INSTRUCTIONS–PARTS LIST
307–712
Rev
P
N
Supersedes
This manual contains IMPORTANT
W
ARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PRO 5000
t
AUTOMATIC MID-RANGE ELECTROSTATIC
AIR SPRAY GUN
7
bar (100 psi) MAXIMUM WORKING AIR PRESSURE
Part Number 218–745, Series B
With 1.2 mm (0.047 in.) spray nozzle and part no. 218–996 air cap assembly
U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774; 4,554,622
U.K. Patent No. 2,140,327B; 2,142,559B; 2,147,158; 2,191,423
Patented 1986, 1987 Canada
Brevete 1986, 1987
French Patent No. 84 07942; 84 10234
Italian Patent No. 1,111,380
Japanese Patent No. 86. 07416
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
E
COPYRIGHT 1985, GRACO INC.
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TABLE OF CONTENTS
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Electrical Tests
est Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 16
T
.
Safety arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
W
Test Power Supply Resistance
Test Resistor Stud Resistance
.
.
. . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . 17
How The Electrostatic Air Spray Gun Works . . . .
5
Service
Installation
Gun Disassembly
Electrode Replacement
Resistor Stud Replacement
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Needle Packing Replacement . . . . . . . . . . . . . 20
Power Cartridge Replacement . . . . . . . . . . . . . . . . . 22
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . 19
Typical Installation
Warning Signs
Ventilate the Spray Booth
Mount the Gun
Connect the Air Line
Connect the Fluid Line
Check the Electrical Grounding
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
6
6
6
7
7
7
8
8
.
.
.
.
.
.
.
.
.
.
Turbine Alternator Removal
Fan Air Valve Replacement
Piston Removal and Repair
.
.
.
. . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . 24
.
Installing Optional Remote Fan Air Adapter
.
. . . . . . .
Operation
Disc Regulator O-Ring Replacement
.
. . . . . . . . . . . . 25
Operating Checklist
Filter the Fluid
Spraying Operation
Selecting a Fluid Nozzle and Air Cap
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
9
9
9
9
Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 25
.
.
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
.
.
.
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjust the Spray Pattern
.
. . . . . . . . . . . . . . . . . . . . . . 10
Maintenance
Daily Care and Cleaning
.
. . . . . . . . . . . . . . . . . . . . . . 11
Technical Data
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . 29
Flush the Spray Gun
.
. . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . 12
How To Order Replacement Parts
.
To Clean or Change Air Cap and Fluid Nozzle
.
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Spray Pattern Troubleshooting Chart . . . . . . . . . . 13
Gun Operation Troubleshooting Chart . . . . . . . . . 14
Electrical Troubleshooting Chart . . . . . . . . . . . . . . 15
TERMS
WARNING: Alerts user to avoid or correct conditions that could
cause bodily harm.
PRESSURE RELIEF PROCEDURE: A safety procedure for re-
lieving air and fluid pressure in the system.
CAUTION: Alerts user to avoid or correct conditions that could
cause damage to or destruction of equipment.
FOR YOUR SAFETY
:
Alerts user to read the additional safety
warnings on the page indicated.
NOTE: Identifies essential procedures or helpful information.
307-712
3
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SAFETY
WARNINGS
SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN
OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED.
READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND
WARNING LABELS BEFORE OPERATING EQUIPMENT.
ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED,
QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE
REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.
EQUIPMENT MISUSE HAZARD
General Safety
Fluid Compatibility
BE SURE all fluids and solvents used are chemically compatible with the
“Wetted Parts” shown in the TECHNICAL DATA. Always read the fluid
Any misuse of the spray equipment or accessories, such as overpres
surizing, modifying parts, using incompatible chemicals and fluids, or us
ing worn or damaged parts, can cause them to rupture and result in seri
ous bodily injury, fire, explosion or property damage.
-
-
-
and solvent manufacturer
this gun.
’s literature before using the fluid or solvent in
NEVER point the spray gun at anyone or at any part of the body. NEVER
put hand or fingers over the fluid nozzle.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including splashing in the eyes
or on the skin, injury from moving parts or electric shock, always follow
this procedure when shutting off the system, when checking or servicing
any part of the spray system, when installing, cleaning or changing fluid
nozzles, and whenever you stop spraying.
ALWAYS follow the Pressure Relief Procedure, at right, before cleaning
or removing the fluid nozzle or servicing any system equipment.
NEVER try to stop or deflect leaks with your hand or body
.
1.
2.
T
urn off all the air to the gun except the cylinder (actuating) air
.
NEVER alter or modify any part of this equipment; doing so could cause it
to malfunction.
Turn off the fluid supply to the gun.
3. Actuate the gun into a grounded metal waste container to relieve fluid
pressure.
CHECK all spray equipment regularly and repair or replace worn or dam
aged parts immediately
-
4. Open the pump drain valve, having a waste container ready to catch
the drainage.
.
5. Leave the pump drain valve open until you are ready to spray again.
System Pressure
This gun has a maximum working air and fluid pressure of 7 bar (100 psi).
Never exceed the maximum working pressure of the gun or any other
component or accessory used in the system.
HAZARDOUS FLUID HAZARD
Improper handling of hazardous fluids or inhaling vapors can cause ex
tremely serious bodily injury, even death, due to splashing in the eyes,
ingestion, inhalation, or bodily contamination.
-
2. Dispose of any waste fluid according to all Local, State and Federal
regulations pertaining to the disposal of hazardous wastes.
3. Read and follow the fluid and solvent manufacturer’s literature
regarding the use of protective clothing and equipment such as eye
protection, respiratory protection, and gloves.
Be sure you know what fluid you are pumping and its specific hazards.
Observe all precautions when handling known or potentially hazardous
fluids, including, but not limited to, the following.
4. Provide for the safe piping and disposal of all exhaust air
.
5. Provide proper ventilation in accordance with accepted industry
standards and governmental regulations. Refer to Ventilate the
Spray Booth, on page 6.
1. Store hazardous fluids in approved containers.
HOSE SAFETY
TIGHTEN all fluid connections securely before each use.
HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to
move equipment. Do not use fluids or solvents which are not compatible
with the inner tube and cover of the hose.
NEVER use a damaged hose. Before each use, check the entire hose for
cuts, leaks, abrasion, bulging cover, or damage or movement of the hose
couplings. If any of these conditions exist, replace the hose immediately
.
4
307-712
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FIRE OR EXPLOSION HAZARD
To reduce the risk of fire, explosion, or electric shock, which may result
from electrical discharge, it is essential that:
6. All persons entering the spray area: shoes must have conductive
soles, such as leather or personal grounding straps must be worn.
,
Rubber or plastic soles are not conductive.
7. The floor of the spray area must be electrically conductive and
grounded. Do not cover the floor with cardboard or any
non-conductive material which would interrupt grounding
continuity.
S
All parts of the electrostatic system are properly grounded.
S
All personnel in or close to the spray area are properly grounded.
S All electrically conductive objects or devices in the spray area, includ
-
ing paint containers, wash cans and tools, are properly grounded.
8. Flammable liquids in the spray area must be kept in approved,
grounded containers. Do not store more than the quantity needed
for one shift.
When operating the electrostatic device, any ungrounded objects in the
spray area (such as people, containers, tools, etc.) can become electri
cally charged. Arcing may occur if these objects then come in contact or
close to ground. Arcing of sufficient energy levels can ignite the fluid be
ing sprayed, fumes from solvents, dust particles, and other flammable
substances. This can cause a fire or explosion and result in serious bod
ily injury and property damage.
-
9. All solvent pails: use only grounded metal pails, which are
conductive. Do not place the pail on any non-conductive surface,
such as cardboard or paper, which would interrupt grounding
continuity.
-
-
10. All air and fluid lines and electric cables must be properly grounded.
Flushing and Cleaning Safety
To reduce the risk of static sparking or splashing, always follow the Pres-
sure Relief Procedure on page 4.
Static electricity can also be generated by the flow of fluid through the
pump, hose, gun, and nozzle, but it is dissipated through proper ground
ing as described in Grounding below
-
.
If you experience any arcing or feel even a slight shock, STOP SPRAY-
ING IMMEDIATELY. Check for proper grounding of the entire system. Be
sure you have corrected the problem before starting to spray again.
Be sure the turbine air (electrostatics) is OFF before flushing or
cleaning any part of the spray system.
Use the lowest possible pressure to flush. Trigger the gun into a grounded
metal waste container
.
