311161B, ASM Zip-Tex 1500 Electric Texture Sprayer

Repair
Zip-Tex 1500 Electric
Texture Sprayer
311161B
EN
- For water-based materials only (Consult your material supplier for Warnings and Application Requirements)
Model 249457
45 psi (0.31 MPa, 3.1 bar) Maximum Working Air Pressure
100 psi (0.69 MPa, 6.9 bar) Maximum Working Fluid Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
CAUTION
Use Zip-Tex 1500 non-bleeder texture gun (model
249458) only. All other guns will damage sprayer.
Related Manuals
311160
311159
310694*
*Auxiliary AIr Hookup Kit
ti4305a
Warnings
Warnings
The following general warnings are related to the safe setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Refer to these Warnings.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent, in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment in well ventilated area only.
• Keep work area free of debris, including solvent, rags and gasoline.
• Ground equipment in the work area. See Grounding instructions.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
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 sprayer and extension cords.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your ASM 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.
• Comply with all applicable safety regulations.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property
damage. See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s warnings.
2
311161B
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
CAUTION
Water or material remaining in unit when temperatures are below freezing can damage pump and/or delay startup.
To insure water and material are completely drained out of unit: remove hose from material outlet,
• remove hose from material outlet,
• tip sprayer forward 45° to allow material (water) to flow out of pump inlet.
Before adding material or starting unit in cold weather, circulate warm water through pump.
311161B
3
Component Identification
Component Identification
B
C
R
P
K
A
E
G
F
ti4500c
S
W
D
H
M
U
V
L
T
4
311161B
Component Identification
Component Identification
ITEM
COMPONENT
A
Main Power Switch
B
Nozzle Storage
C
Hopper
D
Hopper Connect/Disconnect
E
RotoFlex™ HD Pump
F
Material Outlet
G❖
Burp Guard
H
Air Outlet
K
Fluid Flow Regulator and Pressure Gauge
L
Gun Nozzle (5 sizes)
M
Gun (see manual 311159)*
P
Prime Switch
R
Power Cord
S
Pump Access Screw
T
Hose - 25-ft.
U
Material Thickness Gauge
V
Cleaning Ball
W
Spare Hose Gaskets
❖ Before adding material to hopper, install burp guard. When only a small amount of material remains in hopper, the
burp guard prevents material from shooting out when the unit is turned off. This material could splash in the operator’s
eyes or skin, or into the air.
311161B
5
Preparation
Preparation
Pressure Relief Procedure
Grounding and Electric Requirements
1 Turn Main Power Switch
(A) OFF.
The sprayer must be grounded. Grounding reduces the
risk of electrical shock by providing an escape wire for
the electrical current.
2
Unplug sprayer.
ti4292a
• The sprayer cord includes a
grounding wire with an appropriate grounding prong.
3 Turn fluid flow regulator
(K) all the way down to
reduce pressure.
Ground
K
ti4295a
• The plug must be plugged into
an outlet that is properly
installed and grounded in
accordance with all local codes
and ordinances.
ti4303a
4 Open gun air valve (aa).
ti4296a
A
ti4000a
5 Aim gun into hopper
(C) or bucket and
squeeze tirgger until
all air and material
pressure is relieved.
• Do not modify plug! If it will not
fit in outlet, have grounded outlet installed by a qualified electrician.
• Sprayer model electric requirements are provided on page
32.
ti4297a
Extension Cords
• Only use an extension cord with
an undamaged 3-prong plug.
Ground
ti4294a
• For up to 100 ft (30.48 m) cord,
use 3-wire, 12 AWG (2.5 mm2)
minimum.
6
ti4295a
311161B
Preparation
Auxiliary Air Compressor
Hose Lengths
• Use Auxiliary Air Hookup Kit 287328 when additional
atomization air is necessary.
• The system comes with a twin line hose set consisting of a 1 in. ID x 25 ft (25 mm x 7.6 m) material hose
and a 3/8 in. ID air hose. Additional hose sections can
be added. Total final length of hose used should not
exceed 100 feet in length.
