Spraytech 0509026 User Manual

Printed in the U. S. A.

LineCrew 1600

Line Striper

Owner’s Manual

Model Number 0509026

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

Table of Contents

Safety Precautions.................................................................2

Français ..............................................................................18

Español...............................................................................20

General Description ...............................................................4

Operation ................................................................................4

Setup ....................................................................................4

Preparing to Paint.................................................................5

Painting.................................................................................6

Operating the Front Caster...................................................6

Pressure Relief Procedure ...................................................6

Cleanup ...................................................................................7

Maintenance............................................................................7

General Repair and Service Notes.......................................7

Maintaining the Engine .........................................................8

Replacing the Filter...............................................................8

Replacing the PRIME/SPRAY Valve.....................................8

Replacing the Potentiometer ................................................9

Replacing the Pump ON/OFF Switch...................................9

Replacing the Transducer...................................................10

Replacing the Electronic Pressure Control (EPC) Board ...10

Replacing the Slider Assembly and Slider Housing............11

Replacing the Gears...........................................................12

Servicing the Clutch Assembly...........................................12

Servicing the Fluid Section.................................................14

Troubleshooting ...................................................................17

Parts Listings........................................................................22

Main Assembly....................................................................22

Drive Assembly...................................................................23

Cart Assembly.....................................................................24

Fluid Section Assembly ......................................................26

Electrical Schematic ...........................................................26

Filter Assembly ...................................................................27

PRIME/SPRAY Assembly ...................................................27

Caster Assembly.................................................................27

Suction Hose Assembly......................................................28

Return Hose Assembly.......................................................28

Labels .................................................................................28

Limited Warranty..................................................................32

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.

HAZARD: Injection injury - A high pressure stream

produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation. See a physician immediately.

DO NOT TREAT AN INJECTION INJURY AS A SIMPLE CUT! Injection can lead to amputation. See a physician immediately.

The maximum operating range of the gun is 3300 PSI /

22.8 MPa fluid pressure.

WARNING

NOTE: Notes give important information which should

be given special attention.

CAUTION

WARNING

PREVENTION:

• NEVER aim the gun at any part of the body.

•NEVER allow any part of the body to touch the fluid stream. DO NOT allow body to touch a leak in the fluid hose.

• NEVER put your hand in front of the gun. Gloves will not provide protection against an injection injury.

•ALWAYS lock the gun trigger, shut the pump off, and release all pressure before servicing, cleaning the tip or guard, changing tip, or leaving unattended. Pressure will not be released by turning off the motor. The PRIME/SPRAY knob must be turned to PRIME to relieve the pressure. Refer to the PRESSURE RELIEF PROCEDURE described in the pump manual.

•ALWAYS keep the tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device.

•ALWAYS remove the spray tip before flushing or cleaning the system.

• The paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.

•NEVER use a spray gun without a trigger lock and trigger guard in place and in good working order.

• All accessories must be rated at or above 3300 PSI / 22.8 MPa. This includes spray tips, guns, extensions, and hose.

HAZARD: EXPLOSION OR FIRE - Solvent and paint fumes

can explode or ignite. Severe injury and/or property damage can occur.

PREVENTION:

• Provide extensive exhaust and fresh air introduction to keep the air within the spray area free from accumulation of flammable vapors.

•Avoid all ignition sources such as static electric sparks, open flames, pilot lights, and hot objects. Connecting or disconnecting power cords or working light switches can make sparks.

•Do not smoke in spray area.

• Fire extinguisher must be present and in good working order.

• Place paint pump in a well ventilated area. Flammable vapors are often heavier than air. Floor area must be extremely well ventilated. The paint pump contains arcing parts that emit spark and can ignite vapors.

• The equipment and objects in and around the spray area must be properly grounded to prevent static sparks.

• Use only conductive or grounded high pressure fluid hose. Gun must be grounded through hose connections.

• Power cord must be connected to a grounded circuit (electric models only).

• Always flush unit into a separate metal container, at low pump pressure, with spray tip removed. Hold gun firmly against side of container to ground container and prevent static sparks.

• Follow the material and solvent manufacturer's warnings and instructions.

• Use extreme caution when using materials with a flashpoint below 70° F (21° C). Flashpoint is the temperature that a fluid can produce enough vapors to ignite.

