Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun Instructions

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Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun Instructions | Manualzz

Instructions

Pro Xp

Auto WBx Waterborne

External Charge Electrostatic

Air Spray Gun

3A4798F

EN

For electrostatic finishing and coating applications in Class I, Div. I hazardous locations or Group

II, Zone 1 explosive atmospheres, using conductive waterborne fluids that meet at least one of the following conditions for non-flammability:

• Material does not sustain burning in accordance with the Standard Test Method for Sustained Burning of Liquid Mixtures, ASTM D4206.

• Material is classified as non-ignitable or hard to ignite as defined by EN 50176.

For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Press

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

Important Safety Instructions

Read all warnings and instructions in this manual and in related manuals. Save these instructions.

See page 2 for Table of Contents

and page 3 for

Models

.

2

Table of Contents

Table of Contents

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

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How the Electrostatic Air Spray Gun Works . . . . 7

Operating the Spray Function . . . . . . . . . . . . . . . 7

Operating the Electrostatics . . . . . . . . . . . . . . . . 7

Gun Features and Options . . . . . . . . . . . . . . . . . 7

Smart Gun Features . . . . . . . . . . . . . . . . . . . . . . 7

System Overview . . . . . . . . . . . . . . . . . . . . . . . . 8

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Install the System . . . . . . . . . . . . . . . . . . . . . . . 10

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 10

Install the Air Line Accessories . . . . . . . . . . . . . 10

Install the Fluid Line Accessories . . . . . . . . . . . 11

Install the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Install the Pro Xp Auto Control Module . . . . . . 13

Connect the Air and Fluid Lines . . . . . . . . . . . . 13

Manifold Connections . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Check Gun Electrical Grounding . . . . . . . . . . . 17

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 18

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 18

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 18

Flush Before Using Equipment . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . 19

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 20

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 21

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 22

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Daily Care and Cleaning Checklist . . . . . . . . . . 23

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Clean the Gun Daily . . . . . . . . . . . . . . . . . . . . . 23

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 24

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Test Total Gun Resistance . . . . . . . . . . . . . . . . . 25

Test Gun Resistance with Probe Removed . . . . 26

Test Charging Probe Resistance . . . . . . . . . . . . 26

Test Power Supply Resistance . . . . . . . . . . . . . 27

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Spray Pattern Troubleshooting . . . . . . . . . . . . . 28

Gun Operation Troubleshooting . . . . . . . . . . . . 29

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 30

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Prepare the Gun for Service . . . . . . . . . . . . . . . 31

Remove the Gun from the Manifold . . . . . . . . . 31

Install the Gun on the Manifold . . . . . . . . . . . . . 32

Air Cap and Nozzle Replacement . . . . . . . . . . . 32

Electrode Replacement . . . . . . . . . . . . . . . . . . . 33

Charging Probe Pin Replacement . . . . . . . . . . . 33

Fluid Packing Rod Removal . . . . . . . . . . . . . . . 34

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . 35

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 37

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 37

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 38

Power Supply Removal and Replacement . . . . 38

Turbine Removal and Replacement . . . . . . . . . 39

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Standard Pro Xp Auto Waterborne External Charge

Air Spray Gun Models . . . . . . . . . . . . . . . . . 41

Smart Pro Xp Auto Waterborne External Charge

Air Spray Gun Models . . . . . . . . . . . . . . . . . 43

Packing Rod Assembly . . . . . . . . . . . . . . . . . . . 45

Turbine Assembly . . . . . . . . . . . . . . . . . . . . . . . 46

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Air Caps and Fluid Nozzles . . . . . . . . . . . . . . . . . . 51

Fluid Nozzle Selection Chart . . . . . . . . . . . . . . . 51

Fluid Nozzle Performance Charts . . . . . . . . . . . 52

Air Cap Selection Chart . . . . . . . . . . . . . . . . . . . 54

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 65

Graco Pro Xp Warranty . . . . . . . . . . . . . . . . . . . . . 66

3A4798F

Models

All models have a 1.5 mm nozzle.

Part No.

LA1T28

LA2T28

60

60

LA1M28 60

LA2M28 60 kV Display

Standard

Standard

Smart

Smart

Rear

Bottom

Rear

Bottom

Manifold Mount

Approvals

2575

0359

0.24 mJ

FM14ATEX0081

FM22UKEX0032

EN 50050-1

Ta 0°C-50°C

Related Manuals

Manual No. Description

332989 Instructions - Pro Xp Auto Control Module

Models

3A4798F 3

4

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion 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-spe cific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire, explosion, and electric shock:

Electrostatic equipment must be used only by trained, qualified personnel who understand the require ments of this manual.

• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. Resistance must not exceed 1 megohm. See Grounding instructions.

• Only use grounded Graco conductive air supply hoses.

• Do not use pail liners unless they are conductive and grounded.

• Stop operation immediately if static sparking occurs or you feel a shock .

Do not use equipment until you identify and correct the problem.

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

• Use and clean equipment only in well ventilated area.

• Interlock the gun air and fluid supply to prevent operation unless ventilation air flow is above the minimum required value.

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

• Never spray or flush solvent at high pressure.

• To clean the exterior of the equipment, cleaning solvents must have a flash point at least 15°C (59°F) above ambient temperature. Non-ignitable fluids are preferred.

• 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 sparking).

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

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

• Keep the spray area clean at all times. Use non-sparking tools to clean residue from the booth and hangers.

• Keep a working fire extinguisher in the work area.

• Use conductive waterborne fluids that meet at least one of the following conditions for non-flammability:

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

Burning of Liquid Mixtures, ASTM D4206.

• Material is classified as non-ignitable or hard to ignite as defined by EN 50176.

3A4798F

Warnings

3A4798F

PRESSURIZED EQUIPMENT HAZARD

Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before 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.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Specifications in all equipment manuals.

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

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.

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

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• 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.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible solvents to clean plastic structural or pressure-containing parts.

• See Technical Specifications in all equipment manuals for materials of construction. Consult the solvent manufacturer for information and recommendations about compatibility.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read Safety Data Sheet (SDS) 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.

5

Warnings

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

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

6 3A4798F

Introduction

Introduction

How the Electrostatic Air Spray

Gun Works

The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed.

The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s external charging probe.

The pump supplies fluid to the hose and gun, where the fluid is atomized by the air cap and the atomized parti cles are electrostatically charged as they pass the external charging probe. The charged fluid is attracted to the grounded workpiece. The external charging allows the fluid supply to remain grounded at all times and therefore eliminates the need for an isolation sys tem.

Operating the Spray Function

Applying a minimum of 60 psi (0.42 MPa, 4.2 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This pro vides the proper air lead and lag when triggering the gun. A spring returns the piston when the cylinder air is shut off.

Operating the Electrostatics

To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco

Grounded Turbine Air Hose. The air enters the manifold and is directed to the inlet of the power supply turbine.

The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The atomized fluid is charged by the external charging probe. The charged fluid is attracted to the nearest grounded object.

Gun Features and Options

• The gun's full voltage setting is 60kV.

• The gun is designed for use with a reciprocator, and can be mounted directly on a 1/2 in. (13 mm) rod. With additional brackets, the gun can be mounted for robotic applications.

• The gun’s quick-disconnect design enables its removal without disconnecting the fluid and air lines to the gun.

Smart Gun Features

Smart gun models with the Pro Xp Auto Control Module have the ability to:

• Display the spraying voltage and current

• Change the gun voltage setting

• Display the gun turbine speed

• Store spray profiles

• Communicate equipment faults to a PLC

• Display and set maintenance totalizers

• Use a PLC to select a spray profile

See the Pro Xp Auto Control Module manual 332989 for more information.

3A4798F 7

Introduction

System Overview

Typical System Installation

F IGURE 1 shows a typical electrostatic air spray system. It is not an actual system design. For assistance in design

ing a system to suit your particular needs, contact your Graco distributor.

Non-Hazardous Location Hazardous Location

F IG . 1. Typical System Installation

C

D

A

B

E

Gun

Graco Grounded Turbine Air Hose

Atomizer, Fan, and Cylinder Air

Air Supply and controls

Grounded Fluid Supply and controls

8

J

K

L

G

H

Smart System Components

F Programmable Logic Controller (PLC)

Pro Xp Auto Control Module

Power Supply (24 Volt)

Bulkhead (optional)

Fiber Optic F/O Cable

I/O Cable

3A4798F

Gun Overview

M

Introduction

F

K

2

TA

1

A2

EXH

P

A1

CYL

J

A C

H

D

B

F

IG

. 2. Gun Overview

Key

H

J

F

G

M

C

D

A

B

Air Cap

Fluid Nozzle

Retaining Ring

Shroud

Manifold/Mounting Bracket

Turbine

Power Supply

Electrode

External Charging Probe

3A4798F

G

Manifold Fittings and Indicators

A1 Atomization Air Inlet Fitting

A2 Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

1

2

Fiber Optic Fitting Transmit

(Operational on Smart models only)

Fiber Optic Fitting Receive

(Operational on Smart models only)

K

P

ES Indicator Light (Standard models only)

Fluid Supply Inlet Fitting

TA Turbine Air Inlet Fitting (to drive turbine)

EXH Exhaust Outlet Fitting

9

Installation

Installation

Install the System

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

• Do not install or service this equipment unless you are trained and qualified.

• Be sure your installation complies with local, state, and national codes for the installation of electrical apparatus in a Class I, Div. I, hazardous location or a Group II, Zone I explosive atmosphere location.

• Comply with all local codes and regulations.

Warning Signs

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.

Ventilate the Spray Booth

Electrically interlock the gun air and fluid supply with the ventilators to prevent gun operation any time that the ventilation air flow falls below minimum values.

Check and follow all local codes and regulations regarding air exhaust velocity requirements. Verify the operation of the interlock at least once a year.

NOTE: The minimum allowable air exhaust velocity is

60 feet/minute (19 linear meters/minute). High velocity air exhaust will decrease the operating efficiency of the electrostatic system.

Install the Air Line Accessories

See F IGURE 3.

1. Install a bleed-type master air valve (L) on the main air line (W) to shut off all air to the gun.

2. Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your fin ished workpiece and can cause the gun to mal function.

3. Install a bleed-type air pressure regulator (M) on each of the air supply lines (B, C, D, E) to control air pressure to the gun.

Do not operate the gun unless ventilating air flow is above the minimum required value. Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun.

Interlock the gun air and fluid supply to prevent oper ation unless ventilating air flow is above the minimum required value.

