AIRLESSCO 305-227 Sure Stripe Service Instruction Manual

SERVICE/OPERATION
MANUAL

Introduction

Shipped Complete:
Part # 305-227 SURE STRIPE 4000 with spray gun and 50’ of hose.
INTRODUCTION
The 4000 is the compact piston pump striper that delivers the professional results and range of features needed by pavement striping contractors—and it’s an incredible value! It’s based on our proven LP Piston Pump used daily by thousands of painting contractors. The large onepiece piston along with Airlessco’s patented triple-life packing system results in reduced maintenance, lower operating costs, and longer equipment life. A clutch actuated .8 gpm paint system features an electronic pressure control system. The 4000 is powered by a dependable 4 hp Honda GX series commercial OHV 4-cycle engine. It’s built on a small, compact frame, that’s easy to use, and quick to clean. Designed-in balance & light weight make it ideal for one-man operation. Foot operated parking brake holds machine on inclines. Our 008 Silver Contractor spray gun can spray wtih an up to .029” tip. It mounts on any corner, and has a quick release for painting parking curbs or pavement using stencils. It features a tungsten carbide ball and seat, the “No Drips” REV-GUARD patented REV-TIP ™ ™ base, and our reversible tips that clear clogs literally in a snap.
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 9 and understand all warnings on pages 2 thru 6.5
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.

GETTING STARTED

Safety Warnings
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are using. Store & dispose of hazardous fluids according to manufacturer, local, state & national guidelines. ALWAYS wear protective eye wear, gloves, clothing and respirator as recommended by fluid 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 flammable material in spraying area.
•  NEVER spray in vicinity of open flame 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 fluid under pressure. If the tip or line is plugged, follow the PRESSURE RELIEF PROCEDURE as outlined on page 9.

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 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 fingers 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.
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
OBSERVE ALL WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY.
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 fingers over the spray tip. Do not use a rag or any other material over your fingers. Paint will penetrate through material and into the hand.• NEVER try to stop or deflect 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 9, 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 fluid connections before each use.

MEDICAL TREATMENT
If any fluid 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
  If any fluid appears to penetrate your skin, get
  EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Have him read the following “NOTE TO PHYSICIAN”.
  NOTE TO PHYSICIAN:
  Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. DO NOT DELAY treatment to research toxicity. Toxicity is a concern with 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 spray highly flammable materials.
  • NEVER smoke while in spraying area.
  • 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 fire extinquishing equipment is readily available and properly maintained.

NEVER LEAVE SPRAYER UNATTENDED WITH PRESSURE IN THE SYSTEM. FOLLOW PRESSURE RELIEF PROCEDURES ON PAGE 9.
GROUNDING
Ground the sprayer and other components in the system to reduce the risk of static sparking, fire or explosion which can result in serious bodily injury and property damage.
Always ground all of these components:

• Sprayer: Be sure grounding chain (supplied) is in contact with the ground.
• Fluid Hose: use only grounded hoses.
• Spray gun or dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.
• Object being sprayed: according to your local code.
• All solvent pails used when flushing 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 500 Ft. (150 m.) overall combined hose length to assure electrical continuity.
AVOID COMPONENT RUPTURE
This sprayer operates at 3000 psi (205 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 fluid 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 fittings with your hand or any part of the body. Turn off the unit and release pressure by following PRESSURE RELIEF PROCEDURE on page 9,.
• ALWAYS use approved high pressure fittings and replacement parts.
• ALWAYS ensure fire extinquishing equipment is readily available and properly maintained.

WARNING
Do not use halogenated solvents in this system. 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 & guns are available if you need to use these solvents.
FLUSHING
Reduce risk of injection injury, static sparking or splashing by following the specific cleaning procedure on page 5.

• ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 9.
• ALWAYS remove the spray tip before flushing. Hold a metal part of the gun firmly to the side of a metal pail and use the lowest possible fluid pressure during flushing.
• NEVER use cleaning solvents with flash 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 fire, always locate the sprayer at least 20 feet (6 m.) away from the spray area. Do not plug in or unplug any electrical cords in the 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 fluid 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:

• When spraying with flammable liquids, unit must be located a minimum of 25 feet away from spraying area in a well ventilated area. Ventilation must be sufficient enough to prevent the accumulation of vapors.
• 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.
• 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.
• Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.
• Do not smoke in spraying/cleaning area.

