AIRLESSCO LP500 User Manual
Operation/Repair/Parts
LP 400/500/600/700
Mustang 5100/8100
3A1185H
Airless Paint Sprayer
For application of architectural paints and coatings. For professional use only. Not
approved for use in European explosive atmosphere locations.
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
For model information, see page 2.
Related Manuals
Gun Manual
312363 - English
312364 - Spanish
312365 - French
EN
Models
Models
ti16112a
ti16111a
Vac HiBoy Stand LoBoy
120V
North America
240V
Europe
110V
UK
230V
Australia
230V Asia 17M002 LP600 - Series A 17M000 LP400 - Series A
230V CN 17M005 LP600 - Series A 17M003 LP400 - Series A
24F568 LP500 - Series B
24F571 LP600 - Series B
24F581 Mustang 5100 - Series B
24F583 Mustang 8100 - Series B
16M373 LP500 - Series A
16M374 LP600 - Series A
16M375 LP700 - Series A
16M380 LP500 - Series A
16M381 LP600 - Series A
16M382 LP700 - Series A
16M393 LP600 - Series A 16M389 LP400 - Series B
24F567 LP500 - Series C
24F579 Mustang 5100 - Series C
16M371 LP400 - Series A
16M372 LP500 - Series A
16M378 LP400 - Series A
16M379 LP500 - Series A
16M390 LP500 - Series B
17M001 LP500 - Series A
17M004 LP500 - Series A
ti16113a
24F569 LP500 - Series C
24F570 LP600 - Series C
16M391 LP500 - Series B
16M392 LP600 - Series B
2 3A1185H
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 or warning labels, 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
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that
is properly installed and grounded in accordance with all local codes and ordinances.
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either
flat blade terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a
qualified electrician.
• This product is for use on a nominal 120V or 230V circuit and has a grounding plug similar to the plug
illustrated in the figure below.
120V US
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
Extension Cords:
• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that
accepts the plug on the product.
• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG
(2.5 mm
• An undersized cord results in a drop in line voltage and loss of power and overheating.
2
) minimum to carry the current that the product draws.
230V
3A1185H 3
Warnings
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:
• Do not spray flammable or combustible materials near an open flame or sources of ignition such as
cigarettes, motors, and electrical equipment.
• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity
creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray
system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall
be properly grounded to protect against static discharge and sparks. Use Airlessco conductive or
grounded high-pressure airless paint sprayer hoses.
• Verify that all containers and collection systems are grounded to prevent static discharge.
• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.
• Do not use a paint or a solvent containing halogenated hydrocarbons.
• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump
assembly in a well ventilated area. Do not spray pump assembly.
• Do not smoke in the spray area.
• Do not operate light switches, engines, or similar spark producing products in the spray area.
• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets
(MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents
manufacturer’s safety instructions.
• Fire extinguisher equipment shall be present and working.
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
4 3A1185H
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, page 8 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, page 8 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.
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, page 8 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.
3A1185H 5
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, page 8 and disconnect all power sources.
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.
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.
6 3A1185H
Component Identification
E
D
Component Identification
B
ti17301a
A
C
A Power switch Turns sprayer ON and OFF
B Pressure Control Knob Adjusts pressure. Turn clockwise to increase pressure and
counterclockwise to decrease pressure.
C Prime/Pressure Relief Valve Primes pump and relieves pressure from gun, hose and tip.
D Prime/Pressure Relief Valve Open
Position
E Prime/Pressure Relief Valve Closed
Position
Relieves pressure from gun, hose and tip and primes the unit
when in the open position. Valve is in open position when there
is a wider gap between valve handle and cam body.
Refer to Pressure Relief Procedure page 8.
Pressurizes system when closed. Valve is in closed position
when there is a slight gap between valve handle and cam body.
3A1185H 7
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.
Hold metal part of the gun in contact with
grounded metal pail. Use minimum pressure.
If the spray tip or hose is clogged, follow Steps 1
through 4 above. Expect paint to splash into the
bucket while relieving pressure during Step 3.
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
relieve pressure.
Setup
• To reduce the risk of static sparking, fire or
explosion which can result in serious bodily injury
and property damage. Always ground the sprayer
and system components and the object being
sprayed, as instructed in the safety warning
section of this manual.
