Troubleshooting

Tools Required: Garden hose.

Sometimes, although rare, after a long period of storage, the sprayer's diaphragm pump may become non-responsive. Priming the system correctly is critical to restoring functionality. One of the most effective methods is forcing water into the pump through the inlet filter inside the tank.

 Watch the video below to effectively prime your unresponsive sprayer.

STEP 1: Remove the mesh screen holder from the inlet filter.

• Take the tank lid off and locate the inlet filter at the bottom of the tank.
• Turn the inlet filter until the mesh screen is facing up.
• Remove the white piece of the inlet filter containing the mesh screen. On Series 2 models, you will have to remove the rubber elbow as well.

STEP 2: Insert a charged battery into the sprayer and bring a hose up to the inlet filter barb.

STEP 3: Turn the sprayer on the highest setting (Level 5) and deliver water into the barb.

• Turn the water on and allow water to enter through the inlet filter barb. 
  
• Rapidly squeeze and release the spray gun trigger until water comes out. 
• Once water begins flowing, reattach the inlet filter screen. Make sure to turn the inlet filter until it faces the bottom on the tank.
  

Tools Required: Garden hose.

Sometimes, although rare, after a long period of storage, the sprayer's diaphragm pump may become non-responsive. Priming the system correctly is critical to restoring functionality. One of the most effective methods is forcing water into the pump through the inlet filter inside the tank.

 Watch the video below to effectively prime your unresponsive SwapTank™ sprayer.

STEP 1: Disconnect the spray hose assembly from the quick-connect at the base of the tank.

STEP 2: Add a bit of water into the sprayer's tank.

STEP 3: Insert a charged battery into the sprayer and turn it on.

STEP 4: Bring the garden hose to the male quick-connect at the sprayer base and channel water into it for a few seconds.

STEP 5: Reattach the hose assembly and test the sprayer.

Tools Required: voltmeter, Phillip's screwdriver, pliers.

If your sprayer is unresponsive, there are a number of areas that may be the source of the problem. Watch the video below to learn about common issues and the steps required to resolve them.

STEP 1: Check the battery.

• Insert a charged, functional battery into the sprayer.
• If you don't have a spare functional battery, press the indicator button on your battery. If no LED lights appear or the lights are red, the battery must be replaced.
• A voltmeter can be used to check the battery in question; turn your voltmeter to 200V DC. Hold the positive electrode on the positive battery terminal and hold the negative electrode to the negative battery terminal. It should read close to 18V. If thee is a low or zero reading, the battery must be replaced. 

STEP 2: Check the pressure dial/rocker switch.

• For dual-pressure units: unscrew the cover plate and set aside. Unscrew the strain relief fitting. Using pliers, disconnect the spade fitting from the power switch and move to the neighboring extra set of wire contacts. Test the sprayer.
• For variable-pressure units: if the dial rotates continuously without a stopping point, replace the dial.

STEP 3: Check the microswitch.

• Locate the microswitch housing (shaped like the letter "P") at the bottom of the pump. Remove the top and bottom screw from the housing to reveal the microswitch.
  
• Using pliers, remove the connection that sits furthest away from the pump. Do not pull on the wire; squeezing the tab while pulling on the connector will release the pin and it should come off with ease.
• Insert a battery into the sprayer and turn the unit on. Bypass the microswitch by touching the disconnected terminal to the terminal that is still connected to the pump. Note: you may need to pull down the see-through rubber insulators to ensure metal-to-metal connection.
• If this test causes the pump to turn on, you have a defective microswitch. If this test does not activate the pump and you know your battery to be functional, you likely need a replacement circuit board.
  

Tools Required: Phillip's head screwdriver, flathead screwdriver.

STEP 1: Check for leaks from the spray gun assembly.

STEP 2: Check for leaks from the hose and pump.

• Unscrew the cover plate and remove. With water in the sprayer, start spraying and look for leaks.
• If the sprayer is leaking from where the hose connects to the pump, tighten the hose clamp.
• If you notice leaking from the pump diaphragm, replace the pump.

