Graco 309423D ASM Zip-Spray 1900 Airless Paint Sprayer Owner's Manual

Repair Instructions and Parts List 309423

Rev. D

1900 Airless Paint Sprayer

3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure

Hi-Boy

Model 233782, A, B

Stand

Model 246649, A

Related manuals

. . . . . . . 309427

. . . . . . . 309428 ti3915a

. . . . . . . 10803

Hi-Boy

233782

Table of Contents

Component Function and Identification

Grounding

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Repair Information

Spin Test

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

10

Motor Brush Replacement

On/Off Switch Replacement

. . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . . . . . . . 12

Pressure Control Repair . . . . . . . . . . . . . . . . . . . . . . . 14

Drive Housing Replacement . . . . . . . . . . . . . . . . . . . . 17

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Displacement Pump Replacement . . . . . . . . . . . . . . . 19

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ASM Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ASM Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIRE AND EXPLOSION HAZARD

A Fire and explosion hazard exists any time you spray or flush flammable fluids.

To help prevent fire or explosion when spraying flammable fluids

Be sure sprayer is adequately grounded through electrical outlet as follows:

– Use only grounded electrical outlets.

– Use only 3-wire extension cords.

– Make sure ground prongs are intact on sprayer and extension cords.

Motor in this sprayer is a source of sparks. Keep sprayer in well-ventilated area, at least 20 feet (6 meters) away from gun when spraying or flushing.

Do not use plastic drop cloths when spraying or flushing flammable fluids.

Avoid all ignition sources, such as pilot lights, cigarettes, and plastic drop cloths (static arc hazard). Do not plug in or unplug power cords or turn lights on or off in spray area.

Tape wall switches to prevent them from being turned off or on.

Do not smoke in spray area.

Use only ASM airless paint hoses.

Use outdoors or in a well-ventilated area.

EQUIPMENT MISUSE HAZARD

Misuse can cause the equipment to rupture or malfunction and result in serious injury.

To help prevent injury

Do not modify the extension tube or roller frame or use parts not designed for this equipment.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in this or any other pressurized aluminum equipment.

Such use could result in a chemical reaction, with the possibility of explosion.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in eyes eyes or on skin, inhaled, or swallowed.

To help prevent injury or death from toxic fluids

Know specific hazards of fluid you are using; store hazardous fluid in approved tub; dispose of hazardous fluid according to all local, state, and national guidelines.

Always wear protective eyewear, gloves, clothing, and respirator as recommended by fluid and solvent manufacturer.

RECOIL HAZARD

Due to the high pressure fluid emitted, a strong recoil action may occur when you trigger the In–line

Valve. If you are unprepared, your hand could be forced back toward your body or you could lose your balance and fall, resulting in serious injury.

FLUID INJECTION HAZARD

If high-pressure fluid pierces skin, the injury might look like “just a cut” but is a serious wound. Get immediate medical attention.

To help prevent injection

Always put trigger safety lever in SAFETY ON position when not spraying.

Always shut off power and relieve pressure when you stop spraying and before you service or clean sprayer, remove parts, or repair leaks. See

Pressure Relief Procedure below.

Do not allow children to use this equipment.

Keep clear of tip and/or roller frame. Never point at yourself or anyone else.

SAFETY ON pressure

FLUID SPLASHBACK HAZARD

To avoid splashing fluid when spraying into pail, always aim at inside wall of pail.

Make sure gun is assembled with correct gasket for fluid being sprayed.

PRESSURIZED EQUIPMENT HAZARD

This sprayer is capable of producing up to 2800 psi (19 MPa, 193 bar) maximum working pressure. To avoid component rupture and injury, do not operate sprayer with components rated less than pressure of sprayer.

Sprayer is equipped with a pressure drain that automatically relieves overpressure in the event of a fault condition. This automatic pressure relief may cause splashing of fluid. Correct fault before you resume spraying.

NOTE: Inadequate flushing and/or dried paint in drain system may prevent proper overpressure relief.

ELECTROCUTION HAZARD

Failure to observe the following electrical hazards could result in serious injury, including burns or electrocution.

To help prevent harmful electric shock

Use only grounded electrical outlets.

Only use 3-wire extension cords.

Make sure ground prongs are intact on sprayer and extension cords.

Keep electrical connections and inside of shroud dry.

Avoid contact with power lines.

Only use ASM paint hoses.

Unplug sprayer before servicing.

STARTUP HAZARD AFTER THERMAL

OVERLOAD

Motor has thermal overload switch to shut itself down if overheated. To reduce risk of injury from motor restarting unexpectedly when it cools, always turn Power switch OFF if motor shuts down.

2 309423

Component Identification and Function

T

A

H

J

B

R P S

K

F

D

E

G

N

U

V

M ti3916a

Fig. 1

A Motor

B Drive Assembly

DC motor, permanent magnet, fan cooled

Transfers power from DC motor to displacement pump

D

E

F

Displacement Pump

Fluid Outlet

Prime Valve

Transfers fluid to be sprayed from source through spray gun

Spray gun is connected here

Used to prime and drain sprayer (also relieves fluid outlet pressure) when open

Final filter of fluid to spray gun G Fluid Filter (optional)

H Pressure Adjusting Knob Controls fluid outlet pressure

J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet. Works with pressure adjusting knob.

