Graco Pro Xp H60T10, Pro Xp H85T10, Pro Xp H85M10, Pro Xp H60M10, Pro Xp H85M57 Instructions Manual

Instructions-Parts

Pro

Pro Pro
Air

Air Air

For

For For
For

For For
use

use use

3000psi(21MPa,210bar)Maximum
FluidWorkingPressure
100psi(0.7MPa,7bar)MaximumAir
WorkingPressure

Seepage3formodelpartnumbersand
approvalinformation.

Xp™

Xp™ Xp™

Assisted

- --Assisted Assisted

use

use use
use

use use

only.

only. only.

Class

in ininClass Class

Group

in ininGroup Group

Important

Important Important
Thisequipmentcouldpresenthazardsifnotoperatedaccordingto
theinformationinthismanual.Read Read
this

manual

this this

manual manual

Electrostatic

Electrostatic Electrostatic

Spray

Spray Spray

Div.

I, I,I,Div. Div.

II,

II, II,

Safety

Safety Safety

before

before before

Hazardous

I IIHazardous Hazardous

Zone

Zone Zone

Explosive

1 11Explosive Explosive

Instructions

Instructions Instructions

using

using using

Gun

Gun Gun

Locations

Locations Locations

Atmosphere

Atmosphere Atmosphere

Read

the

equipment.

the the

equipment. equipment.

using

Group

using using

Group Group

Locations

Locations Locations

all

warnings

all all

warnings warnings

Save

Save Save

and

and and

these

instructions.

these these

instructions. instructions.

materials.

D DDmaterials. materials.

using

Group

using using

Group Group

instructions

instructions instructions

IIA

materials.

IIA IIA

materials. materials.

in

in in

3A2495K

EN

For

professional

For For

professional professional

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

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

Approvals...........................................................3

RelatedManuals................................................3

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

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

HowtheElectrostaticAASprayGun

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

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

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

Installation..........................................................14

WarningSign...............................................14

VentilatetheSprayBooth.............................14

AirSupplyLine............................................15

FluidSupplyLine.........................................15

Grounding...................................................17

GunSetup..........................................................21

GunSetupProcedure...................................21

CheckGunElectricalGrounding...................24

CheckFluidResistivity.................................25

CheckFluidViscosity...................................25

FlushBeforeUsingEquipment......................25

Operation...........................................................26

PressureReliefProcedure............................26

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

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

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

DailyCareandCleaningChecklist................28

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

CleantheGunDaily.....................................30

DailySystemCare.......................................31

ElectricalTests...................................................32

TestGunResistance....................................32

TestPowerSupplyResistance.....................33

TestGunBarrelResistance..........................34

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

SprayPatternTroubleshooting......................35

GunOperationTroubleshooting....................36

ElectricalTroubleshooting............................37

Repair................................................................39

PreparetheGunforService.........................39

AirCap,SprayTip,andFluidSeatHousing

Replacement..................................40

ElectrodeReplacement................................41

FluidTubeRemovalandReplacement...........42

FluidFilterReplacement...............................42

GunBarrelRemoval.....................................43

GunBarrelInstallation..................................43

FluidNeedleReplacement............................44

PowerSupplyRemovaland

Replacement..................................45

AlternatorRemovalandReplacement...........46

FanAirAdjustmentValveRepair..................48

AtomizingAirAdjustmentValve

Repair............................................48

ESOn-OffValveRepair...............................49

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

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

AirSwivelandExhaustValve

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

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

StandardAir-AssistedSprayGun

Assembly.......................................53

SmartAir-AssistedSprayGun

Assembly.......................................55

AlternatorAssembly.....................................57

ESOn-OffValveAssembly...........................58

FanAirAdjustmentValveAssembly..............59

AirCapAssembly........................................60

SmartModuleAssembly...............................60

SprayTipSelectionChart....................................61

AEMFineFinishSprayTips..........................61

AEFFineFinishPre-Ori󰘰ceSpray

Tips...............................................62

RoundSprayTips........................................63

RecommendedFilterSizes...........................64

RepairKitsandAccessories................................65

GunAccessories..........................................65

InlineFluidFilterKitAccessories...................65

OperatorAccessories...................................66

SystemAccessories.....................................66

Signs..........................................................66

TestEquipment...........................................66

Hoses.........................................................67

Dimensions........................................................68

TechnicalSpeci󰘰cations......................................69

GracoProXpWarranty.......................................70

2

3A2495K

Models

2575

Models

Models Models

Part

No.

Part Part

No. No.

kV

kV kV

Display

Display Display

H60T1060

H60M1060

H85T1085

H85M1085

H85T57*

H85M57*

*HighAirFlowGunModels,equippedwithESOn-OffwithAirRestrictorValve,whichlimitsair󰘱owtothe
turbine.Forapplicationsthatrequirehighair󰘱owattheaircap.

Approvals

Approvals Approvals

85

85

G

II IIII2 22G G

0.24mJT6

Standard

Smart

Standard

Smart

Standard

Smart

FM12ATEX0068

EN50050–1

Ta0°C–50°C

Related

Related Related

Manual

Manual Manual

3A2499

307263ProbeandMeter,Instructions

308393

309227

309455TestFixture,HighVoltageProbe,andkVMeter,Instructions

406999

No.

No. No.

Manuals

Manuals Manuals

Description

Description Description

RoundSprayKit,Instructions

GunWasherKit,Instructions

GunFlushBoxModule,Instructions

VoltageTesterConversionKit,Instructions

3A2495K3

Warnings

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰c
hazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanual
whereapplicable.

WARNING

WARNING WARNING

FIRE,

EXPLOSION,

FIRE, FIRE,

EXPLOSION, EXPLOSION,

Flammablefumes,suchassolventandpaintfumes,inwork work
Paintorsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent
󰘰re,explosion,andelectricshock:

•Electrostaticequipmentmustbeusedonlybytrained,quali󰘰edpersonnelwhounderstand
therequirementsofthismanual.

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

•OnlyusegroundedGracoconductiveairsupplyhoses.

•Donotusepaillinersunlesstheyareconductiveandgrounded.
Stop

•Stop Stop

•Checkgunresistance,hoseresistance,andelectricalgroundingdaily.

•Useandcleanequipmentonlyinwellventilatedarea.

•Interlockthegunairand󰘱uidsupplytopreventoperationunlessventilationair󰘱owisabove

•UseonlyGroupIIAorGroupDmaterials.

•Usecleaningsolventswithhighestpossible󰘱ashpointwhen󰘱ushingorcleaningequipment.

•Neversprayor󰘱ushsolventathighpressure.

•Tocleantheexterioroftheequipment,cleaningsolventsmusthavea󰘱ashpointatleast15°

•Alwaysturntheelectrostaticsoffwhen󰘱ushing,cleaningorservicingequipment.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

•Donotplugorunplugpowercordsorturnlightsonoroffwhen󰘱ammablefumesarepresent.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Keepthesprayareacleanatalltimes.Usenon-sparkingtoolstocleanresiduefromthe

•Keepaworking󰘰reextinguisherintheworkarea.

operation

operation operation

equipmentuntilyouidentifyandcorrecttheproblem.

theminimumrequiredvalue.

Cor59°Faboveambienttemperature.Non-ignitable󰘱uidsarepreferred.

plasticdropcloths(potentialstaticsparking).

boothandhangers.

AND

ELECTRIC

AND AND

ELECTRIC ELECTRIC

immediately

immediately immediately

ifstaticsparkingoccursoryoufeelashock.Donotuse

SHOCK

SHOCK SHOCK

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplodee.

Grounding

instructions.

4

3A2495K

WARNING

WARNING WARNING

SKIN

INJECTION

SKIN SKIN

INJECTION INJECTION
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
treatment.

treatment. treatment.

•Donotspraywithouttipguardandtriggerguardinstalled.

•Engagetriggerlockwhennotspraying.

•Donotpointgunatanyoneoratanypartofthebody.

•Donotputyourhandoverthespraytip.

•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure

orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

HAZARD

HAZARD HAZARD

Get

immediate

immediate immediate

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopsprayingandbeforecleaning,checking,

Warnings

surgical

surgical surgical

3A2495K5

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,requestSafetyDataSheets(SDSs)from
yourdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

PLASTIC

PLASTIC PLASTIC
Manycleaningsolventscandegradeplasticpartsandcausethemtofail,whichcouldcause
seriousinjuryorpropertydamage.

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

•Useonlycompatiblesolventstocleanplasticstructuralorpressure-containingparts.

•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

HAZARD

HAZARD HAZARD

EQUIPMENT

EQUIPMENT EQUIPMENT

63A2495K

GunOverview

Gun

Gun Gun

How

How How
Works

Works Works

Thisisnotanairspraygun.Tohelpprevent
seriousinjuryfrompressurized󰘱uid,suchasskin
injection,andsplashing󰘱uid,readandfollowthe
Skin

Skin Skin

Theair-assistedsprayguncombinesairlessand
airsprayingconcepts.Thespraytipatomizes
andshapesthe󰘱uidintoafanpattern,asdoes
aconventionalairlessspraytip.Airfromtheair
capfurtheratomizesthe󰘱uidandcompletesthe
atomizationofthe󰘱uidtailstoproduceauniform
pattern.

Asthegunistriggered,partoftheregulatedair
operatesthealternatorturbineandtherestofthe
airhelpsatomizethe󰘱uidbeingsprayed.The

Overview

Overview Overview

the

Electrostatic

the the

Electrostatic Electrostatic

Injection

Injection Injection

Hazard

Hazard Hazard

Warnings

Warnings Warnings

AA

AA AA

Spray

Spray Spray

onpage5.

Gun

Gun Gun

alternatorgeneratespower,whichisconvertedby
thepowercartridgetosupplyhighvoltagetothe
gun’selectrode.

The󰘱uidiselectrostaticallychargedasitpasses
theelectrode.Thecharged󰘱uidisattractedtothe
groundedworkpiece,wrappingaroundandevenly
coatingallsurfaces.

Theregulatedairthatisdirectedtotheaircapcan
befurthercontrolledusingthegun’satomizingair
adjustmentvalve.Thisvalvecanbeusedtorestrict
air󰘱owtotheaircapwhilemaintainingsuf󰘰cientair
󰘱owtothealternator.Theatomizingairadjustment
valvedoesnotcontrolpatternwidth.Tochange
patternwidth,useanewtipsize,orusethefan
adjustmenttonarrowthepatternwidth.

Thehighworking󰘱uidpressureofthisgunprovides
thepowerneededtoatomizehighersolidsmaterials.

NOTE:

NOTE: NOTE:
gun’satomizingairadjustmentvalvecompletelyoff.
Closingthisvalvedoesnotaffectalternatoroperation.

Forairlessatomization,ifdesired,turnthe

3A2495K

7

GunOverview

Controls,

Controls, Controls,

Theelectrostaticgunincludesthefollowingcontrols,indicators,andcomponents(seeFig.1).Forinformation
onSmartguns,alsoseeSmartGuns,page9.

Figure1GunOverview

Item

Item Item

A

Indicators,

Indicators, Indicators,

Description

Description Description

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

and

Components

and and

Components Components

Purpose

Purpose Purpose

BFluidInlet

C

D

EElectrode

FFanAirAdjustmentValve

G

H

J

K

LInlineFluidFilter

TurbineAirExhaust

AirCap/TipGuardand
SprayTip

AtomizingAirAdjustment
Valve

TriggerSafetyLockLockstriggertopreventgunfromspraying.

ESOn-OffValveTurnselectrostaticsON(I)orOFF(O).

ESIndicator(standard
gunonly;forSmart
gunindicator,see

OperatingMode,page9)

1/4npsm(m),for󰘱uidsupplyhose.

Barbed󰘰tting,forsuppliedexhausttube.

SeeSprayTipSelectionChart,page61,foravailablesizes.

Supplieselectrostaticchargetothe󰘱uid.

Adjustsfansizeandshape.Canbeusedtodecreasepatternwidth.

Adjustsatomizingair󰘱ow.

LitwhenESisON(I).Colorindicatesalternatorfrequency.Seethe
LEDindicatortableintheGunSetupProcedure,page21.

Provides󰘰nal󰘰ltrationof󰘱uid.Locatedinside󰘱uidtube󰘰tting.

83A2495K

GunOverview

Smart

Smart Smart

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

•OperatingMode

•DiagnosticMode

Operating

Operating Operating

Bar

Bar Bar

SeeFig.2andSmartGunKey,page11.The
OperatingModedisplaysgundataduringnormal
spraying.Thedisplayusesabargraphtoshowthe
voltagelevelinkiloVolts(kV)andthecurrentlevelin
microAmperes(uA).Thebargraphrangeisfrom0
to100%foreachvalue.

IftheuAbargraphLEDsareblue,thegunisready
tospray.IftheLEDsareyelloworred,thecurrentis
toohigh.The󰘱uidmaybetooconductive,orsee

ElectricalTroubleshooting,page37forotherpossible

causes.

