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Instructions/Parts List
ELECTROSTATIC, WATERBORNE, AIR SPRAY
WB100 Isolation System and
PRO
™
Xs3 Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability:
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. FM
• 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.
See page 3 for a List of Models
U.S. Patent Pending
309293E
TI2139a
WB 100
Isolation Enclosure
PRO Xs3
Smart Gun and
Fluid Hose
TI1681A
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
2
List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
Table of Contents
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
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 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 70
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 70
309293D
List of Models
List of Models
Part No.
245897
245898
233825
244581
245301
244582
245305
245252
246592
246593
244581
244582
246511
246431
Gun Model
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
FM Approved
Description
Waterborne Isolation Enclosure with standard electrostatic air spray gun, grounded air hose, and shielded waterborne fluid hose
Waterborne Isolation Enclosure with smart electrostatic air spray gun, grounded air hose, and shielded waterborne fluid hose
Waterborne Isolation Enclosure without hoses and gun.
Standard Electrostatic Air Spray Gun, for waterborne coatings
Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose
Smart Electrostatic Air Spray Gun, for waterborne coatings,
Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose
Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)
Waterborne Isolation Enclosure with standard electrostatic air spray gun, grounded air hose, and unshielded waterborne fluid hose
Waterborne Isolation Enclosure with smart electrostatic air spray gun, grounded air hose, and unshielded waterborne fluid hose
EN 50059 Compliant
Standard Electrostatic Air Spray Gun, for waterborne coatings.
Smart Electrostatic Air Spray Gun, for waterborne coatings.
Waterborne Isolation Enclosure, without hoses and gun
Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
309293D 3
4
Warning
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.
• 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
Voltage Discharge and Grounding Procedure,
page
• 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.
309293D
309293D
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
• 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.
• 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
6
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 Data 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.
• 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.
309293D
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.
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.
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.
309293D 7
Introduction
Gun Overview
The electrostatic gun includes the following controls
• 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
• 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.
ES INDICATOR
DISPLAY
LO VOLTAGE
ES HI/LO
ES ON/OFF
RESTRICTOR
ES ON/OFF
AIR
FLUID
RESTRICTOR
0
KV
µα
100
%
LO
ES
HI
AIR
FLUID
Standard Model ti1266a
Smart Model ti1253a
TRIGGER
AIR CAP
ELECTRODE
FLUID TUBE
TI1681A
AIR INLET
Fig. 1. Gun Overview
8 309293D
Installation
Installation
System Requirements
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.
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.
Install the System
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.
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.
F IG . 2. on page 10 shows a PRO Xs electrostatic water-
borne air spray system. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
309293D 9
Installation
B*
AA
BB
TI1896C
K*
X
G
M
L
B*
A
Gun ES ON/OFF valve: I is ON, 0 is OFF
C D E U
Q*
S
P*
N
W
J
Y
Z
V*
T
R
F
H
TI1775C
Fig. 2. Typical Installation: PRO Xs Waterborne System
Key
G
H
E
F
C
D
A
B*
Main Air Supply Line
Main Air Supply Shutoff Valve (bleed-type)
Pump Air Pressure Gauge
Pump Air Pressure Regulator kV Meter
Pump
Pump Suction Hose
Paint Container
J
K*
L
M
Bleed Resistor
Enclosure Safety Interlock
Isolated Enclosure
Gun Air Line Filter
N
P*
Gun Air Pressure Regulator
Graco Red Grounded Air Supply Hose
Q* Air Hose Ground Wire
T
U
R
S
Graco Waterborne Fluid Hose
Waterborne Electrostatic Air Spray Gun
Grounding Rod
Ground Terminal
X
Y
V* Main Ground Wire
W Strain Relief/Ground Fitting
Pump Air Supply Line
Grounding Cylinder
Z Pump Fluid Outlet Fitting
AA Isolated Enclosure Door
BB Enclosure T-Handle Locking Screw
* Required for safe operation. Must be purchased separately.
10 309293D
Installation
Ventilate the Spray Booth
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
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.
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).
Connect the Air Line
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.
Ground the Cabinet
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.
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 F IG . 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.
309293D 11
Installation
1.
Remove the gun air inlet fitting (35). See F IG . 3..
Shielded Hose 245252
C
J
B
T
F
A
16
A
104
A 7.40 in. (188 mm)
B 2.0 in. (50 mm)
108
Fig. 4. Waterborne Hose Dimensions (At Gun)
107
106 105
103
102
101
35
38
39
TI2155A
Fig. 3. Connect the Fluid Hose
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.