Grounding
The following are minimum requirements for grounding a basic electro
-
static system. Your system may include other equipment or objects
which must also be grounded. Always check your local electrical code for
detailed grounding instructions. Be sure your system is connected to a
true earth ground.
To flush or purge equipment, ALWAYS use solvents with a flash point
equal to or greater than that of the fluid being sprayed.
To clean the exterior of the equipment, ALWAYS use solvents with a flash
point of higher than 38
_
C
(100_ F).
1. Pump: ground by using a ground wire and clamp as described in
your separate pump instruction manual.
ALWAYS remove all solvent from the system before reactivating the
spray gun.
2. Air compressors and hydraulic power supplies: ground according to
the manufacturer’s recommendations.
Use only non-sparking tools to clean residue from the booth and hangers.
3. Electrostatic Spray Gun: obtain grounding through connection to a
properly grounded air supply hose. Use only the Graco Electrically
Conductive Air Supply Hose; see ACCESSORIES section to order
.
Ventilate the Spray Booth
To prevent hazardous concentrations of toxic and/or flammable vapors,
spray only in a properly ventilated spray booth.
Connect the air hose ground wire to a true earth ground.
4. Object being sprayed: keep the work piece hangers clean and
grounded at all times. Contact points must be sharp points or knife
edges.
NEVER operate the spray gun unless the ventilating fans are operating.
5. All electrically conductive objects or devices in the spray area,
including paint containers and wash cans, must be properly
grounded.
Check and follow all National, State and Local codes regarding air ex
-
haust velocity requirements. Check and follow all local safety and fire
codes and OSHA standard 1910–107(b)(5)(i).
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards––particularly the
General Standards, Part 1910.107 and any other appropriate regulations––should be consulted in connection with the installation, operation, and
maintenance of electrostatic spray painting equipment.
HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge, to supply high
voltage current to the gun’s ionizing electrode.
The pump supplies fluid to the hose and gun, where the
fluid is electrostatically charged as it passes the elec-
trode. The charged fluid is attracted to the grounded
workpiece, wrapping around and evenly coating all sur-
faces.
307-712
5
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TYPICAL INSTALLATION
Electric Box
Main Air Line
P
Fluid Line
A
J
L
J
Q
KEY
A
B
C
D
E
Air Supply Shut-off Valve (bleed-type)
Air & Water Separator
Ball Valve
Air Line Lubricator
Air Regulator
F
Pump
Fluid Filter
Drain Valve
Pump Ground Wire
Air Filter (40 micron)
L
N
P
Fluid Regulator
ES Automatic Gun
G
H
J
Normally Closed, 3-Way Air Solenoid
alve or 3-Way Manual Valve
Exhaust Hose
V
K
Q
The Typical Installation shown above is only a guide for
selecting and installing electrostatic air spray systems. It
is not an actual system design. The particular type and
size system for your operation must be custom designed
for your needs. For assistance in designing a system,
contact your Graco representative.
Ventilate the Spray Booth
WARNING
To prevent hazardous concentrations of toxic and/
or flammable vapors, spray only in a properly ven
-
tilated spray booth. Never operate the spray gun
unless ventilation fans are operating. The air
supply to the gun must be electrically interlocked
with the ventilators to prevent operation of the
power supply unless ventilating fans are running.
WARNING
Installing and servicing this equipment requires ac-
cess to parts which may cause electric shock or other
serious bodily injury if work is not performed properly
Do not install or service this equipment unless
you are trained and qualified.
.
Check and follow all of the National, State and Lo
cal codes regarding air exhaust velocity require-
ments.
-
Be sure your installation complies with National,
State and Local codes for the installation of electrical
apparatus in a Class 1, Group D, Divisions 1 and 2
Hazardous Location.
Check and follow all local safety and fire codes and
OSHA standard 1910–107(b)(5)(i).
NOTE: High velocity air exhaust will decrease the oper
-
ating efficiency of the electrostatic system. The
minimum allowable air exhaust velocity is 19 lin
ear meters/minute (60 ft/min).
-
Warning Signs
A
warning sign in English and one in Spanish is supplied
with the gun. Mount warning signs in the spray area
where they can easily be seen and read by all operators.
This sign is also available in French and German. See the
ACCESSORIES section to order
.
6
307-712
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INSTALLATION
6. Connect the cylinder air line to the gun’s cylinder air
Mount the Gun
Mount the gun on a stationary support or on a reciprocat
inlet (marked CYL).
-
ing arm. The mounting rod must be properly grounded.
7. Connect the atomizing air line to the gun’s atomizing
air inlet (marked ATOM).
Mount the gun so the front of the gun is 254 to 300 mm (10
to 12 in.) from the work piece.
8. Connect the turbine air supply line to the gun’s air in
-
let (marked ES). The gun air inlet fitting has a left
hand thread. Connect the air supply hose ground
wire to a true earth ground.
Connect the Air Line (Refer to the Typical
Installation Drawing)
WARNING
To reduce the risk of electric shock or other serious
9. A remote fan air adapter is available to control the fan
air at the control booth. See Installing the Optional
Remote Fan Air Adapter, on page 8.
bodily injury the air supply hose must be electrically
,
connected to a true earth ground. Use Only Graco
Electrically Conductive Air Supply Hose. This
hose, and the gun, have special threads which pre
vent using any other type of hose with the gun. See
-
Connect the Fluid Line (Refer to the Typical
Installation Drawing)
the ACCESSORIES section to order the hose.
1. Before connecting the fluid line, blow it out with air
and flush it with solvent. Use solvent which is com-
patible with the fluid to be sprayed.
1. Install an air line filter (K) and an air and water sepa
-
rator (B) on the main air line to ensure a dry, clean air
supply to the gun. Dirt and moisture can ruin the ap
pearance of your finished workpiece and can cause
the gun to malfunction.
2. Install a fluid regulator (L) on the fluid line to control
fluid pressure to the gun.
-
3. Install a fluid filter (G) and drain valve (H) at the pump
outlet.
2. Install an air line lubricator (D) close to the pump air
inlet.
WARNING
The fluid drain valve (H) is required in your system
3. Install a normally closed, 3-way air solenoid (P) or
manual valve on the turbine, cylinder and remote fan
air supply lines. (The remote fan line is optional.)
to assist in relieving fluid pressure in the displace
-
ment pump, hose and gun; triggering the gun to
relieve pressure may not be sufficient. Install a
drain valve close to pump’s fluid outlet. The drain
4. Install a bleed-type air regulator (E) on the pump,
turbine, atomizing, cylinder, and remote fan (option-
al) air supply lines to control air pressure to the pump
and gun.
valve reduces the risk of property damage or seri
-
ous bodily injury, including splashing in the eyes or
on skin and contamination from hazardous fluids.
5. Install a bleed-type air shutoff valve (A) on the main
air line, the pump line, and each gun air supply line to
shut off air to the pump and gun.
4. Connect the fluid line to the gun fluid inlet.
CAUTION
Do not use metal fittings at the gun barrel. For cir
culation systems, use plastic fittings.
-
WARNING
The bleed–type air shutoff valve (A) is required in
your system to relieve air trapped between this
valve and the pump after the air regulator is
closed. Trapped air can cause the pump to cycle
unexpectedly, which could result in serious bodily
injury, including splashing in the eyes or on the skin
and injury from moving parts.
7
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INSTALLATION
KEY
Check the Electrical Grounding
Y
Z
Turbine Air Inlet
rue Earth Ground
WARNING
T
Proper electrical grounding of every part of your
AA Ohmmeter
system is essential. For your safety, read the warn
-
BB Grounded Air Hose
ing section, FIRE OR EXPLOSION HAZARD, on
page 5. Ground the system as explained there.
AA
Z
Then check your system as explained below
.
1. Shut off all air lines to the gun.
2. Shut off the fluid supply to the gun.
BB
3. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
a. With the electrically conductive air hose (BB)
connected and properly grounded, use a
megohmmeter (AA) (shown in ACCESSORIES
section) to measure the resistance between the
gun body (Y) and a true earth ground (Z). Use an
applied voltage of 500 volts minimum to 1000
volts maximum. See Fig 1.
b. If the resistance is greater than 2 megohms,
check the tightness of the ground connections,
and be sure the air supply hose ground wire is
connected to a true earth ground. If the resis-
tance is still greater than 2 megohms, replace
the air supply hose.
Fig 1
2. Apply PTFE tape to the threads of the remote fan air
adapter (part no. 181–053) and install it in the gun
body (1). Torque the adapter to 1.1–1.4 N
in-lb).
