Graco 3A2494D User Manual

Instructions-Parts

Pro

Pro Pro

Gun

Gun Gun

For

For For
For

For For
professional

professional professional

100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure

See

See See
numbers

numbers numbers
information.

information. information.

Xp™

Xp™ Xp™

use

use use
use

use use

Class

in ininClass Class

in

Group

in in

Group Group

use

use use

Important

Important Important
Readallwarningsandinstructionsinthismanual.
Save

these

Save Save

these these

page

page page

for

3 33for for

and

and and

Electrostatic

Electrostatic Electrostatic

Div.

I, I,I,Div. Div.

II,

II, II,

only.

only. only.

Safety

Safety Safety

instructions.

instructions. instructions.

model

model model

approval

approval approval

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

part

part part

Air

Air Air

Spray

Spray Spray

3A2494D

EN

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

using

Group

using using

Group Group

Locations

Locations Locations

spray

D DDspray spray

materials.

materials. materials.

using

Group

using using

Group Group

IIA

spray

IIA IIA

spray spray

materials.

materials. materials.

For

For For

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

Models...............................................................3

Warnings...........................................................4

GunOverview....................................................7

HowtheElectrostaticSprayGun

Works............................................7

Controls,Indicators,andComponents...........8

SmartGuns.................................................9

Installation..........................................................15

WarningSign...............................................15

VentilatetheSprayBooth.............................15

AirSupplyLine............................................16

FluidSupplyLine.........................................16

GunSetup..........................................................18

GunSetupChecklist....................................18

Grounding...................................................21

CheckGunElectricalGrounding...................25

CheckFluidResistivity.................................26

CheckFluidViscosity...................................26

FlushBeforeUsingEquipment......................26

GuidelinesforAbrasiveMaterials..................26

Operation...........................................................27

PressureReliefProcedure............................27

Startup........................................................27

Shutdown....................................................27

Maintenance......................................................28

Flushing......................................................28

CleantheGunDaily.....................................29

DailySystemCare.......................................30

ElectricalTests...................................................31

TestGunResistance....................................31

TestPowerSupplyResistance.....................32

TestElectrodeResistance............................32

Troubleshooting..................................................33

SprayPatternTroubleshooting......................33

GunOperationTroubleshooting....................34

ElectricalTroubleshooting............................35

Repair................................................................37

PreparetheGunforService.........................37

AirCapandNozzleReplacement..................38

ElectrodeReplacement................................39

FluidPackingRodRemoval..........................40

PackingRodRepair.....................................40

BarrelRemoval............................................42

BarrelInstallation.........................................42

PowerSupplyRemovaland

Replacement..................................43

AlternatorRemovalandReplacement...........44

FluidTubeRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................47

AtomizingAirRestrictorValveRepair............48

ESOn-OffandFluidAdjustmentValve

Repair............................................49

AirValveRepair...........................................50

SmartModuleReplacement..........................51

AirSwivelandExhaustValve

Replacement..................................52

Parts..................................................................53

StandardAirSprayGunAssembly................53

RoundSprayAssembly................................55

StandardHighConductivityAirSprayGun

Assembly.......................................56

SmartHighConductivityAirSprayGun

Assembly.......................................58

SmartAirSprayGunAssembly.....................60

PackingRodAssembly.................................62

AlternatorAssembly.....................................63

ESOn-OffandFluidAdjustmentValve...........64

FanAirAdjustmentValveAssembly..............65

AtomizingAirRestrictorValve

Assembly.......................................65

SmartModuleAssembly...............................66

HighConductivityFluidTube

Assembly.......................................67

AirCapsandFluidNozzles.................................68

FluidNozzleSelectionChart.........................68

FluidNozzlePerformanceCharts..................68

AirCapSelectionChart................................70

AirConsumptionCharts...............................71

RepairKits,RelatedManuals,and

Accessories..........................................73

GunAccessories..........................................73

OperatorAccessories...................................74

SystemAccessories.....................................74

TestEquipment...........................................74

Hoses.........................................................75

Dimensions........................................................76

TechnicalData...................................................77

GracoProXpWarranty.......................................78

2

3A2494D

Models

Models

Models Models

Part

No.

Part Part

No. No.

L40T1040

L40T1440

L40T1540

L40T1640

L60T1060

L60T1160

L60T1260

L60T1660

L60M1060

L60M1260

L60M1660

L85T1085

L85T1685

L85M1085

kV

kV kV

1.5

1.5 1.5
mm

mm mm

Nozzle

Nozzle Nozzle

Round

1.2

Round Round

1.2 1.2
Spray

mm

Spray Spray

mm mm

✔✔✔

✔✔✔✔

✔✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

✔✔✔

Standard

Standard Standard
Display

Display Display

Smart

Smart Smart
Display

Display Display

Standard

Standard Standard
Coatings

Coatings Coatings

High

High High
Conductivity/

Conductivity/ Conductivity/
High

Wear

High High

Wear Wear

Increased

Increased Increased
Transfer

Transfer Transfer
Ef󰘰ciency

Ef󰘰ciency Ef󰘰ciency

L85M1685

✔✔✔

G

II IIII2 22G G

EEx0.24mJT6

FM12ATEX0068

EN50050

Ta0°C–50°C

3A2494D 3

Warnings

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inwork work
prevent󰘰re,explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorcloseto
sprayarea.Resistancemustnotexceed1megohm.SeeGrounding Grounding

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.
Stop

•Stop Stop

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilatingfansareon.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworking󰘰reextinguisherintheworkarea.

operation

operation operation

equipmentuntilyouidentifyandcorrecttheproblem.

5°Caboveambienttemperature.

plasticdropcloths(potentialstaticarc).

AND

ELECTRIC

AND AND

ELECTRIC ELECTRIC

immediately

immediately immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

SHOCK

SHOCK SHOCK

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelp

Grounding

instructions.

4

3A2494D

WARNING

WARNING WARNING

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

Warnings

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

PLASTIC

PLASTIC PLASTIC
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.

•SeeTechnical Technical
solventmanufacturer’sMSDSsandrecommendations.

TOXIC

TOXIC TOXIC
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadMSDS’stoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.

PERSONAL

PERSONAL PERSONAL
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:

Pressure

PARTS

PARTS PARTS

Technical

FLUID

FLUID FLUID

OR

OR OR

PROTECTIVE

PROTECTIVE PROTECTIVE

Relief

Procedure

Relief Relief

Procedure Procedure

CLEANING

CLEANING CLEANING

Data

Data Data

inthisandallotherequipmentinstructionmanuals.Read󰘱uidand

FUMES

FUMES FUMES

SOLVENT

SOLVENT SOLVENT

EQUIPMENT

EQUIPMENT EQUIPMENT

whenyoustopspraying/dispensingandbefore

HAZARD

HAZARD HAZARD

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.

3A2494D 5

Warnings

WARNING

WARNING WARNING

EQUIPMENT

EQUIPMENT EQUIPMENT
Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

MISUSE

MISUSE MISUSE

HAZARD

HAZARD HAZARD

Technical

Data

Data Data

Pressure

inallequipmentmanuals.

Relief

Relief Relief

Technical

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Data

Data Data

6 3A2494D

GunOverview

Gun

Gun Gun

How

How How

Theairhosesuppliesairtothespraygun.Partof
theairoperatesthealternatorturbineandtherest
oftheairatomizesthe󰘱uidbeingsprayed.The
alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Spray

Spray Spray

Gun

Gun Gun

Works

Works Works

Thepumpsupplies󰘱uidtothe󰘱uidhoseandgun,
wherethe󰘱uidiselectrostaticallychargedasit
passestheelectrode.Thecharged󰘱uidisattracted
tothegroundedworkpiece,wrappingaroundand
evenlycoatingallsurfaces.

3A2494D

7

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowing
controls,indicators,andcomponents(seeFig.

1).ForinformationonSmartguns,alsosee

SmartGuns,page9.

Figure1GunOverview

Item

Item Item

Indicators,

Indicators, Indicators,

Descrip-

Descrip- Descrip­tion

tion tion

Purpose

Purpose Purpose

and

Components

and and

Components Components

Item

Item Item

Descrip-

Descrip- Descrip­tion

tion tion

Purpose

Purpose Purpose

A

BFluidInlet

C

D

EElectrode

FFanAir

G

AirSwivel
Inlet

TurbineAir
Exhaust

AirCap
and
Nozzle

Needle

Adjust­ment
Valve

Atomizing
Air
Restrictor
Valve

1/4npsm(m)left-handthread,
forGracogroundedairsupply
hose.

3/8npsm(m),for󰘱uidsupply
hose.

Barbed󰘰tting,forsupplied
exhausttube.

SeeAirCapsandFluid

Nozzles,page68,foravail-

ablesizes.

Supplieselectrostaticcharge
tothe󰘱uid.

Adjustsfansizeandshape.
Canbeusedtodecrease
patternwidth.

Restrictsaircapair󰘱ow.
Replacewithplug(included)
ifdesired.

HFluidAd-

justment
Knob

J

K

ESOn-Off
Valve

ESIndica­tor(stan­dardgun
only;for
Smartgun
indica­tor,see

Operating
Mode,
page9)

Adjusts󰘱uid󰘱owbylimiting
󰘱uidneedletravel.Useonly
inlow󰘱owconditions,to
reducewear.

TurnselectrostaticsON(I)or
OFF(O).

LitwhenESisON(I).Colorin­dicatesalternatorfrequency.
SeetheLEDindicatortable
intheGunSetupChecklist,

page18.

8 3A2494D

GunOverview

Smart

Smart Smart

TheSmartGunmoduledisplayssprayingvoltage,
current,alternatorspeed,andthevoltagesetting(low
orhigh).Italsoallowstheusertochangetoalower
sprayingvoltage.Themodulehastwomodes:

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2,andTable1onpage10.TheOperating
Modedisplaysgundataduringnormalspraying.The
displayusesabargraphtoshowthevoltagelevelin
kiloVolts(kV)andthecurrentlevelinmicroAmperes
(uA).Thebargraphrangeisfrom0to100%foreach
value.

IfthebargraphLEDsareblue,thegunisreadyto
spray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee

ElectricalTroubleshooting,page35forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

•Thelowvoltageindicator(LO)lights
whentheswitchissettoLO.Thelow
voltagesettingisuseradjustable.See

AdjustingtheLowVoltageSetting,page10.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Hz

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafter1second,
increasetheairpressure.

•Iftheindicatorchangestoredafter1second,
reducetheairpressure.

Figure2SmartGunModuleinOperatingMode

3A2494D 9

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3,andTable1onpage10.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page35.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

NOTE: NOTE:
appear.Ifthegunhasbeendisassembled,wait8
secondsbeforesprayingtoensurethatanError
conditionhasnotoccurred.

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4,andTable1onpage10.The
possiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsettingitwillreturntotheminimumsetting

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5,
andTable1onpage10.

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

10 3A2494D

GunOverview

Table

Table Table

Item

Item Item

VA

LO

kV

uA

LSLOSETbutton

Key

for

Figs.

1 11. ..Key Key

for for

2–9.

Figs. Figs.

2–9. 2–9.

Description

Description Description

VoltageAdjustmentSwitch

LowVoltageModeIndicator

Voltage(kV)Display

Current(uA)Display

Purpose

Purpose Purpose

Two-positionswitchsetssmart
gunvoltagetolowsetting(LO)or
highsetting(HI).Thisswitchis
functionalinOperatingModeand
inDiagnosticMode.

Lights(blue)whenthesmartgun
issettoLowVoltage.

Displaysactualsprayingvoltage
ofthegun,inkV.InOperating
Mode,displayisabargraph.
InDiagnosticMode,voltageis
displayedasanumber.

Displaysactualsprayingcurrent
ofthegun,inuA.InOperating
Mode,displayisabargraph.
InDiagnosticMode,currentis
displayedasanumber.

Pressmomentarilytoenterthe
LowVoltageSettingscreen.

Pressandholdforapproximately5
secondstoenterorexitDiagnostic
Mode.

WhileinDiagnosticMode,press
momentarilytoadvancethrough
screens.

WhileontheLowVoltageLock
Screen(inDiagnosticMode),
pressandholdtoturnthelockon
oroff.

LVLowVoltageDisplayDisplaysthelowvoltagesetting

asanumber.Thesettingcanbe
changed.SeeFig.4.

LKLowVoltageLocked

Appearsifthelowvoltagesetting
islocked.SeeFig.5andFig.9.

3A2494D

11

GunOverview

Item

Item Item

LD

ERErrorDisplay

VIVoltageIndicatorInDiagnosticMode,thetwotop

CICurrentIndicator

ASAlternatorSpeedDisplay

Hz

Description

Description Description

LODisplay

AlternatorSpeedIndicatorInOperatingMode,indicatorcolor

Purpose

Purpose Purpose

AppearsontheLowVoltageLock
Screen.SeeFig.9.

AppearsiftheSmartmoduleloses
communicationwiththepower
supply.SeeFig.3.

rightLEDsofthescreenlight,
indicatingthatthevaluedisplayed
isinkV.SeeFig.6.

InDiagnosticMode,thetwo
bottomrightLEDsofthescreen
light,indicatingthatthevalue
displayedisinuA.SeeFig.7.

InDiagnosticMode,Hzlevelis
displayedasanumber.SeeFig.

8.

variestoshowthealternator
speedstatus:

•greenindicatesthealternator
speedisatthecorrectlevel.

•Iftheindicatorchangestoamber
after1second,thealternator
speedistoolow.

•Iftheindicatorchangestored
after1second,thealternator
speedistoohigh.Theindicator
willalsoturnrediftheError
displayappears.

InDiagnosticMode,theindicator
isgreenwhenintheAlternator
Speed(Hertz)screen.

12

3A2494D

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

NOTE: NOTE:
lowvoltagesetting;thesettingisnotadjustablein
DiagnosticMode.However,thevoltageadjustment
switch(VA)canbesettoHIorLOinOperatingMode
andinDiagnosticMode.

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page13.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Voltage

Voltage Voltage

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7,andTable
1onpage10.Toenterthisscreen,presstheLO
SETbuttonwhileintheVoltage(kiloVolts)Screen.

Thisscreendisplaysthesprayingcurrentofthegun
asanumber(uA),roundedtothenearest5uA.The
twobottomrightLEDs(CI)ofthedisplaypanellight,
indicatingthattheCurrent(microAmperes)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6,
andTable1onpage10.Toenterthisscreen,press
andholdtheLOSETbuttonforapproximately5
secondswhileintheOperatingMode.

Thisscreendisplaysthesprayingvoltageofthe
gunasanumber(kV),roundedtothenearest5kV.
ThetwotoprightLEDs(VI)ofthedisplaypanel
light,indicatingthattheVoltage(kiloVolts)Screen
isdisplayed.Thedisplayisareadoutandcannot
bechanged.

