L4 Handgun Hose

Assembly
Product Manual

Manual Number: 19600-110

1-800-642-7876
 L4 Handgun Hose
Assembly
Product Manual

Manual Number: 19600-110

Date: 7/30/09

230 VAC models are

certified for use in countries
requiring the CE mark.

 Copyright 2009 Astro Packaging

 Copyright 2009 Astro Packaging
 Table of Contents

1 Safety Precautions for Hot Melt Applicator Equipment ......................................... 1

1.1 Intended Use .............................................................................................................................. 1
1.2 Personal Safety .......................................................................................................................... 1
1.3 Electrical Safety ......................................................................................................................... 1
1.4 Emergency Power Disconnect.................................................................................................. 1
1.5 Follow Directions ....................................................................................................................... 1
1.6 Safety Symbols and Signal Words ........................................................................................... 2
2 Introduction ................................................................................................................ 3
2.1 Description ................................................................................................................................. 3
2.2 Features...................................................................................................................................... 3
3 Specifications ............................................................................................................. 4
3.1 Electrical..................................................................................................................................... 4
3.2 Physical ...................................................................................................................................... 4
3.3 Performance............................................................................................................................... 4
3.4 Environmental ............................................................................................................................ 4
3.5 Dimensions ................................................................................................................................ 5
4 Installation .................................................................................................................. 6
4.1 General ....................................................................................................................................... 6
4.2 Inspection................................................................................................................................... 6
4.3 Fluid Connection – Hose to Handgun ...................................................................................... 6
4.4 Electrical Connection for RTD Version - Hose to Handgun .................................................... 7
4.5 Electrical Connection for Thermostat Version - Hose to Handgun ........................................ 8
4.6 Hose to Melt Unit Connection ................................................................................................... 8
5 Operation .................................................................................................................... 9
5.1 Setup and Initial Operation........................................................................................................ 9
5.2 Operation.................................................................................................................................. 10
5.2.1 Handgun Operation ............................................................................................................. 10
5.2.2 Precautions to Prevent Equipment Damage ........................................................................ 10
5.3 System Shutdown.................................................................................................................... 10
6 Maintenance.............................................................................................................. 11
6.1 Preventive Maintenance .......................................................................................................... 12
6.1.1 Daily Maintenance............................................................................................................... 12
6.1.2 Semiannual Maintenance .................................................................................................... 12

Copyright 2009 Astro Packaging L4 Handgun 19600-110

7 Troubleshooting ....................................................................................................... 16
7.1 Troubleshooting Table ............................................................................................................ 16
7.2 Thermostat Hose - Male Connector Pin Location and Function........................................... 21
7.3 Solid State RTD Hose - Male Connector Pin Location and Function ................................... 22
8 Repair and Replacement ......................................................................................... 23
8.1 Trigger Microswitch Adjustment (Switched Version Only) ................................................... 24
8.2 Packing Cartridge Replacement ............................................................................................. 25
8.3 Swivel Disassembly, Sleeve, and Thrust Bearing Replacement........................................... 26
9 Parts List ................................................................................................................... 28
9.1 Switched and Unswitched L4 Handguns................................................................................ 28
9.2 Standard Nozzles ..................................................................................................................... 30
9.3 T Bar Nozzles ........................................................................................................................... 31
9.4 Slot Nozzles.............................................................................................................................. 32
9.5 Hoses........................................................................................................................................ 33
9.6 Optional Thermostat Kits ........................................................................................................ 34
9.7 Accessories and Tools ............................................................................................................ 34
Appendix A Resistance Tables ................................................................................. 35
Table 1. RTD Sensor Resistance .................................................................................................. 35
Table 2. Heater Resistance for L4 Handguns............................................................................... 35
Table 3. Heater Resistance for L4 Handgun Hoses in Ohms ...................................................... 35

Copyright 2009 Astro Packaging L4 Handgun 19600-110

1 Safety Precautions for Hot Melt Applicator Equipment
This manual contains important safety information and instructions.
Failure to comply with these instructions can result in death, injury or
permanent damage to this equipment and will void the warranty.
1.1 Intended Use
This equipment is designed for use with standard adhesive and sealant
materials with flash points above 232 °C (450 °F). Use of flammable
material or material not compatible with the specifications of this
equipment can cause injury to operator and damage to equipment.
The manufacturer has designed this equipment for safe operation.
Specified models are in compliance with EN 60204-1:1997. However,
heated thermoplastics and other hot melt materials are dangerous and
care must be exercised to ensure operational safety. Handling must be in
accordance with hot melt manufacturer specifications. Never exceed the
maximum application temperature recommended by the adhesive
manufacturer.
Dispose of hot melt properly. Refer to the Materials Safety Data Sheet
(MSDS) of the hot melt for recommended disposal methods.
1.2 Personal Safety
Wear the following protection when working on or around this equipment:
Always wear heat resistant gloves rated to 205 °C (400 °F) and allow all
system temperatures to stabilize below 193 °C (380 °F) before servicing.
Properly ventilate equipment according to MSDS of equipment.
Wear Safety Goggles
Trained operators and service technicians should be aware of exposed
surfaces of the unit that cannot be practically safeguarded. These
exposed surfaces may be hot and take time to cool after the unit has
been operating.
Wear Heat-Resistant Keep parts of the body away from rotating parts. Do not wear loose
Safety Gloves articles of clothing when operating or servicing units with rotating parts.
Remove wristwatches, rings, necklaces, or other jewelry and cover or pin
up long hair before performing any work on or with the unit.
Trained operators may perform only external equipment adjustments.
Trained service technicians must perform internal adjustments and
service.
Wear Protective Clothing
1.3 Electrical Safety
Determine voltage of this equipment before installation and confirm
compatibility with available power. Equipment must be connected to a
properly grounded circuit and installed in accordance with all applicable
electrical codes. Ground fault protection must be provided in supply
circuitry at site installation.
Models designed to EN60204-1: 1997 require power cords be approved
to a harmonized (HAR) standard and rated for 70 °C (158 °F). A HAR
approved Type B plug and strain relief for power cord are required to
meet standard IEC 309. Power conducting wires must be nominal
2 2
5.3 mm (10 AWG) maximum and nominal 2.1 mm (14 AWG) minimum.
1.4 Emergency Power Disconnect
In the event of a malfunction, turn off power to the equipment at the
power off switch and remove source power to the system at the nearest
main disconnect.
1.5 Follow Directions
Read the product manual thoroughly before installation, operation or
maintenance. Failure to do so can result in a serious accident or
equipment malfunction. The manufacturer will not be held liable for
injuries or damage caused by misuse of this equipment.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 1

1.6 Safety Symbols and Signal Words
The following safety symbols and signal words are used throughout the
manual and on the product to alert the reader and operator to personal
safety hazards or to identify conditions that may result in equipment or
property damage.
General Safety Symbols
DANGER: Indicates a hazard, which, if not avoided, will result in serious
! injury, including death, or equipment and property damage.

WARNING: Indicates a hazard, which, if not avoided, can result in

! serious injury, or equipment and property damage.

CAUTION: Indicates a hazard, which, if not avoided, can result in

! minor injury, or equipment and property damage.

