AIRLESSCO TS1500 (24F573) B Series Use and care manual

3A1183C
EN
Operation/Repair/Parts
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
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Gun Manual 3A0413
ti17342a

Warnings
23A1183C
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
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 mm2) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.

Warnings
3A1183C 3
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:
• 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.

Warnings
43A1183C
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.
WARNINGWARNINGWARNING
WARNING

Warnings
3A1183C 5
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.
WARNINGWARNINGWARNING
WARNING

Component Identification
63A1183C
Component Identification
ti17939a
A
B
PRIME
PRESSURE
ti17343a
C
D
EF
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
Pressurizes system when closed.
E Prime/Pressure Relief Valve Open
Position
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

Operation
3A1183C 7
Operation
Setup
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. Fill the Packing Nut with 5 drops of ASM Packing
Seal Fluid.
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
• 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.
ti15987a
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.
• 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.

Operation
83A1183C
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.
4. Turn Pressure Control Knob to low.
5. Open the Prime/Pressure Relief Valve to the open -
“Priming Position”. This will allow an easy start.
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.
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.
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.
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/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.
ti16028a
ti17939a
HIGH PRESSURE
PRIME
PRESSURE
ti17402a
Closed
(Pressure)
Open
(Priming and
Pressure Relief)
ti15989a
NOTICE
To prevent damage and freezing during storage,
never leave water in the fluid pump

Operation
3A1183C 9
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.
NOTE: Operating the sprayer at higher pressure than
needed wastes material, causes early tip wear, and
shortens sprayer life.
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 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 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.
Optional Air Atomizer
• 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.
• 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
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.

Maintenance
10 3A1183C
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, damag-
ing 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 replace-
ment 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.
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, air-
less 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 con-
trol knob to high pressure. (The pump has to cycle fast
with no pressure in the pump). Run the pump for 20 min-
utes and the brushes will be run in.
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
ti15992a

Maintenance
3A1183C 11
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 hav-
ing 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 pres-
sure fluid line from the pump.
7. Using a 9/16” wrench, unscrew the two tie rod lock-
nuts.
8. Pull the pump off the tie rods.
ti16032a
6
ti16033a

Maintenance
12 3A1183C
Fluid Pump Reinstall
1. Loosen the packing nut and extend piston rod to
fully up position. Slip sleeve over the piston rod.
2. Insert one of the retaining rings through the packing
nut and rest the sleeve on top of it.
3. Connect the connecting rod with the fluid pump by
installing the coupling halves. Slide sleeve over the
coupling halves and secure with retaining rings.
4. Remove the retaining ring from the packing nut and
insert into coupling halves.
5. Secure the fluid pump housing to the tie rods and
screw locknuts with washers on loosely.
6. Tighten the tie rod locknuts evenly to 30 ft. lb.
NOTE: After all the rod locknuts are tight, the alignment
of both rods should allow easy assembly and disassem-
bly of the coupling. If any binding, loosen and retighten
all the rod locknuts to improve the alignment. Misalign-
ment causes premature wear of seal and packings.
7. Tighten packing nut clockwise until resistance
against the packings can be felt. Turn it one full turn
more.
8. Start the pump and operate it slowly (at low engine
speed) to check the piston rod for binding. Adjust tie
rod lock nuts if necessary to eliminate binding.
9. Prime the unit and run at maximum pressure for
several minutes, then release the pressure and
repeat step 6.
10. Fill the wet cup (packing nut) with five drops of TSO
(Throat Seal Oil).
ti15994a
ti15995a ti15996a
ti15997a
ti15998a

Maintenance
3A1183C 13
Service
Pressure Relief Procedure
1. Engage gun trigger lock.
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
4. Disengage gun trigger lock. Hold metal part of gun
against grounded metal pail and trigger gun into pail
to relieve pressure.
5. Engage gun trigger lock.
6. Open any fluid prime/pressure relief valves in sys-
tem. Leave prime/pressure relief valve open until
ready to dispense again.
Tools Needed
•Vise
• 12” adjustable open end wrench (2)
• Hammer, 20 oz maximum
• Small screwdriver
• Throat Seal Liquid
• Pick or long small screwdriver
Cleaning and Inspecting Parts
1. Clean and inspect parts. Pay particular attention to
the ball seats in the intake valve and piston, which
must have no nicks or wear, and the inside of the
sleeve and the outside of the piston rod, which must
not be worn or scratched. Replace worn or damage
parts.
2. Remove and clean the sleeve when you are repack-
ing the pump.
Repair When Pump is Off the Sprayer
Disassembling the pump
1. Remove packing nut (202) and throat adjustment
spacer (228).
The system pressure must be manually relieved to pre-
vent the system from starting or spraying accidentally.
To reduce the risk of an injury from accidental spray
from the gun, splashing fluid or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system equipment
• or install or clean the spray nozzle
• Never use sharp or pointed tools to remove sleeve
or other components which could result in pump
rupture and cause serious bodily injury. If the
sleeve cannot be removed easily, return the sleeve
and cylinder to your Graco/Airlessco distributor for
removal.
228
202
7568a

