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  4. 510E
  5. Service & Operation Manual

AIRLESSCO 510E Service & Operation Manual

Manual is about: airless paint sprayer

Summary of 510E

  • Page 1

    Form no. 001-492 june 2006.

  • Page 2

    2 product diagrams & parts lists manifold filter parts list 14 gear & pump assembly 17 upper & lower seats 18 fluid pump 20 carry frame machine parts list 21 lo-boy machine parts list 22 hi-boy machine parts list 23 suction assemblies 24 electrical system drawing - 5/6 series 28 quick reference guid...

  • Page 3

    1 introduction max. Pressure 3000 psi 3000 psi 3000 psi output (freeflow) 0.5 gpm 0.7 gpm 0.8 gpm output (at pressure) 0.46 gpm 0.54 gpm 0.6 gpm tip size 1 gun up to 0.021 1 gun up to 0.023 1 gun up to 0.026 motor- output dc tefc .6 hp dc tefc .8 hp dc. Tefc. .8 hp weight 38 lbs 41 lbs. 65 lbs. Lp46...

  • Page 4

    2 safety warnings note: united states government safety standards have been adopted under the occupational safety & health act. These standards, particularly the general standards, part 1910 & construction standards, part 1926 should be consulted. Do not use halogenated solvents in this system. The ...

  • Page 5

    3 safety warnings always inspect spraying area • keep the spraying area free from obstructions. • make sure the spraying area has good ventilation to safely remove vapors and mists. • never keep fl ammable material in spraying area. • never spray in vicinity of open fl ame or other sources of igniti...

  • Page 6

    4 safety warnings keep clear of moving parts always follow recommended pressure and operating instructions • always use approved high pressure fi ttings and re place ment parts. • always ensure fi re extinquishing equip ment is readi ly avail able and properly maintained. Flushing when spraying & cl...

  • Page 7

    5 1. New sprayer 1. New sprayer your sprayer was factory tested in an oil solution which was left in the pump. Before using oil-base paint, fl ush with mineral spirits only. Before using water-base paint fl ush with mineral spirits, followed by soapy water, then a clean water fl ush. 2. Changing col...

  • Page 8

    6 1. Be sure the gun safety latch is engaged and there is no spray tip in the gun. Refer to page 14 on how to lock the safety latch and the gun's safety features. Figure 4 2. Pour enough clean, compatible solvent into a large, empty metal pail to fi ll the pump and hoses. 3. Place the suction tube i...

  • Page 9

    7 1. Connect the hose and gun. 1. Connect the hose and gun. A. Remove the plastic cap plug from the outlet tee and screw a conductive or grounded 3000 psi airless spray hose onto fl uid outlet. B. Connect an airless spray gun to the other end of the hose. C. Do not use steel braided airless hose. Us...

  • Page 10

    8 1. Learn the functions of the controls. 2. Prepare the material 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 3. Starting the sprayer (see figure 7, 8 & 9) (se...

  • Page 11

    9 4. Adjusting the pressure 4. Adjusting the pressure a. Turn the pressure control knob clockwise to increase pressure and counterclockwise to decrease pres sure. B. Always use the lowest pressure necessary to completely atomize the material. Note: operating the sprayer at higher pres sure than need...

  • Page 12

    Important! To avoid possible serious body injury, always follow this procedure whenever the sprayer is shut off, when check ing 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...

  • Page 13

    Spray gun operation re vers ible spray tip tip guard trig ger guard major components of spray gun and reversible spray tip spray gun attach spray gun to airless unit and tighten fi t tings se cure ly. Set the gun safety latch. (also may be called gun safety lock, or trigger lock) * the gun safety la...

  • Page 14: Problem

    Problem cause correction coarse spray, spotty pattern pressure setting low irratic spray gun/hand motion increase pressure setting use a steady, parallel pass excessive overspray (fogging) pressure setting high paint over thinned/reduced/cut reduce pressure setting use less thinner/water/reducer spr...

  • Page 15: New

    During use, especially with latex paint, high pres sure will cause the orifi ce to grow larger. This de stroys the pattern. Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make cut ting-in diffi cult, and decreases sprayer per formance. Two tips having the s...

  • Page 16

    14 electric motor maintenance 1. Lubrication - this motor is supplied with prelubricated ball bearings, lubricated for life of bearing. 2. Motor brushes - these need periodic inspection and replacement as wear indicates. Brushes for the leeson motor (lp540/690) pn 331-131 have an initial length of 3...