GAS ENGINE PRECAUTIONS
WARNING
Gasoline & its vapors are extremely flammable & explosive.
Fire or explosion can cause severe burns or death.
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 approximately 11⁄2 inches below top of neck to allow for fuel expansion.
• Keep gasoline away from sparks, open flames, pilot lights, heat and other ignition sources.
• Check fuel lines, tank, cap and fittings frequently for cracks or leaks. Replace if necessary.

WHEN STARTING ENGINE

• Make sure spark plug, muffler, 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 floods, set choke to OPEN/RUN position, place throttle in FAST and crank until engine starts.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which causes gasoline to spill.
• Do not choke carburetor to stop engine.

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.

WARNING
Starting engine creates sparking.
Sparking can ignite nearby flammable gases.
Explosion and fire could result.

• If there is natural or LP gas leakage in area, do not start engine.
• Do not use pressurized starting fluids because vapors are flammable.

WARNING
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, impellers, pulleys, sprockets, etc. must be securely attached.

WARNING
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 fitting clothing, dangling drawstrings or items that could become caught.

WARNING
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.

WARNING
Running engines produce heat. Engine parts, especially mufflers, become extremely hot.
Severe thermal burns can occur on contact.
Combustible debris, such as leaves, grass, brush, etc. can catch fire.

• Allow muffler, engine cylinder and fins to cool before touching.
• Remove accumulated combustibles from muffler 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.

WARNING
Unintentional sparking can result in fire 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.

Flushing
IMPORTANT: 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 solvent such as mineral spirits or water.

3. Changing from water-base to oil-base paint
   Flush with soapy water, then mineral spirits.

4. Changing from oil-base to water-base paint
   Flush with mineral spirits, followed by soapy water, then do a clean water flush.

5. Storage
   Oil-base paint: Flush with mineral spirits.
   Water-base paint: Flush with water, then mineral spirits and leave the pump, hose and gun filled with mineral spirits. For longer storage (and in areas where there is the potential for freezing temperatures), use mixture of mineral spirits and motor oil (half & half). Shut off the sprayer, follow Pressure Relief Procedure on page 9 to relieve pressure and make sure prime valve is left OPEN.

6. Start up after storage
   Before using water-base paint, flush with soapy water and then do a clean water flush. When using oil-base paint, flush out the mineral spirits with the material to be sprayed.

Daily Maintenance

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. Airlessco Throat Seal Oil
   6 ounce bottle Part # 188-187
   1 quart bottle Part # 188-392

2. Inspect the packing nut daily. Your pump has Airlessco’s patented Triple Life Packing System.
   Packing life will be extended a minimum of three times if the following “Packing Adjustment” procedure is followed:
   If seepage of paint into the packing nut and/or movement of the piston upward is found (while not spraying), the packing nut should be tightened enough to stop leakage only, but not any tighter.
   Overtightening will damage the packings and reduce the packing life.

3. Check suction nut daily.

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 safety latch. Refer to the separate instruction manual provided with your gun on its safety features and how to engage safety latch.

2. Turn the unit off.

3. Disengage the gun safety latch and trigger the gun to relieve residual fluid pressure.
   Hold metal part of the gun in contact with grounded metal pail.
   USE MINIMUM PRESSURE !

4. Turn Prime/Pressure Relief Valve (PR Valve) to the open (priming) position to relieve residual fluid pressure. There will be a wider gap between valve handle and cam body when in open position. In the closed position there is only a very slight gap.
   Note: The valve handle can move both clockwise and counter clockwise and can face different directions.

5. Re-engage gun safety latch and close Prime/Pressure Relief Valve.

If the SPRAY TIP OR HOSE IS CLOGGED, follow Step 1 through 5 above. Expect paint splashing into the bucket while relieving pressure during Step 4.
If you suspect that pressure hasn’t been relieved due to damaged Prime/Pressure Relief Valve or other reason, engage the gun safety latch and take your unit to an authorized Airlessco Service Center.
Starting Up

1. Learn the Functions of the Controls.
   PRIME/PRESSURE (PR) RELIEF VALVE is used to prime pump and to relieve pressure from gun, hose and tip.
   Prime/Pressure Relief Valve (Prime/PR Valve)
   Used to relieve pressure from gun, hose & tip and to prime the unit when in OPEN position. (It is in open position when there is a wider gap between valve handle and cam body)
   When in CLOSED position, there is only a very slight gap between handle & body.
   When closed the system is pressurized. Handle as a loaded firearm! PRESSURE CONTROL KNOB is used to adjust pressure. Turn clockwise (CW) to increase pressure and counterclockwise (CCW) to decrease pressure.

2. Prepare the Material
   a. Prepare the material according to the material manufacturer’s recommendations.
   b. Place the suction tube into the material container.

