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ICI ProSpray 404 User Manual

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30 pages
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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, 5, 6 and 7
ALL SERVICE PROCEDURES MUST BE PERFORMED
BY AUTHORIZED SERVICE CENTER.
OPERATION MANUAL & PARTS LIST
FOR MODELS ProSpray 404, ProSpray 505
and ProSpray 606 Airless Paint Sprayers
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ICI ProSpray 404 Specifications

General IconGeneral
BrandICI
ModelProSpray 404
CategoryPaint Sprayer
LanguageEnglish

Summary

Introduction

Specifications

Details the technical specifications of the ProSpray models.

Manual Notations

Explains the meaning of WARNING, CAUTION, IMPORTANT, and NOTE.

Flushing Procedures

New Sprayer Flushing

Procedure for flushing a new sprayer before initial use.

Changing Paint Types

Steps to flush the sprayer when changing paint colors or types.

Storage Flushing

Procedure for flushing the sprayer before storage.

Startup After Storage Flushing

Flushing steps when starting the sprayer after a period of storage.

How to Flush

Prepare for Flushing

Engage safety latch, remove tip, and prepare gun.

Solvent and Pump Priming

Pour solvent, place suction tube, and prime pump.

Flushing Process

Operate pump with PR valve open then closed, releasing pressure.

Post-Flush Procedures

Engage safety latch, prepare for spraying or storage.

Setting Up and Starting Up

Connecting Hose, Gun, and Grounding

Steps for connecting components and ensuring proper grounding.

Electrical Service and Flushing

Checking electrical requirements and performing initial flushing.

Understanding Controls and Material Prep

Familiarization with controls and preparing the paint.

Adjusting Pressure and Clogged Tips

Adjusting spray pressure, handling clogs, and shutting down the unit.

Shutting Down and System Overview

Steps for safe shutdown and overview of the pressure system.

ProSpray Pressure System

System Overview and Usage

Guidance on pressure settings and LCD display usage.

Comprehensive Safety Warnings

High Pressure Spray Injury Risks

Detailed warnings about injection injuries and immediate medical care.

Operational Safety Precautions

Rules for handling the equipment, spraying area, and personal protection.

Component-Specific Safety

Safety guidelines for spray guns, tips, and dealing with toxic fluids.

Pressure Relief Procedure

Step-by-Step Relief Process

Detailed steps to safely relieve pressure in the system.

Handling Clogged Tips/Hoses

Specific instructions for dealing with clogged spray tips or hoses.

Hoses and Grounding

Hoses Safety and Maintenance

Guidelines for using, inspecting, and maintaining spray hoses.

Grounding System Components

Instructions for grounding the sprayer and related parts.

Safety Precautions

Moving Parts and Component Rupture

Warnings about moving parts and potential component failure.

Static Sparking and Fire Prevention

Measures to prevent static discharge fires and explosions.

Flushing and Flammable Material Safety

Safe practices for flushing and handling flammable paints.

Airlesco 007 Spray Gun

Spray Gun Assembly and Operation

Instructions for attaching and using the spray gun.

Spray Tip Assembly and Clog Removal

Procedures for assembling the spray tip and clearing clogs.

Spray Technique

Basic Spraying Principles

Fundamental techniques for proper spray application.

Distance, Angle, and Movement

Guidance on spray gun distance, angle, and motion.

Spray Technique (Continued)

Spraying Strokes and Overlap

Techniques for consistent strokes and pattern overlap.

Spray Patterns and Pressure Adjustment

Identifying spray patterns and adjusting pressure for optimal results.

Airless Spray Gun Operation

Troubleshooting Common Defects

Identifies common spray gun defects, their causes, and corrections.

Testing Spray Patterns

Methods for testing and evaluating spray patterns.

Airlesco 007X & 007XL Spray Guns

Spray Gun Components and Parts List

Identification of all parts for the Airlesco 007X/XL spray guns.

Airlesco 007X & 007XL Spray Gun Maintenance

Adjusting and Replacing Gun Components

Procedures for adjusting the spray gun and replacing parts.

Cleaning and Clearing Clogs

Instructions for cleaning the spray gun and removing tip clogs.

Tip Selection and Maintenance

Understanding Tip Selection and Replacement

Guidance on choosing and replacing spray tips for optimal performance.

Regular Pump Maintenance

Daily inspection and maintenance of the pump packing nut.

Electric Motor Maintenance

Lubrication and Brush Replacement

Procedures for motor lubrication and changing brushes.

Troubleshooting

Common Pump and Motor Issues

Diagnosing and resolving issues like spitting, leaks, and low pressure.

Troubleshooting: Machine Does Not Start

Diagnosing Startup Issues

Step-by-step guide to identify why the machine fails to start.

Electrical Board Calibration

Zero Calibration Procedure

Steps to perform zero calibration on the electrical board.

Pressure Calibration Procedure

Steps to calibrate pressure settings for the electrical board.

LCD Calibration Procedure

Steps to calibrate the Liquid Crystal Display (LCD).

Electrical Board Calibration (Continued)

Low Pressure Voltage Trimpot Calibration

Procedure for calibrating the low pressure voltage trimpot.

Electrical System

System Diagram and Parts

Diagram and list of components in the electrical system.

Replacement of Electrical Components

Pressure Control Assembly and Sensor Replacement

Steps for replacing the pressure control board and sensor.

Potentiometer, LCD, and Switch Replacement

Procedures for replacing the potentiometer, LCD display, and toggle switch.

Fuse Holder Replacement

Instructions for replacing the fuse holder assembly.

Servicing the Fluid Pump

Fluid Pump Disconnect and Reinstall

Steps for disconnecting and reconnecting the fluid pump.

Gearbox Sleeve Bearing Replacement

Gearbox Bearing Replacement Procedure

Instructions for replacing the gearbox sleeve bearing.

Gear and Pump Assembly

Servicing the Gearbox Assembly

Detailed steps for disassembling and servicing the gearbox.

Servicing Piston Rod and Upper Check Valve

Piston Rod Assembly and Disassembly

Procedures for servicing the piston rod and upper check valve.

Servicing Lower Suction Valve

Lower Suction Valve Maintenance

Steps for servicing the lower suction valve assembly.

V-Packing Replacement

V-Packing Disassembly and Reassembly

Detailed steps for replacing V-packings in the fluid pump.

Fluid Pump Parts

Fluid Pump Component Identification

Identifies parts for the fluid pump assembly based on figures.

ProSpray 404 / 505 Components

ProSpray 404/505 Parts Identification

Lists and identifies parts for the ProSpray 404 and 505 models.

ProSpray 606 Lo-Pro Components

ProSpray 606 Lo-Pro Parts Identification

Lists and identifies parts for the ProSpray 606 Lo-Pro model.

ProSpray 606 Hi-Pro Components

ProSpray 606 Hi-Pro Parts Identification

Lists and identifies parts for the ProSpray 606 Hi-Pro model.

Suction Assemblies

Suction Assembly Diagrams and Parts

Diagrams and parts lists for various suction assemblies.

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