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  5. Operations Manual & Parts List

ICI ProSpray 404 Operations Manual & Parts List

Manual is about: ICI ProSpray 404/505/606 Airless Paint Sprayers

Summary of ProSpray 404

  • Page 1

    P.O.Box 8006, moorpark, ca. 93020-8006 tel: 800-467-3571 form no. 001- 205 may 99 ship to: 5397 commerce ave. Moorpark, ca. 93021 warning : before operating, doing any service or maintenance procedure, learn & follow the pressure relief procedure on page 6. Read & understand all warnings on pages 4,...

  • Page 2: Table of Contents

    Table of contents introduction 1 flushing guidelines 1 how to flush 2 setting up 3 starting up 3 & 4 warnings 4, 5, 6 & 7 pressure relief procedure 6 airlessco 007 gun 8 spray technique 9, 10 airless spray gun operation 11 airlessco 007 gun parts & repair 12,13 spray tip selection chart 14 regular m...

  • Page 3: Introduction

    1 5. Storage 6. Start up after storage before using water-base paint, flush with soapy water and then a clean water flush. When using oil-base paint, flush out the mineral spirits with the material to be sprayed. Prospray 404 prospray 505 prospray 606 pressure 3000 psi 3000 psi 3000 psi output 0.4 g...

  • Page 4: How to Flush

    2 warning - to reduce the risk of static sparking which can cause fire or explosion, always hold a metal part of the gun firmly against the metal pail when flushing. This also reduces splashing. Refer to fig. 5. Figure 5 maintain firm metal to metal contact between gun and container 6. Disengage the...

  • Page 5: Starting Up

    3 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 fluid outlet. B. Connect an airless spray gun to the other end of the hose. C. Do not use steel braided airless hose. Use nylon braided airless hose o...

  • Page 6: Starting Up  Continued

    4 4. Adjusting the pressure a. Turn the pressure control knob cw to increase pressure and ccw to decrease pressure. B. Always use the lowest pressure necessary to completely atomize the material. Caution - operating the sprayer at higher pres- sure than needed, wastes material, causes early tip wear...

  • Page 7: Warnings  Continued

    5 warnings continued hazardous fluid or toxic fumes can cause serious in- jury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are us- ing. Store & dispose of hazardous fluids according to manufacturer, local, state & national guidelines. Always wear ...

  • Page 8: Warnings  Continued

    6 hoses tighten all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coup- ling and result in an injection injury or serious bodily injury. Warnings continued pressure relief procedure to avoid possible ...

  • Page 9: Warnings  Continued

    7 warnings continued keep clear of moving parts always follow recommended pressure and operating instructions. Always use approved high pressure fittings and re- placement parts. Always ensure fire extinquishing equipment is readily available and properly maintained. Flushing when spraying & cleanin...

  • Page 10: Airlessco 007 Spray Gun

    8 airlessco 007 spray gun major components of spray gun and reversible spray tip attach spray gun to whip hose and tighten fittings securely. Set the gun safety latch.(also may be called gun safety lock) * refer to fig. A. * the gun safety latch should always be set when the gun is not being trigger...

  • Page 11: Spray Technique

    9 spray technique good spray gun technique is at the core of any spray paint operation. Operator skill and efficiency is as important as good equipment and good paint. Good spray technique is a skill that can be quickly learned by following these simple instructions. If you are not familiar with spr...

  • Page 12: Spray Technique

    10 spray technique it is important to "trigger" the gun after gun movement (arm movement) has started and release trigger (shut gun off) before gun movement ends. Gun movement is always longer than actual paint (spray) stroke. In that manner, even blending and uniform paint coat thickness is achieve...

  • Page 13: Airless Spray Gun Operation

    11 airless spray gun operation defects cause correction coarse spray low pressure increase the pressure. Excessive fogging high pressure reduce the pressure to satisfactory pattern distribution. (overspray) material too thin use less thinner. Pattern too wide spray angle too large use smaller spray ...

  • Page 14

    12 airlessco 007x & 007xl spray guns 2 3 4 5 6 8 10 11 12 13 14 15 16 18 20 21 22 23 24 25 17 19 7 9 9a 26 1 2 3 4 5 6 7 8 9 9a 10 11 12 13 14 15 16 17 18 19 20 21 21 22 23 24 25 26 561-001 560-xxx 561-025 561-026 120-023 120-005 120-035 120-037 120-011 120-033 120-022 120-046 120-002 120-045 120-02...

  • Page 15

    13 adjusting spray gun hold gun with trigger locked (25) and push trigger against the lock (17). Then adjust nut (15) so that the retainer (14) will move freely back and forth approximately 1/32" to allow valve spring unit (9) to seat the valve ball (8). Important: readjust nut (15) periodically for...

  • Page 16: Regular Maintenance

    14 regular maintenance 1. Keep the displacement pump packing nut/wet cup 1/3 full of tso (throat seal oil) at all times. The tso helps protect the packings and rod. 2. Inspect the packing nut daily. Your pump has a patented triple life packing system. Packing life will be extended a minimum of three...

