Honda Power Equipment GPX 165 User Manual
GPX 165
SprayTECH
1770 Fernbrook Lane
Minneapolis, MN 55447
Technical Assistance: 1-800-292-4637
Order Entry: 1-800-443-4500
Fax: 1-800-525-9501
www.spraytechinc.com
Gas Piston Pump
Do not use this equipment before reading this manual!
Owner’s Manual
NOTE: This manual contains important warnings and
Printed in the U. S. A.
instructions. Please read and retain for reference.
Model Numbers:
Bare 0509009
Complete 0509039
Bare w/5 Gal. Siphon 0509055
Complete w/5 Gal. SIphon 0509059
0306 © 2006 SprayTECH. All rights reserved. Form No. 0555890A
Table of Contents
WARNING
CAUTION
WARNING
afety Precautions.................................................................2
S
rançais ..............................................................................18
F
spañol...............................................................................20
E
pecifications .........................................................................3
S
eneral Description ...............................................................4
G
peration ................................................................................4
O
etup ....................................................................................4
S
reparing to Paint.................................................................4
P
ainting.................................................................................5
P
ressure Relief Procedure ...................................................6
P
praying ..................................................................................6
S
praying Technique ..............................................................6
S
ractice.................................................................................6
P
leanup ...................................................................................7
C
aintenance............................................................................7
M
eneral Repair and Service Notes.......................................7
G
aintaining the Engine .........................................................8
M
eplacing the Filter...............................................................8
R
Replacing the PRIME/SPRAY Valve.....................................8
Replacing the Potentiometer ................................................9
Replacing the Sprayer ON/OFF Switch................................9
Replacing the Transducer...................................................10
Replacing the Electronic Pressure Control (EPC)
Replacing the Slider
Replacing the Gears
Servicing the Clutch
Servicing the Fluid Section
Troubleshooting ...................................................................17
Parts Listings........................................................................22
Main Assembly....................................................................22
Drive Assembly...................................................................23
Fluid Section Assembly ......................................................24
Cart Assembly.....................................................................25
Filter Assembly ...................................................................25
PRIME/SPRAY Assembly ...................................................26
5 Gallon Siphon Set (optional) ...........................................26
Electrical Schematic ...........................................................27
Labels .................................................................................27
Accessories ........................................................................27
Limited Warranty..................................................................28
Assembly and Slider Housing............11
...........................................................12
Assembly ...........................................12
.................................................14
Assembly.10
B. WARNING – To reduce the risk of fire or explosion:
1. Do not spray flammable or combustible materials near
an open flame, pilot lights or sources of ignition such as
hot objects, cigarettes, motors, electrical equipment and
electrical appliances. Avoid creating sparks from
connecting and disconnecting power cords.
2. For units intended for use with only water-based
materials — Do not spray or clean with flammable
liquids. For use with water-based liquids only.
3. For units intended for use with only water-based or
mineral spirit-type materials with a minimum flash point
of 21ºC (69.8ºF) — Do not spray or clean with liquids
having a flash point of less than 21ºC (69.8ºF). Flash
point is the temperature at which a fluid can produce
enough vapor to ignite.
4. Paint or solvent flowing through the equipment is able
to result in static electricity. Static electricity creates a
risk of fire or explosion in the presence of paint or
solvent fumes. All parts of the spray system, including
the pump, hose assembly, spray gun and objects in and
around the spray area shall be properly grounded to
protect against static discharge and sparks. Use only
conductive or grounded high-pressure airless paint
sprayer hoses specified by the manufacturer.
5. Verify that all containers and collection systems are
grounded to prevent static discharge.
6. For electric units — connect to a grounded outlet and use
grounded extension cords. Do not use a 3 to 2 adapter.
