Wagner SprayTech 3000 User Manual
SERVICE/OPERATION
Form No. 001-683 FEB2305
MANUAL
Table of Contents
INTRODUCTION
Spray & Stripe Speci cations 1
Safety Warnings
GETTING STARTED
How to Flush 7
Flushing 8
Setting Up 9
Pressure Relief Procedure 10
Daily Maintenance 10
Starting Up 11
Striping Operation 12
Striping Tip Guide
REPAIRS/MAINTENANCE
INSTRUCTIONS
2
13
Spray Gun Operation 14
Spray Gun Troubleshooting 15
Field Troubleshooting
Servicing the Fluid Pump 17
Servicing the Piston Rod 18
Servicing the Suction Assembly 18
Packing Replacement 19
Inspection & Replacement of
Control Valve, Ball & Seat 21
16
PRODUCT DIAGRAMS & PARTS LISTS
Gearbox Assembly
Gun Assembly
Gun Mount Assembly
22
23
23
Bypass Valve Assembly 24
Suction Assembly 25
Frame Assembly 26
Manufactured by: AIRLESSCO BY DUROTECH CO.
Moorpark, CA 93021 Tel: 805-523-0211 Fax: 805-523-1063
www.airlessco.com email: techsupport@airlessco.com
SUBJECT TO CHANGE WITHOUT NOTICE.
Copyright © 2005, All rights reserved.
Introduction
INTRODUCTION
The heart of the Spray & Stripe series
is the time tested and contractor proven
Airlessco “LP” piston paint pump. Designed
for spraying 1700 gallons per year, this
pump is used daily by thousands of painting
professionals worldwide--with a reputation for
trouble free performance that’s unmatched in
the industry.
They’re small, compact, easy to use, and
quick to clean. Even changing colors is
a breeze. Stripe with water-based paints
made for traf c lines or athletic elds. A
professional quality spray gun is mounted on
a multi-position spray arm. Their balance
and light weight make them ideal for a oneman operation.
A quick release of the spray gun from
its mount lets you paint using stencils, or
utilize the 50' of supplied hose and the spray
gun to paint with exterior latex and enamel
paints.
Flexibility makes the Spray & Stripe
popular with cities, school districts, and
sports programs for parking lot or athletic
eld striping, and for use as a mobile airless
spraying station. It’s perfect for painting
fences, buildings, and covering graf ti.
Model 3000 Specifications:
Part # 305-229
Max Pressure 0-2500 PSI (170 Bar)
Max Output .62 GPM (2.35 Litres/min.)
Max Tip 1 gun @ 0.027 inch 1 x 8" (30cm) line
Motor Output Briggs & Stratton 3.5 hp
Model 3500 Speci cations:
Part # 305-240 (Fixed front wheel model)
305-245 (Front swivel wheel model)
Max Pressure 0-2500 PSI (170 Bar)
Max Output 0.62 GPM (2.35 Litres/min.)
Max Tip 1 gun @ 0.027 inch. 1 x 12” (30cm) line
Motor Output Honda 3 hp
Part #305-245
Spray & Stripe 3500 shown has
the optional Front Swivel Wheel
with RADIUS MEMORY™
IMPORTANT WARNING !!
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!!
High pressure spray can cause extremely serious injury.
OBSERVE ALL WARNINGS!
Before operating this unit, read and follow all safety warnings and
instructions related to the usage of this equipment. READ, LEARN,
and FOLLOW the Pressure Relief Procedure on Page 10 and
understand all warnings on pages 2 thru 6.
All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.
NO MODIFICATIONS or alterations of any Airlessco Equipment or part is allowed.
1
Safety Warnings
TOXIC FLUID HAZARD
Hazardous uid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know
the hazards of the uid you are using. Store & dispose of hazardous uids according to manufacturer, local, state & national
guidelines. ALWAYS wear protective eye wear, gloves, clothing and respirator as recommended by uid manufacturer.
ALWAYS INSPECT SPRAYING AREA
• ALWAYS keep spraying area free from obstructions.
• ALWAYS make sure area has good ventilation to safely remove vapors and mists.
• NEVER keep ammable material in spraying area.
• NEVER spray in vicinity of open ame or other sources of ignition.
SPRAY GUN SAFETY
• ALWAYS set safety lock on the gun in "LOCKED" position when not in use and before servicing or cleaning.
• NEVER remove or modify any part of the gun.
• ALWAYS REMOVE SPRAY TIP when cleaning. Flush unit with LOWEST POSSIBLE PRESSURE.
• ALWAYS check operation of all gun safety devices before each use.
• Be very careful when removing the spray tip or hose from gun. A plugged line contains uid under pressure. If the tip or
line is plugged, follow the PRESSURE RELIEF PROCEDURE as outlined on page 10.