K ON/OFF Switch

M 50 ft (15 m) Main Hose

Power switch that controls main power to sprayer

1/4 in. ID, grounded, nylon hose with spring guards on both ends

N Spray Gun

P Super Zip Tip

R Tip Guard

S Thumb Lock Safety

T Power Cord Rack

U Suction Hose

V Drain Tube

High pressure spray gun with gun safety latch

Uses high pressure fluid to clear tip clogs without removing tip from spray gun

Tip guard reduces risk of injection injury

Gun safety latch inhibits accidental triggering of spray gun

Holds wrapped power cord for storage

Transfers fluid to be sprayed from source to pump

Fluid outlet used to drain and prime the sprayer

309423 3

General Repair Information

Pressure Relief Procedure

1.

Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

WARNING

INJECTION HAZARD

System pressure must be manually relieved to prevent system from starting or spraying accidentally. Fluid under high pressure can be injected through skin and cause serious injury. To reduce risk of injury from injection, splashing fluid, or moving parts, follow Pressure Relief Procedure whenever you: are instructed to relieve pressure, stop spraying, check or service any system equipment, or install or clean spray tip.

WARNING

ELECTRIC SHOCK HAZARD

MOVING PARTS HAZARD

To reduce risk of serious injury, including electric shock, do not touch moving or electrical parts with fingers or tools while testing repair. Shut off and unplug sprayer when inspection is complete. Install all covers, gaskets, screws and washers before operating sprayer.

2.

Test repair after problem is corrected.

3.

If sprayer does not operate properly , review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, pages 5 – 9, for other possible solutions.

1. Lock gun safety latch.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4.

Unlock gun safety latch. Hold metal part of gun firmly to grounded metal pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open pressure drain valve. Leave pressure drain valve open until ready to spray again.

If suspected that spray tip or hose is completely clogged, or that pressure has not been fully relieved after following steps above , VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose obstruction.

WARNING

HOT SURFACES HAZARD

EXPLOSION HAZARD

Motor and drive housing may be very hot during operation and could burn skin if touched.

Flammable materials spilled on hot, bare motor could cause fire or explosion.

Have motor shroud in place during operation to reduce risk of burns, fire or explosion.

CAUTION

To reduce risk of pressure control malfunction:

Use needle nose pliers to disconnect wire. Never pull on wire, pull on connector.

Mate wire connectors properly. Center flat blade of insulated male connector in female connector.

Route wires carefully to avoid interference with other connections of pressure control. Do not pinch wires between cover and control box.

CAUTION

Do not run sprayer dry for more than 30 seconds to avoid damaging pump packings.

4.

Install motor shroud before operation of sprayer and replace if damaged. Motor shroud prevents overheating, and protects operator from possible electrical shock by touching terminals of capacitor.

It can also reduce risk of burns, fire or explosion; see preceding WARNING .

4 309423

Grounding

WARNING

Improper installation or alteration of grounding plug results in risk of electric shock, fire or explosion that could cause serious injury or death.

1.

100–120 Vac models require a 50/60 Hz, 15A circuit with a grounding receptacle. See Fig. 2.

2.

Do not alter ground prong or use adapter.

grounded outlets grounding prong

Fig. 2

3.

120 Vac: A 12 AWG, 3 wires with grounding prong,

300 ft (90 m) extension cord may be used. Long lengths reduce sprayer performance.

Troubleshooting

Relieve pressure ; page 4.

MOTOR WON’T OPERATE

TYPE OF PROBLEM

Basic Fluid Pressure

Problems

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

1. Pressure control knob setting. Motor will not run if at minimum setting (fully counterclockwise).

1. Slowly increase pressure setting to see if motor starts.

2. Spray tip or fluid filter may be clogged.

2. Relieve pressure and clear clog or clean filter; refer to separate gun or tip instruction manual.

Basic Mechanical

Problems

1. Pressure control knob setting.

2. Pump (13) for frozen or hardened paint.

1. Motor stops running when pressure setting is reached.

2. Thaw sprayer if water or water-based paint has frozen in sprayer. Place sprayer in warm area to thaw. Do not start sprayer until thawed completely. If paint hardened (dried) in sprayer, replace pump packings. ( Displacement Pump Replacement, page 19.)

2. Displacement pump connecting rod pin (9a).

Pin must be completely pushed into connecting rod (9) and retaining spring (9b) must be firmly in groove of pump pin. See Fig. 10.

2. Push pin into place and secure with spring retainer.

3. Motor (1). Remove drive housing assembly

(10). See page 17. Try to rotate fan by hand.

3. Replace motor (1) if fan won’t turn. See page

18.

Basic Electrical Problems 1. Motor control board. Board shuts down and displays error code.

