312537G - ASM Electric Airless Sprayers, Repair-Parts
Contents
1. WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK go to next check When check is not OK refer to this column E XX is displayed 1 Fault condition exists 1 Determine fault correction from table page 12 False tripping of WatchDog 1 Operating conditions out of 1 Turn pressure down Refer to operation system EMPTY is dis WatchDog parameters Pump manual for adjusting Operate without played Pump does not run output is low see below WatchDog active see operation manual Pump output is low 1 Spray tip worn 1 Follow Pressure Relief procedure Warn ing then replace tip See your separate gun or tip manual 2 Spray tip clogged 2 Relieve pressure Check and clean spray tip 3 Paint supply 3 Refill and reprime pump 4 Intake strainer clogged 4 Remove and clean then reinstall 5 Intake valve ball and piston ball 5 Remove intake valve and clean Check are not seating properly balls and seats for nicks replace if neces sary see pump manual 310643 or 310894 Strain paint before using to remove particles that could clog pump 6 Suction hose connections 6 Tighten any loose connections Check for missing or damaged seals 7 Fluid filter tip filter or tip is 7 Clean filter see operation manual clogged or dirty 8 Prime valve leaking 8 Relieve pressure Repair prime valve 9 Verify pump does not continue to 9 Service pump see pump manual 310643 stroke when gun trigger is or 310894 released2. Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 Install cover 96 with four screws 38 23 Pressure Control Board 240 Vac Filter Board Relieve pressure page 8 Removal 1 Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 52 3 Remove bottom two screws 39 disconnect potentiometer connector C from motor control board 52 Disconnect power cord connectors D and filter board connectors J from ON OFF switch 83 and remove control panel 68 4 Disconnect WatchDog switch connector X from motor control board 5 Disconnect motor control board power connectors K from filter board 146 6 Remove four screws 163 from filter board 146 Tighten 2 screws Installation 1 Install filter board 146 with four screws 163 2 Connect motor control board power connectors K to filter board 146 3 Connect filter board power connectors J to top two terminals of ON OFF switch 33 and power cord connectors D to bottom two terminals of ON OFF switch 4 Connect potentiometer connector C to motor control board 52 5 Connect WatchDog switch X to motor control board 6 Install control panel 68 with two screws 39 Connect display connector A to motor control board 52 8 Install cover 96 with four screws 38 FSS 240 Vac to 14 17 in Ib 69 pa p
3. j N 2 v ti13495a ti12997a 30 312537G Pressure Control Board Installation 1 Install o ring 20 and transducer 86 in filter 3 Install control box 61 and control panel 68 base 67 Torque to 35 45 ft lb 47 61 Nem with four screws 39 Install grommet onto transducer 86 and transducer into control box 40 ti13496a 4 Connect potentiometer connector C to motor 2 Connect transducer connector E to motor contro board control board 95 til2999a 5 ti13493a 312537G 31 Drive and Bearing Housing Replacement Drive and Bearing Housing Replacement NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing Disassembly e Relieve pressure page 8 32 Hemove screw 31 two nuts 24 pail hanger 55 and pump rod cover 108 Hemove pump 91 see Displacement Pump Replacement page 36 695 795 page 38 1095 1595 Mark V Hemove two screws 158 and shroud 72 Hemove four screws 31 and front cover 51 Remove four screws 14 and washers 12 to remove bearing housing 83 and connecting rod 85 Remove five screws 6 and pull drive housing 90 off motor 84 Assembly Make sure gear 89 and thrust washers 28 30 90a 36 see page 29 are in place Brush grease onto gear teeth 1 Push drive housing 90 onto motor 84 and i
4. CF areenlarou nd eee Pressure E p Transducer ExT Potentiometer Model 247564 Series A Motor La Black Pressure Transducer 48 312537G Wiring Diagrams Series A Wiring Diagram Models 247563 247565 Series A Motor green ground ah ON OFF O Switch S Black MIS 4 wee ti10901a green ground i Pressure z Transducer Brown Potentiometer VA 312537G 49 Wiring Diagram Series B Wiring Diagram Series B Models 247558 247559 247561 247562 Series B Thermal Switch Potentiometer X Pressure Transducer ee n Dip Switch ME Sensor EI Leads 9a Fi n m O O00 ti14159b Black Power Plug Seo gt green ground gt 50 31253937G Wiring Diagram Series B Wiring Diagram Model 247564 Series B Thermal Switch Potentiometer Pressure Transducer 99 gar o Black L i Dip Switch L Sensor Leads C A Brown PA j Blue ON OFF amp Switch Brown green ground comet Plug 2 NC ti14161a 312537G 51 Wiring Diagram Series B Wiring Diagram Models 247563 247565 Series B Thermal Switch Potentiometer Pressure Transducer 9 e aa 5 9 Black n Dip Switch L Sensor Leads Q CS B Yh rown KT Blue ON OFF amp Switch Brown green ground dai Plug ti14160b 312537G Notes 312537G Notes 53 ASM Standard Warranty ASM
5. A to motor control board Install cover 96 with four screws 38 312537G Pressure Control Board 100 120 Vac North American and Japan Taiwan Tighten 2 screws to 14 17 in Ib Qe SY DZD ti12994b 21 312537G Pressure Control Board 240 Vac Motor Control Board Removal Installation 1 Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar Relieve pressure page 8 Wait 5 minutes before servicing 2 Apply thermal compound a For 2 capacitor boards and 6 capacitor Remove all four screws 38 and cover 96 boards with the Powerbar shown in Figure 1 below apply a small amount of thermal compound 15U114 or 110009 5 to shaded component areas on rear of motor control 2 Disconnect display connector A from motor control board 52 3 Remove bottom two screws 39 disconnect board 52 potentiometer connector C from motor control board 52 Disconnect power cord connectors P D and filter board connectors J from 52 5 ON OFF switch 33 and remove control panel N 68 4 Disconnect WatchDog switch connector X from motor control board 5 Disconnect motor control board power connectors K from filter board 146 ti17334a Figure 1 6 Remove top two screws 39 and control box 61 b For 6 capacitor boards with the powerbar shown in Fig 2 below apply a small
