ASM Zip-Tex 1500 Electric 249457 Operating instructions

311161B
EN
Repair
Zip-Tex 1500 Electric
Texture Sprayer
- 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
Related Manuals
*Auxiliary AIr Hookup Kit
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.
311160
311159
310694*
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Warnings
2311161B
Warnings
The following general warnings are related to the safe setup, use, grounding, maintenance and repair of this equip-
ment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-spe-
cific 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 explo-
sion:
• 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.

Warnings
311161B 3
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
WARNING
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.

Component Identification
4311161B
Component Identification
A
C
F
H
K
M
L
E
B
D
P
T
U
S
R
V
W
G
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Component Identification
311161B 5
Component Identification
❖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.
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)*
PPrimeSwitch
RPowerCord
S Pump Access Screw
T Hose - 25-ft.
U Material Thickness Gauge
V Cleaning Ball
W Spare Hose Gaskets

Preparation
6311161B
Preparation
Pressure Relief Procedure
1 Turn Main Power Switch
(A) OFF.
2 Unplug sprayer.
3 Turn fluid flow regulator
(K) all the way down to
reduce pressure.
4 Open gun air valve (aa).
5 Aim gun into hopper
(C) or bucket and
squeeze tirgger until
all air and material
pressure is relieved.
Grounding and Electric Requirements
The sprayer must be grounded. Grounding reduces the
risk of electrical shock by providing an escape wire for
the electrical current.
• The sprayer cord includes a
grounding wire with an appro-
priate grounding prong.
• The plug must be plugged into
an outlet that is properly
installed and grounded in
accordance with all local codes
and ordinances.
• Do not modify plug! If it will not
fit in outlet, have grounded out-
let installed by a qualified elec-
trician.
• Sprayer model electric require-
ments are provided on page
32.
Extension Cords
• Only use an extension cord with
an undamaged 3-prong plug.
• For up to 100 ft (30.48 m) cord,
use 3-wire, 12 AWG (2.5 mm2)
minimum.
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K
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A
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Ground
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Ground
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Preparation
311161B 7
Auxiliary Air Compressor
• Use Auxiliary Air Hookup Kit 287328 when additional
atomization air is necessary.
Generators
7500 W (7.5 KW) minimum.
Tips for Using Generators
• Before running sprayer, make sure it is at room tem-
perature. This will reduce startup current.
• Run generator at full throttle.
Hose Lengths
• The system comes with a twin line hose set consist-
ing 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. CAUTION
Sprayer air hose fitting can get hot! Allow sprayer to
cool down 5 minutes before removing air hose.

Removing and Replacing Hopper, Front and Back Covers
8311161B
Removing and Replacing Hopper, Front and Back Covers
Before performing any service on sprayer
always:
• 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.
Hopper
Removing Hopper
1 To remove hopper
loosen fitting.
Fittings are
hand-tightened
and should not
require tools to
loosen.
2 Lift hopper straight
up, off frame.
Replacing Hopper
1 To replace
hopper, position
drain over fitting
as far as it will go,
making sure
identification label
faces out.
2 Hand tighten fit-
ting.
Front Cover
Removing Cover
1 Remove hopper.
2 Unscrew and
remove
knob (S).
3 Place you
hand under
front, bot-
tom edge of
cover.
(3a) Lift
cover up,
(3b) then
pull bottom
toward you
and out to remove cover.
Replacing Cover
1 Place your
hand under
front, bottom
edge of cover.
(1a) Position
top edge of
cover under
top metal lip
on sprayer
frame.
(1b) Then
push up on
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.
2 Replace knob (S). Hand tighten fitting.
3 Replace hopper.
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S
3a
3b
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S
1a
1b

