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1. BLACK Mt L2 T 0 O O L1 ON OFF SWITCH x 5 2 M I 1 O o E WHITE J POTENTIOMETER POWER CORD x 2 Q 2 9 3 CI I 6489A Tja uu PA E TRANSDUCER MOTOR Fig 13 310944 23 Pressure Control Repair Motor Control Board Diagnostics Note Keep a new transducer on hand to use for test 1 Fig 6 13 Remove four screws 23 and cover 56 CAUTION 2 Turn ON OFE switch Do not allow sprayer to develop fluid pressure with 3 LED operation and reference following out transducer installed Leave drain valve open if table test transducer is used 4 Relieve pressure and unplug sprayer before ser vicing control board page 6 LED SPRAYER OPERATION INDICATES WHAT TO DO BLINKS Sprayer shuts down and LED stays ON Motor open circuit or bad Check motor brushes and control board armature If OK replace mo tor control board Two times Sprayer shuts down and LED continues Run away pressure Pres f Replace motor control board repeatedly to blink two times repeatedly sure great
2. Sun Power swich tat contol man powere spay __ SOROS m Wain SerayGon An pressure spray gun saa Tip Uses high pressure dt clear tp cogs witout removing Wp spray gun Cw Reversbee Tp Guard Gun SateryLock Gun safety etch bis accidental GGE iym Sucton Tube Taste fuid to be sprayed om source pump 310944 5 General Repair Information Pressure Relief Procedure NAN 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 Pres sure Relief Procedure whenever you 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 CAUTION To reduce risk of p
3. 3 Fig 16 Cycle pump with piston rod A in its lowest position 4 Fig 16 Remove suction tube 97 and hose 65 B MG A 65 79 97 Fig 16 na 5 Fig 17 Use screwdriver push retaining spring 27 up and push out pin 112 from connection rod cross link Fig 17 6 Fig 18 Loosen locknut with a hammer Unscrew pump Fig 18 Repair See manual 311061 for pump repair instructions Installation Na 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 Make sure pin and retaining spring are properly installed CAUTION If the pump locknut loosens during operation the threads of the bearing housing will be damaged Make sure locknut is properly tightened 1 Fig 12 Pull piston rod out 1 5 in Screw in pump until holes in connecting rod cross link and piston rod align Fig 19 2 Fig 17 Push pin 112 into hole And push retain ing spring 27 into groove all the way around connecting rod 3 Fig 20 Screw locknut down onto pump until nut stops Screw pump into bearing housing until locknut stops it Back off pump and locknut to align pump outlet to best position of hose to filter hous ing 69 Tighten locknut by hand then tighten with a hammer to approximately 75 5 ft lb 102 Fig 20 4 Fig 21 Fill packin
4. PLATE control SCREW cap hex hd SCREW mach PACKING o ring PIN grooved GASKET seat valve NUT shaft sealing KNOB potentiometer SCREW mach phillips BOOT toggle RING locking SCREW mach slot hex HANDLE valve drain COVER control box INSERT filter FILTER fluid BOWL filter PACKING o ring VALVE drain BASE valve POTENTIOMETER adjustment HOSE coupled QTY m HA FA pa pa pa pa FA FA FA EA EA NJ NJ HS PART NO 245906 243222 15C140 15B961 114689 195423 115810 114421 15C141 117794 241943 110997 241994 243539 114296 198994 109575 118138 118137 164672 118335 DESCRIPTION CORD SET jumper IEC 320 TRANSDUCER pressure HOUSING filter BOX control BUSHING Strain relief GROMMET transducer SWITCH toggle BUSHING strain relief not shown PLATE Spacer SCREW mach sltd hex hd BOARD control SCREW flange hex KIT repair filter board see pg 20 CONDUCTOR ground see pg 20 BUSHING step GUARD transducer SCREW threadforming hexhead FITTING adapter reducer FITTING elbow street 89_ ADAPTER NUT panel 310944 QTY pa pa N PI Q H H H p 37 Parts Drawing Model 249162 N 310944 38 Model 249162 REF NO 6 10 12 14 15 16 17 19 20 22 24 25 27 28 31 33 34 37 39 41 44 46 49 52 53 54 55 57 PART N
5. WARNING SKIN IN ECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like justa cut but itis a serious injury that can result in amputation Get immediate surgical attention D Do not point gun at anyone or any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment EQUIPMENT MISUSE HAZARD Misuse can cause death or Serious injury D Do not exceed the maximum working pressure or temperature rating of the lowest rated system component Read Technical Data in all equipment manuals D Use 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 complete information about your material request MSDS from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine ASM replacement parts only 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 overbend hoses or use hoses to pull equipment Keep children and animals
