Graco 3A2497Bpro Xp 60 Aa Wb And Wb3000 Users Manual 3A2497B, Instructions Parts For Pro Electrostatic Air Assisted Waterborne Spray Gun Isolation Encl

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Instructions - Parts

WB3000 Isolation System &

Pro Xp™ 60 AA WB Gun 3A2497B

EN

Air-assisted spray system for use when electrostatically spraying conductive, waterborne fluids that

meet at least one of the conditions for non-flammability listed on page 3.

For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these

instructions.

3000 psi (21 MPa, 210 bar) Maximum

Fluid Working Pressure

100 psi (0.7 MPa, 7 bar) Maximum

Air Working Pressure

See page 3 for model part numbers

and approval information.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

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

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

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

How the Electrostatic AA Spray Gun

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

Spraying Waterborne Fluids

Electrostatically .............................. 7

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

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

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

System Requirements .................................. 15

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

Install the System......................................... 15

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

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

Ground the Cabinet...................................... 16

Connect the Waterborne Fluid Hose.............. 17

Agitator Kit Accessory .................................. 20

Gun Setup.......................................................... 21

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

Check Gun Electrical Grounding ................... 23

Flush Before Using Equipment...................... 24

Operation........................................................... 25

Operating Checklist...................................... 25

Fluid Voltage Discharge and Grounding

Procedure ...................................... 25

Pressure Relief Procedure............................ 26

Fill the Fluid Supply...................................... 27

Adjust the Spray Pattern............................... 28

Shutdown .................................................... 30

Maintenance ...................................................... 31

Flushing ...................................................... 31

Clean the Gun Daily ..................................... 33

Daily System Care ....................................... 35

Electrical Tests................................................... 36

Test Gun Resistance.................................... 36

Test Power Supply Resistance ..................... 37

Test Gun Barrel Resistance.......................... 38

Test Ground Strip Resistance ....................... 39

Test Cylinder Resistance.............................. 39

Troubleshooting.................................................. 40

Voltage Loss Troubleshooting....................... 40

Spray Pattern Troubleshooting...................... 43

Gun Operation Troubleshooting .................... 44

Electrical Troubleshooting ............................ 45

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

Prepare the Gun for Service ......................... 47

Air Cap, Spray Tip, and Fluid Seat Housing

Replacement.................................. 48

Electrode Replacement ................................ 49

Gun Barrel Removal..................................... 50

Gun Barrel Installation.................................. 50

Fluid Needle Replacement............................ 51

Power Supply Removal and

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

Alternator Removal and Replacement ........... 53

Fan Air Adjustment Valve Repair .................. 55

Atomizing Air Adjustment Valve

Repair............................................ 55

ES On-Off Valve Repair ............................... 56

Air Valve Repair........................................... 57

Smart Module Replacement.......................... 58

Air Swivel and Exhaust Valve

Replacement.................................. 59

Parts.................................................................. 60

Standard Air-Assisted Spray Gun

Assembly ....................................... 60

Smart Air-Assisted Spray Gun

Assembly ....................................... 62

Isolation Enclosure....................................... 64

Alternator Assembly ..................................... 67

ES On-Off Valve Assembly........................... 68

Fan Air Valve Assembly ............................... 69

Air Cap Assembly ........................................ 70

Smart Module Assembly............................... 70

Spray Tip Selection Chart.................................... 71

AEM Fine Finish Spray Tips.......................... 71

AEF Fine Finish Pre-Orifice Spray

Tips ............................................... 72

Repair Kits, Related Manuals, and

Accessories .......................................... 73

Gun Accessories.......................................... 73

Operator Accessories................................... 73

System Accessories..................................... 73

Hoses ......................................................... 74

Test Equipment ........................................... 74

245895 Agitator Kit ...................................... 75

Dimensions ........................................................ 76

Technical Data ...................................................77

Graco Pro Xp Warranty....................................... 78

23A2497B

Models

Models

Models which are FM Approved and Compliant with EN50059

FM approved for use with fluids that meet the following condition:

• Material does not sustain burning in accordance with the Standard Test Method

for Sustained Burning of Liquid Mixtures, ASTM D4206.

0.35 J, with

24M508 Hose

FM12ATEX0080

EN 50059

Ta 0°C – 50°C

Models Compliant with EN 50059 when used

with fluids that meet the following criteria:

• Materials which cannot be ignited, in any mixture with air, by an energy source

of less than 500 mJ.

Part No. Model Description

24N551 WB3000 Waterborne Isolation Enclosure 24N550 with standard

electrostatic air-assisted spray gun H60T18, grounded air hose

235070, and unshielded waterborne fluid hose 24M508.

24P632 WB3000 Waterborne Isolation Enclosure 24N550 with smart electrostatic

air-assisted spray gun H60M18, grounded air hose 235070,

and unshielded waterborne fluid hose 24M508.

24N550 WB3000 Waterborne Isolation Enclosure for unshielded hoses. Does not

include hoses and gun.

H60T18 ProXp60AAWB Standard Electrostatic Air-assisted Spray Gun, for waterborne

coatings.

H60M18 ProXp60AAWB Smart Electrostatic Air-assisted Spray Gun, for waterborne

coatings.

24M508 -—— Unshielded Waterborne Fluid Hose Assembly, 25 ft (7.6 m).

3A2497B 3

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The

exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific

risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout

the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of an isolated waterborne system can result in electric

shock. To help prevent electric shock:

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close

to spray area. See Grounding instructions.

• Connect the electrostatic gun to a voltage isolation system that will discharge the system

voltage when not in use.

•Allcompo

nents of the isolation system that are charged to high voltage must be contained

within an isolation enclosure that prevents personnel from making contact with thehigh

voltage components before the system voltage is discharged.

• Follow the Fluid Voltage Discharge and Grounding Procedure when instructed to discharge

the voltage; before cleaning, flushing, or servicing the system; before approaching the front of

the gun; and before opening the isolation enclosure for the isolated fluid supply.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been

discharged.

•Donott

ouch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode

during gun operation. Follow the Fluid Voltage Discharge and Grounding Procedure.

• Interlock the gun air supply with the voltage isolation system to shut off the air supply anytime

the isolation system enclosure is opened.

• Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not

use black or gray-colored Graco air hoses.

• Do not splice hoses together. Install only one continuous Graco waterborne fluid hose

between the isolated fluid supply and the spray gun.

43A2497B

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Combustible dust in work area canigniteorexplode.Tohelppreventfireandexplosion:

• Fluids used must meet the following flammability requirements:

•FM, FMc Approved:

Material does not sustain burning in accordance with the Standard Test Method for

Sustained Burning of Liquid Mixtures, ASTM D4206.

•CE-EN 50059 Compliant:

Materials which cannot be ignited, in any mixture with air, by an energy source of

less than 500mJ.

•Stop operation immediately if static sparking occurs or you feel a shock. Do not use

equipment until you identify and correct the problem.

• Check gun resistance, hose resistance, and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

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

•Onlyusen

on-flammable solvents when flushing or cleaning equipment.

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

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and

plastic drop cloths (potential static arc).

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

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

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin.Thismay

look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

•Dono

t stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,

or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious

injury or property damage.

•Us

e only compatible water-based solvents to clean plastic structural or pressure-containing

parts.

•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and

solvent manufacturer’s MSDSs and recommendations.

3A2497B 5

Warnings

WARNING

TOXIC FLUID OR FUMES

Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,

inhaled, or swallowed.

•ReadMSDSsto

know the specific hazards of the fluids you are using.

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

guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,

including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective

equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

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

manufacturer.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated

system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data

in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete

information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

•Turnof

f all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals

and create safety hazards.

•Makes

ure all equipment is rated and approved for the environment in which you are using it.

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

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

•Dono

t kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

63A2497B

Gun Overview

Gun Overview

How the Electrostatic AA Spray Gun

Works

This is not an air spray gun. To help prevent

serious injury from pressurized fluid, such as skin

injection, and splashing fluid, read and follow the

Skin Injection Hazard Warnings on page 5.

The air-assisted spray gun combines airless and

air spraying concepts. The spray tip atomizes

and shapes the fluid into a fan pattern, as does

a conventional airless spray tip. Air from the air

cap further atomizes the fluid and completes the

atomization of the fluid tails to produce a uniform

pattern.

As the gun is triggered, part of the regulated air

operates the alternator turbine and the rest of the

air helps atomize the fluid being sprayed. The

alternator generates power, which is converted by

the power cartridge to supply high voltage to the

gun’s electrode.

The gun’s internal power supply provides high

voltage. The fluid is electrostatically charged as it

passes the electrode. The charged fluid is attracted

to the grounded workpiece, wrapping around and

evenly coating all surfaces.

The regulated air that is directed to the air cap can

be further controlled using the gun’s atomizing air

adjustment valve. This valve can be used to restrict

air flow to the air cap while maintaining sufficient air

flow to the alternator. The atomizing air adjustment

valve does not control pattern width. To change

pattern width, use a new tip size, or use the fan

adjustment to narrow the pattern width.

The high working fluid pressure of this gun provides

the power needed to atomize higher solids materials.

NOTE: For airless atomization, if desired, turn the

gun’s atomizing air adjustment valve completely off.

Closing this valve does not affect alternator operation.

Spraying Waterborne Fluids

Electrostatically

This electrostatic air-assisted spray gun is designed

to spray onlywaterborne fluids which meet the

following flammability requirements:

•FM, FMc Approved:

Material does not sustain burning in accordance

with the Standard Test Method for Sustained

Burning of Liquid Mixtures, ASTM D4206.

•CE-EN 50059 Compliant:

Materials which cannot be ignited, in any mixture

with air, by an energy source of less than 500mJ.

When connected to a voltage isolation system,

all of the fluid in the spray gun, fluid hose, and

isolated fluid supply is charged to high voltage,

which means that the system has more electrical

energy than a solvent-based system. Therefore,

only non-flammable fluids (as defined under

Models, page 3 ) can be sprayed with the system or

be used to clean, flush, or purge the system.

Precautions must be taken when using electrostatic

waterborne equipment to avoid potential shock

hazards. When the spray gun charges the isolated

fluid to high voltage, it is similar to charging a

capacitor or a battery. The system will store some of

the energy while spraying and retain some of that

energy after the spray gun is shut off. Do not touch

the gun nozzle or come within 4 in. (102 mm) of

the electrode until the stored energy is discharged.

The amount of time it takes to discharge the

energy depends on the system design. Follow the

Fluid Voltage Discharge and Grounding Procedure,

page 25 before approaching the front of the gun.

The Graco warranty and approvals are void if the

electrostatic spray gun is connected to a non-Graco

voltage isolation system or if the gun is operated

above 60 kV.

3A2497B 7

Gun Overview

Controls, Indicators, and Components

The electrostatic gun includes the following

controls, indicators, and components (see Fig.

1). For information on Smart guns, also see

Smart Guns, page 9 .

Item Description Purpose

AAir Swivel

Inlet

1/4 npsm(m) left-hand

thread, for Graco

red-colored grounded

air supply hose.

B Fluid Hose Graco waterborne fluid

hose

CTurbine Air

Exhaust

Barbed fitting, for supplied

exhaust tube.

DAir Cap/Tip

Guard and

Spray Tip

See Spray Tip Selection

Chart, page 71, for avail-

able sizes.

EElectrode Supplies electrostatic

charge to the fluid.

Item Description Purpose

FFanAir

Adjustment

Valve

Adjusts fan size and shape.

Canbeusedtodecrease

pattern width.

GAtomizing Air

Adjustment

Valve

Adjusts atomizing air flow.

HTrigger Safety

Lock

Locks trigger to prevent

gun from spraying.

JES On-Off

Valve

Turns electrostatics ON (I)

or OFF (O).

KES Indica-

tor (standard

gun only; for

Smart gun in-

dicator, see

Operating

Mode, page

9)

Lit when ES is ON (I).

Color indicates alternator

frequency. See the LED

indicator table on page 30.

Figure 1 Gun Overview

83A2497B

Gun Overview

Smart Guns

The Smart Gun module displays spraying voltage,

current, alternator speed, and the voltage setting (low

or high). It also allows the user to change to a lower

spraying voltage. The module has two modes:

• Operating Mode

• Diagnostic Mode

Operating Mode

Bar Graph

See Fig. 2, and Table 1 on page 11. The Operating

Mode displays gun data during normal spraying. The

display uses a bar graph to show the voltage level in

kiloVolts (kV) and the current level in microAmperes

(uA). The bar graph range is from 0 to 100% for each

value.

If the uA bar graph LEDs are blue, the gun is ready

to spray. If the LEDs are yellow or red, the current is

too high. See Electrical Troubleshooting, page 45.

