Page 1
INSTRUCTIONS–PARTS LIST
Parts
309240L
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
First choice when
quality counts.t
Two- , Three- , and Four-Stage
HVLP Turbine Sprayers
120V AC 50/60 Hz
HVLP 2500t with Two-Stage Turbine
Model 233421
5 psi (34 kPa, 0.3 bar) Maximum Working Pressure
HVLP 3800t with Three-Stage Turbine
Model 233422
6 psi (41 kPa, 0.4 bar) Maximum Working Pressure
HVLP 4900t with Four-Stage Turbine
Model 233425
8 psi (55 kPa, 0.5 bar) Maximum Working Pressure
Model descriptions are in Turbine
Components Table on page 4.
Related Manuals
HVLP Compressor/Cart 309241. . . . . . . . . . . . . . . . . . .
HVLP Turbine Spray Gun 309205. . . . . . . . . . . . . . . . . .
7947A
4900 Shown
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Page 2
Table of Contents
Symbols
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 22. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 22. . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D Ground the equipment. See Grounding on page 6.
D If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D When flammable liquid is sprayed or used for flushing or cleaning the equipment, the turbine must
be placed at least 20 feet (6.1 m) away from areas where hazardous concentrations of flammable
vapors are likely to occur.
D Use additional air hose if necessary to ensure that the turbine is operated in a clean, dry,
well-ventilated area.
D Never place the turbine inside a spray booth! Use this equipment outdoors or in extremely
well-ventilated areas.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
2 309240
Page 3
INSTRUCTIONS
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before you operate the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest-rated system component.
HVLP 2500 turbine has a working pressure of 5 psi (0.3 bar, 34 kPa).
HVLP 3800 turbine has a working pressure of 6 psi (0.4 bar, 41 kPa).
HVLP 4900 turbine has a working pressure of 8 psi (0.5 bar, 55 kPa).
D Use fluids and solvents that are compatible with the equipment wetted parts. See Specifications
on page 21 for wetted parts information.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the gun fluid nozzle.
D Do not stop or deflect leaks with your hand, body, glove, or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Follow the Pressure Relief Procedure on page 10 if the fluid nozzle clogs and before you clean,
check, or service the equipment.
D Tighten all fluid connections before you operate the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
D Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in the turbine spray system, which contains aluminum and/or
galvanized-coated parts. Such use could result in a serious chemical reaction, with the possibility
of explosion, which could cause death, serious injury, and/or substantial property damage.
309240 3
Page 4
General Information
HVLP Turbine Sprayers
The HVLP 2500, HVLP 3800, and HVLP 4900
Turbines, compressor/cart, and spray guns can spray
most coatings or finishes currently being used for
automotive refinish, industrial, aerospace, marine,
wood, plastic, and architectural applications.
To produce high-quality paint finishes, the spray gun
typically utilizes inbound air pressure of 5 psi (0.3 bar,
34 kPa) for HVLP 2500; 6 psi (0.4 bar, 41 kPa) for
HVLP 3800; and 8 psi (0.5 bar, 55 kPa) for HVLP
4900. A cone of air, produced by the gun, carries and
directs the paint from the gun to the surface,
minimizing overspray and increasing transfer
efficiency. This enables painters to comply with new
clean air laws that are designed to reduce VOC
(volatile organic compounds) emissions, eases paint
application by requiring fewer paint passes to obtain
coverage, and saves on both material and clean-up
time.
See HVLP Turbine Spray Gun manual 309205 for
more information on the operation and use of the
turbine spray gun.
Unpacking Turbine
Unpack the Graco Turbine Sprayer from the shipping
carton, and inspect for any possible shipping damage.
If there is any damage, call your distributor.