The spray booth must have a ventilation system.

Trapped air can cause the gun to spray unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. The solenoid valves (K) must have a quick exhaust port so trapped air will be relieved between the valve and gun when the sole noids are shut off.

4. Install a solenoid valve (K) on the cylinder air line (E) to actuate the gun. The solenoid valve must have a quick exhaust port.

5. Install a solenoid valve (K) to actuate the turbine.

10 3A4798F

Installation

Install the Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump out let.

2. Install a fluid regulator on the fluid line to control fluid pressure to the gun.

F IGURE 3 shows a typical electrostatic air spray system. It is not an actual system design. For assistance in design

ing a system to suit your particular needs, contact your Graco distributor.

The turbine air (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.

L

See Warning above A

K

L

L

W

K

M

Non-Hazardous Location

F IG . 3. Typical Installation

Key to F IGURE 3

A Air Hose Ground Wire

B Graco Grounded Turbine Air Hose (TA)

C Atomizing Air Hose, 5/16 in. (8 mm) OD (A1)

D Fan Air Hose, 5/16 in. (8 mm) OD (A2)

E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

N

B C D

E

Hazardous Location

Manifold Back View

K Solenoid Valve, requires quick exhaust port

L Bleed-Type Master Air Valve

M Air Pressure Regulator

N True Earth Ground

W Main Air Line

G

3A4798F 11

Installation

Install the Gun

See F IGURE 4.

1. Loosen the manifold’s two set screws (29) and slide the manifold (20) onto a 1/2 in. (13 mm) mounting rod.

2. Position the gun and tighten the two set screws.

For added positioning reliability, insert a 1/8 in. (3 mm) locating pin into the slot (NN) in the bracket and through a hole in the rod.

NN 29 b. Firmly press the charging probe onto the gun in the Connect/Disconnect position (CP), where the probe pin passes by the fitting slot.

2.88 in.

(73.2 mm)

20

F IG . 4. Mounting

8.00in.

(203.2 mm)

To nozzle tip

3. Select a charging probe. Two probes are included with the gun.

• Long charging probe: For the best transfer effi ciency and wrap

• Short charging probe: For low profile electro static charging

4. Connect the charging probe.

a. Liberally apply dielectric grease to the probe fitting, charging probe, and the two o-rings (CC and CR).

CC

CR

c. Press the probe towards the barrel and rotate the charging probe from the Connect/Discon nect Position (CP) to the spray position (SP).

NOTE: For proper performance, do not operate electrostatics if the charging probe is not in the spray position.

12 3A4798F

Installation

Install the Pro Xp Auto Control

Module

The Pro Xp Auto Control Module is required for use with smart models. To install a Pro Xp Auto Control Module, see the module instruction manual 332989.

Connect the Air and Fluid Lines

F IGURE 3 shows a schematic of air and fluid line con

-

nections, and F IGURE 5 shows the manifold connec

tions. Connect the air and fluid lines as instructed below.

To reduce the risk of electric shock, the turbine air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air Hoses.

1. Connect the Graco Grounded Turbine Air Hose (B) to the gun's turbine air inlet (TA) and connect the air hose ground wire (A) to a true earth ground (N). The gun turbine air inlet fitting has left-hand threads to prevent connecting another type of air hose to the turbine air inlet.

2. Check the electrical grounding of the gun as

instructed on page 17.

3. Before connecting the fluid line (P), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

3A4798F 13

Installation

Manifold Connections

Rear Inlet Bottom Inlet

2

1

TA

A2

P

CYL

A1

A1

EXH

P

A2

CYL

2

1

TA

EXH

F IG . 5. Manifold Connections

A1

A2

1

2

P

CYL

TA

EXH

Atomization Air Inlet Fitting

Connect a 5/16 in. (8mm) OD tube between this fitting and the air supply.

Fan Air Inlet Fitting

Connect a 5/16 in. (8 mm) OD tube between this fitting and the air supply.

Cylinder Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the shortest hose length possible.

Fiber Optic Fitting Transmit (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 15).

Fiber Optic Fitting Receive (Operational on Smart models only)

Connect the Graco Fiber Optic cable (see page 15).

Fluid Supply Inlet Fitting

Connect a 1/4 npsm swivel fitting between this fitting and the fluid supply.

Turbine Air Inlet Fitting

Connect the Graco Electrically Conductive Air Hose between this fitting (left-hand thread) and the solenoid.

Connect the air hose ground wire to a true earth ground.

Exhaust

Connect an exhaust tube to route the turbine exhaust air. 3 ft. max length. Fitting is for 5/16 in. OD tube.

14 3A4798F

Installation

Fiber Optic Cable Connection

(Operational on Smart models only)

NOTE: Only use the supplied fiber optic cable.

The fiber optic cable allows the gun to communicate with the Pro Xp Auto control module.

For a One-Gun System

1. Connect Port 1 of the gun 1 manifold to Port 1 of the Control Module.

2. Connect Port 2 of the gun 1 manifold to Port 2 of the Control Module.

For a Two-Gun System

1. Connect Port 1 of the gun 2 manifold to Port 5 of the Control Module.

2. Connect Port 2 of the gun 2 manifold to Port 6 of the Control Module.

F IG . 6. Making Fiber Optic Connections

R

Port 1

V

Non-Hazardous Location

U

Port 2

Port 5 Port 6

Hazardous Location H

1

2

Gun 1

H*

Q

Q

R

H

P

U

V

Pro Xp Auto Air Spray Gun

24 Volt Power Supply Connection

Remote I/O Connection

Pro Xp Auto Control Module

Bulkhead (optional)

Fiber Optic Cable

P

V

U

Gun 2

F

IG

. 7. Fiber Optic Schematic

3A4798F 15

Installation

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode.

Improper grounding can cause electric shock.

Ground all equipment, personnel, objects being sprayed, and conductive objects in or close to the spray area. The resistance must not exceed 1 meg ohm. Grounding provides an escape wire for the elec tric current.

When operating the electrostatic gun, any ungrounded objects (such as people, containers, and tools) in the spray location can become electrically charged.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded.

Your system must be connected to a true earth ground.

Check ground connections daily. Check your local electrical codes and regulations for detailed grounding instructions.

• Pump: Ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

• Electrostatic Air Spray Gun: Ground the gun by connecting the Graco Grounded Turbine Air Hose to the turbine air inlet and connecting the air hose

ground wire to a true earth ground. See Check Gun

Electrical Grounding, page 17.

• Air compressors and hydraulic power supplies:

Ground the equipment according to the manufacturer's recommendations.

• All air and fluid lines must be properly grounded.

• All electrical cables must be properly grounded.

• All persons entering the spray area: Shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic.

• Object being sprayed: Keep the workpiece hangers clean and grounded at all times.

Resistance must not exceed 1 megohm.

• 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.

• Flammable liquids in the spray area must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

• All electrically conductive objects or devices in the spray area, including fluid containers and wash cans, 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.

• 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.

16 3A4798F

Installation

Check Gun Electrical Grounding

earth ground. If the resistance is still too high, replace the turbine air hose.

N

TA

Megohmmeter Part No. 241079 (AA-see F IGURE 8) is

not approved for use in a hazardous location. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless:

• The gun has been removed from the hazardous location;

• Or all spraying devices in the hazardous location are turned off, ventilation fans in the hazardous location 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, explo sion, 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 turbine air hose.

2. Make sure the turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground.

3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4. Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N). a.

If using a black or gray turbine air hose, use a megohmmeter to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm.

b.

If using a red turbine air hose, use an ohmmeter to measure the resistance. The resistance should not exceed 100 ohms.

5. If the resistance is greater than the maximum read ing specified above for your hose, check the tight ness of the ground connections and be sure the turbine air hose ground wire is connected to a true

AA

B

WLD

F IG . 8. Check Gun Electrical Grounding

3A4798F 17

Installation

Check Fluid Resistivity

To reduce the risk of fire, explosion, or electric shock, check the fluid resistivity in a non-hazardous location only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous location.

Check that the resistivity of the fluid being sprayed meets the requirements for an electrostatic air spray system. Graco Part No. 722886 Resistance Meter and

722860 Probe are available as accessories. Follow the instructions included with the meter and probe.

The Pro Xp Auto WBx gun is intended to spray very conductive waterborne materials and other materials less than 1 megohm-cm.

Check Fluid Viscosity

A viscosity cup and stopwatch are needed to check fluid viscosity.

1. Completely submerge the viscosity cup in the fluid.

Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2. Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3. Record the fluid type, elapsed time, and size of the viscosity cup.

4. Compare to the chart supplied by viscosity cup manufacturer to determine your fluid viscosity.

5. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

Install the Fabric Cover

See F IGURE 9.

1. Install a fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold.

2. Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for the presence of any paint or solvent. See

Check for

Fluid Leakage on page 24. Strap down the

exhaust tube to prevent it from moving around.

YY

XX

YY

WLD

F

IG

. 9. Fabric Cover

Flush Before Using Equipment

The equipment was tested in fluid at the factory. To avoid contaminating your fluid, flush the equipment with a compatible solvent before using the equipment.

See Flushing , page 23.

18 3A4798F

Operation

Operation

Pressure Relief Procedure

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as splashing, follow the Pres sure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equip ment.

1. Turn off all the air to the spray gun except the cylin der air, which triggers the gun. If an air pilot fluid regulator is used in the system, the air pressure is needed at the regulator air inlet.

2. Turn off the fluid supply to the gun.

3. Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure.

4. If an air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

5. Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6. Turn off the main air supply by closing the bleed-type master air valve on the main air supply line. Leave the valve closed until you are ready to spray again.

Startup

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient opera tion.

All operators are properly trained to safely operate an automatic electrostatic air spray system as instructed in this manual.

All operators are trained in the

Pressure

Relief Procedure on page 19.

The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See

Grounding on page 16.

The condition of the gun’s electrical compo nents has been checked as instructed in

Electrical Tests on page 25.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

All debris (including flammable fluids and rags) is removed from the spray area.

All flammable fluids in the spray booth are in approved, grounded containers.

All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

The manifold exhaust tubes have been checked for the presence of any fluid as instructed in

Check for Fluid Leakage

on

page 24.

3A4798F 19

Operation

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet.

To reduce the risk of an injury, follow the Pressure

Relief Procedure whenever you are instructed to

relieve the pressure.

1. Relieve the pressure. Follow the Pressure Relief

Procedure , page 19.

