Operation/Repair/Parts 3A1188A Airless Paint Sprayer ENG For application of architectural paints and coatings. For professional use only. Airlessco - HSS9000 (24F577) - HSS11000 (24F578) 3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and in your gun manual. Save all instructions.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING WARNING SKIN INJECTION HAZARD High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment. • Do not aim the gun at, or spray any person or animal. • Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body. • Always use the nozzle tip guard. Do not spray without nozzle tip guard in place. • Use Airlessco nozzle tips.
Warnings WARNING WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide, which is colorless and odorless.
Component Identification Component Identification A ti16100a B ti16099a C ti16101a NOTE: The valve handle can move both clockwise and counter clockwise and can face different directions. A Pressure Control Knob Adjusts pressure. Turn clockwise to increase pressure and counterclockwise to decrease pressure. B Prime/Pressure (PR) Relief Valve Open Position Relieves pressure from gun, hose and tip and primes the unit when in the open position.
Operation Operation Pressure Relief Procedure 5. Re-engage gun trigger lock and close Prime/Pressure Relief Valve. To reduce risk of injury, follow this pressure relief procedure whenever you see this symbol throughout this manual, Also, perform this procedure whenever you: ti16099a • Stop spraying If the spray tip or hose is clogged, follow Steps 1 through 5 above. Expect paint to splash into the bucket while relieving pressure during Step 4.
Operation Fill the Packing Nut/Wet Cup Oil- or Water-based Materials 1. Fill the Packing Nut/Wet Cup with 5 drops of Airlessco Throat Seal Oil (TSO). • When changing from water-based material to oil based material, flush with soapy water and then mineral spirits. • When changing from oil based material to water base material, flush with mineral spirits, followed by soapy water, then a clean water flush. • When flushing with solvents, ground pail and gun.
Operation 5. Open the prime valve to the open - “Priming Position”. This will allow an easy start. Open (Priming and Pressure Relief) 12. Disengage the gun trigger lock and squeeze the trigger. At the same time, slowly turn the pressure control knob clockwise, just enough to move liquid at low pressure. 13. Allow the pump to operate until clean solvent comes from the gun. ti16100a 14. Release the trigger and engage the gun trigger lock. 6. Turn the engine ON/OFF switch to ON. 7.
Operation 2. Place the pump or suction tube into the material container. g. Turn the pressure control knob to desired spray pressure. 3. Start the sprayer. h. Disengage the gun safety lock and you are ready to start spraying. a. Prime/PR Valve must be “OPEN” in the priming position. b. Pressure Control Knob must be in low pressure. c. Turn the engine ON/OFF switch to ON. d. Move the choke toward the closed position. e. Move the throttle lever slightly to the left. f.
Operation Storage Short Term Long Term 1. Flush sprayer with compatible solvent before storing, then fill the pump and hoses with an oil based solvent such as mineral spirits or Graco or Airlessco Pump Armor. For longer storage, use Graco or Airlessco Pump Armor. Shut off sprayer, Relieve Pressure, page 6, and make sure prime valve is left open.
Maintenance Maintenance • • The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and can cause serious injury. To reduce the risk of injury from injection, splashing fluid, or moving parts. follow the Pressure Relief Procedure, page 6, whenever you: • • • • are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tip.
Maintenance • Use only BPR6ES (NGK) or W20EPR-U (NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in (0.7 to 0.8 mm) Use spark plug wrench when installing and removing plug. Servicing the Fluid Pump Fluid Pump Removal 1. Relieve Pressure, page 6. Cleaning a Clogged Tip 2. Flush the material you are spraying out of the machine. 3. Remove the front cover. • Clogged standard flat tip - clean only after the tip is removed from the gun. See Pressure Relief Procedure, page 6 4.
Maintenance Disassembly of the Fluid Pump 4. Use a hammer to tap piston rod (8) out of cylinder (15), or flip pump over and tap piston rod against work bench. NOTICE Do not clean or wipe piston valve threads. Cleaning the piston valve threads could destroy the special sealing patch and cause the piston valve to come loose during operation. 8 1. Remove packing nut (3). 3 15 ti8848a 5. Remove piston rod from sleeve. ti8845a 2. Unscrew intake valve from cylinder. ti8849a ti8846a 3.
Maintenance 7. Remove packing and glands from piston rod. Note orientation for installation. Reassembly of the Fluid Pump If pin works loose, parts could break off and project through the air, resulting in serious injury or property damage. Make sure pin is properly installed. NOTICE If the pump jam nut loosens during operation, the threads of the bearing housing and drive train will be damaged. Tighten jam nut as specified. ti8851a 8. Remove throat packings and glands from cylinder.
Maintenance Servicing Valve Assemblies Reassembly of the Outlet Valve 1. Mount piston in vise. Disassembly of the Outlet Valve 1. Remove Fluid Pump from machine. See Fluid Pump Removal, page 12 2. Remove Outlet Valve Assembly. See Disassembly of the Fluid Pump, page 13. 3. Unscrew piston valve (14) from piston rod (8). Clean and inspect parts. The piston has a special thread locking/sealing patch.
Maintenance Packing Replacement Procedures 1. Soak all Leather Packings in oil for 5-10 minutes before assembly. 2. Place glands and packing on inverted piston in the following order and orientation. 4. Install piston valve (14) to piston rod(8). Torque to 55 +/-3 ft-lb (74.57 =/- 4 N-m). 14 8 a. Male gland (10) b. Alternate blue UHMWPE (6) and leather packings (1) c. Female gland (11) d. Backup washer (12) e. Piston wiper ti8850a 14 5. Place male gland (9) in cylinder. 12 6.