2.
For the fluid hose to fit properly, it must be stripped and assembled to the dimensions in F IG . 4.. 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
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.
Unshielded
Hose 246431
T
A
C
J
A 1.25 in (32 mm)
TI2742A
Fig. 5.
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 F IG . 3..
4.
Loosen the strain relief nut (102) so the bracket can move freely on the hose.
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.
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).
8.
Connect the other end of the hose to the isolated fluid supply as follows:
12 309293D
Installation 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
IG . 7..
C
Shielded
Hose 245252
T J
B
See Warning below.
T
C
Z
W
J
L
A
A 14.5 in. (368 mm)
B 0.75 in. (19 mm)
TI2166A
Fig. 6. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)
Fig. 9. Unshielded fluid connection
See Warning at right.
T
C
Z
W
L
J
TI2744A
WARNING
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.
TI1897A
Fig. 7. Shielded Fluid Hose Connection at Graco
WB100
Unshielded
Hose 246431
C
J
T 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 F IG . 10..
NOTE: Ground layer (C) of hose must be grounded at isolation system.
J
T
L
A 12.0 in (305 mm)
A
Fig. 8.
TI2743A
C (see note above)
TI1966A
Fig. 10. Shielded Fluid Hose Connection at Non-Graco Isolated Enclosure
309293D 13
c.
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.
Installation
7.
Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).
8.
Return the system to service.
402
Connect to elbow (282) inside control box (258)
407
401
406
Install tube A2 here
CAUTION
Factory Mutual approval is valid only when this gun is used with Factory Mutual approved voltage isolation systems.
403
408
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).
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 F IG . 11.. Route the agita-
tor tube (407) into the cabinet.
6.
Replace the back of the control box (258).
404
406 (Ref)
Fig. 11. 245895 Agitator Kit
TI2137A
14 309293D
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.
1.
Discharge the system voltage (page 20).
2.
Relieve the pressure (page 20).
3.
Open the isolated enclosure door.
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.
6.
Unscrew the two pump mounting screws (S, F IG .
12.) and remove the pump from the isolation enclo-
sure.
7.
Remove the back of the control box (258).
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 F IG . 12..
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.
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.
Connect to elbow (282) inside control box (258)
Connect waterborne fluid hose here
506 501
507
502
504
Connect tube A2 here
Fig. 12. Fluid Regulator Kit
S
Tube A1
503
505
TI2149A
309293D 15
Installation
Select a Fluid Nozzle and Air
Cap
WARNING
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
197477 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
Part No.
197263
197264
197265
Table 1: Fluid Nozzles
Size, mm (in.)
0.75 (.030)
1.0 (.042)
1.2 (.047)
Part No.
197266
197267
197268
Size, mm (in.)
1.5 (.055)
1.8 (.070)
2.0 (.080)
Part No.
197477
197478
197479
197480
197481
Table 2: Air Caps
Pattern Shape and Length in. (mm)
Round end;
15-17 (381-432)
Round end;
15-17 (381-432)
Tapered end;
13-15 (330-381)
Round end;
16-18 (406-457)
Tapered end;
17-19 (432-483)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Medium to high production.
Light to medium viscosity.
Low to medium production.
Light to medium viscosity.
Medium to high production.
Medium to high viscosity and high solids.
Low to medium production.
Medium to high viscosity and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
16 309293D
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.
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.
• 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. ti1259a
• Graco Waterborne Fluid Hose: the hose is grounded through the conductive layer. Install the hose as
• 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.
• All electrically conductive objects or devices in the spray area: including fluid containers, tools, and wash cans, must be properly grounded.
309293D 17
Installation
Check Electrical Grounding
1.
Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.
2.
Turn the ES ON/OFF valve OFF.
BB ti1273a
AA
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.
CC
TI2161A
Fig. 13. Check Gun Grounding
7.
Using an ohmmeter (AA), measure the resistance between the cabinet ground lug (214) and a true
earth ground (CC). See F IG . 14.. The resistance
must be less than 100 ohms.
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 F IG . 13..
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.
AA
214
CC
TI2163A
Fig. 14. Check Cabinet Grounding
18 309293D
Operation
Operation
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
Ventilation fans are operating properly.
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
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 enclo-
sure, 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
Fluid Hose is in good condition with no cuts or abrasions of the PTFE layer. Replace hose if damaged.
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.
309293D 19
Pressure Relief Procedure
Operation
Fluid Voltage Discharge and
Grounding Procedure
WARNING
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
• 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.