Guns

Guns Guns

Mode

Mode Mode

Graph

Graph Graph

Voltage

Voltage Voltage

Thevoltageadjustmentswitch(VA)allowsthe
operatortochangefromlowtohighvoltage.

•Thehighvoltagesettingisdeterminedbythe
maximumvoltageofthegunandisnotadjustable.

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

AdjustingtheLowVoltageSetting,page10.

NOTE:

NOTE: NOTE:
haslostcommunicationwiththepowersupply.See

ErrorDisplay,page10,forfurtherinformation.

Adjustment

Adjustment Adjustment

IftheErrordisplayappears,theSmartmodule

Switch

Switch Switch

Hz

Indicator

Hz Hz

Indicator Indicator

TheHzindicatorfunctionsthesameastheES
indicatoronstandardguns.Theindicatorlightsto
showthealternatorspeedstatus,andhasthree
colors:

•Greenindicatesthealternatorspeediscorrect.

•Iftheindicatorchangestoamberafteronesecond,
increasetheairpressure.

•Iftheindicatorchangestoredafteronesecond,
theairpressureistoohigh.Decreaseairpressure
untiltheindicatorisgreen.Tomaintainahigher
airpressure,installESOn/OffValveRestrictorKit
26A294.Then,adjustthepressureasneededto
ensuretoensuretheindicatorremainsgreen.

Figure2SmartGunModuleinOperatingMode

3A2495K9

GunOverview

Error

Error Error

IftheSmartmodulelosescommunicationwith
thepowersupply,theErrordisplayappears,the
Hzindicatorturnsred,andtheSmartmoduleis
disabled.SeeFig.3andSmartGunKey,page11.
ThiscanoccurinOperatingModeorDiagnostic
Mode.SeeElectricalTroubleshooting,page37.
CommunicationmustberestoredtomaketheSmart
modulefunctional.

NOTE:

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

NOTE:

NOTE: NOTE:
displaywillnotappear.

Display

Display Display

Ittakes8secondsfortheErrordisplayto

Ifthereisnopowertothegun,theError

foryourgun.Continuepressingthebuttonuntilyou
reachthedesiredsetting.

NOTE:

NOTE: NOTE:
returntotheOperatingScreen.

NOTE:

NOTE: NOTE:

LockSymbol,page10.

Figure4LowVoltageSettingScreen(Unlocked)

Lock

Lock Lock

After2secondsofinactivitythedisplaywill

Thelowvoltagesettingmaybelocked.See

Symbol

Symbol Symbol

Figure3ErrorDisplay

Adjusting

Adjusting Adjusting

Thelowvoltagesettingisuseradjustable.Toaccess
thelowvoltagesettingscreenwheninOperating
Mode,presstheLOSETbutton(LS)momentarily.
Thescreenwilldisplaythecurrentlowvoltage
setting.SeeFig.4andSmartGunKey,page11.
Thepossiblerangesare:

•85kVguns:40–85kV

•60kVguns:30–60kV

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

the

Low

the the

Voltage

Low Low

Voltage Voltage

Setting

Setting Setting

Thelowvoltagesettingmaybelocked.Whenlocked,
animage(LK)appearsonthescreen.SeeFig.5
andSmartGunKey,page11.

•WheninHImode,thelowvoltagesettingisalways always
locked.ThelocksymbolwillappearwhentheLO
SETbuttonispressed.

•WheninLOmode,thelocksymbolwill
only

only only

appearifthelockisenabled.See

LowVoltageLockScreen,page13,tolockor

unlockthelowvoltagesetting.

Figure5LowVoltageSettingScreen(Locked)

always

103A2495K

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.

3A2495K

11

GunOverview

Diagnostic

Diagnostic Diagnostic

DiagnosticModeincludesfourscreenswhichdisplay
gundata:

•Voltage(kiloVolts)Screen

•Current(microAmperes)Screen

•AlternatorSpeed(Hertz)Screen

•LowVoltageLockScreen

NOTE:

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

ToenterDiagnosticMode,pressandholdtheLOSET
(LS)buttonforapproximately5seconds.Thedisplay
willgototheVoltage(kiloVolts)Screen,page12.

Toadvancetothenextscreen,presstheLOSET
buttonagain.

ToexitDiagnosticMode,pressandholdtheLOSET
buttonforapproximately5seconds.Thescreenwill
returntoOperatingMode.

NOTE:

NOTE: NOTE:
Mode,thelastscreenviewedwillbedisplayedwhen
thegunisretriggered.

NOTE:

NOTE: NOTE:
fromtheLowVoltageLockScreen.See

LowVoltageLockScreen,page13fordetails.

Mode

Mode Mode

YoumustbeinOperatingModetoadjustthe

IfthegunisdetriggeredwhileinDiagnostic

DiagnosticModecannotbeexited

Figure6Voltage(kiloVolts)Screen

Current

Current Current

TheCurrent(microAmperes)Screenisthesecond
screenintheDiagnosticMode.SeeFig.7and

SmartGunKey,page11.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,page11.Toenterthisscreen,
pressandholdtheLOSETbuttonforapproximately
5secondswhileintheOperatingMode.

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

PresstheLOSETbuttontoadvancetothe

Current(microAmperes)Screen,page12.Press

andholdforapproximately󰘰vesecondstoreturnto
OperatingMode.

(kiloVolts)

(kiloVolts) (kiloVolts)

Screen

Screen Screen

PresstheLOSETbuttontoadvancetothe

AlternatorSpeed(Hertz)Screen,page13.Press

andholdforapproximately󰘰vesecondstoreturnto
OperatingMode.

Figure7Current(microAmperes)Screen

12

3A2495K

GunOverview

Alternator

Alternator Alternator

TheAlternatorSpeed(Hertz)Screenisthethird
screenintheDiagnosticMode.SeeFig.8and

SmartGunKey,page11.Toenterthisscreen,

presstheLOSETbuttonwhileintheCurrent
(microAmperes)Screen.

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

TheHzindicatorlightsgreentoshowthatyouare
viewingtheAlternatorSpeed(Hertz)Screen.

PresstheLOSETbuttontoadvancetothe

LowVoltageLockScreen,page13.Pressandhold

forapproximately5secondstoreturntoOperating
Mode.

Speed

Speed Speed

(Hertz)

(Hertz) (Hertz)

Screen

Screen Screen

Low

Voltage

Low Low

Voltage Voltage

TheLowVoltageLockScreenisthefourth
screenintheDiagnosticMode.SeeFig.9and

SmartGunKey,page11.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

3A2495K13

Installation

Installation

Installation Installation

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseelectricshock
orotherseriousinjuryifworkisnotperformed
properly.

•Donotinstallorservicethisequipmentunless
youaretrainedandquali󰘰ed.

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

•Complywithalllocalcodesandregulations.

Fig.10(TypicalInstallation)showsatypical
electrostaticair-assistedspraysystem.Itisnotan
actualsystemdesign.Forassistanceindesigning
asystemtosuityourparticularneeds,contactyour
Gracodistributor.

Warning

Warning Warning

Sign

Sign Sign

Ventilate

Ventilate Ventilate

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

Thesprayboothmusthaveaventilationsystem.

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

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

the

Spray

the the

Spray Spray

Booth

Booth Booth

Mountwarningsignsinthesprayareawherethey
caneasilybeseenandreadbyalloperators.An
EnglishWarningSignisprovidedwiththegun.

14

3A2495K

Air

Supply

Air Air

Supply Supply

Toreducetheriskofelectricshock,theairsupply
hosemustbeelectricallyconnectedtoatrueearth
ground.Use Use
Hose.

Hose. Hose.

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

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

Toreducetheriskofseriousinjurydueto
componentrupture,includingskininjection,
pumppressuremustbelimitedbythepumpair
regulator.Donotrelyonthegun󰘱uidregulator
tolimitthe󰘱uidpressuretothegun.

Line

Line Line

Use

only

Graco

only only

Graco Graco

Grounded

Grounded Grounded

Air

Supply

Air Air

Supply Supply

Installation

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

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

Fluid

Fluid Fluid

1.Blowoutthe󰘱uidline(FL)withairand󰘱ushit

2.Installa󰘱uidpressureregulator(FR)onthe󰘱uid

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

Supply

Supply Supply

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

linetocontrol󰘱uidpressuretothegun.

removeparticlesandsedimentwhichcouldclog
thespraynozzle.

NOTE:

NOTE: NOTE:
additional󰘰ltration.

Thegunincludesaninline󰘱uid󰘰lterfor

Line

Line Line

The󰘱uidsupplypumpmustbepreventedfrom
producinga󰘱uidpressuregreaterthanthe
3000psi(21MPa,210bar)

FluidPressure

supplypressuretoa30:1ratiopumpmustnot
exceed100psi(0.7MPa,7bar).

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

Trappedaircancausethepumptocycle
unexpectedly,whichcanresultinserious
injury,includingskininjectionandsplashing
󰘱uidintheeyesorontheskin.Donotoperate
theequipmentwithoutthebleed-typeairvalve
(BV)installed.

ofthegun.Forexample,theair

MaximumWorking

Toreducetheriskofseriousinjury,including
skininjectionandsplashing󰘱uidintheeyesor
ontheskin,donotoperateequipmentwithout
the󰘱uiddrainvalve(FD)installed.

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

3A2495K15

Installation

NON

HAZARDOUS

NON NON

- --HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

HAZARDOUS

HAZARDOUS HAZARDOUS

LOCATION

LOCATION LOCATION

Figure10TypicalInstallation

Typical

Typical Typical

Item

Item Item

AF

AG*GunAirHoseGroundWire

AH*GracoGroundedAirHose(left-hand

ALPumpAirLineLubricator

BV*PumpBleed-TypeAirShutoffValve

EGElectrostaticAirSprayGun

FD*

FFFluidFilter

FGFluidPressureGauge

FL

FRFluidPressureRegulator

Installation

Installation Installation

Description

Description Description

AirFilter/WaterSeparator

threads)

FluidDrainValve

FluidSupplyLine

Key

Key Key

Item

Item Item

FV

GRGunAirPressureRegulator

MA

PG*PumpGroundWire

PRPumpAirPressureRegulator

RVPumpRunawayValve

SPSupplyPump

SV*VentilationFanInterlockSolenoidValve

*Theseitemsarerequiredforsafeoperation.They
mustbepurchasedseparately.

Description

Description Description

FluidShutoffValve

MainAirSupplyLine

NOTE:

NOTE: NOTE:
aGracoaccessory.

Thesolenoidvalveisnotofferedas

163A2495K

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.

•

ElectrostaticAir-AssistedSprayGun:

thegunbyconnectingtheGracoGrounded
AirHosetothegun,andconnectingtheair
hosegroundwiretoatrueearthground.See

CheckGunElectricalGrounding,page24.

•

Pump/󰘱uidsource:

byconnectingitsgroundwiretoatrueearth
ground.

Groundthepump/󰘱uidsource

Installation

Ground

Allpersonsenteringthesprayarea:

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

•

Objectbeingsprayed:

cleanandgroundedatalltimes.

Keeptheworkpiecehangers

mustwear

•

Allelectricallyconductiveobjectsordevicesinthe
sprayarea:

•

Fluidandwastecontainers:

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

•

Aircompressors:

tothemanufacturer'srecommendations.

•

Allairand󰘱uidlines

Useonlygroundedhoseswithamaximumof100
feet(30.5m)combinedhoselengthtoensure
groundingcontinuity

The󰘱oorofthesprayarea:

•
conductiveandgrounded.Donotcoverthe󰘱oor
withcardboardoranynon-conductivematerial
whichwouldinterruptgroundingcontinuity

mustbeproperlygrounded.

Groundall󰘱uidand

Groundtheequipmentaccording

mustbeproperlygrounded.

mustbeelectrically

3A2495K

17

Installation

•

Flammableliquidsinthesprayarea:

inapproved,groundedcontainers.Donotuse

mustbekept

plasticcontainers.Donotstoremorethanthe
quantityneededforoneshift.

•

Allsolventpails:

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

Useonlyapproved,grounded

183A2495K

Installation

Figure11GroundtheOperatorOperatorisgroundedthroughthegunhandleand

conductiveshoes.

Figure12GroundtheObjectbeingSprayedObjectbeingsprayedisgroundedthroughcontact

withthehangerandconveyorsystem.

3A2495K19

Installation

Figure13GroundtheGunGunisgroundedthroughtheconductiveairhose.

Figure14GroundtheFluidSupplyFluidsupplylineandsourcemustbegrounded.

203A2495K

GunSetup

Gun

Gun Gun

Gun

Gun Gun

Seethe󰘰gurebelowtolocatetheelectrostaticgun
controls.

Figure15ElectrostaticGunControls

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

Setup

Setup Setup

Setup

Setup Setup

Procedure

Procedure Procedure

4.ConnecttheGracogroundedairhosetothegun

airinlet.Thegunairinlet󰘰ttinghasleft-hand
threads.

