312361L - 390 Electric Airless Sprayer, Repair-Parts
Contents
1. Parts Hi Boy Models 247485 247486 247487 247494 247495 247531 247532 Parts Hi Boy 32 ti10336c 312361L Parts List Hi Boy Models 247485 247486 247487 247494 247495 247531 247532 30 30a 31 32 33 34 35 36 37 38 39 40 41 42 57 Part 288216 287489 117493 109032 15J812 117501 255434 255435 255492 255490 255491 HSE1450 289316 249194 287 054 180131 255487 287053 196750 196762 2 6883 255475 195150 162453 235004 15E813 15B652 15J801 103413 115099 15M671 259485 249041 312361L Description Qty FRAME cart hi 1 HANDLE cart 1 SCREW mach hex washer hd 10 SCREW mach pnh HANGER pail SCREW mach slot hex wash hd KIT shield motor includes 4 70 71 72 Models 247485 247487 Model 247486 Models 247494 247495 Model 247531 Model 247532 HOSE cpld 1 4 in x 50 ft GUN 500 2 finger ASM GEAR assembly combination GEAR crankshaft includes 28 BEARING thrust HOUSING drive includes 4 10 11 ROD connecting includes 30a 31 SPRING retaining PIN straight COVER front PUMP displacement includes 35 Manual 312362 NUT jam pump FITTING 1 4 npsm x 1 4 npt STRAINER 3 4 16 unf NUT jam WASHER suction TUBE suction intake O RING WASHER garden hose HOSE cpld MOTOR electric includes 57a 57b Models 247485 247486 247494 1 247531 247532 Models 247487 247495 1 Nap h b2. 2 Install shroud 12 and two screws 4 see illustra tion page 15 3 Hi Boy Models Only Connect high pressure hose at pump outlet See page 12 312361L ti9134b 19 Pressure Control Assembly Replacement Pressure Control Assembly Replacement See Wiring Diagram page 26 5 Pull wires through hole K 6 Turn pressure control knob 17 counter clockwise as far as you can to access flats on either side of pressure control Removal 7 Loosen and unscrew pressure control 1 Relieve pressure page 5 Disconnect power cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet See page 11 3 Remove two screws 4 and shroud 12 see illus tration page 15 4 Disconnect pressure switch connector A from con trol board 18 Pull bushing 23 from hole K ti9128a If you plan to reuse pressure control be careful not to damage or tangle wires when unscrewing pressure control 8 Remove pressure control ti9129a 20 312361L Pressure Control Assembly Replacement Installation 3 Apply loctite to pressure control knob B threads 4 Screw pressure control threads B into manifold and torque to 150 in lb 17 0 N m NOTICE Be careful when tightening pressure control knob that wires are not pinched between pressure control and fluid manifold 5 Tuck wires into pressure control wire cap 21 and f route wires toward cap opening
3. HOUSING drive ROD connecting includes 30a 31 SPRING retaining PIN straight COVER PUMP displacement ST NUT jam pump FITTING 1 4 npsm x 1 4 npt STRAINER 3 4 16 unf Qty 10 kk AL eh ds J ee ee ee ee Ref 37 38 39 40 41 42 43 44 65 6 68 69Y 70Y 87 88 89 100 110 111 Part 15E813 15B652 15J801 103413 115099 15M670 15J745 235014 224807 2 1089 111600 195811 15K092 244035 M70809 104361 243080 15E288 15E289 195707 255485 249041 195400 15R669 15M772 15K359 195833 245651 222385 111733 197193 242001 28 121 15R616 15R613 Parts List Direct Immersion Stand Description NUT jam WASHER suction TUBE suction intake O RING WASHER garden hose HOSE coupled MANIFOLD filter 190 210ES VALVE drain BASE valve HANDLE valve drain PIN grooved LABEL instruction TUBE drain DEFLECTOR barbed FITTING barbed hose O RING FILTER fluid INSERT manifold CAP filter LABEL identification MOTOR electric includes 57a 57b Model 255891 Model 255890 CLIP spring LABEL front L1900 brand LABEL side L1900 brand LABEL warning LABEL warning ENG FRE SPA FLUID TSL TAG warning TOOL wrench adjustable TOOL hammer CORD SET 190 210ES Europe adapter 240V 190 210ES Italy Denmark Switzer land adapter 240V LABEL crown LABEL shroud top lt ee ee b h b b h a ee eo a ee a a a a eS h ee h h
4. What To Check If check is OK go to next check Pressure control knob setting Motor will not run if set at mini mum fully counter clockwise Spray tip or fluid filter may be clogged Pump frozen or hardened paint Displacement pump connecting rod pin Pin must be completely pushed into connecting rod and retaining spring must be firmly in groove or pump pin Motor Remove drive housing assembly See page 13 Drive Housing Replacement Try to rotate fan by hand Troubleshooting What To Do When check is not OK refer to this column Slowly increase pressure setting to see if motor starts Relieve pressure page 5 Then clear clog or clean gun filter Refer to gun instruction man ual 312363 Thaw sprayer if water or water based paint has frozen in sprayer Place sprayer in warm area to thaw Do not start sprayer until thawed com pletely If paint hardened dried in sprayer replace pump packings See page 11 Dis placement Pump Replacement Push pin into place and secure with spring retainer See page 11 Displacement Pump Replacement Replace motor if fan won t turn See page 25 Motor Replacement Troubleshooting What To Check What To Do Problem If check is OK go to next check When check is not OK refer to this column Basic Electrical Electric supply ON OFF switch in Turn ON OFF switch to ON position Reset See wiring diagram page OFF position Meter must read _ buildin