6. Fig 7 310944 17 On Off Switch Replacement 110 Vac Model 249170 Removal Installation A N 1 Install new ON OFF switch 18 Install locking ring NA 24 and toggle boot 25 1 Relieve pressure page 6 2 Connect four wires A to ON OFF switch 18 2 Remove four screws 23 and pressure control 3 Install pressure control cover 56 with four screws cover 56 23 3 Disconnect four wires A at ON OFF switch 18 4 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 18 110 Vac ti6585a Fig 8 18 310944 Wiring Diagram 110 Vac Model 249170 ON OFF SWITCH c POWER PLUG GREEN PRO BLACK 23 1 165844 RED 4 pe B POTENTIOMETER FROM MOTOR 1 u NG YELLOW PRESSURE TRANSDUCER o 1 j BROWN L BLUE zZ pol gt 22 310944 19 On Off Switch Replacement 240 Vac Model 249171 Removal Installation 1 Install new ON OFF switch 18 Install locking ring 24 and toggle boot 25 1 Relieve pressure page 6 2 Connect four wires A to ON OFF switch 18 2 Remove pressure control cover 56 3 Install pressure control cover 56 3 Remove display connector from plug Disconnect four wires A at ON OFF swi
7. Use an armature Replace motor page 28 tester growler or perform spin test page 12 Inspect windings for burns 4 Pressure control board 100 by performing Replace with a new motor control board motor control board diagnostics page 24 If 100 page 24 diagnostics indicate substitute with a good board CAUTION Do not perform this check until motor armature is determined to be good A bad motor armature can burn outa good board 1 Basic Electrical Problems page NO TAG 1 Perform necessary procedures 2 ON OFF switch 86 page 16 Be sure spray 2 Replace ON OFF switch page 16 er is unplugged Disconnect wires from switch Check switch with ohmmeter Reading must be infinity with ON OFF switch OFF and zero with switch ON 3 For damaged or pinched wires in pressure 3 Replace damaged parts page 24 control page 24 1 Basic Electrical Problems page NO TAG 1 Perform necessary procedures 2 Electrical supply with volt meter 2 If voltage is too high do notoperate Meter must read 85 130 Vac for 100 120 Vac sprayer until corrected models and 210 255 Vac for 220 240 Vac models 3 Tightness of pump packing nut Overtighten 3 Loosen packing nut Check for leaking ing tightens packings on rod restricts pump around throat Replace pump packings if action and damages packings necessary page 29 310944 11 Spin Test Setup x Electric Shock Hazard page 6 To check arm
8. toggle RING locking SCREW mach slot hex HANDLE valve drain COVER control box INSERT filter FILTER fluid BOWL filter PACKING o ring VALVE drain BASE valve POTENTIOMETER adjustment HOSE coupled QTY m HA FA pa pa pa pa FA FA FA EA EA NJ NJ HS PART NO 241996 243222 15C140 15F625 114689 195423 115810 115632 150141 117794 287704 110997 241993 243539 114296 198994 109575 118138 118137 164672 118335 DESCRIPTION CORD SET power TRANSDUCER pressure HOUSING filter BOX control BUSHING Strain relief GROMMET transducer SWITCH toggle RETAINER power cord PLATE spacer SCREW mach sitd hex hd BOARD control SCREW flange hex KIT repair filter board see pg 18 CONDUCTOR ground see pg 18 BUSHING step GUARD transducer SCREW threadforming hexhead FITTING adapter reducer FITTING elbow street 89_ ADAPTER NUT panel 310944 QTY N PH Q H H H p 35 Parts Drawing ti6618a TI3205B 36 310944 Model 249171 REF NO 18 21 23 26 29 30 32 36 38 42 43 45 51 56 57 58 59 61 62 63 64 65 PART NO 15B 906 111801 115492 111457 111600 111699 112382 15F537 115494 195428 105658 115498 277089 198935 196773 243080 15C139 104361 235014 224807 236352 243994 Parts List DESCRIPTION
9. 073019 to pad 2 Install motor control board 100 with five screws 38 3 Connectto motor control board 100 D Lead E to transducer D Lead D to potentiometer D Two line voltage leads D Four motor leads two yellow black and red 4 Install cover 56 with four screws 23 310944 25 Pressure Control Repair Pressure Adjust Potentiometer Pressure Control Transducer Removal Refer to Fig 6 13 depending on sprayer and voltage MA Ng Relieve pressure page 6 2 Remove four screws 23 and cover 56 3 Disconnect lead E from control board 100 4 Disconnect hose 65 Remove three screws 98 and filter housing 69 Refer to page Fig 6 13 depending on sprayer and voltage 5 Thread transducer lead E plastic connector through transducer grommet 124 6 Remove pressure control transducer 68 and o ring 26 from filter housing 69 Installation 1 Install o ring 26 and pressure control transducer 68 in filter housing 69 Torque to 30 35 ft lb 2 Thread transducer lead E plastic connector up through transducer grommet 124 3 Install filter housing 69 with three screws 98 Connect hose 65 4 Connect lead E to control board 100 5 Install cover 56 with four screws 23 26 310944 Removal Refer to Fig 6 13 depending on sprayer and voltage me Ng Relieve pressure page 6 2 Remove four screws 23 an
