ASM Zip-Spray ESP User manual

Operating Instructions 310749
Rev. C
2800 psi (193 bar, 19 MPa) Maximum Working Pressure
Model 248772, Series A
– For portable spray applications of architectural
paints and coatings – (Specifications, page 2)
ti3587B
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Use water based or mineral spirit–type material
only. Do not use materials having flash points lower
than 70_(21_). For information about your material
request MSDS from distributor or retailer.

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Specifications
This equipment is not intended for applications in places such as cabinet shops or other “factory”, fixed
locations or for repetitive applications. If you intend to use this equipment in this type of application, you must com-
ply with NFPA 33 and OSHA requirements which have similar expectations.
The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the
manual, refer back to these pages for a description of the specific hazard.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
DUse equipment only in well ventilated area.
DEliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop clothes (potential static arc).
DSprayer generates sparks. When flammable liquid is used in or near sprayer or for flushing or
cleaning, keep sprayer at least 20 ft (6 m) away from explosive vapors.
DKeep work area free of debris, including solvent, rags and gasoline.
DDo not plug or unplug power cords or turn lights on or off when flammable fumes are present.
DGround equipment and conductive objects in work area. Read Grounding instructions.
DIf there is static sparking or you feel a shock, stop operating immediately. Do not use equip-
ment until you identify and correct the problem.
DKeep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
DTurn off and disconnect power cord before servicing equipment.
DUse only grounded electrical outlets
DUse only 3–wire extension cords.
DEnsure ground prongs are intact on sprayer and extension cords.
DDo not expose to rain. Store indoors.
SKIN INJECTION HAZARD
High pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
DDo not point gun at anyone or any part of the body.
DDo not put your hand over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DEngage trigger lock when not spraying.
DFollow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.

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WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
DDo not exceed the maximum working pressure or temperature rating of the lowest rated
system component. Read Technical Data in all equipment manuals.
DUse fluids and solvents that are compatible with equipment wetted parts. Read Technical
Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For com-
plete information about your material, request MSDS from distributor or retailer.
DCheck equipment daily. Repair or replace worn or damaged parts immediately with genuine
ASM replacement parts only.
DDo not alter or modify equipment.
DUse equipment only for its intended purpose. Call your Graco distributor for information.
DRoute hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces.
DDo not kink or overbend hoses or use hoses to pull equipment.
DKeep children and animals away from work area.
DDo not operate the unit when fatigued or under the influence of drugs or alcohol.
DComply 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 and/or substantial property
damage.
TOXIC FLUID HAZARD
Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
DRead MSDS’s to know the specific hazards of the fluids you are using.
DStore hazardous fluid in approved containers and dispose of it according to all applicable
guidelines.
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:
DProtective eye wear.
DClothing and respirator as recommended by the fluid and solvent manufacturer.
DGloves.
DHearing protection.

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DThe sprayer requires a 120V AC, 60 Hz,
15A circuit with grounding receptacle.
Never use an outlet that is not grounded
or an adapter.
DDo not use the sprayer if the electrical cord
has a damaged ground prong. Only use an
extension cord with an undamaged, 3–prong
plug.
DRecommended extension cords for use
with this sprayer:
D25 ft (7.6 m) 18 AWG
D50 ft (15.2 m) 16 AWG
D100 ft (30.5 m) 14 AWG
D150 ft. (45.7 m) 12 AWG
Smaller gauge or longer extension cords may reduce
sprayer performance.
Grounding and Electric Requirements
DGround sprayer gun through connection to
a properly grounded fluid hose and pump.
DGround fluid supply container. Fol-
low local code.
DGround solvent pails used when flush-
ing. Follow local code. Use only conduc-
tive, 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.
ti5850a
ti5572a
The sprayer must be grounded. Grounding reduces the risk of static and
electric shock by providing an escape wire for the electrical current due to
static build up or in the event of a short circuit.
ti3001b

5310749
DGround the metal pail by connecting a
ground wire to the pail by clamping one
end to pail and the other end to ground
such as as water pipe.
DMaintain grounding continuity when
flushing or relieving pressure by holding
metal part of spray gun firmly to side of a
grounded metal pail, then trigger gun.
Grounding and Electric Requirements
Thermal Overload
DMotor has a thermal overload switch to
shut itself down if overheated.
ti5851a
To reduce risk of injury from motor staring
unexpectedly when it cools, always turn power
switch OFF if motor shuts down.

