Graco 3A2495C - Manual

Gun Overview Gun Overview How the Electrostatic AA Spray Gun Works This is not an air spray gun. To help prevent serious injury from pressurized fluid, such as skin injection, and splashing fluid, read and follow the Skin Injection Hazard Warnings on page 5. The air-assisted spray gun combines airless...

Gun Overview Smart Guns The Smart Gun module displays spraying voltage, current, alternator speed, and the voltage setting (low or high). It also allows the user to change to a lower spraying voltage. The module has two modes:• Operating Mode• Diagnostic Mode Operating Mode Bar Graph See Fig. 2, and...

Gun Overview Error Display If the Smart module loses communication with the power supply, the Error display appears, the Hz indicator turns red, and the Smart module is disabled. See Fig. 3, and Table 1 on page 11. This can occur in Operating Mode or Diagnostic Mode. See Electrical Troubleshooting, ...

Gun Overview Diagnostic Mode Diagnostic Mode includes four screens which display gun data:• Voltage (kiloVolts) Screen• Current (microAmperes) Screen• Alternator Speed (Hertz) Screen• Low Voltage Lock ScreenNOTE: You must be in Operating Mode to adjust the low voltage setting; the setting is not adj...

Gun Overview Alternator Speed (Hertz) Screen The Alternator Speed (Hertz) Screen is the third screen in the Diagnostic Mode. See Fig. 8, and Table 1 on page 11. To enter this screen, press the LO SET button while in the Current (microAmperes) Screen.This screen displays the alternator speed as a 3 d...

Installation Installation 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 wit...

Installation Air Supply Line To reduce the risk of electric shock, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air Supply Hose. 1. See Fig. 10. Use the Graco Grounded Air Supply Hose (AH) to supply air to the gun. The gun air inlet fitting has a ...

Gun Setup Gun Setup Gun Setup Checklist See Fig. 11 to locate the electrostatic gun controls. Figure 11 Electrostatic Gun Controls1. Turn OFF (O) the ES On-Off switch (J). 2. Shut off the air bleed valve to the gun. 3. Check gun resistance. See Test Gun Resistance, page 32 . 4. Connect the Graco gro...

Gun Setup Grounding When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Ground all equipment, personnel...

Gun Setup Check Gun Electrical Grounding Megohmmeter Part No. 241079 (AA-see Fig. 16) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:• The gun has been removed from the hazardous area; • Or all spraying dev...

Gun Setup Check Fluid Resistivity To reduce the risk of fire, explosion, or electric shock, check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.Failure to follow this warning could cause fire, explosion, or elec...

Operation Operation Pressure Relief Procedure This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cl...

Maintenance Maintenance 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 compa...

Maintenance Clean the Gun Daily 1. Turn OFF (O) the ES On-Off switch. 2. Follow the Pressure Relief Procedure, page 27 . 3. Remove the air cap/tip guard and spray tip. 4. Flush the gun, see Flushing, page 28 . 5. Follow the Pressure Relief Procedure, page 27 . 6. Clean the outside of the gun with a ...

Maintenance Daily System Care 1. Follow the instructions under Clean the Gun Daily, page 29 . Follow the Pressure Relief Procedure, page 27 . 2. Clean the fluid and air filters. 3. Check for fluid leaks. Tighten all fittings. 4. Clean workpiece hangers. Use non-sparking tools. 5. Check the movement of t...

Electrical Tests Electrical Tests Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. NOTICE The gun body resistor cartridge is part of the body and is not replaceable. To avoid destroying the gun body, do not attempt to ...

Electrical Tests Test Power Supply Resistance 1. Remove the power supply (11). See Power Supply Removal and Replacement, page 45 . 2. Remove the alternator (15) from the power supply. See Alternator Removal and Replacement, page 46 . 3. Measure resistance from the power supply's ground strips (EE) t...

Electrical Tests Test Gun Barrel Resistance 1. Insert a conductive rod (B) into the gun barrel (which was removed for the power supply test) and against the metal contact (C) in the front of the barrel. 2. Measure the resistance between the conductive rod (B) and the conductive ring (9). The resista...

Troubleshooting Troubleshooting Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. To reduce the risk of a skin...

Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Atomizing air pressure too high. Close atomizing air valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage. Excessive spray fog. Fluid too thin. Increase visc...

