ASM 2300, Instructions-Repair/Parts

Page 1: ...uctions Read all warnings and instructions in this manual Save these instructions Model 249159 and 249168 120 Vac Model 246803 and 249169 240 Vac 3000 psi 207 bar 20 7 MPa Maximum Working Pressure Related manuals 309971 Model 249168 249169 246803 Model 249159 309053 Model 246803 Series A B 311062 Models 249159 249168 249169 246803 Series C ti6748a 309878 ...

Page 2: ...ammable or combustible materials used in places such as cabinet shops or other factory or fixed locations If you intend to use this equipment in this type of application you must comply with NFPA 33 and OSHA requirements for the use of flammable and combustible materials ...

Page 3: ...static arc D Sprayer generates sparks When flammable liquid is used in or near sprayer or for flushing or cleaning keep sprayer at least 20 ft 6 m away from explosive vapors D Keep work area free of debris including solvent rags and gasoline D Do not plug or unplug power cords or turn lights on or off when flammable fumes are present D Ground equipment and conductive objects in work area Read Grou...

Page 4: ...ur ASM distributor for information D Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces D Do not kink or overbend hoses or use hoses to pull equipment D Keep children and animals away from work area D Do not operate the unit when fatigured or under the influence of drugs or alcohol D Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZA...

Page 5: ... 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 M 50 ft 15 m Main Hose 1 4 in ID grounded nylon hose with spring guards on both ends N Spray Gun High pressure spray gun with gun safety latch P Tip Uses high pressure fluid to clear tip clogs without removing tip from spray ...

Page 6: ...rs properly Center flat blade of insulated male connector in female connector D Route wires carefully to avoid interference with other connections of pressure control Do not pinch wires between cover and control box 1 Keep all screws nuts washers gaskets and electrical fittings removed during repair proce dures These parts are not normally provided with replacement assemblies To reduce risk of ser...

Page 7: ... fil ter refer to separate gun or tip instruction manual Basic Mechanical Problems 1 Pump 13 for frozen or hardened paint 1 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 completely If paint hardened dried in sprayer replace pump packings See page 25 Displacement Pump Replace ment 2 Displacement pump connecting ...

Page 8: ...n brush holder to assure free vertical brush movement 6 Motor armature commutator for burn spots gouges and extreme roughness See page 12 6 Remove motor and have motor shop resur face commutator if possible See page 24 7 Motor armature for shorts using armature tester growler or perform spin test See page 12 7 Replace motor See page 24 Refer to the wiring dia grams in this manual to identify test ...

Page 9: ... to pressure control circuit board 35 for damaged or loose wires or con nectors Inspect wiring insulation and terminals for signs of overheating 8 Be sure male terminal blades are centered and firmly connected to female terminals Replace any loose terminal or damaged wiring Securely reconnect terminals 9 For loose motor brush leads and terminals See page 12 9 Tighten terminal screws Replace brushe...

Page 10: ... sary page 25 Strain paint before using to remove particles that could clog pump 5 Leaking around throat packing nut which may indicate worn or damaged packings See page 25 5 Replace packings page 25 Also check piston valve seat for hardened paint or nicks and replace if necessary Tighten packing nut wet cup 6 Pump rod damage 6 Repair pump page 25 Motor runs but pump does not stroke 1 Displacement...

Page 11: ...by performing motor control board diagnostics on page 21 If diag nostics indicate substitute with a good board CAUTION Do not perform this check until mo tor armature is determined to be good A bad motor armature can burn out a good board 4 Replace with a new pressure control board 35 See page 21 1 Basic Electrical Problems on page 7 1 Perform necessary procedures 2 ON OFF switch 23 See page 18 Be...

Page 12: ...Test Continuity 1 Connect red and black motor leads together with test lead Turn motor fan by hand at about two revolutions per second 2 If uneven or no resistance check for broken brush springs brush leads motor leads loose brush terminal screws motor lead terminals worn brushes Repair as needed page 12 3 If still uneven or no resistance replace motor page 24 9578A Fig 3 F G 39 Motor Brush Replac...