7. Do not use a paint or solvent containing halogenated
AN 1td foe asseeS25.1td214.294 14cqN 1td fo6]TJ waterCp[(spr.49 5i4d[ 125.44nstruction 5sd[ 125.44n1ide1py(7c7 u(3.)9l21lowi384 118 l114.19 01rpr.7pr.491ini(25sd[ 125.44n1ide7Aj[(spr.49 5i4d[ 125.4454-e)]TJ1rp[ 1)225sprs53*4e with 85i4d[ 1clu6 298.5164 112phall2prw[ l6or)]TJ4]TJe2(V)54(or)]TJ4]s s214.294 29J4ro6]TJ wr.73ya[(lilar19 01rpr.73ya[(.7137 c1-d3 m1156]TJ21gat8 8a 5i4dwooe)55ed)]TJ/Go[(.7cflMnded high-pressur[ 5294 29J4rolAic124.0 unno 29 -11.14485 -1.2804ro6]TJ( (lild[ 2(n sI1de)-1(d ou(nere 1e4 29J4ro6]TJ w2he)-1(d ou(nere 1e4 29J4ro6]TJ w2he)-1(d ou(nere 1e4 29J4ro6]TJ discharge and sparkTJ discharge a8[(TJ c6SR1.14nstTJ022 747.6556 Tmrgentainers 56 Tmrg4phargeAa029Js4ro654 oud ext2s 5i4d oeates a)][55e759ch8 e)-1(d oud spw1gat8 dla)]emperatue1I1d5q122 eea)]empera7528 w2he)Ie 1e4 29J4ro6TNilar19[ 1c447re aar190 kh2spr.49 5i4d[ 125.44nstruction p4 unno truc92 flMnr190 kh2sprRHf 5iionhali5.44nsth2ext2s 5i4d o1de)v2he)Ie sion cords. Do not use a 3 to 2 adapter)55(.)]TJ-1.14485 -125h2sprRHfO6) siond oarkTJ r7t5 si25N54]s s2hhargeAa026 T22nv3i Do not r7t i 5iio a 3 to 2 adapter)55(.)]TJ-1.14485 -125h2sprRHfO697.4t5 s25N54]s s2J r7t5 st spray oargde.r7t5 soele s(97la5N54]s dapte...22 1ioele s(97.4t5 s25N54]s s2J r7t5 st spray oargde.r7t5 soele s(97la5N54]s d 298.7116 cle s(97cga )5e so2acle s(97 s2 )5 nost spray0 8l su4ro6r05L45 m1108s26r0O6) siond oarkTJ 4r0O6) siond 9(97 70wm solnd (nd u 9(97 1e872 311.21nd u23th f)-1(do21n0 u23tark s 1elnd4]s30 uA3tark252.1ATmrgentai27 4e s 5.4s 597.48 reventioele s(971 m1108s26r0O6rK11S m1108s26r0O6re23ta Ire aar190 kh2(s644nt-qBHtark252.7 s2 )5 asol71 m1108s26r0O6rK11S m11)rNf)-1(do8096 071tay o1)r031w6 071tay-08el to lp3tar Fscha1108s26r0Or8 244.6l to lp3t8s232.4ro6r0552.7 s2 )c14.085 307 SN54]s s2J r7t5 st sprS1-e)]Tc2J r7t23th f)-1(do21n0 u23tark s 1elnd4E2.7 s2 )Elp3t-1(do82 316.7343th ss 44nt-ql6nypJ/Gtd )Ai or97la5N54]s d 298ro6r0552.7 s2
nr71 m1108s26r0O6rK11S m1108s26r0O6re23ta Ire aar190 kh2(s644nt-qBHl7Fewat141 04nt-qBHta2 8o6t141 -1 04nqrb[rk252.7134037nerW47.244.6l to lp3t8s232.4ro6r0552.7 s2 8o6r0ss 44nt-ql6n6-1 04nqrb[0ssto lpW3i1108s26rr47.2(TJ l)118 ero60ct corea 3 to2(s644.t co6la)q 6 cle s(97cg co6la)q 661 gh v47.aV)54(or)Elp3t8s232.4rd oarkTJ e1 mhy134847 s2 2 p35 oul(34847 s2 tpp5l7Fe7....s2 2.6556edmn3a7S53i115sa44nt412ext2s 5i4d.444256edmn3io13r7t5 st sei5kTJ e1 mhy1 16.1269 135.4809 23ta2 8o6t141 -11Es809 d u2i51[s4 6r0ss 597.48sprRHfO6) sf53Er218g1115sa44nt412ext2s47.48 r484 Tm(412exo1 jela)q 661 11 Tmrg4phm f7.
Safety Precautions
This manual contains information that must be read and
understood before using the equipment. When you come to
an area that has one of the following symbols, pay particular
attention and make certain to heed the safeguard.
This symbol indicates a potential hazard that may cause
serious injury or loss of life. Important safety information
will follow.
