Operation/Repair/Parts
Airless Paint Sprayer
3A1188C
HSS9000, HSS11000
For application of architectural paints and coatings. For professional use only.
HSS9000 Models: 24F577, 16M530, 16M614, 865903
HSS11000 Models: 24F578, 16M615,
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.
Gun Manual 3A0413
EN
ti16098a
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.
WARNING
WARNINGWARNINGWARNING
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.
2 3A1188C
Warnings
WARNING
WARNINGWARNINGWARNING
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 3300 psi. Use Airlessco replacement parts or accessories that are
rated a minimum of 3300 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.
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.
3A1188C 3
Warnings
WARNING
WARNINGWARNINGWARNING
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.
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
This product contains a chemical known to the State of California to cause cancer, birth defects or other
reproductive harm. Wash hands after handling.
4 3A1188C
Component Identification
A
Component Identification
ti16100a
B
ti16101a
ti16099a
C
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. 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.
3A1188C 5
Operation
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
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.
1. Engage the gun trigger lock. Refer to the separate
instruction manual provided with gun for safety features 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.
5. Re-engage gun trigger lock and close Prime/Pressure Relief Valve.
ti16099a
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 tie nut or hose coupling nut.
Setup
Hold metal part of the gun in contact with
grounded metal pail. Use minimum pressure.
ti15989a
4. Turn Prime/Pressure Relief Valve (PR Valve) to the
open (priming) position to relieve residual pressure.
ti16100a
Grounding
Always ground the following components:
• Sprayer - Connect a ground wire and clamp (supplied) 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.
6 3A1188C
Operation
Fill the Packing Nut/Wet Cup
1. Fill the Packing Nut/Wet Cup with 5 drops of Airlessco Throat Seal Oil (TSO).
ti2272f
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
• Fuel spilled on a hot surface can cause a fire or
explosion and cause serious bodily injury and
property damage.
• Always shut off the engine and let it cool before
filling the tank.
• Carefully fill the fuel tank to avoid spilling any fuel.
1. Close the fuel shutoff valve.
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
• 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.
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 features and how to engage the trigger lock.
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.
Prime and Flush Storage Fluid
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.
Before beginning a new spraying project you need to
prime the sprayer and flush the storage fluid out of the
sprayer.
3A1188C 7
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 Pressure Control Knob to low pressure.
ti16028b
Operation
5. Open the prime valve to the open - “Priming Position”. This will allow an easy start.
(Priming and Pressure Relief)
Open
ti16100a
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.
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.
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.
ti15989a
Throttle Lever
Choke Lever
Fuel Valve
ti14793a
10. After the engine is warm, gradually close the choke
lever, raise the RPM of engine slightly by moving
throttle to the left. Close the prime valve.
Closed (Pressure)
ti14790a
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.
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, 10.
17. Whenever shutting down the sprayer, follow Pres-
sure Relief Procedure, page 6.
NOTICE
To prevent damage and freezing during storage,
never leave water in the fluid pump
Startup
NOTICE
Do not start the engine without fluid pump having
enough fluid so that it can be primed. Running fluid
pump dry will decrease life of the pump packings.
Operating the sprayer at higher pressure than
needed wastes material, causes early tip wear, and
shortens sprayer life.
1. Prepare the material according to the material man-
ti15989a
8 3A1188C
ufacturer’s recommendations.
Operation
2. Place the pump or suction tube into the material
container.
3. Start the sprayer.
a. Prime/PR Valve must be “OPEN” in the prim-
ing position.
b. Pressure Control Knob must be in low pres-
sure.
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. 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.
g. After the engine is warm, gradually close the
choke lever, raise the RPM of engine slightly
by moving throttle to the left. Close the prime
valve.
h. 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.
i. 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.
g. Turn the pressure control knob to desired
spray pressure.
h. Disengage the gun safety lock and you are
ready to start spraying.
Adjusting the Pressure
• 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
1. Turn the Pressure Control Knob Clockwise to
increase pressure and counterclockwise to
decrease pressure.
2. Always use the lowest pressure necessary to completely atomize the material.
3. If more coverage is needed, use a larger tip rather
than increasing the pressure.
4. Check the spray pattern. The tip size and angle
determines the pattern width and flow rate.
