Graco Pro Xp Instruction Manual

Instructions-Parts

Pro

Pro Pro
Air

Air Air

For

For For
For

For For
use

use use

100psi(0.7MPa,7.0bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7.0bar)MaximumAir
WorkingPressure

Seepage3formodelpartnumbersand
approvalinformation.

Xp™

Xp™ Xp™

Spray

Spray Spray

use

use use
use

use use

only.

only. only.

Class

in ininClass Class

Group

in ininGroup Group

Important

Important Important
Thisequipmentcouldpresenthazardsifnotoperatedaccordingto
theinformationinthismanual.Readallwarningsandinstructionsin
thismanualbeforeusingtheequipment.Save Save

Electrostatic

Electrostatic Electrostatic

Gun

Gun Gun

Div.

I, I,I,Div. Div.

II,

II, II,

Safety

Safety Safety

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

3A2494P

EN

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

using

Group

using using

Group Group

Locations

Locations Locations

Save

these

instructions.

these these

instructions. instructions.

materials.

D DDmaterials. materials.

using

Group

using using

Group Group

IIA

materials.

IIA IIA

materials. materials.

For

professional

For For

professional professional

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

Approvals...........................................................7

RelatedManuals................................................7

Warnings...........................................................8

GunOverview....................................................11

HowtheElectrostaticSprayGun

Works............................................11

Controls,Indicators,andComponents...........12

SmartGuns.................................................13

Installation..........................................................18

WarningSign...............................................18

VentilatetheSprayBooth.............................18

AirSupplyLine............................................19

FluidSupplyLine.........................................19

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

GunSetup..........................................................25

GunSetupProcedure...................................25

SoftSprayGunSetupProcedure..................28

HVLPGunSetupProcedure.........................29

RoundSprayGunSetupProcedure..............31

AbrasiveMaterialGunSetup

Procedure......................................33

CheckGunElectricalGrounding...................34

CheckFluidResistivity.................................35

CheckFluidViscosity...................................35

FlushBeforeUsingEquipment......................35

Operation...........................................................36

PressureReliefProcedure............................36

Startup........................................................37

Shutdown....................................................37

Maintenance......................................................38

DailyCareandCleaningChecklist................38

Flushing......................................................38

CleantheGunDaily.....................................40

DailySystemCare.......................................41

ElectricalTests...................................................42

TestGunResistance....................................42

TestPowerSupplyResistance.....................43

TestElectrodeResistance............................43

Troubleshooting..................................................44

SprayPatternTroubleshooting......................44

GunOperationTroubleshooting....................45

ElectricalTroubleshooting............................46

Repair................................................................47

PreparetheGunforService.........................47

AirCapandNozzleReplacement..................48

ElectrodeReplacement................................49

FluidPackingRodRemoval..........................50

PackingRodRepair.....................................50

BarrelRemoval............................................52

BarrelInstallation.........................................52

PowerSupplyRemovaland

Replacement..................................53

AlternatorRemovalandReplacement...........54

FluidTubeRemovalandReplacement...........56

FanAirAdjustmentValveRepair..................57

AtomizingAirRestrictorValveRepair............58

ESOn-OffandFluidAdjustmentValve

Repair............................................59

AirValveRepair...........................................60

SmartModuleReplacement..........................61

AirSwivelandExhaustValve

Replacement..................................62

Parts..................................................................63

GunModelswithStandardDisplay................63

GunModelswithSmartDisplay....................66

PackingRodAssembly.................................69

AlternatorAssembly.....................................70

ESOn-OffandFluidAdjustmentValve...........71

FanAirAdjustmentValveAssembly..............72

QuickAdjustFanValveAssembly.................72

AtomizingAirRestrictorValve

Assembly.......................................73

SmartModuleAssembly...............................74

RoundSprayAssembly................................75

HighConductivityFluidTubeAssembly:40

kV..................................................77

HighConductivityFluidTubeAssembly:60

kVand85kV..................................78

FluidNozzles.....................................................79

FluidNozzleSelectionChart.........................79

FluidNozzlePerformanceCharts..................80

AirCaps.............................................................82

AirCapSelectionGuide...............................82

AirConsumptionCharts...............................87

ElectrodeSelectionChart....................................88

RepairKitsandAccessories................................89

GunAccessories..........................................89

InlineFluidFilterKitAccessories...................90

OperatorAccessories...................................90

SystemAccessories.....................................90

Signs..........................................................91

TestEquipment...........................................91

Hoses.........................................................92

Dimensions........................................................93

TechnicalSpeci󰘰cations......................................94

CaliforniaProposition65.....................................94

2

3A2494P

Models

Models

Models Models

General

General General

Equippedwithstandardelectrode,nozzle,aircapand󰘱uidtube.ForapplyingaClassA󰘰nishwithstandard
andspecialtycoatings.

Part

Part Part

L40M10A40

L40T10

L40T12A40

L60M10

L60M12

L60T10

L60T12

L60T21A60

L85M10

L85M12A85

L85T10

L85T12A85

L85T50*

Gun

Gun Gun

No.

No. No.

Models

Models Models

Series

Series Series

C

C

C

C

C

C

C

A85

kV

kV kV

40

60

60

60

60

85

85

Display

Display Display

SmartStd1.5StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

SmartStd1.5StdStdStd

SmartStd1.2StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

StdStd1.0StdStdStd

SmartStd1.5StdStdStd

SmartStd1.2StdStdStd

StdStd1.5StdStdStd

StdStd1.2StdStdStd

StdStd1.5StdStdStd

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

Fluid

Tube

Fluid Fluid

Tube Tube

*Equippedwithaquick-adjustfanvalve

3A2494P3

Models

High

High High

EquippedwithalongerHighConductivity󰘱uidtubeforsprayinglowerresistivitymaterial.Mostmodelsare
alsoequippedwithhighwearelectrode,precisionhighwearnozzle,andstandardaircap.Forapplyinga
classA󰘰nishwithabrasiveandmetalliccoatings.

Conductivity

Conductivity Conductivity

Part

No.

Part Part

No. No.

L40M16A40

L40T13B40

L40T16

L40T26A40

L60M26A60

L60M16

L60T26A60

L60T13B60

L60T16

L85M16

L85M26A85

L85T16

Series

Series Series

C

C

C

C

C

Gun

Gun Gun

Models

Models Models

kV

kV kV

40

60

60

85

85

Display

Display Display

Smart

Std

Std

Std

Smart

Smart

Std

Std

Std

Smart

Smart

Std

Electrode

Electrode Electrode

HW1.5PHW

HW

HW1.5PHW

HW1.2PHW

HW1.2PHW

HW1.5PHW

HW1.2PHW

HW

HW1.5PHW

HW1.5PHW

HW1.2PHW

HW1.5PHW

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

1.5StdStdHC

1.5StdStdHC

Air

Cap

Air Air

Cap Cap

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

L85T26A85

L85T56*

*Equippedwithaquick-adjustfanvalve

kV

Booster

kV kV

Booster Booster

The40kVBoosterprovidesthetransferef󰘰ciencyofa60kVguninasmaller,morecompactsize.

Part

No.

Part Part

No. No.

L40M14A40

L40M15A40

L40T14

L40T15

A85

Gun

Gun Gun

Series

Series Series

C

C

Models

Models Models

kV

kV kV

40

40

Std

Std

Display

Display Display

SmartStd1.5StdStdStd

Smart

StdStd1.5StdStdStd

Std

HW1.2PHW

HW1.5PHW

Electrode

Electrode Electrode

HW1.5PHW

HW1.5PHW

StdHC

StdHC

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

StdHC

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

4

3A2494P

Models

Round

Round Round

Equippedwithroundspraynozzleandaircap.Forroundspraypatternapplications.

Part

Part Part

L40T31A40

L40T32A40

L60T11

L60T31A60

L60T32A60

L85T31A85

L85T32A85

Soft

Soft Soft

Equippedwithsoftsprayaircap.ForapplyingaclassA󰘰nishtosmall,lightweightparts.

Part

Part Part

L40T71A40

Spray

Spray Spray

No.

No. No.

Spray

Spray Spray

No.

No. No.

Gun

Gun Gun

Series

Series Series

C

Gun

Gun Gun

Series

Series Series

Models

Models Models

kV

kV kV

60

Models

Models Models

kV

kV kV

Display

Display Display

StdStdSmallPatternStd

StdStd

StdStd

StdStdSmallPatternStd

StdStd

StdStdSmallPatternStd

StdStd

Display

Display Display

StdStd1.0StdSoftSprayStd

Electrode

Electrode Electrode

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

MediumPattern

LargePattern

MediumPattern

MediumPattern

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Fluid

Air

Cap

Air Air

Cap Cap

Air

Cap

Air Air

Cap Cap

Tube

Fluid Fluid

Tube Tube

Std

Std

Std

Std

Fluid

Tube

Fluid Fluid

Tube Tube

L60M71A60

L60M72A60

L60T71A60

L60T72A60

L85M71A85

L85T71A85

Aerospace

Aerospace Aerospace

Equippedwithaerospaceaircap,highwearelectrode,andprecisionhighwearnozzle.Forapplyinghigh
solidsandaerospacecoatings.

Part

No.

Part Part

No. No.

L85T73A85

L85T75A85

L85T78A85

Gun

Gun Gun

Series

Series Series

Models

Models Models

kV

kV kV

SmartStd1.0StdSoftSprayStd

SmartStd1.2StdSoftSprayStd

StdStd1.0StdSoftSprayStd

StdStd1.2StdSoftSprayStd

SmartStd1.0StdSoftSprayStd

StdStd1.0StdSoftSprayStd

Display

Display Display

Std

Std

Std

Electrode

Electrode Electrode

HW1.2PHW

HW1.5PHW

HW1.8PHW

Nozzle

Nozzle Nozzle

(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

AEROStd

AEROStd

AEROStd

Fluid

Fluid Fluid

Tube

Tube Tube

3A2494P5

Models

HVLP

HVLP HVLP

EquippedwithHVLPaircap.

Part

Part Part

L40M77A40

L40T77A40

L60M77A60

L60T77A60

L85M77A85

L85T77A85

High

High High

EquippedwithESOn-OffwithAirRestrictorandFluidAdjustmentValve,whichlimitsair󰘱owtotheturbine.
Forapplicationsthatrequirehighair󰘱owattheaircap.

Part

Part Part

L60M57A60

Gun

Gun Gun

No.

No. No.

Air

Air Air

No.

No. No.

Models

Models Models

Series

Series Series

Flow

Flow Flow

Series

Series Series

kV

kV kV

Gun

Gun Gun

kV

kV kV

Display

Display Display

SmartStd1.5Std

StdStd1.5Std

SmartStd1.5Std

StdStd1.5Std

SmartStd1.5Std

StdStd1.5Std

Models

Models Models

Display

Display Display

SmartStd1.5StdStdStd

Electrode

Electrode Electrode

Electrode

Electrode Electrode

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

Air

Cap

Air Air

Cap Cap

HVLP

HVLP

HVLP

HVLP

HVLP

HVLP

Air

Cap

Air Air

Cap Cap

Fluid

Tube

Fluid Fluid

Tube Tube

Std

Std

Std

Std

Std

Std

Fluid

Tube

Fluid Fluid

Tube Tube

L60T57A60

L85M57A85

L85T57A85

Fixed

Fixed Fixed

EquippedwithESOn-OffandFixedFluidValve,whichextendselectrodeandnozzlelife.Forapplicationswith
abrasive,metallic,andextremelyabrasivematerials.

Part

Part Part

L60T98A60

L60T99A60

L85T90A85

L85T96A85

Fluid

Fluid Fluid

No.

No. No.

Flow

Flow Flow

Series

Series Series

Gun

Gun Gun

kV

kV kV

StdStd1.5StdStdStd

SmartStd1.5StdStdStd

StdStd1.5StdStdStd

Models

Models Models

Display

Display Display

StdShort

StdShort

Std

Std

Electrode

Electrode Electrode

HW1.5PHW

HW1.5PHW

Nozzle

Nozzle Nozzle
(mm)

(mm) (mm)

1.5PHW

1.5PHW

Air

Cap

Air Air

Cap Cap

StdStd

StdHC

StdStd

StdHC

Fluid

Tube

Fluid Fluid

Tube Tube

63A2494P

Approvals

2575

Approvals

Approvals Approvals

G

II IIII2 22G G

0.24mJT6

FM12ATEX0068

EN50050-1

Ta0°C–50°C

Related

Related Related

Manual

Manual Manual

3A2498

3A6929

3A7005

3A6833

307263ProbeandMeter,Instructions

308393

309227

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions(largepattern)

RoundSprayKit,Instructions(smallandmediumpattern)

QuickAdjustFanValveKit,Instructions

HVLPVeri󰘰cationKit,Instructions

GunWasherKit,Instructions

GunFlushBoxModule,Instructions

VoltageTesterConversionKit,Instructions

3A2494P

7

Warnings

Warnings

Warnings Warnings

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

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inworkareacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰re,
explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.

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

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.
Stop

•Stop Stop

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairand󰘱uidsupplytopreventoperationunlessventilationair󰘱owisabove

•UseonlyGroupIIAorGroupDmaterials.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Neversprayor󰘱ushsolventathighpressure.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast15°

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsourcessuchaspilotlights,cigarettes,portableelectriclamps,and

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepthesprayareacleanatalltimes.Usenon-sparkingtoolstocleanresiduefromthe

•Keepaworking󰘰reextinguisherintheworkarea.

operation

operation operation

equipmentuntilyouidentifyandcorrecttheproblem.

theminimumrequiredvalue.

Cor59°Faboveambienttemperature.Non-ignitable󰘱uidsarepreferred.

plasticdropcloths(potentialstaticsparking).

boothandhangers.

AND

ELECTRIC

AND AND

ELECTRIC ELECTRIC

immediately

immediately immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

SHOCK

SHOCK SHOCK

HAZARD

HAZARD HAZARD

Grounding

instructions.

83A2494P

WARNING

WARNING WARNING

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

EQUIPMENT

EQUIPMENT EQUIPMENT

HAZARD

HAZARD HAZARD

Warnings

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

EQUIPMENT

EQUIPMENT EQUIPMENT
Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Speci󰘰cations

Speci󰘰cations Speci󰘰cations
Forcompleteinformationaboutyourmaterial,requestaSafetyDataSheet(SDS)from
yourdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

PLASTIC

PLASTIC PLASTIC
Manycleaningsolventscandegradeplasticpartsandcausethemtofail,whichcouldcause
seriousinjuryorpropertydamage.

Pressure

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

Relief

Procedure

Relief Relief

Procedure Procedure

HAZARD

HAZARD HAZARD

Technical

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

CLEANING

CLEANING CLEANING

SOLVENT

SOLVENT SOLVENT

whenyoustopspraying/dispensingandbefore

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pressure

HAZARD

HAZARD HAZARD

Relief

Relief Relief

inallequipmentmanuals.

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Technical

•Useonlycompatiblesolventstocleanplasticstructuralorpressure-containingparts.

•SeeTechnical Technical

Technical

thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

inallequipmentmanualsformaterialsofconstruction.Consult

3A2494P9

Warnings

WARNING

WARNING WARNING

TOXIC

TOXIC TOXIC
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

PERSONAL

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

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

FLUID

FLUID FLUID

guidelines.

manufacturer.

OR

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

HAZARD

HAZARD HAZARD

EQUIPMENT

EQUIPMENT EQUIPMENT

103A2494P

GunOverview

Gun

Gun Gun

How

How How

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

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Spray

Spray Spray

Gun

Gun Gun

Works

Works Works

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

3A2494P

11

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents(seeFig.1).Forinformation
onSmartguns,seeSmartGuns,page13.

Figure1GunOverview

Item

Item Item

A

BFluidInlet

Indicators,

Indicators, Indicators,

Description

Description Description

AirSwivelInlet1/4npsm(m)left-handthread,forGracogroundedairsupplyhose.

and

Components

and and

Components Components

Purpose

Purpose Purpose

3/8npsm(m),for󰘱uidsupplyhose.

C

D

EElectrodeNeedle

FFanAirAdjustment

G

HFluidAdjustment

J

K

TurbineAir
Exhaust

AirCapandNozzleShapesthespraypattern.SeeAirCaps,page82and

Valve

AtomizingAir
RestrictorValve

Knob

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(stan­dardgunonly;for
Smartgunindica­tor,seeOperating

Mode,page13)

Barbed󰘰tting,forsuppliedexhausttube.

FluidNozzles,page79foravailablesizes.

Supplieselectrostaticchargetothe󰘱uid.See

ElectrodeSelectionChart,page88.

Adjustsfansizeandshape.Canbeusedtodecreasepatternlength.

Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.

Adjusts󰘱uid󰘱owbylimiting󰘱uidneedletravel.Useonlyinlow󰘱ow
conditions,toreducewear.

LitwhenESisON(I).Colorindicatesalternatorfrequency.SeetheLED
indicatortableintheGunSetupProcedure,page25.

12

3A2494P

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page15.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.

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

ElectricalTroubleshooting,page46forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

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

AdjustingtheLowVoltageSetting,page14.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page14,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Hz

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A160.Then,adjustthepressureasneededto
ensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

3A2494P13

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page15.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page46.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

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

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page14.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page15.
Thepossiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

•40kVguns:20–40kV

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

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page15.

