ASM 249159 User manual

309879LInstructions--Repair/Parts
2300 and M2300 Airless Sprayer
- For portable spray application of architectural paints and coatings -
Important Safety Instructions
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.......

2309879
Specifications
This equipment is not intended for use with flammable 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.

3309879
Warnings
The following are general warnings related to the setup, use, grounding, maintenance and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When these symbols appear through the
manual, refer back to these pages for a description of the specific hazard.
WARNING
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:
DUse equipment only in well ventilated area.
DEliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop clothes (potential static arc).
DSprayer 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.
DKeep work area free of debris, including solvent, rags and gasoline.
DDo not plug or unplug power cords or turn lights on or off when flammable fumes are present.
DGround equipment and conductive objects in work area. Read Grounding instructions.
DIf there is static sparking or you feel a shock, stop operating immediately. Do not use equipment
until you identify and correct the problem.
DKeep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
DTurn off and disconnect power cord before servicing equipment.
DUse only grounded electrical outlets.
DUse only 3--wire extension cords.
DEnsure ground prongs are intact on sprayer and extension cords.
DDo not expose to rain. Store indoors.

4309879
WARNING
SKIN INJECTION HAZARD
High pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical attention.
DDo not point gun at anyone or any part of the body.
DDo not put your hand over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DEngage trigger lock when not spraying.
DFollow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking or servicing equipment.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
DDo not exceed the maximum working pressure or temperature rating of the lowest rated system
component. Read Technical Data in all equipment manuals.
DUse fluids and solvents that are compatible with equipment wetted parts. Read Technical Data in
all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
DCheck equipment daily. Repair or replace worn or damaged parts immediately with genuine ASM
replacement parts only.
DDo not alter or modify equipment.
DUse equipment only for its intended purpose. Call your ASM distributor for information.
DRoute hoses and cables away from traffic areas, sharp edges, moving parts and hot surfaces.
DDo not kink or overbend hoses or use hoses to pull equipment.
DKeep children and animals away from work area.
DDo not operate the unit when fatigured or under the influence of drugs or alcohol.
DComply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment. Such use could result in a serious chemical reaction,
with the possibility of explosion, which could cause death, serious injury and/or substantial property
damage.
TOXIC FLUID HAZARD
Toxic fluid or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
DRead MSDS’s to know the specific hazards of the fluids you are using.
DStore hazardous fluid in approved containers and dispose of it according to all applicable guidelines.
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:
DProtective eye wear.
DClothing and respirator as recommended by the fluid and solvent manufacturer.
DGloves.
DHearing protection.

5309879
Component Identification and Function
Fig. 1
RPS
N
M
D
B
H
F
E
A
U
V
J
G
K
W
ti6749a
AMotor DC motor, permanent magnet, totally enclosed, fan cooled
BDrive Assembly Transfers power from DC motor to displacement pump
DDisplacement Pump Transfers fluid to be sprayed from source through spray gun
EFluid Outlet Spray gun is connected here
FPrime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when
open
GFluid Filter Final filter of fluid to spray gun
HPressure Adjusting Knob Controls fluid outlet pressure
JPressure Control Controls motor speed to maintain fluid outlet pressure at displacement pump
outlet. Works with pressure adjusting knob.
KON/OFF Switch Power switch that controls main power to sprayer
M50 ft (15 m) Main Hose 1/4 in. ID, grounded, nylon hose with spring guards on both ends
NSpray Gun High pressure spray gun with gun safety latch
PTip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
RTip Guard Tip guard reduces risk of injection injury
SThumb Lock Safety Gun safety latch inhibits accidental triggering of spray gun
TPower Cord Rack Holds wrapped power cord for storage
USuction Hose Transfers fluid to be sprayed from source to pump
VDrain Tube Fluid outlet used to drain and prime the sprayer
WPressure Gauge Displays current fluid pressure level

