Graco WB100, Pro Xp 60 WB MRG, Pro Xp 60 WB Instructions-parts List Manual

Instructions-Parts

WB100

WB100 WB100
Pro

Pro Pro

Air

Air Air
one

one one
For

For For

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

Seepages3and4formodelpart
numbersandapprovalinformation.

Xp™

Xp™ Xp™

spray

spray spray

of

the

of of

the the

professional

professional professional

Important

Important Important
Readallwarningsandinstructionsinthismanual.Save Save
instructions.

instructions. instructions.

Isolation

Isolation Isolation

60

WB

60 60

WB WB

system

system system

conditions

conditions conditions

for

use

for for

use

use use

Safety

Safety Safety

when

use use

when when

for

non

for for

non non

- --󰘱ammability 󰘱ammability

only.

only. only.

Instructions

Instructions Instructions

System

System System

Gun

Gun Gun

electrostatically

electrostatically electrostatically

󰘱ammability

and

and and

3A2496H

EN

spraying

spraying spraying

listed

on

listed listed

on on

conductive,

conductive, conductive,

page

3.

page page

3. 3.

Save

these

these these

waterborne

waterborne waterborne

󰘱uids

that

meet

at

󰘱uids 󰘱uids

that that

meet meet

least

at at

least least

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

RelatedManuals..................................................4

Warnings.............................................................5

GunOverview......................................................8

HowtheElectrostaticSprayGunWorks...........8

SprayingWaterborneFluids

Electrostatically................................8

Controls,Indicators,andComponents.............9

SmartGuns.................................................10

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

SystemRequirements..................................15

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

InstalltheSystem.........................................15

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

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

GroundtheCabinet......................................16

ConnecttheWaterborneFluidHose..............17

Grounding...................................................22

AgitatorKitAccessory..................................24

FluidRegulatorKitAccessory.......................25

GunSetup..........................................................26

GunSetupProcedure...................................26

SoftSprayGunSetupProcedure..................30

HVLPGunSetupProcedure.........................31

RoundSprayGunSetupProcedure..............33

AbrasiveMaterialGunSetup

Procedure......................................35

MoldReleaseGunSetupProcedure.............36

CheckGunElectricalGrounding...................38

FlushBeforeUsingEquipment......................38

Operation...........................................................39

PressureReliefProcedure............................39

FluidVoltageDischargeandGrounding

Procedure......................................39

FilltheFluidSupply......................................40

Startup........................................................40

Shutdown....................................................41

Maintenance......................................................42

DailyCareandCleaningChecklist................42

Flushing......................................................42

CleantheGunDaily.....................................44

DailySystemCare.......................................46

ElectricalTests...................................................47

TestGunResistance....................................47

TestPowerSupplyResistance.....................48

TestElectrodeResistance............................49

TestGroundStripResistance.......................50

TestCylinderResistance..............................50

Troubleshooting..................................................51

VoltageLossTroubleshooting.......................51

SprayPatternTroubleshooting......................54

GunOperationTroubleshooting....................55

ElectricalTroubleshooting............................56

Repair................................................................58

PreparetheGunforService.........................58

AirCapandNozzleReplacement..................59

AirCap,SprayTip,andNozzle

Replacement(Model

L60M19)........................................60

ElectrodeReplacement................................61

NeedleReplacement(ModelL60M19)...........62

FluidPackingRodRemoval..........................62

PackingRodRepair.....................................63

BarrelRemoval............................................65

BarrelInstallation.........................................65

PowerSupplyRemovaland

Replacement..................................66

AlternatorRemovalandReplacement...........67

FanAirAdjustmentValveRepair..................69

AtomizingAirRestrictorValveRepair............70

ESOn-OffandFluidAdjustmentValve

Repair............................................71

AirValveRepair...........................................72

SmartModuleReplacement..........................73

AirSwivelandExhaustValve

Replacement..................................74

Parts..................................................................75

StandardWaterborneAirSprayGun

Assembly.......................................75

SmartWaterborneAirSprayGun

Assembly.......................................77

MoldReleaseSmartAirSprayGun

Assembly.......................................79

IsolationEnclosure.......................................81

TubingandWiring.......................................84

PackingRodAssembly.................................86

AlternatorAssembly.....................................87

ESOn-OffandFluidAdjustmentValve...........88

FanAirAdjustmentValveAssembly..............89

AtomizingAirRestrictorValve

Assembly.......................................89

AirCapAssembly........................................90

SmartModuleAssembly...............................90

RoundSprayAssembly................................91

FluidNozzles.....................................................93

FluidNozzleSelectionChart.........................93

FluidNozzlePerformanceCharts..................94

AirCaps.............................................................96

AirCapSelectionGuide...............................96

AirConsumptionCharts.............................101

SprayTipSelectionChart(ModelL60M19MRG

GunOnly)...........................................102

AEMFineFinishSprayTips........................102

AEFFineFinishPre-Ori󰘰ceSpray

Tips.............................................103

RoundSprayTips......................................104

RepairKitsandAccessories..............................105

Dimensions......................................................109

TechnicalSpeci󰘰cations....................................111

2

3A2496H

Models

2575

Models

Models Models

FMapprovedforusewith󰘱uidsthatmeetthefollowingcondition:

•MaterialdoesnotsustainburninginaccordancewiththeStandardTest
MethodforSustainedBurningofLiquidMixtures,ASTMD4206.

0.35

0.35 0.35

Part

Part Part

24N580WB100WaterborneIsolationEnclosure233825withstandardelectrostaticairspraygun

24P629WB100WaterborneIsolationEnclosure233825withsmartelectrostaticairspraygun

24P630WB100WaterborneIsolationEnclosure246511withstandardelectrostaticairspraygun

24P631WB100WaterborneIsolationEnclosure246511withsmartelectrostaticairspraygun

233825WB100

24P734WB100

246511WB100

L60T17ProXp60

with

50

hose

J, J,J,with with

FM12ATEX0080

FM12ATEX0080 FM12ATEX0080

No

No No

50 50

ft ftfthose hose

EN

50059

EN EN

50059 50059

Ta

0°C

Ta Ta

50°C

0°C 0°C

– ––50°C 50°C

Model

Model Model

WB

max

max max

•Materialswhichcannotbeignited,inanymixturewithair,byanenergy

Description

Description Description

L60T17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.

L60M17,groundedairhose235070,andshieldedwaterborne󰘱uidhose24M732.

L60T18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

L60M18,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

WaterborneIsolationEnclosureforshieldedhoses.Doesnotincludehosesandgun.

WaterborneIsolationEnclosure246511withMRGsmartelectrostaticairspraygun
L60M19,groundedairhose235070,andunshieldedwaterborne󰘱uidhose24M733.

WaterborneIsolationEnclosureforunshieldedhoses.Doesnotincludehoses
andgun.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

ModelsCompliantwithEN50059whenused

with󰘱uidsthatmeetthefollowingcriteria:

sourceoflessthan500mJ.

L60M17ProXp60

L60T18ProXp60

L60M18ProXp60

L60M19ProXp60

WBMRG

24M732

24M733

25N916

25N917

-——

-——

-——

-——

WB

WB

WB

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

StandardElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,forwaterbornecoatings.

SmartElectrostaticAirSprayGun,formoldreleaseapplications.

ShieldedWaterborneFluidHoseAssembly,25ft(7.6m).

UnshieldedWaterborneFluidHoseAssembly,25ft(7.6m).

ShieldedWaterborneFluidHoseAssembly,50ft(15.2m).

UnshieldedWaterborneFluidHoseAssembly,50ft(15.2m).

3A2496H3

RelatedManuals

Related

Related Related

Manual

Manual Manual

3A2498

307263ProbeandMeter,Instructions

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions

VoltageTesterConversionKit,Instructions

4

3A2496H

Warnings

Warnings Warnings

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

WARNING

WARNING WARNING

FIRE

AND

FIRE FIRE

Combustibledustinwork work

•Fluidsusedmustmeetthefollowing󰘱ammabilityrequirements:

Stop

•Stop Stop
equipmentuntilyouidentifyandcorrecttheproblem.

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairsupplytopreventoperationunlessventilationair󰘱owisabovethe
minimumrequiredvalue.

•Onlyusenon-󰘱ammablesolventswhen󰘱ushingorcleaningequipment.

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepsprayareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepaworking󰘰reextinguisherintheworkarea.

EXPLOSION

AND AND

EXPLOSION EXPLOSION

FM,

FMc

•FM, FM,
MaterialdoesnotsustainburninginaccordancewiththeStandardTestMethodfor
SustainedBurningofLiquidMixtures,ASTMD4206.

CE

•CE CE
Materialswhichcannotbeignited,inanymixturewithair,byanenergysourceof
lessthan500mJ.

operation

operation operation

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

immediately

immediately immediately

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelpprevent󰘰reandexplosion:

Compliant:

Compliant: Compliant:

ifstaticsparkingoccursoryoufeelashock.Donotuse

Warnings

3A2496H5

Warnings

WARNING

WARNING WARNING

ELECTRIC

ELECTRIC ELECTRIC

Impropergrounding,setup,orusageofanisolatedwaterbornesystemcanresultinelectric
shock.Tohelppreventelectricshock:

•Groundallequipment,personnel,objectbeingsprayed,andconductiveobjectsinorclose
tosprayarea.SeeGrounding Grounding

•Connecttheelectrostaticguntoavoltageisolationsystemthatwilldischargethesystem
voltagewhennotinuse.

•Allcomponentsoftheisolationsystemthatarechargedtohighvoltagemustbecontained
withinanisolationenclosurethatpreventspersonnelfrommakingcontactwiththehigh
voltagecomponentsbeforethesystemvoltageisdischarged.

•FollowtheFluid Fluid
thevoltage;beforecleaning,󰘱ushing,orservicingthesystem;beforeapproachingthefrontof
thegun;andbeforeopeningtheisolationenclosurefortheisolated󰘱uidsupply.

•Donotenterahighvoltageorhazardousareauntilallhighvoltageequipmenthasbeen
discharged.

•Donottouchthegunnozzleorelectrode,orcomewithin4in.(102mm)oftheelectrode
duringgunoperation.FollowtheFluid Fluid

•Interlockthegunairsupplywiththevoltageisolationsystemtoshutofftheairsupplyanytime
theisolationsystemenclosureisopened.

•Onlyusethered-coloredGracoelectricallyconductivegunairhosewiththisgun.Donot
useblackorgray-coloredGracoairhoses.

•Donotsplicehosestogether.InstallonlyonecontinuousGracowaterborne󰘱uidhose
betweentheisolated󰘱uidsupplyandthespraygun.

PRESSURIZED

PRESSURIZED PRESSURIZED
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.

SHOCK

SHOCK SHOCK

Fluid

HAZARD

HAZARD HAZARD

Grounding

Voltage

Voltage Voltage

EQUIPMENT

EQUIPMENT EQUIPMENT

instructions.

Discharge

Discharge Discharge

HAZARD

HAZARD HAZARD

and

Grounding

and and

Grounding Grounding

Fluid

Voltage

Voltage Voltage

Procedure

Procedure Procedure

Discharge

Discharge Discharge

and

and and

wheninstructedtodischarge

Grounding

Grounding Grounding

Procedure

Procedure Procedure

.

•FollowthePressure Pressure
cleaning,checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopspraying/dispensingandbefore

63A2496H

Warnings

WARNING

WARNING WARNING

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
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

HAZARD

HAZARD HAZARD

Technical

inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.

CLEANING

CLEANING CLEANING

SOLVENT

SOLVENT SOLVENT

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Pressure

HAZARD

HAZARD HAZARD

Relief

Relief Relief

inallequipmentmanuals.

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Technical

•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.

•SeeTechnical Technical

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

Technical

thesolventmanufacturerforinformationandrecommendationsaboutcompatibility.

FLUID

FLUID FLUID

guidelines.

manufacturer.

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

OR

FUMES

OR OR

FUMES FUMES

PROTECTIVE

PROTECTIVE PROTECTIVE

inallequipmentmanualsformaterialsofconstruction.Consult

EQUIPMENT

EQUIPMENT EQUIPMENT

3A2496H

7

GunOverview

Gun

Gun Gun

How

How How
Works

Works Works

Theairhosesuppliesairtothespraygun.Partofthe
airoperatesthealternatorturbineandtherestofthe
airatomizesthe󰘱uidbeingsprayed.

Thealternatorgeneratespower,whichisconverted
bythepowercartridgetosupplyhighvoltagetothe
gun’selectrode.

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

Spraying

Spraying Spraying
Electrostatically

Electrostatically Electrostatically

Thiselectrostaticairspraygunisdesignedtospray
only

only only
󰘱ammabilityrequirements:

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Waterborne

Waterborne Waterborne

waterborne󰘱uidswhichmeetthefollowing

Spray

Spray Spray

Fluids

Fluids Fluids

Gun

Gun Gun

CE-EN

•CE-EN CE-EN
Materialswhichcannotbeignited,inanymixture
withair,byanenergysourceoflessthan500mJ.

Whenconnectedtoavoltageisolationsystem,
allofthe󰘱uidinthespraygun,󰘱uidhose,and
isolated󰘱uidsupplyischargedtohighvoltage,
whichmeansthatthesystemhasmoreelectrical
energythanasolvent-basedsystem.Therefore,
onlynon-󰘱ammable󰘱uids(asde󰘰nedunder

Models,page3)canbesprayedwiththesystemor

beusedtoclean,󰘱ush,orpurgethesystem.

Precautionsmustbetakenwhenusingelectrostatic
waterborneequipmenttoavoidpotentialshock
hazards.Whenthespraygunchargestheisolated
󰘱uidtohighvoltage,itissimilartocharginga
capacitororabattery.Thesystemwillstoresomeof
theenergywhilesprayingandretainsomeofthat
energyafterthespraygunisshutoff.Donottouch
thegunnozzleorcomewithin4in.(102mm)of
theelectrodeuntilthestoredenergyisdischarged.
Theamountoftimeittakestodischargethe
energydependsonthesystemdesign.Followthe

FluidVoltageDischargeandGroundingProcedure,
page39,beforeapproachingthefrontofthegun.

50059

50059 50059

Compliant:

Compliant: Compliant:

FM,

FMc

•FM, FM,
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

Approved:

FMc FMc

Approved: Approved:

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

TheGracowarrantyandapprovalsare

83A2496H

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents.ForinformationonSmart
guns,alsoseeSmartGuns,page10.

Figure1GunOverview

Item

Item Item

Indicators,

Indicators, Indicators,

Description

Description Description

and

Components

and and

Components Components

Purpose

Purpose Purpose

A

BFluidInlet

C

D

EElectrodeNeedle

FFanAirAdjustmentValve

G

HFluidAdjustmentKnob

J

K

AirSwivelInlet1/4npsm(m)left-handthread,forGracored-coloredgroundedair

TurbineAirExhaust

AirCapandNozzleSeeAirCaps,page96andFluidNozzles,page93foravailable

AtomizingAirRestrictor
Valve

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(standard
gunonly;forSmart
gunindicator,see

OperatingMode,page10)

supplyhose.