CAUTION
Attaching auxiliary air to sprayer without using the
Auxiliary Air Hookup Kit will damage sprayer.
Generators
CAUTION
Sprayer air hose fitting can get hot! Allow sprayer to
cool down 5 minutes before removing air hose.
7500 W (7.5 KW) minimum.
Tips for Using Generators
• Before running sprayer, make sure it is at room temperature. This will reduce startup current.
• Run generator at full throttle.
311161B
7
Removing and Replacing Hopper, Front and Back Covers
Removing and Replacing Hopper, Front and Back Covers
Front Cover
Before performing any service on sprayer
always:
Removing Cover
•
•
•
•
•
•
•
Read all warnings, page 2.
Read operating instructions manual, 311160.
Relieve Pressure, page 6.
Turn main power switch (A) OFF.
Unplug sprayer from outlet.
Remove air and material hoses.
Clean sprayer. See Operation Manual 311160.
1 Remove hopper.
2 Unscrew and
remove
knob (S).
3 Place you
hand under
front, bottom edge of
cover.
(3a) Lift
cover up,
(3b) then
S
pull bottom
toward you
and out to remove cover.
Hopper
Removing Hopper
1 To remove hopper
loosen fitting.
Fittings are
hand-tightened
and should not
require tools to
loosen.
3a
ti4408a
3b
Replacing Cover
2 Lift hopper straight
up, off frame.
ti4503a
Replacing Hopper
1 To replace
hopper, position
drain over fitting
as far as it will go,
making sure
identification label
faces out.
1 Place your
hand under
front, bottom
edge of cover.
(1a) Position
top edge of
1a
cover under
top metal lip
on sprayer
1b
frame.
(1b) Then
push up on
S
cover so lower
plastic edge
of cover has room to clear front metal frame and slide
cover into place. To position cover correctly, it will go
in at an angle.
ti4411a
2 Hand tighten fitting.
ti4504a
2 Replace knob (S). Hand tighten fitting.
3 Replace hopper.
8
311161B
Removing and Replacing Hopper, Front and Back Covers
Back Cover
To access the motor and all other components, it is
necessary to remove the hopper, front and back covers.
Replacing Cover
1 To reposition cover
on sprayer frame,
tip the cover back,
toward you and
slide it down, into
place in the base of
the frame. Then
push the top back
into place. Align
screw holes in side
and top of cover
with holes in frame.
Removing Cover
1 Completely
remove 6
screws (2 on top
and each side)
from cover.
ti4430a
ti4432a
2 Lift cover up and
then tilt it back
and off sprayer
frame.
2 Replace and
tighten screws.
ti4431a
311161B
ti4433a
9
RotoFlex™ HD Pump
RotoFlex™ HD Pump
4 Rotate pump assembly
sideways. Pull entire
assembly out of front of
sprayer frame.
Use RotoFlex HD Pump Replacement Kit 287314.
IMPORTANT
• After replacing RotoFlex HD Pump hose, always
follow Hose Break-In Procedure, page 12,
before operating sprayer.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
ti4376a
.
Then remove hopper and front cover, page 8.
1 Loosen and remove hose
extension.
ti4377a
ti4378a
2 Loosen and remove knob.
5 Separate the inner and
outer hose brackets.
6 Slide hose ends out of
slots in outer hose
bracket.
• Slide out of short slot
first.
ti4374a
3 Slide RotoFlex HD hose
off rollers.
ti4519a
7 Pull hose out of inner
hose bracket.
ti4379a
8 Discard pump hose.
10
311161B
RotoFlex™ HD Pump
Reassembly
4 Slide plates together, inserting inner plate in outer
plate, matching alignment holes.
1 Bend and kink new
pump hose from kit in
the middle as shown,
making sure dots on
hose fittings face each
other.
