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Instructions - Parts
Read all warnings and instructions in this manual.
100 psi (0.7 MPa, 7.0 bar) Maximum
Fluid Working Pressure
100 psi (0.7 MPa, 7.0 bar) Maximum Air
Working Pressure
3A2496D
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Models............................................................... 3
Models with FM Approval Only...................... 3
Models which are FM Approved and
Compliant with EN50059 ................. 4
Warnings ........................................................... 5
Gun Overview .................................................... 8
How the Electrostatic Spray Gun
Works ............................................ 8
Electrostatically .............................. 8
Controls, Indicators, and Components ........... 8
Smart Guns ................................................. 10
Installation.......................................................... 16
System Requirements .................................. 16
Warning Sign ............................................... 16
Install the System......................................... 16
Ventilate the Spray Booth ............................. 16
Air Supply Line ............................................ 17
Ground the Cabinet...................................... 17
Connect the Waterborne Fluid Hose.............. 18
Agitator Kit Accessory .................................. 24
Fluid Regulator Kit Accessory ....................... 25
Gun Setup.......................................................... 26
Select a Fluid Nozzle and Air Cap ................. 26
Grounding ................................................... 26
Check Gun Electrical Grounding ................... 28
Flush Before Using Equipment...................... 29
Operation ........................................................... 30
Operating Checklist...................................... 30
Fluid Voltage Discharge and Grounding
Procedure ...................................... 30
Pressure Relief Procedure............................ 31
Fill the Fluid Supply...................................... 31
Adjust the Spray Pattern............................... 32
Shutdown .................................................... 35
Maintenance ...................................................... 36
Flushing ...................................................... 36
Clean the Gun Daily ..................................... 37
Daily System Care ....................................... 38
Electrical Tests ................................................... 39
Test Gun Resistance.................................... 39
Test Power Supply Resistance ..................... 40
Test Electrode Resistance ............................ 41
Test Ground Strip Resistance ....................... 42
Test Cylinder Resistance.............................. 42
Troubleshooting.................................................. 43
Voltage Loss Troubleshooting....................... 43
Spray Pattern Troubleshooting...................... 46
Gun Operation Troubleshooting .................... 47
Electrical Troubleshooting ............................ 48
Repair................................................................ 50
Prepare the Gun for Service ......................... 50
Air Cap and Nozzle Replacement.................. 51
Air Cap, Spray Tip, and Nozzle
L60M19) ........................................ 52
Electrode Replacement ................................ 54
Needle Replacement (Model L60M19) ........... 55
Fluid Packing Rod Removal.......................... 56
Packing Rod Repair ..................................... 57
Barrel Removal ............................................ 58
Barrel Installation ......................................... 58
Replacement .................................. 59
Alternator Removal and Replacement ........... 60
Fan Air Adjustment Valve Repair .................. 62
Atomizing Air Restrictor Valve Repair ............ 63
ES On-Off and Fluid Adjustment Valve
Repair............................................ 64
Air Valve Repair........................................... 65
Smart Module Replacement.......................... 66
Replacement .................................. 67
Parts.................................................................. 68
Standard Waterborne Air Spray Gun
Assembly ....................................... 68
Smart Waterborne Air Spray Gun
Assembly ....................................... 70
Mold Release Smart Air Spray Gun
Assembly ....................................... 72
Isolation Enclosure....................................... 74
Tubing and Wiring ....................................... 77
Packing Rod Assembly................................. 79
Alternator Assembly ..................................... 80
ES On-Off and Fluid Adjustment Valve ........... 81
Fan Air Adjustment Valve Assembly .............. 82
Atomizing Air Restrictor Valve
Assembly ....................................... 82
Air Cap Assembly ........................................ 83
Smart Module Assembly............................... 84
Air Caps and Fluid Nozzles ................................. 85
Spray Tip Selection Chart (Model L60M19 MRG
Gun Only) ............................................. 90
Repair Kits, Related Manuals, and
Accessories .......................................... 92
Dimensions ........................................................ 96
Technical Data ................................................... 97
Graco Pro Xp Warranty ....................................... 98
2 3A2496D
24N580
24P629
233825
L60T17
L60M17
24M732
WB100
WB100
WB100
Pro Xp 60 WB
Pro Xp 60 WB
- — —
Waterborne Isolation Enclosure 233825 with standard electrostatic air spray gun L60T17, grounded air hose 235070, and shielded waterborne fluid hose 24M732.
Waterborne Isolation Enclosure 233825 with smart electrostatic air spray gun L60M17, grounded air hose 235070, and shielded waterborne fluid hose 24M732.
Waterborne Isolation Enclosure for shielded hoses. Does not include hoses and gun.
Standard Electrostatic Air Spray Gun, for waterborne coatings.
Smart Electrostatic Air Spray Gun, for waterborne coatings.
Shielded Waterborne Fluid Hose Assembly, 25 ft (7.6 m).
3A2496D 3
4
24P630
24P631
24P734
246511
L60T18
L60M18
L60M19
24M733
WB100
WB100
WB100
WB100
Pro Xp 60 WB
Pro Xp 60 WB
Pro Xp 60 WB
MRG
- — —
Waterborne Isolation Enclosure 246511 with standard electrostatic air spray gun L60T18, grounded air hose 235070, and unshielded waterborne fluid hose 24M733.
Waterborne Isolation Enclosure 246511 with smart electrostatic air spray gun L60M18, grounded air hose 235070, and unshielded waterborne fluid hose 24M733.
Waterborne Isolation Enclosure 246511 with MRG smart electrostatic air spray gun L60M19, grounded air hose 235070, and unshielded waterborne fluid hose 24M733.
Waterborne Isolation Enclosure for unshielded hoses. Does not include hoses and gun.
Standard Electrostatic Air Spray Gun, for waterborne coatings.
Smart Electrostatic Air Spray Gun, for waterborne coatings.
Smart Electrostatic Air Spray Gun, for mold release applications.
Unshielded Waterborne Fluid Hose Assembly, 25 ft (7.6 m).
3A2496D
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
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
• Connect the electrostatic gun to a voltage isolation system that will discharge the system voltage when not in use.
• All components of the isolation system that are charged to high voltage must be contained within an isolation enclosure that prevents personnel from making contact with the high voltage components before the system voltage is discharged.
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.
• Do not touch the gun nozzle or electrode, or come within 4 in. (102 mm) of the electrode
• 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.
3A2496D 5
6
• Fluids used must meet the following flammability requirements:
Material does not sustain burning in accordance with the Standard Test Method for
Sustained Burning of Liquid Mixtures, ASTM D4206.
Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.
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 fans are on.
• Only use non-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.
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
solvent manufacturer’s MSDSs and recommendations.
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
3A2496D
3A2496D
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.
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 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.
• 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.
• Make sure 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.
• Do not 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.
7
The air hose supplies air to the spray gun. Part of the air operates the alternator turbine and the rest of the air atomizes 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 pump supplies fluid to the fluid hose and gun, where 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.
This electrostatic air spray gun is designed to spray flammability requirements:
Material does not sustain burning in accordance with the Standard Test Method for Sustained
Burning of Liquid Mixtures, ASTM D4206.
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
) 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 30
, before approaching the front of the gun.
void if the electrostatic spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.
The electrostatic gun includes the following controls, indicators, and components (see Fig.
1). For information on Smart guns, also see
.
8 3A2496D
Figure 1 Gun Overview
Item Description
A
B
C
Air Swivel Inlet 1/4 npsm(m) left-hand thread, for
Graco red-colored grounded air supply hose.
Fluid Inlet Graco waterborne fluid supply hose
Turbine Air Exhaust Barbed fitting, for supplied exhaust tube.
D
E
F
Air Cap and Nozzle See
, for available sizes.
Electrode Needle
Fan Air Adjustment
Valve
Supplies electrostatic charge to the fluid.
Adjusts fan size and shape. Can be used to decrease pattern width.
Item Description
G
H
J
K
Atomizing Air
Restrictor Valve
Fluid Adjustment
Knob
ES On-Off Valve
ES Indicator (standard gun only; for
Smart gun indicator, see
Restricts air cap air flow. Replace with plug (included) if desired.
Adjusts fluid flow by limiting fluid needle travel. Use only in low flow conditions, to reduce wear.
Turns electrostatics
ON (I) or OFF (O).
Lit when ES is
ON (I). Color indicates alternator frequency. See the
LED indicator table on page 36.
3A2496D 9
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
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.
• The low voltage indicator (LO) lights when the switch is set to LO. The low voltage setting is user adjustable. See
Adjusting the Low Voltage Setting, page 11 .
See Fig. 2, and Table 1 on page 12. 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 bar graph LEDs are blue, the gun is ready to spray. If the LEDs are yellow or red, the current is too high. The fluid may be too conductive, or see
Electrical Troubleshooting, page 48
for other possible causes.
has lost communication with the power supply. See
for further information.
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.
Figure 2 Smart Gun Module in Operating Mode
10 3A2496D
return to the Operating Screen.
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 12.
This can occur in Operating Mode or Diagnostic
Mode. See
Electrical Troubleshooting, page 48 .
Communication must be restored to make the Smart module functional.
appear. If the gun has been disassembled, wait 8 seconds before spraying to ensure that an Error condition has not occurred.
display will not appear.
Figure 4 Low Voltage Setting Screen (Unlocked)
The low voltage setting may be locked. When locked, an image (LK) appears on the screen. See Fig. 5, and Table 1 on page 12.
locked. The lock symbol will appear when the LO
SET button is pressed.
• When in LO mode, the lock symbol will
Low Voltage Lock Screen, page 15 , to lock or
unlock the low voltage setting.
Figure 3 Error Display
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. See Fig. 4, and Table 1 on page 12. 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.