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1.Turn power switch OFF and unplug power cord.
2.Turn Spray–Prime/Drain valve to
PRIME/DRAIN to relieve pressure.
Pressure Relief Procedure
3.Turn pressure to lowest setting. Hold metal
part of gun firmly to a grounded metal pail.
Trigger gun to relieve pressure.
4.Engage trigger lock.
DLeave Spray–Prime/Drain valve in PRIME/DRAIN
position until you are ready to spray again.
DIf you suspect the spray tip is clogged or that
pressure has not been fully relieved after follow-
ing the above steps, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to
relieve pressure gradually. Then loosen com-
pletely. Clear hose or tip obstruction.
Follow Pressure Relief Procedure when you
stop spraying and before cleaning, checking, servicing or transporting
equipment.
PRIME
PRIME
9600B

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Gun
Power Switch
Pressure Control Knob
Component Identification
Suction
Tube
Inlet Screen
Spray/Prime Valve
Prime/drain position
Paint position
Prime Tube
Fluid Outlet Fitting

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5.Turn power switch OFF.
6.Connect one end of grounded fluid hose to
Gun. Use a wrench to tighten.
Setup
7.Connect other end of hose to sprayer
fluid outlet fitting. Use a wrench to
tighten.
8.Turn pressure control knob all the way left
(counterclockwise) to minimum pressure.
ti3586ati3586B

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1.Turn Spray/Prime valve to PRIME.
2.Separate prime tube (smaller) from suction
tube (larger).
Priming – Oil–based or Water–based Materials
3.Place prime tube in waste pail.
4.If spraying oil–based materials, submerge suc-
tion tube in mineral spirits or compatible oil–
based cleaning solution.
If spraying water–based materials, submerge
suction tube in water.
PRIME
WASTE
5.Plug sprayer into grounded outlet.
6.Point Gun into waste pail.
Mineral Spirits WATER
OR
WASTE
prime
tube
suction
tube

10 310749
Priming – Oil–based or Water–based Materials
7.Turn power switch ON.
8.Turn up pressure control knob until
pump starts.
30 to 60
seconds WASTE
9.Allow fluid to flow out of prime tube, into
waste pail, for 30 to 60 seconds.
10.Turn power switch OFF.
11.Submerge suction tube in paint.
12.Turn power switch ON.
PAINT

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13.When paint starts to come out of prime
tube, pull and hold gun trigger, and turn
Spray/Prime valve to SPRAY.
When paint comes out of gun, release
trigger.
Priming – Oil–based or Water–based Materials
14.Attach prime tube to suction tube.
15.Proceed to Spraying Operation, page 15.
NOTE: Motor stopping indicates pump and
hose are primed with paint.
pull and hold trigger
paint
Release trigger
SPRAY
WASTE
ti3586a
ti3586a
prime
tube
suction
tube
Pump Check Valves
Storing pump in water, inadequate flushing, or
ingested 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.
HINT: To determine if the inlet valve ball is sticking, unscrew inlet valve from pump and check it.
If sprayer continues to cycle (motor and pump run) after you release gun trigger, the pump valves may be
obstructed or worn. If they are worn, Valve Repair Kits are available. Consult an authorized service
center.
tap here
9564C
CAUTION: Excessive shock will fracture or cause
other damage to the pump.