DOTS
5 Replace bracket
assembly in housing
making sure the
mounting screw hole,
located in the top center of the inner plate,
faces up.
ti3127a
2 Insert hose ends
through holes in inner
hose bracket, keeping
dots on fittings facing
each other and kinked
portion of hose horizontal to the underside
of bracket.
ti4383a
6 Slide pump hose
around rollers. Make
sure the rollers are
horizontally parallel to
each other.
alignment
holes
ti4520a
7 Slide feet on the bottom of hose bracket,
into the slot on the
bottom of sprayer.
3 Slide hose ends into
outer hose bracket,
making sure dots on fittings face each other
and alignment holes
are together.
• Slide into long slot
first.
ti4429a
8 Replace knob. Hand
tighten.
9 Reattach hose extension.
10 Replace front cover
and hopper. See
Removing and
Replacing Hopper,
Front and Back Cover,
page 8.
ti4381a
ti4386a
311161B
11
RotoFlex™ HD Pump
Hose Break-In Procedure
3 Turn power switch (A) on.
1 Make sure fluid flow
regulator (K) is turned all
the way down.
ti4653a
4 Hold in prime switch (P).
K
P
ti4303a
2 Pour approximately 1 gallon
hot water in
sprayer hopper
to lubricate the
pump.
ti4364a
WATER
5 Turn fluid flow regulator
(K) up to full pressure.
ti4301a
K
ti4655a
6 Run sprayer dry for 1 to 1-1/2 minutes.
12
311161B
Compressor and Motor Repair
Compressor and Motor Repair
Use Compressor and Motor Replacement Kit, 287344.
Kits include motor/compressor and mounting hardware.
4 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
Then remove hopper, front and back covers, page 8.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
ti4388b
5 Slide belt off motor pully.
1 Remove two screws and
access cover on the left
side of the motor.
ti4459a
6 Disconnect air line from
compressor to cooler
and remove.
ti4457a
2 Remove ground nut and
disconnect green ground
wire.
ti4460a
ti4458a
7 Remove 3 screws on
right side of cover and
remove cover.
3 Disconnect black and white
wires to motor.
ti4479a
ti4405a
ti4478a
311161B
13
Compressor and Motor Repair
Reassembly
8 Loosen 2 shoulder
bolts about 2-3 turns.
Do not remove them.
1 Using two new shoulder
bolts and rubber mounts
included in your kit, insert
bolts into openings until
they start to snug up on
rubber mounts.
ti4463a
ti4465a
9 Remove single
shoulder bolt on other
side of motor completely.
2 Slide new motor into
sprayer frame, aligning
motor frame opening
under bolts. Tighten bolts.
ti4425a
ti4468a
10 Slide out motor
assembly.
3 Replace shoulder bolt
on left side with new
bolt from your kit.
Tighten bolt.
ti4424a
ti4462a
4 Replace end cover.
Replace and tighten 3
screws.
11 Completely remove old
shoulder bolts and rubber mounts.
ti4484a
ti4464a
12 Thoroughly clean inside housing to remove dust and
debris.
ti4485a
5 Reattach air line to cooler
and compressor. Tighten
fitting.
ti4516a
14
311161B
Compressor and Motor Repair
6 Slide belt over pulleys and set tension. See Replacing
Belt, page 18.
8 Replace reattach green
ground wire and grounding
nut.
7 Reattach black and white
wires to motor.
Wires are not polarity
sensitive.
ti4470a
ti4412a
9 Replace cover plate and
screws.
10 Replace RotoFlex HD
Pump and hose extension, page 10.
11 Replace front and back
covers and hopper. See
Removing and Replacing
Hopper, Front and Back
Cover, page 8.
311161B
ti4471a
15
Compressor Rebuild Kit
Compressor Rebuild Kit
4 Remove 3/8 in. bolt
holding piston to
motor shaft.
To replace piston, seals and sleeve.
Use Compressor Rebuild Kit 287331.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
ti4707a
Then remove back cover, page 8.
1 Disconnect air line to
motor.
5 Loosen 4 bolts on top
of motor housing.
ti4460a
2 Remove 3 screws in
side of motor cover.