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page17,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

14

3A2494P

GunOverview

Smart

Smart Smart

Table

Table Table

Item

Item Item

VA

LO

kV

uA

LSLOSETbuttonPressmomentarilytoentertheLowVoltageSettingscreen.

Gun

Key

Gun Gun

Key Key

Key

for

Figs.

1 11Key Key

for for

Description

Description Description

VoltageAdjustmentSwitchTwo-positionswitchsetsSmartgunvoltagetolowsetting(LO)or

LowVoltageMode
Indicator

Voltage(kV)DisplayDisplaysactualsprayingvoltageofthegun,inkV.InOperatingMode,

Current(uA)DisplayDisplaysactualsprayingcurrentofthegun,inuA.InOperatingMode,

2–9.

Figs. Figs.

2–9. 2–9.

Purpose

Purpose Purpose

highsetting(HI).ThisswitchisfunctionalinOperatingModeandin
DiagnosticMode.

Lights(blue)whentheSmartgunissettoLowVoltage.

displayisabargraph.InDiagnosticMode,voltageisdisplayedas
anumber.

displayisabargraph.InDiagnosticMode,currentisdisplayedas
anumber.

Pressandholdforapproximately5secondstoenterorexitDiagnostic
Mode.

WhileinDiagnosticMode,pressmomentarilytoadvancethrough
screens.

WhileontheLowVoltageLockScreen(inDiagnosticMode),press
andholdtoturnthelockonoroff.

LVLowVoltageDisplayDisplaysthelowvoltagesettingasanumber.Thesettingcanbe

changed.SeeFig.4.

LKLowVoltageLocked

LD

ERErrorDisplay

VIVoltageIndicator

CICurrentIndicatorInDiagnosticMode,thetwobottomrightLEDsofthescreenlight,

ASAlternatorSpeedDisplayInDiagnosticMode,Hzlevelisdisplayedasanumber.SeeFig.8.

Hz

LODisplayAppearsontheLowVoltageLockScreen.SeeFig.9.

AlternatorSpeedIndicatorInOperatingMode,indicatorcolorvariestoshowthealternatorspeed

Appearsifthelowvoltagesettingislocked.SeeFig.5andFig.9.

AppearsiftheSmartmodulelosescommunicationwiththepower
supply.SeeFig.3.

InDiagnosticMode,thetwotoprightLEDsofthescreenlight,
indicatingthatthevaluedisplayedisinkV.SeeFig.6.

indicatingthatthevaluedisplayedisinuA.SeeFig.7.

status:

•Greenindicatesthealternatorspeedisatthecorrectlevel.

•Iftheindicatorchangestoamberafteronesecond,thealternator
speedistoolow.

•Iftheindicatorchangestoredafteronesecond,thealternatorspeed
istoohigh.TheindicatoralsoturnsrediftheErrordisplayappears.

InDiagnosticMode,theindicatorisgreenwhenintheAlternator
Speed(Hertz)screen.

3A2494P15

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

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

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page16.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page17fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page15.Toenterthisscreen,press

theLOSETbuttonwhileintheVoltage(kiloVolts)
Screen.

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

(microAmperes)

(microAmperes) (microAmperes)

Screen

Screen Screen

Voltage

Voltage Voltage

TheVoltage(kiloVolts)Screenisthe󰘰rstscreento
appearafterenteringDiagnosticMode.SeeFig.6
andSmartGunKey,page15.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page16.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page17.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

163A2494P

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page15.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page17.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page15.Toenterthisscreen,press

theLOSETbuttonwhileintheAlternatorSpeed
(Hertz)Screen.

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

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

NOTE:

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

DiagnosticModecannotbeexitedfromthis

Lock

Screen

Lock Lock

Screen Screen

Figure8AlternatorSpeed(Hertz)Screen

Figure9LowVoltageLockScreen

3A2494P

17

Installation

Installation

Installation Installation

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.

•Besureyourinstallationcomplieswithlocal,
state,andnationalcodesfortheinstallation
ofelectricalapparatusinaClassI,Div.I,
hazardouslocationoraGroupII,ZoneI
explosiveatmospherelocation.

•Complywithalllocalcodesandregulations.

Fig.10(TypicalInstallation)showsatypical
electrostaticairspraysystem.Itisnotanactual
systemdesign.Forassistanceindesigningasystem
tosuityourparticularneeds,contactyourGraco
distributor.

Warning

Warning Warning

Sign

Sign Sign

Ventilate

Ventilate Ventilate

Donotoperatethegununlessventilatingair󰘱owis
abovetheminimumrequiredvalue.Providefresh
airventilationtoavoidthebuildupof󰘱ammableor
toxicvaporswhenspraying,󰘱ushing,orcleaning
thegun.Interlockthegunairand󰘱uidsupply
topreventoperationunlessventilatingair󰘱owis
abovetheminimumrequiredvalue.

Thesprayboothmusthaveaventilationsystem.

Electricallyinterlockthegunairand󰘱uidsupplywith
theventilatorstopreventgunoperationanytimethat
theventilationair󰘱owfallsbelowminimumvalues.
Checkandfollowalllocalcodesandregulations
regardingairexhaustvelocityrequirements.Verify
theoperationoftheinterlockatleastonceayear.

NOTE:Theminimumallowableairexhaust
velocityis60feet/minute(19linearmeters/minute).
High-velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.

the

Spray

the the

Spray Spray

Booth

Booth Booth

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

183A2494P

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

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

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

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

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Installation

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

2.Installa󰘱uidregulator(FR)onthe󰘱uidlineto

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

4.The󰘱uiddrainvalve(FD)isrequiredinyour

Supply

Supply Supply

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

control󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog
thespraynozzle.

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

systemtoassistinrelieving󰘱uidpressureinthe
displacementpump,hose,andgun.Triggering
theguntorelievepressuremaynotbesuf󰘰cient.
Installadrainvalveclosetothepump's󰘱uid
outlet.

Line

Line Line

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

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

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

3A2494P19

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

HAZARDOUS

HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

Figure10TypicalInstallation

Typical

Typical Typical

Item

Item Item

ADAirLineDrainValve

AF

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FL

FRFluidPressureRegulator

Installation

Installation Installation

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

FV

GRGunAirPressureRegulator

MA

PG*PumpGroundWire

PRPumpAirPressureRegulator

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve.

*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE:
asaGracoaccessory.

Thesolenoidvalveisnotoffered

203A2494P

Installation

Grounding

Grounding Grounding

Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundallequipment,personnel,objects
beingsprayed,andconductiveobjectsinorclose
tothesprayarea.Theresistancemustnotexceed
1megohm.Groundingprovidesanescapewire
fortheelectriccurrent.

Whenoperatingtheelectrostaticgun,any
ungroundedobjects(suchaspeople,containers,and
tools)inthespraylocationcanbecomeelectrically
charged.

Thefollowingareminimumgroundingrequirements
forabasicelectrostaticsystem.Yoursystemmay
includeotherequipmentorobjectswhichmustbe
grounded.Yoursystemmustbeconnectedtoa
trueearthground.Checkgroundconnectionsdaily.
Checkyourlocalelectricalcodesandregulationsfor
detailedgroundinginstructions.

Allpersonsenteringthesprayarea

•

shoeshavingconductivesolessuchasleather,
orwearpersonalgroundingstraps.Donot
wearshoeswithnon-conductivesolessuchas
rubberorplastic.Ifglovesarenecessary,wear
theconductiveglovessuppliedwiththegun.If
non-Gracoglovesareworn,cutoff󰘰ngersorpalm
areaofglovestoensureyourhandcontactsthe
groundedgunhandle.Conductiveglovesand
footwearmustnotexceed100megohmperEN
ISO20344,EN1149–5.

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

ElectrostaticAirSprayGun:

byconnectingtheGracoGroundedAirHose
(AH)tothegun,andconnectingtheairhose
groundwiretoatrueearthground.See

CheckGunElectricalGrounding,page34.

•

Pump/󰘱uidsource:

byconnectingitsgroundwiretoatrueearth
ground.

•

Allelectricallyconductiveobjectsordevicesinthe
sprayarea

•

Fluidandwastecontainers:

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

Aircompressors:

•
tothemanufacturer'srecommendations.

•

Allairand󰘱uidlines

Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity.

mustbeproperlygrounded.

Groundthepump/󰘱uidsource

Groundtheequipmentaccording

mustbeproperlygrounded.

Groundthegun

Groundall󰘱uidand

3A2494P

21

Installation

•

The󰘱oorofthesprayarea

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

Flammableliquidsinthesprayarea

inapproved,groundedcontainers.Donotuse
plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.

•

Allsolventpails:

metalcontainers,whichareconductive.Donot
useplasticcontainers.Useonlynon-󰘱ammable
solvents.Donotstoremorethanthequantity
neededforoneshift.

Useonlyapproved,grounded

mustbekept

22

3A2494P

Installation

Figure11GroundtheOperatorOperatorisgroundedthroughbareskincontactwith

thegunhandleandconductiveshoes.Aconductive
glovecanalsobeused.

Figure12GroundtheObjectBeingSprayedObjectbeingsprayedisgroundedthroughcontact

withthehangerandconveyorsystem.

3A2494P23

Installation

Figure13GroundtheGunGunisgroundedthroughtheconductiveairhose.

Figure14GroundtheFluidSupplyFluidsupplylineandsourcemustbegrounded.

24

3A2494P

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Foradditionalstepstosetupspecialtyguns,
seeSoftSprayGunSetupProcedure,page28,

RoundSprayGunSetupProcedure,page31,
HVLPGunSetupProcedure,page29,and
AbrasiveMaterialGunSetupProcedure,page33.

Seethe󰘰gurebelowtolocatetheelectrostaticgun
controls.

Figure15ElectrostaticGunControls

Setup

Setup Setup

Setup

Setup Setup

Procedure

Procedure Procedure

4.Checkgunresistance.Followthestepsin

TestGunResistance,page42.

5.ConnecttheGracogroundedairhosetothegun

airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.

6.FollowallstepsinGrounding,page21.

7.Followallstepsin

CheckGunElectricalGrounding,page34.

Readingmustbelessthan1megohm.

8.Verifythatthematerialresistivitymeets

requirementsforelectrostaticspray.See

CheckFluidResistivity,page35.

9.Connecttheexhausttubeandsecurewiththe

clampprovided.

1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.

NOTE:

NOTE: NOTE:
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page79and
AirCapSelectionGuide,page82.

Toinstallthenozzleandaircap,see

AirCapandNozzleReplacement,page48.

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

3.Shutofftheairbleedvalvetothegun.

Toselectadifferent

10.Connectthe󰘱uidhosetothegun󰘱uidinlet.

11.Flushifneeded.SeeFlushing,page38.

12.Positiontheaircapasneeded.

3A2494P25

GunSetup

13.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.

14.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.

15.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.

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

Table

Table Table

using

using using

mm)

mm) mm)

Pressure

2 22. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered

triggered triggered

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

18.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Green

Amber

LED

3 33. ..LED LED

Color

Color Color

Red

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

263A2494P

GunSetup

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

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

22.Sprayatestpattern.Checktheatomization.

•Ifover-atomizationoccursatminimum
pressure,adjusttheatomizingairrestrictor
valve.

•Ifatomizationisinadequate,increaseair
pressureordecrease󰘱uid󰘱ow.

23.Adjustthefanairadjustmentvalve.

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

•Fullyopenthefanairadjustmentvalve,
counterclockwise,forthelongestpattern.

•Turnthevalveclockwisetorestrictthefanair
andcreateashorterpattern.

24.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page44.

3A2494P

27

GunSetup

Soft

Spray

Soft Soft

Spray Spray

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

Toachieveasoftspraypatternforsmallorlightweight
parts,dothefollowing:

1.Selectasoftspraygunmodel.See

SoftSprayGunModels,page5.

•Toconvertagunforsoftspray,

installasoftsprayaircap.See

AirCapSelectionGuide,page82.

•Forbestresults,installa1.0

mmor1.2mmnozzle.See

FluidNozzleSelectionChart,page79.

2.Followsteps1–14inthe

GunSetupProcedure,page25.

3.Adjusttheatomizingair.Fullyclosetheatomizing
airrestrictorvalve(G)counterclockwise.Then,
opentheatomizingairrestrictorvalve(G)one
halfturntooneturn.

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

Table

Table Table

using

using using

mm)

mm) mm)

6.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Green

Amber

Pressure

4 44. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

Color

Color Color

Red

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

LED

5 55. ..LED LED

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

Air

Regulator

Air Air

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

triggered

triggered triggered

bar)

bar) bar)

5.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.

7.Continuewithsteps19–24inthe

GunSetupProcedure,page25.

NOTE:

NOTE: NOTE:
productionrateof3.5oz/min(100cc/min).For
bestsoftsprayresults,limittheproductionrate
to7oz/min(200cc/min)orless.

NOTE:

NOTE: NOTE:
much,adjusttheatomizingairrestrictorvalve
(G)counterclockwiseslightlytolimittheair󰘱ow.
Toimproveatomization,adjusttheatomizingair
restrictorvalve(G)clockwiseslightlytoincrease
theair󰘱owordecreasethe󰘱uid󰘱ow.

Thesoftsprayaircapisoptimizedfora

Iftheobjectbeingsprayedismovingtoo

283A2494P

GunSetup

HVLP

HVLP HVLP

Mostairqualityauthoritiesacceptelectrostatic
sprayingasthemostef󰘰cientprocessandameans
tocomplywithenvironmentalregulation.Follow
theGunSetupProcedure,page25whenspraying
electrostaticallywithanHVLPaircap.
Whenelectrostaticsprayingcannotbeeffectively
usedoncertainpartsormaterials,anHVLPguncan
beusedtocomplywithenvironmentalregulationsin
mostareas.Tobeincompliancetheairpressures
attheaircapmustbelessthan10psi.Follow
theprocedurebelowtosetupthespraygunfor
non-electrostaticHVLPoperation.

1.SelectanHVLPgunmodel.See

2.Followsteps1–12inthe

3.Fullyopenthe󰘱uidadjustmentvalve(H)

Gun

Gun Gun

HVLPGunModels,page6.

ToconvertagunforHVLP,installanHVLPair
cap.SeeAirCapSelectionGuide,page82.

GunSetupProcedure,page25.

counterclockwise.

Setup

Setup Setup

Procedure

Procedure Procedure

b.Fullyopentheatomizingairrestrictorvalve

(G)clockwise.

c.TurnOFF(I)theESOn-Offswitch(J).

d.Setthegunairregulatortodeliver30

psi(0.21MPa,2.1bar)atthegunwhen
triggered.

4.Adjusttheairintheaircap.

a.Fullyopenthefanairadjustmentvalve(F)

counterclockwise.

Table

Table Table

5.Shutofftheairtothegun.

Pressure

6 66Pressure Pressure

Air

Hose

Air Air

Hose Hose

(m)

in ininft ftft(m) (m)

5/16

inch

5/16 5/16

inch inch

diameter

diameter diameter

15(4.6)43(0.29,3)

25(7.6)50(0.34,3.4)

50(15.3)70(0.48,4.8)

Drop

Drop Drop

Length

Length Length

using

using using

(8

mm)

(8 (8

mm) mm)

hose

hose hose

Air

Regulator

Air Air

Regulator Regulator

Setting

Setting Setting

(MPa,

(MPa, (MPa,

gun

gun gun

psi

in ininpsi psi

bar)

with

bar) bar)

with with

triggered

triggered triggered

3A2494P29

GunSetup

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

7.Turnontheairtothegun.

8.Sprayatestpattern.Checktheatomization.

•Ifover-atomizationoccursadjusttheatomizing
airrestrictorvalve.

•Ifatomizationisinadequate,increaseair
pressureordecrease󰘱uid󰘱ow.

9.Adjustthefanairadjustmentvalve.

•Ifdesired,turnthevalveclockwisetorestrict
thefanairandcreateashorterpattern.

10.VerifythattheaircappressuresmeetHVLP
requirementsof10PSI(0.07MPa,0.7bar)or
lessusingtheHVLPveri󰘰cationkit25E919.See
manual3A6833.Adjustthefanairadjustment
valve(F)andatomizingairrestrictorvalveto
achieve10PSIorlessasneeded.

303A2494P

GunSetup

Round

Round Round

Toachievearoundspraypattern,dothefollowing:

1.Selectaroundspraygunmodelorconvertan

2.Followsteps1–11inthe

3.Fullyopenthe󰘱uidadjustmentvalve(H)

Spray

Spray Spray

existingguntoroundspray.

•Toselectaroundspraygunmodel,see

RoundSprayGunModels,page5.

•Toconvertagunforroundspray,installa
roundspraykit.SeeRoundSprayAccessories
inGunAccessories,page89.

•Toachieveasoftpatternforsmallparts
orincreasedtransferef󰘰ciency,selectthe
mediumpatternorsmallpatternmodels.

GunSetupProcedure,page25.

counterclockwise.

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

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

6.Setthegunairregulatortodeliveraminimum
45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.