Removing and Replacing Hopper, Front and Back Covers
311161B 9
Back Cover
To access the motor and all other components, it is
necessary to remove the hopper, front and back covers.
Removing Cover
1 Completely
remove 6
screws (2 on top
and each side)
from cover.
2 Lift cover up and
then tilt it back
and off sprayer
frame.
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.
2 Replace and
tighten screws.
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RotoFlex™ HD Pump
10 311161B
RotoFlex™ HD Pump
Use RotoFlex HD Pump Replacement Kit 287314.
Disassembly
First read and follow instructions in the Before
performing any service on sprayer section, page 8.
Then remove hopper and front cover, page 8.
1 Loosen and remove hose
extension.
2 Loosen and remove knob.
3 Slide RotoFlex HD hose
off rollers.
4 Rotate pump assembly
sideways. Pull entire
assembly out of front of
sprayer frame.
.
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.
7 Pull hose out of inner
hose bracket.
8 Discard pump hose.
IMPORTANT
• After replacing RotoFlex HD Pump hose, always
follow Hose Break-In Procedure, page 12,
before operating sprayer.
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RotoFlex™ HD Pump
311161B 11
Reassembly
1 Bend and kink new
pump hose from kit in
the middle as shown,
making sure dots on
hose fittings face each
other.
2 Insert hose ends
through holes in inner
hose bracket, keeping
dots on fittings facing
each other and kinked
portion of hose hori-
zontal to the underside
of bracket.
3 Slide hose ends into
outer hose bracket,
making sure dots on fit-
tings face each other
and alignment holes
are together.
• Slide into long slot
first.
4 Slide plates together, inserting inner plate in outer
plate, matching alignment holes.
5 Replace bracket
assembly in housing
making sure the
mounting screw hole,
located in the top cen-
ter of the inner plate,
faces up.
6 Slide pump hose
around rollers. Make
sure the rollers are
horizontally parallel to
each other.
7 Slide feet on the bot-
tom of hose bracket,
into the slot on the
bottom of sprayer.
8 Replace knob. Hand
tighten.
9 Reattach hose exten-
sion.
10 Replace front cover
and hopper. See
Removing and
Replacing Hopper,
Front and Back Cover,
page 8.
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DOTS
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alignment
holes
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RotoFlex™ HD Pump
12 311161B
Hose Break-In Procedure
1 Make sure fluid flow
regulator (K) is turned all
the way down.
2 Pour approxi-
mately 1 gallon
hot water in
sprayer hopper
to lubricate the
pump.
3 Turn power switch (A) on.
4 Hold in prime switch (P).
5 Turn fluid flow regulator
(K) up to full pressure.
6 Run sprayer dry for 1 to 1-1/2 minutes.
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K
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WATER
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P
K
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Compressor and Motor Repair
311161B 13
Compressor and Motor Repair
Use Compressor and Motor Replacement Kit, 287344.
Kits include motor/compressor and mounting hardware.
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.
1 Remove two screws and
access cover on the left
side of the motor.
2 Remove ground nut and
disconnect green ground
wire.
3 Disconnect black and white
wires to motor.
4 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
5 Slide belt off motor pully.
6 Disconnect air line from
compressor to cooler
and remove.
7 Remove 3 screws on
right side of cover and
remove cover.
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Compressor and Motor Repair
14 311161B
8 Loosen 2 shoulder
bolts about 2-3 turns.
Do not remove them.
9 Remove single
shoulder bolt on other
side of motor com-
pletely.
10 Slide out motor
assembly.
11 Completely remove old
shoulder bolts and rub-
ber mounts.
12 Thoroughly clean inside housing to remove dust and
debris.
Reassembly
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.
2 Slide new motor into
sprayer frame, aligning
motor frame opening
under bolts. Tighten bolts.
3 Replace shoulder bolt
on left side with new
bolt from your kit.
Tighten bolt.
4 Replace end cover.
Replace and tighten 3
screws.
5 Reattach air line to cooler
and compressor. Tighten
fitting.
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Compressor and Motor Repair
311161B 15
6 Slide belt over pulleys and set tension. See Replacing
Belt, page 18.
7 Reattach black and white
wires to motor.
8 Replace reattach green
ground wire and grounding
nut.
9 Replace cover plate and
screws.
10 Replace RotoFlex HD
Pump and hose exten-
sion, page 10.
11 Replace front and back
covers and hopper. See
Removing and Replacing
Hopper, Front and Back
Cover, page 8.
Wires are not polarity
sensitive.
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Compressor Rebuild Kit
16 311161B
Compressor Rebuild Kit
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.
Then remove back cover, page 8.
1 Disconnect air line to
motor.
2 Remove 3 screws in
side of motor cover.
Remove cover.
3 Remove fan bolt from
center of fan and
remove fan from
housing.
4 Remove 3/8 in. bolt
holding piston to
motor shaft.
5 Loosen 4 bolts on top
of motor housing.
6 Remove bolts and
housing from motor.
7 Remove piston rod
from motor.
8 Using parts in kit
replace piston, seals
and sleeve.
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Compressor Rebuild Kit
311161B 17
Reassembly
1 Insert new piston rod from
kit in motor housing.
2 Replace and tighten
piston bolt.
3 Replace top motor
hosing and 4 bolts.
4 Tighten bolts.
5 Replace motor fan
and center fan bolt.
6 Tighten bolt.
7 Replace motor
cover and screws.
8 Reconnect air line
from motor to
cooler.
9 Replace back cover.
See Removing and
Replacing Hopper,
Front and Back
Cover, page 8.
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Removing and Replacing Belt
18 311161B
Removing and Replacing Belt
Use Belt Replacement Kits 118845.
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.
Removing Belt
1 Loosen 4 bolts (2 each
side) to loosen tension on
belt.
2 Loosen 2 bolts (1 each
side) holding down sup-
port rod.
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.
At the same time, slide in
the new belt.
Replacing Belt
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.
2 Replace support rod.
Tighten 2 bolts (1 each
side) to secure support-
ing rod.
3 Insert crow bar under
assembly as shown and
raise motor assembly
until desired belt ten-
sion is achieved.
4 While holding motor
assembly in place with
crow bar. Spin pulley to
assure proper belt
engagement. Adjust
motor assembly position
as necessary.
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Removing and Replacing Belt
311161B 19
5 Tighten all 4 bolts.
6 Turn belt one more
time with your hand to
make sure teeth are
properly engaged and
tension is correct.
7 Replace RotoFlex HD
Pump and hose exten-
sion, page 10.
8 Replace back and front
covers and hopper.
See Removing and
Replacing Hopper, Front and Back Cover, page 8.
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.
A loose belt will not last long. If in doubt, tighten
more.
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Roller Replacement
20 311161B
Roller Replacement
Use Roller Replacement Kit 287321.
Kit includes 2 rollers, 4 nylon washer, and 2 retaining
rings.
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.
1 Remove snap ring.
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.
Reassembly
1 Replace roller assembly.
2 Reinstall snap ring.
3 Replace RotoFlex HD Pump and hose extension,
page 10.
4 Replace back and front covers and hopper. See
Removing and Replacing Hopper, Front and Back
Cover, page 8.
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a
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