AIRLESSCO SP200 User Manual

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Page 1

Repair and Parts

SP200, SP300, AllPro Mustang 2400,

3A0997F

Mustang 3100

For portable spray application of architectural paints and coatings. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

SP200/Mustang 2400 Model: Use water based or mineral-spirit type material only. Do not use materials having flash points lower than 70°F (21°C). This

Related Manuals

3A0994

See page 2 for model information, including maximum working pressure and approvals.

includes, but is not limited to, acetone, xylene, toluene, or naptha. For more information about your material request MSDS from distributor or retailer.

SP200 Model 24F557 Mustang 2400 Model 24F559 Series A, B, C

SP300 Model 24F558 Mustang 3100 Model 24F560 Series A

Page 2

Models

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.

Model Name Series

SP200

Mustang 2400

SP300

Mustang 3100

A, B, C

Dispense Rate gpm

(lpm)

0.24 gpm

(0.91 lpm)

0.34 gpm

(1.29 lpm)

Hose Length and

Diameter

1/4 in. x 25 ft

(6.4 mm x 7.5 m)

1/4 in. x 50 ft

(6.4 mm x 15m)

Gun Model Maximum Working Pressure

200 Series 2800 psi (19 MPa, 193 bar)

500 Series 3000 psi (21 MPa, 207 bar)

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Warnings

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

GROUNDING

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

• Improper installation of the grounding plug is able to result in a risk of electric shock.

• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat blade terminal.

• The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

• Check with a qualified electrician or serviceman when the grounding instructions are not completely understood, or when in doubt as to whether the product is properly grounded.

• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

• This product is for use on a nominal 120V circuit and has a grounding plug similar to the plug illustrated in the figure below.

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• Only connect the product to an outlet having the same configuration as the plug.

• Do not use an adapter with this product.

Extension Cords:

• Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that accepts the plug on the product.

• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG (2.5 mm

• An undersized cord results in a drop in line voltage and loss of power and overheating.

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) minimum to carry the current that the product draws.

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Warnings

WARNING

WARNINGWARNINGWARNING

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:

• Do not spray flammable or combustible materials near an open flame or sources of ignition such as cigarettes, motors, and electrical equipment.

• Paint or solvent flowing through the equipment is able to result in static electricity. Static electricity creates a risk of fire or explosion in the presence of paint or solvent fumes. All parts of the spray system, including the pump, hose assembly, spray gun, and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks. Use Airlessco conductive or grounded high-pressure airless paint sprayer hoses.

• SP200/Mustang 2400 Model: Do not clean with materials having flash points lower than 70° F (21° C). Use water-based material or mineral spirits-type material only. For complete information about your fluid, request the MSDS from the fluid distributor or retailer.

• Verify that all containers and collection systems are grounded to prevent static discharge.

• Connect to a grounded outlet and use grounded extensions cords. Do not use a 3-to-2 adapter.

• Do not use a paint or a solvent containing halogenated hydrocarbons.

• Keep spray area well-ventilated. Keep a good supply of fresh air moving through the area. Keep pump assembly in a well ventilated area. Do not spray pump assembly.

• Do not smoke in the spray area.

• Do not operate light switches, engines, or similar spark producing products in the spray area.

• Keep area clean and free of paint or solvent containers, rags, and other flammable materials.

• Know the contents of the paints and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvents manufacturer’s safety instructions.

• Fire extinguisher equipment shall be present and working.

• 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.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. 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 power and extension cords.

• Do not expose to rain. Store indoors.

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Warnings

WARNING

WARNINGWARNINGWARNING

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment.

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Use Airlessco nozzle tips.

• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing the nozzle tip to clean.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and follow the Pressure Relief Procedure for turning off the unit.

• High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that injection occurs, get immediate surgical treatment.

• Check hoses and parts for signs of damage. Replace any damaged hoses or parts.

• This system is capable of producing 3000 psi. Use Airlessco replacement parts or accessories that are rated a minimum of 3000 psi.

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

• Verify that all connections are secure before operating the unit.

• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Always wear appropriate gloves, eye protection, and a respirator or mask when painting.

• Do not operate or spray near children. Keep children away from equipment at all times.

• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.

• Stay alert and watch what you are doing.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not kink or over-bend the hose.

• Do not expose the hose to temperatures or to pressures in excess of those specified by Airlessco.

• Do not use the hose as a strength member to pull or lift the equipment.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

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Warnings

WARNING

WARNINGWARNINGWARNING

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

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 MSDSs 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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

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Page 7

Installation

Grounding and Electric Requirements

Sprayer must be grounded. Grounding reduces the

risk of static and electric shock by providing an escape wire for electrical current due to static build up or in the event of a short circuit.

• This sprayer requires a 120 Vac, 60 Hz, 15A circuit with a grounding receptacle.

• Never use an outlet that is not grounded or an adapter.

• Do not use the sprayer if the electrical cord has a damaged ground prong.

• Only use an extension cord with an undamaged 3-prong plug.

Recommended extension cords for use with this sprayer:

• 50 ft (15.0 m) 14 AWG (2.1 mm

• 100 ft (30.0 m) 12 AWG (3.3 mm

Spray gun

grounded fluid hose and pump.

: ground through connection to a properly

)

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Fluid supply container

Solvent pails used when flushing

Use only conductive metal pails, placed on a grounded surface such as concrete. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

Grounding the metal pail

pail by clamping one end to pail and other end to ground such as a water pipe.

Maintaining 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.

: follow local code.

: connect a ground wire to the

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Thermal Overload

Motor has a thermal overload switch to shut itself down if overheated. If unit overheats, allow approximately 45 minutes for unit to cool. Once cool, switch will close and unit will restart.

To reduce risk of injury from motor starting unexpectedly when it cools, always turn power switch OFF if motor shuts down.

NOTE: Smaller gauge or longer extension cords may reduce sprayer performance.

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Page 8

Component Identification

A B C

D E

G H J

L M Q R

S T U

V X

Airless spray gun Sprays fluid. Power switch Turns sprayer ON and OFF. Pressure control knob Increases (clockwise) and decreases (counter-clockwise) fluid

pressure in pump, hose, and spray gun.

Pump fluid outlet fitting Threaded connection for paint hose.