Sm (10–12
Installing Optional Remote Fan Air Adapter
NOTE: See ACCESSORIES to order the Remote Fan
3. Install the 90_ elbow (part no. 108–234) in the
Air Adapter 181–053 and 90 Elbow 108–234.
_
adapter.
1. Place a wrench on the flats of the valve housing (55)
and remove the fan air valve assembly from the gun
body (1). See Fig 20, page 23.
4. Install the remote fan air line, solenoid valve, air regu
-
lator and shut-off valve as instructed in Connect the
Air Lines, on page 7.
8
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OPERATION
WARNING
Pressure Relief Procedure
2. Turn off the fluid supply to the gun.
To reduce the risk of serious bodily injury, including
splashing in the eyes or on the skin, injury from moving
parts or electric shock, always follow this procedure
3. Trigger the gun into a grounded metal waste con
-
tainer to relieve fluid pressure.
when shutting off the system, when checking or serv
-
4. Engage the gun safety latch.
icing any part of the spray system, when installing,
cleaning or changing fluid nozzles, and whenever you
stop spraying.
5. Open the pump drain valve, having a waste con-
tainer ready to catch the drainage.
1. Turn off all the air to the gun except the cylinder
(actuating) air.
6. Leave the pump drain valve open until you are
ready to spray again.
Operating Checklist
Spraying Operation
Check the following list daily, before starting to operate
the system, to help ensure you of safe, efficient
operation.
This gun has a built-in lead and lag operation. The gun
begins emitting air before the fluid is discharged. When
you release the trigger, the fluid stops before the air flow
stops. This helps prevent fluid build-up on the air cap.
1. Be sure all operators are properly trained to
safely operate an automatic air spray system.
Adjust the system’s control device, if it is automatic, so
the gun starts spraying just before meeting the work
piece, and stops as soon as the work piece has passed.
2. Be sure all operators are trained how to prop
-
erly and completely relieve system pressure.
When spraying, the ES indicator lights (BB) should glow
indicating the electrostatic charge. See Fig 4.
,
3. Be sure the system is thoroughly grounded.
See FIRE OR EXPLOSION HAZARD, page
5, and Check the Electrical Grounding,
page 8.
Selecting a Fluid Nozzle and Air Cap
WARNING
4. Be sure the operator and all persons entering
To reduce the risk of serious bodily injury, including
splashing in the eyes or on the skin or electric
shock, always follow the Pressure Relief Proce-
dure, above, before installing, or removing the fluid
the spray area are properly grounded by wear
-
ing shoes with conductive soles or personal
grounding straps.
nozzle/air cap assembly
.
5. Be sure ventilation fans are operating prop-
erly.
This gun is supplied with fluid nozzle 181–299 and air cap
180–739. See Instruction Manual 307–803 for air cap
consumption and fluid nozzle flow rate information.
6. Be sure the work piece hangers are clean and
grounded. Contact points must be sharp
points or knife edges.
The fluid output and pattern shape depends on the fluid
nozzle size, fluid viscosity, and fluid pressure. If your
7. Be sure all refuse is removed from the spray
booth.
application requires a different nozzle and air cap combi
-
nation, use manual 307–803 to select the appropriate
fluid nozzle and air cap.
8. Be sure all flammable liquids in the spray
booth are in approved, grounded containers.
9. Be sure all conductive objects within 6 m
(20 ft) of the gun are electrically grounded and
the floor of the spray area is electrically con-
ductive and grounded.
To install a different fluid nozzle and air cap, see To Clean
or Change Air Cap and Fluid Nozzle, page 12.
Filter the Fluid
Filter the fluid to remove coarse particles and sediment
which could clog the spray nozzle.
307-712
9
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OPERATION
NOTE: Provide a 3.1 bar (45 psi) clean, dry, regulated air
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow
supply to the gun to ensure full voltage from the
power supply. The gun may be operated at lower
and air flow DO NOT turn the turbine air on yet.
.
turbine air pressure, but may lose some electro
-
static effect. Do not operate the turbine at an air
pressure greater than 3.1 bar (45 psi) as there is
no benefit and turbine life will be reduced.
1. Adjust the fluid flow for the appropriate flow rate by
using the fluid pressure regulator installed in the fluid
line. Check the fluid nozzle chart in manual 307–803
for the appropriate flow rate for the air cap. Start with
the lowest rate shown and increase it until you get the
desired flow rate.
NOTE: A remote fan air adapter is available to control
the fan air at the control booth. See
ACCESSORIES.
2. For fine adjustment of how much fluid is sprayed,
tighten or loosen the trigger adjusting nut (24). See
Fig 4. Turn the nut out to reduce the amount of fluid
sprayed or turn it in to increase the amount.
See the Spray Pattern Troubleshooting Chart
on page 13 to correct spray pattern problems.
KEY
24
51
56
Trigger Adjusting Nut
ES Indicator Light
Fan Adjusting Knob
3. Close the fan adjusting knob (56) by turning it fully
clockwise.
56
51
4. Use an air pressure regulator to adjust the degree of
atomization. Always use the lowest air pressure pos
-
sible for the most efficiency.
5. Use the fan adjusting knob to change the shape of
the spray pattern. Turn the knob counterclockwise
for a wide pattern and clockwise for a solid, round
pattern. When increasing to a wide, flat pattern, it
may be necessary to increase the supply of fluid to
the gun to maintain the same amount of coverage
over a large area.
Fig 4
24
6. First, complete all the checks under the Operating
Checklist on page 9. Then turn the turbine air on.
When spraying, the ES indicator light (51) should
glow, indicating the electrostatic charge.
10
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MAINTENANCE
5. Flush the spray gun before changing fluids or colors
and whenever you are done operating the gun. See
Flush the Spray Gun
Daily Care and Cleaning
CAUTION
.
Clean all parts with a non–conductive solvent,
compatible with the fluid being sprayed. Conduc-
tive solvents can cause the gun to malfunction.
6. Check the electrode wire. Straighten if bent, and re
-
place if broken or damaged. See Electrode
Replacement.
Do not use any cleaning method which may al
low solvent into the gun air passages. Solvent
left in the gun passages could result in a poor qual
-
7. Clean the air cap and spray nozzle daily, minimum;
some applications require more frequent cleaning.
-
ity paint finish and may draw current and reduce
the electrostatic effect. Point the gun down while
cleaning to prevent dirty solvent from running back
into the air passages. NEVER IMMERSE THE
GUN IN SOLVENT.
Replace the spray nozzle and air cap if they are dam
aged. See To Clean or Change Air Cap and Fluid
Nozzle.
-
Flush the Spray Gun
WARNING
WARNING
To reduce the risk of fire or explosion and serious
bodily injury, the turbine air (electrostatics) must
be off before flushing.
For your safety, always follow the Pressure Relief
Procedure Warning on page 9 when shutting off
the system, when you stop spraying, and before
checking, servicing, installing, cleaning or chang-
ing any part in the system.
1. Follow the Pressure Relief Procedure Warning on
page 9.
1. Clean the fluid and air line filters daily
.
2. Disconnect and plug the fluid line.
2. Check all of the work hangers for build-up of material;
clean them, if necessary
3. Connect the solvent supply to the gun.
4. Flush the gun with solvent until it is clean.
5. Follow the Pressure Relief Procedure Warning,
.
3. All loose or ungrounded objects must be removed
from the spray booth.
then disconnect the solvent supply
.
4. Clean the outside of the gun daily with a soft cloth
dampened in a compatible solvent.
6. Reconnect the fluid supply line.
8. Actuate the gun until it is clear of solvent.
307-712
11
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MAINTENANCE
KEY
To Clean or Change Air Cap and Fluid Nozzle
15
Fluid Nozzle
BB
CAUTION
BB Air Cap Assembly
Do not use metal tools to clean the air cap holes as
this may scratch them, and make sure the elec-
trode wire is not damaged. Scratches in the air cap
holes or a damaged electrode wire can distort the
spray pattern.
81
Locking Pin
DETAIL
DETAIL
Equipment needed:
Soft bristle brush (supplied).
Fluid nozzle wrench (supplied).
Solvent compatible with fluid being sprayed.
15
Unlocked
Position
Locked
Position
Procedure:
81
1. Follow the Pressure Relief Procedure Warning on
81
page 9.
2. Remove the air cap assembly (BB). See Fig 6.
3. Turn the locking pin (81) to the unlocked position.
Fig 5
4. Squeeze the gun trigger and remove the fluid nozzle
(15) with the fluid nozzle wrench (66g) supplied.