5.FollowallstepsunderGrounding,page17.

6.Followallstepsunder

CheckGunElectricalGrounding,page24.

Readingmustbelessthan1megohm.

7.Verifythatthematerialresistivitymeets

requirementsforelectrostaticspray.See

CheckFluidResistivity,page25.

8.Connecttheexhausttubeandsecurewiththe

clampprovided.

2.Shutofftheairbleedvalvetothegun.

3.Checkgunresistance.See

TestGunResistance,page32.

9.Connectthe󰘱uidhosetothegun󰘱uidinlet.

10.Flushifneeded.SeeFlushing,page28.

3A2495K

21

GunSetup

Toreducetheriskofaskinin­jectioninjury,alwaysfollowthe

PressureReliefProcedure,page26,

beforeremovingorinstallingthespraytip,air
cap,ortipguard.

15.CheckthattheESOn-OffswitchisOFF(O).

11.The󰘱uidoutputandpatternwidthdepend
onthesizeofthespraytip,the󰘱uid
viscosity,andthe󰘱uidpressure.Usethe

SprayTipSelectionChart,page61,asaguide

forselectingtheappropriatespraytipforyour
application.

12.Alignthespraytiptabwiththegrooveintheair
cap.Installthetip.

13.Installtheaircapandretainingring.Orientate
theaircapandtightentheretainingringsecurely.

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

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

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

18.TurnON(I)theESOn-Offswitch.

22

3A2495K

GunSetup

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

Table

Table Table

Indicator

Indicator Indicator

Amber

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

LED

2 22. ..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
RestrictorKit26A294.Adjustthe
pressureasneededtoensurethe
indicatorremainsgreen.

Colors

Colors Colors

Description

Description Description

21.Turntheatomizingairadjustmentvalve
counterclockwiseuntilanytailsdisappear.

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

23.Sprayatestpiece.Examinetheedges
forcoverage.Ifwrapispoor,see

Troubleshooting,page35.

Table

Table Table

mm]

mm] mm]

Pressure

3 33. ..Pressure Pressure

Air

Hose

Air Air

Hose Hose

Length

Length Length

(using

(using (using

in ininft ftft(m) (m)

5/16

5/16 5/16

diameter

diameter diameter

15(4.6)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)

NOTE:

NOTE: NOTE:

Regulator

Regulator Regulator

psi

in ininpsi psi

[with

gun

[with [with

gun gun

Setting

Setting Setting

(MPa,

(MPa, (MPa,

bar)

bar) bar)

triggered]

triggered] triggered]

openthefanairadjustmentvalveslightly.(Excessive
fanair󰘱owcancausepaintbuildupontheaircap.)

Ifanarrowerpatternisneededoccasionally,

3A2495K23

GunSetup

Check

Check Check

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

•Thegunhasbeenremovedfromthehazardous

•Orallsprayingdevicesinthehazardous

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

GracoPartNo.241079Megohmmeterisavailable
asanaccessorytocheckthatthegunisproperly
grounded.

1.Haveaquali󰘰edelectricianchecktheelectrical

2.TurnOFF(O)theESOn-Offswitch.

Gun

Gun Gun

location;

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

groundingcontinuityofthespraygunandair
hose.

Electrical

Electrical Electrical

Grounding

Grounding Grounding

5.Makesurethegroundedairhoseisconnected
andthehosegroundwireisconnectedtoatrue
earthground.

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

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

3.Turnofftheairand󰘱uidsupplytothegun.Follow
thePressureReliefProcedure,page26.

4.Disconnectthe󰘱uidhose.

24

Figure16CheckGunElectricalGrounding

3A2495K

GunSetup

Check

Check Check

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

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

Fluidresistivityreadingsofatleast20megohms-cm
generallyprovidethebestelectrostaticresultsand
arerecommended.

Table

Table Table

Fluid

Fluid Fluid

Fluid

4 44. ..Fluid Fluid

Resistivity

Resistivity Resistivity

Resistivity

Resistivity Resistivity

Megohms Megohms

Levels

Levels Levels

Megohms

cm

- --cm cm

Check

Check Check

Aviscositycupandstopwatchareneededtocheck
󰘱uidviscosity.

1.Completelysubmergetheviscositycupin

2.Watchthestreamof󰘱uidcomingfromthebottom

3.Recordthe󰘱uidtype,elapsedtime,andsizeof

4.Iftheviscosityistoohighortoolow,contactthe

Flush

Flush Flush

Theequipmentwastestedin󰘱uidatthefactory.To
avoidcontaminatingyour󰘱uid,󰘱ushtheequipment
withacompatiblesolventbeforeusingtheequipment.
SeeFlushing,page28.

Fluid

Fluid Fluid

the󰘱uid.Liftthecupoutquickly,startingthe
stopwatchassoonasthecupiscompletely
removed.

ofthecup.Assoonasthereisabreakinthe
stream,shutoffthestopwatch.

theviscositycup.

materialsupplier.Adjustasnecessary.

Before

Before Before

Viscosity

Viscosity Viscosity

Using

Using Using

Equipment

Equipment Equipment

1–55–2020–200200–2000

Testelec­trostatic
perfor­mance

Goodelec­trostatic
results

Bestelec­trostatic
results

Goodelec­trostatic
results

3A2495K25

Operation

Operation

Operation Operation

Pressure

Pressure Pressure

Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.

1.TurnOFF(O)theESOn/Offswitch.

2.Engagethetriggerlock.

Relief

Relief Relief

Procedure

Procedure Procedure

4.Disengagethetriggerlock.

5.Triggerthegunintoagroundedmetalwaste
containertorelievethe󰘱uidpressure.

6.Engagethetriggerlock.

7.Openthepumpdrainvalve,havingawaste
containerreadytocatchthedrainage.Leave
thepumpdrainvalveopenuntilyouareready
tosprayagain.

3.Turnofftheairbleedvalvestothe󰘱uidsource
andtothegun.

8.Ifthespraytiporhoseiscompletelycloggedor
pressureisnotfullyrelieved,slowlyloosenthe
hoseendcoupling.Nowclearthespraytipor
hose.

263A2495K

Operation

Startup

Startup Startup

FollowallstepsunderGunSetupProcedure,page21.

Checkthefollowinglistdaily,beforestartingto
operatethesystem,tohelpensureyouofsafe,
ef󰘰cientoperation.

•Alloperatorsareproperlytrainedtosafelyoperate
anautomaticelectrostaticairspraysystemas
instructedinthismanual.

•Alloperatorsaretrainedinthe

PressureReliefProcedure,page26.

•Thewarningsignprovidedwiththegunismounted
inthesprayareawhereitcanbeeasilyseenand
readbyalloperators.

•Thesystemisthoroughlygroundedandthe
operatorandallpersonsenteringthesprayarea
areproperlygrounded.SeeGrounding,page17.

•Theconditionofthegun’selectrical
componentshasbeencheckedasinstructedin

ElectricalTests,page32.

•Ventilationfansareoperatingproperly.

•Workpiecehangersarecleanandgrounded.

•Alldebris(including󰘱ammable󰘱uidsandrags)is
removedfromthesprayarea.

•All󰘱ammable󰘱uidsinthespraybootharein
approved,groundedcontainers.

•Allconductiveobjectsinthesprayareaare
electricallygroundedandthe󰘱oorofthespray
areaiselectricallyconductiveandgrounded.

Shutdown

Shutdown Shutdown

Toreducetheriskofaninjury,followthe

PressureReliefProcedure,page26wheneveryou

areinstructedtorelievethepressure.

1.Flushthegun.SeeFlushing,page28.

2.FollowthePressureReliefProcedure,page26.

3.Hangthegunfromitshook,withthenozzle
pointingdown.

3A2495K

27

Maintenance

Maintenance

Maintenance Maintenance

Daily

Daily Daily

Checkthefollowinglistdailyuponcompletionof
equipmentusage.















Care

Care Care

Flushthegun.SeeFlushing,page28.

Cleanthe󰘱uidandairline󰘰lters.

Cleantheoutsideofthegun.See

CleantheGunDaily,page30.

Cleantheaircapandspraytipdaily,at
aminimum.Someapplicationsrequire
morefrequentcleaning.Replacethespray
tipandaircapiftheyaredamaged.See

CleantheGunDaily,page30.

Checktheelectrodeandreplace
ifbrokenordamaged.See

ElectrodeReplacement,page41.

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

Checkelectricalgrounding.See

CheckGunElectricalGrounding,page24.

and

Cleaning

and and

Cleaning Cleaning

Checklist

Checklist Checklist

Flushing

Flushing Flushing

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

•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.

•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.

Toreducetheriskof󰘰re,explosion,orelectric
shock:

•TurnOFF(O)theESOn-Offswitchbefore
󰘱ushingthegun.

•Alwaysgroundequipmentandwastecontainers.

•Flushequipmentonlyinawell-ventilatedarea.

•UseonlyGroupIIA󰘱ushingmaterials.
Non-ignitable󰘱uidsarepreferred.

•Toavoidstaticsparkingandinjuryfrom
splashing,always󰘱ushatthelowestpossible
pressure.

NOTICE

NOTICE NOTICE

Donotusemethylenechlorideasa󰘱ushingor
cleaningsolventwiththisgunasitwilldamage
nyloncomponents.

1.TurnOFF(O)theESOn-Offswitch.

2.FollowthePressureReliefProcedure,page26.

3.Removeandcleantheaircapandspraytip.

283A2495K

Maintenance

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

5.Pointthegunintoagroundedmetalpail.Flush
untilcleansolvent󰘱owsfromthegun.

6.FollowthePressureReliefProcedure,page26.
Engagethetriggerlock.

7.Shutoffordisconnectthesolventline.

8.Alignthespraytiptabwiththegrooveintheair
cap.Checktheconditionofthetipgasket(27a),
andreplaceifdamaged.Installthetip.

9.Reinstalltheaircap,tipguard,andretainingring.

10.Hangthegunfromitshook,withthenozzle
pointingdown.

11.Whenreadytosprayagain,reconnect
the󰘱uidsupplyline.Followthe

GunSetupProcedure,page21.

3A2495K29

Maintenance

Clean

Clean Clean

•Cleanallpartswithanon-conductive,compatible

•Fluidintheairpassagescouldcausethegunto

1.TurnOFF(O)theESOn-Offswitch.

2.FollowthePressureReliefProcedure,page26.

3.Removetheaircap/tipguardandspraytip.

the

Gun

the the

Gun Gun

solvent.Conductivesolventscancausethegun
tomalfunction.

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

Daily

Daily Daily

NOTICE

NOTICE NOTICE

6.Cleantheoutsideofthegunwithacompatible
solvent.Useasoftcloth.Pointthegundownto
preventsolventfromenteringthegunpassages.
Donotimmersethegun.

4.Flushthegun,seeFlushing,page28.

5.FollowthePressureReliefProcedure,page26.

303A2495K

Maintenance

7.Cleantheaircap/tipguardandspraytipwitha
softbrushandcompatiblesolvent.

8.Ifnecessary,useatoothpickorothersofttoolto
cleantheaircapholes.Donotusemetaltools.

Daily

Daily Daily

1.FollowthePressureReliefProcedure,page26.

2.Cleanthe󰘱uidandair󰘰lters.

3.Checkfor󰘱uidleaks.Tightenall󰘰ttings.

4.Cleanworkpiecehangers.Usenon-sparking

System

System System

tools.

Care

Care Care

9.Alignthespraytiptabwiththegrooveintheair
cap.Checktheconditionofthetipgasket(27a),
andreplaceifdamaged.Installthetip.

10.Installtheaircapandretainingring.Orientate
theaircapandtightentheretainingringsecurely.

5.Checkthemovementofthetriggerandvalves.
Lubricateifnecessary.

6.CheckGunElectricalGrounding,page24.

7.Hangthegunfromitshook,withthenozzle
pointingdown.

3A2495K31

ElectricalTests

Electrical

Electrical Electrical

Electricalcomponentsinsidethegunaffect
performanceandsafety.Usethefollowing
procedurestotesttheconditionofthepowersupply
andgunbody,andelectricalcontinuitybetween
components.

Thegunbodyresistorcartridgeispartofthebody
andisnotreplaceable.Toavoiddestroyingthegun
body,donotattempttoremovethebodyresistor.

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

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

Tests

Tests Tests

NOTICE

NOTICE NOTICE

Test

Test Test

1.Flushanddrythe󰘱uidpassage.

2.Measureresistancebetweentheelectrode

Gun

Gun Gun

needletip(25a)andtheairswivel(21).The
resistanceshouldbe:

•106–150megohmsfor60kVguns

•150–195megohmsfor85kVguns

Ifoutsidethisrange,goto

TestPowerSupplyResistance,page33.Ifin

range,seeElectricalTroubleshooting,page37for
otherpossiblecausesofpoorperformance.