InstaClean

(SP300, Mustang 3100)

ProX Power-Piston Easy Access door, not shown)

(SP300, Mustang 3100)

Easy Access

(SP300, Mustang 3100)

Suction tube Draws fluid from paint pail into pump. Prime tube (with diffuser) Drains fluid in system during priming and pressure relief. Prime/Spray valve

Inlet screen Prevents debris from entering pump. Paint hose Transports high-pressure fluid from pump to spray gun. Tip guard Reduces risk of fluid injection injury. Reversible spray tip

Gun trigger safety lever (page 10) Prevents accidental triggering of spray gun. Gun fluid inlet fitting Threaded connection for paint hose. Power Flush attachment Connects garden hose to suction tube for power flushing

Gun fluid filter Filters fluid entering spray gun to reduce tip clogs. Pail Hanger

(SP300, Mustang 3100)

™

fluid filter

™

door

™

Pump (behind

• Filters fluid coming out of pump to reduce tip plugging and improve finish.

• Self cleans only during pressure relief.

Pumps and pressurizes fluid and delivers it to paint hose.

Easy Access door permits quick access to outlet valve. To remove door, insert flat blade of screwdriver into slot on the bottom of the door.

• In PRIME position (pointing down) directs fluid to prime tube.

• In SPRAY position (pointing forward) directs pressurized fluid to paint hose.

• Automatically relieves system pressure in overpressure situations.

• Atomizes fluid being sprayed, forms spray pattern and controls fluid flow according to hole size.

• Reverse unclogs plugged tips without disassembly.

water-base fluids.

For transporting pail by its handle.

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Component Identification

3A0997F 9

Mustang 2

ASM 500

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Page 10

Operation

See Operation manual 3A0994 for basic information on sprayer set-up, flushing, and storage.

Trigger Lock

Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

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Trigger Locked Mustang 2

Trigger Unlocked Mustang 2

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Pressure Relief Procedure

Follow this Pressure Relief Procedure whenever you stop spraying and before cleaning, checking, servicing,

or transporting equipment.

1. Turn power switch OFF and unplug power cord.

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2. Turn Prime/Spray valve to PRIME to relieve pressure.

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3. Hold gun firmly to side of pail. Trigger the gun to relieve pressure.

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Trigger Locked ASM 500

Trigger Unlocked ASM 500

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Pressure Control Knob Settings

High Pressure

Spray

Low Pressure

Spray

4. Engage trigger lock.

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NOTE: Leave Prime/Spray valve in the PRIME 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 tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction. Read Unclogging Spray Tip instructions in the Sprayer or Gun Operation manual.

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Prime/

Clean

Rolling

NOTE: To select function, align symbol on pressure control knob with setting indicator on sprayer.

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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.

To reduce risk of serious injury, including electric shock:

• Do not touch moving or electric pars with fingers or tools while testing repair.

• Unplug sprayer when power is not required for testing.

• Install all covers, gaskets, screws and washers before you operate sprayer.

General Repair Information

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.

• Keep all screws, nuts, washers, gaskets, and electrical 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 Basic

Troubleshooting, page 12 and Advanced Trouble- shooting, page 17.

• Overspray may build up in the air passages. Remove any overspray and residue from air passages and openings in the enclosures whenever you service sprayer.

• Do not operate the sprayer without the cover in place. Replace if damaged. Covers direct cooling air around motor to prevent overheating.

3A0997F 11

Page 12

Basic Troubleshooting

Check everything in this Basic Troubleshooting table before you bring the sprayer to a Graco/Airlessco authorized service center.

Problem Cause Solution

Power switch is on and sprayer is plugged in, but motor does not run, and pump does not cycle.

Pressure is set at zero pressure. Turn pressure control knob clock-

wise to increase pressure setting.

Electric outlet is not providing power.

Extension cord is damaged. Replace extension cord. Read

Sprayer electric cord is damaged. Check for broken insulation or wires.

Motor or control is damaged. Take sprayer to Graco/Airlessco

• Check that lighted plug on sprayer is lit (this indicates electric power at outlet).

• Reset building circuit breaker or replace fuse.

Grounding and Electric Requirements, page 7.

Replace electric cord if damaged.

authorized service center.

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Basic Troubleshooting

Problem Cause Solution

Pump does not prime. Prime/Spray Valve is in SPRAY

position.

Inlet screen is clogged or suction tube is not immersed.

Pump was not primed with flushing fluid.

Inlet valve check ball is stuck. Remove suction tube and place a

Turn Prime/Spray Valve to PRIME position (pointing down).

Clean debris off inlet screen and make sure suction tube is immersed in fluid.

Remove suction tube from paint. Prime pump with water or solvent-based flushing fluid, see Operation manual 3A0994.

pencil into the inlet section to dislodge the ball, allowing pump to prime properly. Or, Power Flush sprayer, see Operation manual 3A0994.

AutoPrime may need replacement. Turn power switch ON and listen for “tap” in pump. If you do not hear “tap”, AutoPrime is damaged. Take sprayer to Graco/Airlessco authorized service center.

Inlet valve check ball or seat is dirty Remove inlet fitting. Clean or

replace ball and seat.

Outlet valve check ball is stuck. SP300, Mustang 3100: Insert

screw driver in slot and remove Easy-Access door, page 8. Unscrew outlet valve with a 3/4 in. socket. Remove and clean assembly.

SP200, Mustang 2400: Remove outlet fitting and clean outlet check ball.

Suction tube is leaking. Check suction tube for cracks and

cuts. Make sure suction tube clamp is on hose. Replace suction tube if cracked or damaged.

Pump valves are worn. Check for worn valves, see page 14.

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Page 14

Basic Troubleshooting

Problem Cause Solution

Pump cycles but does not build up pressure.

Pump cycles, but paint only dribbles or spurts when spray gun is triggered.

Prime/Spray valve in PRIME position (pointing down).

Turn Prime/Spray valve to SPRAY position (pointing forward).

Pump is not primed. Prime pump, see Operation manual

3A0994.

Inlet screen is clogged or suction tube is not immersed.

Clean debris off inlet screen and make sure suction tube is immersed in fluid.

Suction tube is leaking. Check suction tube for cracks and

cuts. Make sure suction tube clamp is on hose. Replace suction tube if cracked or damaged.

Prime/Spray Valve is worn or obstructed with debris.

Take sprayer to Graco/Airlessco authorized service center.

