ti2076 Operation, Repair, and Parts 309420L 2800 psi (193 bar, 19 MPa) Maximum Working Pressure* Model 233792, Series B * The best operating pressure is the lowest pressure that provides an even paint supply to the roller and typically does not exceed 300 psi (2.1 MPa, 21 bar). Also Includes: Combo Gun and Pressure Roller D 24 in. (61 cm) Maxipole Extension D 1/4 in. x 25 ft hose D 9 in. (23 cm) roller frame D 1/2 in. (13 mm) nap roller cover – For portable spray application of architectural paints and coatings – Use water based or mineral spirit–type material only. Do not use materials having flash points lower than 70_ (21_). For information about your material request MSDS from distributor or retailer. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.
Transcript
ti2076
Operation, Repair, and Parts 309420L
2800 psi (193 bar, 19 MPa) Maximum Working Pressure*Model 233792, Series B
* The best operating pressure is the lowest pressure that provides an even paint supply to the roller and typically does not exceed 300 psi (2.1 MPa, 21 bar).
Also Includes: Combo Gun and Pressure Roller
� 24 in. (61 cm) Maxipole Extension� 1/4 in. x 25 ft hose� 9 in. (23 cm) roller frame� 1/2 in. (13 mm) nap roller cover
– For portable spray application of architectural paints and coatings –
Use water based or mineral spirit–type materialonly. Do not use materials having flash pointslower than 70� (21�). For information aboutyour material request MSDS from distributor orretailer.
Important Safety InstructionsRead all warnings and instructions in thismanual. Save these instructions.
SpecificationsThis equipment is not intended for use with flammable or combustible materials used in places such ascabinet shops or other “factory” or fixed locations. If you intend to use this equipment in this type ofapplication, you must comply with NFPA 33 and OSHA requirements for the use of flammable andcombustible materials.
The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment.Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbolsappearing in the body of the manual refer to these general warnings. When these symbols appear throughout themanual, refer back to these pages for a description of the specific hazard.
WARNINGFIRE AND EXPLOSION HAZARDFlammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To helpprevent fire and explosion:
� Use equipment only in well ventilated area.
� Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plasticdrop clothes (potential static arc).
� Sprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing orcleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.
� Keep work area free of debris, including solvent, rags and gasoline.
� Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
� Ground equipment and conductive objects in work area. Read Grounding instructions.
� If there is static sparking or you feel a shock, stop operating immediately. Do not use equipmentuntil you identify and correct the problem.
� Keep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARDImproper 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 sprayer and extension cords.
� Do not expose to rain. Store indoors.
PRESSURIZED ALUMINUM PARTS HAZARDDo not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents orfluids containing such solvents in this equipment. Such use could result in a serious chemical reaction,with the possibility of explosion, which could cause death, serious injury and/or substantial propertydamage.
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WARNINGSKIN INJECTION HAZARDHigh pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look likejust a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
� Do not point gun at anyone or any part of the body.
� Do not put your hand over the spray tip.
� Do not stop or deflect leaks with your hand, body, glove, or rag.
� Engage trigger lock when not spraying.
� Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,checking or servicing equipment.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARDMisuse can cause death or serious injury.
� Do not exceed the maximum working pressure or temperature rating of the lowest rated systemcomponent. Read Technical Data in all equipment manuals.
� Use fluids and solvents that are compatible with equipment wetted parts. Read Technical Data inall equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete informationabout your material, request MSDS from distributor or retailer.
� Check equipment daily. Repair or replace worn or damaged parts immediately with genuine ASMreplacement parts only.
� Do not alter or modify equipment.
� Use equipment only for its intended purpose. Call your Graco distributor for information.
� Route hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces.
� Do not kink or over bend hoses or use hoses to pull equipment.
� Keep children and animals away from work area.
� Do not operate the unit when fatigued or under the influence of drugs or alcohol.
� Comply with all applicable safety regulations.
TOXIC FLUID HAZARDToxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, orswallowed.
� Read MSDS’s to know the specific hazards of the fluids you are using.
� Store hazardous fluid in approved containers and dispose of it according to all applicable guide-lines.
PERSONAL PROTECTIVE EQUIPMENTYou must wear appropriate protective equipment when operating, servicing, or when in the operatingarea of the equipment to help protect you from serious injury, including eye injury, inhalation of toxicfumes, burns, and hearing loss. This equipment includes, but is not limited to:
� Protective eye wear.
� Clothing and respirator as recommended by the fluid and solvent manufacturer.
� Gloves.
� Hearing protection.
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� The sprayer requires a 120V AC, 60 Hz, 15A circuitwith grounding receptacle. Never use an outlet that isnot grounded or an adapter.
� Do not use the sprayer if the electrical cord has a damagedground prong. Only use an extension cord with an undamaged,3–prong plug.
� Recommended extension cords for use with this sprayer:� 25 ft (7.6 m) 18 AWG� 50 ft (15.2 m) 16 AWG� 100 ft (30.5 m) 14 AWG� 150 ft. (45.7 m) 12 AWG
Smaller gauge or longer extension cords may reduce sprayerperformance.
Grounding and Electric Requirements
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� Ground sprayer gun through connection to aproperly grounded fluid hose and pump.
� Ground fluid supply container. Follow local code.