1. Motor Control Board Diagnostics, page 14.

2. Electrical supply. Meter must read 85–130 Vac for 100–120 Vac models.

2. Reset building circuit breaker; replace building fuse. Try another outlet.

3. Extension cord. Check extension cord continuity with volt meter.

3. Replace extension cord.

4. Sprayer power supply cord (79). Inspect for damage such as broken insulation or wires.

4. Replace power supply cord.

309423 5

Troubleshooting

MOTOR WON’T OPERATE (Continued)

TYPE OF PROBLEM

Basic Electrical Problems

(continued)

WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

5.

That motor leads are securely fastened and properly mated.

5. Replace loose terminals; crimp to leads. Be sure terminals are firmly connected.

Clean circuit board terminals. Securely reconnect leads.

6. For loose motor brush lead connections and terminals. See page 10.

6. Tighten terminal screws. Replace brushes if leads are damaged. See page 10.

7. Brush length which must be 1/2 in. minimum.

See page 10.

7. Replace brushes. See page 10.

NOTE: Brushes do not wear at the same rate on both sides of motor. Check both brushes.

8. For broken or misaligned motor brush springs.

Rolled portion of spring must rest squarely on top of brush. See page 10.

8. Replace spring if broken. Realign spring with brush. See page 10.

9. Motor brushes may be binding in brush holders.

See page 10.

9. Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.

10.Motor armature commutator for burn spots, gouges and extreme roughness.

See page 10.

10.Remove motor and have motor shop resurface commutator if possible, page 18.

11. Motor armature for shorts using armature tester

(growler) or perform spin test. See page 10.

11. Replace motor, page 18.

Refer to wiring diagram on page 13, to identify test points (TP).

1. Power supply cord (79). Connect volt meter between TP1 (neutral) and TP2 (L2, 120 Vac).

Plug in sprayer. Meter must read 85–130 Vac for

100–120 Vac models.

Unplug sprayer.

1. Replace power supply cord.

2. ON/OFF switch (23). Connect volt meter between L1 or L and L2 or N terminal on ON/OFF switch. Plug in sprayer and turn ON.

Meter must read 85–130 Vac for 100–120 Vac models.

2. Replace ON/OFF switch, page12.

3. Motor thermal cutoff switch. Turn sprayer OFF.

Check for continuity between TO1 and TO2 with ohmmeter.

3. If thermal switch is open (no continuity), allow motor to cool. If switch remains open after motor cools, replace motor. If thermal switch closes after motor cools, correct cause of overheating.

4. All terminals for damage or loose fit.

4. Replace damaged terminals and reconnect securely.

6 309423

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM

Low Output

WHAT TO CHECK

If check is OK, go to next check

1. For worn spray tip.

WHAT TO DO

When check is not OK refer to this column

1. Follow Pressure Relief Procedure, then replace tip. See your separate gun or tip manual.

2. Verify pump does not continue to stroke when gun trigger is released.

2. Service pump, page 19.

3. Filter clogged (If optional filter is installed).

3. Relieve pressure. Check and clean filter.

4. Prime valve leaking.

5. Suction hose connections.

4. Relieve pressure. Repair prime valve.

5. Tighten any loose connections.

6. Electrical supply with volt meter.

Meter must read 85–130 Vac for 100–120 Vac models. Low voltages reduce sprayer performance.

6. Reset building circuit breaker; replace building fuse. Repair electrical outlet or try another outlet.

7. Extension cord size and length; must be at least

12 gauge wire and no longer than 300 ft. Longer cord lengths reduce sprayer performance.

7. Replace with a correct, grounded extension cord.

8. Leads from motor to pressure control circuit board (35) for damaged or loose wires or connectors. Inspect wiring insulation and terminals for signs of overheating.

8. Be sure male terminal blades are centered and firmly connected to female terminals.

Replace any loose terminal or damaged wiring. Securely reconnect terminals.

9. For loose motor brush leads and terminals, page 10.

9. Tighten terminal screws. Replace brushes if leads are damaged, page 10.

10.For worn motor brushes which must be 1/2 in.

minimum, page 10.

10. Replace brushes, page 10.

11. For broken and misaligned motor brush springs. Rolled portion of spring must rest squarely on top of brush.

11. Replace spring if broken. Realign spring with brush, page 10.

12.Motor brushes for binding in brush holders, page 10.

12.Clean brush holders, remove carbon dust with small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.

13.Low stall pressure.

13. Do either or both: a.

Turn pressure control knob fully clockwise. Make sure pressure control knob is properly installed to allow full clockwise position.

b.

Try a new transducer.

14.Motor armature for shorts by using an armature tester (growler) or perform spin test, page 10.

14.Replace motor, page 18.

309423 7

Troubleshooting

LOW OR FLUCTUATING OUTPUT

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

Motor runs and pump strokes 1. Paint supply.

2. Intake strainer clogged.

WHAT TO DO

When check is not OK refer to this column

1. Refill and reprime pump.

2. Remove and clean, then reinstall.

3. Suction tube or fittings loose.

3. Tighten; use thread sealant or sealing tape on threads if necessary.

4. To see if intake valve ball and piston ball are seating properly, page 19.

4. Remove intake valve and clean. Check balls and seats for nicks; replace if necessary, page 19. Strain paint before using to remove particles that could clog pump.