6. Prime valve not leak ing 10 Leaking around throat packing 10 Replace packings see pump manual Also nut which may indicate worn or check piston valve seat for hardened paint damaged packings or nicks and replace if necessary Tighten packing nut wet cup 11 Pump rod damage 11 Repair pump See pump manual 310643 or 310894 12 Low stall pressure 12 Turn pressure knob fully clockwise Make sure pressure control knob is properly installed to allow full clockwise position If problem persists replace pressure trans ducer 13 Piston packings are worn or 13 Replace packings see pump manual damaged 310643 or 310894 10 312537G Troubleshooting TYPE OF PROBLEM WHAT TO CHECK If check is OK go to next check WHAT TO DO When check is not OK refer to this column Pump output is low 14 O ring in pump is worn or dam aged 14 Replace o ring see pump manual 310643 or 310894 15 Intake valve ball is packed with 15 Clean intake valve see pump manual material 310643 or 310894 16 Pressure setting is too low 16 Increase pressure see pump manual 310643 or 310894 17 Large pressure drop in hose with 17 Use larger diameter hose and or reduce heavy materials overall length of hose Use of more than 100 ft of 1 4 in hose significantly reduces performance of sprayer Use 3 8 in hose for optimum performance 50 ft minimum Motor runs but pump does not strok
7. amount of thermal compound 15U114 or 110009 5 into both pockets of the Power 7 Disconnect transducer connector E from motor control board 8 Disconnect motor connectors F G and H from bar 69 and scrape across the pocket with motor control board the provided scraper so an even layer is 9 Remove motor shroud disconnect and remove remaining in the pocket wiring from baffle 10 Remove six screws 27 two screws 102 and motor control board NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 22 312537G Install two screws 102 six screws 27 and control board Install and torque two screws 102 to values in illustration on page 24 Install motor control board 52 with six screws 27 Torque to 9 11 in lb 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect wiring and install onto baffle Install motor shroud Connect transducer connector E to motor control board Connect motor control board power connectors K to filter board 146 312537G 9 11 12 13 14 15 Pressure Control Board Install control box 61 with top two screws 39 Connect filter board power connectors J and power cord connectors D to ON OFF switch 33 Connect potentiometer connector C to motor control board Connect WatchDog switch X to motor control board
8. control PLATE power bar GASKET control box PLUG Autoclean includes 125 TUBE diffusion CORD power Models 247558 247559 247561 247562 Model 247564 Models 247563 247565 VALVE prime includes 80a 80b GASKET seat valve SEAT valve BASE valve POTENTIOMETER assembly TRANSDUCER pressure control includes 20 FILTER fluid 30 mesh 60 mesh original equipment 100 mesh 200 mesh COVER control STUD board SCREW mach pmh sems SPACER manifold PLUG pipe GASKET FITTING hydraulic SCREW mach torx slt SEAL washer FILTER board Model 247564 Models 247563 247565 CORD SET adapter Model 247563 Model 247565 RETAINER plug adapter Models 247563 247565 CORD SET Italy Denmark Switzerland Model 247563 KIT repair coil includes Nut amp Screw LABEL side control Models 247563 247564 Qty ee ee eS 1 St DOI 1 A Extra Danger and Warning tags and labels available free 45 Parts Series B Parts Series B ti14148a 312537G 46 Parts List Series B 34 35 38 39 40 42 47 50 52 59A 60A 61 65 66 Part No 100721 117285 C19817 107505 111457 15C972 110963 114391 113045 15V996 15C979 15D527 116167 15F537 105510 116252 112381 15D033 164672 186620 15V591 258964 258965 15D523 243301 195833 195792 195793 15G953 15D431 15R261 15R2
9. 247563 247564 247565 Models 247559 247562 FRAME cart LABEL front Models 247558 247565 Model 247559 Model 247561 Model 247562 LABEL side Models 247558 247565 Model 247559 Model 247561 Model 247562 Models 247563 247564 TUBE intake includes 109 CLIP spring FLUID starter kit not shown HOUSING bearing includes 55 24 MOTOR electric Models 247558 247561 247564 Series A Models 247559 247562 Series A o ll 1 1 Ref 85 87 89 90 90a 91 93 153 152 160 167 168 170 171 Part No 289581 25 535 25 538 241008 241920 28 614 28 289 28 283 28 284 107089 248204 244240 28 668 15R559 114000 287489 15C859 118494 187437 2 6980 119 250 15D088 115477 222385 Parts Series A and B Description Models 247563 247565 Series A Models 247558 247561 247564 247559 247562 Series B Models 247563 247565 Series B ROD connecting includes 43 DEFLECTOR threaded Models 247558 247559 247561 247562 247565 Models 247563 247564 GEAR combination includes 28 30 HOUSING drive M1 includes 6 36 90a Models 247558 247561 247563 247564 247565 Models 247559 247562 WASHER race thrust PUMP displacement includes 109 HOSE return line includes 87 Models 247558 247559 247561 247562 247565 Models 247563 247564 HOSE coupled 1 4 x 15 75 SCREW co
10. Board 100 120 Vac North American and Japan Taiwan Motor Control Board Removal e Helieve pressure page 8 Wait 5 minutes before servicing Remove four screws 38 and cover 96 2 Disconnect display connector A from motor control board 3 Remove bottom two screws 39 and allow control panel 68 to hang down freely 4 Disconnect control board power lead s D from ON OFF switch 33 and motor control board 52 5 Disconnect potentiometer connector C from motor control board 6 Disconnect WatchDog 49 switch connector X from motor control board 7 Disconnect 15 20A switch 178 1595 model only 8 Disconnect transducer connector E from motor control board 9 Disconnect motor connectors F G and H from motor control board 10 Remove motor shroud Disconnect and remove wiring from baffle 11 Remove nut and screw 88 and disconnect ground wire 87 Disconnect coil connector Y Remove coil 81 12 Remove top two screws 39 and control box 61 13 Remove six screws 27 two screws 102 and control board 312537G Installation Use Acetone or equivalent solvent to thoroughly remove thermal paste from the pockets of the Powerbar Apply thermal compound a For2 capacitor boards and 6 capacitor boards with the Powerbar shown in Figure 1 below apply a small amount of thermal compound 15U1 14 or 110009 5 to shaded component areas on rear of motor control b