2. Select and install the appropriate air cap and nozzle for your application. See

Air Cap and Nozzle

Replacement , page 32.

3. Loosen the air cap retaining ring, and rotate the air cap for a vertical or horizontal spray pattern. See

F IGURE 10. 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.

NOTE: Use the short charging probe when spray ing horizontal patterns.

6. Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size.

NOTES:

• When increasing to a wide, flat pattern, it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.

• See Spray Pattern Troubleshooting on page 28 to

correct spray pattern problems.

Vertical Pattern

Horizontal Pattern

F IG . 10. Air Cap Positions

4. Adjust the fluid flow with the fluid pressure regula -

tor. Refer to the Performance Charts on pages 52

to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.

5. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization.

For example, for a fluid flow rate of 10 ounces per minute (0.3 liters per minute), a typical atomization pressure would be 20-30 psi (1.4-2.1 bar, 0.14-0.21

MPa) at the gun manifold.

For the most efficiency, always use the lowest air pressure possible.

20 3A4798F

Operation

Adjust the Electrostatics

1. Turn on the turbine air (TA) and adjust the air pres -

sure per the settings in Table 1 . Set the proper

pressure at the turbine air hose inlet when air is flowing .

Table 1. Approximate Dynamic Turbine Air Pressures

Turbine Air

Hose Length ft

(m)

15 (4.6)

25 (7.6)

36 (11)

50 (15.3)

75 (22.9)

100 (30.5)

Air pressure at turbine air hose inlet for full voltage psi (bar, MPa)

54 (3.8, 0.38)

55 (3.85, 0.38)

56 (3.9, 0.39)

57 (4.0, 0.40)

59 (4.1, 0.41)

61 (4.3, 0.43)

2. Check the turbine speed of the gun by checking the indicator light on the standard gun body or for the smart gun check the actual turbine speed on the

Pro Xp Auto Control Module. See the following table. Adjust the air pressure as necessary to keep the indicator light green or the values within

400-750 Hz.

Smart models display values, standard models display color indicator lights.

Table 2. Indicator Colors

Description Indicator

Color

Green

400-750 Hz

Amber

<400

Red

>750

When spraying, the indicator should remain green, indicating sufficient air pressure to the turbine.

If the indicator changes to amber after 1 second, the air pressure is too low.

Increase air pressure until the indicator is green.

If the indicator changes to red after 1 second, the air pressure is too high.

Decrease air pressure until the indicator is green. Excessive turbine speed can shorten the bearing life and will not increase the voltage output.

Spraying

To reduce the risk of electric shock, do not touch the gun electrode or come within 4 in. (10 cm) of the noz zle during gun operation.

1. Apply a minimum of 60 psi (4.2 bar, 0.42 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air

(A2), and fluid (P).

2. Turn the gun functions on and off by using the air solenoid valves on the cylinder (CYL) and turbine

(TA) air supply lines.

3. To change a smart model to a lower voltage setting, see the Pro Xp Auto Control Module 332989.

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage. See

Check for

Fluid Leakage on page 24.

3A4798F 21

Operation

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomiza tion (A1) and fan (A2) air lines, using the bleed-type air shutoff valves.

2. Apply 60 psi (4.2 bar, 0.42 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

Shutdown

To reduce the risk of an injury, follow the Pressure

Relief Procedure whenever you are instructed to

relieve the pressure.

1. Flush the gun, see

Flushing , page 23.

2. Follow the Pressure Relief Procedure , page 19.

3. Clean the equipment. See

Maintenance on page

23.

22 3A4798F

Maintenance

Maintenance

To reduce the risk of an injury, follow the Pressure

Relief Procedure whenever you are instructed to

relieve the pressure.

Daily Care and Cleaning

Checklist

Check the following list daily upon completion of equip ment usage.

Flush the gun. See

Flushing , page 23.

Clean the fluid and air line filters.

Clean the outside of the gun. See Clean the Gun

Daily , page 23.

Clean the air cap and fluid nozzle daily, minimum.

Some applications require more frequent clean ing. Replace the fluid nozzle and air cap if they

are damaged. See Clean the Gun Daily , page 23.

Check the electrode and replace if broken or damaged. See

Electrode Replacement

on page

33.

Check for fluid leakage from the gun and fluid hoses. See

Check for Fluid Leakage on page

24. Tighten fittings or replace equipment as

needed.

Check Gun Electrical Grounding

,

page 17 .

Flushing

• 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.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

To reduce the risk of fire and explosion, turn off the turbine air before flushing the gun and always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at lowest possible pressure.

NOTICE

Do not use methylene chloride as a flushing or clean ing solvent with this gun as it will damage nylon com ponents.

1. Turn off the turbine air.

2. Switch the fluid supply to a compatible solvent.

3. Trigger the gun to flush the fluid passages clean.

Clean the Gun Daily

NOTICE

• Clean all parts with a compatible solvent.

Conductive solvents can cause the gun to malfunction.

• Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the turbine life. Whenever possible, point the gun down when cleaning it. Do not use any cleaning method which could allow fluid into the gun air passages.

1. Turn off turbine air (TA).

2. Flush the gun. See Flushing , page 23

3. Follow the

Pressure Relief Procedure , page 19.

4. Clean the outside of the gun with a compatible sol vent. Use a soft cloth. Wring out excess fluid from cloth. Point the gun down to prevent solvent from entering the gun passages. Do not immerse the gun.

WLD

WLD WLD

3A4798F 23

Maintenance

24

5. Clean the air cap.

a. Follow the

Pressure Relief Procedure , page

19.

b. Remove the air cap assembly (24, 25) and

shroud (26). See F

IGURE

11.

c. Wipe the fluid nozzle (4) of the gun clean with a cloth dampened in solvent. Avoid getting any solvent into the air passages. Whenever possi ble, point the gun down when cleaning it.

d. If it appears that there is paint inside the fluid nozzle (4) air passages, remove the gun from

the line for servicing. See Air Cap and Nozzle

Replacement , page 32 to remove the fluid

nozzle for cleaning or replacement.

e. Clean the air cap (25) with a soft bristle brush and solvent, or submerge the air cap in suitable solvent and wipe it clean. Do not use metal tools.

f. Open and slide the shroud (26) onto the gun.

g. Carefully install the air cap (25). Be sure to insert the electrode (3) through the center hole of the air cap. Rotate the air cap to the desired position.

h. Make sure the u-cup (24a) is in place on the retaining ring (24). The lips must face forward.

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.

i. Test gun resistance, page 25.

Check for Fluid Leakage

If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.

To reduce the risk of an injury, follow the

Relief Procedure

During operation, periodically check all openings of the

gun shroud (ZZ) for the presence of fluid. See F

IGURE

12. Fluid in these areas indicates leakage into the

shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.

If fluid is seen in these areas:

1. Stop spraying immediately.

2. Relieve the pressure. See

Pressure Relief Proce dure , page 19.

3. Remove the gun for repair.

Pressure

whenever you are instructed to

relieve the pressure.

ZZ

ZZ

F IG . 12. Check for Fluid Leakage

26

24

24a

25

4

3

F IG . 11. Clean Air Cap and Fluid Nozzle

3A4798F

Electrical Tests

Electrical Tests

Electrical components inside the gun affect perfor mance and safety. The following procedures test the condition of the power supply, gun body, charging probe, and electrical continuity between components.

Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.

Megohmmeter Part No. 241079 (AA-see F IGURE 13) is

not approved for use in a hazardous location. To reduce the risk of sparking, do not use the megohm meter to check electrical grounding unless:

• The gun has been removed from the hazardous location;

• Or all spraying devices in the hazardous location are turned off, ventilation fans in the hazardous location 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, explo sion, and electric shock and result in serious injury and property damage.

Test Total Gun Resistance

1. Flush and dry the fluid passage.

2. Measure the resistance between the charging probe tip (3) and the turbine air inlet fitting (TA). The resistance should be 116–170 megohms for guns with the long charging probe installed. The resis tance should be 101–140 megohms for guns with the short charging probe installed.

3. If outside this range go to Test Gun Resistance with Probe Removed , page 26. If in range, and

there are performance concerns, see

Electrical

Troubleshooting , page 30 for other possible

causes of poor performance.

AA

3

TA

F IG . 13. Test Total Gun Resistance

TA

3A4798F 25

Electrical Tests

Test Gun Resistance with Probe

Removed

Measure the resistance between the turbine air inlet fit ting and the charging probe fitting. The resistance should be 101-140 megohms. If outside this range, check the power supply and barrel resistance. If in range, test the charging probe resistance.

Test Charging Probe Resistance

NOTE: This section only applies to guns with long charging probes.

Measure the resistance between the metal spring in the charging probe (DD) and the charging probe tip (BB).

• For long charging probes, the resistance should be

15–30 megohms.

• For short charging probes, the resistance should be

0 megohms.

If outside this range, replace the charging probe. If in range, inspect the spring and barrel socket for possible causes of poor continuity. Reassemble the charging probe and retest the total gun resistance.

F IG . 14. Test Gun Resistance

F IG . 15. Test Charging Probe Resistance

26 3A4798F

Electrical Tests

Test Power Supply Resistance

1. Remove the power supply (7). See Power Supply

Removal and Replacement , page 38.

2. Remove the turbine (8) from the power supply. See

Turbine Removal and Replacement , page 39.

3. Measure resistance from the power supply's ground strips (EE) to the spring (7a). The resistance should be 86–110 megohms. See F IGURE 16.

If outside this range, replace the power supply. If in range, and there are performance concerns, go to

Test Barrel Resistance , page 27.

4. Refer to

Electrical Troubleshooting , page 30 for

other possible causes of poor performance.

5. Be sure the spring (7a) is in place before reinstalling the power supply.

Test Barrel Resistance

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

(removed for the power supply test) and against the metal contact (HH) in the front of the barrel.

2. Measure the resistance between the conductive rod (GG) and the charging probe socket (CC). The resistance should be 15-30 megohms.

• If the resistance is outside the range, replace the barrel.

• If resistance is in range, reassemble the gun and test the gun resistance.

• If you still have problems, refer to Electrical

Troubleshooting , page 30 for other possible

causes of poor performance.

7a EE

WLD

F IG . 16. Test Power Supply Resistance F

IG

. 17. Test Barrel Resistance

3A4798F 27

Troubleshooting

Troubleshooting

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed prop erly. Do not install or repair this equipment unless you are trained and qualified.

To reduce the risk of an injury, follow the Pressure

Relief Procedure whenever you are instructed to

relieve the pressure.