Specific Symbols and Signal Words

DANGER: High Voltage. Can cause serious injury, including
death. Disconnect electrical power at external source before
servicing.

WARNING: Hot Surface. Can cause serious injury and burns.

Wear heat resistant clothing, gloves and safety goggles.

WARNING: Disconnect electrical power at external source.

Failure to do so can cause electrical shock.

WARNING: High Pressure. System contents under pressure. Can

cause serious injury and burns or equipment and property
damage. Relieve pressure before servicing.

Other Product Symbols

PE
On Off Ground Protective Earth

Tank Heated Hose Applicator Pump Motor

- +
Set Temp Standby Temp Overtemp Adhesive Flow

Tank Heater Alarm Actual Temp Source Power

Valve Group Manual Task Input Output

The manufacturer reserves the right to make design changes for product
improvement. This manual may not reflect all details of these
improvements.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 2

2 Introduction
2.1 Description
The L4 Handgun is a lightweight, manually operated extrusion
applicator for hot melt adhesives and other thermoplastic
materials. A flexible heated hose supplies hot melt adhesive from
the melt unit to the handgun.

The L4 Handgun is a manually controlled valve that links the

handgun trigger to a needle contained in the handgun body. A
carbide ball tip seals against a matching seat at the end of the
needle.

The L4 Handgun comes either “switched” or “unswitched”. The

switched version has the pump motor control at the handgun
trigger. The unswitched version has the pump motor control
located on the melt unit control panel.

The L4 Handgun is also available in a high temperature model

that comes equipped with o-rings rated for high continuous
temperatures for more rigorous applications. This high
temperature handgun is available in both the switched and
unswitched versions of the L4 Handgun.

2.2 Features
ˆ Continuous 360° rotation on unswitched version
ˆ Up to 360° rotation for switched version
ˆ Lightweight and maneuverable design
ˆ Safety trigger lock
ˆ Cool touch handle
ˆ Thermostat or solid state temperature control models
ˆ Various extrusion nozzles
ˆ Available in 115 VAC and 230 VAC versions

4
097006

Copyright 2009 Astro Packaging L4 Handgun 19600-110 3

3 Specifications
3.1 Electrical
Input voltage ------------------------- 115 VAC
------------------------------------------ 230 VAC
Power requirements: Handgun -- 80 W
Hose-------- 2.4 m (8 ft), 200 W
-------------- 3.6 m (12 ft), 300 W
-------------- 4.9 m (16 ft), 400 W
Heater type: Handgun ------------- Replaceable cartridge
Hose ------------------ Wire wound element
RTD type------------------------------ 100 ohm, platinum
3.2 Physical
Handgun weight --------------------- 0.8 kg (1.75 lb)
Hose length and weight ----------- 2.4 m (8 ft) 2.25 kg (7.5 lb)
------------------------------------------ 3.6 m (12 ft) 3.40 kg (10.0 lb)
------------------------------------------ 4.9 m (16 ft) 4.50 kg (12.5 lb)

3.3 Performance
Operating pressure ----------------- 10.34 kPa (500 psi) maximum
Warm-up time------------------------ 30 – 45 minutes
Viscosity------------------------------- Maximum 25,000 cps
Temperature control:
Thermostat models:
Handgun--------------------- Fixed bimetallic thermostat in gun.
Values from 93-218 °C (200-425 °F)
Hose-------------------------- Adjustable thermostat in melt unit with
capillary bulb sensor in hose. Adjustable
from 150-205 °C (300-400 °F)
Solid-state/RTD models:
Handgun--------------------- RTD sensor in gun with controller in
melt unit. Adjustable from 37-230 °C
(100-450 °F)
Hose-------------------------- RTD sensor in hose with controller in
melt unit. Adjustable from 37-230 °C
(100-450 °F)

3.4 Environmental
Operating temperature------------- 37 – 230 °C (100 – 446 °F)
Storage temperature --------------- -30 – 70 °C (-22 – 158 °F)

Copyright 2009 Astro Packaging L4 Handgun 19600-110 4

3.5 Dimensions

18.5 cm 4.1 cm
7.4 in. 1.6 in.

18.5 cm
7.4 in.

0970052

Copyright 2009 Astro Packaging L4 Handgun 19600-110 5

4 Installation
4.1 General
The L4 Handgun is shipped in one of three configurations:
Complete Hot Melt Applicator System
The handgun is attached to the hose, and the hose is attached to
the melt unit. No installation is required.
Spare Handgun Hose Assembly
The handgun is attached to the hose. Installation requires
attaching the input end of the hose to the melt unit, as indicated in
melt unit product manual.
Spare Handgun without Hose
Installation requires making fluid and electrical connections
between the handgun and the hose.

4.2 Inspection
1. Inspect the handgun and hose surfaces for possible shipping
damage.
2. Retighten all electrical connections.
3. Remove all shipping materials and check for other loose
material.

4.3 Fluid Connection – Hose to Handgun

1. Remove the pivot sleeve shell [1] by removing the 4 screws
holding the shell halves together.
2. Rotate the pivot sleeve [5] so that the heater side faces up.
The heater is larger in diameter than the RTD sensor.
3. Remove and discard the plastic cap on the swivel connector
7 thread [3], and attach the hose fitting [2]. Tighten firmly.
6 4. Hold the wing [4] of the swivel connector with an open-end
5 09 70047 wrench across the flat portion, and tighten the hose fitting [2]
4 with another open-end wrench.
3
2
1
7
5
0970046

4 2

Copyright 2009 Astro Packaging L4 Handgun 19600-110 6

4.4 Electrical Connection for RTD Version - Hose to Handgun
1. Thread the wire bundle from the hose under the wire retaining
clip [7] on the pivot sleeve. Ensure wires lie flat in the wire
channel [6].

2. Locate the 2 heater wires [8], (one is brown; one is either red,
blue, or white), coming from the hose. Individually insert the
heater wires into the vacant slots on the heater terminal
block [10] opposite the wires going to the heater [9].

3. Secure the green/yellow ground wire [13] with the screw

5
11 located on the pivot sleeve [5] above the heater terminal
10 block [10]. The terminal lug must lie flat against the side of the
pivot sleeve.
7
4. Locate the 2 RTD sensor wires [12], (black and white wires
twisted together), from the hose. Individually insert the wires
9 6 into the vacant slots in the terminal block [11] opposite the
wires going to the RTD sensor.

5. Tuck the excess wire into the space between the hose cuff
and the pivot sleeve as needed.
12
8, 13 WARNING: Possible electric shock can occur if
!
wires do not lie flat and side-by-side, not crossing
each other within the channel. When replacing
09

8
60

shells, exercise care to ensure wires are not

2 02

pinched between the shells and pivot sleeve.

6. Place one pivot sleeve shell half [1] over the hose and pivot
sleeve [5], and position the terminal blocks [10 and 11] into
the shell.