5. armature tester growler or per ment form Spin Test page 14 Pressure control not plugged in Insert pressure control connector into control to control board board 8 312361L Troubleshooting What To Check What To Do Problem If check is OK go to next check When check is not OK refer to this column 1 Worn spray tip Relieve pressure page 5 Replace tip Refer to gun instruction manual 312363 Verify pump does not continue to Service pump See page 11 Displacement stroke when gun trigger is Pump Replacement released Low Output Prime valve leaking Relieve pressure page 5 Then repair prime valve See page 22 Drain Valve Replace ment Suction tube connections Tighten any loose connections Check o ring on suction tube Electric supply with volt meter Reset building circuit breaker replace building Meter must read 100 130 Vac fuse Repair electrical outlet or try another 210 260 Vac Low voltages outlet reduce sprayer performance Extension cord size and length Replace with a correct grounded extension cord See page 4 Grounding and Electric Requirements Leads from motor to circuit board Be sure male terminal pins are centered and for damaged or loose wire con __ firmly connected to female terminals Replace nectors Inspect wiring insulation any loose terminals or damaged wiring and terminals for signs of over Securely reconnect terminals heating Worn motor brus
6. or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non ASM component parts Nor shall ASM be liable for malfunction damage or wear caused by the incompatibility of ASM equipment with structures accessories equipment or materials not supplied by ASM or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by ASM This 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 equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a 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 not limited to incidental or
7. Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage BURN HAZARD Equipment surfaces can become very hot during operation To avoid severe burns do not touch hot equipment Wait until equipment has cooled completely MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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 TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to 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 e
8. Insert stripped end into end of a butt splice E on new brush assembly Crimp ends of butt splice E around each wire Pull gently on each wire to be sure wire does not pull out of butt splice Wrap new tie wrap around motor and wires only Trim off excess Be sure pressure hose is not caught in tie wrap Connect motor connector D to control board 18 Replace shroud 12 and two screws 4 see illus tration page 15 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 312361L Control Board Replacement See VViring Diagram page 26 Removal 1 Relieve pressure page 5 Disconnect povver cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet see page 11 3 Remove two screws 4 and shroud 12 see illustra tion page 15 4 Disconnect pressure control assembly connector A from control board 18 ti6143b 5 Disconnect motor connector D from control board 18 6 Remove three screws 11 securing control board to housing two are located on the front and one on the back next to the power cord 312361L Control Board Replacement ti11554a 7 Pull control board out slightly and then slide control board back and off of frame NOTE Make sure power cord is free and not wrapped around cord wrap 8 Remove grommet and wires from strain relief NOTE Ground wire remains attached to sprayer with grounding screw Stra
9. h b ee ee ee ee Y Replacement Danger and Warning labels tags and cards are available at no cost 37 Parts Drawing Direct Immersion Stand Parts Drawing Direct Immersion Stand Models 255890 255891 ti11633a 38 312361L Parts Drawing Direct Immersion Stand Parts List Direct Immersion Stand Models 255890 255891 Ref Part Description Qty 1 258027 FRAME stand 1 2 15R792 LEG cart 2 4 117493 SCREW mach hex washer hd 10 7 289119 LEVER handle cam includes 3 5 6 7 4 a PIN pivot handle cart 4 7b SCREW cap socket head 4 C NUT lock hex 4 312361L Ref Part Description 63 120595 CLIP tool 64 RIVET blind 1 8 x 1 4 in 66 120151 RETAINER caplug 112 151783 ISOLATOR foot 113 122667 SCREW drill hex washer oAARA BRD 39 ASM Standard Warranty ASM warrants all equipment referenced 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 to the original purchaser for use With the exception of any special extended or limited warranty published by ASM ASM will for a 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 not be liable for general wear and tear
