Graco 309293N, WB100 Isolation System and Pro Xs3 Spray Gun Instructions | Manualzz
Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and PRO™
Xs3 Spray Gun
309293N
EN
For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the
following conditions for non-flammability. For professional use only.
FM Approved
•
The fluid has a flash point above 140F (60C) and a maximum
organic solvent concentration of 20%, by weight, per ASTM Standard D93.
•
The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
CE-EN 50059 Compliant
•
Materials which cannot be ignited, in any mixture with air,
by an energy source of less than 500 mJ.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
WB 100
Isolation Enclosure
See page 3 for a List of Models
For patent information, see www.graco.com/patents.
PRO Xs3
Smart Gun
and
Fluid
TI1681A
Table of Contents
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic Air Spray Gun Works . . . . 7
Spraying Waterborne Fluids Electrostatically . . . 7
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Requirements . . . . . . . . . . . . . . . . . . . . . 9
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11
Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . 11
Connect the Waterborne Fluid Hose . . . . . . . . . 11
245895 Agitator Kit . . . . . . . . . . . . . . . . . . . . . . 14
245944 Fluid Regulator Kit . . . . . . . . . . . . . . . . 15
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check Electrical Grounding . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 19
Fluid Voltage Discharge and Grounding Procedure
20
Pressure Relief Procedure . . . . . . . . . . . . . . . . 20
Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . 21
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low Voltage Adjustment (Smart Guns Only) . . 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 27
Clean the Air Cap and Fluid Nozzle . . . . . . . . . 29
Grease Door Latch Threads . . . . . . . . . . . . . . . 29
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . 30
Test Power Supply Resistance . . . . . . . . . . . . . 31
Test Electrode Resistance . . . . . . . . . . . . . . . . 32
Test Ground Strip Resistance . . . . . . . . . . . . . . 33
Test Cylinder Resistance . . . . . . . . . . . . . . . . . 33
2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Voltage Loss Troubleshooting . . . . . . . . . . . . . . 34
Spray Pattern Troubleshooting . . . . . . . . . . . . . 37
Gun Operation Troubleshooting . . . . . . . . . . . . 38
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 39
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Prepare the Gun for Service . . . . . . . . . . . . . . . 41
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 42
Electrode Replacement . . . . . . . . . . . . . . . . . . . 43
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 44
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 45
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 46
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Supply Removal and Replacement . . . . 47
Turbine Alternator Removal and Replacement . 48
Fan Air Adjustment Valve Repair . . . . . . . . . . . 49
Fluid Adjustment Valve Repair . . . . . . . . . . . . . 50
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 50
Atomizing Air Restrictor Valve Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 51
ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 65
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 65
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 66
Miscellaneous Accessories . . . . . . . . . . . . . . . . 66
Technical Specifications . . . . . . . . . . . . . . . . . . . . 69
California Proposition 65 . . . . . . . . . . . . . . . . . . . 69
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70
309293N
List of Models
List of Models
FM Approved
Part No.
Gun Model
Description
245897
PRO Xs3
Waterborne Isolation Enclosure with standard electrostatic air
spray gun, grounded air hose, and shielded waterborne fluid
hose
245898
PRO Xs3
Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and shielded waterborne fluid
hose
233825
Waterborne Isolation Enclosure without hoses and gun.
244581,
Series B
PRO Xs3
Standard Electrostatic Air Spray Gun, for waterborne coatings
245301,
PRO Xs3
Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
244582,
Series B
PRO Xs3
Smart Electrostatic Air Spray Gun, for waterborne coatings,
245305
PRO Xs3
Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
245252
Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
EN 50059 Compliant
244581,
Series B
PRO Xs3
Standard Electrostatic Air Spray Gun, for waterborne coatings.
244582,
Series B
PRO Xs3
Smart Electrostatic Air Spray Gun, for waterborne coatings.
246511
309293N
Waterborne Isolation Enclosure, without hoses and gun
246431
PRO Xs3
Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).
246592
PRO Xs3
Waterborne Isolation Enclosure with standard electrostatic air
spray gun, grounded air hose, and unshielded waterborne fluid
hose
246593
PRO Xs3
Waterborne Isolation Enclosure with smart electrostatic air
spray gun, grounded air hose, and unshielded waterborne fluid
hose
3
Symbols
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
WARNING
Electric Shock Hazard
Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous
condition and result in electric shock or other serious injury.
4
•
Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all conductive objects in the spray area. See Grounding, page 17.
•
The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
•
All components of the isolation system that are charged to high voltage must be contained
within an enclosure that prohibits personnel from making contact with the high voltage components before the system voltage is discharged.
•
Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when instructed
to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the safety enclosure for the isolated fluid supply.
•
Do not touch the gun nozzle or come within 4 in. (102 mm) of the nozzle during gun operation
or for 30 seconds after operation stops, to allow the voltage to discharge through the bleed
resistor. Place the gun in the holster (accessory) during this 30 second period. Refer to Fluid
Voltage Discharge and Grounding Procedure, page 20.
•
Electrically connect a metal part of the fluid supply unit to the bleed resistor.
•
The gun air supply must be interlocked with the isolation system to shut off the air supply anytime the isolation system enclosure is opened.
•
Use only the red-colored Graco electrically conductive gun air hose with this gun. Do not use
black or grey-colored Graco air hoses.
•
Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and
the spray gun. Do not splice hoses together.
•
Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.
309293N
Warning
WARNING
Fire and Explosion Hazard
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in a fire or explosion.
•
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements in this manual.
•
Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all other electrically conductive objects in the spray area. See Grounding, page 17.
•
Check gun resistance daily. See Test Gun Resistance on page 30.
•
If there is any static sparking while using the equipment, stop spraying immediately. Identify
and correct the problem.
•
Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. See Ventilate the
Spray Booth on page 11.
•
Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front
cover of this manual.
•
Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable fluids, as defined on the front cover of this manual.
•
Do not flush with the gun electrostatics turned on.
•
Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the
spray area.
•
Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
•
Use only non-sparking tools to clean residue from the booth and hangers.
Toxic Fluid Hazard
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on
the skin, swallowed, or inhaled.
309293N
•
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
•
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
•
Wear appropriate protective clothing, gloves, eyewear, and respirator.
5
Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in a serious injury.
•
This equipment is for professional use only.
•
Read all manuals, tags, and labels before operating the equipment.
•
Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.
•
Do not alter or modify equipment. Use only genuine Graco parts and accessories.
•
Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply
with this gun.
•
Check the equipment daily. Repair or replace worn or damaged parts immediately.
•
Do not exceed the maximum working pressure of the lowest rated system component. Maximum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).
•
Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical Specifications section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
•
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below -40F (-40C).
•
Wear hearing protection when operating this equipment.
•
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
Pressurized Equipment Hazard
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.
6
•
Do not point the spray gun at anyone or at any part of the body.
•
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
•
Follow the Pressure Relief Procedure, page 20, when you stop spraying and before cleaning,
checking, or repairing equipment.
•
Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
•
Tighten all fluid connections before each use.
309293N
Introduction
Introduction
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 electrode.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
The fluid source supplies fluid to the hose and gun. The
gun must be connected to a voltage isolation system to
maintain voltage at the gun. In an isolation system, the
entire fluid supply is electrostatically charged. The
charged fluid is attracted to the grounded workpiece,
wrapping around and evenly coating all surfaces.
Spraying Waterborne Fluids
Electrostatically
This electrostatic air spray gun is designed to spray only
waterborne fluids with a flash point above 140F (60C)
and a maximum organic solvent concentration of 20%,
by weight, per ASTM Standard D93. Also, the fluid must
not sustain burning when tested per ASTM Standard
D4206 Sustained Burn Test.
When connected to a voltage isolation system, all of the
fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based
system. Therefore, only non-flammable fluids (as
defined on the front cover of this manual) can be
sprayed with the system or be used to clean, flush, or
purge the system.
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards.
When the spray gun charges the isolated fluid to high
voltage, it is similar to charging a capacitor or a battery.
The system will store some of the energy while spraying
and retain some of that energy after the spray gun is
shut off. It is not safe to touch the front end of the gun
until the stored energy is discharged. The amount of
time it takes to discharge the energy depends on the
system design. Follow the Fluid Voltage Discharge
and Grounding Procedure on page 20 before
approaching the front of the gun.
309293N
7
Introduction
Gun Overview
The electrostatic gun includes the following controls
(see FIG. 1.).
•
FLUID adjustment valve. Adjusts fluid rod travel.
Use only in low flow conditions, to reduce wear.
•
Fan AIR adjustment valve. Adjusts fan size and
shape.
•
Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
•
ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
•
ES INDICATOR (standard gun only). Green when
ES is ON (I).
•
Voltage/current DISPLAY (smart models only).
Shows voltage (V) and current (A). Green=spray,
yellow/red=see Electrical Troubleshooting, page
39.
•
ES HI/LO switch (smart models only). Sets voltage to HI or LO (factory settings).
•
LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings. Page 21.
DISPLAY
ES INDICATOR
LO VOLTAGE
ES HI/LO
0
KV
100%
μα
ES ON/OFF
HI
LO
I
ES
ES
ES ON/OFF
O
RESTRICTOR
I
AIR
ES
O
AIR
RESTRICTOR
FLUID
FLUID
ti1266a
ti1253a
Standard Model
Smart Model
TRIGGER
AIR CAP
ELECTRODE
AIR INLET
FLUID TUBE
TI1681A
Fig. 1. Gun Overview
8
309293N
Installation
Installation
System Requirements
Install the System
A safe, well designed voltage isolation system should
have the following features:
•
All components of the isolation system that are
charged to high voltage must be contained within an
enclosure that prohibits persons from making contact with the high voltage components before the
system voltage is discharged.
•
A bleed resistor to drain off the system voltage when
the spray gun is not in use.
•
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the system components.
•
The system must include a means for automatically
discharging the system voltage when anyone opens
the isolation enclosure.
CAUTION
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
•Do not install or service this equipment
unless you are trained and qualified.
•Be sure your installation complies with all
National, State and Local safety and fire
codes, NFPA 33, NEC 504 and 516, and
OSHA standard 1910.107.
FIG. 2. on page 10 shows a PRO Xs electrostatic waterborne air spray system. For assistance in designing a
system to suit your particular needs, contact your Graco
distributor.
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
Warning Sign
Mount the warning sign, Part No. 186118, in the spray
area where it can be seen and read by all operators.
Additional warning signs are available at no charge.
