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AIRLESSCO LP540 - User Manual

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A
IRLESSCO
LP460 - LP540 - LP690
ALLPRO
510E - 710E - 810E
AIRLESS PAINT SPRAYER
SERVICE/OPERATION
MANUAL
A
Form No. 001-492 July 2004
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Summary

Introduction

LP Series Specifications

Provides key performance specifications for the LP series airless paint sprayers.

Safety Warnings Overview

Introduces essential safety precautions and warnings for equipment operation.

Manual Notations

Explains symbols and conventions used throughout the manual for clarity.

Safety Warnings

Injection Hazard and Medical Alert

Details severe risks of fluid injection and critical immediate medical response procedures.

General Safety Precautions

Outlines general guidelines for safe operation, handling, and environmental considerations.

Safety Warnings (Continued)

Spray Gun and Hose Safety

Covers safe practices for using the spray gun, including trigger lock and hose maintenance.

Toxic Fluid and Grounding Safety

Addresses hazards of toxic fluids and the importance of proper electrical grounding.

Safety Warnings (Continued)

Component Rupture and Static Spark Prevention

Warns against component rupture and details methods to prevent static sparking fires.

Flushing Safety Precautions

Provides essential safety guidelines and warnings specific to the flushing process.

Flushing Procedures

New Sprayer and Color Change Flushing

Details flushing procedures for new units and when changing paint colors.

Storage and Start-up Flushing

Explains flushing for storage and after periods of inactivity for optimal preservation.

How to Flush

Step-by-Step Flushing Guide

Provides detailed, sequential instructions for flushing the airless sprayer system.

Setting Up

Hose, Gun, and Electrical Connections

Guides on connecting the hose and gun, and checking the electrical setup.

Grounding and Sprayer Flushing

Covers essential grounding steps and initial sprayer flushing procedures.

Starting Up

Control Functions and Material Prep

Explains control functions and how to prepare materials before starting the sprayer.

Sprayer Priming and Startup Steps

Details the sequence of actions to safely prime and start the sprayer.

Starting Up (Continued)

Adjusting Pressure and Avoiding Tip Clogs

Covers how to adjust spray pressure and prevent tip clogs for efficient operation.

Shutting Off the Sprayer Safely

Provides instructions for safely shutting down the sprayer after use.

Pressure Relief Procedure

Steps for Relieving System Pressure

Outlines the critical steps to safely relieve pressure in the sprayer system.

Daily Maintenance Overview

Introduces daily maintenance tasks required for optimal sprayer performance.

Daily Maintenance

Packing Nut Lubrication and Inspection

Details how to lubricate and adjust the packing nut for pump longevity.

Spray Gun Operation

Spray Gun Components and Assembly

Identifies major components and details spray tip assembly procedures.

Spray Gun Cleaning and Clog Removal

Explains how to clean the gun, filter, and remove spray tip clogs.

Airless Spray Gun Troubleshooting

Common Spray Gun Defects and Corrections

Lists common spray gun issues and their corresponding solutions for efficient repair.

Testing the Spray Pattern

Describes methods to test and evaluate the spray pattern for proper application.

Spray Tip Selection

Tip Identification and Orifice Size Chart

Explains tip identification and provides a chart of orifice sizes and fan widths.

Spray Tip Replacement Guidance

Provides reasons and guidance for replacing worn spray tips to maintain performance.

Electric Motor Maintenance

Motor Brush Inspection and Replacement

Covers the inspection, maintenance, and replacement of motor brushes for optimal motor life.

Manifold Filter - PN 111-200-99

Manifold Filter Assembly Details

Details the manifold filter assembly, its parts, and replacement.

Field Troubleshooting

Unit Priming and Pressure Issues

Addresses common problems related to priming the unit and maintaining spray pressure.

Unit Operation and Fuse Issues

Covers troubleshooting for units that do not run or have fuse-related problems.