  • Page 17

    15 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 ...

  • Page 18

    16 servicing the fluid pump note: check everything in the troublshooting chart before disassembling the fluid pump. Fluid pump removal - refer to figure 11 1. Follow the pressure relief procedure page 10. 2. Flush the material you are spraying out of the machine. 3. Remove the connecting rod shield ...

  • Page 19

    17 gear and pump assembly figure 12 - do not operate -- machine without cover guard in place. Servicing gear box assembly servicing gear box assembly 1. Remove fl uid pump as per "fluid pump disconnect" procedures. 2. Remove frame from the gearbox by loosening the four mounting screws. 3. Refer to f...

  • Page 20

    18 servicing the piston rod - outlet valve * 331-196 331-195 disassembly of the outlet valve refer to figure 13 1. Disconnect the fluid pump. 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 th...

  • Page 21

    19 reassembly - figure 15 & 16 1. Take lower male gland (331-014) & place it down on the fl at 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, leath...

  • Page 22: Continued)

    20 packing replacement procedures ( continued) 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 assem...

  • Page 23

    21 carry frame models figure 17 part number description 100-003 swivel 100-180 prime p/r valve 100-312 screw (4) 100-318 bolt (2) 106-500 sensor seal 111-037 heatsink screw (4) 115-019 hose connector (1/4 npsxnpt) 117-044 knob 117-090 fan cover screws (3) 119-048 screw (4) 301-191 fan retaining clip...

  • Page 24

    22 figure 18 lo-boy models part number description 100-003 swivel 331-476 cup assembly 100-180 prime valve 100-318 bolts (2) 100-377 screw (4) 106-500 sensor seal 111-037 heatsink screws (4) 113-019 wheel 10” (2) 113-030 spacer (2) 115-019 hose connector (1/4” npsxnpt) 117-044 knob 117-090 fan cover...

  • Page 25

    23 hi-boy models part number description 100-003 swivel 100-180 prime valve 100-318 bolt (2) 100-390 screw (2) 106-500 sensor seal 111-037 heatsink screws 113-019 wheel 10” (2) 113-031 spacer (2) 117-044 knob 117-090 fan cover screw (3) 119-048 screw (4) 143-029 collar (2) 115-019 hose connector (1/...

  • Page 26

    24 suction assemblies figure 20 - loboy & carry frames figure 21 - hiboy frame 1 2 3 4 5 6 7 pn 331-284 (hi-boy chassis) 331-034 331-292 301-348 116-103 331-400 141-008 331-090r suction nut suction seat ass'y bypass hose spring clip inlet tube inlet strainer fitting figure 21 parts list item # part ...

  • Page 27

    25 note: anytime a sensor, pressure control assembly (board) or both are replaced, the following calibrations must be per formed. 1. Zero calibration 1. Place prime/pressure relief valve in the prime (open) position. 2. Set the pressure control knob to the minimum setting (ccw). 3. Remove the screws...

  • Page 28

    26 electrical board calibration (continued) 4. Phase limit trimpot calibration formerly known as the low voltage or master voltage calibration 1. Attach a 50', 1/4" airless hose, airless gun with .017 tip and a 5000 psi glycerin fi lled pressure gauge to the pump. 2. Place the suction tube into a bu...

  • Page 29

    27 pressure control knob (potentiometer) troubleshooting - machine does not start cause steps (see figure 22) steps (see figure 22) step 1: after making sure that the machine is plugged into the wall, verify that the on-off switch is in the on position and that the pressure control knob is turned al...

  • Page 30

    28 electrical system figure 22 part number description 117-044 knob 117-207 jumper 331-490 .6 hp dc motor 4 series 331-068 .8 hp dc motor 5/6 series 331-168 electrical power cord 331-184 spacer 331-185 strain relief 331-294-99 sensor 331-297 potentiometer 331-311 toggle switch 331-312 fuse holder 33...

  • Page 31

    29 pressure control assembly (electrical control board) pressure control assembly (electrical control board) 1. Unplug machine's power cord. 2. Remove four screws from heatsink housing. 3. Disconnect all leads from pressure control assembly. 4. Reassemble in reverse order. Sensor 1. Remove the 4 scr...

  • Page 32

    30 pressure control knob used to adjust pressure only. Does not relieve pressure from gun and system! Turn clockwise to increase pressure, counterclockwise to decrease pressure. Step 1a. Read safety rules! Read & understand all warnings & safety rules before operating equipment. Know how to lock the...