Smith AirVerter Stencil Pro CT-100 User manual

© 2000 Smith Eastern Corporation
StencilProStencilPro
Smith Eastern Corporation
10630-S Riggs Hill Road •Jessup, Maryland 20794-9425 USA
301.497.7600 •800.937.HVLP (4857) •Fax [phone]
[email protected] •www.airverter.com
ComplianceCompliance •• QualityQuality •• PerformancePerformance •• ReliabilityReliability
HVLP PAINT SPRAY SYSTEM
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Stencil Pro ModelsStencil Pro Models
CT-100CT-100
CT-200CT-200

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Why AirVerter Spray Gun Systems Work Better
To accomplish effective atomization of a liquid at low pressure (below 10 PSI) it is necessary to
substantially decrease pressure (PSI) and increase air volume (CFM). AirVerter®systems, by design, do
not exceed 10 PSI at the spray head and prevent the operator from taking AirVerter®spray guns out of
compliance with EPA and California’s South Coast Air Quality Management District (SCAQMD)
regulations.
Please Read This Owner’s Manual BEFORE
Using Your Stencil Pro Spray Gun
DO NOT OPERATE THIS EQUIPMENT WITHOUT USING PROPER
PERSONAL SAFETY EQUIPMENT INCLUDING RESPIRATOR, GOGGLES
AND SAFETY CLOTHING. OBSERVE ALL PRECAUTIONS RELATED TO
SPRAYING. WARNING
THIS EQUIPMENT IS OPERATED USING PRESSURIZED AIR. ALWAYS
DISCONNECT SPRAY GUN FROM AIR AND FLUID HOSES AND
DEPRESSURIZE SYSTEM PRIOR TO ANY MAINTENANCE OR
DISASSEMBLY PROCEDURE.
WARRANTY
Smith Eastern Corporation warrants to the Purchaser that the Stencil Pro (CT-100) Spray Gun is
free from defects in material or workmanship under normal use and service for a period of twelve
(12) months from the date of purchase. Should any failure appear during this period, Smith
Eastern shall, if given prompt written notice by the Purchaser, correct such nonconformity by repair
or replacement of the nonconforming part, F.O.B. Smith Eastern’s repair facility. Repair parts are
warranted for ninety (90) days from the date of shipment, but repairs or replacements to original
equipment shall not renew or extend the warranty period of such equipment. Equipment and parts
furnished by Smith Eastern but manufactured by others shall be limited to the warranty offered by
the manufacturer thereof.
Smith Eastern reserves the right to limit this warranty in cases of misuse or abuse. Any
modifications to spray guns or recommended procedures will void the warranty.
The foregoing warranty is exclusive and in lieu of other warranties of quality or performance,
expressed, implied or statutory, including any warranties of merchantability or of fitness for a
particular purpose.