11. CHECK HOW TO CHECK Sprayer does not run at all See flow chart page 18 Digital display is blank Control board status light never lights Sprayer does not run at all Check transducer or transducer 1 Make sure there is no pressure in the system see connections Pressure Relief page 8 Check fluid path for clogs such as clogged filter Digital display shows E202 NN l1 2 Use airless paint spray hose with no metal braid a m 1 4 in x 50 ft minimum Smaller hose or metal braid LJ LL hose may result in high pressure spikes 3 Setsprayer to OFF and disconnect power to Control board status light blinks sprayer 2 times repeatedly 4 Check transducer and connections to control board Disconnect transducer from control board socket Check that transducer and control board contacts are clean and secure 6 Reconnect transducer to control board socket Connect power set sprayer ON and control knob 1 2 turn clockwise If sprayer does not run properly set sprayer to OFF and go to next step 7 Install new transducer Connect power set sprayer ON and control knob 1 2 turn clockwise Replace control board if sprayer does not run properly 12 312537G Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 03 Control board status light blinks 3 times repeatedly Check transducer or transducer con
12. Install cover 96 with four screws 38 312537G Pressure Control Board 110 Vac U K Filter Board Relieve pressure page 8 Wait 5 minutes before Servicing Removal Installation 1 Remove four screws 38 and cover 96 1 Connect motor control board power connectors 2 Disconnect display connector A from motor K to filter board 146 Connect filter control board 52 connector L to power cord connector L 3 Remove bottom two screws 39 Disconnect 2 Install filter board 146 with four screws 163 potentiometer connector C from motor control 3 Connect filter board power connector J and board 52 Disconnect filter board connector power cord connector D to ON OFF switch J and power cord connector D from ON OFF 33 Switch 33 Remove control panel 68 4 Connect potentiometer connector C to motor 4 Disconnect motor board control power control board 52 connectors K from filter board 146 Disconnect filter connector L from power cord C PAM n connector L onnect display connector A to motor contro board 52 5 Remove four screws 163 from filter board 146 7 nstall cover 96 with four screws 38 Install control panel 68 with two screws 39 312537G 27 Pressure Control Board 110 Vac U K O 2 Ges R CA T g x 7 N gt E N a WOOD m m Y E TIN 3 9 D esse 3 Z A E A Pt Met S15 D72 L esSzl ti12
13. are secure before operating the unit Know how to stop the unit and bleed pressure quickly Be thoroughly familiar with the controls EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Always wear appropriate gloves eye protection and a respirator or mask when painting Do not operate or spray near children Keep children away from equipment at all times Do not overreach or stand on an unstable support Keep effective footing and balance at all times Stay alert and watch what you are doing Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not kink or over bend the hose Do not expose the hose to temperatures or to pressures in excess of those specified by Graco Do not use the hose as a strength member to pull or lift the equipment PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material
14. 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 contained 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 comvpatents Original instructions This manual contains English MM 312537 AGRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2007 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www asmcompany com Revised January 2013
15. supplier for compatibility 312537G 5 Warnings MOVING PARTS HAZARD Moving parts can pinch cut 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 and disconnect all power sources 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 hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 312537G Component Identification and Function Component Identification and Function SERIAL _ PART NO 1 Premium Digital Display 2 ON OFF switch 3 Pressure control 4 Prime Spray valve 7 Sphnue o pudom menue 2 mogero ooo S Modelseraltag 14 WatchDog Switch not Mark V 312537G ti13451a General Repair Information Pressure Relief Procedure System pressure must be manually relieved to pre ent system from starting or spraying accidentally Fl
16. 39 28 285 312537G Description PLUG pipe PACKING o ring SCREW cap socket PACKING o ring PACKING o ring PIN grooved SCREW cap flng SCREW grounding SCREW sems mach phillips GROMMET SWITCH rocker Models 247558 247559 247561 247562 247564 Models 247563 247565 KNOB potentiometer Models 247558 247559 247561 247562 247565 Models 247563 247564 WASHER lock spring SCREW 10 taptite phillips SCREW mach pan hd GROMMET transducer NIPPLE adapter LABEL symbol ground HANDLE Models 247558 247559 247561 247562 247565 CONTROL board includes 27 102 Models 247558 247559 247561 247562 247564 Models 247563 247565 LABEL warning Models 247558 247559 247561 247562 Models 247563 247564 247565 LABEL warning Models 247558 247559 247561 247562 Model 247565 Models 247563 247564 BOX control Models 247558 247559 247561 247562 Models 247563 247564 247565 LABEL ctrl box cover Models 247558 247559 247565 Models 247561 247562 CAP filter includes 9 74 00 3 D 2 DDOaaZ A DB Om 1 1 1 1 1 Ref 67 68 69 70 73 74 15 75a 75b 75C 80 81 86 92 96 101 102 113 114 115 118 122 125 132 134 134a 134b 137 139 148 169 Part No 15C838 15C947 15V937 15D036 248314 15C766 15H064 15D530 15D529 24B156 24A382 256219 244984 2440
17. 71 244067 244068 244069 277110 15V938 114420 15F844 104813 15C973 116793 115478 15D541 248219 25 905 242001 242005 195551 28 121 28 943 15F506 Parts Series B Description BASE filter PANEL control PLATE power bar GASKET control box PLUG Autoclean includes 125 TUBE diffusion CORD power Models 247558 247559 247561 247562 Model 247564 Models 247563 247565 VALVE prime includes 80a 80b GASKET seat valve SEAT valve BASE valve POTENTIOMETER assembly TRANSDUCER pressure control includes 20 FILTER fluid 30 mesh 60 mesh original equipment 100 mesh 200 mesh COVER control STUD board SCREW mach pmh sems SPACER manifold PLUG pipe GASKET FITTING hydraulic SCREW mach torx slt SEAL washer FILTER board Model 247564 Models 247563 247565 CORD SET adapter Model 247563 Model 247565 RETAINER plug adapter Models 247563 247565 CORD SET Italy Denmark Switzerland Model 247563 KIT repair coil includes Nut amp Screw LABEL side control Models 247563 247564 Qty ee ee 9 1 LL oL o GQ A Extra Danger and Warning tags and labels available free 47 Wiring Diagrams Series A Wiring Diagrams Series A Models 247558 247559 247561 247562 Series A Motor ON OFF Switch RAMOS O green ground Oe Sy my QUY Power Plug