4.Adjusttheairintheaircap.

a.Fullyclosetheatomizingairrestrictorvalve

(G)counterclockwise.Then,openthe
atomizingairrestrictorvalve(G)oneturn.

b.Fullyclosethefanairadjustmentvalve(F)

clockwise.

Table

Table Table

using

using using

mm)

mm) mm)

Pressure

7 77. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)55(0.38,3.8)

25(7.6)65(0.45,4.5)

50(15.3)80(0.56,5.6)

Drop

Drop Drop

Air

Air Air

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Regulator

Regulator Regulator

psi

in ininpsi psi

with

gun

with with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered

triggered triggered

3A2494P31

GunSetup

7.VerifythattheESindicator(K)[Hzindicatoron
Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Amber

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

LED

8 88. ..LED LED

Color

Color Color

Green

Red

Indicator

Indicator Indicator

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangestoamber
afteronesecond,theairpressure
istoolow.Increaseairpressure
untiltheindicatorisgreen.

Iftheindicatorchangestored
afteronesecond,theairpressure
istoohigh.Decreaseairpressure
untiltheindicatorisgreen.To
maintainahigherapplicationair
pressure,installESOn/OffValve
RestrictorKit26A160.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

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

11.Sprayatestpattern.Checktheatomization.

NOTE:

NOTE: NOTE:
objectbeingsprayedismovingtoomuch,
adjusttheatomizingairrestrictorvalve(G)
counterclockwiseslightlytolimittheair󰘱ow.To
improveatomization,adjusttheatomizingair
restrictorvalve(G)clockwiseslightlytoincrease
theair󰘱owordecreasethe󰘱uid󰘱ow.

Iftheatomizationistoo󰘰ne,orifthe

9.Startthepump.Adjustthe󰘱uidregulatorto
achievetheproductionratethatyouwant.

NOTE:

NOTE: NOTE:
aproductionrateof5oz/min(150cc/min).For
bestroundsprayresults,limittheproductionrate
to10oz/min(300cc/min)orless.

Theroundsprayaircapisoptimizedfor

12.Adjustthepatternsize.

•Forthelargestspraypattern,fullyclosethefan
airadjustmentvalve(F)clockwise.

•Forthesmallestspraypattern,fullyopenthe
fanairadjustmentvalve(F)counterclockwise.

13.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page44.

323A2494P

GunSetup

Abrasive

Abrasive Abrasive

NOTE:

NOTE: NOTE:
taskseachday:

•Cleanthegun.SeeCleantheGunDaily,page40.

•Inspecttheelectrodeandreplaceifdamaged.See

ElectrodeReplacement,page49.

Toextendwearlifewithabrasive,metallic,and
extremelyabrasivematerials,dothefollowing:

1.Selectahighconductivityor

󰘰xed󰘱uid󰘱owgunmodel.See

HighConductivityGunModels,page4and
FixedFluidFlowGunModels,page6.

2.Toconvertagunforabrasivematerials:

•Selectahighwear,short,
orhardenedelectrode.See

ElectrodeSelectionChart,page88.

•Selectaprecisionhighwear
orhighwearnozzle.See

FluidNozzleSelectionChart,page79.

Sizethenozzleproperlytoreduce󰘱uid
pressurebelow30psi(0.21MPA,2.1bar),
producingan8-12in(200-300mm)󰘱uid
stream.

•Use24N632ESOn-OffandFixedFluidValve.

3.Followsteps1–19inthe

GunSetupProcedure,page25.

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

Material

Material Material

Toextendwearlife,performthefollowing

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

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

6.Sprayatestpattern.Checktheatomization.If
over-atomizationoccursatminimumpressure,
adjusttheatomizingairrestrictorvalve.If
atomizationisinadequate,increaseairpressure
ordecrease󰘱uid󰘱ow.

NOTE:

NOTE: NOTE:
toextendelectrodewirewearlife.Reducethe
guninletairpressureoradjusttheatomizingair
restrictorvalve(G)counterclockwisetoreduce
atomizingairwhentheapplicationallows.

7.Adjustthefanairadjustmentvalve.

•Fullyopenthefanairadjustmentvalve,

•Turnthevalveclockwisetorestrictthefanair

NOTE:

NOTE: NOTE:
extendelectrodewirewearlife.Reducethegun
inletairpressureoradjustthefanairadjustment
valve(F)clockwisetoreducefanairwhenthe
applicationallows.

8.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page44.

Usetheminimumatomizingairpressure

counterclockwise,forthelongestpattern.

andcreateashorterpattern.

Usetheminimumfanairpressureto

NOTE:

NOTE: NOTE:
knobinthefull󰘱owpositionatalltimesor
install24N632ESOn-OffandFixedFluidValve.
Alwaysuseanexternal󰘱uidregulator.Donot
usethe󰘱uidadjustmentknobtosetthe󰘱uid
pressure.

Operatethegunwiththe󰘱uidadjustment

3A2494P33

GunSetup

Check

Check Check

MegohmmeterPartNo.241079(AA-seeFig.16)
isnotapprovedforuseinahazardouslocation.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous

•Orallsprayingdevicesinthehazardous

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.241079Megohmmeterisavailable
asanaccessorytocheckthatthegunisproperly
grounded.

1.Haveaquali󰘰edelectricianchecktheelectrical

2.TurnOFF(O)theESOn-Offswitch.

Gun

Gun Gun

location;

locationareturnedoff,ventilationfansinthe
hazardouslocationareoperating,andthereare
no󰘱ammablevaporsinthearea(suchasopen
solventcontainersorfumesfromspraying).

groundingcontinuityofthespraygunandair
hose.

Electrical

Electrical Electrical

Grounding

Grounding Grounding

5.Makesurethegroundedairhose(AH)is
connectedandthehosegroundwireis
connectedtoatrueearthground.

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

7.Iftheresistanceisgreaterthan1megohm,check
thetightnessofthegroundconnectionsandbe
suretheairhosegroundwireisconnectedtoa
trueearthground.Iftheresistanceisstilltoo
high,replacetheairhose.

3.Turnofftheairand󰘱uidsupplytothegun.Follow
thePressureReliefProcedure,page36.

4.Disconnectthe󰘱uidhose.

Figure16CheckGunElectricalGrounding

343A2494P

GunSetup

Check

Check Check

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

Checkthattheresistivityofthe󰘱uidbeingsprayed
meetstherequirementsforanelectrostaticairspray
system.GracoPartNo.722886ResistanceMeter
and722860Probeareavailableasaccessories.
Followtheinstructionsincludedwiththemeterand
probe.

Fluidresistivityreadingsofatleast20megohms-cm
generallyprovidethebestelectrostaticresultsand
arerecommended.

Ahighconductivitykitorhighconductivityhosemay
berequiredforreadingslessthan20megohm-cm.

Table

Table Table

Fluid

Fluid Fluid

Fluid

9 99. ..Fluid Fluid

Resistivity

Resistivity Resistivity

Resistivity

Resistivity Resistivity

Levels

Levels Levels

Check

Check Check

Aviscositycupandstopwatchareneededtocheck
󰘱uidviscosity.

1.Completelysubmergetheviscositycupin

2.Watchthestreamof󰘱uidcomingfromthebottom

3.Recordthe󰘱uidtype,elapsedtime,andsizeof

4.Iftheviscosityistoohighortoolow,contactthe

Flush

Flush Flush

Theequipmentwastestedin󰘱uidatthefactory.To
avoidcontaminatingyour󰘱uid,󰘱ushtheequipment
withacompatiblesolventbeforeusingtheequipment.
SeeFlushing,page38.

Fluid

Fluid Fluid

the󰘱uid.Liftthecupoutquickly,startingthe
stopwatchassoonasthecupiscompletely
removed.

ofthecup.Assoonasthereisabreakinthe
stream,shutoffthestopwatch.

theviscositycup.

materialsupplier.Adjustasnecessary.

Before

Before Before

Viscosity

Viscosity Viscosity

Using

Using Using

Equipment

Equipment Equipment

Megohms

Megohms Megohms

1–77–2020–200200–2000

HighCon­ductivity
Kitrecom­mended

HighCon­ductivity
Kitmaybe
needed

cm

- --cm cm

Bestelec­trostatic
results

Goodelec­trostatic
results

3A2494P35

Operation

Operation

Operation Operation

Pressure

Pressure Pressure

Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing,
followthePressureReliefProcedurewhenyou
stopsprayingandbeforecleaning,checking,or
servicingtheequipment.

1.TurnOFF(O)theESOn/Offswitch.

2.Turnofftheairbleedvalvestothe󰘱uidsource
andtothegun.

Relief

Relief Relief

Procedure

Procedure Procedure

4.Openthepumpdrainvalve,havingawaste
containerreadytocatchthedrainage.Leave
thepumpdrainvalveopenuntilyouareready
tosprayagain.

5.Ifthenozzleorhoseiscompletelycloggedor
pressureisnotfullyrelieved,slowlyloosenthe
hoseendcoupling.Nowclearthenozzleorhose.

3.Triggerthegunintoagroundedmetalwaste
containertorelievethe󰘱uidpressure.

363A2494P

Operation

Startup

Startup Startup

FollowallstepsunderGunSetupProcedure,page25.

Beforeoperatingthesystem,checkthefollowinglist
dailytoensuresafe,ef󰘰cientoperation.

•Alloperatorsareproperlytrainedtosafelyoperate

anelectrostaticairspraysystemasinstructedin
thismanual.

•Alloperatorsaretrainedinthe

PressureReliefProcedure,page36.

•Thewarningsignprovidedwiththegunismounted

inthesprayareawhereitcanbeeasilyseenand
readbyalloperators.

•Thesystemisthoroughlygroundedandthe

operatorandallpersonsenteringthesprayarea
areproperlygrounded.SeeGrounding,page21.

•Theconditionofthegun’selectrical

componentshasbeencheckedasinstructedin

ElectricalTests,page42.

•Ventilationfansareoperatingproperly.

•Workpiecehangersarecleanandgrounded.

•Alldebris(including󰘱ammable󰘱uidsandrags)is

removedfromthesprayarea.

•All󰘱ammable󰘱uidsinthespraybootharein

approved,groundedcontainers.

•Allconductiveobjectsinthesprayareaare

electricallygroundedandthe󰘱oorofthespray
areaiselectricallyconductiveandgrounded.

Shutdown

Shutdown Shutdown

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page36wheneveryou

areinstructedtorelievethepressure.

1.Flushthegun.Followthestepsin

Flushing,page38.

2.FollowthePressureReliefProcedure,page36.

3.Hangthegunfromitshook,withthenozzle
pointingdown.

3A2494P37

Maintenance

Maintenance

Maintenance Maintenance

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page36,whenever

youareinstructedtorelievethepressure.

Daily

Daily Daily

Checkthefollowinglistdailyuponcompletionof
equipmentusage.















Care

Care Care

Flushthegun.SeeFlushing,page38.

Cleanthe󰘱uidandairline󰘰lters.

Cleantheoutsideofthegun.See

CleantheGunDaily,page40.

Cleantheaircapand󰘱uidnozzledaily,
ataminimum.Someapplicationsrequire
morefrequentcleaning.Replacethespray
tipandaircapiftheyaredamaged.See

CleantheGunDaily,page40.

Checktheelectrodeandreplace
ifbrokenordamaged.See

ElectrodeReplacement,page49.

Checkfor󰘱uidleakagefromthegunand󰘱uid
hoses.Tighten󰘰ttingsorreplaceequipment
asneeded.

Checkelectricalgrounding.See

CheckGunElectricalGrounding,page34.

and

Cleaning

and and

Cleaning Cleaning

Checklist

Checklist Checklist

Flushing

Flushing Flushing

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

•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.

•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.

Toreducetheriskof󰘰re,explosion,orelectric
shock:

•TurnOFF(O)theESOn-Offswitchbefore
󰘱ushingthegun.

•Alwaysgroundequipmentandwastecontainers.

•Flushequipmentonlyinawell-ventilatedarea.

•UseonlyGroupIIA󰘱ushingmaterials.
Non-ignitable󰘱uidsarepreferred.

•Toavoidstaticsparkingandinjuryfrom
splashing,always󰘱ushatthelowestpossible
pressure.

NOTICE

NOTICE NOTICE

Donotusemethylenechlorideasa󰘱ushingor
cleaningsolventwiththisgunasitwilldamage
nyloncomponents.

1.TurnOFF(O)theESOn-Offswitch.

383A2494P

Maintenance

2.FollowthePressureReliefProcedure,page36.

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

4.Pointthegunintoagroundedmetalpail.Flush
untilcleansolvent󰘱owsfromthegun.

5.FollowthePressureReliefProcedure,page36.

6.Shutoffordisconnectthesolventline.

7.Hangthegunfromitshook,withthenozzle
pointingdown.

8.Whenreadytosprayagain,reconnect
the󰘱uidsupplyline.Followthe

GunSetupProcedure,page25.

3A2494P39

Maintenance

Clean

Clean Clean

•Cleanallpartswithanon-conductive,compatible

•Fluidintheairpassagescouldcausethegunto

1.TurnOFF(O)theESOn-Offswitch.

2.Flushthegun.Followthestepsin

3.FollowthePressureReliefProcedure,page36.

the

Gun

the the

Gun Gun

solvent.Conductivesolventscancausethegun
tomalfunction.

malfunctionandcoulddrawcurrentandreduce
theelectrostaticeffect.Fluidinthepowersupply
cavitycanreducetheturbinelife.Whenever
possible,pointthegundownwhencleaningit.
Donotuseanycleaningmethodwhichcould
allow󰘱uidintothegunairpassages.

Flushing,page38.

Daily

Daily Daily

NOTICE

NOTICE NOTICE

4.Cleantheoutsideofthegunwithacompatible
solvent.Useasoftcloth.Pointthegundownto
preventsolventfromenteringthegunpassages.
Donotimmersethegun.

403A2494P

Maintenance

5.Cleantheaircap.

a.Removetheaircap.

b.Cleantheaircap,retainingring,andnozzle

withasoftbrushandcompatiblesolvent.

c.Ifnecessary,useatoothpickorothersoft

tooltocleantheaircapholes.Donotuse
metaltools.

Daily

Daily Daily

1.FollowthePressureReliefProcedure,page36.

2.Cleanthe󰘱uidandair󰘰lters.

3.Checkfor󰘱uidleaks.Tightenall󰘰ttings.

4.Cleanworkpiecehangers.Usenon-sparking

5.Checkthemovementofthetriggerandvalves.

System

System System

tools.

Lubricateifnecessary.

Care

Care Care

d.Reinstalltheaircap.Tightensecurely.

6.CheckGunElectricalGrounding,page34.

7.Hangthegunfromitshook,withthenozzle

pointingdown.

3A2494P

41

ElectricalTests

Electrical

Electrical Electrical

Electricalcomponentsinsidethegunaffect
performanceandsafety.Usethefollowing
procedurestotesttheconditionofthepowersupply
andgunbody,andelectricalcontinuitybetween
components.

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

MegohmmeterPartNo.241079(AA-seeFig.17)
isnotapprovedforuseinahazardouslocation.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous
location;

•Orallsprayingdevicesinthehazardous
locationareturnedoff,ventilationfansinthe
hazardouslocationareoperating,andthereare
no󰘱ammablevaporsinthearea(suchasopen
solventcontainersorfumesfromspraying).

Tests

Tests Tests

Test

Test Test

1.Flushanddrythe󰘱uidpassage.

2.For For

3.For For

Ifoutsidethisrange,testthegun
untriggered.Ifstilloutsidethisrange,goto

TestPowerSupplyResistance,page43.Ifinrange,

seeElectricalTroubleshooting,page46forother
possiblecausesofpoorperformance.

Gun

Gun Gun

For
L40T15

L40T15 L40T15
verifythatthemetalpininthebarrelisproperly
grounded.Measureresistancebetweenthe
metalpin(GP)andtheairswivel(21).The
resistanceshouldbelessthan100ohms.Ifthe
resistanceis100ohmsormore,replacethegun
body.

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

•75–120megohmsfor40kVguns

•104–148megohmsfor60kVguns

•148–193megohmsfor85kVguns

Resistance

Resistance Resistance

Model

Model Model

all

all all

guns

guns guns

guns:

guns: guns:

L40M14,

L40M14, L40M14,

only:

only: only:

Triggerthegunandmeasure

L40T14,

L40T14, L40T14,

Testthebarrelcontinuityto

L40M15,

L40M15, L40M15,

and

and and

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

Figure17TestGunResistance

42

3A2494P

ElectricalTests

Test

Test Test

1.Removethepowersupply(11).Followthesteps

2.Removethealternator(15)

3.Measureresistancefromthepowersupply's

4.Ifoutsidethisrange,replacethe

5.Ifyoustillhaveproblems,referto

6.Besurethespring(11a)isinplacebefore

Power

Power Power

inPowerSupplyRemovalandReplacement,

page53.

fromthepowersupply.See

AlternatorRemovalandReplacement,page54.

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

•60–85megohmsfor40kVguns

•86–110megohmsfor60kVguns

•130–160megohmsfor85kVguns

powersupply.Ifinrange,goto

TestElectrodeResistance,page43.