309293N
9
Installation
B*
Gun ES ON/OFF valve: I is ON, 0 is OFF
BB
Q*
M
C
A
D E U
S
B*
K*
AA
P*
L
X
N
G
TI1896C
R
W
J
V*
Y
F
Z
T
H
TI1775C
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
S
Waterborne Electrostatic Air Spray Gun
A
Main Air Supply Line
T
Grounding Rod
B*
Main Air Supply Shutoff Valve (bleed-type)
U
Ground Terminal
C
Pump Air Pressure Gauge
V*
Main Ground Wire
D
Pump Air Pressure Regulator
W
Strain Relief/Ground Fitting
E
kV Meter
X
Pump Air Supply Line
F
Pump
Y
Grounding Cylinder
G
Pump Suction Hose
Z
Pump Fluid Outlet Fitting
H
Paint Container
AA
Isolated Enclosure Door
J
Bleed Resistor
BB
Enclosure T-Handle Locking Screw
K*
Enclosure Safety Interlock
*
Required for safe operation. Must be purchased separately.
L
Isolated Enclosure
M
Gun Air Line Filter
N
Gun Air Pressure Regulator
P*
Graco Red Grounded Air Supply Hose
Q*
Air Hose Ground Wire
R
Graco Waterborne Fluid Hose
10
309293N
Installation
Ventilate the Spray Booth
WARNING
Flammable or Toxic Vapor Hazard
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do not
operate the gun unless ventilation fans are
operating.
Check and follow all National, State, and Local codes
regarding air exhaust velocity requirements.
4. Connect the main air supply line (A) to the
bleed-type air valve (B). The bleed valve shuts off all
air to the system. Install an additional bleed-type air
valve (B) upstream of the air filter (M) to isolate the
filter for servicing.
WARNING
Pressurized Equipment Hazard
The bleed-type air valve (B) is required in
your system to relieve air trapped between
the valve and the fluid supply unit after the
air regulator (D) is shut off. Trapped air can cause the
fluid supply unit to cycle unexpectedly, which can
result in serious injury, including splashing fluid in the
eyes or on the skin.
NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 linear ft/min
(18.3 linear meters/minute).
Ground the Cabinet
Connect the Air Line
Connect the main ground wire (V) to a true earth
ground.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
serious injury, you must use the red-colored
Graco Electrically Conductive Air Hose for
the gun air supply hose, and you must connect the hose ground wire to a true earth ground. Do
not use the black or grey-colored Graco air hoses.
1. Install an air line filter/water separator (M) on the
main air supply line to ensure a dry, clean air supply
to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the
gun to malfunction.
2. Install a bleed-type air regulator (N) on the gun air
line (P).
3. Connect the red-colored Graco Grounded Air Supply Hose (P) between the gun air regulator (N) and
the gun's air inlet. The gun air inlet fitting has a
left-hand thread. Connect the air supply hose
ground wire (Q) to a true earth ground.
309293N
Connect the Waterborne Fluid
Hose
Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. See FIG. 3.. The waterborne fluid hose (101) consists of an inner PTFE tube (T) and an abrasion-resistant outer jacket (J). Shielded hose 245252 also has a
conductive layer (C), The conductive layer is connected
to ground at the gun fitting bracket (104).
Before connecting the waterborne fluid hose to the gun,
blow it out with air and flush with water to remove contaminants. Flush the gun before using it.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, install
only one continuous Graco waterborne
hose between the isolated fluid supply and
the gun. Do not splice hoses together.
11
Installation
1. Remove the gun air inlet fitting (35). See FIG. 3.
2. For the fluid hose to fit properly, it must be stripped
and assembled to the dimensions in FIG. 5. Push
the inner tube (T) into the fitting (F) until the tube
bottoms. A new Graco waterborne fluid hose comes
fully assembled to these dimensions.
CAUTION
A
16
Be careful not to cut into the inner tube (T) of the
hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.
104
108
Shielded Hose 245252
107
106
35
105
103
102
C
38
39
101
J
B
T
TI2155b
F
A
Fig. 3. Connect the Fluid Hose
A
7.40 in. (188 mm)
NOTE: In a shielded hose system, if a hose failure
occurs where high voltage arcs through the inner tube,
voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the
grounded enclosure.
B
2.0 in. (50 mm)
Using unshielded fluid hoses minimizes the system
capacitance, resulting in faster response times and a
large reduction in the energy stored in the system, as
compared to shielded hoses. However, without the
ground shield, a weak static charge can occasionally
build up on the outer surface of the hose. To minimize
any static charge felt on the hose surface, bundle the air
and fluid hose together, and wrap with a protective
cover, as shown in FIG. 4.
Fig. 5. Waterborne Hose Dimensions (At Gun)
Unshielded
Hose 246431
C
J
T
A
A
1.25 in (32 mm)
TI2742A
Fig. 6.
3. Generously apply dielectric grease (40) to the o-ring
(107) and the threads of the fitting (106). Pull the fitting back 1-1/2 in. (38 mm) and apply grease to the
exposed PTFE hose to fill the area between the
hose and the fitting. Make sure the barrel inlet is
clean and dry, then screw the fitting into the fluid
inlet of the gun barrel (16). See FIG. 3.
4. Loosen the strain relief nut (102) so the bracket can
move freely on the hose.
TI21188a
5. Align the bracket (104) holes with the air inlet and
exhaust outlet. Secure with the air inlet fitting (35).
Tighten the strain relief nut (102) to secure the hose.
Fig. 4. Bundling the Air and Fluid Hoses
12
309293N
Installation
6. Check that the nut (105) is tightened securely to the
ferrule housing (103).
7. Press the exhaust tube (38) onto the barbed
adapter (A). Secure with the clamp (39).
Unshielded
Hose 246431
C
J
T
8. Connect the other end of the hose to the isolated
fluid supply as follows:
A
A
a. Graco WB100 Enclosure: Slide hose through
the strain relief fitting (W). Ensure conductive
layer (C) has passed through fitting. Tighten to
55 in-lb (6.2 N•m). Pull back on hose to check it
is secure. Comply with the requirements in
Warning at right. See FIG. 7. and FIG. 8..
12.0 in (305 mm)
TI2743A
Fig. 9.
See Warning below.
C
W
J
C
Shielded
Hose 245252
T
J
T
B
Z
A
A
14.5 in. (368 mm)
B
0.75 in. (19 mm)
L
TI2166A
Fig. 7. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
TI2744A
Fig. 10. Unshielded fluid connection
WARNING
See Warning at right.
C
W
J
T
Z
L
TI1897A
Fig. 8. Shielded Fluid Hose Connection at Graco
WB100
309293N
Electric Shock Hazard
For Shielded hose systems:
Conductive hose layer (C) must be
grounded through its connection to the isolation system’s grounded enclosure (L) or
grounded safety fence. To maintain grounding continuity, the conductive hose layer (C) must be engaged
in the ferrule when the strain relief nut is tightened.
Failure to properly install the hose in the strain relief
could result in an electric shock.
b. Non-Graco Isolated Enclosure: Connect hose
as instructed in the isolation system manual,
and comply with the requirements in the Warning at right. Refer to FIG. 11..
13
Installation
7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
NOTE: Ground layer (C) of hose must
be grounded at isolation system.
8. Return the system to service.
J
T
407
L
C (see note above)
401
TI1966A
Fig. 11. Shielded Fluid Hose Connection at Non-Graco Isolated Enclosure
c.
402
Connect to elbow (282)
inside control box (258)
Connect the end of the tube (T) to the pump
fluid outlet fitting (Z).
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
406
Install tube A2 here
403
408
404
CAUTION
Factory Mutual approval is valid only when this gun is
used with Factory Mutual approved voltage isolation
systems.
406 (Ref)
245895 Agitator Kit
To add an agitator to the Graco isolation system, order
Part No. 245895. See page 67 for the kit parts list.
1. Discharge the system voltage (page 20).
2. Relieve the pressure (page 20).
TI2137A
Fig. 12. 245895 Agitator Kit
3. Open the isolated enclosure door.
4. Remove the back of the control box (258).
5. Remove tube (A2) from elbow (282) at the air manifold; see the tubing diagram on page 64. Install the
Y fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. See FIG. 12.. Route the agitator tube (407) into the cabinet.
6. Replace the back of the control box (258).
14
309293N
Installation
245944 Fluid Regulator Kit
To add a fluid regulator to the Graco isolation system,
order Part No. 245944. See page 68 for the kit parts list.
Connect to elbow (282) inside
control
box (258)
Connect waterborne fluid
hose here
Tube A1
1. Discharge the system voltage (page 20).
506
2. Relieve the pressure (page 20).
501
507
3. Open the isolated enclosure door.
504
502
4. Remove the 1/4 OD tube (A1) from the pump air
inlet; see the tubing diagram on page 64.
5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.
505
Connect
tube A2
here
503
S
6. Unscrew the two pump mounting screws (S, FIG.
13.) and remove the pump from the isolation enclosure.
7. Remove the back of the control box (258).
TI2149A
Fig. 13. Fluid Regulator Kit
8. Remove tube (A2) from elbow (282) at the air manifold; see page 64. Install the Y fitting (506) in the
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.
9. Replace the back of the control box (258).
10. Assemble the fluid regulator kit as shown in FIG. 13..
11. Reinstall the pump in the isolation enclosure. Use
the two mounting holes to the left of the holes used
previously, to allow clearance for the fluid regulator.
12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.
13. Connect the waterborne fluid hose to the fluid regulator outlet fitting (501).
14. Return the system to service.
NOTE: The cabinet air regulator and gauge (216, 217)
will now operate the air piloted fluid regulator (504). The
pump will now operate at the inlet air pressure.
309293N
15
Installation
Select a Fluid Nozzle and Air
Cap
WARNING
Table 1: Fluid Nozzles
Part No.
Size,
mm (in.)
Part No.
Size,
mm (in.)
197263
0.75 (.030)
197266
1.5 (.055)
197264
1.0 (.042)
197267
1.8 (.070)
197265
1.2 (.047)
197268
2.0 (.080)
Table 2: Air Caps
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
before removing or installing a fluid nozzle
and/or air cap.
The gun is supplied with Part No. 197266 Nozzle and
24A276 Air Cap. If you require a different size, refer to
Table 1 and Table 2 , and instruction manual 309419, or
consult with your Graco distributor. See Air Cap/Nozzle
Replacement on page 42.
A wide pattern kit (P/N 24A431) is included with the gun
and if installed, will provide fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to
reduce the amount of fan air.)
Part No.
Pattern Shape
and Length in.
(mm)
Recommended Fluids and
Production Rates
24A438
Round end;
15-17 (381-432)
Light to medium viscosity.
Up to 15 oz/min (450
cc/min)
24A279
Round end;
14-16 (356-406)
Medium to high viscosity
and high solids.
Up to 15 oz/min (450
cc/min)
24A376*
Tapered end;
17-19 (432-483)
Light to medium viscosity.
Up to 15 oz/min (450
cc/min)
24A274
Tapered end;
12-14 (305-356)
Light to medium viscosity.
Up to 15 oz/min (450
cc/min)
Round end;
11-13 (279-330)
Medium to high viscosity
and high solids.
Up to 15 oz/min (450
cc/min)
For use with 2.0 mm nozzle.
24A439
* Also available in the following colors:
24A276 - blue
24A277 - red
24A278 - green
16
309293N
Installation
Grounding
•
Voltage Isolation System: electrically connect to a
true earth ground, as instructed in the voltage isolation system manual.