18. 996b 312537G 28 Pressure Control Board Pressure Adjust Potentiometer Removal Installation 1 Install gasket 115 nut and potentiometer 82 on control panel 68 Torque nut to 30 35 in Ib 3 38 3 95 Nem ti12998a 2 nstall pressure control knob 34 Check pressure control knob alignment to ti13493a potentiometer shaft Turn shaft fully clockwise and attach knob in full ON position with a hex wrench 2 Disconnect potentiometer connector C from motor control board 95 34 ti12997 Connect potentiometer connector C to motor 3 Remove pressure control knob 34 with a hex control board wrench 4 Remove gasket 115 nut and potentiometer 4 82 from control panel 68 l 68 ti13493a ti12998a 312537G 29 Pressure Control Board Pressure Control Transducer Removal 4 Remove four screws 39 and control box 61 Allow control panel 68 to hang down freely Relieve pressure page 8 Wait 5 minutes before servicing 1 Remove four screws 38 and cover 96 i13493a 5 Remove grommet 40 from control box then remove transducer 86 and o ring 20 from 2 Disconnect transducer connector E from filter base 67 motor control board 95 ti7260a v 20 ti13495a 6 Remove grommet 40 from transducer and save for reuse 95 ti12999a 3 Disconnect potentiometer connector C from motor control board Q WA J
19. CJ C3 CJ CJ D gt ue ti13140a SS Resistance Table 695 O ohms 795 2k ohms 1095 3 9k ohms MARK V 3 9k ohms Reconnect thermal device connector to control board socket Connect power turn sprayer ON and control knob 1 2 turn clockwise If sprayer does not run replace control board Sprayer does not run at all Digital display shows E 09 Control board status light blinks 9 times repeatedly Check the connections Control is not receiving a motor position sensor signal Turn power OFF Disconnect motor position sensor and inspect for damage at connectors Reconnect sensor Turn power ON If error continues replace motor Sprayer does not run at all Digital display shows E 10 Control board status light blinks 10 times repeatedly Check to see if control board is over heating Make sure motor air intake is not blocked Make sure fan has not failed Make sure control board is properly connected to back plate and that conductive thermal paste is used on power components Replace control board Replace motor 16 312537G Troubleshooting Sprayer Will Not Shut Off 1 Relieve Pressure page 8 Leave prime valve open 2 Remove control box cover so the control board and power switch OFF status light can be viewed if available Troubleshooting Procedure Plumb pressure gauge into paint hose plug sprayer in an
20. Filter Board 24 110 Vac U K Motor Control Board 25 110 Vac U K Filter Board 27 Pressure Adjust Potentiometer 29 Pressure Control Transducer 30 Drive and Bearing Housing Replacement 32 DISASSOMDIV scie derer Dacia eed eds 32 ASSOInDIV gx antri ri uo Ee dta DUREE Gob ee 32 Motor Replacement 34 piso EIC 34 Installation l l 34 Table of Contents Displacement Pump Replacement for 695 795 36 REMOVAL xus eeoa eios Sod RR Ske ls fu ob ed 36 Installation llle 37 Displacement Pump Replacement 1095 1595 Mark V 38 Removal ote kee twee deere dake Geer 38 Installation si sasa 0 0 0 cee ee 39 NOIES sheet sees bulb eee ee oe 41 Parts Series A and B 42 Parts List Series A and B 43 Parts Serles A saci ai late ra iat int anda 44 Parts List Series A 45 Paris Series B 522r re raint aia 46 Parts List Series B 47 Wiring Diagrams Series A 48 Wiring Diagram 0 ce eee 49 Wiring Diagram Series B 50 Wiring Diagram 2 c e34 c08N e aa ct ea 3 e Bai a 51 Wiring Diagram 0 ee ee 52 Models 247563 247565 Series B 52 NOIES rrt 53 ASM Standard Warranty 54 312537G Warnings Warnings The following warnings are for the set
21. Repair and Parts Al AA Bw fa Electric Airless Sprayers aaa EN For Portable Airless Spraying of Architectural Coatings and Paints For professional use only Not for use in explosive atmospheres ASM Zip Spray 2700 Plus 110V 247558 ASM Zip Spray 2700 Plus 240V 247565 ASM Zip Spray 3100 Plus 110V 247559 ASM AlIPro Mach 8600 Plus 110V 247561 ASM AllPro Mach 11000 Plus 110V 247562 ASM H2900 Plus 110V 247564 ASM H2900 Plus 240V 247563 3300 psi 22 8 MPa 227 bar Maximum Working Pressure e IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual Save these instructions Related Manuals 312538 Le m 312363 English fk 312364 Spanish 312365 French amp 310643 ti13450a O C Intertek PROVEN QUALITY LEADING TECHNOLOGY Table of Contents Table of Contents 2 Warnings 220 EI xime theta em 3 Component Identification and Function 7 General Repair Information 8 Pressure Relief Procedure 8 Grounding 54 2 099 0219 aa 9 270 hese Boa da 9 Troubleshooting lees 10 Mechanical Fluid Flow 0 10 Elecitleal 43 du ques bao dre dicio bs 12 Pressure Control Board 19 100 120 Vac North American and Japan Taiwan Motor Control Board 19 240 Vac Motor Control Board 22 240 Vac
22. a e 1 58 1 92 N c O I Us 24 312537G Pressure Control Board 110 Vac U K Motor Control Board Removal Installation 1 Use Acetone or equivalent solvent to N thoroughly remove thermal paste from the pockets of the Powerbar Relieve pressure page 8 2 Apply thermal compound Remove four screws 38 and cover 96 a For 2 capacitor boards and 6 capacitor boards with the Powerbar shown in Figure 1 2 Disconnect display connector A from motor below apply a small amount of thermal control board compound 15U114 or 110009 5 to shaded 3 Remove bottom two screws 39 and allow component areas on rear of motor control control panel 68 to hang down freely board 52 4 Disconnect control board power lead s D Gu from ON OFF switch 33 and motor control 52 e 5 board 52 N 5 Disconnect potentiometer connector C from motor control board 6 Disconnect WatchDog 49 switch connector X from motor control board 7 Disconnect 15 20A switch 178 1595 model only Figure 1 8 Disconnect transducer connector E from motor control board ti17334a b For 6 capacitor boards with the powerbar shown in Fig 2 below apply a small 9 Disconnect motor connectors F G and H amount of thermal compound 15U114 or from motor control board 110009 5 into both pockets of the Power 10 Remove motor shroud Disconnect and remove bar 69 and scrape across the pocket with wiring from baffle the