ElectricalTroubleshooting,page46for

otherpossiblecausesofpoorperformance,or
contactyourGracodistributor.

reinstallingthepowersupply.

Supply

Supply Supply

Resistance

Resistance Resistance

Test

Test Test

Removetheelectrode(3).See

ElectrodeReplacement,page49.Measure

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

NOTE:

NOTE: NOTE:
testingthepowersupplyandelectrode:

•Checkthattheconductiveo-ring(4a)ismaking

•Checkthatthepowersupplyspring(11a)ismaking

Electrode

Electrode Electrode

Ifthegunresistanceisstilloutofrangeafter

contactwiththebarrelpin.

contactwiththebarrelpin.

Resistance

Resistance Resistance

Figure18TestPowerSupplyResistance

Figure19TestElectrodeResistance

3A2494P43

Troubleshooting

Troubleshooting

Troubleshooting Troubleshooting

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseanelectricshock
orotherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorrepairthisequipment
unlessyouaretrainedandquali󰘰ed.

CheckallpossibleremediesintheTroubleshootingChartbeforedisassemblingthegun.

Spray

Spray Spray

Somespraypatternproblemsarecausedbytheimproperbalancebetweenairand󰘱uid.

Problem

Problem Problem

Flutteringorspittingspray.

Improperspraypattern. Damagedordirtynozzleoraircap.

Pattern

Pattern Pattern

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

No󰘱uid.Re󰘰llsupply.

Loose,dirty,damaged
nozzle/seat.

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

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page36,whenever

youareinstructedtorelievethepressure.

Solution

Solution Solution

Cleanorreplacenozzle.See

CleantheGunDaily,page40,or
AirCapandNozzleReplacement,
page48.

Cleanorreplace.SeeAirCapand

NozzleReplacement,page48.

Fluidbuilduponaircapornozzle.

Fanairpressuretoohigh.Decrease.

Fluidtoothin.Increaseviscosity.

Fluidpressuretoolow.Increase.

Fanairpressuretoolow.Increase.

Fluidtoothick.Reduceviscosity.

Toomuch󰘱uid.Decrease󰘱ow.

Didnotapply50%overlap.Overlapstrokes50%. Streaks.

Dirtyordamagedaircap.

44

Clean.See

CleantheGunDaily,page40.

Cleanorreplaceaircap.See

CleantheGunDaily,page40,or
AirCapandNozzleReplacement,
page48.

3A2494P

Troubleshooting

Gun

Gun Gun

Operation

Operation Operation

Problem

Problem Problem

Excessivesprayfog.

“OrangePeel”󰘰nish.

Fluidleaksfromthe󰘱uidpacking
area.

Airleaksfromthefrontofthegun.

Fluidleakagefromthefrontofthe
gun.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

Atomizingairpressuretoohigh.

Fluidtoothin,or󰘱uid󰘱owistoo
low.

Atomizingairpressuretoolow.

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

Fluidtoothick.Reduceviscosity.

Wornpackingsorrod.

Airvalveisnotseatingproperly.

Wornordamaged󰘱uidpacking
rodorelectrode.

Solution

Solution Solution

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

Increaseviscosityorincrease󰘱uid
󰘱owrate.

Openatomizingairvalvemoreor
increasegunairinletpressure;
uselowestairpressurenecessary.

Replacepackings.See

PackingRodRepair,page50.

Replaceairvalve.See

AirValveRepair,page60.

Replacepackingrod(2e)
orelectrode(3).See

PackingRodRepair,page50or
ElectrodeReplacement,page49.

Gundoesnotspray.

Dirtyaircap.

Excessivepaintwrapbackto
operator.

Worn󰘱uidnozzleseat.Replacenozzle(4).See

AirCapandNozzleReplacement,
page48.

Loose󰘱uidnozzle.

Damagednozzleo-ring.

Low󰘱uidsupply.Add󰘱uidifnecessary.

Dirtyorclogged󰘱uidnozzle.Clean.See

Closedordamaged󰘱uid
adjustmentvalve.

Misalignedaircapand󰘱uidnozzle.Clean󰘱uidbuildupoffaircap

Poorgrounding.

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

Tighten.

Replaceo-ring.SeeAirCapand

NozzleReplacement,page48.

CleantheGunDaily,page40.

Openvalve,orsee

ESOn-OffandFluidAdjustment
ValveRepair,page59.

and󰘱uidnozzleseat.See

CleantheGunDaily,page40.

SeeGrounding,page21.

3A2494P45

Troubleshooting

Electrical

Electrical Electrical

Problem

Problem Problem

Poorwrap.

lit.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

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

Gunairpressuretoolow(ESindicator
isamber).

Atomizingairpressuretoohigh.Decrease.

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

Poorlygroundedparts.Resistancemustbe1megohmorless.

Faultygunresistance.

Low󰘱uidresistivity.SeeCheckFluidResistivity,page35.

Fluidleaksfromthepacking(2c)and
causesashort.

Faultyalternator.

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

Nopower.

Solution

Solution Solution

Checkairpressuretogun;minimum45
psi(0.32MPa,3.2bar)neededatgun
forfullvoltage.

Cleanworkpiecehangers.

SeeTestGunResistance,page42.

SeePackingRodRepair,page50.

SeeAlternatorRemovaland

Replacement,page54.

Checkpowersupply,alterna­tor,andalternatorribboncable.
SeePowerSupplyRemovaland

Replacement,page53andAlternator
RemovalandReplacement,page54.

Operatorgetsshockfrom
workpiece.

Voltage/currentdisplay
staysred(Smartguns
only).

ESorHZindicatoris
amber.

ESorHzindicatorisred.

Errordisplayappears
andHzindicatorisred
(Smartgunsonly).

Operatornotgroundedorisnear
ungroundedobject.

Gunnotgrounded.SeeCheckGunElectrical

Workpiecenotgrounded.Resistancemustbe1megohmorless.

Gunistooclosetothepartbeing
sprayed.

Check󰘱uidresistivity.SeeCheckFluidResistivity,page35.

Dirtygun.

Alternatorspeedistoolow.Increaseairpressureuntilindicator

Alternatorspeedistoohigh.Decreaseairpressureuntilindicatoris

Smartmodulehaslostcommunication
withthepowersupply.

SeeGrounding,page21. Operatorgetsmildshock.

Grounding,page34,and
TestGunResistance,page42.

Cleanworkpiecehangers.

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

SeeCleantheGunDaily,page40.

isgreen.Toavoidover-atomization,
usetheatomizingairrestrictorvalveto
reducetheatomizingairtotheaircap.

green.

Checkforgoodconnections
betweentheSmartModule
andthepowersupply.See

SmartModuleReplacement,page61a-

ndPowerSupplyRemovaland

Replacement,page53.

463A2494P

Repair

Repair

Repair Repair

Prepare

Prepare Prepare

Installingandrepairingthisequipmentrequires
accesstopartsthatmaycauseelectricshockor
otherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorservicethisequipment
unlessyouaretrainedandquali󰘰ed.

Toreducetheriskofinjury,followthePressure
ReliefProcedurebeforecheckingorservicingany
partofthesystemandwheneveryouareinstructed
torelievethepressure.

•Checkallpossibleremedies
inTroubleshooting,page44beforedisassembling
thegun.

•Useavisewithpaddedjawstopreventdamage
toplasticparts.

the

Gun

the the

Gun Gun

for

Service

for for

Service Service

•Lubricatesomepackingrodparts(2)andcertain
󰘱uid󰘰ttingswithdielectricgrease(44),asspeci󰘰ed
inthetext.

•Lightlylubricateo-ringsandsealswithnon-silicone
grease.OrderPartNo.111265Lubricant.Donot
over-lubricate.

•OnlyusegenuineGracoparts.Donotmixoruse
partsfromotherProGunmodels.

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

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

1.Flushthegun.Followthestepsin

Flushing,page38.

2.Relievethepressure.Followthe

PressureReliefProcedure,page36.

3.Disconnectthegunairand󰘱uidlines.

4.Removethegunfromtheworksite.Repairarea

mustbeclean.

3A2494P

47

Repair

Air

Cap

Air Air

Cap Cap

and

Nozzle

and and

Nozzle Nozzle

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Triggerthegunwhileremovingthenozzletohelp
drainthegunandpreventanypaintorsolventleft
inthegunfromenteringtheairpassages.

1.Followthestepsin

PreparetheGunforService,page47.

2.Removetheretainingring(6)andaircap(5).

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

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

NOTE:

NOTE: NOTE:
111265,onthesmallo-ring(4b).Donot
over-lubricate.Donotlubricatetheconductive
contactring(4a).Excessivegreasecanmixwith
paintandblemishthe󰘰nishontheworkpiece.

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

NOTE:

NOTE: NOTE:
showsomewearatthepointwhereitmakes
contactwiththebarrelpin.Thisisnormaland
doesnotrequirereplacement.

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

6.Triggerthegunwhileinstallingthe󰘱uidnozzle
(4)withthemulti-tool(41).Tightenuntilthe󰘱uid
nozzleseatsinthegunbarrel(1/8to1/4turn
pasthand-tight).

Usenon-siliconegrease,PartNo.

Theconductivecontactring(4a)may

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

8.FollowthestepsinTestGunResistance,page42.

Figure20AirCapandNozzleReplacement

483A2494P

Repair

Electrode

Electrode Electrode

1.Followthestepsin

PreparetheGunforService,page47.

2.Removetheaircapandnozzle.See

AirCapandNozzleReplacement,page48.

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

4.Applylow-strength(purple)threadlockertothe
electrodeandpackingrodthreads.Installthe
electrode󰘰nger-tight.Donotovertighten.

5.Installthe󰘱uidnozzleandaircap.See

AirCapandNozzleReplacement,page48.

Toavoiddamagingtheplasticthreads,bevery
carefulwheninstallingtheelectrode.

6.FollowthestepsinTestGunResistance,page42.

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Figure21ElectrodeReplacement

3A2494P49

Repair

Fluid

Fluid Fluid

1.Followthestepsin

2.Removetheaircapand󰘱uidnozzle.See

3.Removetheelectrode.See

4.Loosenthetriggerscrews(13)andremovethe

5.Removethepackingrod(2),usingthemulti-tool

6.Checkallpartsforwearordamageandreplace

Packing

Packing Packing

PreparetheGunforService,page47.

AirCapandNozzleReplacement,page48.

ElectrodeReplacement,page49.

trigger(12).

(41).Removethespring(17).

ifnecessary.

Rod

Removal

Rod Rod

Removal Removal

Packing

Packing Packing

NOTE:

NOTE: NOTE:
partsorasanassembly.

Adjust

Adjust Adjust

NOTE:

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

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

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

Rod

Rod Rod

Youmayreplacethepackingrodasindividual

the

the the

Thegunbeginsemittingairbeforethe󰘱uid

Repair

Repair Repair

Air

Flow

Lead

and

Air Air

Flow Flow

Lead Lead

Lag

and and

Lag Lag

Figure22FluidPackingRodRemoval

3.Tightenthenutstogetherto󰘰xtheminthenew
position.

503A2494P

Repair

Reassemble

Reassemble Reassemble

NOTE:

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

1.Placethepackingnut(2f)andseal(2b‡)onthe

2.Filltheinnercavityofthespacer(2h‡)with

3.Placethe󰘱uidpacking(2c‡)onthepackingrod

Beforeinstallingthe󰘱uidpackingrodintothe

󰘱uidrod(2e).Flatsonthepackingnutmustface
thebackofthe󰘱uidrod.Thesealo-ringmust
faceawayfromthepackingnut.

dielectricgrease(44).Placethespaceronthe
󰘱uidrod(2e)inthedirectionshown.Generously
applydielectricgreasetotheoutsideofthe
spacer.

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

the

Packing

the the

Packing Packing

Rod

Rod Rod

4.Lightlytightenthepackingnut(2f).Thepacking

nutisproperlytightenedwhenthereis3lb(13.3
N)ofdragforcewhenslidingthepackinghousing
(2g)assemblyalongtherod.Tightenorloosen
thepackingnutasneeded.

5.Installtheo-ring(2a‡)ontheoutsideofhousing

(2g).Lubricatetheo-ringwithnon-silicone
grease,PartNo.111265.Donotover-lubricate.

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

shown.

7.Installthepackingrodassembly(2)intothe

gunbarrel.Usingthemulti-tool(41),tightenthe
assemblyuntiljustsnug.

8.Installtheelectrode.See

ElectrodeReplacement,page49,step4.

9.Installthenozzleandaircap.See

AirCapandNozzleReplacement,page48,

steps5–7.

10.Installthetrigger(12)andscrews(13).

11.FollowthestepsinTestGunResistance,page42.

Figure23PackingRod

3A2494P51

Repair

Barrel

Barrel Barrel

1.Followthestepsin

2.Carefullyloosenthenut(N)fromthebracket󰘱uid

3.Loosenthetwoscrews(27).

4.Holdthegunhandle(16)withonehandandpull

NOTE:

NOTE: NOTE:
removethealternator/powersupplyassemblyfrom
thebarrel.

Removal

Removal Removal

PreparetheGunforService,page47.

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

NOTICE

NOTICE NOTICE

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

thebarrel(1)straightoffthehandle.

Ifthepowersupplyremainsinthebarrel,

Barrel

Barrel Barrel

1.Besurethegasket(28*)andgroundingspring

2.Makesurethespring(11a)isinplaceonthetipof

3.Tightenthetwoscrews(27)oppositelyand

4.Assemblethe󰘱uidtube(T)intothebracket󰘰tting

5.FollowthestepsinTestGunResistance,page42.

Installation

Installation Installation

(18)areinplace.Makesurethegasketair
holesarealignedproperly.Replacethegasketif
damaged.

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

evenly(aboutahalfturnpastsnugor15–25in-lb,

1.7–2.8N•m).

Toavoiddamagingthegunbarrel,donot
over-tightenthescrews(27).

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

Liberally

NOTICE

NOTICE NOTICE

applydielectric

Figure24BarrelRemoval

523A2494P

Figure25BarrelInstallation

Repair

Power

Power Power
Replacement

Replacement Replacement

•Inspectthegunhandlepowersupplycavityfordirt
ormoisture.Cleanwithaclean,dryrag.

•Donotexposegasket(28)tosolvents.Replace
thegasketifdamaged.

1.Followthestepsin

2.FollowthestepsinBarrelRemoval,page52.

3.Graspthepowersupply(11)withyourhand.

4.Inspectthepowersupplyandalternatorfor

5.Toseparatethepowersupply(11)fromthe

6.Followthestepsin

Supply

Supply Supply

PreparetheGunforService,page47.

Becarefulwhenhandlingthepowersupply
(11)toavoiddamagingit.

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

Modelsonly,

fromthesocketatthetopofthehandle.

damage.

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

Modelsonly,

(24)fromthepowersupply.Slidethealternator
upandoffthepowersupply.

TestPowerSupplyResistance,page43.

Replacethepowersupplyifnecessary.
Torepairthealternator,see

AlternatorRemovalandReplacement,page54.

Removal

Removal Removal

NOTICE

NOTICE NOTICE

disconnectthe󰘱exiblecircuit(24)

disconnectthe6–pin󰘱exiblecircuit

and

and and

OnSmart

OnSmart

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

Figure26ConnectFlexibleCircuit

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

BarrelInstallation,page52.

11.FollowthestepsinTestGunResistance,page42.

NOTICE

NOTICE NOTICE

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

7.

Smartmodelsonly:

circuit(24)tothepowersupply.

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

3A2494P53

connectthe6–pin󰘱exible

Figure27PowerSupply

Repair

Alternator

Alternator Alternator

NOTE:

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

1.Followthestepsin

2.Removethepowersupply/alternatorassembly

3.Measureresistancebetweenthetwoouter

4.Usinga󰘱atbladescrewdriver,prytheclip(15h)

5.Ifnecessary,rotatethefan(15e)soitsblades

Replacealternatorbearingsafter2000hours

PreparetheGunforService,page47.

anddisconnectthealternator.SeePowerSupply

RemovalandReplacement,page53.

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

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

clearthefourbearingtabs(T)ofthehousing
(15d).

Removal

Removal Removal

and

Replacement

and and

Replacement Replacement

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

Figure29AlternatorCross-Section

(Ref.28♦isnotshowninthe󰘰gure.)

Figure28FanOrientation

NOTICE

NOTICE NOTICE

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

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

8.Removethetopbearing(15b2).

9.Removethebottombearing(15b1).

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

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

543A2494P

Repair

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

13.Carefullypressthecoilassembly(15a)intothe
frontofthehousing(15d♦)whilealigningthe
pinonthecoilwiththeslotinthehousing.The
3–wireconnector(PC)mustbepositionedbelow
thewidernotch(W)ofthehousingtabs,as
showninFig.45.Besurethecoilalignmentpins
(P)arepositionedasshowninFig.44.

14.Rotatethefan(15e)soitsbladesclearthefour
bearingtabs(T)atthebackofthehousing.
Ensurethatthebladesofthebottombearing
(15b1♦)alignwiththetabs.

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

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

17.Installthealternatoronthepowersupply,and
installbothpartsinthehandle.SeePower

SupplyRemovalandReplacement,page53.

