ASM Allpro A Series User manual

Repair and Parts
Mach 8600 and Mach 11000
Airless Paint Sprayers
- For portable spray application of architectural paints and coatings -
Model 246796 (Series A, B) and 249308
3000 psi (20.7 MPa, 207 bar) Maximum Working Pressure
309902F
Manufactured by
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti3639b
Related Manuals
309904.......
307806.......
Model 246796,
Series A
311061.......
Model 246796,
Series B
Model 249308

2309902
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.
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 throughout 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.
DWhen flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet
(6 m) away from explosive vapors.
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 sprayer to rain. Store indoors.
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 treatment.
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.

3309902
WARNING
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. See Technical Data in all equipment manuals.
DUse fluids and solvents that are compatible with equipment wetted parts. See Technical Data in
all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from the fluid 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 over bend hoses or use hoses to pull equipment.
DKeep children and animals away from work area.
DDo not operate unit when fatigued 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 guide-
lines.
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.

4309902
Component Identification and Function
K
E
H
B
A
D
G
F
V
U
T
ti3709b
N
M
P
RS
AMotor DC motor, permanent magnet, 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 hose 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
PSpray Tip Uses high pressure fluid to clear tip clogs without removing tip from spray gun
RReversible Tip Guard Tip guard reduces risk of injection injury
SGun Safety Lock Gun safety latch inhibits accidental triggering of spray gun
TPower Cord Rack Holds wrapped power cord for storage
USuction Tube Transfers fluid to be sprayed from source to pump
VDrain Tube Fluid outlet used to drain and prime the sprayer

5309902
General Repair Information
Pressure Relief Procedure
Read warnings, page 2.
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.
C
A
UTION
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.
Read warning, page 2.
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 8 -- 12, for other possible solutions.
Read warnings, page 2.
C
A
UTION
Do not run sprayer dry for more than 30 seconds to
avoid damaging pump packings.
4. Install motor shield before operation of sprayer
and replace if damaged. Motor shield prevents
overheating, and protects operator from possible
electrical shock by touching terminals of capacitor.
It can also reduce risk of burns, fire or explosion;
see preceding WARNING.

6309902
DThe sprayer requires a 120V AC, 60 Hz, 15A
circuit with grounding receptacle. Never use
an outlet that is not grounded or an adapter.
DDo not use the sprayer if the electrical
cord has a damaged ground prong.
Onlyuseanextensioncordwithan
undamaged, 3--prong plug.
DRecommended extension cords for
use with this sprayer:
D25 ft (7.6 m) 18 AWG
D50 ft (15.2 m) 16 AWG
D100 ft (30.5 m) 14 AWG
D150 ft (45.7 m) 12 AWG
Smaller gauge or longer extension cords
may reduce sprayer performance.
Grounding and Electric Requirements
DGround sprayer gun through connection to
a properly grounded fluid hose and pump.
DGround fluid supply container.
Follow local code.
DGround solvent pails used when flush-
ing. Follow local code. Use only conduc-
tive, metal pails, placed on a grounded
surface such as concrete. Do not place the
pail on a non--conductive surface such as
paper or cardboard, which interrupts the
grounding continuity.
ti5850a
ti5572a
The sprayer must be grounded. Grounding reduces the risk of static
and electric shock by providing and escape wire for the electrical
current due to static build up or in the event of a short circuit.
ti3001b

7309902
DGround the metal pail by clamping one end
of ground wire to pail and the other end to
ground, such as a water pipe.
DMaintain grounding continuity when
flushing or relieving pressure by hold-
ing metal part of spray gun firmly to
side of a grounded metal pail, then
trigger gun.
Grounding and Electric Requirements
ti5851a
ti6762a

