*Part No. 24N548 is used as a supply pump in the WB3000 Waterborne Isolation System. It includes a pump
bracket and items 7-19, 21, 23, and 28-42 on page 25. See manual 3A2497 for warnings and instructions for a
waterborne system.
3A0732J3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
WARNINGWARNINGWARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SPECIAL CONDITIONS FOR SAFE USE
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
43A0732J
Warnings
WARNING
WARNINGWARNINGWARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A0732J5
Warnings
63A0732J
Installation
Installation
Prepare the Operator
All persons who operate the equipment must be trained
in the safe, efficient operation of all system components
as well as the proper handling of all fluids. All operators
must thoroughly read all instruction manuals, tags, and
labels before operating the equipment.
Prepare the Site
Ensure that you have an adequate compressed air
supply.
Bring a compressed air supply line from the air compressor to the pump location. Be sure all air hoses are
properly sized and pressure-rated for your system. Use
only electrically conductive hoses. The air hose should
have a 3/8 npt(m) thread. A quick disconnect coupling is
recommended.
Keep the site clear of any obstacles or debris that could
interfere with the operator's movement.
Have a grounded, metal pail available for use when
flushing the system.
•The spray gun (H) dispenses the fluid. The gun
houses the spray tip (not shown), which is available
in a wide range of sizes for different spray patterns
and rates of flow. Refer to gun manual for tip installation.
•The redhose (G) provides the gun air supply.
•The blue hose (K) provides the gun fluid supply.
•The suction kit with strainer (J) allows the pump
to draw fluid from a 5 gallon (19 liter) pail.
Inline Fluid Filter Kits
Inline fluid filter kits are available as an accessory in
stainless steel (24F271) or aluminum (24F272), to filter
particles from fluid as it leaves the pump. Kits include a
60 mesh (250 micron) stainless steel element.
Air Line Accessories
Install the following accessories in the order shown in
F
IG
. 2, using adapters as necessary.
Supplied Components
See FIG. 2 on page 9.
•The red-handled bleed-type master air valve (D)
is required in your system to relieve air trapped
between it and the air motor and gun when the valve
is closed. Do not block access to the valve.
•The pump air regulator (F) controls pump speed
and outlet pressure by adjusting the air pressure to
the pump.
•The air pressure relief valve(P) opens automatically to prevent overpressurization of the pump.
•The gun air regulator (E) adjusts the air pressure
to the air-assisted spray gun.
•An air-line filter (C) removes harmful dirt and mois-
ture from the compressed air supply.
•A second bleed-type air shutoff valve (B) isolates
the air line accessories for servicing. Locate
upstream from all other air line accessories.
3A0732J7
Installation
Wall Mount Packages
1. Be sure the wall can support the weight of the
pump, bracket, hoses and accessories, as well as
the stress caused during operation.
2. Position the wall bracket at a convenient height. Do
not stretch the suction hose tight; let it hang to assist
fluid flow into the pump. For ease of operation and
service, make sure the pump air inlet, fluid inlet, and
fluid outlet ports are easily accessible.
3. Using the wall bracket as a template, drill mounting
holes in the wall. Hole diameters and wall mounting
dimensions are shown on page 40.
4. Attach the bracket to the wall. Use screws that are
long enough to keep the pump from vibrating during
operation.
NOTE: Be sure the bracket is level.
Grounding
2. Air and fluid hoses: Static electricity may build up
when fluids flow through pumps, hoses, and sprayers. At least one hose must be electrically conductive, with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check
electrical resistance of hoses. If total resistance to
ground exceeds 25 megohms, replace hose immediately.
3. Air compressor: follow manufacturer's recommendations.
4. Spray gun: ground through connection to a properly grounded fluid hose and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow your
local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
The equipment must be grounded. Grounding
reduces the risk of static and electric shock by
providing an escape wire for the electrical current
due to static build up or in the event of a short circuit.
1. Pump: See FIG. 1. Verify that the ground wire (26)
is attached to the ground screw (23), and the screw
is tightened securely to the adapter plate (10). Use
any of the three threaded holes in the adapter plate.
Connect the other end of the ground wire to a true
earth ground.
10
26
23
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Prime the Pump, page 10.
ti16282a
FIG. 1. Ground Wire
83A0732J
Setup
Installation
1. See FIG. 2. Attach one end of fluid hose (K) to pump
outlet (or optional inline fluid filter outlet).