Figure30Alternator

3A2494P55

Repair

Fluid

Fluid Fluid

1.FollowthePressureReliefProcedure,page36.

2.Removethenut(22)fromthebracket(20).

3.Inspectthetubeand󰘰ttingsfordamage.Replace

4.Loosenthe󰘰tting(9)toremovethe󰘱uidtube

5.Optionally,onhighconductivitymodels,thecap

Tube

Tube Tube

asneeded.

(14)fromthebarrel(1).

andcovercanberemoved.Usealongroddown
thecenterofthecoiledtubetoforcethecapoff
thecover,thenslidethecoveroffthecoil.

Removal

Removal Removal

and

Replacement

and and

Replacement Replacement

8.Withtheferrules(7,8)seatedtothebracket(20),
screwthenut(22)securelyontothebracket.
Makesurethetop󰘰ttingremainstight.

6.Applydielectricgrease(44)tothethreadsofthe
󰘰tting(9)andtheo-ring(10),andalongtheinside
diameterofthe󰘰tting(9).Slidethe󰘰tting(9)onto
the󰘱uidtube(14)

NOTE:

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

NOTE:

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

7.Verifythattheferrules(7★)and(8★)arein
place.Pushthe󰘱uidtubeintothebarrelinletand
holditinplacewhilethreadingthe󰘰ttingintothe
barrel(1).Torqueto25–35in-lb(2.8–3.9N•m).

On40kVguns,theo–ring(10★)isnot

On60kVand85kVguns,checkthatthe

Figure31FluidTube

Figure32FluidTube,HCModels

563A2494P

Fan

Air

Fan Fan

1.Followthestepsin

PreparetheGunforService,page47.

2.Placeawrenchonthe󰘱atsofthevalvehousing

(30a)andunscrewthevalvefromthehandle
(16).

NOTE:

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

3.Removetheretainingring(30d).

4.Turnthevalveshaft(30b)counterclockwiseuntil

itcomesfreefromthevalvehousing(30a).

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

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

7.Whenreassemblingthefanairvalve(30),lightly

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

Adjustment

Air Air

Adjustment Adjustment

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

Valve

Valve Valve

Repair

Repair Repair

Repair

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

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

Figure33FanAirAdjustmentValve

3A2494P57

Repair

Atomizing

Atomizing Atomizing

1.Followthestepsin

PreparetheGunforService,page47.

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

NOTE:

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

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

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

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

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

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

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

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

NOTE:

NOTE: NOTE:
desired,installthesuppliedplug(42).

Iftheatomizingairrestrictorvalveisnot

Air

Restrictor

Air Air

Restrictor Restrictor

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

Valve

Valve Valve

Repair

Repair Repair

Figure34AtomizingAirRestrictorValve

Figure35AlignValveStem

583A2494P

Repair

ES

On

Off

and

ES ES

On On

- --Off Off

Fluid

and and

Fluid Fluid

Adjustment

Adjustment Adjustment

Valve

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page47.

2.Loosenthecaptivescrew(26p).Removethe

valve(26)fromthehandle.

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

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

NOTE:

NOTE: NOTE:
lubricantontheo-ringscanbepushedintothe
gunairpassageandblemishthe󰘰nishonthe
workpiece.

Donotover-lubricateparts.Excessive

4.Cleanandinspectpartsfordamage.Replace
ifnecessary.

NOTE:

NOTE: NOTE:
mustpointupward.

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

Theprotrusionontheretainerplate(26h)

Figure36ESOn-OffValveRepair,24N630and
26A160

Figure37ESOn-OffValveRepair,24N632

3A2494P59

Repair

Air

Valve

Air Air

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page47.

2.FollowthestepsinBarrelRemoval,page52.

3.Removethescrews(13)andtrigger(12).

4.RemovetheESOn-OffValve.SeeESOn-Off

andFluidAdjustmentValveRepair,page59,

steps1and2.

5.Removethespring(34).

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

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

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

9.InstalltheESOn-OffValve.SeeESOn-Offand

FluidAdjustmentValveRepair,page59,steps

3and5.

10.Installthetrigger(12)andscrews(13).

11.FollowthestepsinBarrelInstallation,page52.

Figure38InstallU-Cup

Figure39AirValve

603A2494P

Repair

Smart

Smart Smart

IftheErrordisplayappears,theSmartModulehas
lostcommunicationwiththepowersupply.Checkfor
goodconnectionsbetweentheSmartModuleand
thepowersupply.

Ifthemodule’sLEDsarenotlighting,replacethe
module.

1.Followthestepsin

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

3.Removetheremainingthreescrews(31d)from

4.PulltheSmartModuleoutthebackofthegun.

5.Removethegasket(31b).

6.Installanewgasket(31b)onthenewcartridge

7.Alignthemodule’sribboncable(RC)with

8.Installthepivotscrew(31e),o-ring(31f),and

9.Installthethreeremainingscrews(31d).Torque

Module

Module Module

PreparetheGunforService,page47.

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

thecartridge.

Disconnecttheribboncable(RC)fromthe
connector(GC)inthegunhandle.

(31a).Makesurethenotchedcornersofthe
gasketareatthetop.

thegun’scable(GC)andslidethemsecurely
together,asshown.Tucktheconnectedcables
intotherecessofthegunhandle.Installthe
module󰘱ushtothebackofthegunhandle.

ESHI/LOswitchinthebottomleftcornerofthe
cartridge(31a).

to7–9in-lb(0.8–1.0N•m).

Replacement

Replacement Replacement

Figure40SmartModule

Figure41AlignRibbonCables

3A2494P61

Repair

Air

Swivel

Air Air

Swivel Swivel

Replacement

Replacement Replacement

1.Followthestepsin

PreparetheGunforService,page47.

2.Toreplacetheairexhaustvalve:

a.Removetheclamp(43)andtheexhausttube

(36).

b.Unscrewtheswivel(21)fromthegunhandle

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

c.Pulltheexhaustvalve(19)fromthehandle

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

d.Installtheo-ring(19a*)ontheexhaustvalve

(19).Lubricatetheo-ringwithalightcoating
ofnon-siliconegrease.

e.Installtheexhaustvalve(19)inthehandle

(16).

f.Applythreadsealanttothetopthreadsofthe

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

g.Installthetube(36)andclamp(43).

3.Toreplacetheairinletswivel:

and

Exhaust

and and

Exhaust Exhaust

Valve

Valve Valve

Figure42AirInletFittingandAirExhaustValve

a.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.

b.Applythreadsealanttothetopthreadsofthe

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

623A2494P

Parts

1

Parts

Parts Parts

Gun

Gun Gun

Models

Models Models

with

Standard

with with

Standard Standard

Display

Display Display

Torqueto20in-lb(2N•m).

3A2494P63

Parts

Gun

Models

Gun Gun

Models Models

with

Standard

with with

Standard Standard

Display

Display Display

Toidentifycomponents,seeModels,page3.

Part

No.

Ref.

Ref. Ref.
No.

No. No.

1■

2

3

4

4a24N645

4b111507

5

624N644

6a*

9

10★102982

11

Part Part

24N665

24N666

24N667

24N668

SeePackingRodAssembly,page69

SeeElectrodeSelectionChart,page88

24N651

24N704

25N856

NOZZLE;includes4aand4b.See

FluidNozzleSelectionChart,page79.

SeeAirCapSelectionGuide,page82.

198307

111286

111286

111285FERRULE,back;40kVgun1 8‡★

111285FERRULE,back;60and85kV

24N656

24N657

24N658

25N852

25N851

24N659

24N660

24N661

Description

No. No.

Description Description

BODY,gun;40kVgun

BODY,gun;60kVgun

BODY,gun;85kVgun

BODY,gun;40kVboostergun

ELECTRODE,standard

ELECTRODE,highwear

ELECTRODE,short

O-RING,conductive

O-RING;󰘱uoroelastomer

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

FERRULE,front;40kVgun

FERRULE,front;60and85kV
guns

guns

FITTING,󰘱uid;40kVgun

FITTING,󰘱uid;60kVgun

FITTING,󰘱uid;85kVgun

FITTING,󰘱uid;60kVgun,HC
󰘱uidtube

FITTING,󰘱uid;85kVgun,HC
󰘱uidtube

PACKING,o-ring;60and85
kVgunsonly

POWERSUPPLY,40kVgun

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

Part

No.

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1 7‡★

2

2

1

1

1

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

11a24N979

1224N663

1324A445

14

1524N664

16

17185111

18197624

19249323VALVE,exhaust1

19a*

2024N741

2124N626

2224N698NUT1

2324N633VALVE,air1

23a*

Part Part

24N695

24N696

24N697

25N844

25N843

25N842

24N751HANDLE;40kVgun1

24N752HANDLE;60kVgun1

24N753HANDLE;85kVgun1

112085

276733

Description

No. No.

Description Description

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

TUBE,󰘱uid,STD;40kVgun

TUBE,󰘱uid,STD,withsleeve;
60kVgun

TUBE,󰘱uid,STD,withsleeve;
85kVgun

TUBE,󰘱uid;HC,40kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

TUBE,󰘱uid;HC,60kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

TUBE,󰘱uid;HC,85kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

See

AlternatorAssembly,page70

SPRING,compression

SPRING,compression

O-RING

BRACKET

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

SEAL,airvalve

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

643A2494P

Parts

Part

No.

Ref.

Ref. Ref.
No.

No. No.

26

2724N740

28*

29

30

Part Part

SeeESOn-OffandFluidAdjustmentValve,

page71

24N630

26A160

24N632

25N921

SeeAtomizingAirRestrictorValveAssembly,

page73

24T304

24N733

SeeFanAirAdjustmentValveAssembly,page72

24N634

24N732

25N919

Description

No. No.

Description Description

VALVE,ESOn/OffandFluid
AdjustmentValve;forall
modelsexceptasnoted

VALVE,ESOn-OffwithAir
RestrictorandFluidAdjustment
Valve;forHighAirFlowgun
models

VALVE,ESOn-OffandFixed
FluidValve;forFixedFluid
Flowmodels

SCREW,hexsocket;sst;
packageof2

GASKET,barrel

VALVE,airrestrictor;forall
otherguns

VALVE,airrestrictor;for
L60T11

VALVE,fanair;forallother
guns

VALVE,fanair;forL60T11

VALVE,fanair;quickadjust
withspringreturn

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

34185116

35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

46

47▲179791

48▲16P802

5024N783

Part

No.

Part Part

188749

24N603

24N604

Description

No. No.

Description Description

SPRING,compression

PACKING,u-cup

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

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shipped
loose;foruseinsteadofitem

29)

CLAMP,exhausttube(shipped
loose)

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

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

COVER,gun,40and60kV
guns;packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,and
cardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit24N789
(purchaseseparately).

‡ThesepartsareincludedinFluidSealRepairKit24N790
(purchaseseparately).

■Gunbodies(Ref.1)includethebarrelgasket(Ref.28).

NOTE:

NOTE: NOTE:
ferrules(7★)and(8★)arepartofthetop󰘰tting(9).

On40kVguns,theo–ring(10★)isnotused,and

3A2494P65

Parts

1

Gun

Gun Gun

Models

Models Models

with

Smart

with with

Smart Smart

Display

Display Display

Torqueto20in-lb(2N•m).

663A2494P

Gun

Models

Gun Gun

Models Models

with

Smart

with with

Smart Smart

Display

Display Display

Toidentifycomponents,seeModels,page3.

Part

No.

Ref.

Part Part

Ref. Ref.
No.

No. No.

24N665

1■

24N666

24N667

24N668

2

SeePackingRodAssembly,page69

3

SeeElectrodeSelectionChart,page88

24N651

24N704

4

NOZZLE;includes4aand4b.See

FluidNozzleSelectionChart,page79.

4a24N645

4b111507

5

AIRCAP;seeAirCapSelectionGuide,page82

624N644

198307

6a*

7‡

111286

8‡111285FERRULE,back2

24N656

9

24N657

24N658

25N852

25N851

10102982

24N659

11

24N660

24N661

11a24N979

1224N663

1324A445

Description

No. No.

Description Description

BODY,gun;40kVgun

BODY,gun;60kVgun

BODY,gun;85kVgun

BODY,gun;40kVboostergun

ELECTRODE,standard

ELECTRODE,highwear

O-RING,conductive

O-RING;󰘱uoroelastomer

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

FERRULE,front

FITTING,󰘱uid;40kVgun

FITTING,󰘱uid;60kVgun

FITTING,󰘱uid;85kVgun

FITTING,󰘱uid;60kVgun,HC
󰘱uidtube

FITTING,󰘱uid;85kVgun,HC
󰘱uidtube

PACKING,o-ring

POWERSUPPLY,40kVgun

POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

Parts

Part

No.

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

Part Part

Ref. Ref.
No.

No. No.

14

SeeHighConductivityFluidTubeAssembly:60

kVand85kV,page78

24N695

24N696

24N697

25N844

25N843

25N842

1524N664

25N850HANDLE,smart;40kVgun1

16

24N754HANDLE,smart;60kVgun1

24N755HANDLE,smart;85kVgun1

17185111

18197624

19249323VALVE,exhaust1

112085

19a*

2024N741

2124N626

2224N698NUT1

2324N633VALVE,air1

276733

23a*

24245265

24N630

26

26A160

2724N740

Description

No. No.

Description Description

TUBE,󰘱uid,STD;40kVgun

TUBE,󰘱uid,STD,withsleeve;
60kVgun

TUBE,󰘱uid,STD,withsleeve;
85kVgun

TUBE,󰘱uid;HC,40kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

TUBE,󰘱uid;HC,60kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

TUBE,󰘱uid;HC,85kVgunwith
cover;includes7,8,9,10,22;
seeHighConductivityFluid

TubeAssembly:60kVand85
kV,page78.

See

AlternatorAssembly,page70

SPRING,compression

SPRING,compression

O-RING

BRACKET

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

SEAL,airvalve

CIRCUIT,󰘱exible

SeeESOn-OffandFluid

AdjustmentValve,page71

SeeESOn-OffandFluid

AdjustmentValve,page71

SCREW,hexsocket;sst;
packageof2

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3A2494P67

Parts

Part

No.

Ref.

Part Part

Ref. Ref.
No.

No. No.

25N921

28*

2924T304

3024N634

3124N756

34185116

188749

35*

36185103

40107460

41276741

4224N786

Description

No. No.

Description Description

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page73

SeeFanAirAdjustmentValve

Assembly,page72

SeeSmartModuleAssembly,

page74

SPRING,compression

PACKING,u-cup

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

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shipped
loose;foruseinsteadofitem

29)

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

43110231

44116553

45117824

46

47▲179791

48▲16P802

5024N783

Part

No.

Part Part

24N603

24N604

Description

No. No.

Description Description

CLAMP,exhausttube

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

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

COVER,gun,60kVguns;
packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

HOOK;includesscrew

Qty

Qty Qty

1

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,and
cardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit24N789
(purchaseseparately).

‡ThesepartsareincludedinFluidSealRepairKit24N790
(purchaseseparately).

■Gunbodies(Ref.1)includethebarrelgasket(Ref.28).

683A2494P

Parts

Packing

Packing Packing

Part

No.

Part Part

No. No.
Includesitems2a-2k
Part

No.

Part Part

No. No.
Includesitems2a-2k
Part

No.

Part Part

No. No.
Includesitems2a-2k

Rod

Rod Rod

24N653

24N653 24N653

24N654

24N654 24N654

24N655

24N655 24N655

Assembly

Assembly Assembly

40

kV

Packing

40 40

kV kV

Packing Packing

60

kV

Packing

60 60

kV kV

Packing Packing

85

kV

Packing

85 85

kV kV

Packing Packing

Rod

Assembly

Rod Rod

Assembly Assembly

Rod

Assembly

Rod Rod

Assembly Assembly

Rod

Assembly

Rod Rod

Assembly Assembly

Part

No.

Ref.

Ref. Ref.
No.

No. No.

2a‡111316

2b‡116905

2c‡178409

2d‡178763

2e

Part Part

24N701

24N702

Description

No. No.

Description Description

O-RING

SEAL

PACKING,󰘱uid

PACKING,needle

ROD,packing,40kVguns
(includesitems2jand2k)

ROD,packing,60kVguns

Qty

Qty Qty

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

2f

2g185495

2h‡186069

2j◆

2k◆

Part

No.

Part Part

197641NUT,packing1

———

———

Description

No. No.

Description Description

HOUSING,packing

SPACER,packing

NUT,triggeradjustment(part
ofitem2e)

NUT,triggeradjustment(part
ofitem2e)

(includesitems2jand2k)

24N703

ROD,packing,85kVguns

1

(includesitems2jand2k)

‡ThesepartsareincludedinFluidSealRepairKit

Partslabeled———arenotavailableseparately.

24N790(purchaseseparately).

◆ThesepartsareincludedinTriggerAdjustmentNut
Kit24N700(purchaseseparately).

3A2494P69

Qty

Qty Qty

1

1

1

1

Parts

Alternator

Alternator Alternator

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly

24N664

24N664 24N664

Alternator

Alternator Alternator

Assembly

Assembly Assembly

Ref.

Ref. Ref.
No.

No. No.

15a24N705

15b♦24N706

15c24Y264

15d♦24N707

Part

Part Part
No.