12 310749
1.Turn Spray/Prime valve to PRIME.
Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
2.Separate prime tube (smaller) from suction
tube (larger).
NOTE: To spray water–based materials after spraying oil–based materials, follow the
procedure outlined below, using water instead of mineral spirits to flush system.
3.Place prime tube in waste pail.
4.Submerge suction tube in mineral spirits.
5.Plug sprayer into grounded outlet.
6.Point Gun into waste pail.
PRIME
WASTE
Mineral Spirits
prime
tube
suction
tube
WASTE

13310749
Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
7.Turn power switch ON.
8.Turn up pressure control knob until
pump starts.
9.Allow fluid to flow out of prime tube, into
waste pail, for 30 to 60 seconds.
10.Turn power switch OFF.
11.Submerge suction tube in paint.
30 to 60
seconds WASTE
PAINT

14 310749
Priming – Preparing to Spray Oil–Based Materials After Spraying Water–Based Materials
12.Turn power switch ON.
13.When paint starts to come out of prime tube, pull
and hold gun trigger and turn Spray/Prime valve
to spray. When paint
comes out of gun release trigger.
NOTE: The motor stopping indicates the
pump and hose are primed with paint.
14.Transfer prime tube to paint pail.
pull and hold trigger
paint
Release trigger
SPRAY
WASTE
ti3586a
ti3586a
NOTE: If pump does not prime after 30 seconds see Pump Check Valves, page 7
prime
tube
suction
tube

15310749
1.Engage trigger safety.
Spraying Operation
NOTE:
DTip must be pushed all the way into base.
DNever pull trigger when arrow shaped handle
is between SPRAY and UNCLOG position.
2.Assemble tip and base parts in order shown.
3.Screw tip and base assembly on gun and
tighten nut by hand.
9600B
Tip must be pushed
all the way into base.
Base
Tip
Retaining nut
Point the arrow shaped handle on the
Uni–tip forward to SPRAY and backward to
UNCLOG obstructions
UNCLOG – arrow
points backward
SPRAY – arrow
points forward
SAFETY ON
Put trigger safety lever
in SAFETY ON position
before you rotate
arrow-shaped handle.

16 310749
Tip Selection
Selecting a Tip Hole Size
Tips come in a variety of hole sizes for a range of fluids. Your Zip Spray ESP sprayer includes the tip most likely to
satisfy common spraying applications. Use the following table to determine the range of recommended tip hole
sizes for each fluid type. If you need a tip other than the one supplied, see the Uni–tip Selection Chart below.
Tip Hole Sizes
(expressed as
Coatings
(
expressed as
diameter, based on
area of elliptical
orifice)
stains enamels
oil-base
primers and
paints
interior
latex paints
exterior
latex paints
acrylics
0.011 in. (0.28 mm) X
0.013 in. (0.33 mm) X X X X
0.015 in. (0.38 mm) X X X X
0.017 in. (0.43 mm) X X X X
0.019 in. (0.48 mm) X X
HINTS:
DAs you spray, the tip wears and enlarges. Starting
with a tip hole size smaller than the maximum will
allow you to spray within the rated flow capacity of
the sprayer while using the tip you selected.
Uni–tip Selection Chart
Tip
Part No.
Fan Width
12 in. (305 mm)
from surface Hole Size
69–411 8 to 10 in.
(203 to 254 mm)
0.011 in. (0.28 mm)
69–511 10 to 12 in.
(254 to 305 mm)
0.011 in. (0.28 mm)
69–313 6 to 8 in.
(152 to 203 mm)
0.013 in. (0.33 mm)
69–413 8 to 10 in.
(203 to 254 mm)
0.013 in. (0.33 mm)
69–415 8 to 10 in.
(203 to 254 mm)
0.015 in. (0.38 mm)
69–515 10 to 12 in.
(254 to 305 mm)
0.015 in. (0.38 mm)
69–417 8 to 10 in.
(203 to 254 mm)
0.017 in. (0.43 mm)
69–517 10 to 12 in.
(254 to 305 mm)
0.017 in. (0.43 mm)
69–519 10 to 12 in.
(254 to 305 mm)
0.019 in. (0.48 mm)
69–619 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 size order Part No. 69–413.
Using the Right Tip for the Job
Consider the coating and the surface to be sprayed.
Make sure you use the best tip hole size for that
coating and the best fan width for that surface.
Tip Hole Size
Tip hole size controls the flow rate — the amount of
paint that comes out of the gun.
HINTS:
DGenerally, use larger tip hole sizes with thicker
coatings and smaller tip hole sizes with thinner
coatings.
DThe maximum tip hole size that a sprayer can
support is related to its maximum flow rate. The
maximum tip hole size supported by the Zip Spray
ESP sprayer is 0.015 in. (0.38 mm).
DTips wear with use and need periodic replacement.
Fan Width
Fan width is the size of the spray pattern, which deter-
mines the area covered with each stroke. For a given
tip hole size, narrower fans deliver a thicker coat, and
wider fans deliver a thinner coat.
HINTS:
DSelect a fan width best suited for the surface being
sprayed.
DWider fans allow for faster coverage on broad,
open surfaces.
DNarrower fans allow for better control on small,
confined surfaces.

