ICI ProSpray 404 Operations Manual & Parts List Download

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P.O.BOX 8006, MOORPARK, CA. 93020-8006 TEL: 800-467-3571

FORM NO. 001- 205 MAY 99

SHIP TO: 5397 COMMERCE AVE. MOORPARK, CA. 93021

WARNING

: Before operating, doing any service or maintenance

procedure, learn & follow the pressure relief procedure on page 6.
Read & understand all warnings on pages 4, 5, 6 and 7

ALL SERVICE PROCEDURES MUST BE PERFORMED

BY AUTHORIZED SERVICE CENTER.

OPERATION MANUAL & PARTS LIST

FOR

MODELS ProSpray 404, ProSpray 505

and ProSpray 606 Airless Paint Sprayers

Summary of Contents for ProSpray 404

Page 1: ...re operating doing any service or maintenance procedure learn follow the pressure relief procedure on page 6 Read understand all warnings on pages 4 5 6 and 7 ALL SERVICE PROCEDURES MUST BE PERFORMED BY AUTHORIZED SERVICE CENTER OPERATION MANUAL PARTS LIST FOR MODELS ProSpray 404 ProSpray 505 and ProSpray 606 Airless Paint Sprayers ...

Page 2: ...ric Motor Maintenance 15 Troubleshooting 15 Troubleshooting Machine Does not Start 16 Electrical Board Calibration 17 Electrical System 18 Replacement of Electrical Components 19 LCD Display Parts List 19 Servicing the Fluid Pump 20 Gear and Pump Assembly 21 Servicing Piston Rod Upper Check Valve 22 Servicing Lower Suction Valve 22 V Packing Replacement 23 Fluid Pump Parts List 24 ProSpray 404 505...

Page 3: ...es that are essential to proper equipment repair and maintenance NOTE Identifies essential procedures or extra information FLUSHING Read prior to using your sprayer 1 New Sprayer Your ProSpray unit was factory tested in an oil solution which was left in the pump Before using oil base paint flush with mineral spirits only Before using water base paint flush with mineral spirits followed by soapy wa...

Page 4: ... the metal pail and force the solvent from the pump and hose Engage the gun safety latch Refer to Storage Procedure on Page 1 11 Whenever you shut off the sprayer follow the PRESSURE RELIEF PROCEDURE on Page 6 1 Be sure the gun safety latch is engaged and there is no spray tip in the gun Refer to separate gun instruction manual on how to lock the safety latch remove spray tip and the guns safety f...

Page 5: ...e must be OPEN in the priming position b When you have ensured that gun safety latch is engaged attach tip and Safety Guard c Turn the ON OFF Toggle Switch to the ON position d Turn Pressure Control Knob CW to prime pump e After the pump is primed turn Prime PR Valve to the Closed position f Turn Pressure Control Knob to the desired spray pressure LCD displays pressure g Disengage the gun safety l...

Page 6: ...r a short break follow the Pressure Relief Procedure Warning on page 6 b Clean the tip gun as recommended in gun instruction manual c Flush the sprayer at the end of each work day if the material you are spraying is water based or if it could harden in the sprayer overnight See Flushing pages 1 and 2 Use a compatible solvent to flush then fill the pump and hoses with an oil based solvent such as m...

Page 7: ...your hand or body ALWAYS have gun tip guard in place when spraying ALWAYS lock gun trigger when you stop spraying ALWAYS remove tip from the gun to clean it NEVER try to blow back paint this is not an air spray sprayer ALWAYS follow the PRESSURE RELIEF PROCE DURE as shown on page 6 before cleaning or remov ing the spray tip or servicing any system equipment Be sure equipment safety devices are ope...

Page 8: ...rall resistance Overall end to end resistance of unpressurized hose must not exceed 29 megohms max for any coupled length or combination of hose lengths If hose exceeds these limits replace it imme diately Never exceed 500 ft 150 m overall combined hose length to assure electrical continuity 1 Engage gun safety latch Refer to separate instruction manual provided with your gun on its safety feature...

Page 9: ...RE whenever you stop spraying and before adjust ing removing or repairing any part of the sprayer NEVER alter or modify any part of the equipment to avoid possible component rupture which could result in serious bodily injury and property damage NEVER use weak or damaged or non conductive paint hose Do not allow kinking or crushing of hoses or al low it to vibrate against rough or sharp or hot sur...

Page 10: ... Be sure the pressure relief procedure is followed before assembling tip and housing to the gun 2 Insert Rev Tip cylinder into REV GUARD guard housing assembly 3 Guide the metal seat into REV GUARD guard housing assembly through the retaining nut and turn until it seats against the cylinder 4 Insert the O ring gasket onto the metal seat so that it fits into the grooves 5 Finger tighten the REV GUA...

