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Instructions - Parts Pro Xp™ Xp™ Electrostatic Xp™ Electrostatic Electrostatic Air Air Spray Spray Spray 3A2494D For use use in in in Class Class I, I, I, Div. Class Div. Div. I I I Hazardous Hazardous Locations Hazardous Locations Locations using using using Group Group...
Air Cap and Nozzle Replacement....38 Hoses ............75 Electrode Replacement ........ 39 Fluid Packing Rod Removal......40 Dimensions ............76 Packing Rod Repair ........40 Technical Data ........... 77 Barrel Removal ..........42 Barrel Installation ......... 42 Graco Pro Xp Warranty ........78 3A2494D...
Models Models Models Models Part Part No. Part Nozzle Nozzle Nozzle Standard Standard Standard Smart Smart Smart Standard Standard Standard High High High Increased Increased Increased Display Display Display Display Display Display Coatings Coatings Coatings Conductivity/ Conductivity/ Conductivity/ Transfer Transfer Transfer Round Round...
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray area. Resistance must not exceed 1 megohm. See Grounding Grounding Grounding instructions. • Only use grounded Graco conductive air supply hoses. • Do not use pail liners unless they are conductive and grounded. • Stop Stop...
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Warnings WARNING WARNING WARNING PRESSURIZED PRESSURIZED PRESSURIZED EQUIPMENT EQUIPMENT EQUIPMENT HAZARD HAZARD HAZARD Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow the Pressure Pressure Pressure Relief Relief Relief Procedure Procedure...
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Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD 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 Technical Data Data in all equipment manuals.
Gun Overview Gun Overview Overview Overview How the the Electrostatic Electrostatic Spray Spray Gun Gun Works Works Electrostatic Spray Works The air hose supplies air to the spray gun. Part of The pump supplies fluid to the fluid hose and gun, the air operates the alternator turbine and the rest where the fluid is electrostatically charged as it of the air atomizes the fluid being sprayed.
Air Swivel 1/4 npsm(m) left-hand thread, Fluid Ad- Adjusts fluid flow by limiting Inlet for Graco grounded air supply justment fluid needle travel. Use only hose. Knob in low flow conditions, to reduce wear. Fluid Inlet 3/8 npsm(m), for fluid supply hose.
Gun Overview Smart Guns Guns Smart Smart Guns Voltage Voltage Adjustment Voltage Adjustment Switch Adjustment Switch Switch 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 The voltage adjustment switch (VA) allows the spraying voltage.
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Gun Overview Error Error Error Display Display Display for your gun. Continue pressing the button until you reach the desired setting. If the Smart module loses communication with NOTE: NOTE: After 2 seconds of inactivity the display will NOTE: the power supply, the Error display appears, the return to the Operating Screen.
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Gun Overview Table 1 1 1 . . . Key Key for for Figs. Figs. 2–9. 2–9. Table Table Figs. 2–9. Item Description Purpose Item Item Description Description Purpose Purpose Voltage Adjustment Switch Two-position switch sets smart gun voltage to low setting (LO) or high setting (HI).
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Gun Overview Item Description Purpose Item Item Description Description Purpose Purpose LO Display Appears on the Low Voltage Lock Screen. See Fig. 9. Error Display Appears if the Smart module loses communication with the power supply. See Fig. 3. Voltage Indicator In Diagnostic Mode, the two top right LEDs of the screen light, indicating that the value displayed...
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Gun Overview Diagnostic Diagnostic Diagnostic Mode Mode Mode Diagnostic Mode includes four screens which display gun data: • Voltage (kiloVolts) Screen • Current (microAmperes) Screen • Alternator Speed (Hertz) Screen • Low Voltage Lock Screen NOTE: You must be in Operating Mode to adjust the NOTE: NOTE: low voltage setting;...
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Gun Overview Alternator Alternator Alternator Speed Speed (Hertz) Speed (Hertz) (Hertz) Screen Screen Screen Low Voltage Voltage Lock Voltage Lock Screen Lock Screen Screen The Alternator Speed (Hertz) Screen is the third The Low Voltage Lock Screen is the fourth screen in screen in the Diagnostic Mode.
It is not an actual system design. For assistance velocity requirements. in designing a system to suit your particular needs, contact your Graco distributor. High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.
