SERVICE/OPERATION MANUAL Form No.
Table of Contents INTRODUCTION SureStripe 4000 Specifications Safety Warnings 1 2 GETTING STARTED Flushing Setting Up Pressure Relief Procedure Daily Maintenance Starting Up Striping Operation Striping Tip Guide 7 8 9 9 10 12 13 PRODUCT DIAGRAMS & PARTS LISTS Gun Mount Assembly Gearbox Assembly Suction Assembly Swivel Wheel Assembly Frame Assembly REPAIRS/MAINTENANCE INSTRUCTIONS Spray Gun Operation Spray Gun Troubleshooting Field Troubleshooting Servicing the Fluid Pump Servicing the Piston Rod Servic
Introduction INTRODUCTION The 4000 is the compact piston pump striper that delivers the professional results and range of features needed by pavement striping contractors—and it’s an incredible value! It’s based on our proven LP Piston Pump used daily by thousands of painting contractors. The large one-piece piston along with Airlessco's patented triple-life packing system results in reduced maintenance, lower operating costs, and longer equipment life. A clutch actuated .
Safety Warnings TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes or on skin, inhaled or swallowed. Know the hazards of the fluid you are using. Store & dispose of hazardous fluids according to manufacturer, local, state & national guidelines. ALWAYS wear protective eye wear, gloves, clothing and respirator as recommended by fluid manufacturer. ALWAYS INSPECT SPRAYING AREA • ALWAYS keep spraying area free from obstructions.
Safety Warnings HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. OBSERVE ALL WARNINGS. THIS SPRAYER IS FOR PROFESSIONAL USE ONLY. INJECTION HAZARD 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. • NEVER put hands or fingers over the spray tip. Do not use a rag or any other material over your fingers.
Safety Warnings GROUNDING Ground the sprayer and other components in the system to reduce the risk of static sparking, fire or explosion which can result in serious bodily injury and property damage. Always ground all of these components: • Sprayer: Be sure grounding chain (supplied) is in contact with the ground. • Fluid Hose: use only grounded hoses. • Spray gun or dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.
Safety Warnings FLUSHING Reduce risk of injection injury, static sparking or splashing by following the specific cleaning procedure on page 5. ALWAYS follow the PRESSURE RELIEF PROCEDURE on page 9. ALWAYS remove the spray tip before flushing. Hold a metal part of the gun firmly to the side of a metal pail and use the lowest possible fluid pressure during flushing. NEVER use cleaning solvents with flash points below 140º F. Some of these are: acetone, benzene, ether, gasoline and naphtha.
Safety Warnings 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. Starting engine creates sparking. Sparking can ignite nearby flammable gases. Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting or death. • Start and run engine outdoors.
Flushing IMPORTANT: Read Prior to Using Your Sprayer 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 solvent such as mineral spirits or water. 3. Changing from water-base to oil-base paint Flush with soapy water, then mineral spirits. 4.
Daily Maintenance 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. Airlessco Throat Seal Oil 6 ounce bottle Part # 188-187 1 quart bottle Part # 188-392 2. Inspect the packing nut daily. Your pump has Airlessco’s patented Triple Life Packing System.
Pressure Relief Procedure IMPORTANT! To avoid possible serious body injury, always follow this procedure whenever the sprayer is shut off, when checking 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 separate instruction manual provided with your gun on its safety features and how to engage safety latch. 2. Turn the unit off. 3.
Starting Up 1. Learn the Functions of the Controls. PRIME/PRESSURE (PR) RELIEF VALVE is used to prime pump and to relieve pressure from gun, hose and tip. Prime/Pressure Relief Valve (Prime/PR Valve) Used to relieve pressure from gun, hose & tip and to prime the unit when in OPEN position. (It is in open position when there is a wider gap between valve handle and cam body) When in CLOSED position, there is only a very slight gap between handle & body. When closed the system is pressurized.
Starting Up Follow the "Pressure Relief Procedure". To reduce the risk of injection, never hold your hand, body, fingers or hand in a rag in front of the spray tip when cleaning or checking for a cleared tip. Always point the gun toward the ground or into a waste container when checking to see if the tip is cleared or when using a self-cleaning tip. When you spray into the paint bucket, always use the lowest spray pressure and maintain firm metal to metal contact between gun and container.
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 from the single wheel assembly allows for easier loading/unloading from a van. 2. Choose the gun arm position There are multiple holes in the frame for mounting the gun arm.
Striping Tip Guide Rev-Tip for Striping STRIPING TIP - ORIFICE SIZE (Inches) TM Fan Width (6” from surface) (mm) in 25-51 1-2 2-4 4-6 6-8 .015 .011 .013 .009 .017 .021 .019 .023 .025 .027 Latex Latex Latex .031 .035 113ST 115ST 117ST 119ST 51-102 215ST 217ST 219ST 221ST 102-152 152-203 315ST 317ST 319ST 321ST Oil Base Oil Base Latex Striping Paint Latex Latex Water Flow Rate (gpm) (water @ 2000psi, 138 bar) (lpm) .12 .49 .18 .69 .24 .91 .31 1.17 .38 1.47 .47 1.79 .57 .67 2.
Spray Gun Operation 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 should always be set when the gun is not being triggered. Read all warnings and safety precautions supplied with the spray gun and in product manual. MAJOR COMPONENTS OF SPRAY GUN & REVERSIBLE REV-TIP™ ™ Reversible Spray Tip Tip Guard Gun Safety Latch or Lock Trigger Guard Gun Handle.