Page 11: ... I L T E D G U N W R O N G CORRECT DISTANCE CORRECT GUN ANGLE Hold the spray gun 12 15 inches away from the work surface and keep it perpendicular straight to the surface Move the spray gun parallel to the work and at a right angle to the surface Move the gun at a steady rate in order to apply a good coverage The wet coat should be just under the thickness at which a run or sag will occur Slow gun...

Page 12: ...form as possible FOR EVEN PAINT COAT OVERLAP HALF THE WIDTH OF EACH PAINT STROKE Adjust pressure control knob so that paint is completely atomized from the spray gun Insufficient pressure will result in tailing Too much pressure will result in excess fog and overspray excessive tip wear and increased sprayer wear and tear TAILING GOOD PATTERN FOG OVERSPRAY Inside and outside corners can be sprayed...

Page 13: ...oo viscous Thin cautiously Application too heavy Reduce pressure and or use tip in next larger nozzle group Coating fails to Material too viscous Thin cautiously close smooth over Spray pattern irreg Orifice clogged Clean carefully ular deflected Tip damaged Replace with new tip Craters or pock Solvent balance Use 1 to 3 short solvents remainder long solvents marks bubbles This is most likely to h...

Page 14: ... Tip Seal metal Rev Tip Seal O ring Screw 3 Guard Valve Seat Complete Valve Ball with Holder Valve Spring Unit Seals PTFE 2 Trigger Pin Washer 2 Gun Head Retainer Pin 2 Retainer 120 021 120 056 120 048 120 055 120 049 120 082 120 090CX 120 090FX 120 088 120 087 115 019 120 044 120 085 Nut Washer Safety Latch or Lock Wave Washer Retaining Ring Seal Filter Complete Coarse Filter Complete Fine Spring...

Page 15: ...p objects to scrape away dried paint as they would cause leakage around the seal Reassembling is done in reverse sequence IMPORTANT When reassembling install valve spring unit 9 with spring loose CLEANING 007 SPRAY GUN Immediately after the work is finished flush the gun out with a solvent Brush pins 13 with solvent and oil them lightly so they will not collect dried paint TO REMOVE CLOGS REVERSIB...

Page 16: ... 213 313 413 513 613 015 215 315 415 515 615 715 815 017 217 317 417 517 617 717 019 219 319 419 519 619 819 021 321 421 521 621 721 821 023 323 423 523 623 025 325 425 525 625 027 327 427 527 627 031 431 531 631 831 035 535 635 Water Flow Rate gpm Tip Flow Rate water lpm Fan Width REV TIPS P N 560 XXX FLAT TIPS P N 570 XXX Water 2000 psi 138 bar Tip Identification All tips have a 6 digit part num...

Page 17: ...n with 0 017 tip on unit turn the Prime PR Control Valve to the Prime position and turn the unit on Turn the Pressure Control Knob to maximum pressure fully CW position and let the pump cycle at high speed in the prime position for 20 minutes This will allow the brushes to run in properly giving a longer life TROUBLESHOOTING PROBLEM CAUSE SOLUTION The fluid supply is low or empty Air entrapped in ...

Page 18: ...oupler STEP 6 If all checks out fine in Steps 1 through 5 and the green light is still out the pressure control assembly is defective and must be replaced STEP 7 If the green light is ON the power source fuse and thermal coupler are okay Plug another sensor into the board If the unit starts the sensor was faulty and must be replaced When a replacement sensor is not available use a multimeter to te...

Page 19: ...OFF during this calibration the sensor is defective and should be replaced 8 When calibration is complete move jumper from both PZ R terminals to single terminal on P ZR 2 PRESSURE CALIBRATION 1 Attach a 50 1 4 airless hose airless gun with 0 017 tip and a 5000 psi glycerine filled pressure gauge to the pump 2 Place the suction tube into a bucket of Coro chek and water 3 Turn Prime pressure relief...

Page 20: ...e low pressure voltage trimpot so that the deadband is less than 100 psi and the pressure increase after the gun trigger is released is less than 200 psi These pressures are guidelines and may vary slightly from pump to pump BLK GREEN 2 1 3 4 5 6 7 9 10 11 12 13 LCD SENSOR P ZR POT ZERO LIGHT 8 L1 S1 S2 L2 A1 A2 PRESSURE LCD ZERO RED RED BLK BLK WHITE BLK WHITE POWER LIGHT BLK LOW PRESSURE VOLTAGE...

Page 21: ...ig 11 and remove LCD Display assembly Item 6 Fig 11 3 If unable to loosen the four nuts hold them and unscrew the four screws Item 1 Fig 11 Then remove the LCD Display Assembly If the display is removed in this manner the mylar label Item 2 Fig 11 must be replaced 4 Reassemble in reverse order while making sure that the four spacers Item 4 Fig 11 and the four washers Item 7 Fig 11 are in place Tig...