23. cker Models 247558 247559 247561 247562 247564 Models 247563 247565 KNOB potentiometer Models 247558 247559 247561 247562 247565 Models 247563 247564 WASHER lock spring SCREW 10 taptite phillips SCREW mach pan hd GROMMET transducer NIPPLE adapter LABEL symbol ground HANDLE Models 247558 247559 247561 247562 247565 Models 247563 247564 CONTROL board includes 27 102 Models 247558 247559 247561 247562 247564 Models 247563 247565 LABEL warning Models 247558 247559 247561 247562 Models 247563 247564 247565 LABEL warning Models 247558 247559 247561 247562 Model 247565 Models 247563 247564 BOX control Models 247558 247559 247561 247562 Models 247563 247564 247565 LABEL ctrl box cover Models 247558 247559 247565 Models 247561 247562 CAP filter includes 9 74 BASE filter c lt a 0 WMO NNW Ref 68 69 70 73 74 75 79a 75b 75c 80 80a 80b 81 82 86 92 96 101 102 113 114 115 118 122 125 132 134 134a 134b 137 139 148 169 Part No 15C947 15C840 15D036 248314 15C766 15H064 15D530 15D529 235014 2 1364 15E022 224807 256219 244984 244071 244067 244068 244069 277110 15D160 114420 15F844 104813 150973 116793 115478 15D541 248219 248220 242001 242005 195551 28 121 28 943 15F506 Parts Series A Description PANEL
24. d turn power Mechanical problem See the proper fluid pump manual for the sprayer for further trouble shooting procedures switch ON Does sprayer reach or ex ceed its maximum pressure YES Unplug the transducer from control NO Replace the control board board Does motor stop running YES Bad transducer Replace and test with a new one 312537G 17 Sprayer Will Not Run See following page for steps Remove control box cover Turn sprayer ON Observe control board status light on control board see page 12 No light See Step 1 Do Once Normal operation you have over 100 AC volts Light on Control board di iz Continuously commanding motor to run Flashing See Error Code section for further troubleshooting YES See Step 3 Is the proper reading pres ent through the ther mal switch wires Troubleshooting See Step 2 Do Repair or you have over replace 100 AC volts power cord YES Replace the ON OFF switch If motor is hot let cool and re test If Step 4 still shows incor rect resistance replace motor The motor has a defective thermal device YES See step 4 Does the motor run YES Replace potentiometer Pressure switch 18 Connect a test transducer to the board Does the motor run Replace the control board Replace the transducer 312537G Pressure Control Board Pressure Control
25. e Displacement pump pin 32 damaged or missing see pump manual 310643 or 310894 Replace pump pin if missing Be sure retainer spring 31 is fully in groove all around connecting rod see pump manual 310643 or 310894 2 Connecting rod assembly 43 2 Replace connecting rod assembly see damaged see pump manual pump manual 310643 or 310894 310643 or 310894 3 Gears or drive housing dam 3 Inspect drive housing assembly and gears aged page 32 for damage and replace if necessary see pump manual 310643 or 310894 Excessive paint leakage into 1 Throat packing nut is loose 1 Remove throat packing nut spacer throat packing nut Tighten throat packing nut just enough to stop leakage 2 Throat packings are worn or 2 Replace packings see pump manual damaged 310643 or 310894 3 Displacement rod is worn or 3 Replace rod see pump manual 310643 or damaged 310894 Fluid is spitting from gun 1 Airin pump or hose 1 Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming Tip is partially clogged Clear tip see tip guard manual 309640 Fluid supply is low or empty Hefill fluid supply Prime pump see pump manual 310643 or 310894 Check fluid supply often to prevent running pump dry Pump is difficult to prime 1 Airin pump or hose 1 Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible du
26. hten to 70 in lb ti6299a ti7330a 8 Fill pump with Pump Defender until fluid flows onto top of seal 40 312537G Notes Notes 312537G 41 Parts Series A and B Parts Series A and B 129 ti10896b C See page 21 J 312537G 42 Parts List Series A and B Ref 6 8 10 11 62 71 72 76 77 79 83 84 Part No 150753 15E891 156306 119420 121296 106115 110141 15C871 277091 109032 112746 116038 110963 112746 114672 114699 118444 116191 100057 162453 176817 176818 189920 277185 16C457 192723 2 6928 2 6931 288605 15R257 15R259 15R226 15R228 15R258 15R260 15R227 15R229 15R416 248214 2 8204 245651 246709 289579 289580 312537G Description SCREW mach torx hex CLIP retaining WASHER flat WHEEL pneumatic Models 247558 247559 247561 247562 247565 Models 247563 247564 WASH lock spring SCREW cap socket hd CAP leg Models 247558 247559 247561 247562 247565 Models 247563 247564 SCREW mach pnh NUT hex flanged WASHER wave spring SCREW cap flng hd NUT hex WASHER thrust WASHER thrust SCREW machine hex washer hd WASHER thrust SCREW cap hex hd FITTING 1 4 NPSM x 1 4 NPT SPRING retaining PIN str hdls STRAINER 1 11 1 2 NPSM COVER drive plastic HANGER pail NUT retaining SHIELD motor painted Models 247558 247561
27. ive 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 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
28. lacement assemblies o reduce risk of serious injury including electric shock do not touch moving or electrical parts with ingers or tools while testing repair Shut off and un plug sprayer when inspection is complete Install all covers guards gaskets screws washers and shroud 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 page 10 for other possible solutions 312537G Grounding Improper installation or alteration of grounding plug results in risk of electric shock fire or explosion that could cause serious injury or death 1 Ultra Max Il 695 795 and 1095 100 200 Vac models require a 50 60 Hz 15A circuit with a grounding receptacle Ultra Max II 1595 Mark V 120 Vac models require a 50 60 Hz 20A circuit with a grounding receptacle 220 240 Vac models require a 50 60 Hz 10A circuit with a grounding receptacle 312537G Grounding 2 Do not alter ground prong or use adapter ti2810a S b AG E 3 120 Vac A 12 AWG 3 wires with grounding prong 300 ft 90 m extension cord may be used 220 240 Vac You may use a 3 wire 1 0 mm 12 AWG minimum extension cord up to 90 m long Long lengths reduce sprayer performance Troubleshooting Mechanical Fluid Flow Relieve pressure page 8 Troubleshooting