5. Leaking around throat packing nut which may indicate worn or damaged packings, page 19.

5. Replace packings, page 19. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut/wet-cup.

6. Pump rod damage.

6. Repair pump, page 19.

7. Capacitor failure. Visually inspect capacitor near terminals. Ensure that orange safety relief plug is intact.

7. Replace capacitor.

Motor runs but pump does not stroke

1. Displacement pump pin (9a) (damaged or missing), page 19.

1. Replace pump pin if missing. Be sure retainer spring (9b) is fully in groove all around connecting rod, page 19.

2. Connecting rod assembly (9) for damage, page 17.

2. Replace connecting rod assembly, page 17.

3. Gears or drive housing, page 17.

3. Inspect drive housing assembly and gears for damage and replace if necessary, page 17.

8 309423

Troubleshooting

MOTOR IS HOT AND RUNS INTERMITTENTLY

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

Motor is hot and runs intermittently.

1. Determine if sprayer was operated at high pressure with small tips, which causes low motor RPM and excessive heat build up.

1. Decrease pressure setting or increase tip size.

2. Be sure ambient temperature where sprayer is located is no more than 90 F and sprayer is not located in direct sun.

2. Move sprayer to shaded, cooler area if possible.

ELECTRICAL SHORT

TYPE OF PROBLEM WHAT TO CHECK

If check is OK, go to next check

WHAT TO DO

When check is not OK refer to this column

Building circuit breaker opens as soon as sprayer switch is turned on.

1. All electrical wiring for damaged insulation, and all terminals for loose fit or damage. Also wires between pressure control and motor. See page

18.

1. Repair or replace any damaged wiring or terminals. Securely reconnect all wires.

CAUTION

Any short in any part of the motor power circuit will cause the control circuit to inhibit sprayer operation. Correctly diagnose and repair all shorts before checking and replacing control board.

2. For missing inspection plate gasket (see page

18), bent terminal forks or other metal to metal contact points which could cause a short.

2. Correct faulty conditions.

3. Motor armature for shorts. Use an armature tester (growler) or perform spin test, page 10. Inspect windings for burns.

3. Replace motor, page 18.

4. Motor control board (35) by performing motor control board diagnostics, page 14. If diagnostics indicate, substitute with a good board.

4. Replace with a new pressure control board

(35), page 14.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

CAUTION: Do not perform this check until motor armature is determined to be good. A bad motor armature can burn out a good board.

1. Basic Electrical Problems, page 5.

1. Perform necessary procedures.

2. ON/OFF switch (23), page 12. Be sure sprayer is unplugged!

Disconnect wires from switch.

Check switch with ohmmeter. Reading must be infinity with ON/OFF switch OFF, and zero with switch ON.

2. Replace ON/OFF switch, page 12

3. For damaged or pinched wires in pressure control, page 14.

3. Replace damaged parts, page 14.

Sprayer quits after sprayer operates for 5 to 10 minutes.

1. Basic Electrical Problems, page 5.

1. Perform necessary procedures.

2. Electrical supply with volt meter.

Meter must read 85–130 Vac for 100–120 Vac models.

2. If voltage is too high, do not operate sprayer until corrected.

3. Tightness of pump packing nut. Over tightening tightens packings on rod, restricts pump action, and damages packings.

3. Loosen packing nut. Check for leaking around throat. Replace pump packings, if necessary, page 19.

.

309423 9

1.

Setup

Electric Shock Hazard, page 4.

Spin Test

To check armature, motor winding and brush electrical continuity:

Relieve pressure, page 4.

Armature, Brushes, and Motor Wiring Open

Circuit Test (Continuity)

1.

Connect red and black motor leads together with test lead. Turn motor fan by hand at about two revolutions per second.

2.

If uneven or no resistance, check for: broken brush springs, brush leads, motor leads; loose brush terminal screws, motor lead terminals; worn brushes. Repair as needed; page 10.

3.

If still uneven or no resistance, replace motor, page 18.

2.

Remove drive housing, page 17.

3.

Fig. 3. Remove pressure control cover (39). Disconnect motor leads (F) and (G).

4.

Fig. 4. Remove motor shroud (74).

Armature Short Circuit Test

Quickly turn motor fan by hand. If no electrical shorts, motor coasts two or three revolutions before complete stop. If motor does not spin freely, armature is shorted. Replace motor, page 18.

39

Fig. 3

F

G

Motor Brush Replacement

Motor Brush Removal

Replace brushes worn to less than 1/2 in. Check both sides. Brush Repair Kit 243215.

1.

Read General Repair Information, page 4.

74

9578A

2.

Relieve pressure, page 4.

3.

Fig. 4. Remove four screws (18) and motor shroud (74).

4.

Pry off two brush caps (A). Tag locations of red (+) and black (–) motor leads.

5.

Fig. 5. Remove screw (C) and discard brush (B) for motor with capacitor attached. Remove brush lead from control box for motor without capacitor attached.

(Continued on page 11)

Fig. 4

18 A

TI0053

10 309423

Motor Brush Replacement

6.