• Plastic can cause static sparks. Never hang plastic to enclose a spray area. Do not use plastic drop cloths when spraying flammable materials.

• Use lowest possible pressure to flush equipment.

NOTE TO PHYSICIAN: Injection into the skin is a traumatic injury. It is

important to treat the injury as soon as possible. DO NOT delay treatment to research toxicity. Toxicity is a concern with some coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

GAS ENGINE (WHERE APPLICABLE)

Always place pump outside of structure in fresh air. Keep all solvents away from the engine exhaust. Never fill fuel tank with a running or hot engine. Hot surface can ignite spilled fuel. Always attach ground wire from pump unit to a grounded object, such as a metal water pipe. Refer to engine owner’s manual for complete safety information.

HAZARD: EXPLOSION HAZARD DUE TO INCOMPATIBLE

MATERIALS - Will cause severe injury or property damage.

PREVENTION:

• Do not use materials containing bleach or chlorine.

• Do not use halogenated hydrocarbon solvents such as mildewcide, methylene chloride and 1,1,1 trichloroethane. They are not compatible with aluminum.

• Contact your coating supplier about the compatibility of material with aluminum.

HAZARD: HAZARDOUS VAPORS - Paints, solvents,

insecticides, and other materials can be harmful if inhaled or come in contact with the body. Vapors can cause severe nausea, fainting, or poisoning.

PREVENTION:

• Use a respirator or mask if vapors can be inhaled. Read all instructions supplied with the mask to be sure it will provide the necessary protection.

•Wear protective eyewear.

•Wear protective clothing as required by coating manufacturer.

HAZARD: GENERAL - This product can cause severe

injury or property damage.

PREVENTION:

• Read all instructions and safety precautions before operating equipment.

• Always disconnect the motor from the power supply before working on the equipment (electric models only).

• Follow all appropriate local, state, and national codes governing ventilation, fire prevention, and operation.

• 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.

• Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety devices of the pump manufacturer.

• Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a paint hose. Replace it with another grounded high-pressure hose.

• All hoses, swivels, guns, and accessories must be rated at or above 3300 PSI/22.8 MPa.

• Do not spray outdoors on windy days.

•Wear clothing to keep paint off skin and hair.

• Always unplug cord from outlet before working on equipment.

• Do not use this equipment to spray water or acid.

Do not lift by cart handle when loading or unloading.

CAUTION

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.

WARNING

General Description

This airless sprayer is a precision power tool used for spraying many types of materials. Read and follow this instruction manual carefully for proper operating instructions, maintenance, and safety information.

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 suction hose and the return hose are attached and secure.

2. 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.

3. Install the gun support bar.

a. Loosen the support bar clamps on each side of the cart. b. Slide the gun support bar through the cart. c. Tighten the support bar clamps to secure the gun

support bar in position.

Always follow the Pressure Relief Procedure when shutting the sprayer down for any purpose, including servicing or adjusting any part of the spray system, changing or cleaning spray tips, or preparing for cleanup.

4. Position the first spray gun.

a. Disengage the trigger cable from the tensioning clamp.

NOTE: The gun support bar and the spray gun(s) can

be mounted on either side of the sprayer.

NOTE: The spray gun, hose, and cables are mounted to

the gun support bar at the factory.

NOTE: USE 3/8” SPRAY HOSE FOR MAXIMUM

PERFORMANCE, MINIMUM PRESSURE DROP, AND MINIMUM PRESSURE FLUCTUATION.

WARNING

Always disengage the trigger cable from the tensioning clamp before making any adjustments to the spray gun position.

b. Loosen the support bar clamps and slide the gun

support bar to the desired horizontal position.

c. Loosen the gun riser clamp and slide the spray gun to

the desired vertical position.

4. Install the second gun assembly, if desired. Refer to the installation instructions that come with the second gun assembly accessory.

5. Set the trigger selector for proper spray gun operation. The right handlebar triggers the gun or guns. The selector on the trigger must be set for the first gun, both guns, or the second gun .

Always turn the trigger lock on the spray gun to the locked position before making any adjustments to the trigger selector. Also, release the trigger cable from its block by lifting the cable up and out of the block. There will be a brief triggering of the gun while releasing the trigger cable.

a. First Gun — The first

gun position is with the selector in the left position. Push the lever toward the inside of the frame until the pin engages the left plate.

b. Both Guns — The dual

gun position is with the selector in the center position. Push the lever toward the center position until the pin engages both plates. The pin must engage both plates.

c. Second Gun — The

second gun position is with the selector in the right position. Push the lever away from the inside of the frame until the pin engages the right plate. 5. Turn the pressure control knob fully counterclockwise to its lowest pressure setting.