Gracowaterborne󰘱uidsupplyhose

Barbed󰘰tting,forsuppliedexhausttube.

sizes.

Supplieselectrostaticchargetothe󰘱uid.

Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.

Restrictsaircapair󰘱ow.Replacewithplug(included)ifdesired.

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

LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableonpage36.

3A2496H9

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page12.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.

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

ElectricalTroubleshooting,page56forotherpossible

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,page11.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page11forfurtherinformation.

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
ensuretoensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

103A2496H

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page12.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page56.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

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

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page11.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page12.

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page12.
Therangeis30–60kV.

SettheVoltageAdjustmentswitch(VA)toLO.Press
theLOSETbuttonrepeatedlytoincreasethesetting
inincrementsof5.Whenthedisplayreachesthe
maximumsetting(60kV)itwillreturntotheminimum
setting(30kV).Continuepressingthebuttonuntil
youreachthedesiredsetting.

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page14,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

3A2496H

11

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.

12

3A2496H

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
andDiagnosticMode.

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

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page14fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page12.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,page12.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page13.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page14.Press

andholdforapproximately5secondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

3A2496H13

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page12.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.

Thisscreendisplaysthealternatorspeedasa3
digitnumber(AS),roundedtothenearest5Hz.The
displayisareadoutandcannotbechanged.Ifthe
alternatorspeedisgreaterthan999Hz,thedisplay
willshow999.

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page14.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page12.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

14

3A2496H

Installation

Installation

Installation Installation

System

System System

Theuseofmultiplegunswithoneisolationcabinet
maycauseelectricshock,󰘰re,orexplosion.To
helppreventinjuryorequipmentdamage,useonly
onegunperisolationcabinet.

AGracovoltageisolationsystemmusthavethe
followingfeatures:

•Anisolationenclosurethatpreventspersonsfrom
makingcontactwiththehighvoltagecomponents
beforethesystemvoltageisdischarged.All
componentsoftheisolationsystemthatare
chargedtohighvoltagemustbecontainedwithin
theenclosure.

•Ableedresistortodrainoffthesystemvoltage
whenthespraygunisnotinuse.Ametalpartof
the󰘱uidsupplyunitmustbeelectricallyconnected
tothebleedresistor.

•Asafetyinterlockthatautomaticallydischargesthe
systemvoltagewhenanyoneopenstheisolation
enclosure.

Requirements

Requirements Requirements

Install

Install Install

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless

•Complywithalllocalcodesandregulations

Fig.19showsatypicalelectrostaticairspraysystem.
Itisnotanactualsystemdesign.Forassistance
indesigningasystemtosuityourparticularneeds,
contactyourGracodistributor.

Ventilate

Ventilate Ventilate

the

the the

youaretrainedandquali󰘰ed.

System

System System

the

Spray

the the

Spray Spray

Booth

Booth Booth

NOTICE

NOTICE NOTICE

Thesystemshouldnothaveanyseverearcing
occurringwhentheisolationmechanismopens
andcloses.Severearcingwillshortenthelifeof
thesystemcomponents.

NOTE:

NOTE: NOTE:
voidiftheelectrostaticspraygunisconnectedtoa
non-Gracovoltageisolationsystemorifthegunis
operatedabove60kV.

Warning

Warning Warning

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

TheGracowarrantyandapprovalsare

Sign

Sign Sign

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:Theminimumallowableairexhaustvelocity
is60feet/minute(19linearmeters/minute).High
velocityairexhaustwilldecreasetheoperating
ef󰘰ciencyoftheelectrostaticsystem.

3A2496H15

Installation

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

Toreducetheriskofelectricshockorother
seriousinjury,youmustusethered-coloredGraco
ElectricallyConductiveAirHoseforthegunair
supply,andyoumustconnectthehoseground
wiretoatrueearthground.Donotusetheblack
orgray-coloredGracoairhoses.

1.SeeFig.19.Installanairline󰘰lter/water
separator(M)onthemainairsupplylineto
ensureadry,cleanairsupplytothegun.Dirtand
moisturecanruintheappearanceofyour󰘰nished
workpieceandcancausetheguntomalfunction.

2.TheWB100systemincludesableed-typeair
regulator(N)onthegunairsupplyline(P),to
controlairpressuretothegun.

3.Connectthered-coloredGracoElectrically
ConductiveAirHose(P)betweenthegunair
regulator(N)andthegun’sairinlet.Thegunair
inlet󰘰ttinghasaleft-handthread.Connectthe
airsupplyhosegroundwire(Q)toatrueearth
ground.

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Trappedaircancausethe󰘱uidsupplyunitto
cycleunexpectedly,whichcanresultinserious
injury,includingsplashing󰘱uidintheeyesor
ontheskin.Donotoperatetheequipment
withoutthebleed-typeairvalve(B)installed.

4.TheWB100systemincludesableed-typeair
valve(B).Thebleed-typeairvalveisrequired
toshutoffallairtothesystemandrelieveair
trappedbetweenthevalveandthe󰘱uidsupply
unitaftertheairregulatorisshutoff.Connectthe
mainairsupplyline(A)tothebleedvalve.

5.Installanadditionalbleed-typeairvalve(CC)
upstreamoftheair󰘰lter(M)toisolatethe󰘰lter
forservicing.

Ground

Ground Ground

Connectthemaingroundwire(V)toatrueearth
ground.

the

Cabinet

the the

Cabinet Cabinet

163A2496H

Installation

Connect

Connect Connect

AlwaysuseaGracowaterborne󰘱uidhosebetween
thevoltageisolationsystem󰘱uidoutletandthegun
󰘱uidinlet.Thewaterborne󰘱uidhose(101)consists
ofaninnerPTFEtube(T)andanabrasion-resistant
outerjacket(J).Shieldedhose24M732alsohas
aconductivelayer(C),Theconductivelayeris
connectedtogroundatthegun󰘰ttingbracket(104).

Beforeconnectingthewaterborne󰘱uidhosetothe
gun,blowitoutwithairand󰘱ushwithwaterto
removecontaminants.Flushthegunbeforeusingit.

Toreducetheriskofelectricshock,installonly
onecontinuousGracowaterbornehosebetween
theisolated󰘱uidsupplyandthegun.Donotsplice
hosestogether.

1.Removethegunairinlet󰘰tting(21).

NOTE:

NOTE: NOTE:
failureoccurswherehighvoltagearcsthrough
theinnertube,voltagewillbedischargedto
groundthroughtheconductivehoselayer.When
properlyinstalled,theconductivehoselayeris
groundedthroughitsconnectiontothegrounded
enclosure.

Usingunshielded󰘱uidhosesminimizesthe
systemcapacitance,resultinginfasterresponse
timesandalargereductionintheenergystored
inthesystem,ascomparedtoshieldedhoses.
However,withoutthegroundshield,aweak
staticchargecanoccasionallybuilduponthe
outersurfaceofthehose.Tominimizeany
staticchargefeltonthehosesurface,bundle
theairand󰘱uidhosetogether,andwrapwitha
protectivecover,asshown.

the

Waterborne

the the

Waterborne Waterborne

Inashieldedhosesystem,ifahose

Fluid

Fluid Fluid

Hose

Hose Hose

Figure10ConnecttheFluidHose

Figure11BundlingtheAirandFluidHoses

3A2496H

17

Installation

2.Forthe󰘱uidhoseto󰘰tproperly,itmustbe
strippedandassembledtothedimensionsshown
inFig.12.Applydielectricgreasetotheinner
tube(T)ofthehose.Slidethe󰘰tting(F)onto
thetube(T).Pressthebarbed󰘰tting(G)intothe
tubeuntilitsshoulderbottomsonthetube.A
newGracowaterborne󰘱uidhosecomesfully
assembledtothesedimensions.

NOTICE

NOTICE NOTICE

Becarefulnottocutintotheinnertube(T)of
thehosewhenstrippingthehose.Nicksor
cutsinthePTFEtubewillcausepremature
hosefailure.

Figure12ShieldedHose24M732Dimensions
atGun

4.Loosenthestrainreliefnut(102)sothebracket
canmovefreelyonthehose.

5.Alignthebracket(104)holeswiththeairinletand
exhaustoutlet.Securewiththeairinlet󰘰tting
(21).Tightenthestrainreliefnut(102)tosecure
thehose.

6.Checkthatthenut(105)istightenedsecurelyto
theferrulehousing(103).

7.Presstheexhausttube(36)ontotheexhaust
valvebarb(C).Securewiththeclamp(43).

8.Connecttheotherendofthehosetotheisolated
󰘱uidsupplyasfollows:

GracoWB100Enclosure:

a.

thestrainrelief󰘰tting(W).Ensureconductive
layer(C)haspassedthrough󰘰tting.Tighten
to55in-lb(6.2N•m).Pullbackonhoseto
checkitissecure.

For

Shielded

For For

Shielded Shielded

Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.

Hose

Hose Hose

Slidehosethrough

Systems:

Systems: Systems:

Figure13UnshieldedHose24M733Dimensions
atGun

3.Generouslyapplydielectricgrease(44)tothe
o-ring(107)andthethreadsofthe󰘰tting(106).
Pullthe󰘰ttingback1-1/2in.(38mm)andapply
greasetotheexposedPTFEhoseto󰘰llthearea
betweenthehoseandthe󰘰tting.Makesurethe
barrelinletiscleananddry,thenscrewthe󰘰tting
intothe󰘱uidinletofthegunbarrel(1).

Figure14ShieldedHose24M732
DimensionsatWB100Enclosure

183A2496H

Installation

Figure15ShieldedHose24M732
ConnectionatWB100Enclosure

Non-GracoIsolatedEnclosure:

b.

hoseasinstructedintheisolationsystem
manual.

For

Shielded

For For

Shielded Shielded

Conductivehoselayer(C)mustbe
groundedthroughitsconnectiontothe
isolationsystem’sgroundedenclosure(L)
orgroundedfence.Tomaintaingrounding
continuity,theconductivehoselayer(C)
mustbeengagedintheferrulewhenthe
strainreliefnutistightened.Failureto
properlyinstallthehoseinthestrainrelief
couldresultinanelectricshock.

Hose

Systems:

Hose Hose

Systems: Systems:

Connect

Figure16UnshieldedHose24M733
DimensionsatWB100Enclosure

Figure17UnshieldedHose24M733
ConnectionatWB100Enclosure

Figure18ShieldedFluidHoseConnection
atNon-GracoIsolationEnclosure

c.Connecttheendofthetube(T)tothepump

󰘱uidoutlet󰘰tting(Z).

NOTE:

NOTE: NOTE:
arevoidiftheelectrostaticspraygunis
connectedtoanon-Gracovoltageisolation
systemorifthegunisoperatedabove60kV.

TheGracowarrantyandapprovals

3A2496H19

Installation

Figure19TypicalInstallation,ProXpWB100
WaterborneSystem

203A2496H

Installation

Typical

Typical Typical

Installation

Installation Installation

Item

Item Item

A

B*Bleed-TypeAirShutoffValve

CPumpAirPressureGauge

DPumpAirPressureRegulator

EkVMeter

FPump

GPumpSuctionHose

H

J*

K*EnclosureSafetyInterlock

LIsolatedEnclosure

M

N

P*GracoRedGroundedAirHose(left-handthreads)

Q*GunAirHoseGroundWire

Key

Key Key

Description

Description Description

MainAirSupplyLine

PaintContainer

BleedResistor

GunAirLineFilter

GunAirPressureRegulator

R

SWaterborneElectrostaticAirSprayGun

T

U

V*MainGroundWire

W

X

Y

Z

AA

BB

CCAccessoryBleed-TypeAirShutoffValve

*Theseitemsarerequiredforsafeoperation.TheyareincludedwiththeWB100system.

GracoWaterborneFluidHose

GroundingRod

GroundTerminal

StrainReliefFitting

PumpAirSupplyLine

GroundingCylinder

PumpFluidOutletFitting

IsolatedEnclosureDoor(notshown,toillustrateinternalcomponents.Doormustbeclosed
andlockedtooperatesystem).

EnclosureT-HandleLockingScrew(partofdoorassembly)

3A2496H

21

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.

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

VoltageIsolationSystem:

voltageisolationsystemtoatrueearthground.
SeeGroundtheCabinet,page16.

•

ElectrostaticAirSprayGun:

byconnectingthered-coloredGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page38.

•

GracoShieldedWaterborneFluidHose
(24M732):

conductivelayer.Installasinstructedunder

ConnecttheWaterborneFluidHose,page17.

•

Allelectricallyconductiveobjectsordevicesinthe
sprayarea:

•

Fluidandwastecontainers:

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

Aircompressors:

•
tothemanufacturer'srecommendations.

•

Allairlines

groundedhoseswithamaximumof100feet(30.5
m)combinedhoselengthtoensuregrounding
continuity.

Thehoseisgroundedthroughthe

mustbeproperlygrounded.

Groundtheequipmentaccording

mustbeproperlygrounded.Useonly

Electricallyconnectthe

Groundthegun

Groundall󰘱uidand

22

3A2496H

•

The󰘱oorofthesprayarea:

conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity.

mustbeelectrically

•

Allsolventpails:

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

Useonlyapproved,grounded

Installation

3A2496H23

Installation

Agitator

Agitator Agitator

ToaddanagitatortotheGracoisolationsystem,order
PartNo.245895.See245895AgitatorKit,page108,
forthekitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

DischargeandGroundingProcedure,page39).

2.Relievethepressure(see

PressureReliefProcedure,page39).

3.Opentheisolatedenclosuredoor.

4.Removethebackofthecontrolbox(258).

5.Removetube(A2)fromelbow(282)attheair
manifold;seeTubingandWiring,page84.
InstalltheY󰘰tting(402)intotheelbow.Install
tubes(A2)and(407)intotheY󰘰tting.Routethe
agitatortube(407)intothecabinet.

6.Replacethebackofthecontrolbox(258).

7.Assembletheotherpartsofthekitasshown.
Securetheagitatorwiththesetscrew(408).

8.Returnthesystemtoservice.

Kit

Accessory

Kit Kit

Accessory Accessory

Figure20245895AgitatorKit

24

3A2496H

Installation

Fluid

Fluid Fluid

Toadda󰘱uidregulatortotheGracoisolation
system,orderPartNo.245944.See

245944FluidRegulatorKit,page108forthe

kitpartslist.

1.Dischargethesystemvoltage(seeFluidVoltage

2.Relievethepressure(see

3.Opentheisolatedenclosuredoor.

4.Removethe1/4in.(6mm)ODtube(A1)fromthe

5.Removethewaterborne󰘱uidhosefromthepump

6.Unscrewthetwopumpmountingscrews(S)and

7.Removethebackofthecontrolbox(258).