Check all possible remedies in the Troubleshooting

Chart before disassembling the gun.

Spray Pattern Troubleshooting

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

Problem

Fluttering or spitting spray.

Cause Solution

No fluid.

Refill supply.

Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 32.

Improper spray pattern.

Streaks.

Air in fluid supply.

Damaged nozzle or air cap.

Check fluid source. Refill.

Replace, page 32.

Fluid buildup on air cap or nozzle.

Fan air pressure too high.

Fluid too thin.

Fluid pressure too low.

Fan air pressure too low.

Clean. See page 23.

Decrease.

Increase viscosity.

Increase.

Increase.

Fluid too thick.

Too much fluid.

Did not apply 50% overlap.

Dirty or damaged air cap.

Reduce viscosity.

Decrease flow.

Overlap strokes 50%.

Clean, page 23 or replace, page 32.

28 3A4798F

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Excessive spray fog.

“Orange Peel” finish.

Fluid leaks from the fluid packing area

Air leaks from the air cap

Fluid leakage from the front of the gun

Gun does not spray

Atomizing air pressure too high.

Fluid too thin.

Atomizing air pressure too low.

Poorly mixed or filtered fluid.

Fluid too thick.

Worn packings or rod.

Worn piston stem o-rings.

Worn fluid seat.

Loose fluid nozzle.

Damaged nozzle o-ring.

Low fluid supply.

Damaged air cap.

Dirty or clogged fluid nozzle.

Damaged fluid nozzle.

Piston not actuating.

Actuator arm is out of position.

Decrease air pressure as low as pos sible.

Increase viscosity.

Increase air pressure; use lowest air pressure necessary.

Remix or re-filter fluid.

Reduce viscosity.

Replace; see page 33

Replace; see page 36.

Replace fluid nozzle (4) and/or elec -

trode needle (7); see page 32.

Tighten; see page 32.

Replace; see page 32.

Add fluid if necessary.

Replace; see page 32.

Clean; see page 32.

Replace; see page 32.

Check cylinder air. Check piston

u-cup (34d); see page 36.

Check actuator arm and nuts. See

page 37.

Dirty air cap Misaligned air cap and fluid nozzle. Clean fluid buildup off air cap and

fluid nozzle seat; see page 23.

Damaged nozzle orifice.

Fluid is coming on before the air.

Replace nozzle (4); see page 32.

Check actuator arm and nuts. See

page 37.

Excessive paint wrap back to spray gun

Air leaks from manifold

Poor Grounding

See Grounding, page 16

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

Gun not securely tightened to the manifold

Worn or missing o-rings

Tighten manifold screws

Replace o-rings. See page 37

Tighten manifold screws.

Fluid leaks at the quick-disconnect. Gun not securely tightened to the manifold

Fluid seal o-rings are worn or miss ing.

Inspect or replace o-rings.

3A4798F 29

Troubleshooting

Electrical Troubleshooting

Problem

Poor wrap (in general, the external charge gun has less wrap than a direct charge waterborne).

Cause

ES On/Off switch is OFF (O).

Solution

Turn ON (I).

ES or Hz indicator is not lit

ES indicator light is amber (standard models only)

ES indicator light is red (standard models only)

No voltage or low voltage reading on the Pro Xp Auto Control module

Pro Xp Auto Control Module displays event code (smart models only)

Gun air pressure too low (ES indica tor is amber).

-

Atomizing air pressure too high.

Decrease.

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

Poorly grounded parts.

Check air pressure to gun; minimum

45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.

Faulty gun resistance.

Faulty alternator.

Weak electrostatic field.

Resistance must be 1 megohm or less. Clean workpiece hangers.

See Test Total Gun Resistance

on

page 25.

Replace alternator.

No power

Install a long charging probe on the gun.

Check power supply, turbine, turbine ribbon cable. See

Power Supply

Removal and Replacement , page

38 and Turbine Removal and

Replacement , page 39.

Turbine speed is too low

Turbine speed is too high

Damaged fiber optic cable or con nection.

-

Increase air pressure until indicator is green.

Decrease air pressure until indicator is green

Check; replace damaged parts. See

Pro Xp Auto Control Module manual

332989.

Turbine air is not turned on.

Turn on.

See manual 332989 for Event Code

Troubleshooting.

30 3A4798F

Repair

Prepare the Gun for Service

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 prop erly. Do not install or repair this equipment unless you are trained and qualified.

Remove the Gun from the

Manifold

See F IGURE 18.

1. Holding the gun firmly in hand, loosen the two screws (21) from the back and bottom of the mani fold.

The screws (21) should stay on the manifold.

2. Remove the gun from the manifold and take it to the service area.

The 5 o-rings (18) should stay on the gun.

To reduce the risk of injury, follow the Pressure

Relief Procedure

before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

• Check all possible remedies in

Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to plastic parts.

• 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.

1. Flush and clean the gun, page 23.

2. Relieve the pressure. Follow Pressure Relief Pro cedure, page 19.

3. Remove the gun from the manifold, page 31.

4. Remove the gun from the work site. Repair area must be clean.

18

18

21

Rear Manifold

21

Bottom Manifold

F IG . 18. Remove Gun from Manifold

Repair

3A4798F 31

Repair

Install the Gun on the Manifold

See F IGURE 18.

1. Make sure the five o-rings (17) are in place on the gun. Inspect the parts for damage and replace them as needed.

2. Secure the gun to the manifold by tightening the two screws (19).

Air Cap and Nozzle

Replacement

1. Follow the steps in

Prepare the Gun for Service , page 31.

2. Remove the retaining ring (24) and air cap (25). See

F IGURE 19.

3. Point the gun up while removing the fluid nozzle (4) assembly with the multi-tool (48).

24

24a

25

48

4

4a

4b

3

The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of fire and explosion or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never oper ate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine

Graco part.

NOTE: 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). Excessive grease can mix with paint and blemish the finish on the workpiece.

4. Make sure the electrode needle (3) is finger-tight.

5. 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).

6. Install the fluid nozzle (4) with the multi-tool (48).

Tighten until the fluid nozzle seats in the gun barrel

(1/8 to 1/4 turn past hand tight).

7. Place the shroud onto the gun. Optionally, secure with a screw.

8. Carefully install the air cap (25). Be sure to insert the electrode (3) through the center hole of the air cap. Rotate the air cap to the desired position.

9. Make sure the u-cup (24a) is in place on the retain ing ring (24). The lips must face forward. 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.

10. Install the gun onto the manifold. See

Install the

Gun on the Manifold .

F IG . 19. Air Cap and Nozzle Replacement

32 3A4798F

Repair

Electrode Replacement

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap and nozzle. See page 32, steps

1–3.

3. Unscrew the electrode (3) with the multi-tool (48).

F IGURE 20.

4. Apply low-strength (purple) thread sealant or equiv alent to the replacement electrode and packing rod threads. Install the electrode finger-tight. Do not over tighten.

5. Install the fluid nozzle. See page 32, steps 5 and 6.

6. Install the air cap. See page 32, steps 7 and 8.

7. Install the gun onto the manifold. See Install the

Gun on the Manifold , page 32.

Charging Probe Pin

Replacement

1. Remove the charging probe from the gun.

2. With a flathead screwdriver, unscrew the pin from the charging probe.

3. Inspect the threads for damage. Replace the probe if it is damaged.

4. Clean the threads on the charging probe.

5. Apply low-strength thread sealant (purple Loctite® or equivalent) to the new pin threads. NOTE: Loc tite® is a registered trademark of the Loctite Cor poration.

6. Install the pin finger-tight.

7. Clean off any excess thread sealant.

48

WL

F IG . 20. Electrode Replacement

NOTICE

To avoid equipment damage, use only the 26A416

Electrode Needle. Alternate electrodes are not accept able for use and do not fit the packing rod threads.

F

IG

. 21. Charging Probe Pin Replacement

3A4798F 33

Repair

Fluid Packing Rod Removal

You may replace the packing rod as an assembly, as

described below, or as individual parts (see page 35).

The assembly is pre-adjusted at the factory.

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap. See page 32, step 2. Remove

the gun shroud (26).

3. Remove the jam nut (16), actuator arm (15), and

adjustment nut (16). See F IGURE 25.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4. Remove the fluid nozzle (4) and electrode (3).

5. Remove the packing rod (2), using the multi-tool

(48). See F IGURE 22.

6. Check all parts for wear or damage and replace if necessary.

Before installing the packing rod, clean the internal sur face of the barrel (1) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are pres ent, replace the barrel.

48

1

16

WLD

F IG . 22. Fluid Packing Rod Removal

34 3A4798F

Packing Rod Repair

You may replace the packing rod as individual parts, as

described below, or as an assembly (see page 33). The

assembly is pre-adjusted at the factory.

Before installing the fluid packing rod into the gun bar rel, 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 volt age arcing. If marks are present, replace the barrel.

1. Follow the steps in

Fluid Packing Rod Removal

,

page 34.

2. 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.

3. Fill the inner cavity of the spacer (2h‡) with dielec tric grease (43). Place the spacer on the fluid rod

(2e) in the direction shown. Generously apply dielectric grease to the outside of the spacer.

4. 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).

5. Lightly tighten the packing nut (2f). The packing nut is properly tightened when there is 3 lb (13.3N) of drag force when sliding the packing housing (2g) assembly along the rod. Tighten or loosen the packing nut as needed.

6. 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.

7. Install the spring (5) against the nut (2j) as shown.

8. Install the packing rod assembly (2) into the gun barrel. Using the multi-tool (48), tighten the assem bly until just snug.

9. Install the electrode. See Electrode Replacement

,

page 33, step 4.

10. Install the nozzle and air cap. See

Air Cap and

Nozzle Replacement , page 32, steps 5–8.

5

2k 2j

Repair

2e

2f

2b‡

2h‡

2c‡

2d‡

2g

2a‡

F IG . 23. Packing Rod

3A4798F 35

Repair

Piston Repair

1. Follow the steps in

Prepare the Gun for Service , page 31.

2. Remove the air cap. See page 32, step 2. Remove

the gun shroud (26).

3. Remove the jam nut (16), actuator arm (15), and

adjustment nut (16). See F IGURE 25.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4. Remove piston cap (13) from the rear of the gun.

5. Push on the piston rod (11) to push the piston out the back of the gun.

6. Inspect the o-rings (11d, 11e, 11f, 11g) for damage.

See Table 3 and F IGURE 24.