3. Install a fluid filter (FF) near the pump outlet, to remove particles and sediment which could clog 1. See Fig. 10. Use the Graco Grounded Air Supply the spray nozzle. Hose (AH) to supply air to the gun. The gun air inlet fitting has a left-hand thread.
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Air Line Drain Valve Fluid Shutoff Valve Air Filter/Water Separator Gun Air Pressure Regulator Gun Air Hose Ground Wire Main Air Supply Line Graco Grounded Air Hose (left-hand Pump Ground Wire threads) Pump Air Pressure Regulator Pump Air Line Lubricator Supply Pump Pump Bleed-Type Air Shutoff Valve Ventilation Fan Interlock Solenoid Valve.
Setup Checklist Checklist Setup Checklist See Fig. 11 to locate the electrostatic gun controls. 5. Connect the Graco grounded air hose to the gun air inlet. The gun air inlet fitting has left-hand threads. 6. Follow all steps under Grounding, page 7.
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Gun Setup 13. Fully open the fan air adjustment valve (F) 17. Set the gun air regulator to deliver a minimum counterclockwise. 45 psi (0.32 MPa, 3.2 bar) at the gun when triggered, to ensure full spraying voltage. See the table below. Table Table Table 2 2 2 .
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Gun Setup 19. Shut off the air to the gun. Turn OFF (O) the ES 22. Spray a test pattern. Check the atomization. If On-Off switch (J). over-atomization occurs at minimum pressure, adjust the restrictor valve. If atomization is inadequate, increase air pressure or decrease fluid flow.
Electrostatic Air Spray Gun: • ground the gun by connecting the Graco Grounded Air Hose (AH) to the gun, and connecting the air hose ground wire to a true earth ground. See Check Gun Electrical Grounding, page 3A2494D...
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If gloves are necessary, wear the conductive gloves supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle.
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Gun Setup Figure 12 Ground the Operator Figure 13 Ground the Object Being Sprayed 3A2494D...
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Gun Setup Figure 14 Ground the Gun Figure 15 Ground the Fluid Supply 3A2494D...
7. If the resistance is greater than 1 megohm, check the tightness of the ground connections and be Graco Part No. 241079 Megohmmeter is available sure the air hose ground wire is connected to a as an accessory to check that the gun is properly true earth ground.
3. Record the fluid type, elapsed time, and size of Graco Part No. 722886 Resistance Meter and the viscosity cup. 722860 Probe are available as accessories to check 4. If the viscosity is too high or too low, contact the that the resistivity of the fluid being sprayed meets material supplier.
Operation Operation Operation Operation Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 4. Open the pump drain valve, having a waste container ready to catch the drainage. Leave the pump drain valve open until you are ready to spray again. 1.
Maintenance Maintenance Maintenance Maintenance Flushing Flushing Flushing • Flush before changing fluids, before fluid can dry 2. Follow the Pressure Relief Procedure, page 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.
Maintenance Clean the the Gun Gun Daily Daily Clean Clean Daily 1. Turn OFF (O) the ES On-Off switch. 5. Remove the air cap. 2. Flush the gun. See Flushing, page 6. Clean the air cap, retaining ring, and nozzle with a soft brush and compatible solvent.
Maintenance Daily System System Care Care Daily Daily System Care 1. Follow the Pressure Relief Procedure, page 4. Clean workpiece hangers. Use non-sparking tools. 2. Clean the fluid and air filters. 3. Check for fluid leaks. Tighten all fittings. 5. Check the movement of the trigger and valves. Lubricate if necessary.
Electrical Tests Electrical Tests Tests Electrical Electrical Tests Test Gun Gun Resistance Resistance Test Test Resistance Use the following procedures to test the condition of the power supply and gun body, and electrical continuity between components. 1. Flush and dry the fluid passage. Use megohmmeter Part No.
5. If you still have problems, refer to Electrical Troubleshooting, page 35 other possible causes of poor performance, or contact your Graco distributor. 6. Be sure the spring (11a) is in place before reinstalling the power supply. Figure 19 Test Electrode Resistance...
Troubleshooting Troubleshooting Troubleshooting Troubleshooting Installing and servicing this equipment requires To reduce the risk of an injury, follow the access to parts which may cause an electric shock Pressure Relief Procedure, page 27, whenever or other serious injury if the work is not performed you are instructed to relieve the pressure.