Page 13: ...damaging parts 1 Fig 6 Install new brush F with lead into brush holder C 2 Fig 5 Slide brush lead D into terminal E 3 Fig 6 Install spring clip A Push down to set hook B into brush holder C Fig 6 03881 1 B C E F 4 Repeat for other side 5 Test brushes a Remove pump 13 Displacement Pump Replacement page 25 b With sprayer OFF turn pressure control knob fully counterclockwise to minimum pressure Plug ...

Page 14: ...Disconnect four wires A from ON OFF switch 23 4 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 2 Connect four wires A to ON OFF switch 23 3 Install pressure control cover 39 with four screws 18 Fig 7 39 A 18 23 36 52 E D 35 25 24 37 22 ti0056b ...

Page 15: ...om inductor coil of filter board may destroy wire insulation that comes in contact with it Exposed wires could cause shorts and component damage Bundle and tie all loose wires so none lay in contact with inductor coil of filter board Caution Blue Green Yellow Brown Yellow Brown Blue TI0059A Capacitor Blue Red Black Blue TP1 TP2 Brown L1 L2 ...

Page 16: ...3 Disconnect four wires A at ON OFF switch 23 4 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 2 Connect four wires A to ON OFF switch 3 Install pressure control cover 39 Fig 9 39 A 23 36 52 E D 25 24 C 35 37 18 22 ti0055c ...

Page 17: ...act with it Exposed wires could cause shorts and component damage Bundle and tie all loose wires so none lay in contact with inductor coil of filter board Caution Pressure Transducer ON OFF Switch Power Plug Potentiometer Filter Board Capacitor Blue Brown TP1 TP2 Blue Brown L1 L2 Yellow Green Yellow from Motor Black White Red White Red Black ...

Page 18: ...C 4 Disconnect four wires A at ON OFF switch 23 5 Remove toggle boot 25 and locking ring 24 Remove ON OFF switch 23 Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 2 Connect four wires A to ON OFF switch 3 Install display connector B in plug C 4 Install pressure control cover 39 Fig 11 9585c A 24 25 37 35 B C E D 52 39 18 36 23 ...

Page 19: ...uctor coil of filter board may destroy wire insulation that comes in contact with it Exposed wires could cause shorts and component damage Bundle and tie all loose wires so none lay in contact with inductor coil of filter board Caution Inductor Coil Blue Green Yellow Brown Yellow Black Brown Blue Brown Blue TPT2 TPT1 L2 L1 Ref 29 Ref 23 Digital Display ti6650a ...

Page 20: ...ng 24 Remove ON OFF switch 23 Installation 1 Install new ON OFF switch 23 Install locking ring 24 and toggle boot 25 2 Connect two wires A to ON OFF switch 3 Install pressure control cover 39 with four screws 18 Fig 13 Wiring Diagram 23 33 27 32 26 Ref 45 22 52 29 21 18 2524 51 28 30 39 36 35 Ref 1 37 34 134 ti6036a ON OFF Switch Power Plug Potentiometer from Motor Red White Black Black Green Pres...

Page 21: ... and cover 39 2 Turn ON OFF switch ON 3 Observe LED operation and reference following table 4 Relieve pressure and unplug sprayer before ser vicing control board page 6 LED BLINKS SPRAYER OPERATION INDICATES WHAT TO DO Once Sprayer runs Normal operation Do nothing Two times repeatedly Sprayer shuts down and LED continues to blink two times repeatedly Run away pressure Pres sure greater than 4500 p...

Page 22: ...r up through transducer grommet 28 3 Install filter housing 45 with two screws 22 4 Connect lead E to motor control board 35 5 Install cover 39 with four screws 18 Pressure Adjust Potentiometer Removal 1 Relieve pressure page 6 2 Fig 7 Remove four screws 18 and cover 39 3 Disconnect all leads from motor control board 35 4 Remove five screws 36 and board 35 5 Remove potentiometer knob 27 sealing sh...