•
Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
•
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.
•
All solvent pails: use only grounded metal pails,
which are conductive. Do not use plastic containers.
Do not place the pail on a non-conductive surface
such as paper or cardboard. Do not store more than
the quantity needed for one shift.
•
All electrically conductive objects or devices in the
spray area: including fluid containers, tools, and
wash cans, must be properly grounded.
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any
ungrounded objects in the spray area (people, containers, tools, etc.) can become
electrically charged. Improper grounding
can result in static sparking, which can
cause a fire, explosion, or electric shock.
Follow the grounding instructions below.
The following are minimum grounding requirements for
a basic electrostatic waterborne system. Your system
may include other equipment or objects which must be
grounded. Check your local electrical code for detailed
grounding instructions. Your system must be connected
to a true earth ground.
•
Electrostatic Air Spray Gun: ground the gun by connecting the red-colored Graco Grounded Air Hose
and connecting the air hose ground wire to a true
earth ground. See Check Electrical Grounding,
page 18.
ti1259a
•
•
Graco Waterborne Fluid Hose: the hose is grounded
through the conductive layer. Install the hose as
instructed on page 11.
All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are necessary, wear the conductive gloves
that are supplied with the gun. If non-Graco gloves
are worn, cut off fingers or palm area of glove to
ensure your hand contacts the grounded gun handle.
309293N
17
Installation
Check Electrical Grounding
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
earth ground (CC). See FIG. 15.. The resistance
must be less than 100 ohms.
2. Turn the ES ON/OFF valve OFF.
I
ES
O
ti1273a
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
4. Make sure the red-colored grounded air hose (R) is
connected and the hose ground wire is connected to
a true earth ground.
214
AA
CC
TI2163A
Fig. 15. Check Cabinet Grounding
ti1259a
5. Using an ohmmeter (AA), measure the resistance
between the gun handle (BB) and a true earth
ground (CC). The resistance should not exceed 100
ohms. See FIG. 14..
6. If the resistance is greater than 100 ohms, check the
tightness of the ground connections and be sure the
air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
BB
AA
CC
TI2161A
Fig. 14. Check Gun Grounding
18
309293N
Operation
Operation
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
All operators are properly trained to safely
operate an electrostatic waterborne air spray
system as instructed in this manual.
All operators are trained in the Pressure
Relief Procedure on page 20.
The electrostatics are turned off and properly
grounded according to the.Fluid Voltage Discharge and Grounding Procedure on page
20 before any person enters the safety enclosure, before cleaning, and before performing
any maintenance or repair.
The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Grounding
on page 17.
Fluid Hose is in good condition with no cuts or
abrasions of the PTFE layer. Replace hose if
damaged.
Ventilation fans are operating properly.
Workpiece hangers are clean and grounded.
All debris, including flammable fluids and rags,
is removed from the spray area.
Only fluids with a flash point above 140F
(60C) and a maximum organic solvent concentration of 20%, by weight, may be in the
spray area.
All conductive objects in the spray area are
electrically grounded and the floor of the spray
area is electrically conductive and grounded.
309293N
19
Operation
Fluid Voltage Discharge and
Grounding Procedure
Pressure Relief Procedure
WARNING
WARNING
Pressurized Equipment Hazard
Electric Shock Hazard
The fluid supply is charged with high voltage until the voltage is discharged. Contact
with the charged components of the isolation system or spray gun electrode will
cause an electric shock. To avoid an electric shock,
follow the Fluid Voltage Discharge and Grounding
Procedure:
•
whenever you are instructed to discharge the
voltage
•
before cleaning, flushing, or servicing the system
equipment
•
before approaching the front of the gun
•
or before opening the safety enclosure for the
isolated fluid supply.
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. To reduce the risk
of an injury from electric shock, accidental spray from
the gun, splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
•
are instructed to relieve the pressure
•
stop spraying
•
check or service any of the system equipment
•
or install or clean the fluid nozzle.
1. Turn the ES ON/OFF valve OFF.
I
1. Turn the ES ON/OFF valve OFF and wait 30 seconds.
I
ES
ES
O
ti1273a
2. Follow the Fluid Voltage Discharge and Grounding Procedure at left.
O
ti1273a
2. Remove the door T-handle locking screw. This will
shut off the air to the gun and trigger the grounding
cylinder to discharge any remaining electrical
charge.
3. Use the grounding rod to touch the pump and supply pail. If you see any arcs, see Electrical Troubleshooting on page 39.
3. Turn off the main air supply valve (B).
ti1289a
4. Trigger the gun into a grounded metal waste container to relieve the air and fluid pressure.
ti1276a
5. Relieve fluid pressure in the fluid supply unit as
instructed in your fluid supply unit manual.
20
309293N
Operation
Fill the Fluid Supply
1. Discharge the system voltage (page 20).
WARNING
2. Relieve the pressure (page 20).
Fire and Explosion Hazard
To reduce the risk of fire and explosion, only
use this equipment with fluids that meet at
least one of the following conditions for
non-flammability:.
ti1276a
3. Open the isolated enclosure door.
4. Remove the pail cover from the pail, holding a rag
over the suction tube strainer to prevent any fluid
from dripping into the isolated enclosure. Place the
cover and suction tube outside the enclosure.
•
The fluid has a flash point above 140F (60C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
•
The fluid does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
5. Remove the supply pail from the enclosure.
CAUTION
Be sure to wipe up all fluid spills in the isolated enclosure. Fluid can create a conductive path and cause
the system to short out.
6. Clean up any fluid spills in the enclosure, using a
soft cloth and a non-flammable, compatible solvent.
7. Fill the supply pail with fluid and return it to the
enclosure. Clean up any spills.
8. Reinstall the pail cover, holding a rag over the suction tube strainer to prevent fluid spills while you
place the pump suction tube in the pail.
9. Close the isolated enclosure door and fasten
securely with the T-handle locking screw.
WARNING
Electric Shock Hazard
Contact with the charged components of
the spray gun will cause an electric shock.
Do not touch the gun nozzle or electrode or
come within 4 in. (102 mm) of the front of the gun
during operation or until performing the Fluid Voltage
Discharge and Grounding Procedure on page 20.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 20 when you stop spraying and
whenever you are instructed to discharge the voltage.
WARNING
Adjust the Spray Pattern
Component Rupture Hazard
Follow the steps below to establish the correct fluid flow
and air flow.
To reduce the risk of component rupture,
which can cause serious injury, do not
exceed the maximum working pressure of
the lowest rated system component. This equipment
has a 100 psi (0.7 MPa, 7 bar) maximum working air
and fluid pressure.
309293N
21
Operation
4. Fully open the fan air adjustment valve.
WARNING
0
KV
100%
μα
HI
LO
Pressurized Equipment Hazard
ES
ES
I
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
whenever you are instructed to relieve the
pressure.
O
ti1269a
1. Make sure the ES ON/OFF valve is OFF.
I
5. Fully open the fluid adjustment valve.
ES
O
0
KV
100%
μα
HI
LO
ES
ti1273a
ES
I
O
2. Turn on the main air supply valve (B).
ti1267a
6. Fully open the atomizing air restrictor valve.
3. Position the air cap by loosening the air cap retaining ring, and rotating the air cap for a vertical or horizontal spray pattern. Tighten the retaining ring until
the air cap is held firmly in place; you should not be
able to rotate the air cap horns by hand.
ti1272a
Vertical Pattern
7. Make sure the ES ON/OFF valve is OFF.
I
ES
O
Horizontal Pattern
ti1273a
22
309293N
Operation
8. Adjust the pump air regulator to start the fluid supply
unit. Adjust the fluid flow with the air pressure regulator until the stream from the gun travels 8-12 in.
(200-300 mm) before falling off. Typically, if fluid
pressure is below 5 psi (.04 MPa, 0.4 bar) or above
20 psi (0.14 MPa, 1.4 bar), a change of nozzle size
is recommended. Refer to instruction manual
309419 to set the fluid pressure for various fluid
flows, according to the size of the fluid nozzle being
used.
10. Spray a test pattern. Check the atomization. If overatomization occurs at minimum pressure, adjust the
air atomizing restrictor valve. If atomization is inadequate, increase the air pressure.
8-12 in. (200-300 mm)
ti1282a
TI1760A
9. Set the gun air regulator to deliver a minimum 40 psi
(0.28 MPa, 2.8 bar) at the gun when triggered, for
maximum transfer efficiency. See Table 3 .
11. Adjust the fan air adjustment valve: clockwise for a
rounder pattern, counterclockwise for a wider pattern.
ti1283a
TI1281A
Table 3: Air Regulator Settings
Air Hose Length
ft (m)
Air Regulator Setting
psi (MPa, bar)
(5/16 in. [8 mm] diameter)
(with gun triggered)
15 (4.6)
50 (0.35, 3.5)
25 (7.6)
60 (0.42, 4.2)
50 (15.3)
75 (0.52, 5.2)
NOTE:
•
For the most efficiency, always use the lowest air
pressure possible.
•
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.
309293N
WARNING
Electric Shock Hazard
When the ES ON/OFF switch is turned ON,
the fluid supply is charged with high voltage
until the voltage is discharged. Contact with
the charged components of the spray gun
will cause an electric shock. Do not touch the gun
nozzle or electrode or come within 4 in. (102 mm) of
the front of the gun during operation.
12. Turn the ES ON/OFF switch ON (I).
I
ES
O
ti1284a
23
Operation
13. Check that the ES indicator or display is lit, or check
that the kV indicator on the isolated enclosure reads
45-55 kV. If not, see Electrical Troubleshooting on
page 39 for possible problems.
0
KV
100%
μα
HI
I
ES
O
LO
ES
I
ES
O
ti1266a
ti1253a
14. Check the kV meter on the isolated enclosure;
45-55 kV is normal.
15. Spray a test piece. Examine the edges for coverage.
If wrap is poor, see Spray Pattern Troubleshooting on page 37.
ti1285a
16. When you finish spraying, perform the Shutdown
procedure on page 25.
24
309293N
Operation
Shutdown
2. Remove the LO VOLTAGE adjustment plug (53). Set
the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
Table 4 . Also see FIG. 16..
1. Discharge the system voltage (page 20).
2. Flush the spray gun. See page 26.
OFF
ON
2
ti1276a
0
KV
1
100%
μα
53
ti1529a
WARNING
Fig. 16. Low Voltage Adjustment Switches
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on whenever
you are instructed to relieve the pressure.
Table 4: Low Voltage Adjustment
Factory Setting
3. Relieve the pressure (page 20).
1
2
kV
ON
ON
50
OFF
40
OFF
ON
35
OFF
OFF
30
> ON
ti1276a
4. Hang the gun from its hook or place it in the accessory holster, with the nozzle pointing down. Be sure
to keep the gun from grounding out.
ti1288a
Low Voltage Adjustment (Smart
Guns Only)
The ES HI/LO switch enables you to switch between full
voltage and a lower voltage output. The lower voltage is
factory set, but can be adjusted.