29. nections control board is not detecting a pressure signal Set sprayer to OFF and disconnect power to sprayer Check transducer and connections to control board Disconnect transducer from control board socket Check to see if transducer and control board contacts are clean and secure Reconnect transducer to control board socket Connect power set sprayer ON and control knob to 1 2 turn clockwise If sprayer does not run set sprayer to OFF and go to next step Connect a confirmed working transducer to control board socket Set sprayer ON and control knob to 1 2 turn clockwise If sprayer runs install new transducer Replace control board if sorayer does not run Check transducer resistance with ohmmeter less than 9k ohm between red and black wires and 3 6k ohm between green and yellow wires 312537G 13 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 05 C rau D 74617 Control board status light blinks 5 times repeatedly 14 Control is commanding motor to run but motor shaft does not rotate Possibly locked rotor condition an open connection exists between motor and control there is a problem with motor or control board or motor amp draw is excessive Remove pump and try to run sprayer If motor runs check for locked or frozen pump or drive train If sprayer does not run continue
30. nstall with five screws 6 Torque to 190 210 in Ib 21 23 Nem Install bearing housing 83 with four screws 14 and washers 12 Torque to 25 30 ft Ib 34 40 Nem Install front cover 51 with four screws 31 Install shroud 72 with two screws 158 Install pump 91 see Displacement Pump Replacement page 36 695 795 page 38 1095 1595 Mark V Install pump rod cover 108 and pail hanger 55 with screw 31 and two nuts 24 312537G Drive and Bearing Housing Replacement 158 ti13000a 33 312537G Motor Replacement Removal e Relieve pressure page 8 1 Remove pump 91 see Displacement Pump Replacement page 36 695 795 page 38 1095 1595 Mark V NOTICE Do not drop gear cluster 89 when removing drive housing 90 Gear cluster may stay engaged in motor front end bell or drive housing 2 Remove drive housing 90 see Drive Housing Replacement page 32 3 Remove shroud 58 4 Remove four screws 38 and control cover 96 5 Remove bottom two screws 39 and allow control panel 68 to hang down freely 6 Disconnect all three motor connectors from motor control board 52 Disconnect motor leads 8 Remove top two screws 39 and control housing 61 9 Remove strain relief 29 from motor wires and power bar plate 69 34 10 11 12 Motor Replacement Remove motor wires from baffle 278075 and remove baffle Remove two screw
31. ntrol housing HANDLE cart SHIELD pump rod PACKING o ring LABEL torque GROMMET cover SCREW shoulder hex washer FAN motor SCREW mach torx pan hd TAG WARNING not shown HSE1450 HOSE cpld 1 4 in x 50 ft 289316 288899 124172 15R611 15R612 15R617 2 8075 Models 247558 247559 247561 247562 247563 247564 247565 GUN contractor Models 247558 247559 247561 247562 247563 247564 247565 SHELF PEM assembly WASHER retaining Nylon 10 32 LABEL shroud top Models 247563 247564 LABEL front Models 247563 247564 LABEL crown Models 247563 247564 BAFFLE Qty 1 1 DDD S 4 A Extra Danger and Warning tags and labels available free 253132 KIT repair tube 43 Parts Series A Parts Series A ti10900a 134a 312537G 44 Parts List Series A 34 35 38 39 40 42 47 50 52 59A 60A 61 65 66 67 Part No 100721 117285 C19817 107505 111457 15C972 110963 114391 113045 15D087 15C979 15D527 116167 15F537 105510 116252 112381 15D033 164672 186620 15C780 15F536 289577 289578 15D523 243301 195833 195792 195793 15G953 15D431 15R261 15R239 287285 15C838 312537G Description PLUG pipe PACKING o ring SCREW cap socket PACKING o ring PACKING o ring PIN grooved SCREW cap flng SCREW grounding SCREW sems mach phillips GROMMET SWITCH ro
32. oard 52 gt C1 no C1 K ti17334a b For 6 capacitor boards with the powerbar shown in Fig 2 below apply a small amount of thermal compound 15U114 or 110009 5 into both pockets of the Power bar 69 and scrape across the pocket with the provided scraper so an even layer is remaining in the pocket Figure 2 NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 19 20 Install two screws 102 six screws 27 and motor control board Install and torque two screws 102 to values in illustration Install motor control board 52 with six screws 27 Torque to 9 11 in Ib 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect and install wiring in baffle Install motor shroud Install control box 61 with top two screws 39 Install coil 81 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 11 12 13 14 16 Pressure Control Board Connect transducer connector E to motor control board Connect 15 20A switch 178 1595 model only Connect motor control board power lead s D to ON OFF switch 33 Connect WatchDog 49 switch connector X to motor control board Connect potentiometer connector C to motor control board Install control panel 68 with two screws 39 15 Connect display connector
33. oor 1 Flush pump a Ratchet pump door forward 2 Stop pump with piston rod in its lowest position Read Skin Injection Hazard page 5 3 Do Pressure Relief page 8 ti6373a 4 Separate drain hose from sprayer b Twist latch u bolt out of pump door recess ti7326a c Place u bolt on pump door outer edge d If pump door is stuck do steps e f and 8 otherwise go to step 9 e Twist latch u bolt back from pump door outer edge ti6374a ti6300a J R O E j p XL f Place u bolt on pump door protrusion ti6375a 38 312537G 8 Ratchet pump door forward ti6377a 9 Open pump door ti7331a 312537G Displacement Pump Replacement 1095 1595 Mark V Installation 1 Adjust piston rod with pin holder to pull out piston rod Tap piston rod on hard surface to push in piston rod 2 Push pump collar flush with bearing housing ledge to be able to close pump door ti6325a Q as i S k gt Y ni ER SUR Dy S ari d ses t tib492a 3 Slide pump into connecting rod Push pump pin until it is fully retained NOTE Pin will snap into position 39 Displacement Pump Replacement 1095 1595 Mark V 4 Close pump door and rotate latch into position 6 Tighten latch and rotate latch lock into locked Do not tighten latch position ti7329a TI6312a 5 Rotate pump to align with paint hose Connect 7 Attach drain hose to sprayer paint hose and hand tig
34. or use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below e Only connect the product to an outlet having the same configuration as the plug e Do not use an adapter with this product Extension Cords e Use only a 3 wire extension cord that has a 3 blade grounding plug and a 3 slot receptacle that accepts the plug on the product e Make sure your extension cord is not damaged If an extension cord is necessary use 12 AWG 2 5 mm minimum to carry the current that the product draws e An undersized cord results in a drop in line voltage and loss of power and overheating 312537G 3 Warnings 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 e Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes motors and electrical equipment Paint or solvent flowing through the equipment is able to result in static electricity Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes All parts of the spray system including the pump hose assembly spray gun and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless paint sprayer hoses Do not clean with materials having flash points lower