This symbol indicates a potential hazard to you or to the
equipment. Important information that tells how to
prevent damage to the equipment or how to avoid causes
of minor injuries will follow.
NOTE: Notes give important information that should
A. SAVE THESE INSTRUCTIONS – To reduce the risks of
be given special attention.
IMPORT
fire or explosion, electrical shock, and the injury to
persons, read and understand all instructions
included in this manual. Be familiar with the controls
and the proper usage of the equipment.
ANT SAFETY
INSTRUCTIONS
2 © SprayTECH. All rights reserved.
3. Always use the nozzle tip guard. Do not spray without
WARNING
WARNING
CAUTION
the nozzle tip guard in place.
. Only use a nozzle tip specified by the manufacturer.
4
5. Use caution when cleaning and changing nozzle tips.
In the case where the nozzle tip clogs while spraying,
ALWAYS lock gun trigger, shut pump off, and release
all pressure before servicing, cleaning tip or guard, or
changing tip. Pressure will not be released by turning
off the motor. The PRIME/SPRAY valve handle must
be turned to PRIME to relieve the pressure. Refer to
PRESSURE RELIEF PROCEDURE described in the
pump manual.
6. Do not leave the unit energized or under pressure while
unattended. When the unit is not in use, turn off the unit
and relieve the pressure in accordance with the
manufacturer’s instructions.
7. High-pressure spray is able to inject toxins into the
body and cause serious bodily injury. In the event that
injection occurs, seek medical attention immediately.
8. Check hoses and parts for signs of damage, a leak can
inject material into the skin. Inspect hose before each
use. Replace any damaged hoses or parts.
9. This system is capable of producing 3300 PSI / 22.8
MPa. Only use replacement parts or accessories that
are specified by the manufacturer and that are rated a
minimum of 3300 PSI. This includes spray tips, nozzle
guards, guns, extensions, fittings, and hose.
10. Always engage the trigger lock when not spraying.
Verify the trigger lock is functioning properly.
11. Verify that all connections are secure before operating
the unit.
12. Know how to stop the unit and bleed pressure quickly.
Be thoroughly familiar with the controls. Pressure will
not be released by turning off the motor. The
PRIME/SPRAY valve handle must be turned to PRIME
to relieve the pressure. Refer to PRESSURE RELIEF
PROCEDURE described in the pump manual.
13. Always remove the spray tip before flushing or cleaning
the system.
D. WARNING – To reduce the risk of injury:
1. Always wear appropriate gloves, eye protection,
clothing and a respirator or mask when painting.
Hazardous vapors – Paints, solvents, insecticides, and
other materials can be harmful if inhaled or come in
contact with body. V
fainting or poisoning.
2. Do not operate or spray near children. Keep children
away from equipment at all times.
3. Do not overreach or stand on an unstable support.
Keep effective footing and balance at all times.
Stay alert and watch what you are doing.
4.
5. Do not operate the unit when fatigued or under the
influence of drugs or alcohol.
Do not kink or over-bend the hose. Airless hose can
6.
develop leaks from wear
can inject material into the skin.
7. Do not expose the hose to temperatures or pressures in
excess of those specified by manufacturer.
Do not use the hose as a strength member to pull or lift
8.
the equipment.
9. Use lowest possible pressure to flush equipment.
Follow all appropriate local, state and national codes
10.
governing ventilation, fire prevention and operation.
11. The United States Government Safety Standards have
been adopted under the Occupational Safety and
Health Act (OSHA). These standards, particularly part
1910 of the General Standards and part 1926 of the
Construction Standards should be consulted.
apors can cause severe nausea,
, kinking and abuse. A
leak
12. Before each use, check all hoses for cuts, leaks,
abrasion or bulging of cover. Check for damage or
movement of couplings. Immediately replace hose if
any of those conditions exist. Never repair a paint hose.
Replace with a conductive high-pressure hose.
3. Do not spray outdoors on windy days.
1
14. Always unplug cord from outlet before working on
equipment.
Do not lift by cart handle when loading or unloading.
Gasoline Engine Safety
The engine exhaust from this unit contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
1. Gas engines are designed to give safe and dependable
service if operated according to instructions. Read and
understand the engine Owner's Manual before operating
the engine. Failure to do so could result in personal injury
or equipment damage.
2. To prevent fire hazards and to provide adequate
ventilation, keep the engine at least 1 meter (3 feet) away
from buildings and other equipment during operation. Do
not place flammable objects close to the engine.