Make sure the front of the gun is pointed down. See
Fig 6.
KEY
CC Electrode
15
16
Fluid Noz
Air Cap A
66g Wrench
5. Use the soft bristle brush (66a) supplied and solvent
to clean the air cap, fluid nozzle, and front part of the
gun.
16
CC
6. Squeeze the gun trigger and screw the fluid nozzle
back into the gun. Tighten the nozzle securely with
the wrench (66g) supplied. Torque the fluid nozzle to
1.1–1.4
NSm (10–12 in–lb). See Fig 6. Turn the lock
-
ing pin to the locked position.
T
orq
1.1–1.4
(10–12 i
7. Carefully reinstall the air cap assembly. Avoid bend
ing the electrode (CC).
-
8. Tighten the retaining nut so it is snug. If the nut is tight
enough, you will feel resistance when turning the air
cap. If too tight, the spray pattern will be distorted.
Fig
6
12
307-712
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SPRAY
PATTERN TROUBLESHOOTING CHART
WARNING
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious
bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and
qualified.
To reduce the risk of serious bodily injury, including splashing fluid or solvent in the eyes or on the skin, always follow
the Pressure Relief Procedure Warning on page 9 before checking, adjusting, cleaning or repairing the gun or
any part of the system. Disconnect the fluid hose from the gun.
NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.
PROBLEM:
CAUSE
SOLUTION
IMPROPER SPRA
Y
PATTERN
Fluttering or spitting
spray
Insufficient fluid supply
.
Adjust fluid regulator or fill fluid tank.
Loose fluid nozzle or damaged fluid
nozzle taper seat.
Tighten or replace fluid nozzle
See page 12.
Dirt between fluid nozzle, taper seat
Clean. See page 12.
and body
.
Loose or cracked coupler at fluid inlet.
Loose fluid tube in cup or tank.
T
ighten or repair
.
Tighten.
Fluid build-up on air cap; partially
clogged horn holes. Full air pressure
from clean horn hole forces fan pattern
toward clogged end.
Clean with soft implement or
submerge in suitable solvent and wipe
clean. See page 12.
Damaged fluid nozzle or air cap holes.
Replace damaged part. See page 12.
Fluid build-up on the perimeter of fluid
nozzle orifice, or partially clogged fluid
nozzle orifice.
Remove obstruction. Never use wire
or hard instruments. See page 12.
Too high atomization air pressure.
Reduce air pressure or adjust air
adjusting valve.
Fluid too thin.
Regulate fluid viscosity.
Not enough fluid pressure.
Increase fluid pressure.
Low atomization air pressure.
Fluid too thick.
Increase air pressure.
Regulate fluid viscosity
.
Too much fluid.
Reduce fluid flow. Reduce fluid
pressure on pressure feed guns and/
or adjust fluid adjusting screw until
proper pattern is obtained.
Streaks
Last coat of fluid applied too wet.
oo much air pressure.
Apply drier finish with multiple
strokes.
T
Use least air pressure necessary.
Insufficient air pressure.
Increase air pressure.
Non-uniform spray pattern.
Clean or replace air cap.
See page 12.
NOTE: Some improper patterns are caused by the improper balance between air and fluid.
307-712
13
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GUN OPERATION TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Leakage from fluid pack- Worn needle packing.
ing nut.
Replace packing assembly
.
See page 20.
Air leakage from front
of gun.
Air valve not seating properly
.
Clean, service. See page 24.
Loosen packing. See page 24.
Air stem packing too tight.
Electrode worn or damaged.
Fluid leakage from
front of gun.
Replace electrode. See page 18.
Worn fluid seat.
Replace fluid nozzle and/or electrode.
See page 18.
Fluid packing too tight.
Loose fluid nozzle.
Adjust packing screw. See page 20.
Tighten fluid nozzle. See page 12.
Cylinder air to gun not completely shut off. Adjust screw
.
“Orange Peel” finish.
Excessive spray fog.
Insufficient air pressure.
Increase, use least air pressure
needed for good results.
Fluid poorly mixed or filtered.
Improper thinner being used.
Remix or refilter fluid.
Use proper thinner
.
Too much air pressure.
Reduce, use least air pressure
needed for good results.
Fluid thinned too much.
Fluid low
Properly thin fluid.
No fluid sprays from
gun.
.
Check, add if necessary.
Damaged air cap.
Replace air cap. See page 12.
Clean fluid nozzle. See page 12.
Dirty or clogged fluid nozzle.
Damaged fluid nozzle.
Check, replace fluid nozzle.
See page 12.
Air Valve not actuating.
Damaged fluid needle
Check cylinder air, fluid needle packing,
and needle. Replace parts as necessary
.
See page 21.
Replace. See page 20.
Equipment covered
with fluid.
Exhaust air flow insufficient or not directed Check for proper CFM, check baffles
properly.
and direction of air flow.
Improper distance between gun and
work piece.
Adjust distance to 203–305 mm
(8–12 in.).
Dirty air cap.
Misalignment between air cap and
fluid nozzle.
Remove and clean air cap and fluid
nozzle as described on page 12, then
reinstall them.
14
307-712
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ELECTRICAL TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Poor wrap–around.
*Turbine alternator not operating.
Check air supply to turbine. Check for
dirt or moisture in turbine. See page 23.
Improper distance between gun
and workpiece.
Adjust spraying distance to
203–305 mm (8–12 in.).
Parts poorly grounded.
Clean hangers, check for proper
ground on conveyer or track.
High booth exhaust velocity
.
Reduce within code limits.
Reduce air pressure.
Atomizing air pressure too high.
Fluid pressure too high.
Reduce fluid pressure.
Fluid viscosity
.
Check supplier for proper fluid for
electrostatic spray
.
Fluid resistivity too low
.
Check fluid resistivity with paint
meter and probe.
Faulty gun resistance.
Check gun resistance. See page 16.
Faulty resistor stud resistance.
Check resistor stud resistance.
See page 17.
Faulty power supply resistance.
Check power supply resistance.
See page16.
Faulty electrode.
Replace electrode. See page 18.
*Faulty turbine alternator
.
Be sure plug is in place on back of
turbine alternator housing.Remove and
test turbine alternator. See page 23.
Operator gets mild
shock.
Operator not properly grounded or is in
contact with ungrounded object.
Be sure floor is properly grounded.
W
ear shoes with conductive soles
or wear personal grounding straps.
Be sure operator is not in contact
with or carrying any metallic items
which could build up electrical charge.
Gun not properly grounded.
See Check the Electrical Grounding,
page 8. Be sure Graco electrically con-
ductive air supply hose is being used
and is properly grounded.
Operator gets mild
shock when touching
work piece.
W
ork piece not properly
Clean work piece hangers. Check for
proper ground on conveyor or track.
grounded.
*ES indicator light not on when gun is triggered.
307-712
15
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ELECTRICAL TESTS
The performance of the spray gun is directly affected by
KEY
A
1
14
86
Megohmmeter
Gun Body
Electrode
the condition of the electrical components contained
inside the gun. The electrical tests below can be used to
determine the condition of the power supply (5) and the
resistor stud (17) as well as the continuity of the electrical
path between the components.
A
Air Inlet Adapter
Use megohmmeter 218–979 (see ACCESSORIES) and
an applied voltage of 500 volts to complete these electri
-
cal tests. Connect the leads as shown.
WARNING
To reduce the risk of sparking, which could cause
fire or explosion and result in serious bodily injury
,
DO NOT use the megohmmeter in the hazardous
area. Remove the gun from the hazardous area
before testing it.
1
86
Test Gun Resistance
NOTE: Check the resistance with the gun triggered and
untriggered.
Measure the resistance between the end of the electrode
(14) and the gun air inlet adapter (86). See Fig 7. The re
-
sistance should be between 115 to 152 megohms. If the
resistance is outside the specified range, go to the next
test. If the resistance is correct, refer to the Electrical
Troubleshooting Chart on page 15 for other possible
causes of poor performance.
14
Fig 7
KEY
Test Power Supply Resistance
A
Megohmmeter
Remove the power cartridge (2) from the gun body (1).
EE Connector Prong
2a
5
5c
Turbine Alternator
Power Supply
Contact Spring
See Power Cartridge Replacement
.
Remove the turbine alternator (2a) from the power sup-
ply (5). See urbine Alternator Removal
A
T
.