10. away from work area Do not operate the unit when fatigued or under the influence of drugs or alcohol Comply 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 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 D Protective eye wear D Clothing and respirator as recommended by the fluid and solvent manufacturer D Gloves D Hearing protection 4 310944 Component Identification and Function ti3709b DC motor permanent magnet fan cooled B Drive Assembly Transfers power from DC motor to displacement pump D Displacement Pump Transfers fluid to be sprayed from source through spray gun Fluid Outlet Spray gun hose is connected here pem cc Used to prime and drain sprayer also relieves fluid outlet pressure when open Fluid Filter Final filter of fluid to spray gun Pressure Kabang Knob
11. check is OK go to next check When check is not OK refer to this column Motor runs and pump strokes 11 Paint supply 1 Refill and reprime pump 2 Intake strainer clogged 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 ballare 4 Remove intake valve and clean Check seating properly page 29 balls and seats for nicks replace if neces sary page 29 Strain paint before using to remove particles that could clog pump 5 Leaking around throat packing nut which 5 Replace packings page 29 Also check may indicate worn or damaged packings piston valve seat for hardened paint or page 29 nicks and replace if necessary Tighten packing nut wet cup 6 Pump rod damage 6 Repair pump page 29 7 Capacitor failure Visually inspect capacitor 7 Replace capacitor near terminals Ensure that orange safety relief plug is intact Motor runs but pump does 1 Displacement pump 112 damaged or 1 Replace pump pin if missing Be sure re stroke missing page 29 tainer spring 27 is fully in groove all around connecting rod page 29 2 Connecting rod assembly 76 fordamage 2 Replace connecting rod assembly page 27 page 27 3 Gears or drive housing page 27 3 Inspect drive housing assembly and gears for damage and replace if neces sary page 27 10 310944 ELEC
12. control housing GASKET NUT cap PLATE power bar HOUSING control SCREW 8 taptite phil VALVE drain includes 29 30 50 51 63 141 SPRING compression POTENTIOMETER adjust pressure CORD power PANEL control lt q amp ES pH HA HH REF NO PARTNO DESCRIPTION 68 243222 TRANSDUCER pressure contl includes 26 69 196676 HOUSING filter 73 196675 BOWL filter 74 196676 CAP 80 243984 FILTER FLUID 60 mesh 86 116098 SWITCH power 89 116171 BUSHING Strain relief 96 116200 SPACER shaft 106 196707 GASKET control ULTRA 108 116304 SCREW mach pan hd 111 196786 DIFFUSER tube 112 246710 BOARD control 134 196781 PLUG power bar 141 193709 SEAT valve 145 119786 SPACER al 6 32 unc x 375 146 15F743 HARNESS wire motor Included in Filter Repair Kit 244513 Also available 244070 30 mesh 244065 100 mesh 244066 200 mesh 310944 QTY m gH p 41 Notes 42 310944 Technical Data Model 100 120V Generator Motor Cycles per A Hz Minimum HP W gallon liter W P 2700 1 15 1 10 4000 1 0 466 244 64 6 0 8 3 0 0 027 0 019 1 4 in 50 60 50 60 3100 1 15 50 o 4000 1 2 560 200 53 1 1 3 8 0 031 0 021 Basic Sprayer Wetted Parts zinc plated carbon steel polyurethane po
13. 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 13 9 Motor brushes may be binding in brush hold ers See page 13 10 Motor armature commutator for burn spots gouges and extreme roughness See page 13 11 Motor armature for shorts using armature tester growler or perform spin test See page 12 1 Replace power supply cord 2 Replace ON OFF switch page 16 3 If thermal switch is open no continuity al low 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 8 310944 Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Low Output 1 For worn spray tip 1 Follow Pressure Relief Procedure then replace tip See your separate gun or tip manual gun trigger is released 6 Electrical supply with volt meter 6 Reset building circuit breaker replace Meter must read 85 130 Vac for 100 120 Vac building fuse R epair electrical outlet or try models Low voltages reduce sprayer perfor another outlet mance Extension cord size and length must be at 7 Replace with a correct grounded exten least 12 gauge wire and no lo
14. 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 eventwill ASM be liable for indirect incidental special or consequential damages resulting from ASM supplying equipmenthere under orthe furnishing performance or use ofany 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 thatthe presentdocument as wellas alldocuments 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 All written and visual data contained in this document reflects the latest product information available at the time of publication ASM reserves the right to make changes at any time without notice MM 310944 ASM Company 3500 North Ist Avenue Sioux Falls SD 57104 WWW asmcompany com 3 2005 Rev 5 2006 44 310944
