Graco 3A2495C User Manual

Instructions - Parts

Pro Xp™ Electro

Air-Assisted

For use in Class I, Div. I Hazardous Locations using Group D spray materials. For use in Group II, Zone 1 Explosive Atmosphere Locations using Group IIA spray materials. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions.

3000 psi ( Fluid Wor

100 psi ( Air Work

21 MPa, 210 bar) Maximum

king Pressure

0.7 MPa, 7 bar) Maximum

ing Pressure

Spray Gun

static

3A2495C

See pag and app

e 3 for model part numbers

roval information.

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

Gun Overview .................................................... 7

How the Electrostatic AA Spray Gun

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

Controls, Indicators, and Components ........... 8

Smart Guns ................................................. 9

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

Warning Sign............................................... 15

Ventilate the Spray Booth............................. 15

Air Supply Line ............................................ 16

Fluid Supply Line ......................................... 16

Gun Setup.......................................................... 18

Gun Setup Checklist .................................... 18

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

Check Gun Electrical Grounding ................... 25

Check Fluid Resistivity ................................. 26

Check Fluid Viscosity ................................... 26

Flush Before Using Equipment...................... 26

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

Pressure Relief Procedure............................ 27

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

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

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

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

Clean the Gun Daily..................................... 29

Daily System Care ....................................... 31

Electrical Tests................................................... 32

Test Gun Resistance.................................... 32

Test Power Supply Resistance ..................... 33

Test Gun Barrel Resistance .......................... 34

Troubleshooting.................................................. 35

Spray Pattern Troubleshooting...................... 35

Gun Operation Troubleshooting .................... 36

Electrical Troubleshooting ............................ 37

air................................................................ 39

Rep

pare the Gun for Service ......................... 39

Pre

Cap, Spray Tip, and Fluid Seat Housing

Air

placement.................................. 40

ectrode Replacement ................................ 41

Fluid Tube Rem Fluid Filter R Gun Barrel Rem Gun Barrel In Fluid Needle Power Supply

Alternator Fan Air Adju Atomizing A

ES On-Off V Air Valve R Smart Modu Air Swivel

Parts.................................................................. 54

Standard Air-Assisted Spray Gun

Smart Air-Assisted Spray Gun

Alternator Assembly ..................................... 58

ES On-Off Valve Assembly........................... 59

Fan Air Valve Assembly ............................... 60

Air Cap Assembly ........................................ 61

Smart Module Assembly............................... 61

Spray Tip Selection Chart....................................62

AEM Fine Finish Spray Tips.......................... 62

AEF Fine Finish Pre-Oriﬁce Spray

r Kits, Related Manuals, and

Repai

Acces Gun Ac Syste Test E Hose Oper

Dimensions ........................................................ 66

Technical Data ...................................................67

co Pro Xp Warranty....................................... 68

Gra

cessories.......................................... 64

m Accessories..................................... 64

quipment ........................................... 64

s ......................................................... 65

ator Accessories................................... 65

oval and Replacement........... 42

eplacement............................... 42

oval..................................... 43

stallation.................................. 43

Replacement............................ 44

Removal and

Replacement

Removal and Replacement ........... 46

stment Valve Repair .................. 48

ir Adjustment Valve

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

alve Repair ............................... 50

epair........................................... 51

le Replacement.......................... 52

and Exhaust Valve

Replaceme

Assembly....................................... 54

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

Tips ............................................... 63

sories .......................................... 64

.................................. 45

nt.................................. 53

3A2495C

Models

Part No. kV

H60T10 60

H60M10 60

H85T10 85

H85M10 85

Smart Display Standard Display

✔

II 2 G

EEx 0.24 mJ T6

FM12ATEX0068

EN 50050

Ta 0°C – 50°C

3A2495C 3

Warnings

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

FIRE, EXPL

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent ﬁre, explosion, and electric shock:

• Electrostatic equipment must be used only by trained, qualiﬁed personnel who understand the requirements of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. Resistance must not exceed 1 megohm. See Grounding instructions.

•Onlyuseg

• Do not use pail liners unless they are conductive and grounded.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Check gu

• Use and clean equipment only in well ventilated area.

• Interlock the gun air supply to prevent operation unless ventilating fansareon.

• Use cle

• To clean the exterior of the equipment, cleaning solvents must have a ﬂash point at least 5°C above ambient temperature.

• Always turn the electrostatics off when ﬂushing, cleaning or servicing equipment.

• Elimi plast

• Do not plug or unplug power cords or turn lights on or off when ﬂammable fumes are present.

• Keep spray area free of debris, including solvent, rags and gasoline.

•Keep

OSION, AND ELECTRIC SHOCK HAZARD

rounded Graco conductive air supply hoses.

n resistance, hose resistance, and electrical grounding daily.

aning solvents with highest possible ﬂash point when ﬂushing or cleaning equipment.

nate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and ic drop cloths (potential static arc).

a working ﬁre extinguisher in the work area.

3A2495C

Warnings

WARNING

SKIN INJECTION HAZARD High-pressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray w

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

•Donotputyo

• Do not stop or deﬂect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten al

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and solvent manufacturer’s MSDSs and recommendations.

TOXIC F Toxic ﬂ inhale

• Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using.

•Store

LUID OR FUMES

uids or fumes can cause serious injury or death if splashed in the eyes or on skin,

d, or swallowed.

hazardous ﬂuid in approved containers, and dispose of it according to applicable

lines.

guide

ithout tip guard and trigger guard installed.

ur hand over the spray tip.

l ﬂuid connections before operating the equipment.

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

ective eyewear, and hearing protection.

•Prot

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

3A2495C 5

Warnings

WARNING

EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.

• Do not operat

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alte and create

• Make sure all equipment is rated and approved for the environment in which youareusingit.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hos

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

•Complyw

e the unit when fatigued or under the inﬂuence of drugs or alcohol.

the work area while equipment is energized or under pressure.

r or modify equipment. Alterations or modiﬁcations may void agency approvals

safety hazards.

es and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.

ith all applicable safety regulations.

6 3A2495C

Gun Overview

How the Electr

ostatic AA Spray Gun

Works

This is not an air spray gun. To help prevent serious injury from pressurized ﬂuid, such as skin injection, and splashing ﬂuid, read and follow the Skin Injection Hazard Warnings on page 5.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip atomizes and shapes the ﬂuid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the ﬂuid and completes the atomization of the ﬂuid tails to produce a uniform pattern.

As the gun is triggered, part of the regulated air operates the alternator turbine and the rest of the air helps atomize the ﬂuid being sprayed. The

alternator ge the power car gun’s electr

The ﬂuid is electrostatically charged as it passes the electrode. The charged ﬂuid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

The regulated air that is directed to the air cap can be further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air ﬂow to the air cap while maintaining sufﬁcient air ﬂow to the alternator. The atomizing air adjustment valve does not control pattern width. To change patternwidth,useanewtipsize,orusethefan adjustment to narrow the pattern width.

Thehighw the power

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off. Closing this valve does not affect alternator operation.

nerates power, which is converted by

tridge to supply high voltage to the

ode.

orking ﬂuid pressure of this gun provides

needed to atomize higher solids materials.

3A2495C

Gun Overview

Controls, Ind

The electrostatic gun includes the following controls, indicators, and components (see Fig.

1). For information on Smart guns, also see

Smart Guns, page 9 .

Item Description Purpose

B Fluid Inlet

EElectrode

FFanAir

Air Swivel Inlet

Turbine Air Exhaust

Air Cap/Tip Guard and Spray Tip

Adjustment Valve

icators, and Components

1/4 npsm(m) left-hand thread, for Graco grounded air supply hose.

1/4 npsm(m supply hos

Barbed ﬁtting, for supplied exhaust tube.

See Spray Tip Selection

Chart, page 62, for avail-

able sizes.

Supplie charge

Adjusts fan size and shape. Canbeusedtodecrease pattern width.

), for ﬂuid

s electrostatic to the ﬂuid.

Item Description Purpose

L Inline F

Atomizing Air Adjustment Valve

Trigger Safety Lock

ES On-Off Valve

ES Indicator (standard gun only; for Smart gun indicator, see

Operating Mode, page

9 )

luid

Filter

Adjusts atomi

Locks trigge gun from spra

Turns elect or OFF (O).

Lit when ES is ON (I). Color indicates alternator frequency. See the LED indicator table in the Gun

Setup Checklist, page 18.

Provides ﬁnal ﬁltration of ﬂuid. Located inside ﬂuid tube ﬁtting.

zing air ﬂow.

rtoprevent

ying.

rostatics ON (I)

Figure 1 Gun Overview

8 3A2495C

Smart Guns

Gun Overview

The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:

• Operating Mo

• Diagnostic M

Operating M

ode

Bar Graph

See Fig. 2, Mode displ display u kiloVolt (uA). The value.

If the uA bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. The ﬂuid may be too conductive, or see

Electrical Troubleshooting, page 37 for other possible

causes.

and Table 1 on page 11. The Operating

ays gun data during normal spraying. The

ses a bar graph to show the voltage level in

s (kV) and the current level in microAmperes

bar graph range is from 0 to 100% for each

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the operator to change from low to high voltage.

• The high volt maximum volt

•Thelowvolt when the swi voltage set

Adjusting t

NOTE: If the Error display appears, the Smart module has lost communication with the power supply. See

Error Display, page 10, for further information.

age setting is determined by the

age of the gun and is not adjustable.

age indicator (LO) lights

tch is set to LO. The low

ting is user adjustable. See

he Low Voltage Setting, page 10.

Hz Indicator

The Hz indicator functions the same as the ES indicator on standard guns. The indicator lights to show the alternator speed status, and has three colors:

• Green indicates the alternator speed is correct.

• If the indicator changes to amber after 1 second, increase the air pressure.

• If the indicator changes to red after 1 second, reduce the air pressure.

Figure2 SmartGunModuleinOperatingMode

3A2495C 9

Gun Overview

Error Display

If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, page 37. Communication must be restored to make the Smart module functional.

NOTE: It takes 8 seconds for the Error display to appear. If the gun has been disassembled, wait 8 seconds before spraying to ensure that an Error condition has not occurred.