4. Prime the Pump
a. Allow pump to operate until paint comes from
gun.
b. Release the trigger and engage the gun trig-
ger lock.
c. Turn Prime Valve OPEN to the prime position
ensuring the pressure is released from the
system.
d. Turn Pressure Control Knob to minimum pres-
sure.
e. Install spray tip onto gun.
f. Close the prime valve to the pressure position.
3A1188C 9
Shutdown
1. Relieve Pressure, page 6.
2. Clean the tip and gun as recommended in the separate 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.
Operation
Storage
Short 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 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.
10 3A1188C
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.
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pump valve to OFF (down) and turn pressure
control knob fully counter clockwise.
Maintenance
Daily Maintenance
The following maintenance procedures should be performed daily:
• Check engine oil level and fill as necessary.
• Check hydraulic oil level and fill as necessary
• Check hose for wear and damage.
• Check gun safety for proper operation.
• Check pressure drain valve for proper orientation.
• Check pressure drain valve for proper operation.
• Check and fill the gas tank.
• Check that displacement pump is tight.
• Check level of Throat Seal Liquid (TSL) in displacement pump packing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid
buildup on piston rod and premature wear of
packings and pump corrosion.
• Remove any debris or media from hydraulic rod.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above. Very slowly loosen tip
guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or
hose.
NOTE: For detailed engine maintenance and specifications, refer to separate Honda Engines Owner’s Manual.
Other Maintenance
After the first 20 hours of operation:
• Drain engine oil and refill with clean oil. Refer to the
Honda Engines Owner’s Manual for correct oil viscosity.
On a weekly basis:
• Remove engine air filter cover and clean element.
Replace element, if necessary. If operating in an
unusually dusty environment: check filter daily and
replace, if necessary. Replacement elements can
be purchased from your local Honda dealer.
• Remove any debris or media from hydraulic rod.
After each 100 hours of operation:
• Change engine oil. Reference Honda Engines
Owner’s Manual for correct oil viscosity.
Semi-Annually:
• Check belt wear, replace if necessary.
3A1188C 11
Maintenance
Yearly or 2000 hours:
• Replace hydraulic oil and filter with Graco hydraulic
oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8
liter) and filter 116919. Replace belt.
Spark Plug:
• 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.
Cleaning a Clogged Tip
• Clogged standard flat tip - clean only after the tip is
removed from the gun. See Pressure Relief
Procedure, page 6
1. Follow Pressure Relief Procedure, page 6.
2. Clean the front of the tip frequently (with toothbrush
only) during the day to keep material from building
up and clogging the tip.
Servicing the Fluid Pump
Fluid Pump Removal
1. Relieve Pressure, page 6.
2. Flush the material you are spraying out of the
machine.
3. Remove the front cover.
4. Remove the suction tube (25) and paint hose (26)
(remove at swivel end).
25
26
5. Push retaining ring up (27); push out pin (28).
ti2272a
3. To clean and clear a tip if it clogs, refer to the separate instruction manual received with your gun and
nozzle.
28
27
ti2272b
6. Loosen jam nut (28). Unscrew pump.
28
ti2272c
12 3A1188C
Maintenance
Disassembly of the Fluid Pump
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.
1. Remove packing nut (3).
3
ti8845a
2. Unscrew intake valve from cylinder.
4. Use a hammer to tap piston rod (8) out of cylinder
(15), or flip pump over and tap piston rod against
work bench.
8
15
ti8848a
5. Remove piston rod from sleeve.
ti8846a
3. Disassemble intake valve. Clean and inspect
O-ring. You may need to use a pick to remove
O-ring.
ti16102b
ti8849a
6. Unscrew piston valve (14) from piston rod (8). Clean
and inspect parts. The piston has a special thread
locking/sealing patch. Do not remove the patch. The
patch allows for disassembly/assembly procedures
®
before it is necessary to apply Loctite
to the
threads.
14
8
ti8850a
3A1188C 13
Maintenance
7. Remove packing and glands from piston rod. Note
orientation for installation.
ti8851b
8. Remove throat packings and glands from cylinder.
Discard throat packings and glands.
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.
1. Screw jam nut to bottom of pump threads. Screw
pump completely into manifold. Unscrew pump from
manifold until pump outlet aligns with hose. Hand
tighten jam nut, then tap 1/8 to 1/4 turn with hammer
to torque to 75 ft-lb (101 N-m).
ti8853b
ti2272d
2. Slowly pull engine starter rope (27) until pump rod
pin hole is aligned with hydraulic rod hole. Push pin
(28) into hole. Push retaining ring into groove.