7. Place the second pivot sleeve shell half [1] and secure it with
the 4 screws.

8. On switched models, attach the cable assembly from the

hose to the connector on the handgun handle.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 7

4.5 Electrical Connection for Thermostat Version - Hose to Handgun
1. Thread the wire bundle from the hose under the wire retaining
clip [7] on the pivot sleeve. Ensure the wires lie flat in the wire
channel [6]. See the previous page for additional illustrations.
5
10 2. Locate the 2 heater wires [8] (one is brown; one is either red,
blue, or white), coming from the hose. Individually insert the
heater wires into the vacant slots on the heater terminal
7 block [10] opposite the wires going to the heater [9].
3. Secure the green/yellow ground wire [13] with the screw
6 located on the pivot sleeve [5] above the heater terminal
9
block [10]. The terminal lug must lie flat against the side of the
pivot sleeve.
4. Tuck the excess wire into the space between the hose cuff
and the pivot sleeve as needed.

8, 13 ! WARNING: Possible electric shock can occur if

wires do not lie flat and side-by-side, not crossing
each other within the channel. When replacing
09

8 shells, exercise care to ensure wires are not

70
08

pinched between the shells and pivot sleeve.

3

5. Place one pivot sleeve shell half [1] over the hose and pivot
sleeve [5] and position the terminal block [10] into the shell.
6. Place the second pivot sleeve shell half [1] and secure it with
the 4 screws.
7. On switched models, attach the cable assembly from the
hose to the connector on the handgun handle.

4.6 Hose to Melt Unit Connection

To install the hose to the melt unit, see the appropriate melt unit
manual.

• The fluid connection is made underneath the melt unit to the

pump block or the manifold.

• The electrical connection is made by properly attaching the

hose electrical connector to the melt unit electrical connector.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 8

5 Operation
CAUTION: To prevent inadvertent discharge during start-up,
!
leave trigger safety in locked position until appropriate
steps are performed in initial start-up procedure.

! CAUTION: Do not operate hot melt system at pressures

capable of causing the adhesive to extrude beyond 46 cm
(18 in.) from the nozzle tip.

! CAUTION: The system may retain pressure even when

handgun trigger is released and pump motor is off.

DANGER: Do not operate the handgun with its body shells

!
removed or damaged. This gun contains voltages that can
be fatal.

5.1 Setup and Initial Operation

1. Start the system in accordance with the melt unit manual.

2. Unlock the trigger safety.

3. Quickly trigger the handgun to initiate adhesive flow.

4. Test adhesive pressure. Adhesive pressure should be as low

as possible for the desired application. If exiting adhesive
pressure is too great:
• Decrease pump pressure at the melt unit flow control valve.
• Change nozzle to a larger orifice size.

5. Begin operation.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 9

5.2 Operation
Handgun Unlocked 5.2.1 Handgun Operation
1. Operate the melt unit according to the melt unit manual.
2. Warm the melt unit to operating temperature.
3. Turn the pump motor switch on before operating the handgun.
On unswitched models, the pump is continuously on. On
switched models, the pump is on and the system is
pressurized only when the handgun trigger is pulled.
4. In the unlocked position, depress the handgun trigger to allow
0960351a
pressurized adhesive to flow out the nozzle.

Handgun Locked 5. Release the trigger to stop the adhesive flow.

6. Place the trigger safety in the locked position when the
handgun is not in use to prevent inadvertent triggering.
7. Hang the handgun by the opening at the top of the gun
handle. The trigger safety must be in the locked position.

0960352a

5.2.2 Precautions to Prevent Equipment Damage

1. Do not trigger the handgun when it is cold. Damage to
packing cartridge will result.
2. Never force a cold handgun to swivel before it is fully heated.
This can destroy the swivel seal and cause the handgun to
leak.
3. Use caution when rotating the handgun around the hose. On
switched models, damage can result to the cord set between
the hose and the handgun handle causing improper
application.

5.3 System Shutdown

1. Shut down the system in accordance with the melt unit
manual.
2. Place the handgun trigger safety in the locked position.
3. Hang the handgun by the hole in the handle.

WARNING: Never hang handgun by its trigger area.

!
Hanging by its trigger area may cause accidental discharge
resulting in burns.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 10

6 Maintenance

! DANGER: Handgun contains electrical

components with voltages that can be fatal.
Disconnect electrical power from external source
before performing maintenance.

! CAUTION: Relieve system pressure before

opening any fluid connection to prevent inadvertent
contact with hot material.

! CAUTION: Never heat any component of a hot

melt system with a torch or other open flame. If
necessary to heat a component for maintenance or
repair, use an electric oven with forced air circula-
tion or a flameless electric heat handgun. Do not
heat plastic handgun shells above 230 °C
(450 °F).

! WARNING: Halogenated hydrocarbon solvents

are dangerous when used to clean aluminum
components in a pressurized fluid system. Halo-
genated hydrocarbon fluids include fluorocarbon
solvents, chlorinated solvents, brominated
solvents, and iodinated solvents. No available
stabilizers prevent halogenated hydrocarbon
solvents from reacting under all conditions with
aluminum components in a pressurized fluid
pumping system. Never clean any aluminum
component or flush any pressurized system using
halogenated hydrocarbon solvents. Use Type R
Solvent or contact your solvent or adhesive
supplier for a non-halogenated hydrocarbon
solvent for cleaning and flushing (e.g., Strip-N-
Clean®, P/N 11200-X).

Copyright 2009 Astro Packaging L4 Handgun 19600-110 11

6.1 Preventive Maintenance
6.1.1 Daily Maintenance
1. Clean exposed surfaces to remove hot melt adhesive, which
can char and cause erratic operation.

6.1.2 Semiannual Maintenance

WARNING: Vibration and heating/cooling cycles

!
may loosen connections resulting in possible
electric shock hazard or equipment damage.

Handgun Inspection
1. With handgun at operating temperature, disconnect electrical
power from external source.
2. Turn off pump motor at melt unit.
3. Activate trigger to relieve trapped residual pressure.
4. Remove the pivot sleeve shell by removing the 4 screws.
5. Inspect wiring for signs of wear or damage to the insulation.
6. Check electrical and fluid connections for tightness.

Nozzle Cleaning

! CAUTION: Do not heat Strip-N-Clean® solvent

above 245 °C (475 °F) or with an open flame or in
an uncontrolled heating device. Doing so creates a
fire hazard. Use only a controlled heating device to
heat the solvent above melting point of adhesive.

CAUTION: Failure to relieve system pressure can

!
result in serious burns when nozzle is removed.

SAFETY: Solvents may present a toxic or fire

!
hazard, even at room temperature. Use extreme
care in selecting a cleaning solvent other than
Type R solvent.

Nozzle clogging occurs when a filter screen is damaged or

charred material is in hose or handgun. Char may occur if
adhesive is heated above application temperature recommended
by adhesive manufacturer. If this occurs, it may be necessary to
clean or replace nozzle, hose, and/or handgun.
1. Raise handgun to operating temperature in accordance with
melt unit manual.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 12

 2. Turn off pump motor at melt unit.
3. Activate trigger to relieve any trapped residual pressure in
system and place the handgun in the locked position.
4. Remove nozzle.
5. Place nozzle in a container of heated Strip-N-Clean® or other
appropriate solvent.
NOTE: Some solvents may not be compatible with the adhesive.
Sludge formation can further compound the problem. Test solvent
with a small sample of adhesive for compatibility before using it in
system.
6. Clean nozzle following one of the methods below:
• Insert pin-type probe into nozzle in opposite direction of
adhesive flow.
• Place parts in an ultrasonic cleaner filled with heated Strip-
N-Clean®.
NOTE: Do not use an open torch, drill, or broach to clean a
nozzle. Brass brushes are effective in cleaning nozzle exterior –
do not use steel brushes.
7. Reattach nozzle on handgun.
8. Allow handgun to reach operating temperature, and tighten
nozzle.
9. Check for leaks.

