ASM AllPro Mach 5400 Plus 110V Product Service Manual Download Page 25 | Manualshive

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Power Cord Replacement

312361D

25

Power Cord Replacement

See Wiring Diagram, page 27.

Removal

1.

Follow Control Board Replacement removal
instructions, steps 1-8, page 25.

2.

Disconnect power cord connectors (C) from control
board (18).

3.

Disconnect green ground wire (G) from sprayer by
loosening grounding screw (20).

Installation

1.

Follow Control Board Replacement installation
instructions, steps 1-4, page 19.

2.

Reconnect, green ground wire (G) to green ground-
ing screw (20) on frame. Be sure terminal on ground
faces UP or wires could get caught in shroud.

3.

Reconnect power cord connectors (C) to control
board (18).

4.

Reattach motor connector (B) and pressure control
switch connect (A).

5.

Install shroud (12) and two screws (4) (see illustra-
tion, page 17).

18

G

20

240V

120V

ti6126b

18

C

C

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Summary of Contents for AllPro Mach 5400 Plus 110V

Page 1: ...60 312363 English 312362 312364 Spanish 312365 French Related Manuals ti10305a ti10320a Stand Models ASM Zip Spray 2100 Plus 110V 247482 ASM AllPro Mustang 4700 Plus 110V 247483 ASM Zip Spray 2100 Plus 240V 247484 Hi Boy Models ASM Zip Spray 2100 Plus 110V 247485 ASM AllPro Mustang 4700 Plus 110V 247486 ASM Zip Spray 2100 Plus 240V 247487 ASM L1900 Plus 110V 247494 ASM L1900 Plus 240V 247495 ASM Z...

Page 2: ...ts on or off when flammable fumes are present Ground equipment and conductive objects in work area Read Grounding instructions If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause elec...

Page 3: ...containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage BURN HAZARD Equipment surfaces can become very hot during operation To avoid severe burns do not touch hot equipment Wait until equipment has cooled completely MOVING PARTS HAZARD Moving parts can pinch or amputate fing...

Page 4: ... K M U E R ti10381a J H Item Component A Pressure Control B ON OFF switch C Pressure Gauge not on all models D Power Cord E Fluid Outlet F Prime Valve G Cord Wrap H Pump J Suction Hose K Drain Hose M Fluid Hose N Gun P Tip R Guard S Trigger Safety Lock T Serial Number ID Label U Filter Cover ...

Page 5: ...ressure Control B ON OFF switch C Pressure Gauge not on all models D Power Cord E Fluid Outlet F Prime Valve H Pump J Suction Hose K Drain Hose M Fluid Hose N Gun P Tip R Guard S Trigger Safety Lock T Serial Number ID Label U Filter Cover V Pail Hook T ti10306a M N J K H D V C F A B U R P S E ...

Page 6: ...m maximum length 240V 3 wire 16 AWG 1 0 mm2 minimum 300 ft 90 m maximum length Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent and Oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a non conductive surface such as paper or cardboar...

Page 7: ...ing 2 Hold gun against side of grounded metal flushing pail Trigger gun to relieve pressure 3 Turn prime valve down If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction 4 Engage tri...

Page 8: ...ed on hot bare motor could cause fire or explosion To reduce risk of burns fire or explosion do not operate sprayer with cover removed To reduce risk of serious injury including electric shock Do not touch moving or electric parts with fingers or tools while testing repair Unplug sprayer when power is not required for testing Install all covers gaskets screws and washers before you operate sprayer...

Page 9: ...chanical 1 Pump frozen or hardened paint Thaw sprayer if water or water based paint has frozen in sprayer Place sprayer in warm area to thaw Do not start sprayer until thawed com pletely If paint hardened dried in sprayer replace pump packings See page 13 Dis placement Pump Replacement 2 Displacement pump connecting rod pin Pin must be completely pushed into connecting rod and retaining spring mus...

Page 10: ...inals Securely recon nect leads 6 Motor thermal switch Yellow motor leads must have continuity through thermal switch Replace motor See page 18 Motor Replace ment 7 Brush cap missing or loose brush lead connections Install brush cap or replace brushes if leads are damaged See page 18 Motor Brush Replacement 8 Brush length which must be 1 4 in 6mm minimum NOTE Brushes do not wear at the same rate o...

Page 11: ...ension cord See page 6 Grounding and Electric Requirements 7 Leads from motor to circuit board for damaged or loose wire con nectors Inspect wiring insulation and terminals for signs of over heating Be sure male terminal pins are centered and firmly connected to female terminals Replace any loose terminals or damaged wiring Securely reconnect terminals 8 Worn motor brushes which must be 1 4 in 6 m...

Page 12: ...lacement 2 Connecting rod assembly for damage Replace connecting rod assembly See page 13 Displacement Pump Replacement 3 Gears or drive housing Inspect drive housing assembly and gears for damage and replace if necessary See page 15 Drive Housing Replacement Motor is hot and runs intermittently 1 Be sure ambient temperature where sprayer is located is not more than 115 F 46 C and sprayer is not l...