1. Set the ES HI/LO switch to LO.
309293N
25
Maintenance
Maintenance
Flush the Spray Gun
1. Turn the ES ON/OFF valve OFF and wait 30 seconds for the voltage to bleed off.
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
I
ES
O
ti1273a
WARNING
Fire, Explosion, and Electric Shock Hazard
2. Discharge the system voltage (page 20).
3. Relieve the pressure (page 20).
To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
ti1276a
Follow the Fluid Voltage Discharge and
Grounding Procedure on page 20 before
flushing.
Only flush, purge, or clean the gun with fluids that
meet at least one of the following conditions for
non-flammability:
•
•
The fluid has a flash point above 140F (60C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
4. Change the fluid source to solvent.
5. Point the gun into a grounded metal pail. Flush until
clean solvent flows from the gun.
ti1276a
6. Relieve the pressure.
The fluid does not sustain burning when tested
per ASTM Standard D4206 Sustained Burn Test.
ti1276a
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
whenever you are instructed to relieve the
pressure.
7. Open the isolated enclosure door. Leave the flushing fluid in the system until you are ready to spray
again.
8. Hang the gun from its hook, with the nozzle pointing
down. Be sure to keep the gun from grounding out.
ti1288a
9. Before using the system electrostatically again,
make sure no flammable vapors are present.
26
309293N
Maintenance
Daily Care and Cleaning
CAUTION
•
Clean the outside of the gun daily with a soft cloth
dampened with a non-flammable solvent, as
defined on page 26.
•
Check for fluid leaks. Tighten all fittings.
•
Clean the air cap and fluid nozzle daily, minimum.
See page 29. Some applications require more frequent cleaning.
•
Fluid in the air passages could cause the gun to
malfunction and could draw current and reduce the
electrostatic effect. Fluid in the power supply cavity
can reduce the alternator life. Do not use any
cleaning method which could allow fluid into the
gun air passages.
•
Hang the gun with its nozzle pointing down when it
is not being used.
•
Clean the workpiece hangers with non-sparking
tools.
•
Clean the fluid and air line filters daily.
•
Check the movement of the trigger and valves.
Lubricate if necessary.
Do not point the gun up while cleaning it.
Do not immerse the gun in fluid.
ti1294a
Do not wipe the gun with a cloth that is heavily saturated; wring out the excess fluid.
ti1295a
ti1293a
309293N
27
Maintenance
CAUTION
•
Inspect the cabinet and clean up any spilled paint.
Conductive paint residue allowed to contact
grounded parts may short out the electrostatics.
•
Keep the inside of the cabinet clean, for proper
operation.
•
Visually inspect the ground strip (240) for damage.
Replace if needed. Measure the resistance weekly.
See page 33.
240
28
309293N
Maintenance
Clean the Air Cap and Fluid
Nozzle
NOTE: If it appears that there is paint inside the fluid
nozzle (7) air passages, remove the gun from the line for
servicing.
Equipment Needed
7. Carefully install the air cap (9). Be sure to insert the
electrode (29) through the center hole of the air cap.
Rotate the air cap to the desired position.
•
soft bristle brush
•
non-flammable solvent
Procedure
8. Tighten the retaining ring (27) until the air cap is
held firmly in place; you should not be able to rotate
the air cap horns by hand.
1. Turn the ES ON/OFF valve OFF. Wait 30 seconds.
9. Test gun resistance, page 30.
I
ES
O
7
29
9
ti1273a
27
ti1297a
2. Discharge the system voltage (page 20).
3. Relieve the pressure (page 20).
Fig. 17. Clean Air Cap and Fluid Nozzle
ti1276a
4. Remove the retaining ring (27) and air cap (9). See
FIG. 17..
Grease Door Latch Threads
Inspect the door T-handle locking screw regularly, to
ensure the threads are well greased. Apply silicone-free
grease to the threads when necessary.
CAUTION
Do not use metal tools to clean the
air cap or fluid nozzle holes as this
could scratch them, and make sure
the electrode is not damaged.
Scratches in the air cap or nozzle or
a damaged electrode can distort the
spray pattern.
5. Clean the air cap (9) with the soft bristle brush and
non-flammable solvent or submerge the air cap in
solvent and wipe it clean.
6. With the gun pointing down, clean the fluid nozzle
(7) and the front of the gun with a soft brush dampened with non-flammable solvent.
309293N
29
Electrical Tests
Electrical Tests
Electrical components inside the gun affect performance
and safety. The following procedures test the condition
of the power supply (18) and electrode (29), and electrical continuity between components.
AA
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
29
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
FIG. 18.) is not approved for use in a hazardous area. To reduce the risk of sparking,
do not use the megohmmeter to check electrical grounding unless:
35
•The gun has been removed from the hazardous area;
•Or all spraying devices in the hazardous
area are turned off, ventilation fans in the
hazardous area are operating, and there
are no flammable vapors in the area
(such as open solvent containers or
fumes from spraying).
TI1688B
Fig. 18. Test Gun Resistance
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
Test Gun Resistance
1. Prepare the gun for service as instructed on page
41.
2. Measure resistance between the electrode needle
tip (29) and the air swivel (35); it should be 117-137
megohms. If outside this range, go to the next test. If
you still have problems, refer to Voltage Loss Troubleshooting on page 34 for other possible causes
of poor performance, or contact your Graco distributor.
30
309293N
Electrical Tests
Test Power Supply Resistance
1. Prepare the gun for service as instructed on page
41.
2. Remove the power supply (18), page 46.
3. Remove the turbine alternator (19) from the power
supply, page 47.
4. Measure resistance from the power supply's ground
strips (EE) to the spring (18b). See FIG. 19..
5. The resistance should be 95-105 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
6. Be sure the spring (18b) is in place before reinstalling the power supply.
18b
EE
ti1599a
Fig. 19. Test Power Supply Resistance
309293N
31
Electrical Tests
Test Electrode Resistance
1. Prepare the gun for service as instructed on page
41.
2. Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the
metal contact (C) in the front of the barrel.
3. Measure the resistance between the conductive rod
(B) and the electrode (29). The resistance should be
20-30 megohms. See FIG. 20..
F
29
E
ti1548a
4. If in range, refer to Electrical Troubleshooting on
page 39 for other possible causes of poor performance, or contact your Graco distributor.
5. Remove the electrode (29), page 43. Measure the
resistance between the contact (E) and the electrode wire (F). The resistance should be 20-30 megohms. If out of range, replace the electrode. See
FIG. 21..
6. Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, FIG. 22.), and the electrode
contact (E) are clean and undamaged.
Fig. 21. Electrode
ti1513a
7a
Fig. 22. Nozzle Conductive O-Ring
C
29
B
ti1499a
Fig. 20. Test Electrode Resistance
32
309293N
Electrical Tests
Test Ground Strip Resistance
See FIG. 23.. Using an ohmmeter, measure the resistance between the latch housing (206) and the ground
lug (214). The ground strip is grounded through the cart
back to the ground lug. Resistance must be less than
100 ohms. If greater than 100 ohms, replace the ground
strip (240).
209
214
206
214
Fig. 24. Test Cylinder Resistance
Fig. 23. Test Ground Strip Resistance
Test Cylinder Resistance
See FIG. 24.. Remove the enclosure door. Using an
ohmmeter, measure the resistance from the pump (209)
to the ground lug (214). Resistance must be less than
100 ohms. If greater than 100 ohms, replace the
grounding cylinder.
309293N
33
Troubleshooting
Troubleshooting
Spray Gun
WARNING
•
Fluid leakage
•
Dielectric breakdown at the fluid hose connection or
fluid packings
•
Not enough air pressure for the turbine
•
Faulty power supply
•
Excessive overspray on gun surfaces
•
Fluid in the air passages
Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
an electric shock or other serious injury if
the work is not performed properly. Do not install or
repair this equipment unless you are trained and
qualified.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 20 before checking or servicing
the system and whenever you are instructed to discharge the voltage.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
before checking or servicing any part of the
system and whenever you are instructed to
relieve the pressure.
Waterborne Fluid Hose
•
Dielectric failure of hose (pin-hole leak through
PTFE layer)
•
Air gap in the fluid column between the gun and isolated fluid supply, causing a low voltage reading on
the isolation system voltage meter.
Voltage Isolation System
•
Fluid leakage
•
Dirty interior
Voltage Loss Troubleshooting
Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due
to spraying current demands and voltage isolation system losses.
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically
connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage isolation
system itself, you need to determine which component
in the system is most likely causing a problem. Possible
causes include the following:
34
309293N
Troubleshooting
Visual Check
First, check the system for any visible faults or errors to
help isolate whether the spray gun, fluid hose or voltage
isolation system has failed. A voltage probe and meter,
part no. 236003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting
tests that follow.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
2. Check that the voltage isolation system valves and
controls are properly set for operation.
3. Check that the interior of the isolated enclosure is
clean.
4. Check that the spray gun and voltage isolation system have sufficient air pressure.
10. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay
special attention to the following areas:
• Packing area of the spray gun
•
Fluid hose: check for leakage or any bulges in the
outer cover, which may indicate an internal leak
•
Internal voltage isolation system components
Tests
If you still have no voltage, separate the spray gun and
hose from the voltage isolation system and check
whether the gun and hose alone will hold voltage with
the following test.
1. Flush the system with water and leave the lines
filled with water.
2. Discharge the system voltage (page 20).
5. Check that the gun ES ON/OFF valve is in the ON
position and that the gun ES indicator light is on. If
the ES indicator light is not on, remove the spray
gun for service and complete the electrical tests on
pages 30- 32.
6. Check that the voltage isolation system's enclosure
door is closed and that any safety interlocks are
engaged and working properly.
7. Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage
from ground.
8. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap
in the fluid hose can break the electrical continuity
between the spray gun and the isolated fluid supply
and cause a low voltage reading on a voltage meter
connected to the isolated fluid supply.
9. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a
conductive path back to the grounded gun handle.
Install a new gun cover and clean the exterior of the
gun.
3. Relieve the pressure (page 20).
4. Disconnect the fluid hose from the voltage isolation
system.
NOTE: Avoid allowing any water to leak out of the fluid
hose as that could cause a significant air gap in the fluid
column up to the gun electrode, which can break the
conductivity path and conceal a potential failure area.
5. Position the end of the hose as far as possible away
from any grounded surface. The end of the hose
must be at least 1 ft. (0.3 m) from any ground. Make
sure that no one is within 3 ft. (0.9 m) of the end of
the hose.
6. Turn the ES ON/OFF valve to ON and trigger the
gun just enough to turn on the air to the gun but not
the fluid. Measure the voltage at the gun electrode
with a voltage probe and meter.
7. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a
grounded rod.