Figure 5 Low Voltage Setting Screen (Locked)
3A2496D 11
LV
LK
LD
ER
VI
12
VA
LO kV uA
LS
Voltage Adjustment Switch
Low Voltage Mode Indicator
Voltage (kV) Display
Current (uA) Display
LO SET button
Low Voltage Display
Low Voltage Locked
LO Display
Error Display
Voltage Indicator
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.
Lights (blue) when the smart gun is set to Low Voltage.
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.
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.
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.
Displays the low voltage setting as a number. The setting can be changed. See Fig. 4.
Appears if the low voltage setting is locked. See Fig. 5 and Fig. 9.
Appears on the Low Voltage Lock
Screen. See Fig. 9.
Appears if the Smart module loses communication with the power supply. See Fig. 3.
In Diagnostic Mode, the two top right LEDs of the screen light, indicating that the value displayed is in kV. See Fig. 6.
3A2496D
CI
AS
Hz
Current Indicator
Alternator Speed Display
Alternator Speed Indicator
In Diagnostic Mode, the two bottom right LEDs of the screen light, indicating that the value displayed is in uA. See Fig. 7.
In Diagnostic Mode, Hz level is displayed as a number. See Fig.
8.
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.
3A2496D 13
Diagnostic Mode includes four screens which display gun data:
• Voltage (kiloVolts) Screen
• Current (microAmperes) Screen
• Alternator Speed (Hertz) Screen
• Low Voltage Lock Screen 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 14
.
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.
Mode, the last screen viewed will be displayed when the gun is retriggered.
from the Low Voltage Lock Screen. See
Low Voltage Lock Screen, page 15
for details.
Figure 6 Voltage (kiloVolts) Screen
The Current (microAmperes) Screen is the second screen in the Diagnostic Mode. See Fig. 7, and Table
1 on page 12. 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 15
. Press and hold for approximately 5 seconds to return to
Operating Mode.
The Voltage (kiloVolts) Screen is the first screen to appear after entering Diagnostic Mode. See Fig. 6, and Table 1 on page 12. 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 14 . Press
and hold for approximately 5 seconds to return to
Operating Mode.
Figure 7 Current (microAmperes) Screen
14 3A2496D
The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table
1 on page 12. 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 15
. Press and hold for approximately 5 seconds to return to Operating
Mode.
The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode. See Fig. 9, and Table 1 on page 12. 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).
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 8 Alternator Speed (Hertz) Screen
Figure 9 Low Voltage Lock Screen
3A2496D 15
A Graco voltage 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.
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 safety and fire codes, NFPA
33, NEC 504 and 516, and OSHA standard
1910.107.
Fig. 19 shows a typical electrostatic air spray system.
It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
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.
void if the electrostatic spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.
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.
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).
16 3A2496D
1.
See Fig. 19. 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 WB100 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 air supply hose ground wire (Q) to a true earth 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 WB100 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.
Connect the main ground wire (V) to a true earth ground.
3A2496D 17
Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet. The waterborne fluid hose (101) consists of an inner PTFE tube (T) and an abrasion-resistant outer jacket (J). Shielded hose 24M732 also has a conductive layer (C), The conductive layer is connected to ground at the gun fitting bracket (104).
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).
failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.
Using unshielded fluid hoses minimizes the system capacitance, resulting in faster response times and a large reduction in the energy stored in the system, as compared to shielded hoses.
However, without the ground shield, a weak static charge can occasionally build up on the outer surface of the hose. To minimize any static charge felt on the hose surface, bundle the air and fluid hose together, and wrap with a protective cover, as shown.
Figure 10 Connect the Fluid Hose
18
Figure 11 Bundling the Air and Fluid Hoses
3A2496D
2.
For the fluid hose to fit properly, it must be stripped and assembled to the dimensions shown in Fig. 12. Apply dielectric grease to the inner tube (T) of the hose. Slide the fitting (F) onto the tube (T). Press the barbed fitting (G) into the tube until its shoulder bottoms on the tube. A new Graco waterborne fluid hose comes fully assembled to these dimensions.
Be careful not to cut into the inner tube (T) of the hose when stripping the hose. Nicks or cuts in the PTFE tube will cause premature hose failure.
Figure 12 Shielded Hose 24M732 Dimensions at Gun
Figure 13 Unshielded Hose 24M733 Dimensions at Gun
3.
Generously apply dielectric grease (44) to the o-ring (107) and the threads of the fitting (106).
Pull the fitting back 1-1/2 in. (38 mm) and apply grease to the exposed PTFE hose to fill the area between the hose and the fitting. Make sure the barrel inlet is clean and dry, then screw the fitting into the fluid inlet of the gun barrel (1).
4.
Loosen the strain relief nut (102) so the bracket can move freely on the hose.
5.
Align the bracket (104) holes with the air inlet and exhaust outlet. Secure with the air inlet fitting
(21). Tighten the strain relief nut (102) to secure the hose.
6.
Check that the nut (105) is tightened securely to the ferrule housing (103).
7.
Press the exhaust tube (36) onto the exhaust valve barb (C). Secure with the clamp (43).
3A2496D 19
8.
Connect the other end of the hose to the isolated fluid supply as follows: a.
Graco WB100 Enclosure: Slide hose through the strain relief fitting (W). Ensure conductive layer (C) has passed through fitting. Tighten to 55 in-lb (6.2 N•m). Pull back on hose to check it is secure. Comply with the
Conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (L) or grounded fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule when the strain relief nut is tightened. Failure to properly install the hose in the strain relief could result in an electric shock.
Figure 15 Shielded Hose 24M732
Connection at WB100 Enclosure
Figure 16 Unshielded Hose 24M733
Dimensions at WB100 Enclosure
Figure 14 Shielded Hose 24M732
Dimensions at WB100 Enclosure
Figure 17 Unshielded Hose 24M733
Connection at WB100 Enclosure
20 3A2496D
b.
Non-Graco Isolated Enclosure: Connect hose as instructed in the isolation system manual, and comply with the requirements
Conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (L) or grounded fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule when the strain relief nut is tightened. Failure to properly install the hose in the strain relief could result in an electric shock.
Figure 18 Shielded Fluid Hose Connection at Non-Graco Isolation Enclosure c.
Connect the end of the tube (T) to the pump fluid outlet fitting (Z).
void if the electrostatic spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.
3A2496D 21
Figure 19 Typical Installation, Pro Xp WB100
Waterborne System
22 3A2496D
C
D
A
B*
E
F
G
H
J*
K*
L
M
N
P*
Q*
R
Main Air Supply Line
Bleed-Type Air Shutoff
Valve
Pump Air Pressure
Gauge
Pump Air Pressure
Regulator kV Meter
Pump
Pump Suction Hose
Paint Container
Bleed Resistor
Enclosure Safety
Interlock
Isolated Enclosure
Gun Air Line Filter
Gun Air Pressure
Regulator
Graco Red Grounded
Air Hose (left-hand threads)
Gun Air Hose Ground
Wire
Graco Waterborne Fluid
Hose
X
Y
Z
T
U
V*
W
S
AA
Waterborne
Electrostatic Air Spray
Gun
Grounding Rod
Ground Terminal
Main Ground Wire
Strain Relief Fitting
Pump Air Supply Line
Grounding Cylinder
Pump Fluid Outlet
Fitting
Isolated Enclosure Door
(not shown, to illustrate internal components.
Door must be closed and locked to operate system).
BB
CC
Enclosure T-Handle
Locking Screw (part of door assembly)
Accessory Bleed-Type
Air Shutoff Valve
* These items are required for safe operation. They are included with the WB100 system.
3A2496D 23
To add an agitator to the Graco isolation system, order
Part No. 245895. See
245895 Agitator Kit, page 94 ,
for the kit parts list.
1.
Discharge the system voltage (see
Discharge and Grounding Procedure, page 30
).
2.
Relieve the pressure (see
Pressure Relief Procedure, page 31 ).
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 20 245895 Agitator Kit
24 3A2496D
To add a fluid regulator to the Graco isolation system, order Part No. 245944. See
245944 Fluid Regulator Kit, page 95
for the kit parts list.
1.
Discharge the system voltage (see
Discharge and Grounding Procedure, page 30
).
2.
Relieve the pressure (see
Pressure Relief Procedure, page 31 ).
3.
Open the isolated enclosure door.
4.
Remove the 1/4 in. (6 mm) OD tube (A1) from the
pump air inlet; see Tubing and Wiring , page 77
.
5.
Remove the waterborne fluid hose from the pump fluid outlet fitting (231) and remove the fitting.
6.
Unscrew the two pump mounting screws (S) and remove the pump from the isolation enclosure.
7.
Remove the back of the control box (258).
8.
Remove tube (A2) from elbow (282) at the air
manifold; see Tubing and Wiring , page 77
Install the Y fitting (506) in the elbow. Install tubes (A2) and (507) into the Y fitting. Route the tube (507) into the cabinet.
9.
Replace the back of the control box (258).
10. Assemble the fluid regulator kit as shown.
11. Reinstall the pump in the isolation enclosure.
Use the two mounting holes to the left of the holes used previously, to allow clearance for the fluid regulator.
12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.
13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).
14. Return the system to service.
217) will now operate the air piloted fluid regulator
(504). The pump will now operate at the inlet air pressure.
Figure 21 245944 Fluid Regulator Kit
3A2496D 25
To reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, follow the
Pressure Relief Procedure, page 31 , before
removing or installing a fluid nozzle and/or air cap.
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
.
are supplied with Part No. 24N616 Nozzle and 24N477 Air Cap. If you require a different size, see
Air Caps and Fluid Nozzles, page 85 ,
or consult with your Graco distributor. See
Air Cap and Nozzle Replacement, page 51 .
Model L60M19 Mold Release Gun is supplied with
Part No. 24N748 Nozzle, 24N727 Air Cap, and a spray tip of choice. If you require a different size spray tip, see
Spray Tip Selection Chart (Model
, or consult with your Graco distributor. See
Nozzle Replacement (Model L60M19), page 52 .