Pump check ball is stuck. Read Pump does not prime sec-

tion in Troubleshooting, page 13.

Pressure is set too low. Slowly turn pressure control knob

clockwise to increase pressure setting which will turn motor on to build pressure.

Spray tip is clogged. Unclog spray tip, see Operation

manual 3A0994.

InstaClean fluid filter is clogged.

(SP300, Mustang 3100)

Clean or replace InstaClean fluid filter, see Operation manual 3A0994.

Spray gun fluid filter is clogged. Clean or replace gun fluid filter, see

Operation manual 3A0994.

Spray tip is too large or worn. Replace tip.

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Page 15

Basic Troubleshooting

Problem Cause Solution

Pressure is set at maximum but cannot achieve a good spray pattern.

Spray tip is clogged. Unclog spray tip, see Operation

manual 3A0994.

Reversible spray tip is in UNCLOG position.

Rotate arrow-shaped handle on spray tip so it points forward on gun.

Spray tip is too large for sprayer. Select smaller spray tip.

Spray tip is worn beyond capability

Replace spray tip.

of sprayer.

Extension cord is too long or not heavy enough gauge.

Replace extension cord. See

Grounding and Electrical Requirements, page 7.

Spray gun fluid filter is clogged. Clean or replace spray gun fluid fil-

ter, see Operation manual 3A0994.

InstaClean fluid filter is clogged.

(SP300/Mustang 3100)

Clean or replace InstaClean fluid filter, see Operation manual 3A0994.

Inlet screen is clogged. Clean debris off inlet screen.

Pump valves are worn. Check for worn pump valves.

Prime sprayer with paint Trigger gun momentarily. When trig-

ger is released, pump should cycle momentarily and stop. If pump continues to cycle, pump valves may be worn.

Spray gun stopped spraying. Pump is not cycling.

When paint is sprayed, it runs down the wall or sags.

When paint is sprayed, coverage is inadequate.

Material is too thick. Thin material.

Hose is too long (if extra section is

Remove extra section of hose.

added).

Spray tip is clogged. Unclog spray tip, see Operation

manual 3A0994.

Coat is going on too thick. Move gun faster.

Choose a tip with smaller hole size.

Choose tip with wider fan.

Make sure gun is far enough from surface.

Coat is going on too thin. Move gun slower.

Choose tip with larger hole size.

Choose tip with narrower fan.

Make sure gun is close enough to surface.

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Page 16

Basic Troubleshooting

Problem Cause Solution

Fan pattern varies dramatically while spraying.

Pressure control switch is worn and causing excessive pressure variation.

Take sprayer to Graco/Airlessco authorized service center.

Sprayer does not turn on promptly when resuming spraying.

Cannot trigger spray gun. Spray gun trigger lock is locked. Rotate trigger safety lever to unlock

trigger lock, page 10.

Paint is coming out of pressure control switch.

Prime/Spray valve actuates automatically relieving pressure through

Pressure control switch is worn. Take sprayer to Graco/Airlessco

authorized service center.

System is over pressurizing. Take sprayer to Graco/Airlessco

authorized service center.

prime tube.

Paint leaks down outside of pump. Pump packings are worn. Take sprayer to Graco/Airlessco

authorized service center.

Motor is hot and runs intermittently. Motor automatically shuts off due to excessive heat. Damage can occur if cause is not corrected. See Ther- mal Overload, page 7.

Vent holes in enclosure are plugged or sprayer is covered.

Extension cord is too long or not a heavy enough gauge.

Keep vent holes clear of obstructions and overspray and keep sprayer open to air.

Replace extension cord. Read

Grounding and Electrical Requirements, page 7.

Unregulated electrical generator being used has excessive voltage.

Use electrical generator with a proper voltage regulator. Sprayer requires 120VAC, 60 Hz, 1500-Watt generator.

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Advanced Troubleshooting

See Basic Troubleshooting first, page 12 for problems that are more easily remedied.

General Problem: Motor Does Not Operate

Specific Problem Cause Solution

Advanced Troubleshooting

Power switch is on and sprayer is plugged in; pump does not cycle.

Basic mechanical problems. Paint is frozen or hardened in

See Basic Troubleshooting, page 12.

pump.

Unplug sprayer from electrical outlet. If paint is frozen in sprayer: Do NOT try to start sprayer until completely

thawed or you may damage the motor, control board, and/or drivetrain.

1. Turn power switch OFF.

2. Place sprayer in warm area for several hours.

3. Plug sprayer in.

4. Turn power switch ON and flush sprayer with water or mineral spirits.

a. Turn on sprayer. b. Turn prime valve to PRIME position.

If paint hardened in sprayer: SP300, Mustang 3100: Replace pump pack-

ings. See List of Kits, page 26. SP200, Mustang 2400: Replace complete

pump. See List of Kits, page 26. Remove all residue from inlet and outlet valves.

Gears are damaged.

SP300, Mustang 3100: Yok e is broken because pump is locked up due to dried paint or worn packings.

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Remove motor enclosure and rotate motor fan to check for bad gears. If gears bind or slip, remove pump cover and replace failed gears. See List of Kits, page 26.

Repair or replace using Gear/Yoke Kit. See List of Kits, page 26.

Replace pump packings on SP300 sprayers. See List of Kits, page 26.

Page 18

Advanced Troubleshooting

Specific Problem Cause Solution

Basic electrical problems. Motor overheated. Allow motor to cool for 45 minutes. Retry.

Electrical outlet is damaged. Reset building circuit breaker or replace fuse. Try

another outlet. Check electric supply with volt meter. Meter must

read 85 to 130V AC. If voltage is too high, do not plug sprayer in until outlet is corrected.

Control board leads are improperly fastened, improperly mated, or corroded.

Replace any loose terminals. Make sure all leads and harnesses are firmly connected.

SP300, Mustang 3100: Check pressure control harness connection on front side of drive housing.

Clean control board terminals. Securely reconnect leads.

Motor brushes are worn. Check length of BOTH brushes (brushes do not

wear evenly on both sides of the motor). Brush length must be 0.25 in. (6.4mm). If brushes are worn replace motor using Motor Kit, page 26.

Motor armature commutator damaged.

Check for burn spots, gouges and extreme roughness. If damaged or if shorts are evident, replace motor using Motor Kit, page 26.

