Campbell Hausfeld AL2810 Operating Instructions And Parts Manual

Operating Instructions And Parts Manual for Campbell Hausfeld AL2810 Paint Sprayer (32 pages)

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86/86426-al2810_operating_instructions_and_parts_manual.pdf file (09 Apr 2024)
  • Manufacturer: Campbell Hausfeld
  • Category of Device: Paint Sprayer
  • Document: AL2810, File Type: PDF Operating Instructions And Parts Manual
  • Updated: 09-04-2024
  • Count of Pages: 32
Download AL2810 Manual (32 pages)

Campbell Hausfeld AL2810: Read PDF Manual Online

Data: UPD 9th April 2024

Campbell Hausfeld AL2810 Paint Sprayer PDF Operating Instructions And Parts Manual (Updated: Tuesday 9th of April 2024 07:56:16 AM)

Rating: 4.9 (rated by 86 users)

Compatible devices: AL2130, DH7600, PS120B, HV2000 Series, IFT232, PHS920SFSS, PS240R, TL2402.

Recommended Documentation:

Campbell Hausfeld AL2810: Text of Operating Instructions And Parts Manual

(Ocr-Read Version Summary of Contents, UPD: 09 April 2024)
  • Airless Paint

    Systems

    Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.

    Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or

    property damage! Retain instructions for future reference.

    Operating Instructions and Parts Manual

    IN422500AV 12/02

    BUILT TO LAST

    Thank you for purchasing a Campbell Hausfeld product. If you have any technical

    questions about this product, please call 1-800-626-4401.

    For Parts and Accessories: 1-800-626-4401

    AL2810

    For parts, product & service information

    visit www.chpower.com

    © 2002 Campbell Hausfeld/Scott Fetzer

    REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

  • 2

    Operating Instructions and Parts Manual

    Airless Paint Systems

    Description

    Airless paint sprayers are capable of

    spraying a wide variety of latex, oil-

    based, and alkyd paints, as well as

    stains, preservatives and other non-

    abrasive finishes.

    These sprayers are also powerful and

    versatile enough to be used with a

    variety of options (roller attachment,

    extra lengths of hose, etc.) to make it

    an even more efficient tool.

    NOTE: Guns pictured in illustrations

    may be different than the one included

    with your unit.

    Safety Guidelines

    This manual contains information that

    is very important to know and

    understand. This information is

    provided for SAFETY and to PREVENT

    EQUIPMENT PROBLEMS. To help

    recognize this information, observe the

    following symbols.

    Danger indicates

    an imminently

    hazardous situation which, if not

    avoided, WILL result in death or serious

    injury.

    Warning indicates

    a potentially

    hazardous situation which, if not

    avoided, COULD result in death or

    serious injury.

    Caution indicates a

    potentially

    hazardous situation which, if not

    avoided, MAY result in minor or

    moderate injury.

    Notice indicates

    important

    information, that if not followed, MAY

    cause damage to equipment.

    NOTICE

    !

    CAUTION

    !

    WARNING

    !

    DANGER

    Unpacking

    After unpacking the unit, inspect

    carefully for any damage that may

    have occurred during transit. Make

    sure to tighten fittings, bolts, etc.,

    before putting unit into service.

    Do not operate

    unit if damaged

    during shipping, handling or use.

    Damage may result in bursting and

    cause injury or property damage.

    General Safety

    Information

    1. Read all manuals included with this

    product carefully. Be thoroughly

    familiar with the controls and the

    proper use of the equipment.

    2. Always wear a mask or respirator

    and eye protection when painting.

    Be certain mask or respirator will

    provide necessary protection

    against inhalation of harmful

    vapors.

    3. Keep visitors away and NEVER allow

    children or pets in the work area.

    !

    WARNING

    www.chpower.com

    Table of Contents

    Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

    Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

    Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

    General Safety Information . . . . . . . . . . . . . . . . . . . . . . .2

    Pre-Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    How to Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

    Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

    Spray Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

    Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

    Spray Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

    Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

    Replacement of Electrical Control Board . . . . . . . . . .8

    Pressure Calibration on Electrical Board . . . . . . . . . . .9

    Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

    Fluid Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

    Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

    Outlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

    Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .11

    Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

    Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .12

    Oil and Lubrication Procedure . . . . . . . . . . . . . . . . .13

    V-Packing Replacement . . . . . . . . . . . . . . . . . . . . . . .13

    Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . .14

    Parts Diagrams and Parts Lists . . . . . . . . . . . . . . . . . . . .18

    Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

    Specifications

    Max. Pressure . . . . . . . . . . . . . 3000 psi

    Output. . . . . . . . . . . . . . . . . . . 1.5 GPM

    Tip size . . . . . . . . . . . 1 gun up to 0.041

    2 guns up to 0.028

    Engine . . . . . . . . . . . . . . . 5.5HP Honda

    Weight . . . . . . . . . . . . . . . . . . . 160 lbs.

    AL2810

  • Airless Paint Systems

    3

    Operating Instructions and Parts Manual

    General Safety

    Information

    (Cont.)

    4. Do not smoke or eat when spraying

    paint, insecticides, or other

    flammable substances.

    5. Always work in a clean

    environment. To avoid injury and

    damage to the workpiece, do not

    aim the spray gun at any dust or

    debris.

    6. When spraying and cleaning,

    always follow the instructions and

    safety precautions provided by the

    material manufacturer (Refer to

    MSDS).

    GASOLINE ENGINE PRECAUTIONS:

    ● Locate unit 25 feet away from

    spray area in well-ventilated area.

    ● NEVER operate in closed building

    unless exhaust is piped outside.

    ● NEVER allow hose to lay against

    engine mufflers or hot parts.

    ● NEVER refill fuel tank while engine

    is hot or running.

    SKIN INJECTION HAZARD:

    ● High pressure spray

    can inject toxins

    into blood stream.

    If injection occurs,

    seek emergency medical treatment.

    Use a face mask/respirator

    and protective clothing

    when spraying. Always

    spray in a well ventilated

    area to prevent health and fire

    hazards. Refer to Material Safety Data

    Sheets (MSDS) of spray material for

    details.

    ● Never try to stop leaks with any

    part of your body.

    !

    WARNING

    !

    WARNING

    !

    WARNING

    ● This system is capable of producing

    3000 psi. Use only Campbell

    Hausfeld replacement parts rated

    at 3000 psi or higher.

    ● Never spray without tip guard.

    ● Ensure trigger lock is functioning

    properly.

    ● Always engage trigger lock when

    not spraying.

    ● Do not remove spray tip while

    cleaning pump.

    ● Never leave equipment pressurized

    while unattended.

    ● Do not clean spray tip while it is

    attached to the spray gun. Remove

    spray tip from gun to clean tip

    guard.

    ● Ensure tightness of high pressure

    connections.

    ● Do not use pliers to tighten or

    loosen high pressure connections.

    ● Motor is equipped with an automatic

    thermal overload. Motor will restart

    without warning, after cooling.

    Never aim or

    spray at yourself

    or anyone else or serious injury could

    occur.

    FIRE OR EXPLOSION HAZARD:

    ● Do not use solvents with flash

    points less than 70°F (21°C) to clean

    this equipment (examples of

    acceptable cleaning solvents are

    water, mineral spirits, lacquer

    thinner, Xylene and high flash

    napha. A partial example list of

    unacceptable cleaning solvents are

    low flash napha, mek, acetone,

    alcohol and toluene).

    Do not spray flammable

    materials in vicinity of

    open flame or near

    ignition sources. Motors, electrical

    equipment and controls can cause

    !

