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Manual Dc3000,4000

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September 2018
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DC-3000, DC-4000 OWNER'S MANUAL DC-3000 DC-4000 stand DC-4000 cart WARNING..Read all instructions carefully before assembling components and operating sprayer. Incorrect procedure could result in damage to the unit, severe personal injury and/or property damage. When spraying flammable materials, sprayer must be placed at least 20 feet from target in a well-ventilated area. Vapours can be ignited by static discharge or electrical sparks and result in severe personal injury. LEMMER airless sprayers generate high fluid pressure. Improper use could result in an injection injury. VANCOUVER • KELOWNA • CALGARY • EDMONTON • WINNIPEG • TORONTO • MONTRÉAL 1 TABLE OF CONTENTS SAFETY PRECAUTIONS ...................................................................... 3 & 4 TECHNICAL SPECIFICATIONS ................................................................... 5 PUMP COMPONENTS ................................................................................. 6 SETTING UP OF UNIT ................................................................................. 7 ELECTRONIC CONTROLS .......................................................................... 7 TIP SELECTION & MAINTENANCE ...................................................... 8 & 9 HOW TO SELECT TIP SIZE AND PROPER FILTER ................................. 10 STARTUP PROCEDURE: UNIT PRIMING AND FLUSHING .................................................. 11 PRIMING UNIT IN PAINT .............................................................. 11 TO TURN UNIT OFF ..................................................................... 11 HINTS FOR AIRLESS SPRAYING: PAINTING AND TIP SELECTION ................................................. 12 SPRAY PAINTING METHOD ........................................................ 12 HELPFUL HINTS FOR TROUBLE FREE PAINTING: SPRAYER ...................................................................................... 12 PAINT ............................................................................................ 12 SPRAY TIPS .................................................................................. 12 FILTERS ........................................................................................ 12 PAINT HOSE ................................................................................. 12 ELECTRICAL ................................................................................ 13 EXTENSION CORD ...................................................................... 13 CLEANING INSTRUCTIONS ............................................................. 14 & 15 MAINTENANCE & SERVICE .............................................................. 16 - 20 TROUBLESHOOTING ................................................................................ 21 OTHER QUALITY LEMMER PRODUCTS .................................................. 22 ACCESSORIES FOR LEMMER AIRLESS EQUIPMENT ........................... 23 L-65 PARTS ....................................................................................... 24 & 25 DC-3000 PARTS ................................................................................ 26 & 27 DC-4000 PARTS ................................................................................ 28 & 29 DC-7000 PARTS ................................................................................ 30 & 31 DISTRIBUTION CENTRES ACROSS CANADA ......................................... 32 LEMMER WARRANTY ............................................................................... 32 2 SAFETY PRECAUTIONS WARNING 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) HIGH PRESSURE! ATTENTION Injection hazard: Airless Painting Equipment can 1) Risque d’injection de peinture: Le matériel de cause serious injury if the spray penetrates the pulvérisation sans air peut entraîner de graves blessures skin. Do not point the gun at anyone or any part of s’il y a pénétration de la peau par la peinture. Ne jamais the body. The tip guard provides some protection pointer le pistolet vers une personne ou vers soi-même. against accidental injection injuries, but is mostly a La garde de la buse limite le risque de blessures warning device. Never put your hand, fingers or accidentelles par injection mais constitue principalement body over the spray tip. Gloves and clothing do not un élément de mise-en-garde. Ne jamais mettre la main, necessarily offer any protection either. Keep the les doigts ou toutes parties du corps contre la buse. Le gun trigger safety lever in locked postion when not INJECTION HAZARD! port de gants et de vêtements n'est pas nécessairement spraying. Always have the tip guard in place while une forme de protection non plus.Laisser le cran de sureté spraying. du pistolet en position fermée quand il nést pas utilisé. In case of penetration seek medical aid immediately! Toujours avoir la garde en place pour peindre. Note to physician: Injection into skin is a serious En cas d’accident, demander immédiatement des soins médicaux. traumatic injury. It is important to treat the injury Note au médicin: La pénétration de peinture dans la peau peut causer surgically as soon as possible. Do not delay treatde graves blessures. Il est important de traîter la blessure à la ment to research toxicity. Toxicity is a concern with chirurgie aussitôt possible. Ne pas retarder le traitement pour some exotic coatings injected into the bloodstream. rechercher la toxicité. La toxicité peut avoir de graves conséquences Consultation with a plastic surgeon or reconstructive quand certains enduits exotiques son injectés directement dans le hand surgeon may be advisable. Be prepared to tell systéme sanguin. Une consultation avec un chirurgien spécialisant en the doctor what fluid was injected. reconstruction de mains serait conseillable. Soyez prêts à décrire au This system is capable of producing 3200 PSI. To médecin quel liquide a été injecté. avoid rupture and injury, do not operate this pump with 2) Ce matériel peut produire une pression de 3200 lbf/po2. Afin d’éviter components rated less than 3200 PSI working pressure des ruptures et des blessures, ne pas utiliser cette pompe avec des (including but not limited to spray guns, hose and hose éléments dont la pression nominale de service est inférieure à 3200 lbf/po2 connections). (y compris les pulvérisateurs, tuyaux flexibles et raccords). Do not spray paints or other inflammable fluids 3) Ne jamais pulvériser à l’interieur un produit inflammable qui a un point indoors which have a flash point below 21 degree C, 70 éclair inférieur à 21 degrés C,70 degrés F. L’endroit où vous peinturez doit degree F. Keep spray area well ventilated. Before toujours être bien aéré. Avant de pulvériser s’assurer qu’il n’y a aucune spraying, turn off all pilot lights and open flames. flamme ou pilot (veilleuse) de fournaise en marche dans l’appartement. Wear a respirator which is approved for the product 4) Servez-vous d’un masque respiratoire qui est certifié pour le produit que being sprayed. vous pulvérisez. Do not use halogenated hydrocarbon solvents in this 5) Ne pas utiliser de solvants contenant des hydrocarbures halogénés system; it contains aluminium parts and may explode. avec ce matériel. Il contient des particules d'aluminium et peut exploser. Les Cleaning agents, coatings, paints, and adhesives may agents de nettoyage, enduits, peintures et, adhésifs, peuvent contenir des contain halogenated hydrocarbon solvents. Don't take solvants contenant des hydrocarbures halogénés. Soyez prudents; chances, consult your material supplier to be sure. (ex: consultez votre fournisseur pour les informations nécessaires. (ex: methylene chloride and 1,1,1 - Trichlorethane) méthylène chloride and 1,1,1 - Trichloréthane) Caution: When a flammable liquid is sprayed there may 6) Attention: La pulvérisaton d'un liquide inflammable peut entraîner un be danger of fire or explosion especially in a closed risque d'incendie ou d'explosion, surtout dans les espaces fermés. area. 7) Attention: Étincelles électriques. Ne pas placer la pompe à moins de 6 Caution: Arcing parts. Keep the pump at least 20 feet mètres des vapeurs explosives. away from explosive vapors. 8) Attention: La pression du produit que l’on pulvérise peut produire une Caution: Static electricity can be developed by airless charge électrostatique. Mettre le matériel et l'objet à pulvériser à la terre. spraying. Ground unit and object to be sprayed. On Sur les modèles électriques, le cordon électrique doit être attaché à une electric units, unit power cord must be connected to a prise de courrant reliée à terre. Le cordon de rallonge doit être à 3 fils. Des grounded outlet. Use only three wire extension cords. décharges d'électricité statique peuvent se produire si le matériel n'est pas Static explosion can occur with ungrounded unit. mis à la terre. Flush system with spray tip removed. Always use 9) Retirer l'embout de pulvérisation avant de rincer le matériel tout en lowest pressure possible. utilisant une pression aussi basse que possible. Always follow safety precautions and warnings printed 10) Toujours prendre les précautions nécessaires et observer toutes les on paint container. consignes de sécurité figurant sur le pot de peinture. Only use spray guns and hoses supplied by Lemmer. 11) N'utiliser que les pulvérisateurs et les tuyaux flexibles fournis par User assumes all risk and liability when using spray guns Lemmer. Les personnes qui utilisent des pulvérisateurs et des tuyaux or hoses not complying with minimum specification and flexibles non conformes aux standards d'utilisation et de sécurité minimum safety devices of Lemmer Spray Systems Ltd. du fabricant de la pompe le font à leurs propres risques et seront les seuls Inspect hoses before each use. Never use a damaged responsables. hose. High pressure in hoses with wear, leaks or splits 12) Examiner soigneusement le tuyau avant de s'en servir. Il ne faut jamais may cause the hose to rupture and cause serious utiliser un tuyau endommagé ou avec des fentes. Un tuyau à haute pression personal injury. Never try to stop or deflect leaks with any qui n'est pas en bon état représente un serieux danger de blessure à la part of your body. personne en cas de crevaison soudaine. Il ne faut jamais essayer d'arrêter Use extreme caution when cleaning spray tip guard. des fuites de liquide avec n'importe quelle partie de votre corps. DO NOT try to wipe off build up around the spray tip 13) Il est nécessaire d'exercer beaucoup de précaution pendant le before following shut down procedure. Follow the Shut nettoyage de la protection de la buse. Ne jamais essayer d'enlever la down Procedure, then follow the spray tip manufacturer’s peinture qui aurait pu s'accumuler sur la buse avant d'avoir suivi les instructions for removing and cleaning the spray tip. consignes de sécurité concernant le nettoyage et le remplacement de la Never attempt to change spray tip or leave the unit buse. unattended without first shutting off pump, releasing fluid 14) Ne jamais essayer de changer la buse ou laisser l'appareil sans surveillance pressure, and locking the trigger safety lock. avant d'arrêter le moteur, couper la pression et verrouiller la gâchette du Use extreme caution when changing spray tip. Follow pistolet. the Shut down Procedure, then follow the spray tip 15) Le remplacement d'une buse doit être fait avec beaucoup de manufacturer’s instructions for changing the spray tip. précaution. Référez-vous au PROCÉDÉ D'ENTRETIEN. 3 SAFETY PRECAUTIONS 16) Do not pull on hoses to move equipment, DO NOT kink or bend the hose sharply. 17) Keep children or anyone not familiar with airless spray systems away from equipment and work area. 18) Conductive metal containers must be used when flushing flammable fluids through the system. Always flush at low pressure with spray tip removed. A metal part of the spray gun must be held firmly against the grounded metal pail when flushing or relieving pressure from the gun. 19) Trigger guard helps reduce the risk of accidentally triggering the gun if dropped or bumped. Do not use a spray gun without a trigger guard. 16) Il ne faut jamais essayer de déplacer l'appareil en tirant sur le tuyau. Il faut aussi éviter tout tortillement du tuyau. 17) Les enfants et le personnes n'ayant aucune expérience avec ce genre de pulvérisateur doivent êtres gardés à l'écart de l'appareil et du chantier de travail. 18) Quand on décharge des liquides inflammables il faut utiliser des pots conducteurs en métal. Quand on relâche la pression avec le pistolet, une partie métallique du pistolet doit être en contact avec le pot en métal muni de mise à la terre. 19) La protection de la gâchette réduit le risque d'activement involontaire si on laisse tomber le pistolet ou s'il est frappé par accident. Ne jamais utiliser le pistolet sans la protection de gâchette. 20) Shut Down Procedure Always follow Shut Down Procedure before starting any troubleshooting, servicing or cleaning. 1) Engage the trigger safety lock in the locked position. Test the trigger safety lock to ensure the lock is working properly. 2) Turn the On/Off switch to the Off position. 