The sprayer must be grounded. Grounding reduces the risk of static andelectric shock by providing an escape wire for the electrical current due tostatic build up or in the event of a short circuit.
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Grounding and Electric Requirements
� Ground solvent pails used when flushing. Follow local code. Useonly conductive, metal pails, placed on a grounded surface such asconcrete. Do not place the pail on a non–conductive surface suchas paper or cardboard, which interrupts the grounding continuity.
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� Ground the metal pail by connecting a ground wire to thepail by clamping one end to pail and the other end toground such as as water pipe.
� Maintain grounding continuity when flushing orrelieving pressure by holding metal part of spray gunfirmly to side of a grounded metal pail, then trigger gun.
Thermal Overload
� Motor has a thermal overload switchto shut itself down if overheated.To reduce risk of injury from motor staring
unexpectedly when it cools, always turn powerswitch OFF if motor shuts down.
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1. Turn power switch OFF and unplug power cord.
2. Turn Spray–Prime/Drain valve to PRIME/DRAIN to relieve pressure.
Pressure Relief Procedure
3. Turn pressure to lowest setting. Hold metalpart of gun firmly to a grounded metal pail.Trigger gun to relieve pressure.
4. Engage trigger lock.
� Leave Spray–Prime/Drain valve in PRIME/DRAIN position until you are ready to sprayagain.
� If you suspect the spray tip is clogged orthat pressure has not been fully relievedafter following the above steps, VERYSLOWLY loosen tip guard retaining nut orhose end coupling to relieve pressuregradually. Then loosen completely. Clearhose or tip obstruction.
PRIME
PRIME
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Combo Gun
Power Switch
Pressure Control Knob
Component Identification
Suction Tube
Inlet Screen
Spray/Prime Valve
Prime/drain position
Paint position
Prime Tube
Pressure Roller
Fluid Outlet Fitting
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1. Turn power switch OFF.
2. Connect one end of grounded fluid hose toCombo Gun. Use a wrench to tighten.
Setup
3. Connect other end of hose to sprayerfluid outlet fitting. Use a wrench totighten.
4. Turn pressure control knob all the way left(counterclockwise) to minimum pressure.
NOTE: The Combo Gun can be usedas an airless spray gun for small jobsby attaching a Super Zip Base and tip.
For larger jobs the sprayer can beused for airless spraying by attachingan airless spray gun rated at 2800 psi(193 bar, 19 MPa) Maximum WorkingPressure or higher.
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1. Turn Spray/Prime valve to PRIME.
2. Separate prime tube (smaller) from suctiontube (larger).
Priming – Oil–based or Water–based Materials
3. Place prime tube in waste pail.
4. If spraying oil–based materials, submerge suc-tion tube in mineral spirits or compatible oil–based cleaning solution.
If spraying water–based materials, submergesuction tube in water.
primetube
suctiontube
WASTE
Mineral Spirits WATER
OR
PRIME
5. Plug sprayer into grounded outlet.
6. Point gun into waste pail.
WASTE
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Priming – Oil–based or Water–based Materials
7. Turn power switch ON.
8. Turn up pressure control knob untilpump starts.
30 to 60seconds WASTE
9. Allow fluid to flow out of prime tube, intowaste pail, for 30 to 60 seconds.
10. Turn power switch OFF.
11. Submerge suction tube in paint.
12. Turn power switch ON.
PAINT
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Priming – Oil–based or Water–based Materials
13. When paint starts to come out of primetube, pull and hold gun trigger, and turnSpray/Prime valve to SPRAY.
When paint comes out of gun, releasetrigger.
pull and hold trigger
paint
WASTE
Release trigger
SPRAY
primetube
suctiontube
14. Attach prime tube to suction tube
Pump Check Valves
Storing pump in water, inadequate flushing, oringested debris can cause either of the pump’stwo check valves to malfunction. If the pumpdoes not prime after 30 seconds, try to jar thecheck balls loose by tapping the inlet valve witha small wrench as the sprayer is on and running.
HINT: To determine if the inlet valve ball is sticking, unscrew inlet valve from pump and check it.
If sprayer continues to cycle (motor and pump run) after you release gun trigger, the pump valves may beobstructed or worn. If they are worn, Valve Repair Kits are available. Consult an authorized servicecenter.
tap here9564C
CAUTION: Excessive shock will fracture or causeother damage to the pump.
NOTE: Motor stopping indicates pump andhose are primed with paint.
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Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
1. Turn Spray/Prime valve to PRIME.
PRIME
2. Separate prime tube (smaller) from suctiontube (larger).
3. Place prime tube in waste pail.
4. Submerge suction tube in mineral spirits.
primetube
suctiontube
WASTE
Mineral Spirits
5. Plug sprayer into grounded outlet.
6. Point Gun into waste pail.
WASTE
NOTE: To spray water–based materials after spraying oil–based materials, follow the procedure outlined below,using water instead of mineral spirits to flush system.
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Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
7. Turn power switch ON.
8. Turn up pressure control knob untilpump starts.
30 to 60seconds WASTE
9. Allow fluid to flow out of prime tube, intowaste pail, for 30 to 60 seconds.
10. Turn power switch OFF.
11. Submerge suction tube in paint.
PAINT
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Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
12. Turn power switch ON.
13. When paint starts to come out of prime tube,pull and hold gun trigger, and turn Spray/Primevalve to SPRAY.
When paint comes out of gun, release trigger.