6. Make sure the pump ON/OFF switch is in the OFF position.

7. 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.

8. Check the engine oil level. The gasoline engine oil level is determined by the manufacturer. Refer to the engine manufacturer's service manual (supplied).

9. Close the fuel shut-off lever and fill the gas tank with gasoline. Use only high quality, unleaded gasoline.

CAUTION

NOTE: The height of the spray gun affects the width of

the spray pattern (i.e., the lower the gun, the smaller the line width). Tip size also affects line width.

Front Caster

Trigger

Throttle

Oil Cup

Gun

Trigger

Airless

Sprayer

Fluid

Section

Gun Riser

Gun

Support Bar

Airless Spray Gun

Engine

Filter Assembly

PRIME/ SPRAY Val ve

Outlet Fitting

Tip Assembly

CAUTION

WARNING

Adjusting the Trigger Tension

Use the following procedure to adjust the spring tension of the trigger lever on the gun holder assembly. The trigger lever pulls and releases the spray gun trigger when operated from the trigger on the cart. The proper tension ensures that the gun will shut off when the gun trigger is released. To ensure proper tension, there should be approximately a 1/32” to 1/16” gap between the trigger lever and the spray gun trigger.

Always keep the trigger lock on the spray gun in the locked position while making adjustments to the system.

1. Using a 5/32” hex wrench, loosen the set screw on the cable block.

2. Move the cable block in the appropriate direction to create a gap of 1/32” to 1/16” between the trigger lever and spray gun trigger.

a. Slide the cable block toward the gun to increase the

gap between the trigger lever and spray gun trigger.

b. Slide the cable block away from the gun to decrease

the gap between the trigger lever and spray gun trigger.

3. Tighten the set screw securely.

Preparing a New Sprayer

If this unit is new, it is shipped with test fluid in the fluid section to prevent corrosion during shipment and storage. This fluid must be thoroughly cleaned out of the system with mineral spirits before you begin spraying.

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

1. Place the suction tube into a container of mineral spirits that has a flash point of 60ºC (140ºF) or above.

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.

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.

Fuel Valve

Lever

Choke Lever

Engine ON/OFF Switch

Throttle Lever

Starter Rope

CAUTION

7. Turn on the sprayer by moving the pump 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 for 15–30 seconds to flush the test fluid out through the return hose and into the waste container.

10. Turn the pressure control knob fully counterclockwise to its lowest setting.

11.Turn off the sprayer by moving the pump ON/OFF switch to the OFF position.

Preparing to Paint

Before painting, it is important to make sure that the fluid in the system is compatible with the paint that is going to be used.

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

1. Place the suction tube into a container of the appropriate solvent for the material being sprayed (refer to recommendations of the material manufacturer). An example of the appropriate solvent is water for latex 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. 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 pump 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 for 15–30 seconds to flush the old solvent out through the return hose and 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 pump ON/OFF switch to the OFF position.

12. Move the PRIME/SPRAY valve to the SPRAY position.

13. Turn on the sprayer.

14. Turn the pressure control knob slowly clockwise to increase pressure.

15. Unlock the gun by turning the gun trigger lock to the unlocked position.

NOTE: Make sure that the spray gun does not have a

tip or tip guard installed.

CAUTION

NOTE: Incompatible fluids and paint may cause the

valves to become stuck closed, which would require disassembly and cleaning of the sprayer’s fluid section.

Pressure

Control

Knob

Pump ON/OFF Switch

Cable Block (set screw on back)

Spray Gun

Trigger

1/32" to 1/16" Gap

Trigger Lever

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 suction 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.

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 pump 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 pump 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.

Pressure

Control

Knob

Pump ON/OFF Switch

Fuel Valve

Lever

Choke Lever

Engine ON/OFF Switch

Throttle Lever

Starter Rope

WARNING

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.

20. Turn off the sprayer.

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. Test the spray pattern and line position on a long piece of roofing felt or cardboard. a. 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.

b. Check for proper line width and position. If adjustment

to the position of the spray gun is required, refer to the “Setup” procedure earlier in this section.