3. Starting the Sprayer
   a. Prime/PR Valve must be “OPEN” in the priming position.
   b. When you have ensured that the gun safety latch is engaged, attach tip and safety guard.
   c. Turn the engien ON/OFF switch to the “ON” position.
   d. Turn Pressure Control Knob clockwise to prime the pump.
   e. After the pump is primed, turn Prime/PR Valve to the “Closed” position.
   f. Turn Pressure Control Knob to the desired spray pressure.
   g. Disengage the gun safety latch and you are ready to spray.

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 material, causes early tip wear, and shortens sprayer life.
   c. If more coverage is needed, use a larger tip rather than increasing the pressure.
   d. Check the spray pattern. The tip size and angle determines the pattern width and flow rate.
   WARNING
   Follow the “Pressure Relief Procedure”. To reduce the risk of injection, never hold your hand, body, fingers or hand in a rag in front of the spray tip when cleaning or checking for a cleared tip. Always point the gun toward the ground or into a waste container when checking to see if the tip is cleared or when using a self-cleaning tip.
   WARNING
   When you spray into the paint bucket, always use the lowest spray pressure and maintain firm metal to metal contact between gun and container.
   WARNING
   To stop the unit in an emergency, turn the engine off. Then relieve the fluid pressure in the pump and hose as instructed in the Pressure Relief Procedure.
   Avoiding Tip Clogs
   There is an easy way to keep the outside of the tip clean from material build up:
   Every time you stop spraying, for even a minute, lock the gun and submerge it into a small bucket of thinner suitable for the material sprayed.
   Thinner will dissolve the buildup of paint on the outside of tip, tip guard and gun much more effectively if the paint doesn’t have time to dry out completely.
   WARNING
   Be sure to relieve pressure in the pump after filling with Airlessco Pump Conditioner.

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 are spraying is water-based, or if it could harden in the sprayer overnight. See “Flushing”. Use a compatible solvent to flush, then fill the pump and hoses with an oil based solvent such as mineral spirits.
   d. For long term shutdown or storage, refer to the “Flushing” section of this manual.

Striping Operation

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 assembly allows for easier loading/unloading from a van.

2. Choose the gun arm position
   There are multiple holes in the frame for mounting the gun arm. In a standard set up (handle away from the single wheel assembly), the gun arm would be mounted in one of the two mounting holes near the single wheel. This allows for an easier visual check for straight line striping and for basic arc striping. The mounting holes under the handle are usually used when the handle has been placed over the single wheel. Experiment with different combinations to find the set up that you prefer.

3. Setting up the gun
   a. Ensure that a striping tips is in the guns.
   b. Pick a tip size for the desired line width.
   Example: a 217ST tip for a four inch line.
   c. Place gun into the gun holder, so that the top of the taper on the gun handle is flush with the edge of the gun holder.
   d. Set gun height for the desired line width.
   Adjust height by loosening the small black handle on the gun holder assembly and slide the gun arm to the correct height. Now tighten the handle. This will require some experimentation to find the correct height.
   It is suggested that tape, or some other method is used to mark the height of commonly used settings.
   e. Attach the swivel heads to the gun if painting curbs or wide stripes.
   f. Angle the gun slightly forward. This allows the spray pressure from the gun to help blow dirt and debris out of the path of the new stripe.

4. Cable Tension Adjustment
   Once the handle and gun arm assemblies are set up to the preferred position, pressurize the unit and trigger the gun to ensure that they activate and release correctly. If not, adjust the cable tension as follows:
   a. Locate the adjustment knobs on the base of the gun trigger, where the cable connects to the gun trigger assembly.
   b. Loose the locking nut & move the adjusting screw until the slack has been removed from the cable.
   c. Tighten locking nut and retest gun triggers for proper function.
   NOTE: There is additional cable adjustment where the cable attaches to the gun holder assembly. Use only if the gun trigger adjustment is insufficient.

5. Miscellaneous Operations
   a. CURBS: Adjust gun to desired height and turn swivel head towards curb.
   b. WIDE STRIPES: Install wider fan striping tips and raise the gun height to achieve the desired width line.
   c. STENCILS: Install standard spray tip. Remove gun from the gun holder and spray out the stencils.
   d. STANDARD PAINTING: Same as stencils, but use additional paint hose as required.