27
28
ti2272e
3. Fill packing nut with Throat Seal Oil.
ti2272f
14 3A1188C
Maintenance
Servicing Valve Assemblies
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. The patch allows for disassembly/assembly procedures before it is necessary
to apply Loctite
®
to the threads.
14
8
Reassembly of the Outlet Valve
1. Mount piston in vise.
2. Place ball into piston.
3. Install packings, wiper and glands. See Packing
Replacement Procedures, page 16.
4. Apply Loctite to valve seat threads, if special thread
locking/sealing patch is insufficient. (Normally good
for 4 repacks.)
5. Torque valve seat into piston to 55 ft-lbs.
Disassembly of the Inlet Valve
1. Relieve pressure, see page 6.
2. Disassemble intake valve. Clean and inspect
O-ring. You may need to use a pick to remove
O-ring.
ti8850a
4. Remove packing glands from piston rod. Note orientation for installation.
ti8851b
5. Clean and inspect parts for wear or damage,
replace parts as necessary. PTFE O-ring will always
be replaced in this procedure.
ti16102b
Reassembly of the Inlet Valve
1. Reinstall inlet parts in correct order. Reverse inlet
seat if necessary.
2. Run the machine at pressure for several minutes,
inspect for leaks and proper orientation.
3A1188C 15
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.
a. Male gland (10)
b. Alternate blue UHMWPE (6) and leather pack-
ings (1)
c. Female gland (11)
d. Backup washer (12)
e. Piston wiper
6
1
14
12
11
10
4. Install piston valve (14) to piston rod(8). Torque to
55 +/-3 ft-lb (74.57 =/- 4 N-m).
14
8
ti8850a
5. Place male gland (9) in cylinder.
6. Alternately stack UHMWPE (6) and leather packings (1). Note orientation.
7. Place female gland (10) in top of cylinder. Seat
packings.
9
ti8854b
NOTE: The special sealing patch on piston valve
threads is good for 4 repackings. Use Loctite on piston
valve threads after 4 repackings.
3. Insert ball (13) in piston rod (8). If Loctite is applied
to piston threads, insure that none gets on ball.
13
8
ti8855b
1
6
10
ti11819b
16 3A1188C
Maintenance
8. Install packing nut (3) into cylinder and hand tighten.
3
ti8858b
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.
15
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
8
ti11860b
11. Reassemble intake valve with new O-ring, seat and
ball. Seat may be flipped over and used on the other
side. Clean seat thoroughly.
20
Place inside cylinder (15) and push
to shoulder with
sleeve (18)
17
18
16
ti8859b
NOTE: O-ring is not required for safe pump operation.
10. Grease top inch or two of piston rod that goes
through the sleeve/cylinder assembly and throat
packings. Grease piston packings at bottom of piston pump.
19
21
22
23
24
ti16102b
12. Install intake valve on cylinder. Torque to 200 +/- 5
ft-lb (271 +/-7 N.m)
3A1188C 17
Maintenance
13. Torque packing nut to: 140+/- 10 in-lb (15+/-1 N-m)
ti8846a
NOTE: When pump packings begin to leak, tighten
packing nut down until leakage stops or lessens. This
allows approximately 100 gallons of additional operation
before repacking is required.
Hydraulic Motor Rebuild
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 (54.2 N.m).
5. Slowly pull engine starter rope until pump rod pin
hole is aligned with hydraulic rod hole. Push pin into
hole. Push retaining spring into groove.
6. Start engine and operate pump for 30 seconds.
Turn engine OFF. Check hydraulic oil level and fill
with Airlessco hydraulic oil.
17
Removal
1. Relieve Pressure, page 6.
2. Place drip pan or rags under sprayer to catch
hydraulic oil that leaks out during repair.
3. Flush the material you are spraying out of the
machine.
4. Remove the front cover.
5. Remove the suction tube and paint hose (remove at
swivel end).
6. Push retaining ring up; push out pin.
7. Remove hydraulic lines from fittings at top left and
right side of hydraulic motor.
8. Loosen jam nut.
9. Unscrew and remove hydraulic motor cap.
10. Slide piston rod/hydraulic motor cap assembly (A)
from hydraulic motor cylinder.