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

3A2494D 13

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8,andTable
1onpage10.Toenterthisscreen,presstheLOSET
buttonwhileintheCurrent(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3digit
number(AS),roundedtothenearest10Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourthscreenin
theDiagnosticMode.SeeFig.9,andTable1on
page10.Toenterthisscreen,presstheLOSET
buttonwhileintheAlternatorSpeed(Hertz)Screen.

ThisscreendisplaysthestatusoftheLowVoltage
Lock.Ifthesettingislocked,thelockimage(LK)
appearstotheleftoftheLodisplay(LD).Ifthesetting
isunlocked,thelockimagedoesnotappear.

Tochangethelockstatus,pressandholdthe
LOSETbuttonuntilthelockimageappearsor
disappears.Ifthelockisset,theimagewillalso
appearontheLowVoltageSettingScreenwhenin
lowvoltagemode(seeFig.4).

NOTE:

NOTE: NOTE:
screen,becausepressingandholdingtheLOSET
buttonisusedtoturnthelockonoroff.Toexit,
pressLOSETmomentarilytoreturntotheVoltage
(kiloVolts)Screen,thenexitDiagnosticModefrom
there.

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

14

Figure9LowVoltageLockScreen

3A2494D

Installation

Installation

Installation Installation

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.

•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
HazardousLocationoraGroupII,ZoneI
ExplosiveAtmosphereLocation.

•Complywithallapplicablelocal,state,and
national󰘰re,electrical,andothersafety
regulations.

Fig.10showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

Ventilate

Ventilate Ventilate

Providefreshairventilationtoreducetheriskof󰘰re
orexplosioncausedbythebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Donotoperatethegununlessventilation
fansareoperating.

Electricallyinterlockthegunairsupplywiththe
ventilatorstopreventgunoperationwithout
ventilatingfansoperating.Checkandfollowalllocal,
state,andnationalcodesregardingairexhaust
velocityrequirements.

Highvelocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.Airexhaust
velocityof100ft/min(31linearmeters/minute)should
besuf󰘰cient.

Sign

Sign Sign

the

Spray

the the

Spray Spray

Booth

Booth Booth

3A2494D 15

Installation

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

1.SeeFig.10.UsetheGracoGroundedAirSupply
Hose(AH)tosupplyairtothegun.Thegunair
inlet󰘰ttinghasaleft-handthread.Theairsupply
hosegroundwire(AG)mustbeconnectedtoa
trueearthground.Donotconnecttheairsupply
hosetothegunairinletyet.

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Air Air

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

Supply

Supply Supply

2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto

3.Installa󰘱uid󰘰lter(FF)nearthepumpoutlet,to

Supply

Supply Supply

withsolvent.Usesolventwhichiscompatible
withthe󰘱uidtobesprayed.Donotconnectthe
󰘱uidsupplylinetothegun󰘱uidinletyet.

control󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog
thespraynozzle.

Line

Line Line

2.Installanairline󰘰lter/waterseparator(AF)onthe
gunairlinetoensureadry,cleanairsupplytothe
gun.Dirtandmoisturecanruintheappearance
ofyour󰘰nishedworkpieceandcancausethe
guntomalfunction.

3.Installbleed-typeairregulators(PR,GR)on
thepumpandgunairsupplylinestocontrolair
pressuretothepumpandgun.

Trappedaircancausethepumptocycle
unexpectedly,whichcanresultinserious
injury,includingsplashing󰘱uidintheeyesor
ontheskin.Donotoperatetheequipment
withoutthebleed-typeairvalve(BV)installed.

4.Installableed-typeairvalve(BV)onthepump
airsupplyline.Thebleed-typeairvalve(BV)is
requiredinyoursystemtoshutoffairtothepump
andrelieveairtrappedbetweenthevalveand
thepumpaftertheairregulatorisshutoff.Install
anadditionalbleed-typeairvalveonthemainair
line(MA)toisolatetheaccessoriesforservicing.

Toreducetheriskofseriousinjury,including
splashing󰘱uidintheeyesorontheskin,do
notoperateequipmentwithoutthe󰘱uiddrain
valve(FD)installed.

4.The󰘱uiddrainvalve(FD)isrequiredinyour
systemtoassistinrelieving󰘱uidpressureinthe
displacementpump,hose,andgun.Triggering
theguntorelievepressuremaynotbesuf󰘰cient.
Installadrainvalveclosetothepump's󰘱uid
outlet.

5.Installanairbleedvalve(BV)oneachgunair
supplylinetoshutoffairtothegun(s)andrelieve
airtrappedbetweenthevalveandthegunafter
theairregulatorisshutoff.

16 3A2494D

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

AREA

AREA AREA

HAZARDOUS

HAZARDOUS HAZARDOUS

AREA

AREA AREA

Figure10TypicalInstallation

Typical

Typical Typical

Installation

Installation Installation

Item

Item Item

ADAirLineDrainValve

AF

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FL

FRFluidPressureRegulator

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

FV

GRGunAirPressureRegulator

MA

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE:
asaGracoaccessory.

Thesolenoidvalveisnotoffered

3A2494D

17

GunSetup

Gun

Gun Gun

Gun

Gun Gun

SeeFig.11tolocatetheelectrostaticguncontrols.

Figure11ElectrostaticGunControls

1.Thegunisshippedwiththe󰘱uidnozzleandair

2.TurnOFF(O)theESOn-Offswitch(J).

Setup

Setup Setup

Setup

Setup Setup

capinstalled.Checkthattheretainingringis
tight.

NOTE:

NOTE: NOTE:
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page68and
AirCapSelectionChart,page70.To

installthenozzleandaircap,see

AirCapandNozzleReplacement,page38.

Toselectadifferent

Checklist

Checklist Checklist

5.ConnecttheGracogroundedairhosetothegun
airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.

6.FollowallstepsunderGrounding,page21.

7.Followallstepsunder

CheckGunElectricalGrounding,page25.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets
requirementsforelectrostaticspray.See

CheckFluidResistivity,page26.

9.Connecttheexhausttubeandsecurewiththe
clampprovided.

10.Connectthe󰘱uidhosetothegun󰘱uidinlet.

3.Shutofftheairbleedvalvetothegun.

11.Flushifneeded,seeFlushing,page28.

12.Positiontheaircapasdesired.

4.Checkgunresistance.See

TestGunResistance,page31.

18 3A2494D

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)

counterclockwise.

14.Fullyopenthe󰘱uidadjustmentvalve(H)

counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)

clockwise.

17.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.See
thetablebelow.

Table

Table Table

mm]

mm] mm]

18.CheckthattheESindicator(K)[Hzindicatoron
Smartguns]islit.Seethefollowingtable.

Table

Table Table

Pressure

2 22. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

(using

(using (using

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

LED

3 33. ..LED LED

Drop

Drop Drop

(m)

in.

[8

in. in.

[8 [8

hose)

hose) hose)

Indicator

Indicator Indicator

Colors

Colors Colors

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

[with

gun

[with [with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

triggered]

triggered] triggered]

bar)

bar) bar)

16.TurnON(I)theESOn-Offswitch(J).

Indicator

Indicator Indicator

Color

Color Color

Green

Amber

Red

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
after1second,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
after1second,theairpressureis
toohigh.Decreaseairpressure
untiltheindicatorisgreen.

Description

Description Description

3A2494D 19

GunSetup

19.Shutofftheairtothegun.TurnOFF(O)theES
On-Offswitch(J).

20.Startthepump.Adjustthe󰘱uidregulatoruntilthe
streamfromtheguntravels8-12in.(200-300
mm)beforefallingoff.Typically,if󰘱uidpressure
isbelow5psi(.04MPa,0.4bar)orabove30psi
(0.21MPa,2.1bar),achangeofnozzlesizeis
recommended.

22.Sprayatestpattern.Checktheatomization.If
over-atomizationoccursatminimumpressure,
adjusttherestrictorvalve.Ifatomizationis
inadequate,increaseairpressureordecrease
󰘱uid󰘱ow.

23.Adjustthefanairadjustmentvalve:clockwisefor
anarrowerpattern,counterclockwiseforawider
pattern.

21.Turnontheairtothegun.TurnON(I)theES
On-Offswitch(J).

24.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page33.

20 3A2494D

GunSetup

Grounding

Grounding Grounding

Whenoperatingtheelectrostaticgun,any
ungroundedobjectsinthesprayarea(people,
containers,tools,etc.)canbecomeelectrically
charged.Impropergroundingcanresultinstatic
sparking,whichcancausea󰘰re,explosion,or
electricshock.Groundallequipment,personnel,
objectbeingsprayed,andconductiveobjects
inorclosetothesprayarea.Resistancemust
notexceed1megohm.Followthegrounding
instructionsbelow.

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem(seeFigs.12–15).
Yoursystemmayincludeotherequipmentorobjects
whichmustbegrounded.Checkyourlocalelectrical
codefordetailedgroundinginstructions.Yoursystem
mustbeconnectedtoatrueearthground.

•

Pump/󰘱uid source:

byconnectingitsgroundwiretoatrueearth
ground.

groundthepump/󰘱uidsource

•

Object being sprayed:

cleanandgroundedatalltimes.

•

All electrically conductive objects or devices in the
spray area:

•

Fluid and waste containers:

wastecontainersinthesprayarea.Donotusepail
linersunlesstheyareconductiveandgrounded.
When󰘱ushingthespraygun,thecontainerused
tocatchtheexcess󰘱uidmustbeelectrically
conductiveandgrounded.

Air compressors:

•

tothemanufacturer'srecommendations.

mustbeproperlygrounded.

keeptheworkpiecehangers

groundall󰘱uidand

groundtheequipmentaccording

•

Electrostatic Air Spray Gun:

byconnectingtheGracoGroundedAirHose
(AH)tothegun,andconnectingtheairhose
groundwiretoatrueearthground.See

CheckGunElectricalGrounding,page25.

groundthegun

•

All air and 󰘱uid lines

Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.

mustbeproperlygrounded.

3A2494D

21

GunSetup

•

The 󰘱oor of the spray area:

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

All persons entering the spray area:

shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.

mustwear

•

Flammable liquids in the spray area:

inapproved,groundedcontainers.Donotuse
plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.

mustbekept

Key

Key Key

Fig.12

Fig.13

Fig.14

Fig.15Fluidsupplylineandsourcemust

Figs.

to totoFigs. Figs.

12–15

12–15 12–15

Operatorisgroundedthrough
bareskincontactwiththegun
handleandconductiveshoes.A
conductiveglovecanalsobeused.

Objectbeingsprayedisgrounded
throughcontactwiththehanger
andconveyorsystem.

Gunisgroundedthroughthe
conductiveairhose.

begrounded.

22

3A2494D

Figure12GroundtheOperator

GunSetup

Figure13GroundtheObjectBeingSprayed

3A2494D 23

GunSetup

Figure14GroundtheGun

Figure15GroundtheFluidSupply

24

3A2494D

GunSetup

Check

Check Check

MegohmmeterPartNo.241079(AA-seeFig.

16)isnotapprovedforuseinahazardousarea.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous

•Orallsprayingdevicesinthehazardousarea

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.241079Megohmmeterisavailable
asanaccessorytocheckthatthegunisproperly
grounded.

Gun

Gun Gun

area;

areturnedoff,ventilationfansinthehazardous
areaareoperating,andthereareno󰘱ammable
vaporsinthearea(suchasopensolvent
containersorfumesfromspraying).

Electrical

Electrical Electrical

Grounding

Grounding Grounding

5.Makesurethegroundedairhose(AH)is

connectedandthehosegroundwireis
connectedtoatrueearthground.

6.Measuretheresistancebetweenthegunhandle

(BB)andatrueearthground(CC).Usean
appliedvoltageof500minimumto1000volts
maximum.Theresistanceshouldnotexceed1
megohm.SeeFig.16.

7.Iftheresistanceisgreaterthan1megohm,check

thetightnessofthegroundconnectionsandbe
suretheairhosegroundwireisconnectedtoa
trueearthground.Iftheresistanceisstilltoo
high,replacetheairhose.

1.Haveaquali󰘰edelectricianchecktheelectrical
groundingcontinuityofthespraygunandair
hose.

2.TurnOFF(O)theESOn-Offswitch.

3.Turnofftheairand󰘱uidsupplytothegun.Follow
thePressureReliefProcedure,page27.

4.Disconnectthe󰘱uidhose.

Figure16CheckGunElectricalGrounding

3A2494D 25

GunSetup

Check

Check Check

Toreducetheriskof󰘰re,explosion,orelectric
shock,checkthe󰘱uidresistivityinanon-hazardous
areaonly.ResistanceMeter722886andProbe
722860arenotapprovedforuseinahazardous
area.

Failuretofollowthiswarningcouldcause󰘰re,
explosion,orelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.722886ResistanceMeterand
722860Probeareavailableasaccessoriestocheck
thattheresistivityofthe󰘱uidbeingsprayedmeets
therequirementsofanelectrostaticairspraysystem.

Followtheinstructionsincludedwiththemeterand
probe.Readingsof25megohms-cmandabove
providethebestelectrostaticresults.

Ahighconductivitykitorhighconductivityhosemay
berequiredforreadingslessthan25megohm-cm.

Table

Table Table

Fluid

Fluid Fluid

Fluid

4 44. ..Fluid Fluid

Resistivity

Resistivity Resistivity

Resistivity

Resistivity Resistivity

Levels

Levels Levels

Check

Check Check

Tocheck󰘱uidviscosityyouwillneed:

•aviscositycup

•astopwatch.

1.Completelysubmergetheviscositycupin

2.Watchthestreamof󰘱uidcomingfromthebottom

3.Recordthe󰘱uidtype,elapsedtime,andsizeof

4.Iftheviscosityistoohighortoolow,contactthe

Flush

Flush Flush

Theequipmentwastestedin󰘱uidatthefactory.To
avoidcontaminatingyour󰘱uid,󰘱ushtheequipment
withacompatiblesolventbeforeusingtheequipment.

Guidelines

Guidelines Guidelines

Fluid

Fluid Fluid

the󰘱uid.Liftthecupoutquickly,startingthe
stopwatchassoonasthecupiscompletely
removed.

ofthecup.Assoonasthereisabreakinthe
stream,shutoffthestopwatch.

theviscositycup.

materialsupplier.Adjustasnecessary.

Before

Before Before

Viscosity

Viscosity Viscosity

Using

Using Using

for

Abrasive

for for

Abrasive Abrasive

Equipment

Equipment Equipment

Materials

Materials Materials

Megohms

Megohms Megohms

1–77–2525–200200–2000

HighCon­ductivity
Kitrecom­mended

HighCon­ductivity
Kitmaybe
needed

cm

- --cm cm

Bestelec­trostatic
results

Goodelec­trostatic
results

Whensprayingabrasivematerials,followthese
guidelines:

•OrderPartNo.24N704Electrode(blue)for
abrasivematerials.

