3A0997F - SP200, SP300, AllPro Mustang 2400
Contents
1. 179960 Description TUBE drain TUBE suction CLAMP tube CLIP spring SWITCH rocker spdt KIT enclosure SP200 SCREW button thd form BRACKET motor KIT left leg includes 2 screws 47a 47b SCREW hex washer hd thd form NUT lock hex KIT right leg includes 2 screws 47a 47b KIT power cord includes 67a 67b SCREW grounding LABEL warning WIRE jumper HOSE opld 1 4 in x 25 ft GUN spray Mustang 2 KIT gun filter 60m 100m VALVE shutoff not shown FLUID pump Life 8 oz not shown CARD medical wallet not shown Qty lt A LB D mob mb mh A Replacement Warning labels tags cards are available at no cost 16E846 Kit Repair Pump complete Available included 17 22 23 24 25 29 30 27 Parts SP200 Model 24F557 and Mustang 2400 Model 24F559 18 ti17249a 28 3A0997F SP200 Model 24F557 and Mustang 2400 Model 24F559 3A0997F Parts 29 Parts SP300 Model 24F558 and Mustang 3100 24F560 Parts List Ref 23 29 30 31 32 33 34 37 39 40 41 42 44 45 45aA 45bA 45cA 45d 46 47 49 50 51 52 53 55 56 57 58 59 59 62 62 62b 63 63a 63b 63c 63d 63e 30 Part 121939 16H348 288716 116295 195108 244035 115489 235014 115648 187625 224807 HSE1450 289102 118899 16F614 15K521 15K522 15K520 1184442. 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 e Turn off and disconnect power cord before servicing equipment e Use only grounded electrical outlets e Use only 3 wire extension cords e Ensure ground prongs are intact on power and extension cords e Do not expose to rain Store indoors 4 3A0997F Warnings 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 i
3. C to max imum pressure setting 9 Plug electrical cord into 120VAC receptacle 10 Turn power switch B ON e f motor runs replace pressure switch Pres sure Control Switch Kit page 26 e f 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 con trol card 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 1 Unplug electrical cord and Relieve Pressure page 10 2 Remove enclosure and check all control board con nectors for proper installation see Wiring Diagram page 33 3 Check fuse on control board If fuse is blown deter mine the cause before replacing control board see Advanced Troubleshooting page 17 SP300 Mustang 3100 Replace pump using Pump Repair kit See List of Kits page 26 2 fthere is no paint leakage see Advanced Troubleshooting page 17 Pump may not be defective 25 List of Kits List of
4. 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 Take sprayer to Graco Airlessco obstructed with debris authorized service center Pump check ball is stuck Read Pump does not prime sec tion in Troubleshooting page 13 Pump cycles but paint only dribbles Pressure is set too low Slowly turn pressure control knob or spurts when spray gun is trig clockwise to increase pressure set gered ting which will turn motor on to build pressure Spray tip is clogged Unclog spray tip see Operation manual 3A0994 InstaClean fluid filter is clogged Clean or replace InstaClean fluid fil SP300 Mustang 3100 ter see Operation manual 3A0994 opray gun fluid filter is clogged Clean or replace gun fluid filter see Operation manual 3A0994 Spray tip is too large or worn Replace tip 14 3A0997F Basic Troubleshooting Problem Cause Solution Pressure is set at maximum but opray tip is clogged Unclog spray tip see Operation cannot achieve a good spray pat manual 3A0994 tern Reversible spray tip is in UNCLOG Rotate arrow shaped handle on position 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 Heplace extension cord See heavy enough gauge Grounding and
5. 130V AC If voltage is too high do not plug sprayer in until outlet is corrected Control board leads are Replace any loose terminals Make sure all leads improperly fastened improp and harnesses are firmly connected ery malog or SP300 Mustang 3100 Check pressure control corroded i harness connection on front side of drive hous ing Clean control board terminals Securely recon nect 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 Check for burn spots gouges and extreme damaged 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