    WARNING

    !

    WARNING

    !

    WARNING

    electrical arcs that will ignite a

    flammable gas or vapor. Never store

    flammable liquids or gases in the

    vicinity of the unit.

    Do not spray acids,

    corrosive materials,

    toxic chemicals, fertilizers or pesticides.

    Using these materials could result in

    death or serious injury.

    !

    WARNING

    www.chpower.com

    PRESSURE RELIEF PROCEDURE

    Before servicing or resting unit,

    relieve pressure from system by

    following this procedure:

    1. Engage gun trigger lock.

    2. Turn off engine.

    3. Disengage

    gun trigger

    lock and

    trigger gun

    to relieve

    residual fluid

    pressure. Hold metal part of gun

    in contact with grounded metal

    pail.

    4. Re-engage gun trigger lock.

    5. Turn

    Prime/Pressure

    Relief Valve to

    open (priming)

    position to

    relieve fluid

    pressure.

    6. Leave

    Prime/Pressure

    Relief Valve OPEN until you are

    ready to spray again.

    NOTE: If spray tip or hose is clogged,

    follow Step 1 to 5 above. Expect

    paint splashing into the pail while

    relieving pressure during Step 5. If

    you suspect that pressure has not

    been relieved after following the

    above procedure, engage gun trigger

    lock and take your unit to an

    authorized Campbell Hausfeld

    Service Center

    .

    AL2810

    OPEN POSITION

  • 4

    Operating Instructions and Parts Manual

    Airless Paint Systems

    General Safety

    Information

    (Cont.)

    ● Paints and solvents containing

    HALOGENATED HYDROCARBONS can

    react explosively with aluminum. Do

    not use halogenated hydrocarbons

    with this equipment. Consult the

    paint or solvent product label or

    Material Safety Data Sheets (MSDS)

    to help determine if it contains

    halogenated hydrocarbons.

    ● Do not use fuels to clean this

    equipment.

    ● Keep spraying area well ventilated.

    Keep doors and windows open.

    ● Remove all ignition sources (i.e.

    Static electricity, pilot lights,

    cigarettes and electrical arcing).

    ● Airless spraying can cause static

    electricity. Always ground the

    pump and spraying surface.

    ● Do not use solvents containing

    halogenated hydrocarbons.

    Keep hose away

    from sharp objects.

    Bursting hoses may cause injury.

    Examine hoses regularly and replace if

    damaged.

    ● Check hoses for weak or worn

    condition before each use, making

    certain that all connections are

    secure.

    Pre-Operation

    FLUSHING

    1. NEW SPRAYER:

    Your sprayer was

    factory tested in an oil solution which

    was left in the pump. Before using oil-

    based paint, flush with mineral spirits

    only.Before using water-based paint

    flush with mineral spirits, followed by

    soapy water, then a clean water flush.

    2. CHANGING COLORS:

    Flush with a

    compatible solvent such as mineral

    spirits or water.

    !

    CAUTION

    www.chpower.com

    3. CHANGING FROM WATER-BASED TO

    OIL-BASED PAINT: Flush with soapy

    water, then mineral spirits.

    4. CHANGING FROM OIL-BASED TO

    WATER-BASED PAINT: Flush with

    mineral spirits, followed by soapy

    water, then a clean water flush.

    5. STORAGE:

    Always relieve pressure

    (See pressure relief procedure on

    page 3) prior to storage or when

    machine is unattended. Follow the

    storage procedure based on the kind of

    paint you used:

    ● Oil-based paint: Flush with mineral

    spirits.

    ● Water-based paint: Flush with

    water, then mineral spirits. Leave

    the pump, hose and gun filled with

    mineral spirits.

    ● For longer term storage use a 50/50

    mixture of mineral spirits and motor

    oil. Always ensure that there is no

    pressure in the unit, and close the

    prime/pressure relief valve for

    storage.

    Never leave pump

    unattended while it

    is under pressure!

    6. START UP AFTER STORAGE: Before

    using water-base paint, flush with

    soapy water and then a clean water

    flush. Before using oil-based paint,

    flush out the mineral spirits with

    the material to be sprayed.

    HOW TO FLUSH

    IMPORTANT COMPONENTS

    ● Prime/Pressure Relief Valve

    (Prime/PR Valve, Figure 1). Used to

    relieve pressure from gun, hose and

    tip and to prime the unit when in

    OPEN position.

    ● Pressure Control Knob (Figure 2).

    Used to adjust pressure. Turn

    clockwise to increase pressure and

    counterclockwise to decrease it.

    ● Choke Lever, Fuel Valve, and

    !

    WARNING

    Throttle Lever (Figure 3).

    PROCEDURE

    1. Be sure the gun safety lock is

    engaged and there is no spray tip

    in the gun.

    2. Pour enough clean, compatible

    solvent into a large,

    empty metal pail to fill the pump

    and hoses.

    3. Place the suction tube into the pail

    or place the pail under the pump.

    4. Turn the pressure control knob to

    low pressure. Refer to Fig. 2.

    AL2810

    OPEN POSITION

    (Prime and Pressure Relief)

    CLOSED

    POSITION

    (Pressure)

    Figure 1 - Prime/Pressure Relief Valve

    Figure 2 - Pressure Control Knob

    Low Pressure

    High

    Pressure

    Figure 3 - Choke Lever, Fuel Valve,

    and Throttle Lever

    Choke Lever

    Fuel Valve

    Throttle

    Lever

  • Airless Paint Systems

    5

    Operating Instructions and Parts Manual

    Pre-Operation (Cont.)

    5. Open the prime valve to the open -

    "Priming Position". This will allow

    for an easy start. Refer to Figure 1

    on page 4.

    6. Turn the engine ON/OFF switch to

    ON.

    7. Move the choke toward the closed

    position as per Figure 3.

    8. Move the throttle lever slightly to

    the left as per Figure 3.

    9. Turn the fuel valve ON as per Figure

    3. Pull the start rope. Pull the

    engine over against compression

    stroke and then let the rope rewind

    slowly into the starter. Pull firmly

    and rapidly to start the engine. Do

    NOT drop the rope. Hold onto the

    handle while rewinding, or the

    rope may rewind improperly and

    jam the assembly. If the engine

    does not start, open the choke a

    little more. If the engine floods,

    open the choke all the way and

    continue cranking.

    10. After the engine is warm, gradually

    close the choke lever, increase the

    RPM of engine slightly by moving

    throttle to the left. Close the prime

    valve. Refer to Figure 1.

    11. Point the gun into the metal pail

    and hold a metal part of the gun

    firmly against the pail Refer to

    Figure 4.

    12. Disengage the gun trigger lock and

    squeeze the gun trigger. At the

    same time, slowly turn the pressure

    control knob clockwise just enough

    www.chpower.com

    to move liquid at low pressure.

    13. Allow the pump to operate until

    clean solvent comes from the gun.

    14. Release the trigger and engage the

    gun trigger lock.

    15. If you are going to start spraying,

    place the pump or suction tube into

    the supply container. Release the

    gun safety latch and trigger the

    gun into another empty, metal

    container, holding a metal part of

    the gun firmly against the metal

    pail (Figure 4) and force the solvent

    from the pump and hose. When

    paint starts coming from gun, turn

    pressure control knob to minimum

    pressure, place prime valve in prime

    (open) position and engage the

    gun trigger lock.

    16. If you are going to store the

    sprayer, remove the suction tube or

    pump from the solvent pail force

    the solvent from the pump and

    hose. Engage the gun safety

    latch and refer to the "Storage"

    Procedure on page 4, Step 5.