3) Unplug the electrical cord on the sprayer. 4) Open the prime valve to relieve pressure. Leave open until ready to spray or test or clean. 5) Remove the spray tip. 6) Disengage the trigger safety lock. 7) Trigger the gun into a metal pail to relieve any remaining pressure. A metal part of the spray gun should be held firmly against the grounded metal pail when relieving the pressure from the gun. (A grounded metal pail is not required for non-flammables such as latex.) 8) Reset the trigger safety lock to locked position. 20) Procédé à suivre avant tout travail d'entretien ou de nettoyage. 1) Bloquer la gâchette avec le levier de verrouillage. 2) Placer l'interrupteur MARCHE-ARRÊT en position ARRÊT. 3) Débrancher le cordon électrique. 4) Ouvrir la vanne de mise à l'air libre pour relâcher la pression. Gardez-la ouverte jusqu'au moment où vous êtes prêts à utiliser l'appareil. 5) Enlever la buse. 6) Débloquer le levier de verrouillage de la gâchette. 7) Relâcher le reste de la pression en déchargeant avec le pistolet dans un pot en métal. Quand on relâche la pression, une partie métallique du pistolet doit être en contact avec le pot en métal muni de mise à la terre. (Il n'est pas nécessaire d'utiliser un pot avec mise à la terre pour des produits non inflammables, comme par exemple le latex). 8) Ramener le levier de verrouillage en position bloquée. Warning This unit is provided with a thermally protected Reset. If an overload occurs, the thermally protected automatic reset disconnects the motor from the power supply. • Always disconnect motor from power supply before working on equipment. • When thermally protected reset disconnects the motor from the power supply, relieve pressure by turning priming valve to “prime”. • Turn ON-OFF switch to OFF. Caution: The cause of the overload should be corrected before restarting. Important: Read and understand these special safety precautions before operating the unit. Avertissement Cet appariel est équipé d'un disjoncteur à Protection thermique. En cas de surcharge, le disjoncteur automatique coupe le moteur de la source d'alimentation. • Toujours déconnecter le moteur de la source d’alimentation avant de travailler sur l’appareil. • Lorsque le disjoncteur coupe le moteur de la source d’alimentation relâcher la pression en plaçant le clapet d’amorçage en position “amorçage”. • Placer l’interrupteur MARCHE-ARRÊT en position ARRÊT. Attention: La cause de la surcharge doit être eliminée avant de remettre le moteur en marche. Electrical requirements If an extension cord is used, make sure it is a 3 conductor type (has grounding wire) and is CSA approved.Also make sure that its wire size (AWG) is thick enough to carry the amperage your machine requires. The chart below will show the minimum recommended AWG for specific lengths. See next page for pump specifications. Données électriques. Si l'on utilise un cordon de rallonge, veillez à ce qu'il soit à 3 fils (avec mise à la terre) et avec certification CSA. Le calibre des fils doit être suffisant pour l'ampérage qui est nécessaire pour que l'appareil fonctionne. Voir le tableau ci-dessous indiquant les calibres minimuns requis selon les différentes longueurs de la rallonge. Remember; keep the motor clean and dry. Paint acts as an insulator and will cause overheating and/or motor damage. Il est important de garder le moteur propre et à l'abri de l'humidité. L'isolation créée par la peinture sèche pourrait le surchauffer et l'endommager. Do not remove or bend grounding pin under any circumstances, it is essential for safe operation. Cord Length 25 ft 50 ft 75 ft 100 ft 125 ft 150 ft 0-5 16 16 16 16 16 16 Ne jamais enlever la broche de la mise à la terre car elle est essentielle pour la slûreté du travail. 6 16 16 16 16 16 14 7 16 16 16 16 14 14 8 16 16 16 14 14 14 Motor Amperage Rating 9 10 11 12 13 14 16 16 14 14 14 12 16 16 14 14 14 12 16 16 14 14 14 12 14 14 14 14 12 12 14 12 12 12 12 12 12 12 12 12 12 12 15 12 12 12 12 12 12 Minimum recommended AWG 4 16 12 12 12 12 12 12 17 12 12 12 12 12 12 18 12 12 12 12 12 12 19 12 12 12 12 12 12 20 12 12 12 12 12 12 PRODUCT SPECIFICATIONS INTRODUCTION: We appreciate your decision to purchase a Lemmer high quality professional paint spraying system and believe you will find it to be the best sprayer you ever owned. Your Lemmer airless paint machine is capable of spraying a wide variety of latex, oil-based and alkyd paints, as well as stains, preservatives and other architectural coatings. The material you are spraying will have a direct effect on the amount of pressure required for the optimum pattern and coverage to be obtained. We recommend that before actually beginning your job, you carefully read this manual and practice with the sprayer until you feel comfortable using it. The Lemmer DC-3000 & DC-4000 sprayers are powerful and versatile enough to be used with a variety of accessories (extra lenghts of hose, extensions, pressure feed rollers, etc. as shown on page 23) to make them even more versatile systems. Ask your supplier about the recommended accessories for your particular job. PUMP TYPE: The DC-3000 & DC-4000 units use a double acting piston pump, with stationary packings and the DC-4000 has a hard chromed piston. This gives good service life and is a simple to maintain system. The valves are stainless steel balls with tungsten carbide seats, giving very good reliability. Industrial grade DC motors are used in conjunction with reliable pressure control sytems. The DC-4000 uses an innovative electronic control which varies the speed of the pump in accordance with your need for pressure and material flow, with a minimum of fluctuation in spray. This system allows tips as small as .009" to be used for lacquer, yet perform well with large tips in heavy bodied products. ADVANTAGES OF THESE SYSTEMS ARE: •Pump stops working when you do. Minimizes wear. •Motor operates only as fast as the job requires again reducing wear (DC-4000 only). •Accurate spray pattern with minimal overspray. •Minimal or no thinning of paint products. •Pumps straight out of original paint container. •Variable pressure from 0 to 3000 PSI. •Various nozzles are available for slow to fast spraying. •Light weight, compact and portable. •Quiet running and low power consumption. •Steady spraying pressure - no fan fluctuations. •Compact paint pump - quick cleaning, less parts to wear. IMPORTANT NOTICES: Due to the nature of operation of this unit, even though the motor cuts off, or appears to have cut off, it may restart at any time. Even once the switch has been turned off, there will likely be pressure remaining in the system. Do not service the unit unless it has been turned off, unplugged and the pressure has been relieved. Pressure is relieved by turning the prime knob counter clockwise and double checking by triggering the gun. DO NOT USE STEEL BRAID paint spray hose! The DC-3000 & DC-4000 can only be used with fibre braid hose. TECHNICAL SPECIFICATIONS Weight: Capacity, volume @ 2000 psi: Maximum tip size, 1 gun: Maximum tip size, 2 gun: Motor: Power requirements, 110V: 220V: Spraying pressure: Maximum hose length: Maximum power cord: Paint inlet: Paint outlet: Gear oil capacity: Wetted parts: DC-3000 31 lbs (14 kg) .47 gpm .021 (.019 installed) .015 (.013 installed) 3/4 hp dc industrial 6.5A,115VAC,60HZ 0 - 3000 psi 300 feet (91meters) 300 feet (14-16 guage) metric 1/4" npt(m) Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon DC-4000 77 lbs (35 kg) .57 gpm .025 (.023 installed) .017 (.015 installed) 3/4 hp dc industrial 12A,115VAC,60HZ (North America) 6A,220VAC,50HZ (Europe) 0 - 3000 psi 300 feet (91meters) 300 feet (12-14 guage) 1/2" npt(f) 1/4" npt(m) 200 ml. EP 90w Al,Cu,SS,Tc,Tef,Lea,Brass,Nylon,Chrome,Zinc Capability: All conventional coatings, ie: latex, stain, lacquer, varnish, ink, primer, preservatives and many other architectural coatings with the DC-4000 such as block fillers and some elastomerics and glues. 5 PUMP COMPONENTS SPRAY GUN: Important The spray gun is designed To engage trigger specifically for airless spraying. safety lock, turn Since there is no compressed air lever tab to horizonto atomize the paint, atomization tal position. Test is accomplished by forcing the regularily for proper paint at a very high pressure functioning while (3200 psi) through a very small system is shut hole (.017" diameter). Because down. of this high pressure, the spray tip and gun valve are made of tungsten carbide for maximum wear resistance. The gun body is made of forged alloy and anodized for chemical resistance. locked As a safety feature, the spray gun can be locked with the trigger safety lever when you are not unlocked spraying. Be sure to read all warnings concerning the high For models pressures of airless spraying on L45 & L-50 page 3 & 4. PRESSURE CONTROL BOX (DC-3000): A rugged membrane transducer transmits a paint pressure signal to an electronic relay which then powers the motor. This on-off design has a pressure fluctuation of about 200 psi. PRESSURE CONTROL BOX (DC-4000): It balances input from the pressure control box with a signal from the sensor. On the basis of these two inputs, and electronic decision is made regarding how much voltage, if any, is required by the motor to maintain an even pressure. The more pressure set by operator, or pressure drop from a large tip, the more voltage is sent to motor to speed up the pump. When the gun is released, the pressure rises and the motor is turned off. The advantages of this system will become most obvious if you try smaller tips (.011/.013) at lower pressures for lacquering or other fine work. A safety circuit is also incorporated which will turn the pump off if it runs out of paint at spraying pressures. (above approx. 1000 psi) If the unit drops from spraying pressure to below approx. 500 psi, for more than 25 seconds continuously the safety will turn the pump off. This is to reduce the typical packing damage from “dry” running. At pressures below approx. 1000 psi, the safety will not engage, making the unit fully compatible with all types of pressure rollers. It also prevents interference of the safety with typical cleaning procedures. (trigger shown in horizontal locked position) PISTON PUMP (DC-3000 & DC-4000): Uses two sets of packings and two check valves in conjunction with an abrasion resistant piston. This forms a double acting pump; ie pumps on both up and down stroke. Both sets of packings are stationary, eliminating costly cylinder wear. pressure control motor control box speed reducer suction system prime valve paint pump CENTRAL BODY (DC-4000): Is a meeting point of pump and speed reducer. Helps turn rotating motion of motor and reduce into an even up and down motion to drive pump. SPEED REDUCER(DC-3000): Consists of a two stage gear reduction in permanent grease for long life. All bearings are alsopermanently greased. Converts the high speed output of motor into very high torque to drive pump. Figure 1a. - DC-3000 components. speed reducer SPEED REDUCER (DC-4000): Consists of a single stage gear reduction in an oil bath for long life. All major bearings are also lubricated by this oil. Converts the high speed output of motor into very high torque to drive pump. motor pail hook brush cap grease fitting MOTOR (DC-3000): Is an industrial grade high speed unit. Its permanent magnet DC type construction withstands construction site power fluctuations. The higher rpm of this motor results in a compact and lightweight design. prime valve central body control box paint pump MOTOR (DC-4000): Is an industrial grade high quality unit. Due to the permanent magnet DC type construction, the motor will run at different speeds, depending on how much voltage it is sent by pressure control box. This allows for highly accurate control of pressure. Motor also features long life brushes, which are readily accessible from the outside. suction pipe suction screen 6 return hose Figure 1b. - DC-4000 components. SETTING UP OF UNIT TOOLS NEEDED: 2 x 8" or larger crescent wrench gear oil fill plug PROCEDURE: 1) Remove all system components from the box for assembly. 2) Remove protective cap from outlet connection of pump. 3) Install handle and tool box. (DC-4000 only). 4) Connect high pressure airless paint hose to pump outlet. Tighten to approximately 20 ft. lbs. 5) Attach the tip assembly to the spray gun. 6) Connect the paint hose to the swivel connection of the spray gun. Tighten 20 ft lbs. Ensure the gun handle is securely hand tightened to the gun. 7) Double check all connections, the unit is now ready. Note: The pump contains a preservative oil when you receive it, that may drip from the various connections when the protective caps are removed. oil drain connecting bolt packing nut paint pump foot valve Figure 3. - DC-4000 system components. pressure control circuit breaker on/off to prime, turn ccw "spray" "prime" "off" WARNING: INJECTION HAZARD POSSIBLE. DO NOT SPRAY WITHOUT TIP IN PLACE. ALWAYS ENGAGE TRIGGER LOCK BEFORE REMOVING, REPLACING OR CLEANING TIP. NEVER TRY TO CLEAN THE TIP WITH YOUR FINGERS. prime valve indicator light To disengage your trigger lock: Your spray gun is shipped from the factory with the trigger lock in the engaged position (horizontal on the L-65). To disengage, turn the trigger lock down until it is in a vertical position. To engage the trigger lock, turn it back to a horizontal position. sensor assembly paint out (hose connection) Figure 4. - DC-4000 control box components. ELECTRONIC CONTROLS (DC-4000): OFF: The first 10-20 degrees of pressure knob rotation do not activate unit. PRIME ZONE: The next approx. 