Fig. 5. Insert brush (B). Push clip (A) until it snaps into place and secures brush.

8.

Inspect commutator for excessive pitting, burning or gouging. A black color on commutator is normal.

Have commutator resurfaced by a motor repair shop if brushes wear too fast.

CAUTION

When installing brushes, follow all steps carefully to avoid damaging parts.

9.

Test brushes.

7.

Fig. 5. Install red (+) and black (–) motor leads according to tags. Install brush lead end with screw (C) to motor-mounted capacitor or route lead into control box and connect to board.

A a.

Remove pump (13); Displacement Pump

Replacement, page 19.

b.

With sprayer OFF, turn pressure control knob fully counterclockwise to minimum pressure.

Plug in sprayer.

C c.

Turn sprayer ON. Slowly increase pressure until motor is at full speed.

10. Break in brushes.

B a.

Operate sprayer 1 hour with no load.

b.

Install pump (13), Displacement Pump Replacement, page 19.

Fig. 5

TI0053

309423 11

Removal

1.

On/Off Switch Replacement

Installation

Relieve pressure ; page 4.

1.

Install new ON/OFF switch (23). Install locking ring

(24) and toggle boot (25).

2.

Fig. 6. Remove four screws (18) and pressure control cover (39).

3.

Disconnect two wires (A) from ON/OFF switch (23).

4.

Remove toggle boot (25) and locking ring (24).

Remove ON/OFF switch (23).

2.

Connect two wires (A) to ON/OFF switch.

3.

Install pressure control cover (39) with four screws (18).

25

24

A

35

37

18

23 ti3917a

22

52

D E

39

Fig. 6

12 309423

On/Off Switch Replacement

120 Vac

Power

Plug

ON/OFF

Switch

Black

60

34

L2 L1

35

Wiring Diagram

(Capacitor on Motor)

233782, A

Green

White from Motor

Black (–)

ON/OFF

Switch

White

Power

Plug

Black

Green

Pressure

Transducer

Yellow

Potentiometer

Red (+)

Capacitor

TI0060

N

L

M+ M–

Capacitor

TO1 TO2

J7

J8

Wiring Diagram

(Capacitor on PC board)

233782, B

246649, A

Red (+)

Black (–) from Motor

Yellow

Pressure

Transducer

Potentiometer ti2159a

Fig. 7

309423 13

Pressure Control Repair

Motor Control Board Diagnostics

Note: Keep a new transducer on hand to use for test.

CAUTION

Do not allow sprayer to develop fluid pressure without transducer installed. Leave drain valve open if test transducer is used.

1.

Remove four screws (18) and cover (39).

2.

Turn ON/OFF switch ON.

3.

Observe LED operation and reference following table:

4.

Relieve pressure and unplug sprayer before servicing control board ; page 4.

LED

BLINKS

Once

Once and stays ON

Two times repeatedly

Three times repeatedly

Four times repeatedly

Five times repeatedly

Six times repeatedly

SPRAYER OPERATION INDICATES WHAT TO DO

Sprayer runs

Sprayer shuts down and LED continues to blink two times repeatedly

Sprayer shuts down and LED continues to blink three times repeatedly

Normal operation

Sprayer shuts down and LED stays ON Motor open circuit or bad control board

Run away pressure. Pressure greater than 4500 psi

(310 bar, 31 MPa).

Pressure transducer is faulty or missing

Replace motor control board.

See following Motor Control

Board procedure.

Check transducer connection.

Open drain valve. Substitute new transducer for transducer in sprayer. If sprayer runs, replace transducer.

Line voltage is too high

Do nothing

Check motor brushes and armature. If OK, replace motor control board.

Sprayer shuts down and LED continues to blink four times repeatedly

Sprayer shuts down and LED continues to blink five times repeatedly

Sprayer shuts down and LED continues to blink six times repeatedly

Too much current

Motor thermal switch open circuit

Check for voltage supply problems

Check for locked rotor, shorted wiring or motor. Repair or replace failed parts.

Check for binding in pump or drive. Check for bad motor.

14 309423

1.

Removal

Refer to Fig. 6 and 7.

Pressure Control Repair

Motor Control Board

Installation

1.

Clean pad on rear of motor control board. Apply small amount of thermal compound 073019 to pad.

Relieve pressure ; page 4.

2.

Fig. 6. Install motor control board (35) with five screws (36).

2.

Remove four screws (18) and cover (39).

3.

Disconnect at motor control board (35):

Four motor leads: two yellow, black (–) and red (+).

Two line voltage leads.

Lead (D) from potentiometer.

Lead (E) from transducer.

4.

Remove five screws (36) and circuit board (35).

3.

Connect to motor control board (35):

Lead (E) to transducer.

Lead (D) to potentiometer.

Two line voltage leads.

Four motor leads: two yellow, black (–) and red (+).

4.

Install cover (39) with four screws (18).

309423 15

Pressure Control Repair

Pressure Control Transducer

Removal

Refer to Fig. 6 and 7.

1.

Relieve pressure ; page 4.