3. Children and pets must be kept away from the area of
operation due to a possibility of burns from hot engine
components or injury from any equipment the engine may
be used to operate.
4. Know how to stop the engine quickly, and understand the
operation of all controls. Never permit anyone to operate
the engine without proper instructions.
5. Gasoline is extremely flammable and is explosive under
certain conditions.
6. Refuel in a well-ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the refueling
area or where gasoline is stored.
7. Do not overfill the fuel tank. After refueling, make sure the
tank cap is closed properly and securely.
8. Be careful not to spill fuel when refueling. Fuel vapor or
spilled fuel may ignite. If any fuel is spilled, make sure the
area is dry before starting the engine.
9. Never run the engine in an enclosed or confined area.
Exhaust contains poisonous carbon monoxide gas;
exposure may cause loss of consciousness and may lead
to death.
10. The muffler becomes very hot during operation and
remains hot for a while after stopping the engine. Be
careful not to touch the muffler while it is hot. To avoid
severe burns or fire hazards, let the engine cool before
transporting it or storing it indoors.
11. Never ship/transport unit with gasoline in the tank.
Specifications
Gallons per minute (GPM)...............1.65 (6.25 LPM)
Maximum tip size .............................one gun = 0.042”
Maximum pressure ..........................3300 PSI (22.8 MPa)
...............................................
Power
Weight..............................................164 lbs. (74.4 kg)
Maximum hose length......................300’ (91.4 m)
two guns = 0.029”
three guns = 0.023”
four guns = 0.020”
7.0 HP
gas engine
© SprayTECH. All rights reserved. 3
General Description
CAUTION
WARNING
WARNING
his airless sprayer is a precision power tool used for spraying
T
any types of materials. Read and follow this instruction
m
anual carefully for proper operating instructions,
m
aintenance, and safety information.
m
Operation
This equipment produces a fluid stream at extremely high
pressure. Read and understand the warnings in the
Safety Precautions section at the front of this manual
before operating this equipment.
Setup
Perform the following procedure before starting the engine of a
gas-powered sprayer.
1. Ensure that the siphon tube and the return hose are
attached and secure.
2. Attach the supplied grounding cable to a grounded object.
3. Using a wrench, attach a minimum of 50’ of 3/8” nylon
airless spray hose to the 3/8” outlet fitting on the filter
assembly. Tighten securely.
NOTE: Use 3/8” spray hose for maximum performance,
4. Attach an airless spray gun to the spray hose. Using two
NOTE: Do not attach the tip to the spray gun yet.
Make sure all airless hoses and spray guns are electrically
grounded and rated at or above the maximum operating
pressure range of the airless sprayer.
5.
6. Make sure the sprayer ON/OFF switch is in the OFF position.
7.
minimum pressure drop, and minimum
pressure fluctuation.
wrenches (one on the gun and one on the hose), tighten
securely.
Remove the tip if it is already attached.
urn the pressure control knob fully counterclockwise to
T
its lowest pressure setting.
Fill the fluid section oil cup with approximately one
tablespoon of separating oil (P/N 0279920).
Never operate unit for more than ten seconds without
fluid. Operating this unit without fluid will cause
unnecessary wear to the packings.
4. Move the PRIME/SPRAY valve to the PRIME position.
WARNING
WARNING
WARNING
WARNING
NOTE: Hold the return hose in the waste container
5. Move the engine ON/OFF switch to the ON position.
6. Start the engine:
7. Turn on the sprayer by moving the sprayer ON/OFF
. Slowly turn the pressure control knob clockwise to increase
8
9. Allow the sprayer to run for 15–30 seconds to flush the old
10. Turn the pressure control knob fully counterclockwise to
11. Turn off the sprayer by moving the sprayer ON/OFF
NOTE: Make sure that the spray gun does not have a
12. Move the PRIME/SPRAY valve to the SPRAY position.
13. Turn on the sprayer.
14. Turn the pressure control knob slowly clockwise to
15. Unlock the gun by turning the gun trigger lock to the
when moving the PRIME/SPRAY valve to
PRIME in case the sprayer is pressurized.
a. Open the fuel valve lever.
b. Move the throttle lever away from the gas tank.
c. Close the engine choke lever.
d. Holding the frame with one hand, pull the starter rope
rapidly and firmly. Continue to hold the rope as you let it
return. Pull and return the rope until the engine starts.
switch to the ON position.
he pressure until fluid starts to come out of the return hose.
t
Use only enough pressure to keep the fluid coming out.
solvent out through the return hose and into the metal
waste container.
its lowest setting.
switch to the OFF position.
tip or tip guard installed.
increase pressure.
unlocked position.
c. Close the engine
choke lever.
d. Holding the frame
with one hand, pull
the starter rope
rapidly and firmly.