• Ensure proper electrical service and amperage
and that the outlet is properly grounded.
• For generator power, a minimum 7000 watt
generator with a voltage regulation must be used.
ti15989a
4. Re-engage gun trigger lock and turn Prime/Pressure Relief Valve (PR Valve) to the open (priming)
position to relieve residual pressure.
Closed
(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.
(Priming and Pressure Relief)
Open
ti17403a
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.
Fill the Packing Nut/Wet Cup
1. Remove guard and cap.
2. Fill the Packing Nut/Wet Cup with 5 drops of Airlessco Throat Seal Oil (TSO) or Packing Seal fluid.
ti16049a
8 3A1185H
Operation
Flush the Sprayer
1. Flush the sprayer. See Flushing Procedure on
page 9.
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.
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.
instruction manual provided with gun for safety features and how to engage the trigger lock.
ti16028a
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.
High Pressure
ti16048a
5. Open the prime/pressure relief valve to the open “Priming Position”. This will allow an easy start.
Closed
(Pressure)
(Priming and Pressure Relief)
Open
Flushing
ti17403a
• 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.
1. Make sure the gun trigger lock is engaged and there
is no spray tip in the gun. Refer to the separate
3A1185H 9
6. Turn the engine ON/OFF switch to ON.
7. 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.
ti15989a
8. Disengage the gun trigger lock and squeeze the
trigger. At the same time, slowly turn the pressure
Operation
control knob clockwise, just enough to move liquid
at low pressure.
9. Allow the pump to operate until clean solvent comes
from the gun.
10. Release the trigger and engage the gun trigger lock.
11. 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/pressure relief valve in prime
(open) position and engage the gun trigger lock.
12. 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, page 11.
13. Whenever shutting down the sprayer, follow Pres-
sure Relief Procedure, page 8.
NOTICE
To prevent damage and freezing during storage,
never leave water in the fluid pump
Startup
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 8
When adjusting the pressure, turn the Pressure Control
Knob clockwise to increase pressure and counterclockwise to decrease pressure. Always use the lowest pressure necessary to completely atomize the material. If
more coverage is needed, use a larger tip rather than
increasing the pressure.
NOTE: 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 manufacturer’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.
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.
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.
NOTE: Check the spray pattern. The tip size and angle
determines the pattern width and flow rate.
10 3A1185H
Maintenance
Shutdown
1. Relieve Pressure, page 8.
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 9.
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.
• 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 Pump Armor or mineral
spirits. Shut off sprayer, Relieve Pressure, page 8, and
make sure prime/pressure relief valve is left open.
Electric Motor Maintenance
Lubrication
The motor is supplied with pre-lubricated ball bearings,
lubricated for the life of the bearing.
Motor Brushes
Motor brushes need periodic inspection and replacement as wear indicates. Standard brushes have an initial length of 1” and should be replaced when they are
worn to a length of 1/2”. Brush wear is greatly influenced
by individual application and it is recommended that
brush wear be checked at early intervals of operation in
order to determine future required inspection.
To change the brushes:
1. Unplug the machine.
2. Remove the cover over the motor, if applicable.
3. Open the two covers at the rear of the motor.
4. Disconnect the brush wire.
5. Pull out the wire.
6. Push the brush retainer clip in and withdraw.
7. Remove the worn brushes.
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.
Maintenance
Daily Maintenance
1. Keep the displacement pump packing nut/wet cup
lubricated with Airlessco TSO (Throat Seal Oil) at all
times. The TSO helps protect the rod and packings.
2. 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.
8. Install new brushes in the reverse order.
To increase brush life, new brushes (Part #331780)
need to have a run in period. After changing brushes,
set the machine for spraying. With a bucket of Pump
Conditioner and water, a 50’ 1/4” airless hose, airless
gun and tip on unit, open the prime/pressure relief valve
and switch on. The pump will now prime. With pump
running in the prime mode, turn the pressure control
knob to high pressure. (The pump has to cycle fast with
no pressure in the pump). Run the pump for 20 minutes
and the brushes will be run in.
Brush Kit
331780
ti16051a
3A1185H 11
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