8.Removetube(A2)fromelbow(282)attheair

9.Replacethebackofthecontrolbox(258).

10.Assemblethe󰘱uidregulatorkitasshown.

11.Reinstallthepumpintheisolationenclosure.

Regulator

Regulator Regulator

DischargeandGroundingProcedure,page39).

PressureReliefProcedure,page39).

pumpairinlet;seeTubingandWiring,page84.

󰘱uidoutlet󰘰tting(231)andremovethe󰘰tting.

removethepumpfromtheisolationenclosure.

manifold;seeTubingandWiring,page84.
InstalltheY󰘰tting(506)intheelbow.Install
tubes(A2)and(507)intotheY󰘰tting.Routethe
tube(507)intothecabinet.

Usethetwomountingholestotheleftofthe
holesusedpreviously,toallowclearanceforthe
󰘱uidregulator.

Kit

Accessory

Kit Kit

Accessory Accessory

12.Connecttube(A1)totheairinletof󰘱uidregulator
(504).Connecttube(507)tothepumpairinlet.

13.Connectthewaterborne󰘱uidhosetothe󰘱uid
regulatoroutlet󰘰tting(501).

14.Returnthesystemtoservice.

NOTE:

NOTE: NOTE:

217)willnowoperatetheairpiloted󰘱uidregulator

(504).Thepumpwillnowoperateattheinletair
pressure.

Figure21245944FluidRegulatorKit

Thecabinetairregulatorandgauge(216,

3A2496H25

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Toreducetheriskof󰘰reandexplosion,󰘱uidsused
mustmeetthefollowing󰘱ammabilityrequirements:

•FM, FM,

•CE CE

Contactwiththechargedcomponentsofthespray
gunwillcauseanelectricshock.Donottouchthe
gunnozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperationor
untilperformingtheFluidVoltageDischargeand

GroundingProcedure,page39.

FollowtheFluidVoltageDischargeandGrounding

Procedure,page39whenyoustopsprayingand

wheneveryouareinstructedtodischargethe
voltage.

Setup

Setup Setup

Setup

Setup Setup

FM,

FMc

FMc FMc
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

CE

EN

- --EN EN
Materialswhichcannotbeignited,inanymixture
withair,byanenergysourceoflessthan500mJ.

Procedure

Procedure Procedure

Approved:

Approved: Approved:

50059

50059 50059

Compliant:

Compliant: Compliant:

Foradditionalstepstosetupspecialtyguns,
seeSoftSprayGunSetupProcedure,page30,

RoundSprayGunSetupProcedure,page33,
HVLPGunSetupProcedure,page31,
AbrasiveMaterialGunSetupProcedure,page35,

andMoldReleaseGunSetupProcedure,page36.

Seethe󰘰gurebelowtolocatetheelectrostaticgun
controls.

Figure22ElectrostaticGunControls

1.Thegunisshippedwiththe󰘱uidnozzleandair
capinstalled.Checkthattheretainingringis
tight.

NOTE:

NOTE: NOTE:
size󰘱uidnozzleoraircap,see

FluidNozzleSelectionChart,page93and
AirCapSelectionGuide,page96.

Toinstallthenozzleandaircap,see

AirCapandNozzleReplacement,page59.

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

Toselectadifferent

Toreducetheriskofcomponentrupture,which
cancauseseriousinjury,donotexceedthe
maximumworkingpressureofthelowestrated
systemcomponent.Thisequipmenthasa100psi
(0.7MPa,7bar)maximumworkingairand󰘱uid
pressure.

3.Shutofftheairbleedvalvetothegun.

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39wheneveryou

areinstructedtorelievethepressure.

4.Checkgunresistance.Followthestepsin

TestGunResistance,page47.

263A2496H

GunSetup

5.Connectthewaterbornehose.Followthesteps
inConnecttheWaterborneFluidHose,page17.

6.ConnecttheredGracogroundedairhosetothe
gunairinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.SeeAirSupplyLine,page16.

7.FollowallstepsinGrounding,page22.

8.Followallstepsin

CheckGunElectricalGrounding,page38.

Readingmustbelessthan100ohms.

9.Connecttheexhausttubeandsecurewiththe
clampprovided.

10.Flushifneeded.SeeFlushing,page42.

11.Positiontheaircapasneeded.

13.Fullyopenthe󰘱uidadjustmentvalve(H)
counterclockwise.

14.Fullyopentheatomizingairrestrictorvalve(G)
clockwise.

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

12.Fullyopenthefanairadjustmentvalve(F)
counterclockwise.

3A2496H

WhentheESOn-OffswitchisturnedON(I),
the󰘱uidsupplyischargedwithhighvoltage
untilthevoltageisdischarged.Contactwith
thechargedcomponentsofthespraygunwill
causeanelectricshock.Donottouchthegun
nozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperation.

27

GunSetup

16.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

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

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

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

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

Table

Table Table

Indicator

Indicator Indicator

Amber

LED

3 33. ..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

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

283A2496H

GunSetup

21.Sprayatestpattern.Checktheatomization.

•Ifover-atomizationoccursatminimum
pressure,adjusttheatomizingairrestrictor
valve.

•Ifatomizationisinadequate,increaseair
pressureordecrease󰘱uid󰘱ow.

22.Adjustthefanairadjustmentvalve.

•Fullyopenthefanairadjustmentvalve,
counterclockwise,forthelongestpattern.

•Turnthevalveclockwisetorestrictthefanair
andcreateashorterpattern.

WhentheESOn-OffswitchisturnedON(I),
the󰘱uidsupplyischargedwithhighvoltage
untilthevoltageisdischarged.Contactwith
thechargedcomponentsofthespraygunwill
causeanelectricshock.Donottouchthegun
nozzleorelectrodeorcomewithin4in.(102
mm)ofthefrontofthegunduringoperation.

23.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page51.

3A2496H29

GunSetup

Soft

Spray

Soft Soft

Spray Spray

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

Toconvertaguntoachieveasoftspraypatternfor
smallorlightweightparts,dothefollowing:

1.Installasoftsprayaircap.See

AirCapSelectionGuide,page96.

2.Forbestresults,installa1.0mm
or1.2mm󰘱uidnozzle.See

FluidNozzleSelectionChart,page93.

3.Followsteps1–13inthe

GunSetupProcedure,page26.

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

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

Table

Table Table

using

using using

mm)

mm) mm)

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

Table

Table Table

Indicator

Indicator Indicator

Amber

Pressure

4 44. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

Color

Color Color

Green

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.

Colors

Colors Colors

Description

Description Description

Air

Regulator

Air Air

Regulator Regulator

psi

(MPa,

in ininpsi psi

(MPa, (MPa,

with

gun

with with

triggered

gun gun

triggered triggered

Setting

Setting Setting

bar)

bar) bar)

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

Red

8.Continuewithsteps18–23inthe

GunSetupProcedure,page26.

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.

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

Thesoftsprayaircapisoptimizedfora

Iftheobjectbeingsprayedismovingtoo

303A2496H

GunSetup

HVLP

HVLP HVLP

TosprayHVLP,airpressureattheaircapmustbe
10PSI(0.07MPa,0.7bar)orless.Tosetupan
HVLPgun,dothefollowing:

1.InstallanHVLPaircap.See

2.Followsteps1–11inthe

3.Fullyopenthe󰘱uidadjustmentvalve(H)

4.Adjusttheairintheaircap.

Gun

Gun Gun

AirCapSelectionGuide,page96.

GunSetupProcedure,page26.

counterclockwise.

a.Fullyclosethefanairadjustmentvalve(F)

clockwise,thenopenitcounterclockwisetwo
turns.

b.Fullyclosetheatomizingairrestrictorvalve

(G)counterclockwise,thenopenitclockwise
oneturn.

Setup

Setup Setup

Procedure

Procedure Procedure

Table

Table Table

using

using using

mm)

mm) mm)

NOTE:

NOTE: NOTE:
volumeofairtoatomizepaintatlow
pressure.Gunairregulatorstaticpressure
settingsof70PSIorhigheraretypically
required.Toachievetherequiredgunair
pressures,useashorterlengthairhoseora
largerdiameterairhose.SeeGroundedAir
HosesinHoses,page107.

e.VerifythattheESindicator(K)[Hzindicator

onSmartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Pressure

6 66. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

Color

Color Color

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)

TheHVLPaircaprequiresahigh

LED

7 77. ..LED LED

Drop

Drop Drop

(m)

inch

(8

inch inch

(8 (8

hose

hose hose

Indicator

Indicator Indicator

Colors

Colors Colors

Description

Description Description

Air

Regulator

Air Air

Regulator Regulator

Setting

Setting Setting

(MPa,

(MPa, (MPa,

with

gun

with with

gun gun

psi

in ininpsi psi

bar)

bar) bar)

triggered

triggered triggered

Green

Amber

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

Red

d.Setthegunairregulatortodeliveraminimum

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

Whenspraying,theindicator
shouldremaingreen,indicating
suf󰘰cientairpressuretothe
alternatorturbine.

Iftheindicatorchangesto
amberafteronesecond,theair
pressureistoolow.Increase
airpressureuntiltheindicator
isgreen.

Iftheindicatorchangesto
redafteronesecond,theair
pressureistoohigh.Decrease
airpressureuntiltheindicator
isgreen.Tomaintainahigher
applicationairpressure,install
ESOn/OffValveRestrictorKit
26A160.Adjustthepressure
asneededtoensurethe
indicatorremainsgreen.

3A2496H31

GunSetup

f.VerifythattheaircappressuresmeetHVLP

requirementsof10PSI(0.07MPa,0.7
bar)orlessusingtheHVLPveri󰘰cationkit
25E919.Seemanual3A6833.Adjustthe
fanairadjustmentvalve(F)andatomizing
airrestrictorvalvetoachieve10PSIorless
asneeded.

g.VerifythattheESindicator(K)[Hzindicator

onSmartguns]remainsgreen.

5.Continuewithsteps18–23inthe

GunSetupProcedure,page26.

323A2496H

GunSetup

Round

Round Round

Toachievearoundspraypattern,dothefollowing:

1.Installaroundspraykit.SeeRoundSpray

2.Followsteps1–11inthe

3.Fullyopenthe󰘱uidadjustmentvalve(H)

4.Adjusttheairintheaircap.

Spray

Spray Spray

AccessoriesinGunAccessories,page105.To
achieveasoftpatternforsmallpartsorincreased
transferef󰘰ciency,selectthemediumpatternor
smallpatternmodels.

GunSetupProcedure,page26.

counterclockwise.

a.Fullyclosetheatomizingairrestrictorvalve

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

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

6.Setthegunairregulatortodeliveraminimum

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

Table

Table Table

using

using using

mm)

mm) mm)

Pressure

8 88. ..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)

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

b.Fullyclosethefanairadjustmentvalve(F)

clockwise.

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

50(15.3)80(0.56,5.6)

7.VerifythattheESindicator(K)[Hzindicatoron

Smartguns]islit.

Table

Table Table

Indicator

Indicator Indicator

Amber

LED

9 99. ..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

3A2496H33

GunSetup

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

9.Startthepump.Adjustthe󰘱uidregulatorto
achievetheproductionratethatyouwant.

NOTE:

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

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

Theroundsprayaircapisoptimizedfor

11.Sprayatestpattern.Checktheatomization.

NOTE:

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

12.Adjustthepatternsize.

•Forthelargestspraypattern,fullyclosethefan

•Forthesmallestspraypattern,fullyopenthe

13.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page51.

Iftheatomizationistoo󰘰ne,orifthe

airadjustmentvalve(F)clockwise.

fanairadjustmentvalve(F)counterclockwise.

343A2496H

GunSetup

Abrasive

Abrasive Abrasive

NOTE:

NOTE: NOTE:
taskseachday:

•Cleanthegun.SeeCleantheGunDaily,page44.

•Inspecttheelectrodeandreplaceifdamaged.See

ElectrodeReplacement,page61.

Toextendwearlifewithabrasive,metallic,and
extremelyabrasivematerials,dothefollowing:

1.Toconvertagunforabrasivematerials:

•Selectaprecisionhighwear
orhighwearnozzle.See

FluidNozzleSelectionChart,page93.

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

•Use24N632ESOn-OffandFixedFluidValve.

2.Followsteps1–18inthe

GunSetupProcedure,page26.

3.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

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

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

NOTE:

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

Operatethegunwiththe󰘱uidadjustment

NOTE:

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

6.Adjustthefanairadjustmentvalve.

•Fullyopenthefanairadjustmentvalve,

•Turnthevalveclockwisetorestrictthefanair

NOTE:

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

7.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page51.

Usetheminimumatomizingairpressure

counterclockwise,forthelongestpattern.

andcreateashorterpattern.

Usetheminimumfanairpressureto

3A2496H35

GunSetup

Mold

Mold Mold

Tosetupamoldreleasegun,dothefollowing:

1.ModelL60M19MoldReleaseGunissupplied

2.Followsteps2–10inthe

3.The󰘱uidoutputandpatternwidthdependonthe

4.Alignthespraytiptabwiththegrooveintheair

Release

Release Release

withPartNo.24N748Nozzle,24N727AirCap,
andaspraytipofchoice.Ifyourequireadifferent
sizespraytip,seeSprayTipSelectionChart

(ModelL60M19MRGGunOnly),page102,or

consultwithyourGracodistributor.Toinstall
thetip,seeAirCap,SprayTip,andNozzle

Replacement(ModelL60M19),page60.

GunSetupProcedure,page26.

sizeofthespraytip,the󰘱uidviscosity,andthe
󰘱uidpressure.UsetheSprayTipSelectionChart

(ModelL60M19MRGGunOnly),page102,asa

guideforselectingtheappropriatespraytipfor
yourapplication.

cap.Installthetip.

Gun

Gun Gun

Setup

Setup Setup

Procedure

Procedure Procedure

9.Sprayatestpattern.Examinetheparticlesizein
thecenterofthepattern(tailswillberemoved
instep21).Increasethepressureinsmall
increments.Sprayanotherpattern.Compare
particlesize.Continueincreasingpressureuntil
theparticlesizeremainsconstant.Donotexceed
3000psi(21MPa,210bar).

10.TurnON(I)theESOn-Offswitch.

5.Installtheaircapandretainingring.Orientate
theaircapandtightentheretainingringsecurely.

6.Closetheatomizingairadjustmentvalve(G)and
thefanairadjustmentvalve(F).

7.CheckthattheESOn-OffswitchisOFF(O).

8.Startthepump.Setthe󰘱uidregulatorto400psi
(2.8MPa,28bar).

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

Table

10

LED

Table Table

10 10

Indicator

Indicator Indicator

Color

Color Color

Green

Amber

Red

Indicator

. ..LED LED

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
RestrictorKit26A294.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

363A2496H

GunSetup

12.Setthegunairregulatortodeliveraminimum
of45psi(0.32MPa,3.2bar)atthegunwhen
triggered,toensurefullsprayingvoltage.See
thetablebelow.