No. No.

Description

Description Description

COIL,alternator

BEARINGKIT(includestwo
bearings,item15dhousing,
item15efan,item15fcap,
andoneitem15hclip)

SHAFTKIT(includesshaft
andmagnet)

HOUSING;includesitem15f

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

♦ThesepartsareincludedinBearingKit24N706
(purchaseseparately).

Qty

Qty Qty

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.

15e♦

15f♦

15g*

15h♦24N709

28♦*

Part

Part Part
No.

No. No.

———

———

110073

25N921

Description

Description Description

FAN;partofitem15b

CAP,housing;partofitem
15d

O-RING

CLIP;packageof5(oneclip
includedwithitem15b)

GASKET,barrel(notshown)

Qty

Qty Qty

1

1

1

1

1

Partslabeled———arenotavailableseparately.

703A2494P

Parts

ES

On

Off

and

ES ES

On On

- --Off Off

Part

No.

Part Part
Valve

Valve Valve
Part

Part Part
Fluid

Fluid Fluid

Part

Part Part

24N630

No. No.

24N630 24N630

No.

26A160

No. No.

26A160 26A160

Adjustment

Adjustment Adjustment

No.

24N632

No. No.

24N632 24N632

Fluid

and and

Fluid Fluid

ES

On-Off

ES ES

On-Off On-Off

ES

On-Off

ES ES

On-Off On-Off

Valve

Valve Valve

ES

On-Off

ES ES

On-Off On-Off

Adjustment

Adjustment Adjustment

and

Fluid

and and

with

with with

and

and and

Adjustment

Fluid Fluid

Adjustment Adjustment

Air

Restrictor

Air Air

Restrictor Restrictor

Fixed

Fluid

Fixed Fixed

Fluid Fluid

Valve

Valve Valve

Part

No.

Ref.

Ref. Ref.
No.

No. No.

and

and and

Valve

Valve Valve

26a

26b*

26c

26f

26g

26h24N631PLATE,retaining1

26j

26m*

26p24N740

Part Part

———

15D371

———

24N649

24N650

GC2082SCREW,set,sockethead

24N648

25E767

113746

Description

No. No.

Description Description

HOUSING,valve;blackfor
models24N630and24N632,
blueforrestrictedmodel
26A160

O-RING

PISTON,valve

LEVER,ESon-off;includes
26g;models24N630and
26A160

LEVER,ESon-off;includes
26g;model24N632

KNOB,adjustment,󰘱uid,
black;includes26g;model
24N630

KNOB,adjustment,󰘱uid;blue;
includes26g;model26A160

O-RING

SCREW,captive;packof2

Qty

Qty Qty

1

2

1

1

1

2

1

1

1

1

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

3A2494P

71

Parts

Fan

Air

Fan Fan

Part

Part Part
(shown)

(shown) (shown)

Part

Part Part
(for

large

(for (for

large large

Ref.

Ref. Ref.
No.

No. No.

30a

30b

30c*

30d24N646

*ThesepartsareincludedinAirSealRepairKit24N789
(purchaseseparately).

Partslabeled———arenotavailableseparately.

Adjustment

Air Air

Adjustment Adjustment

No.

24N634

No. No.

24N634 24N634

No.

24N732

No. No.

24N732 24N732

pattern

pattern pattern

Part

Part Part

———

———

———

111504

Fan

Fan Fan

Fan

Fan Fan
round

round round

No.

Description

No. No.

Description Description

NUT,valve1

STEM,valve

STEM,valve;roundsprayonly

O-RING

RING,retaining;packageof6

Valve

Valve Valve

Air

Adjustment

Air Air

Adjustment Adjustment

Air

Adjustment

Air Air

Adjustment Adjustment

spray

guns,

spray spray

guns, guns,

Assembly

Assembly Assembly

Valve

Assembly

Valve Valve

Assembly Assembly

Valve

Assembly

Valve Valve

Assembly Assembly

not

shown)

not not

shown) shown)

Qty

Qty Qty

1

1

1

1

Quick

Quick Quick

Part

Part Part
return

return return

Ref.

Ref. Ref.
No.

No. No.

55a

55b

55c

55d

55e

55f

Adjust

Adjust Adjust

No.

25N919

No. No.

25N919 25N919

.

Part

Part Part

24N650

GC2081

GC2080

25P399

25P398

25P397

Fan

Valve

Fan Fan

Valve Valve

Quick

Adjust

Quick Quick

Adjust Adjust

No.

Description

No. No.

Description Description

LEVER1

SCREW,set

SCREW,set

KIT,leveradapter1

KIT,spring1

KIT,shaftassembly

Fan

Fan Fan

Assembly

Assembly Assembly

Valve

with

Valve Valve

spring

with with

spring spring

Qty

Qty Qty

1

2

1

72

3A2494P

Parts

Atomizing

Atomizing Atomizing
Assembly

Assembly Assembly

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly
shown)

shown) shown)

Air

Restrictor

Air Air

Restrictor Restrictor

24T304

24T304 24T304

(shown)

(shown) (shown)

24N733

24N733 24N733

(for

(for (for

Atomizing

Atomizing Atomizing

Atomizing

Atomizing Atomizing

large

pattern

large large

pattern pattern

round

round round

Valve

Valve Valve

Air

Restrictor

Air Air

Restrictor Restrictor

Air

Restrictor

Air Air

Restrictor Restrictor

spray

spray spray

Valve

Valve Valve

Valve

Valve Valve

guns,

not

guns, guns,

not not

Ref.

Ref. Ref.
No.

No. No.

29a

29b

29c*

29d118907

29e

29f

29g

Part

Part Part

———

———

———

111516

———

———

———

No.

Description

No. No.

Description Description

HOUSING,valve

BODY,valve

BODY,valve;roundsprayonly

O-RING

RING,retaining

STEM,valve

KNOB,shaft;roundsprayonly

SETSCREW,knob;round
sprayonly

Qty

Qty Qty

1

1

1

1

1

1

1

1

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

3A2494P73

Parts

Smart

Smart Smart

Part

Part Part

Module

Module Module

No.

24N756

No. No.

24N756 24N756

Assembly

Assembly Assembly

Smart

Module

Smart Smart

Module Module

Assembly

Assembly Assembly

Ref.

Ref. Ref.
No.

No. No.

31a

31b24P433

31c24N787

31d♦

31e♦

31f

Part

Part Part

———

———

———

112319

No.

Description

No. No.

Description Description

CARTRIDGE

GASKET

SWITCH,ESHI/LO

SCREW

SCREW,pivot

O-RING

Qty

Qty Qty

1

1

1

3

1

1

Partslabeled———arenotavailableseparately.

♦ThesepartsareincludedinSmartModuleScrew
Kit24N757(purchaseseparately).

74

3A2494P

Parts

Round

Round Round

Part

Part Part

NOTE:

NOTE: NOTE:

Spray

Spray Spray

No.

24N318

No. No.

24N318 24N318

Assembly

Assembly Assembly

large

pattern

large large

pattern pattern

Itemsmarkedwitha★areshownfor

referenceandarenotincludedinthekit.

Part

No.

Ref.

Ref. Ref.
No.

No. No.
424N729

4a24N645

4b111507

5

2924N733

3024N732

4924N730

Part Part

24N731

Description

No. No.

Description Description

NOZZLE,roundspray;in­cludes4aand4b.See

FluidNozzleSelectionChart,
page79.

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP,roundspray.See

AirCapSelectionGuide,page

82.

ATOMIZINGAIR
RESTRICTORVALVE,
roundspray

FANAIRADJUSTMENT
VALVE,roundspray

DIFFUSER,roundspray

Qty

Qty Qty

1

1

1

1

1

1

1

3A2494P75

Parts

Part

No.

Part Part

Part

Part Part

NOTE:

NOTE: NOTE:

25N836

No. No.

25N836 25N836

No.

25N837

No. No.

25N837 25N837

Itemsmarkedwitha★areshownfor

small

pattern

small small

pattern pattern

medium

medium medium

pattern

pattern pattern

referenceandarenotincludedinthekit.

Part

No.

Ref.

Ref. Ref.
No.

No. No.
3

3c

425N835

4a24N645

4b111507

4c117610

4d111516

5

6

Part Part

25N838

25N839

25N938

25N939

113137

113746
———

———

25N840

25N841
———

Description

No. No.

Description Description

AIRCAP,inner,smallpattern;
includes3a–3c

AIRCAP,inner,medium
pattern;includes3a–3c

DEFLECTOR,smallpattern

DEFLECTOR,mediumpattern

O-RING,smallpattern

O-RING,mediumpattern

DIFFUSER,smallpattern

DIFFUSER,mediumpattern

NOZZLE,roundspray;
includes4a–4d

O-RING,conductive

O-RING;󰘱uoroelastomer

O-RING

CONDUCTIVECONTACT
RING

AIRCAP,smallpattern

AIRCAP,mediumpattern

RETAININGRING

Qty

Qty Qty

1

1

1 3a

1

1 3b

1

1

1

1

1

1

1

1

1

1

1

763A2494P

Parts

High

High High

Part

Part Part

Part

Part Part

Conductivity

Conductivity Conductivity

No.

25N844

No. No.

25N844 25N844

No.

25N937

No. No.

25N937 25N937

40

40 40

40

40 40

Fluid

Fluid Fluid

kV

High

kV kV

High High

kV

High

kV kV

High High

Tube

Tube Tube

Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Assembly:

Assembly: Assembly:

Fluid

Tube

Fluid Fluid

Tube Tube

Fluid

Tube

Fluid Fluid

Tube Tube

40

kV

40 40

kV kV

Assembly,

Assembly, Assembly,

Assembly,

Assembly, Assembly,

Ref.

Ref. Ref.
No.

No. No.

7

8111286FERRULE1

924N656

14

2224N656NUT1

CP

CA

Partslabeled———arenotavailableseparately.

*Highconductivitygunmodelsincludeahigh
conductivity󰘱uidtubeassemblywithacover.High
conductivity󰘱uidtubeassemblieswithnocoverare
availableasanaccessoryonly.

with

cover

with with

cover cover

no

cover

no no

cover cover

Part

No.

Part Part

111285FERULE1

–——

–——

25N943

Description

No. No.

Description Description

FITTING,Fluid;40kV

CoilFluidTube

CAP;includedincoverkit
25N943

Cover,40kVHC󰘱uidtube

Qty

Qty Qty

1

1

1

1

3A2494P

77

Parts

High

High High

Part

Part Part
Part

Part Part

Part

Part Part
Part

Part Part

Conductivity

Conductivity Conductivity

No.

25N843

No. No.

25N843 25N843

No.

25N842

No. No.

25N842 25N842

No.

25N936

No. No.

25N936 25N936

No.

25N935

No. No.

25N935 25N935

60

60 60

85

85 85

60

60 60

85

85 85

Fluid

Fluid Fluid

kV

High

kV kV

High High

kV

High

kV kV

High High

kV

High

kV kV

High High

kV

High

kV kV

High High

Tube

Tube Tube

Conductivity

Conductivity Conductivity
Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Conductivity

Conductivity Conductivity

Assembly:

Assembly: Assembly:

Fluid

Tube

Fluid Fluid

Tube Tube

Fluid

Tube

Fluid Fluid

Tube Tube

Fluid

Tube

Fluid Fluid

Tube Tube

Fluid

Tube

Fluid Fluid

Tube Tube

60

kV

and

85

60 60

kV kV

and and

Assembly,

Assembly, Assembly,
Assembly,

Assembly, Assembly,

Assembly,

Assembly, Assembly,

Assembly,

Assembly, Assembly,

with

cover

with with

cover cover

with

cover

with with

cover cover

no

cover

no no

cover cover

no

cover

no no

cover cover

Ref.

Ref. Ref.
No.

No. No.

7

8111286FERRULE2

9

10102982

14

2224N698NUT1

CP

CA*

Part

Part Part
No.

No. No.

111285FERRULE2

25N852

25N851

———

———

COVER

25N942

25N941

kV

85 85

kV kV

Description

Description Description

FITTING,󰘱uid;60kV(shown)

FITTING,󰘱uid;85kV

O-RING

COILEDFLUIDTUBE

CAP;includedincoverkits
25N941and25N942

Cover,60kVHC󰘱uidtube
(25N843)

Cover,85kVHC󰘱uidtube
(25N842)

Qty

Qty Qty

1

1

1

1

1

1

1

Partslabeled———arenotavailableseparately.

*Highconductivitygunmodelsincludeahigh
conductivity󰘱uidtubeassemblywithacover.High
conductivity󰘱uidtubeassemblieswithnocoverare
availableasanaccessoryonly.

783A2494P

FluidNozzles

Fluid

Fluid Fluid

Fluid

Fluid Fluid

Toreducetheriskofaninjury,followthePressureReliefProcedure,page36,beforeremovingorinstalling
a󰘱uidnozzleand/oraircap.

Fluid

Fluid Fluid
Part

Part Part

24N619

24N613

25N895

25N896

24N616

25N897

24N618

Nozzles

Nozzles Nozzles

Nozzle

Nozzle Nozzle

Nozzle

Nozzle Nozzle

No.

No. No.

Selection

Selection Selection

Ori󰘰ce

Ori󰘰ce Ori󰘰ce
mm

mm mm

0.55(.022)

0.75(.029)

1.0(.042)Green

1.2(.047)Gray

1.5(.055)

1.8(.070)

2.0(.079)

Size

Size Size

(in.)

(in.) (in.)

Chart

Chart Chart

Color

Color Color

Black

Black

Black

Brown

Black

Description

Description Description

Standard

Standard Standard
forstandardcoatings

nozzles

nozzles nozzles

(STD)

(STD) (STD)

25N831

25N832

25N833

25N834

24N620

24N621

24N622

24N623

24N624

24N625

24N729

25N835

1.0(.042)Green

1.2(.047)Gray

1.5(.055)

1.8(.070)

0.75(.029)

1.0(.042)

1.2(.047)

1.5(.055)

1.8(.070)

2.0(.079)

———

———

Precision

Precision Precision

Black

Brown

Blue

Black

Black

withhardenedSSTseatanddamageresistantSSTtip;for
standardcoatings,abrasives,andmetallics

High

High High
withhardenedceramicseat,forabrasivesandmetallics

Round

Round Round
forusewithlargepatternroundsprayaircaponly

Round

Round Round
forusewithmediumorsmallpatternroundsprayaircapsonly

high

wear

high high

wear

nozzles

wear wear

nozzles nozzles

spray

large

spray spray

large large

Spray

Spray Spray

nozzles

wear wear

nozzles nozzles

(HW)

(HW) (HW)

pattern

pattern pattern

medium

medium medium

(PHW)

(PHW) (PHW)

nozzle

nozzle nozzle

small

or ororsmall small

pattern

pattern pattern

nozzle

nozzle nozzle

3A2494P79

FluidNozzles

5

0.5

1.0

1.5

2.0

2.5

3.0

0 1 2

60 120 180 240 300

3 4 5 6 7 8 9 10

10

15

20

25

30

35

40

45

50

Fluid

Fluid Fluid

Nozzle

Nozzle Nozzle

Performance

Performance Performance

Charts

Charts Charts

Usethefollowingproceduretoselecttheproper󰘱uidnozzleforyourapplication.

1.Foreach󰘱uidnozzlechart,󰘰ndthepointonthe
graphcorrespondingtoyourdesired󰘱owrate
andviscosity.Markthepointoneachgraphwith
apencil.

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

Key

Key Key

NOTE:

NOTE: NOTE:

Fluid

to totoFluid Fluid

Nozzle

Nozzle Nozzle

Performance

Performance Performance

Charts

Charts Charts

Fluidpressuresaremeasuredatthesprayguninlet.

260CentipoiseFluid

160CentipoiseFluid

70CentipoiseFluid

20CentipoiseFluid

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

Table

10

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

803A2494P

Ori󰘰ce

10 10

. ..Ori󰘰ce Ori󰘰ce

Size:

0.55

mm

Size: Size:

0.55 0.55

FLUID

FLUID FLUID

oz/min,cc/min

(0.022

mm mm

(0.022 (0.022

FLOW:

FLOW: FLOW:

in.)

in.) in.)

Table

11

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

11 11

. ..Ori󰘰ce Ori󰘰ce

Size:

0.75

mm

Size: Size:

0.75 0.75

FLUID

FLUID FLUID

oz/min,cc/min

(0.030

mm mm

(0.030 (0.030

FLOW:

FLOW: FLOW:

in.)

in.) in.)

FluidNozzles

Table

12

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

Ori󰘰ce

12 12

. ..Ori󰘰ce Ori󰘰ce

13

Ori󰘰ce

13 13

. ..Ori󰘰ce Ori󰘰ce

Size:

1.0

mm

Size: Size:

1.0 1.0

FLUID

FLUID FLUID

oz/min,cc/min

Size:

1.2

Size: Size:

1.2 1.2

(0.040

mm mm

(0.040 (0.040

FLOW:

FLOW: FLOW:

mm

(0.047

mm mm

(0.047 (0.047

in.)

in.) in.)

in.)

in.) in.)