6309879
General Repair Information
Pressure Relief Procedure
System pressure must be manually relieved to prevent
system from starting or spraying accidentally. Fluid
under high pressure can be injected through skin and
cause serious injury. To reduce risk of injury from
injection, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
Dare instructed to relieve pressure,
Dstop spraying,
Dcheck or service any system equipment,
Dor install or clean spray tip.
1. Lock gun safety latch.
2. Turn ON/OFF switch to OFF.
3. Unplug power supply cord.
4. Unlock gun safety latch. Hold metal part of gun
firmly to grounded metal pail. Trigger gun to relieve
pressure.
5. Lock gun safety latch.
6. Open pressure drain valve. Leave pressure drain
valve open until ready to spray again.
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. Now clear
tip or hose obstruction.
CAUTION
To reduce risk of pressure control malfunction:
DUse needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
DMate wire connectors properly. Center flat blade of
insulated male connector in female connector.
DRoute 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 serious injury, including electric shock,
do not touch moving or electrical parts with fingers or
tools while testing repair. Shut off and unplug sprayer
when inspection is complete. Install all covers, gaskets,
screws and washers 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 Guide,
pages 7 -- 11, for other possible solutions.
Motor and drive housing may be very hot during opera-
tion and could burn skin if touched.
Flammable materials spilled on hot, bare motor could
cause fire or explosion. Have motor shroud in place
during operation to reduce risk of burns, fire or explo-
sion.
C
A
UTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shroud before operation of spray-
er and replace if damaged. Motor shroud directs
cooling air around motor to prevent overheating. It
can also reduce risk of burns, fire or explosion; see
preceding WARNING.

7309879
Grounding
The sprayer must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
1. 120 Vac models require a 50 Hz, 15A circuit with
a grounding receptacle. 220--240 Vac models
require a 50 Hz, 10A circuit with a grounding
receptacle. See Fig. 2.
2. Do not alter ground prong or use adapter.
Fig. 2
Grounding Plug Grounded
Outlets
3. A 3--wire, 1.0 mm (12 AWG) (minimum) extension
cord up to 90 m long can be used with this spray-
er. Long lengths reduce sprayer performance.
Troubleshooting
Relieve pressure;page 6.
MOTOR WON’T OPERATE
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
Basic Fluid Pressure
Problems
1. Pressure control knob setting. Motor will not run
if at minimum setting (fully counterclockwise).
1. Slowly increase pressure setting to see if mo-
tor starts.
2. Spray tip or fluid filter may be clogged. 2. Relieve pressure and clear clog or clean 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 rod pin (9a).
Pin must be completely pushed into connecting
rod (9) and retaining spring (9b) must be firmly
in groove of pump pin. See Fig. 16.
2. Push pin into place and secure with springre-
tainer.
3. Motor (1). Remove drive housing assembly
(10). See page 23. Try to rotate fan by hand.
3. Replace motor (1) if fan won’t turn. See page
24.
Basic Electrical Problems 1. Motor control board. Board shuts down and dis-
plays error code.
1. See Motor Control Board Diagnostics,
page 21.
2. Electrical supply.
Meter must read:
For 100--120 Vac models -- 85--130 Vac
For 220--240 Vac models -- 210--255 Vac.
2. Reset building circuit breaker; replace build-
ing fuse. Try another outlet.
3. Extension cord. Check extension cord continu-
ity with volt meter.
3. Replace extension cord.
4. Sprayer power supply cord (79). Inspect for
damage such as broken insulation or wires.
4. Replace power supply cord.

8309879
Troubleshooting
MOTOR WON’T OPERATE (Continued)
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
Basic Electrical Problems
(continued)
1.That motor leads are securely fastened and
properly mated.
1. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely re-
connect leads.
2. For loose motor brush lead connections andter-
minals. See page 12.
2. Tighten terminal screws. Replace brushes if
leads are damaged. See page 12.
3. Brush length which must be 1/2 in. minimum.
See page 12.
NOTE: Brushes do not wear at the same rate on
both sides of motor. Check both brushes.
3. Replace brushes. See page 12.
4. For broken or misaligned motor brush springs.
Rolled portion of spring must rest squarely on
top of brush. See page 12.
4. Replace spring if broken. Realign spring with
brush. See page 12.
5. Motor brushes may be binding in brush holders.
See page 12.
5. Clean brush holders. Remove carbon with
small cleaning brush. Align brush leads with
slot in 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 points (TP).
1. Power supply cord (79). Connect volt meter be-
tween TP1 (neutral) and TP2 (L2, 120 Vac).
Plug in sprayer. Meter must read:
For 100--120 Vac models -- 85--130 Vac
For 220--240 Vac models -- 210--255 Vac. Un-
plug sprayer.
1. Replace power supply cord.
2. ON/OFF switch (23). Connect volt meter be-
tween L1 and L2 terminal on ON/OFF switch.
Plug in sprayer and turn ON. Meter must read:
For 100--120 Vac models -- 85--130 Vac
For 220--240 Vac models -- 210--255 Vac.
2. Replace ON/OFF switch. See page 18.
3. Motor thermal cutoff switch. Turn sprayer OFF.
Check for continuity between TO1 and TO2 with
ohmmeter.
3. If thermal switch is open (no continuity), allow
motor to cool. If switch remains open after
motor cools, replace motor. If thermal switch
closes after motor cools, correct cause of
overheating.
4. All terminals for damage or loose fit. 4. Replace damaged terminals and reconnect
securely.