6
A
9
ti8818a
18 3A1188C
Troubleshooting
Problem Cause Solution
Troubleshooting
General
Gas engine pulls hard (won’t
start)
Gas engine does not start Switch OFF, low oil, no gaso-
Gas engine doesn’t work
properly
Gas engine operates, but displacement pump doesn’t
operate
Hydraulic pressure is too high Turn hydraulic pressure knob counter clock-
line
Faulty engine, Elevation Consult engine manual, supplied
Hydraulic pump valve is OFF Set hydraulic pump valve ON
Pressure setting too low Increase pressure
Displacement pump outlet filter
(if used) is dirty or clogged
Tip or tip filter (if used) is
clogged
Hydraulic fluid too low Shut off sprayer. Add fluid*.
Belt worn, broken, or off Replace belt
Hydraulic pump not working or
damaged
Dried paint seized paint pump
rod
Hydraulic motor not shifting Set pump valve OFF. Turn pressure down.
wise to lowest setting.
Consult engine manual, supplied
Clean the filter
Remove tip and/or filter and clean
Bring sprayer to Airlessco distributor for
repair.
Service pump
Turn engine OFF. Pry rod up or down until
hydraulic motor shifts.
Displacement pump operates,
but output is low on upstroke
Displacement pump operates
but output is low on downstroke and/or on both strokes
Paint leaks and runs over side
of wet-cup
3A1188C 19
Piston ball check not seating
properly
Piston packings worn or damaged
Piston packings worn or damaged
Intake valve ball check not
seating
Suction tube air leak
Loosen wet-cup Tighten wet-cup enough to stop leakage
Throat packings worn or damaged
Service piston ball check.
Replace packings. See Packing Replace-
ment Procedure, page 16.
Tighten packing nut or replace packings. See
Packing Replacement Procedure, page 16.
Service intake valve ball check.
Replace packings. See Packing Replace-
ment Procedure, page 16.
Troubleshooting
Problem Cause Solution
Excessive leakage around
hydraulic motor piston rod
Piston rod seal worn or damaged
Replace these parts
wiper
Fluid delivery is low Pressure setting too low Increase pressure
Displacement pump outlet filter
Clean filter
(if used) is dirty or clogged
Intake line to pump inlet is not
Tighten
tight
Hydraulic motor is worn or
Bring sprayer to Airlessco distributor for repair
damaged
The sprayer overheats Paint buildup on hydraulic com-
Clean
ponents
Spitting from gun Air in fluid pump or hose Check for loose connections on siphon
assembly, tighten, then reprime pump
Loose intake suction Tighten
Fluid supply is low or empty Refill supply container
Excessive Hydraulic pump
Low hydraulic fluid level Turn sprayer OFF. Add fluid.*
noise
*Check hydraulic fluid level often. Do not allow it to become too low. Use only Airlessco approved hydraulic fluid.
20 3A1188C
Parts
Pump (24E350)
22
20
21
14
12121212
24
10
1313
13
Parts
Qty
Ref. Part Description
.
1+ 16C204 CYLINDER, PUMP 1
2 244975 SLEEVE, CYLINDER 1
3 15A303 HOUSING, INTAKE 1
4+ 193395 SEAT, CARBIDE 1
5+ 107098 PACKING, O-RING 1
6+ 107167 BALL, SST 1
7+ 198505 GUIDE, BALL 1
1
8+ 108822 PACKING, O-RING 2
9+ 160325 PACKING, O-RING 1
10+ 24E352 ROD, PISTON 1
11+ 189585 GLAND, PACKING, MALE 1
12+ 198701 PACKING, VEE 8
13+ 198718 PACKING, VEE 6
14+ 15G657 GLAND, FEMALE 1
15+ 189588 GLAND, PACKING, FEMALE 1
16+ 119636 WIPER, PISTON 1
18 249177 VALVE,PISTION 1
19+ 107203 BALL, VALVE, CHECK 1
20 15J792 NUT, PACKING 1
9
21+ 157195 PACKING, O-RING, BUNA-N 1
22+ 112590 PLUG, THROAT SEAL 1
23+ 15F183 WASHER, BACKUP 1
24+ 15G658 GLAND, MALE 1
25+ 233698 SPRING, INTAKE BALL 1
12121212
15
16
23
19
18
11
131313
25
88
7
6
4
5
3
+ Included in Packing Repair Kit 24E351
ti21337a
2
3A1188C 21
Parts
Hydraulic Pump and Reservoir (866205)
137
127
153
139
156
161
128
121
89
123
122
122
87
138
124
140
142
148
151
152
129
132
146
146
133
134
157
117
116
141
162162
160
159
158
ti16103b
115
119
147
144
143
114
113
145
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.