NOTE: If there is no power to the gun, the Error display will not appear.

for your gun. Continue pressing the button until you reach the desired setting.

NOTE: After 2 s return to the O

NOTE: The low voltage setting may be locked. See

Lock Symbol, page 10.

Figure 4 Low Voltage Setting Screen (Unlocked)

econds of inactivity the display will

perating Screen.

Lock Symbol

Figure 3 Error Display

Adjusting the Low Voltage Setting

The low voltage setting is user adjustable. To access the low voltage setting screen when in Operating Mode, press the LO SET button (LS) momentarily. The screen will display the current low voltage setting. SeeFig. 4,andTable1onpage11. The possible ranges are:

• 85 kV guns: 40–85 kV

• 60 kV guns: 30–60 kV

t the Voltage Adjustment switch (VA) to LO. Press

e LO SET button repeatedly to increase the setting

n increments of 5. When the display reaches the

aximum setting it will return to the minimum setting

The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5, and Table 1 on page 11.

• When in HI mode, the low voltage setting is always locked. The lock symbol will appear when the LO SET button is pressed.

• In LO mode, the lock symbol will only appear if the lock is enabled. See

Low Voltage Lock Screen, page 14,tolock

or unlock the low voltage setting.

gure 5 Low Voltage Setting Screen (Locked)

10 3A2495C

Table 1 . Key for Figs. 2–9.

Item Description Purpose

Gun Overview

LS LO SET bu

Voltage Adjustment Switch

Low Voltage Mode Indicator

Voltage (kV) Display

Current (uA) Display

tton

Two-position gun voltage to high setting ( functional i in Diagnosti

Lights (blue) when the smart gun is set to Low Voltage.

Displays ac of the gun, i Mode, disp In Diagnos displayed

Displays actual spraying current of the gun, in uA. In Operating Mode, display is a bar graph. In Diagnostic Mode, current is displayed as a number.

Press momentarily to enter the Low Voltage Setting screen.

Press an seconds Mode.

switch sets smart

low setting (LO) or

HI). This switch is

n Operating Mode and

c Mode.

tual spraying voltage

n kV. In Operating

lay is a bar graph.

tic Mode, voltage is

as a number.

d hold for approximately 5

to enter or exit Diagnostic

LV Low V

LK Low Voltage Locked

oltage Display

While in Diagnostic Mode, press momentarily to advance through screens.

While on the Low Voltage Lock Screen (in Diagnostic Mode), press and hold to turn the lock on or off.

lays the low voltage setting

Disp

umber. The setting can be

as a n

ged. See Fig. 4.

chan

Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.

3A2495C

Gun Overview

Item Description Purpose

LD Lo Display Appears on the Low Voltage Lock

Screen. See Fig. 9.

ER Error Display

VI Voltage Indicator In Diagnostic Mode, the two top

CI Current Ind

AS Alternator Speed Display

Alternator Speed Indicator In Operating Mode, indicator color

icator

Appears if the communicatio supply. See F

right LEDs of the screen light, indicating that the value displayed is in kV. See Fig. 6.

In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayedisinuA.SeeFig. 7.

In Diagnos displaye

varies to show the alternator speed status:

• green in speed is

•Ifthei after 1 speed i

Smart module loses

nwiththepower

ig. 3.

tic Mode, Hz level is

d as a number. See Fig.

dicates the alternator

at the correct level.

ndicator changes to amber

second, the alternator stoolow.

•Ifthei

In Diagnostic Mode, the indicator is green when in the Alternator Speed (Hertz) screen.

ndicator changes to red

1 second, the alternator

after

is too high. The indicator

speed

lsoturnrediftheError

will a

ay appears.

displ

3A2495C

Diagnostic Mode

Diagnostic Mode includes four screens which display gun data:

Gun Overview

• Voltage (kilo

• Current (mic

• Alternator S

• Low Voltage L

NOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adjustable in Diagnostic Mode. However, the voltage adjustment switch (VA) can be set to HI or LO in Operating Mode and in Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET (LS) button for approximately 5 seconds. The display will go to the Voltage (kiloVolts) Screen, page 13.

To advanc button ag

To exit Diagnostic Mode, press and hold the LO SET button for approximately 5 seconds. The screen will return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic Mode,thelastscreenviewedwillbedisplayedwhen the gun is retriggered.

NOTE: D from th

Low Vol

Volta

e Low Voltage Lock Screen. See

ge (kiloVolts) Screen

Volts) Screen

roAmperes) Screen

peed (Hertz) Screen

ock Screen

e to the next screen, press the LO SET

ain.

iagnostic Mode cannot be exited

tage Lock Screen, page 14 for details.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun as a number (uA), rounded to the nearest 5 uA. The two bottom right LEDs (CI) of the display panel light, indicating that the Current (microAmperes) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Alternator Speed (Hertz) Screen, page 14.Press

and hold for approximately 5 seconds to return to Operating Mode.

The Vo appea and T and h seco

This screen displays the spraying voltage of the gun as a number (kV), rounded to the nearest 5 kV. The two top right LEDs (VI) of the display panel light, indicating that the Voltage (kiloVolts) Screen is displayed. The display is a readout and cannot be changed.

Press the LO SET button to advance to the

Current (microAmperes) Screen, page 13.Press

and hold for approximately 5 seconds to return to Operating Mode.

ltage (kiloVolts) Screen is the ﬁrst screen to

r after entering Diagnostic Mode. See Fig. 6, able 1 on page 11. To enter this screen, press old the LO SET button for approximately 5

nds while in the Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2495C 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.

This screen d number (AS), display is a r alternator s will show 99

The Hz indicator lights green to show that you are viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 14. Press and hold

for approximately 5 seconds to return to Operating Mode.

isplays the alternator speed as a 3 digit

rounded to the nearest 10 Hz. The

eadout and cannot be changed. If the

peed is greater than 999 Hz, the display

Low Voltage Lock Screen

The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Alternator Speed (Hertz) Screen.

This screen d Lock. If the s appears to th is unlocked,

To change the lock status, press and hold the LO SET button until the lock image appears or disappears. If the lock is set, the image will also appear on the Low Voltage Setting Screen when in low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this screen, because pressing and holding the LO SET button is used to turn the lock on or off. To exit, press LO SET momentarily to return to the Voltage (kiloVolts) Screen, then exit Diagnostic Mode from there.

isplays the status of the Low Voltage etting is locked, the lock image (LK)

e left of the Lo display (LD). If the setting

the lock image does not appear.

Figure 8 Alternator Speed (Hertz) Screen

Figure 9 Low Voltage Lock Screen

3A2495C

Installation

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

• Do not install or service this equipment unless you are trained and qualiﬁed.

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I Hazardous Location or a Group II, Zone I Explosive Atmosphere Location.

• Comply with all applicable local, state, and national ﬁre, electrical, and other safety regulations.

Fig. 10 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Installation

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

Ventilate the Spray Booth

Provide fresh air ventilation to reduce the risk of ﬁre or explosion caused by the buildup of ﬂammable or toxic vapors when spraying, ﬂushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all local, state, and national codes regarding air exhaust velocity requirements.

High velocity air exhaust will decrease the operating efﬁciency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufﬁcient.

3A2495C 15

Installation

Air Supply Lin

To reduce the risk of electric shock, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air Supply Hose.

1. See Fig. 10. Use the Graco Grounded Air Supply Hose (AH) to supply air to the gun. The gun air inlet ﬁtting has a left-hand thread. The air supply hose ground wire (AG) must be connected to a true earth ground. Do not connect the air supply hose to the gun air inlet yet.

2. Install an air line ﬁlter/water separator (AF) on the gunairlinetoensureadry,cleanairsupplytothe gun. Dirt and moisture can ruin the appearance of your ﬁnished workpiece and can cause the gun to malfunction.

4. Install a blee air supply lin required in yo and relieve a the pump afte an additiona line(MA)toi

5. Install an a supply line air trapped the air reg

d-type air valve (BV) on the pump

e. The bleed-type air valve (BV) is

ur system to shut off air to the pump

ir trapped between the valve and

r the air regulator is shut off. Install

l bleed-type air valve on the main air

solate the accessories for servicing.

ir bleed valve (BV) on each gun air to shut off air to the gun(s) and relieve

between the valve and the gun after

ulator is shut off.

Fluid Supply Line

1. Blow out t with solv with the ﬂ ﬂuid supp

2. Install linetoc

he ﬂuid line (FL) with air and ﬂush it

ent. Use solvent which is compatible

uid to be sprayed. Do not connect the

lylinetothegunﬂuidinletyet.

a ﬂuid pressure regulator (FR) on the ﬂuid

ontrol ﬂuid pressure to the gun.

To reduce the risk of serious injury due to component rupture, including skin injection, pump pressure must be limited by the pump air regulator. Do not rely on the gun ﬂuid regulator tolimittheﬂuidpressuretothegun.

The ﬂu produ 3000 p

Fluid

supp exce

3. Install bleed-type air regulators (PR, GR) on the pump and gun air supply lines to control air pressure to the pump and gun.

Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including skin injection and splashing ﬂuid in the eyes or on the skin. Do not operate the equipment without the bleed-type air valve (BV) installed.

id supply pump must be prevented from

cing a ﬂuid pressure greater than the

si (21 MPa, 210 bar)

Pressure

ly pressure to a 30:1 ratio pump must not

ed 100 psi (0.7 MPa, 7 bar).

of the gun. For example, the air

Maximum Working

3. Install

4. Theﬂuiddrainvalve(FD)isrequiredinyour

a ﬂuid ﬁlter (FF) near the pump outlet, to remove the spr

NOTE: T additi

To reduce the risk of serious injury, including skin injection and splashing ﬂuid in the eyes or on the skin, do not operate equipment without the ﬂuid drain valve (FD) installed.

system to assist in relieving ﬂuid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufﬁcient. Install a drain valve close to the pump's ﬂuid outlet.

particles and sediment which could clog

ay nozzle.

he gun includes an inline ﬂuid ﬁlter for

onal ﬁltration.

