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.
ti3001c
ti10344a

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.
ti2707a ti2718a
ti2614a ti10307a ti2719a

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)

Troubleshooting
312496H 11
Electrical Problems Motor armature for shorts by using an
armature tester (growler) or perform
spin test. See page 16.
Replace motor. See page 24.
Loose motor brushes and terminals. Tighten terminal screws. Replace
brushes if leads are damaged.
Worn motor brushes. (Brushes must
be 1/2 in. minimum.)
Replace brushes.
Broken and 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 are binding in brush
holders.
Clean brush holders, remove carbon
dust with small cleaning brush. Align
brush lead with slot in brush holder
to assure free vertical brush
movement.
Motor runs and pump strokes Low paint supply. Refill and reprime pump.
Intake strainer clogged. Remove and clean, then reinstall.
Suction tube or fittings loose. Tighten; use thread sealant or
sealing tape on threads if necessary.
See if intake valve ball and piston ball
are seating properly. See pump
manual.
Remove intake valve and clean.
Check balls and seats for nicks,
replace if necessary. Strain paint
before using to remove particles that
could clog pump. See pump manual.
Leaking around throat packing nut
which may indicate worn or damaged
packings. See pump manual.
Replace packings. Also check piston
valve seat for hardened paint or nicks
and replace if necessary. Tighten
packing nut/wet-cup. See pump
manual.
Pump rod damage. Replace pump, page 13.
Motor runs but pump does not stroke Displacement pump pin damaged or
missing.
Replace pump pin if missing. Be sure
retainer spring is fully in groove all
around connecting rod, page 13.
Connecting rod assembly damaged. Replace connecting rod assembly.
See pump manual.
Gears or drive housing, page 15. Inspect drive housing assembly and
gears for damage and replace if
necessary, page 15.
Motor is hot and runs intermittently Determine if sprayer was operated at
high pressure with small tips, which
causes low motor RPM and
excessive heat buildup.
Decrease pressure setting or
increase tip size.
Be sure ambient temperature where
sprayer is located is not more than
90°F (32.22°C) and sprayer is not
located in direct sun.
Move sprayer to shaded, cooler area
if possible.
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
12 312496H
Building circuit breaker opens as
soon as sprayer switch is turned on
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 replacing
control board.
All electrical wiring for damaged
insulation and all terminals for loose
fit or damage. Also, wires between
pressure control and motor. See
pages 23 and 25.
Repair or replace any damaged
wiring or terminals. Securely
reconnect all wires.
For missing inspection plate gasket,
see pages 21 and 25, bent terminal
forks or other metal to metal contact
points which case a short.
Correct faulty conditions.
Motor control board by performing
control board diagnostics. See page
16. If diagnostics indicate, substitute
with a good board.
CAUTION: Do not perform this check
until motor armature is determined to
be good. A bad motor armature can
burn out a good board.
Replace with a new pressure control
board. See page 21.
Building circuit breaker opens as
soon as sprayer switch is turned on.
Motor armature for shorts. Use an
armature tester (growler) or perform
spin test. See page 16. Inspect
windings for burns.
Replace motor. See page 24.
Building circuit breaker opens as
soon as sprayer is plugged into outlet
and sprayer is NOT turned on.
Basic Electric Problems, page 8 of
Troubleshooting.
Perform necessary procedures.
ON/OFF switch. See page 20. Be
sure sprayer is unplugged!
Disconnect wires from switch. Check
switch with ohmmeter. Reading must
be infinity with ON/OFF switch OFF,
and zero when switch is ON.
Replace ON/OFF switch. See page
20.
For damaged or pinched wires in
pressure control. See page 21.
Replace damaged parts. See page
21.
Sprayer quits after sprayer operates
for 5 to 10 minutes.
Basic Electric Problems, page 8 of
Troubleshooting.
Perform necessary procedures.
Electrical supply volt meter. Meter
must read:
• 210-255 VAC for 220-240V
models
• 85-130 VAC for 100-120V
models.
If voltage is too high, do not operate
sprayer until corrected.
Tightness of pump packing nut. Over
tightening tightens packings on rod,
restricts pump action, and overloads
motor.
Loosen packing nut. Check for
leaking around throat. Replace pump
packings, if necessary. See pump
manual.
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)

