Graco WB100 Instructions-Parts List Manual Download

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Repair Kits and Accessories

Hoses

Grounded

Grounded Air

Air

Air Hoses

Hoses

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

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

Part

Part No.

No.

Description

Grounded

Grounded Air

Air

Air Hose

Hose

Hose with

with

with stainless

stainless

stainless steel

steel

steel braid

braid

ground

ground path

path

path (Red)

(Red)

235068

6 ft (1.8 m)

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)

Fluid

Fluid Hoses

Hoses

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

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

Part

Part No.

No.

Description

24M732

Shielded Waterborne Fluid Hose, 25
ft (7.6 m), sold separately for gun
model L60T17

24M733

Unshielded Waterborne Fluid Hose,
25 ft (7.6 m), sold separately for gun
model L60T18

25N916

Shielded Waterborne Fluid Hose
Assembly, 50 ft (15.2 m)

25N917

Unshielded Waterborne Fluid Hose
Assembly, 50 ft (15.2 m)

3A2496H

107

Summary of Contents for WB100

Page 1: ... one one one of of of the the the conditions conditions conditions for for for non non non flammability flammability flammability listed listed listed on on on page page page 3 3 3 For For For professional professional professional use use use only only only Important Important Important Safety Safety Safety Instructions Instructions Instructions Read all warnings and instructions in this manual S...

Page 2: ...Gun Operation Troubleshooting 55 Electrical Troubleshooting 56 Repair 58 Prepare the Gun for Service 58 Air Cap and Nozzle Replacement 59 Air Cap Spray Tip and Nozzle Replacement Model L60M19 60 Electrode Replacement 61 Needle Replacement Model L60M19 62 Fluid Packing Rod Removal 62 Packing Rod Repair 63 Barrel Removal 65 Barrel Installation 65 Power Supply Removal and Replacement 66 Alternator Re...

Page 3: ... air spray gun L60T18 grounded air hose 235070 and unshielded waterborne fluid hose 24M733 24P631 WB100 Waterborne Isolation Enclosure 246511 with smart electrostatic air spray gun L60M18 grounded air hose 235070 and unshielded waterborne fluid hose 24M733 233825 WB100 Waterborne Isolation Enclosure for shielded hoses Does not include hoses and gun 24P734 WB100 Waterborne Isolation Enclosure 24651...

Page 4: ...s Manual Manual Manual No No No Description Description Description 3A2498 Round Spray Kit Instructions 307263 Probe and Meter Instructions 309455 Test Fixture High Voltage Probe and kV Meter Instructions 406999 Voltage Tester Conversion Kit Instructions 4 3A2496H ...

Page 5: ...iquid Mixtures ASTM D4206 CE CE CE EN EN EN 50059 50059 50059 Compliant Compliant Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ Stop Stop Stop operation operation operation immediately immediately immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Check gun resistance...

Page 6: ...not enter a high voltage or hazardous area until all high voltage equipment has been discharged Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the electrode during gun operation Follow the Fluid Fluid Fluid Voltage Voltage Voltage Discharge Discharge Discharge and and and Grounding Grounding Grounding Procedure Procedure Procedure Interlock the gun air supply with the volta...

Page 7: ...ute 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 PLASTIC PLASTIC PARTS PARTS PARTS CLEANING CLEANING CLEANING SOLVENT SOLVENT SOLVENT HAZARD HAZARD HAZARD Many solvents can degrade plastic parts and c...

Page 8: ...9 50059 50059 Compliant Compliant Compliant Materials which cannot be ignited in any mixture with air by an energy source of less than 500mJ When connected to a voltage isolation system all of the fluid in the spray gun fluid hose and isolated fluid supply is charged to high voltage which means that the system has more electrical energy than a solvent based system Therefore only non flammable flui...

Page 9: ...g for supplied exhaust tube D Air Cap and Nozzle See Air Caps page 96 and Fluid Nozzles page 93 for available sizes E Electrode Needle Supplies electrostatic charge to the fluid F Fan Air Adjustment Valve Adjusts fan size and shape Can be used to decrease pattern width G Atomizing Air Restrictor Valve Restricts air cap air flow Replace with plug included if desired H Fluid Adjustment Knob Adjusts ...

Page 10: ... guns The indicator lights to show the alternator speed status and has three colors Green indicates the alternator speed is correct If the indicator changes to amber after one second increase the air pressure If the indicator changes to red after one second the air pressure is too high Decrease air pressure until the indicator is green To maintain a higher air pressure install ES On Off Valve Rest...

Page 11: ...mentarily The screen will display the current low voltage setting See Fig 4 and Smart Gun Key page 12 The range is 30 60 kV Set the Voltage Adjustment switch VA to LO Press the LO SET button repeatedly to increase the setting in increments of 5 When the display reaches the maximum setting 60 kV it will return to the minimum setting 30 kV Continue pressing the button until you reach the desired set...

Page 12: ...nostic Mode press and hold to turn the lock on or off LV Low Voltage Display Displays the low voltage setting as a number The setting can be changed See Fig 4 LK Low Voltage Locked Appears if the low voltage setting is locked See Fig 5 and Fig 9 LD LO Display Appears on the Low Voltage Lock Screen See Fig 9 ER Error Display Appears if the Smart module loses communication with the power supply See ...

Page 13: ...rst screen to appear after entering Diagnostic Mode See Fig 6 and Smart Gun Key page 12 To enter this screen press and hold the LO SET button for approximately 5 seconds while in the Operating Mode This screen displays the spraying voltage of the gun as a number kV rounded to the nearest 5 kV The two top right LEDs VI of the display panel light indicating that the Voltage kiloVolts Screen is displ...