Striping Tip Guide REV-TIP™ for Striping
P.N. 562-xxxST
Includes Rev-TipTM, Metal Seal & O-Ring Seal.
Sample: REV-GUARD™
Super Compact
P.N. 561-001
11/16-16 “F” Thread. Fits:
Airlessco, and some ASM,
Wagner, and Campbell Hausfeld. P.N. 561-002
7/8-14 “G” Thread.
Fits some: Graco, Wagner, Titan, Airlessco.
Striping Tips (orange handle) should not be used for regular spraying. They are designed for a single pass application, while spray tips (black handle) are designed for the 1/3 overlap technique used for spray painting.
Spray Tip Replacement: During use high pressure will cause the orifice to grow larger and more round. This destroys the efficiency of the pattern, wasting your material. It can also leave tailing or two heavy lines on the outside of the pattern.

REPAIRS/MAINTENANCE INSTRUCTIONS

Spray Gun Operation
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 should always be set when the gun is not being triggered.
  Read all warnings and safety precautions supplied with the spray gun and in product manual. MAJOR COMPONENTS OF SPRAY GUN & REVERSIBLE REV- TIP™ SPRAY TIP ASSEMBLY

  1. Be sure the pressure relief procedure is followed before assembling tip and housing to the gun.
  2. Insert REV-TIP™ cylinder into the REV-GUARD™ (guard housing assembly).
  3. Guide the metal seat into REV-GUARD™ (guard housing assembly) through the retaining nut and turn until it seats against the cylinder.
  4. Insert the O-Ring gasket onto the metal seat so that it fits into the grooves.
  5. Finger tighten REV-GUARD™ retaining nut onto the gun.
  6. Turn guard in the desired position.
  7. Completely tighten the retaining nut.

CLEANING SPRAY GUN
Immediately after the work is finished, flush the gun out with a solvent. Brush pins with solvent and oil them lightly so they will not collect dried paint.
CLEANING FILTER IN GUN HANDLE
To clean the filter, use a brush dipped in an appropri- ate solvent. Change or clean filters at least once a day.
Some types of latex may require a filter change after four hours of operation.
TO REMOVE CLOGS FROM SPRAY TIP

1. Lock gun safety latch.
2. Turn REV-TIP™ handle 180 degrees.
3. Disengage trigger lock and trigger gun into the pail.
4. If the REV-TIP™ handle appears locked (resists turning), loosen the retaining nut. The handle will now turn easily.
5. Engage gun safety latch and return handle to the spray position.

CLOGGED FLAT TIP
Should the spray tip become clogged, relieve pressure from hose by following the “Pressure Relief Procedure.” Secure gun with the safety latch, take off guard, take out the tip, soak in appropriate solvent & clean with a brush. (Do not use a needle or sharp pointed instrument to clean the tip. The tungsten carbide is brittle and can chip.)
Spray Gun Troubleshooting

Use a steady, parallel pass
Excessive Overspray (Fogging)| Pressure setting high
Paint over thinned/reduced/cut| Reduce pressure setting
Use less thinner/water/reducer
Spray Pattern Excessively Wide| Incorrect fan width selection| Select narrower fan width tip
Spray Pattern Excessively Narrow| Incorrect fan width selection| Select wider fan width tip
Excessive Paint Delivery
Paint Film Runs/Sags| Large tip orifice for application
Paint over thinned/reduced/cut
Excessive pressure
Spray gun/hand speed slow| Select smaller tip orifice
Use less thinner/water/reducer
Reduce pressure setting
Increase pass speed
Spray Pattern Rounded and Heavy:
Pump Does Not Keep Up| Tip worn beyond use| Replace with new tip
Spray Pattern Pulsates/Irratic:
Pump Does Not Keep Up| Pump worn or malfunctioning| Service pump
Thin or Spotty Coverage (Holidays)| Tip worn beyond use
Pump worn or malfunctioning| Select larger tip orifice
Decrease pass speed
Thin Coverage in Center of Pattern (Fingers)| Tip size larger than pump specs
Low pressure setting
Pump worn or malfunctioning| Replace with correct tip for pump
Increase pressure setting
Service pump
Spray Pattern Irregular, Deflected| Tip orifice partialy clogged
Tip damaged| Clean tip carefully
Replace with new tip*
Excess Paint Builds on Tip Guard| Spray gun excessively close to surface
Pressure setting high| Hold gun further from surface sprayed
Reduce pressure setting
Drips, Spits From Tip| Valve seat and/or ball in gun head damaged or worn| Service spray gun, replace valve assembly
Tip Clogs Continually| Debris in paint
Gun filter missing
Coarse filter mesh| Thouroughly strain paint before use
Insure gun filter is in handle
Use fine mesh filter in gun handle
Gun Filter Clogs Quickly| Debris in paint
Pump inlet strainer missing| Thouroughly strain paint before use
Do not operate without intlet strainer

