Operation/Repair/Parts 3A1187E Airless Paint Sprayer EN For application of architectural paints and coatings. For professional use only. Airlessco - GS6250 (24F575), (16M532) 3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these 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 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Always wear appropriate gloves, eye protection, and a respirator or mask when painting. • Do not operate or spray near children. Keep children away from equipment at all times. • Do not overreach or stand on an unstable support. Keep effective footing and balance at all times. • Stay alert and watch what you are doing. • Do not leave the unit energized or under pressure while unattended.
Warnings WARNING WARNING BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns: • Do not touch hot fluid or equipment. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns.
Component Identification Component Identification C PRIME ti14792a ti16292a PRESSURE B A ti16293a 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. Prime/Pressure (PR) Relief Valve Primes pump and relieves pressure from gun, hose and tip.
Operation Operation Pressure Relief Procedure NOTE: If you suspect that pressure hasn’t been relieved due to damaged Prime/Pressure Relief Valve, or other reason, slowly loosen the tip nut or hose coupling. To reduce risk of injury, follow this pressure relief procedure whenever you see this symbol throughout this manual, Also, perform this procedure whenever you: • Stop spraying • Check or repair any part of this system • Install or clean spray nozzle ti16293a 1. Engage the gun trigger lock.
Operation Fill the Packing Nut/Wet Cup • 1. Fill the Packing Nut/Wet Cup 1/3 full with Airlessco Throat Seal Oil (TSO). ti15987a When changing from oil based material to water base material, flush with mineral spirits solvent (also called white spirit), followed by soapy water, then a clean water flush. • When flushing with solvents, ground pail and gun. • Flush before changing colors, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.
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 gun 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. ti16293a 14. Release the trigger and engage the gun trigger lock. 6. Turn the engine ON/OFF switch to ON. 7.
Operation starter. Pull firmly and rapidly to start the engine. Do NOT drop the rope. Hold on to 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. g. After the engine is warm, gradually close the choke, raise the RPM of engine slightly by moving throttle to the left. Close the prime valve. h.
Operation Storage Short Term Start Up After Storage 1. Flush sprayer with compatible solvent before storing, then fill the pump and hoses with an oil based solvent such as mineral spirits solvent (also called white spirit) or Graco or Airlessco Pump Armor. Before using water-base paint, flush sprayer with soapy water and then a clean water flush. When using oil-base paint, flush out the mineral spirits solvent (also called white spirit) with the material to be sprayed.
Maintenance Maintenance Daily Maintenance Regular Maintenance Keep displacement pump packing nut/wet cup lubricated with Airlessco Throat Seal Oil at all times. The TSO helps protect the packings and rod. 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 just enough to stop leakage. Overtightening will damage the packings and reduce the packing life. 1.
Maintenance 5. Remove two retaining rings (4) and slip the sleeve of the coupling down and remove both coupling halves. This will disconnect fluid pump from the connecting rod. 2. Insert one of the retaining rings through the packing nut and rest the sleeve on top of it. 6. Using a 7/8” box wrench disconnect the high pressure fluid line from the pump. 7. Using a 9/16” wrench, unscrew the two tie rod locknuts (10). 8. Pull the pump off the tie rods. ti15995a ti15996a 3.
Maintenance 8. Start the pump and operate it slowly (at low engine speed) to check the piston rod for binding. Adjust tie rod lock nuts if necessary to eliminate binding. Servicing the Outlet Valve 1. Complete all steps of the Fluid Pump Disconnect, page 11. 9. Prime the unit and run at maximum pressure for several minutes, then release the pressure and repeat step 7. 2. Screw the suction nut off the pump and remove inlet valve assembly. 10.
Maintenance Packing Replacement Procedures Disassembly of the Fluid Pump Reassembly of the Fluid Pump 1. Unscrew and remove the packing nut. 1. Take the lower metal male gland and place it down on the flat side. 2. Push the piston rod down through the packings and out of the pump. 3. Now push the packing removal tool up through the pump and remove the top bringing the packings, spacer and springs along with it, leaving the fluid body empty.
Maintenance 11. Take the upper female gland and place on top of the assembled upper packings with the inverted side down. Replacement of Electrical Control Board 12. Take the assembled upper glands and packings (7 pieces) and slide over the top of the piston, making sure the inverted sides are facing down. 1. Remove electrical cover. 13. Take the V-packing holder and replace the white O-ring and the black O-ring with new ones form the packing kit. 14.
Maintenance 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.
Clutch Replacement Clutch Replacement Removing the Clutch Refer to the following parts diagrams: Belt Tensioning, Clutch Assembly, and Power Unit Assembly 1. Remove the gear box cover (Power Unit Assembly, item 1) by disconnecting fluid hose to the manifold filter by unscrewing the four allen head bolts (Power Unit Assembly, item 36). 2. Disconnect the Fluid Pump, page 11. 3. Pull off the spacer tubes (Power Unit Assembly, item 30) and drop the sleeve bearing down and off.
Clutch Replacement 7. Screw differential screw, into coupling screw and nut until 1/16” is showing. See Clutch Assembly, page 27 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.
Troubleshooting Troubleshooting General Problem Cause There is spitting from the gun. The fluid supply is low or empty. Refill the supply container. Air entrapped in the fluid pump or hose. Check for loose connections on the siphon assembly, tighten, then reprime pump. The packing nut/wet cup is loose. Tighten just enough to stop leakage. The upper packings are worn or damaged. Replace the packings. See Packing Replacement Procedures, page 14. Worn Piston Rod. Replace Piston Rod.