Troubleshooting Gun Operation Operation Troubleshooting Troubleshooting Operation Troubleshooting Problem Problem Problem Cause Cause Cause Solution Solution Solution Excessive spray fog. Atomizing air pressure too high. Close restrictor valve part way, or decrease air pressure as low as possible; minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.
Troubleshooting Electrical Troubleshooting Troubleshooting Electrical Electrical Troubleshooting Problem Problem Problem Cause Cause Cause Solution Solution Solution Poor wrap. ES On/Off switch is OFF (O). Turn ON (I). Gun air pressure too low (ES Check air pressure to gun; indicator is amber). minimum 45 psi (0.32 MPa, 3.2 bar) needed at gun for full voltage.
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Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution Voltage/current display stays red Gun is too close to the part being Gun should be 8–12 in. (200–300 (smart guns only). sprayed. mm) from the part. Check fluid resistivity. Check Fluid Resistivity, page Dirty gun.
Service Prepare Prepare Service • Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models. • Air Seal Repair Kit 24N789 is available. The kit must be purchased separately. Kit parts are Installing and repairing this equipment requires marked with an asterisk, for example (6a*).
(4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part. NOTICE NOTICE NOTICE Use non-silicone grease, Part No.
Repair Electrode Replacement Replacement Electrode Electrode Replacement 1. See Prepare the Gun for Service, page 2. Remove the air cap and nozzle. See Air Cap and Nozzle Replacement, page 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.
Repair Fluid Packing Packing Rod Rod Removal Removal Packing Rod Rod Repair Repair Fluid Fluid Packing Removal Packing Packing Repair NOTE: You may replace the packing rod as individual 1. See Prepare the Gun for Service, page NOTE: NOTE: parts or as an assembly. 2.
Repair Assemble Assemble Assemble the the Packing Packing Rod Packing NOTE: NOTE: Before installing the fluid packing rod into the NOTE: 4. Lightly tighten the packing nut (2f). The packing gun barrel, make sure the internal surfaces of the nut is properly tightened when there is 3 lb (13.3 barrel are clean.
Repair Barrel Removal Removal Barrel Installation Installation Barrel Barrel Removal Barrel Barrel Installation 1. See Prepare the Gun for Service, page 1. Be sure the gasket (28*) and grounding spring (18) are in place. Make sure the gasket air 2. Carefully loosen the nut (N) from the bracket fluid holes are aligned properly.
Repair Power Supply Supply Removal Removal and Power Power Supply Removal 9. Insert the power supply/alternator assembly in Replacement the gun handle (16). Make sure the ground strips Replacement Replacement (EE) make contact with the handle. On Smart models, align the connector of the 6–pin flexible •...
Repair Alternator Removal Removal and and Replacement Replacement Alternator Alternator Removal Replacement NOTE: Replace alternator bearings after 2000 hours NOTE: NOTE: of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (♦). 1.
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Repair 12. Hold the coil assembly (15a) on a workbench Ensure that the blades of the bottom bearing with the fan end facing up. Press the fan (15e♦) (15b1♦) align with the tabs. onto the long end of the shaft (S). The fan blades 15.
Repair Fluid Tube Tube Removal Removal and and Replacement Replacement Fluid Fluid Tube Removal Replacement 1. Remove the nut (22) from the bracket (20). 2. Loosen the fitting (9) to remove the fluid tube (14) from the barrel (1). 3. Apply dielectric grease (44) to the threads of the fitting (9) and the o-ring (10).
Repair Fan Air Air Adjustment Adjustment Valve Valve Repair Repair Adjustment Valve Repair 1. See Prepare the Gun for Service, page 8. Reassemble the retaining ring (30d). Unscrew the valve stem from the housing until it is stopped 2. Place a wrench on the flats of the valve housing by the retaining ring.
Repair Atomizing Air Air Restrictor Restrictor Valve Valve Repair Repair Atomizing Atomizing Restrictor Valve Repair 1. See Prepare the Gun for Service, page 2. Place a wrench on the flats of the valve housing (29a) and unscrew the valve from the handle (16).
Repair ES On On - - - Off Off and and Fluid Fluid Adjustment Adjustment Valve Valve Repair Repair Fluid Adjustment Valve Repair 1. See Prepare the Gun for Service, page gun air passage and blemish the finish on the workpiece.