Fuse is blown. Find cause for blown fuse before replacing. Turn

the motor fan to check for a locked gear or pump. Use a continuity meter to check for a short to ground caused by a pinched wire.

SP300, Mustang 3100: Replace the fuse with correct fuse kit. See List of Kits, page 26.

SP200: The fuse is not replaceable. Replace control board. See List of Kits, page 26.

Motor armature shorting. Check for shorts. See Motor Diagnostics, page

23. If shorts are evident, replace motor using Motor Kit, page 26.

Motor armature open circuit. Check motor leads for continuity. If open circuit,

check brushes. Use Motor Kit to replace motor. See List of Kits, page 26.

Control board damaged. CAUTION: Do not perform

control board diagnostics until

See Control Board Diagnostics, page 25. Replace control board if damaged using Control Board Kit, page 26.

you have determined the armature is good. A damaged armature can burn out a good control board.

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Page 19

Specific Problem Cause Solution

Sprayer Wiring Problems

Sprayer power cord damaged. Unplug sprayer power cord.

Advanced Troubleshooting

NOTE: Remove enclosure mounting screws and pull enclosure away from drive housing. Take care not to pull on leads from electrical cord and power switch.

Sprayer power switch damaged.

Motor thermal overload cutoff switch damaged.

WARNING: See Startup Hazard After Thermal Overload on page 7.

Disconnect black power cord wire at power switch. Unplug in-line connection white cord wire. Plug in power cord. Test voltage between black and white wires of

power cord. Meter must read 85 to 130V AC. Replace power cord if no voltage.

1. Unplug sprayer power cord.

2. Disconnect black control board wire at power switch.

3. Unplug in-line connection white cord wire.

4. Plug in power cord.

5. Turn power switch ON.

6. Test voltage between open terminal of power switch and white power cord wire. Meter must read 85 to 130V AC.

7. Replace power switch if no voltage.

1. Unplug sprayer power cord.

2. Remove motor harness from control card.

3. Check for continuity between yellow leads or motor harness. (SP300, Mustang 3100)

4. If thermal relief switch is open (no continuity) allow motor to cool.

5. If switch remains open after motor cools, replace motor using Motor Kit, page 26.

6. If thermal relief switch closes after motor cools, find correct cause of overheating.

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Page 20

Advanced Troubleshooting

General Problem: Circuit Breaker is Tripping

Specific Problem Cause Solution

Building circuit breaker opens as soon as sprayer is turned on.

NOTE: Remove enclosure mounting screws and pull enclosure away from drive housing. Take care not to pull on leads from electrical cord and power switch.

Building circuit breaker opens as soon as sprayer is plugged into outlet and sprayer is NOT turned on.

NOTE: Remove enclosure mounting screws and pull enclosure away from drive housing. Take care not to pull on leads from electrical cord and power switch.

Sprayer electrical wiring is pinched or insulation is damaged.

Wires between pressure control switch and control board are pinched.

Motor armature is shorting. Check for shorts. See Motor Diagnostics, page

Control board is damaged. CAUTION: Do not perform

control board diagnostics until you have determined the armature is good. A bad motor armature can burn out a good motor control board.

Sprayer power cord damaged.

Sprayer power switch damaged.

Repair or replace any damaged wiring or terminals. Securely reconnect wires.

23. If shorts are evident, replace motor using Motor Kit, page 26.

See Control Board Diagnostics, page 25. Replace control board if damaged using Control Board Kit, page 26.

Unplug sprayer power cord. Disconnect black power cord wire at power

switch. Unplug in-line connection white cord wire. Plug in power cord. Test voltage between black and white wires of

power cord. Meter must read 85 to 130V AC. Replace power cord if no voltage.

1. Unplug sprayer power cord.

2. Disconnect black control board wire at power switch.

3. Unplug in-line connection white cord wire.

4. Plug in power cord.

5. Turn power switch ON.

6. Test voltage between open terminal of power switch and white power cord wire. Meter must read 85 to 130V AC.

7. Replace power switch if no voltage.

Also see Basic Electrical Problems, and Sprayer Wiring Problems, pages 18 - 19.

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Page 21

Advanced Troubleshooting

General Problem: Erratic Motor Operation

Specific Problem Cause Solution

Sprayer quits after running for 5 to 10 minutes

General Problem: Low or Fluctuating Output

Pump cycles, but output is low or surging.

Building circuit is overloaded. Remove other loads from building circuit or find

another circuit that has less load. See Ground- ing and Electric Requirements, page 7.

Electrical outlet supplying wrong voltage.

Also see Basic Electrical Problems and Sprayer Wiring Problems, pages 18 - 19. Motor is overheating.

Warning: See Thermal Over- load, page 7.

See Basic Troubleshooting, page 12.

Worn or obstructed inlet and outlet valves.

Try another outlet. Check electric supply with volt meter. Meter must read 85 to 130V AC. If voltage is too high, do not use outlet until corrected.

After motor cools, operate sprayer and determine if motor stops when trigger on gun is released. If sprayer runs continuously, replace Pressure Control. See List of Kits, page 26.

Relieve pressure and remove motor enclosure. Turn motor fan by hand to check for binding gears or seized pump. See List of Kits, page 26.

Check for worn pump valves as follows: Prime sprayer with paint. Turn the Prime/Spray

valve to SPRAY position. Turn pressure control fully clockwise.

Trigger spray gun briefly. When spray gun trigger is released pump should

cycle momentarily and stop. If pump continues to cycle, pump valves may be

worn or obstructed. For replacement inlet and outlet valve kits, see

List of Kits, page 26.

Prime/Spray valve is leaking out drain line when Prime/Spray valve is in SPRAY position.

Voltage from electrical outlet is too low. Low voltages reduce sprayer performance.

Extension cord is too long or not heavy enough gauge.

3A0997F 21

Check Prime/Spray valve for debris trapped on seat and for worn parts. Torque to 130-180 in-lb (15.8-18.1 N•m). Replace if parts are worn using Prime/Spray Valve Kit, page 26.

Check voltage of outlet. Meter must read 85 to 130V AC.

Replace extension cord. See Grounding and Electrical Requirements,

page 7.

Page 22

Advanced Troubleshooting

Pump cycles, but output is low or surging.

Motor runs and pump cycles, but pressure does not build up.