Table

11

Table Table

Length

Length Length

(using

(using (using

mm]

mm] mm]

13.Turntheatomizingairadjustmentvalve
counterclockwiseuntilanytailsdisappear.

Pressure

11 11

. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)52(0.36,3.6)

25(7.6)57(0.40,4.0)

50(15.3)68(0.47,4.7)

75(22.9)80(0.56,5.6)

100(30.5)90(0.63,6.3)

Drop

Drop Drop

Air

Air Air

(m)

in.

[8

in. in.

[8 [8

hose)

hose) hose)

in ininpsi psi

[with

[with [with

14.Ifdesiredatomizationisnotachieved,change
thetipsize.Thesmallerthetipori󰘰ce,the󰘰ner
theatomization.

15.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page51.

Regulator

Regulator Regulator

psi

gun

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered]

triggered] triggered]

NOTE:

NOTE: NOTE:
openthefanairadjustmentvalveslightly.(Excessive
fanair󰘱owcancausepaintbuildupontheaircap.)

Ifanarrowerpatternisneededoccasionally,

3A2496H37

GunSetup

Check

Check Check

MegohmmeterPartNo.241079(AA-seeFig.

21)isnotapprovedforuseinahazardousarea.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous

•Orallsprayingdevicesinthehazardousarea

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.241079Megohmmeterisavailable
asanaccessorytocheckthatthegunisproperly
grounded.

1.Haveaquali󰘰edelectricianchecktheelectrical

2.TurnOFF(O)theESOn-Offswitch.

Gun

Gun Gun

area;

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

groundingcontinuityofthespraygunandair
hose.

Electrical

Electrical Electrical

Grounding

Grounding Grounding

7.Iftheresistanceisgreaterthan100ohms,check
thetightnessofthegroundconnectionsandbe
suretheairhosegroundwireisconnectedtoa
trueearthground.Iftheresistanceisstilltoo
high,replacetheairhose.

Figure23CheckGunElectricalGrounding

8.Usinganohmmeter(AA)measuretheresistance
betweenthecabinetgroundlug(214)andatrue
earthground(CC).Theresistancemustbeless
than100ohms.

3.Turnofftheairand󰘱uidsupplytothegun.Follow
thePressureReliefProcedure,page39.The
󰘱uidhosemustnothaveany󰘱uidinit.

4.Disconnectthe󰘱uidhose.

5.Makesurethered-coloredgroundedairhose
(AH)isconnectedandthehosegroundwireis
connectedtoatrueearthground.

6.Measuretheresistancebetweenthegunhandle
(BB)andatrueearthground(CC).Usean
appliedvoltageof500minimumto1000volts
maximum.Theresistanceshouldnotexceed
100ohms.SeeFig.22.

383A2496H

Figure24CheckCabinetGrounding

Flush

Flush Flush

Theequipmentwastestedin󰘱uidatthefactory.To
avoidcontaminatingyour󰘱uid,󰘱ushtheequipment
withacompatiblesolventbeforeusingtheequipment.
SeeFlushing,page42.

Before

Before Before

Using

Using Using

Equipment

Equipment Equipment

Operation

Operation

Operation Operation

Pressure

Pressure Pressure

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

1.TurnOFF(O)theESOn/Offswitch.

2.FollowtheFluidVoltageDischargeand

GroundingProcedure,page39.

3.Turnofftheairbleedvalvestothe󰘱uidsource

andtothegun.

Relief

Relief Relief

Procedure

Procedure Procedure

Fluid

Fluid Fluid
Grounding

Grounding Grounding

The󰘱uidsupplyischargedwithhighvoltageuntil
thevoltageisdischarged.Contactwiththecharged
componentsofthevoltageisolationsystemor
spraygunelectrodewillcauseanelectricshock.
Toavoidanelectricshock,followtheFluid Fluid

Discharge

Discharge Discharge

•wheneveryouareinstructedtodischargethe

•beforecleaning,󰘱ushing,orservicingthesystem

•beforeapproachingthefrontofthegun

•orbeforeopeningtheisolationenclosureforthe

1.TurntheESON/OFFvalveOFFandwait30

voltage

equipment

isolated󰘱uidsupply.

seconds.

Voltage

Voltage Voltage

and

and and

Discharge

Discharge Discharge

Procedure

Procedure Procedure

Grounding

Grounding Grounding

Procedure:

Procedure: Procedure:

and

and and

Fluid

Voltage

Voltage Voltage

4.Triggerthegunintoagroundedmetalwaste

containertorelievethe󰘱uidpressure.

5.Relieve󰘱uidpressureinthe󰘱uidsupplyunitas

instructedinyour󰘱uidsupplyunitmanual.

3A2496H39

2.FullyunscrewthedoorT-handlelockingscrew.
Thiswillshutofftheairtothegunandtriggerthe
groundingcylindertodischargeanyremaining
electricalcharge.

3.Usethegroundingrodtotouchthepump
andsupplypail.Ifyouseeanyarcs,see

ElectricalTroubleshooting,page56.

Operation

Fill

the

Fill Fill

Fluid

the the

Fluid Fluid

Supply

Supply Supply

Startup

Startup Startup

1.FollowtheFluidVoltageDischargeand

GroundingProcedure,page39.

2.FollowthePressureReliefProcedure,page39.

3.Opentheisolatedenclosuredoor.

4.Removethepailcoverfromthepail,holdingarag
overthesuctiontubestrainertopreventany󰘱uid
fromdrippingintotheisolatedenclosure.Place
thecoverandsuctiontubeoutsidetheenclosure.

5.Removethesupplypailfromtheenclosure.

NOTICE

NOTICE NOTICE

Besuretowipeupall󰘱uidspillsintheisolated
enclosure.Fluidcancreateaconductivepath
andcausethesystemtoshortout.

6.Cleanupany󰘱uidspillsintheenclosure,using
asoftclothandanon-󰘱ammable,compatible
solvent.

7.Fillthesupplypailwith󰘱uidandreturnittothe
enclosure.Cleanupanyspills.

8.Reinstallthepailcover,holdingaragoverthe
suctiontubestrainertoprevent󰘱uidspillswhile
youplacethepumpsuctiontubeinthepail.

9.Closetheisolatedenclosuredoorandfasten
securelywiththeT-handlelockingscrew.

FollowallstepsunderGunSetupProcedure,page26.

Beforeoperatingthesystem,checkthefollowinglist
dailytoensuresafe,ef󰘰cientoperation.



Alloperatorsareproperlytrainedtosafely
operateanelectrostaticwaterborneairspray
systemasinstructedinthismanual.



Alloperatorsaretrainedinthe

PressureReliefProcedure,page39.



Theelectrostaticsareturnedoffandsystem
voltageisdischargedaccordingtothe

FluidVoltageDischargeandGrounding
Procedure,page39,beforeanypersonen-

terstheisolationenclosure,beforecleaning,
andbeforeperforminganymaintenanceor
repair.



Thewarningsignprovidedwiththegunis
mountedinthesprayareawhereitcanbe
easilyseenandreadbyalloperators.



Thesystemisthoroughlygroundedand
theoperatorandallpersonsenteringthe
sprayareaareproperlygrounded.See

Grounding,page22.



TheGracowaterborne󰘱uidhoseisingood
conditionwithnocutsorabrasionsofthe
PTFElayer.Replacehoseifdamaged.



Theconditionofthegun’selectrical
componentshasbeencheckedasinstructed
inElectricalTests,page47.



Ventilationfansareoperatingproperly.



Workpiecehangersarecleanandgrounded.



Alldebris(including󰘱ammable󰘱uidsand
rags)isremovedfromthesprayarea.



All󰘱ammable󰘱uidsinthespraybootharein
approved,groundedcontainers.



Allconductiveobjectsinthesprayareaare
electricallygroundedandthe󰘱oorofthe
sprayareaiselectricallyconductiveand
grounded.



Fluidsusedmustmeetthefollowing
󰘱ammabilityrequirements:

FM,

FMc

•FM, FM,
Materialdoesnotsustainburningin
accordancewiththeStandardTestMethod
forSustainedBurningofLiquidMixtures,
ASTMD4206.

CE

•CE CE
Materialswhichcannotbeignited,inany
mixturewithair,byanenergysourceof
lessthan500mJ.

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

Compliant:

Compliant: Compliant:

403A2496H

Operation

Shutdown

Shutdown Shutdown

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39wheneveryou

areinstructedtorelievethepressure.

1.Dischargethesystemvoltage,seeFluidVoltage

DischargeandGroundingProcedure,page39.

2.Flushthegun,seeFlushing,page42

3.FollowthePressureReliefProcedure,page39.

4.Hangthegunfromitshook,withthenozzle
pointingdown.Besuretokeepthegunfrom
groundingout.

3A2496H

41

Maintenance

Maintenance

Maintenance Maintenance

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39,whenever

youareinstructedtorelievethepressure.

Flushing

Flushing Flushing

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

•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.

Daily

Daily Daily

Checkthefollowinglistdailyuponcompletionof
equipmentusage.

Care

Care Care



Flushthegun.SeeFlushing,page42.



Cleanthe󰘱uidandairline󰘰lters.



Cleantheoutsideofthegun.See

CleantheGunDaily,page44.



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

CleantheGunDaily,page44.



Checktheelectrodeandreplace
ifbrokenordamaged.See

ElectrodeReplacement,page61.



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



Checkelectricalgrounding.See

CheckGunElectricalGrounding,page38.

and

Cleaning

and and

Cleaning Cleaning

Checklist

Checklist Checklist

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

FollowtheFluidVoltageDischargeandGrounding

Procedure,page39,before󰘱ushing.

Only󰘱ush,purge,orcleanthegunwith󰘱uidsthat
meetthefollowing󰘱ammabilityrequirements:

FM,

FMc

•FM, FM,
Materialdoesnotsustainburninginaccordance
withtheStandardTestMethodforSustained
BurningofLiquidMixtures,ASTMD4206.

CE

•CE CE
Materialswhichcannotbeignited,inanymixture
withair,byanenergysourceoflessthan500mJ.

Donotusemethylenechlorideasa󰘱ushingor
cleaningsolventwiththisgunasitwilldamage
nyloncomponents.

1.TurnOFF(O)theESOn-Offswitch.Wait30
secondsforthevoltagetobleedoff.

Approved:

FMc FMc

Approved: Approved:

EN

50059

- --EN EN

50059 50059

Compliant:

Compliant: Compliant:

NOTICE

NOTICE NOTICE

2.Dischargethesystemvoltage.SeeFluidVoltage

DischargeandGroundingProcedure,page39.

3.FollowthePressureReliefProcedure,page39.

42

3A2496H

Maintenance

4.Changethe󰘱uidsourcetosolvent.

NOTE:

NOTE: NOTE:
removethespraytipbefore󰘱ushing.See

AirCap,SprayTip,andNozzleReplacement
(ModelL60M19),page60.

5.Pointthegunintoagroundedmetalpail.Flush
untilcleansolvent󰘱owsfromthegun.

6.FollowthePressureReliefProcedure,page39.

ForModelL60M19MoldReleaseGun,

7.Opentheisolatedenclosuredoor.Leavethe
󰘱ushing󰘱uidinthesystemuntilyouareready
tosprayagain.

8.Hangthegunfromitshook,withthenozzle
pointingdown.Besuretokeepthegunfrom
groundingout.

9.Beforeusingthesystemelectrostaticallyagain,
makesureno󰘱ammablevaporsarepresent.

3A2496H43

Maintenance

Clean

Clean Clean

•Cleanallpartswithacompatiblesolvent.

•Fluidintheairpassagescouldcausethegunto

1.TurnOFF(O)theESOn-Offswitch.

2.Flushthegun.SeeFlushing,page42.

3.FollowthePressureReliefProcedure,page39.

the

Gun

the the

Gun Gun

Conductivesolventscancausethegunto
malfunction.

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

Daily

Daily Daily

NOTICE

NOTICE NOTICE

4.Cleantheoutsideofthegunwithanon-󰘱ammable
solvent,asde󰘰nedunderFlushing,page42.
Useasoftcloth.Pointthegundowntoprevent
solventfromenteringthegunpassages.Donot
immersethegun.

44

3A2496H

Maintenance

5.Removetheaircap.

6.Cleantheaircap,retainingring,andnozzlewith
asoftbrushandnon-󰘱ammablesolvent.

7.Ifnecessary,useatoothpickorothersofttoolto
cleantheaircapholes.Donotusemetaltools.

8.Reinstalltheaircap.Tightensecurely.

3A2496H45

Maintenance

Daily

Daily Daily

1.FollowthePressureReliefProcedure,page39.

2.Cleanthe󰘱uidandair󰘰lters.

3.Checkfor󰘱uidleaks.Tightenall󰘰ttings.

4.Cleanworkpiecehangers.Usenon-sparking

5.Checkthemovementofthetriggerandvalves.

6.CheckGunElectricalGrounding,page38.

7.Hangthegunfromitshook,withthenozzle

System

System System

tools.

Lubricateifnecessary.

pointingdown.Besuretokeepthegunfrom
groundingout.

Care

Care Care

8.Cleanthecabinet:

•Inspectthecabinetandcleanupanyspilled

paint.Conductivepaintresidueallowedto
contactgroundedpartsmayshortoutthe
electrostatics.

•Keeptheinsideofthecabinetclean,forproper

operation.

•InspectthedoorT-handlelockingscrew

regularly,toensurethethreadsarewell
greased.Applysilicone-freegreasetothe
threadswhennecessary.

•Visuallyinspectthegroundstrip(240)

fordamage.Replaceifneeded.
Measuretheresistanceweekly.See

TestGroundStripResistance,page50.

463A2496H

ElectricalTests

Electrical

Electrical Electrical

Electricalcomponentsinsidethegunaffect
performanceandsafety.Usethefollowing
procedurestotesttheconditionofthepowersupply
andgunbody,andelectricalcontinuitybetween
components.

PowerSupplyRemovalandReplacement,page66.

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

MegohmmeterPartNo.241079(AA-seeFig.

25)isnotapprovedforuseinahazardousarea.
Toreducetheriskofsparking,donotusethe
megohmmetertocheckelectricalgrounding
unless:

•Thegunhasbeenremovedfromthehazardous
area;

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

Tests

Tests Tests

Test

Test Test

1.Followthestepsunder

2.Triggerthegunandmeasureresistance

Gun

Gun Gun

PreparetheGunforService,page58.

betweentheelectrodeneedletip(3)andthe
airswivel(21).Theresistanceshouldbe
104–150megohms(90–120megohmsfor
ModelL60M19).Ifoutsidethisrange,goto

TestPowerSupplyResistance,page48.

Ifinrange,see

VoltageLossTroubleshooting,page51forother

possiblecausesofpoorperformance,orcontact
yourGracodistributor.