Hz Indicator

The Hz indicator functions the same as the ES

indicator on standard guns. The indicator lights to

show the alternator speed status, and has three

colors:

• Green indicates the alternator speed is correct.

• If the indicator changes to amber after 1 second,

increase the air pressure.

• If the indicator changes to red after 1 second,

reduce the air pressure.

Voltage Adjustment Switch

The voltage adjustment switch (VA) allows the

operator to change from low to high voltage.

• The high voltage setting is determined by the

maximum voltage of the gun and is not adjustable.

•Thelowvolt

age indicator (LO) lights

when the switch is set to LO. The low

voltage setting is user adjustable. See

Adjusting the Low Voltage Setting, page 10.

NOTE: If the Error display appears, the Smart module

has lost communication with the power supply. See

Error Display, page 10 for further information.

Figure2 SmartGunModuleinOperatingMode

3A2497B 9

Gun Overview

Error Display

If the Smart module loses communication with

the power supply, the Error display appears, the

Hz indicator turns red, and the Smart module is

disabled. See Fig. 3, and Table 1 on page 11.

This can occur in Operating Mode or Diagnostic

Mode. See Electrical Troubleshooting, page 45.

Communication must be restored to make the Smart

module functional.

NOTE: It takes 8 seconds for the Error display to

appear. If the gun has been disassembled, wait 8

seconds before spraying to ensure that an Error

condition has not occurred.

NOTE: If there is no power to the gun, the Error

display will not appear.

Figure3 ErrorDisplay

Adjusting the Low Voltage Setting

The low voltage setting is user adjustable. To access

the low voltage setting screen when in Operating

Mode, press the LO SET button (LS) momentarily.

The screen will display the current low voltage

setting. SeeFig. 4,andTable1onpage11. The

range is 30–60 kV.

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

the LO SET button repeatedly to increase the setting

in increments of 5. When the display reaches the

maximum setting (60 kV) it will return to the minimum

setting (30 kV). Continue pressing the button until

you reach the desired setting.

NOTE: After 2 seconds of inactivity the display will

return to the Operating Screen.

NOTE: The low voltage setting may be locked. See

Lock Symbol, page 10.

Figure 4 Low Voltage Setting Screen (Unlocked)

Lock Symbol

The low voltage setting may be locked. When locked,

an image (LK) appears on the screen. See Fig. 5,

and Table 1 on page 11.

• When in HI mode, the low voltage setting is always

locked. The lock symbol will appear when the LO

SET button is pressed.

• When in LO mode, the lock symbol will

only appear if the lock is enabled. See

Low Voltage Lock Screen, page 14,tolockor

unlock the low voltage setting.

Figure 5 Low Voltage Setting Screen (Locked)

10 3A2497B

Gun Overview

Table 1 . Key for Figs. 2–9.

Item Description Purpose

VA Voltage Adjustment Switch Two-position switch sets smart

gun voltage to low setting (LO) or

high setting (HI). This switch is

functional in Operating Mode and

in Diagnostic Mode.

LO Low Voltage Mode Indicator Lights (blue) when the smart gun

is set to Low Voltage.

kV Voltage (kV) Display Displays actual spraying voltage

of the gun, in kV. In Operating

Mode, display is a bar graph.

In Diagnostic Mode, voltage is

displayed as a number.

uA Current (uA) Display Displays actual spraying current

of the gun, in uA. In Operating

Mode, display is a bar graph.

In Diagnostic Mode, current is

displayed as a number.

LS LO SET button Press momentarily to enter the

Low Voltage Setting screen.

Press and hold for approximately 5

seconds to enter or exit Diagnostic

Mode.

While in Diagnostic Mode, press

momentarily to advance through

screens.

While on the Low Voltage Lock

Screen (in Diagnostic Mode),

press and hold to turn the lock on

or off.

LV Low Voltage Display Displays the low voltage setting

as a number. The setting can be

changed. See Fig. 4.

LK Low Voltage Locked Appears if the low voltage setting

is locked. See Fig. 5 and Fig. 9.

LD Lo Display Appears on the Low Voltage Lock

Screen. See Fig. 9.

ER Error Display Appears if the Smart module loses

communication with the power

supply. See Fig. 3.

VI Voltage Indicator In Diagnostic Mode, the two top

right LEDs of the screen light,

indicating that the value displayed

isinkV.SeeFig. 6.

3A2497B 11

Gun Overview

Item Description Purpose

CI Current Indicator In Diagnostic Mode, the two

bottom right LEDs of the screen

light, indicating that the value

displayedisinuA.SeeFig. 7.

AS Alternator Speed Display In Diagnostic Mode, Hz level is

displayed as a number. See Fig.

8.

Hz Alternator Speed Indicator In Operating Mode, indicator color

varies to show the alternator

speed status:

• green indicates the alternator

speed is at the correct level.

• If the indicator changes to amber

after 1 second, the alternator

speed is too low.

• If the indicator changes to red

after 1 second, the alternator

speed is too high. The indicator

will also turn red if the Error

display appears.

In Diagnostic Mode, the indicator

is green when in the Alternator

Speed (Hertz) screen.

123A2497B

Gun Overview

Diagnostic Mode

Diagnostic Mode includes four screens which display

gun data:

• Voltage (kiloVolts) Screen

• Current (microAmperes) Screen

• Alternator Speed (Hertz) Screen

• Low Voltage Lock Screen

NOTE: You must be in Operating Mode to adjust the

low voltage setting; the setting is not adjustable in

Diagnostic Mode. However, the voltage adjustment

switch (VA) can be set to HI or LO in Operating Mode

and Diagnostic Mode.

To enter Diagnostic Mode, press and hold the LO SET

(LS) button for approximately 5 seconds. The display

will go to the Voltage (kiloVolts) Screen, page 13.

To advance to the next screen, press the LO SET

button again.

To exit Diagnostic Mode, press and hold the LO SET

button for approximately 5 seconds. The screen will

return to Operating Mode.

NOTE: If the gun is detriggered while in Diagnostic

Mode,thelastscreenviewedwillbedisplayedwhen

the gun is retriggered.

NOTE: Diagnostic Mode cannot be exited

from the Low Voltage Lock Screen. See

Low Voltage Lock Screen, page 14 for details.

Voltage (kiloVolts) Screen

The Voltage (kiloVolts) Screen is the first screen to

appear after entering Diagnostic Mode. See Fig. 6,

and Table 1 on page 11. To enter this screen, press

and hold the LO SET button for approximately 5

seconds while in the Operating Mode.

This screen displays the spraying voltage of the

gun as a number (kV), rounded to the nearest 5 kV.

The two top right LEDs (VI) of the display panel

light, indicating that the Voltage (kiloVolts) Screen

is displayed. The display is a readout and cannot

be changed.

Press the LO SET button to advance to the

Current (microAmperes) Screen, page 13.Press

and hold for approximately 5 seconds to return to

Operating Mode.

Figure 6 Voltage (kiloVolts) Screen

Current (microAmperes) Screen

The Current (microAmperes) Screen is the second

screen in the Diagnostic Mode. See Fig. 7, and Table

1 on page 11. To enter this screen, press the LO

SET button while in the Voltage (kiloVolts) Screen.

This screen displays the spraying current of the gun

as a number (uA), rounded to the nearest 5 uA. The

two bottom right LEDs (CI) of the display panel light,

indicating that the Current (microAmperes) Screen

is displayed. The display is a readout and cannot

be changed.

Press the LO SET button to advance to the

Alternator Speed (Hertz) Screen, page 14.Press

and hold for approximately 5 seconds to return to

Operating Mode.

Figure 7 Current (microAmperes) Screen

3A2497B 13

Gun Overview

Alternator Speed (Hertz) Screen

The Alternator Speed (Hertz) Screen is the third

screen in the Diagnostic Mode. See Fig. 8, and Table

1 on page 11. To enter this screen, press the LO SET

button while in the Current (microAmperes) Screen.

This screen displays the alternator speed as a 3

digit number (AS), rounded to the nearest 5 Hz. The

display is a readout and cannot be changed. If the

alternator speed is greater than 999 Hz, the display

will show 999.

The Hz indicator lights green to show that you are

viewing the Alternator Speed (Hertz) Screen.

Press the LO SET button to advance to the

Low Voltage Lock Screen, page 14. Press and hold

for approximately 5 seconds to return to Operating

Mode.

Figure 8 Alternator Speed (Hertz) Screen

Low Voltage Lock Screen

The Low Voltage Lock Screen is the fourth screen in

the Diagnostic Mode. See Fig. 9, and Table 1 on

page 11. To enter this screen, press the LO SET

button while in the Alternator Speed (Hertz) Screen.

This screen displays the status of the Low Voltage

Lock. If the setting is locked, the lock image (LK)

appears to the left of the Lo display (LD). If the setting

is unlocked, the lock image does not appear.

To change the lock status, press and hold the

LO SET button until the lock image appears or

disappears. If the lock is set, the image will also

appear on the Low Voltage Setting Screen when in

low voltage mode (see Fig. 4).

NOTE: Diagnostic Mode cannot be exited from this

screen, because pressing and holding the LO SET

button is used to turn the lock on or off. To exit,

press LO SET momentarily to return to the Voltage

(kiloVolts) Screen, then exit Diagnostic Mode from

there.

Figure 9 Low Voltage Lock Screen

143A2497B

Installation

Installation

System Requirements

AGracovolta

ge isolation system must have the

following features:

• An isolation enclosure that prevents persons from

making contact with the high voltage components

before the system voltage is discharged. All

components of the isolation system that are

charged to high voltage must be contained within

the enclosure.

• A bleed resistor to drain off the system voltage

when the spray gun is not in use. A metal part of

the fluid supply unit must be electrically connected

to the bleed resistor.

• A safety interlock that automatically discharges the

system voltage when anyone opens the isolation

enclosure.

NOTICE

The system should not have any severe arcing

occurring when the isolation mechanism opens

and closes. Severe arcing will shorten the life of

the system components.

NOTE: The Graco warranty and approvals are

void if the electrostatic spray gun is connected to a

non-Graco voltage isolation system or if the gun is

operated above 60 kV.

Warning Sign

Mount warning signs in the spray area where they

can easily be seen and read by all operators. An

English Warning Sign is provided with the gun.

Install the System

Installing and servicing this equipment requires

access to parts which may cause electric shock

or other serious injury if work is not performed

properly.

• Do not install or service this equipment unless

you are trained and qualified.

• Be sure your installation complies with local,

state, and national codes for the installation

of electrical apparatus in a Class I, Div. I

Hazardous Location or Group II, Zone I

Explosive Atmosphere Location.

• Comply with all applicable local, state, and

national fire, electrical, and other safety

regulations.

Fig. 12 shows a typical electrostatic air-assisted

spray system. It is not an actual system design.

For assistance in designing a system to suit your

particular needs, contact your Graco distributor.

Ventilate the Spray Booth

Provide fresh air ventilation to reduce the risk of fire

or explosion caused by the buildup of flammable or

toxic vapors when spraying, flushing, or cleaning

the gun. Do not operate the gun unless ventilation

fans are operating.

Check and follow all local, state, and national codes

regarding air exhaust velocity requirements.

High velocity air exhaust will decrease the operating

efficiency of the electrostatic system. The minimum

allowable air exhaust velocity is 60 linear ft/min (18.3

linear meters/minute).

3A2497B 15

Installation

Air Supply Line

1. See Fig. 12. Install an air line filter/water

separator (M) on the main air supply line to

ensure a dry, clean air supply to the gun. Dirt and

moisture can ruin the appearance of your finished

workpiece and can cause the gun to malfunction.

2. The WB3000 system includes a bleed-type air

regulator (N) on the gun air supply line (P), to

control air pressure to the gun.

To reduce the risk of electric shock or other

serious injury, you must use the red-colored

Graco Electrically Conductive Air Hose for the

gun air supply, and you must connect the hose

ground wire to a true earth ground. Do not use

the black or gray-colored Graco air hoses.

3. Connect the red-colored Graco Electrically

Conductive Air Hose (P) between the gun air

regulator (N) and the gun’s air inlet. The gun air

inlet fitting has a left-hand thread. Connect the

airsupplyhosegroundwire(Q)toatrueearth

ground.

Trapped air can cause the fluid supply unit to

cycle unexpectedly, which can result in serious

injury, including splashing fluid in the eyes or

on the skin. Do not operate the equipment

without the bleed-type air valve (B) installed.

