOR REGULAR SPRAYING.
REV-TIP™ for Striping, Part Number 562-xxxST
TIP IDENTIFICATION
• 1st 3-digits identies it as a REV-TIP™ for airless line striping (Part Number 562-xxxST).
• 4th digit is the fan width - the number is half the fan width, e.g., 2means a 4" line width.
• 5th and 6th digits are for the orice size and is measured in thousandths of an inch, e.g., 17 = 0.017 inch.
The higher the number, the larger the tip.
REVERSIBLE STRIPING TIP SIZE CHART
REV-TIPTM FOR STRIPING 562-XXXST
FAN WIDTH (6” FROM SURFACE) ORIFICE SIZE (INCHES)
INCHES MILLIMETERS .013 .015 .017 .019 .021
1-2 25-51 113ST 115ST 117ST
2-4 51-102 215ST 217ST 219ST 221ST
4-6 102-152 315ST 317ST 319ST 321ST
6-8 152-203 415ST 417ST 419ST 421ST
Striping paint Oil Base Oil Base Latex Latex Latex
REV-TIP™ protected By U.S. Patent No. 6,264,115. Other U.S. & foreign patents applied for.
TIP REPLACEMENT
During use, high pressure will cause the orice to grow larger. This destroys the pattern or will leave tailing or two heavy
lines on the outside of the pattern. REPLACE SPRAY TIP FREQUENTLY!
OIL AND LUBRICATION INSTRUCTIONS
BLEED (WEEP HOLE)
FIG. 12
SEALED BEARING
1 OZ. SAE 30 W OIL SEMI-ANNUALLY
OIL IMPREGNATED SLEEVEDIP IN HOT 10 W OIL WHEN REMOVED
FILL PLUG- UNIT HAS GREASE IN
GEARBOX FROM FACTORY AND WILL
NOT REQUIRE CHANGING.
(GREASE - PN: 301-178)
14
REGULAR MAINTENANCE
1. Always stop the pump at the bottom of its stroke when you take a break or at the end of the day. This helps keep
material from drying on the rod, damaging
the packings.
2. Keep the displacement pump packing nut/wet cup 1/3 full of Airlessco Throat Seal Oil at all times. The TSO helps
protect the packings and rod.
3. Lubricate Connecting Rod Pin every 3 months.
4. Inspect the packing nut daily. Your paint pump has Airlessco's patented "Triple Life Packing System". Packing life will
be extended a minimum of 3 times if the proper packing tightening procedure is followed!
PACKING TIGHTENING PROCEDURE:
Inspect the packing nut daily!If seepage of paint into the packing nut and/ or movement of the piston upward is
found (while not spraying), the packing nut should be tightened enough to stop leakage only, but not any tighter.
OVERTIGHTENING WILL DAMAGE THE PACKINGS and reduce the packing life to the life of other piston pumps.
FIELD TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
There is spitting from
the gun.
Paint leaks into the
wet cup
The engine operates, but
the paint pump doesn't
cycle.
The engine and displacement pump operates, but
paint pressure is too low
or none
The displacement pump
operates, but the
output is too low on
the downstroke or both
strokes.
The displacement pump
operates, but the output
is too low on the
upstroke.
The uid supply is low or empty.
Air entrapped in the uid pump or
hose.
The packing nut/wet cup is loose.
The upper packings are worn
or damaged.
Worn Piston Rod.
The pressure setting is too low.
The clutch is not engaged.
The displacement pump is seized.
The pressure setting is too low.
The tip or gun lter is clogged.
The tip is worn.
The uid displacement pump lter is
clogged.
There is a large pressure drop
in the uid hose.
The inlet valve ball is not seating
properly.
The outlet valve ball is not seating
properly.
The lower packings are worn or
damaged.
Rell the supply container.
Check for loose connections on the
siphon assembly, tighten, then reprime pump.
Tighten just enough to stop leakage.
Replace the packings. See pages 18-19.
Replace Piston Rod
Increase the pressure. See page 6.
See Troubleshooting pg. 23.
Service the pump. See page 18-19.
Increase the pressure, see page 6.
Remove the tip and/or lter and clean them.
Replace Tip.
Clean the lter.
Use a larger diameter hose.
Service the inlet valve see page 17.
Service the outlet valve per
page 17.
Replace the packings. See page 18-19.
Clutch does not engage.
Clutch slippage.
Engine stops
See Troubleshooting page 23.
Call Authorized Service Center.
Refer to Engine Manual.
17
SERVICING THE FLUID PUMP
NOTE: CHECK EVERYTHING IN THE TROUBLESHOOTING CHART BEFORE DISASSEMBLING THE SPRAYER.
FLUID PUMP DISCONNECT
1. Flush out the material you are
spraying, if possible.
2. Follow the Pressure Relief
Procedure on page 8. Stop the
pump in the middle of down
stroke.
3. Remove the suction tube and uid
hose (if so equipped) from the
uid pump.
4. Remove the connecting rod shield
from the pump.
5. Remove 2 retaining rings and slip
the sleeve of the coupling down
and remove both coupling halves.
This will disconnect uid pump
from the connecting rod.
6. Using a 7/8” box wrench,
disconnect the high pressure uid
line from the pump.
7. Using a 9/16” wrench, unscrew
the two tie rod locknuts.
8. Pull the pump off the tie rods.
FIG. 13
1
FLUID PUMP REINSTALL
1. Loosen the packing nut & extend piston rod to fully up position.
Slip sleeve over the piston rod. See gure 15.
2. Insert one of the retaining rings through the packing nut and
rest the sleeve on top of it. See gure 16 & 17.
3. Connect the connecting rod with the uid pump by installing
the coupling halves. Slide sleeve over the coupling halves and
secure with retaining ring. See gure 18.
