AIRLESSCO TS1500 User Manual

Operation/Repair/Parts

3A1183D

Airless Paint Sprayer

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

Airlessco - TS1500 (24F573) Series B

3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

Related Manuals

Gun Manual 3A0413

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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

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 circuit and has a grounding plug similar to the plug illustrated in the figure below.

• 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.

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) minimum to carry the current that the product draws.

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 Graco 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.

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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.

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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.

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.

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Component Identification

PRIME

PRESSURE

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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 Closed

Position

E Prime/Pressure Relief Valve Open

Position

Pressurizes system when closed.

Relieves pressure from gun, hose and tip and primes the unit when in the open position. Refer to Pressure Relief Procedure page 13

F Heatsink

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Operation

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 electrical service is 120 VAC, 20 amp minimum and the outlet is properly grounded.

• For generator power, a minimum 7000 watt generator with a voltage regulation must be used.

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

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.

Flushing

1. Fill the Packing Nut with 5 drops of ASM Packing Seal Fluid.

• 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.

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1. Make sure the gun trigger lock in engaged and there is no spray tip in the gun. Refer to the separate

Flush the Sprayer

1. Flush the sprayer. See Flushing Procedure on page 7.

3A1183D 7

Operation

instruction manual provided with gun for safety features and how to engage the trigger lock.

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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.

PRIME

HIGH PRESSURE

8. Allow the pump to operate until clean solvent comes from the gun.

9. Release the trigger and engage the gun trigger lock.

10. 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.

11. 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.

12. Whenever shutting down the sprayer, follow Pres- sure Relief Procedure, page 13.

NOTICE

To prevent damage and freezing during storage, never leave water in the fluid pump

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PRESSURE

5. Open the Prime/Pressure Relief Valve to the open “Priming Position”. This will allow an easy start.

Open

(Priming and

Pressure Relief)

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Closed

(Pressure)

6. 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.

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7. 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.

Startup

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/Pressure Relief Valve must be “OPEN”

in the priming 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/Pres-

sure Relief 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.

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Operation

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 13

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.

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 13, and make sure prime/pressure relief 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.

NOTE: Check the spray pattern. The tip size and angle

determines the pattern width and flow rate.

Shutdown

1. Relieve Pressure, page 13.

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.

Optional Air Atomizer

NOTICE

Atomizer must be cleaned after each use, any debris will cause poor spray performance.

To eliminate the back flow of material into the air system, always turn the air on first.

• For best performance use at least a minimum of 1 gallon per minute paint sprayer.

• For fog finish and fine orange peel use tip #13 or 16 and apply maximum air flow.

• For medium orange peel and splatter coat, use tip #14 or 17 and apply medium air flow.

• For heavy splatter coat and knockdown finish use tip #15 or 17 and apply less air flow.

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Maintenance

Regular Maintenance

1. Always stop the pump at the bottom of its stroke when you take a break or at the end of the day. This helps keep material from drying on the rod, damaging the packings.

2. Keep displacement pump packing nut/wet cup 1/3 full of Airlessco Throat Seal Oil at all times. The TSO helps protect the packings and rod.

3. Lubricate Connecting Rod Pin every 3 months.

Daily Maintenance

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.

Oil and Lubrication Instructions

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. Brushes have an initial length of 1 and 1/4” and should be replaced when they are worn to a length of 5/8”. 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.

3. Open the two covers at the rear of the motor.

Sealed Bearing

Oil impregnated sleeve - dip in hot 10W oil when removed

Fill plug- unit has grease in gearbox from factory and will not require changing. (Grease - PN

301178)

Bleed (Weep Hole)

1 oz. SAE 30W Oil

semi-annually

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4. Loosen the screw under the brush.

5. Pull out the wire.

6. Push the brush retainer clip in and withdraw.

7. Remove the worn brushes.

8. Install new brushes in the reverse order.

To increase brush life, new brushes (Part #301146 for 110 volt) 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.

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Maintenance

Replacement of Belt/Belt Adjustment

NOTE: The Cog Belt System does not require align-

ment. When upper sheave is placed on motor shaft it is pushed on until a positive stop is reached. The set screws are then loctited. The lower pulley is placed on gearbox and held in place with keyway and snap ring. The flange on upper sheave holds the belt in alignment and the belt self aligns on lower pulley eliminating having to align.

1. Remove cover from unit.

2. Remove tensioner Assembly. Loosen screws. Move gearbox forward to allow removal and replacement of belt.

3. Retighten screws into gearbox until they bottom out. This will align gearbox correctly.

4. Replace tensioner with bolts and leave loose to allow adjusting belt tension.

5. Tighten belt. When properly tightened the deflection play should be 1/4 inch when pushing hard with thumb. (20 ft/lbs)

NOTE: When placing belt on pulleys and inserting the tensioner against belt, ensure cogs on belt are engaged into cogs on pulleys before tightening belts. Rotating upper pulley while holding the tensioner against the belt will allow proper engagement of cogs prior to tightening.

Servicing the Fluid Pump

NOTE: Before disassembling the sprayer refer to Trou-

bleshooting to try and resolve the problem.

Fluid Pump Disconnect

1. Flush out the material you are spraying, if possible.

2. Relieve Pressure, page 13. Stop the pump in the middle of down stroke.

3. Remove the suction tube and fluid hose (if so equipped) from the fluid pump.

4. Remove the connecting rod shield from the pump.

5. Remove two retaining rings (6), slip the sleeve of the coupling down, and remove both coupling halves. This will disconnect fluid pump from the connecting rod.

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.

8. Pull the pump off the tie rods.

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