10. 483 247484 24P912 262901 Parts Stand ti10332a 28 312361L Parts List Stand Models 247482 247483 247484 24P912 262901 Ref 12a 15 16 26 27 28 29 30 30a 31 32 33 34 35 36 37 39 40 Part 15E823 116139 119723 117493 15B589 117501 255432 255433 24R018 2 420 HSE1450 289316 249194 287054 180131 255488 287053 196750 196762 2 6883 259475 195150 162453 246385 114958 246386 117559 312361L Description FRAME stand mount 1 GRIP handle 1 TAPE foam 1 SCREW mach hex washer hd 11 COVER pump rod 1 SCREW machine hex washer head 9 KIT shield motor includes 11 71 72 70 Model 247482 247484 Model 247483 Model 24P912 SHIELD motor model 262901 HOSE cpld 1 4 x 50 ft GUN 500 2 Finger GEAR reducer GEAR crankshaft includes 28 BEARING thrust HOUSING drive includes 4 11 10 ROD connecting includes 30a 31 SPRING retaining PIN straight COVER front PUMP displacement includes 35 Manual 312362 NUT jam pump FITTING 1 4 npsm x 1 4 npt STRAINER 7 8 14 unf STRAP tie HOSE suction set includes 41 40 36 O RING a a ee ae a 7 Ref 41 42 49 50 574 5 a 57b 63 64 67 68 69 70 Part 115099 15M670 249051 244035 255485 249041 249043 119653 15G838 122667 2 6864 112759 15M774 15M766 16U188 16U166 15M775 15M763 16U189 16U167 119688 119277 4249042 Parts List Stand Descr
11. 7493 117501 249005 248929 Description SCREW mach hex washer hd SCREW mach slot hex wash hd CONTROL pressure includes 21 22 23 Models 247485 247486 247494 247531 247532 110V Models 247487 247495 240V CONTROL board 2554831 Model 247485 247486 247494 247531 247532 110V 2554844 Models 247495 247487 240V 15B119 15B471 253368 115498 15E794 15A464 115756 189930 15J745 235014 111699 15E022 224807 18 625 312361L CORD power Models 247485 247486 247531 247532 110V Models 247487 247495 240V Model 247494 110V SCREW mach slot hex wash hd CAP wire control pressure LABEL pressure control knob BUSHING universal LABEL caution MANIFOLD Filter 190 210 ES VALVE drain includes 44a 44b GASKET seat SEAT valve BASE valve HANDLE valve drain Models 247485 247486 247487 247531 247532 Qty 10 7 ee ee ee h b ee ee ee Ref 51 53t 54 55 56 67 71Y 72Y 93 Part 2 1089 111600 195811 15K092 244035 255465 M70809 104361 245527 15E288 15E289 195707 195400 15R359 195833 242005 242001 Parts List Hi Boy Description Models 247494 247495 PIN grooved LABEL instruction TUBE drain DEFLECTOR barbed Models 247485 247486 247487 247531 247532 Models 247494 247495 FITTING barbed hose O RING FILTER fluid 60 mesh INSERT manifold CAP filter LABEL identification CLIP spring LA
12. BEL 190 210 261825 261830 war LABEL warning CORD SET ADAPTER Model 247487 Model 247495 h ee d Y Replacement Danger and Warning labels tags and cards are available at no cost 119277 Fuse replacement 110V 119688 FUSE replacement 240V t Other filters available 245528 100 mesh 245526 200 mesh 35 Parts Drawing Direct Immersion Stand Parts Drawing Direct Immersion Stand Models 255890 255891 ti11632a 36 312361L Parts List Direct Immersion Stand Models 255890 255891 Ref Part 117493 119783 115523 15B589 117501 255432 114531 15J651 Description SCREW mach hex washer hd FITTING tee swivel GAUGE pressure fluid COVER pump rod SCREW mach slot hex wash hd SHIELD motor SCREW mach hex washer hd COVER 210 190ES HSE1450 HOSE cpld 1 4 in x 50 ft 289316 249005 248929 249052t 249053 253368 253370 115498 15E794 15A464 115756 195551 189930 249194 287054 180131 259168 287053 196750 196762 2 6883 246428 195150 162453 187651 312361L GUN 500 2 finger ASM CONTROL pressure includes 21 22 23 Model 255891 Model 255890 CONTROL board Model 255891 Model 255890 CORD Model 255891 Model 255890 jumper SCREW mach slot hex wash hd CAP wire control pressure LABEL pressure control knob BUSHING universal RETAINER plug adapter LABEL caution GEAR assembly combination GEAR crankshaft BEARING thrust
13. Feed wires through Tx hal K housing hole K ep 7 EE 6 Insert bushing 23 in hole K K 7 Connect pressure switch connector A to control board 18 23 B 21 o ring 8 Install shroud 12 and two screws 4 see illustra 1 Inspect pressure control before installation to verify l tion page 15 o ring is installed 9 Hi Boy Models Only Connect high pressure hose 2 Align pressure control wire cap 21 on fluid mani at pump outlet see page 12 fold so opening faces toward motor 312361L Es Drain Valve Replacement Drain Valve Replacement Installation 1 Install new seat gasket 44a and valve seat 44b on end of drain valve Removal 2 Screw drain valve 44 into filter manifold 43 Torque to 120 to 130 in lb 1 Relieve pressure page 5 Disconnect power cord from outlet 3 Push valve base 45 over drain valve 44 and then valve drain handle 46 over valve base 2 Remove pin 47 from drain valve handle 46 4 Install pin 47 in drain valve handle If necessary 3 Pull drain valve handle and valve base 45 from use a hammer to tap pin in place completely drain valve 44 4 Unscrew drain valve from filter manifold 43 5 Remove valve seat 44b and seat gasket 44a from inside of filter manifold or end of drain valve ti11549a 22 312361L Drain Line Replacement Removal 1 Cut drain line 49 from barbed fitting 51 2 Unscrew bar