Trigger Adjustment
8.7 mm 1. Turn off main power.
(3.43 in.) 2. Remove the handgun handle shell by removing the 5 screws.
3. Holding the lock nut [1] with a wrench, loosen the trigger
linkage [2].
4. Thread the linkage in or out to achieve a distance, between
the edge of the trigger and the front end of the handgun body,
1 2 of 85 mm (3.43 in.). Make the measurement while the
assembly is set in the shell half.
5. Lock the trigger linkage [2] in place with the lock nut [1].
0
006
097
6. Replace the shell halves and tighten the screws.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 13

 Thrust Bearing Lubrication

! WARNING: Swivel connector and hose fitting must

be heated to disconnect hose from the handgun. Do
not heat these parts with a torch or open flame. Use
a flameless electric heat gun for heating handgun
components. Wear safety glasses, safety gloves
and protective clothing to prevent injury from hot
melt unit parts, splashed adhesive material and hot
handgun surfaces.

1. Disconnect and lock out electrical input power. It is not

necessary to disconnect any electrical connections to service
the thrust bearing.
2. Turn off the pump motor switch at the melt unit.
3. If the handgun is hot, activate the trigger to relieve pressure.
4. Remove the pivot sleeve shell by removing the 4 screws.
1
5. Remove the hose from the handgun at the hose connector.
6. Handle the handgun carefully to avoid undue strain on
internal wiring or hose cord set.
7. Remove the 2 screws [6] and washers [7] securing the swivel
2 connector [8] to the pivot sleeve [2].
8. Remove the swivel connector [8] and the conical spring [9]
3
from the pivot sleeve [2].
9. Remove the retaining ring [3] from the end of the handgun
body [1].
11 10. Remove the thrust bearing [11].
10 4
11. Clean and repack the thrust bearing [11] with a high
9 5 temperature grease. High temperatures will carbonize
8 standard greases causing the bearing to bind. Do not remove
7 the pivot sleeve [2] from the handgun body [1].
6 12. Inspect the swivel connector [8] seal and the backup ring [10]
located inside the handgun body [1]. Replace these parts if
there is evidence of hardening, cracking, or other damage.
0960184 13. Lubricate the swivel connector [8] seal with bearing lubricant.
14. Reassemble the swivel connector [8] seal and backup
ring [10].
15. Reinstall the thrust bearing [11] with the printed side of the
bearing facing the handgun body [1].
16. Reinstall the retaining ring [3] in the retaining ring groove
using snap-ring pliers.
17. Reinstall the conical spring [9], (smaller end first), and the
swivel connector [8] into the handgun.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 14

 18. Install the 2 screws [6] and washers [7] to retain the swivel
connector [8]. Tighten finger tight.
1 19. Rotate the pivot sleeve [2] to allow the swivel connector [8] to
self-center.
20. Tighten the screws [6] and check for free rotation. If binding
occurs, loosen the screws [6] and rotate the pivot sleeve [2].
Retighten the screws [6] and check for free rotation. Repeat
2 as necessary.
21. Connect the hose to the handgun at the hose connector and
3 tighten.
22. Replace shells and secure with four screws.
23. Restore system to operating conditions in accordance with
11 melt unit manual.
10 4
9 5
8
7
6

0960184

Copyright 2009 Astro Packaging L4 Handgun 19600-110 15

7 Troubleshooting
7.1 Troubleshooting Table

Problem Solutions
Handgun Does Not Heat 1. Fuse failure in melt unit: Check fuse in melt unit.
Replace fuse, and check circuit for overload.
2. Control relay failure in melt unit: If plug-in type relay,
switch relay with a good relay. Replace relay. If wired-
in type relay, such as T150, move wiring to a good
relay. Replace temperature controller board.
3. Handgun heater failure: Check heater resistance at L4
electrical connector: use ohmmeter, Resistance Chart
in Appendix A, and Pin Location Diagrams in
sections 7.2 and 7.3. If resistance is out of
specification, replace heater.
4. Intermittent or broken connection in heater or sensor
circuit: Check all wiring connections in the heater and
sensor circuit. Refer to the melt unit schematic. Repair
or reinstall any loose or broken connections. Remove
left pivot sleeve shell to access RTD and heater
terminal blocks. Check continuity of heater and sensor
through-wires in hose using Pin Location Diagrams in
sections 7.2 and 7.3. Replace hose if necessary.
5. Handgun sensor failure: Check sensor resistance at
RTD terminal block on pivot sleeve: use Ohmmeter,
Resistance Chart in Appendix A. If resistance is out of
specification, replace sensor.
6. Thermostat fails open (thermostat models only): Check
thermostat at terminal block on pivot sleeve for
continuity while handgun is cold. If no continuity,
replace thermostat.
7. Applicator zone not learned (microprocessor
controllers only): See temperature controller manual.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 16

 Hose Does Not Heat 1. Fuse failure in melt unit: Check hose fuse in melt unit if
present. Replace fuse, and check circuit for overload or
short circuit.
2. Temperature control relay failure in melt unit: If plug-in
type relay, switch relay with a good relay. Replace
relay. If wired-in type relay such as T150, move wiring
to a good relay. Replace temperature controller board.
3. Hose heater failure: Check heater resistance at pins 2
and 6 of input electrical connector: use Ohmmeter,
Resistance Chart in Appendix A, and Pin Location
Diagrams in sections 7.2 and 7.3. If resistance is out of
specification, replace hose.
4. Broken connection in heater or sensor circuit: Check all
wiring connections in the heater and sensor circuit.
Refer to the melt unit schematic. Repair or reinstall any
loose or broken connections.
5. Hose sensor failure: Check sensor resistance at pins 8
and 9 of input connector: use Ohmmeter, Resistance
Chart in Appendix A. If resistance is out of
specification, replace hose.
6. Applicator zone not learned (applies to microprocessor
controllers only): See temperature controller manual.
7. Hose controller failure: If capillary type thermostat,
ensure capillary bulb is fully inserted in tube on input
end of hose. Fully insert capillary bulb into tube as
needed. Ensure tube is not crimped. If tube is crimped,
replace hose controller. If RTD sensor controller, check
possible causes listed above. Replace hose controller.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 17