14. Attach prime tube to suction tube
pull and hold trigger
paint
WASTE
Release trigger
SPRAY
primetube
suctiontube
NOTE: Motor stopping indicates pump andhose are primed with paint.
NOTE: If pump does not prime after 30 seconds see Pump Check Valves, page 7
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1. Engage the Combo Gun safety latch.
Operation
NOTE: Trigger the Combo Gun briefly onlywhen you need more paint. Determine howoften you must trigger the gun to maintainan even paint supply to the roller.
2. Firmly tighten pressure roller to extension.
3. Attach pressure roller assembly to Combo Gun.
NOTE: To create a tight seal, you may need to usea wrench to tighten.
4. Turn pressure control knob to roller symbol.
5. Disengage Combo Gun safety latch. TriggerCombo Gun and roll the surface until paintcomes to roller.
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Operation
6. Increase pump pressure only if triggeringCombo Gun cannot supply enough paintfor your rolling speed.
7. Whenever you stop painting, relievepressure, page 7, and elevate rollerend of extension tube to preventpaint from draining out.
Flush the pump, Combo Gun andpressure roller immediately aftereach use to prevent paint from dryingin the pressure roller and damagingit. Cleanup page 20.
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Rolling Techniques
1. Rolling vertically, roll out the letter “M”.
2. Cross roll, horizontally, to spread the paint.
3. Finish with light vertical strokes until theentire area has been evenly covered.
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Ceilings, Woodwork and Walls
1. Ceilings: Using a paint brush, apply astarting row of paint approximately thewidth of your brush where the walls andceiling meet.
2. With the roller, apply paint to the ceiling,working the short way of the room andapplying as wide a strip as possible.
1. Woodwork & Walls: Using a brush, paintwoodwork first. Apply a starting row ofpaint approximately the width of the paintbrush around the woodwork and wherethe walls meet the ceiling.
2. With the roller, apply paint to the walls, follow-ing the Roller Techniques described on page18.
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Cleanup
1. Relieve the pressure. Turn power switch OFF,page 7.
2. Remove roller cover and diffuser from roller frameas follows:
a. Using your thumb, slide clip down and releaseend caps, diffuser, and roller cover into a pail.
b. Remove roller cover from diffuser.
Leave the roller assembly attached to Combo Gun for this procedure.
c. Pull end caps off diffuser.
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3. Clean roller cover, caps and diffuser with water or acompatible solvent for non–water–based materials.
4. Place roller frame in paint pail. Be sure the holes in theframe are facing inside the paint pail.
5. Place suction tube in bucket of water or compatible sol-vent for non–water–based materials. For flushing wa-ter–based materials, follow Zip Flush procedure, page16.
6. Turn pressure control knob to roller symbol.
Cleanup (continued)
Solvent
Paint
Solvent
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7. Turn power switch ON.
Cleanup (continued)
8. Trigger Combo Gun.
9. Turn Spray/Prime valve to SPRAY.
10. Continue to trigger Combo Gun until flushingfluid begins to dilute paint. Then release Combo Gun trigger.
11. Place roller frame in another bucket.
Flush until fluid coming out of roller frame is clear.
12. Relieve pressure, page 7. Turn power switchOFF.
Solvent
WARNING
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1. Relieve pressure, page 7. Turn power switch OFF.
2. Screw Zip Flush attachment onto garden hose.
3. Turn lever to close Zip Flush attachment.
garden hose
open closed
Zip Flush
close
WASTEinlet screen
Cleanup – Flushing After Spraying Water–based Paint
4. Unscrew inlet screen from suction tube and place inwaste pail.
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5. Connect garden hose to suction tube with Zip Flush at-tachment. Leave prime tube in waste pail.
6. Turn lever to open Zip Flush attachment. Turn on gar-den hose.
Zip Flush
garden hose
7. Align arrow on sprayer with bucket symbol on PressureKnob.
open
Cleanup – Flushing After Spraying Water–based Paint
Suction tube
8. Turn power switch ON.
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9. Place roller frame in waste pail and trigger Combo Gun.Be sure the holes of the roller frame are facing insidethe pail.
10. Turn Spray/Prime Valve to SPRAY.
11. Keep Combo Gun triggered for 1–2 minutes until some-what clear water flows out of roller frame.
Cleanup – Flushing After Spraying Water–based Paint
WASTE
1–2 MIN.
WASTE
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12. Turn Spray/Prime Valve to PRIME.
13. Let water flow through sprayer into waste pail for 20 seconds.
Cleanup – Flushing After Spraying Water–based Paint
14. Turn Power Switch OFF.
20 SEC.
WASTE
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15. Close Zip Flush attachment. Turn off garden hose.
16. Unscrew Zip Flush attachment from suction hose.
17. Remove roller frame and extension from Combo Gun.
Cleanup – Flushing After Spraying Water–based Paint
closed
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Always pump storage fluid through the pumpsystem after cleaning. Water left in the sprayerwill corrode and ruin pump. Recommendedstorage fluids: ASM Pump Life, Pump Shield, orMineral Spirits.