STEP 3: Make changes to the adjustment screw.

• Stand the sprayer upright and fill the sprayer with a bit of water. Turn it on.
• Locate the microswitch house (shaped like the letter "P") at the bottom of the pump.
• Use a Phillip's head screwdriver to tighten or loosen the adjustment screw (located between the two screws holding the microswitch housing in place) up to one full turn.
• Activate the sprayer's trigger to test the response. Keep making adjustments until the trigger performs appropriately.
  

STEP 4: Check the pressure dial.

• If you have a variable-pressure unit, try turning the power dial. If it rotates continuously, the dial will have to be replaced.

Tools Required: water, push pin, Phillips screwdriver, cloth/towel

STEP 1: Check the chemicals that were used in the sprayer.

• Check the chemical labels to make sure all the solutions used are compatible with the materials in the sprayer.
• Ingredients such as petroleum oil distillates and essential oils will break down the seals and require a diaphragm pump replacement.

STEP 2: Inspect the nozzles for clogs.

• Clear any buildup with a push pin.

STEP 3: Check the inlet filter.

• Locate the inlet filter at the bottom of the tank and make sure the mesh filter screen is present.
• If the mesh screen is dirty, remove the white inlet screen holder and rinse it under fresh water.
• Wipe the mesh screen with a clean cloth.
  
• Reinstall the inlet filter screen.

STEP 4: Check the interior jumper hose.

• Remove the seven screws around the front cover plate and open the sprayer up.
• Locate the interior jumper hose by the diaphragm pump. If the jumper hose is twisted, it must be replaced (see "Replacing the exterior hose and interior jumper hose" below).

STEP 5: Close the sprayer up.

• Once troubleshooting is complete, re-attach the front cover plate using the seven screws.

STEP 1: For variable-pressure sprayers.

• Check if the pressure dial is rotating continuously with no stopping point. If so, the dial and circuit board must be replaced.
• If the dial is functioning normally, replace the circuit board only.

STEP 2: For dual-pressure sprayers.

• Replace the circuit board.

STEP 1: Check the trigger for leaks.

STEP 2: Check the adjustment screw.

• Unscrew the cover plate and set aside.
• Locate the microswitch housing (shaped like the letter "P") at the bottom of the pump.
• Using a Phillip's head screwdriver, turn the adjustment screw (located between the two screws securing the microswitch housing in place) up to a full turn.
• Keep making small adjustments until the trigger behaves normally.

Tools Required: Phllips head screwdriver, needle nose pliers.

If you purchased a Tool Only sprayer, these adapters are included. Replacement QuickSwap™ Battery Adapters can be purchased online here or with your preferred chemical/tool distributor.

• Make sure the sprayer is off and the battery has been removed. Out of the box, your sprayer will have a FlowZone holster pre-installed. Locate it under the battery door.
• Remove the installed battery adapter by unscrewing the 4 screws.
• Turn the battery adapter over to reveal the circuit board wires.
• Using the pliers, gently pinch the tabs on the connectors to disconnect them from the battery holster. You may have to slide the rubber protectors down to access the tabs.
• Set the holster aside and select the QuickSwap™ adapter you wish to install. The battery adapter's compatibility is noted on its label.
  
• Connect your chosen QuickSwap™ adapter to the circuit board. Insert the red wire into the positive terminal (+) and the black wire into the negative terminal (-).
• Set the QuickSwap™ adapter into place on the sprayer cover by gently tucking the wires behind.
• Secure the adapter into place using the 4 screws.

Tools Required: knife, Phllip's head screwdriver, pliers.

Replacement circuit boards can be purchased online here or with your preferred chemical/tool distributor.