• Electrostatic Air 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 28 .
• Graco Shielded Waterborne Fluid Hose
(24M732): the hose is grounded through the conductive layer. Install as instructed under
Connect the Waterborne Fluid Hose, page 18
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 1 megohm. Follow the grounding instructions below.
26 3A2496D
• Object being sprayed: keep the workpiece hangers clean and grounded at all times.
• All solvent pails: use only approved, grounded metal containers, which are conductive. Do not use plastic containers. Use only non-flammable solvents. Do not store more than the quantity needed for one shift.
• 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.
• 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 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.
3A2496D 27
5.
Make sure the red-colored grounded air hose
(AH) is connected and the hose ground wire is connected to a true earth ground.
Megohmmeter Part No. 241079 (AA-see Fig.
21) 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.
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. 22.
7.
If the resistance is greater than 100 ohms, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.
3.
Turn off the air and fluid supply to the gun. Follow the
Pressure Relief Procedure, page 31 . The
fluid hose must not have any fluid in it.
4.
Disconnect the fluid hose.
Figure 22 Check Gun Electrical Grounding
28 3A2496D
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 23 Check Cabinet Grounding
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.
3A2496D 29
Check the following list daily, before starting the system.
⃞ All operators are properly trained to safely operate an electrostatic waterborne air spray system as instructed in this manual.
⃞ All operators are trained in the
Pressure Relief Procedure, page 31
.
⃞ The electrostatics are turned off and system voltage is discharged according to the
Fluid Voltage Discharge and Grounding
, before any person enters the isolation enclosure, before cleaning, and before performing any maintenance or repair.
⃞ The system is grounded according to the instructions in
.
⃞ The Graco waterborne fluid hose is in good condition with no cuts or abrasions of the
PTFE layer. Replace hose if damaged.
⃞ Ventilation fans are operating properly.
1.
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.
• 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.
Turn the ES ON/OFF valve OFF and wait 30 seconds.
⃞ All debris, including flammable fluids and rags, is removed from the spray area.
⃞ Fluids used must meet the following flammability requirements:
Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures,
ASTM D4206.
Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.
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 48
.
30 3A2496D
1.
Turn OFF (O) the ES On/Off switch.
1.
Follow the
Grounding Procedure, page 30 .
2.
Follow the
Pressure Relief Procedure, page 31
.
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.
2.
Follow the
Grounding Procedure, page 30 .
3.
Turn off the air bleed valves to the fluid source and to the gun.
4.
Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
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.
5.
Relieve fluid pressure in the fluid supply unit as instructed in your fluid supply unit manual.
3A2496D 31
Follow the steps below to establish the correct fluid flow and air flow. See Fig. 24 to locate the electrostatic gun controls.
To reduce the risk of fire and explosion, fluids used must meet the following flammability requirements:
Material does not sustain burning in accordance with the Standard Test Method for Sustained
Burning of Liquid Mixtures, ASTM D4206.
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 front of the gun during operation or until performing the
.
Follow the
Fluid Voltage Discharge and Grounding
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 working air and fluid pressure.
Figure 24 Electrostatic Gun Controls
1.
The gun is shipped with the fluid nozzle and air cap installed. Check that the retaining ring is tight.
or air cap, see
Fluid Nozzle Selection Chart, page 85
and
Air Cap Selection Chart, page 87
.
To install the nozzle and air cap, see
Air Cap and Nozzle Replacement, page 51
L60M19 Mold Release Gun is supplied with Part
No. 24N748 Nozzle, 24N727 Air Cap, and a spray tip of choice. If you require a different size spray tip, see
Spray Tip Selection Chart (Model
L60M19 MRG Gun Only), page 90 , or consult
with your Graco distributor. To install the tip, see
Air Cap, Spray Tip, and Nozzle Replacement
2.
Turn OFF (O) the ES On-Off switch (J).
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 31
whenever you are instructed to relieve the pressure.
3.
Turn on the master air bleed valve to the gun.
32 3A2496D
4.
Position the air cap by loosening the air cap retaining ring, and rotating the air cap for a vertical or horizontal spray pattern. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.
8.
Make sure the ES On-Off switch (J) is OFF (O).
5.
Fully open the fan air adjustment valve (F) counterclockwise.
9.
Adjust the pump air regulator to start the fluid supply unit. Adjust the fluid flow with the air pressure regulator until the stream from the gun travels 8-12 in. (200-300 mm) before falling off.
Typically, if fluid pressure is below 5 psi (.04
MPa, 0.4 bar) or above 30 psi (0.21 MPa, 2.1
bar), a change of nozzle size is recommended.
6.
Fully open the fluid adjustment valve (H) counterclockwise.
10. Set the gun air regulator to deliver a minimum
45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage. See the table below.
7.
Fully open the atomizing air restrictor valve (G) clockwise.
15 (4.6)
25 (7.6)
50 (15.3)
55 (0.38, 3.8)
65 (0.45, 4.5)
80 (0.56, 5.6)
3A2496D 33
11. Spray a test pattern. Check the atomization. If over-atomization occurs at minimum pressure, adjust the restrictor valve. If atomization is inadequate, increase air pressure or decrease fluid flow.
14. Check that the ES indicator (Hz indicator on
Smart guns) is lit, or check that the kV indicator on the isolated enclosure reads 45–55 kV. See the following table.
12. Adjust the fan air adjustment valve: clockwise for a narrower pattern, counterclockwise for a wider pattern.
When the ES On-Off switch is turned ON (I), the fluid supply is charged with high voltage until the voltage is discharged. 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 front of the gun during operation.
13. Turn ON (I) the ES On-Off switch (J).
Green
Amber
Red
When spraying, the indicator should remain green, indicating sufficient air pressure to the alternator turbine.
If the indicator turns amber after 1 sec, the air pressure is too low.
Increase air pressure until the indicator is green.
If the indicator turns red after 1 sec, the air pressure is too high.
Decrease air pressure until the indicator is green.
15. Check the kV meter on the isolated enclosure;
45–55 kV is normal.
16. Spray a test piece. Examine the edges for coverage. If wrap is poor, see
Spray Pattern Troubleshooting, page 46 .
17. When you finish spraying, perform
.
34 3A2496D
1.
Discharge the system voltage, see
Discharge and Grounding Procedure, page 30
.
2.
Flush the gun, see
3.
Follow the
Pressure Relief Procedure, page 31
.
4.
Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.
3A2496D 35
• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.
• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.
3.
Follow the
Pressure Relief Procedure, page 31
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 30 , before flushing.
Only flush, purge, or clean the gun with fluids that meet the following flammability requirements:
Material does not sustain burning in accordance with the Standard Test Method for Sustained
Burning of Liquid Mixtures, ASTM D4206.
Materials which cannot be ignited, in any mixture with air, by an energy source of less than 500mJ.
4.
Change the fluid source to solvent.
remove the spray tip before flushing. See
Air Cap, Spray Tip, and Nozzle Replacement
5.
Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.
6.
Follow the
Pressure Relief Procedure, page 31
.
Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.
1.
Turn OFF (O) the ES On-Off switch. Wait 30 seconds for the voltage to bleed off.
7.
Open the isolated enclosure door. Leave the flushing fluid in the system until you are ready to spray again.
8.
Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.
.
2.
Discharge the system voltage. See
Discharge and Grounding Procedure, page 30
.
9.
Before using the system electrostatically again, make sure no flammable vapors are present.
36 3A2496D
1.
Turn OFF (O) the ES On-Off switch.
5.
Remove the air cap.
2.
Flush the gun. See
3.
Follow the
Pressure Relief Procedure, page 31
.
4.
Clean the outside of the gun with a non-flammable solvent, as defined under
Use a soft cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun.
6.
Clean the air cap, retaining ring, and nozzle with a soft brush and non-flammable solvent.
7.
If necessary, use a toothpick or other soft tool to clean the air cap holes. Do not use metal tools.
8.
Reinstall the air cap. Tighten securely.
3A2496D 37
1.
Follow the
Pressure Relief Procedure, page 31
.
2.
Clean the fluid and air filters.
3.
Check for fluid leaks. Tighten all fittings.
4.
Clean workpiece hangers. Use non-sparking tools.
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.
• Keep the inside 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 the resistance weekly. See
Test Ground Strip Resistance, page 42
.
5.
Check the movement of the trigger and valves.
Lubricate if necessary.
6.
Check Gun Electrical Grounding, page 28
.
7.
Hang the gun from its hook, with the nozzle pointing down. Be sure to keep the gun from grounding out.
38 3A2496D
Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components.
Power Supply Removal and Replacement, page 59
.
Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.
1.
Follow the steps under
Prepare the Gun for Service, page 50 .
2.
Trigger the gun and measure resistance between the electrode needle tip (3) and the air swivel (21). The resistance should be
104–150 megohms (90–120 megohms for
Model L60M19). If outside this range, go to
Test Power Supply Resistance, page 40
If in range, see
Voltage Loss Troubleshooting, page 43
for other possible causes of poor performance, or contact your Graco distributor.
Megohmmeter Part No. 241079 (AA-see Fig.
25) 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.
Figure 25 Test Gun Resistance
3A2496D 39
1.
Follow the steps under
Prepare the Gun for Service, page 50 .
2.
Remove the power supply (11).
3.
Remove the turbine alternator (15) from the power supply.
4.
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 Electrode Resistance, page 41
.
5.
Be sure the spring (11a) is in place before reinstalling the power supply.
Figure 26 Test Power Supply Resistance
40 3A2496D
1.
Follow the steps under
Prepare the Gun for Service, page 50 .
2.
Insert a conductive rod (FF) into the gun barrel
(which was removed for the power supply test) and against the metal contact (DD) in the front of the barrel.
3.
