ASM Zip-Spray 1700 Operation, Repair, And Parts Download

Page: 24 / 38

24 309421

Advanced Troubleshooting

NOTE:

See

Basic Troubleshooting

on page 22 for the problems that are more easily remedied.

General Problem: Motor Does Not Operate

SPECIFIC PROBLEM

CAUSE

SOLUTION

Power switch is on and
sprayer is plugged in but

See

Basic Troubleshooting

page 22.

sprayer is plugged in, but
pump does not cycle.

Basic Mechanical
Problems

Paint is frozen or hardened in pump.

Unplug sprayer from electrical outlet.

NOTE: If frozen, do not try to start sprayer
until completely thawed

, or damage to motor,

control board, and/or drivetrain may occur.

Make sure power switch (B) is OFF. Place
sprayer in warm area for several hours, then
plug in and turn on. Slowly increase pressure
setting to see if motor starts.

If paint hardened in sprayer, replace pump
packings and remove all residue from valves.

See

Pump Service

on page 33.

Motor is damaged.

Remove gear, and try to rotate motor shaft by
hand. See

Motor Diagnostics

on page 32. If

shaft will not turn, replace motor using

Motor

Kit

245063 (see

List of Kits

, page 31).

Yoke is broken, because pump is locked up by
dried paint or worn packings.

Repair as necessary or replace using

Gear/Yoke Repair Kit

245062 (see

List of

Kits

, page 31).

Basic Electrical Problems

Motor is overheated.

Allow to cool for 30 minutes. Retry.

Electrical outlet is damaged.

Reset building circuit breaker or replace
building fuse. Try another outlet.

Check electric supply with volt meter. Meter
must read 85 to 130V AC. If voltage is too
high, do not plug sprayer in until outlet is
corrected.

Control board leads are improperly fastened or
improperly mated.

Replace any loose terminals. Make sure all
leads and harnesses are firmly connected.

Check pressure control harness connection on
front side of drive housing.

Clean control board terminals. Securely
reconnect leads.

Motor brushes are worn.

NOTE:

Brushes do not wear at the same rate on

both sides of motor. Check both brushes.

Check length of brushes. Brush length must
be 0.25 in. (6.4 mm) minimum. If brushes are
worn, replace motor using

Motor Kit

245063

(see

List of Kits

, page 31).

Motor armature commutator is damaged.

Check for burn spots, gouges and extreme
roughness. Have motor shop resurface
commutator if possible, or replace motor using

Motor Kit

245063 (see

List of Kits

, page 31).

Summary of Contents for Zip-Spray 1700

Page 1: ...ions in this manual Save these instructions Table of Contents Warnings 2 Grounding and Electrical Requirements 4 Pressure Relief Procedure 5 Component Function and Identification 6 Setup 8 Priming 9 Tip Selection 14 Spraying Techniques 16 Shutdown and Cleaning 18 General Repair Instructions 21 Basic Troubleshooting 22 Advanced Troubleshooting 24 List of Kits 31 Motor Diagnostics 32 Control Board D...

Page 2: ...aning keep sprayer at least 20 ft 6 m away from explosive vapors D Keep work area free of debris including solvent rags and gasoline D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present D Ground equipment and conductive objects in work area Read Grounding instructions D If there is static sparking or you feel a shock stop operating immediately Do not use eq...

Page 3: ...ued or under the influence of drugs or alcohol D Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids 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 a...

Page 4: ...ance D Ground sprayer gun through connection to a properly grounded fluid hose and pump D Ground fluid supply container Follow local code D Ground solvent pails used when flushing Follow local code Use only conductive metal pails placed on a grounded surface such as concrete Do not place the pail on a non conductive surface such as paper or cardboard which interrupts the grounding continuity Fig 3...

Page 5: ...owest setting Hold metal part of gun firmly to a grounded metal pail Trigger gun to relieve pressure Fig 8 ti6912a 4 Engage trigger lock Fig 9 ti6763b D Leave Spray Prime Drain valve in PRIME DRAIN position until you are ready to spray again D If you suspect the spray tip is clogged or that pressure has not been fully relieved after following the above steps VERY SLOWLY loosen tip guard retaining ...