4. Remove the retaining ring from the packing nut and insert into
coupling halves. See gure 19
5. Secure the uid pump housing to the tie rods and screw
locknuts with washers on loosely.
6. Tighten the tie rod locknuts evenly to 30 ft. lb.
NOTE: AFTER ALL THE ROD LOCKNUTS ARE TIGHT, THE
ALIGNMENT OF BOTH RODS SHOULD ALLOW EASY ASSEMBLY
AND DISASSEMBLY OF THE COUPLING. IF ANY BINDING, LOOSEN
AND RETIGHTEN ALL THE ROD LOCKNUTS TO IMPROVE THE
ALIGNMENT. MISALIGNMENT CAUSES PREMATURE WEAR OF
SEAL AND PACKINGS.
7. Tighten packing nut clockwise until resistance against the
packings can be felt. Turn it one full turn more.
8. Start the pump and operate it slowly (at low engine speed)
to check the piston rod for binding. Adjust tie rod lock nuts if
necessary to eliminate binding.
9. Prime the unit and run at maximum pressure for several
minutes, then release the pressure & repeat step 7.
10. Fill the wet cup (packing nut) with ve drops of TSO (Throat
Seal Oil).
FIG. 14
FIG. 15
FIG. 16
2
PARTS LIST FIGURE 13
Item No. Part No. Description
3
4
5
6
4
7
8
9
13
12
11
10
1
2 301-320 Cover
3 301-046 Rod End
4 189-048 Retaining Ring
5 189-046 Coupling Set
6 198-047 Retaining Sleeve
7 301-467 Front Shield
8 187-410 SL Paint Pump Assy
9 187-002 Suction Nut
10 140-051 Nut (2)
11 140-035 Lock Washer (2)
12 301-059 Spacer (2)
13 100-328 Stud (2)
301-203-99
301-204-99
Gearbox 3/4” (810/910E)
Gearbox 1” (1100/1110E)
FIG. 17
FIG. 18
16
SERVICING INLET & OUTLET VALVES
DISASSEMBLY OF THE OUTLET VALVE
1. Using the rod collar tool (189-211) , screw the suction
nut, containing intake seat support, off of the uid body.
See Fig. 19.
2. Remove the inlet seat, O-ring, inlet
ball and inlet retainer with O-ring. See Fig. 19.
3. Clean all parts and inspect them for wear or damage,
replacing parts as needed. Old O-rings should be
replaced with new ones.
NOTE: INLET SEAT (187-065) IS REVERSIBLE.
4. Clean inside of uid body.
5. Reassemble the valve and screw it onto the uid body if
no further service is needed.
SERVICING THE OUTLET VALVE
1. Complete all steps of the Fluid Pump Disconnect
procedure on page 16.
2. Screw the suction nut off the pump and remove inlet
valve assembly.
3. Using the rod collar tool, loosen the packing nut and
push the piston down and out of the uid body.
4. Place piston holder (187-248) in a vise. Slide piston
into holder and lock in place with a 1/4" pin (187-250).
5. Clean all parts and inspect them carefully for wear or
damage. Inspect the outside of the piston rod for scoring
or wear. Replace these parts if needed. A worn piston
rod will cause premature wear of packings.
6. Using 3/8" allen wrench to unscrew retainer from piston.
7. Remove outlet seat, O-ring, outlet ball and outlet retainer.
8. Inspect outlet ball and seat for wear. Replace as
required.
NOTE: OUTLET SEAT (187-061) IS REVERSIBLE.
9. Install parts back into piston rod as per Fig. 20. Place
two drops of loctite No. 242 (blue) on threads of the
retainer before assembling and torque to 20 ft-lbs.
FIG. 19
FIG. 20
1
2
3
4
5
6
7
8
9
10
11
12
PARTS LIST FIGURE 19 & 20
Item No. Part No. Description
1 106-014 Black O-Ring
2 187-016 Inlet Retainer
3 187-020 Inlet Ball
4 187-065 Inlet Seat
5 106-017 White O-Ring
6 187-001 Suction Fitting
7 187-002 Suction Nut
8 187-051 Retainer
9 187-061 Outlet Seat
10 106-021 White O-Ring
11 115-022 Outlet Ball
12 187-062 Outlet Retainer
13 187-330-99 Piston
13
187-248
187-250
19
PACKING REPLACEMENT PROCEDURES
DISASSEMBLY OF THE FLUID PUMP
1. Unscrew & remove the packing nut.
2. Push the piston rod down through the packings & out of
the pump.
3. Now push the packing removal tool up through the pump
& remove from the top bringing the packings, spacer &
springs along with it, leaving the uid body empty.
*NOTE: MAKE SURE ALL PACKINGS & GLANDS HAVE
BEEN REMOVED FROM THE FLUID PUMP.
4. Clean inside of uid body.
5. Disassemble all parts & clean for reassembly. Discard
any old packings. Save the metal upper glands. Replace
metal lower glands with new metal glands from the
packing kit.
* NOTE: IF THE OLD PACKING HAD A METAL GLAND
FOR (187-058), DISCARD & REPLACE WITH A NEW
PLASTIC ONE FROM PACKING KIT.
6. Lubricate leather packing in lightweight oil for 10 minutes
prior to reassembly.
REASSEMBLY
1. Take the lower metal male gland and place it down on
the at side.
2. Take three of the lower polyethylene V-packings and two
of the leather V-packings and place onto your male gland
in the following order with the inverted side down:
polyethylene, leather, polyethylene, leather, polyethylene.
3. Take the female adaptor, which is inverted on both
sides, and place it on top of your assembled
lower packings.
4. Follow step 2 above but with packings inverted
side up.
5. Take the second lower male gland and place it on top
of your assembled packings with the rounded
side down.
6. Take your assembled glands & packings (13 pieces all
ogether) and slide on to the lower half of the piston.