20 degrees of rotation will turn the motor on at a constant slow speed, when the prime valve is in the open (prime) position. This is the best speed for priming and cleaning the unit. It also works well for power rolling. The safety cutout is not activated in this zone. Maximum pressure in the prime zone is about 1000 psi. tip. trigger lock. tip housing. SPRAYING ZONE: As the pressure knob is turned past the prime zone (with prime valve open) the motor will suddenly change from a constant low speed to full speed. When the prime valve is closed, this will give fully adjustable pressure from about 900 psi to approximately 3000 psi. The safety circuit is activated throughout the spray zone. Safety turns motor off if the pressure drops from spraying pressure to less than 500 psi for more than 25 seconds (continuous). If the pump were to run out of paint, the gun would have to be held open to ensure that the pressure drop is enough to activate safety. This is to prevent accidental triggering of safety with large tips, air bubbles in paint etc. Indicator light will go off if safety has been activated. Safety is re-set by turning power OFF for 3-5 seconds. gun handle with filter inside. hand tight only! trigger guard for safety. do not remove! high pressure swivel, 1/4"npt. Figure 2. - L-65 gun components. 7 TIP SELECTION FAN FAN FLOW PART NO. ORIFICE AT 1' ANGLE LTR/MIN TIP SELECTION: A standard size .017 tip will give good performance in latex or oil base materials of moderate viscosities. TIP MARKING L043-091 L043-092 L043-093 L043-094 L043-095 L043-096 .009 .009 .009 .009 .009 .009 2" 4" 6" 8" 10" 12" 10 20 30 40 50 60 DEG. DEG. DEG. DEG. DEG. DEG. 0.26 0.26 0.26 0.26 0.26 0.26 109 209 309 409 509 609 L043-111 L043-112 L043-113 L043-114 L043-115 L043-116 L043-117 .011 .011 .011 .011 .011 .011 .011 2" 4" 6" 8" 10" 12" 14" 10 20 30 40 50 60 70 DEG. DEG. DEG. DEG. DEG. DEG. DEG. 0.40 0.40 0.40 0.40 0.40 0.40 0.40 111 211 311 411 511 611 711 L043-131 L043-132 L043-133 L043-134 L043-135 L043-136 L043-137 L043-138 .013 .013 .013 .013 .013 .013 .013 .013 2" 4" 6" 8" 10" 12" 14" 16" 10 20 30 40 50 60 70 80 DEG. DEG. DEG. DEG. DEG. DEG. DEG. DEG. 0.60 0.60 0.60 0.60 0.60 0.60 0.60 0.60 113 213 313 413 513 613 713 813 L043-151 L043-152 L043-153 L043-154 L043-155 L043-156 L043-157 .015 .015 .015 .015 .015 .015 .015 2" 4" 6" 8" 10" 12" 14" 10 20 30 40 50 60 70 DEG. DEG. DEG. DEG. DEG. DEG. DEG. 0.80 0.80 0.80 0.80 0.80 0.80 0.80 115 215 315 415 515 615 715 L043-171 L043-172 L043-173 L043-174 L043-175 L043-176 L043-177 L043-178 .017 .017 .017 .017 .017 .017 .017 .017 2" 4" 6" 8" 10" 12" 14" 16" 10 20 30 40 50 60 70 80 DEG. DEG. DEG. DEG. DEG. DEG. DEG. DEG. 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 117 217 317 417 517 617 717 817 L043-192 L043-193 L043-194 L043-195 L043-196 L043-197 L043-198 .019 .019 .019 .019 .019 .019 .019 4" 6" 8" 10" 12" 14" 16" 20 30 40 50 60 70 80 DEG. DEG. DEG. DEG. DEG. DEG. DEG. 1.3 1.3 1.3 1.3 1.3 1.3 1.3 219 319 419 519 619 719 819 L043-213 L043-214 L043-215 L043-216 L043-217 L043-218 L043-219 .021 .021 .021 .021 .021 .021 .021 6" 8" 10" 12" 14" 16" 18" 30 40 50 60 70 80 90 DEG. DEG. DEG. DEG. DEG. DEG. DEG. 1.6 1.6 1.6 1.6 1.6 1.6 1.6 321 421 521 621 721 821 921 L043-234 L043-235 L043-236 L043-237 L043-238 L043-239 .023 .023 .023 .023 .023 .023 8" 10" 12" 14" 16" 18" 40 50 60 70 80 90 DEG. DEG. DEG. DEG. DEG. DEG. 1.9 1.9 1.9 1.9 1.9 1.9 423 523 623 723 823 923 L043-254 L043-255 L043-256 L043-257 L043-258 L043-259 .025 .025 .025 .025 .025 .025 8" 10" 12" 14" 16" 18" 40 50 60 70 80 90 DEG. DEG. DEG. DEG. DEG. DEG. 2.3 2.3 2.3 2.3 2.3 2.3 425 525 625 725 825 925 L043-274 L043-275 L043-276 L043-277 L043-278 L043-279 .027 .027 .027 .027 .027 .027 8" 10" 12" 14" 16" 18" 40 50 60 70 80 90 DEG. DEG. DEG. DEG. DEG. DEG. 2.7 2.7 2.7 2.7 2.7 2.7 427 527 627 727 827 927 L043-294 L043-295 L043-296 L043-297 L043-298 L043-299 .029 .029 .029 .029 .029 .029 8" 10" 12" 14" 16" 18" 40 50 60 70 80 90 DEG. DEG. DEG. DEG. DEG. DEG. 3.1 3.1 3.1 3.1 3.1 3.1 429 529 629 729 829 929 L043-313 L043-314 L043-315 L043-316 L043-317 L043-318 .031 .031 .031 .031 .031 .031 6" 8" 10" 12" 14" 16" 30 40 50 60 70 80 DEG. DEG. DEG. DEG. DEG. DEG. 3.5 3.5 3.5 3.5 3.5 3.5 331 431 531 631 731 831 The following chart gives a basic idea of what tips the Lemmer sprayers can handle performance wise and what tip is appropriate for which material. Gun filter sizing is also included in the chart for handy reference. For a much more detailed look at tip sizes, please consult the detailed tip chart on page 10. Tip size Paint type Filter size .011 Lacquers, industrial enamel, red very thin paints. .013 Oil stains, pigmented lacquers, yellow red oxide primer. .015 Normal application of latex, oil base, yellow stains and , solid color oil stains. .017 Fast application of latex paints white and stains, oil base paints. .019 Heavier body latex paints. white .021 Fast application of heavier latex white paint, smooth block filter when properly thinned. .023 Maximum tip on DC-4000/L-1. not req’d .027 Maximum tip on L-5,000. not req’d .033 Maximum tip on L-7,500. not req’d .043 Maximum tip on L-10,000. not req’d The maximum tip for a pump is the largest tip that will deliver a proper pressure for spraying without overworking or overloading. When a tip is used for some period of time, it can wear beyond the maximum for the pump, which will cause low pressure and poor spray pattern. Stains and thick latex products often cause the most rapid wear of the tip, while clear lacquers and varnishes cause the least wear. Thus tip life can vary from as little as 50 gallons to as much as 200 or more, depending on the product being sprayed and the pressure used. Filters for the gun are picked not because of the type of paint being used, but to protect a given size of tip. You pick the tip for the type of paint and job being done and then choose the filter to protect that tip. The chart on page 10 gives much more detail about tip and filter choices. THE TWO MOST IMPORTANT THINGS TO REMEMBER ABOUT TIPS..... 1) Low pressure means longer life, for tips and the pump. Less overspray too! 2) Worn tips waste paint and overwork the pump, wearing it out quickly. 8 ZIP TIP INFORMATION TO CHANGE ZIP TIPS: 1) Rotate zip-tip 90˚. 2) Remove from housing. 3) Install new zip tip. 4) Rotate 90˚ to spray position. 3 2 1 4 Figure 5. - Zip tip Pos. Part nos. 1 2 3 4 L043-001 L043-007 L043-005 L043-006 L043-008 L043-009 L043-*** Description Figure 7. - Removing tip seal. Zip Tip housing with guard Zip Tip guard (not shown separately) Zip Tip seal kit (includes gasket #3) Spring, 3/pkg (not shown separately) Nylon gasket Tube of 8x nylon gaskets Zip Tip - see chart on opposite page TO CHANGE SEAL ASSEMBLY: 1) Relieve line pressure and set gun safety. 2) Remove zip tip housing from gun. 3) Remove zip tip from housing. 4) Insert zip tip cylinder into front of housing and press seal assembly out of housing. 5) Install zip tip (4) through slot in guard and into body. 6) Insert seal ass'y (2) through gun nut to seat seal around zip tip cylinder (press firmly to insure seal is tight against cylinder). 7) Insert tip/gun washer (3) over spring (in gun nut). Install unit on gun. Tighten gun nut. FEATURES: Fast Tip Size Changes - no tools required. Long Seal Life - withstands harsh solvents - won't swell or leak - replaces in minutes. Tip Rotates Easily - even under “high pressure” clog-up. Venturi-Guard - less paint accumulation - helps protect against accidental injection and prevents tip from slipping out of position. Patented Diffuser - safer unclogging in clean-out position. IMPORTANT: The seal ass'y (2) is a wear part that must be replaced periodically. If leaking occurs, replace the seal ass'y immediately before it damages the tip (4). TO OPERATE: When tip clogs, turn zip-tip handle 180˚ to "cleanout position". Trigger gun and line pressure will purge clog. DO NOT spray or empty the hose in "clean out" position, this will cause extreme wear and premature failure. Always remove the tip when cleaning out the hose. TO CLEAN PLUGGED TIP: 1) Rotate the tip to the “Clean” position. 2) Pull trigger and spray. This should clear the tip of any blockage. 3) Rotate the tip back to the “Spray” position and continue spraying. 4) If the clogging continues, clean or replace the gun filter and see the section in this manual on instructions for straining and thinning paint. Clean Position Spray Position Figure 6. - Tip unclogging. CAUTION: DO NOT USE A NEEDLE OR SHARP OBJECT TO CLEAN THE TIP. TUNGSTEN CARBIDE IS BRITTLE AND CAN BE CHIPPED. 9 HOW TO SELECT TIP SIZE AND PROPER FILTER (BASIC INFORMATION) Coating Lacquer, varnish, furniture stain 2" 1-09 R Fan Size (measured at 1 foot) 4" 6" 8" 10" 2-09 R 3-09 R 4-11 R 5-11 R 12" 6-11 R 1-09 R 2-11 R 3-11 R 4-13 R 5-13 R 6-15 Y 1-11 R 2-13 Y 3-13 R 4-15 Y 5-15 Y 6-17 W (viscosity of 15 to 35 seconds, similar to vegetable oil) Industrial enamels, stain, colored lacquer (viscosity of 25 to 50 seconds, similar to dish washing liquid) Shop primer, solid stain, oil base, latex (viscosity of 40 to 100 seconds, similar to 10-30 motor oil) Flat oil base, latex 1-13 Y 2-15 W 3-15 Y 4-17 W 5-17 W 6-19 W (viscosity of 60 to 150 seconds, similar to 50 weight oil) Thick latex, prepared blockfiller 1-15 W 2-17 W 3-17 W 4-19 W 5-19 W 6-21 * 1-17 W 2-19 W 3-19 W 6-23 * (viscosity of 150 to 200 seconds, similar to gear oil) Most block fillers 4-21 * 5-21 * (viscosity of over 200 seconds, are not measurable with the Lemmer cup) explanation of tip and filter sizing: eg:4-15 Y 4 = half of fan width (8" @ 1 foot) 15 = orifice size in thousands of an inch (.015) Y = Yellow 100 mesh filter. (R = Red 180 mesh) (Y = Yellow 100 mesh) (W = White 50 mesh) (* = *not recommended) Measure the paint’s viscosity as follows: (note, paints that are intended to be rolled should be thinned for air or airless spraying. A general rule of thumb is 5 to 15% for latex and oils, 30% or more for fine finishes. (consult your paint supplier for best results). a) Submerge the Lemmer Viscosity cup in the paint. b) Lift the cup out of the paint and begin timing. c) Stop timing when the steady paint stream is first broken. d) The time recorded is the paint’s viscosity. i iok for L-1500i Pump maximum tip size Pump Absolute maximum To allow for tip wear L-1400 L-1500 kDC-3000 kDC-4000 L-1 VN .015 .017 .021 .025 .025 .013 .015 .019 .023 (2X.015) .023 (2X.015) Notes: Approximate wear values comparing tungsten tips and paint type. (Paint is in gallons) New tip size .015 .017 .019 .027 worn to worn to worn to worn to Tip worn to .017 .019 .021 .029 Lacquer 400 Latex 75 150 250 Block filler 75 250 Road marking paint 2 20 50 200 Tip chart example: Latex stain is being sprayed onto a fence. The paint is fairly thick (like a very heavy motor oil) and the L-1500 is the spray machine. The maximum tip is a .015 for an L-1500. Draw a line along the .015 tips as shown below. Everything above the line is sprayable with the L1500. Now just choose the fan width. For fences a 6” width will give a lot of control, so the intersecting best choice would be a 315 tip with a yellow gun filter. Tip volume at various pressures. —Gallons per minute— Results are based on water, heavier viscosities will produce less volume. This is especially noticeable with large tips and very heavy coatings. TIP 500 1000 1500 2000 SIZE PSI PSI PSI PSI .009 .039 .055 .067 .078 .011 .06 .08 .10 .12 .013 .09 .12 .15 .18 .015 .12 .16 .20 .23 .017 .16 .23 .27 .32 .019 .20 .27 .33 .39 .021 .24 .33 .41 .47 .023 .28 .40 .49 .57 .025 .33 .47 .58 .68 .027 .37 .52 .64 .76 .029 .47 .65 .79 .98 .031 .53 .75 .91 1.1 .035 .69 .9 1.0 1.2 .043 1.1 1.5 1.8 2.1 .053 1.5 2.2 2.9 3.4 .057 1.8 2.5 3.1 3.5 .063 2.2 3.1 3.9 4.4 .067 2.5 3.5 4.3 5.0 .073 2.9 4.1 5.1 5.9 .079 3.6 5.1 6.3 7.3 .085 3.9 5.5 6.7 7.8 .089 4.3 6.0 7.4 8.5 .099 5.3 7.5 9.2 10.6 The two most important things to remember about tips..... 1) Low pressure means longer life, for tips and the pump. Less overspray too! 2) Worn tips waste paint and overwork the pump, causing premature pump wear. The maximum tip for a pump is the largest tip that will deliver a proper pressure for spraying without overworking or overloading. When a tip is used for some period of time, it can wear beyond the maximum size recommended for the pump, which will cause low pressure and poor spray pattern. • Stains and thick latex products often cause the most rapid wear of the tip, while clear lacquers and varnishes cause the least wear. Thus tip life can vary from as little as 50 gallons to as much as 200 or more, depending on the product being sprayed and the pressure used. • Filter screen mesh for the gun or pump are picked not because of the type of paint being used, but to protect a given size of tip. Pick the tip for the type of paint and job being done and then choose the filter to protect that tip. 10 STARTUP PROCEDURE PRIMING UNIT IN PAINT: Follow same procedure as steps 1-7 of “Priming and Flushing”, but instead using paint. Then continue with the remaining steps as outlined below. 