Troubleshooting Electrical Troubleshooting Problem Cause Solution ES On/Off switch is OFF (O). Turn ON (I). Gun air pressure too low (ES indicator is amber). Check air pressure to gun; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage. Atomizing air pressure too high. Decrease. Fluid...

Repair Repair Prepare the Gun for Service Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. To reduce the risk of ...

Repair Air Cap, Spray Tip, and Fluid Seat Housing Replacement 1. See Prepare the Gun for Service, page 39 . 2. Remove the retainer ring (22) and air cap/tip guard assembly (25). Figure 20 Remove Air Cap 3. Disassemble the air cap assembly. Check the condition of the u-cup (22a), o-ring (25b), and ti...

Repair NOTICE Do not overtighten the fluid seat housing (24). Overtightening may damage the housing and the gun barrel, resulting in improper fluid shutoff. 6. Trigger the gun and install the fluid seat housing (24). Tighten until snug, then 1/4 turn more. 7. Check that the spray tip gasket (27a) is in...

Repair Fluid Tube Removal and Replacement 1. See Prepare the Gun for Service, page 39 . 2. Disconnect the bottom fluid tube nut (C).3. Carefully unscrew the top fluid tube nut (D). NOTICE Be careful not to damage the fluid tube assembly (19) when cleaning or installing it, especially the sealing surfac...

Repair Gun Barrel Removal 1. See Prepare the Gun for Service, page 39 . 2. Disconnect the bottom fluid tube nut (N). Carefully separate the tube assembly (T) from the bracket (7). 3. Loosen the two screws (6). NOTICE To avoid damaging the power supply (11), pull the gun barrel straight away from the ...

Repair Fluid Needle Replacement 1. See Prepare the Gun for Service, page 39 . 2. Remove the air cap assembly and fluid seat housing. See Air Cap, Spray Tip, and Fluid Seat Housing Replacement, page 40 . 3. Remove the gun barrel. See Gun Barrel Removal, page 43 . 4. Remove the trigger screws (13) and ...

Repair Power Supply Removal and Replacement • Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag. • Do not expose gasket (5) to solvents.1. See Prepare the Gun for Service, page 39 . 2. See Gun Barrel Removal, page 43 . NOTICE Be careful when handling the po...

Repair Alternator Removal and Replacement NOTE: Replace alternator bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (♦).1. See Prepare the Gun for Service, page 39 . 2. Remove the power supply/alternator assembly and discon...

Repair Fan Air Adjustment Valve Repair 1. See Prepare the Gun for Service, page 39 . 2. Place a wrench on the flats of the valve assembly (30) and unscrew it from the handle (16).NOTE: You may replace the valve as an assembly (go to step 9 ) or as individual parts (steps 3 - 9 ). 3. Remove the retain...

Repair Atomizing Air Adjustment Valve Repair 1. See Prepare the Gun for Service, page 39 . 2. Place a wrench on the flats of the valve assembly (29) and unscrew it from the handle (16). 3. Inspect the valve assembly. If damaged, install a new valve (29). 4. Before installing the valve assembly in the...

Repair ES On-Off Valve Repair 1. See Prepare the Gun for Service, page 39 . 2. Loosen the captive screw (26p). Remove the valve (26) from the handle. 3. Lubricate the o-rings (26b* and 26g*) with non-silicone grease, Part No. 111265. Do not over-lubricate.NOTE: Do not over-lubricate parts. Excessive...

Repair Air Valve Repair 1. See Prepare the Gun for Service, page 39 . 2. See Gun Barrel Removal, page 43 . 3. Remove the screws (13) and trigger (12).4. Remove the ES On-Off Valve. See ES On-Off Valve Repair, page 50 . 5. Remove the spring (2).6. Push on the front of the air valve shaft to force it ...

Repair Smart Module Replacement If the Error display appears, the Smart Module has lost communication with the power supply. Check for good connections between the Smart Module and the power supply.If the module’s LEDs are not lighting, replace the module.1. See Prepare the Gun for Service, page 39 ...

Repair Air Swivel and Exhaust Valve Replacement 1. See Prepare the Gun for Service, page 39 . 2. To replace the air exhaust valve: a. Remove the clamp (36) and the exhaust tube (35). b. Unscrew the swivel (21) from the gun handle (16). The swivel is a left-hand thread. Remove the bracket (7). c. Pul...