    17. Whenever you shut off the sprayer

    follow the Pressure Relief

    Procedure warning on page 3.

    SETTING UP

    1. Connect the hose and gun.

    a. Remove the plastic cap plug from

    the outlet and screw a conductive or

    grounded 3000 psi spray hose onto

    fluid outlet.

    b. Connect an airless spray gun to the

    other end of the hose, but do not

    install the spray tip yet!

    NOTE: Do not use thread sealer on

    swivel unions as they are made to self

    seal.

    NOTE: The first 50' of hose should

    always be 3/8".

    2. Fill the Packing Nut/Wet Cup 1/3 full

    with Throat Seal Oil (TSO) supplied.

    See Figure 5.

    3. Check the engine oil level.

    a. Unscrew the oil fill plug. The

    dipstick is attached to the plug.

    b. Without threading the plug into

    place, check to be sure the oil is up

    to the top mark on the dipstick.

    c. If oil is needed, refer to engine

    manual.

    4. Fill the fuel tank.

    Fuel spilled on a hot

    surface can cause a

    fire or explosion and cause serious

    bodily injury and property damage.

    Always shut off engine and let it cool

    before filling the tank, and carefully

    follow steps a to c below, making sure

    you do not spill any fuel.

    a. Close the fuel shutoff valve.

    b. Use only clean, fresh, well-

    known brands of unleaded regular

    grade gasoline.

    c. Remove the fuel cap and fill

    tank. Be sure the air vent in the fill

    cap is not plugged so fuel can flow

    to the carburetor, then replace the

    cap.

    SPRAY TIP SELECTION

    See Tip Selection Chart on Page 6.

    Spray tip selection is based on paint

    viscosity, paint type, and job needs. For

    light viscosity (thin paints), use a

    smaller tip. For heavier viscosities

    (thicker paints), use a larger tip size.

    Spray tip size is based on how many

    gallons of paint per minute can be

    sprayed through the tip. Do not use a

    tip larger than the maximum pump

    !

    WARNING

    AL2810

    Figure 4 - Spray Gun Against Metal

    Container

    Figure 5 - Applying throat seal oil

  • 6

    Operating Instructions and Parts Manual

    Airless Paint Systems

    www.chpower.com

    Pre-Operation (Cont.)

    flow rate or capacity the sprayer can

    accommodate. Pump flow rate is

    measured in gallons per minute (GPM).

    PATTERN WIDTH

    Thickness of the paint coat is

    determined by spray tip “fan width,”

    rate of the spray gun movement, and

    distance to surface.

    SPRAY TIP SELECTION

    Two tips having the same tip size, but

    different pattern widths, will deliver

    the same amount of paint over a

    different area (wider or narrower

    strip).

    A spray tip with a narrow pattern

    width makes it easy to spray in tight

    places.

    SPRAY TIP REPLACEMENT

    During use, especially with latex paint,

    high pressure will cause the orifice to

    grow larger. This destroys the pattern.

    Replace tips before they become

    excessively worn. Worn tips waste

    paint, cause overspray, make cutting-in

    difficult, and decrease sprayer

    performance.

    Table 1 - Tip Selection Chart

    AL2810

    Quadraflow

    TM

    Tip

    for painting

    (12" from surface)

    Fan Width (in.) (mm)

    .009 .011 .013 .015 .017 .019 .021 .023 .025 .027 .035

    4-6 102-152

    6-8 152-203

    AL3116 AL3117 AL3119 AL3122 AL3125

    8-10 203-254

    AL2211 AL2213 AL3126 AL3131

    10-12 254-305

    AL3118 AL3120 AL2215 AL2217 AL3130 AL3132 AL3135 AL3137

    AL3139

    12-14 305-356

    AL3121 AL3124 AL3127 AL2219 AL2221 AL3136 AL3138

    AL3140

    14-16 356-406

    16

    -

    18 406

    -

    457

    AL3134

    Gun Filter 2 types (part #)

    l---------AL086101AJ------l l--------------AL086100AJ---------------l

    Lacquer, Varnish

    Stain, Sealer

    Enamel

    Exterior Stain

    Vinyl, Acrylic, Latex

    Vinyl, Oil Base Alkyd

    Latex, Acrylic

    Block Filler

    Elastomer

    Ceiling Hi Build, Mil White

    St

    ruc

    t

    ura

    l

    St

    ee

    l

    Heavy Coatings

    Water Flow Rate (gpm)

    .12 .18 .24 .31 .38 .47 .57 .67 .77

    1.03

    1.31

    (water @ 2000psi,

    138

    bar)

    (lpm)

    .49 .69 .91 1.17 1.47 1.79 2.15 2.54 2.96

    3.90

    4.98

    Paint Flow Rate (gpm)

    .10 .15 .21 .27 .33 .40 .49 .58 .66

    .88

    1.12

    (latex paint @ 2000psi, 138

    bar/1.36 spec. gr.)

    (lpm)

    .38 .57 .79 1.02 1.25 1.51 1.85 2.20 2.50

    3.33

    4.24

    (gpm)

    .25 .25 .33 .40 .50 .60 .75 .88 1.00

    1.25

    1.50

    (lpm)

    1.00 1.00 1.25 1.50 1.90 2.30 2.80 3.30 3.80

    4.70

    5.70

    Orifice Size (inches)

    Tip Selection Chart

    Consult

    y

    our paint manufacturer for application recommendation

    *pump will support tip worn to next larger size.

    .029

    .031

    Pump Minimum

    Output*

    Wood Interior

    Wood Exterior

    Masonry

    REMOVE FILTER

    

     

     

  • 7

    Airless Paint Systems

    Operating Instructions and Parts Manual

    www.chpower.com

    Operation

    STARTING UP

    1. Learn the functions of the controls

    (see “How to Spray / Important

    Components” for more

    information).

    2. Prepare the Material

    a. Prepare the material according

    to material manufacturer's

    recommendations.

    b. Place the pump or suction tube

    into the material container.

    3. Start the sprayer.

    a. Prime/PR Valve must be open in

    the priming position.

    b. Pressure Control Knob must be

    in low pressure position.

    c. Follow procedure under “How

    to Flush,” page 5, Steps 6 to 12.

    To stop the unit in

    an emergency or

    before performing any service or

    maintenance procedure follow the

    Pressure Relief Procedure on page 3 to

    relieve the fluid pressure.

    4. Prime the pump.

    a. Allow pump to operate until

    paint comes from gun.

    b. Release the trigger and engage

    the gun safety latch.

    c. Turn Prime Valve OPEN to the

    prime position ensuring the

    pressure is released from the

    system.

    d. Turn Pressure Control Knob to

    minimum pressure.

    e. Install spray tip onto gun.

    f. Close the prime valve to the

    pressure position.

    g. Turn the pressure control knob

    to desired spray pressure.

    h. Disengage the gun safety lock

    and you are ready to start

    spraying.

    !

    WARNING

    If you spray paint

    into the paint

    bucket, always use the lowest spray

    pressure and maintain firm metal-to-

    metal contact between gun and

    container.

    5. Adjust pressure.

    a. Turn the Pressure Control Knob

    clockwise to increase pressure and

    counterclockwise to decrease

    pressure.

    b. Always use the lowest pressure

    necessary to completely atomize

    the material.