Measure the resistance from the center prong (EE) in the
power supply to the contact spring (5c) on the other end
of the power supply. See Fig 8.
The resistance should be 95 to 122 megohms. If the re
-
sistance is outside the specified range, the power supply
is defective and must be replaced. If the resistance of the
power supply is correct, proceed to the next test.
If you still have problems, refer to the Electrical
Troubleshooting Chart for other possible causes of
poor performance, or contact the nearest authorized
service agency
.
EE
5c
5
2a
Fig
8
16
307-712
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ELECTRICAL TESTS
KEY
Test Resistor Stud Resistance
A
Megohmmeter
Insert a conductive rod (FF) into the gun barrel (removed
for the power supply test) and against the metal contact
(GG) in the front of the barrel. See Fig 9.
FF Conductive Rod
GG Metal Contact
14
20
A
Electrode
Gun Barrel
Measure the resistance between the conductive rod (FF)
and the gun electrode (14). The resistance should be 20
to 30 megohms. If the resistance is correct, refer to the
Electrical Troubleshooting Chart for other possible
causes of poor performance, or contact the nearest
authorized service agency
.
If the resistance is outside the specified range, remove
the electrode (14). See Electrode Replacement. Meas
-
ure the resistance between the conductive rod (FF) and
the resistor in the inside diameter of resistor stud (17).
20
The resistance should be 20 to 30 megohms. If the resis
tance is correct, the electrode wire is defective and must
-
GG
be replaced. See Electrode Replacement. If the resis-
tance is outside the specified range, the resistor is defec
tive and the resistor stud (17) must be replaced. See Re-
sistor Stud Replacement
-
.
FF
If you still have problems, refer to the Electrical
Troubleshooting Chart for other possible causes of
poor performance, or contact the nearest authorized
14
Fig
9
service agency
.
307-712
17
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SERVICE
2. Unscrew and remove the electrode (14) with the
Gun Disassembly
wrench (66c) supplied. See Fig 10. If the needle shaft
assembly (9) turns while trying to loosen the elec-
trode, hold the needle shaft assembly nut with a
small wrench.
WARNING
Installing and servicing this equipment requires
access to parts which may cause electric shock or
other serious bodily injury if the work is not per-
formed properly. Do not install or service this
equipment unless you are trained and qualified.
3. Install the new electrode (14) with the wrench (66c).
Do not over tighten.
CAUTION
Follow the Pressure Relief Procedure Warning,
page 9, before servicing the gun or any part of the
system. Disconnect the fluid hose from the gun.
To avoid damaging the plastic threads, be very
careful when installing the electrode.
NOTE: Check all possible remedies in the
Troubleshooting Charts before disassembling
the gun.
4. Reinstall fluid nozzle and air cap assembly as
described in To Clean or Change Air Cap and
Fluid Nozzle
.
CAUTION
KEY
If the plastic parts of the gun must be held se-
curely, ALWAYS clamp them in padded vice jaws
to prevent damage to the parts.
9
Fluid Needle Shaft Assembly
66c Wrench
66c
ALWAYS lubricate o–rings and seals with petro-
leum jelly
.
9
ALWAYS remove gun from worksite for service or
repair. Service or repair area must be clean.
Flush the gun as described under Flush the Spray Gun.
Follow the Pressure Relief Procedure Warning on
page 9. Disconnect the air and fluid line from the gun.
Gun Assembly Note
Whenever you are tightening plastic parts where there is
no torque specified in the instructions, tighten the parts
finger-tight and then retighten with a wrench 1/4 to 1/2
turn.
Electrode Replacement
1. Remove the air cap assembly and fluid nozzle as de
-
scribed in To Clean or Change Air Cap and Fluid
Nozzle.
Fig 10
18
307-712
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SERVICE
3. Using the wrench supplied, install the resistor stud in
Resistor Stud Replacement
the front of the gun barrel. Tighten until snug.
WARNING
Old/New Style Resistor Stud and Electrode
To reduce the risk of sparking, which could cause
fire or explosion, BE SURE the electrode and stud
you install are black. The old style electrode and
stud in the Series A Guns were white. DO NOT mix
old style parts with new style parts.
4. Install the electrode as described in Electrode Re-
placement.
5. Install the fluid nozzle and air cap assembly as
described in To Clean or Change Air Cap and
Fluid Nozzle
.
KEY
1. Remove the air cap assembly and fluid nozzle as
12
17
18
Washer
Resistor Stud
O-Ring
described in To Clean or Change Air Cap and
Fluid Nozzle
.
2. Remove the electrode as described in Electrode
Replacement.
12
18
3. Using the wrench (59h) supplied, unscrew and
remove the resistor stud (17) with the o-ring (18) and
washer (12). See Fig 11.
17
To install the resistor stud:
1. Lubricate the o-ring (18) with petroleum jelly and
install it on the resistor stud (17).
2. Install the washer (12) in the gun barrel.
Fig 1
1
307-712
19
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SERVICE
KEY
Barrel Removal
1. Unscrew the nut (34) at the gun’s fluid inlet adapter
31
52
Fluid
Cap Screw
Tube
(35). See the PARTS DRAWING.
66f Wrench
2. Pull the fluid tube (31) out of the fluid adapter (35).
3. Remove the trigger by removing the screws and
spacers from the gun.
66f
52
4. Remove the ES indicator lights from the socket head
cap screws (52).
31
5. Using the wrench (66f) supplied, loosen and remove
the two socket head cap screws (52) from the gun.
See Fig 12.
6. Hold the gun body with one hand and pull straight up
to remove the gun barrel (20). See Fig 13.
CAUTION
Fig 12
KEY
To avoid damaging the power cartridge, always
pull the gun barrel straight away. If necessary,
gently move the gun barrel from side to side to free
2
Power Cartridge
it from the gun body
.
6
20
Gasket
Gun Barrel
20
6
NOTE: The gasket (6) should be left in the gun body if
the gasket is not to be replaced.
To install the barrel (20), follow the procedure below:
1. Be sure the gasket (6) is in place. Replace if dam-
aged. Place the barrel over the power cartridge (2)
and onto the gun body. See Fig 13.
2
2. Install the two socket head cap screws (52) and
tighten with the wrench (66f). See Fig 12.
3. Snap the ES indicator lights in place over the socket
head cap screws (52).
Fig 13
4. Insert the fluid tube (31) into the gun’s fluid inlet
adapter (35) and tighten the nut (34).
5. Install the trigger with the screws and spacers. Test
the gun resistance as instructed on page 16.
KEY
Fluid Needle Packing Replacement
1. Remove the air cap assembly and fluid nozzle as
9e
Packing Nut
66b
66b Wrench
described in To Clean or Change Air Cap and
Fluid Nozzle
.
2. Remove the electrode as described under Elec-
trode Replacement
.
9e
3. Remove the gun barrel as described under Barrel
Removal.
Fig 14
4. Unscrew the packing nut (9e) using the wrench (66b)
supplied. See Fig 14.
20
307-712
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SERVICE
5. Carefully remove the fluid needle assembly (9)14.froInmstall the air cap assembly and fluid noz
the rear part of the gun barrel (20). See Fig 15d.escIfribtehde inTo Clean or Change Air Cap
packing assembly (9a) or insulator (9g) are stilFl luiind Nozzl.e
the barrel, insert the packing removal rod (66d) into
15. Trigger the gun to check the needle adjus
The air should come fully on before the fluid
on. Adjust the needle adjusting nut (9c) un
the front of the barrel to gently push them out. Refer
to Fig 16.
NOTE: If the insulator (9g) is removed, be sure to pirnosptaelrl lead and lag is achieved.
it so the insulator end with holes is facing the
packing assembly (9a).
If the fluid comes on ,tooremsoooven the trigger
and back the needle adjusting nut (9c) out
6. Wipe the internal surfaces of the barrel clean with a
from the barrel) slightly.
soft brush or cloth.
If the fluid comes on tootightlaetne, the needle
CAUTION
Clean all parts in nonĆconductive solvent compatĆ
ible with the fluid being used, such as xylol or minĆ
adjusting nut (9c) slightly (turn towards barrel).
After adjustment is complete, tighten the locking
(9d) against the adjusting nut (9c).
eral spirits. Use of conductive solvents can cause
the gun to malfunction.
KEY
9
Fluid Needle Assembly
7. Remove the packing assembly (9a) from the needle
9c
20
Needle Adjusting Nut
Gun Barrel
(9b).