8. If the meter reading is 45 to 55 kV, the gun and fluid
hose are okay, and the problem is in the voltage isolation system.
If the reading is below 45 kV, the problem is in the
gun or fluid hose.
309293N
35
Troubleshooting
9. Flush the fluid hose and gun with enough air to dry
out the fluid passages.
10. Turn the ES ON/OFF valve to ON and trigger the
gun. Measure the voltage at the gun electrode with
a voltage probe and meter.
11. If the meter reading is 45-55 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue
with step 12.
13. Before reassembling the gun, clean and dry the gun
fluid inlet tube. Repack the inner spacer of the fluid
packing rod with dielectric grease and reassemble
the gun.
14. Reconnect the fluid hose.
15. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.
If the reading is below 45 kV, do the electrical tests
on page 30 to check the gun and power supply
resistance. If those tests show the gun and power
supply are okay, continue with step 12.
12. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the component that is failing.
• Fluid hose
Check for leakage or any bulges in the outer cover,
which may indicate a pin-hole leak through the
PTFE layer. Disconnect the fluid hose from the gun,
and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.
Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.
•
Make sure the hose is properly stripped (see step 2
on page 12). Restrip or replace the hose.
Fluid packings
•
Remove the packing assembly from the gun as
instructed on page 44, and look for signs of fluid
leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.
Fluid hose connection joint to the spray gun
A breakdown at the fluid hose connection joint
would be caused by fluid leaking past the o-ring
seals on the end of the hose. Remove the hose at
the gun connection and look for signs of fluid leakage along the PTFE tube.
36
309293N
Troubleshooting
Spray Pattern Troubleshooting
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray.
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Clean or replace nozzle, page 42.
Air in fluid supply.
Check fluid source. Refill.
Damaged nozzle or air cap.
Replace, page 42.
Fluid buildup on air cap or nozzle.
Clean. See page 29.
Fan air pressure too high.
Decrease.
Fluid too thin.
Increase viscosity.
Fluid pressure too low.
Increase.
Fan air pressure too low.
Increase.
Improper spray pattern.
Streaks.
309293N
Fluid too thick.
Reduce viscosity.
Too much fluid.
Decrease flow.
Did not apply 50% overlap.
Overlap strokes 50%.
Dirty or damaged air cap.
Clean or replace, page 42.
37
Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Solution
Excessive spray fog.
Atomizing air pressure too high.
Close restrictor valve some, or
decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8
bar) needed at gun for full voltage.
Fluid too thin.
Increase viscosity.
Atomizing air pressure too low.
Open atomizing air valve more or
increase gun air inlet pressure; use
lowest air pressure necessary.
Poorly mixed or filtered fluid.
Remix or refilter fluid.
Fluid too thick.
Reduce viscosity.
Fluid leaks from the fluid packing
area
Worn packings or rod.
Replace packings or rod; see page
45.
Air leaks from the front of the gun
Air valve (21) is not seating properly. Clean and service air valve; see
page 50.
Fluid leakage from the front of the
gun
Worn or damaged packing rod (26).
Replace; see page 45
Worn fluid seat.
Replace fluid nozzle and/or electrode
needle; see pages 42 to 43.
Loose fluid nozzle (7).
Tighten; see page 42.
“Orange Peel” finish.
Gun does not spray
Damaged nozzle o-ring (7b).
Replace; see page 42.
Low fluid supply.
Add fluid if necessary.
Damaged air cap (9).
Replace; see page 42.
Dirty or clogged fluid nozzle (7).
Clean; see page 42.
Damaged fluid nozzle (7).
Replace; see page 42.
Damaged fluid adjustment valve (25). Replace; see page 50.
Dirty air cap
38
Misaligned air cap (9) and fluid nozzle (7).
Clean fluid buildup off air cap and
fluid nozzle seat; see page 29.
309293N
Troubleshooting
Electrical Troubleshooting
Problem
Cause
Solution
Voltage still present at gun after fol- ES ON/OFF valve is not turned OFF. Turn OFF.
lowing the Fluid Voltage Discharge
and Grounding Procedure
Poor wrap.
309293N
Did not wait long enough for voltage
to discharge.
Wait longer before touching electrode
with grounded rod. Check for bleed
resistor failure.
Air pocket in fluid line leaves fluid
near gun isolated.
Determine cause and correct. Purge
air from fluid line.
Voltage isolation system failed.
Service voltage isolation system.
Grounding cylinder not operating.
Check resistance of grounding cylinder, page 33. Replace if needed.
ES ON/OFF valve OFF (0).*
Turn ON (I).
Gun air pressure too low.
Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.
Atomizing air pressure too high.
Decrease.
Fluid pressure too high.
Decrease.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Poorly grounded parts.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance.
See Test Gun Resistance on page
30.
Fluid leaks from the packing (26d)
and causes a short.
Clean the packing rod cavity.
Replace the packing rod. See page
45.
Faulty turbine alternator.
Be sure the plug is in place on the
back of the turbine alternator housing. Remove and test the turbine
alternator. See page 48.
The KV HI-LO lever is on LO.
Check the lever actuation; replace if
needed.
Spilled paint, dried paint, or other
contaminants inside WB100 enclosure, causing a short circuit.
Clean interior of enclosure.
39
Troubleshooting
Problem
Cause
Solution
ES indicator or voltage/current display is not lit.
ES ON/OFF valve OFF (0).*
Turn ON (I).
No power.
Replace power supply. See page 47.
Gun too close to part.
Should be 8-12 in. (200-300 mm).
Check fluid resistivity.
See Operation on page 19.
Dirty gun.
Clean. See page 27.
Operator not grounded or is near
ungrounded object.
See Grounding on page 17.
Gun not grounded.
See Check Electrical Grounding on
page 18 and Test Gun Resistance
on page 30.
Voltage/current display stays red
(smart guns only).
Operator gets mild shock.
A weak static charge has built up on Bundle and wrap the air and fluid
the surface of an unshielded fluid
hoses together. See Connect the
hose. This is a charge on the hose
Waterborne Fluid Hose, page 11.
surface, not a failure of the hose insulation.
Operator gets shock from workpiece. Workpiece not grounded.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
40
309293N
Repair
Repair
Prepare the Gun for Service
WARNING
•
Check all possible remedies in Troubleshooting
before disassembling the gun.
•
Use a vise with padded jaws to prevent damage to
plastic parts.
•
Lubricate the power supply o-ring (18a), some packing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
•
Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
•
Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are marked
with a double asterisk, for example (26a**).
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of a fire, explosion, or
electric shock:
•Follow the Fluid Voltage Discharge and
Grounding Procedure on page 20 and
be sure the ES ON/OFF valve is OFF
before flushing, checking, or servicing
the system and whenever you are
instructed to discharge the voltage.
•Clean all parts with a non-flammable fluid
as defined on the front cover of this manual.
•Do not service this equipment unless you
are trained and qualified.
•Do not touch the gun nozzle or come within
4 in. (102 mm) of the nozzle during gun
operation or until you perform the Fluid
Voltage Discharge and Grounding
Procedure on page 20.
1. Follow the Fluid Voltage Discharge and Grounding Procedure on page 20.
2. Flush the gun, page 26.
3. Blow the fluid lines dry with air.
4. Relieve the pressure, page 20.
WARNING
Pressurized Equipment Hazard
To reduce the risk of injury, follow the Pressure Relief Procedure on page 20 before
checking or servicing any part of the system
and whenever you are instructed to relieve the pressure.
5. Disconnect the gun air and fluid lines at the isolation
system.
6. Remove the gun from the worksite. Repair area
must be clean.
NOTE:
309293N
41
Repair
Air Cap/Nozzle Replacement
WARNING
CAUTION
Fire, Explosion, and Electric Shock Hazard
Hold the front end of the gun up and trigger the gun
while removing the nozzle to help drain the gun and
prevent any paint or solvent left in the gun from entering the air passages.
1. Prepare gun for service, page 41.
2. Remove the retaining ring (27) and air cap (9). See
FIG. 25..
3. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).
The nozzle contact ring (7a) is a conductive
contact ring, not a sealing o-ring. To reduce
the risk of sparking or electric shock, do not
remove the nozzle contact ring (7a) except
to replace it and never operate the gun without the contact ring in place. Do not replace
the contact ring with anything but a genuine
Graco part.
NOTE: Use non-silicone grease, Part No. 111265, on
the small o-ring (7b). Do not over-lubricate. Do not lubricate the contact ring (7a).
27
4. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).
27a*
NOTE: Make sure the electrode needle (29) is fingertight (page 43).
5. Trigger gun while installing the fluid nozzle (7) with
the multi-tool (37). Tighten until the fluid nozzle
seats in the gun barrel (1/8 to 1/4 turn past
hand-tight).
9
37
7
6. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
7. Test gun resistance, page 30.
7a
7b
ti1501a
Fig. 25. Air Cap/Nozzle Replacement
42
309293N
Repair
Electrode Replacement
1. Prepare the gun for service, page 41.
2. Remove the air cap and nozzle, page 42.
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
turning, FIG. 26..
37
CAUTION
To avoid damaging the plastic threads, be very careful when installing the electrode.
4. Apply low-strength (purple) Loctite® or equivalent
thread sealant to the electrode and packing rod
threads. Install the electrode finger-tight. Do not
overtighten.
TI1682a
5. Install the fluid nozzle and air cap, page 42.
6. Test gun resistance, page 30.
309293N
Fig. 26. Electrode Replacement
43
Repair
Fluid Packing Removal
1. Prepare the gun for service, page 41.
2. Remove the air cap and fluid nozzle, page 42.
3. Remove the electrode, page 43.
4. Loosen the trigger screws (8) and trigger (30). See
FIG. 27..
37
5. Remove the packing rod (26), using the multi-tool
(37).
30
CAUTION
8
Clean all parts in non-conductive solvent compatible
with the fluid being used, such as xylol or mineral
spirits. Use of conductive solvents can cause the gun
to malfunction.
TI1683A
6. Check all parts for wear or damage and replace if
necessary.
44
Fig. 27. Fluid Packing Removal
309293N
Repair
Packing Rod Repair
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.
NOTE: Before installing the fluid packing rod into the
gun barrel, make sure the internal surfaces of the barrel
are clean. Remove any residue with a soft brush or
cloth. Check the inside of the barrel for marks from high
voltage arcing. If marks are present, replace the barrel.
To assemble the individual parts:
1. Place the packing nut (26e) and seal (26b**) on the
fluid rod (26h). Flats on the packing nut must face
the back of the fluid rod. The seal o-ring must face
away from the packing nut. See FIG. 28..
2. Fill the inner cavity of the spacer (26g**) with dielectric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
4. Lightly tighten the packing nut (26e). The packing
nut is properly tightened when there is 3 lb (13.3 N)
of drag force when sliding the packing housing (26f)
assembly along the rod. Tighten or loosen the packing nut as needed.
