ASM Zip-Spray 233782 Repair Instructions And Parts List Download | Manualshive

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309423

Parts Drawing – Sprayer

9540d

Zip Spray 1900 Sprayer

Model 246649

7

10

128

71

9

12

9b

1

74

9a

10a

59

62

84 Ref

103

113

85

13

10b

3

87

92

31

77

63

Ref 19

31

19

49

82

78

65

68

45

58

57

56

55

53

84

38

Ref 84

Ref 78

47

69

22

22

112

67

70

86

2

75

18

18

62

127

126

22

67

PARTS, PAGE 24

114

135

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Summary of Contents for Zip-Spray 233782

Page 1: ...onent Function and Identification 3 Grounding 5 Troubleshooting 5 General Repair Information 4 Spin Test 10 Motor Brush Replacement 10 On Off Switch Replacement 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 ti1644b 10803 Related manuals 309428 309427 Hi Boy 233782 ...

Page 2: ...ts 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 ...

Page 3: ...e Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet Works with pressure adjusting knob K ON OFF Switch Power switch that controls main power to sprayer M 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends N Spray Gun High pressure spray gun with gun safety latch P Super Zip Tip Uses high pressure fluid to clear tip clogs with...

Page 4: ...le connector Route wires carefully to avoid interference with other connections of pressure control Do not pinch wires between cover and control box 1 Keep all screws nuts washers gaskets and electrical fittings removed during repair proce dures These parts are not normally provided with replacement assemblies WARNING ELECTRIC SHOCK HAZARD MOVING PARTS HAZARD To reduce risk of serious injury inclu...

Page 5: ...s 1 Pressure control knob setting 1 Motor stops running when pressure setting is reached 2 Pump 13 for frozen or hardened paint 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 Dis placement Pump Replacement page 19 2 Displacement pump connectin...

Page 6: ...aning 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 resur face 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 o...

Page 7: ...om motor to pressure control circuit board 35 for damaged or loose wires or con nectors 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 br...

Page 8: ...ould 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 re lief plug is intact 7 Replace...

Page 9: ...e 18 4 Motor control board 35 by performing motor control board diagnostics page 14 If diagnos tics indicate substitute with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 4 Replace with a new pressure control board 35 page 14 1 Basic Electrical Problems page 5 1 Perform necessary procedures 2 ON OFF swit...

Page 10: ...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 9578A Fig 3 F G 39 Motor Brush Replacement Motor Brush Removal Replace brushes worn to less than 1 2 in Chec...

Page 11: ...to board Fig 5 A TI0053 B C 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 9 Test brushes 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 Turn sprayer ON Slow...

Page 12: ...ect two wires A from ON OFF switch 23 4 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 2 Connect two wires A to ON OFF switch 3 Install pressure control cover 39 with four screws 18 ti2157a Fig 6 39 A 18 23 36 52 E D 35 36 25 24 37 22 ...

Page 13: ...Red Wiring Diagram Yellow White Black Black Capacitor TI0060 Green Fig 7 L2 L1 60 35 34 Capacitor on Motor Wiring Diagram Capacitor on PC board 233782 A 233782 B 246649 A ti2159a Pressure Transducer ON OFF Switch Power Plug Potentiometer from Motor Capacitor Black Green White Yellow Black Red N L M M TO1 TO2 J7 J8 ...

Page 14: ...continues to blink two times repeatedly Run away pressure Pres sure greater than 4500 psi 310 bar 31 MPa Replace motor control board See following Motor Control Board procedure Three times repeatedly Sprayer shuts down and LED continues to blink three times repeatedly Pressure transducer is faulty or missing Check transducer connection Open drain valve Substitute new transducer for transducer in s...

Page 15: ...ds Lead D from potentiometer Lead E from transducer 4 Remove five screws 36 and circuit board 35 Installation 1 Clean pad on rear of motor control board Apply small amount of thermal compound 073019 to pad 2 Fig 6 Install motor control board 35 with five screws 36 3 Connect to motor control board 35 Lead E to transducer Lead D to potentiometer Two line voltage leads Four motor leads two yellow bla...

