Graco ASM Zip-Spray 2300 Plus Operating instructions

312496H
EN
Repair
Electric Airless Sprayers
- For portable spray application of architectural paints and coatings. For
professional use only.-
Maximum Working Pressure: 3300 psi (227 bar, 22.7 MPa)
ASM Zip-Spray™ 2300 Plus 240V: 247533
ASM M2300 Plus 110V: 247534
ASM M2300 Plus 240V: 247535
ASM Zip-Spray™ 2300 Plus 2400: 24M722
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions. Save these instructions. Contact ASM
Customer Service or your local ASM distributor to obtain a manual in your language.
ti18835a
ti18834a
312478
312363 (English)
312362
312364 (Spanish)
312365 (French)

Warning
2 312496H
Warning
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. Refer back to
these warnings. Additional, product-specific warnings may be found throughout the body of this manual where appli-
cable.
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:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Sprayer generates sparks. When flammable liquid is used in or near the sprayer or for flushing or
cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords or turn lights 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 electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose 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.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warning
312496H 3
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. Read Technical Data in all equipment manuals.
• Use 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine ASM
replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your ASM distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or overbend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
• Keep children and animals away from work area.
• Do not operate the unity when fatigued or under the influence of drugs or alcohol.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
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 fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to 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:
• Protective eye wear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection

Component Identification
4 312496H
Component Identification
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 Hose 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
V Pail Hook (Not used on 24M722 - Stand Unit)
R
P
S
M
N
J
K
D
F
C
E
U
H
T
B
A
G
ti18836a

Installation
312496H 5
Installation
Grounding and Electric
Requirements
The sprayer cord includes a grounding wire with an
appropriate grounding contact.
The plug must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances. Do not use an adaptor.
.
240V Units: 210-255 VAC, 50/60 Hz, 7.5A, 1 phase, circuit with a grounding recepta-cle.
Do not use the sprayer if the electrical cord has a dam-
aged ground prong. Do not modify plug. If it will not fit in
the outlet, have a grounded outlet installed by a qualified
electrician.
Power Requirements
• 100-120V units require 100-120VAC, 50/60 Hz,
15A, 1 phase
• 230V units require 230VAC, 50/60 Hz, 7.5A, 1
phase
• Never use an outlet that is not grounded or an
adapter
Only use an extension cord with an undamaged
ground contact. If an extension cord is necessary, use a
3-wire, 12 AWG (2.5 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 nonconductive surface, such
as paper or cardboard, which interrupts grounding conti-
nuity.
Grounding the metal pail: Connect a ground wire to
the pail by clamping one end to pail and other end to
ground such as a water pipe.
Maintain grounding continuity when flushing or
relieving pressure: Hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
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Operation
6 312496H
Operation
Pressure Relief Procedure
To reduce risk of injury from injection, follow this proce-
dure whenever you are instructed to relieve pressure,
stop spraying, service equipment or install or clean
spray tip. Read Warnings, page 2.
1. Turn power switch OFF and unplug power cord.
2. Turn pressure to lowest setting. Hold gun to side of
grounded metal flushing bucket. Trigger gun to
relieve pressure, turn prime valve down.
3. Engage gun trigger lock if unit is being shut down or
left unattended.
NOTE: Leave Spray - Prime/Drain Valve in the
PRIME/DRAIN position until you are ready to spray
again.
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 the tip guard
retaining nut or hose end coupling to relieve pressure
gradually, then loosen completely. Then clear the hose
or tip obstruction.
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General Repair Information
312496H 7
General Repair Information
Flammable materials spilled on hot, bare motor could
cause fire or explosion. To reduce risk of burns, fire or
explosion, do not operate sprayer with cover removed.
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See Trouble-
shooting, page 13.
• Install motor shroud before operation of sprayer and
replace if damaged. Motor shroud directs cooling air
around motor to prevent overheating. It can reduce
risk of burns, fire or explosion, or cut fingers.
• Overspray may build up in the air passages.
Remove any overspray and moisture from air pas-
sages and openings in the enclosure whenever you
service sprayer.
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 test-
ing.
• Install all covers, gaskets, screws and washers
before you operate sprayer.
NOTICE
To reduce risk of pressure control malfunction:
• Use needle nose pliers to disconnect wire. Never
pull on wire, pull on connector.
• Mate wire connectors properly. Center flat blade
of insulated male connector in female connector.
• Route wires carefully to avoid interference with
other connections or pressure control. Do not
pinch wires between cover and control box.
NOTICE
• Do not run sprayer dry for more than 30 seconds.
Doing so could damage pump packings.
• Protect the internal drive parts of this sprayer from
water. Openings in the cover allow for air cooling of
the mechanical parts and electronics inside. If
water gets in these openings, the sprayer could
malfunction or be permanently damaged.
• Prevent pump corrosion and damage from freezing.
Never leave water or water-base paint in sprayer
when its not in use in cold weather. Freezing fluids
can seriously damage sprayer. Store sprayer with
Pump Armor to protect sprayer during storage.