9309879
Troubleshooting
LOW OR FLUCTUATING OUTPUT
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
Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn-
ing, then replace tip. See your separate
gun or tip manual.
2. Verify pump does not continue to stroke when
gun trigger is released.
2. Service pump. See page 25.
3. Filter clogged. 3. Relieve pressure. Check and clean filter.
4. Prime valve leaking. 4. Relieve pressure. Repair prime valve.
5. Suction hose connections. 5. Tighten any loose connections.
6. Electrical supply with volt meter.
Meter must read:
For 100--120 Vac models -- 85--130 Vac
For 220--240 Vac models -- 210--255 Vac. Low
voltages reduce sprayer performance.
6. Reset building circuit breaker; replace
building fuse. Repair electrical outlet or try
another outlet.
7. Extension cord size and length; must be at least
12 gauge wire and no longer than 300 ft. Longer
cord lengths reduce sprayer performance.
7. Replace with a correct, grounded exten-
sion cord.
8. Leads from motor 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 brushes
if leads are damaged. See page 12.
10.For worn motor brushes which must be 1/2 in.
minimum. See page 12.
10. Replace brushes. See page 12.
11.For broken and misaligned motor brush
springs. Rolled portion of spring must rest
squarely on top of brush.
11.Replace spring if broken. Realign spring
with brush. See page 12.
12.Motor brushes for binding in brush holders. See
page 12.
12.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with slot in brush holder to assure free verti-
cal brush movement.
13.Low stall pressure. 13. Do either or both:
a. Turn pressure control knob fully
clockwise. Make sure pressure
control knob is properly installed
to allow full clockwise position.
b. Try a new transducer.
14.Motor armature for shorts by using an armature
tester (growler) or perform spin test. See page
12.
14.Replace motor. See page 24.

10 309879
Troubleshooting
LOW OR FLUCTUATING OUTPUT
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
Motor runs and pump strokes 1. Paint supply. 1. Refill and reprime pump.
2. Intake strainer clogged. 2. Remove and clean, then reinstall.
3. Suction tube or fittings loose. 3. Tighten; use thread sealant or sealing tape
on threads if necessary.
4. To see if intake valve ball and piston ball are
seating properly. See page 25.
4. Remove intake valve and clean. Check
balls and seats for nicks; replace if neces-
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 pump pin (9a) (damaged or
missing), page 25.
1. Replace pump pin if missing. Be sure re-
tainer spring (9b) is fully in groove all
around connecting rod, page 25.
2. Connecting rod assembly (9) for damage,
page 23.
2. Replace connecting rod assembly,
page 23.
3. Gears or drive housing, page 23. 3. Inspect drive housing assembly and gears
for damage and replace if necessary,
page 23.

11309879
Troubleshooting
MOTOR IS HOT AND RUNS INTERMITTENTLY
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
Motor is hot and runs intermit-
tently.
1. Determine if sprayer was operated at high
pressure with small tips, which causes low
motor RPM and excessive heat build up.
1. Decrease pressure setting or increase tip
size.
2. Be sure ambient temperature where sprayer
is located is no more than 90_F and sprayer
is not located in direct sun.
2. Move sprayer to shaded, cooler area if pos-
sible.
ELECTRICAL SHORT
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
Building circuit breaker opens
as soon as sprayer switch is
turned on.
1. All electrical wiring for damaged insulation, and
all terminals for loose fit or damage. Also wires
between pressure control and motor. See page
24.
1. Repair or replace any damaged wiring or
terminals. Securely reconnect all wires.
2. For missing inspection plate gasket (see page
24), bent terminal forks or other metal to metal
contact points which could cause a short.
2. Correct faulty conditions.
3. Motor armature for shorts. Use an armature
tester (growler) or perform spin test. See page
12. Inspect windings for burns.
3. Replace motor. See page 24.
4. Motor control board (35) 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 sure
sprayer is unplugged! Disconnect wires from
switch. Check switch with ohmmeter. Reading
must be infinity with ON/OFF switch OFF, and
zero with switch ON.
2. Replace ON/OFF switch. See page 18.
3. For damaged or pinched wires in pressure con-
trol. See page 21.
3. Replace damaged parts. See page 21.
Sprayer quits after sprayer op-
erates for 5 to 10 minutes.
1. Basic Electrical Problems on page 7. 1. Perform necessary procedures.
2. Electrical supply with volt meter. Meter must
read:
For 100--120 Vac models -- 85--130 Vac
For 220--240 Vac models -- 210--255 Vac
2. If voltage is too high, do not operate
sprayer until corrected.
3. Tightness of pump packing nut. Over tightening
tightens packings on rod, restricts pump action,
and damages packings.
3. Loosen packing nut. Check for leaking
around throat. Replace pump packings, if
necessary. See page 25.
.
CAUTION
Any short in any part of the
motor power circuit will cause
the control circuit to inhibit
sprayer operation. Correctly
diagnose and repair all shorts
before checking and replac-
ing control board.
Building circuit breaker opens
as soon as sprayer is plugged
into outlet and sprayer is NOT
turned on.