2.

Remove four screws (18) and cover (39).

3.

Disconnect lead (E) from motor control board (35).

4.

Remove two screws (22) and filter housing (45).

5.

Thread transducer lead plastic connector down through transducer grommet (28).

6.

Remove pressure control transducer (52) and packing o-ring (51) from filter housing.

Installation

1.

Install packing o-ring (51) and pressure control transducer (52) in filter housing (45). Torque to

30–35 ft-lb.

2.

Thread transducer lead plastic connector up through transducer grommet (28).

3.

Install filter housing (45) with two screws (22).

4.

Connect lead (E) to motor control board (35).

5.

Install cover (39) with four screws (18).

Pressure Adjust Potentiometer

Removal

Refer to Fig. 6 and 7.

1.

Relieve pressure ; page 4.

2.

Remove four screws (18) and cover (39).

3.

Disconnect all leads from motor control board (35).

4.

Remove five screws (36) and board (35)

5.

Remove potentiometer knob (27), sealing shaft nut

(33) and pressure adjust potentiometer (26).

Installation

1.

Install pressure adjust potentiometer (26), sealing shaft nut (33) and potentiometer knob (27).

a.

Turn potentiometer fully clockwise.

b.

Install knob at full clockwise position.

2.

Install board (35) with five screws (36).

3.

Connect all leads to motor control board (35).

4.

Install cover (39) with four screws (18).

16 309423

CAUTION

Do not drop gear cluster (7) when removing drive housing (10). Gear cluster may stay engaged in motor front end bell or drive housing.

Disassembly

1.

Drive Housing Replacement

Relieve pressure ; page 4.

2.

Remove pump (13), Displacement Pump Replacement, page 19.

3.

Fig. 8. Remove two screws (18a).Tip sprayer up.

Remove two screws (18b) and remove shroud

(74).

4.

Remove two front screws (22).

5.

Remove two back screws (22).

6.

Pull drive housing (10) off of motor (1).

Assembly

1.

Push drive housing (10) onto motor (1)

2.

Install two front screws (22).

3.

Install two back screws (22).

4.

Fig. 8. Install shroud (74) with two screw (18a).Tip

sprayer up. Install two screws (18b).

5.

Install pump (13) Displacement Pump

Replacement, page 17.

6.

Install new access cover (10a) with two screws

(10b).

74

18b

18a

1

22

7

10

10a

10b

22

18b ti3918a

Fig. 8

309423 17

Disassembly

1.

Motor Replacement

7.

Remove three screws (22) behind board and remove control housing (21).

Relieve pressure ; page 4.

2.

Remove pump (13), Displacement Pump

Replacement, page 17.

CAUTION

Do not drop gear cluster (7) when removing drive housing (10). Gear cluster may stay engaged in motor front end bell or drive housing.

3.

Remove drive housing (10), Drive Housing Replacement, page 17.

4.

Remove four screws (18) and cover (39).

5.

Disconnect all leads from board (35). Remove five screws (36) and board.

6.

Remove strain relief (37; Fig. 6) and motor fan (2).

8.

Remove four screws (22) and motor (1) from frame (63).

Assembly

1.

Install new motor (1) on frame (63) with four screws (22).

2.

Install control housing (21) with three screws (22).

3.

Install strain relief (37; Fig. 6) and motor fan (2).

4.

Install board (35) with five screws (36). Connect all leads to board (35).

5.

Install drive housing (10), Drive Housing Replacement, page 17.

6.

Install pump (13), Displacement Pump Replacement, page 19.

1

1 35

36

18

39

63

1

Liberally apply grease

Fig. 9

18 309423

22

1

22 ti3919a

1.

Flush pump (13).

2.

Displacement Pump Replacement

Relieve pressure ; page 4.

Removal

4.

Cycle pump until pump pin (9a) is in position to be removed. Remove pump pin (9a).

5.

Fig. 11. Remove suction tube (78) and hose (19).

6.

Loosen pump jam nut (12). Unscrew pump.

3.

Fig. 10. Loosen two screws (10b) and rotate cover (10a).

19

12

10b

10a

78

9a

9573A Fig. 10

TI1647A

Fig. 11

WARNING

If pin works loose, parts could break off due to force of pumping action. Parts could project through the air and result in serious injury or property damage.

Installation

4.

Screw in pump until threads are flush with drive housing opening. Align pump outlet to back.

5.

Fig. 11. Install suction tube (78) and hose (19).

6.

Fig. 13. Screw jam nut (12) up onto pump until nut stops. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately 75 +/–5 ft–lb (102 N m).

CAUTION

If the pump locknut loosens during operation, the threads of the drive housing will be damaged.

T

1.

Fig. 12. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod.

Fig. 13 TI0063

7.

Fig. 14. Fill packing nut with ASM Packing Seal until fluid flows onto top of seal.

A

10b

10a

TI0062

Fig. 12

2.

Fig. 10. Install pump pin (9a). Verify retainer spring

(9b) is in groove of pump pin.

3.

Push pump up until pump threads engage.

Fig. 14 TI0061

8.