4. The WB3000 system includes a bleed-type air

valve (B). The bleed-type air valve is required

to shut off all air to the system and relieve air

trapped between the valve and the fluid supply

unit after the air regulator is shut off. Connect the

main air supply line (A) to the bleed valve.

5. Install an additional bleed-type air valve (CC)

upstream of the air filter (M) to isolate the filter

for servicing.

Ground the Cabinet

Connect the main ground wire (V) to a true earth

ground.

16 3A2497B

Installation

Connect the Waterborne Fluid Hose

Always use a Graco waterborne fluid hose between

the voltage isolation system fluid outlet and the gun

fluid inlet.

Before connecting the waterborne fluid hose to the

gun, blow it out with air and flush with water to

remove contaminants. Flush the gun before using it.

To reduce the risk of electric shock, install only

one continuous Graco waterborne hose between

the isolated fluid supply and the gun. Do not splice

hoses together.

1. Remove the gun air inlet fitting (21).

Figure 10 Connect the Fluid Hose

2. Make sure the barrel fluid inlet is clean and dry.

Apply dielectric grease to the threads of the barrel

connector (101a) and screw it into the fluid inlet.

3. Apply dielectric grease to the threads of the

hose (101) and screw it into the barrel connector

(101a).

4. Align the bracket (B) holes with the air inlet and

exhaust outlet. Secure with the air inlet fitting

(21).

5. Press the exhaust tube (35) onto the exhaust

valve. Secure with the clamp (36).

6. Slide the other end of the hose through the hole

in the side of the isolated enclosure. Connect the

swivel (Z) to the fluid outlet of the pump. Secure

thehosetothesideoftheenclosurewiththe

bracket (W).

NOTE: The Graco warranty and approvals are

void if the electrostatic spray gun is connected

to a non-Graco voltage isolation system or if the

gun is operated above 60 kV.

Figure 11 Unshielded Hose 24M508 Connection at

WB3000 Enclosure

3A2497B 17

Installation

Figure 12 Typical Installation, Pro Xp Waterborne

System

18 3A2497B

Installation

Typical Installation Key

Item Description

AMain Air Supply Line

B* Bleed-Type Air Shutoff

Valve

CPump Air Pressure

Gauge

D Pump Air Pressure

Regulator

E kV Meter

FPump

GPumpSuct

ion Hose

HPaint Container

J* Bleed Resistor

K* Enclosure Safety

Interlock

L Isolated Enclosure

MGun Air Line Filter

NGun Air Pressure

Regulator

P* Graco Red Grounded

Air Hose (left-hand

threads)

Q* Gun Air Hose Ground

Wire

RGraco Waterborne Fluid

Hose

Item Description

SWaterborne

Electrostatic

Air-Assisted Spray

Gun

TGrounding Rod

UGround Terminal

V* Main Ground Wire

WStrain Relief Fitting

XPump Air Supply Line

YGrounding Cylinder

ZPump Fluid Outlet

Fitting

AA Isolated Enclosure Door

(not shown, to illustrate

internal components.

Door must be closed

and locked to operate

system).

BB Enclosure T-Handle

Locking Screw (part of

door assembly)

CC Accessory Bleed-Type

Air Shutoff Valve

* These items are required for safe operation. They

are included with the WB3000 system.

3A2497B 19

Installation

Agitator Kit Accessory

To add an agitator to the Graco isolation system, order

Part No. 245895. See 245895 Agitator Kit, page 75,

for the kit parts list.

1. Discharge the system voltage (see Fluid Voltage

Discharge and Grounding Procedure, page 25).

2. Relieve the pressure (see

Pressure Relief Procedure, page 26).

3. Open the isolated enclosure door.

4. Remove the back of the control box (258).

5. Remove tube (A2) from elbow (282) at the air

manifold; see . Install the Y fitting (402) into

the elbow. Install tubes (A2) and (407) into the

Y fitting. Route the agitator tube (407) into the

cabinet.

6. Replace the back of the control box (258).

7. Assemble the other parts of the kit as shown.

Secure the agitator with the setscrew (408).

8. Return the system to service.

Figure 13 245895 Agitator Kit

20 3A2497B

Gun Setup

Gun Setup

Grounding

When operating the electrostatic gun, any

ungrounded objects in the spray area (people,

containers, tools, etc.) can become electrically

charged. Improper grounding can result in static

sparking, which can cause a fire, explosion, or

electric shock. Ground all equipment, personnel,

object being sprayed, and conductive objects

in or close to the spray area. Resistance must

not exceed 100 ohms. Follow the grounding

instructions below.

The following are minimum grounding requirements

for a basic electrostatic waterborne system. Your

system may include other equipment or objects which

must be grounded. Check your local electrical code

for detailed grounding instructions. Your system must

be connected to a true earth ground.

•

Voltage Isolation System:

Electrically connect the

voltage isolation system to a true earth ground.

See Ground the Cabinet, page 16.

•

Electrostatic Air-Assisted Spray Gun:

ground

the gun by connecting the red-colored Graco

Grounded Air Hose to the gun, and connecting the

air hose ground wire to a true earth ground. See

Check Gun Electrical Grounding, page 23.

•

Object being sprayed:

keep the workpiece hangers

clean and grounded at all times.

•

All electrically conductive objects or devices in the

spray area:

must be properly grounded.

•

Fluid and waste containers:

ground all fluid and

waste containers in the spray area. Do not use pail

liners unless they are conductive and grounded.

When flushing the spray gun, the container used

to catch the excess fluid must be electrically

conductive and grounded.

•

Air compressors:

ground the equipment according

to the manufacturer's recommendations.

•

All air lines

must be properly grounded. Use only

grounded hoses with a maximum of 100 feet (30.5

m) combined hose length to ensure grounding

continuity.

3A2497B 21

Gun Setup

•

The floor of the spray area:

must be electrically

conductive and grounded. Do not cover the floor

with cardboard or any non-conductive material

which would interrupt grounding continuity.

•

All solvent pails:

use only approved, grounded

metal containers, which are conductive. Do not

use plastic containers. Only use non-flammable

solvents. Do not store more than the quantity

needed for one shift.

•

All persons entering the spray area:

must wear

shoes having conductive soles such as leather,

or wear personal grounding straps. Do not

wear shoes with non-conductive soles such as

rubber or plastic. If gloves are necessary, wear

the conductive gloves supplied with the gun. If

non-Graco gloves are worn, cut off fingers or palm

area of gloves to ensure your hand contacts the

grounded gun handle.

223A2497B

Gun Setup

Check Gun Electrical Grounding

Megohmmeter Part No. 241079 (AA-see Fig.

14) is not approved for use in a hazardous area.

To reduce the risk of sparking, do not use the

megohmmeter to check electrical grounding

unless:

• The gun has been removed from the hazardous

area;

• Or all spraying devices in the hazardous area

are turned off, ventilation fans in the hazardous

area are operating, and there are no flammable

vapors in the area (such as open solvent

containers or fumes from spraying).

Failure to follow this warning could cause fire,

explosion, and electric shock and result in serious

injury and property damage.

Graco Part No. 241079 Megohmmeter is available

as an accessory to check that the gun is properly

grounded.

1. Have a qualified electrician check the electrical

grounding continuity of the spray gun and air

hose.

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

3. Turn off the air and fluid supply to the gun. Follow

the Pressure Relief Procedure, page 26.

4. Disconnect thefluidhose.

5. Make sure the grounded air hose is connected

and the hose groundwireisconnectedtoatrue

earth ground.

6. Measure the resistance between the gun handle

(BB) and a true earth ground (CC). Use an

applied voltage of 500 minimum to 1000 volts

maximum. The resistance should not exceed

100 ohms. See Fig. 14.

Figure 14 Check Gun Electrical Grounding

3A2497B 23

Gun Setup

7. If the resistance is greater than 100 ohms, check

the tightness of the ground connections and be

suretheairhosegroundwireisconnectedtoa

true earth ground. If the resistance is still too

high, replace the air hose.

8. Using an ohmmeter (AA) measure the resistance

between the cabinet ground lug (214) and a true

earth ground (CC). The resistance must be less

than 100 ohms.

Figure 15 Check Cabinet Grounding

Flush Before Using Equipment

The equipment was tested in fluid at the factory. To

avoid contaminating your fluid, flush the equipment

with a compatible solvent before using the equipment.

243A2497B

Operation

Operation

Operating Checklist

Check the following list daily, before starting the

system.

⃞All operators are properly trained to operate

an electrostatic waterborne air-assisted spray

system as instructed in this manual.

⃞All operators are trained in the

Pressure Relief Procedure, page 26.

⃞The electrostatics are turned off and system

voltage is discharged according to the

Fluid Voltage Discharge and Grounding

Procedure, page 25, before any person en-

ters the isolation enclosure, before cleaning,

and before performing any maintenance or

repair.

⃞The system is grounded according to the

instructions in Grounding, page 21.

⃞The Graco waterborne fluid hose is in good

condition with no cuts or abrasions of the

inner layer. Replace hose if damaged.

⃞Ventilation fans are operating properly.

⃞All debris, including flammable fluids and

rags, is removed from the spray area.

⃞Fluids used must meet the following

flammability requirements:

•FM, FMc Approved:

Material does not sustain burning in

accordance with the Standard Test Method

for Sustained Burning of Liquid Mixtures,

ASTM D4206.

•CE-EN 50059 Compliant:

Materials which cannot be ignited, in any

mixturewithair,byanenergysourceof

less than 500mJ.

Fluid Voltage Discharge and

Grounding Procedure

The fluid supply is charged with high voltage until

the voltage is discharged. Contact with the charged

components of the voltage isolation system or

spray gun electrode will cause an electric shock.

To avoid an electric shock, follow the Fluid Voltage

Discharge and Grounding Procedure:

• whenever you are instructed to discharge the

voltage

• before cleaning, flushing, or servicing the system

equipment

• before approaching the front of the gun

• or before opening the isolation enclosure for the

isolated fluid supply.

1. Turn the ES ON/OFF valve OFF and wait 30

seconds, to allow the voltage to discharge

through the bleed resistor.

2. Fully unscrew the door T-handle locking screw.

This will shut off the air to the gun and trigger the

grounding cylinder to discharge any remaining

electrical charge.

3. Use the grounding rod to touch the pump

and supply pail. If you see any arcs, see

Electrical Troubleshooting, page 45.

3A2497B 25

Operation

Pressure Relief Procedure

This equipment stays pressurized until pressure

is manually relieved. To help prevent serious

injury from pressurized fluid, such as skin injection,

splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying

and before cleaning, checking, or servicing the

equipment.

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

2. Follow the Fluid Voltage Discharge and

Grounding Procedure, page 25.

3. Engage the trigger lock.

4. Turn off the air bleed valves to the fluid source

and to the gun.

5. Disengage the trigger lock.

6. Trigger the gun into a grounded metal waste

container to relieve the fluid pressure.

7. Engage the trigger lock.

8. Open the pump drain valve, having a waste

container ready to catch the drainage. Leave

thepumpdrainvalveopenuntilyouareready

to spray again.

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

pressure is not fully relieved, slowly loosen the

hose end coupling. Now clear the spray tip or

hose.

26 3A2497B

Operation

Fill the Fluid Supply

1. Follow the Fluid Voltage Discharge and

Grounding Procedure, page 25.

2. Follow the Pressure Relief Procedure, page 26.

3. Open the isolated enclosure door.

4. Remove the pail cover from the pail, holding a rag

over the suction tube strainer to prevent any fluid

from dripping into the isolated enclosure. Place

the cover and suction tube outside the enclosure.

5. Remove the supply pail from the enclosure.

NOTICE

Be sure to wipe up all fluid spills in the isolated

enclosure. Fluid can create a conductive path

and cause the system to short out.

6. Clean up any fluid spills in the enclosure, using

a soft cloth and a non-flammable, compatible

solvent.

7. Fill the supply pail with fluid and return it to the

enclosure. Clean up any spills.

8. Reinstall the pail cover, holding a rag over the

suction tube strainer to prevent fluid spills while

you place the pump suction tube in the pail.

9. Close the isolated enclosure door and fasten

securely with the T-handle locking screw.

3A2497B 27

Operation

Adjust the Spray Pattern

To reduce the risk of fire and explosion, fluids used

must meet the following flammability requirements:

•FM, FMc Approved:

Material does not sustain burning in accordance

with the Standard Test Method for Sustained

Burning of Liquid Mixtures, ASTM D4206.

•CE-EN 50059 Compliant:

Materials which cannot be ignited, in any mixture

with air, by an energy source of less than 500mJ.

Contact with the charged components of the spray

gun will cause an electric shock. Do not touch

the gun nozzle or electrode or come within 4 in.