Page 16: ...r 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 kno...

Page 17: ...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 Inst...

Page 18: ...ve screws 36 and board 6 Remove strain relief 37 Fig 6 and motor fan 2 7 Remove three screws 22 behind board and remove control housing 21 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 al...

Page 19: ...ring operation the threads of the drive housing will be damaged 1 Fig 12 Extend pump piston rod fully Apply grease to top of pump rod at A or inside connecting rod Fig 12 A TI0062 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 4 Screw in pump until threads are flush with drive housing opening Align pump outlet to back 5 Fig ...

Page 20: ...y 1900 Sprayer Model 246649 7 10 128 71 9 12 9b 1 74 9a 10a 59 62 84 Ref 103 113 85 13 10b 3 87 92 31 77 63 Ref 19 31 19 49 82 78 65 68 45 58 57 56 55 53 84 38 Ref 84 Ref 78 47 69 22 22 112 67 70 86 2 75 18 18 62 127 126 22 67 PARTS PAGE 24 114 135 ...

Page 21: ...3 and 55 57 224807 ASSY cam drain valve 1 58 111600 PIN grooved 1 59 187625 HANDLE valve drain 1 62 162453 NIPPLE 1 4 npt m x 1 4 npsm 2 63 241858 FRAME stand mount 1 65 195177 HOLDER suction tube 1 67 107310 PLUG tubing 4 68 115506 SCREW slot hd hex washer hd 1 69 195425 HANDLE sprayer 1 70 100016 WASHER lock 1 71 108063 GRIP handle 1 74 245439 SHROUD motor 1 includes 18 75 126 127 75 198933 VENT...

Page 22: ...12 9b 1 74 9a 10a 59 62 112 13 10b 3 85 31 77 63 31 19 49 72 45 58 57 56 55 53 84 38 84 78 47 22 22 113 67 10 86 2 75 18 18 62 127 126 22 67 130 131 134 133 PARTS PAGE 24 114 69 87 65 82 81 80 66 70 1 88 132 Parts 130 through 134 not used on later models See Parts List Sprayer page 23 ...

Page 23: ...7 224807 ASSY cam drain valve 1 58 111600 PIN grooved 1 59 187625 HANDLE valve drain 1 62 162453 NIPPLE 1 4 npt m x 1 4 npsm 2 63 241934 FRAME cart 1 65 195497 HOOK pail 1 66 101242 RING retaining external 2 67 107310 PLUG tubing 4 69 241938 HANDLE cart 1 70 106062 WHEEL semi pneumatic 2 71 115480 KNOB t handle 2 72 105521 PLUG tubing 4 74 245439 SHROUD motor kit 1 includes 18 75 126 127 75 198933...

Page 24: ...24 309423 Parts Drawing Sprayer 9538A 22 52 29 21 18 25 24 51 28 22 23 33 27 32 39 36 35 26 Ref 1 Ref 45 34 37 60 30 ...

Page 25: ...power 1 30 114421 BUSHING strain relief 1 32 196904 LABEL control 1 33 112382 NUT shaft sealing 1 34 115498 SCREW slot hd hex washer hd 1 35 BOARD control 241989 233782 A 1 245892 233782 B 1 245892 246649 A 1 36 115494 SCREW 6 32 X 1 2 TAPTITE 5 37 115756 BUSHING strain relief 1 39 198943 CONTROL cover 1 51 111457 O RING 1 52 243222 TRANSDUCER pressure control 1 includes 51 60 195866 WIRE jumper 1...

Page 26: ...ator Minimum W Motor HP W Cycles per gallon liter Maximum Delivery gpm lpm Maximum Tip size Fluid Outlet npsm 1 15 50 60 1 10 50 60 3000 7 8 653 680 180 0 38 1 25 0 019 1 4 in Basic Sprayer Wetted Parts zinc plated carbon steel polyurethane polyethylene stainless steel Delrin chrome plating leather V Max UHMWPE aluminum stainless steel tungsten carbide NOTE Delrin and Dimensions Weight lb kg Heigh...

Page 27: ...27 309423 Notes ...

Page 28: ...osts 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 inc...

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