1. Place suction tube in storage fluid bottle andprime tube in waste pail.
2. Turn Prime/Spray valve to PRIME.
3. Turn Pressure Control knob all the way left(counterclockwise) to minimum pressure.
Cleanup – Filling the Sprayer with Storage Fluid
WASTE
prime tube
suction tube
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4. Turn power switch ON.
5. Align arrow on the sprayer with the (roller symbol) on thePressure Control knob.
6. When storage fluid comes out of prime tube (in 5–10seconds) turn power switch OFF.
Cleanup – Filling the Sprayer with Storage Fluid
watch for storage fluid from primetube (in 5 to 10 seconds)
7. Turn Spray/Prime valve to SPRAY to keep storage fluidin sprayer during storage.
WASTE
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General Repair Information
Motor and drive housing may be very hot during opera-tion and could burn skin if touched.
Flammable materials spilled on hot, bare motor couldcause fire or explosion. Have enclosures in placeduring operation to reduce risk of burns, fire, or explo-sion.
� Keep all screws, nuts, washers, gaskets, andelectrical fittings that you remove during repairprocedures. These parts are not normally providedwith replacement assemblies.
� Test repairs after problems are corrected.
� If the sprayer does not operate properly, reviewthe repair procedure to verify that you did it cor-rectly. See Basic Troubleshooting on page andAdvanced Troubleshooting on page 34.
� Overspray may build up in the air passages.Remove any overspray and residue from the airpassages and openings in the enclosures wheneveryou service the sprayer.
Do not operate the sprayer without the enclosure.Replace if damaged. Enclosures direct cooling airaround the motor to prevent overheating. They alsoreduce the risk of burns, fire or explosion. Read thefollowing WARNING.
To reduce risk of serious injury, including electricshock, do not touch moving or electrical parts withfingers or tools while testing repair. Unplug sprayerwhen power is not required for testing. Install all cov-ers, gaskets, screws, and washers before you operatesprayer.
CAUTIONDo not run sprayer dry for more than 30 seconds.Doing so could damage pump packings.
Protect the internal drive parts of this sprayerfrom water. Openings in the enclosures allow for aircooling of the mechanical parts and electronicsinside. If water gets into these openings, the sprayercould malfunction or be permanently damaged.
Prevent pump corrosion and damage from freez-ing. Never leave water or water-base paint inthe sprayer when it is not in use in cold weather.Freezing fluids can seriously damage the sprayer.Store the sprayer with mineral spirits/paint thinner orGraco Pump Armor to protect equipment duringstorage.
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Basic Troubleshooting
Check everything in this Troubleshooting table before you bring the sprayer to an ASM authorized service center.
PROBLEM CAUSE SOLUTION
Pump will not prime.HINT:�Attempt to free check balls
Spray/Prime valve is set atSPRAY.
Turn Spray/Prime valve to PRIME (pointing down).
�Attempt to free check ballsby tapping side of inlet valveas sprayer is stroking.
Spray/Prime valve is plugged Clean/replace drain tube as necessary.as sprayer is stroking.�Strain paint before sprayingand keep sand and debrisout.
Inlet screen is clogged orsuction tube is not immersed.
Clean debris off inlet screen. Make sure suction tube is atbottom of paint pail.
out.� Thoroughly flush after everypaint job.� Do not store in water. Use
Inlet valve check ball is stuck. Remove the tube and place a pencil into the inlet section todislodge the ball, allowing the pump to prime properly.
� Do not store in water. UsePump Storage Fluid ormineral spirits.
Outlet valve check ball isstuck.
Remove hose from sprayer. Unscrew outlet valve to removeassembly. Gently nudge the ball in the outlet assembly with ascrewdriver. Screw the valve back into the pump.
Power switch is on andsprayer is plugged in, butpump does not cycle.
Electrical outlet is notproviding power or extensioncord is damaged or sprayerpower cord is damaged.
Try a different outlet or reset building circuit breaker or replaceextension cord/power cord.
Pressure is set at minimum. Turn Pressure Control Knob to the right (clockwise) toincrease pressure.
Motor or control is damaged. Return sprayer to ASM authorized service center.
Paint is frozen or hardened inpump.
Unplug sprayer from electrical outlet.
NOTE: If frozen, do not try to start sprayer untilcompletely thawed, or damage to motor, control board,and/or drivetrain may occur.
Make sure power switch is OFF. Place sprayer in warm areafor several hours, then plug in and turn on. Slowly increasepressure setting to see if motor starts.
If paint hardened in sprayer, pump packings, valves, drivetrain,or pressure switch may need to be replaced.
Cannot pull Combo Guntrigger.
Trigger safety is in SAFETYON position.
Put trigger safety in SAFETY OFF position.
Combo Gun stops spraying. Tip is clogged. Aim Combo Gun into waste pail. Squeeze trigger.
Pump cycles but does notbuild up pressure. (i.e., willnot stop cycling even though
Pump check valves are dirtyor damaged.
Clean or replace check valves.
not stop cycling even thoughgun trigger is released) Spray/Prime valve is worn or
obstructed with debris.Return sprayer to ASM authorized service center.
Pump is not primed. Priming, page 10.
Inlet screen is clogged orsuction tube is not immersed.
Clean debris off inlet screen. Make sure suction tube is atbottom of pail. Reprime sprayer.