16 3A2495C

NON-HAZARDOUS AREA HAZARDOUS AREA

Installation

Figure 10 Typical Installation

Typical Installation Key

Item Description

AG* Gun Air Hose Ground Wire

AH* Graco Grounded Air Hose (left-hand

AL Pump Air Line Lubricator

BV* Pump Bleed-Type Air Shutoff Valve

EG Electrostatic Air Spray Gun

FD*

FF Fluid Filter

FG Fluid Pressure Gauge

FR Fluid Pressure Regulator

Air Filter/Water Separator

threads)

Fluid Drain Valve

Fluid Supply Line

Item Description

GR Gun Air Pressure Regulator

PG* Pump Ground Wire

PR Pump Air Pressure Regulator

RV Pump Runaway Valve

SP Supply Pump

SV* Ventilation Fan Interlock Solenoid Valve

* These items are required for safe operation. They must be purchased separately.

Fluid Shutoff Valve

Main Air Supply Line

NOTE: The solenoid valve is not offered as a Graco accessory.

3A2495C

Gun Setup

Gun Setup Chec

See Fig. 11 to locate the electrostatic gun controls.

Figure 11 Electrostatic Gun Controls

1. Turn OFF (O) the ES On-Off switch (J).

klist

4. Connect the Graco grounded air hose to the gun air inlet. The gun air inlet ﬁtting has left-hand threads.

5. Follow all steps under Grounding, page 21.

6. Follow all steps under

Check Gun Electrical Grounding, page 25.

Readingmustbelessthan1megohm.

7. Verify that the material resistivity meets requirements for electrostatic spray. See

Check Fluid Resistivity, page 26.

8. Connect the exhaust tube and secure with the clamp provided.

2. Shut off the air bleed valve to the gun.

3. Check gun resistance. See

Test Gun Resistance, page 32.

9. Connect the ﬂuid hose to the gun ﬂuid inlet.

10. Flush if needed. See Flushing, page 28.

18 3A2495C

To reduce the risk of a skin injection injury, always follow the

Pressure Relief Procedure, page 27,

before removing or installing the spray tip, air cap, or tip guard.

11. The ﬂuid output and pattern width depend

on the size of the spray tip, the ﬂuid viscosity, and the ﬂuid pressure. Use the

Spray Tip Selection Chart, page 62, as a guide

for selecting the appropriate spray tip for your application.

12. Align the spray tip tab with the groove in the air

cap. Install the tip.

Gun Setup

15. Check that the ES On-Off switch is OFF (O).

16. Start the pum (2.8 MPa, 28

17. Spray a test the center o in step 21) increment particle s the partic 3000 psi (2

p. Set the ﬂuid regulator to 400 psi

bar).

pattern. Examine the particle size in

f the pattern (tails will be removed

. Increase the pressure in small

s. Spray another pattern. Compare

ize. Continue increasing pressure until

le size remains constant. Do not exceed

1 MPa, 210 bar).

13. Install the air cap and retaining ring. Orientate the air cap and tighten the retaining ring securely.

14. Close the atomizing air adjustment valve (G) and the fan air adjustment valve (F).

18. Turn ON (I) the ES On-Off switch.

3A2495C 19

Gun Setup

19. Check that the ES indicator (K) [Hz indicator on Smart guns] is lit. See the following table.

Table 2 . LED Indicator Colors

Indicator

Color

Green

Amber

Red

20. Set the gun air regulator to deliver a minimum of 45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage. See the table below.

When spraying, the indicator should remain green, indicating sufﬁcient air pressure to the alternator turbine.

If the indicator changes to amber after 1 second, the air pressure is too low. Increase air pressure until the indicator is green.

If the indi after 1 se too high. until the

Description

cator changes to red cond, the air pressure is

Decrease air pressure

indicator is green.

21. Turn the atomizing air adjustment valve counterclockwise until any tails disappear.

22. If desired atomization is not achieved, change the tip size. The smaller the tip oriﬁce, the ﬁner the atomization.

23. Spray a test piece. Examine the edges for coverage. If wrap is poor, see

Troubleshooting, page 35.

Table 3 . Pressure Drop

Air Hose

Length in ft (m)

(using 5/16 in. [8

mm] diameter hose)

15 (4.6) 52 (0.36, 3.6)

25 (7.6) 57 (0.40, 4.0)

50 (15.3) 68 (0.47, 4.7)

75 (22.9) 80 (0.56, 5.6)

100 (30.5) 90 (0.63, 6.3)

Air Regulator Setting

in psi (MPa, bar)

[with gun triggered]

NOTE: If a narrower pattern is needed occasionally, open the fan air adjustment valve slightly. (Excessive fan air ﬂow can cause paint buildup on the air cap.)

20 3A2495C

Grounding

Gun Setup

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a ﬁre, explosion, or electric shock. Ground all equipment, personnel, object being sprayed, and conductive objects in or close to the spray area. Resistance must not exceed 1 megohm. Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic system (see Figs. 12–15). Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

•

Pump/ﬂuid source:

by connecting its ground wire to a true earth ground.

ground the pump/ﬂuid source

•

Object being s

clean and grou

•

All electrically conductive objects or devices in the spray area:

•

Fluid and waste containers:

waste containers in the spray area. Do not use pail liners unless they are conductive and grounded. When ﬂushing the spray gun, the container used to catch the excess ﬂuid must be electrically conductive and grounded.

prayed:

nded at all times.

must be properly grounded.

keep the workpiece hangers

ground all ﬂuid and

•

Electrostatic Air-Assisted Spray Gun:

the gun by connecting the Graco Grounded Air Hose to the gun, and connecting the air hose ground wire to a true earth ground. See

Check Gun Electrical Grounding, page 25.

ground

•

Air compressors:

to the manufacturer's recommendations.

•

All air and ﬂuid lines

Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity

ground the equipment according

must be properly grounded.

3A2495C

Gun Setup

The ﬂoor of the spray area:

• conductive and grounded. Do not cover the ﬂoor with cardboard or any non-conductive material which would interrupt grounding continuity

•

Flammable liquids in the spray area:

in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

must be electrically

must be kept

•

All persons entering the spray area:

shoes having conductive soles such as leather, or wear personal grounding straps. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off ﬁngers or palm area of gloves to ensure your hand contacts the grounded gun handle.

Key to Figs

Fig. 12

Fig. 13

Fig. 14

Fig. 15 Fluid supply line and source must

. 12–15

Operator is grounded through the gun handle and conductive shoes.

Object being sprayed is grounded through contact with the hanger and conveyor system.

Gun is gr conduct

be grounded.

ounded through the

ive air hose.

must wear

3A2495C

Figure 12 Ground the Operator

Gun Setup

Figure 13 Ground the Object being Sprayed

3A2495C 23

Gun Setup

Figure 14 Ground the Gun

Figure 15 Ground the Fluid Supply

3A2495C

Gun Setup

Check Gun Elec

Megohmmeter Part No. 241079 (AA-see Fig.

16) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no ﬂammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause ﬁre, explosion, and electric shock and result in serious injury and property damage.

Graco Part No. 241079 Megohmmeter is available as an accessory to check that the gun is properly grounded.

trical Grounding

5. Make sure the g and the hose gr earth ground.

6. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm. See Fig. 16.

7. If the resistance is greater than 1 megohm, check the tightness of the ground connections and be suretheairhosegroundwireisconnectedtoa true earth ground. If the resistance is still too high, replace the air hose.

rounded air hose is connected

ound wire is connected to a true

1. Have a qualiﬁed electrician check the electrical grounding continuity of the spray gun and air hose.

2. Turn OFF (O) the ES On-Off switch.

3. Turn off the air and ﬂuid supply to the gun. Follow the Pressure Relief Procedure, page 27.

4. Disconnect the ﬂuid hose.

Figure 16 Check Gun Electrical Grounding

3A2495C 25

Gun Setup

Check Fluid Re

To reduce the risk of ﬁre, explosion, or electric shock, check the ﬂuid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

Failure to follow this warning could cause ﬁre, explosion, or electric shock and result in serious injury and property damage.

Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the ﬂuid being sprayed meets the requirements of an electrostatic air-assisted spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

Table 4 . Fluid Resistivity Levels

sistivity

Check Fluid Vi

To check ﬂuid viscosity you will need:

• a viscosity cu

• a stopwatch.

1. Completely submerge the viscosity cup in the ﬂuid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2. Watch the stream of ﬂuid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3. Record the ﬂuid type, elapsed time, and size of the viscosity cup.

4. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

scosity

Flush Before Using Equipment

The equipment was tested in ﬂuid at the factory. To avoid contaminating your ﬂuid, ﬂush the equipment with a compatible solvent before using the equipment.

Megohms-cm

1–5 5–25 25–200 200–2000

Test electrostatic performance

Good electrostatic results

Best electrostatic results

Good electrostatic results

26 3A2495C

Operation

Pressure Reli

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Turn OFF (O) the ES On/Off switch.

2. Engage the trigger lock.

ef Procedure

6. Engage the tr

7. Open the pum

container thepumpdr to spray ag

8. If the spray tip or hose is completely clogged or

pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the spray tip or hose.

igger lock.

pdrainvalve,havingawaste

ready to catch the drainage. Leave

ain valve open until you are ready

ain.

3. Turn off the air bleed valves to the ﬂuid source and to the gun.

4. Dis

5. Trigger the gun into a grounded metal waste

engage the trigger lock.

container to relieve the ﬂuid pressure.

Startup

Follow all steps under Gun Setup Checklist, page 18.

Shutdown

1. Flush the gun. See Flushing, page 28.

2. Follow the Pressure Relief Procedure, page 27.

3. Hang the gun from its hook, with the nozzle pointing down.

3A2495C

Maintenance

Flushing

•Flushbefore in the equipm storing, and

•Flushatthe connectors

•Flushwitha being dispe

To reduce the risk of ﬁre, explosion, or electric shock, turn OFF (O) the ES On-Off switch before ﬂushing the gun.

changing ﬂuids, before ﬂuid can dry

ent, at the end of the day, before

before repairing equipment.

lowest pressure possible. Check

for leaks and tighten as necessary.

ﬂuid that is compatible with the ﬂuid

nsed and the equipment wetted parts.

NOTICE

Do not use methylene chloride as a ﬂushing or cleaning solvent with this gun as it will damage nylon components.