Displacement Pump Replacement
312496H 13
Displacement Pump Replacement
See manual 312362 for pump repair instructions.
Removal
1. Flush pump (13).
2. Loosen screws (12). Push cover (114) up and pull
off sprayer.
3. Remove suction tube (60) and hose (45).
4. Cycle motor until pump pin (32) is in position to be
removed.
5. Disconnect power cord from outlet.
6. Using a flat screwdriver, push retaining spring (31)
up. Push out pump pin (32).
7. Loosen pump jam nut (29). Unscrew and remove
pump (41).
12
114
ti10727a
45
60
ti10455a
32
31
ti9140a
29
41
ti10456a ti10457a

Displacement Pump Replacement
14 312496H
Installation
1. Fully extend pump piston rod. Apply grease to top of
pump rod at (A) or inside connecting rod (43). Install
jam nut (29) on pump threads.
2. Install pump rod (A) into connecting rod (43).
3. Install pump pin (32). Verify retainer spring (31) is in
groove over pump pin.
4. Push pump (41) up until pump threads engage.
5. Screw in pump until threads are flush with top of
drive housing opening.
6. Align pump outlet (J) to back.
7. Screw jam nut (29) counter-clockwise until nut
stops. Tighten jam nut by hand, then tap 1/8 to 1/4
turn with a 20 oz (maximum) hammer to approxi-
mately 75 ft-lb (102 N•m) torque.
8. Install high pressure hose (45) and tighten nut (K) to
approximately 35 ft-lb (47 N•m) torque. Install suc-
tion tube (60) and hand-tighten nut (69).
.
9. Fill packing nut with ASM Packing Seal®until fluid
flows onto top of seal.
10. Replace cover (114) over screws. Push cover down
into place. Tighten screws (12).
If pump pin works loose, parts could break off due to
force of pumping action. Parts could project through
air and result in serious injury or property damage.
NOTICE
If the pump jam nut loosens during operation, the
threads of the drive housing will be damaged.
43
A
29
ti10458a
31
32
ti9144a
ti6111a
J
ti10455a
29
45
K
69
60
ti10455a
ti10728a
114
12
ti10728a

Drive Housing Replacement
312496H 15
Drive Housing Replacement
Removal
1. Relieve Pressure, page 6.
2. Disconnect power cord from outlet.
3. Remove screws (12) and pump rod cover (114).
4. Remove pump, Displacement Pump Replace-
ment, page 13.
5. Remove screws (12) from shroud (23).
6. Remove screws (12) from front cover (22).
7. Remove screws (47).
8. Pull drive housing (42) off motor (54).
9. Remove gear cluster (44) and (40) and thrust
washer (25) from drive housing.
Installation
1. Apply a heavy coat of grease to gears and bearing
surfaces.
2. Install washers (8, 10) on back of gear (40). Install
gear in motor end bell. Using grease for retention,
place washer (10) over bearing inside housing (42).
3. Install washers (1, 9) on back of gear (44). Install in
motor endbell.
4. Install thrust washer (25) on gear (44).
5. Push drive housing (42) on motor endbell as you
guide gear crank (44) through hole in connecting
rod (43).
6. Install screws (47).
7. Install cover (22) and screws (12).
8. Install shroud (23) and screws (12).
9. Install pump (41); Displacement Pump Replace-
ment, page 13.
10. Install pump rod cover (114) with screws (12).
NOTICE
Do not drop gear cluster (44) and (40) when removing
from drive housing (42). Gear cluster may stay
engaged in motor front end bell or drive housing.
47
15
12
50
6
49
47
48
47
59
54
40
44
111
Liberally Apply grease
1

