Graco ASM Zip-Spray 2300 Plus Operating instructions

312496H

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)

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)

This manual suits for next models

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