Repair Air Valve Valve Repair Repair Valve Repair 1. See Prepare the Gun for Service, page 8. Install the air valve (23) and spring (34) into the gun handle (16). 2. See Barrel Removal, page 9. Install the ES On-Off Valve. See ES On-Off and 3.
Repair Smart Module Module Replacement Replacement Smart 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.
Repair Air Swivel Swivel and and Exhaust Exhaust Valve Valve Swivel Exhaust Valve b. Apply thread sealant to the top threads of the Replacement swivel. Screw the swivel into the gun handle. Replacement Replacement Torque to 75–85 in-lb (8.4–9.6 N•m). 1.
Parts Parts Parts Parts Standard Air Air Spray Spray Gun Gun Assembly Assembly Standard Standard Spray Assembly Part No. No. L40T10 L40T10 40 40 kV kV Electrostatic Electrostatic Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L40T10 Electrostatic...
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Parts Part No. No. L40T10 L40T10 40 40 kV kV Electrostatic Electrostatic Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L40T10 Electrostatic Spray Gun, Series Part No. No. L40T14 L40T14 40 40 kV kV High High Efficiency Efficiency Electrostatic Electrostatic Air...
Parts Ref. Ref. Ref. Part Part No. Part Description Description Description Ref. Ref. Ref. Part Part Part No. Description Description Description 185103 24N603 TUBE, exhaust; 1/4 in. (6 mm) COVER, gun, 40 and 60 kV ID (shipped loose) guns; package of 10 107460 24N604 TOOL, wrench, ball end;...
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Parts Standard High High Conductivity Conductivity Air Air Spray Spray Gun Gun Assembly Assembly Standard Standard High Conductivity Spray Assembly Part No. No. L40T16 L40T16 40 40 kV kV Electrostatic Electrostatic High High Conductivity Conductivity Air Air Spray Spray Gun, Gun, Series Series A A A Part...
Parts Part No. No. L40T16 L40T16 40 40 kV kV Electrostatic Electrostatic High High Conductivity Conductivity Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L40T16 Electrostatic High Conductivity Spray Gun, Series Part No. No. L40T15 L40T15 40 40 kV kV High...
Parts Smart High High Conductivity Conductivity Air Air Spray Spray Gun Gun Assembly Assembly Smart Smart High Conductivity Spray Assembly Part No. No. L60M16 L60M16 60 60 kV kV Electrostatic Electrostatic High High Conductivity Conductivity Air Air Spray Spray Gun, Gun, Series Series A A A Part...
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Parts Part No. No. L60M16 L60M16 60 60 kV kV Electrostatic Electrostatic High High Conductivity Conductivity Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L60M16 Electrostatic High Conductivity Spray Gun, Series Part No. No. L85M16 L85M16 85 85 kV kV Electrostatic...
Parts Smart Air Air Spray Spray Gun Gun Assembly Assembly Smart Smart Spray Assembly Part No. No. L60M10 L60M10 60 60 kV kV Electrostatic Electrostatic Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L60M10 Electrostatic Spray Gun, Series...
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Parts Part No. No. L60M10 L60M10 60 60 kV kV Electrostatic Electrostatic Air Air Spray Spray Gun, Gun, Series Series A A A Part Part L60M10 Electrostatic Spray Gun, Series Part No. No. L60M12 L60M12 60 60 kV kV Electrostatic Electrostatic Air Air Spray Spray Gun,...
Parts Packing Rod Rod Assembly Assembly Packing Packing Assembly Part No. No. 24N653 24N653 40 40 kV kV Packing Packing Rod Rod Assembly Assembly Part Part 24N653 Packing Assembly Includes items 2a-2k Part No. No. 24N654 24N654 60 60 kV kV Packing Packing Rod Rod Assembly...
Parts Alternator Assembly Assembly Alternator Alternator Assembly Part No. No. 24N664 24N664 Alternator Alternator Assembly Assembly Part Part 24N664 Alternator Assembly Part Description Part Description Ref. Ref. Ref. Part Part Description Description Ref. Ref. Ref. Part Part Description Description 24N705 COIL, alternator CAP, housing;...
Parts ES On On - - - Off Off and and Fluid Fluid Adjustment Adjustment Valve Valve Fluid Adjustment Valve Part No. No. 24N630 24N630 ES ES On-Off On-Off and and Fluid Fluid Adjustment Adjustment Valve Valve Part Part 24N630 On-Off Fluid Adjustment...