Turbine Configurations
Graco turbines come in the following basic
configurations:
D HVLP 2500 two-stage turbine sprayer
D HVLP 3800 three-stage turbine sprayer
D HVLP 4900 four-stage turbine sprayer
Turbine Components Table
System Model 30-ft (9 m) Hose
HVLP 2500 233421 241413 244117 non-
bleeder style cup gun
244124 (#3)
HVLP 3800 233422 241413 244117 non-
bleeder style cup gun
244124 (#3)
HVLP 4900 233425 241413 244117 non-
bleeder style cup gun
244124 (#3)
Gun /
Fluid Set
with
with
with
Extra/Fluid Sets
none
244125 (#4)
244126 (#5)
244123 (#2)
244125 (#4)
244126 (#5)
244127 (#6)
4 309240
Page 5
Component Identification and Function
C
B
A
H
G
D
J
K
L
E
F
Fig. 1
A Air outlet Connection for turbine air supply to HVLP Turbine Spray Guns (HVLP
4900 units include quick connector)
B Power switch ON/OFF switch for sprayer turbine and rear outlet
C Storage compartment Provides storage for fluid set components
D Turbine handle Folds flat for minimum storage space
E Turbine case Houses air filter and provides dual air flow to motor and turbine; can be
lock-mounted on compressor/cart
F Air filters (pre-filter and main) Provide filtered air for turbine spray gun and turbine motor
G Two-speed switch Allows two-speed operation of turbine sprayer motor (used on HVLP
4900 units)
H Air filter indicator light Indicates air filter performance and maintenance (used on HVLP 3800
and HVLP 4900 units)
J Connector and power cord Provides power for turbine sprayer (power cord provided with turbine)
K Auxiliary power outlet Switched power outlet for compressor/cart or other accessory
L Resettable circuit breaker Provides protection for turbine motor and cart
7947A
309240 5
Page 6
Setup
Grounding
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire, or
explosion that could cause serious injury or death.
This equipment requires a 120V AC, 60 Hz, 15A circuit
with a grounding receptacle. See Fig. 2.
grounded outlets
grounding prong
Fig. 2
Extension cord must be 3-wire, 12 AWG, 50 ft (15 m)
or shorter.
Do not alter the ground prong or use an adapter.
Setup/Use Options
HVLP Turbine Sprayers have a variety of user options.
See Fig. 3.
D See compressor/cart manual 309241 for
information on compressor/cart setup and
operation.
Prepare the Fluid
D Always strain the fluid before you spray; this
includes color, reducer, and hardeners if used.
D When using a turbine spray system, use a
slower drying reducer or thinner to compensate for
the faster drying time caused by the warm air of the
turbine. Do not over reduce.
CAUTION
The performance of the turbine sprayer varies with
the viscosity of the material and the length of the
hose. Keep the hose short to prevent pressure drop.
Paint Reduction — Automotive Type Finishes
Reduce and catalyze all paint to manufacturer’s
specifications. To compensate for the faster drying
time of turbine systems, use a reducer that is one step
slower than what is used for conventional air spray.
Paint Reduction — Industrial or Domestic
Coatings
Reduce and catalyze all paint to manufacturer’s
specifications. If no reductions are given, first
thoroughly mix the fluid to be sprayed. Then gradually
mix in the proper reducer, testing the fluid until you
have the correct spraying consistency.
To test the consistency, remove the stir stick from the
thinned paint. When the paint stream running off the
stir stick breaks into droplets, the first few drops should
be about one second apart.
D See HVLP Turbine Spray Gun manual 309205 for
information on turbine spray gun setup and
operation.
6 309240
Page 7
Setup
Connect the Fluid and Air Supply
See Fig. 3
D The HVLP compressor/cart provides the air supply
for the remote pressure pot.
D The circled letters in Fig. 3 indicate hose line
connections.
1. Connect gun air supply hose (A) between turbine
air outlet (B) and gun air inlet (C). DO NOT use
wrench to tighten connections; hand tighten only.
The HVLP 4900 turbine uses a quick connector at
outlet (B). A wrench is not required for hose
connection.
E
C
2. If using a spray gun cup (D):
Connect the cup to the gun fluid inlet (E).
If using accessory remote pressure pot (F):
Connect fluid supply hose (G) between remote
pressure pot fluid outlet (H) and gun fluid inlet (E).
Connect pressure pot air hose (J) between
pressure pot air regulator inlet (K) and the
compressor/cart air outlet.
Connect to Electric Supply
Plug turbine power cord into grounded outlet.
NOTE: Extension cord must be 3-wire, 12 AWG, 50 ft
(15 m) or shorter.
D
cup-over option
(see manual 309205)
G
Y
remote pressure pot setup for spray gun
K
J
H
to
compressor/
cart
X
G
Y
F
A
E
C
B
D
cup setup for spray gun
X
G
H
A
X
JK
Z
Y
HVLP 4900 Turbine
F
compressor
ti7064a
to
21/2-gallon remote pressure pot
Fig. 3
2-quart remote pressure pot
4958C
309240 7
Page 8
Setup
Fill the Cup or Remote Pressure Pot
Spray Gun Cup
WARNING
The spray gun cup is pressurized by the gun’s air
supply. To reduce the risk of serious injury from
pressurized fluid or accidental spray from the gun,
always turn off the air supply to the gun before you
remove the spray gun cup.
