ASM AllPro Mach 5400 Plus 110V Repair And Parts Manual Download Page 24 | Manualshive

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Power Cord Replacement

24

312361L

Power Cord Replacement

See Wiring Diagram, page 26.

Removal

1.

Remove control board, Control Board Replace-
ment, Removal, page 17.

2.

Remove green ground screw (20) and disconnect
green ground wire (G) from frame.

Installation

1.

Connect green ground wire (G) to frame with green
ground screw (20). Be sure green ground wire ter-
minal faces up or wires could get caught in shroud.

2.

Install control board, Control Board Replacement,
Installation, page 18.

G

20

ti6126b

18

18

120V

240V

C

C

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Summary of Contents for AllPro Mach 5400 Plus 110V

Page 1: ...ustang 4700 Plus 110V 247483 ASM Zip Spray 2100 Plus 240V 247487 ASM Zip Spray 2100 Plus 240V 247484 ASM L1900 Plus 110V 247494 ASM Z21 240V 262901 ASM L1900 Plus 240V 247495 ASM L2100 Plus 240V 24P912 ASM AllPro Mach 5400 Plus 110V 247532 ASM Zip Spray 2300 Plus 110V 247531 Direct Immersion Stand Models ASM L 1900 Plus 110V 255891 ASM L 1900 Plus 240V 255890 Important Safety Instructions Read all...

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

Page 4: ...0V 3 wire 16 AWG 1 0 mm2 minimum NOTE Smaller gauge or longer extension cords may reduce sprayer performance Spray gun ground through connection to a properly grounded fluid hose and pump Fluid supply container follow local code Solvent and Oil based fluids follow local code Use only conductive metal pails placed on a grounded sur face such as concrete Do not place the pail on a non conductive sur...

Page 5: ...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 trigger...

Page 6: ...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 7: ...echanical 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 11 Dis placement Pump Replacement 2 Displacement pump connecting rod pin Pin must be completely pushed into connecting rod and retaining spring mu...

Page 8: ...d terminals Securely recon nect leads 6 Motor thermal switch Yellow motor leads must have continuity through thermal switch Replace motor See page 25 Motor Replace ment 7 Brush cap missing or loose brush lead connections Install brush cap or replace brushes if leads are damaged See page 16 Motor Brush Replacement 8 Brush length which must be greater than 1 4 in 6 mm NOTE Brushes do not wear at the...

Page 9: ...ding 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 greater than 1 4 in 6 mm Replace brush...

Page 10: ...acement 2 Connecting rod assembly for damage Replace connecting rod assembly See page 11 Displacement Pump Replacement 3 Gears or drive housing Inspect drive housing assembly and gears for damage and replace if necessary See page 13 Drive Housing Replacement Motor is hot and runs intermittently 1 Be sure ambient temperature where sprayer is located is not more than 115 F 46 C and sprayer is not lo...

Page 11: ...Loosen two screws 11 and remove pail hanger 10 3 Loosen nut 37 and remove suction tube 39 Loosen nut B and remove coupled hose 42 4 Cycle pump until pin 31 is in position to be removed 5 Disconnect power cord from outlet 6 Push up retaining spring C Push out pump pin 31 7 Loosen pump jam nut 34 Unscrew and remove pump 33 11 10 ti9138a 42 B 37 39 ti9139a C 31 ti9040a 34 33 ti9141a ...

Page 12: ...til nut stops Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately 75 ft lb 102 N m 8 Install suction tube 39 and coupled hose 42 Tighten nuts 37 and B 9 Fill packing nut with ASM Packing Seal until fluid flows onto top of seal Install pail hanger 10 with screws 11 If pump pin works loose parts could break off due to force of pumping action Parts could proj...

Page 13: ... a liberal coat of grease to gears and needle bearing surfaces Install thrust bearing 28 and gears 26 and 27 in motor front endbell 2 Push drive housing 29 into motor front endbell Insert gear crank 27 through hole in connecting rod 30 3 Install four screws 4 and screw 13 4 Install cover 32 with two screws 11 5 Install pump 33 Displacement Pump Replace ment page 11 NOTICE Do not drop gear cluster ...