 Handgun Does Not Reach Set 1. Temperature setting too low, or controller set to
Temperature incorrect scale (°F or °C): Verify Set temperature.
Check temperature scale. Adjust temperature setting
and/or scale. Refer to temperature controller or melt
unit manual.
2. Heater voltage does not match source voltage, or
source voltage is too low for heater voltage rating.:
Check heater voltage rating by measuring heater
resistance at heater terminal block on the pivot sleeve:
Use Ohmmeter, Pin Location Diagrams in sections 7.2
and 7.3, and Resistance Chart in Appendix A. Select a
heater that matches the source voltage. Measure
source voltage with volt meter. Ensure proper voltage
is available.
3. Intermittent or broken connection in sensor circuit
wiring: Check all wiring connections in heater and
sensor circuit. Refer to melt unit schematic. Repair or
reinstall any loose or broken connections. Check
continuity of heater and sensor through wires in hose
using Ohmmeter and Pin Location Diagram. Replace
hose if necessary.
Handgun Overheats 1. Temperature controller set too high or set to incorrect
scale (°F or °C): Verify Set temperature. Check
temperature scale. Adjust temperature setting and/or
scale. Refer to temperature controller or melt unit
manual.
2. Wiring incorrectly connected: Verify electrical
connections from temperature controller to hose and
from hose to handgun are correct. Connect wiring
according correct diagram. See melt unit schematic,
and Pin Location Diagram in hose manual.
3. Thermostat failed closed: Check thermostat at terminal
block on pivot sleeve for continuity while handgun is at
or above operating temperature. If continuity is present
at or above operating temperature, replace thermostat.
Handgun Does Not Swivel 1. Handgun is not at operating temperature: Check Set
and Actual L4 temperature. Adjust temperature setting
and/or wait for L4 to reach Set temperature.
2. Binding or wear on pivot sleeve bearing: Remove pivot
sleeve shell and disassemble. See Section 8. Clean
and lubricate bearing if possible. See Section 8.
3. Binding or wear on thrust bearing: Remove pivot
sleeve shell and disassemble. See Section 8. Replace
bearing if required.
4. Pump pressure too high: Reduce pressure at melt unit
flow control valve. Keep pump pressure below 200 psi.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 18

 Problem Solutions
No Adhesive Flows From 1. No input power: Verify correct power is connected to
Handgun melt unit and handgun. Turn on all necessary circuit
breakers.
2. Low adhesive level: Check adhesive level. Add
adhesive as needed.
3. L4 temperature set too low: Verify handgun Set
Temperature. Adjust temperature setting.
4. Pump motor not operational: Check pump motor
switch. Check tank temperature at base and compare
to pump warmup thermostat rating. Ensure pump
warmup switch has correct rating and is functional.
Check pump run relay in melt unit. Check for motor
overtemperature condition. Allow motor to cool and
restart. Ensure switch is on. Replace if necessary.
Allow warmup time. Replace switch if needed. Replace
relay if necessary. Reduce load on motor by reducing
pump pressure.
5. Fuse failure: Check fuse in melt unit. Replace fuse.
6. Hose failure: Check hose heater resistance: use
ohmmeter, Resistance Chart in Appendix A, and Pin
Location Diagram in hose manual. If resistance is out
of specification, replace hose.
7. Clogged pump filter: Inspect melt unit pump filter.
Clean or replace filter. Refer to melt unit manual.
8. Clogged hose: Remove L4 from hose. Check for
restricted flow and appearance of exiting adhesive.
Clean hose and verify good flow from hose. If unable to
unclog, replace hose.
9. Clogged nozzle: Check flow through handgun without
nozzle. Clean or replace nozzle.
10. Triggering device dirty or faulty: Check trigger and
microswitch adjustment. Check microswitch continuity
at electrical connector. Use ohmmeter, Pin Location
Diagrams in sections 7.2 and 7.3, and Resistance
Chart in Appendix A. Check all connections melt unit to
handgun including hose through-wires for microswitch.
Clean or adjust trigger and microswitch. Replace
microswitch if faulty. Repair/reinstall any loose or
broken connections. Replace hose if needed.
11. Low voltage: Check handgun voltage. Match handgun
voltage to motor rating.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 19

 Problem Solutions
Handgun Fails To Shut Off 1. Triggering device dirty or faulty. Check trigger
adjustment. Refer to section 8. Clean or replace if
needed.
2. Foreign material lodged between seat and packing
cartridge ball tip: Check nozzle assembly. Clean or
replace as needed.
3. Packing cartridge failed: Check packing cartridge for
damage. Replace packing cartridge as needed.
Adhesive Leaks From Handgun 1. Improperly installed hose or loose hose-to-handgun
Handle connection: Inspect hose-to-handgun connection for
leaks. Tighten any loose connections. Refer to
section 4.
2. Damaged seal ring: Check seal ring for damage.
Replace seal ring if damaged. Refer to section 8.
Adhesive Leaks From Pivot 1. Cracked or damaged swivel connector seal: Check
Sleeve Shells seal for damage. Replace swivel connector seal and
backup ring. Refer to section 8.
2. Worn or damaged packing cartridge: Check packing
cartridge. Replace packing cartridge if damaged.
Hose/Handgun Hydraulic Fitting 1. Loose hydraulic fitting: Check hydraulic fitting
Leaks connection. Tighten hydraulic fitting at operating
temperature.
2. Damaged fitting threads on hose hydraulic fitting:
Check fitting threads. Replace hose.
3. Damaged fitting threads on handgun swivel: Check
fitting threads. Replace swivel.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 20

7.2 Thermostat Hose - Male Connector Pin Location and Function

Handgun Hose
Pin Function
1 Ground
2 Heater circuit return
1 2 3
3 Handgun heater (with pin no. 2)
4 5 6
4 Handgun pump motor switch
0960367c
7 8 9
5 Handgun pump motor switch
6 Hose heater
Input End of Hose 7 Blank
8 Blank
9 Blank

Hose Handgun
9-Pin Input
Connector
Ground
1 Thermostat

6
Hose Heater
2 Heater
4
Switch
5
0970084

Copyright 2009 Astro Packaging L4 Handgun 19600-110 21

7.3 Solid State RTD Hose - Male Connector Pin Location and Function

Handgun Hose
Pin Function Pin Function
1 Ground 9 Hose RTD
1 2
2 Heater circuit return 10 Handgun RTD
3 4 5 6
7 8 9 10
3 Handgun heater (with pin no. 2) 11 Handgun RTD
11 12 13 14 4 Handgun pump motor switch 12 Blank
0960379e

15 16 5 Handgun pump motor switch 13 Blank

6 Hose heater circuit (with pin no. 2) 14 Blank
Input End of Hose 7 Blank 15 Blank
8 Hose RTD 16 Blank

Hose Handgun
16-Pin Input
Connector Ground
1
RTD
10
11
2
Hose Heater Heater
6
3
8
RTD
9 Switch
4
5
0970085

Copyright 2009 Astro Packaging L4 Handgun 19600-110 22

8 Repair and Replacement
Refer to Section 9 Parts List for the part numbers of all
replacement parts. Replacement kits come with instructions.

! DANGER: Handgun contains electrical

components with voltages that can be fatal.
Disconnect electrical power from external source
before performing maintenance.

! CAUTION: Relieve system pressure before

opening any fluid connection to prevent injury from
sprayed hot melt adhesive.

! CAUTION: Never heat any component of a hot

melt system with a torch or other open flame. If
necessary to heat a component for maintenance or
repair, use an electric oven with forced air circula-
tion or a flameless electric heat handgun. Do not
heat plastic handgun shells above 230 °C (450 °F).

Carefully read Safety Precautions before servicing the L4.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 23

8.1 Trigger Microswitch Adjustment (Switched Version Only)

CAUTION: Adjust trigger microswitch with the

!
handgun at application temperature for hot melt
adhesive. Wear safety glasses, safety gloves and
protective clothing to prevent injury from hot melt
unit surfaces, splashed hot material and hot
handgun parts.