7. Take the spacer and slide over the top of the piston (it
doesn’t matter which direction it sits), falling onto the
lower packings.
8. Take the three Belleville Springs and 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. Take the upper male gland and place it with the rounded
side up.
10. Take the three upper polyethylene V-packings and two
leather packings and assemble with the inverted side
down, on to the male gland in the following
order: polyethylene, leather, polyethylene, leather,
polyethylene.
11. Take the upper female gland & place on top of your
assembled upper packings with the inverted side
down.
12. Take your assembled upper glands and packings
(7 pieces) and slide on over the top of the piston, making
sure the inverted sides are facing down.
13. Take the V-packing holder and replace the white O-ring
and the black O-ring with new ones from the packing kit.
14. Slide the V-packing holder over the top of the upper
packings so they t inside.
15. Lubricate the inside of the uid pump body and the outside of the packings with a light weight oil.
16. Slide the completed assembly into the uid pump body.
*NOTE: TO KEEP PACKINGS SECURED IN THE
CORRECT POSITION, HOLDTHE PUMP BODY UPSIDE
DOWN AND PUSH THE COMPLETED ASSEMBLY
UPWARDS INTO THE PUMP BODY. ONCE PLACED
INSIDE, TILT THE PUMP BODY BACK UP TO KEEP
ALL PIECES.
17. Thread the packing nut into the top of the uid
body and tighten hand tight.
18. Take the suction retainer and replace the black
O-ring with a new one from the packing kit. Replace the
suction ball with the new one from the kit into the suction
retainer. Place the suction seat into the at side of the
ball guide, over the suction ball. Now place the white
O-ring into the groove around the suction seat.
19. Take the completed suction valve assembly and place
it into the bottom of the uid body, with the rounded side
tting inside.
20. Take the suction seat support and place the at side
down on to the suction valve assembly (threads will be
facing upwards).
21. Thread the suction nut, over the suction seat support.
22. Tighten the packing nut (utilizing the packing nut
adjustment tool) clockwise one full turn.
18
PACKING REPLACEMENT PROCEDURES
FIG. 21
1
21
18
4
16
17
22
20
19
15
14
FIG. 22
22
21
20
19
15
16
14
17
16
18
15
14
23
24
25
13
12
1
2
3
4
5
6
7
8
9
10
11
16
15
PARTS LIST FIGURE 21 & 22
Item No. Part No. Description
1 187-330-99 Piston Rod
2 187-046 Packing Nut
3 187-313 Fluid Body
4 187-315 Spacer
5 106-021 O-Ring
6 187-062 Ball Guide
7 115-022 Outlet Ball
8 187-061 Outlet Seat
9 187-051 Outlet Seat Support
10 187-016 Suction Retainer
11 187-020 Suction Ball
12 187-065 Suction Seat
13 106-014 O-Ring
PARTS LIST FIGURE 21 & 22 CONT
Item No. Part No. Description
14 187-059 Packing Leather
15 187-037 Male Gland
16 187-029 Packing Polyethylene
17 187-058 Female Adaptor
18 187-031 Belleville Springs
19 187-025 Male Gland
20 187-060 Packing Leather
21 187-030 Packing Polyethylene
22 187-026 Female Gland
23 187-047 Packing Holder
24 106-012 White O-Ring
25 106-013 Black O-Ring
19
PAINT SYSTEM
FIG. 23
9
8
11
12
10
7
6
5
4
3 2
1
17
18
19
20
21
1
13
5
9
14
15
16
PARTS LIST FIGURE 23
Item No. Part No. Description
1 120-554 008 Gun
2 100-177 Swivel Elbow 1/4”
3 100-011 Hose 50’ x 1/4”
4 100-023 Hose 50’ 3/8”
5 169-010 Nipple 3/8” M
6 111-200-99 Manifold Filter Assy
7 301-309 Hose 3/8”
8 167-016 Elbow 3/8” M
9 301-253 Manifold
10 100-317 Nut 1/4” M (2)
11 100-345 Bolt 1/4” (2)
20 21
Item No. Part No. Description
PARTS LIST FIGURE 23 CONT
12 169-013 Elbow 3/8” M x 3/8” F
13 100-123 Hose 3/8”
14 100-036 Tee 3/8”
15 119-083 Prime Valve
16 119-086 Bypass Hose Assy
17 100-141 Elbow 1/4”
18 100-119 Ball Valve
19 115-019 Connector 1/4”
20 100-199 Hose 3/8” x 6’
21 100-204 Hose 1/4” x 5’
PRIME VALVE (119-083)
FIG. 24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Item No. Part No. Description
1 115-303 Handle with Label
2 117-046 Screw
3 115-063 Washer
4 115-072 Spacer
5 115-064 Belleville Spring (3)
6 115-065 Retaining Ring
7 115-067 Washer
8 115-071 Valve Stem
9 115-068 O-Ring Black
10 115-069 Ball
11 115-029 Valve Seat
12 115-012 Washer
13 115-073 Valve Body
14 115-074 Inlet Fitting
PARTS LIST FIGURE 24
MANIFOLD FILTER (111-200-99)
FIG. 25
9
8
1
2
3
4
5
6
7
10
PARTS LIST FIGURE 25
Item No. Part No. Description
1 111-202 Base
2 301-356 Spring
3 106-007 O-Ring
4 111-204 Filter 60 Mesh
5 111-203 Support
6 111-201 Base
7 100-159 Swivel
8 100-129 Plug 3/8” (2)
9 100-109 Nipple 3/8”M x 1/4”M
10 100-028 Plug 1/4”
21
23
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, loosen set screw in Pressure Control
Knob and remove knob.
5. Using a 1/2" nutdriver 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 as per procedure below, "Pressure
Calibration on the Electrical Control Board".