Page 14: ...een Low Low Low Voltage Voltage Voltage Lock Lock Lock Screen Screen Screen The Low Voltage Lock Screen is the fourth screen in the Diagnostic Mode See Fig 9 and Smart Gun Key page 12 To enter this screen press the LO SET button while in the Alternator Speed Hertz Screen This screen displays the status of the Low Voltage Lock If the setting is locked the lock image LK appears to the left of the Lo...

Page 15: ...d read by all operators An English Warning Sign is provided with the gun Install Install Install the the the System System 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 Comply with all local codes and regula...

Page 16: ...tor N on the gun air supply line P to control air pressure to the gun 3 Connect the red colored Graco Electrically Conductive Air Hose P between the gun air regulator N and the gun s air inlet The gun air inlet fitting has a left hand thread Connect the air supply hose ground wire Q to a true earth ground Trapped air can cause the fluid supply unit to cycle unexpectedly which can result in serious...

Page 17: ...lated fluid supply and the gun Do not splice hoses together 1 Remove the gun air inlet fitting 21 NOTE NOTE NOTE In a shielded hose system if a hose failure occurs where high voltage arcs through the inner tube voltage will be discharged to ground through the conductive hose layer When properly installed the conductive hose layer is grounded through its connection to the grounded enclosure Using u...

Page 18: ...4 Loosen the strain relief nut 102 so the bracket can move freely on the hose 5 Align the bracket 104 holes with the air inlet and exhaust outlet Secure with the air inlet fitting 21 Tighten the strain relief nut 102 to secure the hose 6 Check that the nut 105 is tightened securely to the ferrule housing 103 7 Press the exhaust tube 36 onto the exhaust valve barb C Secure with the clamp 43 8 Conne...

Page 19: ...ection to the isolation system s grounded enclosure L or grounded fence To maintain grounding continuity the conductive hose layer C must be engaged in the ferrule when the strain relief nut is tightened Failure to properly install the hose in the strain relief could result in an electric shock Figure 18 Shielded Fluid Hose Connection at Non Graco Isolation Enclosure c Connect the end of the tube ...

Page 20: ...Installation Figure 19 Typical Installation Pro Xp WB100 Waterborne System 20 3A2496H ...

Page 21: ...gulator P Graco Red Grounded Air Hose left hand threads Q Gun Air Hose Ground Wire R Graco Waterborne Fluid Hose S Waterborne Electrostatic Air Spray Gun T Grounding Rod U Ground Terminal V Main Ground Wire W Strain Relief Fitting X Pump Air Supply Line Y Grounding Cylinder Z Pump Fluid Outlet Fitting AA Isolated Enclosure Door not shown to illustrate internal components Door must be closed and lo...

Page 22: ...e conductive gloves supplied with the gun If non Graco gloves are worn cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle Object being sprayed Keep the workpiece hangers clean and grounded at all times Voltage Isolation System Electrically connect the voltage isolation system to a true earth ground See Ground the Cabinet page 16 Electrostatic Air Spray Gun ...

Page 23: ...loor with cardboard or any non conductive material which would interrupt grounding continuity All solvent pails Use only approved grounded metal containers which are conductive Do not use plastic containers Use only non flammable solvents Do not store more than the quantity needed for one shift 3A2496H 23 ...

Page 24: ...e Pressure Relief Procedure page 39 3 Open the isolated enclosure door 4 Remove the back of the control box 258 5 Remove tube A2 from elbow 282 at the air manifold see Tubing and Wiring page 84 Install the Y fitting 402 into the elbow Install tubes A2 and 407 into the Y fitting Route the agitator tube 407 into the cabinet 6 Replace the back of the control box 258 7 Assemble the other parts of the ...

Page 25: ... Remove the back of the control box 258 8 Remove tube A2 from elbow 282 at the air manifold see Tubing and Wiring page 84 Install the Y fitting 506 in the elbow Install tubes A2 and 507 into the Y fitting Route the tube 507 into the cabinet 9 Replace the back of the control box 258 10 Assemble the fluid regulator kit as shown 11 Reinstall the pump in the isolation enclosure Use the two mounting ho...

Page 26: ...k of component rupture which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equipment has a 100 psi 0 7 MPa 7 bar maximum working air and fluid pressure To reduce the risk of an injury follow the Pressure Relief Procedure page 39 whenever you are instructed to relieve the pressure For additional steps to set up specialty guns see Soft ...

Page 27: ...lamp provided 10 Flush if needed See Flushing page 42 11 Position the air cap as needed 12 Fully open the fan air adjustment valve F counterclockwise 13 Fully open the fluid adjustment valve H counterclockwise 14 Fully open the atomizing air restrictor valve G clockwise 15 Turn ON I the ES On Off switch J When the ES On Off switch is turned ON I the fluid supply is charged with high voltage until ...

Page 28: ...ator Color Color Color Description Description Description Green When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine Amber If the indicator changes to amber after one second the air pressure is too low Increase air pressure until the indicator is green Red If the indicator changes to red after one second the air pressure is too high Decrease...

Page 29: ...or the longest pattern Turn the valve clockwise to restrict the fan air and create a shorter pattern When the ES On Off switch is turned ON I the fluid supply is charged with high voltage until the voltage is discharged Contact with the charged components of the spray gun will cause an electric shock Do not touch the gun nozzle or electrode or come within 4 in 102 mm of the front of the gun during...

Page 30: ... 38 3 8 25 7 6 65 0 45 4 5 50 15 3 80 0 56 5 6 7 Verify that the ES indicator K Hz indicator on Smart guns is lit Table Table Table 5 5 5 LED LED LED Indicator Indicator Indicator Colors Colors Colors Indicator Indicator Indicator Color Color Color Description Description Description Green When spraying the indicator should remain green indicating sufficient air pressure to the alternator turbine ...