Page 14: ... complete stop there are no electrical shorts If motor does not spin freely armature is shorted Replace motor page 25 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 R...

Page 15: ...tlet see page 11 3 Remove two screws 4 and shroud 12 4 Remove spring clip 57b on back of motor 5 Pull off fan 57a 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 Connect high pressure hose at pump outlet see page 12 57b 57a 4 12 ti12422a ...

Page 16: ...se all new parts included in brush kit Do not reuse old parts if new replacement parts are provided 1 Install new brushes B in motor with wires facing toward front of motor Install positive red brush lead in top of motor and negative black brush lead in side of motor 2 Push each cap A into place over brush Orient each cap with the two projections on either side of the brush lead You will hear a sn...

Page 17: ...ector D from control board 18 6 Remove three screws 11 securing control board to housing two are located on the front and one on the back next to the power cord 7 Pull control board out slightly and then slide control board back and off of frame NOTE Make sure power cord is free and not wrapped around cord wrap 8 Remove grommet and wires from strain relief NOTE Ground wire remains attached to spra...

Page 18: ...r frame 3 Slide control board into place on side of motor front endbell 4 Replace three screws 11 Torque to 30 35 in lb 3 4 3 9 N m 5 Connect motor connector D and pressure control assembly connector A 6 Install shroud 12 with two screws 4 see page 15 7 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 ti6122a 18 Grommet Strain Relief C 120V 240V A D 18 18 D A ti6143b C Bott...

Page 19: ...ve pressure page 5 Disconnect power cord from outlet 2 Hi Boy Models Only Disconnect high pressure hose at pump outlet see page 11 3 Remove two screws 4 and shroud 12 see illustration page 15 4 Remove fuse from control board Installation 1 Install Fuse on control board 2 Install shroud 12 and two screws 4 see illustra tion page 15 3 Hi Boy Models Only Connect high pressure hose at pump outlet see ...

Page 20: ...shroud 12 see illus tration page 15 4 Disconnect pressure switch connector A from con trol board 18 Pull bushing 23 from hole K 5 Pull wires through hole K 6 Turn pressure control knob 17 counter clockwise as far as you can to access flats on either side of pressure control 7 Loosen and unscrew pressure control 8 Remove pressure control 18 A K 23 ti9129a Caution If you plan to reuse pressure contr...

Page 21: ...d torque to 150 in lb 17 0 N m 5 Tuck wires into pressure control wire cap 21 and route wires toward cap opening Feed wires through housing hole K 6 Insert bushing 23 in hole K 7 Connect pressure switch connector A to control board 18 8 Install shroud 12 and two screws 4 see illustra tion page 15 9 Hi Boy Models Only Connect high pressure hose at pump outlet see page 12 K o ring A 23 18 21 ti9129a...

Page 22: ...ld 43 5 Remove valve seat 44b and seat gasket 44a from inside of filter manifold or end of drain valve Installation 1 Install new seat gasket 44a and valve seat 44b on end of drain valve 2 Screw drain valve 44 into filter manifold 43 Torque to 120 to 130 in lb 3 Push valve base 45 over drain valve 44 and then valve drain handle 46 over valve base 4 Install pin 47 in drain valve handle If necessary...

Page 23: ...d fitting 51 and drain line 49 cut and remove remaining drain line material from end of barbed fitting Installation 1 Screw barbed fitting 51 into filter manifold 43 2 Push drain line 49 onto barbed fitting NOTE To make drain line more pliable and easier to install over barbed fitting heat end of drain line 49 with a hair dryer or place end in hot water a few seconds 51 49 ti9156a 43 ...

Page 24: ...l page 17 2 Remove green ground screw 20 and disconnect green ground wire G from frame Installation 1 Connect green ground wire G to frame with green ground screw 20 Be sure green ground wire ter minal faces up or wires could get caught in shroud 2 Install control board Control Board Replacement Installation page 18 G 20 ti6126b 18 18 120V 240V C C ...