Troubleshooting
8 312496H
Troubleshooting
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)
Basic fluid pressure problems Pressure control knob setting. Motor
will not run if at minimum setting (fully
counter-clockwise).
Slowly increase pressure to see if
motor starts.
Spray tip or fluid filter may be
clogged.
Relieve pressure, page 6 and clear
clog, or clean filter; refer to separate
gun or tip instruction manual.
Basic Mechanical Problems Pump frozen or paint hardened in
pump.
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
13, Displacement Pump Replace-
ment.
Displacement pump connecting rod
pin must be completely pushed into
connecting rod and retaining spring
must be firmly in groove of pump pin.
See page 13.
Push pin into place and secure with
spring retainer.
Motor. Remove drive housing assem-
bly. See page 15. Try to rotate fan by
hand.
Replace motor if fan won’t turn. See
page 17.
Motor control board. Board shuts
down and displays error code.
See Motor Control Board Diagnos-
tics, page 22.
Basic Electrical Problems Electric supply. Meter must read:
• 210-255 VAC for 220-240V
models
• 85-130 VAC for 100-120V
models.
Reset building circuit breaker.
Replace building fuse. Try another
outlet.
Extension cord. Check extension
cord continuity with volt meter.
Replace extension cord.
Sprayer power supply cord. Inspect
for damage such as insulation or
wires.
Replace power supply cord, page 25.
Motor leads are securely fastened
and properly mated.
Replace loose terminals; crimp to
leads. Be sure terminals are firmly
connected.
Clean circuit board terminals.
Securely reconnect leads.

Troubleshooting
312496H 9
Basic Electric Problems Motor armature for shorts using
armature tester (growler) or perform
spin test. See page 16.
Replace motor. See page 24.
For loose motor brush lead connec-
tions and terminals.
Tighten terminal screws. Replace
brushes if leads are damaged.
Brush length which must be 1/2 in.
minimum. NOTE: Brushes do not
wear at the same rate on both sides
of motor. Check both brushes.
Replace brushes, page 18.
Broken or misaligned motor brush
springs. Rolled portion of spring must
rest squarely on top of brush.
Replace spring if broken. Realign
spring with brush.
Motor brushes may be binding in
brush holders.
Clean brush holders. Remove carbon
with small cleaning brush. Align
brush leads with slot in brush holder
to assure free vertical brush move-
ment.
Motor armature commutator for burn
spots, gouges or extreme roughness.
Remove motor and have motor shop
resurface commutator if possible.
See page 24.
Note: for the following electric prob-
lems, refer to wiring diagram, page
21 to identify Test Points (TP).
Power supply cord. Connect volt
meter between TP1 (neutral) and
TP2. Plug in sprayer. Meter must
read:
• 210-255 VAC for 220-240V
models
• 85-130 VAC for 100-120V
models.
Unplug sprayer.
Replace power supply cord, page 25.
ON/OFF Switch. Connect volt meter
between L1 and L2 terminal on
ON/OFF switch. Plug in sprayer and
turn ON. Meter must read:
• 210-255 VAC for 220-240V
models
• 85-130 VAC for 100-120V
models.
Replace ON/OFF switch. See pages
21.
All terminals for damage or loose fit. Replace damaged terminals and
reconnect securely.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)

Troubleshooting
10 312496H
Low Output For worn spray tip. Relieve pressure, page 6. Then
replace tip. See your separate gun
manual for additional instruction.
Verify pump does not continue to
stroke when gun trigger is released.
Service pump. See page 13.
Filter clogged. Relieve pressure, page 6. Check
and clean filter.
Prime valve leaking. Relieve pressure, page 6. Repair
prime valve. See Drain Valve
Replacement, page 26.
Suction hose kinks and/or loose
connection.
Correct kink and/or tighten any loose
connections.
Electric supply with volt meter. Low
voltages reduce sprayer
performance. Meter must read:
• 210-255 VAC for 220-240V
models
• 85-130 VAC for 100-120V
models.
Reset building circuit breaker;
replace building fuse. Repair
electrical outlet or try another outlet.
Extension cord size and length; must
be at least 12 gauge wire and no
longer than 300 ft. Longer cord
lengths reduce sprayer performance.
Replace with a correct, grounded,
extension cord.
Low Output Leads from motor to pressure control
circuit board for damaged or loose
wires or connectors. Inspect wiring
insulation and terminals for signs of
overheating.
Be sure male terminal blades are
centered and firmly connected to
female terminals. Replace any loose
terminal or damaged wiring. Securely
reconnect terminals.
Low stall pressure. 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.
Type of Problem
What to Check
(if check is OK, go to next)
What to Do
(When check is not OK, refer to this
column)