Resistance

Resistance Resistance

•Thegunhasbeenremovedfromthehazardous
location;

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

Failuretofollowthiswarningcouldcause󰘰re,
explosion,andelectricshockandresultinserious
injuryandpropertydamage.

Figure17TestGunResistance

323A2495K

ElectricalTests

Test

Test Test

1.Removethepowersupply(11).SeePower

2.Removethealternator(15)

3.Measureresistancefromthepowersupply's

4.Ifoutsidethisrange,replacethe

5.Ifyoustillhaveproblems,referto

6.Besurethespring(11a)isinplacebefore

Power

Power Power

SupplyRemovalandReplacement,page45.

fromthepowersupply.See

AlternatorRemovalandReplacement,page46.

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

•86–110megohmsfor60kVguns

•130–160megohmsfor85kVguns

powersupply.Ifinrange,goto

TestGunBarrelResistance,page34.

Electrical

Electrical Electrical

otherpossiblecausesofpoorperformance,or
contactyourGracodistributor.

reinstallingthepowersupply.

Supply

Supply Supply

Troubleshooting

Troubleshooting Troubleshooting

Resistance

Resistance Resistance

page

, ,,page page

37

37 37

, ,,for

Figure18TestPowerSupplyResistance

3A2495K33

ElectricalTests

Test

Test Test

1.Insertaconductiverod(B)intothegunbarrel

2.Measuretheresistancebetweentheconductive

3.Iftheresistanceisstilloutsidetherange,

4.Iftheresistanceisinrange,replacethe

Gun

Gun Gun

(whichwasremovedforthepowersupplytest)
andagainstthemetalcontact(C)inthefrontof
thebarrel.

rod(B)andtheconductivering(9).The
resistanceshouldbe10–30megohms.Ifthe
resistanceisincorrect,makesurethemetal
contact(C)inthebarrelandtheconductivering
(9)arecleanandundamaged.

removetheconductivering(9)andmeasurethe
resistancebetweentheconductiverod(B)and
thewireleadatthebottomoftheconductivering
groove.

conductivering(9)withanewone.Insertthe
endsoftheconductiveringintotheslots(S)at
thefrontofthebarrel,thenpressthering󰘰rmly
intothegroove(G).

Barrel

Barrel Barrel

Resistance

Resistance Resistance

Figure19TestGunBarrelResistance

Theconductivering(9)isaconductive(metal)
contactring,notasealingo-ring.Toreduce
theriskof󰘰re,explosion,orelectricshock:

•Donotremovetheconductiveringexcept
toreplaceit.

•Neveroperatethegunwithouttheconductive
ringinplace.

•Donotreplacetheconductiveringwith
anythingbutagenuineGracopart.

5.Iftheresistanceisstilloutsidetherange,replace
thegunbarrel.

343A2495K

Troubleshooting

Troubleshooting

Troubleshooting Troubleshooting

Installingandservicingthisequipmentrequires
accesstopartswhichmaycauseanelectricshock
orotherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorservicethisequipment
unlessyouaretrainedandquali󰘰ed.

CheckallpossibleremediesintheTroubleshootingChartbeforedisassemblingthegun.

Spray

Spray Spray

NOTE:

NOTE: NOTE:

Problem

Problem Problem

Flutteringorspittingspray.

Irregularpattern.

Pattern

Pattern Pattern

Somespraypatternproblemsarecausedbytheimproperbalancebetweenairand󰘱uid.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

No󰘱uid.Re󰘰llsupply.

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

Fluidbuildup;partiallypluggedtip.

Worn/damagedtiporaircapholes.

Toreducetheriskofaskininjectioninjury,always
followthePressureReliefProcedure,page26,
wheneveryouareinstructedtorelievethe
pressure.

Solution

Solution Solution

Clean.See

CleantheGunDaily,page30.

Cleanorreplace.

Patternpushedtooneside;air
capgetsdirty.

Tailsinpattern.

Fluidbuilduponaircap/tipguard.

3A2495K35

Aircapholesplugged.

Airpressuretoolow.

Fluidpressuretoolow.Increase.

Airpressuretoohigh.Decrease.

Fluidpressuretoolow.Increase.

Aircapholesplugged.

Clean.See

CleantheGunDaily,page30.

Openatomizingairadjustment
valve.

Clean.See

CleantheGunDaily,page30.

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.

Atomizingairpressuretoolow.

Spraytipistoolarge.Usesmallertip.SeeSprayTip

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

Fluidtoothick.Reduceviscosity.

Worn󰘱uidneedlepackingsorrod.Replacepackings.SeeFluid

Airvalveisnotseatingproperly.

Wornordamaged󰘱uidneedleball.SeeFluidNeedleReplacement,

Solution

Solution Solution

Closeatomizingairvalvepartway,
ordecreaseairpressureaslow
aspossible;minimum45psi(0.32
MPa,3.2bar)neededatgunfor
fullvoltage.

Increaseviscosityorincrease󰘱uid
󰘱owrate.

Openatomizingairvalvemoreor
increasegunairinletpressure;
uselowestairpressurenecessary.

SelectionChart,page61.

NeedleReplacement,page44.

Replaceairvalve.See

AirValveRepair,page50.

page44.

Worn󰘱uidseathousing.SeeAirCap,SprayTip,andFluid

Loosespraytip.Tightenretainingring.

Damagedtipseal.

Gundoesnotspray.

Dirtyaircap.Damagedorpluggedaircap.

Excessivepaintwrapbackto
operator.

Low󰘱uidsupply.Add󰘱uidifnecessary.

Damagedspraytip.Replace.

Dirtyorcloggedspraytip.

Damaged󰘱uidneedle.SeeFluidNeedleReplacement,

Poorgrounding.

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

SeatHousingReplacement,page

40.

SeeAirCap,SprayTip,andFluid

SeatHousingReplacement,page

40.

Clean.See

CleantheGunDaily,page30.

page44.

Cleanaircap.See

CleantheGunDaily,page30.

SeeGrounding,page17.

363A2495K

Troubleshooting

Electrical

Electrical Electrical

Problem

Problem Problem

Poorwrap.

Troubleshooting

Troubleshooting Troubleshooting

Cause

Cause Cause

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

Gunairpressuretoolow(ES
indicatorisamber).

Atomizingairpressuretoohigh.Decrease.

Fluidpressuretoohigh.Decrease,orreplaceworntip.

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

Poorlygroundedparts.Resistancemustbe1megohmor

Faultygunresistance.

Low󰘱uidresistivity.See

Fluidleaksfromthe󰘱uidneedle
packingsandcausesashort.

Faultyalternator.

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

Solution

Solution Solution

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

less.Cleanworkpiecehangers.

See

TestGunResistance,page32.

CheckFluidResistivity,page25.

SeeFluidNeedleReplacement,

page44.

SeeAlternatorRemovaland

Replacement,page46.

Operatorgetsshockfrom
workpiece.

Nopower.

Operatornotgroundedorisnear
ungroundedobject.

Gunnotgrounded.SeeCheckGunElectrical

Workpiecenotgrounded.Resistancemustbe1megohmor

Checkpowersupply,alternator,
andalternatorribboncable.See

PowerSupplyRemovaland
Replacement,page45and
AlternatorRemovaland
Replacement,page46.

SeeGrounding,page17. Operatorgetsmildshock.

Grounding,page24,and
TestGunResistance,page32.

less.Cleanworkpiecehangers.

3A2495K37

Troubleshooting

Problem

Problem Problem

Voltage/currentdisplaystaysred
(smartgunsonly).

ESorHzindicatorisamber.

ESorHzindicatorisred.

ErrordisplayappearsandHz
indicatorisred(Smartgunsonly).

Cause

Cause Cause

Gunistooclosetothepartbeing
sprayed.

Check󰘱uidresistivity.See

Dirtygun.

Alternatorspeedistoolow.Increaseairpressureuntil

Alternatorspeedistoohigh.Decreaseairpressureuntil

Smartmodulehaslost
communicationwiththepower
supply.

Solution

Solution Solution

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

CheckFluidResistivity,page25.

SeeCleantheGunDaily,page30.

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

indicatorisgreen,orinstallES
On-OffwithAirRestrictor,which
limitstheair󰘱owtotheturbine.

Checkforgoodconnections
betweenSmartModuleand
powersupply.SeeSmartModule

Replacement,page51and
PowerSupplyRemovaland
Replacement,page45.

383A2495K

Repair

Repair

Repair Repair

Prepare

Prepare Prepare

Installingandrepairingthisequipmentrequires
accesstopartsthatmaycauseelectricshockor
otherseriousinjuryiftheworkisnotperformed
properly.Donotinstallorservicethisequipment
unlessyouaretrainedandquali󰘰ed.

Toreducetheriskofinjury,followthe

PressureReliefProcedure,page26,before

checkingorservicinganypartofthesystem
andwheneveryouareinstructedtorelievethe
pressure.

•Checkallpossibleremediesin

Troubleshooting,page35,beforedisassembling

thegun.

the

Gun

the the

Gun Gun

for

Service

for for

Service Service

•Useavisewithpaddedjawstopreventdamage
toplasticparts.

•Lubricatethesomeneedleassemblyparts(20)
andcertain󰘱uid󰘰ttingswithdielectricgrease(57),
asspeci󰘰edinthetext.

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

•OnlyusegenuineGracoparts.Donotmixoruse
partsfromotherProGunmodels.

•AirSealRepairKit24N789isavailable.The
kitmustbepurchasedseparately.Kitpartsare
markedwithanasterisk,forexample(3*).

1.Flushthegun.SeeFlushing,page28.

2.Relievethepressure.See

PressureReliefProcedure,page26.

3.Disconnectthegunairand󰘱uidlines.

4.Removethegunfromtheworksite.Repairarea

mustbeclean.

3A2495K39

Repair

Air

Cap,

Air Air

Cap, Cap,

Spray

Spray Spray

Tip,

and

Tip, Tip,

Fluid

and and

Fluid Fluid

Seat

Seat Seat

Housing

Housing Housing

Replacement

Replacement Replacement

1.SeePreparetheGunforService,page39.

2.Removetheretainerring(22)andaircap/tip
guardassembly(25).

Figure20RemoveAirCap

3.Disassembletheaircapassembly.Checkthe
conditionoftheu-cup(22a),o-ring(25b),andtip
gasket(27a).Replaceanydamagedparts.

4.Toreplacetheelectrode(25a),see

ElectrodeReplacement,page41.

Theconductivering(9)isaconductivemetal
contactring,notasealingo-ring.Toreduce
theriskof󰘰re,explosion,orelectricshock:

•Donotremovetheconductiveringexcept
toreplaceit.

•Neveroperatethegunwithouttheconductive
ringinplace.

•Donotreplacetheconductiveringwith
anythingbutagenuineGracopart.

5.Triggerthegunandremovethe󰘱uidseathousing
(24),usingthemulti-tool(61).

Figure21DisassembleAirCapAssembly

Figure22TipGasket

Figure23ReplaceFluidSeatHousing

403A2495K

Repair

NOTICE

NOTICE NOTICE

Donotovertightenthe󰘱uidseathousing(24).
Overtighteningmaydamagethehousingand
thegunbarrel,resultinginimproper󰘱uid
shutoff.

6.Triggerthegunandinstallthe󰘱uidseathousing
(24).Tightenuntilsnug,then1/4turnmore.

7.Checkthatthespraytipgasket(27a)isinplace.
Alignthespraytiptabwiththegrooveintheair
cap(25).Installthespraytip(27)intheaircap.

8.Makesurethattheelectrode(25a)isinstalled
correctlyintheaircap.

9.Checkthattheaircapo-ring(25b)isinplace.

10.Checkthattheu-cup(22a)isinplaceonthe
retainingring(22).Thelipsoftheu-cupmust
faceforward.

NOTICE

NOTICE NOTICE

Toavoiddamagingthetipguard,orientthe
aircapassembly(25)beforetighteningthe
retainingring(22).Donotturntheaircap
whentheretainingringistight.

11.Orientatetheaircapandtightentheretaining
ringsecurely.

12.SeeTestGunResistance,page32.

Electrode

Electrode Electrode

Toreducetheriskof󰘰re,explosion,orelectric
shock,donotoperatethespraygunwithoutthe
electrodeinstalledintheaircap.

1.Followthestepsin

PreparetheGunforService,page39.

2.Removetheaircapassembly(25).See

AirCap,SprayTip,andFluidSeatHousing
Replacement,page40.

3.Pulltheelectrode(25a)outofthebackoftheair
cap,usinganeedle-nosepliers.

4.Pushthenewelectrodethroughtheaircaphole.
Makesuretheshortend(BB)oftheelectrode
engagesthehole(CC)inthebackoftheair
cap.Presstheelectrodeinplace󰘰rmlywithyour
󰘰ngers.

5.Installtheaircapassembly.

6.FollowthestepsinTestGunResistance,page32.

Replacement

Replacement Replacement

Figure24ReplaceElectrode

3A2495K

41

Repair

Fluid

Fluid Fluid

1.SeePreparetheGunforService,page39.