Page 31: ...ting in in in psi psi psi MPa MPa MPa bar bar bar with with with gun gun gun triggered triggered triggered 15 4 6 55 0 38 3 8 25 7 6 65 0 45 4 5 50 15 3 80 0 56 5 6 NOTE NOTE NOTE The HVLP air cap requires a high volume of air to atomize paint at low pressure Gun air regulator static pressure settings of 70 PSI or higher are typically required To achieve the required gun air pressures use a shorte...

Page 32: ...g the HVLP verification kit 25E919 See manual 3A6833 Adjust the fan air adjustment valve F and atomizing air restrictor valve to achieve 10 PSI or less as needed g Verify that the ES indicator K Hz indicator on Smart guns remains green 5 Continue with steps 18 23 in the Gun Setup Procedure page 26 32 3A2496H ...

Page 33: ...ngth Length in in in ft ft ft m m m using using using 5 16 5 16 5 16 inch inch inch 8 8 8 mm mm mm diameter diameter diameter hose hose hose Air Air Air Regulator Regulator Regulator Setting Setting Setting in in in psi psi psi MPa MPa MPa bar bar bar with with with gun gun gun triggered triggered triggered 15 4 6 55 0 38 3 8 25 7 6 65 0 45 4 5 50 15 3 80 0 56 5 6 7 Verify that the ES indicator K ...

Page 34: ...atomization NOTE NOTE NOTE If the atomization is too fine or if the object being sprayed is moving too much adjust the atomizing air restrictor valve G counterclockwise slightly to limit the air flow To improve atomization adjust the atomizing air restrictor valve G clockwise slightly to increase the air flow or decrease the fluid flow 12 Adjust the pattern size For the largest spray pattern fully...

Page 35: ...n with the fluid adjustment knob in the full flow position at all times or install 24N632 ES On Off and Fixed Fluid Valve Always use an external fluid regulator Do not use the fluid adjustment knob to set the fluid pressure 4 Turn on the air to the gun Turn ON I the ES On Off switch J 5 Spray a test pattern Check the atomization If over atomization occurs at minimum pressure adjust the atomizing a...

Page 36: ...7 Check that the ES On Off switch is OFF O 8 Start the pump Set the fluid regulator to 400 psi 2 8 MPa 28 bar 9 Spray a test pattern Examine the particle size in the center of the pattern tails will be removed in step 21 Increase the pressure in small increments Spray another pattern Compare particle size Continue increasing pressure until the particle size remains constant Do not exceed 3000 psi ...

Page 37: ...n in in psi psi psi MPa MPa MPa bar bar bar with with with gun gun gun triggered triggered triggered 15 4 6 52 0 36 3 6 25 7 6 57 0 40 4 0 50 15 3 68 0 47 4 7 75 22 9 80 0 56 5 6 100 30 5 90 0 63 6 3 13 Turn the atomizing air adjustment valve counterclockwise until any tails disappear 14 If desired atomization is not achieved change the tip size The smaller the tip orifice the finer the atomizatio...

Page 38: ...e gun Follow the Pressure Relief Procedure page 39 The fluid hose must not have any fluid in it 4 Disconnect the fluid hose 5 Make sure the red colored grounded air hose AH is connected and the hose ground wire is connected to a true earth ground 6 Measure the resistance between the gun handle BB and a true earth ground CC Use an applied voltage of 500 minimum to 1000 volts maximum The resistance ...

Page 39: ...nd Grounding Grounding Grounding Procedure Procedure Procedure The fluid supply is charged with high voltage until the voltage is discharged Contact with the charged components of the voltage isolation system or spray gun electrode will cause an electric shock To avoid an electric shock follow the Fluid Fluid Fluid Voltage Voltage Voltage Discharge Discharge Discharge and and and Grounding Groundi...

Page 40: ... in the Pressure Relief Procedure page 39 The electrostatics are turned off and system voltage is discharged according to the Fluid Voltage Discharge and Grounding Procedure page 39 before any person en ters the isolation enclosure before cleaning and before performing any maintenance or repair The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read...

Page 41: ... are instructed to relieve the pressure 1 Discharge the system voltage see Fluid Voltage Discharge and Grounding Procedure page 39 2 Flush the gun see Flushing page 42 3 Follow the Pressure Relief Procedure page 39 4 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out 3A2496H 41 ...

Page 42: ...ore 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 To reduce the risk of fire explosion or electric shock turn OFF O the ES On Off switch before flushing the gun Follow the Fluid Voltage Discharge and Grounding Procedure page 39 before flushing Only flush pu...

Page 43: ...grounded metal pail Flush until clean solvent flows from the gun 6 Follow the Pressure Relief Procedure page 39 7 Open the isolated enclosure door Leave the flushing fluid in the system until you are ready to spray again 8 Hang the gun from its hook with the nozzle pointing down Be sure to keep the gun from grounding out 9 Before using the system electrostatically again make sure no flammable vapo...

Page 44: ...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 O the ES On Off switch 2 Flush the gun See Flushing page 42 3 Follow the Pressure Relief Procedure page 39 4 Clean the outside of the gun with a non flammable solvent as defined under Flushing page 42 U...

Page 45: ...lean the air cap retaining ring and nozzle with a soft brush and non flammable solvent 7 If necessary use a toothpick or other soft tool to clean the air cap holes Do not use metal tools 8 Reinstall the air cap Tighten securely 3A2496H 45 ...