TIP GUARD
ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the injection hazard and helps
prevent accidentally placing your ngers or any part of your body close to the spray tip.
SPRAY TIP SAFETY
Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch
immediately.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE and then remove the spray tip to clean it.
• NEVER wipe off build up around the spray tip.
• ALWAYS remove tip & tip guard to clean AFTER pump is turned off and the pressure is relieved by following the
PRESSURE RELIEF PROCEDURE.
KEEP CLEAR OF MOVING PARTS
Keep clear of moving parts when starting or operating the sprayer. Do not put your ngers into any openings to avoid
amputation by moving parts or burns from hot parts.
Precaution is the best insurance against an accident.
When starting the engine, maintain a safe distance from moving parts of the equipment.
Before adjusting or servicing any mechanical part of the sprayer, follow the PRESSURE RELIEF PROCEDURE, and remove
the ignition cable from the spark plug to prevent accidental starting of the sprayer.
LABELING
Keep all labels on the unit clean and readable. Replacement labels are available from the manufacturer.
2
Safety Warnings
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
OBSERVE ALL WARNINGS.
INJECTION HAZARD
Fluids under high pressure from spray or leaks can penetrate the skin and cause extremely serious
injury, including the need for amputation.
• NEVER point the spray gun at anyone or any part of the body.
• NEVER put hands or ngers over the spray tip. Do not use a rag or any other material over your ngers. Paint will
penetrate through material and into the hand.
• NEVER try to stop or deect leaks with your hand or body.
• NEVER try to "blow back" paint, this is not an air spray sprayer.
• ALWAYS have gun tip guard in place when spraying.
• ALWAYS lock gun trigger when you stop spraying.
• ALWAYS remove tip from the gun to clean it.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE, as shown on page 10, before cleaning or removing the
spray tip or servicing any system equipment.
• ALWAYS Be sure equipment safety devices are operating properly before each use.
• ALWAYS tighten all uid connections before each use.
MEDICAL TREATMENT
If any uid appears to penetrate your skin, get EMERGENCY CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT.
* Go to an emergency room immediately.
* Tell the doctor you suspect an injection injury.
* Tell him what kind of material you were spraying with and have him read NOTE TO PHYSICIAN.
MEDICAL ALERT - Airless Spray Wounds NOTE TO PHYSICIAN:
If any uid appears to penetrate your skin, get Injection in the skin is a traumatic injury.
EMERGENCY MEDICAL CARE AT ONCE. DO It is important to treat the injury surgically
NOT TREAT AS A SIMPLE CUT. Tell the doctor as soon as possible. DO NOT DELAY treatment
exactly what uid was injected. Have him read to research toxicity. Toxicity is a concern with
the following "NOTE TO PHYSICIAN". some exotic coatings injected directly into the
bloodstream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
GENERAL PRECAUTIONS
• NEVER alter equipment in any manner. • NEVER smoke while in spraying area.
• NEVER spray highly ammable materials. • NEVER use around children.
• NEVER allow another person to use sprayer unless they are thoroughly instructed on safety use and
given this operators manual to read.
• ALWAYS wear a spray mask, gloves and protective eye wear while spraying.
• ALWAYS ensure re extinquishing equipment is readily available and properly maintained.
NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM.
FOLLOW PRESSURE RELIEF PROCEDURES ON PAGE 10.
3
Safety Warnings
GROUNDING
Ground the sprayer and other components in the system to reduce the risk of static sparking, re or
explosion which can result in serious bodily injury and property damage.
Always ground all of these components:
• Fluid Hose: use only grounded hoses.
• Spray gun or dispensing valve: grounding is obtained through connection to a properly
grounded uid hose and pump.
• Object being sprayed: according to your local code.
• All solvent pails used when ushing should only be metal pails which are conductive.
Once each week, check electrical resistance of hose (when using multiple hose assemblies, check
overall resistance of un-pressurized hose must not exceed 29 megohms (max) for any coupled length
or combination of hose lengths. If hose exceeds these limits, replace it immediately.
Never exceed 300 Ft. (150 m.) overall combined hose length to assure electrical continuity.
AVOID COMPONENT RUPTURE
This sprayer operates at 2500 psi (170 bar). Always be sure that all components and accessories have a
maximum working pressure of at least 3000 psi to avoid rupture which can result in serious bodily injury
including injection and property damage.
• NEVER leave a pressurized sprayer unattended to avoid accidental operation of it which could result in serious
bodily injury.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE whenever you stop spraying and before adjusting,
removing or repairing any part of the sprayer.
• NEVER alter or modify any part of the equipment to avoid possible component rupture which could result in
serious bodily injury and property damage.