11) Remove tip from gun. Unlock trigger. Aim gun into solvent pail and hold trigger open until solvent flow changes to paint. Release and lock trigger. Re-install PRIME VALVE OPERATION: tip. 1. DC-3000: Valve turns continuously left or right. 12) Turn up pressure approximately 1/2 to 3/4 turn from PRIME position is when the valve is "pulled out" and minimum setting. spray is when the valve is "seated in". 13) This about 2000 psi, which is a normal spraying 2. DC-4000: Valve turns left or right. PRIME position is pressure for many medium thickness products. As the when the valve is turned counterclockwise (pulled pressure you have set is reached, the motor will slow out) ,and spray is when the valve is turned clockwise down and cut out. DC-4000 only: as the hose contin(seated in). ues to absorb pressure, it may cut momentarily in a DC-4000 few times, to top up the line pressure. This is the DC-3000 unique “kicker” feature which reduces “buzzing” associated with most other units. This feature helps to increase motor, brush and pressure control life. 14) The motor will run when the gun is open. Motor speed prime (on the DC-4000), or motor on-off cycles (on the DCvalve 3000), is in relation to both the size of the tip, and the pressure you have set. prime Test spray pattern per chart below, and adjust presvalve sure accordingly. Whenever the pump is to be used, it must be prepared for the type of paint to be used. This requires the unit to be flushed out with an appropriate solvent (water for latex, mineral spirits for oil base, etc.). Incorrect flushing can cause gumming of the valves and priming problems. UNIT PRIMING AND FLUSHING: 1) Check that all hose, gun handle and tip connections are tight. 2) Place trigger lock in “LOCK” position. Plug unit into correct power source. 3) Place prime valve into open or “PRIME” position. 4) Turn pressure control to minimum. Turn ON unit. On the DC-4000 green indicator light should be on but motor not running. If motor runs, re-check that pressure control is turned to minimum. 5) Place suction into container of correct solvent. Slowly, turn up the pressure control into the prime zone. Motor will begin to run, watch for flow from return tube. 6) Let pump prime for 20-30 seconds. Close prime valve. Unit will build up a low pressure and cut out. NOTE: Always turn down pressure control before changing position of the prime valve. This reduces shock loading of the pump and possible damage. Figure 8. - Spray pattern examples. NOTE TO TURN UNIT OFF: Always reduce pressure, turn prime valve to prime, trigger gun to release pressure build up in hose, and turn motor off. 7) Turn zip tip to halfway position and remove from gun (see page 9). Turn up pressure about 1/6 turn. This gives a good low pressure for flushing and cleaning. 8) Aim gun into empty metal pail, holding gun body against pail edge to ground gun for safety. Open trigger, and allow solvent to flow for one minute. 9) Release and lock trigger (read static safety on page 4). Turn pressure control to minimum and open prime valve to release pressure. 10) Unit is now flushed out. 11 HINTS FOR AIRLESS SPRAYING WARNING: DO NOT BEGIN SPRAYING BEFORE READING THIS SECTION AND ALL PREVIOUS SAFETY INFORMATION. PAINTING AND TIP SELECTION: Correct adjustment of pressure and proper tip selection are crucial to the best spray pattern.... 1) In any situation, the lowest pressure that gives an adequate spray pattern is the best pressure to use. It will give maximum pump and tip life and produce minimum overspray. 2) Typically, thicker materials require larger tips and higher pressures than thinner paints do. Some very thick paints may require slight thinning (5-10%) depending upon pump and tip size and application. Generally, thinning is performed when a good spray pattern cannot be obtained with an appropriate tip size at maximum pressure. (see figure 8). SPRAY PAINTING METHOD: 1) Keep the gun perpendicular to the surface. Always hold the gun perpendicular to the surface with the tip approximately 12" from the surface. If held at an angle (up and down or side to side) paint will build up unevenly and leave the work splotchy. (See figure 9). Figure 11. - Result of flexing wrist while spraying. 3) Start moving the gun before triggering. To get smooth overlap and prevent initial paint buildup, start your stroke movement before pulling the trigger. At the end of the stroke release the trigger before stopping. NOTE: To assure uniform paint coverage, overlap each stroke by 40% - 50%. 4) Intermittent use. If you are spraying and decide to stop for several minutes, lock the spray gun trigger and submerge the tip in a container of the appropriate solvent. This will prevent paint from hardening in the tiny spray opening and clogging the tip. Be sure to release the pressure by opening prime valve and turning the pump off. Figure 9. - Right and wrong way to hold spray gun. 2) Move with a smooth arm stroke. Move the gun at a steady even pace while keeping the gun perpendicular to the surface. (See figure 10) Do not move the gun by flexing your wrist. Fanning the gun will cause excessive overspray and uneven coverage. (See figure 11). Figure 10. - Proper way to trigger spray gun. 12 HELPFUL HINTS FOR TROUBLE FREE PAINTING SPRAYER: 1) Flush before each use with a solvent that is correct for the paint you will be spraying. ie: Water for latex paints. 2) Clean unit well after each use. A clean unit works better and lasts longer. 3) Flush with mineral spirits when storing the unit for more than 3 or 4 days. PAINT HOSE: 1) INSPECT THE HOSE PERIODICALLY. DO NOT USE KINKED, WORN OR DAMAGED HOSE. SEE WARNINGS ON PAGES 3 & 4! 2) Use only hose that is designed for the high pressures of airless units. Minimum working pressure of 3000 PSI. Be sure it is grounded, static dissipating type hose. 3) Protect both the paint hose and the electric cord from vehicle traffic and sharp cutting edges or objects. 4) For best performance, maximum hose length is about 300 ft. of 1/4". This maximum will largely depend on tip size and thickness of paint. 5) DO NOT USE STEEL BRAID hose! The DC-3000 & DC-4000 can only be used with fibre braid hose. PAINT: 1) Prepare paint according to manufactuer’s recommendations. 2) Remove all skins on paint. 3) Stir paint thoroughly. 4) Strain paint through a fine mesh strainer bag to avoid clogging of pump and filters. (see accessories page). ELECTRICAL: 1) Always ensure the unit is plugged into a grounded outlet providing 115 volt, 15 amp (minimum), 60 cycle service. 2) Start unit with pressure control turned to minimum setting with prime valve open and pressure relieved. 3) Indicator light will show if power is connected and switch is ON. (DC-4000 only). 4) If circuit breaker has tripped, determine the cause of overload before re-setting. SPRAY TIPS: 1) Use minimum pressure that gives a good spray pattern to reduce tip and pump wear and cut down overspray. 2) Replace tips before they become too worn. Worn tips waste paint and overwork the sprayer. FILTERS: 1) Clean the filters after each use of sprayer. 2) Use correct filter for the tip size and paint type. See chart page 10. 3) Push down on filter after inserting it into the gun handle to test if the filter spring is at the bottom. Make sure the filter is inserted with the double lip going into the gun first. EXTENSION CORD: 1) Use only three wire, grounded type extension cord, CSA approved. 2) Use correct wire size of extension cord for correct operation. See chart on page 4. 13 CLEANING INSTRUCTIONS As with all spray equipment, your sprayer must be cleaned properly or it will not operate properly. Clogged valves and filters are the most common causes of problems. If followed, these guidelines will insure trouble free performance from your sprayer. CAUTION: Clean with water if latex is used. Clean with paint thinners for oil based paints. Both water and paint thinner will be refered to as "solvent" from here on in. Figure 13. Clean pump with suitable solvent . CLEAN-UP: To get the best use and longest life from your sprayer, it is very important to clean it out properly. The procedure is simple and is very similar to the flushing procedure performed earlier. Cleaning and flushing would also be required when changing color, or type of paint, ie: latex changing to oil base. 1) Lock gun trigger, turn pressure control to minimum, open prime valve to release all system pressure. 2) Turn zip tip to halfway position and remove from gun. (if so equipped). 3) While unit is running in prime zone, with prime valve open, tilt unit back (or lift suction system out of pail) and allow it 10-15 seconds to pump out paint. 5) Turn pressure control to minimum and close prime valve. 6) Unlock trigger, and with spray tip still removed and pressure in prime zone, aim gun into paint pail and hold trigger open until paint flow stops and solvent flow just begins. Release trigger. Aim gun into solvent pail/hopper and circulate solvent for about two minutes. To reduce splashing, direct the fluid stream along inside of bucket at a side angle and well above the fluid level (or submerge the tip in the solvent). Release trigger. Point spray gun into an empty waste bucket and spray at least 1 gallon of fluid into it. (see figure 14). Figure 12. Pump fluid out. 4) Place suction tube in proper solvent. Clean outside of metal suction tube. 14 CLEANING INSTRUCTIONS 10) Ensure pressure control is turned to minimum and all pressure is released. Open prime valve. Turn pump OFF. 11) Unthread gun handle from gun body to access gun filter. Remove filter and brush clean with appropriate solvent. Inspect filter for pinholes, plugging, or other damage. Replace if required. Re-install with “double lip” end pointing up into gun. Lightly grease handle threads (petroleum jelly, auto grease) and re-install firm hand tight. Brush exterior of gun clean. 12) Remove intake screen on metal suction tube and brush clean, re-install. 13) Storing unit for more than 3 days. If unit was cleaned with an oily paint thinner such as varsol, the unit is now ready for storage (after step 14). If unit was cleaned with water or a strong thinner (ie. lacquer thinner) pump varsol (or mineral spirits) through the entire system by repeating step 8. If varsol is not available, drain all the solvent out of the hose, gun, and pump. (Tungsten carbide parts in the valves will corrode if left in water for long periods of time). 14) Coil up electrical cord and spray hose, inspecting both for signs of damage. Suggested minimum coil size for 1/4" paint hose is 18 inches. Warning! Figure 14. Pump until clean solvent appears. Warning: conductive metal containers must be used when flushing flammable fluids through the system. Always flush at low pressure with spray tip removed. A metal part of the spray gun must be held firmly against the grounded metal pail when flushing or relieving pressure from the gun. 7) Pump solvent out by lifting both suction and return hose out of the solvent. Turn pressure control to minimum and open prime valve to release system pressure. Lock trigger and cleanspray tip before reinstalling on gun. DO NOT COIL PAINT HOSE TOO TIGHTLY. THIS MAY CAUSE KINKS, WHICH WEAKEN THE HOSE. A PAINT HOSE WITH KINKS OR OTHER DAMAGE SHOULD BE CONSIDERED UNSAFE AND BE REPLACED IMMEDIATELY. WARNING: DO NOT CLEAN THE SPRAY GUN UNLESS THE PRESSURE HAS BEEN RELEASED FROM THE SYSTEM. SEE PAGES 3 & 4 FOR FURTHER PRECAUTIONS. Figure 15. Fluid is pumped out. 8) Follow above steps 1-7 using clean solvent to completely flush unit. 9) If changing paint types, ie: latex (water base) to oil base, you would have to flush unit with clean mineral spirits using above steps 1-7. This would prepare the pump for the oil base paint. Water would have to be used as a last flush if changing from oil base paints to latex. 15 MAINTENANCE & SERVICE (DC-3000 & DC-4000) SPRAY GUN: The filter should be cleaned or replaced after each use to minimize tip clogging problems. If the gun valve becomes worn and begins to leak, it should be replaced. See page 25 for overhaul details. 5) Install brushes. If re-using old brushes, put back on same side of motor, same way up as before to reduce break-in time. 6) Install brush caps. DO NOT OVERTIGHTEN, AS BRUSH CAPS ARE BAKELITE AND WILL BREAK! 7) Put unit in solvent, open prime valve, and run unit at low priming speed for approximately 5 minutes to break in brushes. SPRAY TIP: The spray tip is one of the most important elements in producing a quality spray job. It requires periodic replacement (every 50-200 gallons) to maintain performance and to prevent overworking the pump (see page 8 for details). LOWER PACKINGS: No regular service required. The lower packings of this unit are stationary, so that the only wearing part is the piston. Costly replacing of the pump cylinder is eliminated. The packings are self adjusting, and will generally outlast the upper packings. Both sets are included in the packing kit, and should be changed together for best reliability and performance. CHANGING GEAR OIL (DC-4000): 1) Turn unit off, ensure prime valve is open, and all pressure is relieved. Unplug from electrical outlet. 2) Remove oil drain plug from underside of speed reducer. 3) Remove oil fill/vent cap from top of speed reducer. 