Troubleshooting Electrical Problem Clutch does not engage Cause Solution Pressure Control Knob Ensure the pressure control knob is in the maximum clockwise position. Poor Electrical Connection Remove the clutch and electrical box covers. Check all electrical connections between the engine magneto, sensor, control board and clutch for loose connections or damaged leads. Magneto Disconnect the two leads from the control board (blue) and the clutch assembly (black).
Troubleshooting Problem Cause Clutch Assembly Solution 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. If the clutch resistance readings are correct, check spacing between the clutch field and plate. The gap should be .012” to .024”. If the gap is greater than .024 the gap is too wide and the spacer should be removed from the clutch assembly.
Troubleshooting Problem Clogged screens Cause Solution Extraneous material in paint Clean screen Course pigments Use coarse screen if orifice size allows. Poorly milled pigments (paint pigments coagulate) Use courser screen, larger orifice tips. Obtain ball milled paint. If thinner had been added, test to see if a cover screen. Incompatible drop placed on top of paint mixes or flattens out on the paint mixture and thinners on the surface. If not, try different thinner in fresh batch of paint.
Parts Parts Fluid Pump 14 1 2 3 5 12 4 Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part 866143 301320 301046 867468 866074 866069 301467 866267 866241 140051 140035 301059 867641 16F587 Description GEARBOX 1” COVER ROD END RETAINING RING COUPLING SET RETAINING SLEEVE FRONT SHIELD SL PAINT PUMP ASSEMBLY SUCTION NUT NUT LOCK WASHER SPACER STUD LABEL, FRONT Qty.
Parts Inlet Valve 1 2 Ref. 1 2 3 4 5 6 7 3 4 5 Part 556562 866306 101822 867574 867390 866400 866241 Description BLACK O-RING INLET RETAINER INLET BALL INLET SEAT WHITE O-RING SUCTION FITTING SUCTION NUT Qty. 1 1 1 1 1 1 1 6 7 ti15999a Outlet Valve 8 9 10 11 12 13 Ref. Part Description 8* 866274 RETAINER 9 867575 OUTLET SEAT 10 104319 WHITE O-RING 11 867047 OUTLET BALL 12* 866307 OUTLET RETAINER 13* 187330 PISTON * Included in Item No. 13 Qty.
Parts Manifold Filter (865627) 1 Ref. 1 2 3 4 5 6 7 8 9 10 2 3 4 Part 867145 301356 867377 867214 867647 867077 301309 557391 867311 867420 Description BASE SPRING O-RING FILTER 60 MESH SUPPORT BASE HOSE PLUG 3/8” NIPPLE 3/8”M x 1/4”M PLUG 1/4” Qty.
Parts Packing Replacement Ref. 1* 2 3 4 5*+ 6*+ 7+ 8 9* 10 11+ 12 13 14+ 15+ 16 17+ 18+ 19+ 20+ 21 22 23+ 24+ 25 26 27+ 28+ Part 187330 866056 866295 866362 104319 866307 867047 867575 866274 866306 101822 866400 867574 867390 556562 866241 867689 866018 867693 866100 867083 866011 867688 867608 866010 866426 867378 107083 Description Qty. PISTON,2.00 STROKE, SL 1 SCREW,COLLAR 1 BODY,PUMP,MACHINING 1 SPACER,TUBE 1 PACKING,O-RING 1 RETAINER,BALL,.3125,SL 1 BALL,.3125, GR25, PISTON 1 SEAT,UPPER,T.C.
Parts Clutch Replacement 6 7 9 5 4 3 2 1 8 10 Ref. 1 2 3 4 5 6 7 8 9 10 Part 301284 301231 305088 867602 111800 867581 301534 301208 305045 305046 Description CLUTCH REPLACEMENT COG BELT SCREW SHOULDER SCREW SCREW FLANGED SET SCREW BLOCK TENSIONER GEARBOX PLATE SPACER TUBE Qty. 1 1 1 1 4 2 1 1 1 1 ti16007a Clutch Replacement (866054) 10 5 8 9 1 Ref. 1 2 3 4 5 3A1187E 2 7 6 Part Description Qty.
Parts Engine Assembly 4 2 1 Ref. 1 2 3 4 5 Part 114530 305012 109031 866212 555326 5 3 Description HONDA ENGINE ADAPTOR SCREW KEY SET SCREW 6 Qty. 1 1 4 1 1 Ref. 6 7 8 9 Part 565007 866337 301229 867771 7 8 9 ti16009a Description SCREW SHEAVE ASSEMBLY THRUST PLATE SCREW Qty. 4 1 1 1 Frame Assembly Ref. 1 2 3 4 5 6 7 8 9 10 11 12 1 12 2 10 11 4 5 6 8 3 9 7 28 Part 867770 301202 301165 136126 140029 867325 331048 305039 143029 110637 866084 116969 342473▲ 342506▲ Description Qty.
Parts Power Unit Assembly 4 3 2 11 3 12 36 17 18 19 7 13 20 6 1 37 5 15 40 25 16 21 23 39 26 35 21 20 38 ti16010a Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part 301320 301531 301135 301337 301047 301333 301446 305045 305064 305012 114530 301529 305046 109031 305067 102547 305047 140044 331294 867528 140029 867301 867325 3A1187E Description Qty.
Parts Suction Assembly (301594) 6 2 3 4 5 Ref. 1 2 3 Part 866020 867446 866388 1 Description ELBOW PUNCH CLAMP HOSE 54” Qty. 1 2 1 ti16012a Ref. 4 5 6 Part 15F149 187147 15F513 Description TUBE INLET FILTER GASKET, PAIL Qty. 1 1 1 Paint System Assembly 9 13 10 See Packing Replacement Procedures 11 12 8 7 14 5 6 9 5 15 16 1 3 17 2 ti16003a Ref.
Technical Data Technical Data Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum delivery gpm (lpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum tip size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid outlet npsm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