5. Install the o-ring (26a**) on the outside of housing
(26f). Lubricate the o-ring with non-silicone grease,
Part No. 111265. Do not over-lubricate.
6. Install the spring (4) against the nut (E) as shown.
7. Install the packing rod assembly (26) into the gun
barrel. Using the multi-tool (37), tighten the assembly until just snug.
8. Install the trigger (30) and screws (8).
9. Install the electrode, page 43.
10. Install the nozzle and air cap, page 42.
11. Test gun resistance, page 30.
3. Place the packing spreader (26c**), rod packing
(26d**), and housing (26f) on the packing rod (26h).
4
E
TI1489A
26h
26e
**26b
**26c
**26d
**26g
26f
**26a
Fig. 28. Packing Rod
309293N
45
Repair
Barrel Removal
7. Test gun resistance, page 30.
1. Prepare the gun for service, page 41.
2. Remove the air inlet fitting (35) and take the bracket
(104) off the gun handle (17).
104
11
3. Loosen the three screws (11).
16
CAUTION
To avoid damaging the power supply (18), pull the
gun barrel straight away from the gun handle. If necessary, gently move the gun barrel from side to side
to free it from the gun handle.
TI1690A
35
17
17
4. Hold the gun handle (17) with one hand and pull the
barrel (16) straight off the handle. See FIG. 29..
TI1691A
Fig. 29. Barrel Removal
Barrel Installation
*10
18
1. Be sure the gasket (10*) and grounding spring (55)
are in place. Make sure the gasket air holes are
aligned properly. Replace if damaged. See FIG. 30..
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
11
16
55
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
35
101
104
CAUTION
Do not over-tighten the screws (11).
105
TI1692A
Fig. 30. Barrel Installation
4. Position the bracket (104) on the gun handle (17)
and secure with the air inlet fitting (35).
5. Apply dielectric grease (40) to the exposed inner
tube of the fluid hose (101).
6. Check that the nut (105) is tight on the ferrule housing (103).
46
309293N
Repair
Power Supply Removal and
Replacement
NOTE:
•
Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
•
Do not expose gasket (10) to solvents.
1. Prepare gun for service, page 41.
2. Remove the barrel (16), page 46.
9. Lubricate the power supply o-ring (18a*) with dielectric grease (40).
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Models only, connect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
11. Install the barrel (16), page 46.
12. Test gun resistance, page 30.
CAUTION
17
10*
Be careful when handling the power supply (18) to
avoid damaging it.
19a*
19
3. Grasp the power supply (18) with your hand. With a
gentle side to side motion, free the power supply/alternator assembly from the gun handle (17),
then carefully pull it straight out. On Smart Models
only, disconnect the flexible circuit (59) from the
socket at the top of the handle (17). See FIG. 31..
19e
59
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alternator for damage. On Smart Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.
ti1505c
GG
5. Check the power supply resistance, page 31.
Replace if necessary.
NOTE: Before installing the power supply, make sure
the o-rings (18a*, 19a*), spring (18b), and pads (19e)
are in place.
18
*18a
6. On Smart Models only, connect the 6-pin flexible circuit (59) to the power supply.
18b
Fig. 31. Power Supply
7. Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
309293N
47
Repair
Turbine Alternator Removal and
Replacement
NOTE: Replace turbine alternator bearings after 2000
hours of operation. Order Part No. 223688 Bearing Kit.
1. Prepare gun for service, page 41.
2. Remove the power supply/alternator assembly,
page 47.
3. Disconnect the alternator from the power supply,
page 47.
4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be
2.5-3.5 ohms. If outside this range, replace the alternator coil.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
6. Install the alternator on the power supply, page 47.
7. Install the power supply/alternator assembly, page
47.
48
309293N
Repair
Fan Air Adjustment Valve Repair
1. Prepare the gun for service, page 41.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
NOTE: You may replace the valve as an assembly (go to
step 9) or as individual parts (steps 3-9).
3. Remove the retaining ring (20a). See FIG. 32..
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
6. Clean all parts and inspect for wear or damage.
NOTE: Use non-silicone grease, Part No. 111265. Do
not over-lubricate.
7. When reassembling the fan air valve (20), lightly
lubricate the valve threads and screw the stem (20d)
fully into the housing (20c) until bottomed. Install the
o-ring (20b*), lubricate, and unscrew the valve stem
until the o-ring enters the housing.
8. Reassemble the retaining ring (20a). Unscrew the
valve stem from the housing until it is stopped by the
retaining ring.
9. Screw the valve assembly (20) into the gun handle,
using a wrench on the flats of the housing. Torque to
15-25 in-lb (1.7-2.8 N•m).
5. Remove the o-ring (20b).
20d
TI1487A
20b*
20c
20a
Fig. 32. Fan Air Adjustment Valve
309293N
49
Repair
Fluid Adjustment Valve Repair
1. Prepare the gun for service, page 41.
4. Remove the air valve (21) with a pliers. Inspect the
seal (21a*) and replace if damaged. Be sure the
seal is pressed securely onto the valve so the outer
cone is flats.
2. Remove the fluid adjustment valve (25). It can only
be replaced as a complete assembly. See FIG. 33..
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
CAUTION
When removing the air valve (21) be careful not to
damage the seat area.
5. Inspect the u-cup (6*). Do not remove the u-cup
unless damaged. If removed, install the new one
with its lips facing into the gun handle (17).
6. Install the air valve (21) and spring (15) into the gun
handle (17).
25
7. Install the fluid adjustment valve (25). Torque to
15-25 in-lb (1.7-2.8 N•m).
8. Install the barrel, page 46.
TI1684A
Fig. 33. Fluid Adjustment Valve
Air Valve Repair
15
1. Prepare the gun for service, page 41.
21a*
25
21
17
2. Remove the barrel, page 46.
3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See FIG. 34..
*6
TI1685A
Fig. 34. Air Valve
CAUTION
Clean all parts in non-conductive solvent compatible
with the fluid being used, such as xylol or mineral
spirits. Use of conductive solvents can cause the gun
to malfunction.
50
309293N
Repair
Atomizing Air Restrictor Valve
Removal and Replacement
CAUTION
1. Prepare the gun for service, page 41.
2. Remove the atomizing air restrictor valve (23).
Inspect the o-ring (23c*). Replace if necessary. See
FIG. 35..
3. Install a new atomizing air restrictor valve (23), or
disassemble and replace parts individually. The
valve protrusion must be oriented to clear the air
valve (21) shaft.
NOTE: If the atomizing air restrictor valve is not desired,
install the supplied plug (47).
Do not over-lubricate parts. Excessive lubricant on
the o-rings can be pushed into the gun air passage
and blemish the finish on the workpiece.
4. Clean and inspect parts for damage. Replace if necessary.
NOTE: The protrusion on the retainer plate (22d) must
point upward.
5. Reinstall the valve. Torque the screw (48) to 15-25
in-lb (1.7-2.8 N•m).
4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
22d
22f
22g
22e
22b*
22c
22a*
23c*
23a 47
48
TI1488A
23d
23b
Fig. 36. ES ON/OFF Valve
TI1686A
Fig. 35. Atomizing Air Restrictor Valve
ES ON/OFF Valve Repair
1. Prepare the gun for service, page 41.
2. Loosen the screw (48). Remove the valve.
3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
309293N
51
Parts
Parts
Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose, Series A (items 4-55, 101-108)
See page 53 for detail views of the alternator (19), fan adjustment valve
(20), ES ON/OFF valve (22), and packing rod (26).
22
I
ES
19a*
20
O
19e
19
18
28
25
18b
ti1266a
15
17
*18a
7a
25 (Ref)
21
7b
*10
7
21a*
16
9
11
11
27a*
23c*
27
*6
55
8
23a
23b
24
*24a
4
47
23d
30
35***
105
36
104
108 107
106
26
29
38
103
102
101
37
52
39
TI1679A
309293N
Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
20d
19a*
19b
TI1487A
20b*
20c
19b
20a
TI1481a
19e
19d 19c
Ref. No. 26: Packing Rod
Ref. No. 22: ES ON/OFF Valve
22e
26b**
22d 22f
26h
ti1601a
26g**
26c**
22g
22b*
26e
26d**
22c
26f
22a*
48
26a**
TI1488A
309293N
53
Parts
Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-55, 101-108)
Ref.
No.
Part No.
Description
4
185111
SPRING, compression
1
6*
188749
PACKING, u-cup, air valve;
uhmwpe
1
Qty
Ref.
No.
Part No.
Description
20c
197566
. HOUSING, fan valve
1
20d
197567
. STEM, fan valve
1
21
244557
VALVE, air
1
21a*
276733
SEAL, fluoroelastomer
1
Qty
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
22
244558
VALVE, electrostatics, ON/OFF;
includes 22a-22g
1
7a
111261
. O-RING, conductive
1
22a*
111516
. O-RING; CV75
1
7b
111507
. O-RING; fluoroelastomer
1
22b*
113137
. O-RING; fluoroelastomer
1
8
197369
SCREW, trigger
2
22c
198403
. SHAFT, valve
1
9
24A276
AIR CAP
1
22d
198404
. PLATE, retaining
1
10*
197517
GASKET, barrel
1
22e
198453
. WASHER
1
11
197518
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
3
22f
198464
. PIN
1
15
185116
SPRING, compression
1
22g
276753
. KNOB
1
16
244394
BARREL, gun
1
23
244559
VALVE, air, atomizing; includes
23a-23d
1
17
245292
HANDLE, gun; includes item 28
1
23a
197594
. HOUSING, valve
1
18
244542
POWER SUPPLY, 60 kV; includes
18a-18d
1
23b
197591
. SHAFT
1
18a*
103337
. O-RING; fluoroelastomer
1
23c*
168518
. O-RING; fluoroelastomer
2
18b
197624
. SPRING, compression
1
23d
101021
. RING, retaining
1
19
244555
TURBINE, alternator; includes
19a-19e
1
24
249323
VALVE, exhaust; includes 24a
1
24a*
112085
. O-RING; fluorocarbon
1
19a*
110073
. O-RING; fluoroelastomer
1
25
244593
VALVE, adjustment, fluid
1
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
1
26
244521
ROD, packing; includes 26a-26h
1
26a** 111316
. O-RING; fluoroelastomer
1
19c
244577
. COIL
1
26b** 116905
. SEAL
1
19d
111745
. RING, retaining
1
26c** 178409
. SPREADER, packing; uhmwpe
1
19e
198821
. PAD, pressure
2
26d** 178763
. PACKING, rod; acetal
1
20
244556
VALVE, adjustment, fan; includes
20a-20d
1
26e
197641
. NUT, packing
1
20a
101021
. RING, retaining
1
26f
185495
. HOUSING, packing
1
20b*
106560
. O-RING; fluorocarbon
1
26g** 186069
. SPACER, packing; acetal
1
26h
. ROD, packing
1
54
244696
309293N
Parts
Ref.
No.
Part No.