Measure the resistance between the conductive rod (FF) and the electrode (3). The resistance should be 10–30 megohms (less than 5 megohms for Model L60M19).
4.
If in range, go to
Electrical Troubleshooting, page 48
, for other possible causes of poor performance, or contact your Graco distributor.
5.
Remove the electrode (3), see
Electrode Replacement, page 54 . Measure the
resistance between the contact (HH) and the electrode wire (GG). The resistance should be
10-30 megohms. If out of range, replace the electrode.
6.
Make sure the metal contact ring (DD) in the barrel, the nozzle contact ring (4a), and the electrode contact (HH) are clean and undamaged.
Figure 27 Test Electrode Resistance
Figure 28 Electrode
Figure 29 Nozzle Conductive O-Ring
3A2496D 41
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).
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 (227).
Figure 30 Test Ground Strip Resistance
Figure 31 Test Cylinder Resistance
42 3A2496D
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 repair this equipment unless you are trained and qualified.
Follow the
Fluid Voltage Discharge and Grounding
before checking or servicing the system and whenever you are instructed to discharge the voltage.
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:
• 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 To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 31 , whenever
you are instructed to relieve the pressure.
Normal spraying voltage for a system using the waterborne gun is 45-55 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
• Dielectric failure of the hose (pin-hole leak in the
PTFE 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.
• Fluid leakage
• Dirty interior
3A2496D 43
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 gun for service and complete the
.
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:
• Packing area 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
44 3A2496D
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
Discharge and Grounding Procedure, page 30
).
3.
Follow the
Pressure Relief Procedure, page 31
.
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 45 to 55 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system.
• If the meter reading is below 45 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 45-55 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 45 kV, do the
, to check the gun 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 PTFE layer. Disconnect the fluid hose from the gun, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.
• Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.
• Make sure the hose is properly stripped
(see
Connect the Waterborne Fluid Hose, page 18
). Restrip or replace the hose.
b.
Fluid packings:
Remove the packing assembly from the gun
(see
Fluid Packing Rod Removal, page 56
), 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:
A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o-ring seals on the end of the hose.
Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube.
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.
3A2496D 45
Check all possible remedies in the Troubleshooting
Chart before disassembling the gun.
Some spray pattern problems are caused by the improper balance between air and fluid.
Fluttering or spitting spray.
Improper spray pattern.
No fluid.
Loose, dirty, damaged nozzle/seat.
Refill supply.
Clean or replace nozzle, see
Air Cap and Nozzle Replacement, page 51
Air in fluid supply.
Check fluid source. Refill.
Damaged or dirty nozzle or air cap.
Clean or replace. See
.
Fluid buildup on air cap or nozzle.
Clean.
See
.
Fan air pressure too high.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Fluid too thick.
Too much fluid.
Decrease.
Increase viscosity.
Increase.
Increase.
Reduce viscosity.
Decrease flow.
Streaks.
Did not apply 50% overlap.
Dirty or damaged air cap.
Overlap strokes 50%.
Clean or replace air cap. See
Air Cap and Nozzle Replacement, page 51
46 3A2496D
Excessive spray fog.
Atomizing air pressure too high.
Close restrictor 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.
Increase viscosity or increase fluid flow rate.
Fluid too thin, or fluid flow is too low.
Atomizing air pressure too low.
“Orange Peel” finish.
Poorly mixed or filtered fluid.
Fluid leaks from the fluid packing area.
Fluid too thick.
Worn packings or rod.
Air leaks from the front of the gun.
Air valve is not seating properly.
Fluid leakage from the front of the gun.
Gun does not spray.
Dirty air cap.
Excessive paint wrap back to operator.
Worn electrode.
Worn fluid nozzle seat.
Loose fluid nozzle.
Damaged nozzle o-ring.
Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.
Remix or refilter fluid.
Reduce viscosity.
See
See
.
See
Electrode Replacement, page 54
Replace nozzle (4). See
Air Cap and Nozzle Replacement, page 51
Tighten.
See
Add fluid if necessary.
Low fluid supply.
Dirty or clogged fluid nozzle.
Closed or damaged fluid adjustment valve.
Clean.
See
.
Open valve, or see
ES On-Off and Fluid Adjustment
Misaligned air cap and fluid nozzle.
Clean fluid buildup off air cap and fluid nozzle seat. See
.
Poor grounding.
See
Incorrect distance from gun to part.
Should be 8–12 in. (200–300 mm).
3A2496D 47
Voltage still present at gun after following the
.
Poor wrap.
ES or Hz indicator is not lit.
ES On/Off switch is not turned
OFF (O).
Did not wait long enough for voltage to discharge.
Air pocket in fluid line leaves fluid near gun isolated.
Voltage isolation system failed.
Turn OFF (O).
Wait longer before touching electrode with grounding rod.
Check for bleed resistor failure.
Determine cause and correct.
Purge air from fluid line.
Service voltage isolation system.
Grounding cylinder not operating.
See
Test Cylinder Resistance, page 42 .
Replace if needed.
ES On/Off switch is OFF (O).
Gun air pressure too low (ES indicator is amber).
Turn ON (I).
Check air pressure to gun; minimum 45 psi (0.32 MPa, 3.2
bar) needed at gun for full voltage.
Atomizing air pressure too high.
Fluid pressure too high.
Decrease.
Decrease.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Resistance must be 1 megohm or less. Clean workpiece hangers.
Faulty gun resistance.
Fluid leaks from the packing (2c) and causes a short.
See
.
Clean the packing rod cavity, or replace the packing rod. See
Faulty alternator.
ES HI/LO switch is on LO (Smart guns only)
Spilled paint, dried paint, or other contaminants inside the WB100
Enclosure, causing a short circuit.
See
Check switch actuation; replace if needed.
Clean interior of enclosure.
ES On/Off switch is OFF (O).
No power.
Turn ON (I).
Check power supply, alternator, and alternator ribbon cable. See
48 3A2496D
Operator gets mild shock.
Operator gets shock from workpiece.
Voltage/current display stays red
(smart guns only).
ES or Hz indicator is amber.
ES or Hz indicator is red.
Error display appears and Hz indicator is red (Smart guns only).
Operator not grounded or is near ungrounded object.
Gun not grounded.
Gun is too close to the part being sprayed.
Dirty gun.
Alternator speed is too low.
Alternator speed is too high.
Smart module has lost communication with the power supply.
See
A weak static charge has built up on the surface of an unshielded fluid hose. This is a charge on the hose surface, not a failure of the hose insulation.
Workpiece not grounded.
See
.
Bundle and wrap the air and fluid hoses together. See
Waterborne Fluid Hose, page 18 .
Resistance must be 1 megohm or less. Clean workpiece hangers.
Gun should be 8–12 in. (200–300 mm) from the part.
See
Clean the Gun Daily, page 37 .
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.
Decrease air pressure until indicator is green.
Check for good connections between the Smart Module and the power supply. See
and
3A2496D 49
To reduce the risk of fire, explosion, or electric shock:, before flushing the gun.
• Follow the
, and turn OFF
(O) the ES On-Off switch before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.
• Clean all parts with a non-flammable fluid as defined under
.
• Do not service this equipment unless you are trained and qualified.
• Do not touch the gun nozzle or come within 4 in.
(102 mm) of the nozzle during gun operation or until you perform the
Fluid Voltage Discharge and Grounding Procedure, page 30
.
• Check all possible remedies in
before disassembling the gun.
• Use a vise with padded jaws to prevent damage to plastic parts.
• Lubricate some packing rod parts (2) and certain fluid fittings with dielectric grease (44), 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 (6a*).
• Fluid Seal Repair Kit 24N790 is available. The kit must be purchased separately. Kit parts are marked with a symbol, for example (2a‡).
1.
Follow the
Grounding Procedure, page 30 .
2.
Flush the gun. See
3.
Blow the fluid lines dry with air.
4.
Relieve the pressure.
See
Pressure Relief Procedure, page 31 .
5.
Disconnect the gun air and fluid lines at the isolation system.
6.
Remove the gun from the worksite. Repair area must be clean.
50 3A2496D
Trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages.
1.
See
Prepare the Gun for Service, page 50
.
2.
Remove the retaining ring (6) and air cap (5).
3.
Trigger the gun while removing the fluid nozzle
(4) assembly with the multi-tool (41).
7.
Install the air cap (5) and retaining ring (6). Make sure the u-cup (6a*) is in place with the lips facing forward.
8.
See
.
The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. For best performance and to avoid potential damage to the spray gun, do not remove the nozzle contact ring (4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.
Use non-silicone grease, Part No. 111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the conductive contact ring (4a).
4.
Make sure the conductive contact ring (4a) and the small o-ring (4b) are in place on the nozzle
(4). Lightly lubricate the small o-ring (4b).
5.
Make sure the electrode needle (3) is finger-tight.
6.
Trigger the gun while installing the fluid nozzle
(4) with the multi-tool (41). Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).
Figure 32 Air Cap and Nozzle Replacement
3A2496D 51
1.
See
Prepare the Gun for Service, page 50
.
2.
Remove the retainer ring (6) and air cap/tip guard assembly (5).
4.
To replace the electrode (5a), pull the it out of the back of the air cap, using a needle-nose pliers.
Push the new electrode through the air cap hole. Make sure the short end of the electrode engages the hole in the back of the air cap. Press the electrode in place firmly with your fingers.
Figure 33 Remove Air Cap
3.
Disassemble the air cap assembly. Check the condition of the u-cup (6a), electrode (5a), o-ring
(5b), and tip gasket (10a). Replace any damaged parts.
The conductive ring (4c) 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 (4c) 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 nozzle (4), using an adjustable wrench.
Figure 34 Disassemble Air Cap Assembly
Figure 36 Replace Nozzle
52
Figure 35 Tip Gasket
3A2496D
Do not overtighten the nozzle (4).
Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff.
6.