•Sizethenozzleproperlytoreduce󰘱uidpressure
below30psi(0.21MPa,2.1bar),producingan
8–12in.(200–300mm)󰘱uidstream.

•Operatethegunwiththe󰘱uidadjustmentknobin
thefull󰘱owpositionatalltimes.Useanexternal
󰘱uidregulator,notthe󰘱uidadjustmentknob,toset
the󰘱uidpressure.

•Usetheminimumatomizingandfanairpressures
possibletoachieveagoodpattern.

•Followallproceduresunder

CleantheGunDaily,page29.

•Inspecttheelectrodedailyandreplaceifdamaged.
SeeElectrodeReplacement,page39.

26 3A2494D

Operation

Operation

Operation Operation

Pressure

Pressure Pressure

1.TurnOFF(O)theESOn/Offswitch.

2.Turnofftheairbleedvalvestothe󰘱uidsource
andtothegun.

3.Triggerthegunintoagroundedmetalwaste
containertorelievethe󰘱uidpressure.

Relief

Relief Relief

Procedure

Procedure Procedure

4.Openthepumpdrainvalve,havingawaste
containerreadytocatchthedrainage.Leave
thepumpdrainvalveopenuntilyouareready
tosprayagain.

5.Ifthenozzleorhoseiscompletelycloggedor
pressureisnotfullyrelieved,slowlyloosenthe
hoseendcoupling.Nowclearthenozzleorhose.

Startup

Startup Startup

FollowallstepsunderGunSetupChecklist,page18.

Shutdown

Shutdown Shutdown

1.Flushthegun,seeFlushing,page28.

2.FollowthePressureReliefProcedure,page27.

3.Hangthegunfromitshook,withthenozzle
pointingdown.

3A2494D

27

Maintenance

Maintenance

Maintenance Maintenance

Flushing

Flushing Flushing

•Flushbeforechanging󰘱uids,before󰘱uidcandry
intheequipment,attheendoftheday,before
storing,andbeforerepairingequipment.

•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.

•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.

Toreducetheriskof󰘰re,explosion,orelectric
shock,turnOFF(O)theESOn-Offswitchbefore
󰘱ushingthegun.

NOTICE

NOTICE NOTICE

Donotusemethylenechlorideasa󰘱ushingor
cleaningsolventwiththisgunasitwilldamage
nyloncomponents.

1.TurnOFF(O)theESOn-Offswitch.

2.FollowthePressureReliefProcedure,page27.

3.Changethe󰘱uidsourcetosolvent,ordisconnect
the󰘱uidlineandconnectasolventsupplyline
tothegun.

4.Pointthegunintoagroundedmetalpail.Flush
untilcleansolvent󰘱owsfromthegun.

5.FollowthePressureReliefProcedure,page27.

6.Shutoffordisconnectthesolventline.

7.Hangthegunfromitshook,withthenozzle
pointingdown.

8.Whenreadytosprayagain,reconnect
the󰘱uidsupplyline.Followthe

GunSetupChecklist,page18.

28 3A2494D

Maintenance

Clean

Clean Clean

1.TurnOFF(O)theESOn-Offswitch.

2.Flushthegun.SeeFlushing,page28.

3.FollowthePressureReliefProcedure,page27.

4.Cleantheoutsideofthegunwithacompatible

the

Gun

the the

Gun Gun

solvent.Useasoftcloth.Pointthegundownto
preventsolventfromenteringthegunpassages.
Donotimmersethegun.

Daily

Daily Daily

5.Removetheaircap.

6.Cleantheaircap,retainingring,andnozzlewith

asoftbrushandcompatiblesolvent.

7.Ifnecessary,useatoothpickorothersofttoolto

cleantheaircapholes.Donotusemetaltools.

8.Reinstalltheaircap.Tightensecurely.

3A2494D 29

Maintenance

Daily

Daily Daily

1.FollowthePressureReliefProcedure,page27.

2.Cleanthe󰘱uidandair󰘰lters.

3.Checkfor󰘱uidleaks.Tightenall󰘰ttings.

System

System System

Care

Care Care

4.Cleanworkpiecehangers.Usenon-sparking
tools.

5.Checkthemovementofthetriggerandvalves.
Lubricateifnecessary.

6.CheckGunElectricalGrounding,page25.

7.Hangthegunfromitshook,withthenozzle
pointingdown.

30 3A2494D

ElectricalTests

Electrical

Electrical Electrical

Usethefollowingprocedurestotestthecondition
ofthepowersupplyandgunbody,andelectrical
continuitybetweencomponents.

UsemegohmmeterPartNo.241079(AA)andan
appliedvoltageof500V.Connecttheleadsas
shown.

MegohmmeterPartNo.241079(AA-seeFig.

17)isnotapprovedforuseinahazardousarea.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous
area;

•Orallsprayingdevicesinthehazardousarea
areturnedoff,ventilationfansinthehazardous
areaareoperating,andthereareno󰘱ammable
vaporsinthearea(suchasopensolvent
containersorfumesfromspraying).

Tests

Tests Tests

Test

Test Test

1.Flushanddrythe󰘱uidpassage.

2.For For

3.For For

Ifoutsidethisrange,testthegun
untriggered.Ifstilloutsidethisrange,goto

TestPowerSupplyResistance,page32.Ifinrange,

seeElectricalTroubleshooting,page35forother
possiblecausesofpoorperformance.

Gun

Gun Gun

For
thebarrelcontinuitytoverifythatthemetalpin
inthebarrelisproperlygrounded.Measure
resistancebetweenthemetalpin(GP)andthe
airswivel(21).Theresistanceshouldbeless
than100ohms.Iftheresistanceis100ohmsor
more,replacethegunbody.

For
resistancebetweentheelectrodeneedletip(3)
andtheairswivel(21).Theresistanceshouldbe:

•75–120megohmsfor40kVguns

•104–148megohmsfor60kVguns

•148–193megohmsfor85kVguns

Resistance

Resistance Resistance

Model

L40T14

Model Model

L40T14 L40T14

all

guns:

all all

guns: guns:

and

L40T15

and and

L40T15 L40T15

Triggerthegunandmeasure

guns

guns guns

only:

only: only:

Test

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

Figure17TestGunResistance

3A2494D 31

ElectricalTests

Test

Test Test

1.Removethepowersupply(11).SeePower

2.Removethealternator(15)

3.Measureresistancefromthepowersupply's

4.Ifoutsidethisrange,replacethe

5.Ifyoustillhaveproblems,referto

Power

Power Power

SupplyRemovalandReplacement,page43.

fromthepowersupply.See

AlternatorRemovalandReplacement,page44.

groundstrips(EE)tothespring(11a).The
resistanceshouldbe:

•60–85megohmsfor40kVguns

•86–110megohmsfor60kVguns

•130–160megohmsfor85kVguns

powersupply.Ifinrange,goto

TestElectrodeResistance,page32.

ElectricalTroubleshooting,page35for

otherpossiblecausesofpoorperformance,or
contactyourGracodistributor.

Supply

Supply Supply

Resistance

Resistance Resistance

Test

Test Test

Removetheelectrode(3).See

ElectrodeReplacement,page39.Measure

theresistancebetweenthecontact(HH)andthe
electrodewire(GG).Theresistanceshouldbe8-30
megohms.Ifoutofrange,replacetheelectrode.

NOTE:

NOTE: NOTE:
testingthepowersupplyandelectrode:

•Checkthattheconductiveo-ring(4a)ismaking

•Checkthatthepowersupplyspring(11a)ismaking

Electrode

Electrode Electrode

Ifthegunresistanceisstilloutofrangeafter

contactwiththebarrelpin.

contactwiththebarrelpin.

Resistance

Resistance Resistance

6.Besurethespring(11a)isinplacebefore
reinstallingthepowersupply.

Figure18TestPowerSupplyResistance

Figure19TestElectrodeResistance

32 3A2494D

Troubleshooting

Troubleshooting Troubleshooting

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseanelectricshock
orotherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorrepairthisequipment
unlessyouaretrainedandquali󰘰ed.

CheckallpossibleremediesintheTroubleshootingChartbeforedisassemblingthegun.

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page27,whenever

youareinstructedtorelievethepressure.

Troubleshooting

Spray

Spray Spray

Somespraypatternproblemsarecausedbytheimproperbalancebetweenairand󰘱uid.

Problem

Problem Problem

Flutteringorspittingspray.

Improperspraypattern.Damagedordirtynozzleoraircap.

Pattern

Pattern Pattern

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

No󰘱uid.Re󰘰llsupply.

Loose,dirty,damaged
nozzle/seat.

Airin󰘱uidsupply.Check󰘱uidsource.Re󰘰ll.

Fluidbuilduponaircapornozzle.

Fanairpressuretoohigh.Decrease.

Fluidtoothin.Increaseviscosity.

Fluidpressuretoolow.Increase.

Solution

Solution Solution

Cleanorreplacenozzle,see

CleantheGunDaily,page29,or
AirCapandNozzleReplacement,
page38.

Cleanorreplace.SeeAirCapand

NozzleReplacement,page38.

Clean.See

CleantheGunDaily,page29.

Fanairpressuretoolow.Increase.

Fluidtoothick.Reduceviscosity.

Toomuch󰘱uid.Decrease󰘱ow.

Didnotapply50%overlap.Overlapstrokes50%. Streaks.

Dirtyordamagedaircap.

3A2494D 33

Cleanorreplaceaircap.See

CleantheGunDaily,page29,or
AirCapandNozzleReplacement,
page38.

Troubleshooting

Gun

Gun Gun

Operation

Operation Operation

Problem

Problem Problem

Excessivesprayfog.

“OrangePeel”󰘰nish.

Fluidleaksfromthe󰘱uidpacking
area.

Airleaksfromthefrontofthegun.

Fluidleakagefromthefrontofthe
gun.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

Atomizingairpressuretoohigh.

Fluidtoothin,or󰘱uid󰘱owistoo
low.

Atomizingairpressuretoolow.

Poorlymixedor󰘰ltered󰘱uid.Remixorre󰘰lter󰘱uid.

Fluidtoothick.Reduceviscosity.

Wornpackingsorrod.

Airvalveisnotseatingproperly.

Wornordamaged󰘱uidpacking
rodorelectrode.

Solution

Solution Solution

Closerestrictorvalvepartway,or
decreaseairpressureaslowas
possible;minimum45psi(0.32
MPa,3.2bar)neededatgunfor
fullvoltage.

Increaseviscosityorincrease󰘱uid
󰘱owrate.

Openatomizingairvalvemoreor
increasegunairinletpressure;
uselowestairpressurenecessary.

SeePackingRodRepair,page40.

SeeAirValveRepair,page50.

Replacepackingrod(2e)
orelectrode(3).See

PackingRodRepair,page40or
ElectrodeReplacement,page39.

Gundoesnotspray.

Dirtyaircap.

Excessivepaintwrapbackto
operator.

Worn󰘱uidnozzleseat.Replacenozzle(4).See

AirCapandNozzleReplacement,
page38.

Loose󰘱uidnozzle.

Damagednozzleo-ring.

Low󰘱uidsupply.Add󰘱uidifnecessary.

Dirtyorclogged󰘱uidnozzle.Clean.See

Closedordamaged󰘱uid
adjustmentvalve.

Misalignedaircapand󰘱uidnozzle.Clean󰘱uidbuildupoffaircap

Poorgrounding.

Incorrectdistancefromguntopart.Shouldbe8–12in.(200–300mm).

Tighten.

SeeAirCapandNozzle

Replacement,page38.

CleantheGunDaily,page29.

Openvalve,orsee

ESOn-OffandFluidAdjustment
ValveRepair,page49.

and󰘱uidnozzleseat.See

CleantheGunDaily,page29.

SeeGrounding,page21.

34 3A2494D

Troubleshooting

Electrical

Electrical Electrical

Problem

Problem Problem

Poorwrap.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

ESOn/OffswitchisOFF(O).TurnON(I).

Gunairpressuretoolow(ES
indicatorisamber).

Atomizingairpressuretoohigh.Decrease.

Incorrectdistancefromguntopart.Shouldbe8-12in.(200-300mm).

Poorlygroundedparts.Resistancemustbe1megohmor

Faultygunresistance.

Low󰘱uidresistivity.See

Fluidleaksfromthepacking(2c)
andcausesashort.

Faultyalternator.

ESOn/OffswitchisOFF(O).TurnON(I). ESorHzindicatorisnotlit.

Solution

Solution Solution

Checkairpressuretogun;
minimum45psi(0.32MPa,3.2
bar)neededatgunforfullvoltage.

less.Cleanworkpiecehangers.

See

TestGunResistance,page31.

CheckFluidResistivity,page26.

SeePackingRodRepair,page40.

SeeAlternatorRemovaland

Replacement,page44.

Operatorgetsshockfrom
workpiece.

Nopower.

Operatornotgroundedorisnear
ungroundedobject.

Gunnotgrounded.SeeCheckGunElectrical

Workpiecenotgrounded.Resistancemustbe1megohmor

Checkpowersupply,alternator,
andalternatorribboncable.See

PowerSupplyRemovaland
Replacement,page43and
AlternatorRemovaland
Replacement,page44.

SeeGrounding,page21. Operatorgetsmildshock.

Grounding,page25,and
TestGunResistance,page31.

less.Cleanworkpiecehangers.

3A2494D 35

Troubleshooting

Problem

Problem Problem

Voltage/currentdisplaystaysred
(smartgunsonly).

ESorHZindicatorisamber.

ESorHzindicatorisred.

ErrordisplayappearsandHz
indicatorisred(Smartgunsonly).

Cause

Cause Cause

Gunistooclosetothepartbeing
sprayed.

Check󰘱uidresistivity.See

Dirtygun.

Alternatorspeedistoolow.Increaseairpressureuntil

Alternatorspeedistoohigh.Decreaseairpressureuntil

Smartmodulehaslost
communicationwiththepower
supply.

Solution

Solution Solution

Gunshouldbe8–12in.(200–300
mm)fromthepart.

CheckFluidResistivity,page26.

SeeCleantheGunDaily,page29.

indicatorisgreen.Toavoid
over-atomization,usethe
atomizingairrestrictorvalveto
reducetheatomizingairtotheair
cap.

indicatorisgreen.

Checkforgoodconnectionsbe­tweentheSmartModuleandthe
powersupply.SeeSmartModule

Replacement,page51and
PowerSupplyRemovaland
Replacement,page43.

36 3A2494D

Repair

Repair

Repair Repair

Prepare

Prepare Prepare

Installingandrepairingthisequipmentrequires
accesstopartsthatmaycauseelectricshockor
otherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorservicethisequipment
unlessyouaretrainedandquali󰘰ed.

•Checkallpossibleremedies

inTroubleshooting,page33beforedisassembling
thegun.