15. 125Y 248239 DESCRIPTION QTY NUT retaining HOSE coupled 1 4 in x 13 in HOUSING bearing HANDLE cart FRAME cart MOTOR electric 1 hp 110V 249161 249170 KIT repair 1 hp 220V 249171 ROD connecting GEAR combination HOUSING drive PUMP displacement Manual 310643 KIT repair return line 249170 249171 249161 LABEL WARNING NUT hex flanged HOSE coupled TUBE intake SCREW self tap fil hd TAG WARNING not shown KIT label blank CLIP spring PIN str hdls LABEL ID 249161 LABEL ID 249170 249170 LABEL DANGER GUN ASM 400 249161 not shown m HA p HH qa 1 1 Y Replacement Danger and Warning labels tags and cards are available cost 310944 31 Parts Drawing Model 249161 32 310944 Parts List Model 249161 REF REF NO PARTNO DESCRIPTION QTY NO PARTNO DESCRIPTION QTY 66 246447 CORD SET power 1 18 15B906 PLATE control 1 68 243222 TRANSDUCER pressure 1 21 111801 SCREW cap hex hd 2 69 15C140 HOUSING filter 1 23 115492 SCREW mach 12 70 15B961 BOX control 1 26 111457 PACKING o ring 1 73 114689 BUSHING strain relief 1 29 111600 PIN grooved 1 14 195423 GROMMET transducer 1 30 111699 GASKET seat valve 1 86 111930 SWITCH toggle 1 32 112382 NUT shaft sealing 1 87 117745 BUSHING Strain relief 1 36 116167 KNOB potentiometer 1 96 15C141 PLATE space
16. 19 and lockwashers 17 3 Secure pail hanger 54 with nuts 33 4 Install cover 41 with screws 101 page 30 5 Install shield 1 with screws 23 6 Install pump 79 Displacement Pump Replacement page 29 A Torque to 200 10 in Ibs Torque to 110 5 in lbs ti3674a 310944 27 Motor Replacement Disassembly 6 Remove strain relief 73 Refer to page 32 Thread motor leads out through hole in frame 1 Relieve pressure page 6 N 7 Remove four screws 31 nuts 89 and motor 75 2 Remove pump 79 Displacement P ump Assembly Replacement page 29 1 Install new motor 75 on frame with four screws 31 and nuts 89 A CAUTIO N 2 Thread motor leads through hole in frame and into Do not drop gear cluster 77 when removing drive control box 70 housing 78 Gear cluster may stay engaged in 1 motor front end bell or drive housing 3 Install strain relief 73 placement page 27 Connect all leads to board 4 Fig 6 13 Remove four screws 23 and cover 5 Fig 14 Install drive housing 78 Drive Housing 56 Replacement page 27 5 Disconnect all leads from board 100 Remove 6 Install pump 79 Displacement P ump Replace five screws 38 and board 100 ment page 29 78 Liberally apply grease Torque to 125 in Ibs Fig 15 28 310944 Displacement Pump Replacement Removal 1 Flush pump 79 MAN 2 Relieve pressure page 6
17. D Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop clothes potential static arc D Sprayer 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 Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground equipment and conductive objects in work area Read Grounding instructions If there is static sparking or you feel a shock stop operating immediately Do not use equipment until you identify and correct the problem D Keep a fire extinguisher in the work area ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock D Turn off and disconnect power cord before servicing equipment D Use only grounded electrical outlets D Use only 3 wire extension cords D Ensure ground prongs are intact on sprayer and extension cords D Do not expose to rain Store indoors TOXIC FLUID HAZARD Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed D Read 505 5 to know the specific hazards of the fluids you are using D Store hazardous fluid in approved containers and dispose of it according to all applicable guidelines 310944 3 RA INSTRUCTIONS
18. O 114687 100644 101242 104811 105510 106062 106115 107210 107218 108691 109032 110243 176817 114672 111801 112746 112827 114699 161191 287710 162453 183350 112604 192027 195805Y 192719 192723 15F 302 Parts List DESCRIPTION CLIP retainer SCREW cap sch RING retaining ext CAP hub WASHER lock spring hi collar WHEEL semi pneumatic WASHER lock spring hi collar SCREW cap socket hd SCREW cap sch PLUG tubing SCREW mach pnh RING retaining SPRING retaining WASHER thrust SCREW cap hex hd NUT hex BUTTON snap WASHER thrust WASHER thrust COVER housing NIPPLE WASHER STRAINER SLEEVE cart LABEL DANGER ST HANGER pail NUT retaining LABEL crtl box cover QTY H3 NJ ND O UJ HP ND Ui NO NJ 4S s NJ O NJ ND AE REF NO PARTNO DESCRIPTION QTY 61 206994 FLUID ts 8 oz bottle 1 65 243994 HOSE coupled 1 4 in x 13 in 1 67 246709 HOUSING bearing 1 71 239998 HANDLE cart 1 72 196617 FRAME cart 1 75 243723 MOTOR electric 1 76 241008 ROD connecting 1 77 244264 GEAR combination 1 includes 28 and 37 78 287829 HOUSING drive 79 287161 PUMP displacement 1 Manual 311061 82 241920 DEFLECTOR threaded 1 85 195833Y LABEL WARNING 1 89 110996 NUT hex flanged 1 91 15F301 LABEL front 1 95 244240 HOSE drain 1 97 15F597 TUBE intake 1 101 114418 SCREW self tap fil hd 4 111 197124 CLIP spring 1 112 176818 PIN