8309902
Grounding
Your system must be grounded. Read warnings,
page 2.
1. All models require a grounded outlet for power
connection. Circuit must be 50--60 Hz with an
ampere rating equal to or greater than the sprayer.
See Fig. 1.
2. Do not alter ground prong or use adapter. Fig. 1
grounding prong
grounded outlets
3. 120 Vac: A 12 AWG, 3 wires with grounding prong,
300 ft (90 m) extension cord may be used. Long
lengths reduce sprayer performance.
Troubleshooting
Relieve pressure; page 5.
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 counterclock-
wise).
1. Slowly increase pressure setting to see if
motor starts.
2. Spray tip or fluid filter may be clogged. 2. Relieve pressure and clear clog or clean
filter; refer to separate gun or tip instruction
manual.
Basic Mechanical
Problems
1. Pressure control knob setting. 1. Motor stops running when pressure setting
is reached.
2. Pump (13) for frozen or hardened paint. 2. Thaw sprayer if water or water-based paint
has frozen in sprayer. Place sprayer in
warm area to thaw. Do not start sprayer un-
til thawed completely. If paint hardened
(dried) in sprayer, replace pump packings.
(Displacement Pump Replacement, page
25.)
2. Displacement pump connecting rod pin (112).
Pin must be completely pushed into connect-
ing rod (76) and retaining spring (27) must be
firmly in groove of pump pin.
2. Push pin into place and secure with spring
retainer.
3. Motor (75). Remove drive housing assembly
(78). See page 23. Try to rotate fan by hand.
3. Replace motor (75) if fan won’t turn. See
page 24.
Basic Electrical Problems 1. Motor control board. Board shuts down and
displays error code.
1. Motor Control Board Diagnostics, page 20.
2. Electrical supply. Meter must read 85--130
VAC for 100--120 VAC models.
2. Reset building circuit breaker; replace
building fuse. Try another outlet.
3. Extension cord. Check extension cord conti-
nuity with volt meter.
3. Replace extension cord.
4. Sprayer power supply cord (66). Inspect for
damage such as broken insulation or wires.
4. Replace power supply cord.

9309902
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)
5. That motor leads are securely fastened and
properly mated.
5. Replace loose terminals; crimp to leads. Be
sure terminals are firmly connected.
Clean circuit board terminals. Securely re-
connect leads.
6. For loose motor brush lead connections and
terminals. See page 14.
6. Tighten terminal screws. Replace brushes
if leads are damaged. See page 14.
7. Brush length which must be 1/2 in. minimum.
See page 14.
NOTE: Brushes do not wear at the same rate
on both sides of motor. Check both brushes.
7. Replace brushes. See page 14.
8. For broken or misaligned motor brush springs.
Rolled portion of spring must rest squarely on
top of brush. See page 14.
8. Replace spring if broken. Realign spring
with brush. See page 14.
9. Motor brushes may be binding in brush hold-
ers. See page 14.
9. Clean brush holders. Remove carbon with
small cleaning brush. Align brush leads
with slot in brush holder to assure free verti-
cal brush movement.
10.Motor armature commutator for burn spots,
gouges and extreme roughness.
See page 14.
10.Remove motor and have motor shop resur-
face commutator if possible, page 24.
11. Motor armature for shorts using armature
tester (growler) or perform spin test. See page
13.
11. Replace motor, page 24.
Refer to wiring diagrams to
identify test points (TP).
1. Power supply cord (66). Connect volt meter
between TP1 (neutral) and TP2 (L2, 120
VAC). Plug in sprayer. Meter must read
85--130 VAC for 100--120 VAC models.
Unplug sprayer.
1. Replace power supply cord.
2. ON/OFF switch (23). Connect volt meter be-
tween L1 or L and L2 or N terminal on ON/
OFF switch. Plug in sprayer and turn ON.
Meter must read 85--130 VAC for 100--120
VAC models.
2. Replace ON/OFF switch, page 16.
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), al-
low 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.

10 309902
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, 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, 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 85--130 VAC for 100--120
VAC models. 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 perfor-
mance.
7. Replace with a correct, grounded exten-
sion cord.
8. Leads from motor to circuit board (100) for
damaged or loose wires or connectors. In-
spect wiring insulation and terminals for signs
of overheating.
8. Be sure male terminal blades are cen-
tered and firmly connected to female ter-
minals. Replace any loose terminal or
damaged wiring. Securely reconnect ter-
minals.
9. For loose motor brush leads and terminals,
page 14.
9. Tighten terminal screws. Replace
brushes if leads are damaged, page 14.
10.For worn motor brushes which must be 1/2 in.
minimum, page 14.
10. Replace brushes, page 14.
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, page 14.
12.Motor brushes for binding in brush holders,
page 14.
12.Clean brush holders, remove carbon dust
with small cleaning brush. Align brush
lead with slot in brush holder to assure
free vertical 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 arma-
ture tester (growler) or perform spin test, page
13.
14.Replace motor, page 24.