Only fill the cup 3/4 full to help keep the air pressure
tube clean, then install the cover. The under-cup cover
has a latch (H) to secure it to the cup. The over-cup (J)
has threads that keep the lid in place when tightened in
place on the cup.
H
J
21/
gallon
206c
Fig. 5
2. Remove pressure pot cover and fill. Secure cover.
NOTE: 2-quart remote pressure pot only:
Lightly coat the cover threads with petroleum jelly.
2
8069A
2 quart
Fig. 4
Accessory Remote Pressure Pot
WARNING
The accessory remote pressure pots remain pressurized until pressure is manually relieved. To
reduce the risk of serious injury from pressurized
fluid or accidental spray from the gun, always
relieve pressure in the pressure pot before you
loosen or remove the cover.
1. Relieve remote pressure pot pressure as follows
(see Fig. 5):
a. Turn off air supply to pressure pot.
b. 21/2-gallon remote pressure pot:
Pull pressure relief valve ring (206c) until
pressure is completely relieved.
2-quart remote pressure pot:
Turn pressure relief knob (113). Wait until
pressure is completely relieved before you
remove cover. Close knob.
02845
CAUTION
If the 2-quart remote pressure pot is accidentally
tipped over or held at too great of an angle, fluid may
leak into the air regulator and cause damage. Take
precautions to avoid this. If fluid does get into the
regulator, clean it immediately.
8 309240
Page 9
Setup
Prepare Surface to be Sprayed
To get proper adhesion, make sure surface is
completely clean.
Operating Turbine
WARNING
Sparks can be expected in the normal operation of
the turbine motor. These sparks can ignite fumes
from flammable liquids, dust particles, and other
flammable substances in the spray area. This can
cause serious injury and property damage. Be sure
to follow the precautions below:
D When flammable liquid is sprayed or used for
flushing or cleaning equipment, the turbine must
be placed at least 20 feet (6.1 m) away from
areas where hazardous concentrations of
flammable vapors are likely to occur.
D Use additional air hose if necessary to ensure
that the turbine is operated in a clean, dry, well
ventilated area.
HVLP Compressor/Cart Cold Weather
Operation
The HVLP compressor/cart uses a diaphragm
compressor. A new diaphragm may be stiff in cold
weather. If cold enough, the diaphragm is too stiff to
allow the compressor motor to start (the unit hums).
If this occurs, follow these steps:
1. Turn turbine and compressor OFF.
2. Unplug turbine from power source.
3. Pinch and remove filter by hand. Clean or replace
if dirty.
4. Hand spin cooling fan on compressor for a few
revolutions.
5. Reinstall filter.
6. Plug in turbine.
7. Turn turbine and compressor ON. If necessary,
repeat procedure.
D Never place the turbine inside a spray booth!
Use this equipment outdoors or in extremely
well ventilated areas.
D Avoid all ignition sources such as: static
electricity from plastic drop cloths, open flames
like pilot lights, hot objects like cigarettes, arcs
from connecting or disconnecting power cords,
and turning light switches on and off. Extinguish
or remove all sources of ignition.
1. Turn turbine ON a few minutes before spraying to
allow warm-up.
NOTE: When the turbine is not in use for an extended
period of time, turn it off. The turbine does not shut off
automatically.
2. Be sure turbine filter is clean before operating. See
page 11 to check and clean filter.
NOTE: To adjust the spray gun pattern see the turbine
gun manual.
309240 9
Page 10
Shutdown
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of a serious
injury from pressurized fluid, accidental spray from
the gun, or splashing fluid, follow the Pressure
Relief Procedure whenever you
D Are instructed to relieve the pressure
D Stop spraying
D Check or service any of the system equipment
D Install or clean the fluid nozzles
1. Turn off air supply to gun.
2. Turn off turbine sprayer.
WARNING
The turbine hose outlet may be hot. Carefully check
the hose end before you remove the hose.
3. If using remote pressure pot, relieve pressure by
following these steps (see Fig. 6):
a. Turn off air supply to pressure pot.