1. Bring handgun to operating temperature in accordance with

melt unit manual. Depressurize melt unit system to prevent
accidental contact with hot adhesive when the handgun is
triggered.
2. Disconnect switch plug from hose.
3. Position handgun on its right side.
4. Remove handgun handles by removing 5 screws.
5. Remove left-side handle shell.
6. Using an ohmmeter, set for continuity and attach leads to
handgun pins 2 and 4.
7. Slowly depress trigger and watch for indication of electrical
continuity. Continuity should indicate just after packing
1
cartridge shaft begins to move out of handgun body.
097
006
1
2 8. Loosen microswitch mounting screws [2].
9. Slide microswitch [1] toward or away from trigger until
continuity is indicated, just after packing cartridge shaft starts
to move.
NOTE: In some cases, microswitch actuation arm may need to be
bent slightly to achieve proper adjustment.
10. When properly positioned, tighten microswitch mounting
screws [2].
11. Release trigger and ensure no continuity exists when
handgun is not being triggered.
12. Replace left-side shell and tighten screws.
13. Reconnect switch plug to hose. Electrical connectors have
orientation lugs to ensure proper alignment of the connectors
before mating.
14. System is ready for operation.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 24

8.2 Packing Cartridge Replacement
1. Disconnect and lock out electrical power. Depressurize
system.
2. Remove handgun handles by removing 5 screws.
8.7 mm 3. Holding lock nut [7] with a wrench, loosen trigger linkage [8].
(3.43 in.)
4. Remove shoulder screw [13], bearing plate [12], trigger [10]
and trigger spring [9] from packing cartridge shaft [3] by
unthreading linkage [8].
5. Unscrew and remove seat [5], seal ring [6] and nozzle from
body [2].
1 2 6. Pull packing cartridge [3] out of body [2]. Replace if
necessary.
7. Inspect seal ring [6] and replace if damaged or cracked.
0
006
097
8. Install packing cartridge [3] in body.
9. Install seal ring [6] and seat [5] in body [2].
10. Torque seat [5] to 34 N-m (25 ft-lb).
11. Reassemble lock nut [7], trigger linkage [8], trigger spring [9],
trigger [10], bearing plate [12], and shoulder screw [13] onto
packing cartridge shaft [3].
12. Thread trigger linkage [8] toward or away from body [2] until
distance between edge of the trigger [10] and front end of
body [2] is 85 mm (3.4 in.).
13. Lock linkage [8] in place with lock nut [7].
14. Install handle shells [1] and secure with 5 screws.
15. Restore system to normal operation.

7
8
6 9
10
5 11
4 12
3 13
2
1
0970053

Copyright 2009 Astro Packaging L4 Handgun 19600-110 25

8.3 Swivel Disassembly, Sleeve, and Thrust Bearing Replacement
1. Disconnect and lock out electrical power.
2. Relieve system pressure by activating trigger.
3. Remove pivot sleeve shells [2] by removing 4 screws [13].
4. Disconnect handgun from hose.
Note: It is not necessary to disconnect any electrical connections
to service the thrust bearing. However, avoid putting undue strain
on internal wiring or hose cord set.
5. Remove 2 screws [6] and 2 washers [7] securing the swivel
connector [8] to pivot sleeve [3].
6. Remove swivel connector [8] and conical spring [9] from pivot
sleeve [3].
7. Using snap-ring pliers, remove retaining ring [12] from end of
handgun body [1].
8. Remove thrust bearing [11].
9. Slide pivot sleeve [3] off handgun body [1].
10. Inspect sleeve bearing [14] for tears or worn spots and
replace if necessary.
11. Wrap sleeve bearing [14] around body [1].
12. Slide body [1] and sleeve bearing [14] into pivot sleeve [3].
13. Inspect swivel connector seal [4] and backup ring [5] for
evidence of pitting, hardening, or other damage.

CAUTION: The swivel connector seal and thrust

!
bearing require high temperature grease. High
temperatures can carbonize a standard grease
causing the bearing to bind.

14. Lubricate swivel connector seal with bearing lubricant.

15. Assemble swivel connector seal [4] and backup ring [5] in
accordance with figure below.
16. Inspect thrust bearing [11] and replace it if binding. If not
binding, thoroughly clean bearing to remove old grease.
17. Pack thrust bearing [11] with bearing lubricant.
18. Install thrust bearing [11] in pivot sleeve [3] with printed side
of bearing facing body [1].
19. Using snap-ring pliers, reinstall retaining ring [12] into
retaining ring groove on body [1].
20. Reinstall conical spring [9] (small end toward body) and
swivel connector [8] into pivot sleeve [3].
21. Install 2 washers [7] and 2 screws [6] to secure swivel
connector [8]. Tighten finger tight.

Copyright 2009 Astro Packaging L4 Handgun 19600-110 26

 22. Rotate pivot sleeve [3] to allow swivel [8] to self-center.
23. Tighten screws [6] to check for binding and free rotation. If
binding occurs, loosen screws [6] and rotate pivot sleeve [3].
Tighten screws [6] and check for free rotation. Repeat as
necessary.
24. Connect hose to handgun at hose connector.
25. Replace pivot sleeve shells [2] and secure with 4 screws [13].
26. Restore system to operating conditions in accordance with
melt unit manual

14

2
3

13

2
12
11
10 4
9 5
8
7
6

Swivel Bearing Assembly 0960346a

Copyright 2009 Astro Packaging L4 Handgun 19600-110 27

 Item Description Part Number Quantity
1† O-ring,Viton, 0.070" x 0.426"ID 10413 1
1† O-ring,Teflon, 0.070" x 0.426"ID 10493-013 1
2 Seat 70086-09 1
3 Ring, Seal 70086-11 1
4 Cartridge, Packing 73298-01 1
5 Body, Gun (Internal) 70087-03 1
6 Hex Nut,10-32 14441-FA 1
7* Linkage, Trigger 70086-05 1
8* Spring, Trigger 14487-02 1
9* Pin, Dowel 14446-7 1
10* Trigger, Handgun 70085-04 1
11* Plate, Bearing 70086-06 1
12* Screw, Shoulder, 10-24 x 0.375" 14400-001 1
13* Safety, Handgun 70085-05 1
14* Spring, Wave 14508-03 1
15* Shell, Handgun, Right 70085-14 1
16* Screw, 6-32 x 0.50" 14416-CAF 9
17 Sleeve, Pivot 79257-01 2
18 Screw 8-32 x 1.25" 14416-DAL 2
19 Lock Washer, NO.6 14451-CA 2
20 Connector, Swivel 70086-14 1
21 Back-up Ring, 0.35 x 0.38" 10476-01 1
22† O-ring, Viton, 0.070 x 0.239" 10410 1
22† O-ring, Teflon, 0.070 x 0.239" 10493-010 1
23 Spring, conical 14463-7 1
24 Snap ring, 0.625"ID 14502-22 1
25 Thrust Bearing 70086-08 1
26 Retaining ring, 0.625"ID 14502-21 1
27 Terminal Block, 3-Pole 70086-12 1-2
28† Heater, 80w, 120V 12632-02 1
28† Heater, 80w, 240V 12632-03 1
29 Screw, 6-32 x 0.250" 14416-DAD 1
30 Lock Washer, NO.8 14451-DA 1
31 Bearing, sleeve 70086-07 1
32 Pivot Sleeve 70086-16 1
33† RTD Sensor, 100 Ω 79117-06 1
33† Thermostat, 191°C (350°F) Kit APNT350 1
34 Screw, 5-40 x 0.25" 14416-OAC 2
35 Clip, wire 14502-23 1
36* Shells, Handgun, Left 70085-15 1
37 Switch Plug Assembly (switched guns only) 73299-01 1
38 Screw, 5-40 x 0.50" 14413-BAW 2
39 Lock Washer, NO. 4 14451-BC 2
40† O-ring, Viton, 0.070 x 0.426" 10412 1
40† O-ring, Teflon, 0.070 x0.426" 10493-012 1
41 Screw, 6-32 x0.875" SHCS 14431-CDJ 1
* Part of 79257-2 Kit † Multiple options available

