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  5. Repair And Parts Manual

AIRLESSCO AllPro Mustang 2400 Repair And Parts Manual

Other manuals for AllPro Mustang 2400: Operation Manual

Summary of AllPro Mustang 2400

  • Page 1

    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 warni...

  • Page 2: Models

    Models 2 3a0997f 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 ...

  • Page 3: Warnings

    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 manu...

  • Page 4: Warning

    Warnings 4 3a0997f warning warning warning 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 c...

  • Page 5: Warning

    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 fr...

  • Page 6: Warning

    Warnings 6 3a0997f 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 equ...

  • Page 7: Installation

    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 ...

  • Page 8: Component Identification

    Component identification 8 3a0997f component identification a airless spray gun sprays fluid. B power switch 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 con...

  • Page 9

    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.

  • Page 10: Operation

    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 procedur...

  • Page 11: General Repair Information

    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 opera...

  • Page 12: Basic Troubleshooting

    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 cycl...

  • Page 13

    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...

  • Page 14

    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...

  • Page 15

    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 to...

  • Page 16

    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 gu...

  • Page 17: Advanced Troubleshooting

    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 troub...

  • Page 18

    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 volta...

  • Page 19

    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...

  • Page 20

    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 elec...

  • Page 21

    Advanced troubleshooting 3a0997f 21 general problem: erratic motor operation specific problem cause solution sprayer quits after running for 5 to 10 minutes building circuit is overloaded. Remove other loads from building circuit or find another circuit that has less load. See ground- ing and electr...

  • Page 22

    Advanced troubleshooting 22 3a0997f pump cycles, but output is low or surging. Leads from motor or pressure switch to control board are damaged, loose, pinched, or overheated. Be sure terminals are centered and firmly con- nected. Inspect for pinched wiring and wiring insulation and terminals for si...

  • Page 23

    Motor diagnostics (sp200, mustang 2400) 3a0997f 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, page10. 2. Remove ...

  • Page 24

    Pressure control switch diagnostics 24 3a0997f 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 ...

  • Page 25: Pump Diagnostics

    Control board diagnostics (sp300, mustang 3100) 3a0997f 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 con- trol card. Check for a damaged control board or pressure control switch as follows: 1. ...

  • Page 26: List of Kits

    List of kits 26 3a0997f 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 16e8...

  • Page 27: Parts

    Parts 3a0997f 27 parts sp200, model 24f557 and mustang 2400, model 24f559 parts list ▲ 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) ref. Part description qty. 1 16d672 kit, housing cover 1 1a ...

  • Page 28

    Parts 28 3a0997f sp200, model 24f557 and mustang 2400, model 24f559 17 15 14 16 18 31 7a 7b 32 32a 1 1a 37 23 24 25 1b 7 39 33 29 29c 29b 29a 38 35 34 36 35 22 30 ti17249a.

  • Page 29

    Parts 3a0997f 29 sp200, model 24f557 and mustang 2400, model 24f559 47b 44 43 41 32a 32a 40 68 51 47 47a 67 85 85a 84 67b 67a 41 ti17264b.

  • Page 30

    Parts 30 3a0997f sp300, model 24f558 and mustang 3100, 24f560 parts list ▲ replacement warning labels, tags, and cards are available at no cost. Ref. Part description qty. 23 121939 screw, mach 8-16 x 5/8 in. Plastite 4 29 16h348 suction tube 1 30 288716 kit, strainer 1 31 116295 tube clamp 1 32 195...

  • Page 31

    Parts 3a0997f 31 sp300, model 24f558 and mustang 3100, 24f560 81 58 56 68 59a 59 52 68a 85 45d 45 44 47 45a 45b 85 45c 42 110 41 30 33 32 53 34 29 31 63b 23 57 67a 67b 67c 67 46 63c 62b 62a 62 63a 63e 63 63d 50 49 55 37 40 51 39 ti16083a.

  • Page 32

    Parts 32 3a0997f sp300, model 24f558 and mustang 3100, 24f560 70 78 79 71a 77 80 76 75 74 71 71 72.

  • Page 33: Wiring Diagrams

    Wiring diagrams 3a0997f 33 wiring diagrams sp200, model 24f557 and mustang 2400, model 24f559 7)2).' 7()4% "/!2$ !54/ 0/7%2#/2$ ",!#+ ",!#+ -/4/2 ,%!$ 0/7%2#/2$ 7()4% ",!#+ -/4/2 ,%!$ ! 0/7%2#/2$ '2%%. #(!33)3 '2/5.$ /./&& 37)4#( 02%3352% thermal switch 1 1 when assembling motor to pump housing, mak...

  • Page 34

    Wiring diagrams 34 3a0997f sp300, model 24f558 and mustang 3100, 24f560 #(!33)3 7(4 '2. ",+ ",+ /./&& 37)4#( #/.42/, 7)2).' 0/7%2 02%3352% !54/ 2%& * * * * , , , , 7(4 ti9505a.

  • Page 35: Technical Data

    Technical data 3a0997f 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 . . . . . . . . . ...

  • Page 36

    Technical data 3a0997f 36 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 . . . . . . . . . . . . . . . . ....

  • Page 37: Notes

    Notes 3a0997f 37 notes.

  • Page 38: Airlessco Standard Warranty

    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 ...