PRESSURE CALIBRATION OF THE ELECTRICAL CONTROL 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 outlet of
pump between uid pump & airless hose to monitor Fluid
Pump Pressure.
3. Start engine and run at maximum RPM. Turn Prime
Valve to the open (Prime) position. Turn Pressure
Control Knob to maximum position (fully clockwise).
SENSOR
FIG. 26
PRESSURE
CALIBRATION
4
BLACK
3
TRIMPOT
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 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
350-400 psi, 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.
BLACK
GREEN
TO ENGINE
PARTS LIST FIGURE 26
Item No. Part No. Description
1 106-019 O-Ring
2 301-523A Knob
3 117-045 Grommet
4 301-282-99 Control Board
22
BLUE
BLUE
1
2
BLACK
BLACK
TO CLUTCH
(301-264)
ELECTRICAL TROUBLESHOOTING - Clutch Does Not Engage
STEP 1: Ensure that the pressure control knob (POT) is in the maximum (CW) position.
STEP 2: Remove the upper and lower clutch and electrical covers.
STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose
connections or damaged leads. See Fig.26.
STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black). Using a multimeter,
with the engine at maximum RPM, pressure control knob in the maximum position and the prime valve open (priming)
position, test the DC voltage across the boards leads (blue). This voltage must be 13-14 VDC. If the readings are correct,
the board, sensor and magneto are okay and the problem is the clutch assembly. If this is the case, proceed to Step 5. If
the voltage is outside this range go to Step 7.
STEP 5: Measure resistance between the clutch leads (black). This value must be 10-16 ohms. If this reading is out of
specications the clutch is defective and must be replaced, otherwise continue troubleshooting.
STEP 6: If the clutch resistance readings of Step 5 are correct, check spacing between the clutch eld and plate. The gap
should be .012” to .024”. If the gap is greater than .024 the gap is too wide. If this gap is too wide, remove the spacer (Fig.
28, Item 7) from the clutch assembly. Should the clutch still not engage, replace the clutch assembly. See below.
STEP 7: When the DC voltage from the board is not 13-14 VDC, disconnect the control board lead (black) from the
engine magneto lead (pink), located on the side of the engine. With the engine at maximum RPM, pressure control knob
in maximum (CW) position and prime valve open (priming), read the AC voltage from the magneto lead to the sprayer
frame. This reading should be 19-24 VAC. If outside this range, contact your local Honda repair facility for magneto
replacement. If the magneto is producing the proper AC voltage, continue to Step 8.
STEP 8: Test the sensor by reading the resistance between the red and black wires. The resistance runs between 1.5-3
kohms. A defective sensor usually shows no resistance (open). If the reading is outside standards, replace the sensor.
An alternative method to test the sensor, is to plug a new sensor into the board and see if the clutch will engage. Caution!
When using this method, ensure prime/pressure valve is in the prime position. This is important because the sensor
plugged into the board is not measuring pressure in the uid section.
STEP 9: When Steps 7 & 8 have been completed and the magneto and sensor check good, the electrical control board
is the only item left, replace the board. See page 22.
CLUTCH REPLACEMENT
REMOVING THE CLUTCH
REFER TO FIGURES 26-30
1. Remove the gear box cover (Fig 30, item 1) by
disconnecting uid hose to the manifold lter and by
unscrewing the four allen head bolts (Fig 30, item 36).
2. Disconnect the uid pump as described on page 16.
3. Pull off the spacer tubes (Fig 30, item 30) and drop the
sleeve bearing down and off. Slide the connecting rod off
the gear box.
4. Remove the top cover (Fig 30, item 2) by unscrewing the
6 mounting screws. be careful not to lose the 6 matching
grommets.
5. Remove the bottom cover (Fig 30, item 14) by
unscrewing the 2 bolts and nuts.
6. Remove the splash cover (Fig 30, item 12) from the
clutch brackets and spacer tubes.
7. Disconnect the two clutch leads from the electrical
control board leads and the clutch spring (Fig 28, item 9)
from the spacer tube.
8. Loosen (do not remove completely) the block tensioner's
set screws (Fig 27, item 6) to detension the belt.
9. Loosen (do not remove yet) the four plate bolts.
10.Pull the cog belt loose from the engine shaft cog pulley
and let hang loose on the clutch cog pulley.
11.Remove the two vertical bracket screws
(Fig 30, item 20).
12.Remove the four horizontal screws throught the
gearbox plate (Fig 27, item 5) and lift the gear box off the
machine.
13. Place gearbox in vice by gripping the at part of the
drive crank allowing the clutch assembly to face up. Use
caution and not allow gearbox to swing and damage
casting against vice.
14. Hold coupling screw, with 13/16" wrench, then with
5/16" allen wrench, screw differential screw out of
coupling screw and gearbox shaft.
15.Remove the coupling screw from the clutch bore.
NOTE: AFTER EXTENDED USE THE COUPLING SCREW
CAN HANG UP INSIDE OF THE CLUTCH BORE. TAPPING
ON THE SIDE OF THE COUPLING SCREW AND/OR
THE USE OF A LIGHTWEIGHT OIL OR BREAK FREE
PRODUCT CAN EASE THE REMOVAL PROCESS. IN
EXTREME CASES, SCREW THE DIFFERENTIAL SCREW
LARGE THREAD SIZE IN, THEN PLACE A WASHER AND
NUT ON THE SMALL THREAD SIDE. THIS ALLOWS THE
PULLING OR PRYING ON THE COUPLING SCREW IN
ORDER TO REMOVE IT.
11.The clutch and other components can now be slide off
the gear box shaft.
23
CLUTCH REPLACEMENT
INSPECTING THE CLUTCH
1. Inspect clutch and belt, replace as neccessary.
INSTALLING THE CLUTCH
REFER TO FIGURES 27-30
1. With gearbox held in a vice vertically as previously
described, place rst spacer, and bearing, onto gearbox
shaft. See Fig. 28
2. Insert snap rings (2), into recesses of cog pulley portion
of clutch. Place cog pulley portion of clutch with cog belt
attached onto shaft.