(102 mm) of the electrode during operation or

until performing the Fluid Voltage Discharge and

Grounding Procedure, page 25.

Follow the Fluid Voltage Discharge and Grounding

Procedure, page 25 when you stop spraying and

whenever you are instructed to discharge the

voltage.

To reduce the risk of component rupture, which

can cause serious injury, do not exceed the

maximum working pressure of the lowest rated

system component. This equipment has a 100 psi

(0.7 MPa, 7 bar) maximum air working pressure

and a 3000 psi (21 MPa, 210 bar) maximum fluid

working pressure.

To reduce the risk of an injury, follow the

Pressure Relief Procedure, page 26 whenever you

are instructed to relieve the pressure.

Follow the steps below to establish the correct

fluid flow and air flow. See Fig. 16 to locate the

electrostatic gun controls.

Figure 16 Electrostatic Gun Controls

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

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

28 3A2497B

Operation

3. Check gun resistance. See

Test Gun Resistance, page 36.

4. Follow all steps under Grounding, page 21.

5. Follow all steps under

Check Gun Electrical Grounding, page 23.

Reading must be less than 100 ohms.

6. Connect the exhaust tube and secure with the

clamp provided.

7. Flush if needed. See Flushing, page 31.

To reduce the risk of a skin in-

jection injury, always follow the

Pressure Relief Procedure, page 26,

before removing or installing the spray tip, air

cap, or tip guard.

8. The fluid output and pattern width depend

on the size of the spray tip, the fluid

viscosity, and the fluid pressure. Use the

Spray Tip Selection Chart, page 71, as a guide

for selecting the appropriate spray tip for your

application.

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

cap. Install the tip.

10. Install the air cap and retaining ring. Orientate

the air cap and tighten the retaining ring securely.

11. Close the atomizing air adjustment valve (G) and

the fan air adjustment valve (F).

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

13. Start the pump. Set the fluid regulator to 400 psi

(2.8 MPa, 28 bar).

14. Spray a test pattern. Examine the particle size in

the center of the pattern (tails will be removed

in step 18). Increase the pressure in small

increments. Spray another pattern. Compare

particle size. Continue increasing pressure until

the particle size remains constant. Do not exceed

3000 psi (21 MPa, 210 bar).

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

3A2497B 29

Operation

16. Check that the ES indicator (Hz indicator on

Smart guns) is lit, or check that the kV indicator

on the isolated enclosure reads 30–50 kV.

The actual spraying voltage for AA waterborne

systems is 40–50 kV, but because the charging

electrode does not directly contact the fluid, the

voltage measured by the WB3000 kV meter will

be 5–10 kV lower. See the following table.

Table 2 . LED Indicator Colors

Indicator

Color

Description

Green When spraying, the indicator

should remain green, indicating

sufficient air pressure to the

alternator turbine.

Amber If the indicator turns amber after

1 second, the air pressure is too

low. Increase air pressure until

the indicator is green.

Red If the indicator turns red after 1

second, the air pressure is too

high. Decrease air pressure until

the indicator is green.

17. Set the gun air regulator to deliver a minimum of

45 psi (0.32 MPa, 3.2 bar) at gun when triggered,

to ensure full spraying voltage. See the table

below.

Table 3 . Pressure Drop

Air Hose

Length in ft (m)

(using 5/16 in. [8

mm] diameter hose)

Air Regulator Setting

in psi (MPa, bar)

[with gun triggered]

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)

18. Turn the atomizing air adjustment valve

counterclockwise until any tails disappear.

19. If desired atomization is not achieved, change

the tip size. The smaller the tip orifice, the finer

the atomization.

20. Spray a test piece. Examine the edges

for coverage. If wrap is poor, see

Troubleshooting, page 40.

NOTE: If a narrower pattern is needed occasionally,

open the fan air adjustment valve slightly. (Excessive

fan air flow can cause paint buildup on the air cap.)

Shutdown

1. Discharge the system voltage. See Fluid Voltage

Discharge and Grounding Procedure, page 25.

2. Flush the gun. See Flushing, page 31.

3. Follow the Pressure Relief Procedure, page 26.

4. Hang the gun from its hook, with the nozzle

pointing down. Be sure to keep the gun from

grounding out.

30 3A2497B

Maintenance

Maintenance

Flushing

•Flushbefore

changing fluids, before fluid can dry

in the equipment, at the end of the day, before

storing, and before repairing equipment.

•Flushatthe

lowest pressure possible. Check

connectors for leaks and tighten as necessary.

•Flushwitha

non-flammable solvent that is

compatible with the fluid being dispensed and the

equipment wetted parts.

To reduce the risk of fire, explosion, or electric

shock, turn OFF (O) the ES On-Off switch before

flushing the gun.

Follow the Fluid Voltage Discharge and Grounding

Procedure, page 25, before flushing.

Only flush, purge, or clean the gun with fluids that

meet the following flammability requirements:

•FM, FMc Approved:

Material does not sustain burning in accordance

with the Standard Test Method for Sustained

Burning of Liquid Mixtures, ASTM D4206.

•CE-EN 50059 Compliant:

Materials which cannot be ignited, in any mixture

with air, by an energy source of less than 500mJ.

NOTICE

Only use non-flammable solvents when flushing

or cleaning equipment.

1. Turn OFF (O) the ES On-Off switch. Wait 30

seconds for the voltage to bleed off.

2. Discharge the system voltage. See Fluid Voltage

Discharge and Grounding Procedure, page 25.

3. Follow the Pressure Relief Procedure, page 26.

4. Removeandcleantheaircapandspraytip.

5. Change the fluid source to non-flammable

solvent.

6. Point the gun into a grounded metal pail. Flush

until clean solvent flows from the gun.

3A2497B 31

Maintenance

7. Follow the Pressure Relief Procedure, page 26.

Engage the trigger lock.

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

cap. Install the tip.

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

10. Open the isolated enclosure door. Leave the

flushing fluid in the system until you are ready

to spray again.

11. Hang the gun from its hook, with the nozzle

pointing down. Be sure to keep the gun from

grounding out.

12. Before using the system electrostatically again,

make sure no flammable vapors are present.

32 3A2497B

Maintenance

Clean the Gun Daily

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

2. Discharge the system voltage. See Fluid Voltage

Discharge and Grounding Procedure, page 25.

3. Follow the Pressure Relief Procedure, page 26.

4. Remove the air cap/tip guard and spray tip.

5. Flush the gun, see Flushing, page 31.

6. Follow the Pressure Relief Procedure, page 26.

7. Clean the outside of the gun with a non-flammable

solvent, as defined under Flushing, page 31.

Use a soft cloth. Point the gun down to prevent

solvent from entering the gun passages. Do not

immerse the gun.

3A2497B 33

Maintenance

8. Clean the air cap/tip guard and spray tip with a

soft brush and non-flammable solvent.

9. If necessary, use a toothpick or other soft tool to

clean the air cap holes. Do not use metal tools.

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

cap. Install the tip.

11. Install the air cap and retaining ring. Orientate

the air cap and tighten the retaining ring securely.

34 3A2497B

Maintenance

Daily System Care

1. Follow the instructions under

Clean the Gun Daily, page 33. Follow

the Pressure Relief Procedure, page 26.

2. Clean the fluid and air filters.

3. Check for fluid leaks. Tighten all fittings.

4. Clean workpiece hangers. Use non-sparking

tools.

5. Check the movement of the trigger and valves.

Lubricate if necessary.

6. Check Gun Electrical Grounding, page 23.

7. Hang the gun from its hook, with the nozzle

pointing down.

8. Clean the cabinet:

• Inspect the cabinet and clean up any spilled

paint. Conductive paint residue allowed to

contact grounded parts may short out the

electrostatics.

•Keepthein

side of the cabinet clean, for proper

operation.

• Inspect the door T-handle locking screw

regularly, to ensure the threads are well

greased. Apply silicone-free grease to the

threads when necessary.

• Visually inspect the ground strip (240)

for damage. Replace if needed.

Measure theresistanceweekly. See

Test Ground Strip Resistance, page 39.

3A2497B 35

Electrical Tests

Electrical Tests

Use the following procedures to test the condition

of the power supply and gun body, and electrical

continuity between components.

NOTICE

The gun body resistor cartridge is part of the body

and is not replaceable. To avoid destroying the gun

body, do not attempt to remove the body resistor.

Use megohmmeter Part No. 241079 (AA) with an

applied voltage of 500 V. Connect the leads as

shown.

Megohmmeter Part No. 241079 (AA-see Fig.

17) is not approved for use in a hazardous area.

To reduce the risk of sparking, do not use the

megohmmeter to check electrical grounding

unless:

• The gun has been removed from the hazardous

area;

• Or all spraying devices in the hazardous area

are turned off, ventilation fans in the hazardous

area are operating, and there are no flammable

vapors in the area (such as open solvent

containers or fumes from spraying).

Failure to follow this warning could cause fire,

explosion, and electric shock and result in serious

injury and property damage.

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode

needle tip (25a) and the air swivel (21).

The resistance should be 104–150

megohms. If outside this range, go to

Test Power Supply Resistance, page 37.Ifin

range, see Electrical Troubleshooting, page 45 for

other possible causes of poor performance, or

contact your Graco distributor.

Figure 17 Test Gun Resistance

36 3A2497B

Electrical Tests

Test Power Supply Resistance

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

Supply Removal and Replacement, page 52.

2. Remove the alternator (15)

from the power supply. See

Alternator Removal and Replacement, page 53.

3. Measure resistance from the power supply's

ground strips (EE) to the spring (11a). The

resistance should be 90–115 megohms. If outside

this range, replace the power supply. If in range,

go to Test Gun Barrel Resistance, page 38.

4. Be sure the spring (11a) is in place before

reinstalling the power supply.

Figure 18 Test Power Supply Resistance

3A2497B 37

Electrical Tests

Test Gun Barrel Resistance

1. Insert a conductive rod (B) into the gun barrel

(which was removed for the power supply test)

and against the metal contact (C) in the front of

the barrel.

2. Measure the resistance between the conductive

rod (B) and the conductive ring (9). The

resistance should be 10–30 megohms. If the

resistance is incorrect, make sure the metal

contact (C) in the barrel and the conductive ring

(9) are clean and undamaged.

3. If the resistance is still outside the range,

remove the conductive ring (9) and measure the

resistance between the conductive rod (B) and

the wire lead at the bottom of the conductive ring

groove.

4. If the resistance is in range, replace the

conductive ring (9) with a new one. Insert the

ends of the conductive ring into the slots (S) at

the front of the barrel, then press the ring firmly

intothegroove(G).

NOTICE

The conductive ring (9) is a conductive metal

contact ring, not a sealing o-ring. For best

performance and to avoid potential damage to

the spray gun, do not remove the conductive

ring (9) except to replace it and never operate

the gun without the conductive ring in place.

Do not replace the conductive ring with

anything but a genuine Graco part.

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

the gun barrel.

Figure 19 Test Gun Barrel Resistance

38 3A2497B

Electrical Tests

Test Ground Strip Resistance

Using an ohmmeter, measure the resistance between

the latch housing (206) and the ground lug (214).

The ground strip is grounded through the cart back

to the ground lug. Resistance must be less than 100

ohms. If greater than 100 ohms, replace the ground

strip (240).

Figure 20 Test Ground Strip Resistance

Test Cylinder Resistance

Remove the enclosure door. Using an ohmmeter,

measure the resistance from the pump (209) to the

ground lug (214). Resistance must be less than

100 ohms. If greater than 100 ohms, replace the

grounding cylinder.

Figure 21 Test Cylinder Resistance

3A2497B 39

Troubleshooting

Troubleshooting

Installing and servicing this equipment requires

access to parts which may cause an electric shock

or other serious injury if the work is not performed

properly. Do not install or service this equipment

unless you are trained and qualified.

Follow the Fluid Voltage Discharge and Grounding

Procedure, page 25 before checking or servicing

the system and whenever you are instructed to

discharge the voltage.

To reduce the risk of a skin injection injury, always

follow the Pressure Relief Procedure, page 26,

whenever you are instructed to relieve the

pressure.

NOTE: Check all possible remedies in the

Troubleshooting Chart before disassembling the gun.

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the

waterborne gun is 40–50 kV. The system voltage is

lower due to spraying current demands and voltage

isolation system losses.

A loss of spraying voltage can be caused by a

problem with the spray gun, fluid hose, or voltage

isolation system, since all of the system components

are electrically connected through the conductive,

waterborne fluid.