TEST THE PATTERN: Field Troubleshooting

• Loose Suction Nut
• Worn O-Rings
• Hole in Suction Hose
Stuck or Fouled Balls| • Tighten Suction Nut
• Replace O-Ring (106-011) on suction seat, & O-Ring (106- 020) below suction seat
• Replace Suction Hose (331-290) Service outlet valve suction assembly
Unit primes but has no or poor pressure| Pressure set too low
Filter(s) are clogged
Outlet Valve fouled/worn
Prime/Pressure Relief valve bypassing
Packings and/or piston worn| Turn up pressure
Clean or replace gun filter, inlet filter and/or manifold filter
Service outlet valve
Clean or replace prime valve
Tighten packing nut
Repack unit
Unit does not maintain good spraying pressure| Blown spray tip
Packings and/or piston worn
Upper Seat worn| Replace spray tip

Repack unit
Replace upper seat

Servicing the Fluid Pump
Fluid Pump Disconnect
Refer to Figure 1

1. Follow the Pressure Relief Procedure on page 9.
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. Disconnect the sensor (331-294-99) by holding it in place with a 7/8” wrench and unscrewing the hose connector (115-019) with an 11/16” wrench. DO NOT TURN THE SENSOR.
6. Remove the retaining ring (331-062) from the connecting rod (331-038) and slide the sleeve (331- 117) down revealing the connecting rod pin (331-065).
7. Remove the suction tube assembly from the fluid pump (331-209) by unscrewing the suction nut (331-034) with the packing adjustment tool.
8. Using a 1/2” wrench unscrew the two bolts (100-318) from the cover assembly (331-234). The fluid pump (331-209) will be hanging loosely at this point.
9. Remove the connecting rod pin (331-065) out of the connecting rod (331-038), allowing the removal of the fluid pump (331-209) from the machine.

Fluid Pump Reinstall
Refer to Figure 1 & 4

1. Loosen the packing nut and ensure that the piston rod (331-093) is in its upper position in the fluid pump body (331-011). Slip the sleeve (331-117) & the retaining ring (331-062) over the piston rod.
2. Push the piston rod up into the connecting rod (331- 038) & align the holes. Insert the connecting rod pin (331-065) through the connecting rod & piston. Slip the sleeve up over the connecting rod pin and insert the retaining ring into the groove on the connecting rod.
3. Push the two bolts (100-318) through the tube spacers (331-074) & screw them 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 valve assembly by placing the suction seat (331-409), O-ring (106-011), suction ball (331-030) & suction ball guide (331-029) in the suction nut (331-034) & screw onto fluid pump body.
5. Reconnect the sensor (331-294-99) to the fluid pump body. Hold the sensor with a 11/16” wrench while tightening the hose connector (115-019) with an 7/8” wrench. DO NOT TURN THE SENSOR.
6. Start the machine and operate slowly to check the piston rod for binding. Adjust the two bolts, holding the fluid pump body to the cover assembly, if necessary. This will eliminate any binding.
7. Tighten the packing nut clockwise until resistance is felt against the Belleville Springs, then go 3/4 of a turn more. Put five drops of Airlessco Throat Seal Oil into the packing nut.
8. Run the machine at full pressure for several minutes. Release the pressure by following the Pressure Relief Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield (331-111) so that the small hole is in the upper right hand corner.

Servicing the Piston Rod – Outlet Valve
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).
3. Use a 1/4” allen wrench to unscrew the outlet seat retainer (331-026) from the piston.
4. Remove the outlet seat (331-026), O-ring (331-100) and outlet ball (331-027).
5. Inspect outlet ball & seat for wear. Replace as necessary.
6. While piston is still locked in the holder, install parts back into the piston in the following order:

ball, outlet seat and O-ring
Before reinstalling the outlet seat support, apply two drops of Loctite No. 242 (blue) on the threads & torque to 20 ft-lbs.
NOTE: Airlessco LP pump tool kit 188-197 is suggested for this task.
Kit includes: Tightening Bar (189-211), Packing Removal Tool (331-465), Piston Holder (331-195), 3/8” dowel (331-196).![AIRLESSCO 305-227 Sure Stripe Service

• OUTLET VALVE](https://manuals.plus/wp- content/uploads/2024/02/AIRLESSCO-305-227-Sure-Stripe-Service-OUTLET- VALVE.jpg) Servicing the Suction Assembly
  REFER TO FIGURE 4

  1. Un-thread and remove suction nut from the fluid pump body.
  2. Remove suction seat (331-409), O-ring (106-011), suction ball (331-030) and suction retainer (331-029).
  3. Clean all parts and inspect them for wear or damage, replacing parts as needed.
  4. Clean inside of the fluid pump body.
  5. Reassemble lower suction valve assembly by placing the suction seat (331-409), O-ring (106-011), suction ball (331-030) & suction ball guide (331-029) in the suction nut (331-034) & screw onto fluid pump body.