2.Disconnectthebottom󰘱uidtubenut(C).

3.Carefullyunscrewthetop󰘱uidtubenut(D).

4.Applydielectricgrease(57)totheentirelengthof

5.Applylowstrengthsealanttothe󰘱uidtubenut

6.Installthe󰘱uidtubeintothegunbarreland

7.Makesurethe󰘱uid󰘰lter(10)isinplaceinthe

Tube

Tube Tube

Becarefulnottodamagethe󰘱uidtube
assembly(19)whencleaningorinstalling
it,especiallythesealingsurface(E).Ifthe
sealingsurfaceisdamaged,theentire󰘱uid
tubeassemblymustbereplaced.

theplasticextensiononthe󰘱uidtube.

threads.

tightenthetopnut(D)untilsnug,then1/2turn
tighter.Therewillbeagapbetweenthenutand
barrel.Donotover-tightenthenut.

󰘱uid󰘰tting.Tightenthebottomnut(C)securely
ontothe󰘰tting.Makesurethetopnutremains
tight.

Removal

Removal Removal

and

Replacement

and and

Replacement Replacement

NOTICE

NOTICE NOTICE

Fluid

Fluid Fluid

1.SeePreparetheGunforService,page39.

2.Disconnectthebottom󰘱uidtubenut(C).

3.Removethe󰘱uid󰘰lter(10)fromthe󰘱uid󰘰tting.

4.Installthe󰘱uid󰘰lter(10)inthe󰘱uid󰘰tting.Tighten

Filter

Filter Filter

Cleanorreplacethe󰘰lter,asneeded.

thebottomnut(C)ontothe󰘰ttingandtorqueto
140–150in-lb(15.8–16.9N•m).Makesurethe
topnutremainstightat20–30in-lb(2.3–3.4N•m).

Besurethe󰘱uidtube(19)isnottwistedafter
tighteningthebottomnut(C).

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Figure25FluidTube

Figure26ReplaceFluidFilter

42

3A2495K

Repair

Gun

Gun Gun

1.SeePreparetheGunforService,page39.

2.Disconnectthebottom󰘱uidtubenut(N).

3.Loosenthetwoscrews(6).

4.Holdthegunhandle(16)withonehandandpull

NOTE:

NOTE: NOTE:
removethealternator/powersupplyassemblyfrom
thebarrel.

Barrel

Barrel Barrel

Carefullyseparatethetubeassembly(T)from
thebracket(7).

Toavoiddamagingthepowersupply(11),
pullthegunbarrelstraightawayfromthegun
handle.Ifnecessary,gentlymovethegun
barrelfromsidetosidetofreeitfromthegun
handle.

thebarrel(1)straightoffthehandle.

Ifthepowersupplyremainsinthebarrel,

Removal

Removal Removal

NOTICE

NOTICE NOTICE

Gun

Gun Gun

1.Besurethegasket(5*)andgroundingspring

2.Makesurethespring(11a)isinplaceonthe

3.Tightenthetwoscrews(6)oppositelyandevenly

4.Makesurethe󰘱uid󰘰lter(10)isinplaceinthe

5.FollowthestepsinTestGunResistance,page32.

Barrel

Barrel Barrel

(37a)areinplace.Makesurethegasketair
holesarealignedproperly.Replacethegasketif
damaged.

tipofthepowersupply(11).Liberally Liberally
dielectricgrease(57)tothetipofthepower
supply.Placethegunbarrel(1)overthepower
supplyandontothegunhandle(16).

(aboutahalfturnpastsnug,or20in-lbs,2.3
N•m).

Toavoiddamagingthegunbarrel,donot
over-tightenthescrews(6).

󰘱uid󰘰tting.Tightenthebottomnut(N)ontothe
󰘰ttingandtorqueto140–150in-lb(15.8–16.9
N•m).Makesurethetopnutremainstight.

Installation

Installation Installation

Liberally

NOTICE

NOTICE NOTICE

apply

Figure27GunBarrelRemoval

Figure28GunBarrelInstallation

3A2495K43

Repair

Fluid

Fluid Fluid

1.SeePreparetheGunforService,page39.

2.Removetheaircapassemblyand󰘱uidseat

3.Removethegunbarrel.See

4.Removethetriggerscrews(13)andtrigger(12).

5.Unscrewthespringcap(37).Removethespring

6.Besuretheseathousing(24)isremoved.Place

7.Usingtheexternalhexendoftheplasticmulti-tool

Needle

Needle Needle

housing.SeeAirCap,SprayTip,andFluidSeat

HousingReplacement,page40.

GunBarrelRemoval,page43.

(20a).

the2mmballendwrench(60)inthebackof
the󰘱uidneedleassembly.Pushthetoolforward
sothetwosegmentsoftheneedleengage,and
turnitcounterclockwiseabout12fullturnsto
unthreadtheneedle.

(61),carefullypushstraightonthe󰘱uidneedle
ballfromthefrontofthebarreluntilthe󰘱uidseals
releasefromthebore.

Topreventneedleassemblyseparationor
damage,becertainneedleisdisengaged
beforeremoving.

Replacement

Replacement Replacement

NOTICE

NOTICE NOTICE

Figure29RemoveCapandSprings

8.Removethe󰘱uidneedleassemblyfromtheback
ofthegunbarrel.

9.Installthe󰘱uidneedleassemblyinthegunbarrel.
Pushinontheneedlewiththedriver(60)and
tighten.

10.Installthespring(20a).

11.Installthespringcap(37).Makesurethe
groundingspring(37a)isinplace.

12.Installthetrigger(12)andscrews(13).

13.Installthegunbarrel.See

GunBarrelInstallation,page43.

14.Installtheseathousingandaircapassembly.
SeeAirCap,SprayTip,andFluidSeatHousing

Replacement,page40.

15.SeeTestGunResistance,page32.

Figure30RemoveFluidNeedle

Figure31ReplaceFluidNeedle

44

3A2495K

Repair

Power

Power Power

•Inspectthegunhandlepowersupplycavityfordirt

ormoisture.Cleanwithaclean,dryrag.

•Donotexposegasket(5)tosolvents.

1.SeePreparetheGunforService,page39.

2.SeeGunBarrelRemoval,page43.

3.Graspthepowersupply(11)withyourhand.

4.Inspectthepowersupplyandalternatorfor

5.Toseparatethepowersupply(11)fromthe

6.SeeTestPowerSupplyResistance,page33.

7.

Supply

Supply Supply

Becarefulwhenhandlingthepowersupply
(11)toavoiddamagingit.

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

Modelsonly,

fromthesocketatthetopofthehandle.

damage.

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

Modelsonly,

(40)fromthepowersupply.Slidethealternator
upandoffthepowersupply.

Replacethepowersupplyifnecessary.
Torepairthealternator,see

AlternatorRemovalandReplacement,page46.

Smartmodelsonly:

circuit(40)tothepowersupply.

Removal

Removal Removal

NOTICE

NOTICE NOTICE

disconnectthe󰘱exiblecircuit(40)

disconnectthe6–pin󰘱exiblecircuit

connectthe6–pin󰘱exible

and

Replacement

and and

Replacement Replacement

OnSmart

OnSmart

9.Insertthepowersupply/alternatorassemblyin
thegunhandle(16).Makesurethegroundstrips
(EE)makecontactwiththehandle.OnSmart
models,aligntheconnectorofthe6–pin󰘱exible
circuit(40)withthesocket(CS)atthetopofthe
handle.Pushtheconnectorsecurelyintothe
socketasyouslidethepowersupply/alternator
assemblyintothehandle.

Figure32ConnectFlexibleCircuit

10.Makesurethegasket(5*),groundspring
(37a),andpowersupplyspring(11a)are
inplace.Replacegasket(5*)ifdamaged.
Assemblethebarrel(1)tothehandle(16).See

GunBarrelInstallation,page43.

11.SeeTestGunResistance,page32.

NOTICE

NOTICE NOTICE

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

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

Figure33PowerSupply

3A2495K45

Repair

Alternator

Alternator Alternator

NOTE:

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

1.SeePreparetheGunforService,page39.

2.Removethepowersupply/alternatorassembly

3.Measureresistancebetweenthetwoouter

4.Usinga󰘱atbladescrewdriver,prytheclip(15h)

5.Ifnecessary,rotatethefan(15e)soitsblades

Replacealternatorbearingsafter2000hours

anddisconnectthealternator.SeePowerSupply

RemovalandReplacement,page45.

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).

Figure35AlternatorCross-Section

♦5isnotshownintheillustration.

Figure34FanOrientation

NOTICE

NOTICE NOTICE

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

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

8.Removethetopbearing(15b2).

9.Removethebottombearing(15b1).

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

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

463A2495K

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.35.Besurethecoilalignmentpins
(P)arepositionedasshowninFig.34.

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,page45.

Figure36Alternator

3A2495K

47

Repair

Fan

Air

Fan Fan

1.Followthestepsin

PreparetheGunforService,page39.

2.Placeawrenchonthe󰘱atsofthevalveassembly
(30)andunscrewitfromthehandle(16).

NOTE:

NOTE: NOTE:
assembly(gotostep9)orasindividualparts
(steps3-9).

3.Removetheretainingring(30d).

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

5.Removetheo-ring(30c).

6.Cleanallpartsandinspectforwearordamage.

NOTE:

NOTE: NOTE:

111265.Donotover-lubricate.

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

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

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

Adjustment

Air Air

Adjustment Adjustment

Youmayreplacethevalveasan

Usenon-siliconegrease,PartNo.

Valve

Valve Valve

Repair

Repair Repair

Atomizing

Atomizing Atomizing
Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page39.

2.Placeawrenchonthe󰘱atsofthevalveassembly
(29)andunscrewitfromthehandle(16).

3.Inspectthevalveassembly.Ifdamaged,install
anewvalve(29).

4.Beforeinstallingthevalveassemblyinthe
handle,unscrewthevalvestem(29b)fromthe
housing(29a)untilitstops.

5.Installthevalveassemblyintothegunhandle.
Torquethevalvehousing(29a)to15in-lb(1.7
N•m).

Figure38AtomizingAirAdjustmentValve

Air

Adjustment

Air Air

Adjustment Adjustment

Valve

Valve Valve

Figure37FanAirAdjustmentValve

483A2495K

Repair

ES

On

Off

ES ES

On On

Valve

- --Off Off

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page39.

2.Loosenthecaptivescrew(26p).Removethe
valve(26)fromthehandle.

3.Lubricatetheo-rings(26b*and26g*)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(26p)to
15-25in-lb(1.7-2.8N•m).

Theprotrusionontheretainerplate(26f)

Figure39ESOn-OffValve

3A2495K49

Repair

Air

Valve

Air Air

Valve Valve

Repair

Repair Repair

1.Followthestepsin

PreparetheGunforService,page39.

2.FollowthestepsinGunBarrelRemoval,page43.

3.Removethescrews(13)andtrigger(12).

4.RemovetheESOn-OffValve.See

ESOn-OffValveRepair,page49.

5.Removethespring(2).

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

7.Inspecttheu-cup(3).Donotremovetheu-cup
unlessdamaged.Ifremoved,installthenewone
withitslipsfacingintothegunhandle(16).Place
theu-cupontheshaftoftheairvalvetohelpseat
itinthegunhandle.

8.Installtheairvalve(23)andspring(2)intothe
gunhandle(16).

9.InstalltheESOn-OffValve.See

ESOn-OffValveRepair,page49.

10.Installthetrigger(12)andscrews(13).

11.Followthestepsin

GunBarrelInstallation,page43.

Figure40InstallU-Cup

Figure41AirValve

503A2495K

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,page39.

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

Figure42SmartModule

Figure43AlignRibbonCables

3A2495K51

Repair

Air

Swivel

Air Air

Swivel Swivel

1.Followthestepsin

PreparetheGunforService,page39.

2.Toreplacetheairexhaustvalve:

a.Removetheclamp(36)andtheexhausttube

(35).

b.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.
Removethebracket(7).

c.Pulltheexhaustvalve(8)fromthehandle

(16).Inspecttheo-ring(8a)andreplaceif
necessary.

d.Installtheo-ring(8a*)ontheexhaustvalve

(8).Lubricatetheo-ringwithalightcoating
ofnon-siliconegrease.

e.Installtheexhaustvalve(8)inthehandle

(16).

f.Applythreadsealanttothetopthreadsof

theswivel(21).Positionthebracket(7)and
screwtheswivelintothegunhandle(16).
Torqueto75–85in-lb(8.4–9.6N•m).

g.Installthetube(35)andclamp(36).

3.Toreplacetheairinletswivel:

and

Exhaust

and and

Exhaust Exhaust

Valve

Valve Valve

Replacement

Replacement Replacement

Figure44AirInletFittingandAirExhaustValve

a.Unscrewtheswivel(21)fromthegunhandle

(16).Theswivelisaleft-handthread.

b.Applythreadsealanttothetopthreadsofthe

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

523A2495K

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.

