AIRLESSCO SP200 Use and care manual

3A0997F
EN
Repair and Parts
SP200, SP300, AllPro Mustang 2400,
Mustang 3100
For portable spray application of architectural paints and coatings. For professional use
only.
See page 2 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Related Manuals
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
includes, but is not limited to, acetone, xylene,
toluene, or naptha. For more information about your
material request MSDS from distributor or retailer.
3A0994
SP200 Model 24F557
Mustang 2400 Model 24F559
Series A, B, C
SP300 Model 24F558
Mustang 3100 Model 24F560
Series A

Models
23A0997F
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
Dispense Rate gpm
(lpm)
Hose Length and
Diameter Gun Model Maximum Working Pressure
SP200
Mustang 2400 A, B, C 0.24 gpm (0.91 lpm)
1/4 in. x 25 ft
(6.4 mm x 7.5 m) 200 Series 2800 psi (19 MPa, 193 bar)
SP300
Mustang 3100 A0.34 gpm (1.29 lpm)
1/4 in. x 50 ft
(6.4 mm x 15m) 500 Series 3000 psi (21 MPa, 207 bar)

Warnings
3A0997F 3
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.
WARNINGWARNINGWARNING
WARNING
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.
• 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 mm2) minimum to carry the current that the product draws.
• An undersized cord results in a drop in line voltage and loss of power and overheating.
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Warnings
43A0997F
WARNINGWARNINGWARNING
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• 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.

Warnings
3A0997F 5
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.
WARNINGWARNINGWARNING
WARNING

Warnings
63A0997F
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.
WARNINGWARNINGWARNING
WARNING

Installation
3A0997F 7
Installation
Grounding and Electric
Requirements
• 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 mm2)
• 100 ft (30.0 m) 12 AWG (3.3 mm2)
Spray gun:ground through connection to a properly
grounded fluid hose and pump.
NOTE: Smaller gauge or longer extension cords may
reduce sprayer performance.
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.
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.
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.
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.
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To reduce risk of injury from motor starting
unexpectedly when it cools, always turn power switch
OFF if motor shuts down.
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Component Identification
83A0997F
Component Identification
AAirless spray gun Sprays fluid.
BPower switch Turns sprayer ON and OFF.
CPressure control knob Increases (clockwise) and decreases (counter-clockwise) fluid
pressure in pump, hose, and spray gun.
DPump fluid outlet fitting Threaded connection for paint hose.
EInstaClean™fluid filter
(SP300, Mustang 3100)
• Filters fluid coming out of pump to reduce tip plugging and
improve finish.
• Self cleans only during pressure relief.
FProX Power-Piston™Pump (behind
Easy Access door, not shown)
(SP300, Mustang 3100)
Pumps and pressurizes fluid and delivers it to paint hose.
F1 Easy Access™door
(SP300, Mustang 3100)
Easy Access door permits quick access to outlet valve. To
remove door, insert flat blade of screwdriver into slot on the bot-
tom of the door.
GSuction tube Draws fluid from paint pail into pump.
HPrime tube (with diffuser) Drains fluid in system during priming and pressure relief.
JPrime/Spray valve • 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.
LInlet screen Prevents debris from entering pump.
MPaint hose Transports high-pressure fluid from pump to spray gun.
QTip guard Reduces risk of fluid injection injury.
RReversible spray tip • Atomizes fluid being sprayed, forms spray pattern and
controls fluid flow according to hole size.
• Reverse unclogs plugged tips without disassembly.
SGun trigger safety lever (page 10) Prevents accidental triggering of spray gun.
TGun fluid inlet fitting Threaded connection for paint hose.
UPower Flush attachment Connects garden hose to suction tube for power flushing
water-base fluids.
VGun fluid filter Filters fluid entering spray gun to reduce tip clogs.
XPail Hanger
(SP300, Mustang 3100)
For transporting pail by its handle.