14. Protective eye wear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection Installation Grounding and Electric Requirements The sprayer cord includes a grounding wire with an appropriate grounding contact SS en Te Va ti11559a The sprayers require 110 120V Units 100 130 VAC 50 60 Hz 11A 1 phase Circuit vvith a grounding receptacle 240V Units 210 255 VAC 50 60 Hz 7 5A 1 phase cir cuit with a grounding receptacle Never use an outlet that is not grounded or an adapter ti5573a Installation Do not use the sprayer if the electrical cord has a dam aged ground contact Only use an extension cord vvith an undamaged ground contact ti4297a Recommended extension cords e 110 120V 3 wire 12 AWG 2 5 mm minimum e 240V 3 wire 16 AWG 1 0 mm minimum NOTE Smaller gauge or longer extension cords may reduce sprayer performance Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent and Oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a non conductive surface such as paper or cardboard which interrupts grounding continuity Grounding the metal pail connect a ground wire to the pail by clamping one end to pail and other end to ground such as a water pi
15. Repair and Parts ea J 312361L Electric Airless Sprayers EN For portable spray application of architectural paints and coatings For professional use only Maximum Working Pressure 3300 psi 22 7 MPa 227 bar Hi Boy Models Stand Models ASM Zip Spray 2100 Plus 110V 247485 ASM Zip Spray 2100 Plus 110V 247482 ASM AllPro Mustang 4700 Plus 110V 247486 ASM AllPro Mustang 4700 Plus 110V 247483 ASM Zip Spray 2100 Plus 240V 247487 ASM Zip Spray 2100 Plus 240V 247484 ASM L1900 Plus 110V 247494 ASM Z21 240V 262901 ASM L1900 Plus 240V 247495 ASM L2100 Plus 240V 24P912 ASM AllPro Mach 5400 Plus 110V 247532 ASM Zip Spray 2300 Plus 110V 247531 Direct Immersion Stand Models ASM L 1900 Plus 110V 255891 ASM L 1900 Plus 240V 255890 Important Safety Instructions Read all warnings and instructions in this manual Save these instructions lA 312360 eg 312363 312365 312364 A English Fran ais Espa ol Ei 312362 ti11955a PROVEN QUALITY LEADING TECHNOLOGY Warning Warning The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where appli cable d WARNING FIRE AND EXPLOSION HAZARD Flammable fumes such as solven
16. TROL BOARD Models 247482 247483 120V Model 247484 262901 240V CORD Models 247482 247483 120V Model 247484 240V Model 262901 240V SCREW mch slot hex wash hd CAP wire control pressure LABEL control BUSHING LABEL caution FITTING 1 4 npsm x 1 4 npt MANIFOLD filter VALVE drain includes 44a 44b GASKET seat SEAT valve BASE valve HANDLE valve drain Model 24P912 Model 247482 247483 247848 262901 PIN grooved LABEL instruction DEFLECTOR barbed Model 24P912 Qty 11 9 r Ce re E Na a a am Ref Part 244035 51 M70809 52 104361 53 245527 54 15E288 55 15E289 56 195707 71Y 15K359 72Y 195792 81 242001 242005 84 115523 85 119783 86 195551 87Y 15H087 88 15Y118 1119688 1119277 de 249042 Parts List Stand Description Models 247482 247483 247484 262901 FITTING O RING FILTER fluid 60 mesh INSERT filter CAP filter LABEL identification LABEL warning LABEL model 262901 CORD SET ADAPTER Australia Model 24P912 Models 247482 247483 247484 GAUGE pressure fluid Model 254998 262901 FITTING swivel Model 254998 262901 RETAINER LABEL warning model 262901 LABEL FUSE replacement 240V FUSE replacement 110V KIT brush motor replacement Qty ee ee ee ee Y Replacement Danger and Warning labels tags and cards are available at no cost t Other filters available 245528 100 mesh 245526 200 mesh 31
17. at pump outlet see page 11 3 Remove two screws 4 and shroud 12 4 Remove drive housing 29 see page 13 5 Disconnect motor connector H Armature Short Circuit Test Quickly turn motor fan by hand If motor coasts two or three revolutions before complete stop there are no electrical shorts If motor does not spin freely armature is shorted Replace motor page 25 ti5638a Armature Brushes and Motor Wiring Open 4 Reattach motor connector H Circuit Test Continuity dal H 1 Connect red and black motor leads with test lead 5 Replace drive housing see page 13 Turn motor fan by hand at about two revolutions per second 6 Replace shroud 12 and two screws 4 7 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 14 312361L Fan Replacement Removal 1 Relieve Pressure page 5 Disconnect povver cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet see page 11 3 Remove two screws 4 and shroud 12 4 Remove spring clip 57b on back of motor 5 Pull off fan 57a Fan Replacement Installation 1 Slide new fan 57a in place on back of motor Be sure blades of fan face motor as shown 2 Install spring clip 57b 3 Replace shroud 12 and two screws 4 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 ti12422a 312361L 15 Motor Brush Replacement See VViring D