Fig. 10. rotate cover (10a); tighten screws (10b).

309423 19

Zip Spray 1900 Sprayer

Model 246649

18

Parts Drawing – Sprayer

74

127

75

126

2

71

18

69

1

3

7

9

22

78

9b

PARTS, PAGE 24

53

55

56

57

31

59

58

38

114

31

Ref 19

45

47

82

62

49

86

85

Ref 84

84 Ref

19

128

62

84

67

22

77

63

65 ti3920a

92

67

113

10

12

70

68

10b

10a

22

9a

13

103

135

87

Ref 78

112

20 309423

Parts List – Sprayer

1

2

3

7

9

245893

115525

243219

243218

243221

9a 195175

9b 195512

10 243220

†

10a 195099

10b 115492

12 195150

13 243187

18 115492

19 241926

22 115495

31 195847

38 116150

45 195157

47 104361

49 195372

53 111699

55 187615

56 235014

57 224807

58 111600

59 187625

62 162453

Zip Spray 1900 Sprayer

Model 246649

REF

NO.

PART NO.

DESCRIPTION

MOTOR, 120 vac

BLADE, fan motor

GEAR, combination

CRANK SHAFT

CONNECTING ROD includes 9a and 9b

PIN, pump

RETAINER, pin

DRIVE HOUSING includes 10a and 10b

COVER

SCREW

NUT, jam, pump

PUMP

Manual 309428

SCREW, mach slot hex, washer hd

HOSE, coupled, high pressure

SCREW, slot hd, hex, washer hd

ADAPTER, pipe, hex

FITTING, adapter

HOUSING, filter

O–RING

CAP, filter

GASKET, seat, valve

VALVE, seat

ASSY, drain valve includes 53 and 55

ASSY, cam, drain valve

PIN, grooved

HANDLE, valve, drain

NIPPLE, 1/4 npt(m) x 1/4 npsm

QTY

1

1

1

1

1

4

1

8

2

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

REF

NO.

PART NO.

DESCRIPTION QTY

63

65

67

68

69

70 100016

71 108063

74

75

92

103

112

241858

195177

107310

115506

195425

245439

198933

77 115723

78 244354

82 235004

84 244040

85 241920

86 195186

87 114958

206994

115764

116987

113 116986

114 195811

126 195833

127 195838

128 115491

135 156684

FRAME, stand mount

HOLDER, suction tube

PLUG, tubing

SCREW, slot hd, hex, washer hd

HANDLE, sprayer

WASHER, lock

GRIP, handle

SHROUD, motor includes 18, 75, 126, 127

VENT, side

SCREW, mach, pnhd, self–drill

HOSE, suction, flexible

STRAINER

HOSE, drain, includes 85, 86

DEFLECTOR, threaded

CLIP, spring

STRAP, tie

FLUID, TSL, 8 oz

FITTING, elbow, 90

GUN, 400 Series, 4–Finger

Manual 10803

HOSE, coupled, 1/4 in. x 50 ft (15 m)

LABEL, instruction

LABEL, WARNING

LABEL, DANGER

WIPER, rod

UNION, adapter (swivel)

Extra Danger and Warning tags and labels available free.

† Motor Brush Kit 243215 is available

1

1

4

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

309423 21

Zip Spray 1900 Sprayer

Model 233782

Parts Drawing – Sprayer

* Parts 130 through 134 not used on later models. See Parts List – Spraye r, page 23.

69

112

74

18

127

1

75

113

126

2

18

130*

71

133*

134*

131*

132*

1

3

7 ti3921a

87

9

10

22

PARTS, PAGE 24

53

55

56

57

59

58

31

38

114

31

45

72

88

62

47

80

9b

65

19

62

86

67

12

9a

10b

10a

22

13

84

81

84

49

85

78

77

22

63

67

82

66

70

22 309423

Parts List – Sprayer

Zip Spray 1900 Sprayer

Model 233782

REF

NO.

PART NO.

DESCRIPTION

1

2

3

7

9

242009†

245893†

115525

243219

243218

243221

9a 195175

9b 195512

10 243220

10a 195099

10b 115492

12 195150

13 243187

18 115492

19 241926

22 115495

31 195847

38 116150

45 195157

47 104361

49 195139

53 111699

55 187615

56 235014

57 224807

58 111600

59 187625

62 162453

63 241934

65 195497

KIT, MOTOR, 120 vac

233782, A

233782, B

BLADE, fan motor

KIT, GEAR, combination

KIT, CRANK SHAFT

KIT, CONNECTING ROD includes 9a and 9b

PIN, pump

RETAINER, pin

KIT, DRIVE HOUSING includes 10a and 10b

COVER

SCREW

NUT, jam, pump

PUMP

Manual 309428

SCREW, mach slot hex, washer hd

HOSE, coupled, high pressure

SCREW, slot hd, hex, washer hd

ADAPTER, pipe, hex

FITTING, adapter

HOUSING, filter

O–RING

CAP, filter

GASKET, seat, valve

VALVE, seat

KIT, DRAIN VALVE includes 53 and 55

ASSY, cam, drain valve

PIN, grooved

HANDLE, valve, drain

NIPPLE, 1/4 npt(m) x 1/4 npsm

FRAME, cart

HOOK, pail

QTY

1

1

1

1

4

1

8

2

1

1

1

1

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

REF

NO.