NOTE: If the position of the adjusting nut (9c) is
changed, install the adjusting nut to the apĆ
proximate dimension shown in Fig 15. (Final adĆ
justment will be made in step 15.) If the ping
132.7 mm
(5.2 in.)
(9f) was removed, reinstall it over the
8. Install the new packing assembly (9a).
CAUTION
n
9c
9
Carefully screw needle (9b) into new packi
assembly (9a) to avoid damaging the seals.
20
9. Test the drag on the fluid needle. It shoul
small spring
proximately 2.5 to
3
lbs (use
a
measure). If the adjustment is out of tole
tighten or loosen the adjusting screw on the packĆ
Fig 15
ing assembly (9a) slightly and retest. Continue to
adjust until the tolerance is correct.
KEY
10. Install the entire fluid needle assembly (9) into the
9d
9
Fluid Needle Assembly
gun barrel, from the back of the barrel.
9a
9b
Needle Packing Assembly
Fluid Needle
11. Firmly tighten the packing nut (9e) down unt
9c
9d
9e
9f
Adjusting Nut
toms.
Locking Nut
Packing Nut
Spring
9f
CAUTION
9c
9b
When checking the fluid needle movement, D
9g
Insulator
NOT move the needle out of the gun barrel
than 6.35 mm (1/4 in.) to avoid pulling the
out of the packing area and damaging the p
ings.
9e
9g
9
12. Install
the
barrel
as
described Buanrrdeelr
9a
Removal.
13. Install the electrode as describedEleucntdroerde
Replacement.
Fig 16
307-712
21
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SERVICE
5a
KEY
1
Gun Body
Alternator
O-Ring
Plug
5
2a
2b
2c
5
Power
Supply
5a
5b
5c
6
O-Ring
O-Ring
Spring
Gasket
Barrel
5b
5c
6
20
20
2b
20b
See NOTE after
step 3, below.
1
2c
OTE: The power cartridge (2)
includes items 2a, 2b,
2c, and 5.
2a
Fig 17
NOTE: The cushion (20b) is part of the gun barrel and
should never need to be removed. If it is
removed, push the cushion in, adhesive side toĆ
Power Cartridge Replacement
1. Remove the barrel as described Baurnrdeelr
Removal.
ward the barrel, with
hered in the baDrOrel. NOT use the power supĆ
a
rod until it is securely ad
2. Remove the gasket (6) from the gun body (1). See
Fig 17.
ply (5) to press the cushion into the barrel as
will not adhere properly.
CAUTION
4. Insert the new power cartridge in the gun body (1).
The power cartridge is fragile. Be careful when
handling it to avoid damage.
NOTE: See Fig 18 for proper alignment of the power
cartridge (2) in the gun body (1).
3. Grasp the power cartridge with your hand. With
a
5. Install the gasket (6) in the gun body (1).
gentle side to side motion, pull it free from the gun
body (1). Then pull the power cartridge straight out
of the body.
6. Install the barrel on the gun body as described
under Barrel Remova. l
CAUTION
KEY
DO NOT use solvents to clean the power carĆ
1
Gun Body
2
tridge cavity in the gun body (1). Solvent will damĆ
Power Cartridge
1
age electrical
power cartridge.
components
contained
in
the
2
Inspect the power cartridge cavity in the gun
body for dirt or moisture. Clean out the cavity with
a
clean, dry rag if necessary.
Lightly lubricate the o-rings (2b, 5a, 5b) on the
new power cartridge with petroleum jelly. All the
Fig 18
o-rings and the compression spring (5c) must
be in place or the gun will malfunction.
22
307-712
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SERVICE
Turbine Alternator Removal
Fan Air Valve Replacement
1. Remove power cartridge from the gun bod1y. Palasce
described undePrower Cartridge Replacem.ent
a
and remove it from the gun body (1). See
wrench on the flats of the valve ho
2. Carefully twist the turbine alternatocroun(2tear)Ć 2. Remove the retaining ring (46).
clockwise and pull it off the power supply (5) until
3. Rotate the air adjusting (s5c6r)ew counterclockĆ
just disengaged from the coupling. Then continue
wise until it is disengaged from the valve
to slowly pull the turbine alternator away from the
threads. Pull the adjusting screw out of the
housing (55).
power supply, disconnecting the 3Ćwire connector
(HH). See Fig 19.
4. Clean all the parts and inspect them for
3. Using an ohmmeter, test the coil in the turbine alterĆ
damage. If replacing the seal (47), culnoscckrĆew it
nator (2a). Measure the resistance between the two
wise and remove it from the adjusting screw.
outer terminals of the 3Ćwire connector (HH). The
5
resistance should be 3 to ohms. If the reading varĆ
ies from this value, replace the alternator.
5. Apply medium grade thread sealant to the
threads on the end of the adjusting screw
(
install
a
new seal (left hand thread).
4. Measure the resistance between each outer termiĆ
nal of the 3Ćwire connector (HH) and the turbine alĆ
6. When reassembling the fan air valve, lubricate
ternator housing. The resistance should be infinite.
o-ring (54) and the adjusting screw threads
If the resistance is not infinite, replace the alternator.
petroleum jelly.
5. Partially connect the 3Ćwire connector (HH) onto the
7. After the retaining ring (46) is installed on the
prongs inside the power supply (5). See Fig 19. UsĆ
ing screw (56), back the adjusting screw out
small screwdriver, push the connector onto the
ing a
prongs until seated.
valve housing (55) until it bottoms out against
taining ring.
6. Slide the turbine alternator (2a) onto the power supĆ
8. Apply Teflorn paste to the threads of the valve
ing (55) and install it in the gun body (1).
ply, being sure to align the coupling between the
power supply and the turbine alternator housing.
housing to 1.1-1.S4mN (10-12 in-lb).
Then twist the turbine altecrnloactkowr ise to lock
the coupling.
KEY
1
Gun Body
7. Install the power cartridge in the gun body as
46
47
54
55
Retaining Ring
described undePrower Cartridge Replacem.ent
Valve Seal
OĆRing
1
KEY
HH 3-wire Connector
Valve Housing
2a
5
Alternator
Power
2a
Supply
HH
47 46
54
56
5
55
Apply Teflon paste.
Torque to
1.1-1.4 SNm
(10-12 in-lb)
Fig 20
Fig 19
307-712
23
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SERVICE
8. Install the new packing (27) and guide (26) in the
gun body (1); screw the guide in loosely.
Piston Removal and Repair
1. To disconnect the fluid hose (31) from the cover
plate (41), screw the nut (34) off the adapter (35).
NOTE: DO NOT fully tighten the guide (26) yet. The
See Fig 21.
guide must be loose to avoid damaging the
packing (27) when pushing the piston shaft
through the guide.
2. Note the position of the trigger adjusting nut (24) for
reinstallation, then screw it off the piston
shaft.
9. If replacing the uĆcup packing sli(d3e7), it onto the
3. Remove the screws (61) and lock washers (82) from
piston (42) so the lips of the packing will face to
the cover plate (41). Remove the cover plate (41),
wards the front of the gun when the piston is in
spring (38), and retainer cap (74).
stalled. Then install the bunaĆn oĆring (30) and
Vitonr oĆring (79) on the piston.
4. Unscrew and remove the air valve guide (26) and
needle packing (27) from the gun body (1),
10. Install the piston assembly into the gun body (1),
being careful not to damage the piston's lip seal.
5. Push on the end of the piston shaft, and remove the
piston assembly.
11. Install the retainer cap (74) into the cover plate (41).
NOTE: DO NOT remove the uĆcup packing (37) from
12. Install the cover plate (41), spring (38), and retainer
the piston shaft except to replace it as removal
cap (74) with the screws (61) and lock washers (82).
will damage this packing.
13. Actuate the trigger and tighten the air valve guide
6. Clean and inspect parts for wear or damage. ReĆ
(26) with
a
wrench.
place parts as needed.
14. Screw the trigger adjusting nut (24) onto the piston
7. When reassembling the piston assembly, lubricate
shaft to its previously noted position.
79) and the uĆcup packing (42) on
the oĆrings (30
the piston with petroleum jelly. Pack the spring (38)
&
15. Connect the fluid hose (31) to the adapter (35).
with petroleum jelly. Apply Teflon tape to the air valve
guide (26).