Before troubleshooting or servicing the voltage

isolation system itself, you need to determine which

component in the system is most likely causing a

problem. Possible causes include the following:

Spray Gun

• Fluid leakage

• Dielectric breakdown at the fluid hose connection

or fluid packings

• Not enough air pressure for the alternator turbine

• Faulty power supply

• Excessive overspray on gun surfaces

• Fluid in the air passages

Waterborne Fluid Hose

• Dielectric failure of the hose (pin-hole leak in the

inner layer)

• Air gap in the fluid column between the gun and the

isolated fluid supply, causing a low voltage reading

on the isolation system voltage meter.

Voltage Isolation System

• Fluid leakage

• Dirty interior

40 3A2497B

Troubleshooting

Visual Checks

First, check the system for any visible faults or errors

to help isolate whether the spray gun, fluid hose or

voltage isolation system has failed. A voltage probe

and meter, part no. 245277, is helpful for diagnosing

voltage problems and is required for some of the

troubleshooting tests that follow.

1. Check that all of the air and fluid tubes and hoses

are properly connected.

2. Check that the voltage isolation system valves

and controls are properly set for operation.

3. Check that the interior of the isolated enclosure

is clean.

4. Check that the spray gun and voltage isolation

system have sufficient air pressure.

5. Check that the gun ES ON/OFF valve is in the

ON position and that the gun ES indicator light

is on. If the ES indicator light is not on, remove

the spray gunforserviceandcompletethe

Electrical Tests, page 36.

6. Check that the voltage isolation system's

enclosure door is closed and that any safety

interlocks are engaged and working properly.

7. Make sure the voltage isolation system is in

the “isolate” mode, where it is isolating the fluid

voltage from ground.

8. To eliminate air gaps in the fluid column, spray

enough fluid to purge the air out between the

voltage isolation system and the spray gun. An

air gap in the fluid hose can break the electrical

continuity between the spray gun and the isolated

fluid supply and cause a low voltage reading on

a voltage meter connected to the isolated fluid

supply.

9. Check the spray gun cover and barrel for

accumulated overspray. Excessive overspray

can create a conductive path back to the

grounded gun handle. Install a new gun cover

and clean the exterior of the gun.

10. Inspect the entire system for any visible fluid

leakage and repair any fluid leaks that are found.

Pay special attention to the following areas:

•Packinga

rea of the spray gun.

• Fluid hose: check for leakage or any bulges in

the outer cover, which may indicate an internal

leak.

• Internal voltage isolation system components

3A2497B 41

Troubleshooting

Tests

If you still have no voltage, separate the spray gun

and hose from the voltage isolation system and

check whether the gun and hose alone will hold

voltage with the following test.

1. Flush the system with water and leave the lines

filled with water.

2. Discharge the system voltage (see Fluid Voltage

Discharge and Grounding Procedure, page 25).

3. Follow the Pressure Relief Procedure, page 26.

4. Disconnect the fluid hose from the voltage

isolation system.

Avoid allowing any water to leak out of the fluid

hose as that could cause a significant air gap in

the fluid column up to the gun electrode, which

can break the conductivity path and conceal a

potential failure area.

5. Position the end of the hose as far as possible

away from any grounded surface. The end of

the hose must be at least 1 ft. (0.3 m) from any

ground. Make sure that no one is within 3 ft. (0.9

m) of the end of the hose.

6. Turn the ES ON/OFF valve to ON and trigger

the gun just enough to turn on the air to the gun

but not the fluid. Measure the voltage at the gun

electrode with a voltage probe and meter.

7. Discharge the system voltage by waiting 30

seconds and then touching the gun electrode

with a grounded rod.

8. Check the meter reading:

• If the meter reading is 40 to 50 kV, the gun and

fluid hose are okay, and the problem is in the

voltage isolation system.

• If the meter reading is below 40 kV, the

problem is in the gun or fluid hose.

9. Flush the fluid hose and gun with enough air to

dry out the fluid passages.

10. Turn the ES ON/OFF valve to ON and trigger the

gun. Measure the voltage at the gun electrode

with a voltage probe and meter.

• If the meter reading is 40-50 kV, the gun

power supply is okay, and there is probably a

dielectric breakdown somewhere in the fluid

hose or gun. Continue with step 11.

• If the meter reading is below 40 kV, do

the Electrical Tests, page 36,tocheckthegun

and power supply resistance. If those tests

show the gun and power supply are okay,

continue with step 11.

11. A dielectric breakdown is most likely in one of

the following three areas. Repair or replace the

component that is failing.

a. Fluid hose:

• Check for leakage or any bulges in the

outer cover, which may indicate a pin-hole

leak through the inner layer. Disconnect

the fluid hose from the gun, and look for

signs of fluid contamination on the outside

of the inner portion of the fluid tube.

• Inspect the end of the hose connected to

the voltage isolation system. Look for cuts

or nicks.

b. Fluid needle:

Remove the fluid needle from the gun

(see Fluid Needle Replacement, page 51),

and look for signs of fluid leakage or any

blackened areas, which would indicate arcing

is occurring along the packing rod.

c. Fluid hose connection to the spray gun:

Abrea

kdown at the fluid hose connection

joint would be caused by fluid leaking past

the hose fittings. Remove the hose at the

gun connection and look for signs of fluid

leakage.

12. Before reassembling the gun, clean and dry the

gun fluid inlet tube. Repack the inner spacer of

the fluid packing rod with dielectric grease and

reassemble the gun.

13. Reconnect the fluid hose.

14. Check the gun voltage with the voltage probe

and meter before filling the gun with fluid.

423A2497B

Troubleshooting

Spray Pattern Troubleshooting

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

Problem Cause Solution

No fluid. Refill supply.

Fluttering or spitting spray.

Air in fluid supply. Check fluid source. Refill.

Fluid buildup; partially plugged tip. Clean. See

Clean the Gun Daily, page 33.

Irregular pattern.

Worn/damaged tip or air cap holes. Clean or replace.

Pattern pushed to one side; air

cap gets dirty.

Air cap holes plugged. Clean. See

Clean the Gun Daily, page 33.

Air pressure too low. Open atomizing air adjustment

valve.

Tails in pattern.

Fluid pressure too low. Increase.

Air pressure too high. Decrease.

Fluid pressure too low. Increase.

Fluid buildup on air cap/tip guard.

Air cap holes plugged. Clean. See

Clean the Gun Daily, page 33.

3A2497B 43

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Atomizing air pressure too high. Close atomizing air valve part way,

or decrease air pressure as low

as possible; minimum 45 psi (0.32

MPa, 3.2 bar) needed at gun for

full voltage.

Excessive spray fog.

Fluid too thin. Increase viscosity.

Atomizing air pressure too low. Open atomizing air valve more or

increase gun air inlet pressure;

use lowest air pressure necessary.

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

Selection Chart, page 71.

Poorly mixed or filtered fluid. Remix or refilter fluid.

“Orange Peel” finish.

Fluid too thick. Reduce viscosity.

Fluid leaks from the fluid packing

area.

Worn fluid needle packings or rod. See Fluid Needle Replacement,

page 51.

Air leaks from the front of the gun. Air valve is not seating properly. See Air Valve Repair, page 57.

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

page 51.

Worn fluid seat housing. See Air Cap, Spray Tip, and Fluid

Seat Housing Replacement, page

48.

Loose spray tip. Tighten retaining ring.

Fluid leakage from the front of the

gun.

Damaged tip seal. See Air Cap, Spray Tip, and Fluid

Seat Housing Replacement, page

48.

Low fluid supply. Add fluid if necessary.

Damaged spray tip. Replace.

Dirty or clogged spray tip. Clean. See

Clean the Gun Daily, page 33.

Gun does not spray.

Damaged fluid needle. See Fluid Needle Replacement,

page 51.

Dirty air cap. Damaged or plugged air cap. Clean air cap. See

Clean the Gun Daily, page 33.

Poor grounding. See Grounding, page 21.

Excessive paint wrap back to

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

443A2497B

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

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

Gun air pressure too low (ES

indicator is amber).

Check air pressure to gun;

minimum45psi(0.32MPa,3.2

bar) needed at gun for full voltage.

Atomizing air pressure too high. Decrease.

Fluid pressure too high. Decrease, or replace worn tip.

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

Poorly grounded parts. Resistance must be 100 ohms or

less. Clean workpiece hangers.

Faulty gun resistance. See

Test Gun Resistance, page 36.

Fluid leaks from the fluid needle

packings and causes a short.

See Fluid Needle Replacement,

page 51.

Poor wrap.

Faulty alternator. See Alternator Removal and

Replacement, page 53.

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

No power. Check power supply, alternator,

and alternator ribbon cable. See

Power Supply Removal and

Replacement, page 52 and

Alternator Removal and

Replacement, page 53.

Operator not grounded or is near

ungrounded object.

See Grounding, page 21.

Operator gets mild shock.

Gun not grounded. See Check Gun Electrical

Grounding, page 23,and

Test Gun Resistance, page 36.

Operator gets shock from

workpiece.

Workpiece not grounded. Resistance must be 100 ohms or

less. Clean workpiece hangers.

3A2497B 45

Troubleshooting

Problem Cause Solution

Gun is too close to the part being

sprayed.

Gun should be 8–12 in. (200–300

mm) from the part.

Voltage/current display stays red

(smart guns only).

Dirty gun. See Clean the Gun Daily, page 33.

ES or Hz indicator is amber. Air turbine speed is too low. Increase air pressure until

indicator is green. To avoid

over-atomization, use the

atomizing air restrictor valve to

reduce the atomizing air to the air

cap.

ES or Hz indicator is red. Air turbine speed is too high. Decrease air pressure until

indicator is green.

Error display appears and Hz

indicator is red (Smart guns only).

Smart module has lost

communication with the power

supply.

Check for good connections

between Smart Module and

power supply. See Smart Module

Replacement, page 58,and

Power Supply Removal and

Replacement, page 52.

46 3A2497B

Repair

Repair

Prepare the Gun for Service

Installing and repairing this equipment requires

access to parts that may cause electric shock or

other serious injury if the work is not performed

properly. Do not install or service this equipment

unless you are trained and qualified.

To reduce the risk of injury, follow the

Pressure Relief Procedure, page 26, before

checking or servicing any part of the system

and whenever you are instructed to relieve the

pressure.

• Check all possible remedies in

Troubleshooting, page 40, before disassembling

the gun.

• Use a vise with padded jaws to prevent damage

to plastic parts.

• Lubricate the some needle assembly parts (20)

and certain fluid fittings with dielectric grease (57),

as specified in the text.

• Lightly lubricate o-rings and seals with non-silicone

grease. Order Part No. 111265 Lubricant. Do not

over-lubricate.

• Only use genuine Graco parts. Do not mix or use

parts from other PRO Gun models.

• Air Seal Repair Kit 24N789 is available. The

kit must be purchased separately. Kit parts are

marked with an asterisk, for example (3*).

1. Flush the gun. See Flushing, page 31.

2. Relieve the pressure. See

Pressure Relief Procedure, page 26.

3. Disconnect the gun air and fluid lines.

4. Remove the gun from the worksite. Repair area

must be clean.

3A2497B 47

Repair

Air Cap, Spray Tip, and Fluid Seat

Housing Replacement

1. See Prepare the Gun for Service, page 47.

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

guard assembly (25).

Figure 22 Remove Air Cap

3. Disassemble the air cap assembly. Check the

condition of the u-cup (22a), o-ring (25b), and tip

gasket (27a). Replace any damaged parts.

Figure 23 Disassemble Air Cap Assembly

Figure 24 Tip Gasket

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

Electrode Replacement, page 49.

NOTICE

The conductive ring (9) is a conductive metal

contact ring, not a sealing o-ring. For best

performance and to avoid potential damage to

the spray gun, do not remove the conductive

ring (9) except to replace it and never operate

the gun without the conductive ring in place.

Do not replace the conductive ring with

anything but a genuine Graco part.

5. Trigger the gun and remove the fluid seat housing

(24), using the multi-tool (61).

Figure 25 Replace Fluid Seat Housing

48 3A2497B

Repair

NOTICE

Do not overtighten the fluid seat housing (24).

Overtightening may damage the housing and

the gun barrel, resulting in improper fluid

shutoff.

6. Trigger the gun and install the fluid seat housing

(24). Tighten until snug, then 1/4 turn more.

7. Check that the spray tip gasket (27a) is in place.

Align the spray tip tab with the groove in the air

cap (25). Install the spray tip (27) in the air cap.

8. Make sure that the electrode (25a) is installed

correctly in the air cap.

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

10. Check that the u-cup (22a) is in place on the

retainingring(22). Thelipsoftheu-cupmust

face forward.

NOTICE

To avoid damaging the tip guard, orient the

air cap assembly (25) before tightening the

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

when the retaining ring is tight.