Leads from motor or pressure switch to control board are damaged, loose, pinched, or overheated.

Motor brushes are worn. Check length of BOTH brushes (brushes do not

Motor brush springs are broken.

Motor brushes are binding in brush holders.

Motor stops before sprayer reaches correct pressure (stall pressure is too low).

Control board is damaged. CAUTION: Do not perform

control board diagnostics until you have determined the armature is good. A damaged armature can burn out a good control board.

Intake valve or outlet valve is not seating properly.

Pump packings are worn or damaged.

Be sure terminals are centered and firmly connected. Inspect for pinched wiring and wiring insulation and terminals for signs of overheating. Replace any loose terminals or damaged wiring. Securely reconnect terminals.

wear evenly on both sides of the motor). Brush length must be 0.25 in. (6.4mm). If brushes are worn replace motor using Motor Kit, page 26.

If springs are broken, replace motor using Motor Kit, page 26.

Clean brush holders. Remove carbon dust with small cleaning brush.

Replace pressure control using Pressure Con- trol Switch Kit, page 26.

See Control Board Diagnostics, page 25. If damaged, replace control board using Control Board Kit, page 26.

Remove and clean inlet valves and outlet valves. Replace if necessary. See List of Kits, page 26.

Check for leaking around pump. SP300, Mustang 3100: Replace pump pack-

ings. See List of Kits, page 26. SP200, Mustang 2400: Replace complete

pump. See List of Kits, page 26.

General Problem: Excessive Pressure Build Up

Prime/Spray Valve actuates automatically, relieving pressure through drain tube.

22 3A0997F

Pressure control switch has pinched wires.

Water or paint entered pressure control switch or shorted control board.

Control board failed. See Control Board Diagnostics, page 25.

Replace pressure control switch using Pressure Control Switch Kit, page 26.

Use Pressure Control Switch Kit, to replace switch. See List of Kits, page 26.

Replace damaged control board using Control Board Kit, page 26.

Page 23

Motor Diagnostics (SP200, Mustang 2400)

If Motor Diagnostics reveal a damaged motor or if motor brushes are shorter than 1/4 in. (6.4 mm) replace the motor using Motor Kit, page 26.

Setup

1. Unplug power cord and Relieve Pressure, page 10.

2. Remove enclosure and disconnect two black motor

leads to control board (see Wiring Diagram, page

33).

3. Remove motor fan cover by gently prying up on retention tabs on sides of motor. Motor shaft should spin easily when turning fan. If motor shaft does not turn easily, there is a problem with pump, gears, or motor (see Troubleshooting, page 12).

4. Inspect motor windings for evidence of overheating. If windings appear burnt and motor smells, replace motor.

5. Use Ohmmeter to measure resistance across two black motor leads. Resistance of motor should fall within range of 1.5 to 4.5 ohms. If motor falls outside resistance range or is open circuit, replace motor.

6. Use Ohmmeter to measure resistance of motor leads to motor laminations. If resistance is not open circuit, replace motor.

7. Inspect length of both brushes by looking at brush torsion spring. If spring is not bottomed out in slot for brush spring, brush length is acceptable. If brushes are worn out, replace motor.

Motor Diagnostics (SP300, Mustang 3100)

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 1/4 in. (6.4 mm) or if the motor shaft cannot turn, replace the motor using Motor Kit, page 26.

Setup

1. Relieve Pressure, page 10.

2. Unplug electric cord.

3. Remove enclosure and disconnect motor leads from control card.

4. Remove fan brace.

5. Remove four screws and front cover.

6. Remove yoke and guide rods.

7. Remove gear.

Armature Short Circuit Spin Test

Quickly turn motor fan by hand. There should not be electrical shorts and fan should coast two or three revolutions before stopping. If fan does not spin freely, armature is shorted. Replace motor using Motor Kit, page

26.

Armature, Brushes and Motor Wiring Open Circuit Test (Continuity)

1. Connect red and black motor leads together with test lead.

2. Turn motor fan by hand, about two revolutions per second.

3. If there is an uneven resistance or no resistance, replace motor using Motor Kit, page 26.

3A0997F 23

Page 24

Pressure Control Switch Diagnostics

SP200, Mustang 2400, SP300, Mustang 3100

If pressure control switch diagnostics reveal a damaged pressure control, replace it with the correct Pressure Control Switch Kit, see page 26. SP200 and Mustang 2400 sprayers have different pressure control kits because stall pressure is preset at the factory.

1. Unplug power cord and Relieve Pressure, page 10.

2. If paint is leaking from pressure control switch between pressure control knob and base, replace pressure control switch.

3. SP300 and Mustang 3100: Remove front cover, yoke, and pins. Disconnect pressure control switch connector from control board.

SP200 and Mustang 2400: Remove enclosure and disconnect pressure control switch connector from control board. Use finger to support control board when removing pressure control switch connector.

4. Use ohmmeter to check for no continuity between sprayer ground and both pressure control terminals in connector. If either pressure control switch lead is shorted to ground, pressure control switch wires have been pinched to ground during assembly and pressure control switch needs to be replaced.

5. Use Ohmmeter to measure across two terminals in pressure control connector. No continuity or open circuit should exist when pressure control knob is at lowest pressure setting (full counter-clockwise). Replace pressure control switch if continuity exists.

6. Using ohmmeter to measure across two terminals in pressure control connector. Continuity or closed circuit should exist when pressure control knob is set at maximum pressure (full clockwise). Replace pressure control switch if no continuity exists.

24 3A0997F

Page 25

Control Board Diagnostics (SP300, Mustang 3100)

NOTE: Check for motor problems before replacing con-

trol board. A damaged motor may burn out a good control card.

Check for a damaged control board or pressure control switch as follows:

1. Relieve Pressure, page 10.

2. Unplug electrical cord.

3. Remove four cover screws and front cover. Remove motor enclosure.

4. Remove yoke and guide rods.

5. Remove gear.

6. Remove pressure control harness from control board. Using tip of small, flat blade screwdriver, press tab on right side connector to release.

7. Attach harness from a pressure control switch you know is functioning correctly to control board.

NOTE: Pressure control switch does not have to be installed in pump.

8. Turn pressure control adjustment knob (C) +to maximum pressure setting.

9. Plug electrical cord into 120VAC receptacle.

10. Turn power switch (B) ON.

• If motor runs, replace pressure switch. Pres-

sure Control Switch Kit, page 26.