19. Repair and Parts 310944G ASM 2700 and 3100 Airless Paint Sprayers For portable spray application of architectural paints and coatings Models 249161 249162 249170 249171 3000 psi 21 MPa 210 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Related Manuals 310939 311061 C Models 249170 249171 1 Models 249161 249162 clus sie Specifications This equipment is not intended for use with flammable or combustible materials used in places such as cabinet shops or other factory or fixed locations If you intend to use this equipment in this type of application you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials 2 310944 Warnings 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 through 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 D Use equipment only in well ventilated area
20. TRICAL SHORT Building circuit breaker opens as soon as sprayer switch is turned on CAUTION Any shortin any part of the mo tor power circuit will cause the control circuit to inhibit sprayer operation Correctly diagnose and repair all shorts before checking and replacing control board Building circuit breaker opens as soon as Sprayer is plugged into outlet and sprayer is NOT turned on Sprayer quits after sprayer op erates for 5 to 10 minutes Troubleshooting MOTOR IS HOT AND RUNS INTERMITTENTLY TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Motor is hot and runs intermit tently 1 Determine if sprayer was operated at high Decrease pressure setting or increase tip pressure with small tips which causes low size motor RPM and excessive heat build up 2 Be sure ambient temperature where sprayer 2 Move sprayer to shaded cooler area if is located is no more than 90_F and sprayer possible is not located in direct sun 1 All electrical wiring for damaged insulation 1 Repair or replace any damaged wiring or and all terminals for loose fit or damage Also terminals Securely reconnect all wires wires between pressure control and motor See page 28 2 For missing inspection plate gasket bent ter Correct faulty conditions minal forks or other metal to metal contact points which could cause a short 3 Motor armature for shorts
21. ature motor winding and brush electrical continuity MN I AN Relieve pressure page 6 Remove drive housing page 27 Fig 2 Remove four screws 23 and pressure control cover 56 Disconnect motor leads F and G Fig 3 Remove motor shield 1 and inspection covers A 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 28 12 310944 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 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 13 If still uneven or no resistance replace motor page 28 Motor Brush Replacement Motor Brush Removal Replace brushes worn to less than 1 2 in Check both sides Brush Repair Kit 220853 is available Spring clip 110816 may be purchased separately 1 Read General Repair Information page 6 Mar Relieve pressure page 6 3 Fig 3 Remove motor shield 1 Remove two inspection covers A and gaskets on each side of motor 4 Fig 4 Push in spring clip J to release hook B from brus
22. b fully counterclockwise to minimum pressure Plug in sprayer c Turn sprayer ON Slowly increase pressure until motor is at full speed 6 Fig 3 Install gaskets and inspection covers A on a each side of motor Fig 5 LLL 14 310944 Notes 310944 15 On Off Switch Replacement 120 Vac Model 249161 Removal Installation N 1 Install new ON OFF switch 86 Install locking ring 43 and toggle boot 42 1 Relieve pressure page 6 2 Remove four screws 23 and pressure control cover 56 2 Connect two wires A to ON OFF switch Wiring diagram Fig 7 3 Disconnect two wires A from ON OFF switch 86 4 Remove toggle boot 42 and locking ring 43 3 Install pressure control cover 56 with four Remove ON OFF switch 86 screws 23 120 Vac Fig 6 16 310944 Wiring Diagram 120 Vac Model 249161 M L2 2 AR ON OFF SWITCH 1 BLACK ma Pd o E 57 POTENTIOMETER POWER CORD WHITE PRESSURE TRANSDUCER YELLOW 6488A BLACKMHITE RED 4 ROM MOTOR
23. d cover 56 3 Disconnect all leads from control board 100 4 Remove five screws 38 and board 100 5 Remove potentiometer knob 36 sealing shaft nut 32 and pressure adjust potentiometer 64 6 Remove and save panel nut 133 Installation l Install panel nut 133 on potentiometer 64 2 Install pressure adjust potentiometer 64 sealing shaft nut 32 and potentiometer knob 36 a Turn potentiometer fully clockwise b Install knob at full clockwise position 3 Install board 100 with five screws 38 4 Connect all leads to control board 100 5 Install cover 56 with four screws 23 Drive Housing Replacement CAUTION Do not drop gear cluster 77 when removing drive housing 78 Gear cluster may stay engaged in motor front end bell or drive housing Removal Refer to Fig 14 NAN 1 Relieve pressure page 6 2 Remove pump 79 Displacement Pump Replace ment page 29 Fig 16 3 Remove screws 23 and shield 1 4 Remove four screws 101 and cover 41 5 Remove nuts 33 and pail hanger 54 Fig 14 6 Remove screws 19 lockwashers 17 and bearing housing 67 7 Remove two screws 20 and washers 15 8 Remove four back screws 10 and lockwashers 15 and pull drive housing 78 off of motor 75 Installation 1 Push drive housing 78 onto motor 75 Install screws 10 and lockwashers 15 2 Install bearing housing 67 with screws