Page 46: ...h the nozzle pointing down Be sure to keep the gun from grounding out 8 Clean the cabinet Inspect the cabinet and clean up any spilled paint Conductive paint residue allowed to contact grounded parts may short out the electrostatics Keep the inside of the cabinet clean for proper operation Inspect the door T handle locking screw regularly to ensure the threads are well greased Apply silicone free ...

Page 47: ...ices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent containers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage Test Test Test Gun Gun Gun Resistance Resistance Resistance 1 Follow the steps...

Page 48: ...Remove the turbine alternator 15 from the power supply 4 Measure resistance from the power supply s ground strips EE to the spring 11a The resistance should be 90 115 megohms If outside this range replace the power supply If in range go to Test Electrode Resistance page 49 5 Be sure the spring 11a is in place before reinstalling the power supply Figure 26 Test Power Supply Resistance 48 3A2496H ...

Page 49: ...gohms less than 5 megohms for Model L60M19 4 If in range go to Electrical Troubleshooting page 56 for other possible causes of poor performance or contact your Graco distributor 5 Remove the electrode 3 see Electrode Replacement page 61 Measure the resistance between the contact HH and the electrode wire GG The resistance should be 10 30 megohms If out of range replace the electrode 6 Make sure th...

Page 50: ...d lug Resistance must be less than 100 ohms If greater than 100 ohms replace the ground strip 240 Figure 30 Test Ground Strip Resistance Test Test Test Cylinder Cylinder Cylinder Resistance Resistance Resistance Remove the enclosure door Using an ohmmeter measure the resistance from the pump 209 to the ground lug 214 Resistance must be less than 100 ohms If greater than 100 ohms replace the ground...

Page 51: ...rrent demands and voltage isolation system losses A loss of spraying voltage can be caused by a problem with the spray gun fluid hose or voltage isolation system since all of the system components are electrically connected through the conductive waterborne fluid Before troubleshooting or servicing the voltage isolation system itself you need to determine which component in the system is most like...

Page 52: ...or any bulges in the outer cover which may indicate an internal leak Internal voltage isolation system components Tests Tests Tests If you still have no voltage separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test 1 Flush the system with water and leave the lines filled with water 2 Discharge the system...

Page 53: ...eplace the hose b Fluid packings Remove the packing assembly from the gun see Fluid Packing Rod Removal page 62 and look for signs of fluid leakage or any blackened areas which would indicate arcing is occurring along the packing rod c Fluid hose connection to the spray gun A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o ring seals on the end of the hose ...

Page 54: ...ozzle Replacement page 59 Fluttering or spitting spray Air in fluid supply Check fluid source Refill Improper spray pattern Damaged or dirty nozzle or air cap Clean or replace See Air Cap and Nozzle Replacement page 59 Fluid buildup on air cap or nozzle Clean See Clean the Gun Daily page 44 Fan air pressure too high Decrease Fluid too thin Increase viscosity Fluid pressure too low Increase Fan air...

Page 55: ... See Packing Rod Repair page 63 Air leaks from the front of the gun Air valve is not seating properly Replace air valve See Air Valve Repair page 72 Worn electrode Replace electrode See Electrode Replacement page 61 Worn fluid nozzle seat Replace nozzle See Air Cap and Nozzle Replacement page 59 Loose fluid nozzle Tighten Fluid leakage from the front of the gun Damaged nozzle o ring Replace o ring...

Page 56: ...ator is amber Check air pressure to gun minimum 45 psi 0 32 MPa 3 2 bar needed at gun for full voltage Atomizing air pressure too high Decrease Fluid pressure too high Decrease Incorrect distance from gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance page 47 Fluid leaks from the p...

Page 57: ...ess Clean workpiece hangers Gun is too close to the part being sprayed Gun should be 8 12 in 200 300 mm from the part Voltage current display stays red smart guns only Dirty gun See Clean the Gun Daily page 44 ES or Hz indicator is amber Alternator speed is too low Increase air pressure until indicator is green To avoid over atomization use the atomizing air restrictor valve to reduce the atomizin...

Page 58: ... checking or servicing any part of the system and whenever you are instructed to relieve the pressure Check all possible remedies in Troubleshooting page 51 before disassembling the gun Use a vise with padded jaws to prevent damage to plastic parts Lubricate some packing rod parts 2 and certain fluid fittings with dielectric grease 44 as specified in the text Lightly lubricate o rings and seals wi...

Page 59: ... anything but a genuine Graco part NOTE NOTE 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 conductive contact ring 4a and the small o ring 4b are in place on the nozzle 4 Lightly lubricate the small o ring 4b NOTE NOT...

Page 60: ...E The conductive ring 4c is a conductive metal contact ring not a sealing o ring For best performance and to avoid potential damage to the spray gun do not remove the conductive ring 4c except to replace it and never operate the gun without the conductive ring in place Do not replace the conductive ring with anything but a genuine Graco part 5 Trigger the gun and remove the nozzle 4 using an adjus...

Page 61: ...or Service page 58 2 Remove the air cap and nozzle See Air Cap and Nozzle Replacement page 59 3 Unscrew the electrode 3 with the multi tool 41 NOTICE NOTICE NOTICE To avoid damaging the plastic threads be very careful when installing the electrode 4 Apply low strength purple threadlocker to the electrode and packing rod threads Install the electrode finger tight Do not overtighten 5 Install the fl...

Page 62: ... air cap See Air Cap Spray Tip and Nozzle Replacement Model L60M19 page 60 6 See Test Gun Resistance page 47 Figure 38 Electrode Replacement Fluid Fluid Fluid Packing Packing Packing Rod Rod Rod Removal Removal Removal 1 Follow the steps in Prepare the Gun for Service page 58 2 Remove the air cap and fluid nozzle See Air Cap and Nozzle Replacement page 59 3 Remove the electrode See Electrode Repla...