Parts Fan Air Air Adjustment Adjustment Valve Valve Assembly Assembly Atomizing Air Air Restrictor Restrictor Valve Valve Adjustment Valve Assembly Atomizing Atomizing Restrictor Valve Assembly Assembly Assembly Part No. No. 24N634 24N634 Fan Fan Air Air Adjustment Adjustment Valve Valve Assembly Assembly Part Part...
Parts Smart Module Module Assembly Assembly Smart Smart Module Assembly Ref. Part No. Description Ref. Ref. Part Part Description Description Part No. No. 24N756 24N756 Smart Smart Module Module Assembly Assembly Part Part 24N756 Smart Module Assembly — — — CARTRIDGE 24P433 GASKET...
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Parts High Conductivity Conductivity Fluid Fluid Tube Tube Assembly Assembly High High Conductivity Fluid Tube Assembly Part No. No. 24N627 24N627 40 40 kV kV High High Conductivity Conductivity Fluid Fluid Tube Tube Assembly Assembly Part Part 24N627 High Conductivity Fluid Tube Assembly...
Air Caps and Fluid Nozzles Air Caps Caps and and Fluid Fluid Nozzles Nozzles Caps Fluid Nozzles Fluid Nozzle Nozzle Selection Selection Chart Chart Fluid Nozzle Nozzle Performance Performance Charts Charts Fluid Fluid Nozzle Selection Chart Fluid Fluid Nozzle Performance Charts Use the following procedure to select the proper fluid nozzle for your application.
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Air Caps and Fluid Nozzles Table 5 5 5 . . . Orifice Orifice Size: Size: 0.75 0.75 mm mm (0.030 (0.030 in.) in.) Table 8 8 8 . . . Orifice Orifice Size: Size: 1.5 1.5 mm mm (0.059 (0.059 in.) in.) Table...
Air Caps and Fluid Nozzles Air Cap Cap Selection Selection Chart Chart Selection Chart NOTE: NOTE: All air cap pattern shapes and lengths in the NOTE: following chart were measured under the following conditions. Pattern shape and length are material dependent.
Air Caps and Fluid Nozzles Air Consumption Consumption Charts Charts Consumption Charts Key to to to Air Air Consumption Consumption Charts Charts Consumption Charts TEST TEST CONDITIONS: TEST CONDITIONS: CONDITIONS: Fan valve fully open; 85 kV gun. 5/16 in. x 25 ft (8 mm x 7.6 m) hose 5/16 in.
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Air Caps and Fluid Nozzles Table 15 15 . . . 24N274 24N274 Air Air Cap Table 17 17 . . . 24N453 24N453 Air Air Cap Table Table 24N274 Table Table 24N453 AIR CON- CON- CON- AIR CON- CON- CON- SUMPTION SUMPTION...
Repair Kits, Related Manuals, and Accessories Repair Kits, Kits, Related Related Manuals, Manuals, and and Accessories Accessories Repair Repair Kits, Related Manuals, Accessories Gun Part Part Part Description Description Description Manual Manual Description Manual Description Description Repair Repair Repair Kits Kits Kits Repair...
Ground Wire and Clamp. 24R038 Conversion Kit. 16P802 English Warning Sign. Available at 24R038 Voltage Tester Conversion Kit. no charge from Graco. Converts the 245277 Test Fixture for 16P798 English Daily Care Sign. use with the Pro Xp Gun alternator. See manual 406999.
Repair Kits, Related Manuals, and Accessories Hoses Hoses Hoses Grounded Air Air Hoses Hoses Grounded Grounded 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. Part Description Description...
Dimensions Dimensions Dimensions Dimensions Gun Model Model Model A, A, A, in. in. in. (mm) (mm) (mm) B, B, B, in. in. in. (mm) (mm) (mm) C, C, C, in. in. in. (mm) (mm) (mm) Weight, Weight, oz oz Weight, oz (g) L40T10 8.7 (221)
Technical Data Technical Data Data Technical Technical Data Electrostatic Air Air Spray Spray Guns Guns Electrostatic Electrostatic Spray Guns U.S. U.S. U.S. Metric Metric Metric Maximum Working Fluid Pressure 100 psi 0.7 MPa, 7.0 bar Maximum Working Air Pressure 100 psi 0.7 MPa, 7.0 bar Minimum Air Pressure at Gun Inlet 45 psi...
Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months from the date of sale.