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
EQUIPMENT REQUIREMENTS
Air Compressor
Air compressors used with AirVerter®Spray Guns
must be able to HOLD a minimum of 40 PSI while
spraying. Note: Position a pressure gauge in
the air hose nearest the spray gun to be assured
of the PSI required to satisfactorily spray your
coating.
High Pressure Air Hose
A. Air hose lengths up to 50 feet MUST have an
I.D. of 3/8" including fittings.
B. Air hose lengths greater than 50 feet MUST
have an I.D. of 1/2" including fittings.
OPERATING INSTRUCTIONS
OPERATION: Starting:
A. The Stencil Pro CT-100 Spray Gun operates
with the trigger controlling both the fluid flow
and air flow. The Stencil Pro Spray Gun may
be used with either an AirVerter®Inductor
Assembly between the gun and the
compressed air supply, or connected directly
to the compressed air supply. Note: if
connecting directly to the air supply, gun inlet
pressure is limited to 43 PSI.
B. Consult the Needle, Nozzle and Air Cap
Selection Guide to select the proper
combination for the coating and finish
quality desired. Too much pressure will
create unnecessary overspray!
Before Spraying
A. Follow the Air and Paint Management
Guidelines listed on the following page.
B. Before paint is poured into the cup, make
certain paint is properly mixed. This is
particularly true when mixing multi-component
paints. Use a paint shaker, rotary mixer, or
paint paddle to achieve a homogeneous
mixture. (Hint: Split your paint into two parts;
the top will be lighter and the bottom will be
heavier. Completely stir the bottom half of the
paint and slowly add small amounts of the top
half into the heavier bottom.)
C. Strain your paint to remove impurities. Use
a cone strainer or a 100-mesh nylon bag or
equivalent strainer.
D. Thin your paint according to the
manufacturer’s specifications.
E. Ensure needle packings are properly
adjusted. Needle packings are preset at the
factory to proper tension. However, use and
cleaning may alter this setting. To adjust
needle packings to proper tension:
1. With gun disconnected from air and fluid
sources, pull trigger to move the needle out
of the nozzle.
2. Adjust packing nut until needle is held in
the open position by tension from the
needle packings.
3. Loosen packing nut approximately ¼ turn or
until needle returns to closed position.
Spraying
A. Gravity forces paint from the paint container
into the fluid chamber of the gun and out
through the nozzle where the flow of
atomizing air breaks the paint stream into tiny
particles, creating the spray.
1. Needle position controls the amount of
paint flowing through the fluid nozzle.
2. Trigger action controls needle position.
3. The Fluid Control Knob (CT-05-1) at the
rear of the spray gun controls trigger action.
Turning the knob to the right reduces the
fluid flow, turning it to the left increases the
flow.
B. Adjust the pattern by turning the Pattern
Control Knob (CT-07) on the side of the Spray
Gun.
1. Round Pattern - used to draw fine lines with
the gun close to the work, for touch-up
work, camouflage patterns and painting
surfaces in difficult to reach places distant
from the spray gun. This pattern is
achieved by turning the Pattern Control
Knob clockwise

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
2. Full Fan Pattern - used with the spray gun
6"-8" from the work. Overlap not more than
50% of the previous pass. Do not “fog”
coat. This pattern is achieved by turning
the Pattern Control Knob counterclockwise.
3. The full fan pattern may be reduced in size
by gradually turning the Pattern Control
Knob clockwise. Fluid flow must be
reduced at the same time to maintain even
paint distribution.
C. If you are having problems with the operation
of your paint gun, check the Trouble Shooting
Guide at the end of the manual for possible
causes and solutions.
Air and Paint Management Guidelines
Approximate PSI Application
Thin Coatings
ZAHN #2 Test: 16 to 22 seconds
Minimum 40 PSI compressor pressure
Machines and implements, small parts, plant maintenance,
controlled production work, work in enclosed areas with
poor ventilation, priming.
Thin to Medium Coatings
ZAHN #2 Test: 22 to 30 seconds
40 to 60 PSI compressor pressure
Dual gun work for all of the above listed applications - will
support up to 50' of 3/8" ID hose for each gun. Also for
higher production levels of all of the above.
High Solid Coatings
ZAHN #3 Test: 37 + seconds
50 to 70 PSI compressor pressure
Marine epoxies, marine enamels, high production
steelwork, high production with conveyer lines, large
surfaces with thinner viscosity material, latex on wood or
metal.
80% Solids Coatings
60 to 80 PSI compressor pressure Ultra high production levels on extremely large surfaces;
un-thinned epoxies, enamels, latex, urethane.
WARNING
Gun must be de-pressurized prior to any maintenance or disassembly
procedure. Disconnect air hose prior to performing any maintenance
operation.
Cleaning the Stencil Pro Spray Gun
Cleaning and Gun Care
A. Remove the Air Cap and Ring and clean with
solvent.
B. Flush gun thoroughly with solvent.
C. Clean nozzle with brush. Never place the
whole gun in solvent.
D. Clogged holes should never be cleaned with
hard objects as the smallest amount of
damage may badly influence the spray
pattern.
E. Packing must be slightly lubricated after
cleaning of gun.
Spray Gun Performance Is Directly Related To
How Well The Gun Is Cleaned After Use

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Lubricate
A. Use Vaseline or a non-silicone grease to
lubricate the gun.
B. Lubricate all threaded connections for ease
of maintenance.
C. Lubricate the Needle only where it passes
through the needle packings.
D. DO NOT allow lubricant to get into the Fluid
Tube, Nozzle, Air Cap, or interior of the
paint chamber (areas where paint may
come in contact with lubricant).
A – Must Clean
B – Must Lubricate
C – High Wear
A
B
C
A
A
A