Continue to hold
the rope as you let
it return. Pull and
return the rope until
the engine starts.
7. Turn on the sprayer
by moving the sprayer ON/OFF switch to the ON position.
8. Slowly turn the pressure control
knob clockwise to increase the
pressure until fluid starts to
come out of the return hose.
Use only enough pressure to
keep the fluid coming out.
9. Allow the sprayer to run until
paint is coming through the
return hose into the metal
waste container.
10. Turn the pressure control knob fully counterclockwise to
its lowest setting.
11. Turn off the sprayer by moving the sprayer ON/OFF
switch to the OFF position.
12. Remove the return hose from the waste container and place
it in its operating position above the container of paint.
13. Move the PRIME/SPRAY valve to the SPRAY position.
14. Turn on the sprayer.
15. Turn the pressure control knob slowly clockwise to
increase pressure.
16. Unlock the gun by turning the gun trigger lock to the
unlocked position.
Ground the gun by holding it against the
edge of the metal container while
flushing. Failure to do so may lead to a
static electric discharge, which may cause a fire.
16. Trigger the gun into the metal waste container until the old
solvent is gone and fresh solvent is coming out of the gun.
17. Lock the gun by turning the gun trigger lock to the locked
position.
18. Set down the gun and increase the pressure by turning the
pressure control knob slowly clockwise to its highest setting.
19. Check the entire system for leaks. If leaks occur, turn the
sprayer off and follow the “Pressure Relief Procedure” in
this manual before tightening any fittings or hoses.
20. Follow the “Pressure Relief Procedure” in this manual
before changing from solvent to paint.
Be sure to follow the pressure relief procedure when
shutting the unit down for any purpose, including
servicing or adjusting any part of the spray system,
changing or cleaning spray tips, or preparing for cleanup.
Painting
1. Place the siphon tube into a container of paint.
2. Place the return hose into a metal waste container.
3. Turn the pressure control knob fully counterclockwise to
its lowest pressure setting.
4. Move the PRIME/SPRAY valve to the PRIME position.
5. Move the engine ON/OFF switch to the ON position.
6. Start the engine:
a. Open the fuel valve lever.
b. Move the throttle lever away from the gas tank.
Ground the gun by holding it against the
edge of the metal container while
flushing. Failure to do so may lead to a
static electric discharge, which may
cause a fire.
17. Trigger the gun into the metal waste
container until all air and solvent is flushed from the spray
hose and paint is flowing freely from the gun.
18. Lock the gun by turning the gun trigger lock to the locked
position.
19. Turn the pressure control knob fully counterclockwise to
its lowest setting.
Turn off the sprayer.
20.
21. Attach tip guard and tip to the gun as instructed by the tip
guard or tip manuals.
POSSIBLE INJECTION HAZARD. Do not spray without the
tip guard in place. Never trigger the gun unless the tip is in
either the spray or the unclog position. Always engage the
gun trigger lock before removing, replacing or cleaning tip.
22. Turn on the sprayer.
23. Increase the pressure by turning the pressure control
knob slowly clockwise and test the spray pattern on a
piece of cardboard. Adjust the pressure control knob until
the spray from the gun is completely atomized. Try to
keep the pressure control knob at the lowest setting that
maintains good atomization.
NOTE: Turning the pressure up higher than needed to
atomize the paint will cause premature tip wear
and additional overspray.
Pressure Relief Procedure
Heavy Coat
Do not flex wrist while spraying.
Light Coat Light Coat
Be sure to follow the pressure relief procedure when
shutting the unit down for any purpose, including
servicing or adjusting any part of the spray system,
changing or cleaning spray tips, or preparing for cleanup.
1. Lock the gun by turning the gun trigger lock to the locked
position.
2. Turn off the sprayer by moving the sprayer ON/OFF
switch to the OFF position.
3. Turn off the engine by moving the engine ON/OFF switch
to the OFF position.