•Useavisewithpaddedjawstopreventdamage

toplasticparts.

•Lubricatesomepackingrodparts(2)andcertain

󰘱uid󰘰ttingswithdielectricgrease(44),asspeci󰘰ed
inthetext.

•Lightlylubricateo-ringsandsealswithnon-silicone

grease.OrderPartNo.111265Lubricant.Donot
over-lubricate.

the

Gun

the the

Gun Gun

for

Service

for for

Service Service

•OnlyusegenuineGracoparts.Donotmixoruse
partsfromotherProGunmodels.

•AirSealRepairKit24N789isavailable.The
kitmustbepurchasedseparately.Kitpartsare
markedwithanasterisk,forexample(6a*).

•FluidSealRepairKit24N790isavailable.The
kitmustbepurchasedseparately.Kitpartsare
markedwithasymbol,forexample(2a‡).

1.Flushthegun.SeeFlushing,page28.

2.Relievethepressure.See

PressureReliefProcedure,page27.

3.Disconnectthegunairand󰘱uidlines.

4.Removethegunfromtheworksite.Repairarea

mustbeclean.

3A2494D 37

Repair

Air

Cap

Air Air

Cap Cap

and

Nozzle

and and

Nozzle Nozzle

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Triggerthegunwhileremovingthenozzletohelp
drainthegunandpreventanypaintorsolventleft
inthegunfromenteringtheairpassages.

1.SeePreparetheGunforService,page37.

2.Removetheretainingring(6)andaircap(5).

3.Triggerthegunwhileremovingthe󰘱uidnozzle
(4)assemblywiththemulti-tool(41).

Thenozzlecontactring(4a)isaconductive
contactring,notasealingo-ring.Toreduce
theriskofsparkingorelectricshock,donot
removethenozzlecontactring(4a)exceptto
replaceitandneveroperatethegunwithout
thecontactringinplace.Donotreplacethe
contactringwithanythingbutagenuineGraco
part.

nozzleseatsinthegunbarrel(1/8to1/4turn
pasthand-tight).

7.Installtheaircap(5)andretainingring(6).Make
suretheu-cup(6a*)isinplacewiththelipsfacing
forward.

8.SeeTestGunResistance,page31.

NOTICE

NOTICE NOTICE

Usenon-siliconegrease,PartNo.111265,on
thesmallo-ring(4b).Donotover-lubricate.Do
notlubricatetheconductivecontactring(4a).

4.Makesuretheconductivecontactring(4a)and
thesmallo-ring(4b)areinplaceonthenozzle
(4).Lightlylubricatethesmallo-ring(4b).

NOTE:

NOTE: NOTE:
showsomewearatthepointwhereitmakes
contactwiththebarrelpin.Thisisnormaland
doesnotrequirereplacement.

5.Makesuretheelectrodeneedle(3)is󰘰nger-tight.

6.Triggerthegunwhileinstallingthe󰘱uidnozzle
(4)withthemulti-tool(41).Tightenuntilthe󰘱uid

Theconductivecontactring(4a)may

Figure20AirCapandNozzleReplacement

38 3A2494D

Repair

Electrode

Electrode Electrode

1.SeePreparetheGunforService,page37.

2.Removetheaircapandnozzle.See

AirCapandNozzleReplacement,page38.

3.Unscrewtheelectrode(3)withthemulti-tool(41).

Toavoiddamagingtheplasticthreads,bevery
carefulwheninstallingtheelectrode.

4.Applylow-strength(purple)Loctite®orequivalent

threadsealanttotheelectrodeandpackingrod
threads.Installtheelectrode󰘰nger-tight.Donot
overtighten.

5.Installthe󰘱uidnozzleandaircap.See

AirCapandNozzleReplacement,page38.

6.SeeTestGunResistance,page31.

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Figure21ElectrodeReplacement

3A2494D 39

Repair

Fluid

Fluid Fluid

1.SeePreparetheGunforService,page37.

2.Removetheaircapand󰘱uidnozzle.See

3.Removetheelectrode.See

4.Loosenthetriggerscrews(13)andremovethe

5.Removethepackingrod(2),usingthemulti-tool

6.Checkallpartsforwearordamageandreplace

Packing

Packing Packing

AirCapandNozzleReplacement,page38.

ElectrodeReplacement,page39.

trigger(12).

(41).Removethespring(17).

ifnecessary.

Rod

Removal

Rod Rod

Removal Removal

Packing

Packing Packing

NOTE:

NOTE: NOTE:
partsorasanassembly.

Adjust

Adjust Adjust

NOTE:

NOTE: NOTE:
isdischargedandthe󰘱uidstopsbeforetheair󰘱ow
stops.Thepackingrodassemblyispre-adjustedat
thefactoryforproperairleadandlag.Adjustonly
ifnecessary,asfollows.

1.Removethespring(17)fromthenut(2k).

2.Useahexwrenchtoholdtheendofthepacking
rod.Turnbothadjustmentnuts(2j,2k)outto
increasethelead/lagtimefortheair󰘱ow.The
recommendedadjustmentisonehalfturnand
notmorethanonefullturn.

Rod

Repair

Rod Rod

Repair Repair

Youmayreplacethepackingrodasindividual

the

Air

Flow

Lead

and

the the

Air Air

Flow Flow

Lead Lead

Thegunbeginsemittingairbeforethe󰘱uid

Lag

and and

Lag Lag

Figure22FluidPackingRodRemoval

3.Tightenthenutstogetherto󰘰xtheminthenew
position.

40 3A2494D

Repair

Assemble

Assemble Assemble

NOTE:

NOTE: NOTE:
gunbarrel,makesuretheinternalsurfacesofthe
barrelareclean.Removeanyresiduewithasoft
brushorcloth.Checktheinsideofthebarrelfor
marksfromhighvoltagearcing.Ifmarksarepresent,
replacethebarrel.

1.Placethepackingnut(2f)andseal(2b‡)onthe
󰘱uidrod(2e).Flatsonthepackingnutmustface
thebackofthe󰘱uidrod.Thesealo-ringmust
faceawayfromthepackingnut.

2.Filltheinnercavityofthespacer(2h‡)with
dielectricgrease(44).Placethespaceronthe
󰘱uidrod(2e)inthedirectionshown.Generously
applydielectricgreasetotheoutsideofthe
spacer.

3.Placethe󰘱uidpacking(2c‡)onthepackingrod
(2e)withitslipsfacingthefrontoftherod.Install
theneedlepacking(2d‡)withthemaleend
towardthe󰘱uidpacking,theninstallthehousing
(2g).

the

Packing

the the

Packing Packing

Beforeinstallingthe󰘱uidpackingrodintothe

Rod

Rod Rod

4.Lightlytightenthepackingnut(2f).Thepacking
nutisproperlytightenedwhenthereis3lb(13.3
N)ofdragforcewhenslidingthepackinghousing
(2g)assemblyalongtherod.Tightenorloosen
thepackingnutasneeded.

5.Installtheo-ring(2a‡)ontheoutsideofhousing
(2g).Lubricatetheo-ringwithnon-silicone
grease,PartNo.111265.Donotover-lubricate.

6.Installthespring(17)againstthenut(2j)as
shown.

7.Installthepackingrodassembly(2)intothe
gunbarrel.Usingthemulti-tool(41),tightenthe
assemblyuntiljustsnug.

8.Installtheelectrode.See

ElectrodeReplacement,page39.

9.Installthenozzleandaircap.See

AirCapandNozzleReplacement,page38.

10.Installthetrigger(12)andscrews(13).

11.SeeTestGunResistance,page31.

Figure23PackingRod

3A2494D

41

Repair

Barrel

Barrel Barrel

1.SeePreparetheGunforService,page37.

2.Carefullyloosenthenut(N)fromthebracket󰘱uid

3.Loosenthetwoscrews(27).

4.Holdthegunhandle(16)withonehandandpull

NOTE:

NOTE: NOTE:
removethealternator/powersupplyassemblyfrom
thebarrel.

Removal

Removal Removal

󰘰tting(20).Pullthetube(T)outofthe󰘰tting.
Makesurebothferrules(7,8)andthenutstay
withthetube.

NOTICE

NOTICE NOTICE

Toavoiddamagingthepowersupply(11),pull
thegunbarrel(1)straightawayfromthegun
handle(16).Ifnecessary,gentlymovethegun
barrelfromsidetosidetofreeitfromthegun
handle.

thebarrel(1)straightoffthehandle.

Ifthepowersupplyremainsinthebarrel,

Barrel

Barrel Barrel

1.Besurethegasket(28*)andgroundingspring

2.Makesurethespring(11a)isinplaceonthetipof

3.Tightenthetwoscrews(27)oppositelyand

4.Assemblethe󰘱uidtube(T)intothebracket󰘰tting

5.SeeTestGunResistance,page31.

Installation

Installation Installation

(18)areinplace.Makesurethegasketair
holesarealignedproperly.Replacethegasketif
damaged.

thepowersupply(11).Liberally Liberally
grease(44)tothetipofthepowersupply.Place
thebarrel(1)overthepowersupplyandontothe
gunhandle(16).

evenly(aboutahalfturnpastsnug).Donot
over-tightenthescrews(27).

(20).Ensurethattheferrules(7,8)areinplace.
Tightenthenut(N)securelyontothe󰘰tting.
Makesurethetop󰘰ttingremainstight.

Liberally

applydielectric

Figure24BarrelRemoval

42

Figure25BarrelInstallation

3A2494D

Repair

Power

Power Power
Replacement

Replacement Replacement

•Inspectthegunhandlepowersupplycavityfordirt
ormoisture.Cleanwithaclean,dryrag.

•Donotexposegasket(28)tosolvents.

1.SeePreparetheGunforService,page37.

2.SeeBarrelRemoval,page42.

3.Graspthepowersupply(11)withyourhand.

4.Inspectthepowersupplyandalternatorfor

5.Toseparatethepowersupply(11)fromthe

6.SeeTestPowerSupplyResistance,page32.

Supply

Supply Supply

Becarefulwhenhandlingthepowersupply
(11)toavoiddamagingit.

Withagentlesidetosidemotion,freethepower
supply/alternatorassemblyfromthegunhandle
(16),thencarefullypullitstraightout.

Models only,

fromthesocketatthetopofthehandle.

damage.

alternator(15),disconnectthe3-wireribbon
connector(PC)fromthepowersupply.

Models only,

(24)fromthepowersupply.Slidethealternator
upandoffthepowersupply.

Replacethepowersupplyifnecessary.
Torepairthealternator,see

AlternatorRemovalandReplacement,page44.

Removal

Removal Removal

NOTICE

NOTICE NOTICE

disconnectthe󰘱exiblecircuit(24)

disconnectthe6–pin󰘱exiblecircuit

and

and and

On Smart

On Smart

9.Insertthepowersupply/alternatorassemblyin
thegunhandle(16).Makesurethegroundstrips
(EE)makecontactwiththehandle.OnSmart
models,aligntheconnectorofthe6–pin󰘱exible
circuit(24)withthesocket(CS)atthetopofthe
handle.Pushtheconnectorsecurelyintothe
socketasyouslidethepowersupply/alternator
assemblyintothehandle.

Figure26ConnectFlexibleCircuit

10.Makesurethegasket(28*),groundspring(18),
andpowersupplyspring(11a)areinplace.
Assemblethebarrel(1)tothehandle(16).See

BarrelInstallation,page42.

11.SeeTestGunResistance,page31.

Topreventdamagetothecableandpossible
interruptionofthegroundcontinuity,bendthe
alternator’s3–wireribboncable(PC)upward
andback,sothebendfacesthepowersupply
andtheconnectorisatthetop.

7.

Smart models only:

circuit(24)tothepowersupply.

8.Connectthe3-wireribbonconnector(PC)tothe
powersupply.Tucktheribbonforward,under
thepowersupply.Slidethealternator(15)down
ontothepowersupply(11).

3A2494D 43

connectthe6–pin󰘱exible

Figure27PowerSupply

Repair

Alternator

Alternator Alternator

NOTE:

NOTE: NOTE:
ofoperation.OrderPartNo.24N706BearingKit.
Partsincludedinthekitaremarkedwithasymbol(♦).

1.SeePreparetheGunforService,page37.

2.Removethepowersupply/alternatorassembly

3.Measureresistancebetweenthetwoouter

4.Usinga󰘱atbladescrewdriver,prytheclip(15h)

5.Ifnecessary,rotatethefan(15e)soitsblades

Replacealternatorbearingsafter2000hours

anddisconnectthealternator.SeePowerSupply

RemovalandReplacement,page43.

terminalsofthe3-wireconnector(PC);itshould
be2.0–6.0ohms.Ifoutsidethisrange,replace
thealternatorcoil(15a).

offthehousing(15d).Removethecap(15f),
usingathinbladeorscrewdriver.

clearthefourbearingtabs(T)ofthehousing
(15d).

Removal

Removal Removal

and

Replacement

and and

Replacement Replacement

Figure29AlternatorCross-Section

NOTICE

NOTICE NOTICE

Donotscratchordamagethemagnet(M)or
shaft(S).Donotpinchordamagethe3–wire
connector(PC)whendisassemblingand
reassemblingthebearings.

Figure28FanOrientation

6.Pushthefanandcoilassembly(15a)outthe
frontofthehousing(15d).

7.Holdthecoilassembly(15a)onaworkbench
withthefanendfacingup.Usingawideblade
screwdriver,prythefan(15e)offtheshaft(S).

8.Removethetopbearing(15b2).

9.Removethebottombearing(15b1).

10.Installthenewbottombearing(15b1♦)onthe
longendoftheshaft(S).The󰘱attersideofthe
bearingmustfaceawayfromthemagnet(M).
Installinthecoil(15a)sothebearingbladesare
󰘱ushwiththesurfaceofthecoil.

11.Pressthenewtopbearing(15b2♦)ontotheshort
endoftheshaftsothebearingbladesare󰘱ush
withthesurfaceofthecoil(15a).The󰘱atterside
ofthebearingmustfaceawayfromthecoil.

44

3A2494D

Repair

12.Holdthecoilassembly(15a)onaworkbench
withthefanendfacingup.Pressthefan(15e♦)
ontothelongendoftheshaft(S).Thefanblades
mustbeorientedasshown.

13.Carefullypressthecoilassembly(15a)into
thefrontofthehousing(15d♦).The3–wire
connector(PC)mustbepositionedbelowthe
widernotch(W)ofthehousingtabs,asshownin
Fig.45.Besurethecoilalignmentpins(P)are
positionedasshowninFig.44.

14.Rotatethefan(15e)soitsbladesclearthefour
bearingtabs(T)atthebackofthehousing.

Ensurethatthebladesofthebottombearing
(15b1♦)alignwiththetabs.

15.Seatthecoilfullyintothehousing(15d♦).Secure
withtheclip(15h♦),ensuringthatitstabsengage
theslotsinthehousing.