Paint pail is empty. Refill paint pail and reprime sprayer.
Suction tube has vacuum airleak.
Tighten suction tube connection. Inspect for cracks or vacuumleaks. If cracked or damaged, replace suction tube.
Pump check ball is stuck. See “Pump will not prime” section of Trouble Shootinginstructions.
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Basic Troubleshooting
PROBLEM CAUSE SOLUTION
Pump cycles but paint onlydribbles or spurts whentrigger is pulled
Pressure is set too low. Turn Pressure Control Knob to the right (clockwise) toincrease pressure.
trigger is pulled.Tip is clogged. Clear tip. See your gun manual.
Spray tip is too large or worn. Replace tip.
Spay pattern is inconsistent oris leaving stripes
Pressure is set to low. Turn pressure control knob clockwise to increase pressure.is leaving stripes.
Spray tip is worn beyondcapability of sprayer.
Replace spray tip.
Pressure is set at maximum,but cannot achieve a good
tt
Extension cord is too long ornot a heavy enough gauge.
Replace extension cord.g
spray pattern. Tip is too large for sprayer. Select a smaller tip.
Tip is worn beyond capabilityof sprayer.
Replace tip.
Inlet screen is clogged. Clean debris off inlet screen.
Pump valves are worn. Check for worn pump valves as follows: Prime sprayer withpaint. See Priming, page 10. Trigger Combo Gunmomentarily. When trigger is released, pump should cyclemomentarily and stop. If pump continues to cycle, pumpvalves may be worn. Replace check valves.
When paint is sprayed, it runsdown the wall or sags
Coat is going on too thick. Move gun faster.down the wall or sags.
Choose tip with smaller hole size.
Choose tip with wider fan.
Make sure gun is far enough from surface.
When paint is sprayed, coat isnot covering
Coat is going on too thin. Move gun slower.not covering.
Choose tip with larger hole size.
Choose tip with narrower fan.
Make sure gun is close enough to surface.
Motor is hot and runsintermittently
Vent holes in shroud areplugged or sprayer is
Keep vent holes in shroud clear of obstructions and overspray,and keep sprayer open to airintermittently.
NOTE: This is a thermal
plugged, or sprayer iscovered.
and keep sprayer open to air.
NOTE: This is a thermaloverload condition. Motor willautomatically shut off due toexcessive heat.
Extension cord is too long ornot a heavy enough gauge.
Replace extension cord.
excessive heat.
See Start–up Hazard AfterThermal Overload, page 2.Damage can occur if cause is
Unregulated electricalgenerator being used hasexcessive voltage.
Use electrical generator with a proper voltage regulator.Sprayer requires a 120V AC, 60 Hz, 1500-Watt generator.
Damage can occur if cause isnot corrected. Sprayer was operated at high
pressure with small tip, whichcaused frequent motor startsand excessive heat build up.
Decrease pressure setting, or increase tip size.
Building circuit breaker opensafter sprayer operates for 5 to10 minutes
Too many appliances areplugged in on same circuit.
Free up circuit (unplug things), or use a less busy circuit.
10 minutes.OR
Building circuit breaker opensas soon as sprayer is plugged
Extension cord is damaged ortoo long or not a heavyenough gauge.
� Plug in something that you know is working to testextension cord.
� Replace extension cord.as soon as sprayer is pluggedinto outlet, and sprayer isturned on.
Sprayer power cord isdamaged.
Check for broken insulation or wires. Replace power cord ifdamaged.
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Fan pattern variesdramatically while spraying orsprayer does not turn onpromptly when resumingspraying.
Pressure control switch isworn and causing excessivepressure variation.
Return sprayer to ASM authorized service center.
Spray comes out of gun intwo thick streams.
Reversible tip is in CLEANposition.
Rotate arrow–shaped handle on tip so it points forward.
Sprayer does not turn onpromptly when resumingspraying.
Pressure control switch isworn and causing excessivepressure variation.
Return sprayer to ASM authorized service center.
Paint is coming out ofpressure control switch.
Pressure control switch isworn.
Return sprayer to ASM authorized service center.
Pressure drain actuatesautomatically, relievingpressure through prime tube.
System is overpressurizing. Return sprayer to ASM authorized service center.
Paint leaks down outside ofpump.
Pump packings are worn. Replace pump packings.
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Advanced Troubleshooting
NOTE: See Basic Troubleshooting on page 31 for the problems that are more easily remedied.
General Problem: Motor Does Not OperateSPECIFIC PROBLEM CAUSE SOLUTION
Power switch is on andsprayer is plugged in but
See Basic Troubleshooting page 31.sprayer is plugged in, butpump does not cycle.
Basic MechanicalProblems
Paint is frozen or hardened in pump. Unplug sprayer from electrical outlet.
NOTE: If frozen, do not try to start sprayeruntil completely thawed, or damage to motor,control board, and/or drivetrain may occur.
Make sure power switch (B) is OFF. Placesprayer in warm area for several hours, thenplug in and turn on. Slowly increase pressuresetting to see if motor starts.
If paint hardened in sprayer, replace pumppackings and remove all residue from valves.
See Pump Service on page 42.
