AIRLESSCO 3500 User manual

SERVICE/OPERATION

MANUAL

Form No. 001-683 APR0705

Table of Contents

INTRODUCTION

Spray & Stripe Specications 1

Safety Warnings 2

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 13

REPAIRS/MAINTENANCE

INSTRUCTIONS

Spray Gun Operation 14

Spray Gun Troubleshooting 15

Field Troubleshooting 16

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

PRODUCT DIAGRAMS & PARTS LISTS

Gearbox Assembly 22

Gun Assembly 23

Gun Mount Assembly 23

Bypass Valve Assembly 24

Suction Assembly 25

Frame Assembly 26

Swivel Wheel Assembly 27

Manufactured by: AIRLESSCO BY DUROTECH CO.

P.O. Box 8006, Moorpark, CA. 93020-8006, Ship to: 5397 Commerce Ave.,

Moorpark, CA 93021 Tel: 805-523-0211 Fax: 805-523-1063

www.airlessco.com email: [email protected]

SUBJECT TO CHANGE WITHOUT NOTICE.

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!!

High pressure spray can cause extremely serious injury.

OBSERVE ALL WARNINGS!

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.

Introduction

INTRODUCTION 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™

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 one-

man 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 & 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, & covering grafti.

Part #305-240

Spray & Stripe 3500 shown has

the Fixed Swivel Wheel.

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.

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.

Safety Warnings

Keep all labels on the unit clean and readable. Replacement labels are available from the manufacturer.

LABELING

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.

TOXIC FLUID HAZARD

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 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 deect 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.

HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.

OBSERVE ALL WARNINGS.

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.

INJECTION HAZARD

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.

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.

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.

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.

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 overll 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.

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.

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 sufcient 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

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.

FLUSHING

Reduce risk of injection injury, static sparking or splashing by following the specic 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.

Safety Warnings

WHEN STARTING ENGINE

• Make sure spark plug, mufer, 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.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which

causes gasoline to spill.

Gasoline & its vapors are extremely

ammable & explosive.

Fire or explosion can cause severe burns or death.

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.

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.

Safety Warnings

Running engines produce heat. Engine parts,

especially mufers, become extremely hot.

Severe thermal burns can occur on contact.

Combustible debris, such as leaves, grass, brush,

etc. can catch re.

• Allow mufer, engine cylinder and ns to cool before

touching.

• Remove accumulated combustibles from mufer 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.

How to Flush

FIGURE 1

LOCK TRIGGER TO

REMOVE SPRAY TIP

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. Refer to Fig 3.

7. Move the throttle lever slightly to the FAST position.

Refer to Fig 3.

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 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.

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.

Maintain rm metal

to metal contact

between gun and container.

CONTROL VALVE

FIGURE 4

FIGURE 2

FIGURE 3 - Honda Engine

1. New Sprayer

Your Airlessco unit was factory tested in an antifreeze solution which was left in the pump.

Before using oil-base paint, ush with mineral spirits only. Before using water-base paint

ush with soapy water, then do a clean water ush.

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 ush.

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

lled with mineral spirits. For longer storage, use mixture of mineral spirits and motor oil

(half & half). Shut off the sprayer, follow Pressure Relief Procedure on page 10

Flushing

Read prior to using your sprayer

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