113
21/
gallon
206c
Fig. 6
NOTE: Elevate spray gun and pull trigger. This will
allow fluid in fluid hose to drain back into remote
pressure pot.
4. If using a spray gun cup:
Unlatch cup cover; loosen or remove cup from
cover to relieve cup pressure.
5. Clean spray gun and cup as instructed in the
HVLP Turbine Spray Gun manual 309205.
2
2 quart
8069A
2882c
b. 21/2-gallon remote pressure pot:
Pull pressure relief valve ring (206c) until
pressure is completely relieved.
2-quart remote pressure pot:
Turn out pressure relief knob (113) one turn.
Wait until pressure is completely relieved
before you remove cover. Close knob.
10 309240
Page 11
Maintenance
Daily
The turbine systems are lifetime lubricated. The only
maintenance required is filter cleaning and
replacement.
The turbine filter must be clean at all times to provide
sufficient air flow to cool motor and atomize the fluid.
Check turbine pre-filter (22) daily for cleanliness.
Check the main filter (21) weekly, minimum. Clean as
necessary.
NOTE: To check filter, turn on turbine and place piece
of paper against pre-filter. If air intake holds paper in
place, filter is okay.
THe HVLP 3800 and HVLP 4900 models have an air
filter indicator light on the front panel. If the filter is
good the light is out. If the filter is clogged or has low
airflow the light will come on as in Fig. 7 below.
WARNING
To avoid damage to the turbine and possible electric shock, never install a damp filter in the turbine.
CAUTION
To keep out dirt, do not operate the turbine sprayer
without both filters installed.
1
20
21
22
16
Fig. 7
8049A
To clean filter:
1. Turn off and unplug turbine.
2. Loosen four thumbscrews (16), remove filter
retainer (15) and pre-filter (22). See Fig. 8.
3. Remove main filter (21) and clean by using one of
the following three methods:
D Tap filter gently on flat surface, dirty side
down.
CAUTION
To prevent damage to filter, do not use compressed
air on a wet filter.
D Direct compressed air (100 psi [7 bar, 70 kPa]
maximum) through filter panel in the opposite
direction of arrows on side of filter (from the
clean side to the dirty side).
Fig. 8
15
03072
Weekly
Check hose for cracks, leaks, and holes. Replace if
necessary.
Annually or Every 600 Hours, Whichever
Comes First
Replace motor brushes 600 hours after turbine sprayer
operation. If brushes are not replaced, motor failure
will occur.
NOTE: It is recommended that an authorized service
center perform the motor brush replacement procedure
on page 14.
D Soak filter for 15 minutes in water and mild
detergent. Rinse filter until clean. Air dry. Do
not use compressed air on damp or wet filter.
309240 11
Page 12
Notes
12 309240
Page 13
Troubleshooting
PROBLEM CAUSE SOLUTION
No fluid delivery No material, no remote
container pressurization, hose
or pickup tube clogged
Compressor not
starting
Cold weather operation See HVLP Compressor/Cart Cold Weather
Check container for material.
Check for leaks at the container gasket (2-quart
pressure pot cover or 21/2-gallon pressure pot wing
nuts). Tighten wing nuts if loose.
Check for air flow from male quick-disconnect at
compressor outlet (should be approx. 1/4 CFM).
Turn pressure regulator clockwise. Look for pressure
on gauge. (If no pressure on gauge, check air line and
fittings).
Check hole in 21/2-gallon pressure pot cover under
regulator or in 2-quart pressure pot cover at needle
valve. Clean if necessary.
Check for obstructions.
Check if fluid pickup tube is unplugged. Tighten.
Blow out and clear material hose.
Operation on page 9.
Turbine not starting No power Check outlet for power. Cycle red rocker switch.
Check that correct IEC (modular) cord is used and
plugged in.
Check circuit breaker(38). Push to reset.
Poor atomization Dirty filter Clean filter.
Extension cord too long Extension cord must be 3-wire, 12 AWG, 50 ft (15 m)
or shorter.
Hose too long Replace with shorter hose. See Accessories page 20
for shorter hose and Part No.
Circuit breaker trips Filter clogged Clean filter and replace as necessary.
High ambient temperature Move turbine to cooler area.
Excessive brush wear Remove cover and turbine, and check for free motor
rotation and for brush wear. Replace motor brushes if
necessary.