24. Make sure that the spray gun completely shuts off when the gun trigger is released. If adjustment to the trigger tension is required, refer to the “Adjusting the Trigger Tension” procedure earlier in this section.

Operating the Front Caster

The front caster on the cart is designed to track the sprayer in either a straight line or allow free motion. Standing behind the sprayer, the trigger on the left handle of the cart controls the operation of the front caster.

1. To lock the front caster in the straight line position, squeeze then release the caster trigger and move the sprayer forward.

2. To allow free motion of the front caster, squeeze and hold the caster trigger.

Pressure Relief Procedure

1. Lock the gun by turning the gun trigger lock to the locked position.

2. Turn off the sprayer by moving the pump ON/OFF switch to the OFF position.

WARNING

NOTE: To lock the front caster in free motion mode,

squeeze and hold the caster trigger and then push in the locking button on the side of the trigger. Once the locking button is pushed in, the caster trigger can be released. To release the locking pin, squeeze the caster trigger.

NOTE: Turning the pressure up higher than needed to

atomize the paint will cause premature tip wear and additional overspray.

WARNING

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.

5. Unlock the gun by turning the gun trigger lock to the 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.

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 container, place it into an empty five gallon container, then flush solvents.

• Area must be free of flammable vapors.

• Follow all cleanup instructions.

The sprayer, hose, and gun should be cleaned thoroughly 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 suction 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.

6. Move the engine ON/OFF switch to the ON position and start the engine.

7. Turn on the sprayer by moving the pump 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.

9. Allow the solvent to circulate through the sprayer and flush the paint out of 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 ON/OFF switch to the OFF position.

12. Move the PRIME/SPRAY valve to its SPRAY position.

13. Turn on the sprayer.

14. Turn the pressure control knob slowly clockwise to increase pressure.

WARNING

CAUTION

WARNING

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.

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.

16. Continue to trigger the spray gun into the waste container until the solvent coming out of the gun is clean.

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.

General Repair and Service Notes

The following tools are needed when repairing this sprayer:

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

1. Before repairing any part of the sprayer, read the instructions carefully, including all warnings.

Never pull on a wire to disconnect it. Pulling on a wire could loosen the connector from the wire.

CAUTION

NOTE: All Honda engine work should be performed by

a Honda authorized service center.

WARNING

CAUTION

NOTE: For long-term or cold weather storage, pump

mineral sprits through the entire system.

WARNING

2. Test your repair before regular operation of the sprayer to 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.

3. Make certain that the service area is well ventilated in case solvents are used during cleaning. Always wear protective eyewear while servicing. Additional protective 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:

Technical Service...................................1-800-292-4637

Fax ................................................1-800-525-9501

Maintaining the Engine

When transporting a sprayer with a gas engine, make sure the fuel is shut off.

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 high 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

• 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.

Weekly

• 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.

Spark Plug

• 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.

NOTE: For detailed engine specifications and

maintenance, refer to the separate engine manual supplied with this sprayer.

Replacing the Filter

1. Loosen and remove the filter body by hand.

2. Remove the filter and core spring from the filter housing.

3. Remove the core spring from inside the filter.

4. Inspect the filter. Based on inspection, clean or replace the filter.

5. Inspect the filter housing o-ring. Based on inspection, clean or replace the o-ring.

6. Slide the new or cleaned filter over the core spring. Place the filter and core 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.

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.

6. Line up the hole on the valve stem with the hole in the valve handle.

7. Insert the groove pin into the valve handle and through the valve stem to secure the valve handle in position.

NOTE: The filter body should

be hand-tightened, but make sure it is seated fully into the filter housing.

WARNING

Filter

Body

Filter

Core

Spring

Filter

Housing

O-ring

Filter

Housing

Gasket

Filter

Housing

Dowel Pin

Cam Base

Valve Handle

Valve Housing Assembly

Valve Stem

Groove Pin

Replacing the Potentiometer

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.

4. Using a 5/16” socket, loosen the tension nut in the center of the knob. Remove the knob.

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.

Do not over-tighten the seal nut.

10. Turn the potentiometer stem fully counterclockwise.

11. Place the pressure control knob on the potentiometer 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.

Do not over-tighten the knob tension nut. Over-tightening will damage the potentiometer.

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.