Air

Assisted

Air Air

- --Assisted Assisted

H60T10

H60T10 H60T10
H85T10

H85T10 H85T10
H85T57

H85T57 H85T57

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

85

kV

High

85 85

kV kV

High High

Spray

Spray Spray

Air

Flow

Air Air

Flow Flow

Gun

Gun Gun

Air-Assisted

Air-Assisted Air-Assisted
Air-Assisted

Air-Assisted Air-Assisted

Electrostatic

Electrostatic Electrostatic

Assembly

Assembly Assembly

Spray

Gun,

Spray Spray
Spray

Spray Spray

Air-Assisted

Air-Assisted Air-Assisted

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

C

C C
C

C C

Spray

Gun,

Spray Spray

Series

Gun, Gun,

Series Series

A

A A

Torqueto20in-lb(2N•m).

3A2495K53

Parts

Part

No.

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
1

2185116

3*

5*

624N740

7

8249323VALVE,exhaust1

8a*

924N747

10238562FILTER,inline,100mesh;see

11

11a24N979

1224N663

1324A445

1524N664

19

20

20a24N782

2124N626

2224N793

22a*

2324N633VALVE,air1

23a*

2424N725

H60T10

No. No.

H60T10 H60T10

No.

H85T10

No. No.

H85T10 H85T10

No.

H85T57

No. No.

H85T57 H85T57

Part

Part Part

24N746

24N745

188749

25N921

24N742

112085

24N660

24N661

24N761HANDLE;60kVAAgun1 16

24N762HANDLE;85kVAAgun1

24N744

24N743

24N780

24N781

198307

276733

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

85

kV

High

85 85

kV kV

No.

Description

No. No.

Description Description

BODY,gun;60kVgun,includes
gasket(5)

BODY,gun;85kVgun,includes
gasket(5)

SPRING,compression

PACKING,u-cup

GASKET,body

SCREW,hexsocket;packof2

BRACKET

O-RING

RING,conductive

notebelow
POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

See

AlternatorAssembly,page57

TUBE,󰘱uid;60kVgun

TUBE,󰘱uid;85kVgun

NEEDLEASSEMBLY;60kV
gun;includesitem20a

NEEDLEASSEMBLY;85kV
gun;includesitem20a

SPRING,󰘱uidneedle

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

RING,retainer;includes22a

PACKING,u-cup;UHMWPE;
partof22

SEAL

HOUSING,seat

Air

High High

Air Air

Air-Assisted

Air-Assisted Air-Assisted
Air-Assisted

Air-Assisted Air-Assisted

Flow

Electrostatic

Flow Flow

Electrostatic Electrostatic

Spray

Gun,

Spray Spray
Spray

Spray Spray

Air-Assisted

Air-Assisted Air-Assisted

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

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Ref.

Ref. Ref.
No.

No. No.
2524N727

25a24N643

2624N632ForH60T10andH85T10mod-

27AEMxxx

27a183459

2924N792

3024N634

3224E404

32a

35185103

36110231

3724N785

37a197624

3824N786

51112080

54

55▲

56▲16P802

57

58117824

60107460

61276741

6224N783

Spray

Spray Spray

Part

Part Part

26A294

AEFxxx

———

24N603

24N604

179791

116553

C

C C

C

C C

Gun,

Series

Gun, Gun,

Series Series

No.

Description

No. No.

Description Description

SeeAirCapAssembly,page60

ELECTRODE;packageof5

els.SeeESOn-OffValve

Assembly,page58

ForH85T57models.See

ESOn-OffValveAssembly,
page58

TIPASSEMBLY;customer’s
choice;includesitem27a

GASKET,tip

ATOMIZINGAIR
ADJUSTMENTVALVE

SeeFanAirAdjustmentValve

Assembly,page59

STOP,trigger;includesitem32a

PIN,dowel1

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

CLAMP

CAP,spring;includesitem37a

SPRING,compression

PLUG,fancontrol;option,
shippedlooseforuseinplace
ofitem29

TOOL,needle(shippedloose)

COVER,gun,60kVguns;
packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

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

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

TOOL,wrench,ballend
(shippedloose)

MULTI-TOOL(shippedloose)

HOOK;includesscrew

A

A A

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

▲ReplacementDangerandWarninglabels,tags,and
cardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit24N789
(purchaseseparately).

Partslabeled———arenotavailableseparately.

NOTE:

NOTE: NOTE:

SeeInlineFluidFilterKitAccessories,page65for

kitoptionsinstandardandalternatemeshsizes.

543A2495K

Parts

1

Smart

Smart Smart

Part

Part Part
Part

Part Part
Part

Part Part

Air

Assisted

Air Air

- --Assisted Assisted

No.

H60M10

No. No.

H60M10 H60M10

No.

H85M10

No. No.

H85M10 H85M10

No.

H85M57

No. No.

H85M57 H85M57

60

60 60
85

85 85

85

85 85

Spray

Spray Spray

kV

Electrostatic

kV kV

Electrostatic Electrostatic

kV

Electrostatic

kV kV

Electrostatic Electrostatic

kV

High

kV kV

High High

Gun

Gun Gun

Air

Flow

Air Air

Flow Flow

Assembly

Assembly Assembly

Air-Assisted

Air-Assisted Air-Assisted
Air-Assisted

Air-Assisted Air-Assisted

Electrostatic

Electrostatic Electrostatic

Spray

Gun,

Spray Spray
Spray

Spray Spray

Air-Assisted

Air-Assisted Air-Assisted

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

C

C C
C

C C

Spray

Gun,

Spray Spray

Series

Gun, Gun,

Series Series

A

A A

Torqueto20in-lb(2N•m).

3A2495K55

Parts

Part

No.

Part Part
Part

Part Part
Part

Part Part

Ref.

Ref. Ref.
No.

No. No.
1

2185116

3*

5*

624N740

7

8249323VALVE,exhaust1

8a*

924N747

10238562FILTER,inline,100mesh;see

11

11a24N979

1224N663

1324A445

1524N664

19

20

20a24N782

2124N626

2224N793

22a*

2324N633VALVE,air1

23a*

2424N725

2524N727

H60M10

No. No.

H60M10 H60M10

No.

H85M10

No. No.

H85M10 H85M10

No.

H85M57

No. No.

H85M57 H85M57

Part

Part Part

24N746

24N745

188749

25N921

24N742

112085

24N660

24N661

24N763HANDLE,smart;60kVAAgun1 16

24N764HANDLE,smart;85kVAAgun1

24N744

24N743

24N780

24N781

198307

276733

60

kV

Electrostatic

60 60

kV kV

Electrostatic Electrostatic

85

kV

Electrostatic

85 85

kV kV

Electrostatic Electrostatic

85

kV

High

85 85

kV kV

High High

No.

Description

No. No.

Description Description

BODY,gun;60kVgun,includes
gasket(5)

BODY,gun;85kVgun,includes
gasket(5)

SPRING,compression

PACKING,u-cup

GASKET,body

SCREW,hexsocket;sst;
packageof2

BRACKET

O-RING

RING,conductive

notebelow
POWERSUPPLY,60kVgun

POWERSUPPLY,85kVgun

SPRING

TRIGGER;includesitem13

SCREW,trigger;packageof2

See

AlternatorAssembly,page57

TUBE,󰘱uid;60kVgun

TUBE,󰘱uid;85kVgun

NEEDLEASSEMBLY;60kV
gun;includesitem20a

NEEDLEASSEMBLY;85kV
gun;includesitem20a

SPRING,󰘱uidneedle

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

RING,retainer;includes22a

PACKING,u-cup;UHMWPE;
partof22

SEAL

HOUSING,seat

SeeAirCapAssembly,page60

Air-Assisted

Air-Assisted Air-Assisted
Air-Assisted

Air-Assisted Air-Assisted

Air

Flow

Air Air

Electrostatic

Flow Flow

Electrostatic Electrostatic

Spray

Gun,

Spray Spray
Spray

Spray Spray

Air-Assisted

Air-Assisted Air-Assisted

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

Series

Gun, Gun,

Series Series

Gun,

Series

Gun, Gun,

Series Series

Ref.

Ref. Ref.
No.

No. No.
25a24N643

2624N632ForH60M10andH85M10

27AEMxxx

27a183459

2924N792

3024N634

3124N756

3224E404

32a

35185103

36110231

3724N785

37a197624

3824N786

40245265

51112080

54

55▲

56▲16P802

57

58117824

60107460

61276741

6224N783

Spray

Spray Spray

Part

Part Part

26A294

AEFxxx

———

24N603

24N604

179791

116553

C

C C

C

C C

Gun,

Series

Gun, Gun,

Series Series

No.

Description

No. No.

Description Description

ELECTRODE;packageof5

models.SeeESOn-OffValve

Assembly,page58

ForH85M57models.See

ESOn-OffValveAssembly,
page58

TIPASSEMBLY;customer’s
choice;includesitem27a

GASKET,tip

ATOMIZINGAIR
ADJUSTMENTVALVE

SeeFanAirAdjustmentValve

Assembly,page59

SeeSmartModuleAssembly,

page60

STOP,trigger;includesitem32a

PIN,dowel1

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

CLAMP

CAP,spring;includesitem37a

SPRING,compression

PLUG,fancontrol;option,
shippedlooseforuseinplace
ofitem29

CIRCUIT,󰘱exible

TOOL,needle(shippedloose)

COVER,gun,60kVguns;
packageof10

COVER,gun,85kVguns;
packageof10

TAG,warning(notshown)

SIGN,warning(notshown)

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

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

TOOL,wrench,ballend
(shippedloose)

MULTI-TOOL(shippedloose)

HOOK;includesscrew

A

A A

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

▲ReplacementDangerandWarninglabels,tags,and
cardsareavailableatnocost.

*ThesepartsareincludedinAirSealRepairKit24N789
(purchaseseparately).

NOTE:

NOTE: NOTE:

SeeInlineFluidFilterKitAccessories,page65for

kitoptionsinstandardandalternatemeshsizes.

Partslabeled———arenotavailableseparately.

563A2495K

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

15e♦

Part

Part Part
No.

No. No.

———

Description

Description Description

COIL,alternator

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

SHAFTKIT(includesshaft
andmagnet)

HOUSING;includesitem15f

FAN;partofitem15b

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

♦ThesepartsareincludedinBearingKit24N706
(purchaseseparately).

Qty

Qty Qty

1

1

1

1

1

Ref.

Ref. Ref.

No.

No. No.

15f♦

15g*

15h♦24N709

5♦*

Part

Part Part
No.

No. No.

———

110073

25N921

Description

Description Description

CAP,housing;partofitem
15d

O-RING

CLIP;packageof5(oneclip
includedwithitem15b)

GASKET,barrel(notshown
indrawing)

Qty

Qty Qty

1

1

1

1

Partslabeled———arenotavailableseparately.

3A2495K57

Parts

ES

On

Off

ES ES

On On

Part

No.

Part Part

No. No.

Part

No.

Part Part

No. No.

Valve

- --Off Off

Valve Valve

24N632

24N632 24N632

26A294

26A294 26A294

Assembly

Assembly Assembly

ES

On-Off

ES ES

On-Off On-Off

ES

On-Off

ES ES

On-Off On-Off

Valve

Assembly

Valve Valve

Assembly Assembly

Valve

with

Air

Valve Valve

with with

Restrictor

Air Air

Restrictor Restrictor

Assembly

Assembly Assembly

Part

No.

Ref.

Ref. Ref.
No.

No. No.

26a

26b*

26c

26f

26g

Part Part

———

15D371

———

24N650

GC2081SCREW,set,sockethead

Description

No. No.

Description Description

HOUSING,valve;blackfor
24N632,bluefor26A294

O-RING

PISTON,valve

LEVER,ESon-off;includes
26g

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Part

No.

Qty

Qty Qty

1

2

1

1

1

Ref.

Ref. Ref.
No.

No. No.

26h

26m*

26p

Part Part

24N631

16J578

113746

24N740

GC2081SCREW,captive;packof2;

Description

No. No.

Description Description

PLATE,retaining;forkit
24N632

PLATE,retaining;forkit
26A294

O-RING

SCREW,captive;packof2;
forkit24N632

forkit26A294

Qty

Qty Qty

1

1

1

1

Partslabeled———arenotavailableseparately.

583A2495K

Parts

Fan

Air

Fan Fan

Part

Part Part

Adjustment

Air Air

Adjustment Adjustment

No.

24N634

No. No.

24N634 24N634

Fan

Fan Fan

Valve

Valve Valve

Air

Adjustment

Air Air

Adjustment Adjustment

Assembly

Assembly Assembly

Valve

Assembly

Valve Valve

Assembly Assembly

Ref.

Ref. Ref.

No.

No. No.

30a

30b

30c*

30d24N646

*ThesepartsareincludedinAirSealRepairKit
24N789(purchaseseparately).