Page 23: ...ig 14 Tip sprayer up Remove screw 74c and remove shroud 74 4 Remove two front screws 22 5 Remove two back screws 22 6 Pull drive housing 10 off of motor 1 Assembly 1 Push drive housing 10 onto motor 1 2 Install two front screws 22 3 Install two back screws 22 4 Fig 14 Tip sprayer up Install shroud 74 with screw 74c 5 Install pump 13 Displacement Pump Replace ment page 25 6 Instal new access cover ...

Page 24: ...d 35 Remove five screws 36 and board 6 Remove strain relief 37 page 34 38 7 Remove three screws 22 behind board and remove control housing 21 8 Remove four screws 22 and motor 1 from frame 63 Assembly 1 Install new motor 1 on frame 63 with four screws 22 2 Install control housing 21 with three screws 22 3 Install strain relief 37 page 34 38 4 Install board 35 with five screws 36 Connect all leads ...

Page 25: ...If the pump locknut loosens during operation the threads of the drive housing will be damaged 1 Fig 18 Extend pump piston rod fully Apply grease to top of pump rod at A or inside connecting rod Fig 18 A ti6753a 2 Fig 16 Install pump pin 9a Verify retainer spring is in groove of pump pin 3 Push pump up until pump threads engage 4 Screw in pump until threads are flush with drive housing opening Alig...

Page 26: ...eries A 7 10 128 9 9b 1 74 9a 10a 74b 74a 74c 59 62 Ref 79 112 85 13 69 10b 3 92 Ref 19 31 19 48 82 78 129 45 58 57 56 55 53 79 38 49 86 22 22 113 67 63 12 70 90 89 88 A 14 22 73 72 71 A 83 47 126 127 74b ti6754a 133 114 Detail A Detail A 2 ...

Page 27: ...PIN grooved 1 59 187625 HANDLE valve drain 1 63 241867 FRAME cart 1 67 108691 PLUG tubing 2 68 15F594Y LABEL drive 2 69 239998 HANDLE cart 1 70 110243 RING retaining 2 71 192027 SLEEVE cart 2 72 111590 BUTTON snap 2 73 183350 WASHER 2 74 15C391 SHROUD motor 1 includes 74a 74b 74c 126 and 127 74a 195159 BRACKET shroud 1 74b 114531 SCREW slot hd hex washer hd 2 74c 115843 SCREW mach pnhd self drill ...

Page 28: ...nd C Series C shown 7 10 9 9b 1 74 74b 74a 74c 59 Ref 79 112 85 69 3 92 129 58 57 56 55 53 22 113 67 63 70 90 88 A 22 73 72 71 A 83 126 127 74b Detail A Detail A 22 10b 49 114 10a 79 64 45 47 48 Ref 19 128 9a 62 13 19 12 78 82 86 75 77 81 76 ti6755a ...

Page 29: ... 108691 PLUG tubing 2 68 15F594Y LABEL drive 2 69 239998 HANDLE cart 1 70 110243 RING retaining 2 71 192027 SLEEVE cart 2 72 111590 BUTTON snap 2 73 183350 WASHER 2 74 287159 SHROUD motor 1 includes 74a 74b 74c 126 and 127 74a 195159 BRACKET shroud 1 74b 114531 SCREW slot hd hex washer hd 2 74c 115843 SCREW mach pnhd self drill 1 75 15B652 WASHER suction series C 1 76 115099 WASHER garden hose ser...

Page 30: ...14421 BUSHING strain relief 1 32 15A356 LABEL control 1 33 112382 NUT shaft sealing 1 34 115498 SCREW slot hd hex washer hd 1 35 241992 BOARD control 1 36 241992 SCREW 6 32 X 1 2 TAPTITE 5 37 115756 BUSHING strain relief 1 39 198935 CONTROL cover black 1 40 241994 BOARD filter 1 41 243539 CONDUCTOR ground 1 42 241946 BOARD display LCD 43 LABEL control 1 15F573Y Series A B 15G024Y Series C 44 11552...