WARNING
Pressurized Equipment Hazard
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.
1.
Turn the ES ON/OFF valve OFF and wait 30 seconds. ti1273a ti1273a
2.
Follow the Fluid Voltage Discharge and Grounding Procedure at left.
3.
Turn off the main air supply valve (B).
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.
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 309293D
Operation
Fill the Fluid Supply
1.
Discharge the system voltage (page 20).
2.
Relieve the pressure (page 20) .
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.
5.
Remove the supply pail from the enclosure.
WARNING
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:.
• 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.
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.
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow and air flow.
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
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
Component Rupture Hazard
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.
309293D 21
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.
1.
Make sure the ES ON/OFF valve is OFF.
Operation
4.
Fully open the fan air adjustment valve.
0
KV
µα
100
%
LO
ES
HI
5.
Fully open the fluid adjustment valve.
ti1269a
0
KV
µα
100 %
LO
ES
HI ti1273a
2.
Turn on the main air supply valve (B).
ti1267a
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.
6.
Fully open the atomizing air restrictor valve. ti1272a
Vertical Pattern 7.
Make sure the ES ON/OFF valve is OFF.
Horizontal Pattern ti1273a
22 309293D
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)
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 .
ti1282a
11. Adjust the fan air adjustment valve: clockwise for a rounder pattern, counterclockwise for a wider pattern.
TI1281A
Table 3: Air Regulator Settings
Air Hose Length ft (m)
(5/16 in. [8 mm] diameter)
15 (4.6)
25 (7.6)
50 (15.3)
Air Regulator Setting psi (MPa, bar)
(with gun triggered)
50 (0.35, 3.5)
60 (0.42, 4.2)
75 (0.52, 5.2)
• 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.
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).
ti1284a ti1283a
309293D 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.
15. Spray a test piece. Examine the edges for coverage.
If wrap is poor, see Spray Pattern Troubleshooting on page 37.
0
KV
µα
100
%
LO
ES
HI ti1266a
14. Check the kV meter on the isolated enclosure;
45-55 kV is normal.
ti1253a ti1285a
16. When you finish spraying, perform the
Shutdown procedure on page 25.
24 309293D
Operation
Shutdown
1.
Discharge the system voltage (page 20).
2.
Flush the spray gun. See page 26.
ti1276a
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.
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 F IG . 15..
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on whenever
you are instructed to relieve the pressure.
3.
Relieve the pressure (page 20).
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.
OFF
2 1
ON
0
KV
µα
100 % ti1529a
53
Fig. 15. Low Voltage Adjustment Switches
Table 4: Low Voltage Adjustment
1
ON
Factory Setting > ON
OFF
OFF
2
ON
OFF
ON
OFF kV
50
40
35
30 ti1288a
309293D 25
Maintenance
Maintenance
Flush the Spray Gun
Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun.
1.
Turn the ES ON/OFF valve OFF and wait 30 seconds for the voltage to bleed off.
ti1273a
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF before flushing the gun.
Follow the
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.
• The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.
2.
Discharge the system voltage (page 20).
3.
Relieve the pressure (page 20) .
ti1276a
4.
Change the fluid source to solvent.
5.
Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.
6.
Relieve the pressure.
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.
ti1276a
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 309293D
Maintenance
Daily Care and Cleaning
CAUTION
• Clean the outside of the gun daily with a soft cloth dampened with a non-flammable solvent, as
• Check for fluid leaks. Tighten all fittings.
• Clean the air cap and fluid nozzle daily, minimum.
See page 29. Some applications require more fre-
quent 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.
Do not immerse the gun in fluid.
ti1294a
• 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 wipe the gun with a cloth that is heavily saturated; wring out the excess fluid.
ti1295a
309293D ti1293a
27
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.
240
Maintenance
28 309293D
Maintenance
Clean the Air Cap and Fluid
Nozzle
Equipment Needed
• soft bristle brush
• non-flammable solvent
Procedure
1.
Turn the ES ON/OFF valve OFF. Wait 30 seconds.
2.
Discharge the system voltage (page 20).
3.
Relieve the pressure (page 20).
ti1273a
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.
If it appears that there is paint inside the fluid nozzle (7) air passages, remove the gun from the line for servicing.
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.
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.
9.
29
7
9
27 ti1297a ti1276a
4.
Remove the retaining ring (27) and air cap (9). See
F IG . 16..
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.
Fig. 16. Clean Air Cap and Fluid Nozzle
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.