Resistance

Resistance Resistance

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

Figure25TestGunResistance

3A2496H

47

ElectricalTests

Test

Test Test

1.Followthestepsunder

2.Removethepowersupply(11).

3.Removetheturbinealternator(15)fromthe

4.Measureresistancefromthepowersupply's

5.Besurethespring(11a)isinplacebefore

Power

Power Power

PreparetheGunforService,page58.

powersupply.

groundstrips(EE)tothespring(11a).The
resistanceshouldbe90–115megohms.If
outsidethisrange,replacethepowersupply.Ifin
range,gotoTestElectrodeResistance,page49.

reinstallingthepowersupply.

Supply

Supply Supply

Resistance

Resistance Resistance

Figure26TestPowerSupplyResistance

483A2496H

ElectricalTests

Test

Test Test

1.Followthestepsunder

2.Insertaconductiverod(FF)intothegunbarrel

3.Measuretheresistancebetweentheconductive

4.Ifinrange,goto

5.Removetheelectrode(3),see

6.Makesurethemetalcontactring(DD)in

Electrode

Electrode Electrode

PreparetheGunforService,page58.

(whichwasremovedforthepowersupplytest)
andagainstthemetalcontact(DD)inthefront
ofthebarrel.

rod(FF)andtheelectrode(3).Theresistance
shouldbe10–30megohms(lessthan5megohms
forModelL60M19).

ElectricalTroubleshooting,page56,forother

possiblecausesofpoorperformance,orcontact
yourGracodistributor.

ElectrodeReplacement,page61.Measurethe

resistancebetweenthecontact(HH)andthe
electrodewire(GG).Theresistanceshouldbe
10-30megohms.Ifoutofrange,replacethe
electrode.

thebarrel,thenozzlecontactring(4a),and
theelectrodecontact(HH)arecleanand
undamaged.

Resistance

Resistance Resistance

Figure27TestElectrodeResistance

Figure28Electrode

Figure29NozzleConductiveO-Ring

3A2496H49

ElectricalTests

Test

Test Test

Usinganohmmeter,measuretheresistancebetween
thelatchhousing(206)andthegroundlug(214).
Thegroundstripisgroundedthroughthecartback
tothegroundlug.Resistancemustbelessthan100
ohms.Ifgreaterthan100ohms,replacetheground
strip(240).

Ground

Ground Ground

Strip

Strip Strip

Resistance

Resistance Resistance

Test

Test Test

Removetheenclosuredoor.Usinganohmmeter,
measuretheresistancefromthepump(209)tothe
groundlug(214).Resistancemustbelessthan
100ohms.Ifgreaterthan100ohms,replacethe
groundingcylinder(227).

Cylinder

Cylinder Cylinder

Resistance

Resistance Resistance

Figure30TestGroundStripResistance

Figure31TestCylinderResistance

503A2496H

Troubleshooting

Troubleshooting Troubleshooting

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseanelectricshock
orotherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorrepairthisequipment
unlessyouaretrainedandquali󰘰ed.

Troubleshooting

areelectricallyconnectedthroughtheconductive,
waterborne󰘱uid.

Beforetroubleshootingorservicingthevoltage
isolationsystemitself,youneedtodeterminewhich
componentinthesystemismostlikelycausinga
problem.Possiblecausesincludethefollowing:

Spray

Spray Spray

Gun

Gun Gun

FollowtheFluidVoltageDischargeandGrounding

Procedure,page39beforecheckingorservicing

thesystemandwheneveryouareinstructedto
dischargethevoltage.

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39,whenever

youareinstructedtorelievethepressure.

CheckallpossibleremediesintheTroubleshooting
Chartbeforedisassemblingthegun.

Voltage

Voltage Voltage

Normalsprayingvoltageforasystemusingthe
waterbornegunis45-55kV.Thesystemvoltageis
lowerduetosprayingcurrentdemandsandvoltage
isolationsystemlosses.

Alossofsprayingvoltagecanbecausedbya
problemwiththespraygun,󰘱uidhose,orvoltage
isolationsystem,sinceallofthesystemcomponents

Loss

Loss Loss

Troubleshooting

Troubleshooting Troubleshooting

•Fluidleakage

•Dielectricbreakdownatthe󰘱uidhoseconnection
or󰘱uidpackings

•Notenoughairpressureforthealternatorturbine

•Faultypowersupply

•Excessiveoversprayongunsurfaces

•Fluidintheairpassages

Waterborne

Waterborne Waterborne

•Dielectricfailureofthehose(pin-holeleakinthe
PTFElayer)

•Airgapinthe󰘱uidcolumnbetweenthegunandthe
isolated󰘱uidsupply,causingalowvoltagereading
ontheisolationsystemvoltagemeter.

Voltage

Voltage Voltage

•Fluidleakage

•Dirtyinterior

Fluid

Fluid Fluid

Isolation

Isolation Isolation

Hose

Hose Hose

System

System System

3A2496H51

Troubleshooting

Visual

Visual Visual

First,checkthesystemforanyvisiblefaultsorerrors
tohelpisolatewhetherthespraygun,󰘱uidhoseor
voltageisolationsystemhasfailed.Avoltageprobe
andmeter,partno.245277,ishelpfulfordiagnosing
voltageproblemsandisrequiredforsomeofthe
troubleshootingteststhatfollow.

1.Checkthatalloftheairand󰘱uidtubesandhoses

2.Checkthatthevoltageisolationsystemvalves

3.Checkthattheinterioroftheisolatedenclosure

4.Checkthatthespraygunandvoltageisolation

5.CheckthatthegunESON/OFFvalveisinthe

6.Checkthatthevoltageisolationsystem's

7.Makesurethevoltageisolationsystemisin

8.Toeliminateairgapsinthe󰘱uidcolumn,spray

9.Checkthesprayguncoverandbarrelfor

10.Inspecttheentiresystemforanyvisible󰘱uid

Checks

Checks Checks

areproperlyconnected.

andcontrolsareproperlysetforoperation.

isclean.

systemhavesuf󰘰cientairpressure.

ONpositionandthatthegunESindicatorlight
ison.IftheESindicatorlightisnoton,remove
thespraygunforserviceandcompletethe

ElectricalTests,page47.

enclosuredoorisclosedandthatanysafety
interlocksareengagedandworkingproperly.

the“isolate”mode,whereitisisolatingthe󰘱uid
voltagefromground.

enough󰘱uidtopurgetheairoutbetweenthe
voltageisolationsystemandthespraygun.An
airgapinthe󰘱uidhosecanbreaktheelectrical
continuitybetweenthespraygunandtheisolated
󰘱uidsupplyandcausealowvoltagereadingon
avoltagemeterconnectedtotheisolated󰘱uid
supply.

accumulatedoverspray.Excessiveoverspray
cancreateaconductivepathbacktothe
groundedgunhandle.Installanewguncover
andcleantheexteriorofthegun.

leakageandrepairany󰘱uidleaksthatarefound.
Payspecialattentiontothefollowingareas:

•Packingareaofthespraygun.

•Fluidhose:checkforleakageoranybulgesin
theoutercover,whichmayindicateaninternal
leak.

•Internalvoltageisolationsystemcomponents

Tests

Tests Tests

Ifyoustillhavenovoltage,separatethespraygun
andhosefromthevoltageisolationsystemand
checkwhetherthegunandhosealonewillhold
voltagewiththefollowingtest.

1.Flushthesystemwithwaterandleavethelines
󰘰lledwithwater.

2.Dischargethesystemvoltage(seeFluidVoltage

DischargeandGroundingProcedure,page39).

3.FollowthePressureReliefProcedure,page39.

4.Disconnectthe󰘱uidhosefromthevoltage
isolationsystem.

Avoidallowinganywatertoleakoutofthe󰘱uid
hoseasthatcouldcauseasigni󰘰cantairgapin
the󰘱uidcolumnuptothegunelectrode,which
canbreaktheconductivitypathandconceala
potentialfailurearea.

5.Positiontheendofthehoseasfaraspossible
awayfromanygroundedsurface.Theendof
thehosemustbeatleast1ft.(0.3m)fromany
ground.Makesurethatnooneiswithin3ft.(0.9
m)oftheendofthehose.

6.TurntheESON/OFFvalvetoONandtrigger
thegunjustenoughtoturnontheairtothegun
butnotthe󰘱uid.Measurethevoltageatthegun
electrodewithavoltageprobeandmeter.

7.Dischargethesystemvoltagebywaiting30
secondsandthentouchingthegunelectrode
withagroundedrod.

8.Checkthemeterreading:

•Ifthemeterreadingis45to55kV,thegunand

󰘱uidhoseareokay,andtheproblemisinthe
voltageisolationsystem.

•Ifthemeterreadingisbelow45kV,the

problemisinthegunor󰘱uidhose.

9.Flushthe󰘱uidhoseandgunwithenoughairto
dryoutthe󰘱uidpassages.

10.TurntheESON/OFFvalvetoONandtriggerthe
gun.Measurethevoltageatthegunelectrode
withavoltageprobeandmeter.

•Ifthemeterreadingis45-55kV,thegun

powersupplyisokay,andthereisprobablya
dielectricbreakdownsomewhereinthe󰘱uid
hoseorgun.Continuewithstep11.

•Ifthemeterreadingisbelow45kV,dothe

ElectricalTests,page47,tocheckthegunand

powersupplyresistance.Ifthosetestsshow
thegunandpowersupplyareokay,continue
withstep11.

523A2496H

11.Adielectricbreakdownismostlikelyinoneof
thefollowingthreeareas.Repairorreplacethe
componentthatisfailing.

a.Fluidhose:

•Checkforleakageoranybulgesinthe
outercover,whichmayindicateapin-hole
leakthroughthePTFElayer.Disconnect
the󰘱uidhosefromthegun,andlookfor
signsof󰘱uidcontaminationontheoutside
ofthePTFEportionofthe󰘱uidtube.

•Inspecttheendofthehoseconnectedto
thevoltageisolationsystem.Lookforcuts
ornicks.

•Makesurethehoseisproperlystripped
(seeConnecttheWaterborneFluidHose,

page17).Restriporreplacethehose.

b.Fluidpackings:

Removethepackingassemblyfromthegun
(seeFluidPackingRodRemoval,page62),
andlookforsignsof󰘱uidleakageorany
blackenedareas,whichwouldindicatearcing
isoccurringalongthepackingrod.

c.Fluidhoseconnectiontothespraygun:

Troubleshooting

Abreakdownatthe󰘱uidhoseconnection
jointwouldbecausedby󰘱uidleakingpast
theo-ringsealsontheendofthehose.
Removethehoseatthegunconnectionand
lookforsignsof󰘱uidleakagealongthePTFE
tube.

12.Beforereassemblingthegun,cleananddrythe
gun󰘱uidinlettube.Repacktheinnerspacerof
the󰘱uidpackingrodwithdielectricgreaseand
reassemblethegun.

13.Reconnectthe󰘱uidhose.

14.Checkthegunvoltagewiththevoltageprobe
andmeterbefore󰘰llingthegunwith󰘱uid.

3A2496H53

Troubleshooting

Spray

Spray Spray

CheckallpossibleremediesintheTroubleshooting
Chartbeforedisassemblingthegun.

Problem

Problem Problem

Flutteringorspittingspray.

Improperspraypattern. Damagedordirtynozzleoraircap.

Pattern

Pattern Pattern

Troubleshooting

Troubleshooting Troubleshooting

Somespraypatternproblemsarecausedbythe
improperbalancebetweenairand󰘱uid.

Cause

Cause Cause

No󰘱uid.Re󰘰llsupply.

Loose,dirty,damaged
nozzle/seat.

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

Fluidbuilduponaircapornozzle.

Fanairpressuretoohigh.Decrease.

Fluidtoothin.Increaseviscosity.

Fluidpressuretoolow.Increase.

Solution

Solution Solution

Cleanorreplacenozzle,see

CleantheGunDaily,page44,or
AirCapandNozzleReplacement,
page59.

Cleanorreplace.SeeAirCapand

NozzleReplacement,page59.

Clean.See

CleantheGunDaily,page44.

Fanairpressuretoolow.Increase.

Fluidtoothick.Reduceviscosity.

Toomuch󰘱uid.Decrease󰘱ow.

Didnotapply50%overlap.Overlapstrokes50%. Streaks.

Dirtyordamagedaircap.

Cleanorreplaceaircap.See

CleantheGunDaily,page44,or
AirCapandNozzleReplacement,
page59.

543A2496H

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.

Wornelectrode.

Worn󰘱uidnozzleseat.Replacenozzle.SeeAirCapand

Solution

Solution Solution

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

Increaseviscosityorincrease󰘱uid
󰘱owrate.

Openatomizingairvalvemoreor
increasegunairinletpressure;
uselowestairpressurenecessary.

Replacepackings.See

PackingRodRepair,page63.

Replaceairvalve.See

AirValveRepair,page72.

Replaceelectrode.See

ElectrodeReplacement,page61.

NozzleReplacement,page59.

Gundoesnotspray.

Dirtyaircap.

Excessivepaintwrapbackto
operator.

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,page59.

CleantheGunDaily,page44.

Openvalve,orsee

ESOn-OffandFluidAdjustment
ValveRepair,page71.

and󰘱uidnozzleseat.See

CleantheGunDaily,page44.

SeeGrounding,page22.

3A2496H55

Troubleshooting

Electrical

Electrical Electrical

Problem

Problem Problem

Voltagestillpresentat
gunafterfollowingthe

FluidVoltageDischargeand
GroundingProcedure,page39.

Poorwrap.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

ESOn/Offswitchisnotturned
OFF(O).

Didnotwaitlongenoughfor
voltagetodischarge.

Airpocketin󰘱uidlineleaves󰘱uid
neargunisolated.

Voltageisolationsystemfailed.Servicevoltageisolationsystem.

Groundingcylindernotoperating.See

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

Gunairpressuretoolow(ES
indicatorisamber).

Atomizingairpressuretoohigh.Decrease.

Fluidpressuretoohigh.Decrease.

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

Solution

Solution Solution

TurnOFF(O).

Waitlongerbeforetouching
electrodewithgroundingrod.
Checkforbleedresistorfailure.

Determinecauseandcorrect.
Purgeairfrom󰘱uidline.

TestCylinderResistance,page50.

Replaceifneeded.

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

Poorlygroundedparts.Resistancemustbe1megohmor

less.Cleanworkpiecehangers.

Faultygunresistance.

Fluidleaksfromthepacking(2c)
andcausesashort.

Faultyalternator.

ESHI/LOswitchisonLO(Smart
gunsonly)

Spilledpaint,driedpaint,orother
contaminantsinsidetheWB100
Enclosure,causingashortcircuit.

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

Nopower.

See

TestGunResistance,page47.

Cleanthepackingrodcavity,or
replacethepackingrod.See

PackingRodRepair,page63.