Copyright 2009 Astro Packaging L4 Handgun 19600-110 28

Copyright 2009 Astro Packaging L4 Handgun 19600-110 29
9.2 Standard Nozzles

Extrusion Nozzles
Description Orifice Diameter Part Number

Nozzle, standard 0.51 mm (0.020 in.) 73861-020

Nozzle, standard 0.76 mm (0.030 in.) 73861-030
Nozzle, standard 1.02 mm (0.040 in.) 73861-040
0970063
Nozzle, standard 1.52 mm (0.060 in.) 73861-060
Nozzle, standard 2.29 mm (0.090 in.) 73861-090

Nozzle, extended 1.07 mm (0.042 in.) 73862-042

Nozzle, extended 1.55 mm (0.062 in.) 73862-062
0970062
Nozzle, extended 2.29 mm (0.090 in.) 73862-090
Nozzle, extended 3.30 mm (0.130 in.) 73862-130

Standard Nozzle Adapters

Description Part Number

Adapter, L1 Nozzle to L4 Handgun 70168-1

(Use with nozzles: 73059-XX, 73059-XXX,
73060-XXX, 73060S-XXX, 73065-XX, 73118-XX)

Adapter, L1 Nozzle to L4 Handgun 70188-1

(Use with nozzles: 73063-XXX, 73064-XX,
73061-XXX, 73062-XXX)
7
097006

L4 Down Apply Nozzle Adapter

Description Part Number

L4 Down Apply Adapter kit 79302-01

(Use with nozzles: 73861-XXX, 73862-XXX)

Copyright 2009 Astro Packaging L4 Handgun 19600-110 30

9.3 T Bar Nozzles
T Bar Nozzles
73059-413 T Bar Nozzle, 2 Orifice, .020" @ 0.50" spacing
73059-402 T Bar Nozzle, 2 Orifice, .020" @ 3.125" spacing
73059-407 T Bar Nozzle, 2 Orifice, .060" @ 0.75" spacing
73059-419 T Bar Nozzle, 2 Orifice, .020" @ 1.25" spacing
73059-421 T Bar Nozzle, 2 Orifice, .030" @ 1.25" spacing
73059-422 T Bar Nozzle, 2 Orifice, .060" @ 1.25" spacing
73059-415 T Bar Nozzle, 2 Orifice, .060" @ 1.00" spacing
73059-417 T Bar Nozzle, 2 Orifice, .060" @ 1.50" spacing
73059-418 T Bar Nozzle, 2 Orifice, .060" @ 1.75" spacing
73059-420 T Bar Nozzle, 2 Orifice, .060" @ 2.00" spacing
73059-403 T Bar Nozzle, 3 Orifice, .050" @ 1.00" spacing
0950356a

73059-404 T Bar Nozzle, 3 Orifice, .050" @ 0.50" spacing

73059-408 T Bar Nozzle, 3 Orifice, .060" @ 0.75" spacing
73059-410 T Bar Nozzle, 3 Orifice, .070" and .04" @ 0.75" spacing
73059-423 T Bar Nozzle, 3 Orifice, .060" @ 0.625" spacing
73059-411 T Bar Nozzle, 3 Orifice, .020" @ 1.75" spacing
73059-401 T Bar Nozzle, 4 Orifice, .030" @ 0.50" spacing
73059-406 T Bar Nozzle, 4 Orifice, .050" @ 0.50" spacing
73059-409 T Bar Nozzle, 4 Orifice, .060" @ 0.75" spacing
73059-412 T Bar Nozzle, 5 Orifice, .030" @ 0.75" spacing
73059-414 T Bar Nozzle, 5 Orifice, .030" @ 0.50" spacing

Copyright 2009 Astro Packaging L4 Handgun 19600-110 31

9.4 Slot Nozzles
Slot Nozzles
73060-01 Slot Nozzle, .062" opening x 0.50" wide
73060-02 Slot Nozzle, .062" opening x 0.75" wide
73060-03 Slot Nozzle, .062" opening x 1.00" wide
73060-04 Slot Nozzle, .062" opening x 1.25" wide
73060-05 Slot Nozzle, .062" opening x 1.50" wide
0950354a
73060-06 Slot Nozzle, .062" opening x 1.75" wide
73060-07 Slot Nozzle, .062" opening x 2.00" wide

73061-01 Spreader Nozzle, .25" wide x .50"

73061-02 Spreader Nozzle, .25" wide x 1.00" long
73061-03 Spreader Nozzle, .25" wide x 1.50" long
0950355a

73062-01 Extension Nozzle, .125" Orifice x .50", brass

73062-02 Extension Nozzle, .125" Orifice x 1.00", brass
73062-03 Extension Nozzle, .125" Orifice x 1.50", brass
0950333a

73062-04 Extension Nozzle, .125" Orifice x 1.50", stainless

73063-01 Needle Nozzle, .062" Orifice x 1.00" long

73063-02 Needle Nozzle, .062" Orifice x 1.50" long
73063-03 Needle Nozzle, .062" Orifice x 1.75" long
0950351a
73063-04 Needle Nozzle, .025" Orifice x 1.00" long
73063-05 Needle Nozzle, .025" Orifice x 1.50" long
73063-06 Needle Nozzle, .025" Orifice x 1.75" long

73065-001 Mitre Nozzle, 2 Orifice, .030", 45° angle

73065-002 Mitre Nozzle, 2 Orifice, .050", 45° angle
73065-003 Mitre Nozzle, 2 Orifice, .060", 45° angle
0950348a

73065-004 Mitre Nozzle, 2 Orifice, .070", 45° angle

73118-001 "L" Nozzle, 1 Orifice, .060", 1.12" from edge

73118-002 "L" Nozzle, 1 Orifice, .090", 1.12" from edge
0950336a

Use these adapters to modify existing L1 nozzles to be compatible

with L4, L5, and L7 Handguns.
70168-1 Adapter, L1 Nozzle to L4 (Use with: 73059-XX, 73059-XXX,
73060-XXX, 73060S-XXX, 73065-XX, 73118-XX)
70188-1 Adapter, L1 Nozzle to L4 (Use with: 73063-XXX, 73064-XX,
73061-XXX, 73062-XXX)