4. Turn the pressure control knob counterclockwise to its
lowest setting.
. Unlock the gun by turning the gun trigger lock to the
5
unlocked position.
4. Hold the metal part of the gun firmly to
the side of a metal container to ground
the gun and avoid a build up of static
electricity.
5. Trigger the gun to remove any pressure
that may still be in the hose.
6. Lock the gun by turning the gun trigger lock to the locked
position.
7. Move the PRIME/SPRAY valve to the PRIME position.
Spraying
Spraying Technique
The key to a good paint job is an even coating over the entire
surface. This is done by using even strokes. Keep your arm
moving at a constant speed and keep the spray gun at a
constant distance from the surface. The best spraying distance
is 10 to 12 inches between the spray tip and the surface.
Keep the spray gun at right angles to the surface. This means
moving your entire arm back and forth rather than just flexing
your wrist.
WARNING
Knob
Pressure
Control
Knob
Sprayer
ON/OFF
SwitchSwitch
Sprayer
ON/OFF
Switch
WARNING
CAUTION
WARNING
CAUTION
WARNING
WARNING
Cleanup
Special cleanup instructions for use with flammable
solvents:
• Always flush spray gun preferably outside and at least one
hose length from spray pump.
If collecting flushed solvents in a one gallon metal
•
ontainer, place it into an empty five gallon container, then
c
lush solvents.
f
• Area must be free of flammable vapors.
• Follow all cleanup instructions.
he sprayer, hose, and gun should be cleaned thoroughly
T
after daily use. Failure to do so permits material to build
up, seriously affecting the performance of the unit.
Always spray at minimum pressure with the gun nozzle tip
removed when using mineral spirits or any other solvent
to clean the sprayer, hose, or gun. Static electricity
buildup may result in a fire or explosion in the presence of
flammable vapors.
1. Follow the “Pressure Relief Procedure” found in the
Operation section of this manual.
2. Remove the gun tip and tip guard and clean with a brush
using the appropriate solvent.
3. Place the siphon tube into a container of the appropriate
solvent (refer to recommendations of the material
manufacturer). An example of the appropriate solvent is
water for latex paint.
4. Place the return hose into a metal waste container.
5. Move the PRIME/SPRAY valve to its PRIME position.
NOTE: Hold the return hose in the waste container
6. Move the engine ON/OFF switch to the ON position and
7.
8.
9. Allow the solvent to circulate
10.
11. Turn off the sprayer by moving the ON/OFF switch to the
12. Move the PRIME/SPRA
13.
14. Turn the pressure control knob slowly clockwise to
Ground the gun by holding it against the
edge of the metal container while
flushing. Failure to do so may lead to a
static electric discharge, which may cause a fire.
when moving the PRIME/SPRAY valve to
PRIME in case the sprayer is pressurized.
start the engine.
Turn on the sprayer by moving
the sprayer ON/OFF switch to
the ON
Slowly turn the pressure control
knob clockwise to increase the
pressure until fluid starts to
come out of the return hose.
through the sprayer and flush
the paint out of the return hose
into the metal waste container.
T
its lowest setting.
OFF position.
Turn on the sprayer.
increase pressure.
position.
urn the pressure control knob fully counterclockwise to
position.
valve to its SPRA
Y
Y
15. Trigger the gun into the metal waste container until the
paint is flushed out of the hose and solvent is coming out
of the gun.
6. Continue to trigger the spray gun into the waste container
1
ntil the solvent coming out of the gun is clean.
u
17. Follow the “Pressure Relief Procedure” found in the
Operation section of this manual.
18. Store the sprayer in a clean, dry area.
Do not store the sprayer under pressure.
Cleaning the Spray Tip
1. Flush the gun with solvent immediately after the work is
completed.
2. Oil the sliding pins to prevent them from seizing up.
Should the spray tip become clogged, reverse
the spray tip with the lever and pull the trigger.
Once the obstruction comes out of the spray tip,
release the trigger, reverse the spray tip back to
the spray pattern setting, and resume spraying.
Do not attempt to clean the tip with your finger.
Do not use a needle or other sharp pointed instrument to
clean the tip. The hard tungsten carbide is brittle and can
be chipped.
Maintenance
Before proceeding, follow the Pressure Relief Procedure
outlined previously in this manual. Additionally, follow all
other warnings to reduce the risk of an injection injury,
injury from moving parts, or electric shock.