    Operating the

    sprayer at higher

    pressure than needed wastes material,

    causes early tip wear and reduces the

    life of the spray equipment.

    c. If more coverage is needed, use

    a larger tip rather than increasing

    the pressure.

    d. Check the spray tip. The tip size

    and angle determine the pattern

    width and flow rate.

    6. Reduce clutch wear.

    a. The first 50 feet of airless spray

    hose should be 3/8", the larger

    diameter works as a pulsation

    damper and saves unnecessary

    cycling of the clutch. A minimum

    of 100 feet of hose should be used.

    b. Adjust the Engine Speed and

    Pump Pressure. First set the

    throttle lever to the maximum

    RPM setting (fully left). Trigger the

    gun onto a test paper to check the

    spray pattern and atomization.

    Adjust the Pressure Control Knob

    until you get a good pattern.

    Reduce RPM of engine to support

    pressure without overworking

    engines.

    7. Clean tip if clogged. If tip is

    becoming worn, replace it. Worn

    tips waste paint, cause overspray,

    make cutting-in difficult, and

    decrease sprayer performance.

    IMPORTANT: Always follow the

    NOTICE

    !

    WARNING

    Pressure Relief Procedure on page 3

    before servicing unit.

    Never hold your

    hand, body, fingers,

    or hand in a rag in front of the spray

    tip when cleaning or checking it for a

    cleared tip. Always point the gun

    toward the front or into a waste

    container when checking to see if the

    tip is cleared or when using a self-

    cleaning tip.

    a. Follow the Pressure Relief

    Procedure on page 3.

    b. Clean the front of the tip

    frequently (with toothbrush only)

    during the day to keep material

    from building up and clogging the

    tip.

    c. To clean and clear a tip if it clogs,

    refer to the separate instruction

    manual received with your gun and

    nozzle.

    NOTE: When pausing during a paint

    job, keep tip clean by locking the gun

    and submerging the tip in a small

    bucket of paint thinner. This will help

    reduce buildup and drying of paint in

    tip, tip guard, and gun.

    Clean a clogged

    standard flat tip

    only after it has been removed from

    the gun. Follow the Pressure Relief

    Procedure on page 3.

    8. When shutting off the sprayer,

    follow this procedure.

    a. Whenever you stop spraying,

    even for a short break, follow the

    Pressure Relief Procedure on page 3.

    b. Clean the tip and gun as

    recommended by your separate

    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" on page 4.

    Use a compatible solvent to flush,

    then fill the pump and hoses with an

    oil based sovent such as mineral

    spirits.

    NOTICE

    !

    WARNING

    AL2810

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    Operating Instructions and Parts Manual

    Airless Paint Systems

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    Operation (Cont.)

    d. For long term shutdown or

    storage, refer to page 4.

    Be sure to relieve

    pressure in the

    pump after filling with mineral spirits.

    SPRAY TECHNIQUE

    Good Spray Gun Technique is at the

    core of any spray paint operation.

    Operator skill and efficiency is as

    important as good equipment and

    good paint. Good spray technique is a

    skill that can be developed by

    following these simple instructions.

    If you are not familiar with spraying

    techniques, study this section of your

    manual and practice the proper

    technique on pieces of cardboard or a

    suitable surface.

    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. (See Figure 6).

    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 movement or gun held too close

    will result in an overly wet or thick wet

    !

    WARNING

    or thick coat coverage that is likely to

    run or sag.

    Do not wave the spray gun. This

    waving is called arching. Instead, hold

    the spray gun at a 12 to 15 inch

    distance perpendicular from the work.

    (See Figure 7.)

    The closer the spray gun is held to the

    work, the thicker the paint is deposited

    and the faster the gun must be moved

    to prevent sags and runs. Holding the

    gun too far from the work will cause

    excessive fog, overspray, and a thin

    and grainy coat.

    It is important to "trigger" the gun

    after gun movement (arm movement)

    has started and release trigger (shut

    gun off) before gun movement ends.

    Gun movement is always longer than

    actual paint (spray) stroke. In that

    manner, even blending and uniform

    paint coat thickness is achieved over

    the entire surface. When the gun is in

    motion as the trigger is pulled, it

    deposits an even amount of paint.

    Overlap the previous pass by half the

    width of the spray pattern. Aim at the

    bottom of the previous pass.

    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.

    Always use the lowest pressure possible

    to obtain desirable results. Test the

    spray pattern on a piece of cardboard

    or other surface.

    To cover “inside” and “outside”

    corners (on walls or other objects), aim

    the spray gun toward the center of the

    corner. The spray pattern is divided in

    half, and the edges of the spray

    pattern on both walls are the same.

    Electrical System

    REPLACEMENT OF ELECTRICAL

    CONTROL BOARD

    1. Remove electrical cover.

    2. Disconnect sensor lead from

    electrical board.

    3. Disconnect two clutch leads on

    electrical board from leads on

    clutch.

    4. Using a 1/16” allen wrench, loosen

    set screw in Pressure Control Knob

    RIGHT

    WRONG

    Gun is held at an angle,

    fluid disperses unevenly

    Gun is held perpendicular

    to work piece, fluid

    disperses evenly

    Figure 6 - How to hold spray gun when spraying

    Figure 7 - Proper Spray Technique

    INCORRECT

    CORRECT

    Start

    Pull

    Trigger

    Release

    Trigger

    End

    12-15”

    AL2810

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    Airless Paint Systems

    Operating Instructions and Parts Manual

    www.chpower.com

    Electrical System (Cont.)

    and remove knob.

    5. Using a 1/2” nut driver or 1/2” deep

    socket, remove nut from pressure

    control shaft. This will allow

    removal of electrical control board

    from frame.

    6. Replace electrical board assembly in

    reverse order. Adjust pressure

    according to the procedure given in

    Pressure Calibration on Electrical

    Board section.

    PRESSURE CALIBRATION ON

    ELECTRICAL BOARD

    1. Turn "Pressure Calibration" Trimpot

    adjustment on electrical control

    board in the counter clockwise

    direction at least 15 revolutions.

    2. Connect 5000 psi glycerine pressure

    guage on output of pump between

    fluid pump and airless hose to

    monitor Fluid Pump Pressure.

    3. Start engine and run at maximum

    RPM. Turn Prime/Pressure Relief

    Valve to the open (Prime) position.

    Turn Pressure Control Knob to

    maximum position (fully clockwise).

    4. Using an insulated screwdriver,

    adjust "Pressure Calibration"

    Trimpot by turning clockwise until

    the clutch engages. When the

    clutch engages the pump will

    commence Priming. When pump is

    primed, turn the Prime/Pressure

    Relief Valve to the Closed (Pressure)

    position. The pump will begin to

    pressurize and the clutch will

    disengage at a low pressure.

    Continue turning the Trimpot

    clockwise to increase pressure to

    3000 psi.

    5. Trigger gun. The pressure should

    drop approximately 350-400 psi

    (when using a 3/8" hose), the clutch

    will engage and build pressure to

    3000 psi and disengage. Trigger

    gun several times to ensure proper

    pressure setting.

    6. Turn Pressure Control Knob to

    minimum position. The clutch

    should disengage and pump stop

    moving.

    7. Secure leads with tie strap.

    8. Replace cover on unit. Ensure the

    leads are not pinched or damaged

    in the process of replacing covers.

    AL2810

    Figure 8 - Electrical Board/Pressure Calibration

  • 10

    Operating Instructions and Parts Manual

    Airless Paint Systems

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    Service

    FLUID PUMP

    FLUID PUMP DISCONNECT

    1. Flush out the material you are

    spraying, if possible.