1. Turn OFF (O) the ES On-Off switch.

5. Point the gun until clean s

6. Follow the Pressure Relief Procedure, page 27. Engage the trigger lock.

7. Shut off or disconnect the solvent line.

8. Align the spray tip tab with the groove in the air cap. Install the tip.

into a grounded metal pail. Flush

olvent ﬂows from the gun.

2. Follow the Pressure Relief Procedure, page 27.

3. Removeandcleantheaircapandspraytip.

4. Change the ﬂuid source to solvent, or disconnect the ﬂuid line and connect a solvent supply line to the gun.

9. Reinstall the air cap, tip guard, and retaining ring.

10. Hang the gun from its hook, with the nozzle pointing down.

11. When ready to spray again, reconnect the ﬂuid supply line. Follow the

Gun Setup Checklist, page 18.

28 3A2495C

Maintenance

Clean the Gun D

1. Turn OFF (O) the ES On-Off switch.

2. Follow the P

3. Remove the

ressure Relief Procedure, page 27.

air cap/tip guard and spray tip.

aily

6. Clean the outside of the gun with a compatible

solvent. Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun.

4. Flush the gun, see Flushing, page 28.

5. Follow the Pressure Relief Procedure, page 27.

3A2495C 29

Maintenance

7. Clean the air cap/tip guard and spray tip with a soft brush and compatible solvent.

8. If necessary, use a toothpick or other soft tool to clean the air cap holes. Do not use metal tools.

9. Align the spray tip tab with the groove in the air cap. Install the tip.

10. Install the air cap and retaining ring. Orientate the air cap and tighten the retaining ring securely.

30 3A2495C

Maintenance

Daily System C

1. Follow the instructions under

Clean the Gun Daily, page 29. Follow

the Pressure Relief Procedure, page 27.

2. Clean the ﬂuid and air ﬁlters.

3. Check for ﬂuid leaks. Tighten all ﬁttings.

4. Clean workpiece hangers. Use non-sparking tools.

are

5. Check the movement of the trigger and valves. Lubricate if necessary.

6. Check Gun El

7. Hang the gun pointing do

ectrical Grounding, page 25.

from its hook, with the nozzle

wn.

3A2495C 31

Electrical Test

Electrical Tests

Use the follow of the power su continuity be

ing procedures to test the condition

pply and gun body, and electrical

tween components.

NOTICE

The gun body resistor cartridge is part of the body and is not replaceable. To avoid destroying the gun body, do not attempt to remove the body resistor.

Use megohmmeter Part No. 241079 (AA) with an applied voltage of 500 V. Connect the leads as shown.

Megohmmeter Part No. 241079 (AA-see Fig.

17) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

Test Gun Resis

1. Flush and dry the ﬂuid passage.

2. Measure resistance between the electrode needle tip (25a) and the air swivel (21). The resistance should be:

• 106–150 meg

• 150–195 meg

If outside t

Test Power

range, see other poss

Electrical Troubleshooting, page 37 for

ible causes of poor performance.

tance

ohms for 60 kV guns

ohms for 85 kV guns

his range, go to

Supply Resistance, page 33.Ifin

Failure to follow this warning could cause ﬁre, explosion, and electric shock and result in serious injury and property damage.

Figure 17 Test Gun Resistance

32 3A2495C

Electrical Test

Test Power Sup

1. Remove the power supply (11). See Power

Supply Removal and Replacement, page 45.

2. Remove the alternator (15) from the power supply. See

Alternator Removal and Replacement, page 46.

3. Measure resistance from the power supply's ground strips (EE) to the spring (11a). The resistance should be:

• 86–110 mego

• 130–160 me

4. If outside power supp

Test Gun Ba

5. If you sti

Electric

other pos contact y

this range, replace the

ll have problems, refer to

al Troubleshooting on page 23 for

sible causes of poor performance, or

our Graco distributor.

ply Resistance

hms for 60kV guns

gohms for 85kV guns

ly. If in range, go to

rrel Resistance, page 34.

6. Be sure the spring (11a) is in place before reinstalling the power supply.

Figure 18 Test Power Supply Resistance

3A2495C 33

Electrical Test

Test Gun Barre

1. Insert a conductive rod (B) into the gun barrel (which was removed for the power supply test) and against the metal contact (C) in the front of the barrel.

2. Measure the resistance between the conductive rod (B) and the conductive ring (9). The resistance should be 10–30 megohms. If the resistance is incorrect, make sure the metal contact (C) in the barrel and the conductive ring (9) are clean and undamaged.

3. If the resistance is still outside the range, remove the conductive ring (9) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the conductive ring groove.

4. If the resistance is in range, replace the conductive ring (9) with a new one. Insert the ends of the conductive ring into the slots (S) at the front of the barrel, then press the ring ﬁrmly intothegroove(G).

l Resistance

The conductive ring (9) is a conductive (metal) contact ring, not a sealing o-ring. To reduce the risk of ﬁre, explosion, or electric shock:

•Donotremove to replace it

• Never operat ring in place

• Do not repla anything bu

5. If the resistance is still outside the range, replace the gun barrel.

the conductive ring except

e the gun without the conductive

ce the conductive ring with

t a genuine Graco part.

Figure 19 Test Gun Barrel Resistance

34 3A2495C

Troubleshooting

Troubleshootin

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualiﬁed.

NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

To reduce the risk of a skin injection injury, always follow the Pressure Relief Procedure, page 27, whenever you are instructed to relieve the pressure.

Spray Pattern Troubleshooting

NOTE: Some spray pattern problems are caused by the improper balance between air and ﬂuid.

Problem

Fluttering or spitting spray.

Irregular pattern.

Cause Solution

No ﬂuid. Reﬁll supply.

Air in ﬂuid supply. Check ﬂuid source. Reﬁll.

Fluid buildup; partially plugged tip.

Worn/damaged tip or air cap holes.

Clean. See

Clean the Gun Daily, page 29.

Clean or replace.

ern pushed to one side; air

Patt

ets dirty.

cap g

Tails in pattern.

Fluid buildup on air cap/tip guard.

ap holes plugged.

Air c

Air pressure too low.

Fluid pressure too low. Increase.

Air pressure too high. Decrease.

luid pressure too low.

Air cap holes plugged.

Clean. See

Clean the Gun Daily, page 29.

n atomizing air adjustment

Ope

ve.

val

ncrease.

Clean. See

Clean the Gun Daily, page 29.

3A2495C 35

Troubleshootin

Gun Operation

Problem

Excessive spray fog.

“Orange Peel” ﬁnish.

eaks from the ﬂuid packing

Fluid l area.

Air leaks from the front of the gun.

Fluid leakage from the front of the gun.

Troubleshooting

Cause Solution

Atomizing air

Fluid too thin.

Atomizing air pressure too low.

Spray tip is too large. Use smaller tip. See Spray Tip

Poorly m

Fluid too thick. Reduce viscosity.

Worn ﬂu

Air valve is not seating properly.

Worn or damaged ﬂuid needle ball. See Fluid Needle Replacement,

pressure too high.

ixed or ﬁltered ﬂuid.

id needle packings or rod.

Close atomizing air valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.

Increase vi ﬂow rate.

Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.

Selection Chart, page 62.

Remix or

See Flu

page 44.

See Air Valve Repair, page 51.

page 44.

scosity or increase ﬂuid

reﬁlter ﬂuid.

id Needle Replacement,

ﬂuid seat housing.

Worn

Loose spray tip. Tighten retaining ring.

Damaged tip seal.

Gun does not spray.

Dirty air cap. Damaged or plugged air cap.

Excessive paint wrap back to operator.

Low ﬂuid supply. Add ﬂuid if necessary.

amaged spray tip.

Dirty or clogged spray tip.

Damaged ﬂuid needle. See Fluid Needle Replacement,

Poor grounding.

Incorrect distance from gun to part. Should be 8–12 in. (200–300 mm).

ir Cap, Spray Tip, and Fluid

See A

t Housing Replacement, page

Sea

40.

e Air Cap, Spray Tip, and Fluid

at Housing Replacement, page

40.

eplace.

Clean. See

Clean the Gun Daily, page 29.

page 44.

Clean air cap. See

Clean the Gun Daily, page 29.

See Grounding, page 21.

36 3A2495C

Electrical Troubleshooting

Troubleshootin

Problem

Poor wrap.

Cause Solution

ES On/Off switch is OFF (O). Turn ON (I).

Gun air pressure too low (ES indicator is amber).

Atomizing air pressure too high. Decrease.

Fluid press

Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).

Poorly gro

Faulty gun resistance.

Low ﬂuid resistivity. See

Fluid l packin

Faulty alternator.

ES On/Off switch is OFF (O). Turn ON (I).ES or Hz indicator is not lit.

ure too high.

unded parts.

eaks from the ﬂuid needle

gs and causes a short.

Check air pressure to gun; minimum45psi(0.32MPa,3.2 bar) needed at gun for full voltage.

Decrease, o

Resistanc less. Cle

See

Test Gun Resistance, page 32.

Check Fluid Resistivity, page 26.

See Flu

page 44.

See Alternator Removal and

Replacement, page 46.

r replace worn tip.

e must be 1 megohm or

an workpiece hangers.

id Needle Replacement,

perator gets shock from

O workpiece.

No power.

Operator not grounded or is near ungrounded object.

Gun not grounded. See Check Gun Electrical

Workpiece not grounded. Resistance must be 1 megohm or

k power supply, alternator,

Chec

lternator ribbon cable. See

and a

er Supply Removal and

Pow

lacement, page 45 and

Rep

ernator Removal and

Alt

lacement, page 46.

Rep

See Grounding, page 21.Operator gets mild shock.

Grounding, page 25,and Test Gun Resistance, page 32.

less. Clean workpiece hangers.

3A2495C 37

Troubleshootin

Problem

Voltage/current display stays red (smart guns only).

ES or Hz indi

ES or Hz indicator is red.

Error display appears and Hz indicator is red (Smart guns only).

cator is amber.

Cause Solution

Gun is too clos sprayed.

Check ﬂuid resistivity. See

Dirty gun.

Alternator speed is too low. Increase air pressure until

Alternat

Smart module has lost communication with the power supply.

or speed is too high.

e to the part being

Gun should be 8 mm) from the pa

Check Fluid Resistivity, page 26.