• If motor does not run, replace control board

repeat test. Control Board Kit, page 26.

Control Board Diagnostics (SP200, Mustang 2400)

NOTE: Check for motor problems before replacing con-

trol board. A damaged motor may burn out a good control card

1. Unplug electrical cord and Relieve Pressure, page

10.

2. Remove enclosure and check all control board connectors for proper installation (see Wiring Diagram, page 33).

3. Check fuse on control board. If fuse is blown, determine the cause before replacing control board (see

Advanced Troubleshooting, page 17).

Pump Diagnostics

NOTICE

To avoid damage, when repairing or cleaning the pump, never submerge pump in water or allow fluid to enter pressure control.

When pump packings wear, paint begins to leak down the outside of the pump. At the first sign of leakage, replace the pump or additional damage to the drive train could occur.

1. SP200, Mustang 2400: Replace pump using Pump Replacement (Complete). See List of Kits, page

26.

3A0997F 25

SP300, Mustang 3100: Replace pump using Pump Repair kit. See List of Kits, page 26.

2. If there is no paint leakage, see Advanced Troubleshooting, page 17. Pump may not be defective.

Page 26

List of Kits

Kit Number Models Kit Description

289107 SP200, Mustang 2400, SP300, Mustang 3100 AutoPrime 16E829 SP200, Mustang 2400 (Series A, B, C) Control Board 288705 SP300, Mustang 3100 Control Board 244035 SP200, Mustang 2400, SP300, Mustang 3100 Drain Tube Diffuser 16E830 SP200, Mustang 2400 Enclosure (includes labels and screws) 288695 SP300, Mustang 3100 Enclosure (includes labels and screws) 287770 SP300, Mustang 3100 Fan Replacement 288747 SP300, Mustang 3100

16E833 SP200, Mustang 2400 Front Cover 288692 SP300, Mustang 3100 Front Cover 119276 SP300, Mustang 3100 Fuse 16E835 SP200, Mustang 2400 Gear and Drive 289102 SP300, Mustang 3100 Gear/Yoke 245449 SP200, Mustang 2400 Hose 1/4 in. x 25 ft HSE1450 SP300, Mustang 3100 Hose 1/4 in. x 50 ft 288716 SP200, Mustang 2400, SP300, Mustang 3100 Inlet Strainer 256212 SP300, Mustang 3100 Lacquer Conversion Kit 24K633 SP200, Mustang 2400 (Series A, B, C) Leg, Left 24K632 SP200, Mustang 2400 (Series A, B, C) Leg, Right 16E838 SP200, Mustang 2400 Motor, Cinderson 289104 SP300, Mustang 3100 Motor 257803 SP300, Mustang 3100 Power Cord (includes warning label) 244266 SP200, Mustang 2400 Pressure Control Switch 244267 SP300, Mustang 3100 Pressure Control Switch 235014 SP200, Mustang 2400, SP300, Mustang 3100 Prime/Spray Valve 16E844 SP200, Mustang 2400 Pump Inlet Valve 288700 SP300, Mustang 3100 Pump Inlet Valve 16E845 SP200, Mustang 2400 Pump Outlet Valve 243094 SP300, Mustang 3100 Pump Outlet Valve 288818 SP300, Mustang 3100 Pump Repair Kit 16F047 SP200, Mustang 2400 Pump Replacement 288703 SP300, Mustang 3100 Pump Replacement (Complete) 246802 SP200, Mustang 2400 Spray Gun 289316 SP300, Mustang 3100 Spray Gun 197607 SP200, Mustang 2400 Suction Tube 24J019 SP300, Mustang 3100 Suction Tube 16E835 SP200, Mustang 2400 Drive (for Cinderson Motor) 16E842 SP200, Mustang 2400 (Series A, B, C) Power Cord (includes warning label 16E846 SP200, Mustang 2400 Pump Replacement (Complete)

Filter Kit (InstaClean

™

)

26 3A0997F

Page 27

Parts

SP200, Model 24F557 and Mustang 2400, Model 24F559 Parts List

Parts

Ref. Part Description Qty.

1 16D672 KIT, housing cover 1 1a 120724 SCREW 4 1b 16F554 LABEL, SP200, front 1 1b 16F732 LABEL, Mustang 2400, front 1 7 244266 KIT, pressure control (includes 7a,

7b) 7a 15A464 LABEL, control 1 7b 15K530 LABEL 1 14* 16F047 KIT, pump (includes 17, 29, 43) 1 15 16E835 DRIVE (for Cinderson motor) 1 16 16E838 KIT, motor 1 17 16E845 KIT, outlet valve 1 18 24E510 Cover, Gear 1 22 235014 KIT, drain valve 1 23 24E578 BASE, valve 1 24 187625 HANDLE, valve, drain 1 25 111600 PIN, grooved 1 29 16E844 KIT, pump, inlet valve (includes

29a, 29b, 29c) 29a 124249 BALL, intake 1 29b 103338 O-RING 1 29c 123849 SPRING, inlet 1 30 289107 KIT, solenoid 1 31 15Y296 COVER, solenoid 1 32 16E829 KIT, control board (includes 32a) 1 32a 115477 SCREW, mach, torx 6 33 288716 KIT, strainer 1 34 244035 DEFLECTOR, barbed 1 35 115489 CLAMP, drain tube 2

Ref. Part Description Qty.

36 195084 TUBE, drain 1 37 197607 TUBE, suction 1 38 116295 CLAMP, tube 1 39 195400 CLIP, spring 2 40 118899 SWITCH, rocker, spdt 1

41 16F616 KIT, enclosure, SP200 1 43 112689 SCREW, button, thd form 4 44 16D682 BRACKET, motor 1 47 24K633 KIT, left leg, (includes 2 screws,

47a, 47b) 47a 125116 SCREW, hex washer hd, thd form 4 47b 102040 NUT, lock, hex 4 51 24K632 KIT, right leg, (includes 2 screws,

47a, 47b) 67 16E842 KIT, power cord, (includes 67a,

67b) 67a 115498 SCREW, grounding 1 67b▲ 15T069 LABEL, warning 1

68 16E212 WIRE, jumper 1 84 245449 HOSE, cpld, 1/4 in. x 25 ft 1 85 248676 GUN, spray, Mustang 2 1 85a 288748 KIT, gun filter, 60m/100m 1 91 115648 VALVE, shutoff (not shown) 1 92 245650 FLUID, pump Life, 8 oz (not

shown) 93▲ 179960 CARD, medical wallet (not shown) 1

▲ Replacement Warning labels, tags and cards are available at no cost.