Description
1
108
198640
. FITTING, seal
1
. PACKING, u-cup
1
109
24A431
KIT, wide pattern (not shown)
1
276695
HOOK
1
29
276867
NEEDLE, electrode; black
1
30
276698
TRIGGER
1
35*** 245496
SWIVEL, air; 1/4 npsm(m);
left-hand threads
1
*** Included in Swivel Repair Kit 244834.
36
107460
WRENCH, ball end; 4 mm
1
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
37
276741
MULTI-TOOL
1
38
185103
TUBE, exhaust
1
39
110231
CLAMP
1
40
116553
GREASE, dielectric, tube (not
shown)
1
41
244915
COVER, gun; box of 10 (not
shown)
1
42
179791
TAG, warning (not shown);
replacement available at no cost
1
43
180060
SIGN, warning (not shown);
replacement available at no cost
1
47
197967
PLUG
1
48
198058
SCREW, cap, socket hd
1
55
197624
SPRING, grounding
1
101
245252
HOSE, shielded waterborne fluid;
1
246431
HOSE, unshielded waterborne
fluid; includes 102-108
1
198663
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
1
. HOUSING, ferrule (shielded
hose 245252)
HOUSING, ferrule (unshielded
hose 246431)
1
Ref.
No.
Part No.
Description
27
245790
RING, retaining; includes 27a
27a*
198307
28
102
190863
103
185547
15B932
Qty
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
1
1
104
197954
. BRACKET, fluid fitting
1
105
185548
. NUT
1
106
198643
. FITTING, barrel
1
107
102982
. O-RING
1
309293N
Qty
55
Parts
Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
See page 57 for detail views of the alternator (19), fan adjustment valve
(20), ES ON/OFF valve (22), and packing rod (26).
53 (Ref)
0
KV
100%
μα
51 (Ref)
19a*
59
HI
LO
ES
I
19
22
ES
20
O
18
28
18b
19e
ti1253a
53
52
51
54
25
15
21
*18a
7a
25 (Ref)
7b
17
*10
7
16
9
21a*
11
27a*
11
23c*
27
*6
8
55
47
23d
23a
24
*24a
4
23b
30
35***
105
36
104
26
29
38
108 107
103
106
37
56
101
102
39
TI1687A
309293N
Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
19a*
20d
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d 19c
Ref. No. 22: ES ON/OFF Valve
22e
Ref. No. 26: Packing Rod
22d 22f
22g
22b*
26b**
26g**
26c**
26d**
22c
22a*
26e
26h
ti1601a
26f
48
26a**
TI1488A
309293N
57
Parts
Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
58
Ref.
No.
Part No.
Description
4
185111
SPRING, compression
1
6*
188749
PACKING, u-cup, air valve;
uhmwpe
1
Qty
Ref.
No.
Part No.
Description
20b*
106560
. O-RING; fluorocarbon
1
20c
197566
. HOUSING, fan valve
1
20d
197567
. STEM, fan valve
1
21
244557
VALVE, air; includes item 21a
1
21a*
276733
. SEAL, fluoroelastomer
1
22
244558
VALVE, electrostatics, ON/OFF;
includes 22a-22g
1
Qty
7
197266
NOZZLE; 1.5 mm orifice; includes
7a and 7b
1
7a
111261
. O-RING, conductive
1
7b
111507
. O-RING; fluoroelastomer
1
22a*
111516
. O-RING; CV75
1
8
197369
SCREW, trigger
2
22b*
113137
. O-RING; fluoroelastomer
1
9
24A276
AIR CAP
1
22c
198403
. SHAFT, valve
1
10*
197517
GASKET, barrel
1
22d
198404
. PLATE, retaining
1
11
197518
SCREW; socket-hd; 10-24 x 3/4
in. (19 mm)
3
22e
198453
. WASHER
1
15
185116
SPRING, compression
1
22f
198464
. PIN
1
16
244394
BARREL, gun
1
22g
276753
. KNOB
1
17
245293
HANDLE, gun; includes item 28
1
23
244559
VALVE, air, atomizing; includes
23a-23d
1
18
244542
POWER SUPPLY, 60 kV; includes
18a-18d
1
23a
197594
. HOUSING, valve
1
18a*
103337
. O-RING; fluoroelastomer
1
23b
197591
. SHAFT
1
18b
197624
. SPRING, compression
1
23c*
168518
. O-RING; fluoroelastomer
2
19
244555
TURBINE, alternator; includes
19a-19e
1
23d
101021
. RING, retaining
1
24
249323
VALVE, exhaust; includes 24a
1
19a*
110073
. O-RING; fluoroelastomer
1
24a*
112085
. O-RING; fluorocarbon
1
19b
223688
. BEARING KIT; includes front
and rear bearings and fan
1
25
244593
VALVE, adjustment, fluid
1
26
244521
ROD, packing; includes 26a-26h
1
19c
244577
. COIL
1
26a** 111316
. O-RING; fluoroelastomer
1
19d
111745
. RING, retaining
1
26b** 116905
. SEAL
1
19e
198821
. PAD, pressure
2
26c** 178409
. SPREADER, packing; uhmwpe
1
20
244556
VALVE, adjustment, fan; includes
20a-20d
1
26d** 178763
. PACKING, rod; acetal
1
20a
101021
. RING, retaining
1
26e
. NUT, packing
1
197641
309293N
Parts
Ref.
No.
Part No.
Description
Ref.
No.
Part No.
Description
26f
185495
. HOUSING, packing
1
102
198663
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
1
26g** 186069
. SPACER, packing; acetal
1
26h
244696
. ROD, packing
1
27
245790
RING, retaining, air cap; includes
item 27a
1
. HOUSING, ferrule (shielded
hose 245252)
HOUSING, ferrule (unshielded
hose 246431)
1
27a*
198307
. PACKING, u-cup
1
28
276695
HOOK
1
104
197954
. BRACKET, fluid fitting
1
29
276867
NEEDLE, electrode; black
1
105
185548
. NUT
1
30
276698
TRIGGER
1
106
198643
. FITTING, barrel
1
35*** 245496
SWIVEL, air; 1/4 npsm(m);
left-hand threads
1
107
102982
. O-RING
1
36
108
198640
. FITTING, seal
1
107460
WRENCH, ball end; 4 mm
1
109
24A431
KIT, wide pattern (not shown)
1
37
276741
MULTI-TOOL
1
38
185103
TUBE, exhaust
1
39
110231
CLAMP
1
** Included in Fluid Seal Repair Kit 244911.
40
116553
GREASE, dielectric, tube (not
shown)
1
*** Included in Swivel Repair Kit 244834.
41
244915
COVER, gun; box of 10 (not
shown)
1
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
42
179791
TAG, warning (not shown);
replacement available at no cost
1
43
180060
SIGN, warning (not shown);
replacement available at no cost
1
Part No. 245897 Isolation Enclosure, Series A, with air
and shielded wb fluid hoses, standard Xs3 gun (items
201-301)
47
197967
PLUG
1
48
198058
SCREW, cap, socket hd
1
51
244627
SWITCH, ES HI/LO
1
52
111450
O-RING
1
53
276734
PLUG, LO voltage adjustment
1
54
197910
SCREW, pivot
1
55
197624
SPRING, grounding
1
59
245265
CIRCUIT, flexible
1
101
245252
HOSE, shielded waterborne fluid;
1
246431
HOSE, unshielded waterborne
fluid; includes 102-108
1
309293N
Qty
190863
103
185547
15B932
Qty
1
1
* Included in Air Seal Repair Kit 244781.
59
Parts
Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, standard Xs3 gun (items 201-301)
Part No. 245898 Isolation Enclosure, Series A,
with air and wb fluid hoses, smart Xs3 gun (items 201-301)
Part No. 233825 Isolation Enclosure, Series A, for shielded hoses without hoses and gun (items 201-286)
Part No. 246511 Isolation Enclosure, Series A, for unshielded hoses without hoses and gun (items 201-286)
271
253
280 283
216
214
301
258
228
262
239
270
279
283
276
282 252
215
253
268
268
257
257
260
281
217
218
274
226
241
249
262
220
224
279
300
261 256
204
259
256
229
206
242
205
278
227
222
267
225
223
203
221
247
235
207
262
201
201a
243
240
275 263
268
213
210
265
266
285
231
240
Ref. only; not
included
268
244
219
253
60
230
232
211
212
208
236
237
202
245
209
246
309293N
Parts
Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, standard Xs3 gun (items 201-301)
Part No. 245898 Isolation Enclosure, Series A,
with air and wb fluid hoses, smart Xs3 gun (items 201-301)
Part No. 233825 Isolation Enclosure, Series A, for shielded hoses without hoses and gun (items 201-286)
Ref.
No.
Part No.
Description
Part No.
Description
223
101390
WASHER, lock, internal tooth
1
224
154636
WASHER, plain; 0.625 in. ID
2
225
185548
NUT
1
226
190410
RESISTOR, bleed
1
227
116988
CYLINDER ROD
1
228
15A518
HOUSING, cylinder rod
1
229
104267
REGULATOR, air
1
BUSHING; plastic; 3/4 x 1/2 npt
1
Qty
Qty
201
CABINET, enclosure; includes
201a
1
201a 15A947
DOOR, cabinet
1
202
116993
CASTER, brake
4
203
15A660
PLATE
1
204
15A551
T-HANDLE, latch
1
205
15A545
STEM, handle, door
1
206
15A524
HOUSING, latch
1
207
113061
SWITCH, push, air
1
208
Ref.
No.
230
231
114456
ELBOW, tube; 3/8 npt x 3/8 in. (10
mm) OD tube
1
TUBE; 1/2 in. (13 mm) OD; polyethylene
A/R
232
116315
ELBOW, tube; 3/8 npt x 1/2 in. (13
mm) OD tube
1
PUMP, diaphragm; sst; see manual 309303
1
235
15A682
LABEL, warning
1
210
SCREW, hex hd cap; 5/16-18 x
5.5 in. (140 mm)
2
236
116316
FITTING, tube; 1/2 npt x 1/2 in.
(13 mm) OD tube
1
211
WASHER, plain; 0.344 in. ID
2
237
218798
STRAINER, 16 mesh; sst
1
212
NUT, lock; 5/16-18
2
238
114958
STRAP, tie
3
239
222011
GROUND WIRE, 25 ft (7.6 m)
1
240
234018
STRIP, grounding; aluminum
1
241
110209
NUT, regulator
1
242
114051
WASHER, shim, latch
1
243
210084
ROD, ground
1
209
233501
213
241005
COVER, pail
1
214
104029
LUG, ground
1
215
116989
VALVE, air
1
216
111804
REGULATOR, air
1
217
113060
GAUGE, air; 1/8 npt
1
218
116473
VALVE, ball; 1/4 npt(fbe)
1
219
233824
CART, enclosure
220
162453
221
222
244
SCREW, hex hd; 1/4-20 x 5/8 in.