Maintenance
14 3A1183C
2. Unscrew intake valve from cylinder.
3. Disassemble intake valve. Clean and inspect. O-ring
(227) may require a pick for removal.
4. Tap piston rod out of cylinder with a hammer or flip
over and tap piston rod against a bench.
NOTE: Sleeve may come out of cylinder with piston rod.
5. Remove piston rod from sleeve, or remove sleeve
from cylinder.
6. Unscrew piston valve from piston rod. Clean and
inspect parts. The piston has a special thread lock-
ing/sealing patch. Do not remove the patch. The
patch allows for disassembly/assembly procedures
before it is necessary to apply Loctite®to the
threads.
7. Remove packings and glands from piston rod.
7569a
227
7570f
7571a
7572a
7576a
ti3940b

Maintenance
3A1183C 15
8. Remove throat packings and glands from cylinder.
Discard throat packings and glands.
Assembling the pump
1. Soak all leather packings in SAE 30W oil for 1 hour
minimum prior to assembly. Stack male gland (204)
on piston rod. Alternately stack UHMWPE (208) and
leather (218) packings (note orientation) and
backup washer (229) on piston valve (210). The
special sealing patch on piston valve threads is
good for four repackings. Use Loctite®on piston
valve threads after four repackings.
2. Install ball (206) in piston rod. If Loctite®is applied
to piston valve threads, ensure that none gets on
ball.
3. Tighten piston valve to piston rod as specified.
4. Soak all leather packings in SAE 30W oil for 1 hour
minimum prior to assembly. Place male gland (204)
in cylinder. Alternately stack (UHMWPE (203) and
75736b
210
229
216
217
208
204218
7574d
7575a
206
7576a

Maintenance
16 3A1183C
leather packings (223) (note orientation). Place
female gland (224) in top of cylinder. Seat packings.
5. Install seal (201) into packing nut (202), Install
throat adjustment spacer (228) onto packing nut.
Loosely install packing nut into cylinder.
6. Grease piston packings.
7. Slide piston assembly into bottom of sleeve.
8. Grease top inch or two of piston rod that will go
through the cylinder throat packings.
9. Grease O-rings (221) and place on sleeve. Slide
sleeve/piston rod assembly into bottom of cylinder.
Replace O-ring (207) if desired.
NOTE: O-ring (207) is not required for safe pump opera-
tion.
203
224
223
204
7573f
7581a
201
202
228
7578c
NOTICE
Do not slide piston assembly into top of sleeve as
this may damage piston packing.
7577a
7579a
207
221
7582a

Maintenance
3A1183C 17
10. Reassemble intake valve with new O-ring (227),
seat (212) and ball (214), Seat may be flipped over
and used on other side. Clean seat thoroughly.
11. Install intake valve on cylinder. If a wrench is used
torque as follows:
• 80 +/-5-ft-lb
If a wrench is not used, be sure intake valve is bottomed
out against cylinder.
12. Torque packing nut (202) down onto adjustment
spacer (228) 100 +/-10 in-lb.
Remove throat adjustment spacer (228) when pump
packings begin to leak after much use. Then tighten
packing nut down until leakage stops or lessens. This
allows approximately 100 gallons of additional operation
before a repacking is required.
Replacement of Electrical
Components
Pressure Control Assembly (Electrical
Control Board)
1. Unplug machine’s power cord.
2. Remove screws and lower the pressure control
assembly.
3. Disconnect all leads from pressure control assem-
bly.
4. Reassemble in reverse order.
Sensor
1. Remove the screws and lower the pressure control
assembly.
2. Disconnect sensor lead from the board.
3. Unscrew sensor from pressure control assembly
using a 3/4” wrench.
4. Reassemble in reverse order. Use PTFE tape on the
sensor threads prior to reinstalling it into the pres-
sure control assembly.
Potentiometer
1. Lower pressure control assembly as described
above.
2. Disconnect potentiometer lead from pressure con-
trol assembly.
3. Use a 1/16” allen wrench, loosen set screw in the
poteniometer knob and remove knob and spacer.
4. Using a 1/2” wrench or deep socket, remove the nut
from the potentiometer shaft assembly.
5. Pull entire potentiometer assembly out of the frame.
6. Replace in reverse order.
214
212
227
7570f
7569a
202
228
7568a
Always unplug the electrical cord before servicing the
machine.