7. Lubricate the o-rings (11d, 11e, 11f, 11g) with non-silicone grease, Part No. 111265. Do not over-lubricate.

8. Align the two stems (11c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.

9. Install spring (12) and piston cap (13).

10. Install and adjust the actuator arm, page 37.

11e

11f

11c

11d

11g

11e

11f

Atomizing Air Side

F IG . 24. Piston O-Rings

11b

11d

Fan Air Side

11a

WLD

WLD

11g

Table 3. Piston O-Rings

Description

Shaft O-Ring

(11g)

Function

Seals cylinder air along the piston rod (34b). Replace if air leaks along rod.

Front O-Ring

(11e)

Back O-Ring

(11f)

Piston

O-Ring (11d)

Air shutoff seal. Replace if air leaks from air cap when gun is de-trig gered.

Separates cylinder air from fan and atomizing air.

Replace if air leaks from small vent hole at back of manifold when gun is triggered.

O-rings included in air seal repair kit 24W390

36 3A4798F

Adjust the Actuator Arm

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm with the shroud removed.

See F IGURE 25.

1. Install the adjustment nut (16b), actuator arm (15), and jam nut (16a) onto the piston rod (11b).

2. Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (15) and the fluid packing rod nut (E). This allows the atomizing air to actuate before the fluid.

3. Tighten the adjustment nut (16b) against the actua tor arm (15). Check that the 0.125 in. (3 mm) gap has been maintained. In addition, there should be 3 mm of electrode needle travel when the gun is trig gered. Adjust the jam nut position to obtain these dimensions. Tighten the jam nut (16a).

4. Test gun resistance, page 25.

5. Install the gun shroud (26) and air cap (25). See

page 32.

6. Install the gun onto the manifold. See page 32.

0.125 in. (3 mm) gap

Barrel Removal

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap. See page 32, step 2.

3. Remove the gun shroud (26).

4. Carefully loosen the fluid fitting nut (35). Pull the tube (39) out of the fitting (32). Make sure both fer rules (33, 34) and the nut stay with the tube. See

F IGURE 26.

5. Remove the adjustment nuts (16a) and actuator

arm (15). See F IGURE 25.

6. Loosen the two screws (19). See F IGURE 26.

NOTICE

To avoid damaging the power supply, pull the gun bar rel (1) straight away from the gun body (10). If neces sary, gently move the gun barrel from side to side to free it from the gun body.

7. Hold the gun body (10) with one hand and pull the

barrel (1) straight off the body. See F

IGURE

26.

1

Repair

WLD

16a 15 16b 11b E

F

IG

. 25. Actuator Arm Adjustment

10

32

19

F IG . 26. Barrel Removal

WLD

39

33, 34

35

3A4798F 37

Repair

38

Barrel Installation

1. Verify the gasket (9) and grounding spring (6) are in place and the gasket air holes are aligned properly.

Replace the gasket if damaged.

2. Make sure the spring (7a) is in place on the tip of

the power supply (7). See F IGURE 27. Liberally apply

dielectric grease to the tip of the power supply.

Place the barrel (1) over the power supply and onto the gun body (10).

3. Tighten the two barrel screws (19) oppositely and evenly (about 1/4 turn past snug or 20

2.3 Nm). Do not over-tighten.

 5 in-lbs or

NOTICE

To avoid damaging the gun barrel, do not over-tighten the screws (19).

4. Assemble the fluid tube (39) into the fluid fitting (32).

Ensure that the ferrules (33, 34) are in place and tighten the nut (35).

5. Install and adjust the actuator arm (15), jam nut

(16a), and adjustment nut (16b). See

Adjust the

Actuator Arm , page 37.

6. Follow the steps in Test Total Gun Resistance

,

page 25.

7. Install the gun shroud (26) and air cap, page 32.

8. Install the gun onto the manifold. See Install the

Gun on the Manifold , page 32.

19

10

7

9

7a

35

33, 34

16a

15

16b

6

1

Power Supply Removal and

Replacement

• Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag.

• Do not expose gasket (9) to solvents. Replace gasket if damaged.

1. Follow the steps in Prepare the Gun for Service , page 31.

2. Follow the steps in Barrel Removal , page 37.

NOTICE

Be careful when handling the power supply (7) to avoid damaging it.

3. Grasp the power supply (7) with your hand. With a gentle side to side motion, free the power sup ply/turbine assembly from the gun body (10), then carefully pull it straight out.

Smart models only: disconnect the flexible circuit

(30) from the socket at the top of the gun body.

4. Inspect the power supply and turbine for damage.

5. To separate the power supply (7) from the turbine

(8), disconnect the 3-wire ribbon connector (PC) from the power supply.

Smart models only: Disconnect the 6–pin flexible circuit (30) from the power supply. Slide the turbine up and off the power supply.

6. Follow the steps in Test Gun Resistance with

Probe Removed , page 26. Replace the power sup

-

ply if necessary. To repair the turbine, see Turbine

Removal and Replacement , page 39.

NOTICE

To prevent damage to the cable and possible inter ruption of the ground continuity, bend the turbine’s

3–wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.

F IG . 27. Barrel Installation

39

37

7. Connect the 3-wire ribbon connector (PC) to the power supply.

Smart models only: Connect the 6–pin flexible cir cuit (30) to the power supply.

3A4798F

Repair

Tuck the ribbon forward, under the power supply.

Slide the turbine (8) down onto the power supply

(7).

8. Insert the power supply/turbine assembly in the gun body (10). Make sure the ground strips (EE) make contact with the gun body.

Smart models only: Align the connector of the

6–pin flexible circuit (30) with the socket (CS) at the

top of the gun body. See F

IGURE

28.

Push the connector securely into the socket as you slide the power supply/turbine assembly into the gun body.

CS 30

Turbine Removal and

Replacement

NOTE: Replace turbine bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (

).

1. Follow the steps in Prepare the Gun for Service , page 31.

2. Remove the power supply/turbine assembly and disconnect the turbine. See

Power Supply

Removal and Replacement , page 38.

3. Measure resistance between the two outer termi nals of the 3-wire connector (PC); it should be

2.0–6.0 ohms. If outside this range, replace the tur bine coil (8a).

4. Using a flat blade screwdriver, pry the clip (8h

) off the housing (8d). Remove the cap (8f

), using a thin blade or screwdriver.

5. If necessary, rotate the fan (8e) so its blades clear the four bearing tabs (T) of the housing (8d).

8e

T

F IG . 28. Connect Flexible Circuit

9. Make sure the gasket (8), ground spring (6), and power supply spring (7a) are in place. Assemble the

barrel (1) to the body (10). See Barrel Installation , page 38.

10. Follow the steps in Test Total Gun Resistance

,

page 25.

10

CS

9 

8

PC

WLE

F IG . 30. Fan Orientation

P

EE

WLD

F IG . 29. Power Supply

3A4798F

7

30

7a

39

Repair

6. Push the fan and coil assembly (8a) out the front of the housing (8d).

8b2  M 8a 8g 8f

WLE

PC 8h 

8d 8b1

 S

F IG . 31. Turbine Cross-Section.

NOTICE

To prevent damage to the turbine do not scratch or damage the magnet (M) or shaft (S). Do not pinch or damage the 3–wire connector (PC) when disassem bling and reassembling the bearings.

7. Hold the coil assembly (8a) on a workbench with the fan end facing up. Using a wide blade screw driver, pry the fan (8e

) off the shaft (S).

8. Remove the top bearing (8b2

).

9. Remove the bottom bearing (8b1

).

10. Install the new bottom bearing (8b1

) 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 (8a) so the bearing blades are flush with the surface of the coil.

11. Press the new top bearing (8b2

) onto the short end of the shaft so the bearing blades are flush with the surface of the coil (8a). The flatter side of the bearing must face away from the coil.

12. Hold the coil assembly (8a) on a workbench with the fan end facing up. Press the fan (8e

) onto the long end of the shaft (S).The fan blades must be ori -

ented as shown in F

IGURE

30.

13. Carefully press the coil assembly (8a) into the front of the housing (8d

) while aligning the pin on the coil with the slot in the housing. The 3–wire connec tor (PC) must be positioned below the wider notch

(W) of the housing tabs.

14. Rotate the fan (8e

) so its blades clear the four bearing tabs (T) at the back of the housing. Ensure that the blades of the bottom bearing (8b1

) align with the tabs.

15. Seat the coil fully into the housing (8d

). Secure with the clip (8h

),ensuring that its tabs engage the slots in the housing.

16. Ensure that the o-ring (8g) is in place. Install the cap

(8f

).

17. Install the turbine on the power supply, and install both parts in the gun body. See

Power Supply

Removal and Replacement , page 38.

40

F IG . 32. Turbine

8f

8e

8g*

8d

W

8b1

Slot

S

8c

M

8a

8b2

Pin

WLE

PC

8h

3A4798F

Parts

Standard Pro Xp Auto Waterborne External Charge

Air Spray Gun Models

LA1T28, Waterborne, Rear Manifold

LA2T28, Waterborne, Bottom Manifold

1 Torque to 20 in-lbs (2 N•m)

Parts

1

3A4798F

LA2T28 LA1T28

41

Parts

42

LA1T28, Waterborne, Rear Manifold

LA2T28, Waterborne, Bottom Manifold

Ref.

No. Part No. Description

25

26

27

28

29

30

5

6

4a

4b

3

4

1

2

25E637 BODY, gun assy (includes 9)

25E634 See

Packing Rod Assembly , page 45.