Partslabeled———arenotavailableseparately.

Part

Part Part

———

———

111504

No.

Description

No. No.

Description Description

NUT,valve1

STEM,valve

O-RING

RING,retaining;packageof6

Qty

Qty Qty

1

1

1

3A2495K59

Parts

Air

Cap

Air Air

Cap Cap

Part

No.

Part Part

No. No.

Ref.

Ref. Ref.
No.

No. No.

25a24N643

25b24N734

25c

25d24N726

27a183459

24N727

24N727 24N727

Part

Part Part

———

Assembly

Assembly Assembly

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).

603A2495K

SprayTipSelectionChart

Spray

Spray Spray

AEM

AEM AEM

Recommendedforhigh󰘰nishqualityapplicationsatlowandmediumpressures.Orderdesiredtip,Part Part
AEMxxx,

AEMxxx, AEMxxx,

Ori󰘰ce

Ori󰘰ce Ori󰘰ce

Size

Size Size

in.

in. in.

(mm)

(mm) (mm)

0.007
(0.178)

0.009
(0.229)

0.011
(0.279)

0.013
(0.330)

0.015
(0.381)

0.017
(0.432)

0.019
(0.483)

0.021
(0.533)

0.023
(0.584)

0.025
(0.635)

0.029
(0.736)

0.031
(0.787)

0.033
(0.838)

0.037
(0.939)

0.039
(0.990)

*Tipsaretestedinwater.

Tip

Tip Tip

Fine

Fine Fine

wherexxx=3–digitnumberfromthematrixbelow.

Fluid

Fluid Fluid

oz/min

󰘱 󰘱󰘱oz/min oz/min

at

600

at at

600 600

psi

psi psi

MPa,

MPa, MPa,

41

bar)

41 41

bar) bar)

4.0
(0.1)

7.0
(0.2)

10.0
(0.3)

13.0
(0.4)

17.0
(0.5)

22.0
(0.7)

28.0
(0.8)

35.0
(1.0)

40.0
(1.2)

50.0
(1.5)

68.0
(1.9)

78.0
(2.2)

88.0
(2.5)

108.0
(3.1)

118.0
(3.4)

Selection

Selection Selection

Finish

Finish Finish

(4.1

(4.1 (4.1

Spray

Spray Spray

Output

Output Output

(l/min)

(l/min) (l/min)

1000

at atat1000 1000
psi

(7.0

psi psi

(7.0 (7.0

MPa,

MPa, MPa,
70

bar)

70 70

bar) bar)

5.2
(0.15)

9.1
(0.27)

13.0
(0.4)

16.9
(0.5)

22.0
(0.7)

28.5
(0.85)

36.3
(1.09)

45.4
(1.36)

51.9
(1.56)

64.8
(1.94)

88.2
(2.65)

101.1
(3.03)

114.1
(3.42)

140.0
(4.20)

153.0
(4.59)

Tips

Tips Tips

2–4

2–4 2–4

(50–

(50– (50–

100)

100) 100)

107207307

Chart

Chart Chart

Maximum

Maximum Maximum

4–6

4–6 4–6

(100–

(100– (100–

150)

150) 150)

209309409509609

211311411511611711811

213313413513613713813

215315415515615715815

217317417517617717

Pattern

Pattern Pattern

8

6 66- --8 8

(150

-

(150 (150

- -

200)

200) 200)

319419519619719

Width

Width Width

in.

in. in.

10

8 88- --10 10

(200

(200 (200

250)

250) 250)
Spray

Spray Spray

421521621721821

423523623723823

425525625725825

431631831

at

12

in.

at at

12 12

(mm)

(mm) (mm)

10

12

10 10

- --12 12

-

(250

- -

-

(250 (250

- -

300)

300) 300)

Tip

Tip Tip

539

(305

in. in.

(305 (305

12

14

12 12

- --14 14

(300

(300 (300

350)

350) 350)

mm)

mm) mm)

14

14 14

-

(350

- -

(350 (350

400)

400) 400)

737

Part

No.

No. No.

16

16

- --16 16

-

- -

18

16 16

- --18 18

(400

-

(400 (400

- -

450)

450) 450)

829

833

Fluidoutput(Q)atotherpressures(P)canbecalculatedbythisformula:Q=(0.041)(QT) whereQT=
󰘱uidoutput(󰘱oz/min)at600psifromtheabovetablefortheselectedori󰘰cesize.

3A2495K61

SprayTipSelectionChart

AEF

AEF AEF

Recommendedforhigh󰘰nishqualityapplicationsatlowandmediumpressures.AEFtipshaveapre-ori󰘰ce
thatassistsinatomizingsheerthinningmaterials,includinglacquers.

Orderdesiredtip,Part Part

Fine

Fine Fine

Ori󰘰ce

Ori󰘰ce Ori󰘰ce

Size

Size Size

in.

(mm)

in. in.

(mm) (mm)

0.008
(0.203)

0.010
(0.254)

0.012
(0.305)

0.014
(0.356)

0.016
(0.406)

*Tipsaretestedinwater.

Finish

Finish Finish

Part

Fluid

Fluid Fluid

oz/min

󰘱 󰘱󰘱oz/min oz/min

600

at atat600 600
(4.1

(4.1 (4.1
41

41 41

5.6(0.17)7.7(0.22)

9.5(0.28)

12.0
(0.35)

16.0
(0.47)

20.0
(0.59)

psi

psi psi

MPa,

MPa, MPa,

bar)

bar) bar)

Pre

Ori󰘰ce

Pre Pre

- --Ori󰘰ce Ori󰘰ce

No.

AEFxxx,

No. No.

AEFxxx, AEFxxx,

Output

Output Output

(l/min)

(l/min) (l/min)

at

1000

at at

1000 1000

psi

(7.0

psi psi

(7.0 (7.0

MPa,

70

MPa, MPa,

70 70

bar)

bar) bar)

12.5
(0.37)

16.0
(0.47)

21.0
(0.62)

26.5
(0.78)

Spray

Spray Spray

wherexxx=3–digitnumberfromthematrixbelow.

(150

6 66- --8 88(150 (150

200)

200) 200)

310410510610710810

312412512612712812

314414514614714814

Tips

Tips Tips

Maximum

Maximum Maximum

-

- -

8 88- --10 10

(200

(200 (200

416516616716

Pattern

Pattern Pattern

10

250)

- --250) 250)

Width

Width Width

in.

in. in.

10

12

10 10

- --12 12

(250

300)

(250 (250

- --300) 300)

Spray

Spray Spray

at

12

in.

at at

12 12

in. in.

(mm)

(mm) (mm)

12

14

12 12

- --14 14

(300

350)

(300 (300

- --350) 350)

Tip

Tip Tip

608

(305

mm)

(305 (305

mm) mm)

14

16

14 14

- --16 16

(350

400)

(350 (350

- --400) 400)

16

18

16 16

- --18 18

(400

450)

(400 (400

- --450) 450)

Fluidoutput(Q)atotherpressures(P)canbecalculatedbythisformula:Q=(0.041)(QT) whereQT=
󰘱uidoutput(󰘱oz/min)at600psifromtheabovetablefortheselectedori󰘰cesize.

623A2495K

SprayTipSelectionChart

Round

Round Round

Toconverttheguntoaroundspraypattern,use
roundsprayconversionkit24N391.Seemanual
3A2499.

Part

Part Part

2368364A

2368376A

2368387A

2368395B

2368407B

2368419B

23684211B

*Flowsarebasedonwhiteacrylic,enamelpaint.

Spray

Spray Spray

No.

No. No.

Tips

Tips Tips

Size

No.

Size Size

No. No.

300

300 300

11.8oz/min(350cc/min)16.2oz/min(480cc/min)23.7oz/min(700cc/min)

Approximate

Approximate Approximate

psi

(2.1

psi psi

(2.1 (2.1

2.5oz/min(73cc/min)4.1oz/min(120cc/min)5.7oz/min(170cc/min)

2.9oz/min(86cc/min)5.1oz/min(150cc/min)7.4oz/min(220cc/min)

3.2oz/min(95cc/min)5.4oz/min(160cc/min)7.8oz/min(230cc/min)

5.4oz/min(160cc/min)7.8oz/min(230cc/min)11.0oz/min(330cc/min)

7.1oz/min(210cc/min)9.1oz/min(270cc/min)14.2oz/min(420cc/min)

8.8oz/min(260cc/min)11.8oz/min(350cc/min)17.9oz/min(530cc/min)

Flow

Rates

for

Light

to

Flow Flow

Rates Rates

for for

Light Light

(20–40

(20–40 (20–40

MPa,

21

bar)

MPa, MPa,

21 21

600

bar) bar)

600 600

centipoise)*

centipoise)* centipoise)*

psi

(4.2

psi psi

(4.2 (4.2

Medium

to to

Medium Medium

MPa,

42

MPa, MPa,

42 42

Viscosity

Viscosity Viscosity

bar)

bar) bar)

Coatings

Coatings Coatings

1200

psi

(8.4

1200 1200

psi psi

84

84 84

MPa,

(8.4 (8.4

MPa, MPa,

bar)

bar) bar)

3A2495K63

SprayTipSelectionChart

Recommended

Recommended Recommended

Filter

Filter Filter

200mesh25N890

150mesh25N889

100mesh238562

60mesh238564

Filter

Filter Filter

Filter

Size

Size Size

Part

Filter Filter

Part Part

No.

No. No.

Sizes

Sizes Sizes

Round

Ori󰘰ce

Ori󰘰ce Ori󰘰ce

0.007(0.178)

0.009(0.229)

0.011(0.279)

0.011(0.279)

0.013(0.330)

0.013(0.330)

0.015(0.381)

0.017(0.432)

0.019(0.483)

0.021(0.533)

0.023(0.584)

0.025(0.635)

0.023(0.584)

0.025(0.635)

0.029(0.736)

0.031(0.787)

0.033(0.838)

0.037(0.939)

0.039(0.990)

Size

Size Size

in.

(mm)

in. in.

(mm) (mm)

Round Round

Filter

Filter Filter

200mesh25N890

150mesh25N889

100mesh238562

Spray

Spray Spray

Size

Size Size

Tips

Tips Tips

Filter

Part

Filter Filter

Part Part

No.

No. No.

Tip

Part

Tip Tip

Part Part

No.

No. No.

2368364A

2368376A

2368376A

2368387A

2368395B

2368407B

2368419B

23684211B

Tip

Size

Tip Tip

No.

Size Size

No. No.

643A2495K

RepairKitsandAccessories

Repair

Repair Repair

Repair

Repair Repair

24N789

24N706AlternatorBearingRepairKit

Gun

Gun Gun

General

General General

Round

Round Round

Trigger

Trigger Trigger

Fan

Fan Fan

Accessories

Accessories Accessories

Part

No.

Part Part

No. No.

105749

111265

116553

24N603

24N604

24N758

Spray

Spray Spray

Part

No.

Part Part

No. No.

24N319

and

and and

Part

No.

Part Part

No. No.

24N520

24N521

24N633

24P170MetalTriggerKit

Valve

Valve Valve

Part

No.

Part Part

No. No.

24N634

24P172

25N919

Kits

Kits Kits

Kits

Kits Kits

Accessories

Accessories Accessories

Description

Description Description

CleaningBrush.

Non-siliconeLubricant,4oz(113g).

DielectricGrease.1oz(30ml)

GunCovers.For40kVand60kVguns.
Boxof10.

GunCovers.For85kVguns.Boxof10.

DisplayCovers.KeepsSmartdisplay
clean.Packageof5.

Accessories

Accessories Accessories

Description

Description Description

RoundSprayKit.Toconvertastandard
air—assistedsprayguntoaround
sprayaircap.Seemanual3A2499.

Grip

Grip Grip

Description

Description Description

ComfortGrip.Snap-ongripincreases
handlesizetoreduceoperatorfatigue.
Mediumsize.

ComfortGrip.Snap-ongripincreases
handlesizetoreduceoperatorfatigue.
Largesize.

PlasticTriggerKit(includedingun
models)

Accessories

Accessories Accessories

Description

Description Description

FanValve(includedingunmodels)

QuickAdjustFanValveforquickchange
offansize

QuickAdjustFanValvewithspring
return

and

and and

Repair

Repair Repair

AirSealRepairKit

Accessories

Accessories Accessories

Accessories

Accessories Accessories

Kit

Description

Kit Kit

Description Description

Adapter

Adapter Adapter

Part

Part Part

112534

185105

185493

24N642

224754

ES

ES ES

Part

Part Part

24N632

26A294

24P635

Inline

Inline Inline

60mesh

100mesh

150mesh

200mesh

and

Fitting

and and

No.

Description

No. No.

Description Description

AirLineQuickDisconnectFitting

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

AirHoseAdapter;1/4npt(m)x1/4–18
npsm(m)(left-handthread)

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

Valve,ball1/4npsm(left-handthread)

On/Off

On/Off On/Off

Filter

Filter Filter

Valve

Valve Valve

No.