Page 63: ...uid is discharged and the fluid stops before the air flow stops The packing rod assembly is pre adjusted at the factory for proper air lead and lag Adjust only if necessary as follows 1 Remove the spring 17 from the nut 2k 2 Use a hex wrench to hold the end of the packing rod Turn both adjustment nuts 2j 2k out to increase the lead lag time for the air flow The recommended adjustment is one half t...

Page 64: ...lace the fluid packing 2c on the packing rod 2e with its lips facing the front of the rod Install the needle packing 2d with the male end toward the fluid packing then install the housing 2g 4 Lightly tighten the packing nut 2f The packing nut is properly tightened when there is 3 lb 13 3 N of drag force when sliding the packing housing 2g assembly along the rod Tighten or loosen the packing nut a...

Page 65: ...lation Installation 1 Be sure the gasket 28 and grounding spring 18 are in place Make sure the gasket air holes are aligned properly Replace the gasket if damaged 2 Make sure the spring 11a is in place on the tip of the power supply 11 Liberally Liberally Liberally apply dielectric grease 44 to the tip of the power supply Place the barrel 1 over the power supply and onto the gun handle 16 3 Tighte...

Page 66: ...y Resistance page 48 Replace the power supply if necessary To repair the alternator see Alternator Removal and Replacement page 67 NOTICE NOTICE NOTICE To prevent damage to the cable and possible interruption of the ground continuity bend the alternator s 3 wire ribbon cable PC upward and back so the bend faces the power supply and the connector is at the top 7 Smart models only connect the 6 pin ...

Page 67: ...bearing tabs T of the housing 15d Figure 45 Fan Orientation 6 Push the fan and coil assembly 15a out the front of the housing 15d Figure 46 Alternator Cross Section 28 is not shown in illustration NOTICE NOTICE NOTICE To prevent damage do not scratch or damage the magnet M or shaft S Do not pinch or damage the 3 wire connector PC when disassembling and reassembling the bearings 7 Hold the coil ass...

Page 68: ...as shown in Fig 46 Be sure the coil alignment pins P are positioned as shown in Fig 45 14 Rotate the fan 15e so its blades clear the four bearing tabs T at the back of the housing Ensure that the blades of the bottom bearing 15b1 align with the tabs 15 Seat the coil fully into the housing 15d Secure with the clip 15h ensuring that its tabs engage the slots in the housing 16 Ensure that the o ring ...

Page 69: ...nspect the o ring 30c Remove if damaged 6 Clean all parts and inspect for wear or damage NOTE NOTE NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the fan air valve 30 lightly lubricate the valve threads and screw the shaft 30b fully into the housing 30a until bottomed Install the o ring 30c lubricate and unscrew the valve stem until the o ring enters the hous...

Page 70: ...ve if damaged 6 Clean all parts and inspect for wear or damage NOTE NOTE NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the atomizing air restrictor valve 29 lightly lubricate the o ring 29c and push the valve body 29b fully into the housing 29a until bottomed 8 Reassemble the retaining ring 29d Thread the valve stem 29e halfway into the valve body 29b 9 Alig...

Page 71: ...ilicone grease Part No 111265 Do not over lubricate NOTE NOTE NOTE Do not over lubricate parts Excessive lubricant on the o rings can be pushed into the gun air passage and blemish the finish on the workpiece 4 Clean and inspect parts for damage Replace if necessary NOTE NOTE NOTE The protrusion on the retainer plate 26h must point upward 5 Reinstall the valve Torque the screw 27 to 15 25 in lb 1 ...

Page 72: ...of the handle Inspect the rubber seal 23a and replace if damaged 7 Inspect the u cup 35 Do not remove the u cup unless damaged If removed install the new one with its lips facing into the gun handle 16 Place the u cup on the shaft of the air valve to help seat it in the gun handle Figure 53 Install U Cup 8 Install the air valve 23 and spring 34 into the gun handle 16 9 Install the ES On Off Valve ...

Page 73: ... the cartridge 4 Pull the Smart Module out the back of the gun Disconnect the ribbon cable RC from the connector GC in the gun handle 5 Remove the gasket 31b 6 Install a new gasket 31b on the new cartridge 31a Make sure the notched corners of the gasket are at the top 7 Align the module s ribbon cable RC with the gun s cable GC and slide them securely together as shown Tuck the connected cables in...

Page 74: ...ring 19a on the exhaust valve 19 Lubricate the o ring with a light coating of non silicone grease e Install the exhaust valve 19 in the handle 16 f Apply thread sealant to the top threads of the swivel 21 Position the bracket 104 and screw the swivel into the gun handle 16 Torque to 75 85 in lb 8 4 9 6 N m g Check that the nuts 102 105 are tight h Install the tube 36 and clamp 43 3 To replace the ...

Page 75: ...Waterborne Waterborne Waterborne Air Air Air Spray Spray Spray Gun Gun Gun Series Series Series C C C includes items 1 48 Part Part Part No No No 24M732 24M732 24M732 Shielded Shielded Shielded Waterborne Waterborne Waterborne Fluid Fluid Fluid Hose Hose Hose 101 101 101 sold sold sold separately separately separately for for for gun gun gun model model model L60T17 L60T17 L60T17 Part Part Part No...