    2. Follow the Pressure Relief

    Procedure on page 3. Stop the

    pump in the middle of down

    stroke.

    3. Remove the suction tube and fluid

    hose (if so equipped) from the fluid

    pump. Detach the hose from the

    front of the fluid pump.

    4. Remove 2 retaining rings and slip

    the sleeve of the coupling down

    and remove both coupling halves.

    This will disconnect fluid pump

    from the connecting rod.

    5. Unscrew the two tie rod locknuts.

    6. Pull the pump down off the tie

    rods.

    FLUID PUMP REINSTALL

    1. Loosen packing nut and extend

    piston rod so that it is in the “fully

    up” position.

    2. Make sure that spacer tubes (301-

    048) are in place.

    3. Connect connecting rod with fluid

    pump by installing coupling halves.

    Slide sleeve over coupling halves.

    Secure with retaining rings.

    4. Secure the fluid pump housing to

    the tie rods and screw nuts with

    lock washers on loosely.

    5. Tighten the tie rod nuts evenly to

    30 ft. lb.

    6. Reconnect fluid hoses and suction

    tube (if so equipped).

    NOTE: After all the rod locknuts are

    tight, the alignment of both rods

    should allow easy assembly and

    disassembly of the coupling. If there is

    any binding, loosen and retighten all

    the rod locknuts to improve the

    alignment. Misalignment causes

    premature wear of seal and packings.

    7. Tighten the packing nut until there

    is resistance, then tighten it 1 full

    turn. Approximately 4 threads will

    show when new packings are

    installed. Fill the wet cup of the

    packing nut 1/3 full with Throat

    Seal Oil.

    8. Start the pump and operate it

    slowly (at low engine speed and

    pressure setting ) to check the

    piston rod for binding.

    Adjust tie rod lock nuts if necessary

    to eliminate binding.

    9. Run at maximum pressure for

    several minutes, relieve pressure

    and repeat step 7.

    AL2810

    Figure 9 - Inlet Valve, Outlet Valve,

    Piston Assembly

    Piston

    Packing nut/

    wet cup

    Upper

    packing

    Fluid

    outlet

    Distance

    tube

    Lower

    packing

    Wiper

    packing

    Outlet

    valve

    Inlet

    valve

    Suction

    nut

    Fluid

    inlet

    Figure 10 - Piston Assembly

    187-030

    187-031

    187-029

    187-037

    187-026

    187-060

    187-025

    187-315

    187-059

    187-058

  • 11

    Airless Paint Systems

    Operating Instructions and Parts Manual

    www.chpower.com

    halves and remove both coupling

    halves. This will disconnect piston

    rod from connecting rod and

    gearbox assembly.

    3. Screw the suction nut off the pump

    and remove inlet valve assembly.

    4. Using the rod collar tool, loosen

    the packing nut (CCW) and push

    the piston down and out of the

    fluid body.

    5. Place piston holder in a vise. Slide

    the piston into the holder and lock

    in place with a 1/4" pin.

    6. Clean all parts and inspect them

    carefully for wear or damage.

    Inspect the outside of the piston

    rod for scoring or wear. Replace

    these parts if needed. A worn

    piston rod will cause premature

    wear of packings.

    7. Using a 3/8" allen wrench to

    unscrew the outlet seat support

    from the piston.

    8. Remove the outlet seat, O-ring,

    outlet ball and ball cage.

    9. Inspect the outlet ball and seat for

    wear. Replace as required.

    NOTE: Inlet seat is reversible.

    10. Install parts back into piston rod as

    shown in Figure 11.Place two drops

    of loctite No. 242 (blue) on threads

    of the outlet seat support before

    assembling and torque to 20 ft-lbs.

    CLUTCH REPLACEMENT

    NOTE: See clutch assembly parts list on

    page 26.

    Remove clutch as follows:

    1. Remove upper and lower clutch

    covers.

    2. Remove splash cover from clutch

    brackets and spacer tubes.

    3. Disconnect two clutch leads from

    electrical control board leads.

    4. Remove gearbox cover with

    manifold filter from gearbox.

    AL2810

    Service

    (Cont.)

    INLET VALVE

    1. Using the rod collar tool, screw

    suction nut off of fluid body.

    (Suction nut contains intake seat

    support.)

    2. Remove inlet seat, O-ring, inlet ball

    and ball cage with O-ring.

    3. Clean all parts and inspect them for

    wear or damage. Replace parts as

    needed. Old O-rings should be

    replaced with new ones.

    NOTE: Inlet seat is reversible.

    4. Clean inside of fluid body.

    5. Reassemble the valve and screw it

    onto the fluid body if no further

    service is needed.

    OUTLET VALVE

    1. Stop piston rod in middle of its

    stroke. Remove retaining rings.

    2. Slip the sleeve off the coupling

    Figure 11 - Piston Assembly

  • 12

    Operating Instructions and Parts Manual

    Airless Paint Systems

    www.chpower.com

    Service (Cont.)

    Disconnect hose from fluid section.

    5. Disconnect and remove fluid

    section from gearbox, including

    Connecting Rod Assy. (See"Fluid

    Pump Disconnect, page 10)

    6. Remove four nuts (page 20, Item

    23) on the engine side of (Item 18)

    from screws (Item 24) which pass

    through spacer tubes (Item 15). This

    will allow removal of Gearbox &

    Clutch Assembly from "Holder-

    Manifold" (Item 18).

    7. Pull the cog belt loose from the

    engine shaft cog pulley and remove

    the gearbox/clutch assembly from

    the rest of the unit.

    8. Place gearbox in vice by gripping

    the flat part of the drive crank

    allowing the clutch assembly to

    face up. Use caution and not allow

    gearbox to swing and damage

    casting against vice.

    9. Hold coupling screw, with 13/16"

    wrench, then with 5/16" allen

    wrench, screw differential screw

    out of coupling screw and gearbox

    shaft.

    10.Screw large end of differential

    screw into coupling nut assembly

    and pull out of clutch assembly.

    11.The clutch can now be removed

    Spacers, removable spacer,

    replacement clutch, bearings,

    retaining rings should be inspected

    and replaced if needed. (Items 3

    through 8 on Parts List).

    Install new clutch as follows:

    1. With gearbox held as described in

    Step 8 above, place first spacer and

    bearing onto gearbox shaft.

    2. Insert snap rings (2 into recesses of

    cog pulley portion of clutch. Place

    cog pulley portion of clutch with

    cog belt attached onto shaft.

    3. Place second spacer into cog pulley

    portion of clutch. This spacer will

    rest on the first bearing installed.

    4. Insert second bearing on top of

    upper snap ring.

    5. Lay removable spacer on top of last

    bearing. If the clutch air gap is

    larger than .028", do not use

    removable spacer. Put spacer over

    removable spacer, if used, and top

    bearing.

    6. Place coil portion of clutch down

    onto cog pulley portion of clutch

    and center on gearbox shaft.

    7. Screw differential screw into

    coupling screw and nut until 1/16"

    is showing.

    8. Push coupling nut assembly into

    clutch assembly until it comes to a

    positive stop. (Differential screw

    comes into contact with the

    threaded gearbox shaft.)

    9. With 13/16" wrench on coupling

    screw and 5/16" allen wrench in

    differential screw, simultaneously

    with both wrenches screw coupling

    nut assembly into gearbox shaft by

    turning clockwise until a positive

    stop is reached.

    10. Hold coupling nut assembly and

    tighten diffential screw to 30 ft.-lbs.