16.Ensurethattheo-ring(15g)isinplace.Install
thecap(15f).

17.Installthealternatoronthepowersupply,and
installbothpartsinthehandle.SeePower

SupplyRemovalandReplacement,page43.

Figure30Alternator

3A2494D 45

Repair

Fluid

Fluid Fluid

1.Removethenut(22)fromthebracket(20).

2.Loosenthe󰘰tting(9)toremovethe󰘱uidtube

3.Applydielectricgrease(44)tothethreadsofthe

4.Slidethe󰘰tting(9)ontothe󰘱uidtube(14)and

5.Withtheferrules(7,8)seatedtothebracket(20),

Tube

Tube Tube

(14)fromthebarrel(1).

󰘰tting(9)andtheo-ring(10).Ensuretheferrules
(7,8)areinplace.

NOTE:

NOTE: NOTE:
used,andferrules(7★)and(8★)arepartofthe
top󰘰tting(9).

NOTE:

NOTE: NOTE:
sleeve(SL)isinplacenearthetopofthe󰘱uid
tube.

threadthe󰘰ttingintothebarrel(1).Torqueto
25–35in-lb(2.8–3.9N•m).

screwthenut(22)securelyontothebracket.
Makesurethetop󰘰ttingremainstight.

Removal

Removal Removal

On40kVguns,theo–ring(10★)isnot

On60and85kVkVguns,checkthatthe

and

Replacement

and and

Replacement Replacement

Figure31FluidTube

46 3A2494D

Repair

Fan

Air

Fan Fan

Adjustment

Air Air

Adjustment Adjustment

Valve

Valve Valve

Repair

Repair Repair

1.SeePreparetheGunforService,page37.

2.Placeawrenchonthe󰘱atsofthevalvehousing
(30a)andunscrewthevalvefromthehandle
(16).

NOTE:

NOTE: NOTE:
assembly(gotostep9)orreplaceonlytheo-ring
(steps3–9).

3.Removetheretainingring(30d).

4.Turnthevalveshaft(30b)counterclockwiseuntil
itcomesfreefromthevalvehousing(30a).

5.Inspecttheo-ring(30c).Removeifdamaged.

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

7.Whenreassemblingthefanairvalve(30),lightly
lubricatethevalvethreadsandscrewtheshaft
(30b)fullyintothehousing(30a)untilbottomed.
Installtheo-ring(30c*),lubricate,andunscrew
thevalvestemuntiltheo-ringentersthehousing.

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

8.Reassembletheretainingring(30d).Unscrew
thevalvestemfromthehousinguntilitisstopped
bytheretainingring.

9.Screwthevalveassembly(30)intothegun
handle(16),usingawrenchonthe󰘱atsofthe
housing.Torqueto15in-lb(1.7N•m).

Figure32FanAirAdjustmentValve

3A2494D

47

Repair

Atomizing

Atomizing Atomizing

1.SeePreparetheGunforService,page37.

2.Placeawrenchonthe󰘱atsofthevalvehousing
(29a)andunscrewthevalvefromthehandle
(16).

NOTE:

NOTE: NOTE:
assembly(gotostep9)orreplaceonlytheo-ring
(steps3–9).

3.Unscrewthevalvestem(29e).Removethe
retainingring(29d).

4.Turnthevalvebody(29b)counterclockwiseuntil
itcomesfreefromthevalvehousing(29a).

5.Inspecttheo-ring(29c).Removeifdamaged.

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

7.Whenreassemblingtheatomizingairrestrictor
valve(29),lightlylubricatetheo-ring(29c)and
pushthevalvebody(29b)fullyintothehousing
(29a)untilbottomed.

Air

Restrictor

Air Air

Restrictor Restrictor

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

Valve

Valve Valve

Repair

Repair Repair

Figure33AtomizingAirRestrictorValve

8.Reassembletheretainingring(29d).Threadthe
valvestem(29e)halfwayintothevalvebody
(29b).

9.Aligntheslot(S)inthevalvestemwiththerib(R)
inthegunhandle.Screwthevalveassembly(29)
intothegunhandle(16),usingawrenchonthe
󰘱atsofthehousing.Torqueto15in-lb(1.7N•m).

NOTE:

NOTE: NOTE:
desired,installthesuppliedplug(42).

Iftheatomizingairrestrictorvalveisnot

Figure34AlignValveStem

48 3A2494D

Repair

ES

On

Off

and

ES ES

On On

- --Off Off

Fluid

and and

Fluid Fluid

Adjustment

Adjustment Adjustment

Valve

Valve Valve

Repair

Repair Repair

1.SeePreparetheGunforService,page37.

2.Loosenthecaptivescrew(26p).Removethe

valve(26)fromthehandle.

3.Lubricatetheo-rings(26b*and26m*)with

non-siliconegrease,PartNo.111265.Donot
over-lubricate.

NOTE:

NOTE: NOTE:
lubricantontheo-ringscanbepushedintothe

Donotover-lubricateparts.Excessive

gunairpassageandblemishthe󰘰nishonthe
workpiece.

4.Cleanandinspectpartsfordamage.Replace
ifnecessary.

NOTE:

NOTE: NOTE:
mustpointupward.

5.Reinstallthevalve.Torquethescrew(27)to
15-25in-lb(1.7-2.8N•m).

Theprotrusionontheretainerplate(26h)

Figure35ESOn-OffandFluidAdjustmentValve

3A2494D 49

Repair

Air

Valve

Air Air

Valve Valve

Repair

Repair Repair

1.SeePreparetheGunforService,page37.

2.SeeBarrelRemoval,page42.

3.Removethescrews(13)andtrigger(12).

4.RemovetheESOn-OffValve.SeeESOn-Off

andFluidAdjustmentValveRepair,page49.

5.Removethespring(34).

6.Pushonthefrontoftheairvalveshafttoforceit
outthebackofthehandle.Inspecttherubber
seal(23a*)andreplaceifdamaged.

7.Inspecttheu-cup(35).Donotremovetheu-cup
unlessdamaged.Ifremoved,installthenewone
withitslipsfacingintothegunhandle(16).Place
theu-cupontheshaftoftheairvalvetohelpseat
itinthegunhandle.

8.Installtheairvalve(23)andspring(34)intothe
gunhandle(16).

9.InstalltheESOn-OffValve.SeeESOn-Offand

FluidAdjustmentValveRepair,page49.

10.Installthetrigger(12)andscrews(13).

11.SeeBarrelInstallation,page42.

Figure36InstallU-Cup

Figure37AirValve

50 3A2494D

Repair

Smart

Smart Smart

IftheErrordisplayappears,theSmartModulehas
lostcommunicationwiththepowersupply.Checkfor
goodconnectionsbetweentheSmartModuleand
thepowersupply.

Ifthemodule’sLEDsarenotlighting,replacethe
module.

1.SeePreparetheGunforService,page37.

2.Removethepivotscrew(31e),o-ring(31f),and

3.Removetheremainingthreescrews(31d)from

4.PulltheSmartModuleoutthebackofthegun.

5.Removethegasket(31b).

6.Installanewgasket(31b)onthenewcartridge

Module

Module Module

ESHI/LOswitch(31c)atthebottomleftcornerof
theSmartModulecartridge(31a).

thecartridge.

Disconnecttheribboncable(RC)fromthe
connector(GC)inthegunhandle.

(31a).Makesurethenotchedcornersofthe
gasketareatthetop.

Replacement

Replacement Replacement

Figure38SmartModule

7.Alignthemodule’sribboncable(RC)with
thegun’scable(GC)andslidethemsecurely
together,asshown.Tucktheconnectedcables
intotherecessofthegunhandle.Installthe
module󰘱ushtothebackofthegunhandle.

8.Installthepivotscrew(31e),o-ring(31f),and
ESHI/LOswitchinthebottomleftcornerofthe
cartridge(31a).

9.Installthethreeremainingscrews(31d).Torque
to7–9in-lb(0.8–1.0N•m).

Figure39AlignRibbonCables

3A2494D 51

Repair

Air

Swivel

Air Air

Swivel Swivel

Replacement

Replacement Replacement

1.SeePreparetheGunforService,page37.

2.Toreplacetheairexhaustvalve:

a.Removetheclamp(43)andtheexhausttube

(36).

b.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.
Removethebracket(20).

c.Pulltheexhaustvalve(19)fromthehandle

(16).Inspecttheo-ring(19a)andreplaceif
necessary.

d.Installtheo-ring(19a*)ontheexhaustvalve

(19).Lubricatetheo-ringwithalightcoating
ofnon-siliconegrease.

e.Installtheexhaustvalve(19)inthehandle

(16).

and

Exhaust

and and

Exhaust Exhaust

Valve

Valve Valve

b.Applythreadsealanttothetopthreadsofthe

swivel.Screwtheswivelintothegunhandle.
Torqueto75–85in-lb(8.4–9.6N•m).

f.Applythreadsealanttothetopthreadsofthe

swivel(21).Positionthebracket(20)and
screwtheswivelintothegunhandle(16).
Torqueto75–85in-lb(8.4–9.6N•m).

g.Installthetube(36)andclamp(43).

3.Toreplacetheairinletswivel:

a.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.

Figure40AirInletFittingandAirExhaustValve

52 3A2494D

Parts

Parts

Parts Parts

Standard

Standard Standard

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Air

Spray

Air Air

Spray Spray

L40T10

L40T10 L40T10
L40T14

L40T14 L40T14
L60T10

L60T10 L60T10
L60T11

L60T11 L60T11
L60T12

L60T12 L60T12
L85T10

L85T10 L85T10

40

kV

40 40

kV kV

40

kV

40 40

kV kV

60

kV

60 60

kV kV

60

kV

60 60

kV kV

60

kV

60 60

kV kV

85

kV

85 85

kV kV

Gun

Gun Gun

Electrostatic

Electrostatic Electrostatic
High

High High
Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic

Assembly

Assembly Assembly

Air

Spray

Gun,

Air Air

Spray Spray

Ef󰘰ciency

Ef󰘰ciency Ef󰘰ciency

Electrostatic

Electrostatic Electrostatic

Air

Spray

Air Air

Spray Spray

Round

Round Round

Air

Air Air

Air

Air Air

Spray

Spray Spray

Spray

Spray Spray
Spray

Spray Spray

Series

Gun, Gun,

Series Series

Air

Air Air

Gun,

Series

Gun, Gun,

Series Series

Gun,

Gun, Gun,

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

A

A A

Spray

Gun,

Spray Spray

A

A A

Series

Series Series

A,

A, A,
A

A A

Series

Gun, Gun,

Series Series

A

A A

with

1.2

with with

1.2 1.2

A

A A

mm

Nozzle

mm mm

Nozzle Nozzle

3A2494D 53

Parts

Part

No.

Part Part
Part

Part Part
Part

Part Part
Part

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
1

2

324N651NEEDLE,electrode1

4

4a24N645

4b111507

5

624N644

6a*

9

10★102982

11

11a24N979

1224N663

L40T10

No. No.

L40T10 L40T10

No.

L40T14

No. No.

L40T14 L40T14

No.

L60T10

No. No.

L60T10 L60T10

No.

L60T11

No. No.

L60T11 L60T11

No.

L60T12

No. No.

L60T12 L60T12

No.

L85T10

No. No.

L85T10 L85T10

Part

Part Part

24N665

24N666

24N667

24N668

SeePackingRodAssembly,page62

24N616

24N615

24N729

24N477

24N731

198307

111286

111286

111285FERRULE,back;40kVgun1 8‡★

111285FERRULE,back;60and85kV

24N656

24N657

24N658

24N659

24N660

24N661

40

kV

Electrostatic

40 40

kV kV

Electrostatic Electrostatic

40

kV

High

40 40

kV kV

High High

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

No.

Description

No. No.

Description Description

BODY,gun;40kVgun

BODY,gun;60kVgun

BODY,gun;85kVgun

BODY,gun;40kVhigh
ef󰘰ciencygun

NOZZLE,1.5mm;includes4a
and4b
NOZZLE,1.2mm;includes4a
and4b
NOZZLE,roundspray;
includes4aand4b;see

RoundSprayAssembly,page55

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

AIRCAP,roundspray;see

RoundSprayAssembly,page55

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

FERRULE,front;40kVgun

FERRULE,front;60and85kV
guns

guns
FITTING,󰘱uid;40kVgun

FITTING,󰘱uid;60kVgun

FITTING,󰘱uid;85kVgun

PACKING,o-ring;60and85kV
gunsonly

POWERSUPPLY,40kVgun

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

Air

Spray

Air Air

Spray Spray

Ef󰘰ciency

Ef󰘰ciency Ef󰘰ciency

Electrostatic

Electrostatic Electrostatic

Air

Spray

Air Air

Spray Spray

Round

Round Round
Air

Spray

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Gun,

Series

Gun, Gun,

Series Series

Air

Air Air

Gun,

Series

Gun, Gun,

Series Series

Spray

Gun,

Spray Spray

Gun, Gun,

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 7‡★

2

2

1

1

1

1

1

1

1

1

1

A

A A

Spray

Gun,

Spray Spray

A

A A

Series

Series Series

A,

A, A,
A

A A

Ref.

Ref. Ref.
No.

No. No.
1324A445

14

1524N664

16

17185111

18197624

19249323VALVE,exhaust1

19a*

2024N741

2124N626

2224N698NUT1

2324N633VALVE,air1

23a*

2624N630

2724N740

28*

34185116

35*

Series

Gun, Gun,

Series Series

A;

see

A; A;

see see

with

1.2

with with

1.2 1.2

Part

Part Part

24N695

24N696

24N697

24N751HANDLE;40kVgun1

24N752HANDLE;60kVgun1

24N753HANDLE;85kVgun1

112085

276733

24N699

24T304

24N733Forroundspraygunonly;see

24N634

24N732Forroundspraygunonly;

188749

A

A A

Round

Round Round

mm

mm mm

No.

No. No.

Spray

Assembly

Spray Spray

Assembly Assembly

Nozzle

Nozzle Nozzle

Description

Description Description

SCREW,trigger;packageof2

TUBE,󰘱uid;40kVgun

TUBE,󰘱uid,withsleeve;60kV
gun

TUBE,󰘱uid,withsleeve;85kV
gun

See

AlternatorAssembly,page63

SPRING,compression

SPRING,compression

O-RING

BRACKET

SWIVEL,airinlet;M12x1/4
npsm(m);left-handthread

SEAL,airvalve

SeeESOn-OffandFluid

AdjustmentValve,page64

SCREW,hexsocket;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page65

AtomizingAirRestrictorValve
Assembly,page65

SeeFanAirAdjustmentValve

Assembly,page65

seeFanAirAdjustmentValve

Assembly,page65

SPRING,compression

PACKING,u-cup

page

, ,,page page

55

55 55

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 29

1

1 30

1

1

1

54 3A2494D

Parts

Part

No.