6. 4 NPSM external thread Inlet screen on suction tube 35 mesh 450 micron Maximum Delivery with tip 0 34 1 29 Ipm PAIN HOSE s 2 op aor eot heh te don ae do C ede eed 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 Ib 20 kg Weight sprayer hose and gun 46 Ib 21 kg Dimensions Upright LENG DI aranna a oder ends 23 75 in 60 32 cm Lalo ERRARE 17 5 in 44 45 cm NET E 36 5 in 92 71 cm WENO esac ake bea sa ded Road Sata a acie t 23 25 in 59 05 cm MICI sia oto chek ae dea ite EP tec eed 17 5 in 44 45 cm SON 22 0 55 88 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 9 30 F 160 35 C 71 Operating Temperature Rangev 40 F 115 F 4 C 46 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
7. 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 Clean or replace InstaClean fluid fil SP300 Mustang 3100 ter 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 con tinues to cycle pump valves may be worn Material is too thick Thin material Hose is too long if extra section is Remove extra section of hose added Spray gun stopped spraying Pump Spray tip is clogged Unclog spray tip see Operation is not cycling manual 3A0994 When paint is sprayed it runs down the wall or sags 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 When paint is sprayed coverage is inadequate 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 3A0997F Basic Troubleshooting Problem Cause Solution Fan pattern varies dramatically Pressure control switch is worn and Take sprayer to Graco Airlessco while spraying causing excessive pressure varia authorized
8. Kits KiNumber Models KitDeseription 288747 SP300 Mustang 3100 Filter Kit InstaClean 26 3A0997F Parts SP200 Model 24F557 and Mustang 2400 Model 24F559 Parts List Parts Ref Part 1 16D672 1a 120724 1b 16F554 1b 16F732 7 244266 7 15 464 7b 15K530 14 16F047 15 16E835 16 16E838 17 16E845 18 24E510 22 235014 23 24 578 24 187625 25 111600 29 16E844 29a 124249 29b 103338 29c 123849 30 289107 31 15Y296 32 16E829 32a 115477 33 288716 34 244035 35 115489 3A0997F Description KIT housing cover SCREW LABEL SP200 front LABEL Mustang 2400 front KIT pressure control includes 7a 7b LABEL control LABEL KIT pump includes 17 29 43 DRIVE for Cinderson motor KIT motor KIT outlet valve Cover Gear KIT drain valve BASE valve HANDLE valve drain PIN grooved KIT pump inlet valve includes 29a 29b 29c BALL intake O RING SPRING inlet KIT solenoid COVER solenoid KIT control board includes 32a SCREW mach torx KIT strainer DEFLECTOR barbed CLAMP drain tube Qty in A mob mob mb Il ll N HAO Ref 36 37 38 39 40 41 43 44 47 47a 47b 51 67 67a 67bA 68 84 85 85a 91 92 93A Part 195084 197607 116295 195400 118899 16F616 112689 16D682 24K633 125116 102040 24K632 16E842 115498 15T069 16E212 245449 248676 288748 115648 245650
9. Mustang 3100 1 29 Ipm 6 4 mm x 15m 500 Series 3000 psi 21 MPa 207 bar 2 3A0997F Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 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 pr
10. Requirements page 7 3A0997F 21 Advanced Troubleshooting Pump cycles but output is low Leads from motor or pressure Be sure terminals are centered and firmly con or surging switch to control board are nected Inspect for pinched wiring and wiring damaged loose pinched or insulation and terminals for signs of overheating overheated Replace any loose terminals or damaged wiring Securely reconnect terminals 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 brush springs are bro If springs are broken replace motor using Motor ken Kit page 26 Motor brushes are binding in Clean brush holders Remove carbon dust with brush holders small cleaning brush Motor stops before sprayer Replace pressure control using Pressure Con reaches correct pressure trol Switch Kit page 26 stall pressure is too low Control board is damaged See Control Board Diagnostics page 25 If CAUTION Do not perform damaged replace control board using Control control board diagnostics until ORIGIN Page ee you have determined the armature is good A damaged armature can burn out a good control board Motor runs and pump cycles Intake valve or outlet valve is Remove and clean inlet valves and outlet valves but pressure does not build not seating properly Re