Copyright 2009 Astro Packaging L4 Handgun 19600-110 32

9.5 Hoses
Standard L4 Hoses
Description Part Number

Capillary, 100 VAC (for thermostat handguns) 21264-XX

Capillary, 115 VAC (for thermostat handguns) 21260-XX
Capillary, 200 VAC (for thermostat handguns) 21266-XX
Capillary, 230 VAC (for thermostat handguns) 21262-XX
RTD2, 100 VAC (for RTD handguns) 21265-XX
RTD2, 115 VAC (for RTD handguns) 21261-XX
RTD2, 200 VAC (for RTD handguns) 21267-XX
RTD2, 230 VAC (for RTD handguns) 21263-XX

Switched L4 Hoses
Description Part Number

Capillary, 100 VAC (for thermostat handguns) 21272-XX

Capillary, 115 VAC (for thermostat handguns) 21268-XX
Capillary, 200 VAC (for thermostat handguns) 21274-XX
Capillary, 230 VAC (for thermostat handguns) 21270-XX
RTD2, 100 VAC (for RTD handguns) 21273-XX
RTD2, 115 VAC (for RTD handguns) 21269-XX
RTD2, 200 VAC (for RTD handguns) 21275-XX
RTD2, 230 VAC (for RTD handguns) 21271-XX

Hoses are ordered in lengths as follows:

Length Part Number Add-on
2.44 m (8 ft) XXXXX-08
3.66 m (12 ft) XXXXX-12
4.88 m (16 ft) XXXXX-16

Copyright 2009 Astro Packaging L4 Handgun 19600-110 33

9.6 Optional Thermostat Kits

Optional Thermostat Kits

Description Part Number

94 °C (200 °F) 79229-200

107 °C (225 °F) 79229-225
121 °C (250 °F) 79229-250
135 °C (275 °F) 79229-275
149 °C (300 °F) 79229-300
163 °C (325 °F) 79229-325
177 °C (350 °F) 79229-350
191 °C (375 °F), standard 79229-375
204 °C (400 °F) 79229-400
218 °C (425 °F) 79229-425

9.7 Accessories and Tools

Accessories and Tools

Description Part Number

Heat release and heat transfer compound 11207

High temperature lubricant, clear, o-rings 11208
High temperature grease, black, bearings 11209-1
AMP pin extraction tool 11042-2
Kit, extended cuff, L4 Handgun 79412-01
Air line kit, 6.10 m (20 ft) 79350
Handgun hanger kit 79023
Safety gloves 11068-1
Strip-N-Clean ® 11200-X

Copyright 2009 Astro Packaging L4 Handgun 19600-110 34

Appendix A Resistance Tables
Minimum and maximum resistance (R) of common handguns and hoses
Unless otherwise specified, resistance values are measured at 20° + 5° C (68° + 10° F).

Table 1. RTD Sensor Resistance

Temperature Ohms
0 °C (32 °F) 100
38 °C (100 °F) 115
66 °C (150 °F) 126
93 °C (200 °F) 136
121°C (250 °F) 147
149 °C (300 °F) 158
177 °C (350 °F) 168
204 °C (400 °F) 178
Same RTD sensor is used in tank,
hose, and applicator.

Table 2. Heater Resistance for L4 Handguns

Model Voltage Heater Heater Ohms*
Quantity Wattage
L4 230 VAC 1 80 664–720
L4 115 VAC 1 80 170–190
*For applicators with more than 1 heater, resistance
shown is for heaters in parallel.

Table 3. Heater Resistance for L4 Handgun Hoses in Ohms

Part No. (VAC) 2.44 m (8 ft) 3.66 m (12 ft) 4.88 m (16 ft)
L4 Hose, Capillary Sensor
21260 (115 VAC) 71–74 48–50 36–38
21262 (230 VAC) 283–294 192–200 145–152
L4 Hose, RTD Sensor
21285 (115VAC) 75–79 45–52 37–39
21287 (230VAC) 298–315 199–209 149–157

Copyright 2009 Astro Packaging L4 Handgun 19600-110 35

This page intentionally left blank.

36
 Warranty
A. Astro Packaging warrants its products, when operated and maintained in accordance with
Astro Packaging recommended procedures, are free of defects in material and workmanship during the periods
indicated below commencing with the date the product is placed in service.

Product Warranty Period

1. Tank heater (including entire tank when 5 years or 10,000 hours of use,
heater is cast into tank) whichever occurs first
2. Melt unit (unless specified below); pattern 1 years or 4,000 hours of use,
controller; head driver whichever occurs first
®
3. Stationary hose; automatic electric head; JR 1 year or 2,000 hours of use,
Series Hot Melt System or melt unit; standard pail whichever occurs first
UN-loader; standard accessory purchased with a system
4. Manual hose; handgun; Mini Squirt III; any butyl 6 months or 1,000 hours of use,
system; any PUR system (including hose, gun whichever occurs first
or head used with PUR); any spare or replacement
component; pneumatic head; industrial heated hose;
T100 Temperature Controller; nozzle; nozzle bar
5. Rebuilt equipment 90 days or 500 hours of use,
whichever occurs first

B. The sole liability of Astro Packaging and exclusive remedy extended to any Astro Packaging customer shall be limited
to replacing or repairing, at the option of Astro Packaging, any product returned under the terms of this warranty.
Labor and related expenses incurred to install replacement or repaired parts are not covered by this warranty.
C. Astro Packaging is not responsible for repair or replacement of any product that has been subject to abuse,
misuse, alteration, accident, or negligent use, nor for repairs made by an unauthorized person or with parts
other than those provided by Astro Packaging.
D. Astro Packaging assumes no responsibility for the performance of adhesives or other materials used with its
products.
E. The warranty for a product repaired or replaced under this warranty shall continue in effect for the remainder of
the original warranty period, or for ninety (90) days following the day of shipment by Astro Packaging the
repaired or replaced product, whichever period is longer.
F. No warranty is made with respect to custom products or products developed, designed and manufactured to
customer specifications, except as specifically stated in writing by Astro Packaging.
G. Astro Packaging is responsible only for payment of shipping charges for delivery of a repaired or replaced product,
via the least expensive means of transport, to customer or an authorized Sales and Service Center in the
Continental United States only. Payment for shipment to Astro Packaging or an authorized Sales and Service
Center for evaluation, repair or replacement is the responsibility of the customer.
H. For service under this warranty, contact the Factory Authorized Representative from which the product was
purchased.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED,

INCLUDING THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR THE PARTICULAR
PURPOSE.

Complete Reverse Side and Retain for Your Records

Astro Packaging 3845 E. Miraloma Ave, Suite A, Anaheim, CA 92806 1-800-642-7876 phone 714-572-1943 fax
1 of 2
 Equipment Record
Record the information below on all equipment received and retain for your records.
(Systems, melt units, hoses, guns, heads, pattern controllers, drivers, etc)

Products were purchased from:___________________________________________

Astro P
{ ackaging

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received____________ Start-Up Date____________Invoice No.____________

Product Model/Description__________________________Serial No._____________

Product Part Number______________________________ Order No._____________
Date Received_____________ Start-Up Date___________Invoice No.____________

Astro Packaging 3845 E. Miraloma Ave, Suite A, Anaheim, CA 92806 1-800-642-7876 phone 714-572-1943 fax

2 of 2