Ref.

Ref. Ref.
No.

No. No.
36185103

40107460

41276741

4224N786

43110231

44116553

45117824

Part Part

Description

No. No.

Description Description

TUBE,exhaust;1/4in.(6mm)
ID(shippedloose)

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

GREASE,dielectric;1oz(30
ml)tube(notshown)

GLOVE,conductive,medium;
packageof12;alsoavailable
insmall(117823)andlarge
(117825)

Qty

Qty Qty

1

1

1

1

1

1

1

Part

No.

Ref.

Part Part

Ref. Ref.
No.

No. No.

24N603

46

24N604

47▲179791

48▲16P802

4924N730

5024N783

Description

No. No.

Description Description

COVER,gun,40and60kV
guns;packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

DIFFUSER,forround
spraygunonly;see

RoundSprayAssembly,page55

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

‡ThesepartsareincludedinFluidSealRepairKit
24N790(purchaseseparately).

NOTE:

NOTE: NOTE:

On40kVguns,theo–ring(10★)isnotused,
andferrules(7★)and(8★)arepartofthetop󰘰tting
(9).

Round

Round Round

Spray

Spray Spray

Assembly

Assembly Assembly

3A2494D 55

Parts

Standard

Standard Standard

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

High

High High

L40T16

L40T16 L40T16
L40T15

L40T15 L40T15
L60T16

L60T16 L60T16
L85T16

L85T16 L85T16

Conductivity

Conductivity Conductivity

40

kV

Electrostatic

40 40

kV kV

Electrostatic Electrostatic

40

kV

High

40 40

kV kV

60

kV

60 60

kV kV

85

kV

85 85

kV kV

Ef󰘰ciency

High High

Ef󰘰ciency Ef󰘰ciency

Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic

Air

Spray

Air Air

Spray Spray

High

Conductivity

High High

Conductivity Conductivity

Electrostatic

Electrostatic Electrostatic

High

Conductivity

High High

Conductivity Conductivity

High

Conductivity

High High

Conductivity Conductivity

Gun

Gun Gun

Air

Air Air

Assembly

Assembly Assembly

Air

Spray

Gun,

Air Air

Spray Spray

Spray

Gun,

Spray Spray

Gun, Gun,

Air

Spray

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Series

Gun, Gun,

Series Series

Series

Series Series

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

A

A A

A

A A

A

A A
A

A A

56 3A2494D

Part

No.

Part Part
Part

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
1

2

324N704NEEDLE,electrode1

424N623

4a24N645

4b111507

5

624N644

6a*

11

11a24N979

1224N663

1324A445

14

1524N664

16

17185111

18197624

19249323VALVE,exhaust1

19a*

2024N741

2124N626

L40T16

No. No.

L40T16 L40T16

No.

L40T15

No. No.

L40T15 L40T15

No.

L60T16

No. No.

L60T16 L60T16

No.

L85T16

No. No.

L85T16 L85T16

Part

Part Part

24N665

24N666

24N667

24N668

SeePackingRodAssembly,page62

24N477

198307

24N659

24N660

24N661

SeeHighConductivityFluidTube

Assembly,page67

24N751HANDLE;40kVgun1

24N752HANDLE;60kVgun1

24N753HANDLE;85kVgun1

112085

40

kV

Electrostatic

40 40

kV kV

Electrostatic Electrostatic

40

kV

High

40 40

kV kV

60

kV

60 60

kV kV

85

kV

85 85

kV kV

No.

Description

No. No.

Description Description

BODY,gun;40kVgun

BODY,gun;60kVgun

BODY,gun;85kVgun

BODY,gun;40kVhigh
ef󰘰ciencygun

NOZZLE;includes4aand4b

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

POWERSUPPLY,40kVgun

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

See

AlternatorAssembly,page63

SPRING,compression

SPRING,compression

O-RING

BRACKET

SWIVEL,airinlet;M12x1/4
npsm(m);left-handthread

Ef󰘰ciency

High High

Ef󰘰ciency Ef󰘰ciency

Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic

High

Conductivity

High High

Conductivity Conductivity

Electrostatic

Electrostatic Electrostatic

High

Conductivity

High High

Conductivity Conductivity

High

Conductivity

High High

Conductivity Conductivity

Parts

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Air

Air Air
Air

Air Air

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Gun,

Spray Spray

Gun, Gun,

Spray

Spray Spray
Spray

Spray Spray

Ref.

Ref. Ref.
No.

No. No.
2324N633VALVE,air1

23a*

2624N630

2724N740

28*

2924T304

3024N634

34185116

35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

47▲179791

48▲16P802

5024N783

Series

Gun, Gun,

Series Series

Series

Series Series

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Part

No.

Part Part

No. No.

276733

24N699

188749

24N603

24N604

A

A A

A

A A

A

A A
A

A A

Description

Description Description

SEAL,airvalve

SeeESOn-OffandFluid

AdjustmentValve,page64

SCREW,hexsocket;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page65

SeeFanAirAdjustmentValve

Assembly,page65

SPRING,compression

PACKING,u-cup

TUBE,exhaust;1/4in.(6mm)
ID(shippedloose)

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

GREASE,dielectric;1oz(30
ml)tube(notshown)

GLOVE,conductive,medium;
packageof12;alsoavailable
insmall(117823)andlarge
(117825)

COVER,gun,40and60kV
guns;packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 46

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

3A2494D 57

Parts

Smart

Smart Smart

Part

Part Part
Part

Part Part

High

High High

No.

L60M16

No. No.

L60M16 L60M16

No.

L85M16

No. No.

L85M16 L85M16

Conductivity

Conductivity Conductivity

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

Air

Spray

Air Air

Spray Spray

High

High High

High

High High

Gun

Gun Gun

Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Assembly

Assembly Assembly

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

A

A A
A

A A

58 3A2494D

Part

No.

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.

1

2

324N704NEEDLE,electrode1

424N623

4a24N645

4b111507

5

624N644

6a*

11

11a24N979

1224N663

1324A445

14

1524N664

16

17185111

18197624

19249323VALVE,exhaust1

19a*

2024N741

2124A626

2324N633VALVE,air1

23a*

L60M16

No. No.

L60M16 L60M16

No.

L85M16

No. No.

L85M16 L85M16

Part

Part Part

24N666

24N667

SeePackingRodAssembly,page62

24N477

198307

24N660

24N661

SeeHighConductivityFluidTube

Assembly,page67

24N754HANDLE,smart;60kVgun1

24N755HANDLE,smart;85kVgun1

112085

276733

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

No.

Description

No. No.

Description Description

BODY,gun;60kVgun

BODY,gun;85kVgun

NOZZLE;includes4aand4b

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

See

AlternatorAssembly,page63

SPRING,compression

SPRING,compression

O-RING

BRACKET

SWIVEL,airinlet;M12x1/4
npsm(m);left-handthread

SEAL,airvalve

High

Conductivity

High High

Conductivity Conductivity

High

Conductivity

High High

Conductivity Conductivity

Parts

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.
24245265

2624N630

2724N740

28*

2924T304

3024N634

3124N756

34185116

35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

47▲179791

48▲16P802

5024N783

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Part

No.

Part Part

No. No.

24N699

188749

24N603

24N604

A

A A

A

A A

Description

Description Description

CIRCUIT,󰘱exible

SeeESOn-OffandFluid

AdjustmentValve,page64

SCREW,hexsocket;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page65

SeeFanAirAdjustmentValve

Assembly,page65

SeeSmartModuleAssembly,

page66

SPRING,compression

PACKING,u-cup

TUBE,exhaust;1/4in.(6mm)
ID(shippedloose)

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube

GREASE,dielectric;1oz(30ml)
tube(notshown)

GLOVE,conductive,medium;
packageof12;alsoavailable
insmall(117823)andlarge
(117825)

COVER,gun,60kVguns;
packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 46

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

3A2494D 59

Parts

Smart

Smart Smart

Part

Part Part
Part

Part Part
Part

Part Part

Air

Spray

Air Air

Spray Spray

No.

L60M10

No. No.

L60M10 L60M10

No.

L60M12

No. No.

L60M12 L60M12

No.

L85M10

No. No.

L85M10 L85M10

Gun

Gun Gun

60

kV

60 60

kV kV

60

kV

60 60

kV kV

85

kV

85 85

kV kV

Assembly

Assembly Assembly

Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic
Electrostatic

Electrostatic Electrostatic

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

A

A A

A,

with

1.2

mm

A, A,

with with

1.2 1.2

A

A A

Nozzle

mm mm

Nozzle Nozzle

60 3A2494D

Part

No.

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.

1

2

324N651NEEDLE,electrode1

4a24N645

4b111507

5

624N644

6a*

7‡

8‡111285FERRULE,back2

9

10102982

11

11a24N979

1224N663

1324A445

14

1524N664

16

17185111

18197624

19249323VALVE,exhaust1

19a*

2024N741

L60M10

No. No.

L60M10 L60M10

No.

L60M12

No. No.

L60M12 L60M12

No.

L85M10

No. No.

L85M10 L85M10

Part

Part Part

24N666

24N667

SeePackingRodAssembly,page62

24N616

24N615

24N477

198307

111286

24N657

24N658

24N660

24N661

24N696

24N697

24N754HANDLE,smart;60kVgun1

24N755HANDLE,smart;85kVgun1

112085

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

No.

Description

No. No.

Description Description

BODY,gun;60kVgun

BODY,gun;85kVgun

NOZZLE,1.5mm;includes4a
and4b
NOZZLE,1.2mm;includes4a
and4b
O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

FERRULE,front

FITTING,󰘱uid;60kVgun

FITTING,󰘱uid;85kVgun

PACKING,o-ring

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

TUBE,󰘱uid,withsleeve;60kV
gun

TUBE,󰘱uid,withsleeve;85kV
gun

See

AlternatorAssembly,page63

SPRING,compression

SPRING,compression

O-RING

BRACKET

Air

Spray

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Parts

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Qty

Qty Qty

1

1

1

1 4

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

A

A A

A,

with

1.2

mm

A, A,

with with

1.2 1.2

A

A A

Part

Ref.

Part Part

Ref. Ref.
No.

No. No.
2124N626

2224N698NUT1

2324N633VALVE,air1

276733

23a*

24245265

2624N630

2724N740

24N699

28*

2924T304

3024N634

3124N756

34185116

188749

35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

24N603

46

24N604

47▲179791

48▲16P802

5024N783

Nozzle

mm mm

Nozzle Nozzle

No.

Description

No. No.

Description Description

SWIVEL,airinlet;M12x1/4
npsm(m);left-handthread

SEAL,airvalve

CIRCUIT,󰘱exible

SeeESOn-OffandFluid

AdjustmentValve,page64

SCREW,hexsocket;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page65

SeeFanAirAdjustmentValve

Assembly,page65

SeeSmartModuleAssembly,

page66

SPRING,compression

PACKING,u-cup

TUBE,exhaust;1/4in.(6mm)
ID(shippedloose)

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

GREASE,dielectric;1oz(30
ml)tube(notshown)

GLOVE,conductive,medium;
packageof12;alsoavailable
insmall(117823)andlarge
(117825)

COVER,gun,60kVguns;
packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

‡ThesepartsareincludedinFluidSealRepairKit
24N790(purchaseseparately).

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

3A2494D 61

Parts

Packing

Packing Packing

Part

No.

Part Part

No. No.
Includesitems2a-2k
Part

No.

Part Part

No. No.
Includesitems2a-2k
Part

No.

Part Part

No. No.
Includesitems2a-2k

Rod

Assembly

Rod Rod

Assembly Assembly

24N653

24N653 24N653

24N654

24N654 24N654

24N655

24N655 24N655

40

kV

Packing

40 40

kV kV

Packing Packing

60

kV

Packing

60 60

kV kV

Packing Packing

85

kV

Packing

85 85

kV kV

Packing Packing

Rod

Assembly

Rod Rod

Assembly Assembly

Rod

Assembly

Rod Rod

Assembly Assembly

Rod

Assembly

Rod Rod

Assembly Assembly

Part

No.

Ref.

Ref. Ref.
No.

No. No.

2a‡111316

2b‡116905

2c‡178409

2d‡178763

2e

Part Part

24N701

Description

No. No.

Description Description

O-RING

SEAL

PACKING,󰘱uid

PACKING,needle

ROD,packing,40kVguns
(includesitems2jand2k)

24N702

ROD,packing,60kVguns

Qty

Qty Qty

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

2f

2g185495

2h‡186069

2j◆

2k◆

Part

No.

Part Part

197641NUT,packing1

———

———

Description

No. No.

Description Description

HOUSING,packing

SPACER,packing

NUT,triggeradjustment(part
ofitem2e)

NUT,triggeradjustment(part
ofitem2e)

(includesitems2jand2k)

24N703

ROD,packing,85kVguns

1

(includesitems2jand2k)

‡ThesepartsareincludedinFluidSealRepairKit

Partslabeled———arenotavailableseparately.

24N790(purchaseseparately).

◆ThesepartsareincludedinTriggerAdjustmentNut
Kit24N700(purchaseseparately).

62 3A2494D

Qty

Qty Qty

1

1

1

1

Parts

Alternator

Alternator Alternator

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly

24N664

24N664 24N664

Alternator

Alternator Alternator

Assembly

Assembly Assembly

Ref.

Ref. Ref.
No.

No. No.

15a24N705

15b♦24N706

15d♦24N707

15e♦

Part

Part Part
No.

No. No.

———

Description

Description Description

COIL,alternator

BEARINGKIT(includestwo
bearings,item15efan,and
oneitem15hclip)

HOUSING;includesitem15f

FAN;partofitem15b

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

♦ThesepartsareincludedinBearingKit24N706
(purchaseseparately).

Qty

Qty Qty

1

1

1

1

Ref.

Ref. Ref.

No.

No. No.

15f

15g*

15h♦24N709

Part

Part Part
No.

No. No.

———

110073

Description

Description Description

CAP,housing;partofitem
15d

O-RING

CLIP;packageof5(oneclip
includedwithitem15b)

Qty

Qty Qty

1

1

1

Partslabeled———arenotavailableseparately.

3A2494D 63

Parts

ES

On

Off

and

ES ES

On On

- --Off Off

Part

No.

Part Part

24N630

No. No.

24N630 24N630

Fluid

and and

Fluid Fluid

ES

On-Off

ES ES

On-Off On-Off

Adjustment

Adjustment Adjustment

and

Fluid

and and

Adjustment

Fluid Fluid

Adjustment Adjustment

Valve

Valve Valve

Valve

Valve Valve

Part

No.

Ref.

Ref. Ref.
No.

No. No.

26a

26b*

26c

26f

26g

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Part Part

———

15D371

———

24N649

———

Description

No. No.