24. er than 4500 psi See following Motor Control 310 bar 31 MPa Board procedure Three times Sprayer shuts down and LED continues Pressure transducer is Check transducer connection repeatedly to blink three times repeatedly faulty or missing Open drain valve Substitute new transducer for transducer in sprayer If sprayer runs replace transducer Fourtimes Sprayer shuts down and LED continues Line voltage is too high Check for voltage supply repeatedly to blink four times repeatedly problems Five times S prayer shuts down and LED continues Too much current Check for locked rotor repeatedly fto blink five times repeatedly shorted wiring or motor Re pair or replace failed parts Six times Sprayer shuts down and LED continues Motor thermal switch Check for binding in pump or repeatedly to blink six times repeatedly open circuit drive Check for bad motor 24 310944 Pressure Control Repair Motor Control Board Removal Refer to Fig 6 13 depending on sprayer and voltage NAN 1 Relieve pressure page 6 2 Remove four screws 23 and cover 56 3 Disconnect at motor control board 100 D Four motor leads two yellow black and red D Two line voltage leads D Lead D from potentiometer D Lead E from transducer 4 Remove five screws 38 and control board 100 Installation 1 Clean pad on rear of motor control board Apply small amount of thermal compound
25. g nut with ASM TSL until fluid flows onto the top of seal Fig 21 ti3594a 310944 29 Parts Drawing Model 249161 shown DETAIL A A see pg 32 27 depending on 30 310944 Parts List H2700 Sprayer Model 249161 249170 249171 REF NO PARTNO DESCRIPTION QTY 1 287702 SHIELD not shown 1 249170 249171 2 15F566 LABEL left side not shown 1 6 114687 CLIP retainer 1 10 100644 SCREW cap 4 12 101242 RING retaining 2 14 104811 CAP hub 2 15 105510 WASHER lock spring 6 16 119730 WHEEL semi pneumatic orange 2 106062 WHEEL semi pneumatic 249161 17 106115 WASHER lock spring 4 19 107210 S CREW cap socket 4 20 107218 S CREW cap sch 2 22 277091 PLUG tubing 2 108691 PLUG tubing 249161 24 109032 SCREW mach pnh 4 25 101354 PIN spring straight 4 108068 PIN spring straight 249161 27 176817 SPRING retaining 1 28 114672 WASHER thrust 3 31 110963 SCREW cap 4 33 112746 NUT hex 2 34 112827 BUTTON snap 2 37 114699 WASHER thrust 1 39 116191 WASHER thrust 1 4l 287708 COVER 249161 1 287707 COVER 249170 249171 44 162453 NIPPLE 1 46 183350 WASHER 2 49 112604 STRAINER 1 52 192027 SLEEVE cart 2 54 192719 HANGER pail 1 97 101 105 106 111 112 113 129 130 PART NO 192723 243994 246709 245245 196617 246500 243722 241008 244264 246708 248204 287668 241920 195833Y 110996 243993 15F597 114418 222385Y 190774 197124 176818 15F 300 15F571 194
26. h holder Pull out spring clip 5 Fig 4 Loosen terminal screw D Pull brush lead E out of terminal leaving motor lead F in place Remove brush G and spring H 6 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 Continued on page 14 Fig 3 N Motor lead do not disconnect Fig 4 310944 ti3672a 1227 13 Motor Brush Replacement Motor Brush Installation CAUTION CAUTION To avoid damaging pump packing do not run sprayer dry for more than 30 seconds while checking When installing brushes follow all steps carefully to brushes avoid damaging parts 7 Break in brushes l Fig 5 Install brush G with lead into lon 2 ue a Operate sprayer 1 hour with no load b Install pump connecting rod pin 112 refer to 2 Fig 5 Slide brush lead E under washer of termi Installation step 2 page 29 nal screw D and tighten screw Be sure motor lead F is connected at terminal screw 8 Install motor shield 1 3 Fig 5 Place spring H on brush G Install spring N Note apang Cun clip J Push down to hook slots L in brush holder C 4 Repeatfor other side 5 Testbrushes a Remove pump connecting rod pin 112 refer to Removal step 5 page 29 b With sprayer OFF turn pressure control kno
27. lyethylene stainless steel PTFE acetal chrome plating leath er V Maxt UHMWPE aluminum stainless steel tungsten carbide Dimensions 2700 107 48 5 30 76 20 5 52 1 28 71 0 76 310944 43 ASM Standard Warranty ASM warrants all equipmentreferenced 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 fora 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 notbe liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate orimproper maintenance negligence accident tampering orsub stitution of non AS M component parts Nor shall AS M be liable for malfunction damage orwear caused by the incompatibility of ASM equipment with structures accessories equipment or materials notsupplied by ASM or the improper design manufacture installa tion operation or maintenance of structures accessories equipment or materials not supplied by ASM This
