PES SPRAY TECH PVT. LTD.
OPERATION AND
MAINTENANCE MANUAL
CONTENTS
Models -------------------------------------------------------------- 3
Model Part Number -----------------------------------------------3
Safety Warnings ---------------------------------------------------4
Operation Set-up --------------------------------------------------6
Flushing the Gun ---------------------------------------------------6
Air Pattern Adjustment -------------------------------------------7
Safe Operation ----------------------------------------------------- 8
Daily Gun Maintenance ------------------------------------------ 9
Gun Cleaning Method ------------------------------------------- 10
Troubleshooting --------------------------------------------------11
Repair -------------------------------------------------------------- 12
Parts Description ------------------------------------------------- 13
Replacement of Parts -------------------------------------------- 15
Accessories ---------------------------------------------------------15
Memo --------------------------------------------------------------- 16
1
GUN MODELS
X-102 X-202
X-402
2
MODEL PART NUMBER – PRESSURE FEED
EXAMPLE: PRESSURE FEED SPRAY GUN
X-102 – P13 E2P
Gun Model Number Air Cap
Pressure Feed Nozzle & Needle
MODEL PART NUMBER – GRAVITY FEED
EXAMPLE: GRAVITY FEED SPRAY GUN
X-402 – G13 LV2
Gun Model Number Air Cap
Gravity Feed Nozzle & Needle
3
SAFETY WARNINGS
The following warnings are for the setups, use, grounding, maintenance, and
repair of this equipment. The exclamation point symbol alerts you to a
general warning and the hazard symbol refers to procedure-specific risk.
Refer back to these warnings. Additional, product-specific warnings may be
found throughout the body of this manual where applicable.
Fire and explosion ---- Solvents and coating materials can be
highly flammable or combustible when sprayed. ALWAYS refer to the
coating material suppliers instructions and Paint Specification sheets
before using this equipment.
Users must comply with all local and national codes of practice and
insurance company requirements governing ventilation, fire precautions,
operation and housekeeping of working areas.
Static Electricity can be generated by fluid and/or air passing through
hoses, by the spraying process and by cleaning non- conductive parts with
cloths. To prevent ignition sources from static discharges, earth continuity
must be maintained to the spray gun and other metallic equipment used. It
is essential to use conductive air and/or fluid hoses.
Always wear eye protection when spraying or cleaning the spray
gun Gloves must be worn when spraying or cleaning the equipment.
Noise Levels
The A-weighted sound level of spray guns may exceed 85 dB
(A)
depending on the set-up being used. Details of actual noise levels are
available on request. It is recommended that ear protection is worn at all
times when spraying.
4
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To
help prevent fire and explosion.
Use equipment only in well-ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps,
and plastic drop cloths (Potential static arc).
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords or turn lights on or off when flammable fumes are
present.
Ground all equipment in the work area. See grounding instructions.
If there is static sparking or you feel a shock, stop operation immediately. Do not
use equipment until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
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 Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See
Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s
warnings. For complete information about your material, request MSDS forms from
distributor or retailer.
Check equipment daily. Repair or replace worn or damaged parts immediately with
genuine manufacturer’s replacement parts only.
Do not alter or modify equipment.
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.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the
operating area of the equipment to help protect you from serious injury, including eye injury,
inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited
to:
Protective eyewear
Clothing and respirator as recommended by the fluid and solvent manufacturer
Gloves
Hearing protection
5
OPERATION SET-UP
Connect Air and Fluid Lines
1. Shut off the air supply.
2. Install a shutoff valve (not supplied) downstream of the air regulator to
shut off gun air.
3. Install an inline air filter (not supplied) to clean and dry the gun air
supply.
4. Connect a clean, dry, filtered air supply to the air inlet fitting.
Recommended 8mm ID hose
Check that your booth, air provides adequate airflow, see
Technical Data.
5. Connect a fluid hose to the fluid inlet fitting.
6. Connect other end of the fluid hose to a regulated fluid supply line.
FLUSHING THE GUN
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is left in the fluid
passages to protect Parts. To avoid contaminating your fluid with oil, flush
the equipment with a compatible solvent before using the equipment.
6
AIR PATTERN ADJUSTMENTS
Adjust Spray Pattern
1. Rotate the air cap to achieve desired spray pattern.
2. To achieve full fan pattern, open the air control valve by turning the
knob fully Counter clockwise.