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Stencil Pro Illustrated Parts Breakdown
CT-13
CT-03
CT-03-2
CT-12
CT-05-1
CT-05-2
CT-05-3
CT-16
CT-01 CT-15
CT-17
CT-14 CT-18 CT-02-2
CT-02-3
CT-02-4
CT-07
AV-007
AV-011
AV-023
AV-019
AV-021
AV-009
PT-25
CT-24
CT-02
CT-06
CT-04-3
CT-04-4
CT-04-2
CT-04-5
CT-04-1
CT-04
CT-20-01
CT-20-02
CT-20-03
CT-20-04
CT-21 CT-20-05
CT-22
CT-25
CT-05
AV-174
AV-022
AV-005
CT-20
CT-03-1
CT-02-1

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Stencil Pro (CT-100 / CT-200) Parts List
Part # NSN Description
AV-005 4940-01-391-9274 AirVerter®Inductor Assembly
AV-007 4940-01-440-1125 Atomizing Hose Insert (pr)
AV-009 4310-01-395-7387 Inductor Filter (pkg of 5)
AV-011 4730-01-430-9738 Female QD
AV-019 4940-01-395-8179 AirVerter®Inductor (w/o hose assembly)
AV-021 5365-01-395-1464 Filter Retainer
AV-022 4720-01-439-9258 3-ft. Air Hose w/ Inserts 5/8-in. ID
AV-023 4720-01-399-5688 Atomizing Hose 5/8-in. ID (per foot)
AV-174 4940-01-395-8178 Air Control Valve – High Pressure
CT-01 4940-01-439-8272 Air Cap Assembly
CT-02 4940-01-439-7965 Packing Set
CT-02-1 4940-01-439-9947 Gasket
CT-02-2 4940-01-439-9946 Packing Screw
CT-02-3 4940-01-439-9942 Teflon Seal
CT-02-4 4940-01-439-9939 Spring
CT-03 4940-01-439-7056 Cup Assembly
CT-03-1 4940-01-439-9937 Paint Strainer
CT-03-2 4940-01-439-7051 Cup Complete
CT-04 4940-01-439-8993 Trigger Assembly
CT-04-1 4940-01-439-8991 Trigger
CT-04-2 4940-01-439-8987 Trigger Screw
CT-04-3 4940-01-439-8985 Trigger Screw
CT-04-4 4940-01-439-8984 Trigger Pin
CT-04-5 4940-01-439-8983 E-Ring
CT-05 4820-01-439-8979 Fluid Control Assembly
CT-05-1 4820-01-439-8978 Fluid Control Knob
CT-05-2 4820-01-439-8976 Lock Nut For Fluid Control Knob
CT-05-3 4940-01-439-9930 Spring For Paint Needle
CT-06 4940-01-439-9934 Air Control Assembly
CT-07 4940-01-439-9935 Pattern Control Assembly
CT-08 4940-01-439-8279 0.5mm Needle/Nozzle Air Cap Kit
CT-09 4940-01-439-8274 0.8mm Needle/Nozzle Air Cap Kit

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
CT-10 4940-01-439-8276 1.0mm Needle/Nozzle Air Cap Kit
CT-12 4940-01-439-9002 Wrench
CT-13 4940-01-439-8999 Brush
CT-14 4940-01-439-8998 O-Ring
CT-15 4940-01-439-8327 Body
CT-16 4730-01-439-8995 Adapter Connector
CT-17-05 4940-01-439-8321 Needle 0.5mm
CT-17-08 4940-01-439-8319 Needle 0.8mm
CT-17-10 4940-01-439-8317 Needle 1.0mm
CT-18-05 4940-01-439-8289 Nozzle 0.5mm
CT-18-08 4940-01-439-8283 Nozzle 0.8mm
CT-18-10 4940-01-439-8286 Nozzle 1.0mm
CT-20 4940-01-439-7968 Stencil Brush Attachment Kit
CT-20-01 4730-01-439-9003 Fix Screw
CT-20-02 4940-01-439-9005 Adapter - Upper
CT-20-03 4940-01-439-9011 O-Ring
CT-20-04 4940-01-439-9010 Adapter - Lower
CT-20-05 4940-01-439-9009 360 Swivel Adapter
CT-21 4940-01-439-9008 Stencil Brush Jar Cover Assembly
CT-22 4940-01-439-7037 22cc Jar
CT-23 4940-01-439-7045 60cc Jar
CT-24 4730-01-439-9007 Air Connector
CT-25 4710-01-439-9006 Suction Tube
PT-25 4730-01-439-9117 Threaded Male QD