35. power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e Ensure ground prongs are intact on power and extension cords e Do not expose to rain Store indoors 4 312537G Warnings SKIN INJECTION HAZARD Do not aim the gun at or spray any person or animal Keep hands and other body parts away from the discharge For example do not try to stop leaks with any part of the body Always use the nozzle tip guard Do not spray without nozzle tip guard in place Use Graco nozzle tips Use caution when cleaning and changing nozzle tips In the case where the nozzle tip clogs while spraying follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean Do not leave the unit energized or under pressure while unattended When the unit is not in use turn off the unit and follow the Pressure Relief Procedure for turning off the unit High pressure spray is able to inject toxins into the body and cause serious bodily injury In the event that injection occurs get immediate surgical treatment Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3300 psi Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections
36. provided scraper so an even layer is 11 Remove nut and screw 88 and disconnect TS in the pocket ground wire 87 Disconnect coil connector Y Remove coil 81 12 Remove top two screws 39 and control box 61 13 Remove six screws 27 two screws 102 and control board NOTICE To reduce risk of motor control board failure do not overtighten screws 102 which can damage the electric components 312537G 25 26 Install two screws 102 six screws 27 and motor control board Install and torque two screws 102 to values in illustration Install motor control board 52 with six screws 27 Torque to 9 11 in Ib 1 02 1 24 Nem Connect motor connectors F G and H to motor control board Reconnect and install wiring in baffle Install motor shroud Install control box 61 with top two screws 39 Install coil 81 and tighten screw and nut 88 Tighten ground wire screw 87 and coil connector Y 11 12 13 14 15 16 Pressure Control Board Connect transducer connector E to motor control board Connect 15 20A switch 178 1595 model only Connect motor control board power lead s D to ON OFF switch 33 Connect WatchDog 49 switch connector X to motor control board Connect potentiometer connector C to motor control board Install control panel 68 with two screws 39 Connect display connector A to motor control board
37. r amp draw is excessive Perform Field Short Test Test at large 4 pin motor field connector There should not be continuity from pin 4 the ground wire and any of the remaining 3 pins If motor field connector tests fail replace motor Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each model see table below Resistance Table 695 0 ohms 795 2k ohms 1095 3 9k ohms MARK V 3 9k ohms 312537G 15 Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 06 LJ 4 qm E J m gt Control board status light blinks 6 times repeatedly Allow sprayer to cool If sprayer runs when cool correct cause of overheating Keep sprayer in cooler location with good ventilation Make sure motor air intake is not blocked If sprayer still does not run follow Step 1 NOTE Motor must be cooled down for the test Check thermal device connector yellow wires at control board Disconnect thermal device connector from control board socket Make sure contacts are clean and Secure Measure resistance of the thermal device If reading is not correct replace motor Check Motor Thermal Switch Unplug thermal wires Set meter to ohms Meter should read the proper resistance for each model see table below ree 100k ohm gt
38. ring priming 2 Intake valve is leaking 2 Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve 3 Pump packings are worn 3 Replace pump packings see pump man ual 310643 or 310894 4 Paint is too thick 4 Thin the paint according to the supplier s recommendations No display sprayer operates Display is damaged or has bad connection Check connections Replace display 312537G 17 Troubleshooting Electrical A Relieve pressure page 8 To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting wait 30 seconds after unplugging power cord for stored electricity to dissi e Plug sprayer into correct voltage grounded outlet pate Keep clear of electrical and moving parts during e Set power switch OFF for 30 seconds and then ON troubleshooting procedures again This ensures sprayer is in normal run mode Symptom Sprayer does not run or stops running If no digital display is available use control board status light to troubleshoot prob lems Turn ON OFF switch OFF remove control cover and then turn power back ON Observe status light Blinking LED to tal count equals digital error code i e two blinks equals E 02 e Turn pressure control knob clockwise 1 2 turn e View digital display TYPE OF PROBLEM WHAT TO
39. s 23 and nuts 19 on side opposite control Loosen two nuts 19 on side near control and remove motor 84 from cart frame 62 Installation Slide new motor 84 under two screws 23 in cart frame 62 near control Install two screws 23 and nuts 19 on motor side opposite control Install baffle and connect motor wires 4 Tighten all four screws 23 and nuts 19 10 11 12 torque nuts to 115 135 in lb 13 15 Nem Install strain relief 29 onto motor wires and into power bar plate 69 Install control housing 61 with top two screws 39 Connect motor leads Connect all three motor connectors to motor control board 52 Install control panel 68 with two screws 39 Install control cover 96 with four screws 38 Install drive housing 90 see Drive Housing Replacement page 32 Install pump 91 see Displacement Pump Replacement page 36 695 795 page 38 1095 1595 Mark V 312537G Motor Replacement 35 312537G Displacement Pump Replacement for 695 795 Displacement Pump Replacement for 695 795 See pump manual 310643 or 310894 for pump OFF and unplug power cord Push up retaining repair instructions ring 43 and push pump pin out See manual 311362 311363 or 311364 for applicable sprayer part number references Removal 1 Flush pump Qe oo I ti7168a Relieve pressure page 8 2 Remove screw 31 and slide pump rod shield 4 Remove