Ensure that the o-rings (4a, 4b, and 9) are in place on the nozzle. Trigger the gun and install the nozzle (4). Tighten until snug, then 1/4 turn more.
7.
Check that the spray tip gasket (10a) is in place.
Align the spray tip tab with the groove in the air cap (5). Install the spray tip (10) in the air cap.
8.
Make sure that the electrode (5a) is installed correctly in the air cap.
9.
Check that the air cap o-ring (5b) is in place.
10. Check that the u-cup (6a) is in place on the retaining ring (6). The lips of the u-cup must face forward.
To avoid damaging the tip guard, orient the air cap assembly (5) before tightening the retaining ring (6). 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
.
3A2496D 53
1.
See
Prepare the Gun for Service, page 50
.
2.
Remove the air cap and nozzle. See
Air Cap and Nozzle Replacement, page 51
.
3.
Unscrew the electrode (3) with the multi-tool (41).
To avoid damaging the plastic threads, be very careful when installing the electrode.
4.
Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.
5.
Install the fluid nozzle and air cap. See
Air Cap and Nozzle Replacement, page 51
.
6.
See
.
Figure 37 Electrode Replacement
54 3A2496D
1.
See
Prepare the Gun for Service, page 50
.
2.
Remove the air cap and nozzle. See
Air Cap, Spray Tip, and Nozzle Replacement
3.
Unscrew the needle (3).
4.
Apply low-strength (purple) Loctite® or equivalent thread sealant to the needle and packing rod threads. Install the needle finger-tight. Do not overtighten.
5.
Install the fluid nozzle and air cap. See
Air Cap, Spray Tip, and Nozzle Replacement
6.
See
.
Figure 38 Electrode Replacement
3A2496D 55
1.
See
Prepare the Gun for Service, page 50
.
2.
Remove the air cap and fluid nozzle. See
Air Cap and Nozzle Replacement, page 51
.
3.
Remove the electrode.
See
Electrode Replacement, page 54 .
4.
Loosen the trigger screws (13) and remove the trigger (12).
5.
Remove the packing rod (2), using the multi-tool
(41). Remove the spring (17).
6.
Check all parts for wear or damage and replace if necessary.
Figure 39 Fluid Packing Rod Removal
56 3A2496D
parts or as an assembly.
gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.
1.
Place the packing nut (2f) and seal (2b‡) on the fluid rod (2e). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away from the packing nut.
2.
Fill the inner cavity of the spacer (2h‡) with dielectric grease (44). Place the spacer on the fluid rod (2e) in the direction shown. Generously apply dielectric grease to the outside of the spacer.
3.
Place the fluid packing (2c‡) on the packing rod
(2e) with its lips facing the front of the rod. Install the needle packing (2d‡) with the male end toward the fluid packing, then install the housing
(2g) .
4.
Lightly tighten the packing nut (2f). The packing nut is properly tightened when there is 3 lb (13.3
N) of drag force when sliding the packing housing
(2g) assembly along the rod. Tighten or loosen the packing nut as needed.
5.
Install the o-ring (2a‡) on the outside of housing
(2g). Lubricate the o-ring with non-silicone grease, Part No. 111265. Do not over-lubricate.
6.
Install the spring (17) against the nut (2j) as shown.
7.
Install the packing rod assembly (2) into the gun barrel. Using the multi-tool (41), tighten the assembly until just snug.
8.
Install the electrode.
See
Electrode Replacement, page 54 .
9.
Install the nozzle and air cap. See
Air Cap and Nozzle Replacement, page 51
.
10. Install the trigger (12) and screws (13).
11. See
.
Figure 40 Packing Rod
3A2496D 57
1.
3.
See
Prepare the Gun for Service, page 50
.
2.
Remove the air inlet fitting (21) and take the bracket (104) off the gun handle (16).
Loosen the two screws (27).
To avoid damaging the power supply (11), pull the gun barrel (1) straight away from the gun handle (16). 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.
remove the alternator/power supply assembly from the barrel.
1.
Be sure the gasket (28*) and grounding spring
(18) 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 grease (44) to the tip of the power supply. Place the barrel (1) over the power supply and onto the gun handle (16).
3.
Tighten the two screws (27) oppositely and evenly (about a half turn past snug). Do not over-tighten the screws (27).
4.
Position the bracket (104) on the gun handle (16) and secure with the air inlet fitting (21).
5.
Apply dielectric grease (44) to the exposed inner tube of the fluid hose (101).
6.
Check that the nut (105) is tight on the ferrule housing (103).
7.
See
.
Figure 41 Barrel Removal
Figure 42 Barrel Installation
58 3A2496D
• Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.
• Do not expose gasket (28) to solvents.
1.
See
Prepare the Gun for Service, page 50
.
2.
See
(EE) make contact with the handle. On Smart models, align the connector of the 6–pin flexible circuit (24) 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.
Be careful when handling the power supply
(11) to avoid damaging it.
3.
Grasp the power supply (11) with your hand.
With a gentle side to side motion, free the power supply/alternator assembly from the gun handle
(16), then carefully pull it straight out.
On Smart
Models only, disconnect the flexible circuit (24) 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
(24) from the power supply. Slide the alternator up and off the power supply.
6.
See
Test Power Supply Resistance, page 40
.
Replace the power supply if necessary.
To repair the alternator, see
Alternator Removal and Replacement, page 60 .
Figure 43 Connect Flexible Circuit
10. Make sure the gasket (28*), ground spring (18), and power supply spring (11a) are in place.
Assemble the barrel (1) to the handle (16). See
.
11. See
.
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.
7.
Smart models only: connect the 6–pin flexible circuit (24) to the power supply.
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 Figure 44 Power Supply
3A2496D 59
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 50
.
2.
Remove the power supply/alternator assembly and disconnect the alternator. See
Removal and Replacement, page 59 .
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 45 Fan Orientation
6.
Push the fan and coil assembly (15a) out the front of the housing (15d).
Figure 46 Alternator Cross-Section
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 the fan end facing up. Using a wide blade 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.
60 3A2496D
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. 46. Be sure the coil alignment pins (P) are positioned as shown in Fig. 45.
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. Ensure that the o-ring (15g) is in place. Install the cap (15f).
17. Install the alternator on the power supply, and install both parts in the handle. See
Supply Removal and Replacement, page 59
.
Figure 47 Alternator
3A2496D 61
1.
See
Prepare the Gun for Service, page 50
.
2.
Place a wrench on the flats of the valve housing
(30a) and unscrew the valve from the handle
(16).
assembly (go to step 9) or replace only the o-ring
(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.
Inspect the o-ring (30c). Remove if damaged.
6.
Clean all parts and inspect for wear or damage.
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), using a wrench on the flats of the housing. Torque to 15 in-lb (1.7 N•m).
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.
Figure 48 Fan Air Adjustment Valve
62 3A2496D
1.
See
Prepare the Gun for Service, page 50
.
2.
Place a wrench on the flats of the valve housing
(29a) and unscrew the valve from the handle
(16).
assembly (go to step 9) or replace only the o-ring
(steps 3–9).
3.
Unscrew the valve stem (29e). Remove the retaining ring (29d).
4.
Turn the valve body (29b) counterclockwise until it comes free from the valve housing (29a).
5.
Inspect the o-ring (29c). Remove if damaged.
6.
Clean all parts and inspect for wear or damage.
Figure 49 Atomizing Air Restrictor Valve
111265. Do not over-lubricate.
7.
When reassembling the atomizing air restrictor valve (29), lightly lubricate the o-ring (29c) and push the valve body (29b) fully into the housing
(29a) until bottomed.
8.
Reassemble the retaining ring (29d). Thread the valve stem (29e) halfway into the valve body
(29b).
9.
Align the slot (S) in the valve stem with the rib (R) in the gun handle. Screw the valve assembly (29) into the gun handle (16), using a wrench on the flats of the housing. Torque to 15 in-lb (1.7 N•m).
desired, install the supplied plug (42).
Figure 50 Align Valve Stem
3A2496D 63
1.
See
Prepare the Gun for Service, page 50
.
2.
Loosen the captive screw (26p). Remove the valve (26) from the handle.
3.
Lubricate the o-rings (26b* and 26m*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
lubricant on the o-rings can be pushed into the gun air passage and blemish the finish on the workpiece.
4.
Clean and inspect parts for damage. Replace if necessary.
must point upward.
5.
Reinstall the valve. Torque the screw (27) to
15-25 in-lb (1.7-2.8 N•m).
Figure 51 ES On-Off and Fluid Adjustment Valve
64 3A2496D
1.
See
Prepare the Gun for Service, page 50
.
2.
See
3.
Remove the screws (13) and trigger (12).
4.
Remove the ES On-Off Valve. See
ES On-Off and Fluid Adjustment Valve Repair, page 64
.
5.
Remove the spring (34).
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 (35). 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.
8.
Install the air valve (23) and spring (34) into the gun handle (16).
9.
Install the ES On-Off Valve. See
Fluid Adjustment Valve Repair, page 64
.
10. Install the trigger (12) and screws (13).
11. See
.
Figure 53 Air Valve
Figure 52 Install U-Cup
3A2496D 65
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 50
.
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 54 Smart Module
Figure 55 Align Ribbon Cables
66 3A2496D
1.
See
Prepare the Gun for Service, page 50
.
2.
To replace the air exhaust valve: a.
Remove the clamp (43) and the exhaust tube
(36).
b.
Unscrew the swivel (21) from the gun handle
(16). The swivel is a left-hand thread.
Remove the bracket (104).
c.
Pull the exhaust valve (19) from the handle
(16). Inspect the o-ring (19a) and replace if necessary.
d.
Install the o-ring (19a*) on the exhaust valve
(19). Lubricate the o-ring with a light coating of non-silicone grease.
e.
Install the exhaust valve (19) in the handle
(16).
f.
Apply thread sealant to the top threads of the swivel (21). Position the bracket (104) and screw the swivel into the gun handle (16).