Page 25: ...me 1 Installation 1 Install cover 14 on motor 57 Install motor on frame 1 with four screws 4 2 Connect green ground wire G to frame with green ground screw 20 Be sure green ground wire ter minal faces up or wires could get caught in shroud See illustration page 25 3 Install manifold 43 with two screws 4 4 Install control board Control Board Replacement page 17 5 Install drive housing Drive Housing...

Page 26: ...Assembly Power Plug White Green Black from Motor 2 x Yellow ON OFF Switch ti5643a Capacitor Replaceable Fuse Black Power Plug Blue Green Brown ON OFF Switch Pressure Control Assembly Red from Motor 2 x Yellow Capacitor ti5857a Replaceable Fuse 120V ti5643a1 ti5857a 240V ...

Page 27: ...Notes 312361L 27 Notes ...

Page 28: ...Parts Stand 28 312361L Parts Stand Models 247482 247483 247484 24P912 262901 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 30a 57b 57a ...

Page 29: ...ing 1 31 196762 PIN straight 1 32 276883 COVER front 1 33 255475 PUMP displacement 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 49 249051 KIT tube drain includes 51 50 37 1 50 2440...

Page 30: ...Parts Stand 30 312361L Parts Stand Models 247482 247483 247484 24P912 262901 ti10331c 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 88 87 86 ...

Page 31: ... 4 npsm x 1 4 npt 2 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 valve 1 46 HANDLE valve drain 277089 Model 24P912 1 187625 Model 247482 247483 247848 262901 1 47 111600 PIN grooved 1 48 195811 LABEL instruction 1 50 DEFLECTOR barbed 255465 Model 24P912 1 244035 Models 247482 247483 247484 262901 1 51 M70809 FI...

Page 32: ...y 32 312361L 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 1 64 65 15 16 106 104 5 ti10336c ...

Page 33: ...ion 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 249041 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 247495 2 64 CAP hub 119452 ...

Page 34: ...Parts Hi Boy 34 312361L 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 35: ...90 210 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 247531 247532 1 255465 Models 247494 247...

Page 36: ...rawing Direct Immersion Stand Models 255890 255891 ti11632a 68 12 57 27 28 29 26 4 32 11 67 14 34 30 31 33 41 35 10 11 40 38 37 39 36 23 25 18 56 55 22 17 21 54 11 53 52 35 51 47 44 46 45 4 35 9 8 43 49 50 65 4 16 15 76 19 24 100 30a 42 42 110 111 13 69 70 ...

Page 37: ... COVER 1 33 246428 PUMP displacement ST 1 34 195150 NUT jam pump 1 35 162453 FITTING 1 4 npsm x 1 4 npt 3 36 187651 STRAINER 3 4 16 unf 1 37 15E813 NUT jam 1 38 15B652 WASHER suction 1 39 15J801 TUBE suction intake 1 40 103413 O RING 1 41 115099 WASHER garden hose 1 42 15M670 HOSE coupled 1 43 15J745 MANIFOLD filter 190 210ES 1 44 235014 VALVE drain 1 45 224807 BASE valve 1 46 277089 HANDLE valve ...

Page 38: ...Parts Drawing Direct Immersion Stand 38 312361L Parts Drawing Direct Immersion Stand Models 255890 255891 2 7 7a 7b 66 64 7c 63 1 ti11633a 112 113 ...

Page 39: ...and 1 2 15R792 LEG cart 2 4 117493 SCREW mach hex washer hd 10 7 289119 LEVER handle cam includes 3 5 6 7 4 7a PIN pivot handle cart 4 7b SCREW cap socket head 4 7c NUT lock hex 4 63 120595 CLIP tool 2 64 RIVET blind 1 8 x 1 4 in 4 66 120151 RETAINER caplug 4 112 15T783 ISOLATOR foot 4 113 122667 SCREW drill hex washer 8 Ref Part Description Qty ...

Page 40: ...r replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS ...

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