Remove cover.
ti4708a
6 Remove bolts and
housing from motor.
ti4479a
ti4478a
ti4709a
3 Remove fan bolt from
center of fan and
remove fan from
housing.
7 Remove piston rod
from motor.
8 Using parts in kit
replace piston, seals
and sleeve.
ti4706a
16
ti4710a
311161B
Compressor Rebuild Kit
Reassembly
5 Replace motor fan
and center fan bolt.
1 Insert new piston rod from
kit in motor housing.
6 Tighten bolt.
ti4704a
ti4700a
7 Replace motor
cover and screws.
2 Replace and tighten
piston bolt.
3 Replace top motor
hosing and 4 bolts.
ti4701a
ti4485a
8 Reconnect air line
from motor to
cooler.
9 Replace back cover.
See Removing and
Replacing Hopper,
Front and Back
Cover, page 8.
4 Tighten bolts.
ti4703a
311161B
17
Removing and Replacing Belt
Removing and Replacing Belt
Use Belt Replacement Kits 118845.
Replacing Belt
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
1 Using new belt from Kit,
position new belt around
pulleys making sure the
teeth in the belt are
properly engaged with
teeth on pulleys.
Then remove hopper, front and back covers, page 8.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
Removing Belt
ti4392a
1 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
2 Replace support rod.
Tighten 2 bolts (1 each
side) to secure supporting rod.
ti4388b
ti4393a
2 Loosen 2 bolts (1 each
side) holding down support rod.
3 Insert crow bar under
assembly as shown and
raise motor assembly
until desired belt tension is achieved.
ti4388a
ti4469a
3 Using a screw driver for
leverage, lift up on motor
support rod on one side
of motor and ease it out
of the holding bracket far
enough to remove old
belt. Discard old belt.
4 While holding motor
assembly in place with
crow bar. Spin pulley to
assure proper belt
engagement. Adjust
motor assembly position
as necessary.
At the same time, slide in
the new belt.
ti4472a
ti4391a
ti4459a
18
311161B
Removing and Replacing Belt
5 Tighten all 4 bolts.
A correctly tensioned belt will feel very tight. To
measure correct tension, apply 4-5 lbs pressure
at belt midpoint with thumb. Belt should have
approximately 1/8 in. (3.175 mm) deflection.
ti4394a
6 Turn belt one more
time with your hand to
make sure teeth are
properly engaged and
tension is correct.
ti4477a
A loose belt will not last long. If in doubt, tighten
more.
311161B
7 Replace RotoFlex HD
Pump and hose extension, page 10.
ti4473a
8 Replace back and front
covers and hopper.
See Removing and
Replacing Hopper, Front and Back Cover, page 8.
19
Roller Replacement
Roller Replacement
Use Roller Replacement Kit 287321.
Reassembly
Kit includes 2 rollers, 4 nylon washer, and 2 retaining
rings.
1 Replace roller assembly.
Disassembly
ti4398a
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
Then remove hopper, front and back covers, page 8.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
2 Reinstall snap ring.
1 Remove snap ring.
ti4399a
3 Replace RotoFlex HD Pump and hose extension,
page 10.
ti4396a
4 Replace back and front covers and hopper. See
Removing and Replacing Hopper, Front and Back
Cover, page 8.
2 Remove roller assembly
from rotor pins (a).
3 Clean rotor pins (a) and
check for damage. If pins
are worn or damaged,
replace rotor assembly,
(Rotor Assembly
Replacement, page 21.
20
ti4397a
a
311161B
Rotor Assembly Replacement
Rotor Assembly Replacement
Reassembly
Use Pump Assembly Replacement Kit 287255.
1 Put new rotor assembly from kit on shaft.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
2 Insert a wrench in the
pulley to prevent it
from moving.
Then remove hopper, front and back covers, page 8.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
ti4714a
1 To prevent rotor assembly
from moving, insert a long
screw driver or pry bar in the
pulley.
3 Replace bolt. Torque to
40 ft. lbs.
ti4714a
ti4712a
2 Remove large bolt and
washer in center of rotor
assembly.