3. To create a round pattern, turn the pattern air off by turning the air
control valve fully clockwise.
4. Trigger gun and adjust gun air pressure. Refer to Technical Data, for
inlet air Pressure recommendations.
5. To establish the correct fluid flow, turn the fluid control valve
counterclockwise until no Restriction of the trigger movement is felt,
then turn out another half turn.
6. Adjust fluid pressure to achieve desired fluid flow rate.
7. To reduce fluid flow, turn the fluid control valve clockwise.
If you cannot achieve the correct fluid flow with the fluid control
valve, a different sized nozzle may be necessary. For smaller fluid
flow, use the next size smaller Nozzle. For a larger fluid flow, use the
next size larger nozzle.
8. Spray a test pattern. Evaluate the spray pattern size and atomization.
9. To achieve a narrow spray pattern, turn air control valve clockwise.
7
SAFE OPERATION
Operating
Spray Equipment using high pressures may subject to recoil forces. Under
certain circumstances, such forces could result in repetitive strain injury to
the operator.
Pressure Relief Procedure
Trapped air can cause the pump to cycle unexpectedly, which could result in
serious injury from splashing or moving parts.
1. Turn off air and fluid supply.
2. Hold a metal part of the gun firmly to a grounded metal pail. Trigger
the gun to relieve pressure.
Apply Fluid
1. Turn on air and fluid supply to the gun. Set atomizing pressure and
fluid pressure with the gun fully triggered.
2. Adjust the pattern size and shape.
3. To achieve the best results when applying fluid:
Keep the gun perpendicular and 6 to 8 inches (150 to 200 mm) from
object being sprayed.
Use smooth, parallel strokes across the surface to be sprayed with
50% overlap.
NOTE: See Troubleshooting, if you experience an irregular pattern.
8
DAILY GUN MAINTENANCE
General Tasks
Frequently lubricate the gun moving parts with a drop of non-silicone
oil.
Do not disassemble the spray gun if you are having a spray pattern
problem. See Troubleshooting, for information on how to correct the
problem.
Follow the Pressure Relief Procedure,
Clean the fluid and air filters daily.
Check for any fluid leakage from gun and fluid hoses.
Flushing
Flush before changing colors, 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 if necessary. Flush with a fluid that is
compatible with the fluid being dispensed and the equipment wetted parts.
1. Follow Pressure Relief Procedure
2. Disconnect the fluid supply hose and air supply hose from gun.
3. Connect the solvent supply hose to the gun.
4. Start the pump, Always use the lowest possible fluid pressure when
flushing.
5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger
the gun until clean solvent dispenses then turn off solvent supply.
9
GUN CLEANING METHOD
Notes: - Do not submerge the gun in solvent. Solvent dissolves
lubricant, dries out packing, and clogs air passages, and affect O-rings,
leading to Air leakage from the gun.
Do not use metal tools to clean air cap holes as this may scratch them
and distort the spray pattern.
Use a compatible solvent.
1. Flush the Spray Gun,
2. Remove air cap, trigger the gun to release the pressure build up,
remove nozzle, and soak both in a compatible solution.
3. Dip the end of a soft-bristle brush into a compatible solvent. Do not use
a wire brush. With the gun pointed down, clean the front of the gun,
using a soft-bristle brush and compatible solvent.
4. Scrub the air cap retaining ring, air cap, and fluid nozzle with the soft-
bristle brush.
5. To clean out air cap holes, use a soft implement, such as a toothpick, to
avoid damaging critical surfaces.
6. Clean the air cap and fluid nozzle daily, minimum. Some applications
require more frequent cleaning.
7. Do not soak the air-cap retaining ring in solvent for prolonged periods
of time, as it can damage the Air Cap.
8. Trigger the gun while you install the fluid nozzle with the gun tool, if
trigger is not pulled, it can damage the Nozzle & Needle. Tighten the
nozzle securely to obtain a good seal.
9. Install the retaining ring and air cap.
10. Soak a soft cloth with solvent point the gun down and wipe off the
outside of the gun.
