Page 2 - Table of Contents; INTRODUCTION; Manufactured by: AIRLESSCO BY DUROTECH CO.
Table of Contents INTRODUCTION Spray & Stripe Specifi cations 1 Safety Warnings 2-6 GETTING STARTED Flushing 7 Daily Maintenance 8 Pressure Relief Procedure 9 Setting Up to Stripe or Spray 10 Starting Up 11-12 Striping Operation 13 REPAIRS/MAINTENANCE INSTRUCTIONS Spray Gun Operation 14 Spray Gu...
Page 3 - HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!!; Introduction
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. IMPORTANT WARNING !! HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM...
Page 4 - Safety Warnings
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 fingers or any part of your body close to the spray tip. SPRAY TIP SAFETY Use extreme caution when cleaning or changing spray tip...
Page 5 - HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.; NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM.
Safety Warnings 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 fingers over the spray tip. Do not use a rag or any other m...
Page 6 - AVOID COMPONENT RUPTURE; GROUNDING; Always ground all of these components:; use only grounded hoses.; Spray gun or dispensing valve:; grounding is obtained through connection to a properly; Object being sprayed:; according to your local code.
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...
Page 7 - WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS OR PAINT THINNERS:; GAS ENGINE PRECAUTIONS; Construction Standards, part 1926 should be consulted.; FLUSHING; ALWAYS; WHEN STARTING ENGINE
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 overfill fuel tank. Fill tank to approximately11⁄2 inches below top of neck to allow for fuel expansion. • Keep gasoline away from sparks,...
Page 8 - BEFORE PERFORMING ADJUSTMENTS OR; • Disconnect spark plug wire and keep it away from; WHEN TESTING FOR SPARK; • Use approved spark plug tester.
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. ...
Page 9 - Flushing; Read prior to using your sprayer
1. New Sprayer Your Airlessco unit was factory tested in an antifreeze solution which was left in the pump. Before using oil-base paint, flush with mineral spirits only. Before using water-base paint flush with soapy water, then do a clean water flush. 2. Changing Colors Flush with a compatible solv...
Page 10 - Daily Maintenance; Airlessco Throat Seal Oil; Packing life will be extended a minimum of three times if the; Check suction nut daily.
8 8 1. Keep the displacement pump packing nut/wet cup lubricated with Airlessco TSO (Throat Seal Oil) at all times. The TSO helps protect the rod and the packings. Daily Maintenance Airlessco Throat Seal Oil 6 ounce bottle Part # 188-187 1 quart bottle Part # 188-392 2. Inspect the packing nut daily...
Page 11 - Pressure Relief Procedure; splashing into the bucket while relieving pressure during Step 4.
9 Pressure Relief Procedure IMPORTANT! To avoid possible serious body injury, always follow this procedure whenever the sprayer is shut off, when checking it, when installing, changing or cleaning tips, whenever you stop spraying, or when you are instructed to relieve the pressure. 1. Engage the gun...
Page 12 - Setting Up to Stripe or Spray; A small steel chain grounding strap is installed at; Fill the packing nut/wet cup with 5 drops
10 Setting Up to Stripe or Spray 1. Connect the hose and gun. a. If the hose is not already installed on the striper, remove the plastic cap plug from the outlet tee at the spray pump, and screw a conductive or grounded 3000 psi airless spray hose onto fl uid outlet. b. Connect an airless spray gun ...
Page 13 - Starting Up; Adjusting the Pressure; Learn the Functions; Starting the Sprayer
11 Starting Up 4. Adjusting the Pressure a. Turn the Pressure Control Knob Clockwise to increase pressure and counterclockwise to decrease pressure. b. Always use the lowest pressure necessary to completely atomize the material. Note: Operating the sprayer at higher pressure than needed, wastes mate...
Page 14 - When Shutting off the Sprayer; Be sure to relieve pressure in; Avoiding Tip Clogs
12 5. When Shutting off the Sprayer a. Whenever you stop spraying, even for a short break, follow the "Pressure Relief Procedure". b. Clean the tip & gun as recommended in the seperate Gun Manual supplied with the gun/ c. Flush the sprayer at the end of each work day, if the material you...
Page 15 - Miscellaneous Operations; Striping Operation; Refer to fi gure below
1. Choose handle location The choices are, installing the handle opposite of the single wheel assembly (standard set up) or placing the handle directly over the single wheel assembly. The handle location is really a matter of personal preference, however having the handle away from the single wheel ...
Page 16 - Spray Gun Operation; MAJOR COMPONENTS OF SPRAY GUN &; CLEANING SPRAY GUN
Spray Gun Operation Reversible Spray Tip Tip Guard Trigger Guard MAJOR COMPONENTS OF SPRAY GUN & REVERSIBLE REV-TIP ™ SPRAY GUN Attach spray gun to airless unit and tighten fittings securely. Set the gun safety latch. (Also may be called gun safety lock, or trigger lock) * The gun safety latch s...
Page 17 - Spray Gun Troubleshooting; DEFECTS; TEST THE PATTERN
Spray Gun Troubleshooting DEFECTS CAUSE CORRECTION Coarse spray Low pressure Increase the pressure Excessive fogging High pressure Reduce pressure for satisfactory pattern (overspray) Material too thin Use less thinner Pattern too wide Spray angle too large Use smaller spray angle tip Pattern too na...
Page 18 - Field Troubleshooting; PROBLEM; Unit primes but has no
Field Troubleshooting PROBLEM CAUSE SOLUTION Unit doesn't prime Airleak due to: • Loose Suction Nut • Tighten Suction Nut • Worn O-Rings • Replace O-Ring (106-011) on suction seat, & O-Ring (106- 020) below suction seat • Hole in Suction Hose • Replace Suction Hose (331-290) Stuck or Fouled Ball...