Description Description

HOUSING,valve

O-RING

PISTON,valve

LEVER,ESon-off

SCREW,set,sockethead

Part

No.

Qty

Qty Qty

1

4

1

1

2

Ref.

Ref. Ref.
No.

No. No.

26h24N631PLATE,retaining1

26j24N648

26m*

26p

Partslabeled———arenotavailableseparately.

Part Part

113746

———

Description

No. No.

Description Description

KNOB,adjustment,󰘱uid

O-RING

SCREW,captive

Qty

Qty Qty

1

2

1

64 3A2494D

Parts

Fan

Air

Fan Fan

Part

Part Part
(shown)

(shown) (shown)

Part

Part Part
(for

round

(for (for

round round

Ref.

Ref. Ref.
No.

No. No.

30a

30b

30c*

30d24N646

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

Adjustment

Air Air

Adjustment Adjustment

No.

24N634

No. No.

24N634 24N634

No.

24N732

No. No.

24N732 24N732

spray

spray spray

Part

Part Part

———

———

———

111504

Fan

Fan Fan

Fan

Fan Fan

guns,

guns, guns,

No.

Description

No. No.

Description Description

NUT,valve1

STEM,valve

STEM,valve;roundsprayonly

O-RING

RING,retaining;packageof6

Valve

Valve Valve

Air

Adjustment

Air Air

Adjustment Adjustment

Air

Adjustment

Air Air

Adjustment Adjustment

not

shown)

not not

shown) shown)

Assembly

Assembly Assembly

Valve

Valve Valve

Valve

Valve Valve

Atomizing

Atomizing Atomizing

Assembly

Assembly Assembly

Assembly

Assembly Assembly

Part

No.

Part Part

No. No.

Assembly

Assembly

Assembly Assembly

Qty

Qty Qty

1

1

1

1

Assembly Assembly

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly

Part

Ref.

Ref. Ref.
No. No.

29a

29b

29c*

29d118907

29e

29f

29g

Part Part

No.

———

———

———

111516

———

———

———

Air

Restrictor

Air Air

Restrictor Restrictor

24T304

24T304 24T304

(shown)

(shown) (shown)

24N733

24N733 24N733

(for

(for (for

Atomizing

Atomizing Atomizing

Atomizing

Atomizing Atomizing

round

spray

round round

spray spray

No.

Description

No. No.

Description Description

HOUSING,valve

BODY,valve

BODY,valve;roundsprayonly

O-RING

RING,retaining

STEM,valve

KNOB,shaft;roundsprayonly

SETSCREW,knob;round
sprayonly

guns,

guns, guns,

Valve

Valve Valve

Air

Restrictor

Air Air

Restrictor Restrictor

Air

Restrictor

Air Air

Restrictor Restrictor

not

not not

Valve

Valve Valve

Valve

Valve Valve

shown)

shown) shown)

Qty

Qty Qty

1

1

1

1

1

1

1

1

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

3A2494D 65

Parts

Smart

Smart Smart

Part

Part Part

Module

Module Module

No.

24N756

No. No.

24N756 24N756

Assembly

Assembly Assembly

Smart

Smart Smart

Module

Module Module

Assembly

Assembly Assembly

Ref.

Ref. Ref.
No.

No. No.

31a

31b24P433

31c24N787

31d♦

31e♦

31f

Part

Part Part

———

———

———

112319

No.

Description

No. No.

Description Description

CARTRIDGE

GASKET

SWITCH,ESHI/LO

SCREW

SCREW,pivot

O-RING

Qty

Qty Qty

1

1

1

3

1

1

Partslabeled———arenotavailableseparately.

♦ThesepartsareincludedinSmartModuleScrew
Kit24N757(purchaseseparately).

66 3A2494D

Parts

High

High High

Part

No.

Part Part

No. No.
Includesitems14a-14c
Part

No.

Part Part

No. No.
Includesitems14a-14c
Part

No.

Part Part

No. No.
Includesitems14a-14c

Conductivity

Conductivity Conductivity

24N627

24N627 24N627

24N628

24N628 24N628

24N629

24N629 24N629

40

40 40

60

60 60

85

85 85

Fluid

Fluid Fluid

kV

High

kV kV

High High

kV

High

kV kV

High High

kV

High

kV kV

High High

Tube

Tube Tube

Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Assembly

Assembly Assembly

Fluid

Tube

Fluid Fluid

Fluid

Fluid Fluid

Fluid

Fluid Fluid

Assembly

Tube Tube

Assembly Assembly

Tube

Assembly

Tube Tube

Assembly Assembly

Tube

Assembly

Tube Tube

Assembly Assembly

Ref.

Ref. Ref.

No.

No. No.

14a**

14b**

14c**

**Includedin24N735HCAdapterKit.

Partslabeled———arenotavailableseparately.

Part

Part Part
No.

No. No.

———

———

———

Description

Description Description

ADAPTER,bracket,handle1

FERRULE2

NUT,bracket,handle1

Qty

Qty Qty

3A2494D 67

AirCapsandFluidNozzles

Air

Air Air

Fluid

Fluid Fluid

Caps

Caps Caps

Nozzle

Nozzle Nozzle

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page27,before

removingorinstallinga󰘱uidnozzleand/oraircap.

Fluid

Fluid Fluid
Nozzle

Nozzle Nozzle
Part

No.

Part Part

No. No.

24N613

24N614

24N615

24N616

24N617

24N618

24N619

24N620

24N621

24N622

24N623

24N624

24N625

and

and and

Selection

Selection Selection

Color

Color Color

Black

Blue

Description

Description Description

For
standard
coatings

With
hardened
seat,for
abrasives
and
metallics

Fluid

Fluid Fluid

Chart

Chart Chart

Nozzles

Nozzles Nozzles

Fluid

Fluid Fluid

Usethefollowingproceduretoselecttheproper󰘱uid
nozzleforyourapplication.

1.Foreach󰘱uidnozzlechart,󰘰ndthepointonthe

2.Thethickverticallineineachgraphrepresents

Ori󰘰ce

Ori󰘰ce Ori󰘰ce
mm

mm mm

0.75(.029)

1.0(.042)

1.2(.047)

1.5(.055)

1.8(.070)

2.0(.079)

0.55(.022)

0.75(.029)

1.0(.042)

1.2(.047)

1.5(.055)

1.8(.070)

2.0(.079)

Size

Size Size

(in.)

(in.) (in.)

3.Fromthemarkedpoint,moveacrosstothe

Key

Key Key

NOTE:

NOTE: NOTE:
guninlet.

Nozzle

Nozzle Nozzle

graphcorrespondingtoyourdesired󰘱owrate
andviscosity.Markthepointoneachgraphwith
apencil.

thetarget󰘱owrateforthatnozzlesize.Find
thegraphthathasthemarkedpointclosestto
thethickverticalline.Thisistherecommended
nozzlesizeforyourapplication.Signi󰘰cantly
exceedingthetarget󰘱owratemayresultin
lowersprayperformanceduetoexcessive󰘱uid
velocity.

verticalscaleto󰘰ndtherequired󰘱uidpressure.
Iftherequiredpressureistoohigh,usethenext
largestnozzlesize.Ifthe󰘱uidpressureistoolow
(<0.35bar,3.5kPa,5psi),usethenextsmallest
nozzlesize.

Fluid

to totoFluid Fluid

Fluidpressuresaremeasuredatthespray

260CentipoiseFluid

160CentipoiseFluid

70CentipoiseFluid

Performance

Performance Performance

Nozzle

Nozzle Nozzle

Performance

Performance Performance

Charts

Charts Charts

Charts

Charts Charts

20CentipoiseFluid

68 3A2494D

AirCapsandFluidNozzles

Table

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

5 55. ..Ori󰘰ce Ori󰘰ce

Ori󰘰ce

6 66. ..Ori󰘰ce Ori󰘰ce

Size:

0.75

mm

Size: Size:

0.75 0.75

FLUID

FLUID FLUID

oz/min,cc/min

Size:

1.0

Size: Size:

1.0 1.0

(0.030

mm mm

(0.030 (0.030

FLOW:

FLOW: FLOW:

mm

(0.040

mm mm

(0.040 (0.040

in.)

in.) in.)

in.)

in.) in.)

Table

Table Table

FLUID

FLUID FLUID
PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

FLUID

FLUID FLUID
PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

8 88. ..Ori󰘰ce Ori󰘰ce

Ori󰘰ce

9 99. ..Ori󰘰ce Ori󰘰ce

Size:

1.5

mm

Size: Size:

1.5 1.5

Size:

1.8

Size: Size:

1.8 1.8

(0.059

mm mm

(0.059 (0.059

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

mm

(0.070

mm mm

(0.070 (0.070

in.)

in.) in.)

in.)

in.) in.)

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

Table

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

7 77. ..Ori󰘰ce Ori󰘰ce

Size:

1.2

mm

Size: Size:

1.2 1.2

(0.047

mm mm

(0.047 (0.047

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

in.)

in.) in.)

Table

10

Table Table

FLUID

FLUID FLUID
PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

10 10

. ..Ori󰘰ce Ori󰘰ce

oz/min,cc/min

Size:

2.0

mm

Size: Size:

2.0 2.0

FLUID

FLUID FLUID

oz/min,cc/min

(0.080

mm mm

(0.080 (0.080

FLOW:

FLOW: FLOW:

in.)

in.) in.)

3A2494D 69

AirCapsandFluidNozzles

Air

Cap

Air Air

Cap Cap

Selection

Selection Selection

Chart

Chart Chart

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page27,before

removingorinstallinga󰘱uidnozzleand/oraircap.

NOTE:

NOTE: NOTE:

Allaircappatternshapesandlengthsinthe
followingchartweremeasuredunderthefollowing
conditions.Patternshapeandlengtharematerial
dependent.

•

•

•

•

Distance to target:

Inlet air pressure:

Fan air:

Fluid 󰘱ow rate:

adjustedformaximumwidth

10in.(254mm)

50psi(34kPa,3.4bar)

10oz/min(300cc/min)

Part

No.

Part Part

No. No.

(color)

(color) (color)

24N438
(black)

24N279
(black)

24N376
(black)
24N276
(blue)
24N277
(red)
24N278
(green)

24N274
(black)

24N275
(black)

24N439
(black)

24N477
(black)
24W279
(green)

24N453
(black)

♦Centipoise=centistokesx󰘱uidspeci󰘰cgravity.

Pattern

Pattern Pattern
Shape

Shape Shape

Round
end

Round
end

Tapered
end

Tapered
end

Tapered
end

Tapered
end

Round
end

Round
end

Length

Length Length
in.

(mm)

in. in.

(mm) (mm)

15-17
(381-432)

14-16
(356-406)

17-19
(432-483)

12-14
(305-356)

14-16
(356-406)

11-13
(279-330)

15-17
(381-432)

14-16
(356-406)

Recommended

Recommended Recommended
Fluid

Viscosity,

Fluid Fluid

Viscosity, Viscosity,

centipoise

centipoise centipoise
70°F

70°F 70°F

Lighttomedium
(20–70cp)

Mediumtoheavy
(70–260cp),and
highsolids(360+cp)

Lighttomedium
(20–70cp)

Lighttomedium
(20–70cp)

Lighttomedium
(20–70cp),andhigh
solids(360+cp),
aerospacecoatings

Forusewith2.0mm
nozzles.Mediumto
heavy(70–260cp),
andhighsolids(360+
cp)

Lighttomedium
(20–70cp)

Lighttomedium
(20–70cp)

(cp)

(cp) (cp)

(21°C)♦

(21°C)♦ (21°C)♦

Recommended

Recommended Recommended

in

in in

at

at at

Production

Production Production

Upto15oz/min(450
cc/min)

Upto15oz/min(450
cc/min)

Upto15oz/min(450
cc/min)

Upto15oz/min(450
cc/min)

Upto25oz/min(750
cc/min)

Upto20oz/min(600
cc/min)

Upto15oz/min(450
cc/min)

Upto15oz/min(450
cc/min)

Rates

Rates Rates

Transfer

Transfer Transfer
Ef󰘰ciency

Ef󰘰ciency Ef󰘰ciency

BetterBest

BetterBetter

BestBetterBetter

GoodGood

Best

Good

BetterBest

BetterBetter

Atomiza-

Atomiza- Atomiza­tion

tion tion

Good

BestBetter

Cleanli-

Cleanli- Cleanli­ness

ness ness

Good

Good

Best

Best

Good

Good

70 3A2494D

AirCapsandFluidNozzles

Air

Consumption

Air Air

Consumption Consumption

Charts

Charts Charts

Key

Key Key

TEST

TEST TEST

Air

Consumption

to totoAir Air

Consumption Consumption

CONDITIONS:

CONDITIONS: CONDITIONS:

gun.

5/16in.x25ft(8mmx

7.6m)hose

5/16in.x50ft(8mmx

15.2m)hose

Table

11

Table Table

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

scfm

24N438

11 11

. ..24N438 24N438

CON-

CON- CON-

Charts

Charts Charts

Fanvalvefullyopen;85kV

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

Table

13

Table Table

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

24N439

13 13

. ..24N439 24N439

CON-

CON- CON-

scfm

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

Table

12

Table Table
Air

Caps

Air Air

Caps Caps

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

24N376,

12 12

. ..24N376, 24N376,

CON-

CON- CON-

scfm

24N276,

24N276, 24N276,

24N277,

24N277, 24N277,

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

and

24N278

and and

24N278 24N278

Table

14

Table Table

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

24N279

14 14

. ..24N279 24N279

CON-

CON- CON-

scfm

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

3A2494D

71

AirCapsandFluidNozzles

Table

15

Table Table

15 15

. ..24N274 24N274

AIR

CON-

AIR AIR

CON- CON-

SUMPTION

SUMPTION SUMPTION

scfm

Table

16

Table Table

16 16

. ..24N275 24N275

24N274

24N275

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

Air

Cap

Air Air

Cap Cap

Table

17

Table Table

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

Table

Table Table

24N453

17 17

. ..24N453 24N453

CON-

CON- CON-

scfm

18

24N477,

18 18

. ..24N477, 24N477,

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

24W279

24W279 24W279

Air

Cap

Air Air

Cap Cap

AIR

CON-

AIR AIR

CON- CON-

SUMPTION

SUMPTION SUMPTION

scfm

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

AIR

CON-

AIR AIR

CON- CON-

SUMPTION

SUMPTION SUMPTION

scfm

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

72

3A2494D

RepairKits,RelatedManuals,andAccessories

Repair

Repair Repair

Gun

Gun Gun
No.

No. No.

Allgunsin
thismanual.

Gun

Gun Gun

Part

Part Part

105749

111265

116553

24N318

24N603

24N604

24N636

24N642

24N704

Kits,

Kits, Kits,

Part

Part Part

Accessories

Accessories Accessories

No.

No. No.