Motor is damaged. Remove gear, and try to rotate motor shaft byhand. See Motor Diagnostics on page 41. Ifshaft will not turn, replace motor using MotorKit 245080.
Basic Electrical Problems Motor is overheated. Allow to cool for 30 minutes. Retry.
Electrical outlet is damaged. Reset building circuit breaker or replacebuilding fuse. Try another outlet.
Check electric supply with volt meter. Metermust read 85 to 130V AC. If voltage is toohigh, do not plug sprayer in until outlet iscorrected.
Control board leads are improperly fastened orimproperly mated.
Replace any loose terminals. Make sure allleads and harnesses are firmly connected.
Check pressure control harness connection onfront side of drive housing.
Clean control board terminals. Securelyreconnect leads.
Motor brushes are worn.
NOTE: Brushes do not wear at the same rate onboth sides of motor. Check both brushes.
Check length of brushes. Brush length mustbe 0.25 in. (6.4 mm) minimum. If brushes areworn, replace motor using Motor Kit 245080.
Motor armature commutator is damaged. Check for burn spots, gouges and extremeroughness. Have motor shop resurfacecommutator if possible, or replace motor usingMotor Kit 245080.
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Advanced Troubleshooting
General Problem: Motor Does Not Operate (continued)
SPECIFIC PROBLEM CAUSE SOLUTION
Basic Electrical Problems(Continued)
Motor armature is shorting. Check for shorts using armature tester (growler), or performspin test (see Motor Diagnostics on page 41). If shorts areevident, replace motor using Motor Kit 245080.
Control board is damaged.
CAUTION: Do not perform controlboard diagnostics until you havedetermined that the armature is good.A bad motor armature can burn out agood control board.
See Control Board Diagnostics on page 41, and replacecontrol board if damaged using Control Board Kit 245079.
Sprayer Wiring Problems
NOTE: Remove rightenclosure mountingscrews, and pull rightenclosure away from drivehousing. Take care to notpull on the leads fromthe electrical cord andthe Power switch (B).
Sprayer electrical cord is damaged. Unplug sprayer electrical cord. Disconnect black electricalcord wire at Power switch (B), and unplug in-line connectionof white electrical cord wire. Plug in electrical cord, and testvoltage between black and white electrical cord wires.Meter must read 85 to130V AC.
Replace electrical cord if no voltage.
Sprayer power switch (B) is damaged. Unplug sprayer electrical cord. Disconnect black controlboard wire at Power switch (B), and unplug in-lineconnection of white electrical cord wire. Plug in electricalcord, turn Power switch ON, and test voltage between openterminal of Power switch and white electrical cord wire.Meter must read 85 to130V AC.
Replace Power switch (B) if no voltage.
Thermal overload cutoff switch isdamaged.
See Startup Hazard After ThermalOverload in the WARNINGS sectionon page 3.
Unplug sprayer electrical cord. Remove motor harness fromcontrol card, and check for continuity between yellow leadsof motor harness. If thermal relief switch is open (nocontinuity), allow motor to cool. If switch remains open aftermotor cools, replace motor using Motor Kit 245080.
If thermal relief switch closes after motor cools, find andcorrect cause of overheating.
Terminals are damaged or loose. Replace any damaged terminals, and make sure allterminal connections are tight.
36 309420
Advanced Troubleshooting
General Problem: Circuit Breaker is Tripping
SPECIFIC PROBLEM CAUSE SOLUTION
Building circuit breaker opensas soon as sprayer is turned on.
Sprayer electrical wiring is pinched, or insulationis damaged.
Wires between pressure control switch andcontrol board are pinched.
Repair or replace any damaged wiring orterminals. Securely reconnect all wires.
Motor armature is shorting. Check for shorts using armature tester(growler), or perform spin test (see MotorDiagnostics on page 41). If shorts areevident, replace motor using Motor Kit245080.
Control board is damaged.
CAUTION: Do not perform control boarddiagnostics until you have determined that thearmature is good. A bad motor armature can burnout a good control board.
See Control Board Diagnostics on page41, and replace control board if damagedusing Control Board Kit 245079.
Building circuit breaker opensas soon as sprayer is pluggedinto outlet, and sprayer is NOTturned on.
NOTE: Remove rightenclosure mounting screws,and pull right enclosure awayfrom drive housing. Take caret t ll th l d f
Sprayer electrical cord is damaged. Unplug sprayer electrical cord. Disconnectblack electrical cord wire at Power switch (B),and unplug in-line connection of whiteelectrical cord wire. Plug in electrical cord,and test voltage between black and whiteelectrical cord wires. Meter must read85 to130V AC.
Replace electrical cord if no voltage.gto not pull on the leads fromthe electrical cord and thePower switch (B).
Sprayer Power switch (B) is damaged. Unplug sprayer electrical cord, anddisconnect wires from Power switch (B).Check resistance of switch with ohmmeter.Reading must be infinity with Power switchOFF, and zero with Power switch ON.
Replace Power switch if damaged.
See also “Basic Electrical Problems” on page 34 and “Sprayer Wiring Problems” on page 35.
37309420
Advanced Troubleshooting
General Problem: Motor Operation is Erratic
SPECIFIC PROBLEM CAUSE SOLUTION
Sprayer quits after running for 5 to 10 minutes. Electrical outlet is damaged orsupplying the wrong voltage.