Page 76: ...1 24N626 SWIVEL air inlet M12 x 1 4 npsm m left hand thread 1 23 24N633 VALVE air 1 23a 276733 SEAL air valve 1 26 24N630 See ES On Off and Fluid Adjustment Valve page 88 1 27 24N740 SCREW hex socket 10 24 x 0 53 in sst package of 2 1 28 25N921 GASKET barrel 1 29 24T304 See Atomizing Air Restrictor Valve Assembly page 89 1 30 24N634 See Fan Air Adjustment Valve Assembly page 89 1 34 185116 SPRING ...

Page 77: ...erborne Waterborne Air Air Air Spray Spray Spray Gun Gun Gun Series Series Series C C C Part Part Part No No No 24M732 24M732 24M732 Shielded Shielded Shielded Waterborne Waterborne Waterborne Fluid Fluid Fluid Hose Hose Hose 101 101 101 sold sold sold separately separately separately for for for gun gun gun model model model L60M17 L60M17 L60M17 Part Part Part No No No 24M733 24M733 24M733 Unshie...

Page 78: ...d thread 1 23 24N633 VALVE air 1 23a 276733 SEAL air valve 1 24 245265 CIRCUIT flexible 1 26 24N630 See ES On Off and Fluid Adjustment Valve page 88 1 27 24N740 SCREW hex socket 10 24 x 0 53 in sst package of 2 1 28 25N921 GASKET barrel 1 29 24T304 See Atomizing Air Restrictor Valve Assembly page 89 1 30 24N634 See Fan Air Adjustment Valve Assembly page 89 1 31 24N756 See Smart Module Assembly pag...

Page 79: ...kV Electrostatic Electrostatic Electrostatic Mold Mold Mold Release Release Release Air Air Air Spray Spray Spray Gun Gun Gun Series Series Series C C C Part Part Part No No No 24M733 24M733 24M733 Unshielded Unshielded Unshielded Waterborne Waterborne Waterborne Fluid Fluid Fluid Hose Hose Hose 101 101 101 sold sold sold separately separately separately 1 Torque to 20 in lb 2 N m 3A2496H 79 ...

Page 80: ...VALVE air 1 23a 276733 SEAL air valve 1 24 245265 CIRCUIT flexible 1 26 24N630 See ES On Off and Fluid Adjustment Valve page 88 1 27 24N740 SCREW hex socket 10 24 x 0 53 in sst package of 2 1 28 25N921 GASKET barrel 1 Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 29 24N792 ATOMIZING AIR ADJUSTMENT VALVE 1 30 24N634 See Fan Air Adjustment Valve Assembl...

Page 81: ...e Waterborne Waterborne Isolation Isolation Isolation Enclosure Enclosure Enclosure for use with shielded waterborne fluid hose Part Part Part No No No 246511 246511 246511 Waterborne Waterborne Waterborne Isolation Isolation Isolation Enclosure Enclosure Enclosure for use with unshielded waterborne fluid hose 3A2496H 81 ...

Page 82: ...236 116316 FITTING tube 1 2 npt x 1 2 in 13 mm OD tube 1 237 218798 STRAINER 16 mesh sst 1 238 114958 STRAP tie 3 Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 239 222011 GROUND WIRE 25 ft 7 6 m 1 240 234018 STRIP grounding aluminum 1 241 110209 NUT regulator 11 242 114051 WASHER shim atch 1 243 210084 ROD ground 1 244 SCREW hex hd 1 4 20 x 5 8 in 16 ...

Page 83: ... Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty L60T17 L60T18 GUN see Standard Waterborne Air Spray Gun Assembly page 75 1 L60M19 L60M18 GUN see Smart Waterborne Air Spray Gun Assembly page 77 1 301 L60M19 GUN see Mold Release Smart Air Spray Gun Assembly page 79 1 Replacement Danger and Warning labels tags and cards are available at no cost The air hose 3...

Page 84: ...nd and Wiring Wiring Wiring Detail Detail Detail Views Views Views of of of Control Control Control Box Box Box Detail Detail Detail View View View of of of Door Door Door Interlock Interlock Interlock Switch Switch Switch 84 3A2496H ...

Page 85: ...gauge wire from top of bleed resistor to meter C2 251 8 204 green yellow 14 gauge wire from internal box ground lug to cylinder cap C3 273 34 864 green yellow 10 gauge wire from external ground lug to cart Code Code Code Ref Ref Ref No No No Length Length Length in in in mm mm mm Description Description Description C4 239 n a green yellow 25 ft 7 6 m ground wire with clamp from external ground lug...

Page 86: ... 1 2d 178763 PACKING needle 1 2e 24N703 ROD packing includes items 2j and 2k 1 2f 197641 NUT packing 1 Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 2g 185495 HOUSING packing 1 2h 186069 SPACER packing 1 2j NUT trigger adjustment part of item 2e 1 2k NUT trigger adjustment part of item 2e 1 These parts are included in Fluid Seal Repair Kit 24N790 purc...

Page 87: ... and one item 15h clip 1 15c 24Y264 SHAFT KIT includes shaft and magnet 1 15d 24N707 HOUSING includes item 15f 1 Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 15e FAN part of item 15b 1 15f CAP housing part of item 15d 1 15g 110073 O RING 1 15h 24N709 CLIP package of 5 one clip included with item 15b 1 28 25N921 GASKET barrel not shown 1 These parts a...

Page 88: ...ed Fluid Fluid Fluid Valve Valve Valve Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty HOUSING valve black for standard model 24N630 blue for restricted model 26A160 1 26a HOUSING valve model 24N632 1 26b 15D371 O RING 2 26c PISTON valve 1 24N649 LEVER ES on off includes 26g models 24N630 and 36A160 1 26f 24N650 LEVER ES on off includes 26g model 24N632...