• Make sure the sprayer is off and the battery has been removed. Taking your screwdriver, unscrew the cover plate. Loosen the strain relief fitting and set the cover plate aside.
• Unscrew the battery holster and detach it from the sprayer tank. Using your fingers or a pair of pliers, gently remove the wires connected to the battery holster.
• To access the wires underneath the pump. loosen the screws securing the pump to the tank.
• Using the knife, carefully slice the protective tape surrounding the pump-to-circuit board connection. Disconnect the circuit board from the diaphragm pump and slide the wires our from under the pump.
• Disconnect the circuit board from the power dial in the same fashion by slicing the protective tape.
• Follow the previous steps in the reverse order to connect the replacement circuit board. Connect the power dial, connect the pump, and slide the wires under. Secure the diaphragm pump back to the sprayer tank.
• Attach the wires to the back of the battery holster while taking note of the color of the wires. Red = positive; black = negative.
• Place the battery back into position and secure it.
• Insert a battery into the holster and test the sprayer. If the sprayer starts up normally, you may close it up.

Tools Required: Phllip's head screwdriver, pliers (optional).

Replacement microswitches can be purchased online here or with your preferred chemical/tool distributor.

• With the battery taken our of your sprayer, take your screwdriver, unscrew the cover plate, loosen the strain relief fitting, and set the cover aside.
• Locate the microswitch housing (it looks like the letter "P") at the bottom of the pump. Remove the top and bottom screws from the housing to reveal the microswitch.
• Take the microswitch out of the pump. Using pliers or your fingers, gently disconnect the spade connectors from the old microswitch. Note: make sure to remove using the retaining tabs and not by pulling on the wire. Attach the connectors to the replacement microswitch.
• Place the replacement microswitch into its slot and secure the screws back onto the housing.
• Insert a battery into the battery holster and turn your sprayer on. Test the sprayer. If the sprayer is functional, close it up and secure the cover plate.

Tools Required: wrench, Phillips screwdriver, hot water

Replacement hoses can be purchased online here or with your preferred chemical/tool distributor.

• With the battery taken our of your sprayer, twist the exterior hose off the threaded connector.
• Loosen the seven screws securing the front cover plate (three can be found under the battery cover).
• Using the wrench, loosen and remove the nut on the threaded hose connection.
• Open the front cover and locate the interior jumper hose by the diaphragm pump.
• Twist off the collar securing the interior jumper hose to the pump barb.
• Pull the jumper hose off the pump barb and remove it.
• Take the replacement interior jumper hose and dip the end into a container of hot water for 1-2 minutes. This will soften the rubber material and make the next step easier.
• Slide the collar onto the jumper hose and bring it to the pump barb. Wiggle the end of the jumper hose onto the pump barb and secure the collar onto the threads.
• Before closing the front cover plate, remove the nut from the threaded hose connection. Slide the hose connection through the front cover plate while closing the sprayer.
• Hand tighten the nut onto the threaded hose connection.
• Secure the front cover plate onto the sprayer tank using the seven screws.
• Using the wrench, fully tighten the nut onto the threaded hose connection.
• Attach the replacement hose to the exterior hose connection. 

Tools Required: Phllip's head screwdriver, flat-head screwdriver, hot water, knife.

Replacement pumps can be purchased online here or with your preferred chemical/tool distributor.

• With the battery taken our of your sprayer, take your screwdriver, unscrew the cover plate, loosen the strain relief fitting, and set the cover aside.
• Locate the hose clamps securing the hoses to the pump barbs. Using a flat-head screwdriver, loosen both of the clamps. Gently maneuver the outlet hose off of the pump barb and remove it. The jumper hose will be detached later.
• At the point, you may want to detach the circuit board from the cover plate to give yourself more room to work. Using a knife, slice any protective tape around the connection and disconnect the circuit board using your fingers.
• Take the Phillip's head screwdriver and loosen the four screws holding the pump to the tank. You should find the pump-to-circuit board connection underneath the pump. Again, take your knife and slice the protective tape. Then, use your fingers to disconnect the circuit board from the pump.
• Firmly grip the pump and wriggle it off of the jumper hose.
• Connect the replacement pump by following the above directions in reverse: slide the jumper hose onto the pump barb, connect the circuit board, and secure the replacement pump to the tank.
• To re-connect the outlet hose, it may be helpful to dip the end of the hose in a cup of hot water for 10-15 seconds. This allows the material to soften. Slide the hose clamp onto the outlet hose and slip it back onto the pump barb.
• Tighten both hose clamps over the pump barbs with the flat-head screwdriver.
• With a little bit of water in the tank, place a battery into the battery holster and turn your sprayer on to test it. Take note of any leaking around the pump connections. If there is leaking present, tighten the hose clamps further.
• If everything is working properly, slide the circuit board back into its slot on the cover plate and secure the cover plate back onto the tank.