Servicing the Fluid Pump

Fluid Pump Removal Procedure

Step-by-step guide for safely removing the fluid pump assembly from the sprayer.

Fluid Pump Reinstallation Procedure

Step-by-step guide for safely reinstalling the fluid pump assembly.

Servicing the Fluid Pump (Continued)

Outlet Valve Disassembly and Reassembly

Details the process for disassembling and reassembling the outlet valve.

Packing Replacement Procedures

Fluid Pump Packing Disassembly

Guides on how to safely disassemble the fluid pump packings for inspection or replacement.

Fluid Pump Packing Reassembly

Guides on how to safely reassemble the fluid pump packings.

Packing Replacement Procedures (Continued)

Packing Assembly Diagrams

Provides visual aids and diagrams illustrating packing assembly steps.

Gear and Pump Assembly

Gearbox Assembly Servicing

Details the procedures for servicing the gearbox assembly, including inspection and cleaning.

Gearbox Sleeve Bearing Replacement

Explains how to replace the sleeve bearing within the gearbox assembly.

Servicing the Piston Rod - Outlet Valve

Outlet Valve Disassembly and Reassembly

Details the procedures for servicing the piston rod and outlet valve components.

Servicing the Suction Assembly

Suction Assembly Disassembly and Cleaning

Guides on how to disassemble and clean the suction assembly for maintenance.

Electrical Board Calibration (4 Series)

Pressure Calibration (4 Series)

Details the procedure for calibrating the pressure settings on the 4 series control board.

Phase Limit Trimpot Calibration (4 Series)

Explains how to calibrate the phase limit trimpot on the 4 series control board.

Troubleshooting - Machine does not start (4 Series)

Initial Checks: Controls, Fuse, Power Source

Covers initial troubleshooting for power and control issues on 4 series models.

Motor, Sensor, and Potentiometer Checks

Guides on troubleshooting motor, sensor, and potentiometer components on 4 series.

Electrical System (4 Series)

4 Series Electrical System Diagram

Provides a wiring diagram for the 4 series electrical system, illustrating component connections.

Electrical Board Calibration (5;6 Series)

Zero Calibration Procedure (5;6 Series)

Details the steps for performing zero calibration on the 5/6 series control board.

Pressure and LCD Calibration (5;6 Series)

Explains pressure and LCD calibration procedures for the 5/6 series control board.

Electrical Board Calibration (Continued)

Phase Limit Trimpot Calibration (5;6 Series)

Details the procedure for calibrating the phase limit trimpot on the 5/6 series control board.

Troubleshooting - Machine does not start (5;6 Series)

Initial Checks: Controls, Fuse, Power Source (5;6 Series)

Covers initial troubleshooting for power and control issues on 5/6 series models.

Motor, Sensor, and Potentiometer Checks (5;6 Series)

Guides on troubleshooting motor, sensor, and potentiometer components on 5/6 series.

Electrical System (5 & 6 Series)

5 & 6 Series Electrical System Diagram

Provides a wiring diagram for the 5 & 6 series electrical system, illustrating component connections.

Replacement of Electrical Components

Electrical Component Replacement Steps

Details replacement procedures for key electrical components like the control board and sensor.

LP Series Electric Paint Sprayer Quick Reference Guide

Operation Overview and Safety

Covers essential operation steps, including priming, pressure adjustment, and safety.

Cleaning Procedures and Tools

Details the cleaning process, including necessary tools and materials.

Airlessco Accessories

Accessory Catalog Overview

Lists and describes various Airlessco accessories for sprayers, such as conditioners and hoses.

AIRLESSCO LP540 Specifications

General IconGeneral
TypeAirless Paint Sprayer
ModelLP540
Max Pressure3000 PSI
Flow Rate0.54 GPM
Hose Length50 ft
Max Tip Size0.023 inch
Voltage120V
MotorDC Motor
Amperage14 amps
Spray Tip Size0.015 - 0.023 inch

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