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Needle, Nozzle and Air Cap Selection Guide
Select the proper fluid nozzle and needle for the material to be sprayed. Needle and nozzle
are a matched set - machined to act as a valve. Replace the Needle and Nozzle when worn.
Finish Needle
Nozzle Uses or Coating Type Compressor
Air Pressure*
Ultra Fine Finish 0.5
Ultra Fine Finish With Thin Coatings on Small Parts
Ultra Fine Touch Up
Specialty Applications/Wood Working
Water-Based Lacquers, Urethanes
45- 50
Excellent Finish
Good Production 0.8
Automotive Base or Clear Coat
Top Coats For Automotive, Aviation and Marine Use
Wood: Lacquers, Stains, Polyurethanes, Varnishes
Thin Specialty Coatings With Low Mil Build and Fine
Finish Requirements
Water-Based Coatings
45-55
Good Finish
High Production 1.0
Higher Production For The Same Applications As
Above
Fine Finish With Gloss Alkyd Enamel Primers and
Sealers For Automotive, Aviation and Marine
Water-Based Coatings
55-65
*Measured at the gun handle.
Nozzle Size Expressed in Millimeters • 1 Millimeter = .040 (Approximately)
0.5 = .020 0.8 = .032 1.0 = .040

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
Stencil Pro Troubleshooting Guide
Trouble Probable Cause Remedy
Paint Will Not
Flow
1. Blockage in fluid nozzle
2. Loose fluid nozzle
3. Coating is too thick
4. Loose needle packing
1. Clean or replace; strain paint
2. Tighten
3. Thin the coating
4. Adjust packing
Inconsistent
Spray Pattern
(Spits and
Sputters)
1. Running out of paint
2. Loose needle packing 1. Fill cup or pot, but never the top ¼ 2. Adjust packing
Leakage at
Front of Gun
1. Damaged fluid needle
2. Wrong size fluid needle
3. Dirty fluid nozzle
4. Impurities in paint
5. Loose fluid nozzle
6. Fluid adjustment screwed all
the way out
7. Needle not firmly seated in
the nozzle
8. Packing too tight
1. Replace
2. Replace
3. Clean
4. Strain paint
5. Tighten
6. Rotate Fluid Control Knob (CT-05-1)
on rear of gun clockwise
7. Check for nozzle obstruction
8. Loosen and adjust to correct tension
Distorted
Spray Pattern
1. Dirty or damaged air cap
2. Dirty or damaged fluid nozzle
or needle
3. Fluid nozzle partially clogged
4. Fluid nozzle not centered with
air cap
5. Air cap not seated correctly
1. Clean or replace
2. Clean or replace
3. Clean
4. Replace air cap
5. Re-seat air cap

AirVerter® Stencil Pro HVLP Paint Spray System
DO NOT OPERATE SPRAY GUNS WITHOUT PERSONAL SAFETY EQUIPMENT
CT-11 High Wear Kit For Stencil Pro Spray Guns
NSN 4940-01-439-7966
Part # NSN Description QTY
CT-02-3 4940-01-439-9946 Teflon Seal 1
CT-02-4 4940-01-439-9942 Spring 1
CT-04-5 4940-01-439-8983 E Ring 1
CT-05-3 4940-01-439-9930 Spring for Paint Needle 1
CT-06-1 Spring (Air Control) 1
CT-06-4 P. C. Seal 1
CT-06-5 Foamed Rubber 1
CT-07-5 Washer 1
CT-14 4940-01-439-8998 O-Ring 1
CT-26-3 E Ring 1
CT-19 Stencil Brush Accessories – Complete
NSN 4940-01-439-7972
Part # NSN Description QTY
CT-20 4940-01-439-7968 Stencil Brush Attachment Kit 1
CT-21 4940-01-439-9008 Stencil Brush Jar Cover Assembly 1
CT-22 4940-01-439-7037 22cc Jar 1
CT-23 4940-01-439-7045 60cc Jar 1