Description

Description Description

40kV,60kV,and85
kVAirSprayGuns

Description

Description Description

CleaningBrush.

Non-siliconeLubricant,4oz(113g).

DielectricGrease.1oz(30ml)

RoundSprayKit.Toconverta
standardairsprayguntoaround
sprayaircap.Seemanual3A2498.

GunCovers.For40kVand60kV
guns.Boxof10.

GunCovers.For85kVguns.Box
of10.

LowPro󰘰leAtomizingAirRestrictor
Valve

BallSwivel,forgunairinlet.1/4
npsm(left-handthread)

ElectrodeReplacementNeedlefor
AbrasiveMaterials.Blue.

Related

Related Related

Manuals,

Manuals, Manuals,

Manual

Manual Manual

ElectrostaticAir
SprayGuns,
Instructions-Parts

Description

Description Description

and

and and

Repair

Repair Repair

24N789

24N790

24N706AlternatorBearingRepairKit

Part

No.

Part Part

No. No.

24P170MetalTriggerKit.

24P171FourFingerTriggerKit.Toconvert

24P172

185105

185493

112534

24N627,
24N628,
24N629

Accessories

Accessories Accessories

Kits

Repair

Kits Kits

Repair Repair

AirSealRepairKit

FluidSealRepairKit

Description

Description Description

ProXpairspraygunstoafour󰘰nger
trigger.

QuickAdjustValve.Forquick
changeoffansize.

Non-swivelAirInlet;1/4–18npsm(m)
(left-handthread)

AirHoseAdapter;1/4npt(m)x
1/4–18npsm(m)(left-handthread)

AirLineQuickDisconnectFitting.

HighConductivityConversion
Kits.ToconvertastandardPro
XpairsprayguntoanHCgun.
SeeHighConductivityFluidTube

Assembly,page67.

Kit

Description

Kit Kit

Description Description

24N758

3A2494D 73

DisplayCovers.KeepsSmartdisplay
clean.Packageof5.

RepairKits,RelatedManuals,andAccessories

Operator

Operator Operator

Part

No.

Part Part

No. No.

117823

117824

117825

24N520

24N521

System

System System

Part

No.

Part Part

No. No.

222011

16P802

16P798

16P799

Accessories

Accessories Accessories

Description

Description Description

ConductiveGloves,boxof12(small)

ConductiveGloves,boxof12
(medium)

ConductiveGloves,boxof12(large)

ComfortGrip.Snap-ongrip
increaseshandlesizetoreduce
operatorfatigue.Mediumsize.

ComfortGrip.Snap-ongrip
increaseshandlesizetoreduce
operatorfatigue.Largesize.

Accessories

Accessories Accessories

Description

Description Description

GroundWireandClamp.

EnglishWarningSign.Availableat
nochargefromGraco.

EnglishDailyCareSign.

EnglishSetupSign

Test

Test Test

Equipment

Equipment Equipment

Part

No.

Part Part

No. No.

241079Megohmmeter.500Voutput,

722886

722860

245277TestFixture,HighVoltageProbe,

24R038

Description

Description Description

0.01–2000megohms.Usefor
groundcontinuityandgunresistance

Not

for

tests.Not Not

PaintResistanceMeter.Usefor󰘱uid
resistivitytest.Seemanual307263.
Not

for

Not Not

for for

PaintProbe.Usefor󰘱uidresistivity
test.Seemanual307263.Not Not
use

use use

in ininhazardous hazardous

andkVMeter.Usetotestthe
electrostaticvoltageofthegun,and
theconditionofthealternatorand
powersupplywhenbeingserviced.
Seemanual309455.Alsorequires
24R038ConversionKit.

VoltageTesterConversionKit.
Convertsthe245277TestFixturefor
usewiththeProXpGunalternator.
Seemanual406999.

use

for for

use use

in ininhazardous hazardous

use

hazardous

use use

in ininhazardous hazardous

hazardous

areas.

areas. areas.

hazardous

areas.

areas. areas.

areas.

areas. areas.

Not

for

for for

24N528

24N529

24P312

GunFlushBoxAdapterfor60and
85kVguns.Toconvertexistinggun
󰘱ushboxestoholdProXpguns.

GunFlushBoxAdapterfor40kV
guns.Toconvertexistinggun󰘱ush
boxestoholdProXpguns.

GunWasherKit.Toconvertexisting
gunwasherstocleanProXpguns.

74

3A2494D

RepairKits,RelatedManuals,andAccessories

Hoses

Hoses Hoses

Grounded

Grounded Grounded

Air

Hoses

Air Air

Hoses Hoses

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

0.315in.(8mm)ID;1/4npsm(f)x1/4npsm(f)left-handthread

Part

No.

Part Part

No. No.

AirFlex

AirFlex AirFlex

244963

244964

244965

24N736

244966

24N737

244967

24N738

244968

244969

Part

Part Part

Standard

Standard Standard

223068

223069

223070

223071

223072

223073

223074

0.375

0.375 0.375
left

left left

Flexible

Flexible Flexible

No.

No. No.

Grounded

Grounded Grounded

in.

(10

in. in.

(10 (10

hand

thread

- --hand hand

thread thread

Description

Description Description

Grounded

Grounded Grounded

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

25ft(7.6m),with112534Quick
Disconnect

36ft(11m)

36ft(11m),with112534Quick
Disconnect

50ft(15m)

50ft(15m),with112534Quick
Disconnect

75ft(23m)

100ft(30.5m)

Description

Description Description

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

mm)

ID;

mm) mm)

ID; ID;

Air

Air Air

Air

Hose

Air Air

Hose Hose

3/8

npsm(f)

3/8 3/8

npsm(f) npsm(f)

Hose

(Gray)

Hose Hose

(Gray) (Gray)

(Gray)

(Gray) (Gray)

1/4

npsm(f)

x xx1/4 1/4

npsm(f) npsm(f)

Part

No.

Part Part

No. No.

Grounded

Grounded Grounded

ground

ground ground

235068

235069

235070

235071

235072

235073

235074

Fluid

Fluid Fluid

path

path path

Hoses

Hoses Hoses

Air

Air Air

Hose

Hose Hose

(Red)

(Red) (Red)

Description

Description Description

with

with with

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

stainless

stainless stainless

steel

braid

steel steel

braid braid

225 psi (1.4 MPa, 14 bar) Maximum Working
Pressure

1/4in.(6mm)ID;3/8npsm(fbe);nylon;FMapproved.

Part

No.

Part Part

No. No.

215637

215638

High

Conductivity

High High

Conductivity Conductivity

Forhighconductivitymaterials.For For

Description

Description Description

25ft(7.6m)

50ft(15m)

Fluid

Fluid Fluid

Hose

Hose Hose

For

60

kV

guns

60 60

kV kV

guns guns

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

1/4in.(6mm)ID;3/8npsm(f)x5/8–20(m);ptfe;FM
approved.

Part

No.

Part Part

No. No.

24N994

Description

Description Description

26.8ft(8.2m)

only.

only. only.

24A225

24A226

50ft(15m)

75ft(23m)

3A2494D 75

Dimensions

Dimensions

Dimensions Dimensions

Gun

Model

Gun Gun

Model Model

A,

in.

(mm)

A, A,

in. in.

(mm) (mm)

B,

in.

(mm)

B, B,

in. in.

(mm) (mm)

C,

in.

(mm)

C, C,

in. in.

(mm) (mm)

Weight,

Weight, Weight,

oz

(g)

oz oz

(g) (g)

L40T10

L40T14

L40T15

L40T16

L60T10

L60T11

L60T12

L60T16

L60M10

L60M12

L60M16

L85T10

L85T16

L85M10

L85M16

8.7(221)9.2(234)2.4(61)19.8(562)

8.7(221)9.2(234)2.4(61)20.0(568)

8.7(221)9.2(234)2.4(61)20.5(582)

8.7(221)9.2(234)2.4(61)20.5(582)

9.5(241)9.2(234)2.4(61)21.1(600)

8.7(221)9.2(234)2.4(61)21.1(600)

9.5(241)9.2(234)2.4(61)21.1(600)

9.5(241)9.2(234)2.4(61)22.6(642)

9.5(241)10(254)2.4(61)23.7(673)

9.5(241)10(254)2.4(61)23.7(673)

9.5(241)10(254)2.4(61)25.4(720)

10.5(267)9.2(234)2.4(61)23.8(676)

10.5(267)9.2(234)2.4(61)25.5(725)

10.5(267)10(254)2.4(61)26.3(746)

10.5(267)10(254)2.4(61)28.0(794)

76 3A2494D

TechnicalData

Technical

Technical Technical

Electrostatic

Electrostatic Electrostatic

MaximumWorkingFluidPressure100psi0.7MPa,7.0bar
MaximumWorkingAirPressure100psi0.7MPa,7.0bar
MinimumAirPressureatGunInlet
MaximumFluidOperating

Temperature
PaintResistivityRange

AirInletFitting
FluidInletFitting

OutputVoltage

MaximumCurrentDraw
SoundPower(measuredperISO

Standard9216)

SoundPressure(measured1m
fromgun)

WettedPartsPEEK,UHMWPE,FEP,PTFE,acetal,nylon,polyethylene

Data

Data Data

Air

Spray

Air Air

Guns

Spray Spray

Guns Guns

U.S.

U.S. U.S.

45psi0.32MPa,3.2bar

120°F48°C

3megohm/cmtoin󰘰nity.Foratableofelectrostaticresultsatdifferent

resistancelevels,seeCheckFluidResistivity,page26.

1/4npsm(m)left-handthread

3/8npsm(m)

ProXp40Models:40kV

ProXp60Models:60kV

ProXp85Models:85kV

125microamperes

at40psi:90.4dB(A)

at100psi:105.4dB(A)

at40psi:87.0dB(A)

at100psi:99.0dB(A)

at0.28MPa,2.8bar:90.4dB(A)

at0.7MPa,7.0bar:105.4dB(A)
at0.28MPa,2.8bar:87.0dB(A)

at0.7MPa,7.0bar:99.0dB(A)

Metric

Metric Metric

3A2494D

77

Graco

Graco Graco

GracowarrantsallequipmentreferencedinthisdocumentwhichismanufacturedbyGracoandbearingitsname
tobefreefromdefectsinmaterialandworkmanshiponthedateofsaletotheoriginalpurchaserforuse.Withthe
exceptionofanyspecial,extended,orlimitedwarrantypublishedbyGraco,Gracowill,foraperiodoftwelvemonths
fromthedateofsale,repairorreplaceanypartoftheequipmentdeterminedbyGracotobedefective.However,any
de󰘰ciencyinthebarrel,handle,trigger,hook,internalpowersupply,andalternator(excludingturbinebearings)willbe
repairedorreplacedforthirty-sixmonthsfromthedateofsale.Thiswarrantyappliesonlywhentheequipmentis
installed,operatedandmaintainedinaccordancewithGraco’swrittenrecommendations.

Thiswarrantydoesnotcover,andGracoshallnotbeliableforgeneralwearandtear,oranymalfunction,damage
orwearcausedbyfaultyinstallation,misapplication,abrasion,corrosion,inadequateorimpropermaintenance,
negligence,accident,tampering,orsubstitutionofnon-Gracocomponentparts.NorshallGracobeliablefor
malfunction,damageorwearcausedbytheincompatibilityofGracoequipmentwithstructures,accessories,
equipmentormaterialsnotsuppliedbyGraco,ortheimproperdesign,manufacture,installation,operationor
maintenanceofstructures,accessories,equipmentormaterialsnotsuppliedbyGraco.

Thiswarrantyisconditionedupontheprepaidreturnoftheequipmentclaimedtobedefectivetoanauthorized
Gracodistributorforveri󰘰cationoftheclaimeddefect.Iftheclaimeddefectisveri󰘰ed,Gracowillrepairorreplace
freeofchargeanydefectiveparts.Theequipmentwillbereturnedtotheoriginalpurchasertransportationprepaid.
Ifinspectionoftheequipmentdoesnotdiscloseanydefectinmaterialorworkmanship,repairswillbemadeata
reasonablecharge,whichchargesmayincludethecostsofparts,labor,andtransportation.

THIS

WARRANTY

THIS THIS

WARRANTY WARRANTY

INCLUDING

INCLUDING INCLUDING
PARTICULAR

PARTICULAR PARTICULAR

Graco’ssoleobligationandbuyer’ssoleremedyforanybreachofwarrantyshallbeassetforthabove.Thebuyer
agreesthatnootherremedy(including,butnotlimitedto,incidentalorconsequentialdamagesforlostpro󰘰ts,lost
sales,injurytopersonorproperty,oranyotherincidentalorconsequentialloss)shallbeavailable.Anyactionfor
breachofwarrantymustbebroughtwithintwo(2)yearsofthedateofsale.

GRACO

GRACO GRACO
FITNESS

FITNESS FITNESS
OR

OR OR
Graco(suchaselectricmotors,switches,hose,etc.),aresubjecttothewarranty,ifany,oftheirmanufacturer.Graco
willprovidepurchaserwithreasonableassistanceinmakinganyclaimforbreachofthesewarranties.

InnoeventwillGracobeliableforindirect,incidental,specialorconsequentialdamagesresultingfromGraco
supplyingequipmenthereunder,orthefurnishing,performance,oruseofanyproductsorothergoodssoldhereto,
whetherduetoabreachofcontract,breachofwarranty,thenegligenceofGraco,orotherwise.

FORGRACOCANADACUSTOMERS

ThePartiesacknowledgethattheyhaverequiredthatthepresentdocument,aswellasalldocuments,noticesand
legalproceedingsenteredinto,givenorinstitutedpursuantheretoorrelatingdirectlyorindirectlyhereto,bedrawn
upinEnglish.LespartiesreconnaissentavoirconvenuquelarédactionduprésentedocumentseraenAnglais,
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MAKES

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IS ISISEXCLUSIVE, EXCLUSIVE,

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DISCLAIMS

DISCLAIMS DISCLAIMS

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Forpatentinformation,seewww.graco.com/patents.

OriginalInstructions.ThismanualcontainsEnglish,MM3A2494

Graco

Graco Graco

International

International International

GRACO

GRACO GRACO

INC.

AND

INC. INC.

Copyright

Copyright Copyright

SUBSIDIARIES

AND AND

SUBSIDIARIES SUBSIDIARIES

2012,

Graco

Inc.

All

2012, 2012,

Graco Graco

Inc. Inc.

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manufacturing

manufacturing manufacturing

www.graco.com

RevisionD,June2014

612-378-3505

Minneapolis

1441

MINNEAPOLIS,

1441 1441

• ••MINNEAPOLIS, MINNEAPOLIS,

locations

locations locations

MN

MN MN

are

registered

are are

registered registered

55440-1441

55440-1441 55440-1441

ISO

to totoISO ISO

USA

• ••USA USA

9001.

9001. 9001.