Torque to 75–85 in-lb (8.4–9.6 N•m).
g.
Check that the nuts (102, 105) are tight.
h.
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 56 Air Inlet Fitting and Air Exhaust Valve
3A2496D 67
68 3A2496D
Part No.
Description
1
2
3
4
4a
4b
5
6
6a*
11
24N667 BODY, gun
24N655 See
24N652 NEEDLE, electrode, black
24N616 NOZZLE, 1.5 mm; includes 4a and 4b
24N645 O-RING, conductive
111507
24N477
O-RING; fluoroelastomer
AIR CAP
24P892 RING, retainer; includes 6a
198307 PACKING, u-cup; UHMWPE
1
1
1
1
1
1
1
1
1
24N662 POWER SUPPLY, 60 kV gun 1
11a 24N979 SPRING
12 24N663 TRIGGER
13
15
16
17
18
24A445 SCREW, trigger; package of 2
1
1
1
24N664 See
1
24P744 HANDLE; for gun model L60T17 1
24P743 HANDLE; for gun model L60T18 1
185111 SPRING, compression 1
197624 SPRING, compression 1
1
1
1
19 24P036 VALVE, exhaust
19a* 112085 O-RING
21
23
24N626 SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread
24N633 VALVE, air
23a* 276733 SEAL, air valve
26
27
28*
29
30
24N630 See
24N740 SCREW, hex socket; 10–24 x
0.53 in.; sst; package of 2
24N699 GASKET, barrel
24T304 See
24N634 See
1
1
1
1
1
1
1
â–² Replacement Danger and Warning labels, tags, and cards are available at no cost.
Part No.
Description
34
35*
185116 SPRING, compression
188749 PACKING, u-cup
36
40
41
42
43
44
45
46
185103 TUBE, exhaust; 1/4 in. (6 mm)
ID (shipped loose)
107460 TOOL, wrench, ball end; 4 mm
(shipped loose)
1
1
276741 MULTI-TOOL (shipped loose) 1
1 24N786 PLUG, restrictor (shipped loose; for use instead of item 29)
110231 CLAMP, exhaust tube (shipped loose)
116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)
117824 GLOVE, conductive, medium; package of 12; also available in small (117823) and large
(117825)
24N604 COVER, gun; package of 10
1
1
1
1
48â–² 186118 SIGN, warning (not shown)
50 24N783 HOOK; includes screw
1
1
1
1
1 101
102
24M732 HOSE, shielded, waterborne fluid; for gun model L60T17; includes 102–108
24M733 HOSE, unshielded, waterborne fluid; for gun model L60T18; includes 102–108
198663 FERRULE, for shielded hose
24M732
190863 FERRULE, for unshielded hose
24M733
103 185547 HOUSING, ferrule, for shielded hose 24M732
15B932 HOUSING, ferrule, for unshielded hose 24M733
104 197954 BRACKET, fluid fitting
105 185548 NUT
106 16N953 FITTING, barrel
107 102982 O-RING
108 16N916 FITTING, seal
1
1
1
1
1
1
1
1
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
3A2496D 69
70 3A2496D
Part No.
Description
1 24N667 BODY, gun 1
2 24N655 See
24N652 NEEDLE, electrode, black
1
3
4
4a
4b
5
24N616 NOZZLE, 1.5 mm; includes 4a and 4b
24N645 O-RING, conductive
111507 O-RING; fluoroelastomer
6
24N477 AIR CAP
24P892 RING, retainer; includes 6a
6a*
11
198307 PACKING, u-cup; UHMWPE
11a 24N979 SPRING
1
24N662 POWER SUPPLY, 60 kV gun 1
1
1
1
1
1
1
1
Part No.
Description
31
34
35*
36
40
24N756 See
Smart Module Assembly, page 84
185116 SPRING, compression
1
1
188749 PACKING, u-cup 1
185103 TUBE, exhaust; 1/4 in. (6 mm)
ID (shipped loose)
107460 TOOL, wrench, ball end; 4 mm
(shipped loose)
1
1
276741 MULTI-TOOL (shipped loose) 1 41
42
43
44
45
46
24N786 PLUG, restrictor (shipped loose; for use instead of item 29)
110231 CLAMP, exhaust tube (shipped loose)
116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)
117824 GLOVE, conductive, medium; package of 12; also available in small (117823) and large
(117825)
24N604 COVER, gun; package of 10
1
1
1
1
1
48â–² 186118 SIGN, warning (not shown) 1
50
101
102
24N783 HOOK; includes screw
24M732 HOSE, shielded, waterborne fluid; for gun model L60M17; includes 102–108
24M733 HOSE, unshielded, waterborne fluid; for gun model L60M18; includes 102–108
198663 FERRULE, for shielded hose
1
1
1
1
103
190863 FERRULE, for unshielded hose 1
185547 HOUSING, ferrule, for shielded hose
15B932 HOUSING, ferrule, for unshielded hose
104 197954 BRACKET, fluid fitting
1
1
1
105 185548 NUT 1
106 16N953 FITTING, barrel
107 102982 O-RING
108 16N916 FITTING, seal
1
1
1
â–² Replacement Danger and Warning labels, tags, and cards are available at no cost.
3A2496D
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
71
72 3A2496D
Part No.
Description
1
2
3
4
4a
24N667 BODY, gun
24N655 See
24N749 NEEDLE 1
24N748 NOZZLE, seat; includes 4a-4c 1
1
1
1 24N645 O-RING, conductive
111507 O-RING; fluoroelastomer
24P893 RING, conductive
1
1
4b
4c
5
5a
24N727 See
1
24N643 ELECTRODE; package of 5 1
6
6a*
245790 RING, retainer; includes 6a
198307 PACKING, u-cup; UHMWPE
10
10a
11
AEMxxx
AEFxxx
183459
TIP ASSEMBLY; customer’s choice; includes item 27a
GASKET, tip
1
1
24N662 POWER SUPPLY, 60 kV gun 1
1
1
11a 24N979 SPRING
12 24N663 TRIGGER
13
15
16
17
24A445 SCREW, trigger; package of 2 1
24N664 See
24P741 HANDLE, smart
1
1
185111 SPRING, compression
1
1
1
18
19
197624 SPRING, compression
24P036 VALVE, exhaust
19a* 112085 O-RING
21
23
24N626 SWIVEL, air inlet; M12 x 1/4 npsm(m); left-hand thread
24N633 VALVE, air
23a* 276733 SEAL, air valve
24 245265 CIRCUIT, flexible
26
27
24N630 See
24N740 SCREW, hex socket; 10–24 x
0.53 in.; sst; package of 2
1
1
1
1
1
1
1
1
1
â–² Replacement Danger and Warning labels, tags, and cards are available at no cost.
Part No.
Description
28*
29
30
31
34
35*
24N699 GASKET, barrel
24N792 ATOMIZING AIR
ADJUSTMENT VALVE
24N634 See
24N756 See
Smart Module Assembly, page 84
185116 SPRING, compression
188749 PACKING, u-cup
1
1
36
40
41
42
43
44
45
46
185103 TUBE, exhaust; 1/4 in. (6 mm)
ID (shipped loose)
107460 TOOL, wrench, ball end; 4 mm
(shipped loose)
1
1
276741 MULTI-TOOL (shipped loose) 1
24N786 PLUG, restrictor (shipped loose; for use instead of item 29)
110231 CLAMP, exhaust tube (shipped loose)
116553 GREASE, dielectric; 1 oz (30 ml) tube (not shown)
117824 GLOVE, conductive, medium; package of 12; also available in small (117823) and large
(117825)
24N604 COVER, gun; package of 10
1
1
1
1
1
48â–² 186118 SIGN, warning (not shown)
50 24N783 HOOK; includes screw
1
1
1
1
1 101 24M733 HOSE, unshielded, waterborne fluid; includes 102–108
102 190863 FERRULE
103 15B932 HOUSING, ferrule
104 197954 BRACKET, fluid fitting
105 185548 NUT
1
1
106 16N953 FITTING, barrel
107 102982 O-RING
108 16N916 FITTING, seal
1
1
1
1
1
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
3A2496D 73
74 3A2496D
Part No.
Description
201 — — — CABINET, enclosure; includes
201a
201a 15A947 DOOR, cabinet
202 116993 CASTER, brake
203 15A660 PLATE
1
1
4
1
204 15A551 T-HANDLE, latch
205 15A545 STEM, handle, door
206 15A524 HOUSING, latch
207 113061 SWITCH, push, air
208 — — — TUBE; 1/2 in. (13 mm) OD; polyethylene
209 233501 PUMP, diaphragm; sst; see
309303
210 — — — SCREW, hex hd cap; 5/16–18 x
5.5 in. (140 mm)
211 — — — WASHER, plain; 0.344 in. ID
212 — — — NUT, lock; 5/16–18
1
2
2
2
1
1
1
1
A/R
213 241005 COVER, pail
214 104029 LUG, ground
215 116989 VALVE, air
216 111804 REGULATOR, air
217 113060 GAUGE, air; 1/8 npt
218 116473 NIPPLE; 1/4 npt x 1/4 npsm 1
221 185547 FERRULE, housing; for 24N580,
24P629, and 233825
15B932 FERRULE, housing; for 24P630,
24P631, and 246511
1
1
222 198663 FERRULE; for 24N580, 24P629,
190863 and 233825
FERRULE; for 24P630, 24P631,
1
1 and 246511
223 101390 WASHER, lock, internal tooth 1
1
1
1
1
1
224 154636 WASHER, plain; 0.625 in. ID
225 185548 NUT
226 190410 RESISTOR, bleed
227 116988 CYLINDER ROD
228 15A518 HOUSING, cylinder rod
229 104267 REGULATOR, air
230 — — — BUSHING; plastic; 3/4 x 1/2 npt 1
231 114456 ELBOW, tube; 3/8 npt x 3/8 in.