Packing Replacement Procedures
Replacement Instructions:
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 slowly.

5. Disconnect the sensor (331-294-99) by holding it in place with a 7/8” wrench & unscrewing the hose connector (115-019) with an 11/16” wrench.
   DO NOT TURN THE SENSOR.

6. Remove the retaining ring (331-062) from the connecting rod (331-038) and slide the sleeve (331-117) down revealing the connecting rod pin (331-065).

7. Remove the suction tube assembly from the fluid pump (331-209) by unscrewing the suction nut (331-034) with the packing adjustment tool.

8. Using a 1/2” wrench unscrew the two bolts (100-318) from the cover assembly (331-234). The fluid pump (331-209) will be hanging loosely at this point.

9. Remove the connecting rod pin (331-065) out of the connecting rod (331-038), allowing the removal of the fluid pump (331-209) from the machine.

Disassembly of the Fluid Pump – Figure 6

1. Unscrew & remove the packing nut (331-037).
2. Push the piston rod (331-708) down through the packings & out of the pump.
3. Now push the packing removal tool (331-465) up through the pump & remove from the top bringing packings, spacer & springs along with it, leaving fluid body (331-011) empty.
   *Make sure all old packings & glands have been removed from fluid pump.
4. Clean inside of fluid body (331-011).
5. Disassemble all parts & clean for reassembly. Discard any old packings.
6. Lubricate leather packing in lightweight oil for 10 minutes prior to reassembly.

Disassembly of the Outlet Valve – Figure 3

1. Place piston holder (331-195) in a vise. Slide piston into the holder & lock in place with a 3/8” dowel.
2. Use a 1/4” allen wrench to unscrew the outlet seat retainer (331-026) from the piston.
3. Remove the outlet seat (331-026), O-ring (331-100) and outlet ball (331-027).
4. Inspect outlet ball & seat for wear. Replace as necessary.
5. While piston is still locked in the holder, install parts back into the piston in the following order:

ball, outlet seat and O-ring
Before reinstalling the outlet seat support, apply two drops of Loctite No. 242 (blue) on the threads & torque to 20 ft-lbs.
REASSEMBLY – Figure 5 & 6

1. Take lower male gland (331-014) & place it down on the flat side. 

2. Take three of the lower polyethylene packings (331-016) & two of the leather packings (331-306) & place onto the male gland in the following order with the inverted side down :
   Polyethylene, leather, polyethylene, leather, polyethylene.

3. Take the female adaptor (331-305), which is inverted on both sides , & place it on top of your assembled lower packings.

4. Follow step 2 above with your packings inverted side up.

5. Take the second lower male gland and place it on top of your assembled packings with the rounded side down.

6. Take assembled glands & packings (13 pieces) & slide on to the lower half of the piston.

7. Take the spacer (331-018) & slide over the top of the piston (it doesn’t matter which direction it sits), falling onto lower packings.

8. Take three Belleville Springs (331-025) & slide over the top of the piston in the following order:

• First spring, curve facing down
• Second spring, curve facing up
• Third spring, curve facing down 9. Take the upper male gland (331-022) & place it rounded side up. 10. Take three upper polyethylene packings (331-023) & two leather packings (331-307) & assemble with inverted side down , on to the male gland in the following order: polyethylene, leather, polyethylene, leather, polyethylene. 11. Take upper female gland (331-021) & place on top of the assembled upper packings with the inverted side down. 12. Take assembled upper glands & packings (7 pieces) & slide on over the top of the piston, making sure inverted sides are down. 13. Take the packing holder (331-019) & replace the white O-ring (106-009) & the black O-ring (106-010) with new ones from the packing kit. 14. Slide the packing holder over the top of the upper packings so they fit inside. 15. Lubricate inside of the fluid pump body & the outside of the packings with a light weight oil. 16. Slide completed assembly into fluid pump body (331-011).
• To keep packings secured in correct position, hold the pump body upside down & push the completed assembly upwards into the pump body. Once placed inside, tilt pump body back up to keep all pieces in. 17. Tighten packing nut (331-037) onto the top of the fluid pump body & tighten until you feel slight resistance against the Belleville Springs (331-025). Using the Packing Adjustment Tool (189-211), tighten another 3/4 of a turn.