Table

15

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

Ori󰘰ce

15 15

. ..Ori󰘰ce Ori󰘰ce

16

Ori󰘰ce

16 16

. ..Ori󰘰ce Ori󰘰ce

Size:

1.8

mm

Size: Size:

1.8 1.8

FLUID

FLUID FLUID

oz/min,cc/min

Size:

2.0

Size: Size:

2.0 2.0

(0.070

mm mm

(0.070 (0.070

FLOW:

FLOW: FLOW:

mm

(0.080

mm mm

(0.080 (0.080

in.)

in.) in.)

in.)

in.) in.)

FLUID

FLUID FLUID

PRES-

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

Table

14

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

14 14

. ..Ori󰘰ce Ori󰘰ce

Size:

1.5

mm

Size: Size:

1.5 1.5

(0.059

mm mm

(0.059 (0.059

in.)

in.) in.)

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

FLUID

FLOW:

FLUID FLUID

FLOW: FLOW:

oz/min,cc/min

3A2494P81

AirCaps

Air

Air Air

Air

Air Air

Thechartsinthissectioncanassistyouinselecting
anaircap.

•Keepinmindthatmorethanoneaircapcanmeet

•Whenselectinganaircap,considercoating

Caps

Caps Caps

Cap

Cap Cap

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page36,before

removingorinstallinga󰘱uidnozzleand/oraircap.

your󰘰nishrequirements.

properties,partgeometry,patternshape,pattern
size,andoperatorpreferences.

Selection

Selection Selection

Guide

Guide Guide

Measurements

Measurements Measurements

Allaircappatternshapesandlengthsinthefollowing
chartsweremeasuredunderthefollowingconditions,
unlessotherwisenoted:

NOTE:

NOTE: NOTE:
material-dependent.

•Distancetotarget:10in.(254mm)

•Inletairpressure:50psi(34kPa,3.4bar)

•Fanair:adjustedformaximumlength

•Fluid󰘱owrate:10oz/min(300cc/min)

Patternshapeandlengthare

823A2494P

AirCaps

Pattern

Pattern Pattern

NOTE:Patternshapesarein󰘱uencedbythematerialviscosity,󰘱owrate,andairpressuresettings.Thegun
maynotmaintaintheintendeddesignshapeunderallconditions.

•Round Round

•Fan Fan

Shape

Shape Shape

Round

Fan

–Fan Fan

patterns

patterns patterns

patterns

patterns patterns

Fan

patterns

patterns patterns

optionforsmallerpartsorcut-inpainting.

haveaswirling,slow,roundconepatternforexcellent󰘰nishandtransferef󰘰ciency.

havetwostyles:roundendsandtaperedends.

with

with with

round

ends

round round

ends ends

areversatile.Theycanbeusedinanyapplicationandareoftenthebest

Fan

–Fan Fan

patterns

patterns patterns

passes.

with

tapered

with with

tapered tapered

ends

ends ends

arebestforachievingevencoatingthicknesswithoverlappingpaint

3A2494P83

AirCaps

General

General General

Part

Part Part

24N477Black

24W279

24N438BlackAlternate

24N376Black

24N276Blue

24N277Red

24N278

24N274Black

General

General General

Part

Part Part

24N477Black

24W279

24N438BlackAlternateRound

24N376Black

24N276Blue

24N277Red

24N278

24N274Black

Fan

Pattern

Fan Fan

Pattern Pattern

No.

Color

No. No.

Color Color

Green

Green

Fan

Pattern

Fan Fan

Pattern Pattern

No.

Color

No. No.

Color Color

Green

Green

Air

Caps:

Air Air

Caps: Caps:

Description

Description Description

StandardMostversatileaircap.Recommendedformostmaterialsandapplications.Class

LongPattern

ShortPatternShorterpattern,optimizedforpaintingwithoverlappingpasses.

Air

Caps:

Air Air

Caps: Caps:

Description

Description Description

Standard

LongPatternTapered

ShortPattern

Descriptions

Descriptions Descriptions

Guidelines

Guidelines Guidelines

A󰘰nish.

Similartothestandardaircapwithanalternatearrangementofatomizingair.

Longestspraypattern,optimizedforpaintinglargepartswithoverlappingpaint
passes.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pattern

Pattern Pattern

Shape

Shape Shape

Round
end

end

end

Tapered
end

for

Use

for for

Use Use

Nominal

Nominal Nominal
Pattern

Pattern Pattern
Length

Length Length
in.

(mm)

in. in.

(mm) (mm)

15-17
(381-432)

15-17
(381-432)

17-19
(432-483)

12-14
(305-356)

Recommended

Recommended Recommended
Fluid

Viscosity*

Fluid Fluid

Viscosity* Viscosity*

Lighttomedium

Lighttomedium

Lighttomedium

Lighttomedium

Recommended

Recommended Recommended
Production

Production Production
Rates**

Rates** Rates**

Standard

Standard

Standard

StandardGood

Atom-

Atom- Atom­ization

ization ization

Best

Best

BetterBetter

Clean-

Clean- Clean­liness

liness liness

Good

Good

Best

*FluidViscosity,incentipoise(cp)at70°F(21°C).
Centipoise=centistokesx󰘱uidspeci󰘰cgravity.

Lighttomedium20–70cp

Mediumtoheavy70–360cpLow

Highsolids360+cpHigh

**RecommendedProductionRates

Standard300cc/minto500cc/min(10oz/min

VeryHigh

to17oz/min)

100cc/minto300cc/min(3oz/min
to10oz/min)

500cc/minto600cc/min(17oz/min
to20oz/min)

600cc/minto750cc/min(20oz/min
to25oz/min)

843A2494P

AirCaps

Specialty

Specialty Specialty

Part

Part Part

25E670Black

24N275BlackAerospace

24N279Black

24N439Black

25E671BlackHVLPForapplicationswhereHVLPisrequired.

Specialty

Specialty Specialty

Part

Part Part

25E670Black

24N275BlackAerospaceTapered

24N279Black

24N439Black

25E671BlackHVLPRound

Fan

Pattern

Fan Fan

Pattern Pattern

No.

Color

No. No.

Color Color

Fan

Pattern

Fan Fan

Pattern Pattern

No.

Color

No. No.

Color Color

Air

Caps:

Air Air

Description

Description Description

SoftSprayForpaintingsmall,lightweightpartswithaslow-movingspraypattern.Optimized

SolidsOptimizedformediumandheavyviscosityandhighsolidcoatingsatstandard

SolidsHigh
Flow

Air

Air Air

Description

Description Description

SoftSpray

Solids

SolidsHigh
Flow

Descriptions

Caps: Caps:

Descriptions Descriptions

Guidelines

Guidelines Guidelines

forlowproductionrates.

Optimizedforaerospacecoatings.

•ClassA󰘰nish

•Light,medium,andheavyviscosity,andhighsolidcoatings

•Veryhighproductionrates

productionrates.

Requiredforusewith2.0mmnozzles.Optimizedformediumandheavyviscosity
andhighsolidcoatingsathighproductionrates.

Caps:

Speci󰘰cations

Caps: Caps:

Speci󰘰cations Speci󰘰cations

Pattern

Pattern Pattern
Shape

Shape Shape

Round
end

end

Round
end

Tapered
end

end

for

Use

for for

Use Use

Nominal

Nominal Nominal

Pattern

Pattern Pattern

Length

Length Length

in.

(mm)

in. in.

(mm) (mm)

10-12
(254-

305)***

14-16
(356-406)

14-16
(356-406)

11-13
(279-330)

11-13
(279-330)

Recommended

Recommended Recommended
Viscosity*

Viscosity* Viscosity*

LighttomediumLowBetter

Light,medium,and
heavyviscosity,and
highsolids

Mediumtoheavy
viscosityandhigh
solids

Mediumtoheavy
viscosityandhigh
solids

Lighttomedium

Fluid

Fluid Fluid

Recommended

Recommended Recommended
Production

Production Production
Rates**

Rates** Rates**

VeryHigh

Standard

HighBestBetter

StandardGoodGood

Atom-

Atom- Atom-

iza-

iza- iza-

tion

tion tion

Good

Better

Clean-

Clean- Clean­liness

liness liness

Good

Best

Good

*FluidViscosity,incentipoise(cp)at70°F(21°C).
Centipoise=centistokesx󰘱uidspeci󰘰cgravity.

Lighttomedium20–70cp

Mediumtoheavy70–360cpLow

Highsolids360+cpHigh

***Thesoftsprayaircapwasmeasuredwiththe󰘱uid󰘱owrateadjustedto3.5oz/min(100cc/min).

**RecommendedProductionRates

Standard300cc/minto500cc/min(10oz/min

VeryHigh

to17oz/min)

100cc/minto300cc/min(3oz/min
to10oz/min)

500cc/minto600cc/min(17oz/min
to20oz/min)

600cc/minto750cc/min(20oz/min
to25oz/min)

3A2494P85

AirCaps

Round

Round Round

Round

Round Round

Pattern

Pattern Pattern

Part

No.

Part Part

No. No.

24N318BlackLarge

25N837BlackMedium

25N836Black

Pattern

Pattern Pattern

Part

No.

Part Part

No. No.

24N318BlackLargePatternRound

25N837BlackMedium

25N836Black

*FluidViscosity,incentipoise(cp)at70°F(21°C).
Centipoise=centistokesx󰘱uidspeci󰘰cgravity.

Lighttomedium20–70cp

Mediumtoheavy70–360cpLow

Highsolids360+cpHigh

Air

Caps:

Air Air

Caps: Caps:

Color

Color Color

Air

Caps:

Air Air

Caps: Caps:

Color

Color Color

Descriptions

Descriptions Descriptions

Description

Description Description

Pattern

Pattern

Small
Pattern

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Description

Description Description

Pattern

SmallPattern

Guidelines

Guidelines Guidelines

Conventionalroundpatterndesignforlargerpatternsupto8in(20cm).Swirling,
slow,roundconepatternforexcellent󰘰nishandtransferef󰘰ciency.

Dualinnerandouteratomizingairdesignforimprovedatomizationatlowair󰘱ows.
Formediumpatternsupto6inches(15cm).Swirling,slow,roundconepatternfor
excellent󰘰nishandtransferef󰘰ciency.

Dualinnerandouteratomizingairdesignforimprovedatomizationatlowair󰘱ows.
Forsmallpatternsupto4inches(10cm).Swirling,slow,roundconepatternfor
excellent󰘰nishandtransferef󰘰ciency.

Pattern

Pattern Pattern
Shape

Shape Shape

end

Round
end

Round
end

for

Use

for for

Use Use

Nominal

Nominal Nominal
Pattern

Pattern Pattern
Diameter

Diameter Diameter
in.

(mm)

in. in.

(mm) (mm)

8(203)

6(152)

4(102)

Recommended

Recommended Recommended
Viscosity*

Viscosity* Viscosity*

LighttomediumLow

LighttomediumLowBetter

LighttomediumLowBetter

**RecommendedProductionRates

Standard300cc/minto500cc/min(10oz/min

VeryHigh

Fluid

Fluid Fluid

Recommended

Recommended Recommended
Production

Production Production
Rates**

Rates** Rates**

to17oz/min)

100cc/minto300cc/min(3oz/min
to10oz/min)

500cc/minto600cc/min(17oz/min
to20oz/min)

600cc/minto750cc/min(20oz/min
to25oz/min)

Atom-

Atom- Atom-

iza-

iza- iza-

tion

tion tion

GoodGood

Clean-

Clean- Clean­liness

liness liness

Good

Good

863A2494P

AirCaps

60

0

5

10

15

20

25

62 64 66 68 70 72 74 76 78

50 55 60 65 70 75

0

5

10

15

20

25

80

50

2

0

4

6

8

10

12

14

16

18

55 60 65 70 75 80 85

0

0

5

10

15

20

25

30

10 20 30 40 50 60 70 80

Air

Consumption

Air Air

Consumption Consumption

NOTE:

NOTE: NOTE:

Airconsumptionappliestothecompletegun.

Charts

Charts Charts

Key

Key Key

TEST

TEST TEST

Air

Consumption

to totoAir Air

Consumption Consumption

CONDITIONS:

CONDITIONS: CONDITIONS:

Charts

Charts Charts

Fanvalvefullyopen(unlessotherwisenoted),atomizationvalvefullyopen(unless

otherwisenoted),85kvgun,ESon.

5/16in.x25ft(8mmx7.6m)hose

5/16in.x50ft(8mmx15.2m)hose

Table

17

Table Table
24N438

24N438 24N438

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

Table

Table Table

24N477,

17 17

. ..24N477, 24N477,

Air

Cap

Air Air

Cap Cap

CON-

CON- CON-

scfm

18

24N274,

18 18

. ..24N274, 24N274,

24W279,

24W279, 24W279,

WALL

WALL WALL

24N275,

24N275, 24N275,

24N279,

24N279, 24N279,

PRESSURE

PRESSURE PRESSURE

psi

and

and and

24N376,

24N376, 24N376,

24N439

24N439 24N439

and

and and

Air

Cap

Air Air

Cap Cap

Table

19

Table Table

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

NOTE:

NOTE: NOTE:

25E670

19 19

. ..25E670 25E670

CON-

CON- CON-

scfm

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

25E670:Atomizationvalveopenedoneturnfrom
closeaccordingtosoftspraygunsetup.See

SoftSprayGunSetupProcedure,page28.

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

3A2494P87

Table

20

Table Table

CON-

CON- CON-

scfm

AIR

AIR AIR

SUMPTION

SUMPTION SUMPTION

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

25E671

20 20

25E671 25E671

CON-

CON- CON-

scfm

Air

Cap

Air Air

Cap Cap

WALL

PRESSURE

WALL WALL

PRESSURE PRESSURE

psi

ElectrodeSelectionChart

Electrode

Electrode Electrode

Toreducetheriskofaninjury,followthePressureReliefProcedure,page36,beforeremovingorinstalling
anelectrode.

Electrode

Electrode Electrode

24N651

25N856

Part

Part Part

Selection

Selection Selection

No.

No. No.

Color

Color Color

GrayStandard(STD)Electrodeassemblywitha󰘱exible

GrayShort

Chart

Chart Chart

Description

Description Description

Guidelines

Guidelines Guidelines

snap-backwire.

Thestandardwireisresistantto
abrasive󰘱uidwearandalsoresistant
tohandlingdamage.

Electrodeassemblywithashort
snap-backwire.

Theshortwirehasalow-pro󰘰ledesign
thatpositionsthewireclosertotheair
capforconvenience.

Usetheshortwiretoextendwear
lifeoftheelectrodewireinextremely
abrasivematerials.

for

Use

for for

Use Use

24N704Blue

25N857BrownHardenedElectrodeassemblywithahardened

Highwear(HW)

Electrodeassemblywithahardwire.

Thehardwirecanbendanddoesnot
snapbackifitisdamagedbyhandling.

Usethehighwearelectrodetoextend
wearlifeofthewirewithabrasive
materials.

carbidewire.

Thehardenedwireiseasiertobreak
withhandlingthanthestandardor
highwearwires.

Usethehardenedelectrodetoextend
wearlifeofthewirewithextremely
abrasivematerials.

883A2494P

RepairKitsandAccessories

Repair

Repair Repair

Repair

Repair Repair

Part

No.

Part Part

No. No.

24N789

24N790

24N706AlternatorBearingRepairKit

Gun

Gun Gun

General

General General

Trigger

Trigger Trigger

Accessories

Accessories Accessories

Part

No.

Part Part

No. No.

111265

116553

24N603

24N604

24N758

and

and and

Part

No.

Part Part

No. No.

24N633PlasticTriggerKit

24P170MetalTriggerKit

24P171FourFingerTriggerKit,toconvert

Kits

Kits Kits

Kits

Kits Kits

Accessories

Accessories Accessories

Description

Description Description

Non-siliconeLubricant,4oz(113g)

DielectricGrease,1oz(30ml)

GunCovers,for40kVand60kV
guns(boxof10)

GunCovers,for85kVguns(boxof

10)

DisplayCovers.KeepsSmartdisplay
clean(packageof5).

Grip

Grip Grip

Description

Description Description

ProXpairspraygunstoafour󰘰nger
trigger

and

and and

Description

Description Description

AirSealRepairKit

FluidSealRepairKit

Accessories

Accessories Accessories

Accessories Accessories

Accessories

High

Conductivity

High High

Conductivity Conductivity

Part

No.

Part Part

No. No.

25N844

25N843

25N842

25N937

25N936

25N935

Accessories

Accessories Accessories

Description

Description Description

40kVHighConductivityFluidTube
Kit,withcover.Toconverta40kV
gunfromastandard󰘱uidtubetoan
HC󰘱uidtube.

60kVHighConductivityFluidTube
Kit,withcover.Toconverta60kV
gunfromastandard󰘱uidtubetoan
HC󰘱uidtube.

85kVHighConductivityFluidTube
Kit,withcover.Toconvertan85kV
gunfromastandard󰘱uidtubetoan
HC󰘱uidtube.

40kVHighConductivityFluidTube
Kit,nocover

60kVHighConductivityFluidTube
Kit,nocover

85kVHighConductivityFluidTube
Kit,nocover

24N520

24N521

Atomizing

Atomizing Atomizing

Part

No.

Part Part

No. No.