4 Replace RotoFlex HD Pump and hose extension,
page 10.
3 Pull rotor assembly off
shaft.
ti4711a
5 Replace back and front covers and hopper. See
Removing and Replacing Hopper, Front and Back
Cover, page 8.
311161B
21
Air Cylinder and Solenoid Valve
Air Cylinder and Solenoid Valve
Use Cylinder Replacement Kit, 287323.
4 Gently push cylinder forward,
relieving tension on pin. Pull
out pin.
Use Solenoid Replacement Kit 287351.
Disassembly
ti4409a
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
Then remove hopper, front and back covers, page 8.
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
1 Remove hose from quick
release fitting by using your
fingers on one hand to push
in on ring while at the same
time, using the other hand,
gently pull the hose out of the
fitting.
If replacing solenoid valve only, it can be done at
this time.
a Using an adjustable wrench, rotate entire solenoid
valve assembly counter clockwise from cylinder.
b Replace solenoid valve and continue with step 4 of
reassembly.
5 Lift cylinder up and pull it
back.
6 Remove dampening
grommet.
ti4406a
2 Remove electric wire terminal connections.
ti4518a
7 Using a 15/16 in. wrench,
loosen nut, located inside
sprayer frame at the end
of the air cylinder.
ti4416a
3 Remove cotter key located
on the end of the cylinder pin,
by using a pliers to straighten
the ends and pull it out of the
hole.
ti4415a
8 Using a 15/16 in. wrench,
loosen nut on the other
side of the sprayer frame.
9 Pull cylinder out of sprayer
frame.
ti4453a
If replacing cylinder only,
remove solenoid valve
(see a and b above) and
reinstall on new cylinder.
ti4414a
22
311161B
Air Cylinder and Solenoid Valve
Reassembly
6 Replace cotter pin
through hole in pin,
bending ends to secure.
1 Insert crowned backing
nut on shaft of cylinder.
2 Using new cylinder
from kit, position cylinder in sprayer frame,
inserting end of cylinder through pump
bracket mounting hole.
ti4456a
ti4421a
3 Install locking nut flush
to end of shaft.
7 Reattach electric wire
terminals. Terminals are
not polarity sensitive and
can be connected to
either post.
4 Install dampening
grommet.
8 Gently push hose in
quick release fitting.
ti4417a
5 Align hole in end of air cylinder and replace pin.
ti4407a
ti4410a
9 Replace RotoFlex HD Pump and hose extension,
page 10.
10 Replace front cover and hopper. See Removing and
Replacing Hopper, Front and Back Cover, page 8.
ti4455a
311161B
23
Relief Valve and Flow Sensor Manifold
Relief Valve and Flow Sensor Manifold
Reassembly
Use Relief Valve Replacement Kit 287350.
1 Position new relief valve from Kit in back of sprayer.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
Then remove hopper, front and back covers, page 8.
1 Remove air line to
regulator.
2 Remove air line from
cooler to manifold.
2 Replace and tighten screws.
3 Reattach wires to Relief Valve.
4 Reattach air line from cooler to manifold.
5 Reattach air line to regulator.Replace RotoFlex HD
Pump and hose extension, page 10.
6 Replace front cover and hopper. See Removing and
Replacing Hopper, Front and Back Cover, page 8.
ti4423a
3 Disconnect wires to Relief Valve. Pay attention to their
location to insure they are reattached correctly.
4 Remove 2 nuts securing
Relief Valve to sprayer.
ti4418a
5 Remove Relief Valve
from sprayer frame.
ti4419a
24
311161B
Air Flow Sensor Replacement
Air Flow Sensor Replacement
2 Rotate counter-clockwise to
remove sensor
from manifold.
Use Sensor Replacement Kit 287345.
If you are just replacing the sensor, you do not
have to remove the motor first.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
ti4480a
Then remove hopper, front and back covers, page 8.
Reassembly
Remove hose extension and RotoFlex HD Pump
assembly from frame, page 10.
1 Rotate new sensor
from kit clockwise, all
the way into opening
in Relief Valve
housing. Lightly
tighten nut.