26A416 NEEDLE, electrode

25N896 NOZZLE, fluid; includes 4a and 4b

24N645 O-RING, conductive

111507 O-RING; fluoroelastomer

185111 SPRING, compression

197624 SPRING, compression

7

7a

24N660 POWER SUPPLY, 60 kV

24N979 SPRING

8

24N664 See Turbine Assembly , page 46

8g  110073 O-RING

9  25N921 GASKET, barrel

10 25E643 BODY, assy, Auto XP Standard

(includes 18, 19)

11 24W396 PISTON, assy, actuation, auto

11a 17B704 O-RING

13

14

15

11b 111504 O-RING

11c 112319 O-RING

11d 111508 O-RING

12 112640 SPRING, compression

24W397 CAP, piston, actuation

513505 WASHER, plain #10 SST

24W398 ARM, fluid actuator, XP

(includes 16, qty 2)

16 100166 NUT, full hex

18  111450 PACKING, O-RING

19

20

24N740 SCREW, ES gun (pack of 2)

24W392 MANIFOLD, rear inlet, LA1T28

(includes 18, 21, 23, 27, 28, 29, 30, 31)

24W393 MANIFOLD, bottom inlet, LA2T28

(includes 18, 21, 23, 27, 28, 30, 31)

21

23

24

24W399 SCREW, modified, 1/4-20, XP Auto

(pack of 2)

24W411 FITTING, Adapter, M12 TO 1/4, LH, XP

24N644 RING, retainer, assy; includes 24a

24a

198307 PACKING, u-cup; UHMWPE

24N477 AIR CAP, machining, black

25E640 COVER, shroud, Auto XP

114263 FITTING, connector, male

115950 FITTING, connector, 1/4npt (M), 5/16T

110465 SCREW, set (LA1T28 only)

102207 SCREW, set, SCH

Qty

1

4

1

2

7

1

1

1

1

1

2

2

1

1

1

1

3

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

No. Part No. Description

31

32

24X299 FITTING, manifold, rear (LA1T28)

Includes 18 qty 1

24X300 FITTING, manifold, bottom (LA2T28)

Includes 18 qty 1

24X297 FITTING, fluid, A/S, rear, (LA1T28)

Includes 18 qty 1

24X298 FITTING, fluid, bottom (LA2T28)

Includes 18 qty 1, 19 qty 1

37

39

43

33* 111286 FERRULE, front

34* 111285 FERRULE, back

35

36

112644 NUT, swagelock

102982 PACKING, o-ring

24N658 FITTING, fluid barrel

24W385 FLUID TUBE

44  16P802 SIGN, warning (not shown)

46  179791 TAG, warning (not shown)

48 276741 MULTI-TOOL (shipped loose)

81 ✥

25E639 KIT, charging probe, long; includes 85; pack of 2

82 ✥

25E664 KIT, charging probe, short; includes 85; pack of 2

83 118594 O-RING, fluoroelastomer; quantity of 6 included in kit 25E647

84

85

111516 O-RING, fluoroelastomer; quantity of 6 included in kit 24E433

25E644 KIT, replacement pin; pack of 6 (not shown)

Qty

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

Replacement Warning labels, signs, tags, and cards are available at no cost.

Included in Air Seal Repair Kit 24W390 (purchase separately)

* Included in Fluid Seal Repair Kit 24W391 (pur chase separately)

Included in Turbine Assembly 24N664 (pur -

chase separately). See Turbine Assembly

,

page 46.

Two charging probes are included with the gun: A long charging probe for the best transfer effi ciency and wrap, and a short charging probe for low profile electrostatic charging.

3A4798F

Smart Pro Xp Auto Waterborne External Charge

Air Spray Gun Models

LA1M28, Waterborne, Rear Manifold

LA2M28, Waterborne, Bottom Manifold

1 Torque to 20 in-lbs (2 N•m)

Parts

1

3A4798F

LA2M28 LA1M28

43

Parts

44

LA1M28, Waterborne, Rear Manifold

LA2M28, Waterborne, Bottom Manifold

Ref.

No.

Part No. Description

1

2

3

4

25E637 BODY, gun assy (includes 9)

25E634 See Packing Rod Assembly

, page

45.

26A416 NEEDLE, electrode

25N896 NOZZLE, fluid; includes 4a and 4b

4a 24N645 O-RING, conductive

4b 111507 O-RING; fluoroelastomer

185111 SPRING, compression 5

6

7

7a

197624 SPRING, compression

24N660 POWER SUPPLY, 60 kV

24N979 SPRING

24N664 See

Turbine Assembly , page 46

8

8g  110073 O-RING

9



25N921 GASKET, barrel

10 25E645 BODY, assy, Auto XP Smart, rear

(includes 18, 19)

25E646 BODY, assy, Auto XP Smart, bottom (includes 18, 19)

11 24W396 PISTON, assy, actuation, auto

11a 17B704 O-RING

11b 111504 O-RING

11c 112319 O-RING

13

14

15

11d 111508 O-RING

12 112640 SPRING, compression

24W397 CAP, piston, actuation

513505 WASHER, plain #10 SST

24W398 ARM, fluid actuator, XP

(includes 16, qty 2)

100166 NUT, full hex 16

18  * 111450 PACKING, O-ring

19

20

24N740 SCREW, ES gun (pack of 2)

24W392 MANIFOLD, rear inlet, Auto XP

LA1M28 (includes 18, 21, 23, 27,

28, 29, 31)

24W393 MANIFOLD, bottom inlet, Auto XP

LA2M28 (includes 18, 21, 23, 27,

28, 29, 31)

24W399 SCREW, modified, 1/4-20, XP Auto 21

23

24

24a  198307 PACKING, u-cup; UHMWPE

25

26

27

28

(pack of 2)

24W411 FITTING, Adapter, M12 TO 1/4, LH,

XP

24N644 RING, retainer, assy; includes 24a

24N477 AIR CAP, machining, black

25E640 COVER, shroud, Auto XP

114263 FITTING, connector, male

115950 FITTING, connector, 1/4npt (M),

5/16T

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

1

2

7

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

3

Ref.

No.

Part No. Description

29

30

31

32

37

39

43

33*

34*

35

36

110465 SCREW, set

(LA1M28 only)

245265 CIRCUIT, flexible, assy

24X299 FITTING, manifold, rear (LA1M28)

Includes 18 qty 1

24X300 FITTING, manifold, bottom (LA2M28)

Includes 18 qty 1

24X297 FITTING, fluid, A/S, rear (LA1M28)

Includes 18 qty 1

24X298 FITTING, fluid, bottom (LA2M28)

Includes 18 qty 1, 19 qty 1

111286 FERRULE, front

111285 FERRULE, back

112644 NUT, swagelock

102982 PACKING, o-ring

24N658 FITTING, fluid barrel

24W385 FLUID TUBE

116553 GREASE, dielectric; 1 oz (30 ml) tube

(not shown)

44  16P802 SIGN, warning (not shown)

46

179791 TAG, warning (not shown)

48

80

276741 MULTI-TOOL (shipped loose)

24W035 CONTROL MODULE, Pro Xp Auto

(not shown. See 332989) Must be purchased separately.

81 ✥

25E639 KIT, charging probe, long; includes

85; pack of 2

82 ✥

25E664 KIT, charging probe, short; includes

85; pack of 2

83

84

85

118594 O-RING, fluoroelastomer; quantity of

6 included in kit 25E647

111516 O-RING, fluoroelastomer; quantity of

6 included in kit 24E433

25E644 KIT, replacement pin; pack of 6 (not shown)

Qty

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

 Replacement Warning labels, signs, tags, and cards are available at no cost.

 Included in Air Seal Repair Kit 24W390 (purchase sep arately)

* Included in Fluid Seal Repair Kit 24W391 (purchase separately)

 Included in Turbine Assembly 24N664 (purchase separately). See

Turbine Assembly , page 46.

Two charging probes are included with the gun: A long charging probe for the best transfer efficiency and wrap, and a short charging probe for low profile elec trostatic charging.

3A4798F

Packing Rod Assembly

Part No. 25E634 60 kV Packing Rod Assembly

Includes items 2a-2k

2k

2j

2e

2f

2b‡

2h‡

2c‡

2d‡

2g

2a‡

Ref.

No. Part No. Description

2a‡ 111316

2b‡ 116905

2c‡ 178409

2d‡ 178763

2e 25E635

2f 197641

2g 185495

O-RING

SEAL

PACKING, fluid

PACKING, needle

ROD, packing, 60 kV guns

(includes items 2j and 2k)

NUT, packing

HOUSING, packing

Qty

1

1

1

1

1

1

1

Ref.

No. Part No. Description

2h‡ 186069

2j  --------

2k  --------

SPACER, packing

NUT, trigger adjustment (part of item

2e)

NUT, trigger adjustment (part of item

2e)

Qty

1

1

1

These parts are included in Fluid Seal Repair Kit

24W391 (purchase separately).

These parts are included in Trigger Adjustment

Nut Kit 24N700 (purchase separately).

Parts

3A4798F 45

Parts

Turbine Assembly

Part No. 24N664 Turbine Assembly

8f 

8e 

8g*

8d

8b1 

8c

8a

8b2

8h

WLE

Ref.

No. Part No. Description

8a 24N705

8b  24N706

8c 24Y264

8d  24N707

8e  ------

8f  ------

COIL, turbine

BEARING KIT (includes two bear ings, item 8e fan, and one item 8h clip)

SHAFT KIT (includes shaft and mag net)

HOUSING; includes item 8f

FAN; part of item 8b

CAP, housing; part of item 8d

Qty

1

1

1

1

1

1

Ref.

No. Part No. Description

Qty

8g* 110073

8h  24N709

9*  25N921

*

O-RING

CLIP; package of 5 (one clip included with item 15b)

GASKET, barrel (not shown) See

page 41.

These parts are included in Air Seal Repair Kit

24W390 (purchase separately).

These parts are included in Bearing Kit 24N706

(purchase separately).

Parts labeled ------ are not available separately

1

1

1

46 3A4798F

Parts

Robot Mount Bracket Assembly

Part No. 24X820 Mounting Bracket Assembly

Includes items

207

202

204

205

A

203

204

Ref.

No. Part No. Description

201 - - -

202 - - -

203 - - -

204 112222

205 GC2042

206 111788

207 17A612

- - -

PLATE, mounting

LEG

SPACER

SCREW, cap, 1/4-20 x 1.0 in.

WASHER, fender

SCREW, cap, 1/4-20 x 0.75 in.

SCREW, cap, 10-24 x 0.5 in.

Robot adapter plates (not shown; order separately); See Table 4 on page 48

Qty

2

4

4

2

8

1

2

206

201

NOTE: Alignment holes (A) enable orienting gun spray angle at either 60° or 90° for either gun type.

