ASM 249172 Operating instructions

- For Portable Airless Spraying of Architectural Coatings and Paints. For professional use

only. Not for use in explosive atmospheres.-

Models 249172, 247620: 110 Vac UK

Models 249173, 247619: 240 Vac Multi-cord

Maximum Working Pressure: 3300 psi (227 bar, 22.7 MPa)

IMPORTANT SAFETY INSTRUCTIONS

Read all warnings and instructions in this

manual. Save these instructions.

310994E

H3700 Airless Sprayer

Repair

Table of Contents

2310994E

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification and Function . . . . . . . . 6

General Repair Information . . . . . . . . . . . . . . . . . . 7

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . 9

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Control Repair . . . . . . . . . . . . . . . . . . . . 18

110 Vac UK Motor Control Board . . . . . . . . . . . 18

110 Vac U.K. Filter Board . . . . . . . . . . . . . . . . . 20

240 Vac Motor Control Board . . . . . . . . . . . . . . 21

240 Vac UK Filter Board . . . . . . . . . . . . . . . . . . 23

Pressure Adjust Potentiometer . . . . . . . . . . . . . 24

Pressure Control Transducer . . . . . . . . . . . . . . 25

Drive and Bearing Housing Replacement . . . . . . 27

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 29

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Displacement Pump Replacement . . . . . . . . . . . . 31

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

ASM Standard Warranty . . . . . . . . . . . . . . . . . . . . 34

Warnings

310994E 3

Warnings

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.

WARNING

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 qual-

ified electrician.

• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illus-

trated in the figure below.

• Only connect the product to an outlet having the same configuration as the plug.

• Do not use an adapter with this product.

Extension Cords:

• 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.

• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG

(2.5 mm2) minimum to carry the current that the product draws.

• An undersized cord results in a drop in line voltage and loss of power and overheating.

ti9164a

Warnings

4310994E

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:

• 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 sys-

tem, 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 conductive or grounded

high-pressure airless paint sprayer hoses.

• 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.

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 ASM 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 ASM 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 are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

WARNING

Warnings

310994E 5

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 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 ASM.

• Do not use the hose as a strength member to pull or lift the equipment.

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.

PRESSURIZED ALUMINUM PARTS HAZARD

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.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating

area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic

fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eye wear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

WARNING

Component Identification and Function

6310994E

Component Identification and Function

A Motor DC motor, permanent magnet, totally enclosed, fan cooled

B Drive Assembly Transfers power from DC motor to displacement pump

D Displacement Pump Transfers fluid to be sprayed from source through spray gun

E Fluid Outlet Fluid hose is connected here

F Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open

G Fluid Filter Final filter of fluid to spray gun

H Pressure Control Knob Controls fluid outlet pressure

J Pressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump outlet.

Works with pressure adjusting knob.

K ON/OFF Switch Power switch that controls main power to sprayer

T Hose Rack Holds wrapped hose for storage

U Suction Tube Transfers fluid to be sprayed from source to pump

V Drain Tube Fluid outlet used to drain and prime the sprayer

General Repair Information

310994E 7

General Repair Information

Pressure Relief Procedure

1. Turn pressure control knob to zero.

2. Turn ON/OFF switch to OFF.

3. Unplug power supply cord.

4. Hold metal part of gun firmly to grounded metal

pail. Trigger gun to relieve pressure.

5. Lock gun safety latch.

6. Open prime valve. Leave prime valve open until

ready to spray again.

NOTE: If suspected that spray tip or hose is

completely clogged, or that pressure has not

been fully relieved after following steps above,

VERY SLOWLY loosen tip guard retaining nut

or hose end coupling to relieve pressure

gradually, then loosen completely. Then clear

tip or hose obstruction.

1. Keep all screws, nuts, washers, gaskets, and

electrical fittings removed during repair

procedures. These parts are not normally

provided with replacement assemblies.

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 9, for other possible solutions.

System pressure must be manually relieved to pre-

vent system from starting or spraying accidentally.

Fluid 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,

follow Pressure Relief Procedure whenever you:

• are instructed to relieve pressure

• stop spraying

• check or service any system equipment

• install or clean spray tip

NOTICE

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.

To reduce risk of serious injury, including electric

shock, do not touch moving or electrical parts with

fingers or tools while testing repair. Shut off and un-

plug sprayer when inspection is complete. Install all

covers, guards, gaskets, screws, washers and

shroud before operating sprayer.

Grounding

8310994E

Grounding

1. Ultra Max II 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.

2. Do not alter ground prong or use adapter.

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.

Improper installation or alteration of grounding

plug results in risk of electric shock, fire or

explosion that could cause serious injury or

death.

ti2810a

Troubleshooting

310994E 9

Troubleshooting

Mechanical/Fluid Flow

Relieve pressure; page 7.

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

E=XX is displayed 1. Fault condition exists 1. Determine fault correction from table,

page 11.

False tripping of WatchDog

system. EMPTY is dis-

played. Pump does not run.

1. Operating conditions out of

WatchDog parameters. Pump

output is low, see below.

1. Turn pressure down. Refer to operation

manual for adjusting. Operate without

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

are not seating properly

5. Remove intake valve and clean. Check

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

clogged or dirty.

7. Clean filter; see operation manual.

8. Prime valve leaking 8. Relieve pressure. Repair prime valve.

9. Verify pump does not continue to

stroke when gun trigger is

released. (Prime valve not leak-

ing.)

9. Service pump; see pump manual 310643

or 310894.

10. Leaking around throat packing

nut which may indicate worn or

damaged packings.

10. Replace packings; see pump manual. Also

check piston valve seat for hardened paint

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

damaged

13. Replace packings; see pump manual

310643 or 310894.

Troubleshooting

10 310994E

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

material

15. Clean intake valve; see pump manual

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

heavy materials

17. Use larger diameter hose and/or reduce

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 stroke

1. Displacement pump pin (32)

damaged or missing; see pump

manual 310643 or 310894.

1. 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)

damaged; see pump manual

310643 or 310894.

2. Replace connecting rod assembly; see

pump manual 310643 or 310894.

3. Gears or drive housing damaged,

page 27.

3. Inspect drive housing assembly and gears

for damage and replace if necessary; see

pump manual 310643 or 310894.

Excessive paint leakage into

throat packing nut

1. Throat packing nut is loose 1. Remove throat packing nut spacer.

Tighten throat packing nut just enough to

stop leakage.

2. Throat packings are worn or

damaged

2. Replace packings; see pump manual

310643 or 310894.

3. Displacement rod is worn or

damaged

3. Replace rod; see pump manual 310643 or

310894.

Fluid is spitting from gun 1. Air in pump or hose 1. Check and tighten all fluid connections.

Reduce engine speed and cycle pump as

slowly as possible during priming.

2. Tip is partially clogged 2. Clear tip; see tip guard manual 309640.

3. Fluid supply is low or empty 3. Refill 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. Air in pump or hose 1. Check and tighten all fluid connections.

Reduce engine speed and cycle pump as

slowly as possible during 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 1. Display is damaged or has bad

connection

1. Check connections. Replace display.

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

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