309293D 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.
Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.
Test Gun Resistance
1.
Prepare the gun for service as instructed on page
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.
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
F IG . 17.) is not approved for use in a haz-
ardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:
• 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).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.
AA
29
35
TI1688B
Fig. 17. Test Gun Resistance
30 309293D
Electrical Tests
Test Power Supply Resistance
1.
Prepare the gun for service as instructed on page
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 F IG . 18..
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
Fig. 18. Test Power Supply Resistance
EE ti1599a
309293D 31
Electrical Tests
Test Electrode Resistance
1.
Prepare the gun for service as instructed on page
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 F IG . 19..
4.
If in range, refer to
Electrical Troubleshooting on page 39 for other possible causes of poor perfor-
mance, 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.
6.
Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, F IG . 21.), and the electrode
contact (E) are clean and undamaged.
F
Fig. 20. Electrode
29 E ti1513a
Fig. 21. Nozzle Conductive O-Ring
7a ti1548a
C
29
Fig. 19. Test Electrode Resistance
B ti1499a
32 309293D
Electrical Tests
Test Ground Strip Resistance
See F IG . 22.. Using an ohmmeter, measure the resis-
tance 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).
Test Cylinder Resistance
See F IG . 23.. 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.
209
214
206
214
Fig. 22. Test Ground Strip Resistance
TI2165A
Fig. 23. Test Cylinder Resistance
TI2164A
309293D 33
Troubleshooting
Troubleshooting
WARNING
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.
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:
Spray Gun
• 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
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
34 309293D
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.
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
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.
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).
3.
Relieve the pressure (page 20).
4.
Disconnect the fluid hose from the voltage isolation system.
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.
309293D 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.
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.
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.
36 309293D
Troubleshooting
Spray Pattern Troubleshooting
Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Fluttering or spitting spray.
Cause Solution
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Clean or replace nozzle, page 42.
Improper spray pattern.
Streaks.
Air in fluid supply.
Damaged nozzle or air cap.
Check fluid source. Refill.
Fluid buildup on air cap or nozzle.
Fan air pressure too high.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Decrease.
Increase viscosity.
Increase.
Increase.
Fluid too thick.
Too much fluid.
Did not apply 50% overlap.
Dirty or damaged air cap.
Reduce viscosity.
Decrease flow.
Overlap strokes 50%.
309293D 37
Troubleshooting
Gun Operation Troubleshooting
Problem
Excessive spray fog.
“Orange Peel” finish.
Fluid leaks from the fluid packing area
Air leaks from the front of the gun
Fluid leakage from the front of the gun
Gun does not spray
Dirty air cap
Cause Solution
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.
Increase viscosity.
Fluid too thin.
Atomizing air pressure too low.
Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.
Remix or refilter fluid.
Poorly mixed or filtered fluid.
Fluid too thick.
Worn packings or rod.
Reduce viscosity.
Replace packings or rod; see page
Air valve (21) is not seating properly.
Clean and service air valve; see
Worn or damaged packing rod (26).
Worn fluid seat.
Replace fluid nozzle and/or electrode
Loose fluid nozzle (7).
Damaged nozzle o-ring (7b).
Low fluid supply.
Damaged air cap (9).
Dirty or clogged fluid nozzle (7).
Add fluid if necessary.
Damaged fluid nozzle (7).
Damaged fluid adjustment valve (25). Replace; see page 50.
Misaligned air cap (9) and fluid nozzle (7).
Clean fluid buildup off air cap and
fluid nozzle seat; see page 29.
38 309293D
Troubleshooting
Electrical Troubleshooting
Problem Cause Solution
Voltage still present at gun after following the
Fluid Voltage Discharge and Grounding Procedure
ES ON/OFF valve is not turned OFF. Turn OFF.
Poor wrap.
Did not wait long enough for voltage to discharge.
Air pocket in fluid line leaves fluid near gun isolated.
Voltage isolation system failed.
Wait longer before touching electrode with grounded rod. Check for bleed resistor failure.
Determine cause and correct. Purge air from fluid line.
Service voltage isolation system.
Grounding cylinder not operating.
Check resistance of grounding cylin-
der, page 33. Replace if needed.
Turn ON (I).
ES ON/OFF valve OFF (0).*
Gun air pressure too low.
Faulty gun resistance.
Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.
Decrease.
Atomizing air pressure too high.
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.
See
Fluid leaks from the packing (26d) and causes a short.
Faulty turbine alternator.
The KV HI-LO lever is on LO.
Clean the packing rod cavity.