18. bed fitting from filter manifold 43 NOTE To reuse existing barbed fitting 51 and drain line 49 cut and remove remaining drain line material from end of barbed fitting Drain Line Replacement Installation 1 Screw barbed fitting 51 into filter manifold 43 2 Push drain line 49 onto barbed fitting NOTE To make drain line more pliable and easier to install over barbed fitting heat end of drain line 49 with a hair dryer or place end in hot water a few seconds 312361L 49 ti9156a 23 Power Cord Replacement Power Cord Replacement See Wiring Diagram page 26 Installation 1 Connect green ground wire G to frame with green ground screw 20 Be sure green ground wire ter minal faces up or wires could get caught in shroud Removal 2 Install control board Control Board Replacement 1 Remove control board Control Board Replace Installation page 18 ment Removal page 17 2 Remove green ground screw 20 and disconnect green ground wire G from frame ti6126b 24 312361L Motor Replacement Motor Replacement See VViring Diagram page 26 6 Remove two screws 4 and filter manifold 43 Remove green ground screw 20 and ground wire G from motor endbell 8 Remove cover 14 Remove four screws 4 and motor 57 from frame 1 NOTICE Installation Do not drop gear cluster 27 and 26 when removing 1 Install cover 14 on motor 57 Install motor on driv
19. consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available ASM MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY ASM These items sold but not manufactured by ASM such as electric motors switches hose etc are subject 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 event will ASM be liable for indirect incidental special or consequential damages resulting from ASM supplying equipment hereunder or the furnishing performance or use of any 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 that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English ASM Information For the latest information about ASM products visit www asmcompany com TO PLACE AN ORDER contact your ASM distributor or call 1 800 854 4025 to identify the nearest distributor All written and visual data contain
20. e housing 29 Gear cluster may stay engaged in frame 1 with four screws 4 motor front end bell or drive housing 2 Connect green ground wire G to frame with green Removal ground screw 20 Be sure green ground wire ter minal faces up or wires could get caught in shroud 1 Relieve pressure page 5 Disconnect power cord See illustration page 25 from outlet 2 Hi Boy Models Only Disconnect high pressure a a eo WENO Sereno 00a JOC Men ES eager Say 4 Install control board Control Board Replacement 3 Remove pump Displacement Pump page 17 pep comenta ge 5 Install drive housing Drive Housing Replacement 4 Remove drive housing Drive Housing page 13 ds Paget 6 Install pump Displacement Pump Replacement page 11 5 Remove control board Control Board Replacement page 17 7 Hi Boy Models Only Connect high pressure hose at pump outlet See page 12 Liberally apply grease ti12395a 312361L 25 Wiring Diagrams Wiring Diagrams 120V from Motor Red us Black Replaceable Fuse Pressure un Control Assembly Ei ON OFF Switch C e 5 ti5643a II uU AL Black l Capacitor Power 8 I Plug gt White D 1 Green ti5643a1 240V Pressure Control from Motor Assembly Capacitor 2 x Yellow ON OFF Switch ti5857a Blue Brown Power Plug D Green xX L A 5 2 KA J ti5857a 26 312361L Notes 312361L Notes 27 Parts Stand Models 247482 247
21. ed in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This manual contains English MM 312361 ASM Company 3500 N 1st Avenue Sioux Falls SD 57104 Copyright 2008 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www asmcompany com Revised January 2013
22. ent Pump Replacement 2 Connecting rod assembly for Replace connecting rod assembly See page damage 11 Displacement Pump Replacement 3 Gears or drive housing Inspect drive housing assembly and gears for damage and replace if necessary See page 13 Drive Housing Replacement Motor is hot and runs 1 Be sure ambient temperature Move sprayer to shaded cooler area if intermittently where sprayer is located is not possible more than 115 F 46 C and sprayer is not located in direct sun 2 Motor has burned windings indi Replace motor See page 25 Motor cated by removing positive red Replacement brush and seeing burned adja cent commutator bars 3 Tightness of pump packing nut Loosen packing nut Check for leaking around Overtightening tightens packings throat Replace pump packings if necessary on rod restricts pump action and See pump manual 312362 damages packings 10 312361L Displacement Pump Replacement Displacement Pump Replacement See manual 312362 for pump repair instructions 4 Cycle pump until pin 31 is in position to be removed Removal 5 Disconnect povver cord from outlet 6 Push up retaining spring C Push out pump pin 31 1 Relieve pressure page 5 Unplug sprayer from outlet 2 Loosen two screws 11 and remove pail hanger 10 l p F f Ei Mh s E aa N lt 490408 3 Loosen nut 37 and remove suction tube 39 Loosen nut B and remove co