11. Orientate the air cap and tighten the retaining

ring securely.

12. See Test Gun Resistance, page 36.

Electrode Replacement

NOTICE

For best performance and to avoid potential

damage to the spray gun, do not operate the spray

gun without the electrode installed in the air cap.

1. See Prepare the Gun for Service, page 47.

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

Air Cap, Spray Tip, and Fluid Seat Housing

Replacement, page 48.

3. Pull the electrode (25a) out of the back of the air

cap, using a needle-nose pliers.

4. Push the new electrode through the air cap hole.

Make sure the short end (BB) of the electrode

engages thehole(CC)inthebackoftheair

cap. Press the electrode in place firmly with your

fingers.

5. Install the air cap assembly.

6. See Test Gun Resistance, page 36.

Figure 26 Replace Electrode

3A2497B 49

Repair

Gun Barrel Removal

1. See Prepare the Gun for Service, page 47.

2. Remove the air inlet fitting (21) and take the

bracket (B) off the gun handle (16).

3. Loosen the two screws (6).

NOTICE

To avoid damaging the power supply (11),

pull the gun barrel straight away from the gun

handle. If necessary, gently move the gun

barrel from side to side to free it from the gun

handle.

4. Hold the gun handle (16) with one hand and pull

the barrel (1) straight off the handle.

Figure27 GunBarrelRemoval

Gun Barrel Installation

1. Be sure the gasket (5*) and grounding spring

(37a) are in place. Make sure the gasket air

holes are aligned properly. Replace the gasket if

damaged.

2. Make sure the spring (11a) is in place on the

tip of the power supply (11). Liberally apply

dielectric grease (57) to the tip of the power

supply. Place the gun barrel (1) over the power

supply and onto the gun handle (16).

3. Tighten the two screws (6) oppositely and evenly

(about a half turn past snug). Do not over-tighten

the screws (6).

4. Position the bracket (B) on the gun handle (16)

and secure with the air inlet fitting (21).

5. See Test Gun Resistance, page 36.

Figure 28 Gun Barrel Installation

50 3A2497B

Repair

Fluid Needle Replacement

1. See Prepare the Gun for Service, page 47.

2. Remove the air cap assembly and fluid seat

housing. See Air Cap, Spray Tip, and Fluid Seat

Housing Replacement, page 48.

3. Remove the gunbarrel. See

Gun Barrel Removal, page 50.

4. Remove the trigger screws (13) and trigger (12).

5. Unscrew the spring cap (37). Remove the spring

(20a).

6. Insert the supplied driver (60) in the socket at the

back of the fluid needle. Press forward so the two

segments of the needle engage (R). This allows

the needle to be unscrewed from the gun body.

7. Using the multi-tool (61), pull back on the packing

nut (N) to remove the fluid needle assembly.

8. Install the fluid needle assembly in the gun barrel.

Push in on the needle with the driver (60) and

tighten.

9. Install the spring (20a).

10. Install the spring cap (37). Make sure the

grounding spring (37a) is in place.

11. Install the trigger (12) and screws (13).

12. Install the gun barrel. See

Gun Barrel Installation, page 50.

13. Install the seat housing and air cap assembly.

See Air Cap, Spray Tip, and Fluid Seat Housing

Replacement, page 48.

14. See Test Gun Resistance, page 36.

Figure 29 Remove Cap and Springs

Figure 30 Remove Fluid Needle

Figure 31 Replace Fluid Needle

3A2497B 51

Repair

Power Supply Removal and Replacement

• Inspect the gun handle power supply cavity for dirt

or moisture. Clean with a clean, dry rag.

• Do not expose gasket (5) to solvents.

1. See Prepare the Gun for Service, page 47.

2. See Gun Barrel Removal, page 50.

NOTICE

Be careful when handling the power supply

(11) to avoid damaging it.

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

Withagentlesidetosidemotion,freethepower

supply/alternator assembly from the gun handle

(16), then carefully pull it straight out.

On Smart

Models only,

disconnect the flexible circuit (40)

from the socket at the top of the handle.

4. Inspect the power supply and alternator for

damage.

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

alternator (15), disconnect the 3-wire ribbon

connector (PC) from the power supply.

On Smart

Models only,

disconnect the 6–pin flexible circuit

(40) from the power supply. Slide the alternator

up and off the power supply.

6. See Test Power Supply Resistance, page 37.

Replace the power supply if necessary.

To repair the alternator, see

Alternator Removal and Replacement, page 53.

7.

Smart models only:

connect the 6–pin flexible

circuit (40) to the power supply.

To prevent damage to the cable and possible

interruption of the ground continuity, bend the

alternator’s 3–wire ribbon cable (PC) upward

and back, so the bend faces the power supply

and the connector is at the top.

8. Connect the 3-wire ribbon connector (PC) to the

power supply. Tuck the ribbon forward, under

the power supply. Slide the alternator (15) down

onto the power supply (11).

9. Insert the power supply/alternator assembly in

the gun handle (16). Make sure the ground strips

make contact with the handle. On Smart models,

align the connector of the 6–pin flexible circuit

(40) with the socket (CS) at the top of the handle.

Push the connector securely into the socket as

you slide the power supply/alternator assembly

into the handle.

Figure 32 Connect Flexible Circuit

10. Make sure the gasket (5*), ground spring (37a),

and power supply spring (11a) are in place.

Assemble the barrel (1) to the handle (16). See

Gun Barrel Installation, page 50.

11. See Test Gun Resistance, page 36.

Figure 33 Power Supply

52 3A2497B

Repair

Alternator Removal and Replacement

NOTE: Replace alternator bearings after 2000 hours

of operation. Order Part No. 24N706 Bearing Kit.

Parts included in the kit are marked with a symbol (♦).

1. See Prepare the Gun for Service, page 47.

2. Remove the power supply/alternator assembly

and disconnect the alternator. See Power Supply

Removal and Replacement, page 52.

3. Measure resistance between the two outer

terminals of the 3-wire connector (PC); it should

be 2.0–6.0 ohms. If outside this range, replace

the alternator coil (15a).

4. Using a flat blade screwdriver, pry the clip (15h)

off the housing (15d). Remove the cap (15f),

using a thin blade or screwdriver.

5. If necessary, rotate the fan (15e) so its blades

clear the four bearing tabs (T) of the housing

(15d).

Figure 34 Fan Orientation

6. Push the fan and coil assembly (15a) out the

front of the housing (15d).

Figure 35 Alternator Cross-Section

NOTICE

Do not scratch or damage the magnet (M) or

shaft (S). Do not pinch or damage the 3–wire

connector (PC) when disassembling and

reassembling the bearings.

7. Hold the coil assembly (15a) on a workbench

with thefanendfacingup. Usingawideblade

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

8. Remove the top bearing (15b2).

9. Remove the bottom bearing (15b1).

10. Install the new bottom bearing (15b1♦) on the

long end of the shaft (S). The flatter side of the

bearing must face away from the magnet (M).

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

flush with the surface of the coil.

11. Press the new top bearing (15b2♦) onto the short

end of the shaft so the bearing blades are flush

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

of the bearing must face away from the coil.

3A2497B 53

Repair

12. Hold the coil assembly (15a) on a workbench

with the fan end facing up. Press the fan (15e♦)

onto the long end of the shaft (S). The fan blades

must be oriented as shown.

13. Carefully press the coil assembly (15a) into

the front of the housing (15d♦). The 3–wire

connector (PC) must be positioned below the

wider notch (W) of the housing tabs, as shown in

Fig. 35. Be sure the coil alignment pins (P) are

positioned as shown in Fig. 34.

14. Rotate the fan (15e) so its blades clear the four

bearing tabs (T) at the back of the housing.

Ensure that the blades of the bottom bearing

(15b1♦) align with the tabs.

15. Seat the coil fully into the housing (15d♦). Secure

with the clip (15h♦), ensuring that its tabs engage

the slots in the housing.

16. Ensurethattheo-ring(15g)isinplace. Install

the cap (15f).

17. Install the alternator on the power supply, and

install both parts in the handle. See Power

Supply Removal and Replacement, page 52.

Figure 36 Alternator

54 3A2497B

Repair

Fan Air Adjustment Valve Repair

1. See Prepare the Gun for Service, page 47.

2. Place a wrench on the flats of the valve assembly

(30) and unscrew it from the handle (16).

NOTE: You may replace the valve as an

assembly (go to step 9) or as individual parts

(steps 3-9).

3. Remove the retaining ring (30d).

4. Turn the valve shaft (30b) counterclockwise until

it comes free from the valve housing (30a).

5. Remove the o-ring (30c).

6. Clean all parts and inspect for wear or damage.

NOTE: Use non-silicone grease, Part No.

111265. Do not over-lubricate.

7. When reassembling the fan air valve (30), lightly

lubricate the valve threads and screw the shaft

(30b) fully into the housing (30a) until bottomed.

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

the valve stem until the o-ring enters the housing.

8. Reassemble the retaining ring (30d). Unscrew

the valve stem from the housing until it is stopped

by the retaining ring.

9. Screw the valve assembly (30) into the gun

handle (16),usingawrenchontheflatsofthe

housing. Torque to 15 in-lb (1.7 N•m).

Figure 37 Fan Air Adjustment Valve

Atomizing Air Adjustment Valve

Repair

1. See Prepare the Gun for Service, page 47.

2. Place a wrench on the flats of the valve assembly

(29) and unscrew it from the handle (16).

3. Inspect the valve assembly. If damaged, install

a new valve (29).

4. Before installing the valve assembly in the

handle, unscrew the valve stem (29b) from the

housing (29a) until it stops.

5. Install the valve assembly into the gun handle.

Torque the valve housing (29a) to 15 in-lb (1.7

N•m).

Figure 38 Atomizing Air Adjustment Valve

3A2497B 55

Repair

ES On-Off Valve Repair

1. See Prepare the Gun for Service, page 47.

2. Loosen the captive screw (26p). Remove the

valve (26) from the handle.

3. Lubricate the o-rings (26b* and 26g*) with

non-silicone grease, Part No. 111265. Do not

over-lubricate.

NOTE: Do not over-lubricate parts. Excessive

lubricant ontheo-ringscanbepushedintothe

gun air passage and blemish the finish on the

workpiece.

4. Clean and inspect parts for damage. Replace

if necessary.

NOTE: The protrusion on the retainer plate (26f)

must point upward.

5. Reinstall the valve. Torque the screw (26p) to

15-25 in-lb (1.7-2.8 N•m).

Figure 39 ES On-Off Valve

56 3A2497B

Repair

Air Valve Repair

1. See Prepare the Gun for Service, page 47.

2. See Gun Barrel Removal, page 50.

3. Remove the screws (13) and trigger (12).

4. Remove the ES On-Off Valve. See

ES On-Off Valve Repair, page 56.

5. Remove the spring (2).

6. Push on the front of the air valve shaft to force it

out the back of the handle. Inspect the rubber

seal (23a*) and replace if damaged.

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

unless damaged. If removed, install the new one

with its lips facing into the gun handle (16). Place

the u-cup on the shaft of the air valve to help seat

it in the gun handle.

Figure 40 Install U-Cup

8. Install the air valve (23) and spring (2) into the

gun handle (16).

9. Install the ES On-Off Valve. See

ES On-Off Valve Repair, page 56.

10. Install the trigger (12) and screws (13).

11. See Gun Barrel Installation, page 50.

Figure 41 Air Valve

3A2497B 57

Repair

Smart Module Replacement

If the Error display appears, the Smart Module has

lost communication with the power supply. Check for

good connections between the Smart Module and

the power supply.

If the module’s LEDs are not lighting, replace the

module.

1. See Prepare the Gun for Service, page 47.

2. Remove the pivot screw (31e), o-ring (31f), and

ES HI/LO switch (31c) at the bottom left corner of

the Smart Module cartridge (31a).

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

the cartridge.

4. Pull the Smart Module out the back of the gun.

Disconnect the ribbon cable (RC) from the

connector (GC) in the gun handle.

5. Remove the gasket (31b).

6. Install a new gasket (31b) on the new cartridge

(31a). Make sure the notched corners of the

gasket are at the top.

7. Align the module’s ribbon cable (RC) with

the gun’s cable (GC) and slide them securely

together, as shown. Tuck the connected cables

into the recess of the gun handle. Install the

module flush to the back of the gun handle.

8. Install the pivot screw (31e), o-ring (31f), and

ES HI/LO switch in the bottom left corner of the

cartridge (31a).

9. Install the three remaining screws (31d). Torque

to 7–9 in-lb (0.8–1.0 N•m).