(16 mm)
16
1
245
WASHER, plain; 1/4 in. (6 mm)
16
NIPPLE; 1/4 npt x 1/4 npsm
1
246
NUT, hex; 1/4-20
16
185547
FERRULE, housing (233825)
1
247
15B932
FERRULE, housing (246511)
1
248
198663
FERRULE (233825)
1
249
190863
FERRULE (246511)
1
251
309293N
107257
SCREW, thread forming
TUBE; 1/4 in (6 mm) OD; nylon
160430
GAUGE, air
WIRE, 10 gauge; green with yellow stripe
1
A/R
1
A/R
61
Parts
Ref.
No.
Part No.
Description
Ref.
No.
Qty
Part No.
Description
Qty
252
CONNECTOR, swivel tee; 1/8 npt
x 5/32 in. (4 mm) OD tube
1
282
SWIVEL, tube; 1/4 npt x 1/4 in. (6
mm) OD tube
4
253
NUT, hex; 10-32
1
283
2
NIPPLE, reducing; 1/2 npt x 1/4
npt
2
SWIVEL, tube; 1/8 npt x 5/32 in. (4
mm) OD tube
CLAMP
1
256
162449
285
112791
257
101874
TERMINAL, ring
5
286
258
116990
BOX, control
1
300
235070
1
259
113983
RING, retaining; 1/2 in. (13 mm)
1
260
237933
METER, 0-90 kV
1
261
113336
ADAPTER, 1/4 npt
1
HOSE, air, grounded; 0.315 in.
(8 mm) ID; 1/4 npsm(f) x 1/4
npsm(f) left-hand thread; red
cover with stainless steel braid
ground path; 25 ft (7.6 m) long
262
SCREW, pan hd; 10-32 x 5/8 in.
(16 mm)
4
301
245301
1
263
SCREW, pan hd; 10-32 x 1/4 in. (6
mm)
1
GUN, air spray, standard, electrostatic, for waterborne coatings; see page 52; used on
Model 245897
301
245305
HOLDER, tie
3
265
SCREW, button hd; 10-24 x 1.5 in.
(38 mm)
2
GUN, air spray, smart, electrostatic, for waterborne coatings; see page 56; used on
Model 245898
1
264
266
SCREW, button hd; 10-32 x 1.0 in.
(25 mm)
2
267
NUT, hex; M5 x 0.8
2
268
WASHER, lock; no. 10
9
270
116991
TEE, run, manifold
1
271
203953
SCREW, hex hd cap with patch;
10-24 x 3/8 in. (10 mm)
1
272
WIRE, 14 gauge; red
A/R
273
WIRE, ground, 14 gauge; green
with yellow stripe
A/R
274
155541
UNION, swivel; 1/4 npt
1
275
114261
TERMINAL, ring; no. 10
1
276
15A780
PLUG, hex hd
1
278
117314
BULKHEAD CONNECTOR; 1/4
npt
1
279
113319
CONNECTOR, tube; 1/4 npt x 3/8
in. (10 mm) OD tube
2
280
ELBOW, tube
1
281
FITTING, tube; 1/8 npt x 5/32 in.
(4 mm) tube
1
62
TUBE; 3/8 in. (10 mm) OD
A/R
NOTE: Replacement Warning labels, signs, tags, and
cards are available at no cost.
309293N
Parts
Tubing and Wiring Chart
Use the diagrams on page 64 to find the connection
points for the tubing and wiring listed below.
A1
A2
Ref.
No.
248
248
B2
249
B3
B4
249
249
B5
249
C1
272
C2
251
C3
273
C4
239
C5
243
C6
C7
226
272
C8
272
C9
251
E1
286
Code
309293N
Length
Description
in. (mm)
20 (508) 1/4 OD tube, regulator to pump
9 (229)
1/4 OD tube, regulator (216) to manifold
17 (432) 5/32 OD tube, manifold air to door
interlock switch
20 (508) 5/32 OD tube, valve tee to cylinder
5 (127)
5/32 OD tube, regulator (216) to
gauge (2170
22 (559) 5/32 OD tube, valve tee to door interlock switch
9 (229)
red 14 gauge wire from top of bleed
resistor to meter
8 (204)
green/yellow 14 gauge wire from
internal box ground lug to cylinder
cap
34 (864) green/yellow 10 gauge wire from
external ground lug to cart
n/a
green/yellow 25 ft ground wire with
clamp, from external ground lug to
true earth ground
n/a
green/yellow 10 gauge wire from
external ground lug to ground probe
n/a
red wire from bleed resistor to pump
16 (407) red 14 gauge wire from pump to pail
cover with clamp
12 (305) red 14 gauge wire from pump (209)
to ground on cylinder bracket
n/a
green/yellow 10 gauge wire from
meter + to internal box ground lug
4 (102)
3/8 OD tube, bulkhead to manifold
63
Parts
Tubing and Wiring Diagrams
Detail of Control Box
C9
A1 A2
C1
B4
B3
C2, C9
C3, C4, C5
B5
A2
B2
E1
C2
B3
C1
Detail of Door Interlock Switch
C8
A1
C6, C7, C8
C6
B5
TI2144A
B2
C3
64
309293N
Accessories
Accessories
Air Line Accessories
Fluid Line Accessories
Grounded Air Hose (Red Cover)
245252 Shielded Waterborne Fluid Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread; red cover with stainless steel braid ground path.
FM Approved; PTFE; 1/4 in. (6 mm) ID x 25 ft (7.6 m)
For FM approved systems
235068
235069
235070
235071
235072
235073
235074
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Bleed-Type Master Air Valve
Fluid Shutoff/Drain Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving fluid
line pressure at the fluid supply unit.
208630
1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
246431 Unshielded Waterborne Fluid Hose
Relieves air trapped in the air line between this valve
and the fluid supply unit when closed.
107141
3/4 npt
Air Line Shutoff Valve
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
FM Approved; PTFE; 1/4 in. (6 mm) ID x 25 ft (7.6 m)
For compliance with EN 50059.
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754
1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
Air Line Quick Disconnect
112534
Swiveling quick disconnect replaces standard air inlet swivel.
Air Hose Adapter Nipple
185493
Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
Non-Swivel Air Inlet Fitting
185105
Replaces standard swivel. Left-hand thread.
Extended Air Inlet Fitting
189191
309293N
Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
65
Accessories
Gun Accessories
Miscellaneous Accessories
Gun Repair Kits
Ground Wire and Clamp
244781
244911
222011
Air Seal Repair Kit
Fluid Seal Repair Kit
Round Pattern Kits
Consists of fluid tip, diffuser and air cap.
245217
245219
4-6 in. (102-152 mm) diameter
8-10 in. (203-254 mm) diameter
For grounding fluid supply unit and other
components and equipment in the spray
area.
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079
500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Push/Pull Fan Air Valve
Safety Warning Sign
244912
186118
For quick change of fan size.
English Warning Sign. FM Approved. Available at no charge from Graco.
Handle Grips
245263
245264
Medium Grip
Large Grip
Gun Valve Lubricant
111265
Electrostatic Conductive Gloves (box of 12)
117823
117824
117825
Small
Medium
Large
4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
Alternator Bearing Kit
223688
To repair the turbine alternator.
Cleaning Brush
105749
66
For cleaning air cap and fluid nozzle.
309293N
Accessories
Part No. 245895 Agitator Accessory Kit (items 401-408)
407
402
401
406
Ref.
No.
Part No.
Description
401
112698
ELBOW, swivel, male; 1/8 npt(m) x
1/4 in. (6 mm) OD tube
1
402
114158
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
1
403
193315
COLLAR, mounting, agitator
1
404
193316
NUT, collar, agitator
1
405
197298
COVER, pail; 5 gal. (19 liter); carbon steel lid
1
406
224571
AGITATOR; see manual 306565
1
407
purchase
locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
1
408
110272
SCREW, set, socket-hd; 1/4-20 x
1/4 in. (6 mm)
1
405
Qty
403
408
404
406 (Ref)
TI2137A
309293N
67
Accessories
Part No. 245944 Fluid Regulator Accessory Kit (items 501-507)
501
506
507
504
502
505
503
TI2149A
Ref.
No.
Part No.
Description
501
110078
FITTING, tube, fluid; 1/4 npt(m) x
3/8 in. (10 mm) OD tube
1
502
113070
NIPPLE, reducer; 3/8 npt x 1/4 npt
1
503
113576
PLUG; 1/4 npt
1
504
236281
REGULATOR, fluid; see manual
308325
1
505
C20350
ELBOW, 90; 1/4 npt(f) x 1/4 in. (6
mm) OD tube
1
506
114158
FITTING, adapter, Y; 1/4 in. (6
mm) OD tube; mxfxf
1
507
purchase
locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
1
68
Qty
309293N
Technical Specifications
Technical Specifications
Category
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Maximum Fluid Operating Temperature
Short Circuit Current Output
Voltage Output Energy
Sound Power (measured per ISO Standard 9216)
Sound Pressure (measured 1 m from gun)
Gun Air Inlet Fitting, left-hand thread
Gun Fluid Inlet Fitting
Gun Weight
Gun Length
Isolation Enclosure Air Inlet Fitting
Isolation Enclosure Fluid Inlet Fitting
Isolation Enclosure Weight
Isolation Enclosure Height
Isolation Enclosure Width
Isolation Enclosure Depth
Wetted Parts
Data
100 psi (0.7 MPa, 7 bar)
100 psi (0.7 MPa, 7 bar)
40 psi (0.28 MPa, 2.8 bar)
120F (48C)
125 microamperes
.35 J with fluid hose 246431 installed
244581, 245301: 60 kV
244582, 245305: 30-60 kV
at 40 psi (0.28 MPa, 2.8 bar): 90.4 dB(A)
at 100 psi (0.7 MPa, 7 bar): 105.4 dB(A)
at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A)
at 100 psi (0.7 MPa, 7 bar): 99 dB(A)
1/4 npsm(m)
custom inlet for Graco waterborne fluid hose
27.8 oz (788 g)
11.1 in. (28.2 cm)
1/4 npt
3/8 in. OD tube fitting
125 lb (56.3 kg)
44 in. (1118 mm)
24 in. (610 mm)
29 in. (737 mm)
Gun: Stainless Steel; Nylon, Acetal, Ultra-High Molecular
Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten
Wire, Polyethylene
Waterborne Fluid Hose: PTFE
Suction Tube: Polyethylene, Stainless Steel
Triton Pump: See manual 309303
Loctite® is a registered trademark of the Loctite Corporation.
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.
309293N
69
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship
on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part
of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power
supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of
operation from the date of sale. 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 general wear and tear, or any malfunction, damage or wear caused
by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering,
or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the
incompatibility of Graco equipment with 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 reasonable charge, which charges may include the costs of parts,
labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no
other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or
property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within
two (2) years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal
proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les
parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et
procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les
procedures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the distributor closest to you:
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 309293
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2002, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision N, December 2020
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