* 16E846 Kit, Repair, Pump complete Available

(included 17, 22, 23, 24, 25, 29, 30)

3A0997F 27

Page 28

Parts

SP200, Model 24F557 and Mustang 2400, Model 24F559

29c 29a 29b

32a

28 3A0997F

ti17249a

Page 29

SP200, Model 24F557 and Mustang 2400, Model 24F559

Parts

32a

67a

67b

32a

47a

85a

3A0997F 29

47b

ti17264b

Page 30

Parts

SP300, Model 24F558 and Mustang 3100, 24F560 Parts List

Ref. Part Description Qty.

23 121939 SCREW, mach 8-16 x 5/8 in.

plastite 29 16H348 SUCTION TUBE 1 30 288716 KIT, Strainer 1 31 116295 TUBE CLAMP 1 32 195108 DRAIN TUBE 1 33 244035 DEFLECTOR 1 34 115489 DRAIN TUBE CLAMP 2 37 235014 KIT, drain valve 1

115648 SHUTOFF VALVE (not shown) 1 39 187625 DRAIN VALVE HANDLE 1 40 224807 BASE, valve 1 41 HSE1450 HOSE, cpld,1/4 in. x 50 ft '1 42 289102 KIT, gear and yoke 1 44 118899 ROCKER SWITCH 1 45 16F614 Motor Shield 1 45a▲ 15K521 LABEL, warning skin injection 1 45b▲ 15K522 LABEL, warning fire explosion 1 45c▲ 15K520 LABEL, warning elec shock 1 45d 118444 SCREW, mach, hwhd 10-24 x .5

in. 46 15J802 SOLENOID COVER 1 47 15J803 SWITCH BRACKET 1 49 194507 DOWEL PIN, 5/16 2 50 196001 WASHER 2 51 111600 PIN, grooved 1 52 115498 SCREW, ground, 8-32 x .375 in.

taptite 53 195400 SPRING CLIP 1 55 289107 KIT, solenoid 1 56 119275 WIRE CLIP 1 57 15J790 PAIL HOOK 1 58 15J952 POWER CORD, lighted 1 59 288705 KIT, control 1 59a 1 62 244267 KIT, pressure control, includes

62a, 62b 62a 15K530 LABEL, Control 1 62b 15A464 LABEL 1 63 288703 KIT, pump, (complete) includes

37, 39, 40, 51, 63a, 63b, 63c,

63d, 63e 63a 288747 KIT, filter 1 63b 288700 KIT, pump inlet module 1 63c 288818 KIT, packing repair 1 63d 243094 KIT, pump outlet valve 1 63e 195947 ADAPTER, filter 1

Ref. Part Description Qty.

67 288692 KIT, housing cover, includes

67a 15J809 COVER, pump outlet 1 67b 115478 SCREW, mach, 1/4 x 20 x 1.375

67c 16F555 LABEL, front, SP300 1

16F733 LABEL, Mustang 3100, Front 68 289104 KIT, motor, includes 68a 1 68a 287770 KIT, fan 1 70 16F372 SHELF, motor 1 71 262012 KIT, left leg, (includes 2 screws

71a 260212 SCREW, hex washer hd, thd

72 262014 KIT, right leg, (includes 2 screws

73 120788 SCREW, carriage 2 74 15R602 AXLE, cart 1 75 115095 WHEEL, 9 in. 2 76 112612 CAP, hub 2

77 16H354 HANDLE, cart 1 78 15J949 RACK, hose 1 79 120689 NUT, hex, acorn, 5/16 - 18

80 115480 KNOB, t-handle 2 81 260212 SCREW, hw hd, thd form 1/4-20

85 SERIAL LABEL 2 92▲ 179960 SIGN, warning (not shown) 1 110 289316 SPRAY GUN, 500 1 116 121939 SCREW, plastite 4

245650 Fluid, Pumplife, 8 oz (not

▲ 15T069 LABEL, warning

▲ Replacement Warning labels, tags, and cards are available

at no cost.

67a, 67b, 67c

in. taptite

71a)

form

71a)

nickel

x .75 in.

shown)

30 3A0997F

Page 31

SP300, Model 24F558 and Mustang 3100, 24F560

85 45c

45b

63c

Parts

45d

45a

68a

67c

67b

67a

62b

62a

110

63e

63d

63a

63b

59a

3A0997F 31

ti16083a

Page 32

Parts

SP300, Model 24F558 and Mustang 3100, 24F560

71A

7171

32 3A0997F

Page 33

Wiring Diagrams

SP200, Model 24F557 and Mustang 2400, Model 24F559

/./&&

37)4#(

0/7%2#/2$ ",!#+7)2%

Wiring Diagrams

02%3352% 37)4#(

!54/02)-%

!&53%

7)2).'$)!'2!-

",!#+

-/4/2 ,%!$

0/7%2#/2$ 7()4%7)2%

7()4% "/!2$7)2%

#(!33)3

'2/5.$

0/7%2#/2$ '2%%.7)2%

Ref 67a

",!#+

-/4/2 ,%!$

Thermal Switch

ti11322c

When assembling motor to pump housing, make sure Thermal Switch is positioned on top as shown above.

3A0997F 33

Page 34

Wiring Diagrams

*

*

,

,

SP300, Model 24F558 and Mustang 3100, 24F560

/./&&

37)4#(

!54/02)-%

02%3352% 37)4#(

#/.42/,"/!2$



2%&

,

* *

,

#(!33)3'2/5.$

7(4

7)2).'$)!'2!-

'2.