3. Place second spacer, into cog pulley portion of clutch.
This spacer will rest on the rst bearing, installed.
4. Insert second bearing, on top of upper snap ring,
5. Lay removable spacer on top of last bearing. If the
clutch air gap is larger than .024", do not use removable
spacer. Put spacer over removable spacer, if used, and
top bearing.
6. Place coil portion of clutch down onto cog pulley portion
of clutch and center on gearbox shaft.
7. Screw differential screw, into coupling screw and nut
until 1/16" is showing. See Fig. 28
8. Push coupling nut assembly, into clutch assembly until it
comes to a positive stop. (Differential screw comes into
contact with the threaded gearbox shaft.)
9. With 13/16" wrench on coupling screw and 5/16" allen
wrench in differential screw, simultaneously with both
wrenches screw coupling nut assembly into gearbox
shaft by turning clockwise until a positive stop is
reached.
10. Hold coupling nut ass'y and tighten diffential screw
to 30 ft.-lbs. This will expand the coupling assembly,
thereby holding the clutch assembly to gearbox shaft.
Turn clutch observing clutch gap. The pulley should
turn freely with a gap of .012 to .024" between the two
clutch faces. If the gap is greater than .024, remove
the removable spacer. Reassemble and check gap for
proper clearance.
11.Place cog belt over cog pulley portion of clutch. Set
gearbox and clutch assembly on the support brackets
(Fig 30, items 25 & 26), screw in the two vertical bracket
screws (Fig 30, item 20) and start the four horizontal
screws throught the gearbox plate (Fig 27, item 5) and
into the back of the gearbox.
12. Slide cog belt over engine pulley
BELT TENSIONING
13. Slightly loosen the two horizontal screws (Fig 31, items
19-22) that connect the top and bottom supports (Fig 31,
items 24 & 25).
14. Evenly tighten set screws (Fig 27, item 6) until ush with
tip of block tensioner (Fig 27, item 7) . Check tension on
cog belt by pressing hard with thumb. Proper tensioning
should allow for approximately 1/8". If belt is too loose,
tighten set screws further.
15. Once belt tension is correct tighten down the four
horizontal screws that go through the gearbox plate (Fig
30, item 8) and into the back of the gearbox. Also tighten
the two horizontal screws (Fig 31, items 19-20) that
connect the top and bottom supports (Fig 31, items 24 &
25). Reconrm that the belt deection is still 1/8".
15. Reassembly connections, covers and uid pump in
reverse order as described in steps 1-7 of the "Removing
Clutch" instructions.
FIG. 27
5
4
3
2
1
6
7
8
9
10
PARTS LIST FIGURE 27
Item No. Part No. Description
1 301-231 Cog Belt
2 301-284 Clutch Replacement
3 305-088 Screw
4 100-175 Shoulder Screw
5 100-173 Screw Flanged (4)
6 100-174 Set Screw (2)
7 301-534 Block Tensioner
8 301-208 Gearbox
9 305-045 Plate
10 305-046 Spacer Tube
24 25
CLUTCH ASSEMBLY
FIG. 28
1
2
1/16”
5678910
1
2
3
4
Item No. Part No. Description
1 112-041 Differential Screw
2 112-054 Coupling Nut Assy
3 301-264 Replacement Clutch
4 301-037 Bearing (2)
5 301-274 Spacer (2)
6 100-333 Retaining Ring (2)
7 301-413 Removable Spacer
8 301-412 Spacer
9 136-068 Spring
10 301-316 Rubber Edge
PARTS LIST FIGURE 28
ENGINE ASSEMBLY
FIG. 29
1 765432 98
PARTS LIST FIGURE 29
Item No. Part No. Description
1 301-160 Honda GX160 Engine
2 305-012 Adaptor
3 136-091 Screw (4)
4 112-029 Key
5 100-357 Set Screw
6 100-383 Screw (4)
7 301-222A Sheave Assy
8 301-229 Thrust Plate
9 301-230 Screw
25
27
POWER UNIT ASSEMBLY
FIG. 30
1
2 3 4
FIGURE 26 FIGURE 23
8 9 10 11
7
6
5
12
13
34
31, 32, 33