Reset building circuit breaker orreplace building fuse. Try anotheroutlet.
Check electric supply with volt meterCheck electric supply with volt meter.Meter must read 85 to 130V AC. Ifvoltage is too high, do not use outletuntil corrected.
See also “Basic Electrical Problems” on page 34 and “Sprayer WiringProblems” on page 35.
Motor is hot and runs intermittently.
NOTE: This is a thermal overload condition.Motor automatically shuts off due to excessiveheat.
See Startup Hazard After Thermal Overloadin the WARNINGS section on page . Damagecan occur if cause is not corrected.
See Basic Troubleshooting page 31.
General Problem: Output is Low or Fluctuating
SPECIFIC PROBLEM CAUSE SOLUTION
Pump cycles, but output is lowor surging.
See Basic Troubleshooting page 31.
Pump valves are worn or obstructed by debris. Check for worn pump valves as follows:Prime sprayer with paint. Trigger spray gunmomentarily. When spray gun trigger isreleased, pump should cycle momentarilyand stop. If pump continues to cycle, pumpvalves may be worn or obstructed.
See Pump Service on page 42.
Spray–Prime/Drain valve is leaking. Check Spray–Prime/Drain valve for debristrapped on seat and for worn parts. Torque to185 in-lb (21 N�m). Replace if parts are wornusing Spray–Prime/Drain Valve Kit 235014.
Voltage from electrical outlet is too low. Lowvoltages reduce sprayer performance.
Check voltage of outlet. Meter must read85 to 130V AC.
Reset building circuit breaker or replacebuilding fuse.
Repair electrical outlet or try another outlet.
Extension cord is too long or not a heavy enoughgauge.
Replace extension cord.
See Grounding and ElectricalRequirements on page 5.
Leads from motor to control board are damaged,loose, or overheated.
Be sure terminals are centered and firmlyconnected. Inspect wiring insulation andterminals for signs of overheating, andreplace any loose terminals or damagedwiring. Securely reconnect terminals.
38 309420
Advanced Troubleshooting
General Problem: Output is Low or Fluctuating (continued)
SPECIFIC PROBLEM CAUSE SOLUTION
Motor brushes are worn.
NOTE: Brushes do not wear at the same rate onboth sides of motor. Check both brushes.
Check length of brushes. Brush length mustbe 0.25 in. (6.4 mm) minimum. If brushesare worn, replace motor using Motor Kit245080.
Motor brush springs are broken. If springs are broken, replace motor usingMotor Kit 245080 for Zip–Spray–n–Rollmodels or 243236 for Zip–Spray 1700models.
Motor brushes are binding in brush holders. Clean brush holders, remove carbon dustwith small cleaning brush.
Motor stops before sprayer reaches correctpressure (stall pressure is too low).
Replace Pressure Control knob usingPressure Control Switch Kit 244266 forZip–Spray–n–Roll models or 244267 forZip–Spray 1700 models.
Motor armature is shorting. Check for shorts using armature tester(growler), or perform spin test (see MotorDiagnostics on page 41). If shorts areevident, replace motor using Motor Kit245080.
Control board is damaged. CAUTION: Do notperform control board diagnostics until you havedetermined that the armature is good. A badmotor armature can burn out a good controlboard.
See Control Board Diagnostics on page41, and if damaged, replace control boardusing Control Board Kit 245079.
Motor runs and pump cycles,but pressure does not build up.
Intake valve ball or outlet valve ball is not seatingproperly.
Remove and clean valves, and check ballsand seats for nicks; replace if necessary.Strain paint before spraying to removeparticles that could clog pump. See PumpService on page 42.
Pump packings are worn or damaged. Check for leaking around throat packing nut.Replace pump packings if there are leaks.See Pump Service on page 42.
Spray–Prime/Drain valve is leaking. Check Spray–Prime/Drain valve for debristrapped on seat and for worn parts. Torque to185 in-lb (21 N�m). If parts are worn, replacevalve using Spray–Prime/Drain Valve Kit235014.
39309420
Advanced Troubleshooting
General Problem: Output is Low or Fluctuating (continued)
SPECIFIC PROBLEM CAUSE SOLUTION
Spray pattern hasvariations, pressurefluctuates excessively, ormotor runs very slowly.
Leads from motor to control board aredamaged, loose, or overheated.
Be sure terminals are centered and firmlyconnected. Inspect wiring insulation and terminalsfor signs of overheating, and replace any looseterminals or damaged wiring. Securely reconnectterminals.
Pressure control switch leads are pinchedbetween pump and drive housing or betweenfront cover and drive housing.
Make sure pressure control harness is routedbehind pump, through retention clip, andconnected to control board connector at back ofdrive housing (connected with tab to the right).
Control board is damaged.
CAUTION: Do not perform control boarddiagnostics until you have determined that thearmature is good. A bad motor armature canburn out a good control board.
See Control Board Diagnostics on page 41. Ifdamaged, replace control board using ControlBoard Kit 245079.
Pressure control switch is damaged or wornout.
Replace pressure control switch using PressureControl Switch Kit 244266.
General Problem: There is No Output
SPECIFIC PROBLEM CAUSE SOLUTION
Power switch is on andsprayer is plugged in but
See Basic Troubleshooting page 31.sprayer is plugged in, butpump does not cycle.