40. suction tube 76 hose 94 and any 108 forward washers and o rings 5 Loosen pump jam nut 56 Unscrew pump 31 ti7170a peel 3 Cycle pump in JOG mode until pump pin 44 is in position to be removed Turn power switch 36 312537G Displacement Pump Replacement for 695 795 Installation 2 Install pump pin 44 Verify retaining spring 43 is in groove of connecting rod 85 3 Push pump up until pump threads engage If pump pin works loose parts could break off 4 Screw in pump until threads are flush with drive due to force of pumping action Parts could housing opening Align pump outlet to back project through the air and result in serious injury or property damage 5 Install washers o rings and suction tube 76 and hose 94 6 Screw jam nut 56 up onto pump until nut NOTICE stops Tighten jam nut by hand then tap 1 8 to If the pump jam nut loosens during 1 4 turn with a 20 oz maximum hammer to operation the threads of the drive housing will approximately 75 5 ft lb 102 Nem be damaged 7 Install pump rod shield 108 with screw 31 1 Extend pump piston rod 1 5 in Apply greaseto g Fill packing nut with Pump Defender until fluid top of pump rod at A or inside connecting rod flows onto top of seal 1 5 in ti7169a ti7171a 312537G 37 Displacement Pump Replacement 1095 1595 Mark V Displacement Pump Replacement 1095 1595 Mark V Removal 7 Ratchet open pump d
41. than 70 F 21 C Use water based material or mineral spirits type material only For complete information about your fluid request the MSDS from the fluid distributor or retailer Verify that all containers and collection systems are grounded to prevent static discharge Connect to a grounded outlet and use grounded extensions cords Do not use a 3 to 2 adapter Do not use a paint or a solvent containing halogenated hydrocarbons Keep spray area well ventilated Keep a good supply of fresh air moving through the area Keep pump assembly in a well ventilated area Do not spray pump assembly Do not smoke in the spray area Do not operate light switches engines or similar spark producing products in the spray area Keep area clean and free of paint or solvent containers rags and other flammable materials Know the contents of the paints and solvents being sprayed Read all Material Safety Data Sheets MSDS and container labels provided with the paints and solvents Follow the paint and solvents manufacturer s safety instructions Fire extinguisher equipment shall be present and working 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 ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect
42. to step 2 Set sprayer to OFF and disconnect power to sprayer Disconnect motor connector s from control board socket s Check that motor connector and control board contacts are clean and secure If contacts are clean and secure continue to step 4 Set sprayer to OFF and spin motor fan 1 2 turn Restart sprayer If sprayer runs replace control board If sprayer does not run continue to step 5 Perform Spin Test Test at large 4 pin motor field connector Disconnect fluid pump from sprayer Test motor by placing a jumper across pins 1 amp 2 Rotate motor fan at about 2 revolutions per second A cogging resistance to motion should be felt at the fan The motor should be replaced if no resistance is felt Repeat for pin combinations 1 amp 3 and 2 amp 3 Pin 4 the green wire is not used in this test If all spin test is positive continue to step 6 Green Blue Red Black STEP 1 12 3 4 IH Ui Green Blue Red Black STEP 2 3 4 Hi Hi Green Blue Red Black 312537G Troubleshooting TYPE OF PROBLEM WHAT TO CHECK HOW TO CHECK Sprayer does not run at all Digital display shows E 05 rau L 7 LJ LJ Control board status light blinks 5 times repeatedly Control is commanding motor to run but motor shaft does not rotate Possibly locked rotor condition an open connection exists between motor and control there is a problem with motor or control board or moto
43. uid under high pressure can be injected through Skin and cause serious injury To reduce risk of in jury from injection splashing fluid or moving parts ollow Pressure Relief Procedure whenever you are instructed to relieve pressure stop spraying check or service any system equipment install or clean spray tip e mw o e Turn pressure control knob to zero Turn ON OFF switch to OFF Unplug power supply cord Hold metal part of gun firmly to grounded metal pail Trigger gun to relieve pressure Lock gun safety latch Open prime valve Leave prime valve open until ready to spray again If suspected that spray tip or hose is completely clogged or that pressure has not been fully re lieved after following steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Then clear tip or hose obstruction General Repair Information To reduce risk of pressure control malfunction Use needle nose pliers to disconnect wire Never pull on wire pull on connector Mate wire connectors properly Center flat blade of insulated male connector in female connector Route wires carefully to avoid interference with other connections of pressure control Do not pinch wires between cover and control box Keep all screws nuts washers gaskets and electrical fittings removed during repair procedures These parts are not normally provided with rep
44. up use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable GROUNDING This product must be grounded In the event of an electrical short circuit grounding reduces the risk of electric shock by providing an escape wire for the electric current This product is equipped with a cord having a grounding wire with an appropriate grounding plug The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances Improper installation of the grounding plug is able to result in a risk of electric shock When repair or replacement of the cord or plug is required do not connect the grounding wire to either flat blade terminal The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire Check with a qualified electrician or serviceman when the grounding instructions are not completely understood or when in doubt as to whether the product is properly grounded Do not modify the plug provided if it does not fit the outlet have the proper outlet installed by a qualified electrician This product is f
45. 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 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 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 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 defect
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