Replace the packing rod. See page
Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine
Check the lever actuation; replace if needed.
Clean interior of enclosure.
Spilled paint, dried paint, or other contaminants inside WB100 enclosure, causing a short circuit.
309293D 39
Troubleshooting
Problem
ES indicator or voltage/current display is not lit.
Cause
ES ON/OFF valve OFF (0).*
Voltage/current display stays red
(smart guns only).
No power.
Gun too close to part.
Operator gets mild shock.
Check fluid resistivity.
Dirty gun.
Operator not grounded or is near ungrounded object.
Gun not grounded.
Operator gets shock from workpiece. Workpiece not grounded.
Solution
Turn ON (I).
Replace power supply. See page 47.
Should be 8-12 in. (200-300 mm).
See Check Electrical Grounding on page 18 and
Test Gun Resistance on page 30.
Resistance must be 1 megohm or less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
40 309293D
Repair
Repair
Prepare the Gun for Service
WARNING
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
Voltage Discharge and Grounding
• Check all possible remedies in
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**).
WARNING
Pressurized Equipment Hazard checking or servicing any part of the system and whenever you are instructed to relieve the pressure.
To reduce the risk of injury, follow the
Pressure Relief Procedure on page 20 before
1.
Follow the Fluid Voltage Discharge and Grounding Procedure on page 20.
2.
3.
Blow the fluid lines dry with air.
4.
Relieve the pressure, page 20.
5.
Disconnect the gun air and fluid lines at the isolation system.
6.
Remove the gun from the worksite. Repair area must be clean.
309293D 41
Repair
Air Cap/Nozzle Replacement
CAUTION
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.
WARNING
Fire, Explosion, and Electric Shock Hazard
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.
1.
Prepare gun for service, page 41.
2.
Remove the retaining ring (27) and air cap (9). See
3.
Point gun up and squeeze trigger while removing the fluid nozzle (7) assembly with the multi-tool (37).
27
27a*
9
7
37
Use non-silicone grease, Part No. 111265, on the small o-ring (7b). Do not over-lubricate. Do not lubricate the contact ring (7a).
4.
Lightly lubricate the o-ring (7b). Install it and the contact ring (7a) on the nozzle (7).
Make sure the electrode needle (29) is finger- tight
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).
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.
7a
7b
Fig. 24. Air Cap/Nozzle Replacement ti1501a
42 309293D
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
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.
5.
Install the fluid nozzle and air cap, page 42.
6.
Fig. 25. Electrode Replacement
TI1682a
Repair
309293D 43
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
5.
Remove the packing rod (26), using the multi-tool
(37). 30
37
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.
6.
Check all parts for wear or damage and replace if necessary.
Fig. 26. Fluid Packing Removal
8
TI1683A
Repair
44 309293D
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.
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 F IG . 27..
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.
3.
Place the rod packing (26d**), packing spreader
(26c**), and housing (26f) on the packing rod (26h).
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.
4
E
TI1489A
26h
**26a
26f
**26c
**26d
**26g
**26b
26e
Fig. 27. Packing Rod
309293D 45
Repair
Barrel Removal
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).
3.
Loosen the three screws (11).
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).
7.
104
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.
11
4.
Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle. See F IG . 28..
TI1690A
35 17
Barrel Installation
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 F IG . 29..
2.
Place the barrel (16) over the power supply (18) and onto the gun handle (17).
3.
Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
Fig. 28. Barrel Removal
11
18
17
*10
16
CAUTION
Do not over-tighten the screws (11).
55
4.
Position the bracket (104) on the gun handle (17) and secure with the air inlet fitting (35).
101
105
Fig. 29. Barrel Installation
104
TI1692A
35
16
TI1691A
46 309293D
Repair
Power Supply Removal and
Replacement
• 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.
8.
Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
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
Be careful when handling the power supply (18) to avoid damaging it.
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 F IG . 30..
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.
5.
Check the power supply resistance, page 31.
Replace if necessary.
Before installing the power supply, make sure the o-rings (18a*, 19a*), spring (18b), and pads (19e) are in place.
6.
On Smart Models only, connect the 6-pin flexible circuit (59) to the power supply.
7.
Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
19e
19
GG
19a*
10*
*18a 18b
Fig. 30. Power Supply
17
59
18 ti1505c
309293D 47
Repair
Turbine Alternator Removal and
Replacement
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,
3.
Disconnect the alternator from the power supply,
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
48 309293D
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).
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 F IG . 31..
4.