PART NO.

DESCRIPTION QTY

66

67

69

70

71

101242

107310

241938

106062

115480

72 105521

74 245439

75 198933

77 104811

78 198973

80 245527

81 196773

82 245530

84 244042

85 241920

86 195696

87 115979

88 115097

112 116987

113 116986

114 195811

126 195833

127 195838

130 115762*

131 103546*

132 243415*

133 195936*

134 195937*

RING, retaining, external

PLUG, tubing

HANDLE, cart

WHEEL, semi–pneumatic

KNOB, t–handle

PLUG, tubing

SHROUD, motor,kit includes 18, 75, 126, 127

VENT, side

CAP, hub

TUBE, suction

FILTER, fluid

FILTER, insert

STRAINER, kit

KIT, RETURN line

DEFLECTOR, threaded

CLIP, spring

PLUG

SCREW

GUN, 400 Series, 4–Finger

HOSE, 1/4 in. x 50 ft (15 m)

LABEL, instruction

LABEL, WARNING

LABEL, DANGER

SCREW

STRAP, tie, wire

KIT, CAPACITOR

WIRE, jumper, red

WIRE, jumper, black

Extra Danger and Warning tags and labels available free.

† Motor Brush Kit 243215 is available

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

4

1

2

2

4

1

* Used on 233782, A only

309423 23

39

18

30

Parts Drawing – Sprayer

29

25

24

32

27

33

26

23 37

Ref 1

36

34

35

60

22 ti3922a

21 Ref 45

40

28

22

52

51

24 309423

Zip Spray 1900 Sprayer

Parts List – Sprayer

REF

NO.

PART NO.

DESCRIPTION

18 115492

21 276539

22 115495

23 195429

24 105658

25 195428

26 236352

27 116167

28 195423

29 241729

30 114421

32 196904

33 112382

SCREW, slot hd, hex, washer hd

HOUSING, control

SCREW, slot hd, hex, washer hd

SWITCH, toggle

RING, locking

BOOT, toggle

CORD SET, power

BUSHING, strain relief

LABEL, control

NUT, shaft, sealing

QTY

4

1

5

1

1

1

1

1

1

1

POTENTIOMETER, adjust, pressure 1

KNOB, potentiometer

GROMMET, transducer

1

1

REF

NO.

PART NO.

DESCRIPTION

34 115498

35

241989

245892

245892

36 115494

37 115756

39 198935

40 15D086

51 111457

52 243222

60 195866

SCREW, slot hd, hex, washer hd

BOARD, control

233782, A

233782, B

246649, A

SCREW, 6–32 X 1/2, TAPTITE

BUSHING, strain relief

CONTROL, cover

LABEL, identification

O–RING

TRANSDUCER, pressure control includes 51

WIRE, jumper

QTY

1

1

1

1

1

1

1

5

1

1

1

35

Wiring Diagram

(Capacitor on Motor)

233782, A

ON/OFF

Switch

Black

60

1

34

Power

Plug

Green

White from Motor

Black (–)

Ref134

Ref133

Red (+)

Fig. 15

Pressure Transducer

Yellow

Potentiometer

Capacitor

1 Used on 233782 A only

TI0060

309423 25

ON/OFF

Switch

Power

Plug

Black

White

Parts List – Sprayer

N

M+ M–

L

Capacitor

TO1 TO2

J7

J8

Wiring Diagram

(Capacitor on PC Board)

233782, B

246649, A

Green

Red (+)

Black (–) from Motor

Yellow

Pressure

Transducer

Potentiometer ti2159a

Fig. 16

Technical Data

100–120V, ∅ ,

A, Hz

220–240V, ∅ ,

A, Hz

Generator

Minimum W

Motor HP

(W)

1, 15, 50/60 1, 10, 50/60 3000 7/8 (653)

Basic Sprayer Wetted Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . zinc-plated carbon steel, polyurethane, polyethylene, stainless steel, PTFE , Delrin , chrome plating, leather, V-Max UHMWPE, aluminum, stainless steel, tungsten carbide

NOTE: Delrin and PTFE

Cycles per gallon

(liter)

680 (180)

Maximum

Delivery gpm

(lpm)

0.38 (1.25)

Maximum

Tip size

Fluid Outlet npsm

0.019

1/4 in.

Dimensions

Weight lb (kg)

76.5 (28.55)

Height in. (cm)

32.0 (81.28)

Length in. (cm)

24.0 (60.96)

Width in. (cm)

22.0 (55.88)

26 309423

Notes

309423 27

ASM Standard 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.

FOR ASM BRAZILIAN/CANADIAN/COLUMBIAN CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered 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.

28 309423

ASM Company, 3500 N. 1st Avenue, Sioux Falls, SD 57104 www.asmcompany.com

PRINTED IN USA 309423 10/2001, Revised 7/2003