1 Disconnect all
wire
connections.
ti4486a
2 Reconnect all wires.
ti4481a
ti4482a
WHITE WIRE
3 Replace RotoFlex HD
Pump and hose extension, page 10.
ti4487a
ti4488a
4 Replace back and front
covers and hopper.
See Removing and
Replacing Hopper,
Front and Back Cover, page 8.
WHITE WIRE
311161B
25
Troubleshooting
Troubleshooting
Problem
Sprayer won’t run or stops intermittently
Pump won’t pump material or low
output
Cause
Solution
Power switch not on
Turn switch on.
No power at wall outlet
Check outlet by plugging in another
appliance. If appliance does not
work, try another outlet.
Wrong size generator
Use a 7500 watt or larger generator.
Refer to Generator Requirements,
page 7.
Temperature too cold
Allow unit to warm up.
Too many items on same circuit
Unplug other items from circuit.
Internal thermal switch tripped
Self-resetting. Allow unit to cool down
15 minutes and restart. Usually
occurs when wrong size extension
cord is used.
Extension cord too long or wrong
gauge
Use a 12 gage extension cord or
remove extension cord. Refer to
Grounding and Electric Requirements, page 6.
Breaker tripped
Reset breaker.
Air lock
Open air valve on gun.
Mix too thick
Add water to thin material. Use Material Thickness Gauge.
Loose fittings
Check and retighten all fittings.
Plugged gun
Relieve Pressure, page 6. Remove
gun from hose. Clean gun.
RotoFlex HD Pump worn out
Replace hose.
Pump cold or material frozen in pump Move pump to warm room and allow
it to warm up or run hot water through
sprayer.
Soft start won’t work/pump, always
loaded
Sensor is bad
Replace, page 25
Check air system for leaks
Remove shroud and examine for air
leaks
Loose wire
Remove shroud and examine wiring
No air pressure
Rebuild compressor
Sensor is bad
Change sensor, page 25
Air leak due to bad seal keeps valve
open
Replace seal
Normal soft start system delay
Release trigger for 10-15 seconds.
Retry.
Switch is not operating properly
Replace switch
Damaged solenoid valve on cylinder
Check gun supply, hose and sprayer
for leaks
AIr leak
26
311161B
Troubleshooting
Problem
Cause
Material runs out of bottom of sprayer RotoFlex HD Pump worn out
No air from compressor
Speed of application too slow
Solution
Replace hose.
Loose fittings
Check and retighten all fittings.
Gun air valve closed
Open gun air valve.
Gun needle plugged
Clean needle and retry.
Lines not connected
Check all quick disconnect connections to gun and hoses.
Damaged hose
Replace hose.
Worn compressor
Service compressor. Contact a qualified ASM Service Center.
Material too thick
Thin material.
Nozzle too small
Change nozzles to a larger size. See
Operation Manual 311160, Recommended Nozzle Selection Chart,
page 20.
Speed of application too slow (cont.) Flow control set too low
Increase flow control setting
Plugged or dirty gun
Relieve Pressure, page 6. Clean
gun.
Kinked hose
Unkink hose.
Gun fluid flow adjustment set too low Increase flow adjustment with flow
adjustment nut.
Intermittent flow/sputtering or air in
material
Hopper connection not tight
Check gasket. TIghten connection.
Debris in system
Clean
Air quick disconnect does not stay
connected.
Dirty or corroded fitting
Clean thoroughly. Soak in oil. Apply a
few drops of light oil.
Gun will not shut off
Worn nozzle or needle.
Relieve Pressure, page 6. Replace
worn parts.
Debris in needle passage
Relieve Pressure, page 6. Clean.
Fluid leaking at Flow Adjustment Nut Damaged seal.
Relieve Pressure, page 6. Replace
seal.