4. Allow old oil to drain. Replace drain plug. 5) Fill unit with 200 ml of EP 90 gear oil, part no. L034124. Do not overfill! 6) Replace vent cap. Unit is now ready for use. UPPER PACKINGS: Lubricate daily with L034-125 oil. The upper packings are adjusted manually, by turning the brass packing nut to the left, ie; clockwise as viewed from the top. Keep guard in place during operation. IMPORTANT NOTE: The packings should never be over tightened, as this greatly reduces packing and piston life. Never tighten packings with pressure in unit, as a false indication of adjustment will result. A bit of gummy buildup around the packing nut is normal and should be periodically removed with a brush and solvent. This allows lubricant oil to reach packings. Repeat each 500 hr or at each packing replacement. GREASE CENTRAL BODY (DC-4000): 1) Turn unit off, ensure prime valve is open, and all pressure is relieved. 2) Using a grease gun with normal automotive grease, pump 2-5 strokes into nipple on front of central body. Some guns may require removal of pail hook using 5mm allen key. 3) Repeat every 100-200 hour and at each packing change. NOTE: Do not adjust packing while unit is running. Fingers, tools, etc. can be trapped between plunger and packing nut. Loss of finger or serious injury could result. CLEAN COOLING FAN (DC-4000): 1) Turn unit off, ensure prime valve is open, and all pressure is relieved. Unplug from electrical outlet. 2) Remove the 3 x screw from fan cover. 3) Scrape fan, back of motor and inside of cover clean. Clean exterior of motor with wire brush or scraping. 4) Replace cover and screws. TO TIGHTEN UPPER PACKINGS: 1) Turn unit off, ensure prime valve is open, and all pressure is relieved. Unplug from electrical outlet. 2) Remove all buildup from around packing nut. 3) Using a hammer and srewdriver, turn packing nut clockwise a maximum of 1/8 turn. Packings should be only tightened just enough to stop leakage. See notice above. Gentle tightening is normally sufficient. 4) Lubricate packings using L034-125 oil. 5) Replace safety shield over packing area. NOTE: When no further adjustment of packings is possible, the nut will be difficult to turn with reasonable effort. Packings should be replaced. This is to be done “on condition” ie; if fan and motor look dirty, it is time for cleaning. A clean fan and motor run cooler and last longer! BRUSH INSPECTION AND REPLACEMENT (DC-4000): NOTE: Check every 500 hr or at packing replacement. Failure to replace worn brushes will reduce unit performance and drastically shorten motor life. 1) Turn unit off, ensure prime valve is open, and all pressure is relieved. Unplug from electrical outlet. 2) Remove brush caps from side of motor and remove brushes. Keep note of which side of motor and which side up brushes are. 3) Measure length of rectangular part of brush. If 15mm or longer, brush is in near new condition. If 13-15mm, replacement should be seriously considered. If 13mm or shorter, brushes MUST be replaced or motor damage may occur. 4) Blow out motor through brush holes with compressed air. CHECK VALVES: These pumps has two valves, the footvalve at the paint inlet, and the shaft valve in the center of the piston. Both are of stainless steel ball, tungsten seat construction. This means that inexpensive, easily replaced balls are the normal wear point. If the unit will not draw up paint, the footvalve may be stuck. Simply tapping on the side of the footvalve with a wrench will usually suffice. Should this not work, the following steps will show you how to remove and clean the footvalve and check the shaft valve. For shaftvalve disassembly, please see steps 1-12, 16, 17 of packing instructions for the DC-4000. 16 MAINTENANCE & SERVICE (DC-3000) Yoke Pin Retaining clip Front cover plate Torx screw Suction system complete REMOVAL OF FLUID PUMP: 1) Turn unit off, ensure that prime valve is open, and all pressure is relieved. Unplug unit from electrical outlet. 2) Unscrew the suction system, fluid connection hose, and the return hose. (make note of return hose fitting position before loosening). 3) Remove the front cover and pull the retaining clip from the yoke and pin. Push the pin out of the piston and yoke. (use the short end of a hex wrench if necessary). 4) Loosen the locknut at the top of the fluid section and unscrew the pump. REMOVAL OF PUMP PACKINGS: Note: It is recommended to replace the packings main pump once they have been removed to prevent possible housing future damage to the piston. Locknut 5) Hold the foot valve in a vise (contacting on the wrench flats) and unscrew the fluid section. Unscrew the packing nut from the fluid section. Packing nut Note: Do not allow the piston to fall or get damaged in any way. Its finish must be perfectly smooth. Upper spacer 6) Push the piston out through the lower end of the fluid Upper packing section. Tap the top of the piston with a rubber mallet if necessary. Oulet 7) Remove the upper and lower spacers from the fluid fitting section. Note: When removing the packings, be careful not to Cylinder scrape or gouge the inside surface of the cylinder with the screwdriver. 8) Push the packings out of the cylinder with a screwLower packing driver by pushing from the inside out (push from the opposite end). Lower spacer INSTALLING NEW PUMP PACKINGS: 9) Apply a light coat of oil to the packings. Install both packings with the "v" edge with the spring faces into the cylinder, the flat side facing outwards. Piston S.V. ball guide S.V. ball S.V. seat S.V. hex nut Installing lower packings O-ring F.V. ball stop 10) Lower packing; Insert it edge-first into the lower end of the fluid section. Turn the packing inside the cylinder so that the springs of the packing face into the cylinder. To do this, hold the lower edge of the packing in place while pressing the upper edge further into the cylinder. Push the packing as far into the cylinder as it will go. Insert the lower spacer. F.V. housing 11) Upper packing; Place it into the upper end of the fluid section. Position the packing so that it is level and the springs of the packing face into the cylinder. Thread the packing nut into the cylinder to push the packing farther into the cylinder, then remove the packing nut. Insert the upper spacer and push it as far into the cylinder as it will go. Screw the packing nut into the cylinder and torque to 25 - 30 ft/lbs. F.V. ball guide F.V. ball F.V. seat Seat seal 17 MAINTENANCE & SERVICE (DC-3000) 14) Install a new shaft valve ball. 15) Inspect the shaft valve seat for wear. If one side of the seat is still new, install it with the good side facing towards the ball. Note: Do not put piston into a vise. Putting the piston into a vise may cause damage. 16) Apply blue locktite to the shaft valve hex nut threads and thread into shaft. Torque to 12 ft/lbs. 17) Apply a light coat of oil to the piston and insert it, small end first, into the lower end of the fluid section until it seats. Tap the bottom of the piston gently with a rubber mallet if necessary. FOOT VALVE MAINTAINENCE: 18) Remove the o-ring from the foot valve housing. 19) Cover the top of the foot valve housing and turn it upside down to remove the ball stop, ball guide, ball, seat, and seat seal. 20) Install a new seat seal into the housing. Do not reuse the old seal. 21) Inspect the foot valve seat for wear. If one side of the seat is still new, install it with the good side facing towards the ball. 22) Install a new foot valve ball, ball guide, stop plate, and a new o-ring (do not reuse the old o-ring). 23) Hold the foot valve in a vise (contacting on the wrench flats) and screw the fluid section into the foot valve. Torque to 85 - 90 ft/lbs. INSTALLATION OF FLUID PUMP: 24) Turn the locknut on the fluid section until it reaches the bottom of the threads. Thread the fluid section into the main pump housing. Rotate the fluid pump to align the hole in the piston shaft with the holes in the yoke. 25) Insert the pin through the yoke and piston. Snap the retaining clip around the pin and yoke. 26) Screw the fluid section into the main pump housing as far as it will go, then unscrew it slightly so that the outlet hose fitting will align with the connection hose. 27) Firmly tighten the locknut at the top of the fluid section against the main pump housing. Tighten the return line fitting back to its original position. 28) Fill the packing nut with packing lubricating oil. 29) Install the front cover, connection hose, and the suction system. main pump housing Yoke Pin Locknut Packing nut Retaining clip Front cover plate Upper spacer Upper packing Torx screw Oulet fitting Cylinder Lower packing Lower spacer Suction system complete Piston S.V. ball guide S.V. ball S.V. seat S.V. hex nut O-ring F.V. ball stop F.V. ball guide F.V. ball F.V. seat Seat seal F.V. housing PISTON MAINTAINENCE: 12) Turn the piston upside down and use a hex wrench to remove the shaft valve hex nut from the lower end of the piston. 13) Cover the open end of the piston and turn the piston right-side up again to remove the shaft valve ball and seat. Inspect the piston for wear. Install a new ball guide, do not reuse the old ball guide as it is also the seat seal. Use the head of a long nail or screw to seat the ball guide past the threads inside the piston. 18 Wiring diagram, DC-3000 MAINTENANCE & SERVICE (DC-4000) REMOVAL AND CLEANING OF FOOTVALVE: 1) Turn unit off, ensure that prime valve is open, and all pressure is relieved. Unplug unit from electrical outlet. 2) Tilt unit back on handle. 3) Using a large crescent wrench, unscrew footvalve complete with suction tube. The seal for the footvalve is part of the pump cylinder and cannot fall out. 4) Remove retaining clip and ball. 5) While footvalve is removed, you can look up inside pump to see hole in center of shaft where shaft ball is. 6) If hole is obstructed or plugged, use a small screwdriver (or piece of wire) and compressed air to free up ball. Be sure to cover end of return line with a rag so paint/solvent in pump is not blown into your face! 7) Should this not be sufficient, see steps 1-12, 16 and 17 of the DC-4000 packing instructions. Once o.k. proceed to next step. 8) Clean all parts including intake screen and pipe. 9) If ball is very pitted or scored, it must be replaced. Inspect seat inside of footvalve body. If it is damaged the footvalve housing must be replaced. 10) Lightly oil ball and put into footvalve housing. Replace retaining clip. 11) Lubricate nose and threads of footvalve with grease. Thread into unit and tighten 15-20 ft/lb. Unit is now ready to test in solvent etc. 3) Disconnect paint hose, inlet and return hoses from sensor. 4) Using 3mm allen key, remove 4 x bolts from behind control box. Box will come free with about 6-8". 5) There are four wires to disconnect. Disconnect the two from the power cord (the lower pair) first. These go to the switch. 6) The second pair of wires go the the bridge rectifier from the motor (upper pair). Disconnect these. 7) Control box is now free from pump and can be serviced. Should service extend beyond changing of switch or breaker, control box should be sent to nearest Lemmer service center. NOTE: Electrical shock warning. Some components of the control box operate at full 120 volt 15 amp current. Do not attempt to adjust the control box yourself. Excessive and unsafe pressures may be attained by unauthorized tampering. 8) Connect motor wires (upper black/white pair) to bridge rectifier. The black goes to the positive (notched corner) and the white to negative (opposite corner). See diagram. 9) Connect power wires (lower pair of black/white). Black connects to terminal of switch in line with breaker. White wire connects to terminal in line with wire to bridge rectifier. 10) Double check all connections. Mixup of power and motor wires will result in complete destruction of triac and bridge as a minimum. 11) Lift box into place, while gently tucking in extra length of wires. Install and tighten the allen screws. 12) Connect return line, and paint inlet/outlet lines to sensor. Torque 20 ft/lbs. 13) Place suction in solvent, open prime valve and turn pressure to minimum. Ensure switch is OFF. 14) Plug in unit. Turn on and check for indicator light. Prime and test. PRESSURE CONTROL BOX: The pressure control box for the DC-4000 is a precision unit, designed to require no regular service or adjustment. The following instructions are intended to guide you through removal and re-installation of the control box. CONTROL BOX REMOVAL AND REPLACEMENT: 1) Shut down unit, open prime valve to release pressure, and trigger gun to be sure pressure is out of system. 2) Unplug cord from electrical outlet and wrap around handle of unit. black on/off switch circuit breaker triac white bridge motor yellow orange J7 blue purple black white IMPORTANT: the motor wire polarity determines direction of rotation. The wires must be connected as shown to result in a clockwise rotation as viewed from the fan cover. CAUTION: connect the purple and blue wires (J7 & J8) exactly as shown. Incorrect connection will result in erratic motor operation, or no operation at all. J8 J1 CAUTION: connect the orange and yellow wires (J1 & J2) exactly as shown. Incorrect connection will result in erratic motor operation, or no operation at all. J2 circuit board sensor 19 potentiometer (pressure control) Figure 16. Wiring diagram, DC-4000 MAINTENANCE & SERVICE (DC-4000) 17. Thoroughly clean and dry all parts (except old packings). 