Page 89: ... not available separately Atomizing Atomizing Atomizing Air Air Air Restrictor Restrictor Restrictor Valve Valve Valve Assembly Assembly Assembly Part Part Part No No No 24T304 24T304 24T304 Atomizing Atomizing Atomizing Air Air Air Restrictor Restrictor Restrictor Valve Valve Valve Assembly Assembly Assembly shown shown shown Ref Ref Ref No No No Part Part Part No No No Description Description De...

Page 90: ...ange 1 10a 183459 GASKET tip not shown 5 Parts labeled are not available separately Smart Smart Smart Module Module Module Assembly Assembly Assembly Part Part Part No No No 24N756 24N756 24N756 Smart Smart Smart Module Module Module Assembly Assembly Assembly Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 31a CARTRIDGE 1 31b 24P433 GASKET 1 31c 24N787...

Page 91: ... Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 4 24N729 NOZZLE round spray in cludes 4a and 4b See Fluid Nozzle Selection Chart page 93 1 4a 24N645 O RING conductive 1 4b 111507 O RING fluoroelastomer 1 5 24N731 AIR CAP round spray See Air Cap Selection Guide page 96 1 29 24N733 ATOMIZING AIR RESTRICTOR VALVE round spray 1 30 24N732 FAN AIR ADJUSTMENT VALVE r...

Page 92: ...ty Qty 25N838 AIR CAP inner small pattern includes 3a 3c 1 3 25N839 AIR CAP inner medium pattern includes 3a 3c 1 25N938 DEFLECTOR small pattern 1 3a 25N939 DEFLECTOR medium pattern 1 113137 O RING small pattern 1 3b 113746 O RING medium pattern 1 DIFFUSER small pattern 1 3c DIFFUSER medium pattern 1 4 25N835 NOZZLE round spray includes 4a 4d 1 4a 24N645 O RING conductive 1 4b 111507 O RING fluoro...

Page 93: ...lack 25N895 1 0 042 Green 25N896 1 2 047 Gray 24N616 1 5 055 Black 25N897 1 8 070 Brown 24N618 2 0 079 Black Standard Standard Standard nozzles nozzles nozzles STD STD STD for standard coatings 25N831 1 0 042 Green 25N832 1 2 047 Gray 25N833 1 5 055 Black 25N834 1 8 070 Brown Precision Precision Precision high high high wear wear wear nozzles nozzles nozzles PHW PHW PHW with hardened SST seat and ...

Page 94: ...essure 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 Key Key Key to to to Fluid Fluid Fluid Nozzle Nozzle Nozzle Performance Performance Performance Charts Charts Charts NOTE NOTE NOTE Fluid pressures are measured at the spray gun inlet 260 Centipoise Fluid 160 Centipoise Fluid 70 Cent...

Page 95: ...Table Table 16 16 16 Orifice Orifice Orifice Size Size Size 1 5 1 5 1 5 mm mm mm 0 059 0 059 0 059 in in in FLUID FLUID FLUID PRES PRES PRES SURE SURE SURE bar psi FLUID FLUID FLUID FLOW FLOW FLOW oz min cc min Table Table Table 17 17 17 Orifice Orifice Orifice Size Size Size 1 8 1 8 1 8 mm mm mm 0 070 0 070 0 070 in in in FLUID FLUID FLUID PRES PRES PRES SURE SURE SURE bar psi FLUID FLUID FLUID F...

Page 96: ... cap can meet your finish requirements When selecting an air cap consider coating properties part geometry pattern shape pattern size and operator preferences Measurements Measurements Measurements All air cap pattern shapes and lengths in the following charts were measured under the following conditions unless otherwise noted NOTE NOTE NOTE Pattern shape and length are material dependent Distance...

Page 97: ...r excellent finish and transfer efficiency Fan Fan Fan patterns patterns patterns have two styles round ends and tapered ends Fan Fan Fan patterns patterns patterns with with with round round round ends ends ends are versatile They can be used in any application and are often the best option for smaller parts or cut in painting Fan Fan Fan patterns patterns patterns with with with tapered tapered ...

Page 98: ...n Description Pattern Pattern Pattern Shape Shape Shape Nominal Nominal Nominal Pattern Pattern Pattern Length Length Length in in in mm mm mm Recommended Recommended Recommended Fluid Fluid Fluid Viscosity Viscosity Viscosity Recommended Recommended Recommended Production Production Production Rates Rates Rates Atom Atom Atom ization ization ization Clean Clean Clean liness liness liness 24N477 B...

Page 99: ...minal Nominal Nominal Pattern Pattern Pattern Length Length Length in in in mm mm mm Recommended Recommended Recommended Fluid Fluid Fluid Viscosity Viscosity Viscosity Recommended Recommended Recommended Production Production Production Rates Rates Rates Atom Atom Atom iza iza iza tion tion tion Clean Clean Clean liness liness liness 25E670 Black Soft Spray Round end 10 12 254 305 Light to medium...

Page 100: ...Specifications Specifications Specifications Part Part Part No No No Color Color Color Description Description Description Pattern Pattern Pattern Shape Shape Shape Nominal Nominal Nominal Pattern Pattern Pattern Diameter Diameter Diameter in in in mm mm mm Recommended Recommended Recommended Fluid Fluid Fluid Viscosity Viscosity Viscosity Recommended Recommended Recommended Production Production ...

Page 101: ...SUMPTION SUMPTION scfm WALL WALL WALL PRESSURE PRESSURE PRESSURE psi Table Table Table 20 20 20 2N274 2N274 2N274 24N275 24N275 24N275 and and and 24N439 24N439 24N439 Air Air Air Cap Cap Cap 50 55 60 65 70 75 0 5 10 15 20 25 80 AIR AIR AIR CON CON CON SUMPTION SUMPTION SUMPTION scfm WALL WALL WALL PRESSURE PRESSURE PRESSURE psi Table Table Table 21 21 21 25E670 25E670 25E670 and and and 25E671 25...