Excessive current draw Return to authorized service center.
309240 13
Page 14
Repair
WARNING
Turn off turbine and unplug power for the following
procedures.
Turbine Sprayer Disassembly
1. If necessary, clean and replace filter according to
maintenance procedure on page 11.
Motor Brush Replacement
NOTE: It is recommended that this procedure be
performed by an authorized service center.
1. Use Turbine Sprayer Disassembly procedure at
left to take turbine apart. Use Turbine/Motor
Replacement on page 15 to replace turbine.
2. Remove plastic fan cover.
2. Place turbine upside down on work surface.
Remove four cap screws (27) and bumpers (7).
See Fig. 9 below and Parts Drawing on page 16.
3. Carefully lift unit by turbine baseplate (2) from
turbine cover (1), and place upright on work
surface.
4. Repair or replace items as required.
5. Reassemble turbine.
27
7
2
A
3. Remove brushes. Check commutator for
excessive wear.
Note: Do not install new brushes in a turbine in which
the commutator has been damaged by the brush
holders. A motor with this type of damage cannot be
repaired.
4. Install new motor brushes using reverse order.
Keep lead wires from all rotating parts and motor
frame.
CAUTION
Do not run the motor with the air inlet or outlet
sealed off.
5. Reassemble turbine.
1
6. Run motor 30 to 45 minutes at half-rated voltage
to seat motor brushes.
Note: If half-rated voltage is not available, run repaired
unit in series with another turbine for 30 to 45 minutes.
7949A
Fig. 9
Power Cord Replacement
Replace power cord by unplugging from IEC connector
(A). Install new cord. See Fig. 9
14 309240
Page 15
Repair
Turbine/Motor Replacement
The HVLP 2500, HVLP 3800, and HVLP 4900
Turbines each use a different turbine/motor. See the
Turbine/Motor Replacement Kits in the Parts List on
page 17 for a listing of replacement kit parts.
See Parts Drawing on page 16.
1. Use Turbine Sprayer Disassembly procedure on
page 14 to take turbine apart.
2. Remove turbine gasket (25).
3. Remove 3 screws (6).
4. Remove plate (82) and 3 spacers (83).
5. Remove turbine motor wires from spade
connectors.
6. Rotate turbine (24) from outlet fitting (18) and lift
up from turbine spacers (23).
7. Install new turbine gaskets (25 and 41).
8. Reassemble turbine.
9. Connect ground wire to turbine housing as
required.
10. Reconnect wires according to applicable turbine.
See Fig. 10, Fig. 11, or Fig. 12 schematics.
Fig. 11
Motor
HVLP 3800 Turbine
7245A
Fig. 10
Motor
L1
L2
G
GROUND
HVLP 2500 Turbine
Fig. 12
Motor
HVLP 4900 Turbine
7244B
309240 15
Page 16
13
Parts Drawing
81
29
14
1
25
82
24
19
18
4
46
27
28
6
83
23
26
6
20
21
22
15
16, 17
34
16 309240
33
47
31
32, 40
5
42
2
39
36
69
41
11
10
6
3
12
65
12
38
67
68
7
27
37
4
7943C
Page 17
Parts List
Ref
No. Part No. Description Qty
1 276674 COVER, turbine 1
2 197111 BASE PLATE, turbine
(HVLP 2500) 1
192775 BASE PLATE, turbine
(HVLP 3800) 1
192774 BASE PLATE, turbine
(HVLP 4900) 1
3 192786 PLATE, retaining (HVLP 3800 and
HVLP 4900) 1
4 114669 SCREW, pan hd 4
5 192787 DUCT, turbine 1
6 114670 SCREW, cap, hx hd 8
7 113817 BUMPER 4
10 114064 PLUG, inlet 1
11 114065 PLUG, inlet, female
(HVLP 3800 and HVLP 4900) 1
12 114410 SCREW, pan hd, torx 6
13 244166 LID, tool box 1