Maintenance
18 3A1183C
On-Off Toggle Switch
1. Lower the pressure control assembly as described
above.
2. Disconnect the two wires on the toggle switch.
3. Use a 9/16” wrench to loosen the nut on the toggle
switch shaft.
4. Reassemble in reverse order.
Liquid Crystal Display (LCD)
1. Ensure the power switch is OFF and the machine is
unplugged.
2. Detach the pressure control assembly from the
frame by unscrewing the two screws.
3. Disconnect the LCD lead from the pressure control
assembly.
4. Separate the LCD assembly from the frame by
undoing the eight screws.
5. Disassemble LCD from the control by removing the
retaining screws.
6. Remove and replace LCD Display.
7. Reassemble in reverse order.
NOTE: Do not over tighten the screw and nuts. This can
warp the LCD and damage it.
ti17332a

Troubleshooting
3A1183C 19
Troubleshooting
General
Problem Cause Solution
Unit doesn’t prime Airleak due to loose suction nut Tighten suction nut.
Airleak due to worn o-rings Replace o-ring on suction seat and o-ring
below suction seat.
Stuck or fouled balls Service inlet and outlet valves.
Prime/Pressure Relief valve not
opening
Clean or replace Prime/Pressure Relief Valve
Unit primes but has poor or no
pressure
Pressure set too low Turn up pressure.
Filter(s) are clogged Clean or replace gun filter, inlet filter, and/or
manifold filter.
Outlet valve fouled/worn. Service outlet valve.
Prime/pressure relief valve
bypassing
Clean or replace Prime/Pressure Relief Valve
Packings and/or piston worn Tighten packing nut, repack unit.
Unit does not maintain good
spraying pressure
Blown spray tip Replace spray tip.
Packings and/or pistons worn Repack unit.
Upper seat worn Replace upper seat.
Unit does not run See Machine Does Not Start
Machine does not start Control Settings Make sure machine is plugged into the wall.
Verify the on-off switch is in the ON position
and the pressure control knob is turned all the
way to the right (clockwise for maximum pres-
sure).
Pressure Control Assembly
(Board)
If the power indicating light is still out after
checking the control settings and power
source, replace the pressure control assem-
bly.

Troubleshooting
20 3A1183C
Motor Remove the motor brush covers and turn the
machine ON. Set the potentiometer (POT) at
maximum pressure and check for DC voltage
across both brush terminals. It should read
greater than 80 volts DC.
If you have DC voltage, turn the machine off
and unplug it from the wall. Check to make
sure the brushes are making good contact
with the armature. Replace the brushes if they
are less than 5/8” long. If the brushes are
good, replace the motor.
If you do not have DC voltage, see Sensor.
Sensor Plug another sensor board into the board and
perform the zero calibration procedure. If the
machine starts to run, the sensor is bad. If
there is no replacement sensor available, use
a multi-meter to test the resistance across the
red and black wires of the sensor (be sure to
test the plug). You should read 1.5 - 3.5k
ohms. A faulty sensor usually reads no conti-
nuity (open).
If the sensor passes all the tests, see Pres-
sure Control Knob (Potentiometer).
Pressure Control Knob (Poten-
tiometer)
Plug another potentiometer (POT) into the
control board. If the machine starts, the old
POT is bad.
When a replacement POT is not available,
remove the POT lead (with the machine
turned off) from the control board and test the
resistance between the red and black wires
(be sure to test at the plug). The resistance
should read between 8-12k ohms. If it is out-
side of this range replace the POT.
If there is DC voltage at the motor brushes
and the sensor and pressure control knob are
functioning, replace the pressure control
assembly.
Problem Cause Solution