3A4798F 47

Parts

Adapter

Plate

24Y128

24Y129

24Y634

24Y650

24Y172

24Y173

24Y768

24Y769

Robot

MOTOMAN EPX1250

MOTOMAN PX1450

MOTOMAN EPX2850,

Three-roll type

MOTOMAN EPX2050

ABB IRB 580

ABB IRB 5400

MOTOMAN EPX2700

MOTOMAN EPX2800

MOTOMAN EPX2900

KAWASAKI KE610L

KAWASAKI KJ264

KAWASAKI KJ314

ABB IRB 540

ABB IRB 1400

FANUC PAINT MATE

200iA

FANUC PAINT MATE

200iA/5L

FANUC P-145

Table 4. Robot Adapter Plates

Bolt Circle

27.5 mm (1.083 in)

Mounting

Screws

4X M5 x 0.8

32 mm (1.260 in) 8X M6 x 1.0

Locating Pin

Circle

27.5 mm (1.083 in)

- - -

102 mm (4.02 in)

102 mm (4.02 in)

36 mm (1.42 in)

40 mm (1.58 in)

31.5 mm (1.24 in)

100 mm (3.94 in)

6X M6 x 1.0

6X M6 x 1.0

3X M5

4X M6

4X M5

6X M5

102 mm (4.02 in)

102 mm (4.02 in)

- - -

- - -

31.5 mm (1.24 in)

100 mm (3.94 in)

Locating

Pins

5 mm

- - -

2X 4 mm

2X 5 mm

- - -

- - -

1X 5 mm

1X 5 mm

48 3A4798F

Accessories

Accessories

Smart Model Accessories and Fiber Optic

Cables

Part No. Description

24W035 Pro Xp Auto Control Module. See 332989 for details.

Fiber Optic Cables for Gun

See item V in F IGURE 7 on page 15. Connect gun mani

fold to Pro Xp Auto Control Module. See 332989.

Models with Rear Manifolds

(Model numbers LA1xxx or HA1xxx)

Part No. Description

24X003 Fiber Optic Cable, 25 ft (7.6 m)

24X004 Fiber Optic Cable, 50 ft (15 m)

24X005 Fiber Optic Cable, 100 ft (30.5 m)

Models with Bottom Manifolds

(Model numbers LA2xxx or HA2xxx)

Part No. Description

24X006 Fiber Optic Cable, 25 ft (7.6 m)

24X007 Fiber Optic Cable, 50 ft (15 m)

24X008 Fiber Optic Cable, 100 ft (30.5 m)

Fiber Optic Cable Kit

24W875 Parts necessary to replace damaged ends on one cable assembly.

Air Line Accessories

AirFlex ™ Flexible Grounded Air Hose (Grey)

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

244963 6 ft (1.8 m)

244964 15 ft (4.6 m)

244965 25 ft (7.6 m)

244966 36 ft (11 m)

244967 50 ft (15 m)

244968 75 ft (23 m)

244969 100 ft (30.5 m)

Standard Grounded Air Hose (Grey)

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

223068 6 ft (1.8 m)

223069 15 ft (4.6 m)

223070 25 ft (7.6 m)

223071 36 ft (11 m)

223072 50 ft (15 m)

223073 75 ft (23 m)

223074 100 ft (30.5 m)

Grounded Air Hose with stainless steel braid ground path (Red)

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

Part No. Description

235068 6ft(1.8m)

235069 15 ft (4.6 m)

235070 25 ft (7.6 m)

235071 36 ft (11 m)

235072 50 ft (15 m)

235073 75 ft (23 m)

235074 100 ft (30.5 m)

Bleed-Type Master Air Valve

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between this valve and the pump air motor when closed.

Part No. Description

107141 3/4 npt

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

Part No. Description

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

3A4798F 49

Accessories

Fluid Line Accessories

Fluid Hose

225 psi (14 bar, 1.4 MPa) Maximum Working Pressure

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

Part No.

Description

215637

215638

25 ft (7.6 m)

50 ft (15.2 m)

Fluid Shutoff/Drain Valve

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.

Part No.

Description

208630 1/2 npt(m) x 3/8 npt(f); carbon steel and PTFE; for non-corrosive fluids

Gun Mounted Fluid Regulator

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

Part No.

Description

236854 Air-piloted fluid regulator mounts directly to gun manifold for precise fluid control.

System Accessories

Part No.

Description

222011 Ground wire for grounding pump and other components and equipment in the spray area.

12 gauge, 25 ft (7.6 m).

Signs

Part No.

Description

17Z427 English Warning Sign. Available at no charge from Graco.

Fluid Recirculation Fitting

5000 psi (340 bar, 34 Mpa) Maximum Working Pressure

Part No.

Description

24X634 Stainless steel recirculation fitting that mounts directly to the gun fluid inlet fitting. 1/4-18 npsm inlet and outlet.

Round Spray Kits

To convert a standard air spray gun to a round spray air cap.

For use with short charging probe only.

Part No.

Description

24X794

25N837

25N836

Large Pattern Kit

Medium Pattern Kit

Small Pattern Kit

Test Equipment

Part No. Description

241079

722886

722860

245277

24R038

Megohmmeter. 500 V output, 0.01–2000 megohms. Use for ground continuity and gun resistance tests. Not for use in hazardous locations.

Paint Resistance Meter. Use for fluid resistiv ity test. See manual 307263. Not for use in hazardous locations.

Paint Probe. Use for fluid resistivity test. See manual 307263. Not for use in hazardous locations.

Test Fixture, High Voltage Probe, and kV

Meter. Use to test the electrostatic voltage of the gun, and the condition of the turbine and power supply when being serviced. See man ual 309455. Also requires 24R038 Conversion

Kit.

Voltage Tester Conversion Kit. Converts the

245277 Test Fixture for use with the Pro Xp

Gun turbine. See manual 406999.

Gun Accessories

Part No. Description

105749 Cleaning Brush

111265

116553

24V929

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

Dielectric Grease. 1 oz (30 ml)

Gun Covers

Conversion and Repair Kits

Part No.

Description

24W390 Air Seal Repair Kit

24W391 Fluid Seal Repair Kit

24N706 Turbine Bearing Repair Kit

50 3A4798F

Air Caps and Fluid Nozzles

Air Caps and Fluid Nozzles

Fluid Nozzle Selection Chart

To reduce the risk of an injury, follow the

Pressure Relief Procedure

before remov ing or installing a fluid nozzle and/or air cap.

Fluid Nozzle

Part No.

25N831

25N832

25N833

25N834

24N620

24N621

24N622

24N623

24N624

24N625

24N619

24N613

26D094

25N895

25N896

24N616

25N897

24N618

24N729

25N835

Orifice Size, mm (in.)

0.55 (.022)

0.75 (.029)

0.9 (.035)

1.0 (.042)

1.2 (.047)

1.5 (.055)

1.8 (.070)

2.0 (.079)

1.0 (.042)

1.2 (.047)

1.5 (.055)

1.8 (.070)

0.75 (.029)

1.0 (.042)

1.2 (.047)

1.5 (.055)

1.8 (.070)

2.0 (.079)

---------

Color

Black

Black

Black

Green

Gray

Black

Brown

Black

Green

Gray

Black

Brown

Blue

Black

--------Black

Description

Standard nozzles (STD) for standard coatings

Precision high wear nozzles (PHW) with hardened SST seat and damage resistant SST tip; for stan dard coatings, abrasives, and metallics

High wear nozzles (HW) with hardened ceramic seat, for abrasives and metallics

Round spray large pattern nozzle for use with large pattern round spray air cap only

Round spray medium or small pattern nozzle for use with medium or small pattern round spray air caps only

3A4798F 51

Air Caps and Fluid Nozzles

Fluid Nozzle Performance Charts

Use the following procedure to select the proper fluid nozzle for your application.

Table 6: Orifice Size: 0.75 mm (0.030 in.)

1. For each fluid nozzle performance 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 verti cal 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.

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

Key to Fluid Nozzle Performance Charts

NOTE: Fluid pressures are measured at the spray gun inlet.

Table 7: Orifice Size: 1.0 mm (0.040 in.)

260 Centipoise Fluid

160 Centipoise Fluid

70 Centipoise Fluid

20 Centipoise Fluid

Table 5: Orifice Size: 0.55 mm (0.022 in.)

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

52 3A4798F

Table 8: Orifice Size: 1.2 mm (0.047 in.)

Air Caps and Fluid Nozzles

Table 10: Orifice Size: 1.8 mm (0.070 in.)

FLUID

PRESSURE bar, psi

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

Table 9: Orifice Size: 1.5 mm (0.059 in.)

FLUID FLOW: oz/min, cc/min

Table 11: Orifice Size: 2.0 mm (0.079 in.)

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

FLUID

PRESSURE bar, psi

FLUID FLOW: oz/min, cc/min

3A4798F 53

Air Caps and Fluid Nozzles

Air Cap Selection Chart

To reduce the risk of an injury, follow the

Pressure Relief Procedure before remov

ing or installing a fluid nozzle and/or air cap.

The charts in this section can assist you in selecting an air cap.

• Keep in mind that more than one air cap can meet your finish requirements.

• When selecting an air cap, consider coating properties, part geometry, pattern shape, pattern size, and operator preferences.

NOTE: All air cap pattern shapes and lengths in the fol lowing chart were measured under the following condi tions. Pattern shape and length are material dependent.

Air pressures are measured at the inlet of the gun.

• Distance to target: 10 in. (254 mm)

• Atomizing air pressure: 20 psi (138 kPa, 1.38 bar)

• Fan air pressure: 20 psi (138 kPa, 1.38 bar)

• Fluid flow rate: 10 oz/min (300 cc/min)

54 3A4798F

Air Caps and Fluid Nozzles

Pattern Shape

NOTE: Pattern shapes are influenced by the material viscosity, flow rate, and air pressure settings. The gun may not maintain the intended design shape under all conditions.

• Round patterns have a swirling, slow, round cone pattern for excellent finish and transfer efficiency.

• Fan patterns have two styles: round ends and tapered ends.

• Fan patterns with round ends are versatile. They can be used in any application and are often the best option for smaller parts or cut-in painting.

• Fan patterns with tapered ends are best for achieving even coating thickness with overlapping paint passes.

3A4798F 55

Air Caps and Fluid Nozzles

General Fan Pattern Air Caps: Descriptions

Part No.

Color

24N477 Black

24W279

24N438

Green

Black

24N376

24N276

24N277

24N278

24N274

Black

Blue

Red

Green

Black

Description

Standard

Alternate

Long Pattern

Short Pattern

Guidelines for Use

Most versatile air cap. Recommended for most materials and applications. Class

A finish. Often used in waterborne applications.

Similar to the standard air cap with an alternate arrangement of atomizing air.

Longest spray pattern, optimized for painting large parts with overlapping paint passes. Often used in waterborne applications.

Shorter pattern, optimized for painting with overlapping passes.

General Fan Pattern Air Caps: Specifications

Part No.