SeeAlternatorRemovaland

Replacement,page67.

Checkswitchactuation;replaceif
needed.

Cleaninteriorofenclosure.

Checkpowersupply,alternator,
andalternatorribboncable.See

PowerSupplyRemovaland
Replacement,page66.

563A2496H

Troubleshooting

Problem

Problem Problem

Operatorgetsmildshock.

Operatorgetsshockfrom
workpiece.

Voltage/currentdisplaystaysred
(smartgunsonly).

ESorHzindicatorisamber.

ESorHzindicatorisred.

Cause

Cause Cause

Operatornotgroundedorisnear
ungroundedobject.

Gunnotgrounded.SeeCheckGunElectrical

Aweakstaticchargehasbuiltup
onthesurfaceofanunshielded
󰘱uidhose.Thisisachargeonthe
hosesurface,notafailureofthe
hoseinsulation.

Workpiecenotgrounded.Resistancemustbe1megohmor

Gunistooclosetothepartbeing
sprayed.

Dirtygun.

Alternatorspeedistoolow.Increaseairpressureuntil

Alternatorspeedistoohigh.Decreaseairpressureuntil

Solution

Solution Solution

SeeGrounding,page22.

Grounding,page38,and
TestGunResistance,page47.

Bundleandwraptheairand󰘱uid
hosestogether.SeeConnectthe

WaterborneFluidHose,page17.

less.Cleanworkpiecehangers.

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

SeeCleantheGunDaily,page44.

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

indicatorisgreen.

ErrordisplayappearsandHz
indicatorisred(Smartgunsonly).

Smartmodulehaslost
communicationwiththepower
supply.

Checkforgoodconnectionsbe­tweentheSmartModuleandthe
powersupply.SeeSmartModule

Replacement,page73and
PowerSupplyRemovaland
Replacement,page66.

3A2496H57

Repair

Repair

Repair Repair

Prepare

Prepare Prepare

Installingandrepairingthisequipmentrequires
accesstopartsthatmaycauseelectricshockor
otherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorservicethisequipment
unlessyouaretrainedandquali󰘰ed.Toreduce
theriskof󰘰re,explosion,orelectricshock,before
󰘱ushingthegun:

•FollowtheFluidVoltageDischargeand

GroundingProcedure,page39,andturnOFF

(O)theESOn-Offswitchbefore󰘱ushing,
checking,orservicingthesystemandwhenever
youareinstructedtodischargethevoltage.

•Cleanallpartswithanon-󰘱ammable󰘱uidas
de󰘰nedunderModels,page3.

•Donottouchthegunnozzleorcomewithin4in.
(102mm)ofthenozzleduringgunoperationor
untilyouperformtheFluidVoltageDischarge

andGroundingProcedure,page39.

Toreducetheriskofinjury,followthePressure
ReliefProcedurebeforecheckingorservicingany
partofthesystemandwheneveryouareinstructed
torelievethepressure.

the

Gun

the the

Gun Gun

for

Service

for for

Service Service

•Checkallpossibleremedies
inTroubleshooting,page51beforedisassembling
thegun.

•Useavisewithpaddedjawstopreventdamage
toplasticparts.

•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.FollowtheFluidVoltageDischargeand

GroundingProcedure,page39.

2.Flushthegun.SeeFlushing,page42.

3.Blowthe󰘱uidlinesdrywithair.

4.Relievethepressure.See

PressureReliefProcedure,page39.

5.Disconnectthegunairand󰘱uidlinesatthe

isolationsystem.

6.Removethegunfromtheworksite.Repairarea

mustbeclean.

583A2496H

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,page58.

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.

Figure32AirCapandNozzleReplacement

3A2496H59

Repair

Air

Cap,

Air Air

Cap, Cap,

Spray

Spray Spray

Tip,

and

Tip, Tip,

Nozzle

and and

Nozzle Nozzle

Replacement

Replacement Replacement

(Model

(Model (Model

L60M19)

L60M19) L60M19)

1.SeePreparetheGunforService,page58.

2.Removetheretainerring(6)andaircap/tipguard
assembly(5).

Figure33RemoveAirCap

3.Disassembletheaircapassembly.Checkthe
conditionoftheu-cup(6a),electrode(5a),o-ring
(5b),andtipgasket(10a).Replaceanydamaged
parts.

4.Toreplacetheelectrode(5a),pulltheitoutofthe
backoftheaircap,usinganeedle-nosepliers.
Pushthenewelectrodethroughtheaircap
hole.Makesuretheshortendoftheelectrode
engagestheholeinthebackoftheaircap.Press
theelectrodeinplace󰘰rmlywithyour󰘰ngers.

NOTICE

NOTICE NOTICE

Theconductivering(4c)isaconductivemetal
contactring,notasealingo-ring.Forbest
performanceandtoavoidpotentialdamageto
thespraygun,donotremovetheconductive
ring(4c)excepttoreplaceitandneveroperate
thegunwithouttheconductiveringinplace.
Donotreplacetheconductiveringwith
anythingbutagenuineGracopart.

5.Triggerthegunandremovethenozzle(4),using
anadjustablewrench.

Figure36ReplaceNozzle

NOTICE

NOTICE NOTICE

Figure34DisassembleAirCapAssembly

Figure35TipGasket

603A2496H

Donotovertightenthenozzle(4).
Overtighteningmaydamagethehousingand
thegunbarrel,resultinginimproper󰘱uid
shutoff.

6.Ensurethattheo-rings(4a,4b,and9)arein
placeonthenozzle.Triggerthegunandinstall
thenozzle(4).Tightenuntilsnug,then1/4turn
more.

7.Checkthatthespraytipgasket(10a)isinplace.
Alignthespraytiptabwiththegrooveintheair
cap(5).Installthespraytip(10)intheaircap.

8.Makesurethattheelectrode(5a)isinstalled
correctlyintheaircap.

9.Checkthattheaircapo-ring(5b)isinplace.

Repair

10.Checkthattheu-cup(6a)isinplaceonthe
retainingring(6).Thelipsoftheu-cupmustface
forward.

NOTICE

NOTICE NOTICE

Toavoiddamagingthetipguard,orientthe
aircapassembly(5)beforetighteningthe
retainingring(6).Donotturntheaircapwhen
theretainingringistight.

11.Orientatetheaircapandtightentheretaining
ringsecurely.

12.SeeTestGunResistance,page47.

Electrode

Electrode Electrode

1.Followthestepsin

PreparetheGunforService,page58.

2.Removetheaircapandnozzle.See

AirCapandNozzleReplacement,page59.

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

Toavoiddamagingtheplasticthreads,bevery
carefulwheninstallingtheelectrode.

4.Applylow-strengthpurplethreadlockertothe
electrodeandpackingrodthreads.Installthe
electrode󰘰nger-tight.Donotovertighten.

5.Installthe󰘱uidnozzleandaircap.See

AirCapandNozzleReplacement,page59.

Toavoidequipmentdamage,useonlythe
electrodeneedleavailableinkit26A416.
Alternateelectrodesarenotacceptableforuse
anddonot󰘰tthepackingrodthreads.

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

NOTICE

NOTICE NOTICE

Figure37ElectrodeReplacement

3A2496H61

Repair

Needle

Needle Needle

1.SeePreparetheGunforService,page58.

2.Removetheaircapandnozzle.See

3.Unscrewtheneedle(3).

4.Applylow-strength(purple)Loctite®orequivalent

5.Installthe󰘱uidnozzleandaircap.See

6.SeeTestGunResistance,page47.

Replacement

Replacement Replacement

AirCap,SprayTip,andNozzleReplacement
(ModelL60M19),page60.

threadsealanttotheneedleandpackingrod
threads.Installtheneedle󰘰nger-tight.Donot
overtighten.

AirCap,SprayTip,andNozzleReplacement
(ModelL60M19),page60.

(Model

(Model (Model

L60M19)

L60M19) L60M19)

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,page58.

AirCapandNozzleReplacement,page59.

ElectrodeReplacement,page61.

trigger(12).

(41).Removethespring(17).

ifnecessary.

Rod

Removal

Rod Rod

Removal Removal

Figure39FluidPackingRodRemoval

Figure38ElectrodeReplacement

623A2496H

Repair

Packing

Packing Packing

NOTE:

NOTE: NOTE:

Adjust

Adjust Adjust

NOTE:

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

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

Rod

Rod Rod

Youmayreplacethepackingrodasindividualpartsorasanassembly.

the

the the

Thegunbeginsemittingairbeforethe󰘱uid

Repair

Repair Repair

Air

Flow

Air Air

Lead

Flow Flow

Lead Lead

and

Lag

and and

Lag Lag

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

3.Tightenthenutstogetherto󰘰xtheminthenew
position.

3A2496H63

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,page61,step4.

9.Installthenozzleandaircap.See

AirCapandNozzleReplacement,page59,

steps5–7.

10.Installthetrigger(12)andscrews(13).

Figure40PackingRod

643A2496H

Repair

Barrel

Barrel Barrel

1.Followthesteps

2.Removetheairinlet󰘰tting(21)andtakethe

3.Loosenthetwoscrews(27).

4.Holdthegunhandle(16)withonehandandpull

NOTE:

NOTE: NOTE:
removethealternator/powersupplyassemblyfrom
thebarrel.

Removal

Removal Removal

inPreparetheGunforService,page58.

bracket(104)offthegunhandle(16).

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.Positionthebracket(104)onthegunhandle(16)

5.Applydielectricgrease(44)totheexposedinner

6.Checkthatthenut(105)istightontheferrule

7.FollowthestepsinTestGunResistance,page47.

Installation

Installation Installation

(18)areinplace.Makesurethegasketair
holesarealignedproperly.Replacethegasketif
damaged.

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

evenly(aboutahalfturnpastsnug,or20in-lb.,
2N•m).

Toavoiddamagingthegunbarrel,donot
over-tightenthescrews(27).

andsecurewiththeairinlet󰘰tting(21).

tubeofthe󰘱uidhose(101).

housing(103).

Liberally

NOTICE

NOTICE NOTICE

applydielectric

Figure41BarrelRemoval

Figure42BarrelInstallation

3A2496H65

Repair

Power

Power Power

•Inspectthegunhandlepowersupplycavityfordirt
ormoisture.Cleanwithaclean,dryrag.

•Donotexposegasket(28)tosolvents.

1.Followthestepsin

2.FollowthestepsinBarrelRemoval,page65.

3.Graspthepowersupply(11)withyourhand.

4.Inspectthepowersupplyandalternatorfor

5.Toseparatethepowersupply(11)fromthe

6.Followthestepsin

Supply

Supply Supply

PreparetheGunforService,page58.

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,page48.

Replacethepowersupplyifnecessary.
Torepairthealternator,see

AlternatorRemovalandReplacement,page67.

Removal

Removal Removal

NOTICE

NOTICE NOTICE

disconnectthe󰘱exiblecircuit(24)

disconnectthe6–pin󰘱exiblecircuit

and

Replacement

and and

Replacement Replacement

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.

Figure43ConnectFlexibleCircuit

10.Makesurethegasket(28*),groundspring
(18),andpowersupplyspring(11a)arein
place.Replacegasket(28*)ifdamaged.
Assemblethebarrel(1)tothehandle(16).See

BarrelInstallation,page65.

11.FollowthestepsinTestGunResistance,page47.

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).

663A2496H

connectthe6–pin󰘱exible

Figure44PowerSupply

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,page58.

anddisconnectthealternator.SeePowerSupply

RemovalandReplacement,page66.

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).

Figure46AlternatorCross-Section

♦28isnotshowninillustration.

Figure45FanOrientation

NOTICE

NOTICE NOTICE

Topreventdamage,donotscratchordamage
themagnet(M)orshaft(S).Donotpinch
ordamagethe3–wireconnector(PC)when
disassemblingandreassemblingthebearings.

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.

3A2496H67

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.46.Besurethecoilalignmentpins
(P)arepositionedasshowninFig.45.

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,page66.

Figure47Alternator

683A2496H

Repair

Fan

Air

Fan Fan

Adjustment

Air Air

Adjustment Adjustment

Valve

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page58.

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

NOTE:

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

3.Removetheretainingring(30d).

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

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

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

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

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

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

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

Figure48FanAirAdjustmentValve

3A2496H69

Repair

Atomizing

Atomizing Atomizing

1.Followthestepsin

PreparetheGunforService,page58.

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

Figure49AtomizingAirRestrictorValve

Figure50AlignValveStem

703A2496H

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,page58.

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)

Figure51ESOn-OffValveRepair,24N630and
26A160

Figure52ESOn-OffValveRepair,24N632

3A2496H

71

Repair

Air

Valve

Air Air

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page58.

2.FollowthestepsinBarrelRemoval,page65.

3.Removethescrews(13)andtrigger(12).

4.RemovetheESOn-OffValve.SeeESOn-Off

andFluidAdjustmentValveRepair,page71.

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,page71.

10.Installthetrigger(12)andscrews(13).

11.FollowthestepsinBarrelInstallation,page65.

Figure54AirValve

Figure53InstallU-Cup

72

3A2496H

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,page58.

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

Figure55SmartModule

Figure56AlignRibbonCables

3A2496H73

Repair

Air

Swivel

Air Air

Swivel Swivel

Replacement

Replacement Replacement

1.Followthestepsin

PreparetheGunforService,page58.

2.Toreplacetheairexhaustvalve:

a.Removetheclamp(43)andtheexhausttube

(36).

b.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.
Removethebracket(104).

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(104)and
screwtheswivelintothegunhandle(16).
Torqueto75–85in-lb(8.4–9.6N•m).

g.Checkthatthenuts(102,105)aretight.

h.Installthetube(36)andclamp(43).

3.Toreplacetheairinletswivel:

and

Exhaust

and and

Exhaust Exhaust

Valve

Valve Valve

Figure57AirInletFittingandAirExhaustValve

a.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.

b.Applythreadsealanttothetopthreadsofthe

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

74

3A2496H

Parts

1

Parts

Parts Parts

Standard

Standard Standard

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Waterborne

Waterborne Waterborne

L60T17

L60T17 L60T17

L60T18

L60T18 L60T18

24M732

24M732 24M732

24M733

24M733 24M733

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

Shielded

Shielded Shielded

Unshielded

Unshielded Unshielded

Air

Spray

Air Air

Spray Spray

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Gun

Gun Gun

Fluid

Hose

Fluid Fluid

Hose Hose

Fluid

Fluid Fluid

Assembly

Assembly Assembly

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

(101),

sold

(101), (101),

sold sold

Hose

(101),

Hose Hose

(101), (101),

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

separately

separately separately

sold

sold sold

separately separately

separately

C CCincludesitems1–48

C CCincludesitems1–48

for

gun

for for

model

gun gun

model model

for

gun

for for

gun gun

L60T17

L60T17 L60T17

model

model model

L60T18

L60T18 L60T18

Torqueto20in-lb(2N•m).