7(4

",+

0/7%2#/2$

ti9505a

34 3A0997F

Page 35

Technical Data

SP200, Mustang 2400

Electrical Power Requirements . . . . . . . . . . . . . . . . . . . 120 Vac, 60 Hz, 15A, 1 phase

Working Pressure Range. . . . . . . . . . . . . . . . . . . . . . . . 0 - 2800 psi (0-19 MPa, 0-193 bar)

Generator required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500W minimum

Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0A (open frame, universal)

Operating horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 AWG, 3-wire, 6 ft (1.8m)

Fluid inlet fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 in. internal thread (standard garden hose thread)

Fluid outlet fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 NPSM external thread

Inlet screen (on suction tube) . . . . . . . . . . . . . . . . . . . . 35 mesh (450 micron)

Maximum Delivery (with tip). . . . . . . . . . . . . . . . . . . . . . 0.24 gpm (0.91 lpm)

Paint Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 in. x 25 ft. (6.4 mm x 7.5 m)

Maximum tip hole size . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 in. (0.38 mm)

Weight, sprayer only . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 lb (6.0 kg)

Weight, sprayer, hose and gun . . . . . . . . . . . . . . . . . . . 16.5 lb (7.5 kg)

Dimensions: Upright

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 in. (36.8 cm)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 in. (31.5 cm)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9 in. (45.5 cm)

Wetted Parts, pump and hose . . . . . . . . . . . . . . . . . . . . stainless steel, brass, leather, ultra-high molecular

weight polyethylene (UHMWPE), carbide, nylon, aluminum, PVC, polypropylene, fluroelastomer

Wetted Parts, gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, brass, carbide, nylon, plated steel, stainless

steel, UHMWPE, zinc Storage Temperature Range

Operating Temperature Range ✔. . . . . . . . . . . . . . . . . . 40° F - 115° F (4° C - 46° C)

◆ When pump is stored with non-freezing fluid. Pump damage will occur if water or latex paint freezes in pump. ❖ Damage to plastic parts may result if impact occurs in low temperature conditions. ✔ Changes in paint viscosity at very low or very high temperatures can affect sprayer performance.

◆❖ . . . . . . . . . . . . . . . . . . -30° F - 160° F (-35° C - 71° C)

3A0997F 35

Page 36

Technical Data

SP300, Mustang 3100

Electrical Power Requirements . . . . . . . . . . . . . . . . . . . 120 Vac, 60 Hz, 15A, 1 phase

Working Pressure Range. . . . . . . . . . . . . . . . . . . . . . . . 0 - 3000 psi (0-21 MPa, 0-207 bar)

Generator required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500W minimum

Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8A (permanent magnet DC)

Operating horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4

Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 AWG, 3-wire, 6 ft (1.8m)

Fluid inlet fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 in. internal thread (standard garden hose thread)

Fluid outlet fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 NPSM external thread

Inlet screen (on suction tube) . . . . . . . . . . . . . . . . . . . . 35 mesh (450 micron)

Maximum Delivery (with tip). . . . . . . . . . . . . . . . . . . . . . 0.34 gpm (1.29 lpm)

Paint Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 in. x 50 ft. (6.4 mm x 15 m)

Maximum tip hole size . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 in. (0.43 mm)

Weight, sprayer only . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 lb (20 kg)

Weight, sprayer, hose and gun . . . . . . . . . . . . . . . . . . . 46 lb (21 kg)

Dimensions: Upright

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 in. (60.32 cm)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 in. (44.45 cm)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.5 in. (92.71 cm)

Dimensions: Folded

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.25 in. (59.05 cm)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 in. (44.45 cm)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 in. (55.88 cm)

Wetted Parts, pump and hose . . . . . . . . . . . . . . . . . . . . stainless steel, brass, leather, ultra-high molecular

weight polyethylene (UHMWPE), carbide, nylon, alumi-

num, PVC, polypropylene, fluroelastomer

Wetted Parts, gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, brass, carbide, nylon, plated steel, stainless

steel, UHMWPE, zinc Storage Temperature Range

◆❖ . . . . . . . . . . . . . . . . . . -30° F - 160° F (-35° C - 71° C)

Operating Temperature Range ✔. . . . . . . . . . . . . . . . . . 40° F - 115° F (4° C - 46° C)

3A0997F 36

Page 37

Notes

3A0997F 37

Page 38

Airlessco Standard Warranty

Airlessco warrants all equipment referenced in this document which is manufactured by Airlessco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Airlessco, Airlessco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Airlessco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Airlessco’s written recommendations.

This warranty does not cover, and Airlessco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Airlessco component parts. Nor shall Airlessco be liable for malfunction, damage or wear caused by the incompatibility of Airlessco equipment with structures, accessories, equipment or materials not supplied by Airlessco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Airlessco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Airlessco distributor for verification of the claimed defect. If the claimed defect is verified, Airlessco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Airlessco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

AIRLESSCO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY Airlessco. These items sold, but not manufactured by Airlessco (such as electric motors, switches, hose, etc.), are subject

to the warranty, if any, of their manufacturer. Airlessco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Airlessco be liable for indirect, incidental, special or consequential damages resulting from Airlessco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Airlessco, or otherwise.

FOR AIRLESSCO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

TO PLACE AN ORDER OR FOR SERVICE, contact your Airlessco distributor,

or call 1–800–223-8213 to identify the nearest distributor.

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Airlessco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original Instructions. This manual contains English. MM 3A0997

Airlessco, 3501 N. 4th Avenue, Sioux Falls, SD 57104

www.airlessco.com

Revised October 2012

AIRLESSCO SP200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Warnings

Installation

Grounding and Electric Requirements

Component Identification

Operation

Pressure Relief Procedure

Pressure Control Knob Settings

General Repair Information

Basic Troubleshooting

Advanced Troubleshooting

General Problem: Motor Does Not Operate

General Problem: Circuit Breaker is Tripping

General Problem: Erratic Motor Operation

General Problem: Low or Fluctuating Output

General Problem: Excessive Pressure Build Up

Motor Diagnostics (SP200, Mustang 2400)

Motor Diagnostics (SP300, Mustang 3100)

Pressure Control Switch Diagnostics

Control Board Diagnostics (SP300, Mustang 3100)

Control Board Diagnostics (SP200, Mustang 2400)

Pump Diagnostics

List of Kits

Parts

SP200, Model 24F557 and Mustang 2400, Model 24F559 Parts List

SP300, Model 24F558 and Mustang 3100, 24F560 Parts List

Wiring Diagrams

SP200, Model 24F557 and Mustang 2400, Model 24F559

SP300, Model 24F558 and Mustang 3100, 24F560

Technical Data

Notes

Airlessco Standard Warranty