Page 19 - FIGURE 1; Servicing the Fluid Pump; Fluid Pump Disconnect
17 Refer to Figure 1 1. Follow the Pressure Relief Procedure on page 10. 2. Flush the material you are spraying out of the machine. 3. Remove the connecting rod shield (331-111). 4. Move the piston rod (331-093) to its lowest position by cycling pump slowly. 5. Remove the retaining ring (331-062) fr...
Page 20 - Servicing the Piston Rod - Outlet Valve; DISASSEMBLY OF THE OUTLET VALVE; Servicing the Suction Assembly; REFER TO FIGURE 4
Servicing the Piston Rod - Outlet Valve 331-196 331-195 Piston DISASSEMBLY OF THE OUTLET VALVE REFER TO FIGURE 3 1. Disconnect the Fluid Pump following instructions on page 17 . 2. Place piston holder (331-195) in a vise. Slide piston into the holder & lock in place with a 3/8” dowel (331-196). ...
Page 21 - Packing Replacement Procedures; Replacement Instructions:
Packing Replacement Procedures 19 Fluid Pump Removal - Refer to Figure 1 1. Follow the Pressure Relief Procedure on page 9. 2. Flush material you are spraying out of the machine. 3. Remove the connecting rod shield (331-111). 4. Move the piston rod (331-093) to its lowest position by cycling pump sl...
Page 22 - FIGURE 5; FIGURE 6
FIGURE 5 Packing Replacement Procedures FIGURE 6 20 3. Push the two bolts (100-318) through the tube spacers (331-074) & screw into the cover assembly (331-234). Using a 1/2” wrench, tighten the two bolts evenly (alternating between them) until you reach 20 ft-lbs. 4. Reassemble lower suction va...
Page 23 - Electrical Control Board Replacement; Pressure Calibration on the Electrical Control Board
21 Electrical Control Board Replacement Pressure Calibration on the Electrical Control Board 1. Remove electrical cover. 2. Disconnect sensor lead from Electrical Board. 3. Disconnect two clutch leads on Electrical Board from leads on clutch. 4. Using a 1/16" allen, loosen set screw in Pressure ...
Page 24 - Clutch Replacement; INSTALL NEW CLUTCH AS FOLLOWS:
Clutch Replacement INSTALL NEW CLUTCH AS FOLLOWS: REMOVE CLUTCH AS FOLLOWS: 1. Remove clutch and electrical box cover. 2. Disconnect the power lead coming from the engine to the electrical box and feed it through the back of the electrical box. 3. Using a 1/2” wrench along with a 1/2” socket remove ...
Page 25 - Troubleshooting - Clutch Does Not Engage
Troubleshooting - Clutch Does Not Engage STEP 1 : Ensure that the pressure control knob (POT) is in the maximum (CW) position. STEP 2: Remove the clutch and electrical box covers. STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose connecti...
Page 26 - Gear Box Assembly -; Part Number
24 Gear Box Assembly - Part No. 305-196 Part Number Description 100-028 Pipe Plug 100-226 45 degree Elbow 100-318 HXHD Screw 100-380 Screw 100-381 Screw 100-398 Retaining Ring 112-068 Ball Bearing 115-019 Hose Connector 117-008 Ball Bearing 305-199 Shaft Pinion 305-287 Machined End Bell 331-038 Cros...
Page 27 - Cable Retainer Spring
25 Spray Gun Assembly - Part No. 305-280 Gun Mount Assembly - Part No. 305-275 - Part Number Description 100-011 Airless 1/4” x 50’ Hose 116-103 Cable Retainer Spring 120-115 008 Silver Gun w/o Tip 305-275 Gun Mount Ass’y 305-280 Spray Gun Assembly 561-025 Rev-Tip Male Seal 561-026 Rev- Tip Seal 563...
Page 28 - Frame Assembly
Page 29 - Swivel Wheel Assembly; Hose Clamp; Suction Assembly
Swivel Wheel Assembly 27 Part Number Description Qty. 106-020 Teflon O-Ring 1 141-015 Hose Clamp (some models only) 1 331-034 Suction Nut 1 331-035 Suction Elbow 1 331-217 Suction Filter 1 Suction Assembly Part No. 331-290 -
Page 30 - Striping Tip Guide; STRIPING TIP; STRIPING TIP - ORIFICE SIZE; LIGHT
Striping Tip Guide STRIPING TIP REGULAR PAINTING SPRAY TIP UNIFORM PATTERN LIGHT HEAVY Striping Tips should not be used for regular spraying. Striping tips are designed for a single pass application, while spray tips are designed for the 1/3 overlap technique used for spray painting. Spray Tip Repla...
Page 31 - IR; CCESSORIES
XTEND-A-POLE SYSTEM Tip Extensions - Complete with Patented SPRAY CLEAN REV-GUARD TIP EXTENSIONS, “G” THREAD 032-170 6” Long 032-171 12” Long 032-172 18” Long 032-173 24” Long SWIVEL EXTENSION, “G” THREAD 032-184 36” Long EXTENSIONS (BARE POLES) Add Tip Extension or Swivel Extension to create desire...
Page 32 - Rever sible; Cuts Cleaning Time; NEW; Connect adapter to any “F”; The industry’s only “clean water” fl ushing system!
REV-GUARD ™ Spray Painting Striping POSI-LOC ™ SYSTEM Snap in centering of tip. No leaks, splashback or mess. SEAL LOCATING HANDLE Tip handle simplifies installing & aligning the seal. EASIEST ASSEMBLY Fewer parts - Less complicated takes only seconds! INTERCHANGEABLE Can be used with most tip g...