    This will expand the coupling

    assembly, thereby holding the

    clutch assembly to gearbox shaft.

    Turn clutch observing clutch gap.

    The pulley should turn freely with

    a gap of .012 to .024" between the

    two clutch faces. If the gap is

    greater than .028, remove the

    spacer. Reassemble and check gap

    for proper clearance.

    11. Place cog belt over cog pulley

    portion of clutch. Loosen set screws

    until set screws are approximately

    1/4" above block tensioner.

    12. Reassemble the spacers onto

    screws. Simultaneously lift gearbox

    assembly with clutch into position

    by placing cog belt over engine

    shaft log pulley and inserting the

    four screws into Holder-Manifold

    and replacing nuts (4). Tighten nuts

    to hold assembly in place.

    13. Slightly loosen screws (4).

    14. Evenly tighten Set Screws until

    flush with tip of block tensioner..

    Check tension on cog belt by

    pressing hard with thumb. Proper

    tensioning should allow for

    approximately 1/8". If belt is too

    loose, tighten set screws further.

    15. Replace connecting rod and fluid

    section. Preplace front cover on

    gearbox. Connect hose to fluid

    section.

    16. Connect the clutch and board leads.

    Connect spring to spacer tube.

    17. Replace the splash shield.

    18. Test the clutch for proper operation

    19. Replace clutch covers.

    Maintenance

    REGULAR MAINTENANCE

    1. Always stop the pump at the

    bottom of its stroke when you take

    a break or at the end of the day.

    This helps keep material from

    drying on the rod and damaging

    the packings.

    2. Keep the displacement pump

    packing nut/wet cup1/3 full of TSO

    (Throat Seal Oil) at all times. The

    TSO helps protect the packings and

    rod.

    3. Inspect the packing nut daily.

    Your pump has a patented "Triple

    Life Packing System". Packing life

    will be extended a minimum of

    3 times if the following Packing

    Tightening Procedure is

    followed:

    AL2810

  • 13

    Airless Paint Systems

    Operating Instructions and Parts Manual

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    Maintenance (Cont.)

    Inspect the packing nut daily. If

    seepage of paint into the packing

    nut and/or movement of the piston

    upward is found (while not

    spraying), the packing nut should

    be tightened enough to stop

    leakage only, but not any tighter.

    Overtightening will damage the

    packings and reduce the packing

    life.

    4. Lubricate connecting rod pin every

    3 months.

    OIL AND LUBRICATION PROCEDURE

    Figure 12 shows the necessary steps

    involved in proper lubrication.

    V-PACKING REPLACEMENT

    Refer to Figure 9, 10 and 11 on pages

    10 and 11 for corresponding part

    illustrations.

    V-Packing Replacement Kit Severe Duty

    (PN 187-040) contains leather and

    plastic packing, Teflon and Viton O-

    rings, balls and plastic dual-sided

    female adapter and larger male

    glands. Gland Kit: PN 187-064.

    1. Remove fluid pump as described in

    “Fluid Pump Disconnect”

    instructions on page 10.

    2. Unscrew and remove the inlet valve

    per instructions on page 11.

    3. Unscrew and remove the packing

    nut (187-046). Push the piston rod

    down through the packings and

    out of the pump. Utilizing packing

    removal tool (187-249) the

    complete packing set can be

    removed quickly and easily.

    Another method is to wrap some

    masking tape around the bottom of

    the piston. Now push the piston

    back through the pump and

    remove through the top. The

    packings and glands will be

    removed with the piston rod,

    leaving the fluid body empty.

    4. Disassemble and clean all parts for

    reassembly. Discard old packings.

    Save metal upper glands.

    Replace metal lower glands

    with new metal glands from

    Packing Kit. If the old packing

    had metal gland for 187-058

    discard and replace with plastic

    187-058.

    5. Remove the outlet seat support,

    outlet seat, outlet ball, O-ring and

    ball cage as previously described on

    page 11.

    AL2810

    Sealed

    bearing

    Bleed

    (Weep hole)

    1 oz. SAE

    30W oil

    every 3

    months

    Fill Plug.

    NOTE:

    Gearbox has

    permanent gear grease

    and does not require changing.

    Oil

    impregnated

    sleeve. Dip

    in hot 10W

    oil when

    removed.

    Figure 12 - Oil and Lubrication

    Procedure

  • Operating Instructions and Parts Manual

    Airless Paint Systems

    14

    www.chpower.com

    Coarse spray

    Excessive fogging

    (overspray)

    Pattern too wide

    Pattern too narrow

    Too much material

    Too little material

    Thin distrubtion in center

    of pattern “horns”

    Thick skin on work

    Coating fails to close and

    smooth over

    Spray pattern irregular,

    deflected

    Craters or pock marks,

    bubbles on work

    Clogged screens

    Low pressure

    1. High pressure

    2. Material too thin

    Spray angle too large

    Spray angle too small

    1. Nozzle too small

    2. Material too thin

    3. Pressure too high

    1. Nozzle too small

    2. Material too thick

    1. Worn tip

    1. Wrong tip

    1. Material too viscous

    2. Application too heavy

    Material too viscous

    1. Orifice clogged.

    2. Tip damaged.

    Solvent balance

    1. Extraneous material in paint.

    2. Coarse pigments.

    3. Poorly milled pigments (paint

    pigments glocculate) cover

    screen. Incompatible paint

    mixture and thinners.

    Symptom Possible Cause(s) Corrective Action

    Troubleshooting Chart

    Increase the pressure

    1. Reduce pressure to satisfactory pattern distribution.

    2. Use less thinner.

    Use smaller spray angle tip.

    Use larger spray angle tip (if coverage is OK, try tip in same

    nozzle group).

    1. Use next smaller nozzle.

    2. Thicken spray material.

    3. Reduce pressure.

    1. Use next larger nozzle.

    2. Thin spray material.

    1. Change for new tip.

    2. Use nozzle with narrow spray angle.

    1. Thin cautiously.

    2. Reduce pressure and/or use tip in next larger nozzle group.

    Thin cautiously.

    1. Clean carefully.

    2. Replace with new tip.

    Use 1 to 3% “short” solvents remainder “long” solvents.

    (This is most likely to happen with material of low viscosity,

    lacquers, etc.)

    1. Clean screen

    2. Use coarse screen if orifice size allows.

    3. Use coarser screen, larger orifice tips. Obtain ball milled

    paint. If thinner has been added, test to see if a drop

    placed on top of paint mixes or flattens out on the surface.

    If not, try different thinner in fresh batch of paint.

    AL2810

  • 15

    Airless Paint Systems

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    There is splitting from the

    gun.

    Paint leaks into the wet

    cup.

    Engine operates, but

    paint pump does not

    cycle

    Engine and displacement

    pump operate, but paint

    pressure is too low or

    none

    Displacement pump

    operates, but output is

    too low on downstroke

    on on both strokes

    Clutch does not engage.

    Clutch slips.

    Engine stops.

    1. Fluid supply low or empty

    2. Air trapped in fluid pump or

    hose

    1. Packing nut/wet cup is loose

    2. Upper packings worn or

    damaged

    3. Piston rod worn

    1. Pressure setting is too low

    2. Clutch not engaged

    3. Displacement pump stopped

    1. Pressure setting too low.

    2. Tip or gun filter clogged.

    3. Tip worn.

    4. Fluid displacement pump

    filter clogged.

    5. Large pressure drop in fluid

    hose.

    1. Upper check valve ball not

    seating properl.