Page 22: ...ning spring into groove on crosshead assembly c Secure paint pump to cover assembly by two screws up through tube spacers and screw into cover assembly d Tighten screws evenly and alternating to 20 ft lbs GEARBOX SLEEVE BEARING REPLACEMENT FIGURE 12 FIGURE 12 PARTS LIST ITEM NO PART NO DESCRIPTION 1 331 061 Sleeve Bearing 2 331 103 Washers 2 3 331 197 Screws 2 Note When replacing item 1 cover the ...

Page 23: ... 103 SERVICING GEAR BOX ASSEMBLY 1 Remove fluid pump as per Fluid Pump Discon nect procedures page 17 2 Remove frame by removing four screws See Item 21 Fig 20 Refer to Fig 13 for the following steps 3 7 3 Separate the cover assembly 1 from box 6 by removing screws 7 from front of cover and back of box and shoulder screws 8 from front of cover and back of box 4 Lay unit on its back and disassemble...

Page 24: ... pump service is needed reassemble the lower check valve assembly O ring ball and retainer in the suction nut and screw nut onto pump body Tighten suction nut with rod tool 189 211 FIGURE 15 PARTS LIST 4 To reassemble the piston assembly place in block using dowel pin and hold in vise Install O ring 4 Seat 3 and Ball 2 and thread upper and lower pistons together Slowly hand tighten piston Ensure t...

Page 25: ... 16 17 V up e Male Adaptor 15 f Slide on tube spacer 10 g Three Belleville Springs 9 starting with the first spring facing down second one facing up and the third one facing down h Upper male adaptor 8 i Five V Packings V inverted 6 7 k Place O rings 3 4 onto seal holder 2 l Lubricate outside diameter of V packings with white lithium or multipurpose grease m Slide seal holder 2 over Upper Packing ...

Page 26: ...4 Adapter Male 2 4 331 020T O Ring PTFE 16 331 016 V Packing Plastic 6 5 331 021 Adapter Female 17 331 016L V Packing Leather 4 6 331 023 V Packing Plastic 3 18 331 015D Adapter Female 7 331 023L V Packing Leather 2 19 331 011 Fluid Body 8 331 022 Adapter Male 20 331 029 Retainer 9 331 025 Belleville Springs 3 21 331 030 Ball 10 331 018 Tube Spacer 22 331 032T O Ring PTFE 11 331 093 Piston Assembl...

Page 27: ...9US 331 070 331 068 331 212 331 213 117 090 331 094 331 048 100 180 Shield Cover Frame Screw 4 Cover 1 2 HPDC Motor 404 3 4 HPDC Motor 505 Fan Motor Cover Motor Cover Screws 3 Plug Rubber Boot 2 Prime PR Valve 13 14 15 16 17 18 19 20 21 22 23 24 100 003 331 294 114 009R 331 151 331 315 331 321 117 044 111 037 100 312 331 103 331 337 301 191 ProSpray 404 505 FIGURE 18 3 4 2 1 5 6 7 8 9 24 23 19 18 ...

Page 28: ... 17 FIGURE 19 PARTS LIST ITEM NO PART NO DESCRIPTIION ITEM NO PART NO DESCRIPTION 331 111 331 234 331 174 331 176 331 171 100 377 331 222 331 175 331 199US 331 068 331 212 331 213 117 090 113 030 331 326 143 028 143 032 18 19 20 21 22 23 24 25 26 27 28 30 31 331 048 100 180 100 003 331 294 114 009R 331 151 100 312 331 103 331 315 111 037 301 191 117 044 331 337 Rubber Boot 2 Prime PR Valve Swivel ...

Page 29: ...068 331 212 331 213 117 090 113 017 143 028 143 032 331 048 Pail Hook Screw 2 Cover Frame Motor Cover 3 4 HPDC Motor Motor Fan Motor Cover Motor Cover Screws Wheel 2 Washer 2 Retaining Ring 2 Rubber Boot 2 14 15 16 17 18 19 20 21 22 23 24 25 26 100 180 100 003 331 294 114 009R 331 151 331 315 111 037 100 377 331 321 117 044 331 103 100 312 331 337 FIGURE 20 FIGURE 20 PARTS LIST 4 3 2 1 5 6 7 8 9 1...

Page 30: ... 285 141 008 1 2 3 2 3 4 6 5 9 7 8 1 3 PN 331 238 404 505 606 Lo Pro ITEM NO PART NO DESCRIPTION 1 2 3 4 5 6 7 8 9 10 Inlet Strainer Suction Hose Ass y Incl Items 1 2 3 4 5 6 Suction Tube Ferrule Suction Hose Suction Elbow Suction Nut Bypass Hose Ass y Incl Items 7 8 Bypass Hose Fitting Nylon Tie Spring Clip 10 FIGURE 21 PARTS LIST 331 217 331 290 331 384 331 281 331 383 331 035 331 034 331 231 11...

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