Maintenance 8. Install packing nut (3) into cylinder and hand tighten. 3 Carefully slide piston assembly into bottom of sleeve/cylinder assembly until pump rod protrudes out the top and piston packings are totally inside the sleeve. 15 16 18 ti8858a 8 NOTICE Never slide piston assembly into top of sleeve as this may damage piston packings. 9. Install O-rings inside cylinder and on sleeve. Slide sleeve into bottom of cylinder. Replace O-ring if desired.
Maintenance 13. Torque packing nut to: 140+/- 10 in-lb (15+/-1 N-m) 288466 Installation 1. Slide piston rod assembly into hydraulic motor cylinder. 2. Screw down hydraulic motor cap. Unscrew hydraulic motor cap until inlet and outlet align with hydraulic line fittings and test hole in hydraulic motor cap points toward belt guard. 3. Torque jam nut against hydraulic motor cap to 140ft-lb (17 N-m). 4. Install hydraulic lines to fittings to top left and right side of hydraulic motor; torque to 40 ft-lb (54.
Troubleshooting Troubleshooting General Problem Cause Solution Gas engine pulls hard (won’t start) Hydraulic pressure is too high Turn hydraulic pressure knob counter clockwise to lowest setting.
Troubleshooting Problem Cause Solution Excessive leakage around hydraulic motor piston rod wiper Piston rod seal worn or damaged Replace these parts Fluid delivery is low Pressure setting too low Increase pressure Displacement pump outlet filter (if used) is dirty or clogged Clean filter Intake line to pump inlet is not tight Tighten Hydraulic motor is worn or damaged Bring sprayer to Airlessco distributor for repair The sprayer overheats Paint buildup on hydraulic components Clean Spitti
Parts Parts Pump Packing Diagram 2 3 Ref.
Parts Hydraulic Pump and Reservoir (866205) 34 35 33 32 31 1 2, 3 4 5 6 7 8 9 36 30 29 27, 28 26 37 41 38 40 39 25 23, 24 22 10 11, 12, 13, 14, 15 16 21 19, 20 Hydraulic Inlet Assembly 18 17 ti16103a NOTE: Hydraulic Reservoir and Hydraulic System requires 3.5 gallons of Hydraulic Oil #46. The minimum Oil Level must be approximately halfway up the Filler Tube. Never below. Ref.
Parts Hydraulic Motor (24E360) 15 1 2 5 3 5 4 Ref. 4 17 6 7 18 23 8 24 25 21 9 10 11 26 19 12 27 Ref. 6 20 13 22 14 4 9 ti16105a ti8818a Ref. 1* 2 3* 4 5 6 7 8 9 10 11* 12 13 3A1188A Part 106276 155685 178179 288755 117607 15A726 15E596 117609 248991 117328 178207 867062 116813 Description Cap Screw O-Ring Sealing Washer Repair kit, Trip Rod/Piston Fitting Jam Nut Supply Tube Tee Fitting Sleeve Straight Fitting Piston Bearing Ball Valve Fitting Qty. 1 1 1 1 2 1 1 1 1 1 1 1 1 Ref.
Parts Manifold Filter (866123) 1 Ref. 1 2 3 4 5 6 7 8 9 10 11* 2 11 3 10 Part 867145 301356 867214 867017 867652 867077 867417 867420 867311 867377 867647 Description Housing Bowl Spring 60 Mesh Filter Swivel Swivel Housing Base Plug Plug Nipple O-Ring, PTFE Filter Support Qty.
Parts Frame Assembly 6 1, 2, 3, 4 5 7 8, 9, 10, 11, 12 26 25 13 14, 15, 16, 17 24 18 23 22, 16, 14, 15 19 20 ti16106a Ref. 1 2 3 4 5 7 8 9 10 11 12 13 3A1188A Part 140029 136217 867501 867098 136233 867262 866156 866344 331222 867605 866050 866353 Description Washer Nut, Jam, 1/4-20 Screw Stop Bumper Riv-Nut Handle Assy Guide Slide Roll Pin Snap Button Cover Spacer Qty. 1 1 1 1 1 1 1 1 1 1 1 1 Ref.
Parts Complete Sprayer Assembly 15, 16 32 33 34 35 36 1 5 3, 16 30 20, 21, 22 2 3 4 17 19 9, 10 26 11, 12, 13 27, 28 11, 13, 14 31 18 24 Ref.
Parts Power Unit - HSS 9000 7 1 Ref. 1 2 3 4 5 6 7 8 9 2 3 Part 116080 555516 867441 136123 867324 867301 867299 189524 342402▲ Description GX200 Honda Gas Engine Set Screw Pully Screw Nut Lock Washer Lifting Handle/Plate Assy V-Belt (not shown) Warning Decal (not shown) Qty. 1 4 1 1 1 1 1 1 1 ▲ Additional warning labels are available at no cost. 4 ti16108a 6 5 Power Unit - HSS 11000 1 Ref.
Technical Data Technical Data Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 psi (22.8 MPa, 228 bar) Maximum delivery gpm (lpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76(10.2) Maximum tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.052 Fluid outlet npsm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. Weight . . . . . . . . . . . . . . . . . . . . . . . .
Notes Notes 3A1188A 29
Airlessco Standard Warranty Airlessco warrants all equipment referenced in this document which is manufactured by Airlessco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Airlessco, Airlessco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Airlessco to be defective.
