1. DL manuals
  2. AIRLESSCO
  3. Paint Sprayer
  4. 3500
  5. Service & Operation Manual

AIRLESSCO 3500 Service & Operation Manual

Other manuals for 3500: Service And Operation Manual

Summary of 3500

  • Page 1

    Service/operation manual form no. 001-683 feb2305.

  • Page 2

    Table of contents introduction spray & stripe specifi 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 1...

  • Page 3

    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

    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

    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. • neverput hands or fingers over the spray tip. Do not use a rag or any other ma...

  • Page 6

    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 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

    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

    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, compa...

  • Page 10

    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 11

    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 to ...

  • Page 12

    Pressure relief procedure 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. 2. Inspect the packing nut daily. Your pump has a patented triple life packing system. Packing life will be extend...

  • Page 13

    Starting up 1. Learn how to operate the control valve. The control valve sets the prime or pressure position as well as the spraying pressure. When the valve is fully counter-clockwise the unit is in the prime position. As the control valve is turned clockwise, the unit’s output pressure to the gun ...

  • Page 14

    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 fro...

  • Page 15

    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 16

    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 shoul...

  • Page 17

    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 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 balls se...

  • Page 19

    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 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). 3. U...

  • Page 21

    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 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 valve ...

  • Page 23

    Inspection & replacement of control valve, ball & seat 1. Use a wrench to unscrew the control valve with ring seal. 2. Make sure that the control valve knob turns freely and that its stem is not worn unevenly, mushroomed or otherwise damaged. 3. Remove tc guide, verify that it is unbroken, clean and...

  • Page 24

    Gear box assembly - part no. 305-196 22 part number description 100-004 90 degree elbow 100-028 pipe plug 100-318 hxhd screw 100-332 retaining ring 100-380 screw 100-381 screw 100-398 retaining ring 112-068 ball bearing 115-019 hose connector 117-008 ball bearing 305-197 paint pump ass’y 305-199 sha...

  • Page 25

    Spray gun assembly - part no. 305-280 gun mount assembly - part no. 305-275 - 23 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 26

    Bypass valve assembly part no. 305-264 part number description qty. 100-040 hose, whip 2 115-016 control valve seat ass’y 1 115-017 ball 1 115-024 unloader valve 1 115-028 stat-o-seal 1 115-031 guide t.C. 1 188-377 return tube 1 305-194 pr regulator housing 1 24.

  • Page 27

    Suction assembly part no. 331-290 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 25.

  • Page 28

    Frame assembly part no. 305-213 part number description qty. 100-317 nut 5/16-18 centerlock 4 100-320 wing screw, 3/8 1 100-370 screw, hex cap 2 113-031 spacer, 5/8 x 1.00 2 113-032 axel, 13” 1 119-026 screw hex hd 3 136-131 chain sash 1 136-133 key ring 1 139-053 handle, striper 1 140-029 washer, f...

  • Page 29: Quick Flush

    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 guard...

  • Page 30

    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...