Page 13: ...o screws 11 and remove pail hook 10 3 Loosen nut A and remove suction hose B 4 Loosen nut C and remove the high pressure hose D 5 Cycle pump until pin 31 is in position to be removed 6 Disconnect power cord from outlet 7 Use flat screwdriver push to push retaining spring E up Push out pump pin 31 8 Use hammer to loosen pump jam nut 34 Unscrew and remove pump 33 11 ti10323a 10 10 11 ti9138a Stand H...

Page 14: ...20 oz maximum hammer to approximately 75 ft lb 102 N m torque 8 Install high pressure hose D and tighten nut C to approximately 35 ft lb 47 N m torque Install suc tion tube B and hand tighten nut A 9 Fill packing nut with ASM Packing Seal until fluid flows onto top of seal 10 Stand Models Rotate cover 10 and tighten screws 11 Hi Boy Models Install pail hook 10 with screws 11 If pump pin works loos...

Page 15: ... gears and needle bearing surfaces Install thrust bearing 28 and gears 26 and 27 in front endbell housing 2 Push drive housing into front endbell housing Insert gear crank 27 through hole in connecting rod 30 3 Stand Models Install five screws 4 Hi Boy Models Install five screws 4 4 Install cover 32 with two screws 11 5 Install pump 33 Displacement Pump Replacement page 13 CAUTION Do not drop gear...

Page 16: ...complete stop there are no electrical shorts If motor does not spin freely armature is shorted Replace motor page 26 Armature Brushes and Motor Wiring Open Circuit Test Continuity 1 Connect red and black motor leads with test lead Turn motor fan by hand at about two revolutions per second 2 If uneven or no resistance check for missing brush caps broken brush springs brush leads and worn brushes Re...

Page 17: ...let see page 13 3 Remove two screws 4 and shroud 12 4 Remove spring clip 57b on back of motor 5 Pull off fan 57a Installation 1 Slide new fan 57a in place on back of motor Be sure blades of fan face motor as shown 2 Install spring clip 57b 3 Replace shroud 12 and two screws 4 4 Hi Boy Models Only Reconnect high pressure hose at pump outlet see page 14 57b 57a 4 12 ti10339a ...

Page 18: ...op of the motor as shown and the negative black brush lead in the side of the motor 2 Push each cap A into place over brush Orient each cap with the 2 projections on either side of the brush lead You will hear a snap when cap is securely in place 3 Using a wire stripper strip off wire insulation approx imately 1 4 inch 6 mm from the end of each yellow wire C to the motor 4 Insert stripped end into...

Page 19: ...tor connector B from control board 18 6 Remove three screws 11 securing control board to housing two are located on the front and one on the back next to the power cord 7 Pull control board out slightly and then slide it back and off of frame 8 Remove grommet and wires from strain relief 9 Remove two power cord C connectors from control board ti6143a 240V 120V 18 18 A B B A 18 ti6119b 11 Make sure...

Page 20: ...Torque to 30 35 in lbs 3 4 3 9 N m 5 Connect motor connector B and pressure control assembly connector A 6 Install shroud 12 with screw 4 Install front cover 32 with two screws 11 see page 15 7 Hi Boy Model Only Reconnect high pressure hose at pump outlet see page 14 Route power cord 19 between coupled hose 42 to filter manifold and sprayer frame ti6122a 18 Grommet Strain Relief ti6143a 240V 120V ...

Page 21: ...h pressure hose at pump see page 13 3 Remove two screws 4 and shroud 12 see illustration page 17 4 Remove fuse from control board 18 Installation 1 Install new fuse on control board 18 2 Install shroud 12 and two screws 4 see illustration page 17 3 Hi Boy Models Only Reconnect high pressure hose at pump outlet see page 14 Replaceable Fuse ti9134a ...

Page 22: ...ontrol cap 21 on fluid manifold so opening faces toward motor 2 Apply Loctite to threads on pressure control assembly 17 3 Screw pressure control assembly 17 into manifold and torque to 150 in lbs 17 0 N m 4 Route wires around knob and feed through slot in bushing 23 5 Insert bushing 23 in hole K in housing Secure wires to manifold housing with tape 3 6 Reconnect pressure switch connector A to con...

Page 23: ... Thread drain valve 44 into manifold 43 opening 2 Hand tighten securely Using a wrench torque to 120 to 130 in lbs 3 Turn valve stem so hole for pin 47 is positioned at 12 o clock pin can be temporarily inserted to turn valve stem 4 Push base 45 over drain valve 44 and then drain handle 46 over base 45 5 Replace pin 47 in drain handle 46 If necessary use a hammer to tap it in place completely Befo...

Page 24: ...o manifold 2 Push drain line 49 onto barbed fitting 51 If you are only replacing the manifold and will be reusing the existing barbed fitting 51 and drain line 49 you will need to use a sharp knife to cut the remaining drain line material off the end of the barbed fitting 51 To make the drain line more pliable and easier to install over barbed fitting heat end of drain line 49 with a hair dryer or...