3A2496H75

Parts

Part

No.

Part Part
Part

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
124N667

224N655

L60T17

No. No.

L60T17 L60T17

No.

L60T18

No. No.

L60T18 L60T18

No.

24M732

No. No.

24M732 24M732

No.

24M733

No. No.

24M733 24M733

Part

Part Part

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

Shielded

Shielded Shielded

Unshielded

Unshielded Unshielded

No.

Description

No. No.

Description Description

BODY,gun(includesref.28)

SeePackingRodAssembly,

Waterborne

Waterborne Waterborne
Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Fluid

Fluid Fluid

Fluid

Fluid Fluid

page86

324N652NEEDLE,electrode,black1

424N616

4a24N645

4b111507

5

24N477

624P892

198307

6a*

1124N662

11a24N979

1224N663

1324A445

1524N664

24P744

24P743

17185111

18197624

1924P036VALVE,exhaust1

112085

19a*

2124N626

2324N633VALVE,air1

276733

23a*

2624N630

2724N740

25N921

28*

2924T304

3024N634

34185116

188749

35*

36185103

NOZZLE,1.5mm;includes4a
and4b

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

POWERSUPPLY,60kVgun

SPRING

TRIGGER

SCREW,trigger;packageof2

See

AlternatorAssembly,page87

HANDLE;forgunmodelL60T17

HANDLE;forgunmodelL60T18

SPRING,compression

SPRING,compression

O-RING

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

SEAL,airvalve

SeeESOn-OffandFluid

AdjustmentValve,page88

SCREW,hexsocket;10–24x

0.53in.;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page89

SeeFanAirAdjustmentValve

Assembly,page89

SPRING,compression

PACKING,u-cup

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

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Hose

(101),

Hose Hose

Hose

Hose Hose

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1 16

1

1

1

1

1

1

1

1

1

1

1

1

1

1

sold

(101), (101),

sold sold

(101),

(101), (101),

Ref.

Ref. Ref.
No.

No. No.
40107460

41276741

4224N786

43110231

44116553

45117824

46

48▲186118

5024N783

101

103

104197954

105185548NUT1

10616N953

107102982

10816N916

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

separately

separately separately

sold

sold sold

Part

Part Part

24N604

24M732

24M733

25N916

25N917

198663

190863

185547

15B932

separately

separately separately

No.

No. No.

C CCincludesitems1–48
C CCincludesitems1–48

for

gun

for for

model

gun gun

model model

for

gun

for for

gun gun

Description

Description Description

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

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

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

COVER,gun;packageof10

SIGN,warning(notshown)

HOOK;includesscrew

HOSE,shielded,waterborne
󰘱uid,25ft(7.6m);forgunmodel
L60T17;includes102–108;sold
separately

HOSE,unshielded,waterborne
󰘱uid,25ft(7.6m);forgunmodel
L60T18;includes102–108;sold
separately

HOSE,shielded,waterborne
󰘱uid,50ft(15.2m);forgun
modelL60T17;includes
102–108;soldseparately

HOSE,unshielded,waterborne
󰘱uid,50ft(15.2m);forgun
modelL60T18;includes
102–108;soldseparately

FERRULE,forshieldedhose

FERRULE,forunshieldedhose

HOUSING,ferrule,forshielded
hose

HOUSING,ferrule,for
unshieldedhose

BRACKET,󰘱uid󰘰tting

FITTING,barrel

O-RING

FITTING,seal

L60T17

L60T17 L60T17

model

model model

L60T18

L60T18 L60T18

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1 102

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

763A2496H

Parts

1

Smart

Smart Smart

Part

Part Part

Part

Part Part

Part

Part Part

Part

Part Part

Waterborne

Waterborne Waterborne

No.

L60M17

No. No.

L60M17 L60M17

No.

L60M18

No. No.

L60M18 L60M18

No.

24M732

No. No.

24M732 24M732

No.

24M733

No. No.

24M733 24M733

60

60 60

60

60 60

Shielded

Shielded Shielded

Unshielded

Unshielded Unshielded

Air

Spray

Air Air

Spray Spray

kV

Electrostatic

kV kV

Electrostatic Electrostatic

kV

Electrostatic

kV kV

Electrostatic Electrostatic

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Gun

Gun Gun

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Fluid

Fluid Fluid

Assembly

Assembly Assembly

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Hose

(101),

Hose Hose

Fluid

Hose

Fluid Fluid

Hose Hose

sold

(101), (101),

sold sold

(101),

(101), (101),

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

separately

separately separately

sold

separately

sold sold

separately separately

C

C C

C

C C

for

gun

for for

model

gun gun

model model

for

gun

for for

gun gun

L60M17

L60M17 L60M17

model

model model

L60M18

L60M18 L60M18

Torqueto20in-lb(2N•m).

3A2496H

77

Parts

Part

No.

Part Part
Part

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
124N667

224N655

L60M17

No. No.

L60M17 L60M17

No.

L60M18

No. No.

L60M18 L60M18

No.

24M732

No. No.

24M732 24M732

No.

24M733

No. No.

24M733 24M733

Part

Part Part

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

Shielded

Shielded Shielded

Unshielded

Unshielded Unshielded

No.

Description

No. No.

Description Description

BODY,gun(Includesref.28)

SeePackingRodAssembly,

Waterborne

Waterborne Waterborne
Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Fluid

Fluid Fluid

Fluid

Fluid Fluid

page86

324N652NEEDLE,electrode,black1

424N616

4a24N645

4b111507

5

24N477

624P892

198307

6a*

1124N662

11a24N979

1224N663

1324A445

1524N664

24P742

16

24P741

17185111

18197624

1924P036VALVE,exhaust1

112085

19a*

2124N626

2324N633VALVE,air1

276733

23a*

24245265

2624N630

2724N740

25N921

28*

2924T304

3024N634

3124N756

34185116

NOZZLE,1.5mm;includes4a
and4b

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

POWERSUPPLY,60kVgun

SPRING

TRIGGER

SCREW,trigger;packageof2

See

AlternatorAssembly,page87

HANDLE,smart;forgunmodel
L60M17

HANDLE,smart;forgunmodel
L60M18

SPRING,compression

SPRING,compression

O-RING

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

SEAL,airvalve

CIRCUIT,󰘱exible

SeeESOn-OffandFluid

AdjustmentValve,page88

SCREW,hexsocket;10–24x

0.53in.;sst;
packageof2

GASKET,barrel

SeeAtomizingAirRestrictor

ValveAssembly,page89

SeeFanAirAdjustmentValve

Assembly,page89

SeeSmartModuleAssembly,

page90

SPRING,compression

Air

Spray

Gun,

Air Air

Spray Spray

Air

Spray

Air Air

Spray Spray

Hose

(101),

Hose Hose

Hose

Hose Hose

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

sold

(101), (101),

sold sold

(101),

(101), (101),

Ref.

Ref. Ref.
No.

No. No.
35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

46

48▲186118

5024N783

101

103

104197954

105185548NUT1

10616N953

107102982

10816N916

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

separately

separately separately

sold

separately

sold sold

separately separately

Part

Part Part

188749

24N604

24M732

24M733

25N916

25N917

198663

190863

185547

15B932

C

C C
C

C C

for

gun

for for

No.

No. No.

model

gun gun

model model

for

gun

for for

gun gun

Description

Description Description

PACKING,u-cup

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

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

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

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

COVER,gun;packageof10

SIGN,warning(notshown)

HOOK;includesscrew

HOSE,shielded,waterborne
󰘱uid,25ft(7.6m);forgunmodel
L60M17;includes102–108;sold
separately

HOSE,unshielded,waterborne
󰘱uid,25ft(7.6m);forgunmodel
L60M18;includes102–108;sold
separately

HOSE,shielded,waterborne
󰘱uid,50ft(15.2m);forgun
modelL60M17;includes
102–108;soldseparately

HOSE,unshielded,waterborne
󰘱uid,50ft(15.2m);forgun
modelL60M18;includes
102–108;soldseparately

FERRULE,forshieldedhose

FERRULE,forunshieldedhose

HOUSING,ferrule,forshielded
hose

HOUSING,ferrule,for
unshieldedhose

BRACKET,󰘱uid󰘰tting

FITTING,barrel

O-RING

FITTING,seal

L60M17

L60M17 L60M17

model

model model

L60M18

L60M18 L60M18

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 102

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

783A2496H

Parts

1

Mold

Mold Mold
Assembly

Assembly Assembly

Part

Part Part

Part

Part Part

Release

Release Release

No.

L60M19

No. No.

L60M19 L60M19

No.

24M733

No. No.

24M733 24M733

Smart

Smart Smart

60

kV

60 60

kV kV

Unshielded

Unshielded Unshielded

Air

Spray

Air Air

Spray Spray

Electrostatic

Electrostatic Electrostatic

Waterborne

Waterborne Waterborne

Gun

Gun Gun

Mold

Release

Mold Mold

Release Release

Fluid

Fluid Fluid

Air

Spray

Gun,

Air Air

Spray Spray

Hose

(101),

Hose Hose

sold

(101), (101),

sold sold

Series

Gun, Gun,

Series Series

separately

separately separately

C

C C

Torqueto20in-lb(2N•m).

3A2496H79

Parts

Part

No.

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
124N667

224N655

L60M19

No. No.

L60M19 L60M19

No.

24M733

No. No.

24M733 24M733

Part

Part Part

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

Unshielded

Unshielded Unshielded

No.

Description

No. No.

Description Description

BODY,gun(includesref.28)

SeePackingRodAssembly,

Mold

Release

Mold Mold

Release Release

Waterborne

Waterborne Waterborne

Fluid

Fluid Fluid

page86

324N749NEEDLE1

424N748

4a24N645

4b111507

4c24P893

5

24N727

5a

24N643

6245790

198307

6a*

10AEMxxx

AEFxxx

10a183459

1124N662

11a24N979

1224N663

1324A445

1524N664

24P741HANDLE,smart1

16

17185111

18197624

1924P036VALVE,exhaust1

112085

19a*

2124N626

2324N633VALVE,air1

276733

23a*

24245265

2624N630

2724N740

25N921

28*

NOZZLE,seat;includes4a-4c

O-RING,conductive

O-RING;󰘱uoroelastomer

RING,conductive

SeeAirCapAssembly,page90

ELECTRODE;packageof5

RING,retainer;includes6a

PACKING,u-cup;UHMWPE

TIPASSEMBLY;customer’s
choice;includesitem27a

GASKET,tip

POWERSUPPLY,60kVgun

SPRING

TRIGGER

SCREW,trigger;packageof2

See

AlternatorAssembly,page87

SPRING,compression

SPRING,compression

O-RING

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

SEAL,airvalve

CIRCUIT,󰘱exible

SeeESOn-OffandFluid

AdjustmentValve,page88

SCREW,hexsocket;10–24x

0.53in.;sst;packageof2
GASKET,barrel

Air

Spray

Gun,

Air Air

Spray Spray

Hose

(101),

Hose Hose

(101), (101),

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

Ref. Ref.
No.

No. No.
2924N792

3024N634

3124N756

34185116

35*

36185103

40107460

41276741

4224N786

43110231

44116553

45117824

46

48▲186118

5024N783

101

102

103

1

1

1

1

1

104197954

105185548NUT1

10616N953

107102982

10816N916

Series

Gun, Gun,

Series Series

sold

separately

sold sold

separately separately

Part

Part Part

188749

24N604

24M733

25N917

190863FERRULE1

15B932

C

C C

No.

Description

No. No.

Description Description

ATOMIZINGAIR
ADJUSTMENTVALVE

SeeFanAirAdjustmentValve

Assembly,page89

SeeSmartModuleAssembly,

page90

SPRING,compression

PACKING,u-cup

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

TOOL,wrench,ballend;4mm
(shippedloose)

MULTI-TOOL(shippedloose)

PLUG,restrictor(shippedloose;
foruseinsteadofitem29)

CLAMP,exhausttube(shipped
loose)

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

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

COVER,gun;packageof10

SIGN,warning(notshown)

HOOK;includesscrew

HOSE,unshielded,waterborne
󰘱uid,25ft(7.6m);includes
102–108;soldseparately

HOSE,unshielded,waterborne
󰘱uid,50ft(15.2m);includes
102–108;soldseparately

HOUSING,ferrule

BRACKET,󰘱uid󰘰tting

FITTING,barrel

O-RING

FITTING,seal

Qty

Qty Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

803A2496H

Parts

Isolation

Isolation Isolation

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Enclosure

Enclosure Enclosure

233825

233825 233825

246511

246511 246511

Waterborne

Waterborne Waterborne

Waterborne

Waterborne Waterborne

Isolation

Isolation Isolation

Isolation

Isolation Isolation

Enclosure,

Enclosure, Enclosure,

Enclosure,

Enclosure, Enclosure,

forusewithshieldedwaterborne󰘱uidhose

forusewithunshieldedwaterborne󰘱uidhose

3A2496H81

Parts

Part

No.

Ref.

Part Part

Ref. Ref.
No.

No. No.

———

201

201a15A947

202116993

20315A660PLATE1

20415A551T-HANDLE,latch1

20515A545

20615A524

207113061

———

208

209233501PUMP,diaphragm;sst;see

———

210

———

211

———

212

213241005

214104029

215116989VALVE,air1

216111804

217113060

218116473NIPPLE;1/4nptx1/4npsm1

185547

221

15B932

198663

222

190863

223101390

224154636

225185548NUT1

226190410

227116988

22815A518

229104267

———

230

231114456

232116315

235▲15A682LABEL,warning1

236116316

237218798

238114958

Description

No. No.

Description Description

CABINET,enclosure;includes
201a

DOOR,cabinet

CASTER,brake

STEM,handle,door

HOUSING,latch

SWITCH,push,air

TUBE;1/2in.(13mm)OD;
polyethylene

309303
SCREW,hexhdcap;5/16–18x

5.5in.(140mm)
WASHER,plain;0.344in.ID

NUT,lock;5/16–182

COVER,pail

LUG,ground

REGULATOR,air

GAUGE,air;1/8npt

FERRULE,housing;for24N580,
24P629,and233825

FERRULE,housing;for24P630,
24P631,and246511

FERRULE;for24N580,24P629,
and233825

FERRULE;for24P630,24P631,
and246511

WASHER,lock,internaltooth

WASHER,plain;0.625in.ID

RESISTOR,bleed

CYLINDERROD

HOUSING,cylinderrod

REGULATOR,air

BUSHING;plastic;3/4x1/2npt

ELBOW,tube;3/8nptx3/8in.
(10mm)ODtube

ELBOW,tube;3/8nptx1/2in.
(13mm)ODtube

FITTING,tube;1/2nptx1/2in.
(13mm)ODtube

STRAINER,16mesh;sst

STRAP,tie

Part

No.

Qty

Qty Qty

1

1

4

1

1

1

A/R

1

2

2

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

3

Ref.