Motor runs, but pump does notcycle.
Gear and/or yoke are damaged. Replace gear and yoke using Gear/Yoke RepairKit 243230.
Motor does not run. Water or paint entered pressure controlswitch or shorted control board.
Clean out and/or dry out, and retry. Replace ifnecessary using Pressure Control Switch Kit244266.
General Problem: Excessive Pressure is Building Up
Pressure control switch is worn. Replace pressure control switch using PressureControl Switch Kit 244266.
drain tube.Water or paint entered pressure controlswitch or shorted control board.
Clean out and/or dry out, and retry. Replace ifnecessary using Pressure Control Switch Kit244266.
Control board has failed. See Control Board Diagnostics on page 41, andreplace control board if damaged using ControlBoard Kit 245079.
40 309420
List of Kits
Kit Number Kit Description
245077 Pump Inlet Valve Module
196582 Suction Tube
245076 Pump Outlet Valve Module
244035 Drain Tube Diffuser
244266 Pressure Control Switch
245079 Control Board
245078 Pump Repair
245080 Motor Repair
41309420
Motor DiagnosticsCheck for electrical continuity in the motor armature, windings, and brush as follows:
If Motor Diagnostics reveal a damaged motor, or if either of the motor brushes are shorter than 1/4 in. (6.4 mm),or if the motor shaft cannot turn, replace the motor using Motor Kit 245080.
Setup
1. Unplug electrical cord, and relieve pressure.
2. Remove right enclosure, and disconnect motorharness from control board.
3. Remove fan brace.
4. Remove the four cover screws and front cover.
5. Remove yoke and guide rods, and remove gear.
Control Board DiagnosticsCheck for a damaged control board or pressure control switch as follows:
1. Unplug electrical cord, and relieve pressure.
2. Remove the four cover screws and front cover.
3. Remove yoke and guide rods, and remove gear.
4. Remove pressure control harness from controlboard. Using fingernail or tip of small, flat-blade screwdriver, press tab on right sideconnector to release.
5. Attach to the control board a harness from a pres-sure switch that you know is functioning correctly.
NOTE: Pressure control switch does not have tobe installed in pump.
6. Turn pressure control adjustment knob to maximumpressure setting.
7. Plug electrical cord into 120V AC receptacle, andturn Power switch (B) ON.
� If motor runs, replace pressure switch.
� If motor does not run, replace control boardand repeat test using Control Board Kit245079 for dx models, 243228 for Zip–Spray1700 models.
42 309420
Pump Diagnostics
CAUTIONWhen repairing or cleaning the pump, never submerge the pump in water or allow fluid to enter the pressure control.
When the pump packings wear, paint begins to leak down the outside of the pump. Replace the pump packings atthe first sign of leaking, or additional damage to the drive train could occur. Use pump repair kit 245078.
Pump Service
CAUTIONWhen repairing or cleaning the pump, never submerge the pump in water or allow fluid to enter the pressure control.
If the sprayer continues to cycle (motor and pump run) when the spray gun trigger is released, or if performance ispoor even with new spray tips and clean filters, the pump inlet or outlet valve my be obstructed or worn. If a pumpvalve is worn, replace it. See page 40 for a List of Kits.
* The best operating pressure is the lowest pressure that provides an even paint supply to the roller and typically doesnot exceed 300 psi (2.1 MPa, 21 bar).
48 309420
ASM Standard Warranty
ASM warrants all equipment referenced in this document which is manufactured by ASM and bearing its name to be free from defectsin material and workmanship on the date of sale by an authorized ASM distributor to the original purchaser for use. With the exceptionof any special, extended, or limited warranty published by ASM, ASM will, for a period of twelve months from the date of sale, repair orreplace any part of the equipment determined by ASM to be defective. This warranty applies only when the equipment is installed,operated and maintained in accordance with ASM’s written recommendations.
This warranty does not cover, and ASM shall not be liable for general wear and tear, or any malfunction, damage or wear caused byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non–ASM component parts. Nor shall ASM be liable for malfunction, damage or wear caused by the incompatibility of ASMequipment with structures, accessories, equipment or materials not supplied by ASM, or the improper design, manufacture, installa-tion, operation or maintenance of structures, accessories, equipment or materials not supplied by ASM.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized ASM distributor forverification of the claimed defect. If the claimed defect is verified, ASM will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
ASM’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.
ASM MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUTNOT MANUFACTURED BY ASM. These items sold, but not manufactured by ASM (such as electric motors, switches, hose, etc.), aresubject to the warranty, if any, of their manufacturer. ASM will provide purchaser with reasonable assistance in making any claim forbreach of these warranties. In no event will ASM be liable for indirect, incidental, special or consequential damages resulting from ASM supplying equipment here-under, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach ofwarranty, the negligence of ASM, or otherwise.
FOR ASM BRAZILIAN/CANADIAN/COLUMBIAN CUSTOMERSThe Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English.
TO PLACE AN ORDER OR FOR SERVICE, contact your ASM distributor, or call 1–800–854–4025 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. ASM reserves theright to make changes at any time without notice.
MM 309420
ASM Company, 3500 North 1st Avenue, Sioux Falls, SD 57104www.asmcompany.com