  • Page 17: Electric Motor Maintenance

    15 electric motor maintenance 1. Lubrication - this motor is supplied with prelubricated ball bearings, lubricated for life of bearing. 2. Motor brushes need periodic inspection and replacement as wear indicates. Brush wear is greatly influ- enced by individual application. It is recommended that br...

  • Page 18

    16 troubleshooting- machine does not start. Cause solution step 1: ensure that the on-off toggle switch is in the "on" position and that the pressure control knob is fully cw (maximum pressure). Also check that the unit is plugged in. Control settings power source step 3: use a multimeter to check f...

  • Page 19: Electrical Board Calibration

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

  • Page 20: Figure 10

    18 figure 10 electrical system electrical board calibration continued.... 4. Low pressure voltage trimpot calibration 1. Attach a 50', 1/4" airless hose, airless gun with .017 tip and a 5000 psi glycerine filled pressure gauge to the pump. 2. Place the suction tube into a bucket of antifreeze (or co...

  • Page 21: Figure 11

    19 pressure control assembly (electrical control board) 1. Unplug machine's power cord. 2. Remove four screws (item 27, fig. 19) from pressure control assembly. 3. Disconnect all leads from pressure control assembly. (fig. 10). 4. Reassemble in reverse order. Sensor 1. Remove the screws (fig. 19, it...

  • Page 22: Figure 12

    20 note: check everything in the troubleshooting chart before disassembling the fluid pump. See fig 13, page 18. Fluid pump disconnect a. Flush out the material you are spraying, if possible. B. Follow the "pressure relief procedure" on page 6. C. Remove the suction tube assembly from the paint pump...

  • Page 23: Gear and Pump Assembly

    21 7 8 5 4 6 3 2 1 8 15 9 10 12 14 13 17 16 19 18 warning - do not operate machine without cover guard in place. Figure 13 parts list item no. Part no. Description cover ass'y (404,505,606 lo-pro) cover ass'y (606 hi-pro) bearing crosshead assembly gear crank (404) gear crank (505) gear crank (606) ...

  • Page 24: Figure 14

    22 see fig. 14. 1. Disconnect fluid pump as per page 17. 2. Place piston in block (pn 331-195) with the 3/8" dowel pin (pn 331-196) and hold in vise. Note: do not use smaller diameter pin to hold piston. 3. Place a 7/16" allen wrench into lower piston and unscrew lower piston from upper piston. Clea...

  • Page 25: V-Packing Replacement

    23 1. Remove the fluid pump as per “fluid pump disconnect” instructions on page 17. 2. Unscrew the packing nut and suction assembly. Push piston rod out through bottom of pump body. Remove the upper packings, belleville springs, tube spacer and lower packing set using packing removal tool (pn 331-15...

  • Page 26: Fluid Pump

    24 fluid pump pn. 331-209 (lo-pro) pn. 331-236 (hi-pro) figure 17 1 15 2 11 16 17 19 3 4 5 18 6 7 12 20 13 14 21 8 16 17 22 9 11 23 15 10 24 item no. Part no. Description item no. Part no. Description 1 331-037 packing nut 13 331-026 seat 2 331-019 seal holder 14* 331-100 o-ring ptfe 3* 331-020v o-r...

  • Page 27: Prospray 404 / 505

    25 1 2 3 4 5 6 7 8 9 10 11 12 swivel sensor washer seal pressure control assy terminal box knob screw (4) screw (4) washer (4) rubber edge (2) fan retaining clip figure 18 parts list item no. Part no. Description item no. Part no. Description 331-111 331-234 331-143 100-377 331-199us 331-070 331-068...

  • Page 28: Figure 19

    26 shield cover handle bushing (2) frame screw (4) pin (2) spacer (2) motor cover 3/4 hpdc motor fan motor cover motor cover screw (3) spacer (2) tire (2) washer (2) retaining ring (2) figure 19 prospray 606 lo-pro 3 4 5 6 7 8 9 10, 11 12, 13, 28 14 15 16 17 27 18 31 30 see page 25 fig. 21 see page ...

  • Page 29: Prospray 606 Hi-Pro

    27 prospray 606 hi-pro prime/pr valve swivel sensor washer seal pressure control assy screw (4) screw (4) terminal box knob washer (4) screw (4) rubber edge (2) item no. Part no. Description item no. Part no. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 331-336 100-390 331-234h 331-273 331-199us 331-06...

  • Page 30: Suction Assemblies

    28 suction assemblies figure 21 figure 23 1 2 3 4 5 6 1 2 3 4 5 6 figure 23 parts list item no. Part no. Description pn 331-272 (606 hi-pro) figure 22 figure 22 parts list item no. Part no. Description 1 2 3 o-ring, ptfe nut - suction suction elbow 331-036t 331-034 331-035 331-034 331-292 331-237 33...