Parts Parts Standard Air-Assisted Spray Gun Assembly Part No. H60T10 60 kV Electrostatic Air-Assisted Spray Gun, Series A Part No. H85T10 85 kV Electrostatic Air-Assisted Spray Gun, Series A 54 3A2495C

Parts Smart Air-Assisted Spray Gun Assembly Part No. H60M10 60 kV Electrostatic Air-Assisted Spray Gun, Series A Part No. H85M10 85 kV Electrostatic Air-Assisted Spray Gun, Series A 56 3A2495C

Parts Alternator Assembly Part No. 24N664 Alternator Assembly Ref. No. Part No. Description Qty 15a 24N705 COIL, alternator 1 15b♦ 24N706 BEARING KIT (includes two bearings, item 15e fan, and one item 15h clip) 1 15d♦ 24N707 HOUSING; includes item 15f 1 15e♦ — — — FAN; part of item 15b 1 Ref. No. Pa...

Parts ES On-Off Valve Assembly Part No. 24N632 ES On-Off Valve Assembly Ref. No. Part No. Description Qty 26a — — — HOUSING, valve 1 26b* 15D371 O-RING 2 26c — — — PISTON, valve 1 26d 24N650 LEVER, ES on-off; includes item 26e 1 Ref. No. Part No. Description Qty 26e — — — SCREW, set, socket head 2 2...

Parts Fan Air Valve Assembly Part No. 24N634 Fan Air Valve Assembly Ref. No. Part No. Description Qty 30a — — — NUT, valve 1 30b — — — STEM, valve 1 30c* 111504 O-RING 1 30d 24N646 RING, retaining; package of 6 1 * These parts are included in Air Seal Repair Kit 24N789 (purchase separately).Parts la...

Parts Air Cap Assembly Part No. 24N727 Air Cap Assembly Ref. No. Part No. Description Qty 25a 24N643 ELECTRODE; package of 5 1 25b 24N734 O-RING; ptfe; package of 5 (also available in package of 10; order 24E459) 1 25c — — — AIR CAP 1 25d 24N726 GUARD, tip, orange 1 Parts labeled — — — are not avail...

Spray Tip Selection Chart Spray Tip Selection Chart AEM Fine Finish Spray Tips Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AEMxxx, where xxx = 3–digit number from the matrix below. Fluid Output fl oz/min (l/min) Maximum Pattern Width at 12 ...

Spray Tip Selection Chart AEF Fine Finish Pre-Orifice Spray Tips Recommended for high finish quality applications at low and medium pressures. AEF tips have a pre-orifice that assists in atomizing sheer thinning materials, including lacquers.Order desired tip, Part No. AEFxxx, where xxx = 3–digit numbe...

Repair Kits, Related Manuals, and Accessories Repair Kits, Related Manuals, and Accessories Gun Part No. Description Manual Description Repair Kits Repair Kit Description 24N789 Air Seal Repair Kit All guns in this manual. 60 kV and 85 kV Air-Assisted Spray Guns Electrostatic Air-Assisted Spray Guns...

Repair Kits, Related Manuals, and Accessories Hoses Grounded Air Hoses 100 psi (0.7 MPa, 7 bar) Maximum Working Pressure 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread Part No. Description AirFlex Flexible Grounded Air Hose (Gray)244963 6 ft (1.8 m) 244964 15 ft (4.6 m) 244965 25 ft...

Dimensions Dimensions Figure 45 Gun Model A, in. (mm) B, in. (mm) C, in. (mm) Weight, oz (g) H60T10 9.7 (246) 9.1 (231) 2.4 (61) 23.2 (659) H85T10 10.7 (272) 9.2 (234) 2.4 (61) 25.8 (732) H60M10 9.8 (249) 9.9 (251) 2.4 (61) 25.7 (728) H85M10 10.8 (274) 9.9 (251) 2.4 (61) 28.3 (801) 66 3A2495C

Technical Data Technical Data Electrostatic Air-Assisted Spray Guns U.S. Metric Maximum Working Fluid Pressure 3000 psi 21 MPa, 210 bar Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar Minimum Air Pressure at Gun Inlet 45 psi 0.32 MPa, 3.2 bar Maximum Fluid Operating Temperature 120°F 48°C Pain...

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 warran...