Figure 42 Smart Module

Figure 43 Align Ribbon Cables

58 3A2497B

Repair

Air Swivel and Exhaust Valve Replacement

1. See Prepare the Gun for Service, page 47.

2. To replace the air exhaust valve:

a. Remove the clamp (36) and the exhaust tube

(35).

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

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

thebracketoutoftheway.

c. Pull the exhaust valve (8) from the handle

(16). Inspect the o-ring (8a) and replace if

necessary.

d. Install the o-ring (8a*) on the exhaust valve

(8). Lubricate the o-ring with a light coating

of non-silicone grease.

e. Install the exhaust valve (8) in the handle

(16).

f. Apply thread sealant to the top threads of the

swivel (21). Position the bracket and screw

the swivel into the gun handle (16). Torque

to 75–85 in-lb (8.4–9.6 N•m).

g. Install the tube (36) and clamp (43).

3. To replace the air inlet swivel:

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

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

b. Apply thread sealant to the top threads of the

swivel. Screw the swivel into the gun handle.

Torque to 75–85 in-lb (8.4–9.6 N•m).

Figure 44 Air Inlet Fitting and Air Exhaust Valve

3A2497B 59

Parts

Parts

Standard Air-Assisted Spray Gun Assembly

Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

60 3A2497B

Parts

Part No. H60T18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

Ref.

No.

Part No. Description Qty

124N745 BODY, gun 1

2 185116 SPRING, compression 1

3* 188749 PACKING, u-cup 1

5* 24N699 GASKET, body 1

624N740

SCREW, hex socket;

package of 2

1

724N742 BRACKET 1

8 249323 VALVE, exhaust 1

8a* 112085 O-RING 1

924N747

RING, conductive 1

11 24N662 POWER SUPPLY, 60 kV gun 1

11a 24N979 SPRING 1

12 24N663 TRIGGER; includes item 13 1

13 24A445 SCREW, trigger; package of 2 1

15 24N664 See

Alternator Assembly, page 67

1

16 24P746 HANDLE; 60 kV AA gun 1

20 24N781 NEEDLE ASSEMBLY; includes

item 20a

1

20a 24N782 SPRING, fluid needle 1

21 24N626 SWIVEL, air inlet; M12 x 1/4

npsm(m); left-hand thread

1

22 24N793 RING, retainer; includes 22a 1

22a* 198307 PACKING, u-cup; UHMWPE;

part of 22

1

23 24N633 VALVE, air 1

23a* 276733 SEAL 1

24 24N725 HOUSING, seat 1

25 24N727 See Air Cap Assembly, page 70 1

25a 24N643 ELECTRODE; package of 5 1

26 24N632 See ES On-Off Valve Assembly,

page68

1

Ref.

No.

Part No. Description Qty

27 AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s

choice; includes item 27a

1

27a 183459 GASKET, tip 1

29 24N792 ATOMIZING AIR

ADJUSTMENT VALVE

1

30 24N634 See Fan Air Valve Assembly,

page 69

1

32 24E404 STOP, trigger; includes item 32a 1

32a ——— PIN, dowel 1

35 185103 TUBE, exhaust; 1/4 in. (6 mm)

ID (shipped loose)

1

36 110231 CLAMP 1

37 24N785 CAP, spring; includes item 37a 1

37a 197624 SPRING, compression 1

38 24N786 PLUG, fan control; option,

shipped loose for use in place

of item 29

1

50 24N783 HOOK; includes screw 1

51 112080 TOOL, needle (shipped loose) 1

54 24N604 COVER, gun; package of 10 1

55▲ 222385 CARD, warning (not shown) 1

56▲ 186118 SIGN, warning (not shown) 1

57 116553 GREASE, dielectric; 1 oz (30

ml) tube (not shown)

1

58 117824 GLOVE, conductive, medium;

package of 12; also available

in small (117823) and large

(117825)

1

60 107460 TOOL, wrench, ball end

(shipped loose)

1

61 276741 MULTI-TOOL (shipped loose) 1

101 24M508 HOSE, unshielded, waterborne

fluid; includes 101a

1

101a ——— CONNECTOR, barrel 1

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

* These parts are included in Air Seal Repair Kit

24N789 (purchase separately).

Parts labeled — — — are not available separately.

3A2497B 61

Parts

Smart Air-Assisted Spray Gun Assembly

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

62 3A2497B

Parts

Part No. H60M18 60 kV Electrostatic Air-Assisted Spray Gun, Series A, includes items 1–61

Part No. 24M508 Unshielded Waterborne Fluid Hose (101), sold separately

Ref.

No.

Part No. Description Qty

124N745 BODY, gun 1

2 185116 SPRING, compression 1

3* 188749 PACKING, u-cup 1

5* 24N699 GASKET, body 1

624N740

SCREW, hex socket;

package of 2

1

724N742 BRACKET 1

8 249323 VALVE, exhaust 1

8a* 112085 O-RING 1

924N747

RING, conductive 1

11 24N662 POWER SUPPLY, 60 kV gun 1

11a 24N979 SPRING 1

12 24N663 TRIGGER; includes item 13 1

13 24A445 SCREW, trigger; package of 2 1

15 24N664 See

Alternator Assembly, page 67

1

16 24P745 HANDLE, smart; 60 kV AA gun 1

20 24N781 NEEDLE ASSEMBLY; includes

item 20a

1

20a 24N782 SPRING, fluid needle 1

21 24N626 SWIVEL, air inlet; M12 x 1/4

npsm(m); left-hand thread

1

22 24N793 RING, retainer; includes 22a 1

22a* 198307 PACKING, u-cup; UHMWPE;

part of 22

1

23 24N633 VALVE, air 1

23a* 276733 SEAL 1

24 24N725 HOUSING, seat 1

25 24N727 See Air Cap Assembly, page 70 1

25a 24N643 ELECTRODE; package of 5 1

26 24N632 See ES On-Off Valve Assembly,

page68

1

27 AEMxxx

AEFxxx

TIP ASSEMBLY; customer’s

choice; includes item 27a

1

Ref.

No.

Part No. Description Qty

27a 183459 GASKET, tip 1

29 24N792 ATOMIZING AIR

ADJUSTMENT VALVE

1

30 24N634 See Fan Air Valve Assembly,

page 69

1

31 24N756 See Smart Module Assembly,

page 70

1

32 24E404 STOP, trigger; includes item 32a 1

32a ——— PIN, dowel 1

35 185103 TUBE, exhaust; 1/4 in. (6 mm)

ID (shipped loose)

1

36 110231 CLAMP 1

37 24N785 CAP, spring; includes item 37a 1

37a 197624 SPRING, compression 1

38 24N786 PLUG, fan control; option,

shipped loose for use in place

of item 29

1

40 245265 CIRCUIT, flexible 1

50 24N783 HOOK; includes screw 1

51 112080 TOOL, needle (shipped loose) 1

54 24N604 COVER, gun; package of 10 1

55▲ 222385 CARD, warning (not shown) 1

56▲ 186118 SIGN, warning (not shown) 1

57 116553 GREASE, dielectric; 1 oz (30

ml) tube(notshown)

1

58 117824 GLOVE, conductive, medium;

package of 12; also available

in small (117823) and large

(117825)

1

60 107460 TOOL, wrench, ball end

(shipped loose)

1

61 276741 MULTI-TOOL (shipped loose) 1

101 24M508 HOSE, unshielded, waterborne

fluid; includes 101a

1

101a ——— CONNECTOR, barrel 1

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

*T

hese parts are included in Air Seal Repair Kit

24N789 (purchase separately).

Parts labeled — — — are not available separately.

3A2497B 63

Parts

Isolation Enclosure

Part No. 24N550 Waterborne Isolation Enclosure, for use with unshielded waterborne fluid hose; includes

items 201–286

64 3A2497B

Parts

Part No. 24N550 Waterborne Isolation Enclosure, for use with unshielded waterborne fluid hose; includes

items 201–286

Ref.

No.

Part No. Description Qty

201 ——— CABINET; includes 201a 1

201a 15A947 DOOR, cabinet 1

202 116993 CASTER, brake 4

203 ——— PLATE 1

204 15A551 T-HANDLE, latch 1

205 15A545 STEM, handle, door 1

206 15A524 HOUSING, latch 1

207 113061 SWITCH, push, air 1

209 24N548 PUMP; see 3A0732 1

210 ——— SCREW, hex hd cap; 5/16–18 x

5.5 in. (140 mm)

4

211 ——— WASHER, plain; 0.344 in. ID 4

212 ——— NUT, lock; 5/16–18 4

214 104029 LUG, ground 1

215 116989 VALVE, air 1

216 111804 REGULATOR, air 1

217 113060 GAUGE, air; 1/8 npt 1

218 116473 BALL VALVE; 1/4 npt(f) 1

219 233824 CART 1

220 162453 NIPPLE; 1/4 npt x 1/4 npsm 1

226 190410 RESISTOR, bleed 1

227 116988 CYLINDER ROD 1

228 15A518 HOUSING, cylinder rod 1

229 104267 REGULATOR, air 1

230 ——— BUSHING; plastic; 3/4 x 1/2 npt 1

235▲ 15A682 LABEL, warning 1

238 114958 STRAP, tie 5

239 222011 GROUNDWIRE;25ft(7.6m) 1

240 234018 STRIP, grounding; aluminum 1

241 110209 NUT, regulator 11

Ref.

No.

Part No. Description Qty

242 114051 WASHER, shim, ;atch 1

243 210084 ROD, ground 1

244 ——— SCREW, hex hd; 1/4–20 x 5/8

in. (16 mm)

16

245 ——— WASHER,plain;1/4in.(6mm) 16

246 ——— NUT, hex; 1/4–20 16

247 107257 SCREW, thread-forming 1

248 ——— TUBE; 1/4 in. (6 mm) OD; nylon A/R

249 160430 GAUGE, air 1

251 ——— WIRE, 10 gauge; green with

yellow stripe

1

252 ——— CONNECTOR, swivel tee; 1/8

npt x 5/32 in. (4 mm) tube

1

253 ——— NUT, hex; 10–32 5

256 162449 NIPPLE, reducing; 1/2 npt x 1/4

npt

2

257 101874 TERMINAL, ring 5

258 116990 BOX, control 1

259 113983 RING, retaining; 1/2 in. (13 mm) 1

260 237933 METER, 0–90 kV 1

261 113336 ADAPTER; 1/4 npt 1

262 ——— SCREW, pan hd; 10–32 x 5/8 in.

(16 mm)

2

263 ——— SCREW, pan hd; 10–32 x 1/4 in.

(6 mm)

1

264 ——— HOLDER, tie 3

265 ——— SCREW, button hd; 10–24 x 1.5

in. (38 mm)

2

266 ——— SCREW, button hd; 10–32 x 1.0

in. (25 mm)

4

267 ——— NUT, hex; M5 x 0.8 1

268 ——— WASHER, lock; no. 10 9

3A2497B 65

Parts

Ref.

No.

Part No. Description Qty

270 116991 TEE, run, manifold 1

271 203953 SCREW, hex hd cap with patch;

10–24 x 3/8 in. (10 mm)

1

272 ——— WIRE, 14 gauge; red A/R

273 ——— WIRE, ground, 14 gauge; green

with yellow stripe

A/R

274 155541 UNION, swivel; 1/4 npt 1

275 114261 TERMINAL, ring; no. 10 1

276 15A780 PLUG, hex hd 1

278 117314 BULKHEAD CONNECTOR; 1/4

npt

1

279 113319 CONNECTOR, tube; 1/4 npt x

3/8 in. (10 mm) OD tube

2

280 ——— ELBOW, tube 1

281 ——— FITTING, tube; 1/8 npt x 5/32 in.

(4 mm) OD tube

1

Ref.

No.

Part No. Description Qty

282 ——— SWIVEL, tube; 1/4 npt x 1/4 in.

(6 mm) OD tube

4

283 ——— SWIVEL, tube; 1/8 npt x 5/32 in.

(4 mm) OD tube

2

286 ——— TUBE; 3/8 in. (10 mm) OD A/R

300★ 235070 HOSE, air, grounded; 0.315 in.

(8 mm) ID; 1/4 npsm(f) x 1/4

npsm(f) left-hand thread; red

cover with stainless steel braid

ground path; 25 ft (7.6 m) long

1

H60T18 GUN; see Standard Air-Assisted

Spray Gun Assembly, page 60

1301★

H60M18 GUN; see Smart Air-Assisted

Spray Gun Assembly, page 62

1

▲ Replacement Danger and Warning labels, tags,

and cards are available at no cost.