Page 6: ...300 Spray Gun C H F X D A W B M L J P K G E Q R S T V U ti5453b ti6911a 6 309421 Component Identification and Function ...

Page 7: ...t hose in SPRAY position pointing forward D Directs fluid to drain tube in PRIME DRAIN position pointing down D Automatically relieves system pressure in overpressure situations K Fluid inlet connection and inlet valve Where suction tube connects to pump and inlet valve L Inlet screen Prevents debris from entering pump M Paint hose Transports high pressure fluid from pump to spray gun P Airless sp...

Page 8: ...un 3 Connect other end of hose to sprayer NOTE If hose is already connected make sure connections are tight 4 Turn OFF power switch 5 Turn Pressure Control Knob all the way left counterclockwise to minimum pressure NOTE To select function align symbol on Pressure Control Knob label with arrow on sprayer Fig 10 Fig 10 ...

Page 9: ... 13 4 If spraying oil based materials submerge suction tube in mineral spirits or compatible oil based cleaning solution If spraying water based materials submerge suction tube in water Fig 14 Mineral Spirits WATER OR 5 Plug sprayer into grounded outlet 6 Point gun into waste pail Fig 15 WASTE ti6913a 7 Turn power switch ON Fig 16 8 Turn up pressure control knob until pump starts Fig 17 ti6906a 9 ...

Page 10: ...d debris can cause either of the pump s two check valves to malfunction If the pump does not prime after 30 seconds try to jar the check balls loose by tapping the inlet valve with a small wrench as the sprayer is on and running CAUTION Excessive shock will fracture or cause other damage to the pump Fig 21 Tap here ti6915a HINT To determine if the inlet valve ball is sticking unscrew inlet valve f...

Page 11: ... smaller from suction tube larger Fig 23 prime tube suction tube 3 Place prime tube in waste pail Fig 24 4 Place suction tube in bucket of mineral spirits Fig 25 Mineral Spirits 5 Plug sprayer into grounded outlet 6 Point gun into waste pail Fig 26 WASTE ti6913a 7 Turn power switch ON Fig 27 8 Turn up Pressure Control knob until pump starts Fig 28 ti6906a 9 Flush until mineral spirits flow out of ...

Page 12: ...igger and turn Spray Prime valve to SPRAY When paint comes out of gun release trigger Fig 32 WASTE SPRAY pull and hold trigger paint ti6914a NOTE Motor stopping indicates pump and hose are primed with paint 14 Attach drain tube to suction tube NOTE If pump does not prime after 30 seconds see Pump Check Valves page 10 ...

Page 13: ...the way into base 3 Screw tip and base assembly onto gun and tighten retaining nut by hand Fig 34 ti6772a NOTE Point the arrow shaped handle on the Super Uni tip forward to SPRAY and backward to UNCLOG obstructions Fig 35 UNCLOG arrow points backward SPRAY arrow points forward ti6775a ti6774a NOTE D Tip must be pushed all the way into base D Never pull gun trigger when arrow shaped handle is betwe...

Page 14: ... mm 0 013 in 0 33 mm 59 415 8 to 10 in 203 to 254 mm 0 015 in 0 38 mm 59 515 10 to 12 in 254 to 305 mm 0 015 in 0 38 mm 59 417 8 to 10 in 203 to 254 mm 0 017 in 0 43 mm 59 517 10 to 12 in 254 to 305 mm 0 017 in 0 43 mm 59 519 10 to 12 in 254 to 305 mm 0 019 in 0 48 mm 59 619 12 to 14 in 305 to 356 mm 0 019 in 0 48 mm Example For an 8 to 10 in 203 to 254 mm fan width and a 0 013 in 0 33 mm hole siz...

Page 15: ...ontain information about the hole size and about the fan width on the surface when the gun is held 12 in 30 5 cm from the surface being sprayed First digit when doubled approximate fan width Last two digits tip hole size in thousands of an inch 413 tip has a 0 013 in hole size 413 tip has 8 to 10 in fan width ...