• NEVER use weak, damaged or non-conductive paint hoses. Do not allow kinking or crushing of hoses or allow
it to vibrate against rough, sharp or hot surfaces. Before each use, check hoses for damage and wear and ensure
all uid connections are secure.
• REPLACE any damaged hose. NEVER use tape or any device to mend the hose.
• NEVER attempt to stop any leakage in the line or ttings with your hand or any part of the body. Turn off the
unit and release pressure by following PRESSURE RELIEF PROCEDURE on page 10.
• ALWAYS use approved high pressure ttings and replacement parts.
• ALWAYS ensure re extinquishing equipment is readily available and properly maintained.
Do not use halogenated solvents in this system. The prime valve, 2 gun manifold and most
airless guns have aluminum parts and may explode. Cleaning agents, coatings, paints or
adhesives may contain halogenated hydrocarbon solvents. DON'T TAKE CHANCES!
Consult your material suppliers to be sure. Some of the most common of these solvents are:
Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether, Ethylbromide,
Ethylchloride, Tethrachloethane. Alternate valves and guns are available
if you need to use these solvents.
4
Safety Warnings
FLUSHING
Reduce risk of injection injury, static sparking or splashing by following the specic cleaning procedure on page 7.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 10.
• ALWAYS remove the spray tip before ushing. Hold a metal part of the gun rmly to the side of a metal pail and
use the lowest possible uid pressure during ushing.
• NEVER use cleaning solvents with ash points below 140º F. Some of these are: acetone, benzene, ether,
gasoline and naphtha. Consult your supplier to be sure.
• NEVER smoke in the spraying/cleaning area.
PREVENT STATIC SPARKING FIRE/ EXPLOSIONS
ALWAYS be sure all equipment and objects being sprayed are properly grounded. Always ground sprayer, paint
bucket and object being sprayed. See "grounding" on page 4 for detailed grounding information.
Vapors created when spraying can be ignited by sparks. To reduce the risk of re, do not plug in or unplug any
electrical cords in an enclosed spray area,. This can create sparks when there is any chance of igniting vapors still
in the air. Follow the coating & solvent manufacturers safety warnings and precautions.
Use only conductive uid hoses for airless applications. Be sure gun is grounded through hose connections. Check
ground continuity in hose & equipment. Overall (end to end) resistance of un-pressurized hose must not exceed 29
megohms for any coupled length or combination of hose length. Use only high pressure airless hoses with static
wire approved for 3000 psi.
Important: United States Government safety standards have been adopted under the Occupational
Safety & Health Act. These standards, particularly the General Standards, Part 1910, & the
Construction Standards, part 1926 should be consulted.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR PAINT THINNERS:
1. When spraying with ammable liquids, unit must be located a minimum of 25 feet away from spraying area
in a well ventilated area. Ventilation must be sufcient enough to prevent the accumulation of vapors.
2. To eliminate electrostatic discharge, ground the spray unit, paint bucket and spraying object. Use only high
pressure airless hoses approved for 3000 psi which is conductive.
3. Remove spray tip before cleaning gun and hose. Make contact of gun with bucket and spray without the tip in
a well ventilated area, into the grounded steel bucket.
4. Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.
5. Do not smoke in spraying/cleaning area.
GAS ENGINE PRECAUTIONS
WHEN ADDING FUEL
• Turn engine OFF and let engine cool at least 2
minutes before removing gas cap.
• Fill fuel tank outdoors or in well ventilated area.
• Do not overll fuel tank. Fill tank to
approximately1 inches below top of neck to
allow for fuel expansion.
• Keep gasoline away from sparks, open ames,
pilot lights, heat and other ignition sources.
• Check fuel lines, tank, cap and ttings frequently
for cracks or leaks. Replace if necessary.
Fire or explosion can cause severe burns or death.
WHEN STARTING ENGINE
• Make sure spark plug, mufer, fuel cap and air cleaner
are in place.
• Do not crank engine with spark plug removed.
• If fuel spills, wait until it evaporates before starting
engine.
• If engine oods, set choke to OPEN/RUN
position, place throttle in FAST and crank until
engine starts.
Gasoline & its vapors are extremely
ammable & explosive.
WHEN OPERATING EQUIPMENT
• Do not tip engine or equipment at angle which
causes gasoline to spill.
5
Safety Warnings
WHEN TRANSPORTING EQUIPMENT
• Transport with fuel tank EMPTY or with fuel shut-off
valve OFF.
WHEN STORING GASOLINE OR EQUIPMENT WITH
FUEL IN TANK
• Store away from furnaces, stoves, water heaters and
other appliances that have pilot lights or other ignition
source. They can ignite gasoline vapors.
Starting engine creates sparking.
Sparking can ignite nearby ammable gases.
Explosion and re could result.