18. Inspect upper and lower chrome areas of piston. Some scratching is normal. If very extreme scratches or areas missing hard chrome exist, the piston will have to be replaced. A distinct darker, duller color in some areas may indicate wear through the hard chrome. 19. Although new balls are supplied with kit, old ball condition is a good indicator of seat wear. If the old balls are chewed up or visibly smaller, take care to inspect shaft and footvalve seats for wear. 20. Place new upper packings in oil (L034-125) to soak for 510 minutes. 21. Put piston in vice using flats. Install new ball and copper seal. Use a little bit of grease to hold seat in shaft valve nut. Put one or two drops of blue or red locktite on threads. Install by hand into shaft, then use wrench to tighten 40-45 ft/lb. Remove from vice. 22. Lightly grease inside of lower pump cylinder. Install wave washer(s) and male packing spacer with flat end towards washer. Lightly grease each packing and install with lips as per diagram. Install female space V end first and push in tightly by hand. 23. Turn pump cylinder over and lightly grease upper packing bore. Install metal spacerflat end down. Install 1 x plastic packing V end first, then in turn 1 x leather, 1 x plastic, 1 x leather, 1 x plastic. Now put in thick plastic spacer V end down. Lightly grease packing nut inside and on threads. Install gently hand tight. 24. Lightly grease piston surfaces. Insert 10 mm allen wrench for a holding tool, and push piston up through cylinder until it stops. 25. Place pump cylinder open end up in vice. Install brass spacer. 26. Lightly oil new footvalve ball, and place in body. Install retaining clip. Lightly grease nose of valve and threads and install approx. 20 ft./lb in pump cylinder. 27. Use teflon tape on threads of suction pipe. Hold footvalve with wrench and install tube 10-15 ft/lbs. 28. Ensure large locknut pos. # 1 is bottomed out on threads. Now grease threads of pump cylinder. Thread cylinder assy. into central body until pin hole in top of piston just lines up with pin hole in plunger. 29. Place one or two drops red or blue locktite on connecting pin threads. Install pin and tighten 10 ft/lb. 30. Thread pump assembly onto unit until it bottoms out. Now back pump up just enough that the paint outlet is in the correct position. Securely tighten the locknut. (60-70 ft/lb) 31. Install paint hose to pump assembly, tighten 20 ft/lb. Place a container of solvent under pump intake and set unit upright. 32. Gently tighten packing nut until there is a slight resistance. DO NOT OVERTIGHTEN OR PACKING/PISTON LIFE WILL BE GREATLY REDUCED. Tighten just enough to prevent leakage. Lubricate with L034-120/125 oil. 33. Prime and pressure unit checking for leaks. DO NOT TIGHTEN PACKINGS WITH UNIT RUNNING. FINGERS OR TOOLS CAN BE TRAPPED BETWEEN PACKING NUT AND PLUNGER, RISKING LOSS OF fFINGER(S) OR SEVERE PERSONAL INJURY. DC-4000 PACKING (L050-625 KIT) INSTRUCTIONS: 1. Flush unit thorougly with appropriate solvent. 2. Turn pressure control to minimum so that unit stops. Look in opening of central body to observe position of connecting screw. 3. If necessary, turn control to prime and down again (briefly) so that motor runs in short bursts. When motor stops with connecting bolt at bottom of its travel, turn unit OFF. 4. Relieve pressure via prime valve, and unplug unit from electric outlet. Tilt unit back on handle and allow solvent to drain. 5. Using a 5mm allen key, remove pail hook. 6. Using the same wrench, remove connecting screw from plunger. (newer models 1 use a 4mm allen key). upper packings: 7. Disconnect fluid hose 2 male support poly from pump section. leather 8. Using a pipe wrench, 3 poly leather and holding the poly female support footvalve with another wrench, remove suction pipe and screw. 9. Using a large crescent 4 or pipe wrench, loosen locknut pos. # 1. Pump will unscrew by hand. 10. Place pump assy in vice, using flat areas on 5 cylinder, with footvalve facing up. DO NOT OVERTIGHTEN! Remove footvalve. 6 11. Place pump opposite way in vice. Using pliers etc, remove 7 packing nut pos. # 2. 8 12. While holding hand 9 under pump to catch 10 packings: 11 piston, gently tap on top lower male support 12 teflon of piston pos. #6. teflon 13 Packing spacer, pos. # teflon teflon 14 may also fall out at female support 14 this time. 15 13. Gently, using screw16 driver, pry out upper 17 packings and spacers pos. # 3. 14. Remove pump cylinder #4 from vice. Using fingers (or screwdriver and due care) remove spacer, lower packings and wave washer pos. # 14, 13, 12. 15. Remove retaining clip pos. # 15, and ball pos. # 16 from footvalve body. Ball seat is pressed into housing and is not replacable. 16. Place wrench flats of tip of piston in vice, and using 10mm allen wrench, take out shaft valve nut and seat pos.# 11, 10. Take piston from vice and remove shaft ball and copper seal pos. 8, 9. ○ ○ ○ ○ ○ ○ ○ ○ 20 TROUBLESHOOTING Provided you have followed the instructions, the sprayer will operate efficiently and give trouble-free service.Should any unexpected problem arise you can, in most cases, remedy the problem by following the chart below. If yo u find that you cannot correct the problem, then take the sprayer to your nearest authorized service agency. Many of the “causes” listed are unlikely to happen. However, all are included in an attempt to cover every possibility. IT IS ABSOLUTELY ESSENTIAL FOR TROUBLE-FREE OPERATION THAT YOUR AIRLESS SPRAYER BE KEPT CLEAN AND FREE OF RESIDUAL PAINT BUILD-UP ON THE INTERNAL PARTS. IT MUST BE CLEANED AND LUBRICATED AFTER EVERY USE. Cause Problem Ia Sprayer does not start up. (DC-4000 control box, indicator light off) 1) 2) 3) Remedy Blown fuse or tripped circuit breaker on supply or sprayer. Safety shut-off has been activated. (DC-4000 only) Power cord or extension cord not properly connected. 1) 2) 3) Check and replace fuse or reset circuit breaker. (determine cause if possible). Turn off unit 2-5 seconds. Turn pressure to minimum and turn on. Indicator light should be on. Check and repair if necessary. Sprayer does not start up. (DC-4000 control box, indicator light on) 1) 2) Pressure control knob set too low. Clogged spray tip or filters. 1) 2) 3) 4) Frozen or hardened paint in pump. Worn motor brushes. 3) 4) Sprayer starts up but does not draw up paint. 1) Prime valve closed. 1) 2) 3) 4) 5) Pump inlet screen clogged. Suction tube clogged or loose. Stuck or clogged foot valve or shaft valve. Clogged spray tip. 2) 3) 4) 5) 6) Packings dry or worn. 6) 1) Worn spray tip. 1) 2) 3) Pressure control knob loose. Unit not primed. 2) 3) 4) 5) Fluid leakage. Spray tip too large. 4) 5) 6) 7) Worn prime vavle leaking back. Worn of dirty foot valve, shaft valve, or lower packings. Clogged gun filter causes pump not to run after unit is primed and trigger is pulled. 6) 7) 8) Follow Pressure Shut Down Procedure. Replace gun filter. 1) Upper packings worn. 1) 2) Worn piston. 2) Follow Pressure Shut Down Procedure. Tighten packing takeup nut. If still leaking, replace packings. Follow Pressure Shut Down Procedure. Replace packings first. If still leaking, replace piston. 1) 2) 3) Spray tip too large or worn. Pressure set too low. Insufficient fluid delivery. 1) 2) 3) 4) 5) Paint too thick. Gun filter plugged. 4) 5) 1) 2) 1) 2) Replace ball or seat. Disassemble gun and clean. 3) Worn ball or seat on gun. Foreign matter or paint buildup between ball and seat on gun. Ball not in correct position. 3) Adjust rear tension nut. If this doesn’t work examine ball and replace if necessary. 1) 2) Packing or tip is worn. Gun not shutting off. 1) 2) Replace worn or damaged parts. Clean or repair as required. Check gun filter. VIII Spray gun leaks. 1) Worn valve ball on gun. 1) Replace valve ball. IX Spray gun won’t spray. 1) Spray tip or gun filter plugged. 1) Clean spray tip. Clean or replace gun filter. X Low paint output from spray gun. 1) Partially plugged spray tip or filter. 1) Clean or replace gun filter. Clean spray tip. Ib II III Sprayer will not maintain pressure or has low output. 8) IV V VI VII Upper end of fluid section leaks. Poor spray pattern. Spray gun won’t shut off. Spray tip leaks. 21 Turn knob to higher setting. Follow Pressure Shut Down Procedure. Remove and clean spray tip and/or filter. Replace. Remove and clean Fluid Section parts. Re-install. Replace motor brushes. Open prime valve. Keep valve open while pressure control knob is in prime position. Close valve after unit is primed. Remove and clean inlet strainer. Remove and clean suction tube, tighten. Refer to maintenance section of manual. Relieve pressure using the Pressure Shut Down Procedure. Remove spray tip and replace. Repack Fluid Section. Follow Pressure Shut Down Procedure. Replace spray tip. Tighten pressure control knob set screw. Follow priming procedure under Start-up section of owner’s manual. Check and tighten all high-pressure fittings. Follow Pressure Shut Down Procedure. Replace spray tip. Replace valve. Refer to re-pack section of manual Use smaller spray tip size. Increase pressure setting. Follow instructions under "Unit will not maintain pressure or has low output". Reduce viscosity per manufacturer’s recommendations. Follow pressure shut down procedure. Remove and clean filter. OTHER QUALITY LEMMER PRODUCTS LEMMER'S Full line of equipment comes with FIRST CLASS SERVICE in numerous locations across CANADA, and a FULL ONE YEAR WARRANTY. For information on choosing the right sprayer for your job, please contact your nearest LEMMER outlet. ELECTRIC CUP GUNS Hand held airless sprayers to spray all standard paints. They are suitable for large jobs where time is not a factor, and also for the professional to touch up after the large equipment is finished. AIR GUNS & PRESSURE POTS Conventional air spray guns for fine finishing. Suitable for countless industrial and automotive applications. Available in suction, gravity, and pressure feed versions. Each is available in many different needle sizes. HVLP TURBINE & VENTURI UNITS High Volume Low Pressure sprayers are used for fine finishing where overspray must be kept to a minimum. The finish results are equal to or better than conventional air spray. The turbine systems are self contained and do not require an outside air source. The VENTURI spray gun only uses about 8 CFM of shop air. Applications vary from automotive finishing to commercial multicolor architectural coating. AIRLESS ACCESSORIES A very large assortment of hoses, guns, tips, and filters, etc. These items are universal to most airless spray equipment on the market. PAINTING SUNDRIES Overalls, strainer bags, stir rods, etc. A large variety of painting accessories to help make a cleaner and more efficient working environment. AUTOMATIC GUNS Suitable for all heavy duty airless applications. Air actuated, universal rod mounting, and standard 1/4" NPS hose connection. PNEUMATIC PISTON PUMPS ELECTRIC PISTON PUMPS Suitable for heavy coatings on large jobs. Its innovative pump design is driven by a DC motor. Being an air powered airless, these units are generally used for industrial coatings. Applications range from portable lacquering to plumbed-in automatic systems. Also excellent for industry where operating conditions are very demanding. ELECTROSTATIC UNITS The electrostatic WRAP-A-ROUND charge makes this the best method of spraying metal with next to no overspray. It is best suited for industrial paints with an aromatic thinner base, i.e: toluol, xylol. The conversion kit will hook up to most airless pumps and we carry a completely self contained portable system. GAS DIAPHRAGM These sprayers are the same as the electric diaphragm pumps, but with the advantage of a gas engine. All use Honda motors and belt drive systems. ELECTRIC DIAPHRAGM TRANSFER PUMP It can be used to transfer paint to remote locations, or directly to high pressure pumps. At a 1:1 ratio with up to 125 PSI air pressure it can also supply numerous air guns. Commercial airless sprayers for all sizes of jobs and spraying a large variety of paint types. These units are portable and come in many different performance categories. There are small units for spraying a house or barn once a year, and large units for spraying warehouses on a continuous basis. 22 LINEMARKERS Designed to handle the abrasive nature of road marking paint. There are three sizes of walk-behinds, and some are available with two or more guns. Custom systems are also made to order depending on the requirements. ACCESSORIES FOR LEMMER AIRLESS EQUIPMENT PIPE COATING “HOLLOW CONE” TIP ........................................................ L033-5** STRAINER BAGS 1 Gallon strainer bag w/elastic ........ L034-208 5 Gallon strainer bag w/elastic ........ L034-209 GUN FILTERS (for the L-45, L-50, & L-60) Gun filter kit (5 X red & 1 X spring) . L032-100 Gun filter kit (5 X yellow& 1 X spg) . L032-101 Gun filter kit (5 X white& 1 X sprg) .. L032-102 TIP CLEANING BROACH Package of 12X ............................... L033-021 TIP EXTENSIONS 1/4 Meter extension with swivel ...... L033-024 1/2 Meter extension with swivel ...... L033-025 1 Meter extension with swivel ......... L033-026 2 Meter extension with swivel ......... L033-027 FIBRE BRAID AIRLESS HOSE 1/4" X 25' Hose ............................... L031-073 1/4" X 50' Hose ............................... L031-074 STEEL BRAIDAIRLESS HOSE 3/16" X 3' Whip hose ....................... L031-010 3/16" X 5' Whip hose ....................... L031-011 3/16" X 25' Hose ............................. L031-012 3/16" X 50' Hose ............................. L031-013 1/4" X 5' Whip hose ......................... L031-020 1/4" X 25' Hose ............................... L031-021 1/4" X 50' Hose ............................... L031-022 1/4" X 100' Hose ............................. L031-023 HOSE CONNECTORS 1/4"m X 1/4"m ................................. L035-001 3/8"m X 3/8"m ................................. L035-002 1/4"m X 3/8"m ................................. L035-005 “SF” SUPER FINE FINISHING TIP ........................................................ L044-*** Standard tip nut ............................... L032-501 Nylon gasket for standard tip .......... L043-008 COTTON OVERALLS & STIR RODS Small overalls .................................. L034-220 Medium overalls .............................. L034-221 Large overalls ................................. L034-222 Extra large overalls ......................... L034-223 1 Gal stir rod (2-3/8" dia.,3/8"chuck) .... L034-050 1 Gal stir rod (3-1/4" dia.,3/8"chuck) .... L034-051 5 Gal stir rod (4-3/4" dia.,1/2"chuck) .... L034-052 POLE GUNS 3' Pole gun W/O tip assembly ......... L033-050 6' Pole gun W/O tip assembly ......... L033-051 TELESCOPIC PRESSURE FEED ROLLER Telescopic roller .............................. L012-002 3/8 X 12" cover ................................ L012-503 1/2 X 12" cover ................................ L012-504 3/4 X 12" cover ................................ L012-505 1-1/4 X 12" cover ............................ L012-506 End cap kit ...................................... L012-508 GAUGE KIT General use, 1/4" connections ........ L034-104 23 SPRAY HOODS Spray hoods (package of 3) ............ L034-205 RESPIRATOR North respirator (complete) ............. L034-200 L-65 PARTS DIAGRAM & PARTS LIST May00 17 HIGH PRESSURE! Specifications, L-65 Maximum pressure: 3600 psi. Tip thread: 11/16-16 or 7/8-14. Hose connection: 1/4" nps. Wetted parts: Al,SS,TC,Cu, Brass,Tef. 16 15 14* 13 INJECTION HAZARD! 12 11 9 9 10* * note: once #10 & #14 are assembled, the length from end to end must be 88 - 88.5 mm. 8 5 4 1 2 3 18 19 oImportant: this "double lip" end 6 of filter must go in the gun first. 7 Turning this nut tightens the packing. Check occationally and do not over tighten. Important To engage trigger safety lock, turn lever tab to horizontal position. Test regularily for proper functioning while system is shut down. 20 21 • Follow shut down procedure before servicing or cleaning equipment. (see #1 overleaf) • This instruction sheet is only a supplement to your system operating instructions. Read your system manual before operating any high pressure equipment. • Remove filter for cleaning, then reinstall and hand tighten the handle. • To clean gun: flush the inside by spraying proper solvent, and wipe the exterior. (It is not neccessary to disassemble gun components under normal circumstances). • Injection hazard: Airless Painting Equipment can cause serious injury if the spray penetrates the skin. Do not point the gun at anyone or any part of the body. The tip guard provides some protection against accidental injection injuries, but is mostly a warning device. Never put your hand, fingers or body over the spray tip. Gloves and clothing do not necessarily offer any protection either. Keep the gun trigger safety lever in locked postion when not spraying. Always have the tip guard in place while spraying. In case of penetration seek medical aid immediately! Note to physician: Injection into skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected into the bloodstream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable. Be prepared to tell the doctor what fluid was injected. • Do not use halogenated hydrocarbon solvents in this system; it contains aluminium parts and may explode. Cleaning agents, coatings, paints, and adhesives may contain halogenated hydrocarbon solvents. Don't take chances, consult your material supplier to be sure. (ex: methylene chloride and 1,1,1 - Trichlorethane) • Caution: When a flammable liquid is sprayed there may be danger of fire or explosion especially in a closed area. • Use extreme caution when cleaning spray tip guard. DO NOT try to wipe off build up around the spray tip before following shut down procedure. Follow the Shut down Pos. Part nos. 1 2 3 4 5 6 7 8 9 10 11 12 L032-030 L032-035 L032-501 L032-710 L043-008 L032-711 L032-712 L032-589 L032-523 L032-713 L032-714 L032-591 L032-715 L032-507 L032-508 Description 22 locked unlocked 23 24 (trigger shown in horizontal locked position) Procedure, then follow the spray tip manufacturer’s instructions for removing and cleaning the spray tip. • Never attempt to change spray tip or leave the unit unattended without first shutting off pump, releasing fluid pressure, and locking the trigger safety lock. • Conductive metal containers must be used when flushing flammable fluids through the system. Always flush at low pressure with spray tip removed. A metal part of the spray gun must be held firmly against the grounded metal pail when flushing or relieving pressure from the gun. • Trigger guard helps reduce the risk of accidentally triggering the gun if dropped or bumped. Do not use a spray gun without a trigger guard. Qty. Pos. Part nos. L-65 airless gun without tip nut L-65 airless gun without tip nut (G-thread) Tip retainer (11/16" L-thread) opt. Tip retainer (7/8" G-thread) opt. tip (see separate list) opt. Nylon washer 1 Seat, (11/16" L-thread) 1 Seat, (7/8" G-thread) 1 Trigger guard 1 Trigger pin 1 Trigger complete 1 Gun body 1 Pin 2 Ball with shaft 1 Wedge 1 Packing 1 13 14 15 16 17 18 19 20 L032-716 L032-582 L032-588 L032-583 L032-587 L032-590 L032-514 L032-516 L032-517 L032-518 21 L032-519 22 L032-717 23 L032-520 24 L032-521 Accessories: L032-718 L032-719 24 Description Housing Spring shaft Spring Housing nut Retainer cap Lock nut Handle seal Gun filter, white (50 mesh) Gun filter, yellow (100 mesh) Gun filter, red (200 mesh) Filter spring Handle Copper seal Swivel, 1/4" nps Repair kit, L-65-L (#4,10,12,14,18) Repair kit, L-65-G (#4,10,12,14,18) Qty. 1 1 1 1 1 1 1 1 opt. opt. 1 1 1 1 L-65 SPRAY GUN OVERHAUL Use diagram on opposite side for reference. HIGH PRESSURE! Tools needed: 10 mm socket and driver 2 x 8" or larger crescent wrench 1 x L-65 repair kit Cleaning brush and lacquer thinner INJECTION HAZARD! needle nose pliers 10) If the ball (#10) has a groove worn in it, the ball with shaft will have to be replaced. Usually the seat will have to be replaced as well, as it wears against the ball. Both of these parts are included in the repair kit. 11) Lightly grease wedge & packing & assemble together. Install wedge first, and then the packing into gun body until they bottom. 12) Lightly grease spring & outside of housing. Install spring on spring shaft, and put into housing. Install housing nut & tighten until flush with rear face of housing. 13) Thread housing into rear of gun body. Tighten to a maximum of 3-5 ft/lbs. 14) Examine the trigger pins for wear and equal length. Lightly grease and install. 15) Install retainer cap on rear of gun and install locking nut. Tighten locking nut until approximately two threads show out rear of the nut. 16) Thread gun handle into gun body and hand tighten. 17) Lightly grease threads of seat. Install trigger guard over open end of seat. Hold gun trigger in open position and install seat. Tighten to 30-40 ft. lbs. and release trigger. 18) The retainer cap should have a bit of slack in it and should not be bottomed against the gun tightly. The trigger should have 3/8" slack at the bottom of the trigger before engaging against the trigger pins. This slack is very important for the correct operation of your gun. The gun and safety lock will not work properly if this step is not performed correctly. To increase slack, loosen the locknut a little and test slack again. To decrease slack, tighten the locknut a little and test slack again. With too much slack, the gun may not turn on, but the safety lock will work fine. With too little or no slack, the gun may be permanently ON and the safety lock does nothing. DO NOT RUSH OR IGNORE THIS STEP, CORRECT OPERATION OF THE SAFETY TRIGGER LOCK REQUIRES PROPER ADJUSTMENT OF TRIGGER SLACK. 19) Install tip attachment onto gun. Remove gun handle, install spring and filter, lightly grease threads and reinstall. 20) Place trigger in LOCK position. Install gun to hose, tightening securely. Install tip where applicable. The gun is now ready for testing and use. 1) Initiate shut down procedure: Shut Down Procedure: Always follow Shut Down Procedure before starting any troubleshooting, servicing or cleaning. a) Engage the trigger safety lock in the locked position. Test the trigger safety lock to ensure the lock is working properly. b) Turn pressure regulator to minimum. c) Disconnect electric plug from wall socket, or disconnect air supply. d) Open the dump valve to relieve pressure. Leave open until ready to spray or test or clean. e) Remove the spray tip. f) Disengage the trigger safety lock. g) Trigger the gun into a metal pail to relieve any remaining pressure. A metal part of the spray gun should be held firmly against the grounded metal pail when relieving the pressure from the gun. (A grounded metal pail is not required for nonflammables such as latex.) h) Reset the trigger safety lock to locked position. 2) Using the two crescent wrenches, disconnect the gun and gun handle from spray hose. 3) Remove spray tip or attachment assembly from gun. 4) Hold gun trigger open and remove seat (#4) from gun. Release trigger. Never remove or attach seat unless trigger is held in the open position. Permanent and expensive damage to both ball and seat will result! 5) Using 10mm socket and driver, remove adjusting nut (#18) from rear of gun. 6) Grasp retainer cap (#17) and pull away from rear of gun. Remove the two trigger pins (#9) from gun. 7) The ball spring assembly can be removed from the rear of the gun body by unthreading six to eight turns and then pulling firmly towards rear of gun body (#13). Push packing & wedge (#11&12) out of rear of gun body. 8) Remove gun handle from gun and remove filter and filter spring. 9) Using points of needle nose pliers, unscrew housing nut (#16) from housing (#13). Grasp end of shaft (#14) and remove. Take spring (#15) off of shaft for cleaning. 25 DC-3000 PARTS DIAGRAM Feb00 Important, following items require accurate torques: #62 transducer plug ................ 20 ft/lbs #91 packing nut ...................... 25 ft/lbs #101 S.V. hex nut ..................... 12 ft/lbs #108 F.V. housing .................... 90 ft/lbs 34 29 21 12 23 22 27 28 35 32 31 30 33 20 19 39 40 11 10 9 15 16 17 42 18 41 8 6 43 7 3 90 2 44 4 1 5 Do not remove unless replacing 109 91 112 45 112 46 56 47 94 48 112 Caution: Do Not use high pressure water spray against the electric control box. 49 112 50 54 86 85 55 56 84 97 57 111 110 58 83 70 69 68 82 103 104 105 106 107 108 57 71 98 99 100 101 102 81 80 79 78 76 77 112 Packing Kit 26 61 67 75 66 65 64 60 63 62 59 Caution: only use fibre braid high pressure airless hose. Do Not use steel braid hose! DC-3000 PARTS LIST Pos. Part nos. 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 18 19 20 21 22 23 27 28 29 30 31 32 33 34 35 39 40 41 42 43 44 45 46 47 48 49 50 54 55 56 57 58 L045-001 L045-500 L045-501 L045-502 L045-503 L045-504 L045-505 L045-506 L045-507 L045-508 L045-509 L045-510 L045-512 L045-513 L045-514 L045-515 L045-516 L045-517 L045-518 L045-519 L045-520 L045-521 L045-522 L045-523 L045-524 L045-525 L045-526 L045-527 L045-528 L045-529 L045-530 L002-815 L045-531 L045-532 L045-577 L045-578 L045-533 L045-534 L045-535 L045-536 L045-537 L045-538 L045-539 L045-540 L045-541 L045-542 L036-001 L045-543 L045-544 Description Pos. Part nos. Qty. 59 60 61 62 63 64 65 66 67 68 69 70 71 75 76 77 78 79 80 81 82 DC-3000 airless piston pump on stand Torx screw 6 Decal, DC-3000 front cover 1 Front cover plate 1 Retaining clip 1 Pin 1 Yoke 1 Eccentric bearing 1 Main housing 1 Lock washer 4 Screw 4 Handle with grip 1 Handle grip (comes with #11) 1 Washer 1 Ball bearing 3 Roller bearing 1 Output gear 1 Gasket 1 First stage gear 1 Rear housing 1 Washer 3 Screw 3 Relay, 120 volt 1 Screw 1 Capacitor 1 Motor, 3/4 hp dc 1 Screw 2 Fan shroud 2 Jam nut 2 Motor fan 1 Push nut 1 Stand 1 Lock nut 4 Bolt 4 Motor shroud, bare 1 Warning decal right side 1 Warning decal left side 1 Screw 3 Pressure control knob 1 Retaining ring 1 Spring 1 Plunger 1 Switch 1 Control housing 1 Screw 4 Electric cord 1 Strain relief, 90˚ 1 Connector, 1/4"m 2 Fuse holder 1 Fuse, 10 amp 1 83 84 85 86 90 91 94 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 Description Qty. L050-617 18" connection hose 1 L036-091 Elbow, 1/4"m 1 L045-576 Transducer ass'y 1 L045-545 Plug 1 L045-546 O-ring 1 L045-547 O-ring, viton (standard) 1 L045-549 Backup ring 1 L045-550 Tranducer piston 1 L045-551 Transducer body 1 L045-552 O-ring 1 L045-553 Retainer ring 1 L045-554 O-ring 1 L045-555 Plug 1 L035-771 Elbow, 1/4m x 1/4barb 1 L045-511 Prime/spray valve 1 L004-578 Set screw 2 L004-577 Knob 1 L004-509 Cam 1 L004-510 Lock washer 1 L004-511 Spring 1 L004-512 O-ring (standard) 1 L004-571 O-ring (lacquer) opt L045-556 Gasket 1 L045-557 Spacer 1 L045-558 Micro switch 1 L045-559 Screw 2 L060-509 Locknut 1 L045-560 Packing nut 1 L045-563 Cylinder 1 L045-566 Piston 1 L045-567 S.V. ball guide 1 L060-519 S.V. ball 1 L060-520 S.V. seat 1 L060-522 S.V. hex nut 1 L060-525 O-ring 1 L045-568 F.V. ball stop 1 L045-569 F.V. ball guide 1 L045-570 F.V. ball 1 L045-571 F.V. seat 1 L045-572 Seat seal 1 L045-573 F.V. housing 1 L045-574 Suction system 1 L045-579 Suction screen 1 L045-581 Return clip, formed plastic 1 Pump packing kit: L045-580 Packing kit including: 99,102,105,107. Accessories: L034-125 Packing lubricating oil, squeeze bottle L050-621 Owner’s manual Feb00 27 DC-4000 PARTS DIAGRAM Nov99 Caution: only use fibre braid high pressure airless hose. Do Not use steel braid hose! 1 2 7 8 3 40 41 6 4 12 11 5 16 13 15 14 10 46 19 47 43 21 42 31 44 45 48 49 36 31 35 28 27 22 26 36 17 25 50 51 20 29 52 25a 32 24 53 30 54 17 Caution: Do Not use high pressure water spray against the electronic control box. 23 55 65 88 56 57 The newest packing nut is made of bronze and has a groove to identify it. 60 k 89 90 66 67 68 69 70 71 61 62 91 80 72 22 73 74 75 64* 63 36 58 84 81 86 87 82 83 76 92 97 98 96 101 20 93 77 99 100 97 78 103 94 95 *64, Only replace this seal if external leak is evident. Once seal is removed, it must be replaced. 