KEY
1
Gun Body
34
35
37
38
Nut
42
61
74
79
Piston
24
26
27
30
31
Trigger Adjusting Nut
Air Valve Guide
Needle Packing
Adapter
Screws
UĆCup Packing
Spring
Retainer Cap
Viton OĆRing
42
37
74
79
1
41
35
38
Pack with
lubricant
30
61
82
24
27
34
31
Fig 21
24
307-712
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SERVICE
KEY
Disc Regulator OĆRing Replacement
1
1. Unscrew the turbine air line from the adapter (86).
Gun Body
87
88
89
90
OĆRing
3
Regulator Disk
Air Valve
Washer
See Fig 22.
85
86
O-Ring
Adapter
Cap Screw
2. Remove the cap screw (90) and washer (89) from
the gun body (1).
86
3
3. Pull the adapter (86), with the air valve (88), out of
the gun body.
85
88
1
87
4. Unscrew the adapter (86) from the air valve
and remove the disk regulator (3).
5. Clean and inspect parts for wear or damage
replace if necessary.
89
6. Clean and inspect the two oĆrings (87) and
ring (85) on the air valve. Replace if necessa
bricate the oĆrings with petroleum jelly.
90
7. Install the disc regulator (3) into the air valve
its beveled surface faces into the gun.
8. Screw the adapter (86) into the air valve (88), and
install the air valve into the gun body (1).
Fig 22
9. Screw the cap screw (90), with the washer (89), into
the gun body (1).
KEY
1
Gun Body
Muffler
Elbow
10. Screw the turbine air line onto the adapter (67).
76
77
78
Tube
1
Muffler Replacement
1. Remove the fan air valve assembly as instru
Fan Air Valve Replace.ment
78
2. Remove the elbow (76) with the tube (78)
gun body (1). See Fig 23.
77
76
3. With
a
body and replace with
hook, remove the muffler (77) from
new muffler.
a
4. Install the elbow (76) in the gun body.
5. Install the fan air valve assembly as Finasntructed in
Air Valve Replacem.ent
Fig 23
307-712
25
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PARTS LIST
REF
REF
NO. PART NO. DESCRIPTION
QTY
NO. PART NO. DESCRIPTION
QTY
36
37*
38
41
42
46
47
50
51
52
107–208
181–039
108–221
180–924
218–989
105–681
181–383
180–235
218–179
107–100
NUT, ferrule; 5/8–20 UN–2B
3
1
2
218–744
218–111
BODY, gun
1
PACKING, u–cup; UHMW polyethylene
1
1
1
1
1
1
1
2
POWER CARTRIDGE
Includes items 2a & 5
.ALTERNATOR, turbine
Includes items 2b & 2c
..O–RING; buna–N
..PLUG
REGULATOR, disc
SCREW; 1/4–20
.POWER SUPPLY, ES, 75 KV
Includes items 5a, 5b & 5c
..O–RING; Viton
..O–RING; fluorocarbon
..SPRING, compression
GASKET, housing
FLUID NEEDLE ASSY; Includes
items 9a–9g
.PACKING ASSY, needle
.NEEDLE, fluid; Includes items 9c & 9d
..NUT, adjusting
SPRING, compression
PLATE, cover
PISTON, shaft
RING, retaining, external
SEAL, valve
RESTRICTOR (color coded black)
LIGHT, indicator, ES
SCREW, cap, socket hd;
M5 x 0.8 x 12
RESTRICTOR (color coded white)
O–RING; ethylene–propylene
HOUSING, valve
SCREW, adjusting
SCREW, trigger
SCREW, mach, pnh; 6–32
SIGN, warning, English (not shown)
SIGN, warning, Spanish (not shown);
See ACCESSORIES to order French
or German
KIT, tool; Includes items 66a–66h
.BRUSH, cleaning
.WRENCH, packing nut
.WRENCH, needle
.ROD, packing removal
.WRENCH, resistor stud
.WRENCH, barrel
1
2a
217–591
1
2
1
1
1
2b*
2c
3*
4
107–106
180–070
107–107
110–916
218–041
5
2
1
1
1
1
2
4
1
1
1
1
1
1
53
54*
55
56
60
61
62
65
179–994
105–666
181–382
181–381
107–400
100–205
180–060
180–063
5a*
5b*
5c
6*
177–156
106–555
178–504
179–387
222–256
9
1
1
9a
9b
9c
9d
9e
9f
222–255
222–013
183–749
183–750
176–936
105–673
179–388
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
..NUT, locking
.NUT, packing
.SPRING, compression
.INSULATOR, needle
LABEL, warning
66
220–388
66a 105–749
66b 177–732
66c{ 177–007
66d 179–803
66e 107–158
9g
11** 179–790
12{ 181–825
14{ 181–824
WASHER
ELECTRODE (color coded black)
NOZZLE, fluid; 1.2 mm (0.047’’)
(See manual 307–803 for other
available fluid nozzles)
AIR CAP ASSEMBLY
Includes items 16a, 16b & 16c
.RING, retaining
66f
107–460
15
181–299
66g 177–004
66h{ 183–107
.WRENCH, fluid nozzle
TOOL, resistor stud
CAP, retainer, spring
PLUG; 3/8–18 npsm
1
74
75
76
77
78
79
80
81
82
84
85
86
87*
88
89
90
91
181–178
181–599
181–594
181–223
054–134
108–298
181–302
181–303
108–340
104–282
105–796
181–598
103–648
181–597
102–782
105–408
177–128
16
218–996
1
1
1
ELBOW, male, 90
MUFFLER
5
16a 176–930
16b 176–968
16c 180–739
.NUT, retaining
TUBE, polyethylene
O–RING; Viton
HOUSING, pin
178 mm
.AIR CAP (See manual 307–803
for other available air caps)
STUD, resistor (color coded black)
O–RING; Viton; standard
(color coded green)
O–RING, polyethylene; optional
(color coded white)
BARREL, gun; Includes item 20a & 20b
.PLUG; M3 x 0.5 x 6
.CUSHION
1
1
1
4
1
1
1
2
1
1
1
1
17{ 220–923
105–667
18*{
PIN, locking
LOCKWASHER, internal
O–RING; buna–N
O–RING; Viton
ADAPTER; 1/4–18 npsm, LH
O–RING; Viton
1
108–045
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
20
179–412
20a 176–921
20b 186–127
VALVE, air
WASHER, plain
21
23
24
26
27*
28
30*
31
107–207
180–928
180–927
176–941
106–901
108–173
156–454
181–179
FITTING, male
TRIGGER
NUT, adjusting, trigger
GUIDE, valve, air
SCREW, cap, hex hd; M6 x 10 long
SPACER
1
2
*Included in Repair Kit 218–967.
PACKING, needle;PTFE
ELBOW, male
O–RING; buna–N
TUBE, fluid
TAG, warning (not shown)
COLLAR
NUT, tube, flareless
ADAPTER, fluid
**Extra warning tags and labels are supplied at no charge.
{Included in Repair Kit 220–391. Read and follow the Old/New
Style Resistor Stud and Electrode Warning, at left.
32** 179–791
33
34
35
178–131
106–262
181–384
See HOW TO ORDER REPLACEMENT PARTS on page 29.
WARNING
WARNING
When servicing use only genuine Graco replace-
ment parts. Use of other parts or any alteration or
modification of this equipment could cause it to
malfunction, which could result in serious injury,
fire, explosion, or property damage.
Old/New Style Resistor Stud and Electrode
To reduce the risk of sparking, which could cause fire
or explosion, BE SURE the electrode and stud you
install are black. The old style electrode and stud in
the Series A Guns were white. DO NOT mix old style
parts with new style parts
.
307-712
27
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KITS
Repair Kits must be purchased separately
.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
WARNING
When servicing use only genuine Graco replace-
ment parts. Use of other parts or any alteration or
modification of this equipment could result in serious
injury, fire, explosion, or property damage.
NOTE: The Ref. Nos. shown in the kits below correspond to the reference numbers used in the parts list on page 27.
For the best results, use all the parts in the kit, even if the old parts still look good.
Spray Gun Repair Kit 218–967
Resistor Stud and Electrode Kit 220–391
Includes:
Includes:
Ref
Ref
No. Part No. Description
Qty
No. Part No. Description
Qty
2b
3
5a
5b
6
18
27
30
37
54
87
107–106
107–107
177–156
106–555
179–387
105–667
106–901
156–454
181–039
105–666
103–648
O-RING, buna-n
REGULATOR, disc
O-RING, Viton
O-RING, Viton
GASKET, housing
O-RING, Viton
2
1
1
1
1
1
1
2
1
1
2
12
14
17
181–825
181–824
220–923
WASHER
1
1
ELECTRODE (color coded black)
STUD, resistor (color coded
black)
O–RING, Viton
WRENCH, needle
1
1
1
1
18
105–667
66c 177–007
66h 183–107
P
ACKING, needle, PTFE
O-RING, buna-n
ACKING, u-cup, UHMWPE
TOOL, resistor stud
P
O-RING, ethylene-propylene
O-RING, Viton
28
307-712
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SERVICE INFORMATION
TECHNICAL DATA
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.87 Kg (1.90 lb)
Listed below by assembly changed are OLD and NEW
parts.