23. g circuit breaker replace building fuses 26 100 130 Vac 210 260 Vac Try another outlet Extension cord Check extension Replace extension cord cord continuity with volt meter Sprayer power supply cord Replace power supply cord See page 24 Inspect for damage such as bro Power Cord Replacement ken insulation or wires Fuse Check replaceable fuse on Replace fuse after completing motor inspec control board next to ON OFF __ tion See page 19 Fuse Replacement switch Motor leads are securely fas Replace loose terminals crimp to leads Be tened and properly connected to sure terminals are firmly connected control board Clean circuit board terminals Securely recon nect leads Motor thermal switch Yellow Replace motor See page 25 Motor Replace motor leads must have continuity ment through thermal switch Brush cap missing or loose brush Install brush cap or replace brushes if leads lead connections are damaged See page 16 Motor Brush Replacement Brush length which must be Replace brushes See page 16 Motor Brush greater than 1 4 in 6 mm Replacement NOTE Brushes do not wear at the same rate on both sides of motor Check both brushes Motor armature commutator for Remove motor and have motor shop resurface burn spots gouges and extreme commutator if possible See page 25 Motor roughness Replacement Motor armature for shorts using Replace motor See page 25 Motor Replace
24. h h h h b h A M M ee ee eS atk LS LE st st et N Ref 57a 57b 63 64 65 68 69 70 78 90 91 104 106 Part 249043 119653 119451 119730 119452 104811 15B999 15C871 2 1091 15M775 15M763 15R669 15M777 15M768 15M774 15M766 15M772 15M776 15M765 245651 115523 119783 15R613 15R616 Parts List Hi Boy Description FAN motor RING retaining WHEEL semi pneumatic Models 247485 247486 247487 247531 247532 Models 247494 247495 CAP hub Models 247485 247486 247487 247531 247532 Models 247494 247495 CLIP retaining Models 247494 247495 CAP leg Models 247485 247486 247487 247531 247532 Models 247494 247495 LABEL front brand Models 247485 247487 Models 247486 Models 247494 247495 Model 247531 Model 247532 LABEL side brand Models 247485 247487 Model 247486 Model 247494 247495 Model 247531 Model 247532 FLUID TSL 8 oz not shown GAUGE pressure fluid Models 247487 247494 247495 FITTING swivel Models 247487 247494 247495 LABEL shroud top Models 247494 247495 LABEL crown Models 247494 247495 de 249042 KIT brush motor Qty h ee ee b ee ee ee ee d 33 Parts Hi Boy Models 247485 247486 247487 247494 247495 247531 247532 Parts Hi Boy 34 312361L Parts List Hi Boy Models 247485 247486 247487 247494 247495 Ref 4 11 17 18 19 Part 11
25. hes which must Replace brushes See page 16 Motor Brush be greater than 1 4 in 6 mm Replacement Motor brushes binding in brush Clean brush holders Remove carbon dust by holders using compressed air to blow out brush dust Low stall pressure Turn pressure Replace pressure control assembly See control knob fully clockwise page 20 Pressure Control Assembly Replacement Motor armature for shorts by Replace motor See page 25 Motor using an armature tester Replacement growler or perform Spin Test page 14 312361L 9 Troubleshooting What To Check What To Do Problem If check is OK go to next check When check is not OK refer to this column Motor runs and pump 1 Prime Valve Open Close prime valve strokes 2 Paint supply Refill and reprime pump 3 Intake strainer clogged Remove and clean then reinstall 4 Suction tube leaking air Tighten nut Check o ring on tube 5 Intake valve ball and piston ball See Pump Manual 312362 Strain paint before are seating properly using to remove particles that could clog pump 6 Leaking around throat packing See Pump Manual 312362 nut which may indicate worn or damaged packings 7 Pump rod damaged See Pump Manual 312362 1 Displacement pump pin dam Replace pump pin if missing Be sure retaining aged or missing spring is fully in groove all around connecting Motor runs but pump does not stroke rod See page 11 Displacem