Component Identification
3A0997F 9
C
W
B
L
H
G
J
F
U
F1
D
E
X
M
Q
R
A
S
T
V
V
Mustang 2 ASM 500 ti15983a

Operation
10 3A0997F
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.
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.
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.
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.
Pressure Control Knob Settings
NOTE: To select function, align symbol on pressure control knob with setting indicator on sprayer.
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Trigger Locked Mustang 2
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Trigger Unlocked Mustang 2
Trigger Locked ASM 500
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Trigger Unlocked ASM 500
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High Pressure
Spray
Low Pressure
Spray Prime/ Clean Rolling
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General Repair Information
3A0997F 11
General Repair Information
• Keep all screws, nuts, washers, gaskets, and electri-
cal fittings removed during repair procedures. These
parts usually are not provided with replacement kits.
• Test repairs after problems are corrected.
• If sprayer does not operate properly, review repair
procedure to verify you did it correctly. See 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 pas-
sages 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.
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.
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 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.

Basic Troubleshooting
12 3A0997F
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.
• Check that lighted plug on
sprayer is lit (this indicates
electric power at outlet).
• 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.

Basic Troubleshooting
3A0997F 13
Pump does not prime. Prime/Spray Valve is in SPRAY
position.
Turn Prime/Spray Valve to PRIME
position (pointing down).
Inlet screen is clogged or suction
tube is not immersed.
Clean debris off inlet screen and
make sure suction tube is immersed
in fluid.
Pump was not primed with flushing
fluid.
Remove suction tube from paint.
Prime pump with water or sol-
vent-based flushing fluid, see Oper-
ation manual 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.
Problem Cause Solution

Basic Troubleshooting
14 3A0997F
Pump cycles but does not build up
pressure.
Prime/Spray valve in PRIME posi-
tion (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.
Pump cycles, but paint only dribbles
or spurts when spray gun is trig-
gered.
Pressure is set too low. Slowly turn pressure control knob
clockwise to increase pressure set-
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.
(SP300, Mustang 3100)
Clean or replace InstaClean fluid fil-
ter, 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.
Problem Cause Solution

Basic Troubleshooting
3A0997F 15
Pressure is set at maximum but
cannot achieve a good spray pat-
tern.
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
of sprayer.
Replace spray tip.
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 fil-
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
added).
Remove extra section of hose.
Spray gun stopped spraying. Pump
is not cycling.
Spray tip is clogged. Unclog spray tip, see Operation
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.
Problem Cause Solution

Basic Troubleshooting
16 3A0997F
Fan pattern varies dramatically
while spraying.
OR
Sprayer does not turn on promptly
when resuming spraying.
Pressure control switch is worn and
causing excessive pressure varia-
tion.
Take sprayer to Graco/Airlessco
authorized service center.
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-
trol switch.
Pressure control switch is worn. Take sprayer to Graco/Airlessco
authorized service center.
Prime/Spray valve actuates auto-
matically relieving pressure through
prime tube.
System is over pressurizing. Take sprayer to Graco/Airlessco
authorized service center.
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.
Keep vent holes clear of obstruc-
tions and overspray and keep
sprayer open to air.
Extension cord is too long or not a
heavy enough gauge.
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.
Problem Cause Solution

Advanced Troubleshooting
3A0997F 17
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
Power switch is on and
sprayer is plugged in; pump
does not cycle.
See Basic Troubleshooting,
page 12.
Basic mechanical problems. Paint is frozen or hardened in
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. 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.
SP300, Mustang 3100: Yoke
is broken because pump is
locked up due to dried paint or
worn packings.
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.

Advanced Troubleshooting
18 3A0997F
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, improp-
erly 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 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
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
you have determined the
armature is good. A damaged
armature can burn out a good
control board.
See Control Board Diagnostics, page 25.
Replace control board if damaged using Control
Board Kit, page 26.
Specific Problem Cause Solution

Advanced Troubleshooting
3A0997F 19
Sprayer Wiring Problems
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 cord damaged. 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.
Sprayer power switch
damaged.
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.
Motor thermal overload cutoff
switch damaged.
WARNING: See Startup
Hazard After Thermal
Overload on page 7.
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.
Specific Problem Cause Solution

Advanced Troubleshooting
20 3A0997F
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.
Sprayer electrical wiring is
pinched or insulation is dam-
aged.
Repair or replace any damaged wiring or termi-
nals. Securely reconnect wires.
Wires between pressure con-
trol switch and control board
are pinched.
Motor armature is shorting. Check for shorts. See Motor Diagnostics, page
23. If shorts are evident, replace motor using
Motor Kit, page 26.
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.
See Control Board Diagnostics, page 25.
Replace control board if damaged using Control
Board Kit, page 26.
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 power cord dam-
aged.
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.
Sprayer power switch dam-
aged.
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.