11. service center OR tion oprayer 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 con Pressure control switch is worn Take sprayer to Graco Airlessco trol switch authorized service center Prime Spray valve actuates auto System is over pressurizing Take sprayer to Graco Airlessco matically relieving pressure through 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 Vent holes in enclosure are plugged Keep vent holes clear of obstruc Motor automatically shuts off due to or sprayer is covered tions and overspray and keep excessive heat Damage can occur sprayer open to air if cause is not corrected See Ther mal Overload page 7 Extension cord is too long or not a Replace extension cord Read heavy enough gauge Grounding and Electrical Requirements page 7 Unregulated electrical generator Use electrical generator with a being used has excessive voltage proper voltage regulator Sprayer requires 120VAC 60 Hz 1500 Watt generator 16 3A0997F Advanced Troubleshooting Advanced Troubleshooting See Basic Troubleshooting first page 12 for problems that are more easily remedied General Problem Motor D
12. 0 Mustang 3100 If thermal relief switch is open no continuity allow motor to cool If switch remains open after motor cools replace motor using Motor Kit page 26 If thermal relief switch closes after motor cools find correct cause of overheating 19 Advanced Troubleshooting General Problem Circuit Breaker is Tripping Specific Problem 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 20 Cause Sprayer electrical wiring is pinched or insulation is dam aged Wires between pressure con trol switch and control board are pinched Motor armature is shorting 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 dam aged Sprayer power switch dam aged Solution Repair or replace any damaged wiring or termi nals Securely reconnect wires Check for shorts See Motor Diagnostics page 23 If shorts are evi
13. 150802 150803 194507 196001 111600 115498 195400 289107 119275 15J790 150952 288705 244267 15 530 15 464 288703 288747 288700 288818 243094 195947 Description SCREW mach 8 16 x 5 8 in plastite SUCTION TUBE KIT Strainer TUBE CLAMP DRAIN TUBE DEFLECTOR DRAIN TUBE CLAMP KIT drain valve SHUTOFF VALVE not shown DRAIN VALVE HANDLE BASE valve HOSE cpld 1 4 in x 50 ft KIT gear and yoke ROCKER SWITCH Motor Shield LABEL warning skin injection LABEL warning fire explosion LABEL warning elec shock SCREW mach hwhd 10 24 x 5 in SOLENOID COVER SWITCH BRACKET DOWEL PIN 5 16 WASHER PIN grooved SCREW ground 8 32 x 375 in taptite SPRING CLIP KIT solenoid WIRE CLIP PAIL HOOK POWER CORD lighted KIT control KIT pressure control includes 62a 62b LABEL Control LABEL KIT pump complete includes 37 39 40 51 63a 63b 63c 63d 63e KIT filter KIT pump inlet module KIT packing repair KIT pump outlet valve ADAPTER filter Qty 4 N 2 mb mb o cl cl cl s mn mo NN gt mh Ref 67 67a 67b 67c 68 68a 70 71 71a 72 73 74 75 76 T7 78 79 80 81 85 92 110 116 Part 288692 15J809 115478 16F555 16F733 289104 287770 16 72 262012 260212 262014 120788 15R602 115095 112612 16H354 15J949 120689 115480 260
14. 212 179960 289316 121939 245650 15T069 Description KIT housing cover includes 67a 67b 67c COVER pump outlet SCREW mach 1 4 x 20 x 1 375 in taptite LABEL front SP300 LABEL Mustang 3100 Front KIT motor includes 68a KIT fan SHELF motor KIT left leg includes 2 screws 71a SCREW hex washer hd thd form KIT right leg includes 2 screws 71a SCREW carriage AXLE cart WHEEL 9 in CAP hub HANDLE cart RACK hose NUT hex acorn 5 16 18 nickel KNOB t handle SCREW hw hd thd form 1 4 20 x 75 in SERIAL LABEL SIGN warning not shown SPRAY GUN 500 SCREW plastite Fluid Pumplife 8 oz not shown LABEL warning Qty A Replacement Warning labels tags and cards are available at no cost 3A0997F Parts SP300 Model 24F558 and Mustang 3100 24F560 85 45c 3A0997F 31 Parts SP300 Model 24F558 and Mustang 3100 24F560 3A0997F 32 Wiring Diagrams Wiring Diagrams SP200 Model 24F557 and Mustang 2400 Model 24F559 in ma SWITCH TT POWERCORD BLACK WIRE POWERCORD EM HD POWERCORD GREEN WIRE NG WHITE Q BOARD WIRE CHASSIS Ref 67a GROUND BLACK MOTOR PRESSURE VA LEAD SWITCH Thermal Switch AN up m SN BLACK Bb GA MOTOR LEAD WIRING DIAGRAM 4 1322c A When assembling motor t