Description

No. No.

Description Description

ESOn-OffValve(includedinH60M10,
H60T10,H85M10,H85T10)

ESOn/OffValvewithAirRestrictor
forhighatomizationairapplications.
Usethisaccessoryiftheturbinelight
indicatorisredandyouwanttomaintain
ahigherapplicationairpressure.Install
thekit,thenadjustthepressureas
neededtoensuretheindicatorremains
green.

ESAlwaysONvalve.Whenthisvalve
isinstalled,theelectrostaticsareon
anytimeairpressureissuppliedtothe
gun.Fluidadjustmentispossible.Use
with224754ballvalveinstalledatthe
gunairinlet.

Fluid

Fluid Fluid

Size

Size Size

Accessories

Fitting Fitting

Accessories Accessories

Accessories

Accessories Accessories

Filter

Filter Filter

224453

2385633

2385641

2385613

238562(includedingun
models)

25N8911

25N8923

25N8931

25N8943

Kit

Accessories

Kit Kit

Accessories Accessories

Filter

Kit

Filter Filter

Part

Kit Kit

Part Part

No.

No. No.

Qty.

Qty. Qty.

5

1

3A2495K65

RepairKitsandAccessories

Operator

Operator Operator

Part

No.

Part Part

No. No.

117823

117824

117825

System

System System

Part

No.

Part Part

No. No.

222011

24N528

24P312

Accessories

Accessories Accessories

Description

Description Description

ConductiveGloves,boxof12(small)

ConductiveGloves,boxof12
(medium)

ConductiveGloves,boxof12(large)

Accessories

Accessories Accessories

Description

Description Description

GroundWireandClamp

GunFlushBoxAdapter.Toconvert
existinggun󰘱ushboxestoholdProXp
guns.Seemanual309227.

GunWasherKit.Toconvertexisting
gunwasherstocleanProXpguns.See
manual308393.

Signs

Signs Signs

Part

No.

Part Part

No. No.

16P802

16P798

16P799

Test

Test Test

Equipment

Equipment Equipment

Part

Part Part
No.

No. No.

241079Megohmmeter.500Voutput,0.01–2000

722886

722860

Description

Description Description

EnglishWarningSign,availableat
nochargefromGraco

EnglishDailyCareSign

EnglishSetupSign

Description

Description Description

megohms.Useforgroundcontinuity
andgunresistancetests.Not Not
hazardous

hazardous hazardous

PaintResistanceMeter.Usefor󰘱uid
resistivitytest.Seemanual307263.Not Not
for

use

for for

use use

PaintProbe.Usefor󰘱uidresistivitytest.
Seemanual307263.Not Not
hazardous

hazardous hazardous

locations.

locations. locations.

hazardous

in ininhazardous hazardous

locations.

locations. locations.

Not

for

use

for for

locations.

locations. locations.

Not

for

use

for for

use use

in

use use

in in

Not

in

in in

245277TestFixture,HighVoltageProbe,and

kVMeter.Usetotesttheelectrostatic
voltageofthegun,andtheconditionof
thealternatorandpowersupplywhen
beingserviced.Seemanual309455.

663A2495K

RepairKitsandAccessories

Hoses

Hoses Hoses

Grounded

Grounded Grounded

Air

Hoses

Air Air

Hoses Hoses

100psi(0.7MPa,7bar)MaximumWorkingPressure

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

Part

No.

Part Part

No. No.

AirFlex

AirFlex AirFlex

244963

244964

244965

24J138

24N736

244966

24N737

244967

24N738

244968

244969

Part

Part Part

Standard

Standard Standard

223068

223069

223070

223071

223072

223073

223074

0.375

0.375 0.375
left

left left

Flexible

Flexible Flexible

No.

No. No.

Grounded

Grounded Grounded

in.

(10

in. in.

(10 (10

hand

thread

- --hand hand

thread thread

Description

Description Description

Grounded

Grounded Grounded

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

31ft(9.4m)

25ft(7.6m),with112534Quick
Disconnect

36ft(11m)

36ft(11m),with112534Quick
Disconnect

50ft(15m)

50ft(15m),with112534Quick
Disconnect

75ft(23m)

100ft(30.5m)

Description

Description Description

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

mm)

ID;

mm) mm)

ID; ID;

Air

Air Air

Air

Hose

Air Air

Hose Hose

3/8

npsm(f)

3/8 3/8

npsm(f) npsm(f)

Hose

Hose Hose

(Gray)

(Gray) (Gray)

Part

No.

Part Part

No. No.

Grounded

Grounded Grounded

ground

ground ground

235068

235069

(Gray)

(Gray) (Gray)

235070

235071

235072

235073

235074

Air

Air Air

path

path path

Whip

Hoses

Whip Whip

Hoses Hoses

Air

Air Air

Hose

Hose Hose

(Red)

(Red) (Red)

Description

Description Description

with

with with

6ft(1.8m)

15ft(4.6m)

25ft(7.6m)

36ft(11m)

50ft(15m)

75ft(23m)

100ft(30.5m)

stainless

stainless stainless

steel

braid

steel steel

braid braid

100psi(0.7MPa,7bar)MaximumWorkingPressure

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

Part

No.

Part Part

No. No.

Air

Whip

Air Air

path

path path

236130

236131

Fluid

Fluid Fluid

Hose

Whip Whip

Hose Hose

(Red)

(Red) (Red)

Hoses

Hoses Hoses

with

with with

Description

Description Description

stainless

stainless stainless

3ft(0.9m)

6ft(1.8m)

steel

braid

steel steel

ground

braid braid

ground ground

3300psi(22.7MPa,227bar)MaximumWorking
Pressure

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

Part

No.

Part Part

No. No.

240793

240794

Fluid

Whip

Fluid Fluid

Hoses

Whip Whip

Hoses Hoses

Description

Description Description

25ft(7.6m)

50ft(15m)

3200psi(22MPa,220bar)MaximumWorking
Pressure

1/4

npsm(f)

x xx1/4 1/4

npsm(f) npsm(f)

1/8in.(3mm)ID;1/4npsm(f)x1/4npt(m);nylon.

Part

No.

Part Part

No. No.

Description

Description Description

24A225

24A226

50ft(15m)

75ft(23m)

236134

236135

3ft(0.9m)

6ft(1.8m)

3A2495K67

Dimensions

Dimensions

Dimensions Dimensions

Figure45

Gun

Gun Gun

H60T10

H85T10and
H85T57

H60M10

H85M10and
H85M57

Model

Model Model

A,

in.

(mm)

A, A,

in. in.

(mm) (mm)

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

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

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

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

B,

in.

(mm)

B, B,

in. in.

(mm) (mm)

C,

in.

(mm)

C, C,

in. in.

(mm) (mm)

Weight,

Weight, Weight,

oz

(g)

oz oz

(g) (g)

683A2495K

TechnicalSpecications

Technical

Technical Technical

Electrostatic

Electrostatic Electrostatic

MaximumWorkingFluidPressure3000psi21MPa,210bar

MaximumWorkingAirPressure100psi0.7MPa,7.0bar

MinimumAirPressureatGunInlet

AirConsumption

Requiredturbineair󰘱ow6scfm

Rangeoftotalair󰘱owunder
normalsprayingconditions

MaximumFluidOperating
Temperature

AmbientTemperature

PaintResistivityRange

AirInletFitting

FluidInletFitting

OutputVoltage

MaximumCurrentDraw

SoundPower(measuredperISO
Standard9216)

SoundPressure(measured1m
fromgun)

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

Speci󰘰cations

Speci󰘰cations Speci󰘰cations

Air

Assisted

Air Air

- --Assisted Assisted

Spray

Guns

Spray Spray

Guns Guns

170l/min

220–400l/min

Metric

Metric Metric

U.S.

U.S. U.S.

45psi0.32MPa,3.2bar

7.5–14scfm

120°F48°C

41°–122°F5°–50°C

3megohm/cmtoin󰘰nity

1/4npsm(m)left-handthread

1/4–18npsm(m)

ProXp60Models:60kV

ProXp85Models:85kV

125microamperes

at40psi:88.9dB(A)

at100psi:99.7dB(A)

at40psi:86.0dB(A)

at100psi:95.0dB(A)

at0.28MPa,2.8bar:88.9dB(A)

at0.7MPa,7.0bar:99.7dB(A)

at0.28MPa,2.8bar:86.0dB(A)

at0.7MPa,7.0bar:95.0dB(A)

3A2495K69

Graco

Graco Graco

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

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

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

THIS

WARRANTY

THIS THIS

WARRANTY WARRANTY

INCLUDING

INCLUDING INCLUDING
PARTICULAR

PARTICULAR PARTICULAR

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

GRACO

GRACO GRACO
FITNESS

FITNESS FITNESS
OR

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

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

FORGRACOCANADACUSTOMERS

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

MAKES

MAKES MAKES

FOR

FOR FOR

COMPONENTS

COMPONENTS COMPONENTS

Pro

Pro Pro

IS

IS IS

BUT

NOT

BUT BUT

NOT NOT

PURPOSE.

PURPOSE. PURPOSE.

NO

WARRANTY,

NO NO

WARRANTY, WARRANTY,

PARTICULAR

A AAPARTICULAR PARTICULAR

SOLD

SOLD SOLD

Xp

Xp Xp

EXCLUSIVE,

EXCLUSIVE, EXCLUSIVE,

LIMITED

LIMITED LIMITED

BUT

BUT BUT

Warranty

Warranty Warranty

AND

AND AND

TO

WARRANTY

TO TO

WARRANTY WARRANTY

AND

AND AND

PURPOSE,

PURPOSE, PURPOSE,

NOT

MANUFACTURED

NOT NOT

MANUFACTURED MANUFACTURED

LIEU

OF

ANY

IS ISISIN ININLIEU LIEU

DISCLAIMS

DISCLAIMS DISCLAIMS

IN

IN IN

OF OF

OF

MERCHANTABILITY

OF OF

MERCHANTABILITY MERCHANTABILITY

ALL

ALL ALL

CONNECTION

CONNECTION CONNECTION

OTHER

ANY ANY

OTHER OTHER

IMPLIED

IMPLIED IMPLIED

BY

GRACO.

BY BY

GRACO. GRACO.

WARRANTIES,

WARRANTIES, WARRANTIES,

OR

OR OR

WARRANTIES

WARRANTIES WARRANTIES

WITH

ACCESSORIES,

WITH WITH

ACCESSORIES, ACCESSORIES,

Theseitemssold,butnotmanufacturedby

EXPRESS

EXPRESS EXPRESS

WARRANTY

WARRANTY WARRANTY

OF

MERCHANTABILITY

OF OF

MERCHANTABILITY MERCHANTABILITY

EQUIPMENT,

EQUIPMENT, EQUIPMENT,

OR

IMPLIED,

OR OR

OF

OF OF

IMPLIED, IMPLIED,

FITNESS

FITNESS FITNESS

FOR

FOR FOR

AND

AND AND

MATERIALS

MATERIALS MATERIALS

A

A A

Graco

Graco Graco

For

For For

For

For For

To

To To

Phone:

Phone: Phone:

Allwrittenandvisualdatacontainedinthisdocumentre󰘱ectsthelatestproductinformationavailableatthetimeofpublication.

the

latest

the the

latest latest

patent

patent patent

place

an

place place

an an

612-623-6921or ororToll Toll

Information

Information Information

information

information information

information,

information, information,

order,

order, order,

contactyourGracoDistributororcalltoidentifythenearestdistributor.

GRACO

GRACO GRACO

INC.

INC. INC.

Copyright

Copyright Copyright

about

about about

see

see see

Toll

Free:

Free: Free:

Gracoreservestherighttomakechangesatanytimewithoutnotice.

OriginalInstructions.ThismanualcontainsEnglish,MM3A2495

AND

SUBSIDIARIES

AND AND

SUBSIDIARIES SUBSIDIARIES

2012,

Graco

2012, 2012,

Graco Graco

Graco

Graco Graco

products,

products, products,

www.graco.com/patents.

1-800-328-0211Fax: Fax:

International

International International

Inc.

Inc. Inc.

Graco

Graco Graco

All

Graco

All All

Graco Graco

Fax:

Headquarters:

Headquarters: Headquarters:

Of󰘰ces:

Of󰘰ces: Of󰘰ces:

Belgium,China,Japan,Korea

P.O.

BOX

• ••P.O. P.O.

BOX BOX

manufacturing

manufacturing manufacturing

www.graco.com

RevisionK,2019–03

visit

visit visit

www.graco.com.

612-378-3505

Minneapolis

1441

1441 1441

• ••MINNEAPOLIS, MINNEAPOLIS,

MINNEAPOLIS,

locations

locations locations

MN

MN MN

are

registered

are are

registered registered

55440-1441

55440-1441 55440-1441

ISO

to totoISO ISO

USA

• ••USA USA

9001.

9001. 9001.