See Clean the Gun Daily, page 29.

indicator is green. To avoid over-atomization, use the atomizing air restrictor valve to reduce the atomizing air to the air cap.

Decrease indicato

Check for good connections between Smart Module and power supply. See Smart Module

Replacement, page 52 and Power Supply Removal and Replacement, page 45.

r is green.

–12 in. (200–300 rt.

air pressure until

38 3A2495C

Repair

Prepare the Gun for Service

Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualiﬁed.

To reduce the risk of injury, follow the

Pressure Relief Procedure, page 27, before

checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

• Check all

Trouble

the gun.

possible remedies in

shooting, page 35, before disassembling

Repair

• Use a vise with padded jaws to prevent damage to plastic parts.

• Lubricate the some needle assembly parts (20) and certain ﬂuid ﬁttings with dielectric grease (57), as speciﬁed in the text.

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

• Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models.

• Air Seal Repair Kit 24N789 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (3*).

1. Flush the gun. See Flushing, page 28.

2. Relieve the pressure. See

Pressure Relief Procedure, page 27.

3. Disconnect the gun air and ﬂuid lines.

4. Remove t

must be c

he gun from the worksite. Repair area

lean.

3A2495C 39

Repair

Air Cap, Spray

1. See Prepare the Gun for Service, page 39.

2. Remove the retainer ring (22) and air cap/tip guard assembly (25).

Figure 20 Remove Air Cap

3. Disassemble the air cap assembly. Check the condition of the u-cup (22a), o-ring (25b), and tip gasket (27a). Replace any damaged parts.

Tip, and Fluid Seat Housing Replacement

4. To replace the electrode (25a), see

Electrode Replacement, page 41.

The conductive ring (9) is a conductive metal contact ring, not a sealing o-ring. To reduce the risk of ﬁre, explosion, or electric shock:

• Do not remove the conductive ring except to replace it.

• Never operate the gun without the conductive ring in place.

• Do not replace the conductive ring with anything but a genuine Graco part.

5. Trigger the gun and remove the ﬂuid seat housing (24), using the multi-tool (61).

Figure 21 Disassemble Air Cap Assembly

gure 22 Tip Gasket

Figure 23 Replace Fluid Seat Housing

40 3A2495C

Repair

NOTICE

Do not overtighten the ﬂuid seat housing (24). Overtightening may damage the housing and the gun barrel, resulting in improper ﬂuid shutoff.

6. Trigger the g (24). Tighte

7. Check that t Align the sp cap (25). In

8. Make sure t correctly

9. Check that

10. Check that retainin face forw

un and install the ﬂuid seat housing

n until snug, then 1/4 turn more.

he spray tip gasket (27a) is in place. ray tip tab with the groove in the air

stall the spray tip (27) in the air cap.

hat the electrode (25a) is installed

in the air cap.

the air cap o-ring (25b) is in place.

the u-cup (22a) is in place on the

gring(22). Thelipsoftheu-cupmust

ard.

NOTICE

To avoid air cap a retaini when the

damaging the tip guard, orient the

ssembly (25) before tightening the

ng ring (22). Do not turn the air cap

retaining ring is tight.

Electrode Replacement

To reduce the risk of ﬁre, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap.

1. See Prepare the Gun for Service, page 39.

2. Remove the air cap assembly (25). See

Air Cap, Spray Tip, and Fluid Seat Housing Replacement, page 40.

3. Pull the electrode (25a) out of the back of the air cap, using a needle-nose pliers.

4. Push the new electrode through the air cap hole. Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap. Press the electrode in place ﬁrmly with your ﬁngers.

5. Install the air cap assembly.

6. See Test Gun Resistance, page 32.

11. Orientate the air cap and tighten the retaining ring securely.

12. See Test Gun Resistance, page 32.

Figure 24 Replace Electrode

3A2495C

Repair

Fluid Tube Removal and Replacement

1. See Prepare th

2. Disconnect th

3. Carefully uns

e Gun for Service, page 39.

e bottom ﬂuid tube nut (C).

crew the top ﬂuid tube nut (D).

NOTICE

Be careful not to damage the ﬂuid tube assembly (19) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire ﬂuid tube assembly must be replaced.

4. Apply diel the plasti

5. Apply low s threads.

6. Install t tighten t tighter. barrel.

7. Make sur ﬂuid ﬁtt onto the tight.

ectric grease (57) to the entire length of

c extension on the ﬂuid tube.

trength sealant to the ﬂuid tube nut

he ﬂuid tube into the gun barrel and

he top nut (D) until snug, then 1/2 turn

There will be a gap between the nut and

Do not over-tighten the nut.

e the ﬂuid ﬁlter (10) is in place in the

ing. Tighten the bottom nut (C) securely

ﬁtting. Make sure the top nut remains

Fluid Filter Replacement

1. See Prepare th

2. Disconnect th

3. Remove the ﬂui Clean or repl

4. Install the ﬂ the bottom nu 140–150 in-l top nut rema

e Gun for Service, page 39.

e bottom ﬂuid tube nut (C).

d ﬁlter (10) from the ﬂuid ﬁtting.

ace the ﬁlter, as needed.

uid ﬁlter (10) in the ﬂuid ﬁtting. Tighten

t (C) onto the ﬁtting and torque to

b (15.8–16.9 N•m). Make sure the

ins tight at 20–30 in-lb (2.3–3.4 N•m).

NOTICE

Be sure the ﬂuid tube (19) is not twisted after tightening the bottom nut (C).

Figure 25 Fluid Tube

Figure 26 Replace Fluid Filter

3A2495C

Repair

Gun Barrel Rem

1. See Prepare the Gun for Service, page 39.

2. Disconnect the bottom ﬂuid tube nut (N). Carefully separate the tube assembly (T) from the bracket (7).

3. Loosen the two screws (6).

oval

NOTICE

To avoid dam pull the gun handle. If barrel fro handle.

4. Hold the gun handle (16) with one hand and pull the barrel (1) straight off the handle.

NOTE: If t remove th the barr

he power supply remains in the barrel,

e alternator/power supply assembly from

el.

aging the power supply (11),

barrel straight away from the gun

necessary, gently move the gun

msidetosidetofreeitfromthegun

Gun Barrel Ins

1. Be sure the gasket (5*) and grounding spring (37a) are in place. Make sure the gasket air holes are aligned properly. Replace the gasket if damaged.

2. Make sure the spring (11a) is in place on the tip of the power supply (11). Liberally apply dielectric grease (57) to the tip of the power supply. Place the gun barrel (1) over the power supply and onto the gun handle (16).

3. Tighten the two screws (6) oppositely and evenly (about a half turn past snug). Do not over-tighten the screws (6).

4. Make sure the ﬂuid ﬁlter (10) is in place in the ﬂuid ﬁtting. Tighten the bottom nut (N) onto the ﬁtting and torque to 140–150 in-lb (15.8–16.9 N•m). Make sure the top nut remains tight.

5. See Test Gun Resistance, page 32.

tallation

Figure 28 Gun Barrel Installation

Figure 27 Gun Barrel Removal

3A2495C 43

Repair

Fluid Needle Replacement

1. See Prepare th

2. Remove the air housing. See A

Housing Repla

3. Remove the gu

Gun Barrel Re

4. Remove the tr

5. Unscrew the (20a).

6. Insert the s back of the segments o the needle

7. Using the m nut (N) to

8. Install t Push in on tighten.

9. Install

10. Install groundi

he ﬂuid needle assembly in the gun barrel.

thespring(20a).

the spring cap (37). Make sure the

igger screws (13) and trigger (12).

spring cap (37). Remove the spring

upplied driver (60) in the socket at the

ﬂuid needle. Press forward so the two

f the needle engage (R). This allows

to be unscrewed from the gun body.

ulti-tool (61), pull back on the packing

remove the ﬂuid needle assembly.

the needle with the driver (60) and

ng spring (37a) is in place.

e Gun for Service, page 39.

cap assembly and ﬂuid seat

ir Cap, Spray Tip, and Fluid Seat

cement, page 40.

nbarrel. See

moval, page 43.

Figure 29 Remove Cap and Springs

Figure 30 Remove Fluid Needle

11. Install

12. Instal

13. Instal

14. See Te

l the gun barrel. See

Gun Bar

l the seat housing and air cap assembly. See Air

Repla

the trigger (12) and screws (13).

rel Installation, page 43.

Cap, Spray Tip, and Fluid Seat Housing

cement, page 40.

st Gun Resistance, page 32.

Figure 31 Replace Fluid Needle

3A2495C

Repair

Power Supply R

• Inspect the gun handle power supply cavity for dirt

or moisture. Clean with a clean, dry rag.

• Do not expose gasket (5) to solvents.

1. See Prepare the Gun for Service, page 39.

2. See Gun Barrel Removal, page 43.

emoval and Replacement

NOTICE

Be careful when handling the power supply (11) to avoid damaging it.

3. Grasp the power supply (11) with your hand.

With a gentle side to side motion, free the power supply/alternator assembly from the gun handle (16), then carefully pull it straight out.

Models only,

from the socket at the top of the handle.

4. Inspect the power supply and alternator for

damage.

5. To separate the power supply (11) from the

alternator (15), disconnect the 3-wire ribbon connector (PC) from the power supply.

Models only,

(40) from the power supply. Slide the alternator up and off the power supply.

6. See Test Power Supply Resistance, page 33.

Replace the power supply if necessary. To repair the alternator, see

Alternator Removal and Replacement, page 46.

Smart models only:

circuit (40) to the power supply.

disconnect the ﬂexible circuit (40)

disconnect the 6–pin ﬂexible circuit

connect the 6–pin ﬂexible

On Smart

(EE) make contact with the handle. On Smart models, align the connector of the 6–pin ﬂexible circuit (40) with the socket (CS) at the top of the handle. Push the connector securely into the socket as you slide the power supply/alternator assembly into the handle.

Figure 32 Connect Flexible Circuit

10. Make sure the gasket (5*), ground spring (37a), and power supply spring (11a) are in place. Assemble the barrel (1) to the handle (16). See

Gun Barrel Installation, page 43.

11. See Test Gun Resistance, page 32.

To prevent damage to the cable and possible interruption of the ground continuity, bend the alternator’s 3–wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.