★ The air hose (300) and gun (301) are not included

with the 24N550 Isolation Enclosure. They are shown

for illustrative purposes only. See page 3 for a list of

models which include an air hose and gun.

66 3A2497B

Parts

Alternator Assembly

Part No. 24N664 Alternator Assembly

Ref.

No.

Part

No.

Description Qty

15a 24N705 COIL, alternator 1

15b♦ 24N706 BEARING KIT (includes two

bearings, item 15e fan, and

one item 15h clip)

1

15d♦ 24N707 HOUSING; includes item 15f 1

15e♦ ——— FAN; part of item 15b 1

Ref.

No.

Part

No.

Description Qty

15f ——— CAP, housing; part of item

15d

1

15g* 110073 O-RING 1

15h♦ 24N709 CLIP; package of 5 (one clip

included with item 15b)

1

*The

se parts are included in Air Seal Repair Kit

24N789 (purchase separately).

♦ These parts are included in Bearing Kit 24N706

(purchase separately).

Parts labeled — — — are not available separately.

3A2497B 67

Parts

ES On-Off Valve Assembly

Part No. 24N632 ES On-Off Valve Assembly

Ref.

No.

Part No. Description Qty

26a ——— HOUSING, valve 1

26b* 15D371O-RING 2

26c ——— PISTON, valve 1

26d 24N650 LEVER, ES on-off; includes

item 26e

1

Ref.

No.

Part No. Description Qty

26e ——— SCREW, set, socket head 2

26f 24N631 PLATE, retaining 1

26g* 113746 O-RING 1

26p ——— SCREW, captive 1

* These parts are included in Air Seal Repair Kit

24N789 (purchase separately).

Parts labeled — — — are not available separately.

68 3A2497B

Parts

Fan Air Valve Assembly

Part No. 24N634 Fan Air Valve Assembly

Ref.

No.

Part No. Description Qty

30a ——— NUT, valve 1

30b ——— STEM, valve 1

30c* 111504 O-RING 1

30d 24N646 RING, retaining; package of 6 1

* These parts are included in Air Seal Repair Kit

24N789 (purchase separately).

Parts labeled — — — are not available separately.

3A2497B 69

Parts

Air Cap Assembly

Part No. 24N727 Air Cap Assembly

Ref.

No.

Part No. Description Qty

25a 24N643 ELECTRODE; package of 5 1

25b 24N734 O-RING; ptfe; package of 5

(also available in package of

10; order 24E459)

1

25c ——— AIR CAP 1

25d 24N726 GUARD, tip, orange 1

Parts labeled — — — are not available separately.

Smart Module Assembly

Part No. 24N756 Smart Module Assembly

Ref.

No.

Part No. Description Qty

31a ——— CARTRIDGE 1

31b 24P433 GASKET 1

31c 24N787 SWITCH, ES HI/LO 1

31d♦ ——— SCREW 3

31e♦ ——— SCREW, pivot 1

31f 112319 O-RING 1

Parts labeled — — — are not available separately.

♦ThesepartsareincludedinSmartModuleScrew

Kit 24N757 (purchase separately).

70 3A2497B

Spray Tip Selection Chart

Spray Tip Selection Chart

AEM Fine Finish Spray Tips

Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No.

AEMxxx, where xxx = 3–digit number from the matrix below.

Fluid Output

fl oz/min (l/min)

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

2–4

(50–

100)

4–6

(100–

150)

6-8

(150-

200)

8-10

(200-

250)

10-12

(250-

300)

12-14

(300-

350)

14-16

(350-

400)

16-18

(400-

450)

Orifice

Size

in.

(mm)

at 600

psi (4.1

MPa,

41 bar)

at 1000

psi (7.0

MPa,

70 bar) Spray Tip

†0.007

(0.178)

4.0

(0.1)

5.2

(0.15)

107 207 307

†0.009

(0.229)

7.0

(0.2)

9.1

(0.27)

209 309 409 509 609

†0.011

(0.279)

10.0

(0.3)

13.0

(0.4)

211 311 411 511 611 711

0.013

(0.330)

13.0

(0.4)

16.9

(0.5)

213 313 413 513 613 713 813

0.015

(0.381)

17.0

(0.5)

22.0

(0.7)

215 315 415 515 615 715 815

0.017

(0.432)

22.0

(0.7)

28.5

(0.85)

217 317 417 517 617 717

0.019

(0.483)

28.0

(0.8)

36.3

(1.09)

319 419 519 619 719

0.021

(0.533)

35.0

(1.0)

45.4

(1.36)

421 521 621 721 821

0.023

(0.584)

40.0

(1.2)

51.9

(1.56)

423 523 623 723 823

0.025

(0.635)

50.0

(1.5)

64.8

(1.94)

425525625725825

0.029

(0.736)

68.0

(1.9)

88.2

(2.65)

829

0.031

(0.787)

78.0

(2.2)

101.1

(3.03)

431 631 831

0.033

(0.838)

88.0

(2.5)

114.1

(3.42)

833

0.037

(0.939)

108.0

(3.1)

140.0

(4.20)

737

0.039

(0.990)

118.0

(3.4)

153.0

(4.59)

539

* Tips are tested in water.

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT =

fluid output (fl oz/min) at 600 psi from the above table for the selected orificesize.

† These tip sizes include a 150 mesh filter.

3A2497B 71

Spray Tip Selection Chart

AEF Fine Finish Pre-Orifice Spray

Tips

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

that assists in atomizing sheer thinning materials, including lacquers.

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

Fluid Output

floz/min(l/min)

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

6-8 (150-

200)

8-10

(200-250)

10-12

(250-300)

12-14

(300-350)

14-16

(350-400)

16-18

(400-450)

Orifice

Size

in. (mm) at 600 psi

(4.1 MPa,

41 bar)

at 1000

psi (7.0

MPa, 70

bar) Spray Tip

† 0.010

(0.254)

9.5 (0.28)12.5

(0.37)

310 410 510 610 710

0.012

(0.305)

12.0

(0.35)

16.0

(0.47)

312 412 512 612 712 812

0.014

(0.356)

16.0

(0.47)

21.0

(0.62)

314 414 514 614 714 814

0.016

(0.406)

20.0

(0.59)

26.5

(0.78)

416 516 616 716

* Tips are tested in water.

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT =

fluid output (fl oz/min) at 600 psi from the above table for the selected orificesize.

† These tip sizes include a 150 mesh filter.

723A2497B

Repair Kits, Related Manuals, and Accessories

Repair Kits, Related

Manuals, and Accessories

Gun Part No. Description Manual Description Repair Kits Repair Kit

Description

24N789 Air Seal Repair Kit

All guns in this

manual.

60 kV Waterborne

Air-Assisted Spray

Guns

Electrostatic

Waterborne

Air-Assisted

Spray Guns,

Instructions-Parts

24N706 Alternator Bearing

Repair Kit

Gun Accessories

Part No. Description

105749 Cleaning Brush.

111265 Non-silicone Lubricant, 4 oz (113 g).

116553 Dielectric Grease. 1 oz (30 ml)

24N319 Round Spray Kit. To convert a

standard air—assisted spray gun to

a round spray air cap. See manual

3A2499.

24N604 Gun Covers. Box of 10.

24N758 Display Covers. Keeps Smart display

clean. Package of 5.

24P170 Metal Trigger Kit.

24P172 Quick Adjust Valve. For quick

change of fan size.

185105 Non-swivel Air Inlet; 1/4–18 npsm(m)

(left-hand thread)

24N642 Air Inlet Ball Swivel; 1/4–18 npsm(m)

(left-hand thread)

185493 Air Hose Adapter; 1/4 npt(m) x

1/4–18 npsm(m) (left-hand thread)

112534 Air Line Quick Disconnect Fitting.

Operator Accessories

Part No. Description

117823 Conductive Gloves, box of 12 (small)

117824 Conductive Gloves, box of 12

(medium)

117825 Conductive Gloves, box of 12 (large)

24N520 Comfort Grip. Snap-on grip

increases handle size to reduce

operator fatigue. Medium size.

24N521 Comfort Grip. Snap-on grip

increases handle size to reduce

operator fatigue. Large size.

System Accessories

Part No. Description

222011 Ground Wire and Clamp.

186118 English Warning Sign. Available at

no charge from Graco.

3A2497B 73

Repair Kits, Related Manuals, and Accessories

Hoses

Grounded Air Hoses

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f)

left-hand thread

Part No. Description

Grounded Air Hose with stainless steel braid

ground path (Red)

235068 6ft(1.8m)

235069 15 ft (4.6 m)

235070 25 ft (7.6 m)

235071 36 ft (11 m)

235072 50 ft (15 m)

235073 75 ft (23 m)

235074 100 ft (30.5 m)

Test Equipment

Part No. Description

241079 Megohmmeter. 500 V output,

0.01–2000 megohms. Use for

ground continuity and gun resistance

tests.Not for use in hazardous areas.

245277 Test Fixture, High Voltage Probe,

and kV Meter. Use to test the

electrostatic voltage of the gun, and

the condition of the alternator and

power supply when being serviced.

See manual 309455.

743A2497B

Repair Kits, Related Manuals, and Accessories

245895 Agitator Kit

To keep fluid mixed and prevent settling out. Includes

items 401–408.

Ref.

No.

Part No. Description Qty

401 112698 ELBOW, swivel; 1/8 npt(m) x

1/4 in. (6 mm) OD tube

1

402 114158 FITTING, adapter, Y; 1/4 in. (6

mm) OD tube; mxfxf

1

403 193315 COLLAR, mounting, agitator 1

404 193316 NUT, collar, agitator 1

405 197298 COVER, pail; 5 gal. (19 liter) 1

406 224571 AGITATOR; see manual

306565

1

407 pur-

chase

locally

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

OD; 4 ft (1.22 m)

1

408 110272 SCREW, set, socket hd;

1/4–20 x 1/4 in. (6 mm)

1

3A2497B 75

Dimensions

Dimensions

Figure 45

Gun Model A, in. (mm) B, in. (mm) C, in. (mm) Weight without

bracket, oz (g)

H60T18 10.7 (272) 8.9 (226) 2.4 (61) 22.0 (623)

H60M18 10.8 (274) 9.6 (244) 2.4 (61) 24.4 (692)

76 3A2497B

Technical Data

Technical Data

Electrostatic Air—Assisted Spray Waterborne Guns

U.S. Metric

Maximum Working Fluid Pressure 3000 psi 21 MPa, 210 bar

Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar

Minimum Air Pressure at Gun Inlet 45 psi 0.32 MPa, 3.2 bar

Maximum Fluid Operating

Temperature

120°F 48°C

Short Circuit Current Output 125 microamperes

Voltage Output Energy 0.35 J with fluid hose 24M508 installed.

H60T18: 60kV

H60M18: 30–60 kV

Sound Power (measured per ISO

Standard 9216)

at 40 psi: 90.4 dB(A)

at 100 psi: 105.4 dB(A)

at 0.28 MPa, 2.8 bar: 90.4 dB(A)

at 0.7 MPa, 7.0 bar: 105.4 dB(A)

Sound Pressure (measured 1 m

from gun)

at 40 psi: 87.0 dB(A)

at 100 psi: 99.0 dB(A)

at 0.28 MPa, 2.8 bar: 87.0 dB(A)

at 0.7 MPa, 7.0 bar: 99.0 dB(A)

Air Inlet Fitting 1/4 npsm(m) left-hand thread

Fluid Inlet Fitting Custom inlet for Graco waterborne fluid hose.

Isolation Enclosure Air Inlet Fitting 1/4 npt

Isolation Enclosure Fluid Inlet

Fitting

3/8 in. OD tube fitting 10 mm OD tube fitting

Wetted Parts Gun: Stainless Steel, PEEK, UHMWPE, Fluoroelastomer, Acetal,

Nylon, Polyethylene, Tungsten Wire

Waterborne Fluid Hose: PTFE

Suction Tube: Polyethylene, Stainless Steel

Merkur Pump: See manual 3A0732.

3A2497B 77

Graco Pro Xp Warranty

Graco warrants all equipment referenced in this document which is manufacturedbyGracoandbearingitsnametobe

free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of

any special, extended, or limited warranty published by Graco, Graco will,foraperiodoftwelvemonthsfromthedate

of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in

the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or

replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated

and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or

wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence,

accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage

or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not

supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories,

equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco

distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge

any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the

equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which

charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,

INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A

PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees

that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to

person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty

must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR

COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco

(such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide

purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying

equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a

breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal

proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in

English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que

tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou

indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

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

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

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

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

Original Instructions. This manual contains English, MM 3A2497

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2012, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revised July 2013