Page 16: ...y distributed no gaps at edges Fig 36 Start at low pressure setting increase pressure a little at a time until paint is atomized Fig 36 A good spray pattern pressure too low gaps at edges D To prevent excessive tip wear spray at lowest pressure that atomizes paint D If maximum pressure of sprayer is not enough for good spray pattern tip is too large or too worn See Super Uni Tip Selection Chart pa...

Page 17: ...igger after starting stroke release trigger before end of stroke Gun must be moving when trigger is pulled and released Fig 39 Fig 39 pull release Aiming Gun D Aim tip of gun at edge of previous stroke to overlap each stroke by half Fig 40 Fig 40 aim here ...

Page 18: ...ith Power switch OFF lift suction tube and prime tube from paint pail and let them drain into paint for awhile Place suction tube in flushing fluid pail and place prime tube in waste pail Turn Spray Prime valve to PRIME to relieve fluid pressure into waste pail WASTE FLUSHING FLUID 9567A PRIME Fig 41 2 Turn Pressure Control knob to the left counterclockwise to minimum pressure Trigger gun into was...

Page 19: ...m suction tube and place tube in waste bucket 6 Connect garden hose to suction tube with Zip Flush attachment Leave prime tube in waste pail 7 Turn Spray Prime Valve to SPRAY Align arrow on sprayer with bucket symbol on Pressure Control Knob 8 Open lever on Zip Flush attachment Turn on garden hose Note Step 9 is for returning paint in hose back to paint pail One 50 foot 15 meter hose holds approxi...

Page 20: ...hose in storage fluid bottle and prime tube in waste pail 2 Turn Spray Prime Valve to PRIME 3 Turn pressure control knob all the way left counterclockwise to minimum pressure 4 Turn power switch ON 5 Align arrow on sprayer to roller symbol on pressure control knob 6 When storage fluid runs out of prime tube 5 10 seconds turn power switch OFF 7 Turn Spray Prime Valve to SPRAY to keep storage fluid ...

Page 21: ...enclosure Replace if damaged Enclosures direct cooling air around the motor to prevent overheating They also reduce the risk of burns fire or explosion Read the following WARNING CAUTION Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings Protect the internal drive parts of this sprayer from water Openings in the enclosures allow for air cooling of the mechanical pa...

Page 22: ... replace check valves See Pump Service on page 33 Do not store in water Suction tube is leaking Tighten suction tube connection K Inspect for other cracks or vacuum leaks Spray gun stopped spraying Spray tip is plugged Unplug spray tip Pump cycles but does not b ild Pump is not primed Prime pump p y build up pressure Inlet screen is clogged or suction tube is not immersed Clean debris off inlet sc...

Page 23: ... corrected Sprayer was operated at high pressure with very small tip which causes frequent motor starts and excessive heat build up Decrease pressure setting or increase tip size Building circuit breaker opens after sprayer operates for 5 to 10 minutes OR Too many appliances are plugged in on same circuit Free up circuit unplug things or use a less busy circuit OR Building circuit breaker opens as...

Page 24: ...is broken because pump is locked up by dried paint or worn packings Repair as necessary or replace using Gear Yoke Repair Kit 245062 see List of Kits page 31 Basic Electrical Problems Motor is overheated Allow to cool for 30 minutes Retry Electrical outlet is damaged Reset building circuit breaker or replace building fuse Try another outlet Check electric supply with volt meter Meter must read 85 ...

Page 25: ...re at Power switch B and unplug in line connection of white electrical cord wire Plug in electrical cord and test voltage 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 control board wire at Power switch B and unplug in line connection of white electri...

Page 26: ...ard if damaged using Control Board Kit 243228 see List of Kits page 31 Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on NOTE Remove right enclosure mounting screws and pull right enclosure away from drive housing Take care t t ll th l d f Sprayer electrical cord is damaged Unplug sprayer electrical cord Disconnect black electrical cord wire at P...

Page 27: ...age 22 Pump valves are worn or obstructed by debris Check for worn pump valves as follows Prime sprayer with paint Trigger spray gun momentarily When spray gun trigger is released pump should cycle momentarily and stop If pump continues to cycle pump valves may be worn or obstructed See Pump Service on page 33 Spray Prime Drain valve is leaking Check Spray Prime Drain valve for debris trapped on s...