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Tip Selection
Understanding the Tip Number
The last three digits of the tip number (example:
69–413) contain 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

18 310749
Spray Techniques
DSpray should be atomized (evenly dis-
tributed, no gaps at edges). Start at low
pressure setting, increase pressure a
little at a time until paint is atomized.
DTo prevent excessive tip wear, spray at
lowest pressure that atomizes paint.
DIf maximum pressure of sprayer is not
enough for good spray pattern, tip is too
large or too worn. See Uni–tip Selection
Chart, page 16.
Preventing Excessive Tip Wear
good
spray
pattern
pressure
too low
gaps at
edges
Getting Started with Basic Techniques
DHold gun 12 in. (30 cm) from
surface and aim straight at
surface. Tilting gun to direct
spray angle causes an un-
even finish.
12 in.
(30 cm)
even
finish
thin
uneven
finish
thick
DFlex wrist to keep gun pointed
straight. Fanning gun to direct
spray at angle causes uneven
finish.
Triggering Gun
DPull trigger after starting stroke, release
trigger before end of stroke. Gun must be
moving when trigger is pulled and released.
pull release
aim
here
Aiming Gun
DAim tip of gun at edge of previous stroke to
overlap each stroke by half.

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Cleanup
1.Relieve the pressure, page 2.
2.Turn power switch OFF.
3.Turn Spray/Prime valve to PRIME.
For short shutdown periods (breaks on the job) leave suction tube and prime tube in paint and relieve
pressure by turning Spray/Prime Valve to PRIME. For extended periods, clean sprayer by flushing as
instructed in this section.
Pail Flushing
For flushing after spraying non–water/solvent coat-
ings with compatible flushing fluid. For water–based
coatings, see Zip Flushing, page 21.
4.Remove suction tube from paint pail and allow it to
drain into paint pail for a few minutes. Then sub-
merge it in flushing fluid. For flushing water–based
materials, follow Zip Flush procedure, page 16.
5.Place prime tube in waste pail.
6.Turn pressure control knob to the left (counter–
clockwise) to minimum pressure.
WASTE
FLUSHING
FLUID
PRIME

20 310749
7. Point gun into waste pail and trigger gun a few seconds
to relieve pressure that might be in hose.
NOTE: To minimize splashing, aim gun at inside wall
of empty waste pail.
8.Remove tip and base assembly from gun and
place in flushing fluid pail.
Cleanup
9.Turn power switch ON and slowly align arrow
on sprayer with bucket symbol on Pressure
Control knob until pump starts. Continue
flushing until about 1/3 of flushing fluid is
gone from flushing fluid pail.
10.Turn power switch OFF.
11.Turn Spray/Prime valve to SPRAY.
WASTE
12.Trigger gun into paint pail.
13.Turn power switch ON. Continue to trigger
gun and flush sprayer until all the flushing
fluid is gone from flushing fluid pail.
14.Fill using with pump storage fluid, page 24.