353363738
FIGURE 22
FIGURE 40
30
27, 28, 29
20, 21
20, 21, 22, 23
2526
21, 22, 23, 24
19
FIGURE 27
FIGURE 30
14
151617, 18
PARTS LIST FIGURE 30
Item No. Part No. Description
1 301-320 Gearbox Cover
2 301-531 Top Cover
3 301-135 Grommet (6)
4 301-337 Screw (2)
5 301-047 Sleeve Bearing
6 301-333 Connection Rod
7 301-208 Gearbox
8 305-045 Gearbox Mounting Plate
9 305-064 Manifold Holder
10 305-012 Adapter
11 301-160 Honda GX160 Engine
12 301-529 Splash Cover
13 305-046 Tube Spacer (4)
14 136-091 Screw (2)
15 305-067 Bottom Cover
16 100-345 Screw (2)
17 305-047 Stud (4)
18 140-044 Nut (8)
19 301-231 Cog Belt
20 111-044 Screw (4)
PARTS LIST FIGURE 30 CONT
Item No. Part No. Description
21 140-029 Washer (10)
22 113-023 Washer (4)
23 100-317 Nut (4)
24 169-050 Screw (2)
25 301-299 Bottom Support
26 301-232 Top Support
27 100-328 Stud (2)
28 140-035 Washer (2)
29 140-051 Nut (2)
30 301-059 Spacer (2)
31 189-047 Coupling Set Cover
32 189-046 Coupling Set
33 189-048 Retainign Rings
34 301-467 Shield
35 111-037 Screw (4)
36 100-312 Screw (4)
37 305-140 Manifold Filter Bracket
38 100-360 Screw (2)
* 188-160 Grounding Assy
26
FIRST GUN ASSEMBLY - 305-167(4550) 305-391(6050)
FIG. 31
1
6
7
Item No. Part No. Description
1
2 561-002 RevGuard (G Thread)
3* 561-025 Seal-Metal
5
4
3
2
4* 561-026 Seal-Plastic
5 032-028 Swivel Assembly
6 120-554 008 Airless Gun
7 100-177 Elbow
PARTS LIST FIGURE 31
305-150
305-393
Gun Holder (4050)
Gun Holder (6050)
SECOND GUN ASSEMBLY - 305-176(4550) 305-392(6050)
FIG. 32
2
1
7
6
5*
4*
3
8
9
10
11
12
Item No. Part No. Description
1 305-146
2 305-076 Gun Arm (Long)
3 561-002 RevGuard (G Thread)
4 561-025* Metal Seal
5 561-026* Plastic Seal
6 032-028 Swivel Assy
7 120-554 008 Airless Gun
8 100-204 Hose 1/4” x 5’
9 100-199 Hose 3/8” x 6’
10 115-019 Connector
11 100-119 Ball Valve
12 100-141 Elbow
PARTS LIST FIGURE 32
Gun Holder (4550)
305-393
Gun Holder (6050)
BALL VALVE (100-119)
FIG. 33
*
3
*
** *
12
Item No. Part No. Description
PARTS LIST FIGURE 33
1 100-162 Handle
2 100-163 Screw
* Kit-119 Rebuild Kit
27
29
GUN HOLDER ASSEMBLY - 305-150(SS4550 - 1ST GUN) 305-146(SS4550 - 2ND GUN)
305-393(SS6050 - BOTH GUNS)
FIG. 34
2
1
3
8
26
2
25
16
22
24
17
23
18
19
21
20
PARTS LIST FIGURE 34
Item No. Part No. Description
1 305-142 Lever Assy.
2 305-089 Cable Insert (2)
3 305-077
100-685
4 305-141 Cable Adjuster
5 111-052 Tube Connecter
6 305-154 Bracket
7 305-152 Clamp (2)
8 305-157 Knob (3)
9 100-342 Screw
10 305-159 Sleeve Bearing (2)
11 140-045 Jam Nut (2)
12 305-161 Spacer (2)
13 305-079 Wire Swivel Assy.
14 305-155 Lever
15 140-051 Nut
16 116-100 Spring
17 169-050 Screw
18 113-027 Lock Washer
19 305-156 Thrust Washer (2)
20 305-158 Shoulder Screw
21 100-673 Screw
22 305-153
305-297
23 116-105 Spring Clip (1st Gun, 4550 only)
24 143-027 Ball Guide
25 171-008 Screw (2)
26 136-019P Swivel Clam Assy.
Gun Cable Assy. (4550)
Gun Cable Assy. (6050)
GS Holder (2nd Gun-4550)
GS Holder (6050,1st Gun-4550)
4
5
6
7
8
12
11
10
9
15
14
13
28
SWIVEL WHEEL ASSEMBLY - 4550
FIG. 35
12*
15
14
13
11
10
16
17
19
20
21
22
18
9
8
7
6
5
4
23 24
27
23
28
29
10
25, 26
2
1
PARTS LIST FIGURE 35
Item No. Part No. Description
1 143-029 Set Collar (2)
2 143-028 Washer (4)
3 136-230 Axel
4 305-253 Swivel Clamp
5 139-337A Wheel
6 305-257 Swivlel Lock Pin
7 305-258 Swivel Lock
8 136-223 Spring
9 100-223 Grease Fitting
10 119-035 Nut (4)
11 100-344 Washer (2)
*12 305-395 Frame Weldment
13 179-029 Spacer (2)
14 100-648 Screw (2)
15 305-261 Cabel Holder
3
1
2
* The swivel wheel weldment is part
of the entire striper frame weldment.