14. Carefully place the EPC assembly over the EPC housing taking care not to pinch any wires.

15. Install the four screws that secure the EPC assembly to the EPC housing. Tighten securely.

CAUTION

WARNING

Replacing the Pump 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. 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 pump ON/OFF switch inside the EPC housing.

4. Disconnect the switch wires from the pump 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 pump ON/OFF switch inside the EPC housing and remove the switch through the top of the housing.

6. Snap the new pump ON/OFF switch into the switch hole in the EPC housing.

7. Connect the two switch wires to the new pump 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.

WARNING

EPC

Assembly

Screw

EPC

Assembly

EPC

Board

Potentiometer

Cap Pressure Control Knob Seal Nut

EPC Housing

EPC

Assembly

Screw

EPC

Assembly

EPC

Board

Pump ON/OFF Switch

EPC Housing

Replacing the Transducer

WARNING

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.

3. Locate the transducer wire in the EPC housing. This wire will be protruding from a hole in the lower left hand corner of the EPC housing. Disconnect this wire from the EPC board (it has a phone jack-style connector).

4. Break off the locking tab from the phone jack-style connector at the end of the transducer wire.

5. Using a 7/8” open-end wrench, loosen and remove the fluid hose from the fitting on the bottom of the filter assembly.

6. Using a 9/16” open-end wrench, loosen and remove the return hose from the bottom of the filter assembly.

7. Using a 1/2” socket, remove the two hex screws that secure the filter assembly to the cart.

8. Lift the filter assembly off the cart so that the transducer tube moves out of the hole in the gear housing. Gently pull the transducer wire through the housing until it is fully disengaged from the hole.

9. Mount the filter assembly in a vise for easy access to the transducer.

CAUTION

Do not over-tighten the vise.

10. Using a 3/4” open-end wrench, turn the transducer nut counterclockwise to remove the transducer from the filter housing.

11. Locate the new transducer. Make sure that there is a white, PTFE o-ring on the end of the transducer that gets inserted into the filter housing.

12. Insert the transducer into the filter housing port. Rotate the transducer nut clockwise to tighten it into the filter housing. Torque the nut to 360–400 in./lbs.

13. Remove the filter assembly from the vise.

Gear Housing

Fluid

Hose

Fitting

Cart

Filter Assembly

Hex Screw

EPC Assembly Screw

EPC Assembly

EPC Housing

EPC

Board

Transducer

Filter Assembly

Return Hose Fitting

14. Insert the phone jack-style connector on the new transducer wire into the hole in the gear housing from which the old transducer wire was removed. Push the wire and connector until the connector is visible in the EPC housing.

15. Gently pull the wire into the EPC housing while moving the filter assembly to its mounting point on the cart. Guide the end of the transducer tube into the hole in the gear housing.

16. Mount the filter assembly to the cart using the two hex screws and lock washers. Torque the screws to 100–130 in./lbs.

17. Using a 7/8” open-end wrench, attach the fluid hose to the fitting on the bottom of the filter assembly. Tighten securely.

18. Using a 9/16” open-end wrench, attach the return hose to the bottom of the filter assembly. Tighten securely.

19. Plug the phone jack-style connector on the transducer wire into the socket on the EPC board from which the old connector was removed.

20. Carefully place the EPC assembly over the EPC housing taking care not to pinch any wires.

21. Install the four screws that secure the EPC assembly to the EPC housing. Tighten securely.

22. Take the sprayer to a SprayTECH Authorized Service Center for re-calibration.

23. After re-calibration, pressurize the system and check for leaks.

Replacing the Electronic Pressure Control (EPC) Assembly

WARNING

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.

3. Remember the locations of all the wire connections on the EPC board (refer the electrical schematic located in the Parts List section of this manual). If necessary, label all the connections so that they can be replaced in their exact location when the assembly is replaced.

4. Disconnect all the wires from the EPC board.

5. Connect all the wires to the new EPC assembly board (refer to the labels created earlier in this procedure or the electrical schematic in the Parts List section of this manual).

6. Carefully place the EPC assembly over the EPC housing taking care not to pinch any wires.

7. Install the four screws that secure the EPC assembly to the EPC housing. Tighten securely.

8. Take the sprayer to a SprayTECH Authorized Service Center for re-calibration.

EPC Assembly Screw

EPC Assembly

EPC Housing

EPC

Board

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