Needle adjustment won’t adjust
Dirty threads
Clean threads
Nozzle not on gun
Put nozzle on gun
Flow nut set to maximum adjustment Turn flow nut adjustment the other
way
311161B
27
Air Diagram
Air Diagram
2B
Air Cylinder
Air Compressor
54
17
Air Cooler
Regulator
16
82
47
Guage
One Way Valve
One Way Valve
58
Air Flow Control
ti4369a
Wiring Diagram
Air Compressor
Air Cylinder
39
51
32
Prime
Switch
8
Power
Switch
150/151
50
Air Flow
Control
Green
(Green/Yellow)
150/151
White (Blue)
Black (Brown)
ti4370b
(230V)
150/151
28
311161B
Parts
Parts
49A
102
49C
19
49B
22
1E
1D
49
21
9
1B
40
34
1A
53
33
43
1B
9
42
52
62
52
31
38
57
63
36
45
88
38A
38B
37
73
41
101
13
62
88
63
4
55
56
311161B
67
29
Parts
Parts
!
TI#
"
!
!
30
311161B
Parts List
Parts List
Item
No.
1
1A
1B
1D
3
4
5
5A
5B
6
7
8▲
9
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28▲
29
30
31
32
33
34
35
36
37
38
38A
38B
39
40
Part No. Description
287344 KIT, compressor replacement
(includes 1A, and 1B-1D), 230V
287331 KIT, compressor rebuild, 230V
119890 SCREW, shoulder
118886 GROMMET, isolator
119381 COVER, terminal
118844 REGULATOR, air, 1/8 in. NPT
118845 BELT
287323 KIT, cylinder, replacement,
(includes 5A, 5B, 89)
15D576 SPACER, crowned
118871 NUT, lock, 1/2-20
117720 GAUGE, pressure
115244 NUT, regulator
186620 LABEL, ground, symbol
117728 FITTING, compression, union
117693 SWITCH, power
119064 SWITCH, power
15D156 PULLEY, rotor
287350 VALVE, assembly, 230V (includes
sensor) sprayer
287351 VALVE, cylinder, 230V sprayer
118888 HOSE, air (includes 1/4 in. tubing
and one-way valve)
15C968 TUBE, air
287347 HOPPER, texture (includes
bracket)
15D862 NUT, hand
287345 KIT, sensor only, 230V
118876 TUBE, air, aluminum
117637 NUT, compression
287348 SHIELD, front (includes 28)
108471 KNOB, pronged
15D589 BRACKET, hose, outer
15D588 BRACKET, hose, inner
287314 KIT, RotoFlex HD Pump
189286 LABEL, warning
118885 HOSE, coupled (includes grommet)
287254 FRAME, texture, blue
112395 SCREW, cap
15D633 WIRE, jumper
103473 STRAP, tie, wire
15B815 COOLER
116478 WHEEL, pneumatic
101242 RING, retaining, ext.
287265 ROTOR, pump, assbly (includes
38, 38A, 38B)
287321 KIT, roller replacement (includes
38A, 38B and two rollers)
113983 RING, retaining, ext
117726 WASHER, nylon
15D628 CONDUCTOR, ground
103785 RIVET
311161B
Qty
1
1
3
3
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
2
1
2
2
1
2
2
4
1
2
Item
No.
Part No. Description
Qty
41
287327 KIT, repair, shaft, bracket, pump
assbly.