NOTE: All Honda engine work should be performed by
General Repair and Service Notes
The following tools are needed when repairing this sprayer:
1. Before repairing any part of the sprayer, read the
Never pull on a wire to disconnect it. Pulling on a wire
could loosen the connector from the wire.
2. Test your repair before regular operation of the sprayer to
a Honda authorized service center.
Phillips screwdriver 3/8" hex wrench
needle-nose pliers 5/16" hex wrench
adjustable wrench 1/4" hex wrench
rubber mallet 3/16" hex wrench
flat-blade screwdriver 1/8” hex wrench
1/2” open-end wrench 7/8” open-end wrench
instructions carefully, including all warnings.
be sure that the problem is corrected. If the sprayer does
not operate properly, review the repair procedure to
determine if everything was done correctly. Refer to the
Troubleshooting section to help identify other possible
problems.
© SprayTECH. All rights reserved. 7
WARNING
Dowel Pin
Cam Base
Valve Stem
Filter
Housing
Valve Housing
Assembly
Gasket
Valve Handle
Groove Pin
. Make certain that the service area is well ventilated in
3
ase solvents are used during cleaning. Always wear
c
rotective eyewear while servicing. Additional protective
p
equipment may be required depending on the type of
cleaning solvent. Always contact the supplier of solvents
for recommendations.
4. If you have any further questions concerning your
SprayTECH airless sprayer, call SprayTECH:
echnical Service...................................
T
Fax ................................................1-800-525-9501
-800-292-4637
1
Maintaining the Engine
When transporting a sprayer with a gas engine, make sure
the fuel is shut off.
NOTE: For detailed engine specifications and
Important Facts Concerning this Sprayer
This gas-powered sprayer contains a clutch that engages
when the sprayer is pumping. The sprayer’s pressure control
system engages and disengages the clutch to control
pressure. To prevent unnecessary wear to the clutch, it is
advisable to adjust the engine speed and pressure setting to
limit the amount of times the clutch engages and disengages.
To reduce clutch wear, refer to the following examples.
Example:
Operating one gun with a .019 tip — reduce the engine speed
by adjusting the throttle to a low or medium setting and
increase pressure only until the heavy ends of the spray
pattern have been eliminated.
Example:
Operating one gun with .023 tip — increase engine speed to a
higher setting and increase pressure until the heavy ends of
the spray pattern have been eliminated.
Example:
Spraying light-bodied materials at low pressure — to reduce
surging at the gun and to decrease clutch wear, reduce the
engine speed to idle and reduce pressure until the desired
spray pattern is achieved.
Routine Engine Maintenance
Daily
Weekly
Spark Plug
maintenance, refer to the separate engine
manual supplied with this sprayer.
• Check and fill the gas tank.
• After the first 20 hours of operation, drain the oil and refill
with clean oil. Check the engine oil level and fill as
necessary.
• Remove the cover of the air filter and clean the element.
Replace the element if necessary. If operating in an
unusually dusty environment, check the filter daily and
replace if necessary. (Replacement elements can be
purchased from your local SprayTECH dealer.)
• After each 50 hours of operation: Change the engine oil.
• Use only a (NKG) BP6ES plug.
• Gap the plug 0.025” – 0.030” (0.7 – 0.8 mm).
• Make sure to use a spark plug wrench when installing and
removing the plug.
Replacing the Filter
. Loosen and remove the filter
1
ody by hand.
b
2. Remove the filter and filter
support spring spring from the
filter housing.
3. Remove the filter support spring
and adapter from inside the
filter.
4. Inspect the filter. Based on
inspection, clean or replace the
filter.
. Inspect the filter housing o-ring.
5
Based on inspection, clean or
replace the o-ring.
6. Slide the new or cleaned filter
over the adapter and filter
support spring. Place the filter
and filter support spring into the
center of the filter housing.
7. Clean the inside of the filter
body.
8. Slide the filter body over the
filter and thread it into the filter
housing until secure. Make
sure the filter spring is in
position on top of the filter.
NOTE: The filter body should
be hand-tightened,
but make sure it is
seated fully into the
filter housing.
Replacing the PRIME/SPRAY Valve
Perform the following procedure using PRIME/SPRAY valve
replacement kit P/N 0507690.