    2. Lower packings are worn or

    damaged

    Symptom Possible Cause(s) Corrective Action

    Troubleshooting Chart Part II

    1. Refill supply container.

    2. Check for loose hose connections on the siphon

    assembly. Tighten if needed. Reprime pump.

    1. Tighten just enough to stop leakage.

    2. Replace packings.

    3. Replace piston rod.

    1. Increase pressure.

    2. See Troubleshooting Part III - Clutch Does Not Engage

    3. Service pump.

    1. Increase pressure.

    2. Remove tip and/or filter. Clean if necessary.

    3. Replace tip.

    4. Clean filter.

    5. Use a larger diameter hose.

    1. Service upper check valve.

    2. Replace packings.

    See Troubleshooting Part III - Clutch Does Not Engage

    Take unit to an authorized Campbell Hausfeld Service

    Center.

    Refer to engine manual.

  • Operating Instructions and Parts Manual

    16

    www.chpower.com

    AL2810

    STEP 1: Ensure that the pressure control knob is in the maximum (fully clockwise) position.

    STEP 2: Remove the upper and lower clutch and electrical covers.

    STEP 3: Check all electrical connections between the engine magneto, sensor, control board and clutch for loose connections

    or damaged leads. See Figure 8 on page 9.

    STEP 4: Disconnect the two leads from the control board (blue) and the clutch assembly (black). Using a multimeter, with

    the engine at maximum RPM, pressure control knob in the maximum position and the prime valve open (priming) position,

    test the DC voltage across the boards leads (blue). This voltage must be 13-14 VDC. If the readings are correct, the board,

    sensor and magneto are okay and the problem is the clutch assembly. If this is the case, proceed to Step 5. If the voltage is

    outside this range go to Step 7.

    STEP 5: Measure resistance between the clutch leads (black). This value must be 10-16 ohms. If this reading is out of

    specifications the clutch is defective and must be replaced, otherwise continue troubleshooting.

    STEP 6: If the clutch resistance readings of Step 5 are correct, check the spacing between the clutch field and plate. The gap

    must be approximately .028". If this gap is too wide, remove the spacer from the clutch assembly. Should the clutch still not

    engage, replace the clutch assembly. See page 11.

    STEP 7: When the DC voltage from the board is not 13-14 VDC, disconnect the control board lead (black) from the engine

    magneto lead (pink), located on the side of the engine. With the engine at maximum RPM, pressure control knob in

    maximum (fully clockwise) position and prime valve open (priming), read the AC voltage from the magneto lead to the

    sprayer frame. This reading should be 11-30 VAC. If outside this range, contact your local Honda repair facility for magneto

    replacement. If the magneto is producing the proper AC voltage, continue to Step 8.

    STEP 8: Test the sensor by reading the resistance between the red and black wires. The resistance runs between 1.8-3.5

    kohms. A defective sensor usually shows no resistance (open). If the reading is outside standards, replace the sensor. An

    alternative method to test the sensor, is to plug a new sensor into the board and see if the clutch will engage. Caution!

    When using this method, ensure prime/pressure valve is in the prime position. This is important because the sensor plugged

    into the board is not measuring pressure in the fluid section.

    STEP 9: When Steps 7 and 8 have been completed and the magneto and sensor check good, the electrical control board is

    the only item left, replace the board. See page 8.

    Steps to Follow if Clutch Does Not Engage

    Troubleshooting Chart Part III - Clutch Does Not Engage

  • Operating Instructions and Parts Manual

    17

    www.chpower.com

    AL2810

    Notes

  • 18

    For Replacement Parts, Call 1-800-626-4401

    See Figures 10 & 11 on pages 10 & 11 for more Part Numbers in Diagrams

    Please provide following information:

    -Model number

    -Serial number (if any)

    -Part descriptions and number as shown in parts list

    Address parts correspondence to:

    Campbell Hausfeld

    100 Production Drive

    Harrison, OH 45030 U.S.A.

    Paint System Assembly

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

  • 19

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Ref. No. Description Part Number Qty.

    1 007 Gun with swivel (Optional) 120-201XL 1

    2 50’ x 1/4” Hose (Optional) 100-011 1

    3 50’ x 3/8” Hose (Optional) 100-023 1

    4 3/8” M x 3/8” M Nipple 169-010 1

    5 Manifold filter assembly 111-200-99 1

    6 3/8” plug 100-129 1

    7 3/8” cap with ring 100-161 1

    8 1/4” x 1/4” nipple 100-070 1

    9 Ball valve 100-119 1

    10 1/4” M x 1/4” F x 4’ Swivel hose 100-012 1

    11 1/4” M x 1/4” f Elbow 100-004 1

    12 1/4” Return tube 188-177 1

    13 3/8” M x 3/8” F Elbow 169-013 2

    14 3/8” F x 3/8” M x 21” Hose 100-123 2

    15 1/4” M x 3/8” M Elbow 100-141 1

    16 Manifold 301-253 1

    17 1/4” Plug 100-028 2

    18 1/4” Nut 100-317 2

    19 1/4” Bolt 100-345 2

    20 3/8 M x 1/4 M NPS Nipple 100-109 1

    21 SL Fluid Pump 187-410 1

    22 3/8 M x 3/8 M Elbow 167-016 1

    Parts List for Paint System Assembly

  • 20

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Power Unit Assembly

    Part No. 301-530

  • 21

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    301-530

    Ref. No. Description Part Number Qty.

    1 Sleeve bearing 301-047 1

    2 Shield front 301-189 1

    3 Coupling set assembly 189-046A 1

    4 Shield-rear 301-092 1

    5 Spacer-tube 301-048 2

    6 Washer, lock 140-035 2

    7 Nut 140-051 2

    8 Stud 100-328 1

    9 Holder 305-013 1

    10 Cog Belt 301-231 1

    11 Cover-bottom 305-067 1

    12 Adapter 305-012 1

    13 Screw 100-339 4

    14 5.5 HP Engine Assembly 301-524 1

    15 Spacer tube 305-046 4

    16 Clutch assembly 301-264 1

    17 Cover 301-529 1

    18 Holder-manifold 305-064 1

    19 Plate-Gearbox mount 305-045 1

    20 Sensor assembly 331-294-99 1

    21 Pressure control board 301-282-99 1

    22 Knob assembly 301-523A 1

    23 Nut 140-044 8

    24 Screw 305-047 4

    25 Gearbox 301-208 1

    26 Connecting rod assembly 301-333 1

    27 Cover top 301-531 1

    28 Grommet 301-135 6

    29 Screw 100-312 4

    30 Cover-Gearbox 301-320 1

    31 Screw 301-337 2

    32 Bolt 301-547 2

    33 Lock nut 100-317 2

    34 Washer 140-029 4

    35 Washer 100-344 4

    36 Shock mount 301-536 4

    Ground assembly 188-160 1

    Parts List for Power Unit Assembly

  • 22

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Frame Assembly

    Part No. 301-515

    13

    11

    1

    12

    2

    3

    4

    10

    9

    8

    7

    6

    5

  • 23

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    301-515

    Ref. No. Description Part Number Qty.

    1 Frame weldment 301-510 1

    2 Axle 5/8 x 21.81 188-367 1

    3 Spacer 5/8 ID 113-031 2

    4 Wheel 13 x 500-6T 301-165 2

    5 Set collar 5/8 ID 143-029 2

    6 Centerlock nut 5/16-18 100-317 2

    7 Rubber foot 163-008A 2

    8 Spacer .25 x .08 188-185 2

    9 Washer 1.25 x .31 163-011A 2

    10 Screw 5/16-18 169-050 2

    11 Cup 100-170 1

    12 Screw 10-24 301-546 2

    13 Nut 10-24 120-021 2

    Parts List for Frame Assembly

  • 24

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    7

    8

    9

    Engine Assembly

    Part No. 301-524

    2

    3

    4

    5

    6

    1

    301-524

    Ref. No. Description Part Number Qty.