Fluid Pump Reinstallation – Figure 1 & 4

1. Loosen packing nut & ensure that the piston rod (331-093) is in its upper position in the fluid pump body (331-011). Slip the sleeve (331-117) & the retaining ring (331-062) over the piston rod.

2. Push piston rod up into the connecting rod (331-038) & align the holes. Insert the connecting rod pin (331-065) through the connecting rod & piston. Slip the sleeve up over the connecting rod pin & insert retaining ring into the groove on the connecting rod.

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 valve assembly by placing the suction seat (331-409) O-ring (106-011), suction ball (331-030) and suction ball guide (331-029) in the suction nut (331-034) & screw onto the fluid pump body.

5. Reconnect the sensor (331-294-99) to the fluid pump body. Hold sensor with a 7/8” wrench while tightening the hose connector (115-019) with an 11/16” wrench.
   DO NOT TURN THE SENSOR.

6. Start the machine & operate slowly to check the piston rod for binding. Adjust the bolts, holding the fluid pump body to the cover assembly, if necessary. This will eliminate any binding.

7. Tighten packing nut clockwise until resistance is felt against the Belleville Springs, then go 3/4 of a turn more. Put five drops of Airlessco Throat Seal Oil into the packing nut.

8. Run the machine at full pressure for several minutes. Release the pressure by following the Pressure Relief Procedure & readjust the packing nut per step 7 above.

9. Install the connecting rod shield (331-111) so that the small hole is in the upper right hand corner.

Electrical Control Board Replacement

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 Control Knob and remove knob.
5. Using a 1/2″ nutdriver or 1/2″ deep socket, remove nut from pressure control shaft. This will allow removal of electrical control board from frame.
6. Replace Electrical Board Assembly in reverse order. Adjust pressure as per procedure below, “Pressure Calibration on the Electrical Control Board”.

Pressure Calibration on the Electrical Control Board

1. Turn “Pressure Calibration” Trimpot adjustment on electrical control board in the counter clockwise direction at least 15 revolutions.

2. Connect 5000 psi glycerine pressure guage on output of pump between fluid pump & airless hose to monitor Fluid Pump Pressure.

3. Turn Prime/Pressure Relief Valve to the open (Prime) position. Start engine and run at maximum RPM. Turn Pressure Control Knob to maximum position (fully clockwise).

4. Using an insulated screwdriver, adjust “Pressure Calibration” Trimpot by turning clockwise until the clutch engages. When the clutch engages the pump will commence Priming. When pump is primed, turn the Prime/Pressure Relief Valve to the Closed (Pres sure) Position
   The pump will begin to pressurize and the clutch will disengage at a low pressure. Continue turning the Trimpot clockwise to increase pressure to 3000 psi.

5. Trigger gun. The pressure should drop approximately 350-400 psi (when using a 3/8″ hose), the clutch will engage and build pressure to 3000 psi and disengage. Trigger gun several times to ensure proper pressure setting.

6. Turn Pressure Control Knob to minimum position. The clutch should disengage and pump stop moving.

7. Secure leads with tie strap.

8. Replace cover on unit. Ensure the leads are not pinched or damaged in the process of replacing covers.
   

Clutch Replacement
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 the four bolts attaching the engine to the frame.
4. Remove the engine from the frame and set it on your work bench so the clutch face is facing you.
5. Using a small Phillips head screwdriver remove the three screws holding the clutch face to the clutch mount.
6. Disconnect two clutch leads from electrical board leads. Carefully cut the small Zip-tie holding the clutch wires to the gear housing.
7. Using a #2 Phillips screwdriver, remove the two Phillips head screws holding the clutch field to the gear housing.
8. Pull the clutch field off of the pinion gear.

INSTALL NEW CLUTCH AS FOLLOWS:

1. Apply Anti-seize lubricant to the pinion shaft coming out of the gearbox.
2. Slide new clutch field over pinion shaft lining up holes for the Phillips head screws located at the top (indicated by a square tab) and bottom of the field.
3. Feed the black clutch wires into electrical box & plug into matching wires from the control board.
4. Install the new zip-tie (comes with the clutch replacement kit) to the wire mount, keeping the wires from the path of the clutch.
5. Apply blue Lock-tite to the screws and reinstall into the gearbox.
6. Mount the clutch face to the clutch mount. Use a Phillips head screwdriver to tighten the three screws used for mounting the clutch face. Once the screws come to a positive stop, hold them in place with the screwdriver and thread the lock nuts onto the portion of the screws protruding from the rear of the clutch mount. Tighten the lock nuts until they are flush with the clutch mount.
7. Set the engine back on the frame and tighten the nuts and bolts so that you still can move the engie back and forth fairly easily.
8. Using a feeler gauge slide the motor forward until you reach a spacing of .010” between the clutch face and the field. Once you reach this point, finish tight ening the engine bolts, alternating to keep the air gap the same on all sides of the clutch. Replace the clutch cover.