15. After motor cools operate sprayer and deter mine if motor stops when trigger on gun is Warning See Thermal Over released If sprayer runs continuously replace load page 7 Pressure Control See List of Kits page 26 Helieve pressure and remove motor enclosure Turn motor fan by hand to check for binding gears or seized pump See List of Kits page 26 General Problem Low or Fluctuating Output Pump cycles but output is low See Basic Troubleshooting or surging page 12 Worn or obstructed inlet and Check for worn pump valves as follows outlet valves 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 Check Prime Spray valve for debris trapped on out drain line when seat and for worn parts Torque to 130 180 in Ib Prime Spray valve is in 15 8 18 1 Nem Replace if parts are worn using SPRAY position Prime Spray Valve Kit page 26 Voltage from electrical outlet Check voltage of outlet Meter must read 85 to is too low Low voltages 130V AC reduce sprayer performance Extension cord is too long or Replace extension cord not heavy enough gauge See Grounding and Electrical
16. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 m
17. Control board damaged See Control Board Diagnostics page 25 Replace control board if damaged using Control CAUTION Do not perform Board Kit page 26 control board diagnostics until you have determined the armature is good A damaged armature can burn out a good control board 3A0997F Specific Problem Cause Advanced Troubleshooting Solution Sprayer Wiring Problems Sprayer power cord damaged 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 3A0997F 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 Unplug sprayer power cord Disconnect black control board wire at power switch Unplug in line connection white cord wire Plug in power cord Turn power switch ON Test voltage between open terminal of power switch and white power cord wire Meter must read 85 to 130V AC Replace power switch if no voltage Unplug sprayer power cord Hemove motor harness from control card Check for continuity between yellow leads or motor harness SP30
18. Repair and Parts Ay GA WENN SP200 SP300 Mustang 2400 3A0997F Mustang 3100 EN 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 This Related Manuals includes but is not limited to acetone xylene toluene or naptha For more information about your material request MSDS from distributor or retailer LA 3A0994 See page 2 for model information including maximum working pressure and approvals SP200 Model 24F557 SP300 Model 24F558 Mustang 2400 Model 24F559 Mustang 3100 Model 24F560 Series A B C Series A LISTED Intertek Models 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 Dispense Rate gpm Hose Length and Model Name Ipm Diameter Maximum Working Pressure SP200 0 24 gpm 1 4 in x 25 ft Mustang 2400 ABC 0 91 Ipm 6 4 mm x 7 5 m 200 Series 2800 psi 19 MPa 193 bar SP300 0 34 gom 1 4 in x 50 ft
19. ake 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
20. amaged Covers direct cooling air around motor to prevent overheating 3A0997F 11 Basic Troubleshooting Basic Troubleshooting AMG 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 Pressure is set at zero pressure Turn pressure control knob clock plugged in but motor does not run wise to increase pressure setting and pump does not cycle dud 7 Electric outlet is not providing e Check that lighted plug on power sprayer is lit this indicates electric power at outlet e Reset building circuit breaker or replace fuse Extension cord is damaged Replace extension cord Read Grounding and Electric Require ments page 7 Sprayer electric cord is damaged Check for broken insulation or wires Replace electric cord if damaged Motor or control is damaged Take sprayer to Graco Airlessco authorized service center 12 3A0997F Basic Troubleshooting Problem Cause Solution Pump does not prime Prime Spray Valve is in SPRAY Turn Prime Spray Valve to PRIME position position pointing down Inlet screen is clogged or suction Clean debris off inlet screen and tube is not immersed make sure suction tube is immersed in fluid Pump was not primed with flushing Remove suction tube from paint fluid Prime pump with water or sol vent based flushing fluid see Oper ation ma