Motor Diagnostics
16 312496H
Motor Diagnostics
See Wiring Diagram, page 25.
Spin Test
Check for electrical continuity in motor armature, windings and brush as follows:
If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 1/2 in. (12.7 mm) or if the motor
shaft cannot turn, replace the motor, page 24.
Setup
1. Relieve Pressure, page 6.
2. Unplug electric cord.
3. Remove drive housing, Drive Housing Replace-
ment, page 15.
4. Remove pressure control cover (50). Disconnect
connector F.
5. Remove four screws (12) and motor shroud (23)
and inspection covers.
Armature Short Circuit Test
Quickly turn motor fan by hand. If not shorted, motor will
coast 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 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. Repair as needed, page 18.
3. If there is an uneven resistance or no resistance,
check for broken brush springs*, brush leads*, loose
brush terminal screws*, worn brushes*, or motor
lead terminals. Repair as needed, page 18.
4. If still uneven, or no resistance, replace motor using
Motor Kit, page 24.
50
F
ti2572a

Fan Replacement
312496H 17
Fan Replacement
Removal
1. Relieve Pressure, page 6. Disconnect power cord
from outlet.
2. Remove four screws (12) and shroud (23).
3. Remove spring clip (H) on fan (77).
4. Pull off fan (77).
Installation
1. Slide new fan (77) in place on back of motor. Be
sure blades of fan face motor as shown.
2. Install spring clip (H).
3. Replace shroud (23) and four screws (12).
23
ti10731a
77
H
12

Motor Brush Replacement
18 312496H
Motor Brush Replacement
See Wiring Diagram, page 25.
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 287735 is available.
1. Read General Repair Information, page 7.
2. Relieve Pressure, page 6.
3. Remove motor shroud and two inspection covers
(A).
4. Push clip spring (B) to release hook (C) from brush
holder (D). Pull out spring clip (B).
5. Pull brush lead (G) off terminal (F). Remove brush
(E).
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.
7. While rotating fan by hand, using compressed air,
blow air into positive (top) brush holder to remove
brush dust.
NOTE: To contain the dust, turn on your shop vac. Place
the end of a vacuum over the negative (lower) brush
holder while blowing compressed air into the positive
(top) brush holder.
Ati7386a
B
C
G
E
F
D
1
1
2
2
3
3
Motor lead; do not disconnect
Minimum 0.5 in. (12.5 mm)
Included in Brush Repair Kit
ti7387a

Motor Brush Replacement
312496H 19
Motor Brush Installation
NOTE: Use all new parts included in your brush kit. Do
not reuse old parts if new replacement parts are
provided.
1. Install new brush (G) with lead into brush holder (D).
2. Slide brush lead (E) onto terminal (F).
3. Install spring clip (B). Push down to set hook (C) into
brush holder (D).
4. Repeat for other side.
5. Test brushes.
a. Remove pump. Displacement Pump
Replacement, page 13.
b. With sprayer OFF, turn pressure control knob
fully counter-clockwise to minimum pressure.
Plug in sprayer.
c. Turn sprayer ON. Slowly increase pressure until
motor is at full speed.
6. Install brush inspection covers (A) and gaskets.
7. Break in brushes.
a. Operate sprayer 1 hour with no load.
b. Install pump. Displacement Pump
Replacement, page 13.
NOTICE
When installing brushes, follow all steps carefully to
avoid damaging parts.
D
C
G
F
B
E
ti7388a
NOTICE
Do not run sprayer dry for more than 30 seconds
while checking brushes to avoid damaging displace-
ment pump packings.

On/Off Switch Replacement
20 312496H
On/Off Switch Replacement
100/120 VAC and 220/240 VAC
Removal
1. Relieve Pressure, page 6.
2. Remove four screws (12) and pressure control cover
(50).
3. Disconnect four wires (A) from ON/OFF switch (58).
4. Remove toggle boot (30) and locking ring. Remove
ON/OFF switch (58).
Installation
1. Install new ON/OFF switch (58). Install locking ring
and toggle boot (30).
2. Connect four wires (A) to ON/OFF switch (58).
3. Install pressure control cover (50) with four screws
(12).
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