AIRLESSCO 3A1186F User manual

3A1186F

Operation/Repair/Parts

Airless Paint Sprayer

For application of architectural paints and coatings. For professional use only.

Airlessco - GS800 24F574, 16M531

3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure

Related Manuals

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Gun Manual

289316:

312363 - English

312364 - Spanish

312365 - French

24H289:

3A0479 - English

3A0480 - French

3A0481 - Spanish

ti16161a

Warnings

2 3A1186F

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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.

WARNINGWARNINGWARNING

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent

fire and explosion:

• Use equipment only in well ventilated area.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and

can ignite or explode if spilled on hot surface.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are

present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while

spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure

before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn

off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3000 psi. Use Airlessco replacement parts or accessories that are

rated a minimum of 3000 psi.

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

Warnings

3A1186F 3

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. When the unit is not in use, turn

off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not kink or over-bend the hose.

• Do not expose the hose to temperatures or to pressures in excess of those specified by Airlessco.

• Do not use the hose as a strength member to pull or lift the equipment.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical

reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or

property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier

for compatibility.

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. Breathing carbon

monoxide can cause death.

• Do not operate in an enclosed area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

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.

WARNINGWARNINGWARNING

WARNING

Warnings

4 3A1186F

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. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause

cancer, birth defects or other reproductive harm.

WARNINGWARNINGWARNING

WARNING

Component Identification

3A1186F 5

Component Identification

ti14790a

ti14791a

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PRIME

PRESSURE

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.

B Prime/Pressure (PR) Relief Valve Open

Position

Relieves pressure from gun, hose and tip and primes the unit

when in the open position. It is in the Open position when there

is a wider gap between valve handle and cam body.

C Prime/Pressure (PR) Relief Valve

Closed Position

Pressurizes system when closed. It is in the Closed position

when there is only a slight gap between handle and body.

Operation

6 3A1186F

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage the gun trigger lock. Refer to the separate

instruction manual provided with gun for safety fea-

tures and how to engage the trigger lock.

2. Turn the unit off.

3. Disengage the gun trigger lock and trigger the gun

to relieve residual fluid pressure.

Hold metal part of the gun in contact with

grounded metal pail. Use minimum pressure.

4. Turn Prime/Pressure Relief Valve (PR Valve) to the

open (priming) position to relieve residual pressure.

There will be a wider gap between valve handle

and cam body when in open position. In the

closed position there is only a very slight gap.

NOTE: The valve handle can move both clockwise and

counter clockwise and can face different directions.

5. Re-engage gun trigger lock and close Prime/Pres-

sure Relief Valve.

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.

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.

Setup

Grounding

Always ground the following components:

• Sprayer - Connect a ground wire and clamp (sup-

plied) to a true earth ground.

• Fluid Hose - Use only grounded hoses.

• Spray Gun of Dispensing Valve - Grounding is

obtained through connection to a properly grounded

fluid hose and pump.

• Object being sprayed - According to local code.

Connect the hose and gun

1. Remove the plastic cap plug from the outlet and

screw a conductive or grounded 3000 psi spray

hose onto fluid outlet.

2. Connect an airless spray gun to the other end of the

hose. Do not install spray tip.

NOTE: Do not use thread sealer on swivel unions as

they are made to self seal.

NOTE: The 6’ whip hose should always be 3/8”.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury

from pressurized fluid, such as skin injection,

splashing fluid and moving parts, follow the Pressure

Relief Procedure when you stop spraying and before

cleaning, checking, or servicing the equipment.

ti15989a

ti14791a

ti14790a

Operation

3A1186F 7

Fill the Packing Nut/Wet Cup

1. Fill the Packing Nut/Wet Cup with 5 drops of Air-

lessco Throat Seal Oil (TSO).

Check the Engine Oil Level

1. Unscrew the oil fill plug. The dipstick is attached to

the plug.

2. Without threading the plug into place, check to be

sure the oil is up to the top mark of the dipstick.

3. If oil is needed, refer to engine manual.

Fill the Fuel Tank

1. Close the fuel shutoff valve.

2. Use only clean, fresh, well-known brands of

unleaded regular grade gasoline.

3. 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.

Flush the Sprayer

1. Flush the sprayer. See Flushing Procedure on

page 7.

Prime and Flush Storage Fluid

Before beginning a new spraying project you need to

prime the sprayer and flush the storage fluid out of the

sprayer.

Oil- or Water-based Materials

• 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.

• Flush before changing colors, before fluid can dry in

the equipment, at the end of the day, before storing,

and before repairing equipment.

Flushing

1. Make sure the gun trigger lock in engaged and there

is no spray tip in the gun. Refer to the separate

instruction manual provided with gun for safety fea-

tures and how to engage the trigger lock.

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.

NOTICE

The equipment was tested with lightweight oil,

which is left in the fluid passages to protect parts.

To avoid contaminating your fluid with oil, flush the

equipment with a compatible solvent before using

the equipment for the first time.

ti16049a

• To reduce the risk of static sparking, which can

cause fire or explosion, always hold a metal part of

the gun firmly against the metal pail when flushing.

This also reduces splashing.

• Always remove the spray tip before flushing.