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 connections or damaged leads.
STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black). Using a multimeter, with the engine at maximum RPM, pressure control knob in the maximum position and the prime valve open (priming) position, test the DC voltage across the boards leads (blue). This voltage must be 13-14 VDC. If the readings are correct, the board, sensor and magneto are okay and the problem is the clutch assembly. If this is the case, proceed to Step 5. If the voltage is outside this range go to Step 7.
STEP 5: Check the spacing between the clutch field and plate. The gap should be .010” to .014”. If the gap is greater than .014” the gap is too wide. If this gap is too wide, replace the clutch assembly.
STEP 6: When the DC voltage from the board is not 13-14 VDC, disconnect the control board lead (black) from the engine magneto lead (pink), located on the side of the engine. With the engine at maximum RPM (3600), pressure control knob in maximum (CW) position and prime valve open (priming), read the AC voltage from the magneto lead to the sprayer frame. This reading should be 19-24 VAC. If outside this range, contact your local Honda repair facility for magneto replacement. If the magneto is producing the proper AC voltage, continue to Step 7.
STEP 7: Test the sensor by reading the resistance between the red and black wires. The resistance runs between 1.5-3K ohms. A defective sensor usually shows no resistance (open). If the reading is outside standards, replace the sensor. An alternative method to test the sensor, is to plug a new sensor into the board and see if the clutch will engage. Caution! When using this method, ensure prime/ pressure valve is in the prime position. This is important because the sensor plugged into the board is not measuring pressure in the fluid section.
STEP 8: When Steps 6 & 7 have been completed and the magneto and sensor check good, the electrical control board is the only item left, replace the board.

PRODUCT DIAGRAMS & PARTS LISTS

Gun Holder Assembly – Part No. 305-150

Gear Box Assembly Part No. 305-310![AIRLESSCO 305-227 Sure Stripe Service

• Gear Box Assembly](https://manuals.plus/wp- content/uploads/2024/02/AIRLESSCO-305-227-Sure-Stripe-Service-Gear-Box- Assembly.jpg)

Part Number| Description| Part Number| Description| Part Number| Description
---|---|---|---|---|---
100-180| Prime Valve| 305-198| Pinion Shaft| 331-111| Front Shield
100-226| 45 degree Elbow| 305-287| Machined End Bell| 331-117| Sleeve
100-318| HXHD Screw| 331-038| Crosshead Assy| 331-197| FLPHHD Screw
100-380| Screw| 331-046| Ball Bearing| 331-294-99| Pressure Sensor
100-381| Screw| 331-047| Ball Bearing| 331-408| Crank Assy
100-398| Retaining Ring| 331-061| Sleeve Bearing| 331-410| Paint Pump Assy
112-068| Ball Bearing| 331-062| Retaining Ring| 331-537| Machined Cover
115-019| Hose Connector| 331-074| Spacer| Not shown: 331-132 Grease
117-008| Ball Bearing| 331-103| Flat Washer

Suction Assembly Part No. 331-238

Frame Assembly 305-227

Pump/Engine Assembly 305-354

Frame Assembly Parts List Swivel Wheel Assembly REV-TIP™
SPRAY TIP SIZE CHART
Part Number 560-xxx
For sizes not shown, call factory for availability.
TIP IDENTIFICATION:
1st 3-digits identifies it as a REV-TIP™ for airless paint spraying (P.N. 560-xxx) or a REV-TIP™ for airless line striping (P.N. 562-xxxST).
4th digit is the fan width – the number is half the fan width, e.g., 5 means a 10” fan. Exception are the“W” prefix tips which indicate a wide spray pattern.
5th and 6th digits are for the orifice size and is measured in thousandths of an inch, e.g., 17 = 0.017 inch – The higher the number, the larger the tip.

For a complete listing of all available accessories see
the Airlessco Accessories Catalog, Part # 001-357.
https://manual-hub.com/

References

• This page intentionally left blank.
• Manual-Hub.com – Free PDF manuals!

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>