Tools Required: Phllip's head screwdriver, flat-head screwdriver, hot water, pliers (optional).

Replacement cover plates can be purchased online here or with your preferred chemical/tool distributor.

• With the battery taken our of your sprayer, take your screwdriver, unscrew the cover plate, loosen the strain relief fitting, and set the cover aside.
• Locate the hose clamp by the pump and taking the flat-head screwdriver, loosen the hose clamp. Gently pry the end of the hose off of the pump connection.
• Using pliers or your fingers, disconnect the circuit board connections from the dial. The connections should come off easily when squeezing the translucent clips at the connection.
• Slide the hose through the new cover plate with the replacement pressure dial and slide the hose clamp onto the hose.
• Dip the end of the hose into hot water for 10-15 seconds to allow the hose material to expand.
• Bring the end of the hose to the pump barb and slip it on. Slide the hose clamp down until it's over the hose-to-pump connection. Tighten the hose clamp using the flat-head screwdriver until the clamp is secure.
• Bring the circuit board connections to the replacement pressure dial and clip in place.
• Place a battery into the battery holster and turn the sprayer on. Ensure the sprayer operates on all pressure settings by twisting the pressure dial.
• If the sprayer is functional, replace the cover plate and secure with screws.

Tools Required: Phllip's head screwdriver, flat-head screwdriver, pliers (optional).

Replacement power switches can be purchased online here or with your preferred chemical/tool distributor.

• With the battery taken our of your sprayer, take your screwdriver, unscrew the cover plate, loosen the strain relief fitting, and set the cover aside.
• Taking the pliers or using your fingers, gently remove the circuit board connections from the power switch. The connections should come off easily when squeezing the translucent clips.
• Using a flat-head screwdriver, hold down on the tabs on the power switch and pop it out from the sprayer housing.
• Carefully, push the replacement pressure switch in its place.
• Reconnect the red, white, and black wires of the circuit board to the new power switch.
• Place a battery in the battery holster and turn the sprayer on. Ensure the sprayer operates on both pressure settings by flipping the power switch.
• Bring the circuit board connections to the replacement pressure dial and clip in place.
• Place a battery into the battery holster and turn the sprayer on. Ensure the sprayer operates on all pressure settings by twisting the pressure dial.
• If the sprayer is functional, replace the cover plate and secure with screws.

Tools Required: Phllip's head screwdriver.

Replacement battery covers can be purchased online here or with your preferred chemical/tool distributor.

• Using the screwdriver, unscrew and remove the bumpers below the battery door.
• Open the battery door and remove it by holding it upright and pushing down while pulling out.
• Slide the pin out from the spring and old battery door.
• Place the spring into the slots on the replacement battery door. Slide the pin through the spring and replacement battery door.
• Place the battery door over the battery holster and snap it back into place by pressing down.
• Push the spring hinge under and behind the green hinge.
• Close the battery door and clip in place.
• Place the bumpers back into their slots and secure.

Tools Required: Phllip's head screwdriver, wrench.

Replacement spray gun seals can be purchased online here or with your preferred chemical/tool distributor.

• Using the screwdriver, unscrew and remove the exterior housing on your spray gun.
• Using the wrench, loosen the seal nut. Once it's loose enough, the seal nut can be removed using your fingers.
• Assemble the replacement spray gun seal kit by sliding the spring into the smaller end of the sealing component. Then, place the other end of the spring into the seal nut.
• Place the spring into the slots on the replacement battery door. Slide the pin through the spring and replacement battery door. Once the seal kit has been assembled, place it into the trigger where the original was. Tighten the seal nut into the assembly with your fingers and the wrench.
• Place the exterior housing back on and secure in place using the screwdriver.