    1 Honda 5.5 HP Engine 301-160 1

    2 Adapter 305-012 1

    3 Screw 136-091 4

    4 Key 112-029 1

    5 Screw 100-357 1

    6 Screw 100-383 4

    7 Sheave 301-222A 1

    8 Thrust Plate 301-229 1

    9 Screw 301-230 1

    Parts List for Engine Assembly

  • 25

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Clutch Replacement Parts

    Ref. No. Description Part Number Qty.

    1 Cog belt 301-231 1

    2 Clutch 301-264 1

    3 Screw 305-088 1

    4 Shoulder screw 100-175 1

    5 Screw flanged 100-173 4

    6 Set screw 100-174 2

    7 Block tensioner 301-534 1

    8 New gearbox 301-208 1

    9 Plate 305-045 1

    10 Spacer tube 305-046 4

    Parts List for Clutch Replacement

  • 26

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Clutch Assembly

    Ref. No. Description Part Number Qty.

    1 Screw-Differential 112-041 1

    2 Coupling nut assembly 112-054 1

    3 Spacer 301-412 1

    4 Spacer-Removable 301-413 1

    5 Clutch-Replacement 301-264 1

    6 Bearing 301-037 2

    7 Retaining ring 100-333 2

    8 Spacer 301-274 2

    9 Spring 136-068 1

    10 Rubber edge 301-316 1

    Parts List for Clutch Assembly

  • 27

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Ball Valve

    Part No. 100-119

    100-119

    Ref. No. Description Part Number Qty.

    1 Handle 100-162 1

    2 Screw 100-163 1

    3 Ball 100-164 1

    * Repair Kit KIT-119 1

    Parts List for Ball Valve

    1

    2

    *

    3

    *

    *

    *

    *

  • 28

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Manifold Filter

    Part No. 111-200-99

    111-200-99

    Ref. No. Description Part Number Qty.

    1 Base* 111-202 1

    2 Spring* 301-356 1

    3 O-ring* 106-007 1

    4 Filter 111-204 1

    5 Support* 111-203 1

    6 Base* 111-201 1

    7 3/8” M x 3/8” M Elbow 169-013 1

    8 3/8” NPT (M) x 3/8” NPS (M) Hose connector 100-034 1

    9 Plug 3/8” 100-129 1

    10 3/8” NPT (M) x 3/8” NPS (M) Elbow 169-013 1

    11 3/8” Cap with Ring 100-161 1

    * Filter assembly 111-200 1

    Parts List for Manifold Filter

  • 29

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Suction Assembly - 5 Gallon

    Part No. 301-090-99

    Suction Assembly - 55 Gallon

    Part No. 301-543-99

    Ref. No. Description Part Number Qty.

    - Suction Hose Assembly (Includes Items 1-5) for 5 Gallon 301-517 1

    1 Inlet strainer 141-008 1

    2 Suction tube for 5 Gallon 301-514 1

    Suction tube for 55 Gallon 301-545 1

    3 Hose clamps 301-516 2

    4 Hose for 5 Gallon 301-513A 1

    Hose for 55 Gallon 301-544 1

    5 Elbow 100-165 1

    6 Return pipe 188-377 1

    7 Elbow 100-128 1

    8 Whip 100-012 1

    9 Elbow* 100-126 1

    10 Reducer* 100-385 1

    11 Fitting 187-017 1

    12 Suction nut 187-018 1

    * Used on units equipped with either the 100-180 or 331-050 prime valves. The 301-090 suction assembly also includes the

    100-081A Elbow for units with the 138-001 marathon prime valve.

    Parts List for Suction Assembly (5 Gallon and 55 Gallon)

    10

    9 8

    7

    6

    5

    3

    3

    1

    2

    4

    12

    11

    FLUID PUMP

  • 30

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Notes

  • 31

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Notes

  • 32

    Operating Instructions and Parts Manual

    www.chpower.com

    AL2810

    Limited Warranty

    1. DURATION: From the date of purchase by the original purchaser as follows: Standard Duty Paint Application Systems and

    all Paint Application Accessories - 1 year, Serious Duty Paint Application Systems - 3 years, Extreme Duty Paint Application

    Systems - 5 years.

    2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld/A Scott Fetzer Company, 100 Production Drive, Harrison,

    Ohio, 45030, Telephone: 1-800-626-4401.

    3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale or rental) of the

    Campbell Hausfeld Product.

    4. WHAT PRODUCTS ARE COVERED BY THIS WARRANTY: All non-compressor driven paint application systems, HVLP spraying

    systems, and paint application accessories supplied or manufactured by the Warrantor.

    5. WHAT IS COVERED UNDER THIS WARRANTY: Defects in material and workmanship which occur within the duration of the

    warranty period. Warrantor will also cover normal wear items for a period of thirty days from the date of original purchase

    against defects in material and workmanship. These wear items are: HVLP-filters, motor brushes, gun packing, gun

    canister seal, gun check valve and gun air flow ring; Airless-inlet valve, outlet valve, gun valve, filters, tips, all seals and o-

    rings.

    6. WHAT IS NOT COVERED UNDER THIS WARRANTY:

    A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED FROM

    THE DATE OF ORIGINAL PURCHASE AS STATED IN THE DURATION. If product is used for rental purposes, the warranty

    will apply for ninety (90) days from the date of original purchase. Some states do not allow limitation on how long an

    implied warranty lasts, so the above limitations may not apply to you.

    B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE , OR EXPENSE THAT MAY RESULT FROM ANY

    DEFECT, FAILURE, OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some states do not allow the exclusion

    or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

    C. Any failure that results from an accident, purchaser’s abuse, neglect or failure to operate products in accordance with

    instructions provided in the owner’s manual(s) supplied with product. Accident, purchaser’s abuse, neglect or failure to

    operate products in accordance with instructions shall also include the removal or alteration of any safety devices. If

    such safety devices are removed or altered, this warranty is void.

    D. Normal adjustments which are explained in the owner’s manual(s) provided with the product.

    E. Items or services that are normally required to maintain the product: HVLP-filters, motor brushes, gun packing, gun

    canister seal, gun check valve and gun air flow ring; Airless-inlet valve, outlet valve, gun valve, filters, tips, all seals and

    o-rings., or any other expendable part not specifically listed, will only be covered for thirty days from date of original

    purchase.

    7. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantor’s option, products or

    components which are defective, have malfunctioned and/or failed to conform within duration of the warranty period.

    8. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY:

    A. Provide dated proof of purchase and maintenance records.

    B. Deliver or ship the Campbell Hausfeld product or component to the nearest Campbell Hausfeld Authorized Service

    Center. Freight costs, if any, must be borne by the purchaser.

    C. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

    9. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or replacement will be

    scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of

    replacement parts.

    This Limited Warranty applies in the U.S., Canada and Mexico only and gives you specific legal rights. You may also have

    other rights which vary from state to state, or country to country.

  • Campbell Hausfeld AL2810 User Manual
  • Campbell Hausfeld AL2810 User Guide
  • Campbell Hausfeld AL2810 PDF Manual
  • Campbell Hausfeld AL2810 Owner's Manuals

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