24N636

3A2494P89

ComfortGrip.Snap-ongrip
increaseshandlesizetoreduce
operatorfatigue.Mediumsize.

ComfortGrip.Snap-ongrip
increaseshandlesizetoreduce
operatorfatigue.Largesize.

Air

Valve

Air Air

Accessories

Valve Valve

Accessories Accessories

Description

Description Description

LowPro󰘰leAtomizingAirRestrictor
Valve(adjustedwithahextool)

Adapter

Adapter Adapter

Part

Part Part

112534

185105

185493

24N642

224754

and

Fitting

and and

Fitting Fitting

No.

No. No.

Accessories

Accessories Accessories

Description

Description Description

AirLineQuickDisconnectFitting

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

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

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

Valve,ball1/4npsm(left-hand
thread)

RepairKitsandAccessories

ES

On/Off

ES ES

On/Off On/Off

Part

Part Part

26A160

24P634

24N630

24N632

Fan

Fan Fan

Part

Part Part

24N634

24N732

24P172

and

Fluid

and and

No.

No. No.

Air

Adjustment

Air Air

Adjustment Adjustment

No.

No. No.

Adjustment

Fluid Fluid

Adjustment Adjustment

Description

Description Description

ESOn/OffValveRestrictorforhigh
atomizingairapplications.Use
thisaccessoryiftheturbinelight
indicatorisredandyouwantto
maintainahigherapplicationair
pressure.Installthekit,thenadjust
thepressureasneededtoensure
theindicatorremainsgreen.

ESAlwaysONand󰘱uidadjustment
valvekit.Whenthisvalveisinstalled,
theelectrostaticsareonanytimeair
pressureissuppliedtothegun.Fluid
adjustmentispossible.Seemanual
3A6840.

ESOn-OffandFluidAdjustment
Valve

ESOn-OffandFixedFluidValve.
Usetoextendelectrodeandnozzle
lifeinapplicationswithabrasive,
metallic,andextremelyabrasive
materials.

Valve

Valve Valve

Description

Description Description

Standardfanairadjustmentvalve

Fanairadjustmentvalveforlarge
patternroundspray

Quickadjustfanvalveforquick
changeoffansize

Valve

Accessories

Valve Valve

Accessories Accessories

Accessories

Accessories Accessories

Inline

Inline Inline

Filter

Filter Filter

60mesh

100mesh

150mesh

200mesh

Operator

Operator Operator

Part

Part Part

117823

117824

117825

Fluid

Fluid Fluid

Part

No.

Part Part

No. No.

915921FilterHousing3/8

Size

Size Size

No.

No. No.

Filter

Filter Filter

npsm(f)x3/8npsm(m)
with100mesh󰘰lter

238562.

224453Black

238563Black3
238564Black1

238561Black3
238562Black1

25N891Red1
25N892Red3

25N893Yellow1

25N894Yellow3

Accessories

Accessories Accessories

Description

Description Description

ConductiveGloves,boxof12(small)

ConductiveGloves,boxof12
(medium)

ConductiveGloves,boxof12(large)

Kit

Kit Kit

Description

Description Description

Description

Description Description

Accessories

Accessories Accessories

Qty.

Qty. Qty.

1

Filter

Filter Filter

Color

Color Color

Qty.

Qty. Qty.

5

25N919

Round

Round Round

Spray

Spray Spray

Part

No.

Part Part

No. No.

24N318

25N837

25N836

Quickadjustfanvalvewithspring
return.Seemanual3A7005.

Accessories

Accessories Accessories

Description

Description Description

RoundSprayKit,largepattern,to
convertastandardairspraygunto
aroundsprayaircap.Seemanual
3A2498.

RoundSprayKit,mediumpattern,to
convertastandardairspraygunto
aroundsprayaircap.Seemanual
3A6829.

RoundSprayKit,smallpattern,to
convertastandardairspraygunto
aroundsprayaircap.Seemanual
3A6829.

System

System System

Part

Part Part

222011

24N528

24N529

24P312

Accessories

Accessories Accessories

No.

No. No.

Description

Description Description

GroundWireandClamp

GunFlushBoxAdapterfor60kV
and85kVguns.Toconvertexisting
gun󰘱ushboxestoholdProXpguns.
Seemanual309227.

GunFlushBoxAdapterfor40kV
guns.Toconvertexistinggun󰘱ush
boxestoholdProXpguns.See
manual309227.

GunWasherKit.Toconvertexisting
gunwasherstocleanProXpguns.
Seemanual308393.

903A2494P

RepairKitsandAccessories

Signs

Signs Signs

Part

No.

Part Part

No. No.

Description

Description Description

16P802

16P798

16P799

Test

Test Test

Equipment

Equipment Equipment

Part

No.

Part Part

No. No.

241079Megohmmeter.500Voutput,

722886

722860

245277TestFixture,HighVoltageProbe,

EnglishWarningSign,availableat
nochargefromGraco

EnglishDailyCareSign

EnglishSetupSign

Description

Description Description

0.01–2000megohms.Usefor
groundcontinuityandgunresistance

Not

for

tests.Not Not
locations.

locations. locations.

PaintResistanceMeter.Usefor󰘱uid
resistivitytest.Seemanual307263.
Not

for

Not Not

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

use use

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

use

for for

use use

hazardous

in ininhazardous hazardous

use

for for

use use

hazardous

in ininhazardous hazardous

hazardous

in ininhazardous hazardous

locations.

locations. locations.

Not

for

for for

locations.

locations. locations.

24R038

25E919

VoltageTesterConversionKit.
Convertsthe245277TestFixturefor
usewiththeProXpGunalternator.
Seemanual406999.

HVLPAirCapVeri󰘰cationKit.Use
toverifyairpressuresinaircaps
inHVLPapplications.Foruse
with25E671aircap.Seemanual
3A6833.

3A2494P91

RepairKitsandAccessories

Hoses

Hoses Hoses

Grounded

Grounded Grounded

Air

Hoses

Air Air

Hoses Hoses

100psi(0.7MPa,7bar)MaximumWorkingPressure

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

Part

No.

Part Part

No. No.

AirFlex

AirFlex AirFlex

244963

244964

244965

24J138

24N736

244966

24N737

244967

24N738

244968

244969

Part

Part Part

Standard

Standard Standard

223068

223069

223070

223071

223072

223073

223074

0.375

0.375 0.375
left

left left

24A225

24A226

Flexible

Flexible Flexible

No.

No. No.

Grounded

Grounded Grounded

in.

(10

in. in.

(10 (10

hand

thread

- --hand hand

thread thread

Description

Description Description

Grounded

Grounded Grounded

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

31ft(9.4m)

25ft(7.6m),with112534Quick
Disconnect

36ft(11m)

36ft(11m),with112534Quick
Disconnect

50ft(15m)

50ft(15m),with112534Quick
Disconnect

75ft(23m)

100ft(30.5m)

Description

Description Description

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

mm)

ID;

mm) mm)

ID; ID;

50ft(15m)

75ft(23m)

Air

Air Air

Air

Hose

Air Air

Hose Hose

3/8

npsm(f)

3/8 3/8

npsm(f) npsm(f)

Hose

(Gray)

Hose Hose

(Gray) (Gray)

(Gray)

(Gray) (Gray)

1/4

npsm(f)

x xx1/4 1/4

npsm(f) npsm(f)

Part

No.

Part Part

No. No.

Grounded

Grounded Grounded
ground

ground ground

235068

235069

235070

235071

235072

235073

235074

Air

Air Air

path

path path

Whip

Hoses

Whip Whip

Hoses Hoses

Air

Air Air

Description Description

Hose

Hose Hose

(Red)

(Red) (Red)

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

Description

with

stainless

with with

stainless stainless

steel

steel steel

100psi(0.7MPa,7bar)MaximumWorkingPressure

0.188in.(5mm)ID;1/4npsm(m)x1/4npsm(f)

left-handthread

Part

No.

Part Part

No. No.

Air

Whip

Air Air
path

path path

236130

236131

Fluid

Fluid Fluid

Hose

Whip Whip

Hose Hose

(Red)

(Red) (Red)

Hoses

Hoses Hoses

Description

Description Description

with

stainless

with with

stainless stainless

3ft(0.9m)

6ft(1.8m)

steel

braid

steel steel

braid braid

225psi(1.4MPa,14bar)MaximumWorking
Pressure

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

Part

No.

Part Part

No. No.

215637

215638

High

Conductivity

High High

Conductivity Conductivity

Forlowresistivity,highviscositymaterials.For For
kV

guns

kV kV

only.

guns guns

only. only.

Description

Description Description

25ft(7.6m)

50ft(15m)

Fluid

Fluid Fluid

Hose

Hose Hose

100psi(0.7MPa,7bar)MaximumWorkingPressure

braid

braid braid

ground

ground ground

For

60

60 60

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

Part

No.

Part Part

No. No.

24N994

Description

Description Description

26.8ft(8.2m)

923A2494P

Dimensions

Dimensions

Dimensions Dimensions

KV

KV KV

40

40

40

40

60

60

60

60

85

85

85

85

SeeModels,page3forgunpartnumbers.

Display

Display Display

StandardStandard8.7(221)9.2(234)2.4(61)19.8(562)

StandardHC8.7(221)9.2(234)2.4(61)20.5(620)

SmartStandard8.7(221)10(254)2.4(61)22.3(632)

SmartHC8.7(221)10(254)2.4(61)24.3(690)

StandardStandard9.5(241)9.2(234)2.4(61)21.1(600)

StandardHC9.5(241)9.2(234)2.4(61)23.3(660)

SmartStandard9.5(241)10(254)2.4(61)23.7(673)

SmartHC9.5(241)10(254)2.4(61)25.9(733)

StandardStandard10.5(267)9.2(234)2.4(61)23.8(676)

StandardHC10.5(267)9.2(234)2.4(61)26.2(743)

SmartStandard10.5(267)10(254)2.4(61)26.3(746)

SmartHC10.5(267)10(254)2.4(61)28.7(813)

Fluid

Fluid Fluid
Tube

Tube Tube

Dimensions

Dimensions Dimensions

A,

in.

(mm)

A, A,

in. in.

(mm) (mm)

B,

in.

(mm)

B, B,

in. in.

(mm) (mm)

C,

in.

(mm)

C, C,

in. in.

(mm) (mm)

Weight,

Weight, Weight,

oz

(g)

oz oz

(g) (g)

3A2494P93

TechnicalSpecications

Technical

Technical Technical

Electrostatic

Electrostatic Electrostatic

MaximumWorkingFluidPressure100psi0.7MPa,7.0bar

MaximumWorkingAirPressure100psi0.7MPa,7.0bar

MinimumAirPressureatGunInlet

AirConsumption

Requiredturbineair󰘱ow6scfm

Rangeoftotalair󰘱owunder
normalsprayingconditions

MaximumFluidOperating
Temperature

AmbientTemperature

PaintResistivityRange

AirInletFitting

FluidInletFitting

OutputVoltage

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Air

Spray

Air Air

Guns

Spray Spray

Guns Guns

170l/min

425–565l/min

Metric

Metric Metric

U.S.

U.S. U.S.

45psi0.32MPa,3.2bar

15–20scfm

120°F48°C

41°–122°F5°–50°C

3megohm/cmtoin󰘰nity.Foratableofelectrostaticresultsatdifferent

resistancelevels,seeCheckFluidResistivity,page35.

1/4npsm(m)left-handthread

3/8npsm(m)

ProXp40Models:40kV

ProXp60Models:60kV

ProXp85Models:85kV

MaximumCurrentDraw

SoundPower(measuredperISO
Standard9216)

SoundPressure(measured1m
fromgun)

WettedPartsPEEK,UHMWPE,FEP,PTFE,acetal,nylon,polyeth-

California

California California

CALIFORNIA

CALIFORNIA CALIFORNIA

WARNING:

WARNING: WARNING:

RESIDENTS

RESIDENTS RESIDENTS

Proposition

Proposition Proposition

Cancerandreproductiveharm—www.P65warnings.ca.gov.

at40psi:90.4dB(A)

at100psi:105.4dB(A)

at40psi:87.0dB(A)

at100psi:99.0dB(A)

65

65 65

125microamperes

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

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

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

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

ylene,stainlesssteel

943A2494P

Graco

Graco Graco

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

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

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

THIS

WARRANTY

THIS THIS

WARRANTY WARRANTY

INCLUDING

INCLUDING INCLUDING
PARTICULAR

PARTICULAR PARTICULAR

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

GRACO

GRACO GRACO
FITNESS

FITNESS FITNESS
OR

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

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

FORGRACOCANADACUSTOMERS

ThePartiesacknowledgethattheyhaverequiredthatthepresentdocument,aswellasalldocuments,noticesand
legalproceedingsenteredinto,givenorinstitutedpursuantheretoorrelatingdirectlyorindirectlyhereto,bedrawn
upinEnglish.LespartiesreconnaissentavoirconvenuquelarédactionduprésentedocumentseraenAnglais,
ainsiquetousdocuments,avisetprocéduresjudiciairesexécutés,donnésouintentés,àlasuitedeouenrapport,
directementouindirectement,aveclesprocéduresconcernées.

MAKES

MAKES MAKES

FOR

FOR FOR

COMPONENTS

COMPONENTS COMPONENTS

Pro

Pro Pro

IS ISISEXCLUSIVE, EXCLUSIVE,

BUT

NOT

BUT BUT

NOT NOT

PURPOSE.

PURPOSE. PURPOSE.

NO

WARRANTY,

NO NO

WARRANTY, WARRANTY,

PARTICULAR

A AAPARTICULAR PARTICULAR

SOLD

SOLD SOLD

Xp

Xp Xp

EXCLUSIVE,

LIMITED

LIMITED LIMITED

BUT

BUT BUT

Warranty

Warranty Warranty

AND

AND AND

TO

WARRANTY

TO TO

WARRANTY WARRANTY

AND

AND AND

PURPOSE,

PURPOSE, PURPOSE,

NOT

MANUFACTURED

NOT NOT

MANUFACTURED MANUFACTURED

LIEU

OF

ANY

IS ISISIN ININLIEU LIEU

DISCLAIMS

DISCLAIMS DISCLAIMS

IN

IN IN

OF OF

OF

MERCHANTABILITY

OF OF

MERCHANTABILITY MERCHANTABILITY

ALL

ALL ALL

CONNECTION

CONNECTION CONNECTION

OTHER

ANY ANY

OTHER OTHER

IMPLIED

IMPLIED IMPLIED

BY

GRACO.

BY BY

GRACO. GRACO.

WARRANTIES,

WARRANTIES, WARRANTIES,

OR

OR OR

WARRANTIES

WARRANTIES WARRANTIES

WITH

ACCESSORIES,

WITH WITH

ACCESSORIES, ACCESSORIES,

Theseitemssold,butnotmanufacturedby

EXPRESS

EXPRESS EXPRESS

WARRANTY

WARRANTY WARRANTY

OF

MERCHANTABILITY

OF OF

MERCHANTABILITY MERCHANTABILITY

EQUIPMENT,

EQUIPMENT, EQUIPMENT,

OR

IMPLIED,

OR OR

OF

OF OF

IMPLIED, IMPLIED,

FITNESS

FITNESS FITNESS

FOR

FOR FOR

AND

AND AND

MATERIALS

MATERIALS MATERIALS

A

A A

Graco

Graco Graco

For

For For

For

For For

To

place

To To

place place

Phone:

Phone: Phone:

Allwrittenandvisualdatacontainedinthisdocumentre󰘱ectsthelatestproductinformationavailableatthetimeofpublication.

Information

Information Information

the

latest

the the

latest latest

patent

patent patent

an

order,

an an

order, order,

612-623-6921or ororToll Toll

GRACO

GRACO GRACO

information

information information

information,

information, information,

contactyourGracoDistributororcalltoidentifythenearestdistributor.

INC.

INC. INC.

Copyright

Copyright Copyright

about

about about

see

see see

Toll

Free:

Free: Free:

Gracoreservestherighttomakechangesatanytimewithoutnotice.

OriginalInstructions.ThismanualcontainsEnglish,MM3A2494

AND

SUBSIDIARIES

AND AND

SUBSIDIARIES SUBSIDIARIES

2012,

Graco

2012, 2012,

Graco Graco

Graco

Graco Graco

products,

products, products,

www.graco.com/patents.

Headquarters:

Headquarters: Headquarters:

Of󰘰ces:

Of󰘰ces: Of󰘰ces:

P.O.

• ••P.O. P.O.

RevisionP

Fax:

Belgium,China,Japan,Korea

BOX

BOX BOX

manufacturing

manufacturing manufacturing

www.graco.com

1-800-328-0211Fax: Fax:

International

International International

Inc.

Inc. Inc.

Graco

Graco Graco

All

Graco

All All

Graco Graco

visit

visit visit

www.graco.com.

612-378-3505

Minneapolis

1441

1441 1441

• ••MINNEAPOLIS, MINNEAPOLIS,

,June2020

MINNEAPOLIS,

locations

locations locations

MN

MN MN

are

registered

are are

registered registered

55440-1441

55440-1441 55440-1441

ISO

to totoISO ISO

USA

• ••USA USA

9001.

9001. 9001.