Ref. Ref.
No.

No. No.
239222011

240234018

241110209NUT,regulator11

242114051

243210084

244

245

246

247107257

248

249160430

251

252

253

256162449NIPPLE,reducing;1/2nptx1/4

257101874TERMINAL,ring

258116990

259113983

260237933METER,0–90kV1

261113336ADAPTER;1/4npt1

262

263

264

265

266

267

268

270116991

271203953

272

273

274155541

275114261TERMINAL,ring;no.101

27615A780

278117314

279113319

Part Part

———

———

———

———

———

———

———

———

———

———

———

———

———

———

———

———

Description

No. No.

Description Description

GROUNDWIRE;25ft(7.6m)

STRIP,grounding;aluminum

WASHER,shim,;atch

ROD,ground

SCREW,hexhd;1/4–20x5/8
in.(16mm)

WASHER,plain;1/4in.(6mm)

NUT,hex;1/4–2016

SCREW,thread-forming

TUBE;1/4in.(6mm)OD;nylon

GAUGE,air

WIRE,10gauge;greenwith
yellowstripe

CONNECTOR,swiveltee;1/8
nptx5/32in.(4mm)tube

NUT,hex;10–321

npt

BOX,control

RING,retaining;1/2in.(13mm)

SCREW,panhd;10–32x5/8in.
(16mm)

SCREW,panhd;10–32x1/4in.
(6mm)

HOLDER,tie

SCREW,buttonhd;10–24x1.5
in.(38mm)

SCREW,buttonhd;10–32x1.0
in.(25mm)

NUT,hex;M5x0.82

WASHER,lock;no.10

TEE,run,manifold

SCREW,hexhdcapwithpatch;
10–24x3/8in.(10mm)

WIRE,14gauge;redA/R

WIRE,ground,14gauge;green
withyellowstripe

UNION,swivel;1/4npt

PLUG,hexhd

BULKHEADCONNECTOR;1/4
npt

CONNECTOR,tube;1/4nptx
3/8in.(10mm)ODtube

Qty

Qty Qty

1

1

1

1

16

16

1

A/R

1

1

1

2

5

1

1

4

1

3

2

2

9

1

1

A/R

1

1

1

2

823A2496H

Part

No.

Ref.

Ref. Ref.
No.

No. No.
280

281

282

283

285112791

286

300★235070

Part Part

———

———

———

———

———

Description

No. No.

Description Description

ELBOW,tube

FITTING,tube;1/8nptx5/32in.
(4mm)ODtube

SWIVEL,tube;1/4nptx1/4in.
(6mm)ODtube

SWIVEL,tube;1/8nptx5/32in.
(4mm)ODtube

CLAMP

TUBE;3/8in.(10mm)OD

HOSE,air,grounded;0.315in.
(8mm)ID;1/4npsm(f)x1/4
npsm(f)left-handthread;red
coverwithstainlesssteelbraid
groundpath;25ft(7.6m)long

Qty

Qty Qty

1

1

4

2

1

A/R

1

▲ReplacementDangerandWarninglabels,tags,
andcardsareavailableatnocost.

★Theairhose(300)andgun(301)arenotincluded
with233825and246511IsolationEnclosures.They
areshownforillustrativepurposesonly.Seepages3
and4forlistingsofmodelswhichincludeanairhose
andgun.
Thepailisshownforillustrativepurposesbutisnot
included.

Parts

Part

No.

Ref.

Ref. Ref.
No.

No. No.
301★

Part Part

L60T17
L60T18

L60M19
L60M18

L60M19

Description

No. No.

Description Description

GUN;seeStandardWaterborne

AirSprayGunAssembly,page
75

GUN;seeSmartWaterborneAir

SprayGunAssembly,page77

GUN;seeMoldReleaseSmart

AirSprayGunAssembly,page
79

Qty

Qty Qty

1

1

1

3A2496H83

Parts

Tubing

Tubing Tubing

Detail

Detail Detail

and

Wiring

and and

Wiring Wiring

Views

Views Views

Control

of ofofControl Control

Box

Box Box

Detail

View

Detail Detail

View View

Door

of ofofDoor Door

Interlock

Interlock Interlock

Switch

Switch Switch

843A2496H

Parts

Tubing

Tubing Tubing

and

Wiring

and and

Wiring Wiring

Chart

Chart Chart

Usethediagramsto󰘰ndtheconnectionpointsfor
thetubingandwiringlistedbelow.

Code

Code Code

A1248

A2248

B2249

B3249

B4249

B5249

C1

C2

C3

Ref.

Ref. Ref.

272

251

273

Length

No.

Length Length

No. No.

in.

(mm)

in. in.

(mm) (mm)

20(508)1/4ODtube,regulator

9(229)1/4ODtube,regulator

17(432)5/32ODtube,manifoldair

20(508)5/32ODtube,valveteeto

5(127)5/32ODtube,regulator

22(559)5/32ODtube,valveteeto

9(229)red14gaugewirefromtop

8(204)

34(864)

Description

Description Description

(216)topump

(216)tomanifold

todoorinterlockswitch

cylinder

(216)togauge(217)

doorinterlockswitch

ofbleedresistortometer
green/yellow14gaugewire

frominternalboxground
lugtocylindercap

green/yellow10gaugewire
fromexternalgroundlugto
cart

Code

Code Code

C4

C5

C6

C7

C8

C9

E1286

Ref.

Ref. Ref.

239n/a

243n/agreen/yellow10gaugewire

226n/a

272

272

251n/agreen/yellow10gaugewire

Length

No.

Length Length

No. No.

in.

(mm)

in. in.

(mm) (mm)

16(407)red14gaugewirefrom

12(305)red14gaugewirefrom

4(102)3/8ODtube,bulkheadto

Description

Description Description

green/yellow25ft(7.6m)
groundwirewithclamp,
fromexternalgroundlugto
trueearthground

fromexternalgroundlugto
groundprobe

redwirefrombleedresistor
topump

pumptopailcoverwith
clamp

pump(209)togroundon
cylinderbracket

frommeter(+)tointernal
boxgroundlug

manifold

3A2496H85

Parts

Packing

Packing Packing

Part

No.

Part Part

No. No.

Includesitems2a-2k

Rod

Rod Rod

24N655

24N655 24N655

Assembly

Assembly Assembly

Packing

Packing Packing

Rod

Assembly

Rod Rod

Assembly Assembly

Part

No.

Ref.

Part Part

Ref. Ref.
No.

No. No.

2a‡111316

2b‡116905

2c‡178409

2d‡178763

24N703

2e

Description

No. No.

Description Description

O-RING

SEAL

PACKING,󰘱uid

PACKING,needle

ROD,packing(includes
items2jand2k)

197641NUT,packing1

2f

‡ThesepartsareincludedinFluidSealRepairKit
24N790(purchaseseparately).

◆ThesepartsareincludedinTriggerAdjustmentNut

Kit24N700(purchaseseparately).

Part

No.

Qty

Qty Qty

1

1

1

1

1

Ref.

Part Part

Ref. Ref.
No.

No. No.

2g185495

2h‡186069

———

2j◆

———

2k◆

Description

No. No.

Description Description

HOUSING,packing

SPACER,packing

NUT,triggeradjustment(part
ofitem2e)

NUT,triggeradjustment(part
ofitem2e)

Qty

Qty Qty

1

1

1

1

Partslabeled———arenotavailableseparately.

863A2496H

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.

3A2496H87

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

———

24N648

25E767

113746

Description

No. No.

Description Description

HOUSING,valve;blackfor
standardmodel24N630,blue
forrestrictedmodel26A160

HOUSING,valve;model
24N632

O-RING

PISTON,valve

LEVER,ESon-off;includes
26g;models24N630and
36A160

LEVER,ESon-off;includes
26g;model24N632

SCREW,set,sockethead

KNOB,adjustment,󰘱uid;
includes26g;models24N630
and36A160

KNOB,adjustment,󰘱uid;blue;
includes26g;models24N630
and36A160

O-RING

SCREW,captive;packof2

Qty

Qty Qty

1

1

2

1

1

1

2

1

1

1

1

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

883A2496H

Fan

Air

Fan Fan

Part

Part Part
(shown)

(shown) (shown)

Ref.

Ref. Ref.
No.

No. No.

30a

30b

30c*

30d24N646

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

Adjustment

Air Air

Adjustment Adjustment

No.

24N634

No. No.

24N634 24N634

Part

Part Part

———

———

111504

Fan

Fan Fan

No.

Description

No. No.

Description Description

NUT,valve1

STEM,valve

O-RING

RING,retaining;packageof6

Valve

Valve Valve

Air

Adjustment

Air Air

Adjustment Adjustment

Assembly

Assembly Assembly

Valve

Valve Valve

Parts

Atomizing

Atomizing Atomizing
Assembly

Assembly

Assembly Assembly

Qty

Qty Qty

1

1

1

Assembly Assembly

Part

No.

Part Part

No. No.

Assembly

Assembly Assembly

Part

Ref.

Ref. Ref.
No. No.

29a

29b

29c*

29d118907

29e

29f

29g

Part Part

No.

———

———

———

111516

———

———

———

Air

Restrictor

Air Air

Restrictor Restrictor

24T304

24T304 24T304

(shown)

(shown) (shown)

Atomizing

Atomizing Atomizing

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

Valve

Valve Valve

Air

Restrictor

Air Air

Restrictor Restrictor

Valve

Valve Valve

Qty

Qty Qty

1

1

1

1

1

1

1

1

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

3A2496H89

Parts

Air

Cap

Air Air

Cap Cap

Part

No.

Part Part

No. No.

Ref.

Ref. Ref.
No.

No. No.

5a

5b24N734

5c

5d24N726

10a183459

24N727 24N727

Part

Part Part

24N643

———

Assembly

Assembly Assembly

24N727

Air

Cap

Air Air

No.

Description

No. No.

Description Description

ELECTRODE;packageof5

O-RING;ptfe;packageof5
(alsoavailableinpackageof
10;order24E459)

AIRCAP

GUARD,tip,orange

GASKET,tip(notshown)

Assembly

Cap Cap

Assembly Assembly

Partslabeled———arenotavailableseparately.

Smart

Smart Smart

Part

Part Part

Qty

Qty Qty

1

1

1

1

5

Ref.

Ref. Ref.
No.

No. No.

31a

31b24P433

31c24N787

31d♦

31e♦

31f

Module

Module Module

No.

24N756

No. No.

24N756 24N756

Part

No.

Part Part

No. No.

———

———

———

112319

Assembly

Assembly Assembly

Smart

Smart Smart

Description

Description Description

CARTRIDGE

GASKET

SWITCH,ESHI/LO

SCREW

SCREW,pivot

O-RING

Module

Module Module

Assembly

Assembly Assembly

Qty

Qty Qty

1

1

1

3

1

1

Partslabeled———arenotavailableseparately.

♦ThesepartsareincludedinSmartModuleScrew
Kit24N757(purchaseseparately).

903A2496H

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,
page93.

O-RING,conductive

O-RING;󰘱uoroelastomer

AIRCAP,roundspray.See

AirCapSelectionGuide,page

96.

ATOMIZINGAIR
RESTRICTORVALVE,
roundspray

FANAIRADJUSTMENT
VALVE,roundspray

DIFFUSER,roundspray

Qty

Qty Qty

1

1

1

1

1

1

1

3A2496H91

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

923A2496H

FluidNozzles

Fluid

Fluid Fluid

Fluid

Fluid Fluid

Toreducetheriskofaninjury,followthePressureReliefProcedure,page39,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

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

withhardenedSSTseatanddamageresistantSSTtip;for
standardcoatings,abrasives,andmetallics

High

High High
withhardenedceramicseat,forabrasivesandmetallics

high

wear

high high

wear

nozzles

wear wear

nozzles nozzles

nozzles

wear wear

nozzles nozzles

(HW)

(HW) (HW)

(PHW)

(PHW) (PHW)

3A2496H93

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

12

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

943A2496H

Ori󰘰ce

12 12

. ..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

13

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

13 13

. ..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

14

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

Ori󰘰ce

14 14

. ..Ori󰘰ce Ori󰘰ce

15

Ori󰘰ce

15 15

. ..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

17

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Table

Table Table

Ori󰘰ce

17 17

. ..Ori󰘰ce Ori󰘰ce

18

Ori󰘰ce

18 18

. ..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

16

Table Table

FLUID

FLUID FLUID

PRES-

PRES- PRES­SURE:

SURE: SURE:

bar,

psi

Ori󰘰ce

16 16

. ..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

3A2496H95

AirCaps

Air

Air Air

Air

Air Air

Thechartsinthissectioncanassistyouinselecting
anaircap.

•Keepinmindthatmorethanoneaircapcanmeet

•Whenselectinganaircap,considercoating

Caps

Caps Caps

Cap

Cap Cap

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page39,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

963A2496H

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

round

with with

round round

ends

ends ends

areversatile.Theycanbeusedinanyapplicationandareoftenthebest

Fan

patterns

–Fan Fan

patterns patterns

passes.

with

tapered

with with

tapered tapered

ends

ends ends

arebestforachievingevencoatingthicknesswithoverlappingpaint

3A2496H97

AirCaps

General

General General

Part

Part Part

24N477Black

24W479

24N438BlackAlternate

24N376Black

24N276Blue

24N277Red

24N278

24N274Black

General

General General

Part

Part Part

24N477Black

24W479

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.Oftenusedinwaterborneapplications.

Similartothestandardaircapwithanalternatearrangementofatomizingair.

Longestspraypattern,optimizedforpaintinglargepartswithoverlappingpaint
passes.Oftenusedinwaterborneapplications.

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)

983A2496H

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

Caps: Caps:

Description

Description Description

SoftSprayForpaintingsmall,lightweightpartswithaslow-movingspraypattern.Optimized

SolidsOptimizedformediumandheavyviscosityandhighsolidcoatingsatstandard

SolidsHigh
Flow

Air

Caps:

Air Air

Caps: Caps:

Description

Description Description

SoftSpray

Solids

SolidsHigh
Flow

Descriptions

Descriptions Descriptions

Guidelines

Guidelines Guidelines

forlowproductionrates.

Optimizedforaerospacecoatings.

•ClassA󰘰nish

•Light,medium,andheavyviscosity,andhighsolidcoatings

•Veryhighproductionrates

productionrates.

Requiredforusewith2.0mmnozzles.Optimizedformediumandheavyviscosity
andhighsolidcoatingsathighproductionrates.

Speci󰘰cations

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- Atom­iza-

iza- iza­tion

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)

3A2496H99

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

Color

Color Color

Air

Caps:

Air Air

Caps: Caps:

Color

Color Color

Descriptions

Caps: Caps:

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- Atom­iza-

iza- iza­tion

tion tion

GoodGood

Clean-

Clean- Clean­liness

liness liness

Good

Good

1003A2496H