14 197054 FOAM PAD, tool box 1
15 197057 RETAINER, filter 1
16 192895 SCREW, captive 4
17 158486 O-RING 4
18 193057 FITTING, outlet (HVLP 2500) 1
192779 FITTING, outlet
(HVLP 3800 and HVLP 4900) 1
19 156698 O-RING, buna–n 1
20 192789 GASKET, filter (HVLP 3800 and
HVLP 4900) 2
21 240273 FILTER, main, paper 1
(HVLP 3800 and HVLP 4900)
244137 FILTER, main, foam (HVLP 2500) 1
22† 240274 FILTER, pre 1
23 193068 SPACER, turbine (HVLP 2500) 3
192780 SPACER, turbine
(HVLP 3800 and HVLP 4900) 3
24* 240269 TURBINE KIT, 2 stage; 120 volts
(HVLP 2500) 1
240270 TURBINE KIT, 3 stage; 120 volts
(HVLP 3800) 1
241122 TURBINE KIT, 4 stage; 120 volts
(HVLP 4900) 1
25 192812 GASKET, turbine (HVLP 2500) 1
192788 GASKET, turbine
(HVLP 3800 and HVLP 4900) 1
26 192784 BRACKET, handle 2
27 114531 SCREW, cap, hx hd 8
28 113414 NUT, lock 2
29 192785 HANDLE, turbine 1
31 114658 SWITCH, rocker (HVLP 4900) 1
Ref
No. Part No. Description Qty
32 114279 SENSOR, pressure
(HVLP 3800 and HVLP 4900) 1
33 114280 LIGHT, indicator (HVLP 3800 and
HVLP 4900) 1
34 114293 SWITCH, rocker, red 1
36 111593 SCREW, grounding 1
37 102063 WASHER, lock, external tooth 1
38 114290 BREAKER, circuit; 8A, 120V
(HVLP 2500) 1
114403 BREAKER, circuit; 15A, 120V
(HVLP 3800 and HVLP 4900) 1
39 192905 PLATE, deflector
(HVLP 3800 and HVLP 4900) 1
40 193059 GASKET, sensor
(HVLP 3800 and HVLP 4900) 1
41 192845 GASKET, duct 1
42 192846 GASKET, duct 1
46 114287 FITTING, barbed
(HVLP 3800 and HVLP 4900) 1
47 192810 HOSE, air
(HVLP 3800 and HVLP 4900) 1
65 245202 CORD SET, 10 ft. 13 AMP, 120V
(HVLP 2500 and HVLP 3800) 1
240281 CORD SET, 15 ft, 15 AMP, 120V
(HVLP 4900) 1
67Y 193095 LABEL, danger 1
68Y 193096 LABEL, warning 1
69 193126 LABEL, caution 1
75 244122 #2/4/5/6 ACCESSORY KIT
(HVLP 4900) Not shown 1
81 114538 SCREW, mach, pan hd 2
82 194094 PLATE, turbine 1
83 SPACER, turbine
194095 HVLP 2500 3
194096 HVLP 3800 3
194097 HVLP 4900 3
† Pre-filters are available in 5 packs. Order Part No.
240274.
* Turbine Brush Kits are also available. Purchase
separately: 240545 (for HVLP 2500), and 240546
(for HVLP 3800 and HVLP4900).
Y Extra danger and warning labels are available
for free.
309240 17
Page 18
Accessories
21/2-Gallon (9.5 liter) PTFER coated Pot 240045
50 psi (345 kPa, 3.5 bar) Maximum Inlet Air Pressure
21/2-gallon (9.5 liter) capacity, steel tank. Includes air
pressure regulator, gauge, and pressure relief valve.
201
216
217
221
208
209
203
202
212
207
204
205
21/2-gal (9.5 liter)
paint tank liner
(5 pack) 112077
212
Ref.
No. Part No. Description Qty.
201 104655 PRESSURE GAUGE 1
202 151519 REDUCER, 1/4 to 1/8 1
203 M70687 COUPLING 1
204 M70676 O-RING 1
205 M70686 PRESSURE RELIEF VALVE 1
207 244953 GASKET, standard;
polyethylene (3/kit) 1
M70616 GASKET, standard; EPDM
(optional – must order separately 1/kit) 1
244953 GASKET, solvent resistant; 1
208 M70678 WING NUT 5
209 M70677 WASHER 5
212 244288 TANK, paint, 2
with PTFE coat 1
216 169969 QUICK DISCONNECT, male 1
217 104815 PRESSURE REGULATOR 1
221 M71639 HANDLE 1
1
/2-gal (9.5 liter),
18 309240
04957
Page 19
Accessories
2-Quart (1.9 liter) Pressure Pot 287819
50 psi (345 kPa, 3.5 bar) Maximum Inlet Air Pressure
2-quart (1.9 liter) capacity, aluminum cup.