Page 25: ...sening grounding screw 20 Installation 1 Follow Control Board Replacement installation instructions steps 1 4 page 19 2 Reconnect green ground wire G to green ground ing screw 20 on frame Be sure terminal on ground faces UP or wires could get caught in shroud 3 Reconnect power cord connectors C to control board 18 4 Reattach motor connector B and pressure control switch connect A 5 Install shroud ...

Page 26: ...on 1 Install new motor 57 on frame 1 with four screws 4 2 Install fluid manifold 43 with two screws 4 Drain Valve Replacement page 23 3 Install control board 18 with three screws 11 Connect all leads to board See Control Board Replacement page 19 and Wiring Diagram page 27 4 Connect ground wire G to motor with green ground screw 20 5 Install Drive Housing Drive Housing Replacement page 15 6 Instal...

Page 27: ...ROL SSEMBLY 0OWER 0LUG 7HITE REEN LACK FROM OTOR X 9ELLOW 3WITCH APACITOR 2EPLACEABLE USE Black Power Plug Blue Green Brown ON OFF Switch Pressure Control Assembly Red from Motor 2 x Yellow Capacitor ti5857a Replaceable Fuse 120V Model 240V Model ti5643a1 ti5857a ...

Page 28: ...Parts Stand 28 312361D Parts Stand Models 247482 247483 247484 36 39 34 68 1 4 10 11 31 30 35 33 40 41 29 28 27 26 57 12 70 11 2 32 67 4 69 37 64 63 42 50 49 ti10332a 16 15 ...

Page 29: ...Parts Stand 312361D 29 Parts Stand Models 247482 247483 247484 ti10331a 56 55 54 53 52 35 44 47 46 45 44b 44a 51 43 4 22 17 21 11 11 18 19 81 48 72 71 19 50 85 84 20 19 25 23 ...

Page 30: ...nt includes 35 Manual 312362 1 34 195150 NUT jam pump 1 35 162453 FITTING 1 4 npsm x 1 4 npt 2 36 246385 STRAINER 7 8 14 unf 1 37 114958 STRAP tie 1 39 246386 HOSE suction set includes 41 40 36 1 40 117559 O RING 2 41 115099 WASHER garden hose 1 42 15M670 HOSE cpld 1 43 15J745 MANIFOLD filter 1 44 235014 VALVE drain includes 44a 44b 1 44a 111699 GASKET seat 1 44b 15E022 SEAT valve 1 45 224807 BASE...

Page 31: ...312361D 31 Parts Hi Boy Models 247485 247486 247487 247494 247495 247531 247532 12 2 64 63 68 4 42 35 33 36 39 37 38 40 41 31 10 11 11 4 4 29 32 28 27 26 57 69 30 34 4 70 57a 57b 2 7 8 6 9 1 5 1 64 65 15 16 106 104 ...

Page 32: ...1 38 15B652 WASHER suction 1 39 15J801 TUBE suction intake 1 40 103413 O RING 1 41 115099 WASHER garden hose 1 42 15M671 HOSE cpld 1 57 MOTOR electric includes 57a 57b 255485 Models 247485 247486 247494 247531 247532 1 255486 Models 247487 247495 1 57a 249043 FAN motor 1 57b 119653 RING retaining 1 63 WHEEL semi pneumatic 119451 Models 247485 247486 247487 247531 247532 2 119730 Models 247494 2474...

Page 33: ...Parts Hi Boy 312361D 33 Parts Hi Boy Models 247485 247486 247487 247494 247495 247531 247532 56 55 54 53 52 35 4 47 46 45 44 22 17 21 11 43 51 18 50 67 49 19 19 93 93 48 72 71 25 19 19 91 90 23 20 19 ...

Page 34: ...ution 1 43 15J745 MANIFOLD Filter 190 210 ES 1 44 235014 VALVE drain includes 44a 44b 1 44a 111699 GASKET seat 1 44b 15E022 SEAT valve 1 45 224807 BASE valve 1 46 HANDLE valve drain 187625 Models 247485 247486 247487 247531 247532 1 277089 Models 247494 247495 1 47 111600 PIN grooved 1 48 195811 LABEL instruction 1 49 15K092 TUBE drain 1 50 DEFLECTOR barbed 244035 Models 247485 247486 247487 24753...

Page 35: ...87 247494 247495 0 023 Models 247531 247532 Fluid outlet npsm 1 4 in Dimensions Stand 247482 247483 247484 Length 15 75 in 40 0 cm Width 14 0 in 36 0 cm Height 17 in 43 0 cm Weight 30 lbs 13 6 kg Weight with gauge 31 lbs 14 0 kg Dimensions Hi Boy 247485 247486 247487 247494 247495 247531 247532 Length 22 0 in 55 9 cm Width 20 5 in 52 1 cm Height 38 8 in 98 6 cm Weight 59 lbs 26 8 kg Weight with ga...

Page 36: ...ortation 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 damag...

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