28. nger than 300 ft sion cord Longer cord lengths reduce sprayer perfor mance Leads from motor to circuit board 100 for 8 Be sure male terminal blades are cen damaged or loose wires or connectors In tered and firmly connected to female ter spect wiring insulation and terminals for signs minals Replace any loose terminal or of overheating damaged wiring Securely reconnect ter minals 9 Forloose motor brush leads and terminals 9 Tighten terminal screws Replace page 13 brushes if leads are damaged page 13 10 For worn motor brushes which must be 1 2 in 10 Replace brushes page 13 minimum page 13 11 F or broken and misaligned motor brush 11 Replace spring if broken Realign spring springs Rolled portion of spring must rest with brush page 13 squarely on top of brush 12 Motor brushes for binding in brush holders 12 Clean brush holders remove carbon dust page 13 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 Try a new transducer 14 Motor armature for shorts by using an arma 14 Replace motor page 28 ture tester growler or perform spin test page 12 310944 9 Troubleshooting LOW OR FLUCTUATING OUTPUT TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If
29. on page 40 to identify test points TP 1 Power supply cord 66 Connect volt meter Plug in sprayer Meter must read 85 130 Vac for 100 120 Vac models Unplug sprayer 2 ON OFF switch 23 Connect volt meter be tween 11 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 3 Motor thermal cutoff switch Turn sprayer OFF Check for continuity between TO1 and TO2 with ohmmeter between TP1 neutral and TP2 L2 120 Vac building fuse Try another outlet 3 Replace extension cord 4 Replace power supply cord 5 Replace loose terminals crimp to leads Be sure terminals are firmly connected Clean circuit board terminals Securely re connect leads 7 Replace brushes See page 13 8 Replace spring if broken Realign spring with brush See page 13 9 Clean brush holders Remove carbon with small cleaning brush Align brush leads with slot in brush holder to assure free verti cal brush movement 10 Remove motor and have motor shop resur face commutator if possible page 28 11 Replace motor page 28 5 That motor leads are securely fastened and properly mated 6 Forloose motor brush lead connections and 6 Tighten terminal screws Replace brushes terminals See page 13 if leads are damaged See page 13 7 Brush length which must be 1 2 in minimum See page 13 NOTE Brushes do not wear at the same rate on both sides
30. r 1 38 115494 SCREW mach phillips 5 98 117794 SCREW mach sltd hex hd 3 42 195428 BOOT toggle 1 100 287703 BOARD control 1 43 105658 RING locking 1 103 110997 SCREW flange hex 2 45 115498 SCREW mach slot hex 1 104 117625 NUT locking 1 5l 187625 HANDLE valve drain 1 124 114296 BUSHING step 1 56 198935 COVER control box 1 125 198994 GUARD transducer 1 57 196773 INSERT filter 1 126 109575 SCREW threadforming hexhead 1 58 245527 FILTER fluid 60 mesh 1 130 118138 FITTING adapter reducer 1 59 15 139 BOWL filter 1 131 118137 FITTING elbow street 89_ 1 60 15C008 CORD jumper not shown 1 132 164672 ADAPTER 1 61 104361 PACKING o ring 1 133 118335 NUT panel 1 62 235014 VALVE drain 1 63 224807 BASE valve 1 Also available 64 236352 POTENTIOMETER adjustment 1 245528 100 mesh filter 65 243994 HOSE coupled 1 245526 200 mesh filter 310944 33 Parts Drawing Model 249170 O TI3205B 34 310944 Model 249170 REF NO 18 21 23 26 29 30 32 36 38 42 43 45 51 56 57 58 59 61 62 63 64 65 PART NO 15B 906 111801 115492 111457 111600 111699 112382 15F537 115494 195428 105658 115498 277089 198935 196773 243080 15C139 104361 235014 224807 236352 243994 Parts List DESCRIPTION PLATE control SCREW cap hex hd SCREW mach PACKING o ring PIN grooved GASKET seat valve NUT shaft sealing KNOB potentiometer SCREW mach phillips BOOT
31. ressure and clear clog or clean filter refer to Separate gun or tip instruction manual Basic Mechanical 1 Pressure control knob setting 1 Motor stops running when pressure setting Problems 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 un til thawed completely If paint hardened dried in sprayer replace pump packings Displacement Pump Replacement page 29 2 Displacement pump connecting rod pin 112 2 Push pin into place and secure with spring Pin mustbe completely pushed into connect retainer ing rod 76 and retaining spring 27 mustbe firmly in groove of pump pin 3 Motor 75 Remove drive housing assembly 3 Replace motor 75 if fan won tturn See 78 See page 27 Try to rotate fan by hand page 28 310944 7 TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Basic Electrical Problems 1 Motor control board Board shuts down and 1 Motor Control Board Diagnostics page 24 displays error code 2 Electrical supply Meter must read 85 130 Vac 2 Reset building circuit breaker replace for 100 120 Vac models 3 Extension cord Check extension cord conti nuity with volt meter 4 Sprayer power supply cord 66 Inspect for damage such as broken insulation or wires Refer to wiring diagram