22 3A1188C
Parts
Ref. Part Description
Qty
. Ref. Part Description
Qty
87 867311 FITTING,NIPPLE, HX 3/8 X 3/8 1 141 867039 BAFFLE,PLATE 1
89 867017 SWIVEL, 3/8 x 38 NPT M 1 143 866027 BAFFLE,SEAL 1
113 867657 TANK, BOTTOM 1 142 867040 BAFFLE,CLAMP 1
114 119074 GASKET 1 143 866027 BAFFLE,SEAL 1
115 867656 TANK TOP 1 144 866701 SCREW,FL HEX,1/4-20 x .375 3
116 100214 WASHER,LOCK 12 145 189505 PLUG,TANK 1
117 113467 SCREW,CAP,SOCKET HD 12 146 867386 O-RING,2-215 2
119 867226 FITTING,3/8-18 x 3/4-16 1 147 866296 TUBE,PUMP INLET 1
121 867062 VALVE,BALL 3/8” 1 148 866236 NUT,HEX 1
122 116807 SCREW,MACH,PAN HD, 2 151 867644 STRAINER,SUCTION 1
123 867411 PLATE 1 152 867347 O-RING 1
124 866202 TUBE,HYD PRESSURE 1 153 866121 FILLER,BREATHER CAP 1
127 119070 FITTNG,3/4-16 x 1/4-18 1 156 101962 SCREW,SET,SCH 1/4-20 2
128 867654 FITTING,SWIVEL 3/4-16 JIC 1 157 136235 NUT, 7/16-20 1
129* 866279 CONTROL,PRESSURE 1 158 867093 BRACKET,PUMP 1
132* 867700 WASHER,PLAIN 1 159 111800 SCREW,CAP, HEX HD 2
133* 867288 PUMP,HYDRAULIC 1 160 116645 SCREW,CAP, HEX HD 1
134 866201 TUBE,HYDR.BYPASS 1 161 867442 PULLEY,ASSEMBLY 1
137 867218 FILTER,OIL 1 162 867587 SCREW,SET, 4/16-18 x .625 2
138 866129 FITTING,1 3/8-12 UNF 2A 1
139 119093 TUBE,OIL FILTER 1
140 136134 RIVET,POP,3/16 4
.
* 866204 Pump Assembly Includes 129, 132, 133
3A1188C 23
Parts
Hydraulic Motor
172
62
250
249
188
189
173
177
176
175
183
197
171
181
186
168
172
196
178
61
184
185
180
198
179
Ref. Part Description
18
23
38
39
Qty
. Ref. Part Description
248
ti16105b
Qty
18 136217 NUT,JAM,NY-LOC,1/4-20 1 180*+ 117283 PACKING,O-RING 1
23 140047 WASHER,.686x.341 1 181*+ 155685 PACKING,O-RING 1
38 15F911 GUARD,PUMP ROD 1 183* 288755 TRIP ROD/PISTON 1
39 305088 SCRW, SC HD,1/4-20 x2.00 1 184* 15A726 NUT,JAM 1
61 867284 HOSE,HYDR PRESSURE 1 185* 248991 SLEEVE,HYDR. CYLINDER 1
62 867285 HOSE,HYD RETURN (includes 180)
168*+ 100139 PLUG,PIPE 1 186*+ 178179 WASHERIN,SEALING 1
171*+ 106276 SCRE,CAP,HEX HEAD 1 188*+ 178207 BEARING,PISTON 1
172* 117607 FITTING, ELBOW 1 189*+ 178226 SEAL,PISTON 1
173*+ 108014 PACKING,O-RING 2 196* 15E596 TUBE,HYDR. SUPPLY 1
175* 117739 WIPER,ROD 1 198* 15E243 MANIFOLD,ADAPTER 1
176* 112342 BEARING,ROD 1 248 193394 NUT,RETAINER 1
177* 112561 PACKING,BLOCK 1 249 116551 RING,RETAINING 1
178* 117609 FITTING,TEE,BRANCH 1 250 197443 PIN 1
179* 15B564 SCREW,CAP 4
* Included in 24E360 Hydraulic Motor Kit
+Included in 288755 Trip Rod/Pistion Repair Kit
.