• Only metal pails, which are conductive, should be

used as solvent pails when flushing.

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Operation

8 3A1186F

4. Turn Pressure Control Knob counter clockwise to

lowest setting.

5. Open the prime valve to the open - “Priming Posi-

tion”. This will allow an easy start.

6. Turn the engine ON/OFF switch to ON.

7. Move the choke toward the closed position.

8. Move the throttle lever slightly to the left.

9. Turn the fuel valve ON. 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 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 all the

way and continue cranking.

10. After the engine is warm, gradually close the choke,

raise the RPM of engine slightly by moving throttle

to the left. .

11. Point the gun into the metal pail and hold a metal

part of the gun firmly against the pail. Maintain firm

metal to metal contact between gun and container.

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. Close the prime spray valve.

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 trigger lock and trigger the gun into another

empty, metal container, holding a metal part of the

gun firmly against the metal pail, forcing 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

trigger lock. See Storage, 9.

17. Whenever shutting down the sprayer, follow Pres-

sure Relief Procedure, page 6.

Startup

1. Prepare the material according to the material man-

ufacturer’s recommendations.

2. Place the suction tube into the material container.

3. Start the sprayer.

a. Prime/PR Valve must be “OPEN” in the prim-

ing position.

ti21525a

PRIME

PRESSURE

HIGH PRESSURE

ti14791a

Open

(Priming and

Pressure Relief)

Choke Lever Fuel Valve

Throttle Lever

ti14793a

Closed

(Pressure)

ti14790a

NOTICE

To prevent damage and freezing during storage,

never leave water in the fluid pump

ti15989a

Operation

3A1186F 9

b. After ensuring the gun trigger lock is engaged,

attach tip and safety guard.

c. Turn the engine ON/OFF switch to the “ON”

position.Pull rope vigorously until engine

starts.

d. Turn the Pressure Control Knob clockwise to

prime the pump.

e. After the pump is primed, turn the Prime/PR

Valve to the “CLOSED” position.

f. Turn Pressure Control Knob to the desired

spray pressure.

g. Disengage the gun trigger lock to begin spray-

ing.

Adjusting the Pressure

When adjusting the pressure, turn the Pressure Control

Knob clockwise to increase pressure and counterclock-

wise to decrease pressure. Always use the lowest pres-

sure necessary to completely atomize the material. If

more coverage is needed, use a larger tip rather than

increasing the pressure. Check the spray pattern. The

tip size and angle determines the pattern width and flow

rate.

Shutdown

1. Relieve Pressure, page 6.

2. Clean the tip and gun as recommended in the sepa-

rate Gun Manual supplied with the gun.

3. If spraying water-based material or a material that

could harden in the sprayer overnight, flush the

sprayer after use. See Flushing, page 7.

Storage

Short Term

1. Flush sprayer with compatible solvent before stor-

ing, then fill the pump and hoses with an oil based

solvent such as mineral spirits or Graco or Airlessco

Pump Armor.

• For oil base paint: flush with mineral spirits

• For water-base paint: flush with water, then min-

eral spirits and leave the pump, hose and gun

filled with mineral spirits.

Long Term

For longer storage, use Graco or Airlessco Pump

Armor. Shut off sprayer, Relieve Pressure, page 6, and

make sure prime valve is left open.

Start Up After Storage

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 with the material to be

sprayed.

NOTE: Always store unit indoors.

• To reduce the risk of injection, never hold your

hand, body, fingers or hand in a rag in front of the

spray tip when cleaning or checking for a cleared

tip. Always point the gun toward the ground or into

a waste container when checking to see if the tip is

cleared or when using a self cleaning tip.

• When you spray into the paint bucket, always use

the lowest spray pressure and maintain firm metal

to metal contact between the gun and container.

• To stop the unit in an emergency, turn the engine

off. Then relieve the fluid pressure in the pump and

hose. See Pressure Relief Procedure, page 6

NOTICE

NOTE: Operating the sprayer at higher pressure

than needed wastes material, causes early tip wear,

and shortens sprayer life.

Maintenance

10 3A1186F

Maintenance

Daily Maintenance

Keep displacement pump packing nut/wet cup lubri-

cated 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 tight-

ened just enough to stop leakage. Overtightening will

damage the packings and reduce the packing life.

Servicing the Fluid Pump

Fluid Pump Disconnect

1. Relieve Pressure, page 6.

2. Flush the material you are spraying out of the

machine.

3. Remove the connecting rod shield (12).

4. Move the piston rod (10) to its lowest position by

cycling pump slowly.

5. Turn off the motor.

6. Disconnect sensor by holding it in place with a 7/8”

wrench and unscrewing the swivel with a 11/16”

wrench.

7. Remove the retaining ring (3) from the connecting

rod (13) and slide the sleeve (2) down revealing the

connecting rod pin (1).

8. Remove the suction tube assembly from the fluid

pump (9) by unscrewing the suction nut (7) with the

packing adjustment tool. (189211)

9. Using a 1/2” wrench unscrew the two bolts (8) from

the cover assembly (14). The fluid pump (9) will be

hanging loosely at this point.

10. Remove the connecting rod pin (1) out of the con-

necting rod, allowing the removal of the fluid pump

(9) from the machine.

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