21. bleshooting 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 wind ings 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 3A0997F Armature Short Circuit Spin Test Quickly turn motor fan by hand There should not be electrical shorts and fan should coast two or three revo lutions before stopping If fan does not spin freely arma ture is shor
22. can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility 3A0997F 5 Warnings MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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 e Read MSDSs to know the specific hazards of the fluids you are using e 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 e Protective eyewear and hearing protecti
23. dent 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 Unplug sprayer power cord Disconnect black control board wire at power switch Unplug in line connection white cord wire Plug in power cord Turn power switch ON Test voltage between open terminal of power switch and white power cord wire Meter must read 85 to 130V AC Replace power switch if no voltage Also see Basic Electrical Problems and Sprayer Wiring Problems pages 18 19 3A0997F Advanced Troubleshooting General Problem Erratic Motor Operation Specific Problem Solution Sprayer quits after running for Building circuit is overloaded 5 to 10 minutes 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 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 Also see Basic Electrical Problems and Sprayer Wiring Problems pages 18 19 Motor is overheating
24. g priming and pressure relief J Prime Spray valve e n PRIME position pointing down directs fluid to prime tube e n SPRAY position pointing forward directs pressurized fluid to paint hose e Automatically relieves system pressure in overpressure situations Prevents debris from entering pump Panthse Transports high pressure fluid from pump to spray gun Tip guard Reduces risk of fluid injection injury Reversible spray tip Atomizes fluid being sprayed forms spray pattern and controls fluid flow according to hole size e Reverse unclogs plugged tips without disassembly 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 water base fluids Gun fluid filter Filters fluid entering spray gun to reduce tip clogs Pail Hanger For transporting pail by its handle SP300 Mustang 3100 3A0997F Co Component Identification ti15983a N O c O o 23 gt 3A0997F Operation 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 ti15981a ti15980a Trigger Locked Mustang 2 Trig
25. ger Unlocked Mustang 2 ti115987a Trigger Locked ASM 500 ti15979A Trigger Unlocked ASM 500 Pressure Control Knob Settings Deny High Pressure Spray Spray Low Pressure Pressure Relief Procedure Follow this Pressure Relief Procedure whenever you stop spraying and before cleaning checking servicing or transporting equipment se 1 Turn power switch OFF and unplug Mc power cord SE zm ti2018a 2 Turn Prime Spray valve to PRIME to relieve pressure 3 Hold gun firmly to side of pail Trigger the gun to relieve pressure 4 Engage trigger lock ti9207a 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 ti5597a Prime Rolling Clean NOTE To select function align symbol on pressure control knob with setting indicator on sprayer 10 3A0997F General Repair Information General Repair Information NOTICE e Donotrun sprayer dry for more than 30 seconds Doing so could damage pump packings Flammable materials spilled on hot bare motor could cause fire or expl
26. mmediate 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
27. ntaining 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 ti9207a 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 Component Identification Component Identification Airless spray gun oprays fluid Powerswitch Turns sprayer ON and OFF C Pressure control knob Increases clockwise and decreases counter clockwise fluid pressure in pump hose and spray gun D Pump fluid outlet fitting Threaded connection for paint hose E InstaClean fluid filter e Filters fluid coming out of pump to reduce tip plugging and SP300 Mustang 3100 Improve finish e Self cleans only during pressure relief F ProX Power Piston Pump behind Pumps and pressurizes fluid and delivers it to paint hose Easy Access door not shown SP300 Mustang 3100 F1 Easy Access door Easy Access door permits quick access to outlet valve To SP300 Mustang 3100 remove door insert flat blade of screwdriver into slot on the bot tom of the door Suction tube Draws fluid from paint pail into pump Prime tube with diffuser Drains fluid in system durin