1. Drive the groove pin out of the valve handle.
2. Remove the valve handle and the cam base.
3. Using a wrench, loosen and remove the valve housing
assembly.
4. Make sure the gasket is in place and thread the new valve
housing assembly into the filter housing. Tighten securely
with a wrench.
5. Place the cam base over the valve housing assembly.
Lubricate the cam base with grease and line up the cam
with the filter block using the dowel pin.
Line up the hole on the valve stem with the hole in the
6.
valve handle.
Insert the groove pin into the valve handle and through
7.
the valve stem to secure the valve handle in position.
8 © SprayTECH. All rights reserved.
Replacing the Potentiometer
CAUTION
CAUTION
EPC
Housing
Pressure Control Knob
Seal Nut
Cap
EPC
Board
EPC
Assembly
EPC
Assembly
Screw
Potentiometer
WARNING
Replacing the Sprayer ON/OFF Switch
Electrostatic discharge (ESD) potential could cause
damage to electronic pressure control. Use SprayTECH
ESD wrist strap P/N 0507958 or equivalent when working
on electronic pressure control.
1. Perform the Pressure Relief Procedure.
2. Pry off the pressure control knob cap to expose the knob
tension nut.
3. Turn the pressure control knob fully counterclockwise to
the minimum pressure setting.
. Using a 5/16” socket, loosen the tension nut in the center
4
f the knob. Remove the knob.
o
5. Using a Phillips screwdriver, remove the four screws that
secure the electronic pressure control (EPC) assembly to
the EPC housing. Carefully remove the EPC assembly
from the housing. Gently move the assembly away from
the sprayer and allow the assembly to hang from the
housing.
6. Hold the potentiometer inside the EPC housing while
using a 1/2” thin wall socket to remove the seal nut that
secures the potentiometer to the mounting plate. Remove
the potentiometer from the EPC housing.
7. Carefully remove the potentiometer wires from their
connection point on the EPC board.
8. Insert the stem of the new potentiometer through the hole
in the mounting plate from inside the EPC housing.
Position the protruding tab on the potentiometer face into
the hole on the underside of the mounting plate (the wires
will face the open side of the EPC housing).
9. Thread the seal nut onto the threaded portion of the stem
and tighten using a 1/2” thin wall socket.
Electrostatic discharge (ESD) potential could cause
damage to electronic pressure control. Use SprayTECH
ESD wrist strap P/N 0507958 or equivalent when working
on electronic pressure control.
1. Perform the Pressure Relief Procedure.
2. Using a Phillips screwdriver, remove the four screws that
secure the electronic pressure control (EPC) assembly to
the EPC housing. Carefully remove the EPC assembly
from the housing. Gently move the assembly away from
the sprayer and allow the assembly to hang from the
housing.
3. Locate the bottom of the sprayer ON/OFF switch inside
the EPC housing.
4. Disconnect the switch wires from the sprayer ON/OFF
switch. Remember the locations of each of the two wires
(label the wires, if necessary).
5. Depress the mounting tabs on each corner of the sprayer
ON/OFF switch inside the EPC housing and remove the
switch through the top of the housing.
6. Snap the new sprayer ON/OFF switch into the switch hole
in the EPC housing.
7. Connect the two switch wires to the new sprayer ON/OFF
switch. Make sure the wires are connected to the
corresponding terminals from which they were removed
(refer to the labels created earlier in this procedure or the
electrical schematic in the Parts List section of this
manual).
8. Carefully place the EPC assembly over the EPC housing
taking care not to pinch any wires.
9. Install the four screws that secure the EPC assembly to
the EPC housing. Tighten securely.
Do not over-tighten the seal nut.
Do not over-tighten the knob tension nut. Over-tightening
will damage the potentiometer.
10. Turn the potentiometer stem fully counterclockwise.
Place the pressure control knob on the potentiometer
1.
1
stem with the indicator tab resting at the “minimum
pressure” tab on the mounting plate.
12. Tighten the knob tension nut using a 5/16” socket.
13. Connect the potentiometer wires to the EPC board. The
protruding tab on the EPC board connector will mate with
the slot on the potentiometer wires connector. The
connector on the end of the potentiometer wires and the
connector on the EPC board will mate only one way. Do
not force the connectors together.
Carefully place the EPC assembly over the EPC housing
14.
taking care not to pinch any wires.
15. Install the four screws that secure the EPC assembly to
the EPC housing. Tighten securely.
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