2. Attach other end of fluid hose to gun fluid inlet at
base of gun (H).
3. Attach one end of the air hose (G) to gun air regulator (E).
A
D
E
J
G
4. Attach remaining end of the air hose to air inlet at
base of gun (H).
5. Clip fluid and air hoses together with the supplied
hose clips (qty. of 7). Space clips as needed.
6. Attach the fluid suction kit (J) to the pump inlet.
B
C
F
P
M
L
K
Key:
AMain Air Supply Line
BAir Shutoff Valve
CAir Filter
DBleed-type Master Air Valve (required)
EGun Air Pressure Regulator
FPump Air Pressure Regulator
GGun Air Supply Line
HSpray Gun
JFluid Suction Kit
KGun Fluid Supply Line
LPump Ground Wire (required)
MMounting Bracket (used for wall mounting or stand)
NPump Stand
PAir Pressure Relief Valve
N
H
ti15591a
FIG. 2. Typical Installation (Air-Assisted Stand Mount Package Shown)
3A0732J9
Operation
Operation
Pressure Relief Procedure
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from skin
injection, splashing or moving parts.
1. Lock the gun trigger.
2. See F
3. Unlock the gun trigger.
4. Hold a metal part of the gun firmly to a grounded
5. Lock the gun trigger.
6. If you suspect that pressure has not been fully
IG
. 2. Turn off the bleed-type master air valve
(D).
metal waste container. Trigger the gun to relieve
fluid pressure.
relieved after following the steps above, check the
following:
Trigger Lock
See FIG. 3. Always engage gun trigger lock when you
stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped.
Gun Trigger
Locked
tiI6581A
Gun Trigger
Unlocked
a. The spray tip may be completely clogged. Very
slowly loosen the air cap retaining ring to relieve
pressure in the cavity between the ball/seat
shutoff and the plugged tip. Clear the tip orifice.
b. The gun fluid filter or the fluid hose may be com-
pletely clogged. Very slowly loosen the hose
end coupling at the gun and relieve pressure
gradually. Then loosen completely to clear the
obstruction.
c. After following the steps above, if the spray tip
or hose still seems completely clogged, very
slowly loosen the tip guard retaining nut or hose
end coupling and relieve pressure gradually,
then loosen completely. With tip removed, trigger gun into waste container.
ti6582A
FIG. 3. Trigger Lock
Prime the Pump
Have safety spring (9) in place during operation to
reduce risk of pinching or loss of fingers.
1. See FIG. 3. Lock gun trigger. Remove tip guard and
spray tip from gun. Refer to gun manual.
103A0732J
Operation
2. See FIG. 2. Close gun air regulator (E) and pump air
regulator (F) by turning knobs counterclockwise
reducing pressure to zero. Close bleed-type air
valve (D).
3. Connect air line to bleed type air valve.
4. Check that all fittings throughout system are tightened securely.
5. Position pail close to pump. Suction hose is 3 ft
(0.9 m) long. Do not stretch hose tight; let it hang to
assist fluid flow into pump.
6. Hold metal part of gun firmly to side of grounded
metal pail, unlock trigger, and hold trigger open.
7. Open bleed-type air valve. Slowly turn pump air regulator clockwise, increasing pressure until pump
starts.
8. Cycle pump slowly until all air is pushed out and
pump and hoses are fully primed.
9. Release gun trigger and lock trigger safety. Pump
should stall against pressure.
Adjust the Atomization
NOTE: Use this procedure with airless and air-assisted
spray guns.
1. Do not turn on atomizing air supply. Fluid pressure
is controlled by the air pressure supplied to the
pump (pump air regulator). Set fluid pressure at low
starting pressure. For low viscosity fluids (less than
25 sec, #2 Zahn cup) with lower percent solids (typically less than 40%), start at 300 psi (2.1 MPa, 21
bar) at pump outlet. For fluids with higher viscosity
or higher solids content, start at 600 psi (4.2 MPa,
42 bar). Refer to the following example.
Follow Pressure Relief Procedure, page 10. Install the
spray tip and tip guard as explained in your separate
gun manual, supplied.
The fluid output and pattern width depend on the size of
the spray tip, the fluid viscosity, and the fluid pressure.
Use the Spray Tip Selection Chart in your gun instruction manual as a guide for selecting an appropriate
spray tip for your application.
NOTE: The maximum recommended spray tip size is
.019 in. (0.483 mm).