28. nual 3A0994 Inlet valve check ball is stuck Remove suction tube and place a pencil into the inlet section to dis lodge 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 autho rized 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 3A0997F 13 Basic Troubleshooting Problem Cause Solution Pump cycles but does not build up Prime Spray valve in PRIME posi Turn Prime Spray valve to SPRAY pressure tion pointing down position pointing forward Pump is not primed Prime pump see Operation manual 3A0994 Inlet screen is clogged or suction Clean debris off inlet screen and tube is not immersed make sure suction tube is immersed in fluid Suction tube is leaking
29. o pump housing make sure Thermal Switch is positioned on top as shown above 3A0997F 33 Wiring Diagrams SP300 Model 24F558 and Mustang 3100 24F560 IT als TON LLE p A w SWITCH li T AUTO PRIME BLK PRESSURE CONTROL BOARD EN SWITCH CHASSIS GROUND Y REF WHT WHT WIRING DIAGRAM 34 3A0997F Technical Data Technical Data SP200 Mustang 2400 Electrical Power Requirements 120 Vac 60 Hz 15A 1 phase Working Pressure 0 2800 psi 0 19 MPa 0 193 bar Generator required 1500W minimum Eleetrie MOlOE oce Ss coe bene aa 9 0A open frame universal Operating 1 2 POWOL CO adr doen 18 AWG 3 wire 6 ft 1 8m Fluid inlet fitting 0 0 eee 3 4 in internal thread standard garden hose thread Fluid outlet fitting llle 1 4 NPSM external thread Inlet screen on suction tube 35 mesh 450 micron Maximum Delivery with tip 0 24 gpm 0 91 lpm PalhtHoSQ s dk p 1 4 in x 25 ft 6 4 mm x 7 5 m Maximum tip hole 5 1 0 015 in 0 38 mm Weight sprayer only 13 3 Ib 6 0 kg Weight sprayer hose and gun 16 5 Ib 7 5 kg Dimensions Uprigh
30. occurs in low temperature conditions v Changes in paint viscosity at very low or very high temperatures can affect sprayer performance 3A0997F 36 Notes Notes 3A0997F 3 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 struc
31. oes Not Operate Specific Problem Cause Power switch is on and See Basic Troubleshooting sprayer is plugged in pump page 12 does not cycle Basic mechanical problems Paint is frozen or hardened in Unplug sprayer from electrical outlet idis 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 Turn power switch OFF Place sprayer in warm area for several hours Plug sprayer in 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 Hemove 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 is broken because pump is Of Kits page 26 worn packings List of Kits page 26 3A0997F 17 Advanced Troubleshooting Specific Problem Basic electrical problems 18 Cause Solution 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
32. on e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 6 3A0997F 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 e This sprayer requires a 120 Vac 60 Hz 15A circuit with a grounding receptacle 7 oi e Never use an outlet n that is not grounded or an adapter tib573a e Do not use the sprayer if the electrical cord has a damaged ground prong e Only use an extension cord with an undamaged 3 prong plug ti5572a Recommended extension cords for use with this sprayer 50ft 15 0 m 14 AWG 2 1 mm e 100 ft 30 0 m 12 AWG 3 3 mm Spray gun ground through connection to a properly grounded fluid hose and pump NOTE Smaller gauge or longer extension cords may reduce sprayer performance 3A0997F Installation Fluid supply container follow local code Solvent pails used when flushing follow local code 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 connect a ground wire to the pail by clamping one end to pail and other end to ground such as a water pipe Mai
33. operly 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 UT ti9164a e Only connect the product to an outlet having the same configuration as the plug Do not use an adapter with this product Extension Cords e 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 e Make sure your extension cord is not damaged If an extension cord is necessary use 12 AWG 2 5 mm minimum to carry the current that the product draws e An undersized cord results in a drop in line voltage and loss of power and overheating 3A0997F 3 Warnings 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 e 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 p