Page 102: ...400 400 450 450 450 Orifice Orifice Orifice Size Size Size in in in mm mm mm at at at 600 600 600 psi psi psi 4 1 4 1 4 1 MPa MPa MPa 41 41 41 bar bar bar at at at 1000 1000 1000 psi psi psi 7 0 7 0 7 0 MPa MPa MPa 70 70 70 bar bar bar Spray Spray Spray Tip Tip Tip 0 007 0 178 4 0 0 1 5 2 0 15 107 207 307 0 009 0 229 7 0 0 2 9 1 0 27 209 309 409 509 609 0 011 0 279 10 0 0 3 13 0 0 4 211 311 411 51...

Page 103: ... 8 8 10 10 10 200 200 200 250 250 250 10 10 10 12 12 12 250 250 250 300 300 300 12 12 12 14 14 14 300 300 300 350 350 350 14 14 14 16 16 16 350 350 350 400 400 400 16 16 16 18 18 18 400 400 400 450 450 450 Orifice Orifice Orifice Size Size Size in in in mm mm mm at at at 600 600 600 psi psi psi 4 1 4 1 4 1 MPa MPa MPa 41 41 41 bar bar bar at at at 1000 1000 1000 psi psi psi 7 0 7 0 7 0 MPa MPa MPa...

Page 104: ...bar bar bar 600 600 600 psi psi psi 4 2 4 2 4 2 MPa MPa MPa 42 42 42 bar bar bar 1200 1200 1200 psi psi psi 8 4 8 4 8 4 MPa MPa MPa 84 84 84 bar bar bar 236836 4A 2 5 oz min 73 cc min 4 1 oz min 120 cc min 5 7 oz min 170 cc min 236837 6A 2 9 oz min 86 cc min 5 1 oz min 150 cc min 7 4 oz min 220 cc min 236838 7A 3 2 oz min 95 cc min 5 4 oz min 160 cc min 7 8 oz min 230 cc min 236839 5B 5 4 oz min 1...

Page 105: ... No Description Description Description 112534 Air Line Quick Disconnect Fitting 185105 Non swivel Air Inlet 1 4 18 npsm m left hand thread 185493 Air Hose Adapter 1 4 npt m x 1 4 18 npsm m left hand thread 24N642 Ball Swivel for gun air inlet 1 4 npsm left hand thread 224754 Valve ball 1 4 npsm left hand thread ES ES ES On Off On Off On Off and and and Fluid Fluid Fluid Adjustment Adjustment Adju...

Page 106: ...ries Part Part Part No No No Description Description Description 222011 Ground Wire and Clamp 24N528 Gun Flush Box Adapter for 60 kV and 85 kV guns To convert existing gun flush boxes to hold Pro Xp guns See manual 309227 24N529 Gun Flush Box Adapter for 40 kV guns To convert existing gun flush boxes to hold Pro Xp guns See manual 309227 24P312 Gun Washer Kit To convert existing gun washers to cle...

Page 107: ...path Red Red Red 235068 6 ft 1 8 m 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 Fluid Fluid Fluid Hoses Hoses Hoses 225 psi 1 4 MPa 14 bar Maximum Working Pressure 1 4 in 6 mm ID 3 8 npsm fbe nylon Part Part Part No No No Description Description Description 24M732 Shielded Waterborne Fluid Hose 25 ft 7 6 m sold separately for gun ...

Page 108: ...chase locally TUBE nylon 1 4 in 6 mm OD 4 ft 1 22 m 1 408 110272 SCREW set socket hd 1 4 20 x 1 4 in 6 mm 1 245944 245944 245944 Fluid Fluid Fluid Regulator Regulator Regulator Kit Kit Kit To allow precise fluid pressure regulation at the gun Includes items 501 507 Ref Ref Ref No No No Part Part Part No No No Description Description Description Qty Qty Qty 501 110078 FITTING tube fluid 1 4 npt m x...

Page 109: ...B B in in in mm mm mm C C C in in in mm mm mm Weight Weight Weight without without without bracket bracket bracket oz oz oz g g g L60T17 10 5 267 8 9 226 2 4 61 21 7 617 L60T18 10 5 267 8 9 226 2 4 61 21 7 617 L60M18 10 5 267 9 6 244 2 4 61 24 2 687 L60M19 10 8 274 9 7 246 2 4 61 22 2 628 3A2496H 109 ...

Page 110: ...Notes Notes Notes Notes 110 3A2496H ...

Page 111: ...s Voltage Output Energy 0 35 J with fluid hose 24M733 installed L60T17 and L60T18 60 kV L60M17 L60M18 and L60M19 30 60 kV Sound Power measured per ISO Standard 9216 at 40 psi 90 4 dB A at 100 psi 105 4 dB A at 0 28 MPa 2 8 bar 90 4 dB A at 0 7 MPa 7 0 bar 105 4 dB A Sound Pressure measured 1 m from gun at 40 psi 87 0 dB A at 100 psi 99 0 dB A at 0 28 MPa 2 8 bar 87 0 dB A at 0 7 MPa 7 0 bar 99 0 d...

Page 112: ...be brought within two 2 years of the date of sale GRACO GRACO GRACO MAKES MAKES MAKES NO NO NO WARRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND AND AND FITNESS FITNESS FITNESS FOR FOR FOR A A A PARTICULAR PARTICULAR PARTICULAR PURPOSE PURPOSE PURPOSE...

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