28 upper packings: female support poly leather poly leather poly male support lower packings: male support poly poly poly poly female support Packing Kit DC-4000 PARTS LIST Pos. Part nos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 25a 26 27 28 29 30 31 32 35 36 40 41 42 43 44 45 46 47 48 L050-001 L050-003 L050-515 L001-527 L050-521 L050-514 L050-513 L050-512 L050-510 L050-511 L050-509 L050-508 L004-556 L050-507 L050-502 L050-500 L050-505 L050-622 L001-655 L050-626 L050-591 L035-313 L035-313 L013-512 L035-715 L050-617 L032-630 L050-544 L060-595 L060-596 L050-592 L001-590 L050-623 L036-091 L050-600 L055-531 L055-532 L055-534 L006-593 L004-559 L050-588 L050-589 L050-590 L050-630 L050-605 L050-606 L050-599 L035-356 L050-585 L005-529 L004-560 L050-586 L050-587 L001-520 L075-534 L050-535 L001-555 L001-550 L050-520 L050-519 L050-526 L050-532 L050-530 L050-524 L050-523 L050-537 Description Qty. Pos. Part nos. DC-4000 airless piston pump on cart DC-4000 airless piston pump on stand Main housing 1 Vent plug, M16 1 Formed housing seal 1 Bearing (Front) 1 Cam shaft (15 mm) 1 Key 1 Large Gear 1 Bearing 1 Bearing (Support) 1 Motor gear (included with motor) 1 Snap ring 1 Motor bearing, front 1 Oil seal, motor 1 Motor Plate 1 3/4 HP 90 VDC. (110)motor (incl. #12) 1 3/4 HP 180 VDC. (220)motor (incl. #12)1 Motor decal 1 Motor bearing, fan end 1 DC motor brush (each) 2 Bolt M4 x 12 (for housing & sensor) 8 Nylon tubing (1/4" I.D.) cart = 2' 2 Nylon tubing (1/4" I.D.) stand = 5' 10" 6 Nylon tie 7" 1 Coupler, 1/4h x 1/4m 1 18" connection hose 1 Connector 1/4m x 1/4m BSP 2 Switch housing (bare) 1 Triac 1 Bridge rectifier 1 Screw M4 x 18 (for triac & rectifier) 3 Lock nut, M4 (for triac & rectifier) 3 Control box decal 1 Elbow, 1/4" M 2 Pressure sensor ass'y(up to s/n 10499)1 Fluid manifold w/o sensor (new style) 1 Mini sensor (new style,s/n 10500 +) 1 Seal for mini sensor 1 Prime/spray valve 1 Switch, on/off 1 Circuit breaker 15 amp. (115V version) 1 Circuit breaker 8 amp. (220V version) 1 Knob for potentiometer 1 Potentiometer 1 Circuit board (110V) 1 Circuit board (220V) 1 Self tap screw (for PC board) 4 Wire, white, 14awg stranded 1.5 Strain relief, 16/3, thin panel 2 Cable with plug 15' x 16/3 1 Connector, F term. insl (blue) 9 Connector, F term. insl (yellow) 3 Connector, F term. insl (red) 5 Connector, ring #8 2 Marrette (14-18 awg) 2 Drain plug 1 Copper seal 3 Washer, knurled lock (M10) 5 Housing bolt, M10 x 1.5 x 16 allen 5 Oil seal 1 Rod bearing 1 Rod bushing 1 Connecting rod, (incl. Pos 44) 1 Cover screw, M4 x 10 3 Front cover 1 Pail hook 1 49 50 51 52 53 54 55 56 57 58 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 103 Description Qty. L050-538 Bolt for hook M6x12 2 L050-534 Plunger 1 L050-533 Rod pin 1 L050-522 Connecting bolt 1 L050-540 Bushing (self lube bronze) 1 L050-539 Central body bare 1 L050-525 Bolt M8 x 60 4 L050-542 Grease nipple, M8 1 L050-541 Metal guard 1 L036-271 Swivel elbow 1/4F x 1/4M 1 L050-563 Lock nut 1 L050-577 Packing nut 1 L050-572 Upper packings (normal stacked) 1 L050-671 Upper packings (1 piece) 1 L050-672 Spacer (for 1 piece packing only) 1 L050-562 Pump body 1 L050-561 Teflon O-ring 1 L050-571 Piston 1 L001-593 Cone guide 1 L050-569 S.V. ball 1 L050-570 S.V. copper seal 1 L050-568 S.V. seat 1 L050-567 Shaft valve retaining nut 1 L050-565 Wavy washer 3 L050-566 Lower packings (poly) L050-673 Lower packings (1 piece) 1 L050-564 Spacer, 24mm (for stacked packing) 1 L050-674 Spacer, 39mm (for 1 piece packing) 1 L050-582 F.V. ball stop 1 L050-581 F.V. ball 1 L050-578 Foot valve housing with seat 1 L050-583 Suction pipe 1 L001-607 Basket screen (Fine, 1/2") 1 L002-715 Bolt, Hex (5/16" NC x 1-1/2") 1 L005-713 Washer, flat (5/16") 1 L002-714 Washer, split lock (5/16") 1 L002-713 Nut, Hex (5/16" NC) 1 L050-550 Cart (incl pos. 85) 1 L050-552 Cart handle 1 L002-719 Quick Pin 3" 1 L050-553 3/4" plastic cap 2 L002-556 Tool box 1 L002-815 Nut, 1/4 nc 1 L002-817 Flat washer, 1/4 1 L002-709 Hex bolt, 1/4 x 3/4 nc 1 L002-561 Wheel (20mm shaft Dia.) 2 L002-560 Pin, cotter (1/8" x 2") 2 Pump packing kit: L050-625 Packing kit, normal stacked without spacer consisting of: 62,67,68,72,74,75. L050-670 Packing kit, 1 piece packings with spacers consisting of: 62,67,68,72,73,74,75. Assemblies and accessories: L050-624 Pressure control assembly(220V) L050-543 Pressure control assembly(110V) consisting of: 23-30 L034-124 Gear oil EP90W, liter L034-125 Packing lubricating oil, squeeze bottle L050-621 Owner’s manual L001-578 Basket screen, M28 1 L001-577 Suction elbow, 5 gallon x 1" 1 L035-207 O-clamp 2 L035-315 Suction hose per foot 3 L035-732 Hose barb fitting 1 L036-303 Elbow fitting 1 L035-503 Connector fitting 1 L035-313 Return hose per foot 5 Nov99 29 DC-7000 PARTS DIAGRAM Caution: only use fibre braid high pressure airless hose. Do Not use steel braid hose! 1 2 7 3 40 41 8 6 4 12 11 5 16 13 15 14 10 46 19 21 47 43 42 31 44 45 48 49 34 36 28 27 22 26 36 17 35 25 29 50 51 20 25a 32 24 52 Caution: Do Not use high pressure water spray against the electronic control box. 53 30 17 18 23 54 55 88 65 56 57 89 90 60 61 62 91 66 67 68 69 70 71 80 84 81 72 86 87 22 58 36 63 73 74 75 82 83 94 95 92 64* 76 93 77 78 97 *64, Only replace this seal if external leak is evident. Once seal is removed, it must be replaced. 30 upper packings: female support poly leather poly leather poly male support lower packings: male support poly poly poly poly female support male support Packing Kit DC-7000 PARTS LIST Pos. Part nos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 40 41 42 43 L055-001 L050-515 L001-527 L050-521 L050-514 L050-513 L050-512 L050-510 L050-511 L050-509 L050-508 L004-556 L050-507 L055-516 L055-500 L055-505 L055-536 L001-655 L050-626 L050-591 L035-016 L035-313 L035-313 L013-512 L035-715 L050-617 L032-630 L050-544 L060-595 L060-596 L050-592 L001-590 L050-623 L036-091 L055-531 L055-532 L055-534 L050-650 L004-559 L055-517 L050-588 L050-590 L050-630 L055-528 L055-530 L050-599 L035-356 L050-585 L060-543 L004-560 L050-586 L050-587 L001-520 L060-548 L050-535 L001-555 L001-550 L050-520 L050-519 L050-526 Description Pos. Part nos. Qty. DC-7000 airless piston pump on cart Main housing 1 Vent plug, M16 1 Formed housing seal 1 Bearing (Front) 1 Cam shaft (15 mm) 1 Key 1 Large Gear 1 Bearing 1 Bearing (Support) 1 Motor gear (included with motor) 1 Snap ring 1 Motor bearing, front 1 Oil seal, motor 1 Motor Plate 1 1.25 HP 90 VDC. (110)motor (incl. #12) 1 1.25 HP 180 VDC. (220)motor (incl. #12) 1 Motor decal 1 Motor bearing, fan end 1 DC motor brush (each) 2 Bolt M4 x 12 (for housing & sensor) 8 Swivel hose adapter 1/4F x 3/8M 1 Nylon tubing (1/4" I.D.) cart = 2' 2 Nylon tubing (1/4" I.D.) stand = 5' 10" 6 Nylon tie 7" 1 Coupler, 1/4h x 1/4m 1 18" connection hose 1 Connector 1/4m x 1/4m BSP 2 Switch housing (bare) 1 Triac 1 Bridge rectifier 1 Screw M4 x 18 (for triac & rectifier) 3 Lock nut, M4 (for triac & rectifier) 3 Control box decal 1 Elbow, 1/4" M 2 Fluid manifold 1 Mini sensor 1 Seal for mini sensor 1 Prime spray valve (DC-4000 & 7000) 1 Switch, on/off 1 Circuit breaker 20 amp. (115V version) 1 Circuit breaker 15 amp. (220V version) 1 Knob for potentiometer 1 Potentiometer 1 Circuit board (110V) 1 Circuit board (220V) 1 Self tap screw (for PC board) 4 Wire, white, 14awg stranded 1.5 Strain relief, 16/3, thin panel 1 Cable with plug 15' x 14/3 1 Connector, F term. insl (blue) 9 Connector, F term. insl (yellow) 3 Connector, F term. insl (red) 5 Connector, ring #8 2 Strain relief, 14/3, thick panel 1 Drain plug 1 Copper seal 3 Washer, knurled lock (M10) 5 Housing bolt, M10 x 1.5 x 16 allen 5 Oil seal 1 Rod bearing 1 Qty. 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 L055-533 L050-531 L050-524 L050-523 L050-537 L050-538 L050-534 L050-533 L050-522 L050-540 L055-513 L050-525 L050-542 L050-541 L036-271 Rod bushing (heavy duty) Connecting rod, bare Cover screw, M4 x 10 Front cover Pail hook Bolt for hook M6x12 Plunger Rod pin Connecting bolt Bushing (self lube bronze) Central body bare Bolt M8 x 60 Grease nipple, M8 Metal guard Swivel elbow 1/4F x 1/4M 1 1 3 1 1 2 1 1 1 1 1 4 1 1 1 60 61 62 63 64 65 66 67 68 69 70 71 72 L055-514 Lock nut L055-515 Packing nut L055-520 Upper packings L055-511 Pump cylinder L050-561 Teflon O-ring L055-518 Piston L001-593 Cone guide L050-569 S.V. ball L050-570 S.V. copper seal L050-568 S.V. seat L050-567 Shaft valve retaining nut L055-510 Wavy washer L055-521 Lower packings (poly-brass) L055-538 Lower packing (white poly ring) L055-519 Spacer L050-582 F.V. ball stop L050-581 F.V. ball L050-578 Foot valve housing with seat L055-524 Suction pipe L060-580 Screen 3/4" basket (coarse) L002-715 Bolt, Hex (5/16" NC x 1-1/2") L005-713 Washer, flat (5/16") L002-714 Washer, split lock (5/16") L002-713 Nut, Hex (5/16" NC) L050-550 Cart (incl pos. 85) L050-552 Cart handle L002-719 Quick Pin 3" L050-553 3/4" plastic cap L002-556 Tool box L002-815 Nut, 1/4 nc L002-817 Flat washer, 1/4 L002-709 Hex bolt, 1/4 x 3/4 nc L002-561 Wheel (20mm shaft Dia.) L002-560 Pin, cotter (1/8" x 2") L055-522 Adapter seal L055-523 Foot valve adapter Pump packing kit: L055-539 Packing kit consisting of: 62,67,68,72,74,75,94. Assemblies and accessories: L055-525 Pressure control assembly(110V) L055-527 Pressure control assembly(220V) consisting of: 23-30 L034-124 Gear oil EP90W, liter L034-125 Packing lubricating oil, squeeze bottle L050-621 Owner’s manual 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 73 74 75 76 77 78 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 97 31 Description SPRAY SYSTEMS LTD. DISTRIBUTION CENTRES ACROSS CANADA • SALES • SERVICE • PARTS • www.lemmer.com VANCOUVER Lemmer Spray Systems (B.C.) Ltd. 4141 Grandview Highway, Burnaby, BC, V5C 4J1 TEL: (604) 430-3216 FAX: (604) 430-8017 KELOWNA R. Kitchin Paint Spray Equipment Inc. (Lemmer agent) #3 - 2300 Hunter Road, Kelowna, BC, V1X6C1 TEL: (250) 717-0223 FAX: (250) 860-3038 EDMONTON Lemmer Spray Systems Ltd. 17506 - 105th Avenue, Edmonton, AB, T5S 1G4 TEL: (780) 486-3674 FAX: (780) 444-2498 CALGARY Lemmer Spray Systems Ltd. 4624 - 12th Street N.E. Calgary, AB, T2E 4R4 TEL: (403) 250-7735 FAX: (403) 291-9095 (head office) WINNIPEG Lemmer Spray Systems (Man.) Ltd. 1198 Sherwin Road, Winnipeg, MB, R3H 0V2 TEL: (204) 633-3117 FAX: (204) 694-4763 TORONTO MONTRÉAL Lemmer Spray Systems (Ont.) Ltd. 7585 Torbram Rd, #7&8, Mississauga, ON, L4T 1H2 TEL: (905) 673-1555 FAX: (905) 673-3201 Lemmer (Qué.) Inc. 2851 Bd le Corbusier, Chomedey, Laval, QC, H7L 4J5 TEL: (450) 681-8220 FAX: (450) 681-4914 Aug-00 (specifications are subject to change without notice. May-00) (caractéristiques sont sujets à changement sans prévis. Mai-00) LEMMER PAINT SPRAYING EQUIPMENT LIMITED WARRANTY LEMMER Spray Systems Ltd. extends to the original purchaser of its paint spray equipment a limited one year warranty from the date of purchase against defects in material or workmanship provided that the equipment is installed and operated in accordance with the recommendations and instructions written in the owners manual. LEMMER Spray Systems Ltd. will repair or replace, at its option, defective parts without charge if such parts are returned (still intact in the original equipment) with transportation charges prepaid to the nearest LEMMER Spray Systems Ltd. outlet. An original proof of purchase must be attached. THIS WARRANTY DOES NOT COVER: Normal wear and/or defects caused by or related to abrasion, corrosion, abuse, negligence, accident, faulty installation or tampering in a manner which impairs normal operation. Transportation costs and other incidental, direct, special, or consequential damages or loss. Manual #L050-621 32

Manual Dc3000,4000

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