PARTS LIST FIGURE 35 CONT
Item No. Part No. Description
16 100-652 Cable
17 305-259 Lock End Lug
18 305-141 Cable Adjustor
19 100-318 Screw (2)
20 113-023 Washer (2)
21 113-021 Cotter Pin
22 260-029 Hex Castle Nut
23 112-008 Flanged Bearing (2)
24 111-036 Spring Clamp
25 140-040 Washer (2)
26 117-072 Screw (2)
27 136-231 Turnbuckle
28 140-053 Washer
29 100-649 Screw (2)
29
FRAME ASSEMBLY - 4550 (305-411)
FIG. 36
FIGURE 35
27 28 29 30
34 35
31, 32, 33
1, 2, 3, 4
5
6
7, 8, 9, 10
11, 12, 13, 14
15, 16
11, 12, 13, 17
18
26
PARTS LIST FIGURE 36
Item No. Part No. Description
1 136-023 Cable End Lug
2 301-335 Shrink Tubing (2)
3 305-089 Cable Insert
4 305-105 Lever
5 305-058 Rubber Grip (2)
6 305-314 Handle Weldment (Left)
7 113-022 Nut (2)
8 100-686 Paint Hose Hook (4)
9 100-344 Washer (4)
10 100-360 Screw (4)
11 100-696 Nut (2)
12 140-034 Washer (2)
13 140-035 Washer (2)
14 100-695 Screw (2)
15 100-687 Two Channel Strap (3)
16 100-688 Screw (3)
17 139-327 Rivnut (2)
18 301-166 13” Wheel
19, 20, 21, 22, 23, 24, 25
PARTS LIST FIGURE 36 CONT
Item No. Part No. Description
19 188-367 Axle
20 100-369 Wave Washer (2)
21 113-030 Spacer (2)
22 136-131 Chain Sash
23 136-133 Key Ring
24 143-029 Set Collar (2)
25 143-028 Washer (2)
26 305-395 Frame
27 305-396 Bucket Base
28 119-026 Screw (3)
29 305-428 Stop
30 100-621 Cap
31 188-042 Lock Nut (4)
32 305-185 Brake Clamp
33 100-390 Screw (4)
34 100-601 Plug (2)
35 305-315 Handle Weldment (Right)
30 31
SWIVEL LOCK ASSY - 6050 (305-390)
FIG. 37
1
2
3
4
5
6
7
8
9
10
11
12
13
15
14
17
16
305-105PARTS LIST FIGURE 37
Item No. Part No. Description
1 305-020 Adjustable Handle (2)
2 305-091 Seal
3 305-049 Cover-Lock
4 140-042 Washer (3)
5 331-138 Screw (3)
6 305-027 Spacer (2)
7 119-028R Dowel Pin
8 305-031 Base Lock Weldment
9 305-081 Lever
10 305-032 Spring
11 119-019 Washer (2)
12 305-032 Cable Adjuster
13 100-684 Cable Assy Swivel
14 305-089 Cable Insert
15 136-023 Cable End Lug
16 305-105 Lever
17 301-335 Heat Shrink
SWIVEL WHEEL ASSY - 6050 (305-022)
1
FIG. 38
2
3
4
5
PARTS LIST FIGURE 38
6
7
8
9
10
11
12
Item No. Part No. Description
1 301-227 Jam Nut
2 305-025 Swivel Lock
3 305-028 Belleville Springs (2)
4 305-179 Shim
5 301-036 Bearing (2)
6 305-023 Swivel Body
7 305-024 King Pin
8 305-037 Plug (2)
9 113-030 Spacer (2)
10 139-337A Wheel (2)
11 305-038 Axle
12 143-029 Set Collar (2)
31
33
FRAME ASSEMBLY - 6050
FIG. 39
2
1
FIGURE 37
FIGURE 38
FIGURE 30
3
15
7
8
14
13
11
6
5
4
34,35,36
33
9
6
6
5
10
12
23
24
25,26,27
28,29,30,31,32
5,6,18
19,20
5
21
19,22
FIGURE 34
16
FIGURE 37
17
37
38
PARTS LIST FIGURE 39
Item No. Part No. Description
1 305-044 Adjustable Handle
2 305-051M Clamp
3 305-108 Plate
4 305-050 Frame Weldment
5 113-022 Nut (16)
6 113-023 Washer
7 136-123 Screw (4)
8 140-029 Washer (4)
9 301-547 Screw (4)
10 188-042 Nut (4)
11 305-185 Brake Assy
12 100-621 Cap
13 100-390 Screw (4)
14 100-601 Plug (2)
15 305-315 Right Handle
16 305-058 Rubber Grips (2)
17 305-314 Left Handle
18 301-547 Screw (2)
19 100-360 Screw (4)
20 100-344 Washer (4)
PARTS LIST FIGURE 39 CONT
Item No. Part No. Description
21 100-686 Hook (4)
22 111-044 Screw (4)
23 305-144 Bucket Holder (2)
24 305-056 Wheel (2)
25 305-052 Axle
26 305-054 Cotter Pin (2)
27 305-055 Nut (2)
28 136-197 Terminal Ring
29 136-133 Key Ring
30 136-132R Chain 10”
31 171-009 Screw
32 188-042 Washer
33 136-231 Turnbuckle
34 140-051 Nut
35 100-678 Screw
36 140-035 Washer
37 139-353
305-076
38 301-533 Bucket Lid
Gun Arm (Short - 1 Gun)
Gun Arm (Long - 2 Gun)
32
SUCTION ASSEMBLY (301-594)
FIG. 40
1
FOR BYPASS ASSEMBLY SEE FIGURE 23
PARTS LIST FIGURE 40 CONT
Item No. Part No. Description
1 189-573 Elbow
2 250-116 Punch Clamp
3 100-664 Hose 54”
4 301-514 Tube
5 141-008 Inlet Filter
STRIPING ACCESSORIES
STENCIL KIT
For use on any single gun
striper for stencilling or
spraying paint. Includes a
2nd gun, 50’ of ” airless
hose, 18” extension pole
& shut-off ball valve.
PART # 305-399
12GAL CONTAINER
High capacity plastic paint
bucket
PART # 189-006
5432
2
BEAD DISPENSERS
Gravity type glass bead
dispenser kits.
1 GUN 4” PN 305-174
1 GUN 4-6” PN 305-186
2 GUN 4” PN 305-175
2 GUN 4-6” PN 305-178
POINTER
For easy line-up and
striping of long lines.
PART # 136-069
35
NOTES
34
NOTES
35
Quick Flush
Quick Flush
■ The only clean water
■ Cuts sprayer clean-up time in half!
■ Connects to standard garden hose
to backush sprayer through gun
■ Includes "F" and "G" adapters to
work with all brands of gun
ushing system
™
™
Spray protectant for machine
to prevent paint from sticking
to it. Keeps your sprayer
STAY CLEAN
looking new for years!
114-030
20 oz. can
Case quantity:
12 cans
Part # 170-005
THROAT SEAL OIL
Used in the wet cup of a piston pump
to prevent paint from drying on the pis
ton & causing damage to the upper
PAINT HOPPER
For use on small jobs where paint is
kept in smaller than 5 gallon containers.
Threads onto pick-up tube of carry or
LoBoy framed Airlessco sprayers.
packing. Use with all piston pumps.
188-187
6 oz. Bottle
188-392
1 qt. Bottle
331-775 6 Liter Paint Hopper
XTEND-A-POLE SYSTEM
PUMP CONDITIONER
Should be used on piston pumps
between uses to prevent paint from
drying on the piston & causing pack
ing wear.