24 3A1188C
Manifold Filter (866123)
237
234
235
87
236
239
238
Parts
Qty
Ref. Part Description
87 867311 FITTING,NIPPLE HX 3/8 x 3/8 1
91 867420 PLUG, 3/8 NPT 1
234 867377 O-RING,2-125 1
235 867077 BASE,FILTER 1
236 867145 COVER,FILTER 1
237 867647 SUPPORT,FILTER ELEMENT 1
238 867214 FILTER,ELEMENT 1
239 301356 SPRING 1
.
91
ti16104b
Kit,Siphon, 30-55 Gallon (289669)
241
240
245
246
248
244
243
Qty
Ref. Part Description
240 107098 PACKING, O-RING 1
241 108822 PACKING, O-RING 2
242 189920 STRAINER 1
243 15B746 HOSE, DRAIN 1
244 196723 CLIP, SPRING 1
245 198219 HOUSING, INTAKE 1
246 241269 TUBE, SUCTION, 30 GAL 1
247 241920 DEFLECTOR, THREADED 1
248 STRAP, TIE 2
.
247
242
ti21390a
3A1188C 25
Parts
Frame Assembly
81
35
36
36
ti16106b
33
34
16
13
14
15
17
17
17
17
13
13
18
19
20
15
13
12
16
16
21
3
7
21
25
24
8
64
22
19
54
55
56
18
63
53
52
31
17
1
5
6
4
9
10
18
23
11
20
17
1717
2
3
75
30
82
15
13
12
26 3A1188C
Parts
Ref. Part Description
Qty
. Ref. Part Description
Qty
1 867262 HANDLE 1 21 867501 SCREW,PH FL HD,1/4-20 x 1.0 3
2 867605 BUTTON,SNAP .25 2 22 100527 WASHER,PLAIN 2
3 866156 GUIDE 2 23 140047 WASHER 2
4 866344 SLIDE 2 24 866370 SPACER 1
5 331222 PIN,ROLL,.125 x 1.000 4 25 C19209 WASHER,LOCK 1
6 866050 CAP 2 30 867086 COVER,BELT ASSY 1
7 FRAME 1 31 866321 HOSE,RUBBER, 3” 1
867236 HSS9000 33 866780 FRAME,SWING ARM 1
189507 HSS1000 1 34 866262 PIN,LOCK PIVOT 1
8 301170 AXLE 2 35 867292 LOCK,LATCH 1
9 866356 SPACER 2 36 113983 RING,RETAINING,EXT 2
10 301165 WHEEL,PNEUMATIC 2 52 867305 SUPPORT,MOTOR 1
11 143029 COLLAR,SCREW,SET 2 53 867517 SCREW,HEX HEAD 3/8-16 x 3.5 2
12 867519 SCERW,HEX HEAD 4 54 140034 WASHER,.820x.411x.062 4
13 867707 WASHER,.39 x .625 1 55 100133 WASHER,LOCK,3/8 4
14 866353 SPACER 2 56 100307 NUT,HEX 4
15 866412 TUBE, 3.50” LG 2 63 136131 CHAIN,SASH,#8 x 7” 1
16 101566 NUT,LOCK 4 64 136133 RING,RETAINING 1
17 111841 WASHER,PLAIN 5/8 5 75 342404 LABEL,BELT GUARD WARNING 1
18 136217 NUT,JAM NY-LOCK,1/4-20 4 81 LABEL,FRONT 1
19 867098 BUMPER,W/WASHEr 3 16F590 HSS9000
20 119049 SCREW, HS HC 1/4-20 x 1.875 3 16F592 HSS11000
.
(Swing Arm KIT 866880 includes hydraulic moter, paint
pump, and swing arm frame.)