8. Connect the 3-wire ribbon connector (PC) to the power supply. Tuck the ribbon forward, under the power supply. Slide the alternator (15) down onto the power supply (11).

9. Insert the power supply/alternator assembly in the gun handle (16). Make sure the ground strips

Figure 33 Power Supply

3A2495C 45

Repair

Alternator Removal and Replacement

NOTE: Replace of operation. Parts include

1. See Prepare the Gun for Service, page 39.

2. Remove the power supply/alternator assembly and disconnect the alternator. See Power Supply

Removal and Replacement, page 45.

3. Measure resistance between the two outer terminals of the 3-wire connector (PC); it should be 2.0–6.0 ohms. If outside this range, replace the alternator coil (15a).

4. Using a ﬂat blade screwdriver, pry the clip (15h) off the housing (15d). Remove the cap (15f), using a thin blade or screwdriver.

5. If necessary, rotate the fan (15e) so its blades clear the four bearing tabs (T) of the housing (15d).

alternator bearings after 2000 hours

Order Part No. 24N706 Bearing Kit.

dinthekitaremarkedwithasymbol(♦).

Figure 35

Alternator Cross-Section

NOTICE

Do not scratch or damage the magnet (M) or shaft (S). Do not pinch or damage the 3–wire connector (PC) when disassembling and reassembling the bearings.

Figure 34 Fan Orientation

6. Push the fan and coil assembly (15a) out the front of the housing (15d).

7. Hold th with th screwd

8. Remov

9. Remov

10. Insta

11. Pres

ll the new bottom bearing (15b1♦) on the

long e

ng must face away from the magnet (M).

beari

all in the coil (15a) so the bearing blades are

Inst ﬂush

s the new top bearing (15b2♦) onto the short

end o

the surface of the coil (15a). The ﬂatter side

with

he bearing must face away from the coil.

of t

e coil assembly (15a) on a workbench

efanendfacingup. Usingawideblade

river, pry the fan (15e) off the shaft (S).

e the top bearing (15b2).

e the bottom bearing (15b1).

nd of the shaft (S). The ﬂatter side of the

with the surface of the coil.

f the shaft so the bearing blades are ﬂush

46 3A2495C

Repair

12. Hold the coil assembly (15a) on a workbench with the fan end facing up. Press the fan (15e♦) onto the long end of the shaft (S). The fan blades must be oriented as shown.

13. Carefully press the coil assembly (15a) into the front of the housing (15d♦). The 3–wire connector (PC) must be positioned below the wider notch (W) of the housing tabs, as shown in Fig. 35. Be sure the coil alignment pins (P) are positioned as shown in Fig. 34.

14. Rotate the fan (15e) so its blades clear the four bearing tabs (T) at the back of the housing.

Ensure that the blades of the bottom bearing (15b1♦) align with the tabs.

15. Seat the coil fully into the housing (15d♦). Secure with the clip (15h♦), ensuring that its tabs engage the slots in the housing.

16. Ensure that the o-ring (15g) is in place. Install the cap (15f).

17. Install the alternator on the power supply, and install both parts in the handle. See Power

Supply Removal and Replacement, page 45.

Figure 36 Alternator

3A2495C

Repair

Fan Air Adjustment Valve Repair

1. See Prepare th

2. Place a wrench (30) and unscr

NOTE: You may assembly (go (steps 3-9).

3. Remove the re

4. Turn the val it comes fre

5. Remove the o

6. Clean all p

NOTE: Use n

111265. Do

7. When reas lubricat (30b) ful Install t the valve

ve shaft (30b) counterclockwise until

e from the valve housing (30a).

arts and inspect for wear or damage.

not over-lubricate.

sembling the fan air valve (30), lightly

e the valve threads and screw the shaft

ly into the housing (30a) until bottomed.

he o-ring (30c*), lubricate, and unscrew

stem until the o-ring enters the housing.

e Gun for Service, page 39.

on the ﬂats of the valve assembly

ew it from the handle (16).

replace the valve as an

to step 9) or as individual parts

taining ring (30d).

-ring (30c).

on-silicone grease, Part No.

8. Reassemble th the valve stem by the retaini

9. Screw the valv handle (16), housing. Tor

Figure 37 Fan Air Adjustment Valve

e retaining ring (30d). Unscrew from the housing until it is stopped

ng ring.

e assembly (30) into the gun using a wrench on the ﬂats of the que to 15 in-lb (1.7 N•m).

48 3A2495C

Atomizing Air Adjustment Valve Repair

Repair

1. See Prepare th

2. Place a wrench (29) and unscr

3. Inspect the v anewvalve(2

4. Before insta handle, unsc housing (29

5. Install the Torque the v N•m).

alve assembly. If damaged, install

lling the valve assembly in the

rew the valve stem (29b) from the

a) until it stops.

valve assembly into the gun handle.

alve housing (29a) to 15 in-lb (1.7

e Gun for Service, page 39.

on the ﬂats of the valve assembly

ew it from the handle (16).

9).

Figure 38 Ato

mizing Air Adjustment Valve

3A2495C 49

Repair

ES On-Off Valv

1. See Prepare the Gun for Service, page 39.

2. Loosen the captive screw (26p). Remove the valve (26) from the handle.

3. Lubricate the o-rings (26b* and 26g*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

NOTE: Do not lubricant o gun air pass workpiece

ntheo-ringscanbepushedintothe

e Repair

over-lubricate parts. Excessive

age and blemish the ﬁnish on the

4. Clean and inspect parts for damage. Replace if necessary.

NOTE: The pro must point up

5. Reinstall th 15-25 in-lb (

trusion on the retainer plate (26f)

ward.

e valve. Torque the screw (26p) to

1.7-2.8 N•m).

Figure 39 ES On-Off Valve

50 3A2495C

Air Valve Repair

Repair

1. See Prepare th

2. See Gun Barrel

3. Remove the scr

4. Remove the ES

ES On-Off Val

5. Remove the sp

6. Push on the f out the back seal (23a*)

7. Inspect the unless dam with its li the u-cup o it in the gu

ve Repair, page 50.

ront of the air valve shaft to force it

of the handle. Inspect the rubber

and replace if damaged.

u-cup (3). Do not remove the u-cup

aged. If removed, install the new one

ps facing into the gun handle (16). Place

n the shaft of the air valve to help seat

n handle.

e Gun for Service, page 39.

Removal, page 43.

ews (13) and trigger (12).

On-Off Valve. See

ring (2).

8. Install the ai gun handle (16

9. Install the ES

ES On-Off Valv

10. Install the t

11. See Gun Barre

r valve (23) and spring (2) into the

rigger (12) and screws (13).

On-Off Valve. See

e Repair, page 50.

l Installation, page 43.

Figure 40 Install U-Cup

Figure 41 Air Valve

3A2495C 51

Repair

Smart Module R

If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply.

If the module module.

1. See Prepare the Gun for Service, page 39.

2. Remove the pivot screw (31e), o-ring (31f), and ES HI/LO switch (31c) at the bottom left corner of the Smart Module cartridge (31a).

3. Remove the remaining three screws (31d) from the cartridge.

4. Pull the Smart Module out the back of the gun. Disconnect the ribbon cable (RC) from the connector (GC) in the gun handle.

5. Remove the gasket (31b).

6. Install a new gasket (31b) on the new cartridge (31a). Make sure the notched corners of the gasket are at the top.

’s LEDs are not lighting, replace the

eplacement

Figure 42 Smart Module

7. Align the module’s ribbon cable (RC) with the gun’s cable (GC) and slide them securely together, as shown. Tuck the connected cables into the recess of the gun handle. Install the module ﬂush to the back of the gun handle.

8. Install the pivot screw (31e), o-ring (31f), and ES HI/LO switch in the bottom left corner of the cartridge (31a).

9. Install the three remaining screws (31d). Torque to 7–9 in-lb (0.8–1.0 N•m).

Figure 43 Align Ribbon Cables

52 3A2495C

Repair

Air Swivel and

1. See Prepare the Gun for Service, page 39.

2. To replace the air exhaust valve:

a. Remove the cl

(35).

b. Unscrew the s

(16). The sw Remove the b

c. Pull the exh

(16). Inspe necessary

d. Install th

(8). Lubri of non-sil

e. Install t

(16).

f. Apply thr

the swive screw th Torque t

g. Install

Exhaust Valve Replacement

amp (36) and the exhaust tube

wivel (21) from the gun handle

ivel is a left-hand thread.

racket (7).

aust valve (8) from the handle

ct the o-ring (8a) and replace if

e o-ring (8a*) on the exhaust valve

cate the o-ring with a light coating

icone grease.

he exhaust valve (8) in the handle

ead sealant to the top threads of

l (21). Position the bracket (7) and e swivel into the gun handle (16). o 75–85 in-lb (8.4–9.6 N•m).

the tube (35) and clamp (36).

Figure 44 Air Inlet Fitting and Air Exhaust Valve

3. To repl

a. Unscrew the swivel (21) from the gun handle

b. Apply thread sealant to the top threads of the

ace the air inlet swivel:

(16). The swivel is a left-hand thread.

swivel. Screw the swivel into the gun handle. Torque to 75–85 in-lb (8.4–9.6 N•m).

3A2495C 53

Parts

Standard Air-Assisted Spray Gun Assembly

Part No. H60T Part No. H85T

10 60 kV Electrostatic Air-Assisted Spray Gun, Series A 10 85 kV Electrostatic Air-Assisted Spray Gun, Series A

54 3A2495C

Part No. H60T10 60 kV Electrostatic Air-Assisted Spray Gun, Series A Part No. H85T10 85 kV Electrostatic Air-Assisted Spray Gun, Series A

Parts

Ref. No.