-
010-001 Display of 48 - 1 oz. bottles
010-009 1 quart bottle
010-019
1 Gallon bottle
Case quantity: 12 on quarts, 4 on gallons
bags. One dozen per pack.
100-064 Used to cover suction filter
ACCESSORIES
100-065
4 mil poly protects your
airless hose from paint and
roll with perforations each 50'.
100-219
PAINT STRAINERS
Pre-filter your paint using strainer
5 Gallon strainer
HOSE COVER
abrasion damage. Comes in 1000'
Hose Cover Roll
STANDARD TIP EXTENSION, “G” Thread
032-170 6” Long
032-171 12” Long
032-172
032-173 24” Long
SWIVEL EXTENSION, “G” Thread
032-184
BARE POLE
Add Tip Extension or Swivel Extension to
create desired length
032-053 24” Long
032-054 36” Long
032-035
100-426 Case of 6 Rolls
HIGH PRESSURE AIRLESS HOSE
Strong yet flexible, for airless sprayers up to 3300 PSI
100-012
100-204
100-011 1/4” Hose, 50 Ft.
100-037
100-010
Part No: Hose Description
3/16” Whip Hose, 4 Ft.
100-040 1/4” Whip Hose, 3 Ft.
1/4” Whip Hose, 5 Ft.
100-199 3/8” Whip Hose, 6 Ft.
100-023 3/8” Hose, 50 Ft.
1/2” Hose, 50 Ft.
1/4" Hose Connector
100-009 3/8" Hose Connector
Standard Tip Extension
Swivel Extension
Bare Pole
18” Long
36” Long
SWIVEL “G” THREAD
7/8" x 14 Swivel
ADAPTERS
90° Pole to Gun Adapter
032-042
Gun Nut “F” Thread 11/16-16
032-010
Gun Nut “G” Thread 7/8-14
032-011
"F to G" Gun adapter to attach
®
Graco
tips to Airlessco guns.
032-012
AIRLESSCO
-
PROTECT YOUR EQUIPMENT INVESTMENT!
MAIL THE CARD BELOW TO GET ALL THESE BENEFITS!
WARRANTY VERIFICATION
Prompt registration veries your right to protection under the terms and conditions of your warranty.
OWNER CONFIRMATION
Completed warranty registration and purchase invoice copy serves as conrmation of ownership in the
event of product loss by re or theft.
MODEL REGISTRATION
Returning the attached card with a purchase invoice copy, guarantees you’ll receive all information and
special offers for which you are eligible.
#
WARRANTY REGISTRATION CARD
□ Check here if you prefer not to receive technical bulletins, news on
product updates, info on new products, and special offers. Information
provided on this card is condential to Airlessco and will not be made
available to outside parties.
Date of Purchase Model # Purchased
Company
Your Name
Street Address
P.O. Box City
State Zip/Postal Code Country
Phone Fax
eMail Adress
Your feedback on this product is appreciated.
Dear Airlessco,
Serial #
Equipment Owned # Units
Owned
Electric Paint Sprayers
□
0-0.6GMP, 1/2hp
□
0.7-0.8GMP, 3/4hp
□
1-1.25GMP, 1hp
Gasoline Paint Sprayer
□
-1.25GMP, 5.5hp
Pavement/Field Stripers
□
Single Tip Unit
□
Multi Tip Unit
□
Riding Option
Gasoline Pressure Washers
Type of Business
□
Paint Contractor □ Striping Contractor □ Government □ School
□
Proporty Maintenance □ Power Washing □ Equipment Rental
□
Sports Organization □ Stadium/Sports Field Management
Material Usage in Galons per Week
□
0-25 □ 26-50 □ 51-100 □ 101-250 □ 250-500 □ 500+
Buying in Next 6 Months
#
Copyrig ht 2008, Airl essco. All righ ts reserved. Re placement wear pa rts program su bject to change w ithout notice.
FORM # 001- 043 OCT08
AIRLESSCO LP, SL, and Surestripe Sprayers LIMITED WARRANTY
AIRLESSCO warrants the LP, SL, and Surestripe series equipment manufactured by it and bearing it’s name to be
free from defects in material and workmanship on the date of sale by an authorized Airlessco Distributor to the original
purchaser. Airlessco will, for the period of twenty four months from the date of sale, repair or replace any part of the
equipment proven defective. Packings and rods are limited to a 1-time replacement. Cylinder, gearbox, and electric
motors have lifetime coverage. This warranty applies only when the equipment is installed, operated and maintained in
accordance with Airlessco’s written recommendations.
This Warranty does not apply to equipment which has been resold or rented, or has damage from wear caused
by abrasion, corrosion or misuse, negligence, accident, faulty installation or tampering in a manner to impair normal
operation, inadequate or improper maintenance or substitution of non-Airlessco component parts.
This Warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Airlessco Service/Warranty Center for verication of the claim. If the claim is veried, Airlessco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If
inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable
charge, which charges may include the costs of parts, labor and transportation.
Airlessco makes no warranty, and disclaims all implied warranties of merchantability and tness for a particular
purpose, with respect to accessories, equipment, materials or components sold but not manufactured by Airlessco. These
items sold, but not manufactured by Airlessco, such as engines, hoses, etc., are subject to the warranty, if any, of their
manufacturer. Airlessco will provide purchaser with reasonable assistance in making any claim for these warranties.
Date of purchase: Distributor:
Model #: Address:
Serial #:
#
Cut along this line and mail the section below. Retain this section for your records.
Mail along with a copy of your purchase invoice to:
Airlessco Warranty Registration Dept.
5397 N. Commerce Ave.
Moorpark, CA 93021
FORM # 001- 043 OCT08
#
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