26. iagram page 26 Removal Replace brushes vvorn to less than 1 4 in 6 mm Brushes wear differently on each side of motor check both sides 1 Relieve pressure page 5 Disconnect power cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet see page 11 3 Remove two screws 4 and shroud 12 see illustration on page 15 4 Disconnect motor connector D from control board 18 5 Cut tie wrap F 6 Locate two yellow wires C Cut each yellow wire at the center 7 Pry off two brush caps A Remove brushes B from motor 8 Discard old brush assembly 9 Rotate fan by hand and blow compressed air into top brush holder to remove brush dust NOTE Place end of a shop vacuum hose over lower brush holder Turn on shop vacuum when you blow com pressed air into top brush holder Installation NOTE Use all new parts included in brush kit Do not reuse old parts if new replacement parts are provided 1 Install new brushes B in motor with wires facing toward front of motor Install positive red brush lead in top of motor and negative black brush lead in side of motor 2 Push each cap A into place over brush Orient each cap with the two projections on either side of 16 Motor Brush Replacement the brush lead You will hear a snap when cap is securely in place Strip approximately 1 4 inch 6 mm of insulation from end of each yellow wire C from motor
27. in Relief Grommet ti6122a 9 Remove two power cord C connectors from control board ti6143b 17 Installation 1 Push grommet and power cord wires into strain relief in control board 18 Strain Relief cigne ti6122a 2 Connect power cord connectors to terminals indi cated on control board 18 ti6143b NOTE Route power cord 19 between coupled hose 42 to filter manifold and sprayer frame ii l I F ti11555a La 18 Control Board Replacement 3 Slide control board into place on side of motor front endbell ti11553a 4 Replace three screws 11 Torque to 30 35 in lb 3 4 3 9 N m ti6143b Connect motor connector D and pressure control assembly connector A Install shroud 12 with two screws 4 see page 15 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 312361L Fuse Replacement a If the fuse is blown check for e Pinched or shorted wires e A defective motor see Spin Test page 14 e A locked or frozen pump Correct defective condition before replacing fuse Fuse Replacement Removal 1 Relieve pressure page 5 Disconnect power cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet see page 11 3 Remove two screws 4 and shroud 12 see illustration page 15 4 Remove fuse from control board Installation 1 Install Fuse on control board
28. iption VVASHER garden hose HOSE cpld KIT tube drain includes 51 50 37 DEFLECTOR barbed MOTOR electric includes 57a 57b Models 247482 247483 Model 247484 262901 24P912 FAN motor includes 57b RING retaining CUP suction drain SCREW drill hex washer head HANDLE includes 4 2 CAP tubing LABEL front Model 247482 247484 Model 247483 Model 262901 Model 24P912 LABEL side Model 247482 247484 Model 247483 Model 262901 Model 24P912 FUSE replacement 240V FUSE replacement 110V KIT brush motor replacement Qty D a LL LL Lo io i i eo L iL L Y Replacement Danger and Warning labels tags and cards are available at no cost f Other filters available 245528 100 mesh 245526 200 mesh 29 Parts Stand Parts Stand Models 247482 247483 247484 24P912 262901 ti10331c 30 312361L Parts List Stand Models 247482 247483 247484 24P912 262901 Ref 4 11 17 18 44a 44b 46 47 48 50 Part 117493 117501 249005 248929 259483 255484 15B119 15B471 15B470 115498 15E794 15A464 115756 189930 162453 15J745 235014 111699 15E022 224807 277089 187625 111600 195811 259465 312361L Description SCREW mach hex washer hd SCREW machine hex washer head CONTROL pressure includes 21 23 03 Models 247482 247183 120V Model 247484 262901 240V CON
29. l thrust bearing 28 and gears 26 and 27 in motor front endbell Removal 1 Relieve pressure page 5 2 Remove pump 33 Displacement Pump Replace 2 ment page 11 Needle Bearing Surfaces x 3 Disconnect povver cord from outlet g os gt F Z j istiva 2 Push drive housing 29 into motor front endbell Insert gear crank 27 through hole in connecting rod 30 A uea 4 Remove two screws 11 and cover 32 5 Remove screw 13 and four screws 4 6 Pull drive housing 29 out of motor front endbell 7 Remove gear cluster 27 and 26 and thrust bear ing 28 from drive housing ti9149a 3 Install four screws 4 and screw 13 Do not drop gear cluster 27 and 26 when removing drive housing 29 Gear cluster may stay engaged in motor front endbell or drive housing 4 Install cover 82 with two screws 11 5 Install pump 33 Displacement Pump Replace ment page 11 312361L 13 Spin Test Spin Test See Wiring Diagrams page 26 2 If uneven or no resistance check for missing brush caps broken brush springs brush leads and worn 1 ull brushes Repair as needed page 16 MPa bar FSE i a 3 If still uneven or no resistance replace motor page 25 To check armature motor winding and brush electrical continuity 1 Relieve Pressure page 5 Disconnect power cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose
30. pe To maintain grounding continuity when flushing or relieving pressure hold metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun ti11558a 312361L Pressure Relief Procedure Pressure Relief Procedure Follow this Pressure Relief Procedure whenever you are instructed to relieve pressure stop spraying check or service equipment or install or clean spray tip ti8326a 1 Turn OFF power and turn pressure control to lowest pressure setting If you suspect the spray tip or hose is clogged or that 2 Hold gun against side of grounded metal flushing pressure has not been fully relieved after following the pail Trigger gun to relieve pressure steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction 4 Engage trigger safety lock on gun if unit is being shut down or left unattended ti10307a 312361L General Repair Information General Repair Information To reduce risk of serious injury including electric shock Do not touch moving or electric parts with fingers or tools while testing repair Unplug sprayer when power is not required for Flammable materials spilled on hot bare motor testing could cause fire or explosion To reduce risk of burns Install all covers gaskets screws and washers fire or explosion do not operate sprayer with cover before you opera
31. t Do not point gun at anyone or at 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 312361L 312361L Warning WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component Read Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts Read Technical Data in all equipment manuals Read fluid and solvent manufacturers 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 Graco replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco 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 Comply with all applicable safety regulations Keep children and animals away from work area Do not operate the equipment when fatigued or under the influence of drugs or alcohol PRESSURIZED ALUMINUM PARTS HAZARD
32. t and paint fumes in vvorR area can ignite or explode To help prevent fire and explosion Use equipment only in vvell ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Sprayer generates sparks When flammable liquid is used in or near the sprayer or for flushing or cleaning keep sprayer at least 20 feet 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 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 Do 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 treatmen
33. te sprayer removed e Keep all screws nuts washers gaskets and electri NOTICE cal fittings removed during repair procedures These parts usually are not provided with replacement kits Do not run sprayer dry for more than 30 seconds Doing so could damage pump packings e Test repairs after problems are corrected p P Protect the internal drive parts of this sprayer from water Openings in the cover allow for air cooling of the mechanical parts and electronics inside If water gets in these openings the sprayer could e f sprayer does not operate properly review repair procedure to verify you did it correctly See Trouble shooting page 7 malfunction or be permanently damaged e Overspray may build up in the air passages Remove any overspray and residue from air pas sages and openings in the enclosures whenever you service sprayer Prevent pump corrosion and damage from freez ing Never leave water or water base paint in sprayer when its not in use in cold weather Freez ing fluids can seriously damage sprayer Store sprayer with Pump Armor to protect sprayer during e Do not operate the sprayer without the motor shroud storage in place Replace if damaged Motor shroud directs cooling air around motor to prevent overheating and insulates the control board from accidental electric shock 6 312361L Troubleshooting Problem Motor Won t Operate Basic Fluid Pressure Basic Mechanical 312361L
34. upled hose 42 7 Loosen pump jam nut 34 Unscrew and remove pump 33 4ti9138a 34 33 ti9141a ti9139a 312361L 11 Displacement Pump Replacement Installation 5 Screw in pump until threads are flush with top of drive housing opening If pump pin works loose parts could break off due to force of pumping action Parts could project through air and result in serious injury or property damage ti6111a NOTICE If the pump jam nut loosens during operation the threads of the drive housing will be damaged 34 1 Extend pump piston rod fully Apply grease to top of pump rod D Install jam nut 34 on pump threads ti9145a 7 Screw jam nut 34 up onto pump until nut stops Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately LG 49143a 75 ft lb 102 Nem 2 Install pump rod D into connecting rod 30 8 Install suction tube 39 and coupled hose 42 Tighten nuts 37 and B 3 Install pump pin 31 Verify retainer spring 30a is in groove over pump pin ti9139a Es 9 Fill packing nut with ASM Packing Seal until fluid flows onto top of seal Install pail hanger 10 with SIM screws 11 _ ti9144a EN 4 Push pump 33 up until pump LA engage ti9040a 12 312361L Drive Housing Replacement Drive Housing Replacement Installation 1 Apply a liberal coat of grease to gears and needle bearing surfaces Instal
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