11. After cleaning the gun, lubricate the following
a. Fluid control valve threads
b. Trigger pivot pin
c. Fluid needle shaft
d. Air Valve – O-Ring
10
TROUBLESHOOTING
Problem Cause Solution
Spray Pattern (OK) Normal pattern. No action necessary
Spray Pattern Wrong (Heavy Dirty or damaged air cap or Rotate air cap 180°
top or bottom) Fluid nozzle If pattern follows air cap, problem
is in air cap. Clean and inspect. If
pattern is not corrected,
Replace air cap
If pattern does not follow the air
cap, the problem is with the fluid
nozzle, clean and inspect the
nozzle. If the pattern is not
corrected, replace nozzle
Spray Pattern Wrong Pressure too high for viscosity of Reduce air pressure and increase
(Split pattern) the material being sprayed material viscosity
Correct pattern by narrowing fan
size with the fluid control valve
Spray Pattern Wrong Dirty or distorted air horn holes Clean and inspect air cap
If pattern is not corrected, replace
air cap
Gun spitting Air getting into paint stream Check if fluid source is empty and
fill. Tighten fluid nozzle check and
tighten needle packing set & Check
fluid nozzle for damage
Will not spray Fluid control valve turned too far Adjust fluid control valve
clockwise counterclockwise.
Fluid source empty Refill
Excessive air blowing back Loose fluid nozzle Tighten fluid nozzle
Damaged fluid nozzle seal Replace seal
Excessive air leak behind Worn air valve Seat Set Replace
trigger Worn trigger
Gun fluid pressure is too high Using needle/nozzle set with too Use needle/nozzle Set with larger
with gun triggered (cannot small orifice orifice
achieve desired flow rate)
Fluid flow is fluttering while Fluid filter clogged Check fluid filter
Spraying Fluid source empty Refill
Fluid flow fades while spraying Air hose size is too restricted for Use 8mm I.D. air hose
high viscosity fluids higher air flow being used
11
REPAIR
See Parts Page
1. Remove air cap and Check O-ring (Black) and replace if necessary.
2. Trigger gun while unscrewing nozzle to prevent needle damage.
3. Remove Fluid Adjusting Knob, Fluid Spring, Needle, Fluid Adjusting
Guide and inspect. Replace Needle and Guide if necessary.
4. Remove Air Valve spring and push the Air Valve Assembly out from the
back of the gun, inspect. Replace Air Valve Assembly if necessary.
5. Remove Air Valve Guide & Air Valve Seat Set with 10 No. A-N Key,
check the O-Ring, and Replace the Seat Set and the O-Ring if Necessary.
6. Remove E-Locking Ring, Stud and Trigger and wash it properly, and
reinstall.
7. Unscrew Needle Packing Set and Replace the Set.
8. Remove Air Adjusting Valve Set, inspect and replace if necessary.
9. Remove Pattern Adjuster Valve Set, check and if necessary replace the
same.
NOTE: - Do not remove the Fluid Connector (Paint Inlet Point) fitting as it
was attached to the gun body with permanent thread locker. There is also no
need to remove the Air Connector (Air Inlet Point) Fitting.
Re-Assembly
1. Install Air Adjusting Valve Set, Lubricate with Grease.
2. Install Pattern Adjusting Set, Lubricate with Grease.
3. Install Air Valve Guide and Air Valve Seat Set using proper tools.
4. Install Air Valve, Air Valve Spring and Fluid Adjusting Guide.
5. Install Fluid Needle Packing Set.
6. Then place Needle and Needle Spring, slightly lubricate the spring and
install Fluid Adjusting Knob. Lubricate Needle with Grease, which does
not contain Silicon.
7. Trigger gun while replacing Paint Nozzle.
8. Install Air Cap assembly.
9. Lubricate and Trigger Stud for free movement and install Trigger, and
E-Locking Ring.
12
PARTS LIST
Model -- X–102
13
Ref. No Description Part Number Quantity
1 Air Cap Set P-101 1
2 Fluid Nozzle P-102 1
4 Fluid Needle Packing Set P-104 1
5 Pattern Adjusting Valve Set P-105 1
6 Air Valve Guide P-106 1
7 Fluid Adjusting Guide P-107 1
8 Fluid Adjusting Knob P-108 1
9 Fluid Needle Spring P-109 1
10 Fluid Needle Set P-110 1
12 Gun Body P-112 1
13 Air Connector P-113 1
14 Air Adjusting Valve Set P-114 1
15 E Locking Ring P-115 1
16 Trigger Stud P-116 1
17 Trigger P-117 1
18 Air Valve Spring P-118 1
19 Air Valve P-119 1
20 Air Valve Seat Set P-120 1
21 O – Ring P-121 1
22 Fluid Connector P-122 1
Replacement of Parts
1. Nozzle and Needle – Remove parts in the following order 2 and 3, 4.
Replace any other worn or damaged parts and re-assemble in reverse order.