42
287256 BRACKET, compressor
43
118869 TUBE
45
15D610 SHAFT, motor, mount
49
287346 SHIELD, rear, assbly (includes 19,
49A, 49B, 49C)
49A 15D561 COVER, tool tray
49B▲ 15D939 LABEL, warning, English, French,
Spanish
287336 KIT, label, warning, all languages
except those included in 15D939
49C 15D940 LABEL, identification
51
15D634 WIRE, jumper
52
116937 BEARING, flanged, bronze
53
117633 SCREW, torx, tri lob
54
116666 TUBE, air
55
287304 HOSE SET, twin line, 1 in. x 25-ft
56
15C090 GAUGE, thickness, fluid
57
183401 KEY, parallel
58
116720 COUPLER, air, quick disconnect
59
104641 FITTING, bulkhead
60
116658 FITTING, tube, male, 1/4 NPT
62
108851 WASHER, plain
63
106276 SCREW, cap, hex head
66
116171 BUSHING, strain relief
67
113397 BALL, sponge, 30 mm
70
116411 SPRING, compression
71
116477 WASHER, flat, nylon
72
116342 CAP, end
73
112785 SCREW, flanged, hex head
74
115498 SCREW, mach, slot, hex, wash hd
77
102040 NUT, lock, hex
81▲ 198492 LABEL, warning
82
118887 HOSE, air (includes 1/4 in. tubing
and one-way valve)
83▲ 15D089 LABEL, warning, hot surface
88
118866 WASHER, flat
89
801012 GROMMET
90
15G009 LABEL, identification
91
15G010 LABEL, identification
92
15G012 LABEL, identification
93
118872 GASKET
101 249458 GUN, non-bleeder
150 15E056 CORD, power Europe/Australia/China, 230V, 50 Hz (requires
cord set adapter, 152, following)
151 15D902 CORD, power,
152 242005 ADAPTER, cord set, Australia/China
153 195551 RETAINER, (for 15D902)
154 15F966 GUARD, burp
1
1
1
1
1
1
1
2
8
1
1
1
2
1
1
1
2
2
1
2
2
2
2
2
1
2
2
1
1
1
1
1
1
1
4
1
1
1
1
1
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
31
Technical Data
Technical Data
Maximum working fluid pressure
Maximum working air pressure
Material pressure operating range
Compressor
Type
Air delivery
Motor
Hopper capacity
Maximum delivery with texture material
Dimensions
Length
Width
Height
Weight
With hoses and gun
Without hoses and gun
Wetted parts
Sound data
Sound pressure level*
Sound power level#
Generator (minimum size requirement)
Maximum external working air pressure (must use
External Air Hookup Kit 287328 ONLY)
100 psi (6.9 bar)
45 psi (3.1 bar)
0-100 psi (0 to 6.9 bar)
Oilless
6.5 CFM @ 40 psi (184.1 lpm @ 2.8 bar)
230V, 50 Hz 10A
15 US gallons (57 liters)
2.0 gpm (7.57 lpm)
27 in. (685.8 mm) with handles
26 in. (660.4 mm)
40 in. (1016 mm)
147 lb (66.68 kg)
131 lb (59.47 kg)
PVC, Buna-N, anodized aluminum, powder coat
aluminum, brass, polyethylene, SST, UHMW
85.8 db(A)
100.1 db(A)
7500W (7.5 kw)
120 psi (8.3 bar)
*Measured while spraying at 1 m.
#Measured per ISO-3744
32
311161B
Notes
Notes
311161B
33
Warranty
Warranty
ASM warrants all equipment referenced in this document which is manufactured by ASM and bearing its name to be free from defects in material
and workmanship on the date of sale by an authorized ASM distributor to the original purchaser for use. With the exception of any special,
extended, or limited warranty published by ASM, ASM will, for a period of twelve months from the date of sale, repair or replace 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 by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-ASM component parts. Nor shall ASM be liable for malfunction, damage or wear caused by the incompatibility of ASM equipment with
structures, accessories, equipment or materials not supplied by ASM, or the improper design, manufacture, installation, 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 for verification of
the claimed defect. If the claimed defect is verified, ASM will repair or replace free of charge any defective parts. The equipment will be returned to
the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, 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 incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
ASM MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY
ASM. These items sold, but not manufactured by ASM (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their
manufacturer. ASM will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will ASM be liable for indirect, incidental, special or consequential damages resulting from ASM supplying equipment hereunder, or the
furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of ASM, or otherwise.All written and visual data contained in this document reflects the latest product information available at the time
of publication. ASM reserves the right to make changes at any time without notice.
All written and visual data contained in this document reflects the latest product information available at the time of
publication.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English MM 311161
ASM Company, 3500 North 1st Avenue, Sioux Falls, SD 57104
www.asmcompany.com
Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
August 2012
34
311161B
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