Additional warning labels are available at no cost
3A1188C 27
Parts
Sprayer Assembly
28
84
29
86
27
26
40
42
78
74
41
54
55
56
60
57
58
59
251
90
92
88
89
105
107
ti16107b
106
85
Ref. Part Description
Qty
. Ref. Part Description
Qty
26 331342 SCREW,PH PN HD 2 60 867155 COVER,PUMP 1
27 301522 SPRING,CLIP 1 74 342402 LABEL,WARNING 1
28 116969 NUT,LOCK 1 78 342588 LABEL,HYD VALVE CONTROL 1
29 866085 CUP 1 84 342445 LABEL,CAUTION 1
40 865719 PRIME VALVE 1 85 248217 DRAIN HOSE (includes 86) 1
41 116504 FITTING,TEE 1 86 241920 DEFLECTOR 1
42 804582 GAUGE,PRESSURE 1 88 866123 FILTER,ASSY 1
(Models 16M530, 16M614,
89 867017 SWIVEL,3/8x3/8NPT 1
16M615, 865903)
54 140034 WASHER,.820x.411x.062 4 90 557391 PLUG,1/4 NPTF 1
55 100133 WASHER,LOCK,3/8 4 92 198542 CLIP,SPRING 1
56 100307 NUT,HEX 4 105 24F690 GUN,MASTIC (Models 24F577,24F578)
57 100004 SCREW,CAP,HEX HD 2 106 255439 HOSE,1/4”x3” (Models 24F577,24F578) 1
58 331184 SPACER 2 107 HSE3850 HOSE,3/8” x 50’
(Models 24F577,24F578)
59 113783 SCREW,MACHINE,PN HD 4 251 189920 STRAINER 1
Additional warning labels are available at no cost.
.
1
28 3A1188C
Power Unit - HSS 9000
72
Parts
66
68
69
67
Qty
Ref. Part Description
22 100527 WASHER,PLAIN 4
65 867299 FRAME,LIFTING HANDLE 1
66 116080 ENGINE,GAS,HONDA 1
67 867441 PULLEY 1
68 866212 KEY,SQUARE 1
69 555516 SCREW,SOC,5/16-18x.31 1
70 110837 SCREW,FLANGE,HEX 4
71 110838 NUT,LOCK 4
72 189524 BELT,V 1
70
65
22
71
ti16108b
.
3A1188C 29
Parts
Power Unit - HSS 11000
72
67
66
65
68
54
Qty
Ref. Part Description
22 100527 WASHER,PLAIN 4
54 140034 WASHER,.820x.411x.062 4
55 100133 WASHER,LOCK,3/8 4
56 100307 NUT,HEX 4
65 867299 FRAME,LIFTING HANDLE 1
66 803900 ENGINE,GAS,HONDA 1
67 867441 PULLEY 1
68 100454 SCREW,CAP,HEX HD 4
69 866358 SPACER 4
70 110837 SCREW,FLANGE,HEX 4
71 110838 NUT,LOCK 4
70
22
71
69
54
55
56
ti16109b
.
30 3A1188C
Technical Data
Technical Data
Airless Paint Sprayer
US Metric
Maximum working pressure 3300 psi 22.8 MPa, 228 bar
Honda GX200 Engine 6.5 Horsepower
Honda GX270 Engine 9.0 Horespower
Maximum delivery 2.76 gpm 10.2 lpm
Maximum tip size 0.052
Fluid outlet npsm 3/8 in.
Weight
HSS9000 140 lb 63.5 kg
HSS11000 232 lb 105.2 kg
Noise Level (measured at maximum load conditions)
Sound Power 110 dBa
Sound Pressure 96 dBa
Wetted Parts zinc and nickel-plated carbon steel, nylon, stainless
steel, PTFE, acetal, leather, UHMWPE, aluminum, tung-
sten carbide
3A1188C 31
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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Airlessco’s
written recommendations.
This warranty does not cover, and Airlessco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Airlessco component parts. Nor shall Airlessco be liable for malfunction, damage or wear caused by the incompatibility of Airlessco
equipment with structures, accessories, equipment or materials not supplied by Airlessco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Airlessco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Airlessco distributor for verification
of the claimed defect. If the claimed defect is verified, Airlessco will repair or replace free of charge any defective parts. The equipment will be
returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship,
repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Airlessco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
AIRLESSCO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY Airlessco. These items sold, but not manufactured by Airlessco (such as electric motors, switches, hose, etc.), are subject
to the warranty, if any, of their manufacturer. Airlessco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Airlessco be liable for indirect, incidental, special or consequential damages resulting from Airlessco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of
warranty, the negligence of Airlessco, or otherwise.
FOR AIRLESSCO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
TO PLACE AN ORDER OR FOR SERVICE, contact your Airlessco distributor,
or call 1–800–223-8213 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Airlessco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents
Original Instructions. This manual contains English. MM 3A1188
Airlessco, 3501 N. 4th Avenue, Sioux Falls, SD 57104
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.airlessco.com
Revised January 2014
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