2 185116

624N740

8 249323 VALVE, exhaust 1

8a*

924N747

10 238562 FILTER, inline, 100 mesh; see

12 24N663

13 24A445

15 24N664

20a 24N782

21 24N626

22 24N793

22a*

23 24N633 VALVE, air 1

23a*

24 24N725

Part No. Description

24N746

24N745

188749

24N699

24N742

112085

24N660

24N661

24N761 HANDLE; 60 kV AA gun 116

24N762 HANDLE; 85 kV AA gun 1

24N744

24N743

24N780

24N781

198307

276733

BODY, gun; 60 kV gun

BODY, gun; 85 kV gun

SPRING, compression

PACKING, u-cup

GASKET, body

SCREW, hex socket; package of 2

BRACKET

O-RING

RING, conductive

note below POWER SUP

POWER SUP

TRIGGER;

SCREW, t

See

Alterna

TUBE, ﬂuid; 60 kV gun

TUBE, ﬂuid; 85 kV gun

NEEDLE ASSEMBLY; 60 kV gun; includes item 20a

NEEDLE ASSEMBLY; 85 kV gun; includes item 20a

SPRIN

EL, air inlet; M12 x 1/4

SWIV

(m); left-hand thread

npsm RING, retainer; includes 22a

PACKING, u-cup; UHMWPE; part of 22

SEAL

HOUSING, seat

PLY, 60 kV gun

PLY, 85 kV gun

includes item 13

rigger; package of 2

tor Assembly, page 58

G, ﬂuid needle

Qty

Ref. No. 25 24N727

25a 24N643

26 24N632

27 AEMxxx

27a 183459

29 24N792

30 24N634

32 24E404

32a

35 185103

36 110231

37 24N785

37a 197624

38 24N786

51 112080

55▲

56▲ 16P80

58 117824

60 107460

61 276

62 24N

Part No. Description

AEFxxx

———

24N603

24N604

17979

1165

741

783

See Air Cap Assembly, page 61

ELECTRODE; package of 5

See ES On-Off Valve Assembly,

page 59

TIP ASSEMBLY; customer’s choice; includes item 27a GASKET, tip

ATOMIZING AIR ADJUSTMENT VALVE See Fan Air Valve Assembly,

page 60

STOP, trigger; includes item 32a

PIN, dowel 1

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

CLAMP

CAP, spr

SPRING,

PLUG, fa shippe of item TOOL, needle (shipped loose)

COVER, gun, 60 kV guns; package of 10

COVER, gun, 85 kV guns; package of 10

TAG, warning (not shown)

SIGN, warning (not shown)

GREASE, dielectric; 1 oz (30 ml) tube (not shown)

GLOVE, conductive, medium; package of 12; also available in small (117823) and large (117825)

TOOL, wrench, ball end (shipped loose)

MULTI-TOOL (shipped loose)

HOOK; includes screw

ing; includes item 37a

compression

n control; option,

d loose for use in place

Qty

154

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

These parts are included in Air Seal Repair Kit

4N789 (purchase separately).

NOTE: 100 mesh Filter Kits (10) are available. Order 238561 (qty 3) or 224453 (qty 5).

arts labeled — — — are not available separately.

3A2495C 55

Parts

Smart Air-Ass

Part No. H60M10 60 kV Electrostatic Air-Assisted Spray Gun, Series A Part No. H85M10 85 kV Electrostatic Air-Assisted Spray Gun, Series A

isted Spray Gun Assembly

56 3A2495C

Part No. H60M10 60 kV Electrostatic Air-Assisted Spray Gun, Series A Part No. H85M10 85 kV Electrostatic Air-Assisted Spray Gun, Series A

Parts

Ref. No.

2 185116

624N740

8 249323 VALVE, exhaust 1

8a*

924N747

10 238562 FILTER, inline, 100 mesh; see

12 24N663

13 24A445

15 24N664

20a 24N782

21 24N626

22 24N793

22a*

23 24N633 VALVE, air 1

23a*

24 24N725

25 24N727

Part No. Description

24N746

24N745

188749

24N699

24N742

112085

24N660

24N661

24N763 HANDLE, smart; 60 kV AA gun 116

24N764 HANDLE, smart; 85 kV AA gun 1

24N744

24N743

24N780

24N781

198307

276733

BODY, gun; 60 kV gun

BODY, gun; 85 kV gun

SPRING, compression

PACKING, u-cup

GASKET, body

SCREW, hex socket; sst; package of 2

BRACKET

O-RING

RING, conductive

note below POWER SUP

POWER SUP

TRIGGER;

SCREW, t

See

Alterna

TUBE, ﬂuid; 60 kV gun

TUBE, ﬂuid; 85 kV gun

NEEDLE ASSEMBLY; 60 kV gun; includes item 20a

NEEDLE ASSEMBLY; 85 kV gun; includes item 20a

SPRIN

EL, air inlet; M12 x 1/4

SWIV

(m); left-hand thread

npsm RING, retainer; includes 22a

PACKING, u-cup; UHMWPE; part of 22

SEAL

HOUSING, seat

See Air Cap Assembly, page 61

PLY, 60 kV gun

PLY, 85 kV gun

includes item 13

rigger; package of 2

tor Assembly, page 58

G, ﬂuid needle

Qty

Ref. No. 25a 24N643

26 24N632

27 AEMxxx

27a 183459

29 24N792

30 24N634

31 24N756

32 24E404

32a

35 185103

36 110231

37 24N785

37a 197624

38 24N786

40 245265

51 112080

55▲

56▲ 16P802

58 117824

60 107

61 276741

62 24N783

Part No. Description

AEFxxx

———

24N603

24N60

179791

116553

460

ELECTRODE; package of 5

See ES On-Off Valve Assembly,

page 59

TIP ASSEMBLY; customer’s choice; includes item 27a GASKET, tip

ATOMIZING AIR ADJUSTMENT VALVE See Fan Air Valve Assembly,

page 60

See Smart Module Assembly,

page 61

STOP, tri

PIN, dowel 1

TUBE, exh ID (shipp

CLAMP

CAP, spring; includes item 37a

SPRING, compression

PLUG, fan control; option, shipped loose for use in place of item 29 CIRCUIT, ﬂexible

TOOL, needle (shipped loose)

COVER, gun, 60 kV guns; package of 10

COVER, gun, 85 kV guns; package of 10

TAG, warning (not shown)

SIGN, warning (not shown)

GREASE, dielectric; 1 oz (30 ml) tube (not shown)

GLOVE, conductive, medium; package of 12; also available in small (117823) and large (117825)

TOOL, wrench, ball end (shipped loose)

MULTI-TOOL (shipped loose)

HOOK; includes screw

gger; includes item 32a

aust; 1/4 in. (6 mm)

ed loose)

Qty

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

These parts are included in Air Seal Repair Kit

4N789 (purchase separately).

NOTE: 100 mesh Filter Kits (10) are available. Order 238561 (qty 3) or 224453 (qty 5).

arts labeled — — — are not available separately.

3A2495C 57

Parts

Alternator Assembly

Part No. 24N66

4 Alternator Assembly

Ref. No.

15a 24N705

15b♦ 24N706

15d♦ 24N707

15e♦

Part No.

———

Description

COIL, alternator

BEARING KIT (includes two bearings, item 15e fan, and one item 15h clip)

HOUSING; includes item 15f

FAN; part of item 15b

Qty

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

♦ These parts are included in Bearing Kit 24N706 (purchase separately).

Ref. No.

15f

15g*

15h♦ 24N709

Part No.

———

110073

Description

CAP, housing; part of item 15d

O-RING

CLIP; package of 5 (one clip included with item 15b)

Qty

Parts labeled — — — are not available separately.

58 3A2495C

Parts

ES On-Off Valv

e Assembly

Part No. 24N632 ES On-Off Valve Assembly

Ref. No.

26a

26b*

26c

26d 24N650

Part No. Description

———

15D371

———

HOUSING, valve

O-RIN

PISTON, valve

LEVER, ES on-off; includes item 26e

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

Qty

Ref. No.

26e

26f

26g*

26p

Part No. Description

———

24N631 PLATE, retaining 1

113746

———

SCREW, set, socket head

O-RING

SCREW, captive

Qty

Parts labeled — — — are not available separately.

3A2495C 59

Parts

FanAirValveAssembly

Part No. 24N63

4 Fan Air Valve Assembly

Ref. No.

30a

30b

30c*

30d 24N646

Part No. Description

———

111504

NUT, valve 1

STEM, valve

O-RING

RING, retaining; package of 6

Qty

* These parts are included in Air Seal Repair Kit 24N789 (purchase separately).

Parts labeled — — — are not available separately.

60 3A2495C

Parts

Air Cap Assemb

Part No. 24N727 Air Cap Assembly

Ref. No.

25a 24N643

25b 24N734

25c

25d 24N726

Parts l

Part No. Description

ELECTRODE; package of 5

O-RING; ptfe; package of 5 (also available in package of 10; order 24E459)

———

AIR CAP

GUARD, tip, orange

abeled — — — are not available separately.

Qty

Smart Module A

ssembly

Part No. 24N756 Smart Module Assembly

Ref. No.

31a

31b 24P433

31c 24N787

31d♦

31e♦

31f

Part No. Description

———

112319

CARTRIDGE

GASKET

SWITCH, ES HI/LO

SCREW

SCREW, pivot

O-RING

Qty

Parts labeled — — — are not available separately.

♦ThesepartsareincludedinSmartModuleScrew Kit 24N757 (purchase separately).

3A2495C 61

Spray Tip Select

ion Chart

Spray Tip Sele

AEM Fine Finis

Recommended for high ﬁnish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx, where xxx = 3–digit number from the matrix below.

Oriﬁce

Size

in.

(mm)

†0.007 (0.178) †0.009 (0.229) †0.011 (0.279)

0.013 (0.330

0.015 (0.381)

0.017 (0.432)

0.01

83)

(0.4

0.021 (0.533)

0.023 (0.584)

025

0.635)

(

0.029 (0.736)

0.031 (0.787)

0.033 (0.838)

0.037 (0.939)

0.039 (0.990) * Tips are tested in water.