Gun Length
Maximum
Air Pressure Operating Range
Fluid Pressure Operating Range
Voltage Operating Range . . . . . . . . . . . . . . . . . 0–75 KV
. . . 7 megohm cms to infinity
.
W
. . . . . . . . . . . . . . . . . . . . 310 mm (12.25 in.)
orking Pressure . . . . . . . . . 7 bar (100 psi)
. . 0–7 bar (0–100 psi)
0–7 bar (0–100 psi)
.
.
Assembly
Changed Status
Ref
.
No. Part No. Name
.
218–745
Spray Gun NEW
OLD
4
4
100–664 Screw
110–916 Screw
Paint Resistivity Range
Air Inlet
.
Turbine . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm(m) L.H.
Atomizing & Cylinder . . . . . . . . . . . . . . . 1/4 npt(m)
Fluid Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npsm(m)
.
.
Wetted Parts . . . . . . Stainless Steel, Polyethylene,
Nylon, Acetal, Vitonrr,
Delrinr
Vitonrand Delrin are registered trademarks of
r
the DuPont Co.
HOW TO ORDER REPLACEMENT PARTS
1. To be sure you receive the correct replacement
parts, kits or accessories, always give all of the
information requested in the chart below
.
2. Check the parts list to identify the correct part
number; do not use the ref. no. when ordering.
3. Order all parts from nearest Graco distributor
.
6
digit
Part
Number
Qty
Part Description
307-712
29
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ACCESSORIES
Accessories must be purchased separately
.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
WARNING
NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in
your system. Lower rated components may not be able to withstand the pressure developed by the pump and may
rupture, causing serious bodily injury or property damage.
The accessories in the box, below, are approved by Factory Mutual.
WARNING SIGNS
vailable from Graco at no extra charge.
Must be ordered separately
FLUID HOSE ASSEMBLIES (Nylon)
35 bar (500 psi) MAXIMUM WORKING PRESSURE
6.35 mm (0.25 in.) ID, 3/8 npsm(fbe)
A
.
180–060
180–061
180–062
180–063
W
W
W
W
arning Sign (English)
arning Sign (French)
arning Sign (German)
arning Sign (Spanish)
216–076
216–077
216–078
216–079
216–080
8 m (25 ft)
15 m (50 ft)
23 m (75 ft)
30 m (100 ft)
46 m (150 ft)
GROUNDED AIR SUPPLY HOSE
7 bar (100 psi) MAXIMUM WORKING PRESSURE
6.35 mm (0.25 in.) ID, 1/4 npsm(fbe)
FLUID HOSE ASSEMBLIES (Nylon)
14 bar (225 psi) MAXIMUM WORKING PRESSURE
6.35 mm (0.25 in.) ID, 3/8 npsm(fbe)
220–444
218–100
218–101
218–102
218–103
220–119
220–120
1.2 m (4 ft)
5 m (15 ft)
8 m (25 ft)
11 m (36 ft)
15 m (50 ft)
23 m (75 ft)
30.5 m (100 ft)
215–637
215–638
215–639
215–640
215–641
8 m (25 ft)
15 m (50 ft)
75 ft (23 m)
100 ft 30.5 m)
150 ft (46 m)
ACCESSORIES
The accessories below and on page 31 have not been tested by Factory Mutual.
HIGH VOLUME AIR REGULATOR 206–199
AIR LINE ACCESSORIES
0–9 bar (0–125 psi) Regulated Pressure
14 bar (200 psi) Steel Pressure Gauge
1/2 npt(f) in
GROUNDED AIR SUPPLY HOSE
7 bar (100 psi) MAXIMUM WORKING PRESSURE
8 mm (0.315 in.) ID; 1/4 npsm(fbe);
Color coded gray; More flexible than black hose
223–068
223–069
223–070
223–071
223–072
223–073
223–074
1.2 m (4 ft)
5 m (15 ft)
8 m (25 ft)
11 m (36 ft)
15 m (50 ft)
23 m (75 ft)
30.5 m (100 ft)
AIR FILTER & MOISTURE SEPARATOR 106–148
17.5 bar (250 psi) MAXIMUM WORKING PRESSURE
For cleaning and drying air in air spray system.
20 micron element, 5 oz. bowl capacity
,
AIR HOSE ADAPTER 185–493
For connecting two or more air supply hoses together.
3/8 npt(f) inlet and outlet
1/4 npt(m) x 1/4 npsm(m) left–hand thread.
3-WAY AIR VALVE 722–502
30
307-712
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ACCESSORIES
FILTER (AIR OR PAINT) 202–271
GUN MOUNTING ACCESSORIES
52 bar (750 psi)MAXIMUM WORKING PRESSURE
With 250 micron (60 mesh) element,
3/8 npt(f) inlet, 3/8 npt(m) outlet
UNIVERSAL GUN MOUNTING ROD 590–236
RECIPROCATING GUN MNTG. BRACKET 725–973
Note: All safety barriers and interlocks are to be
supplied by the customer
.
STATIONARY GUN MOUNTING STAND 722–562
STATIONARY GUN MOUNTING BRACKET 724–344
SPRAY SYSTEM ACCESSORIES
MISCELLANEOUS ACCESSORIES
ELECTROSTATIC SYSTEM 231–035
Includes items:
REMOTE FAN AIR ADAPTER 181–053
To control fan pattern from the control booth. 1/8–27
npt(f).
218–745
218–101
Automatic Electrostatic Air Spray Gun
Grounded Air Supply Hose (See
page 30 for description)
Must also order: 108–234 90_ Elbow; 1/8 npt(m)
216–076
tion)
106–148
Fluid Hose (See page 30 for descrip-
REMOTE SWITCH & SIGNAL LIGHT 728–386
Air Filter (See page 30 for description)
ELECTROSTATIC SYSTEM 231–036
Includes items:
218–745
218–103
Automatic Electrostatic Air Spray Gun
Grounded Air Supply Hose (See
and page 30 for description)
216–077
106–148
Fluid Hose (See page 30 for description)
Air Filter (See page 30 for description)
ISOLATION STAND
Required for isolating the fluid supply from the ground
when spraying conductive water-base fluid.
CONTROL PANEL 218–394
For one or two gun operation. Includes cabinet mounted
air regulator, air filter, three-way triggering valve and air
atomizing gauge.
728–650 Isolation Stand; 15 gal (57 liter) maximum
727–212 Isolation Stand; 55 gal (209 liter) maxi-
mum
PAINT RESISTANCE METER 722–886
Used with 722–860 Paint Probe to measure resistance of
paint. Not for use in Hazardous areas.
905–576 Same as 727–212 but includes bleed
resistor
P
AINT PROBE 722–860
WATER BASE PACKING KIT 220–014
For converting packings to handle water base fluids.
Used with 722–886 Paint Resistance Meter to
measure resistance of paint. Not for use in
Hazardous areas.
NOTE: The installation of this kit will void the CSA and
FM approval on the PRO4000 Gun.
MEGOHMMETER 218–979
500 Volt output; 0.01–2000 megohms
307-712
31
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THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and work
-
manship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser s sole
’
remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace
any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated
and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tam
-
pering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear
caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied
by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories,
equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If
inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a rea
sonable charge, which charges may include the costs of parts, labor and transportation.
-
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF
ANY OTHER WARRANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LI
ABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CON
SEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACO’S LIABILITY EX
-
-
-
CEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT
WITHIN TWO (2) YEARS OF THE DATE OF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A
PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motor,
switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with rea
sonable assistance in making any claim for breach of these warranties.
-
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER, contact your Graco distribu-
tor, or call this number to identify the distributor closest
to you:
1–800–328–0211 Toll Free
FOR TECHNICAL ASSISTANCE, service repair infor
-
mation or assistance regarding the application of Graco
equipment: 1–800–543–0339 Toll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. .O. BOX 1441 MINNEAPOLIS, MN 55440–1441
P
PRINTED IN U.S.A. 307–712 7–85 Revised 9–90
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32
307-712
|