34. osion To reduce risk of burns fire or explosion do not operate sprayer with cover removed Protect the internal drive parts of this sprayer from water Openings in the cover allow for air cooling of the mechanical parts and electronics To reduce risk of serious injury including electric AR te shock sprayer could malfunction or be permanently damaged e Do not touch moving or electric pars with fingers or tools while testing repair Prevent pump corrosion and damage from freez ing 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 e Unplug sprayer when power is not required for testing e Install all covers gaskets screws and washers before you operate sprayer e Keep all screws nuts washers gaskets and electri cal fittings removed during repair procedures These parts usually are not provided with replacement kits e Test repairs after problems are corrected e f 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 e Overspray may build up in the air passages Remove any overspray and residue from air pas sages and openings in the enclosures whenever you service sprayer e Do not operate the sprayer without the cover in place Replace if d
35. pinched to ground during assembly and pressure control switch needs to be replaced 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 Using ohmmeter to measure across two terminals in pressure control connector Continuity or closed cir cuit should exist when pressure control knob is set at maximum pressure full clockwise Replace pressure control switch if no continuity exists 3A0997F Control Board Diagnostics SP300 Mustang 3100 Control Board Diagnostics SP300 Mustang 3100 NOTE Check for motor problems before replacing con trol board A damaged motor may burn out a good con trol card Check for a damaged control board or pressure control switch as follows Relieve Pressure page 10 maa 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
36. place if necessary See List of Kits page 26 Pump packings are worn or Check for leaking around pump damaged 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 Pressure control switch has Replace pressure control switch using Pressure automatically relieving pres pinched wires Control Switch Kit page 26 sure through drain tube Water or paint entered pres Use Pressure Control Switch Kit to replace sure control switch or shorted switch See List of Kits page 26 control board Control board failed oee Control Board Diagnostics page 25 Replace damaged control board using Control Board Kit page 26 22 3A0997F Motor Diagnostics SP200 Mustang 2400 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 Trou
37. rotect 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
38. t 14 5 in 36 8 cm WE 12 4 in 31 5 KALA 17 91 45 5 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 9 30 F 160 35 C 71 C Operating Temperature Rangev 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 v Changes in paint viscosity at very low or very high temperatures can affect sprayer performance 3A0997F 35 Technical Data SP300 Mustang 3100 Electrical Power Requirements 120 Vac 60 Hz 15A 1 phase Working Pressure Range 3000 psi 0 21 MPa 0 207 bar Generator required 1500W minimum AN AA 5 8A permanent magnet DC Operating horsepower 3 4 POWEN COM 2 COR D e n Eee gee 16 AWG 3 wire 6 ft 1 8m FIUIG inlet HUIDO 2s es Up p t Sce ss 3 4 in internal thread standard garden hose thread Fluid outlet fitting llle 1
39. ted 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 If there is an uneven resistance or no resistance replace motor using Motor Kit page 26 23 Pressure Control Switch Diagnostics 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 18 2 24 Unplug power and Relieve Pressure 10 If paint is leaking from pressure control switch between pressure control knob and base replace pressure control switch 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 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
40. tures 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
Download Pdf Manuals
Related Search