Fluid Output

ﬂoz/min(l/min) at 600 psi (4.1 MPa, 41 bar)

4.0 (0.1)

7.0 (0.2)

10.0 (0.3)

13.0

)

(0.4)

17.0 (0.5)

22.0 (0.7)

28.0 (0.8

35.0 (1.0)

40.0 (1.2)

1.5)

(

68.0 (1.9)

78.0 (2.2)

88.0 (2.5)

108.0 (3.1)

118.0 (3.4)

h Spray Tips

at 1000 psi (7.0 MPa, 70 bar)

5.2 (0.15)

9.1 (0.27)

13.0 (0.4)

16.9 (0.5)

22.0 (0.7)

28.5 (0.85)

36.3

)

(1.0

45.4 (1.36)

51.9 (1.56) 64

1.94)

(

88.2 (2.65)

101.1 (3.03)

114.1 (3.42)

140.0 (4.20)

153.0 (4.59)

ction Chart

2–4

(50–

100)

107 207 307

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

4–6

(100–

150)

209 309 409 509 609

211 311 411 511 611 711

213 313 413 513 613 713 813

215 315 415 515 615 715 815

217 317 417 517 617 717

6-8

(150-

200)

319 419 519 619 719

8-10

(200-

250) Spray Tip

421 521 621 721 821

423 523 623 723 823

431 631 831

10-12

(250-

300)

539

12-14

(300-

350)

14-16

(350-

400)

737

16-18

(400-

450)

829

833

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = ﬂuid output (ﬂ oz/min) at 600 psi from the above table for the selected oriﬁcesize. † These tip sizes include a 150 mesh ﬁlter.

62 3A2495C

Spray Tip Select

ion Cha rt

AEF Fine Finis

h Pre-Oriﬁce Spray

Tips

Recommended f that assists

Order desired tip, Part No. AEFxxx, where xxx = 3–digit number from the matrix below.

Oriﬁce

Size

in. (mm)

†0.010 (0.254)

0.012 (0.305)

0.014 (0.356)

0.016 (0.406)

or high ﬁnish quality applications at low and medium pressures. AEF tips have a pre-oriﬁce

in atomizing sheer thinning materials, including lacquers.

Fluid Output

ﬂ oz/min (l/min)

at 600 psi (4.1 MPa, 41 bar)

9.5 (0.28

12.0 (0.35)

16.0 (0.47)

20.0 (0.59)

)

at 1000 psi (7.0 MPa, 70 bar) Spray Tip

12.5 (0.37)

16.0 (0.47)

21.0 (0.62)

26.5 (0.78)

6-8 (150-

200)

310 410 510 610 710

312 412 512 612 712 812

314 414 514 614 714 814

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

8-10

(200-250)

416 516 616 716

10-12

(250-300)

12-14

(300-350)

14-16

(350-400)

16-18

(400-450)

* Tips are tested in water.

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = ﬂuid output (ﬂ oz/min) at 600 psi from the above table for the selected oriﬁcesize.

† These tip sizes include a 150 mesh ﬁlter.

3A2495C 63

Repair Kits, Rel

ated Manuals, and Accessories

Repair Kits, Related Manuals, and Accessories

Gun Part No.

All guns in thi manual.

Gun Accessories

Part No. Description

105749

111265

116553

24N319

24N603

Cleaning Brush.

Non-silicone Lub

Dielectric Grease. 1 oz (30 ml)

Round Spray Kit. To convert a standard air—assisted spray gun to a round spray air cap. See manual 3A2499.

Gun Covers. Fo guns. Box of 10

Description Manual Description Repair Kits Repair Kit

Description

60kVand85kV Air-Assiste Guns

d Spray

ricant, 4 oz (113 g).

r40kVand60kV

Electrostati Air-Assiste Spray Guns, Instruction

s-Parts

24N789

24N706 Alternator Bearing

System Acces

Part No. Description

222011

16P802

16P798

16P799

24N528

24P312

Ground Wire

English Warning Sign. Available at no charge from Graco.

English Daily Care Sign.

English

Gun Flush Box Adapter. To convert existing gun ﬂush boxes to hold Pro Xp guns.

Gun Washer Kit. To convert existing gun washers to clean Pro Xp guns.

Air Seal Repair Kit

Repair Kit

sories

and Clamp.

Setup Sign

24N604

24N642

24N758

24P170 Metal Trigger Kit.

24P172

185105

185493

112534

Gun Covers. For 85 kV guns. Box of 10.

Ball Swivel, for gun air inlet. 1/4 npsm (left-hand thread)

Display Cov clean. Pac

Quick Adj change of

Non-swivel Air Inlet; 1/4–18 npsm(m) (left-hand thread)

Air Hose Adapter; 1/4 npt(m) x 1/4–18 npsm(m) (left-hand thread)

Air Lin

ers. Keeps Smart display

kage of 5.

ust Valve. For quick

fan size.

e Quick Disconnect Fitting.

Test Equipment

Part No. Description

2410

722886

2860

245277 Test Fixture, High Voltage Probe,

hmmeter. 500 V output,

Mego

–2000 megohms. Use for

0.01 nd continuity and gun resistance

grou

s. Not for use in hazardous

test

as.

are

Paint Resistance Meter. Use for ﬂuid resistivity test. See manual 307263. Not for use in hazardous areas.

Paint Probe. Use for ﬂuid resistivity test. See manual 307263. Not for use in hazardous areas.

and kV Meter. Use to test the electrostatic voltage of the gun, and the condition of the alternator and power supply when being serviced. See manual 309455.

64 3A2495C

Hoses

Repair Kits, Rel

ated Manuals, and Accessories

Grounded Air Hoses

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

AirFlex Flexible Grounded Air Hose (Gray)

244963

244964

244965

244966

244967

244968

244969

Part No. Description

Standard Grounded Air Hose (Gray)

223068

223069

223070

223071

223072

6ft(1.8m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

6ft(1.8m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

Air Whip Hoses

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

0.188 in. (5 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) left-hand thread

Part No. Description

Air Whip Hose with stainless steel braid ground path (Red)

236130

236131

Fluid Hoses

3ft(0.9m)

6ft(1.8m)

3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure

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

Part No. Description

240793

240794

Fluid Whip Hoses

25 ft (7.6 m)

50 ft (15 m)

3200 psi (22 MPa, 220 bar) Maximum Working Pressure

1/8 in. (3 mm) ID; 1/4 npsm(f) x 1/4 npt(m); nylon.

223073

223074

0.375 in. (10 mm) ID; 3/8 npsm(f) x 1/4 npsm(f) left-hand thread

24A225

24A226

Part No. Description

Grounded Air Hose with stainless steel braid ground path (Red)

235068

235069

235070

235071

235072

235073

235074

75 ft (23 m)

100 ft (30.5 m)

50 ft (15 m)

75 ft (23 m)

6ft(1.8m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

Part No. Description

236134

236135

3ft(0.9m)

6ft(1.8m)

Operator Accessories

Part No. Description

117823

117824

117825

24N520

24N521

Conductive Gloves, box of 12 (small)

Conductive Gloves, box of 12 (medium)

Conductive Gloves, box of 12 (large)

Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Medium size.

Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Large size.

3A2495C 65

Dimensions

Figure 45

Gun Model A, in. (mm) B, in. (mm) C, in. (mm) Weight, oz (g)

H60T10

H85T10

H60M10

H85M10

9.7 (246) 9.1 (231) 2.4 (61) 23.2 (659)

10.7 (272) 9.2 (234) 2.4 (61) 25.8 (732)

9.8 (249) 9.9 (251) 2.4 (61) 25.7 (728)

10.8 (274) 9.9 (251) 2.4 (61) 28.3 (801)

66 3A2495C

Technical Data

Electrostatic Air-Assisted Spray Guns

U.S.

Maximum Worki

Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar

Minimum Air Pressure at Gun Inlet

Maximum Fluid Operating Temperature

Paint Resistivity Range

Air Inlet Fitting

Fluid Inlet Fitting

Output Voltage

Maximum Current Draw

Sound Power (measured per ISO Standard 9216)

Sound from g

Wett

Pressure (measured 1 m

un)

ed Parts

ng Fluid Pressure

3000 psi 21 MPa, 210 bar

45 psi 0.32 MPa, 3.2 bar

120°F 48°C

3 megohm/cm to inﬁnity

1/4 npsm(m) left-hand thread

1/4–18 npsm(m)

ProXp60Models: 60kV

ProXp85Models: 85kV

125 microamperes

at 40 psi: 88.9 dB(A)

at 100

at 100 psi: 95.0 dB(A)

PEEK

psi: 99.7 dB(A)

at 40 p

si: 86.0 dB(A)

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

at 0.28 MPa, 2.8 bar: 88.9 dB(A)

at 0.7

8 MPa, 2.8 bar: 86.0 dB(A)

at 0.2

at 0.7 MPa, 7.0 bar: 95.0 dB(A)

Metric

MPa, 7.0 bar: 99.7 dB(A)

3A2495C 67

Graco Pro Xp Warranty

Graco warrants all equipment referenced in this document which is manufacturedbyGracoandbearingitsnametobe free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will,foraperiodoftwelvemonthsfromthedate of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deﬁciency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

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

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

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

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

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

For the latest information about Graco products, visit www.graco.com.

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

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

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

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

Original Instructions. This manual contains English, MM 3A2495

Graco Headquarters: Minneapolis

International Ofﬁces: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN 55440-1441 • USA

www.graco.com

Revised July 2013

Graco 3A2495C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Models

Warnings

Gun Overview

Smart Guns

Bar Graph

Voltage Adjustment Switch

Hz Indicator

Error Display

Lock Symbol

Adjusting the Low Voltage Setting

Table 1 . Key for Figs. 2–9.

Diagnostic Mode

Current (microAmperes) Screen

Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

Installation

Warning Sign

Ventilate the Spray Booth

Fluid Supply Line

Gun Setup

Table 2 . LED Indicator Colors

Table 3 . Pressure Drop

Grounding

Table 4 . Fluid Resistivity Levels

Flush Before Using Equipment

Operation

Startup

Shutdown

Maintenance

Flushing

Electrical Tests

Troubleshooting

Spray Pattern Troubleshooting

Electrical Troubleshooting

Repair

Prepare the Gun for Service

Electrode Replacement

Fluid Tube Removal and Replacement

Fluid Filter Replacement

Fluid Needle Replacement

Alternator Removal and Replacement

Fan Air Adjustment Valve Repair

Atomizing Air Adjustment Valve Repair

Air Valve Repair

Parts

Standard Air-Assisted Spray Gun Assembly

Alternator Assembly

FanAirValveAssembly

Repair Kits, Related Manuals, and Accessories

Gun Accessories

Test Equipment

Hoses

Operator Accessories

Dimensions

Technical Data

Graco Pro Xp Warranty

Graco Information