Includes air pressure regulator, gauge, pressure relief
valve, and rigid hook handle.
WARNING
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in the turbine spray system, which contains aluminum and/or
galvanized-coated parts. Such use could result in a serious chemical reaction, with the possibility
of explosion, which could cause death, serious injury, and/or substantial property damage.
127
120
124
121
119
112
137
130
138
134
133
136
114
123
131
101
103
140
122
139
128
129
109
(Handle is
shipped loose,
inside of 2-qt
container.)
ti7063a
Ref.
No. Part No. Description Qty.
101 104655 PRESSURE GAUGE 1
103 104815 PRESSURE REGULATOR 1
109 287818 POT, 2 quart (1.9 liter), aluminum 1
112 120132 GASKET 1
287821 GASKET KIT 5–pack 1
114 169969 FITTING 1
119 240474 HOSE, fluid; 60 in. long; 1/4 in. ID 1
120 240482 HOSE, air; 54 in. (1.37 m) long 1
121 M70854 HOSE CLAMP 1
122 110440 FITTING TEE 1
123 189557 RESTRICTOR 1
124 M70399 QUICK DISCONNECT, male 1
127 M70402 QUICK DISCONNECT 1
128 120123 LID, cup 1
129 287820 VALVE KIT, check repair 1
130 120130 HANDLE 1
131 120129 NUT, handle 1
133 120127 VALVE, pressure release‘ 1
134 120128 FITTING, outlet 1
136 120125 TUBE, fluid 1
137 120126 CUP, 2–quart 1
138 193218 STRAINER 1
139 120131 FITTING, inlet 1
140 120133 VALVE, pressure relief 1
NOTE:
D See HVLP Finish Systems brochure 300564 for all
accessories.
D Non–silicone lubricant 111265 (4 oz.) is available
for fluid seals and wear areas.
309240 19
Page 20
Fluid Set (FS)/Spray Gun
FS Number
None
244115
Accessories
Standard Turbine Air Hose
Length (ft) Number
30 241413
3 244118
Tie Wrap Kit
(10 pack)
103473
Control Air
Valve
M1638
Material Hose
Length (ft) Number
30
20 309240
240476
Air & Material Hose
Length (ft) Number
30 241423
Notes:
D See HVLP Fine Finish Systems
brochure 300564 for all accessories.
D Non-Silicone Lubricant 111265 (4 oz) is
available for fluid seals and wear areas.
Pressure Pot
PTFE Lined 240045
8483A
Compressor Air Hose
Pot Length (ft) Number
21/
2
gal
2 qt 30
2 240074
240071
Page 21
Specifications
Power requirements 120V AC, 50/60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amps at 120 volts
HVLP 2500 1 phase, 7A minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 1 phase, 12A minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 1 phase, 14A minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cord (extension cord must be 3-wire, 12 AWG, 50 ft [15 m] or shorter)
HVLP 2500 No. 16 AWG, 3 wire, 10 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 No. 16 AWG, 3 wire, 10 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 No. 14 AWG, 3 wire, 15 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unrestricted flow rate
HVLP 2500 58 cfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 80 cfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 82 cfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine stages
HVLP 2500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum turbine hose length
HVLP 2500 40 ft (12 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 60 ft (18 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 60 ft (18 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cup volume 1 quart (0.95 liter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wetted parts
Bare spray gun stainless steel, brass, PTFE, hard-coated aluminum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray gun cup aluminum, polyethylene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-quart (1.9 liter) accessory remote pressure pot aluminum, brass, polyethylene. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
/2-gallon (9.5 liter) accessory remote pressure pot steel with solvent-resistant finish,. . . . . . . . . . . . . . . . . . . . . . .
2
EPDM gasket (standard)
Turbine shipping weight
HVLP 2500 32 lb (14.5 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 3800 34 lb (15.4 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HVLP 4900 36 lb (16.3 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine diameter 5.7 in (144.78 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound level per ISO 3744
Sound power level 89.0 dB(A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure level 78.0 dB(A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
309240 21
Page 22
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. 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 procedures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call 1–800–690–2894 to identify the nearest distributor.
All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
MM 309240
22 309240
International Offices: Belgium, China, Japan, Korea
Graco Headquarters: Minneapolis
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN USA 309240
10/200 Rev. 11/2005
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