2. Fluid Packing Set – Remove Fluid Packing Set, check for any damage &
re-assemble parts and Tight Packing Set with spanner sufficient to seal but
to allow free movement of needle. Lubricate the same with silicone free
grease.
3. Air valve – Remove parts Clean or replaces Valve. Reassemble parts in
reverse order.
Accessories
1. Spanner
2. Cleaning Brush
3. Operation Manual
14
PARTS LIST
Model -- X–202
15
Ref. No Description Part Number Quantity
1 Air Cap Set P-201 1
2 Fluid Nozzle P-202 1
4 Fluid Needle Packing Set P-104 1
5 Pattern Adjusting Valve Set P-205 1
6 Air Valve Guide P-106 1
7 Fluid Adjusting Guide P-107 1
8 Fluid Adjusting Knob P-108 1
9 Fluid Needle Spring P-109 1
10 Fluid Needle Set P-210 1
11 Gun Body P-211 1
12 Air Connector P-112 1
13 Air Adjusting Valve Set P-113 1
14 E Locking Ring P-114 1
15 Trigger Stud P-115 1
16 Trigger P-116 1
17 Air Valve Spring P-117 1
18 Air Valve P-118 1
19 Air Valve Seat Set P-119 1
20 O – Ring P-120 1
21 Fluid Connector P-221 1
Replacement of Parts
1. Nozzle and Needle – Remove parts in the following order 2 and 3, 4.
Replace any other worn or damaged parts and re-assemble in reverse order.
2. Fluid Packing Set – Remove Fluid Packing Set, check for any damage &
re-assemble parts and Tight Packing Set with spanner sufficient to seal but
to allow free movement of needle. Lubricate the same with silicone free
grease.
3. Air valve – Remove parts Clean or replaces Valve. Reassemble parts in
reverse order.
Accessories
1. Spanner
2. Cleaning Brush
3. Operation Manual
16
PARTS LIST
Model -- X–402
17
Ref. No Description Part Number Quantity
1 Air Cap Set P-402 1
2 Fluid Nozzle P-402 1
4 Fluid Needle Packing Set P-104 1
5 Pattern Adjusting Valve Set P-405 1
6 Air Valve Guide P-106 1
7 Fluid Adjusting Guide P-107 1
8 Fluid Adjusting Knob P-108 1
9 Fluid Needle Spring P-109 1
10 Fluid Needle Set P-410 1
12 Gun Body P-412 1
13 Air Connector P-113 1
14 Air Adjusting Valve Set P-114 1
15 E Locking Ring P-115 1
16 Trigger Stud P-116 1
17 Trigger P-117 1
18 Air Valve Spring P-118 1
19 Air Valve P-119 1
20 Air Valve Seat Set P-120 1
21 O – Ring P-121 1
22 Fluid Connector P-422 1
23 Fluid Filter P-423 1
Replacement of Parts
1. Nozzle and Needle – Remove parts in the following order 2 and 3, 4.
Replace any other worn or damaged parts and re-assemble in reverse order.
2. Fluid Packing Set – Remove Fluid Packing Set, check for any damage &
re-assemble parts and Tight Packing Set with spanner sufficient to seal but
to allow free movement of needle. Lubricate the same with silicone free
grease.
3. Air valve – Remove parts Clean or replaces Valve. Reassemble parts in
reverse order.
Accessories
1. Spanner
2. Cleaning Brush
3. Operation Manual
18
MEMO
PES SPRAY TECH PVT. LTD.
736-D, SEC-37, PACE CITY-II
Gurgaon, Haryana – 122001, INDIA
PES SPRAY TECH PVT. LTD.
#G-27, BLOCK-2, ARUN EXCELLO VASANTHAA
183, SH-48, VANDALUR-WALAJABAD ROAD KARANAITHANGAL-PADAPAI,
SRIPERUMBUDUR TALUK, KANCHEEPURAM DIST.-601301(TAMIL NADU)
PES SPRAY TECH UK. LTD.
Hampton House Oldham Road
Middleton, Manchester
United Kingdom
M24 1GT
PES SPRAY TECH PVT. LTD.
736-D, SEC-37, PACE CITY-II, Gurgaon (Haryana) –122001
Mob –9910106841, Website – www.pesspray.com
Email:
[email protected]