Color

24N477

24W279

24N438

24N376

24N276

24N277

24N278

24N274

Black

Green

Black

Black

Blue

Red

Green

Black

Description

Standard

Alternate

Long Pattern

Short Pattern

Pattern

Shape

Nominal

Pattern

Length in. (mm)

Round end 15-17

(381-432)

Round end 15-17

(381-432)

Tapered end

17-19

(432-483)

Tapered end

12-14

(305-356)

Recommended

Fluid Viscosity*

Recommended

Production

Rates**

Light to medium Standard

Light to medium Standard

Light to medium Standard

Light to medium Standard

Atomi zation

Best

Best

Better

Good

Cleanli ness

Good

Good

Better

Best

*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).

Centipoise = centistokes x fluid specific gravity.

Light to medium

Medium to heavy

High solids

20–70 cp

70–360 cp

360+ cp

**Recommended Production Rates

Standard

Low

High

Very High

300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)

100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)

500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)

600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)

56 3A4798F

Air Caps and Fluid Nozzles

Specialty Fan Pattern Air Caps: Descriptions

Part No.

Color

25E670 Black

24N275

24N279

24N439

25E671

Black

Black

Black

Black

Description

Soft Spray

Aerospace

Solids

Solids High

Flow

HVLP

Guidelines for Use

For painting small, lightweight parts with a slow-moving spray pattern. Optimized for low production rates.

Optimized for aerospace coatings.

• Class A finish

• Light, medium, and heavy viscosity, and high solid coatings

• Very high production rates

Optimized for medium and heavy viscosity and high solid coatings at standard pro duction rates.

Required for use with 2.0 mm nozzles. Optimized for medium and heavy viscosity and high solid coatings at high production rates.

For applications where HVLP is required.

Specialty Fan Pattern Air Caps: Specifications

Part No.

Color

25E670

24N275

Black

Black

Description Pattern

Soft Spray

Aerospace

Shape

Nominal

Pattern

Length in. (mm)

Round end 10-12

(254-305)***

Tapered end 14-16

(356-406)

24N279 Black

24N439

25E671

Black

Black

Solids

Solids High

Flow

Tapered end 11-13

(279-330)

HVLP

Round end 14-16

(356-406)

Round end 14-16

(356-406)

Recommended

Fluid Viscosity*

Light to medium

Recom mended

Production

Rates**

Low

Light, medium, and heavy viscosity, and high solids

Medium to heavy viscosity and high solids

Medium to heavy viscosity and high solids

Light to medium

Very High

Standard

High

Standard

Atomi zation

Better

Good

Best

Best

Good

Cleanli ness

Good

Best

Good

Better

Good

*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).

Centipoise = centistokes x fluid specific gravity.

Light to medium

Medium to heavy

High solids

20–70 cp

70–360 cp

360+ cp

**Recommended Production Rates

Standard

Low

High

Very High

300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)

100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)

500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)

600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)

***The soft spray air cap was measured with the fluid flow rate adjusted to 3.5 oz/min (100 cc/min).

3A4798F 57

Air Caps and Fluid Nozzles

Round Pattern Air Caps: Descriptions

Part No.

Color

24N318 Black

25N837

25N836

Black

Black

Description

Large Pattern

Medium Pattern

Small Pattern

Guidelines for Use

Conventional round pattern design for larger patterns up to 8 in (20 cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.

Dual inner and outer atomizing air design for improved atomization at low air flows.

For medium patterns up to 6 inches (15cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.

Dual inner and outer atomizing air design for improved atomization at low air flows.

For small patterns up to 4 inches (10cm). Swirling, slow, round cone pattern for excellent finish and transfer efficiency.

Round Pattern Air Caps: Specifications

Part No.

Color

24N318

25N837

25N836

Black

Black

Black

Description Pattern

Shape

Nominal

Pattern

Diameter in. (mm)

Large Pattern Round end 8 (203)

Medium Pattern Round end 6 (152)

Small Pattern Round end 4 (102)

Recommended

Fluid Viscosity*

Recommended

Production Rates

Atomi zation

Light to medium Low

Light to medium Low

Light to medium Low

Good

Better

Better

Cleanli ness

Good

Good

Good

*Fluid Viscosity, in centipoise (cp) at 70°F (21°C).

Centipoise = centistokes x fluid specific gravity.

Light to medium 20–70 cp

Medium to heavy

High solids

70–360 cp

360+ cp

**Recommended Production Rates

Standard

Low

High

Very High

300 cc/min to 500 cc/min (10 oz/min to 17 oz/min)

100 cc/min to 300 cc/min (3 oz/min to 10 oz/min)

500 cc/min to 600 cc/min (17 oz/min to 20 oz/min)

600 cc/min to 750 cc/min (20 oz/min to 25 oz/min)

58 3A4798F

Dimensions

Dimensions

Rear Inlet Manifold

10.6 in (269 mm)

9.5 in (241.3 mm)

8 in (203 mm)

3.0 in (76.2 mm)

2.6 in (66 mm)

2.5 in (63 mm )

5 in (127 mm)

2.9 in (73 mm)

0.53 in (13.5 mm) 2x 1/4-20 UNC

Bottom Inlet Manifold

10.2 in (259 mm)

3A4798F

2.5 in

(63.5 mm)

2x 1/4-20 UNC

0.60 in (15.24 mm)

7.8 in (198 mm)

9.3 in (236.2 mm)

3.0 in (76.2 mm)

2.6 in (66 mm)

2.5 in (63 mm)

5.8 in

(147 mm)

0.90 in

3x 5/16-18 UNC

1.80 in

59

Dimensions

Robot Mount Gun Dimensions

Typical configuration for a hollow-wrist robot with bottom-manifold gun.

NOTE: Gun shown positioned for 60 ° spray setting in Robot Mount Bracket 24X820.

F

IG

. 33. Dimensions, Gun with a Bottom Manifold, 60° position

A

9.9 in.

(25.1 cm)

B

14.4 in.

(36.6 cm)

C

13.0 in.

(33.0 cm)

D

2.3 in.

(5.8 cm)

E

6.7 in.

(17.0 cm)

60 3A4798F

Typical configuration for a hollow-wrist robot with bottom-manifold gun.

Dimensions

NOTE: Gun shown positioned for 90 ° spray setting in Robot Mount Bracket 24X820.

F IG . 34. Dimensions, Gun with a Bottom Manifold, 90° Position

A

11.7in.

(29.7 cm)

B

11.2 in.

(28.4 cm)

C

9.5 in.

(24.1 cm)

D

4.5 in.

(11.4 cm)

E

5.7 in.

(13.0 cm)

3A4798F 61

Dimensions

Alternate configuration for a robot with rear-manifold gun.

NOTE: Gun shown positioned for 60 ° spray setting in Robot Mount Bracket 24X820.

F IG . 35. Dimensions, Gun with a Rear Manifold, 60° Position

A

9.5 in.

(24.1 cm)

B

14.4 in.

(36.6 cm)

C

13.0 in.

(33.0 cm)

D

2.3 in.

(5.8 cm)

E

6.7 in.

(17.0 cm)

62 3A4798F

Alternate configuration for a robot with rear-manifold gun.

Dimensions

NOTE: Gun shown positioned for 90 ° spray setting in Robot Mount Bracket 24X820.

F IG . 36. Dimensions, Gun with a Rear Manifold, 90° Position

A

11.7 in.

(29.7cm)

B

11.2 in.

(28.4 cm)

C

9.5 in.

(24.1 cm)

D

4.5 in.

(11.4 cm)

E

5.7 in.

(14.5 cm)

3A4798F 63

Air Flow

Air Flow

The gun requires 6 scfm (170 l/min) of turbine air flow (see

Technical Data

). The following graph shows additional air consumption. For example, if both fan and atomizing air are set at 30 psi (2.1 bar) inlet pressure, the gun uses about 5 scfm (142 l/min) fan air and about 7 scfm (198 l/min) atomizing air. Add these amounts to the turbine air for a total of 18 scfm (510 l/min) air consumption. Air flow was tested using air cap 24N477.

16

(453)

14

(396)

12

(340)

10

(283)

8

(227)

6

(170)

4

(113)

2

(57)

0

0

A

B

10

(0.07)

(0.7)

20

(0.14)

(1.4)

30

(0.21)

(2.1)

40

(0.28)

(2.8)

50

(0.35)

(3.5)

60

(0.41)

(4.1)

Gun Inlet Air Pressure - PSI (MPa) (bar)

70

(0.48)

(4.8)

80

(0.55)

(5.5)

A

Atomizing Air

B

Fan Air

64 3A4798F

Technical Data

Technical Data

Pro Xp Auto Air Spray Gun

Maximum fluid working pressure

Maximum working air pressure

Maximum fluid operating temperature

Short circuit current output

Gun Weight (Approximate)

Air Consumption

Required turbine air flow

Typical total air flow with 24N477 air cap at

30 psi (2 bar) atomizing air and fan air inlet pressure

Voltage Output

Standard Models

Smart Models

Noise (dBa)

Sound Power (measured per ISO Standard

9216)

Sound Pressure (measured 1 m from gun)

US

100 psi

100 psi

120°F

2.6 lb

6 scfm

18 scfm

Metric

0.7 MPa, 7 bar

0.7 MPa, 7 bar

48°C

125 microamperes

1.2 kg

60 kV

40-60 kV

170 l/min

510 l/min at 40 psi: 90.4 dB(A) at 100 psi: 105.4 dB(A) at 40 psi: 87 dB(A) at 100 psi: 99 dB(A) at 0.28 MPa, 2.8 bar: 90.4 dB(A) at 0.7 MPa, 7 bar: 105.4 dB(A) at 0.28 MPa, 2.8 bar: 87 dB(A) at 0.7 MPa, 7 bar: 99 dB(A)

Inlet/Outlet Sizes

Turbine air inlet fitting, left-hand thread

Atomizing air inlet fitting

Fan air inlet fitting

Cylinder air inlet fitting

Fluid inlet fitting

Materials of Construction

Wetted Parts

1/4 npsm(m)

5/16 in. OD nylon tube (8 mm)

5/16 in. OD nylon tube (8 mm)

5/32 in. OD nylon tube (4 mm)

1/4-18 npsm(m)

Stainless Steel, Nylon, Acetal, Ultra-High Molecular Weight Poly ethylene, Fluoroelastomer, PEEK, Tungsten Carbide, Polyethylene,

PTFE

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm. – www.P65warnings.ca.gov.

3A4798F 65

Graco Pro Xp Warranty

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, gun body, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

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

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés,

à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

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

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

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

Original instructions.

This manual contains English. MM 3A4798

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2019, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision F, May 2022

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