Before performing any maintenance on a diaphragm airless sprayer, please follow the basic safety information below and make sure that the pressure valve is open and no pressure is in any part of the airless sprayer system. 

Safety when operating airless sprayers is universal for all models and brands. 

SAFETY INSTRUCTIONS

 1. Never pull the trigger of the gun toward people. Unlock the trigger ONLY when you spray the paint or take off the nozzle tip.

2. Never use a damaged hose. Due to the high pressure even a small flaw may cause an accident.

3. Pressure is very high and extremely dangerous. You must handle it with meticulous care.

4. Do not raise the pressure unnecessarily.

5. Connect all the attachments properly and tightly so that no paint would leak. If paint leaks while you are working, stop the pump immediately. Let the air go and lower the pressure.

6. Ensure you are using the correct hose, contact your supplier if in doubt.

7. Read the instruction manual provided with the airless sprayer and all accessories used.

DO NOT UNDERESTIMATE THE POTENTIAL DANGER OF HIGH PRESSURE FLUID IN AN AIRLESS SPRAYER.

1) Diaphragm airless sprayer daily maintenance:

a) Always clean your airless sprayer thoroughly inside and out, make sure that after you have flushed clean water throughout your airless sprayer and airless gun that you remove any excess paint build up from the suction hose and pipe. This also includes removing your suction hose filter and gun filter to ensure that they are both spotless. If you can't clean these two filters it's time to replace them.

b) It is recommended that with a diaphragm airless sprayer using a flexible suction hose set that this be removed after flushing the machine and have clean water run through the hose from each end using a garden hose. You will be surprised how much paint is still inside the suction set even after the machine appears to be clean. The build up of paint inside the suction set will eventually dry, flake and begin fall off over time causing blockages in your suction valve.

c) Once you have finished thoroughly cleaning your airless sprayer, set everything back up and test the airless sprayer with water. Ensure that the machine primes and build pressure, spray the gun several times and hold the trigger open and make sure that the machine holds at a constant pressure, most diaphragm airless sprayers will build to about 3000psi and when using a 517 reversible airless spray tip the pressure drop should be somewhere around 200-500psi with water. Use the gauge on the machine to monitor any pressure fluctuation, if the needle on the gauge is bouncing up and down then your machine may be in need of a service, contact your closest dealer for advice.

d) Once you have pressure tested your diaphragm airless sprayer and everything seems to be OK without any leaks, it's time to add some pump saver to your water for the final flush. Pump saver is a corrosion inhibitor that helps prevent rust and scale from building up on the inside of your airless sprayer. We don't recommend kero or petrol as both of these items are flammable and if you are transporting your airless sprayer inside a van or station wagon the fumes can be annoying or dangerous.

2) Diaphragm airless sprayer monthly maintenance:

a) If you are a heavy airless sprayer user then a monthly strip down of the components in the head is recommended, if your airless sprayer is only used occasionally then this could be stretched to a six monthly interval.

b) Remove your suction set including return hose, remove your suction valve and ensure that no debris or paint build up is occurring on the inside of this valve. Remove the outlet valve and check inside the same way. While both valves are removed check the valves for wear or pitting, if in doubt contact a dealer for help. If you have access to compressed air, try and blow clean air into the ports to blow away any rubbish and debris.

c) Remove the head of the airless sprayer and inspect the condition of the diaphragm for cuts, cracks or wear. Also check that the under side of the head has no damage to any of the sealing rings machined, pressure can cut across these sealing rings can cause leaks and damage to both the head and diaphragm. Refit the head back onto your airless sprayer and using a torque wrench, correctly tension the head bolts to the manufacturers specification.

d) Refit both your suction valve and outlet valve and be sure to clean all threads and apply marine grease to ensure easy removal next time for the same components.

e) Make sure that everything your removed is replaced back and tight. Be sure not loose any seals or copper rings and do not use thread tape, if you need to use thread tape then you are making a mistake, you must use the correct seals.

f) Your airless sprayer is now ready to pressure test, slowly build the pressure making sure that no leaks appear, if you have a leak turn the machine off and fix it. After building pressure in your airless sprayer make sure that it holds pressure as discussed in 1(B).

g) Flush pump saver throughout the entire airless sprayer and put the machine away in storage.

2) Diaphragm airless sprayer yearly maintenance:

a) Follow the procedures as outlined above in addition to changing the pump oil and inspecting the airless paint hose for external abrasions, kinks or damage. Replacing a paint hose while performing routine maintenance is much cleaner than replacing a burst hose on the job with paint that has sprayed out in every direction. Airless paint hoses are cheap at about $99 each, consider changing these over time.

b) Have your machine checked by a professional service agent, as good as you may think you know airless sprayers, we know them better. Dealers repair airless sprayers every day, we know what problems occur and how they occur.

In summary, keep your airless sprayer spotlessly clean, early detection of problems will be easy to see if the machine is clean and cheaper to repair. Down time cost's more than a service because you can not schedule down time on a job.