Spray Gun Troubleshooting DEFECTS CAUSE CORRECTION Coarse spray Low pressure Increase the pressure Excessive fogging (overspray) High pressure Material too thin Reduce pressure for satisfactory pattern Use less thinner Pattern too wide Spray angle too large Use smaller spray angle tip Pattern too narrow Spray angle too small Use larger spray angle tip.
Field Troubleshooting PROBLEM Unit doesn't prime CAUSE Airleak due to: • Loose Suction Nut • Worn O-Rings • Hole in Suction Hose Unit primes but has no or poor pressure Unit does not maintain good spraying pressure 16 SOLUTION • Tighten Suction Nut • Replace O-Ring (106-011) on suction seat, & O-Ring (106020) below suction seat • Replace Suction Hose (331-290) Stuck or Fouled Balls Service outlet valve suction assembly Pressure set too low Turn up pressure Filter(s) are clogged Clean or replace
Servicing the Fluid Pump Fluid Pump Disconnect Fluid Pump Reinstall Refer to Figure 1 & 4 Refer to Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. Follow the Pressure Relief Procedure on page 9. Flush the material you are spraying out of the machine. Remove the connecting rod shield (331-111). Move the piston rod (331-093) to its lowest position by cycling pump slowly. Disconnect the sensor (331-294-99) by holding it in place with a 11/16” wrench and unscrewing the hose connector (115-019) with an 9/16” wrench.
Servicing the Piston Rod - Outlet Valve FIGURE 3 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. Use a 1/4” allen wrench to unscrew the outlet seat retainer (331-026) from the piston. 4. Remove the outlet seat (331-026), O-ring (331-100) and outlet ball (331-027). 5. Inspect outlet ball & seat for wear.
Packing Replacement Procedures 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 slowly. 5. Disconnect the sensor (331-294-99) by holding it in place with a 11/16” wrench & unscrewing the hose connector (115-019) with an 9/16” wrench. DO NOT TURN THE SENSOR. 6.
Packing Replacement Procedures 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 assembly by placing the suction seat (331-409) O-ring (106-011), suction ball (331-030) and suction ball guide (331-029) in the suction nut (331-034) & screw onto the fluid pump body. 5.
Electrical Control Board Replacement 1. Remove electrical cover. 2. Disconnect sensor lead from Electrical Board. 3. Disconnect two clutch leads on Electrical Board from leads on clutch. 4. Using a 1/16" allen, loosen set screw in Pressure Control Knob and remove knob. 5. Using a 1/2" nutdriver or 1/2" deep socket, remove nut from pressure control shaft. This will allow removal of electrical control board from frame. 6. Replace Electrical Board Assembly in reverse order.
Clutch Replacement REMOVE CLUTCH AS FOLLOWS: 1. Remove clutch and electrical box cover. 2. Disconnect the power lead coming from the engine to the electrical box and feed it through the back of the electrical box. 3. Using a 1/2” wrench along with a 1/2” socket remove the four bolts attaching the engine to the frame. 4. Remove the engine from the frame and set it on your work bench so the clutch face is facing you. 5.
Troubleshooting - Clutch Does Not Engage STEP 1: Ensure that the pressure control knob (POT) is in the maximum (CW) position. STEP 2: Remove the clutch and electrical box covers. STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose connections or damaged leads. STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black).
Gun Holder Assembly - Part No.
Gear Box Assembly Part No.
Swivel Wheel Part No. 305-288 Part No. 26 Description Qty. Part No. Description Qty. Part No. Description Qty.
Frame Assembly Part No. 305-295 301-533 Paint Bucket Lid Part Number Description Qty. Part Number Description Qty. 100-369 Wave Washer 2 140-029 Flat Washer 4 100-370 Hex Cap Screw 2 143-027 Ball Guide 1 100-373 Pan HD Screw 4 143-029 Set Collar 2 100-621 Cap 2 188-042 Hex Nut 4 111-044 Screw 5/16-18 x .
REV-TIP TIP IDENTIFICATION: TM 1st 3-digits identifies it as a REV-TIP for airless paint spraying (P.N. 560-xxx) or a REV-TIP for airless line striping (P.N. 562-xxxST). TM TM SPRAY TIP SIZE CHART 4th digit is the fan width - the number is half the fan width, e.g., 5 means a 10” fan. Exception are the“W” prefix tips which indicate a wide spray pattern. Part Number 560-xxx 5th and 6th digits are for the orifice size and is measured in thousandths of an inch, e.g., 17 = 0.
! W NE Reversible REV-TIP Quick Flush ™ Part # 560-xxx REV-TIP for Spray Painting 562-xxxST REV-TIP for Striping Cuts Cleaning Time & Saves Paint ! POSI-LOC SYSTEM ™ Snap in centering of tip. No leaks, splashback or mess. Part # 170-005 Simple to Use...Fast to Finish! SEAL LOCATING HANDLE Tip handle simplifies installing & aligning the seal. EASIEST ASSEMBLY Fewer parts - Less complicated takes only seconds! Each tip individually tested! INTERCHANGEABLE Can be used with most tip guards.
ACCESSORIES AIRLESSCO PUMP CONDITIONER Should be used on piston pumps between uses to prevent paint from drying on the piston & causing packing wear. STAY CLEAN™ to Spray protectant for your machine to prevent paint from sticking to it. 114-030 20 oz. can Display of 48 - 1 oz. bottles 1 quart bottle 1 Gallon bottle 010-001 010-009 010-019 Case order quantity: 12 on quarts, 4 on gallons PAINT STRAINERS Prefilter your paint using strainer bags. One dozen per pack.