(10 mm) OD tube
232 116315 ELBOW, tube; 3/8 npt x 1/2 in.
(13 mm) OD tube
235â–² 15A682 LABEL, warning
1
1
1
236 116316 FITTING, tube; 1/2 npt x 1/2 in.
(13 mm) OD tube
237 218798 STRAINER, 16 mesh; sst
1
1
1
1
1
2
1
1
Part No.
Description
238 114958 STRAP, tie 3
239 222011 GROUND WIRE; 25 ft (7.6 m) 1
240 234018 STRIP, grounding; aluminum
241 110209 NUT, regulator
1
11
242 114051 WASHER, shim, ;atch 1
243 210084 ROD, ground 1
244 — — — SCREW, hex hd; 1/4–20 x 5/8 16 in. (16 mm)
245 — — — WASHER, plain; 1/4 in. (6 mm) 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
251 — — — WIRE, 10 gauge; green with yellow stripe
252 — — — CONNECTOR, swivel tee; 1/8 npt x 5/32 in. (4 mm) tube
253 — — — NUT, hex; 10–32
1
1
1
1
256 162449 NIPPLE, reducing; 1/2 npt x 1/4 npt
257 101874 TERMINAL, ring
2
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)
263 — — — SCREW, pan hd; 10–32 x 1/4 in.
(6 mm)
264 — — — HOLDER, tie
4
1
3
265 — — — SCREW, button hd; 10–24 x 1.5
in. (38 mm)
266 — — — SCREW, button hd; 10–32 x 1.0
in. (25 mm)
267 — — — NUT, hex; M5 x 0.8
268 — — — WASHER, lock; no. 10
2
2
2
9
270 116991 TEE, run, manifold 1
271 203953 SCREW, hex hd cap with patch;
10–24 x 3/8 in. (10 mm)
272 — — — WIRE, 14 gauge; red
1
A/R
273 — — — WIRE, ground, 14 gauge; green with yellow stripe
274 155541 UNION, swivel; 1/4 npt
275 114261 TERMINAL, ring; no. 10
A/R
1
1
276 15A780 PLUG, hex hd
278 117314 BULKHEAD CONNECTOR; 1/4 npt
1
1
3A2496D 75
Part No.
Description
279 113319 CONNECTOR, tube; 1/4 npt x
3/8 in. (10 mm) OD tube
280 — — — ELBOW, tube
286 — — — TUBE; 3/8 in. (10 mm) OD
2
1
281 — — — FITTING, tube; 1/8 npt x 5/32 in.
(4 mm) OD tube
282 — — — SWIVEL, tube; 1/4 npt x 1/4 in.
(6 mm) OD tube
283 — — — SWIVEL, tube; 1/8 npt x 5/32 in.
(4 mm) OD tube
285 112791 CLAMP
1
4
2
1
A/R
â–² Replacement Danger and Warning labels, tags, and cards are available at no cost.
★ The air hose (300) and gun (301) are not included with 233825 and 246511 Isolation Enclosures. They are shown for illustrative purposes only. See pages 3
Part No.
Description
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
301★ L60T17
L60T18
L60M19
L60M18
GUN; see
GUN; see
L60M19 GUN; see
1
1
1
1 and 4 for listings of models which include an air hose and gun.
The pail is shown for illustrative purposes but is not included.
76 3A2496D
3A2496D 77
Use the diagrams to find the connection points for the tubing and wiring listed below.
Code Ref.
Length
A1 248
A2
B2
B3
B4
B5
C1
C2
C3
248
249
249
249
249
272
251
273
20 (508) 1/4 OD tube, regulator
(216) to pump
9 (229) 1/4 OD tube, regulator
(216) to manifold
17 (432) 5/32 OD tube, manifold air to door interlock switch
20 (508) 5/32 OD tube, valve tee to cylinder
5 (127) 5/32 OD tube, regulator
(216) to gauge (217)
22 (559) 5/32 OD tube, valve tee to door interlock switch
9 (229) red 14 gauge wire from top of bleed resistor to meter
8 (204) green/yellow 14 gauge wire from internal box ground lug to cylinder cap
34 (864) green/yellow 10 gauge wire from external ground lug to cart
Code Ref.
Length
C4 239
C5
C6
C7
C8
C9
E1
243
226
272
272
251
286 n/a n/a n/a green/yellow 25 ft (7.6 m) ground wire with clamp, from external ground lug to true earth ground green/yellow 10 gauge wire from external ground lug to ground probe red wire from bleed resistor to pump
16 (407) red 14 gauge wire from pump to pail cover with clamp
12 (305) red 14 gauge wire from pump (209) to ground on cylinder bracket n/a green/yellow 10 gauge wire from meter (+) to internal box ground lug
4 (102) 3/8 OD tube, bulkhead to manifold
78 3A2496D
Includes items 2a-2k
Part No.
Description Part No.
Description
2a‡ 111316 O-RING
2b‡ 116905 SEAL
2c‡ 178409 PACKING, fluid
2d‡ 178763 PACKING, needle
2e 24N703 ROD, packing (includes items 2j and 2k)
2f 197641 NUT, packing
1
1
1
1
1
1
‡ These parts are included in Fluid Seal Repair Kit
24N790 (purchase separately).
â—† These parts are included in Trigger Adjustment Nut
Kit 24N700 (purchase separately).
2g 185495 HOUSING, packing
2h‡ 186069 SPACER, packing
2jâ—† — — — NUT, trigger adjustment (part of item 2e)
2kâ—† — — — NUT, trigger adjustment (part of item 2e)
1
1
1
1
Parts labeled — — — are not available separately.
3A2496D 79
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
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
♦ These parts are included in Bearing Kit 24N706
(purchase separately).
15f — — — CAP, housing; part of item
15d
110073 O-RING 15g*
15h♦ 24N709 CLIP; package of 5 (one clip included with item 15b)
1
1
1
Parts labeled — — — are not available separately.
80 3A2496D
Part No.
Description
26a — — — HOUSING, valve 1
26b* 15D371 O-RING
26c — — — PISTON, valve
26f
26g
24N649 LEVER, ES on-off
— — — SCREW, set, socket head
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
4
1
1
2
Part No.
Description
26h
26j
24N631
24N648
PLATE, retaining
KNOB, adjustment, fluid
26m* 113746 O-RING
26p — — — SCREW, captive
1
1
2
1
Parts labeled — — — are not available separately.
3A2496D 81
Part No.
Description
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.
Part No.
Description
29a — — — HOUSING, valve
29b — — — BODY, valve
— — — BODY, valve; round spray only 1
1
1
29c* 111516 O-RING 1
29d 118907 RING, retaining
29e — — — STEM, valve
29f — — — KNOB, shaft; round spray only 1
29g — — — SETSCREW, knob; round spray only
1
1
1
* These parts are included in Air Seal Repair Kit
24N789 (purchase separately).
Parts labeled — — — are not available separately.
82 3A2496D
Part No.
Description
5a
5b
5c
5d
24N643 ELECTRODE; package of 5
24N734 O-RING; ptfe; package of 5
(also available in package of
10; order 24E459)
— — — AIR CAP
24N726 GUARD, tip, orange
1
1
1
1
Parts labeled — — — are not available separately.
3A2496D 83
Part No.
Description
31a
31b
— — — CARTRIDGE
24P433 GASKET
31c
31f
24N787 SWITCH, ES HI/LO
31d♦ — — — SCREW
31e♦ — — — SCREW, pivot
112319 O-RING
Parts labeled — — — are not available separately.
♦ These parts are included in Smart Module Screw
Kit 24N757 (purchase separately).
1
3
1
1
1
1
84 3A2496D
use Part No. 24N748 Nozzle. See
Smart Air Spray Gun Assembly, page 72 .
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 31 , before
removing or installing a fluid nozzle and/or air cap.
Description Orifice
Use the following procedure to select the proper fluid nozzle for your application.
1.
For each fluid nozzle chart, find the point on the graph corresponding to your desired flow rate and viscosity. Mark the point on each graph with a pencil.
2.
The thick vertical line in each graph represents the target flow rate for that nozzle size. Find the graph that has the marked point closest to the thick vertical line. This is the recommended nozzle size for your application. Significantly exceeding the target flow rate may result in lower spray performance due to excessive fluid viscosity.
3.
From the marked point, move across to the vertical scale to find the required fluid pressure.
If the required pressure is too high, use the next largest nozzle size. If the fluid pressure is too low
(< 0.35 bar, 3.5 kPa, 5 psi), use the next smallest nozzle size.
24N613
24N614
24N615
24N616
24N617
24N618
24N619
24N620
24N621
24N622
24N623
24N624
24N625
Black
Blue
For standard coatings
With hardened seat, for abrasives and metallics
0.75 (.029)
1.0 (.042)
1.2 (.047)
1.5 (.055)
1.8 (.070)
2.0 (.079)
0.55 (.022)
0.75 (.029)
1.0 (.042)
1.2 (.047)
1.5 (.055)
1.8 (.070)
2.0 (.079) gun inlet.
260 Centipoise Fluid
160 Centipoise Fluid
70 Centipoise Fluid
20 Centipoise Fluid
3A2496D 85
bar, psi bar, psi oz/min, cc/min oz/min, cc/min bar, psi bar, psi oz/min, cc/min oz/min, cc/min
86 bar, psi oz/min, cc/min bar, psi oz/min, cc/min
3A2496D
use Part No. 24N727 Air Cap. See
Smart Air Spray Gun Assembly, page 72 .
To reduce the risk of an injury, follow the
Pressure Relief Procedure, page 31 , before
removing or installing a fluid nozzle and/or air cap.
following chart were measured under the following conditions. Pattern shape and length are material dependent.