32. ressure control malfunction D Use needle nose pliers to disconnect wire Never pull on wire pull on connector D Mate wire connectors properly Center flat blade of insulated male connector in female connector D Route wires carefully to avoid interference with other connections of pressure control Do notpinch 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 6 310944 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 7 11 for other possible solutions Wa Motor and drive housing may be very hot during opera tion and could burn skin if touched NW 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 explo sion CAUTION Do not run sprayer dry for more than 30
33. seconds to avoid damaging pump packings 4 Install motor shield before operation of sprayer and replace if damaged Motor shield 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 Grounding 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 grounding prong 1 All models require a grounded outlet for power Fig 1 connection Circuit must be 50 60 Hz with an ampere rating equal to or greater than the sprayer 3 120 Vac A 12 AWG 3 wires with grounding prong See Fig 1 300 ft 90 m extension cord may be used 220 240 Vac Use a 3 wire 1 0mm 12 AWG minimum extension cord up to 90 m long Long 2 Do not alter ground prong or use adapter lengths reduce sprayer performance Troubleshooting MAN Relieve pressure page 6 MOTOR WON T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK go to next check When check is not OK refer to this column Basic Fluid Pressure 1 Pressure control knob setting Motor will not 1 Slowly increase pressure setting to see if Problems run if at minimum setting fully counterclock motor Starts wise 2 Spray tip or fluid filter may be clogged 2 Relieve p
34. str hdls 1 113 248239 GUN ASM 400 notshown 1 114 116986 HOSE airless not shown Y Replacement Danger and Warning labels tags and cards are available at no cost Motor Brush Repair Kit 220853 is available Order separately 310944 39 Parts Drawing Model 249162 6488a CS Ne 23 43 42 68 10899 BLACK M ae EN TAA O O ON OFF SWITCH x aNG e 4 O C POWER CORD lE la ULIT gt gt E gt TRANSDUCER MOTOR 40 310944 Model 249162 PART NO 100721 104361 107505 111801 111457 194102 193710 112382 116167 114391 114420 116354 114689 164672 186620 277110 114797 114688 15F 742 196191 116252 245103 114708 236352 196836 196678 Parts List DESCRIPTION PLUG pipe PACKING o ring PACKING o ring SCREW cap hex hd PACKING o ring HANDLE valve SEAL seat valve NUT shaft sealing KNOB pot SCREW grounding SCREW mach pnh sems phillips BUSHING strain relief BUSHING strain relief ADAPTER LABEL symbol ground COVER
35. tch 18 5 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 18 240 Vac ti6617a Fig 10 20 310944 Wiring Diagram 240 Vac Model 249171 ON OFF SWITCH A YELLOW BROWN BLUE BROWN nn O O O ram y 7 BLACK d ti6619a MOTOR RED 4 NG POTENTIOMETER C PRESSURE TRANSDUCER NG FILTER BOARD GREEN YELLOW Fig 11 POWER CORD 310944 21 On Off Switch Replacement 120 Vac Model 249162 Removal Installation N aaa N 1 Push ON OFF switch 18 into control panel 67 1 Relieve pressure page 6 until inside tabs snap in place 2 Remove four screws 23 and pressure control 2 Connect two wires A to ON OFE switch 18 cover 56 3 Remove two screws 108 and control panel 67 3 Install control panel 67 with two screws 108 4 Disconnect two wires A from ON OFF sm 4 Connect display connector B not available on all 5 Squeeze inside tabs on ON OFF switch 18 and sprayers Install pressure control cover 56 with remove from control panel 67 four screws 23 120 Vac TI0848C see pg 40 Fig 12 22 310944 Wiring Diagram 120 Vac Model 249162
36. 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 equipmentwill be returned to the original purchasertransportation prepaid Ifinspection of the equipmentdoes notdisclose any defect in material or workmanship repairs will be made ata 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 notlimited to incidental or consequential damages for lost profits lostsales injury to person or property orany 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 MERCHANTABLLITY AND FITNESS FORA PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY ASM These items sold butnot manufactured by ASM suchas electric motors switches hose etc are subject

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