Page 28: ... on page 32 If shorts are evident replace motor using Motor Kit 245063 see List of Kits page 31 Control board is damaged CAUTION Do not perform control board diagnostics until you have determined that the armature is good A bad motor armature can burn out a good control board See Control Board Diagnostics on page 32 and if damaged replace control board using Control Board Kit 243228 see List of Ki...

Page 29: ...ed CAUTION Do not perform control board diagnostics until you have determined that the armature is good A bad motor armature can burn out a good control board See Control Board Diagnostics on page 32 If damaged replace control board using Control Board Kit 243228 see List of Kits page 31 Pressure control switch is damaged or worn out Replace pressure control switch using Pressure Control Switch Ki...

Page 30: ... pressure control switch using Pressure Control Switch Kit 244267 see List of Kits page 31 Water or paint entered pressure control switch or shorted control board Clean out and or dry out and retry Replace if necessary using Pressure Control Switch Kit 244267 see List of Kits page 31 Control board has failed See Control Board Diagnostics on page 32 and replace control board if damaged using Contro...

Page 31: ...ludes fan shroud brace 287773 Series C Motor Drive Housing 243231 Series A and B Fan Shroud Base 287770 Series C Fan 243228 Control Board 245062 3 8 Shaft Gear Yoke Guides bronze bearing equipped cover and motor castings 245578 Inlet Strainer for inlet of suction tube 245053 Pump Replacement complete pump Does not include Pressure Control Switch 244267 Re use pressure control switch from pump bein...

Page 32: ...1 Connect red and black motor leads together with test lead Turn motor fan by hand at about two revolutions per second 2 If there is uneven resistance or no resistance replace motor using Motor Kit 245063 see List of Kits page 31 Control Board Diagnostics Check for a damaged control board or pressure control switch as follows 1 Unplug electrical cord and relieve pressure 2 Remove the four cover sc...

Page 33: ...e to the drive train could occur Use Pump Repair Kit 245569 see List of Kits page 31 Pump Service CAUTION When 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 perfor mance is poor even with new spray tips and clean fil ters the pump inlet or...

Page 34: ...ker 1 115499 Series A and B 118899 Series C 67 195433 SUPPORT right Series A 1 15D923 SUPPORT right Series B and C 1 68 195434 SUPPORT left Series A 1 15D924 SUPPORT left Series B and C 1 69 195436 FRAME cart 1 70 195435 HANDLE cart 1 71 15D650 HOSE RACK 1 Ref No Part No Description Qty 72 115097 SCREW curved head 2 73 115480 KNOB t handle 2 74 197285 AXLE 1 75 195367 SPACER 2 76 115095 WHEEL 9 in...

Page 35: ... and B 63 66 61 62 79 67 68 79 77 76 75 74 80 72 65 72 47 51 73 113 70 1 65 13 54 58 46 71 86 85 20 87 88 89 52 69 36 52 81 43 44 45 19 18 52 84 102 48 125 125 25 17 94 88 2 127 95 96 149 126 1 Apply light coat of lithium based grease 1 40 151 ti5451b 26 ...

Page 36: ...es C 63 62 79 67 68 79 77 76 75 74 80 72 65 72 73 113 70 1 65 13 71 86 85 20 87 88 89 69 36 52 81 43 44 45 19 18 84 102 25 17 26 94 88 2 127 95 96 149 1 Apply light coat of lithium based grease 1 40 66 47 51 54 58 46 52 52 48 125 125 ti6917a 151 126 ...

Page 37: ...e thread Fluid outlet fitting 1 4 npsm external thread Inlet screen on suction tube 35 mesh 450 micron Wetted parts pumps and hose Stainless steel brass leather ultra high molecular weight polyethylene UHMWPE carbide nylon aluminum PVC polypropylene fluroelastomer Generator requirement 1500 Watt minimum Electric power requirement 120V AC 60 Hz 1 phase 15A Storage temperature range 30_ to 160_F 35_...

Page 38: ...S EXPRESS OR IMPLIED INCLUDING BUT NOT 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 other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other ...

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