• Distance to target: 10 in. (254 mm)
• Inlet air pressure: 50 psi (34 kPa, 3.4 bar)
• Fan air: adjusted for maximum width
• Fluid flow rate: 10 oz/min (300 cc/min)
24N438
(black)
24N279
(black)
Round end
Round end
15-17
(381-432)
14-16
(356-406)
Light to medium
(20–70 cp)
Medium to heavy
(70–260 cp), and high solids (360+ cp)
Light to medium
(20–70 cp)
24N376
(black)
24N276
(blue)
24N277
(red)
24N278
(green)
24N274
(black)
24N275
(black)
Tapered end
17-19
(432-483)
Tapered end
Tapered end
12-14
(305-356)
14-16
(356-406)
Light to medium
(20–70 cp)
Light to medium
(20–70 cp), and high solids (360+ cp), aerospace coatings
24N439
(black)
Tapered end
11-13
(279-330)
For use with 2.0 mm nozzles. Medium to heavy (70–260 cp), and high solids (360+ cp)
Light to medium
(20–70 cp)
24N477
(black)
24W279
(green)
Round end
15-17
(381-432)
24N453
(black)
Round end
14-16
(356-406)
Light to medium
(20–70 cp)
♦ Centipoise = centistokes x fluid specific gravity.
Up to 15 oz/min (450 cc/min)
Up to 15 oz/min (450 cc/min)
Up to 15 oz/min (450 cc/min)
Up to 15 oz/min (450 cc/min)
Up to 25 oz/min (750 cc/min)
Up to 20 oz/min (600 cc/min)
Up to 15 oz/min (450 cc/min)
Up to 15 oz/min (450 cc/min)
Better
Better
Best
Good
Best
Good
Better
Better
Best
Better
Better
Good
Good
Best
Best
Better
Good
Good
Better
Best
Best
Better
Good
Good
3A2496D 87
gun.
5/16 in. x 25 ft (8 mm x
7.6 m) hose
5/16 in. x 50 ft (8 mm x
15.2 m) hose scfm psi scfm psi scfm scfm psi psi
88 3A2496D
scfm psi scfm psi scfm scfm psi psi
3A2496D 89
Spray Tip Selection Chart (Model L60M19 MRG Gun Only)
12 in.
(305
† 0.007
(0.178)
† 0.009
(0.229)
† 0.011
(0.279)
0.013
(0.330)
0.015
(0.381)
0.017
(0.432)
0.019
(0.483)
0.021
(0.533)
0.023
(0.584)
0.025
(0.635)
0.029
(0.736)
0.031
(0.787)
17.0
(0.5)
22.0
(0.7)
28.0
(0.8)
35.0
(1.0)
4.0
(0.1)
7.0
(0.2)
10.0
(0.3)
13.0
(0.4)
40.0
(1.2)
50.0
(1.5)
68.0
(1.9)
78.0
(2.2)
22.0
(0.7)
28.5
(0.85)
36.3
(1.09)
45.4
(1.36)
5.2
(0.15)
9.1
(0.27)
13.0
(0.4)
16.9
(0.5)
51.9
(1.56)
64.8
(1.94)
88.2
(2.65)
101.1
(3.03)
0.033
(0.838)
88.0
(2.5)
114.1
(3.42)
0.037
(0.939)
0.039
(0.990)
108.0
(3.1)
118.0
(3.4)
140.0
(4.20)
153.0
(4.59)
* Tips are tested in water.
107 207
209
211
213
215
217
307
309
311
313
315
317
319
409
411
413
415
417
419
421
423
425
431
509
511
513
515
517
519
521
523
525
539
609
611
613
615
617
619
621
623
625
631
Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.
† These tip sizes include a 150 mesh filter.
711
713
715
717
719
721
723
725
737
813
815
821
823
825
829
831
833 where QT =
90 3A2496D
Spray Tip Selection Chart (Model L60M19 MRG Gun Only)
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.
† 0.010
(0.254)
0.012
(0.305)
9.5 (0.28) 12.5
(0.37)
12.0
(0.35)
16.0
(0.47)
0.014
(0.356)
0.016
(0.406)
16.0
(0.47)
20.0
(0.59)
* Tips are tested in water.
21.0
(0.62)
26.5
(0.78)
310
312
314
410
412
414
416
510
512
514
516
610
612
614
616
710
712
714
716
Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.
† These tip sizes include a 150 mesh filter.
812
814 where QT =
3A2496D 91
Repair Kits, Related Manuals, and Accessories
All guns in this manual.
Manual Description Repair
60 kV Waterborne
Air Spray Guns
60 kV Mold Release
Air Spray Guns
Electrostatic
Waterborne Air
Spray Guns,
Instructions-Parts
24N789
24N790
24N706
Air Seal Repair Kit
Fluid Seal Repair
Kit
Alternator Bearing
Repair Kit
105749
111265
116553
24N318
24N604
24N758
24P170
Cleaning Brush.
Non-silicone Lubricant, 4 oz (113 g).
Dielectric Grease. 1 oz (30 ml)
Round Spray Kit. To convert a standard air spray gun to a round spray air cap. See manual 3A2498.
Gun Covers. Box of 10.
Display Covers. Keeps Smart display clean. Package of 5.
Metal Trigger Kit.
24P172
185105
24N642
185493
112534
Quick Adjust Valve. For quick change of fan size.
Non-swivel Air Inlet; 1/4–18 npsm(m)
(left-hand thread)
Air Inlet Ball Swivel; 1/4–18 npsm(m)
(left-hand thread)
Air Hose Adapter; 1/4 npt(m) x
1/4–18 npsm(m) (left-hand thread)
Air Line Quick Disconnect Fitting.
92 3A2496D
Repair Kits, Related Manuals, and Accessories
117823
117824
117825
24N520
24N521
Conductive Gloves, box of 12 (small)
Conductive Gloves, box of 12
(medium)
Conductive Gloves, box of 12 (large)
Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Medium size.
Comfort Grip. Snap-on grip increases handle size to reduce operator fatigue. Large size.
241079
245277
Megohmmeter. 500 V output,
0.01–2000 megohms. Use for ground continuity and gun resistance
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.
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
222011
186118
Ground Wire and Clamp.
English Warning Sign. Available at no charge from Graco.
235068
235069
235070
235071
235072
235073
235074
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
3A2496D 93
Repair Kits, Related Manuals, and Accessories
To keep fluid mixed and prevent settling out. Includes items 401–408.
Part No.
Description
401 112698 ELBOW, swivel; 1/8 npt(m) x
1/4 in. (6 mm) OD tube
402 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf
403 193315 COLLAR, mounting, agitator
404 193316 NUT, collar, agitator
405 197298 COVER, pail; 5 gal. (19 liter)
406 224571 AGITATOR; see manual
306565
407 purchase locally
TUBE, nylon; 1/4 in. (6 mm)
OD; 4 ft (1.22 m)
408 110272 SCREW, set, socket hd;
1/4–20 x 1/4 in. (6 mm)
1
1
1
1
1
1
1
1
94 3A2496D
To allow precise fluid pressure regulation at the gun.
Includes items 501–507.
Repair Kits, Related Manuals, and Accessories
Part No.
Description
501 110078 FITTING, tube, fluid; 1/4 npt(m) x 3/8 in. (10 mm) tube
502 113070 NIPPLE, reducer; 3/8 npt x 1/4 npt
503 113576 PLUG; 1/4 npt
504 236281 REGULATOR, fluid; see manual 308325
505 C20350 ELBOW, 90°; 1/4 npt(f) x 1/4 in. (6 mm) OD tube
506 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf
507 purchase locally
TUBE, nylon; 1/4 in. (6 mm)
OD; 4 ft (1.22 m)
1
1
1
1
1
1
1
3A2496D 95
L60T17
L60T18
L60M18
L60M19
10.5 (267)
10.5 (267)
10.5 (267)
10.8 (274)
8.9 (226)
8.9 (226)
9.6 (244)
9.7 (246)
2.4 (61)
2.4 (61)
2.4 (61)
2.4 (61)
21.7 (617)
21.7 (617)
24.2 (687)
22.2 (628)
96 3A2496D
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Maximum Fluid Operating
Temperature
Short Circuit Current Output
Voltage Output Energy
100 psi
100 psi
45 psi
120°F
0.7 MPa, 7.0 bar
0.7 MPa, 7.0 bar
0.32 MPa, 3.2 bar
48°C
Sound Power (measured per ISO
Standard 9216)
Sound Pressure (measured 1 m from gun)
Air Inlet Fitting
Fluid Inlet Fitting
Isolation Enclosure Air Inlet Fitting
Isolation Enclosure Fluid Inlet
Fitting
Wetted Parts
125 microamperes
0.35 J with fluid hose 24M733 installed.
L60T17 and L60T18: 60 kV
L60M17, L60M18, and L60M19: 30–60 kV at 40 psi: 90.4 dB(A) at 0.28 MPa, 2.8 bar: 90.4 dB(A) at 100 psi: 105.4 dB(A) at 40 psi: 87.0 dB(A) at 100 psi: 99.0 dB(A)
1/4 npsm(m) left-hand thread
Custom inlet for Graco waterborne fluid hose.
3/8 in. OD tube fitting at 0.7 MPa, 7.0 bar: 105.4 dB(A) at 0.28 MPa, 2.8 bar: 87.0 dB(A) at 0.7 MPa, 7.0 bar: 99.0 dB(A)
1/4 npt
10 mm OD tube fitting
Gun: Stainless Steel, PEEK, UHMWPE, Fluoroelastomer, Acetal,
Nylon, Polyethylene, Tungsten Wire
Waterborne Fluid Hose: PTFE
Suction Tube: Polyethylene, Stainless Steel
Triton Pump: See manual 309303.
3A2496D 97
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. 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
INCLUDING
PARTICULAR
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
FITNESS
OR
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.
For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.
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 3A2496 www.graco.com
Revision D, June 2013
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