Page 31: ...31 309879 Notes ...

Page 32: ...9 7 10 128 9 9b 1 74 9a 74b 74a 74c 59 62 13 69 3 92 19 129 58 57 56 55 53 22 67 63 12 70 90 88 A 22 73 72 71 A 83 126 127 74b Detail A Detail A 22 10b 49 114 10a 79 64 45 47 48 Ref 19 85 79 78 82 86 76 80 77 75 43 68 ti6679a 91 104 105 106 93 102 ...

Page 33: ... 277091 PLUG tubing 2 68 15F594Y LABEL drive 2 69 239998 HANDLE cart 1 70 110243 RING retaining 2 71 192027 SLEEVE cart 2 72 111590 BUTTON snap 2 73 183350 WASHER 2 74 287159 SHROUD motor 1 includes 74a 74b 74c 126 and 127 74a 195159 BRACKET shroud 1 74b 114531 SCREW slot hd hex washer hd 2 74c 115843 SCREW mach pnhd self drill 1 75 115099 WASHER garden hose 1 76 15B652 WASHER suction 1 77 15E813 ...

Page 34: ...land 1 30 114064 BUSHING strain relief 120 Vac 114421 BUSHING strain relief 240 Vac 1 32 15A356 LABEL control 1 33 112382 NUT shaft sealing 1 34 115498 SCREW slot hd hex washer hd 1 35 241990 BOARD control 120 Vac 241992 BOARD control 240 Vac 1 36 241992 SCREW 6 32 X 1 2 TAPTITE 5 37 115756 BUSHING strain relief 1 39 198935 CONTROL cover black 1 40 241993 BOARD filter 120 Vac 241994 BOARD filter 2...

Page 35: ...35 309879 Notes ...

Page 36: ...49159 Series A 7 10 128 9 9b 1 74 9a 74b 74a 74c 59 62 Ref 79 112 85 13 69 3 92 19 82 78 129 58 57 56 55 53 86 22 113 67 63 12 70 90 88 A 22 73 72 71 A 83 126 127 74b Detail A Detail A 22 10b 49 114 10a 79 61 45 47 48 Ref 19 ti6035b ...

Page 37: ...1 PLUG tubing 1 69 239998 HANDLE cart 1 70 110243 RING retaining 2 71 192027 SLEEVE cart 2 72 111590 BUTTON snap 2 73 183350 WASHER 2 74 15C391 SHROUD motor 1 includes 74a 74b 74c 126 and 127 74a 195159 BRACKET shroud 1 74b 114531 SCREW slot hd hex washer hd 2 74c 115843 SCREW mach pnhd self drill 1 75 115099 WASHER garden hose 1 76 15B652 WASHER suction 1 77 15E813 NUT intake tube 1 78 15F551 TUB...

Page 38: ...gle 1 24 15A435 RING locking 1 25 195428 BOOT toggle 1 26 236352 POTENTIOMETER adjust pressure 1 27 116167 KNOB potentiometer 1 28 195423 GROMMET transducer 1 29 241874 CORD SET power 1 30 114421 BUSHING strain relief 1 32 15A356 LABEL control 1 33 112382 NUT shaft sealing 1 34 115498 SCREW slot hd hex washer hd 1 35 241990 BOARD control 1 36 115494 SCREW 6 32 X 1 2 TAPTITE 5 37 115756 BUSHING str...

Page 39: ... zinc plated carbon steel polyurethane polyethylene stainless steel PTFE DelrinR chrome plating leath er V Maxt UHMWPE aluminum stainless steel tungsten carbide nylon thermoplastic elastomer brass nickel plated brass NOTE DelrinR is a registered trademark of the DuPont Co Dimensions Weight lb kg Height in cm Length in cm Width in cm 395 495 495 Height in cm Length in cm Width in cm 57 26 59 27 66 ...

Page 40: ... 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 i...