12 309879
Spin Test
Setup
Electric Shock Hazard; page 6.
To check armature, motor winding and brush electrical
continuity:
1. Relieve pressure;page 6.
2. Remove drive housing; page 23.
3. Fig. 3. Remove pressure control cover (39). Dis-
connect motor leads (F) and (G).
4. Fig. 4. Remove motor shroud (74) and inspection
covers (A).
Armature Short Circuit Test
Quickly turn motor fan by hand. If no electrical shorts,
motor coasts two or three revolutions before complete
stop. If motor does not spin freely, armature is
shorted. Replace motor; page 24.
Armature, Brushes, and Motor Wiring Open
Circuit 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 Replacement
Motor Brush Removal
Replace brushes worn to less than 1/2 in. Brushes
wear differently on each side of motor, check both
sides. Brush Repair Kit, page 27. Spring clip, 112766,
may be purchased separately.
1. Read General Repair Information; page 6.
2. Relieve pressure;page 6.
3. Fig. 4. Remove motor shroud (74) and two inspec-
tion covers (A).
(Continued on page 13)
A
74
Fig. 4
7703B

13309879
Motor Brush Replacement
4. Fig. 5. Push in spring clip (A) to release hook (B)
from brush holder (C). Pull out spring clip (A).
5. Fig. 5. Pull brush lead (D) out of terminal (E).
Remove brush (F).
Fig. 5
A
B
E
D
F
C
1
1
Motor lead; do not disconnect
2 Minimum 0.5” (12.5 mm)
03881
3Included in Brush Repair Kit
3
2
6. Inspect commutator for excessive pitting, burning
or gouging. A black color on commutator is normal.
Have commutator resurfaced by a motor repair
shop if brushes wear too fast.
Motor Brush Installation
CAUTION
When installing brushes, follow all steps carefully to
avoid 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 in sprayer.
c. Turn sprayer ON. Slowly increase pressure
until motor is at full speed.
CAUTION
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displace-
ment pump packings.
6. Install brush inspection covers and gaskets.
7. Break in brushes.
a. Operate sprayer 1 hour with no load.
b. Install pump (13); Displacement Pump Re-
placement, page 25.

14 309879
On/Off Switch Replacement
120 Vac (249168)
Removal
1. Relieve pressure;page 6.
2. Fig. 7. Remove four screws (18) and pressure
control cover (39).
3. 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

15309879
Wiring Diagram
120 Vac (249168)
Fig. 8
Pressure Transducer
ON/OFF
Switch
Power
Plug
Potentiometer
from Motor
Filter Board
Red (+)
Heat from 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

16 309879
On/Off Switch Replacement
240 Vac (249169)
Removal
1. Relieve pressure;page 6.
2. Fig. 9. Remove pressure control cover (39).
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

17309879
Wiring Diagram
240 Vac (249169)
Fig. 10
TI0058A
Heat from 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
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 (--)

18 309879
On/Off Switch Replacement
240 Vac (246803)
Removal
1. Relieve pressure;page 6.
2. Fig. 11. Remove pressure control cover (39).
3. Remove display connector (B) from plug (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
BC
E
D
52
39
18
36
23

19309879
Fig. 12
240 Vac (246803)
Wiring Diagram
Ref 52
Pressure Transducer
ON/OFF
Switch
Power
Cord
Ref 26
Potentiometer
from Motor
Filter Board
Red (+)
Heat from 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
Inductor Coil
Blue
Green/
Yellow
Brown
Yellow
Black(--)
Brown Blue
Brown
Blue
TPT2
TPT1
L2 L1
Ref 29
Ref 23
Digital Display
ti6650a

20 309879
On/Off Switch Replacement
120 Vac (249159)
Removal
1. Relieve pressure;page 6.
2. Fig. 13. Remove four screws (18) and pressure
control cover (39).
3. Disconnect two 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 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
Pressure
Transducer
Yellow
TI3515A
A