2. Hold gun perpendicular and approximately 12
inches (304 mm) from surface.
3. Move gun first, then pull gun trigger to spray onto
test paper.
4. Increase fluid pressure in 100 psi (0.7 MPa, 7 bar)
increments, just to the point where a further
increase in fluid pressure does not significantly
improve fluid atomization. Refer to the following
example.
5. If you are using an air-assisted spray gun, see
Adjust the Spray Pattern on page 12.
Increment
psi (MPa, bar)
Incremental
Fluid Pressure
psi (MPa, bar)
3A0732J11
Operation
Adjust the Spray Pattern
NOTE: Use this procedure with air-assisted spray guns
only.
1. See F
OUT (narrower
pattern)
IG
. 4. Close off pattern adjustment air by turning knob (AA) clockwise (in) all the way. This sets
gun for its widest pattern.
AA
AA
IN (wider
pattern)
3. See F
IG
. 4. For narrower pattern, turn pattern
adjustment valve knob (AA) counterclockwise (out).
If pattern is still not narrow enough, increase air
pressure to gun slightly or use different size tip.
no air
too little air
correct
amount of
air
TI0792A
FIG. 5. Spray Pattern Problems
Shutdown
ti6559A
FIG. 4. Pattern Air Knob
2. See F
IG
. 5. Set atomizing air pressure at about 5 psi
(0.35 bar, 35 kPa) when triggered. Check spray pattern, then slowly increase air pressure until tails are
completely atomized and pulled into spray pattern.
Do not exceed 100 psi (0.7 MPa, 7 bar) air pressure
to gun.
Follow Pressure Relief Procedure, page 10.
Always flush the pump before the fluid dries on the displacement rod. See Flush the Pump on page 13.
123A0732J
Maintenance
Maintenance
Tighten Threaded Connections
Before each use, check all hoses for wear or damage.
Replace as necessary. Check that all threaded connections are tight and leak-free.
Flush the Pump
Read all Warnings. Follow all Grounding instructions. See page 8.
Flush the pump:
•Before first use
•When changing colors or fluids
•Before repairing equipment
•Before fluid dries or settles out in a dormant pump
(check the pot life of catalyzed fluids)
Flush at the lowest pressure possible. Flush with a fluid
that is compatible with the fluid you are pumping and
with the wetted parts in your system. Check with your
fluid manufacturer or supplier for recommended flushing
fluids and flushing frequency.
1. Follow Pressure Relief Procedure, page 10.
2. Remove tip guard and spray tip from gun. Refer to
separate gun manual.
3. Place suction tube in grounded metal pail containing
cleaning fluid.
4. Set pump to lowest possible fluid pressure, and start
pump.
5. Hold a metal part of the gun firmly to a grounded
metal pail.
6. Trigger gun. Flush system until clear solvent flows
from gun.
7. Follow Pressure Relief Procedure, page 10.
8. Clean the tip guard, spray tip, and fluid filter element
separately, then reinstall them.
•At the end of the day
•Before storing the pump.
9. Clean inside and outside of suction tube and suction
hose.
3A0732J13
Troubleshooting
Troubleshooting
NOTE: Check all possible problems and causes before
disassembling the pump.
Relieve the pressure before checking or servicing
the equipment.
ProblemCauseSolution
Air motor will not run.Damaged air valve (214). Replace or service air valve (214). See
page 18.
Damaged pilot valve (213).Replace pilot valves (213). See page 20.
Air continuously exhausting around air
motor piston rod.
Air continuously exhausting from muffler.
Air motor “bounces” at top of stroke.Damaged bottom pilot valve (213).Replace bottom pilot valve (213). See
Air motor “bounces” at bottom of
stroke.
Icing inside motor.Air motor operating at high pressure or
Damaged u-cups (207).Replace piston rod u-cups (207). See
page 22.
Damaged air valve plate (305) or cup
(312).
Damaged top pilot valve (213).Replace top pilot valve (213). See page
high cycle rate.
Replace or service air valve (214). See
page 18.
page 20.
20.
Reduce pressure, cycle rate, or duty
cycle of motor.
Reduce dew point of compressed air in
moisture coalescing filter.
Pump fails to operate.Restricted line or inadequate air supply;
closed or clogged valves.
Obstructed fluid hose or gun; fluid hose ID
is too small.
Fluid dried on the displacement rod (119).Clean; keep the packing nut wet-cup filled
Pump operates but does not prime.Held open or worn ball check valves or pis-