• If there is natural or LP gas leakage in area, do not
start engine.
• Do not use pressurized starting uids because vapors
are ammable.
Rapid retraction of starter cord (kickback) will pull
hand and arm toward engine faster than you can let go.
Broken bones, fractures, bruises or sprains could result.
• When starting engine, pull cord slowly until resistance is
felt, then pull rapidly.
• Remove all external equipment/engine loads before starting
engine.
• Direct coupled equipment components such as, but not
limited to, blades, impellors, pulleys, sprockets, etc. must
be securely attached.
Rotating parts can contact or entangle hands, feet,
hair, clothing or accessories.
Traumatic amputation or severe laceration can result.
• Operate equipment with guards in place.
• Keep hands and feet away from rotating parts.
• Tie up long hair and remove jewelry.
• Do not wear loose tting clothing, dangling drawstrings or
items that could become caught.
Running engines produce heat. Engine parts,
especially mufers, become extremely hot.
Severe thermal burns can occur on contact.
Combustible debris, such as leaves, grass, brush,
etc. can catch re.
• Allow mufer, engine cylinder and ns to cool before
touching.
• Remove accumulated combustibles from mufer area and
cylinder area.
• Install and maintain in working order a spark arrester
before using equipment on forest covered, grass covered
and brush covered unimproved land. The state of
California requires this (Section 4442 of the California
Public Resources Code). Other states may have similar
laws. Federal laws apply on federal land.
Unintentional sparking can result in re
or electric shock.
Unintentional start up can result in entanglement,
traumatic amputation, or lacerations.
BEFORE PERFORMING ADJUSTMENTS OR
REPAIRS
• Disconnect spark plug wire and keep it away from
spark plug.
• Disconnect battery at negative terminal (only
engines with electric start).
WHEN TESTING FOR SPARK
• Use approved spark plug tester.
• Do not check for spark with spark plug removal.
Engines give off carbon monoxide, an odorless,
colorless, poison gas.
Breathing carbon monoxide can cause nausea,
fainting or death.
• Start and run engine outdoors.
• Do not start or run engine in enclosed area, even if doors or
windows are open.
6
How to Flush
FIGURE 1
LOCK TRIGGER TO
REMOVE SPRAY TIP
FIGURE 2
CONTROL VALVE
FIGURE 3 - Briggs Engine
FIGURE 3 - Honda Engine
FIGURE 4
Maintain rm metal
to metal contact
between gun and container.
1. Be sure the gun safety latch is engaged and there is
no spray tip in the gun. Refer to Fig. 1. Refer to your
separate instruction manual provided with your gun
on its safety features and how to engage safety latch.
2. Pour enough clean, compatible solvent (or water when
using water-base paint) into a large, empty metal pail to
ll the pump and hoses.
3. Place the suction tube into the pail
4. Turn the control valve to the prime position or fully
counterclockwise. Refer to Fig. 2.
5. Turn the engine ON/OFF switch to ON.
6. Move the choke to the closed position.
7. Move the throttle lever slightly to the FAST position.
8. Turn the fuel valve ON (Honda only). Pull the start rope.
Pull the engine over against compression stroke and then
let the rope rewind slowly into the starter. Pull rmly and
rapidly to start the engine. Do NOT drop the rope. Hold
onto the handle while rewinding, or the rope may rewind
improperly and jam the assembly. If the engine does not
start, open the choke half way. If the engine oods, open
the choke all the way and continue cranking.
9. After the engine is warm, gradually open the choke
lever, increase the RPM of engine by squeezing the
throttle control trigger on the handlebars.
10. Point the gun into the metal pail and hold a metal part of
the gun rmly against the pail Refer to g. 4.
To reduce the risk of static sparking, which can
cause re or explosion, always hold a metal
part of the gun rmly against the metal pail
when ushing. This also reduces splashing.
Refer to Fig.4.
11. Disengage the gun safety latch and squeeze the gun
trigger. Turn the control valve clockwise just enough
to move liquid at low pressure.
12. Allow the pump to operate until clean solvent comes
from the gun.
13. Release the trigger and engage the gun safety latch.
14. If you are going to start spraying, place the pump or
suction tube into the supply container. Release the
gun safety latch and trigger the gun into another
empty, metal container, holding a metal part of the
gun rmly against the metal pail (Fig. 4) and force
the solvent from the pump and hose. When paint
starts coming from the gun, turn control valve to
prime or fully counter clockwise position and engage
the gun safety latch.
15 . If you are going to store the sprayer, remove the
suction tube or pump from the solvent pail force the
solvent from the pump and hose. Engage the gun
safety latch and refer to the “Storage” Procedure on
page 8.
16 . Whenever you shut off the sprayer follow the
Pressure Relief Procedure warning on page 10.
7
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