Turn the valve stem (20d) counterclockwise until it comes free from the valve housing (20c).
5.
Remove the o-ring (20b).
6.
Clean all parts and inspect for wear or damage.
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).
20d
TI1487A
20b*
20a
20c
Fig. 31. Fan Air Adjustment Valve
309293D 49
Repair
Fluid Adjustment Valve Repair
1.
Prepare the gun for service, page 41.
2.
Remove the fluid adjustment valve (25). It can only
be replaced as a complete assembly. See F IG . 32..
3.
Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
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.
CAUTION
When removing the air valve (21) be careful not to damage the seat area.
25
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).
7.
Install the fluid adjustment valve (25). Torque to
15-25 in-lb (1.7-2.8 N•m).
8.
Fig. 32. Fluid Adjustment Valve
TI1684A
Air Valve Repair
1.
Prepare the gun for service, page 41.
2.
3.
Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See F IG . 33..
*6
17
21a*
21
15
25
TI1685A
Fig. 33. 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 309293D
Repair
Atomizing Air Restrictor Valve
Removal and Replacement
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
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.
If the atomizing air restrictor valve is not desired, install the supplied plug (47).
4.
Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
23d
23c*
23a
47
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.
CAUTION
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.
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).
22g
22b*
22e
22d 22f
22c
22a*
23b
48
TI1488A
TI1686A
Fig. 34. Atomizing Air Restrictor Valve
Fig. 35. ES ON/OFF Valve
ES ON/OFF Valve Repair
1.
Prepare the gun for service, page 41.
309293D 51
Parts
Parts
Part No. 244581 60 kV Electrostatic Gun, Series A (items 4-55)
Part No. 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose, Series A (items 4-55, 101-108)
22
20
See page 53 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
19e
19
19a*
18 ti1266a
*18a
18b
25 (Ref)
27
27a*
9
7
7a
7b
11
16
*10
28
17
21a*
21
15
25
23c*
11
29
55
*6
8
26
36
*24a
30
4
37
108
107
106
101
105
104
103
102
23d
23a
24
23b
47
35***
39
38
TI1679A
52 309293D
Parts
Ref. No. 19: Alternator
19b
19b
19a*
TI1481a
20a
Ref. No. 20: Fan Adjustment Valve
20d
20b*
20c
19e
19d 19c
Ref. No. 22: ES ON/OFF Valve
22c
22b*
22e
22d
22f
22a*
48
22g
TI1488A
Ref. No. 26: Packing Rod
26c**
26d**
26g**
26b**
26e
26h
26f
26a**
TI1487A ti1601a
309293D 53
Parts
Part No. 244581 60 kV Electrostatic Gun, Series A (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
6*
7
8
9
7a
7b
111261
111507
197369
197477
10* 197517
11 197518
15
16
17
18
18a*
18b
19
19a*
19b
19c
19d 111745
19e 198821
20
20a
20b*
20c
185111
188749
197266
185116
244394
245292
244542
103337
197624
244555
110073
223688
244577
244556
101021
106560
197566
SPRING, compression
PACKING, u-cup, air valve; uhmwpe
NOZZLE; 1.5 mm orifice; includes
7a and 7b
. O-RING, conductive
. O-RING; fluoroelastomer
SCREW, trigger
AIR CAP
GASKET, barrel
SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)
SPRING, compression
BARREL, gun
HANDLE, gun; includes item 28
POWER SUPPLY, 60 kV; includes
18a-18d
. O-RING; Viton
®
. SPRING, compression
TURBINE, alternator; includes
19a-19e
. O-RING; Viton
®
. BEARING KIT; includes front and rear bearings and fan
. COIL
. RING, retaining
. PAD, pressure
VALVE, adjustment, fan; includes
20a-20d
. RING, retaining
. O-RING; fluorocarbon
. HOUSING, fan valve
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
3
23a 197594
23b 197591
23c* 168518
23d 101021
24 244560
24a* 106555
25 244593
26 244521
26a** 111316
26b** 116905
26c** 178409
26d** 178763
26e 197641
26f 185495
26g** 186069
26h 244696
27 245790
Ref.
No.
Part No.
Description
20d 197567
21 244557
21a* 276733
22 244558
22a*
22b*
22c
22d
22e
22f
111516
113137
198403
198404
198453
198464
22g 276753
23 244559
. STEM, fan valve
VALVE, air
SEAL, fluoroelastomer
VALVE, electrostatics, ON/OFF; includes 22a-22g
. O-RING; CV75
. O-RING; fluoroelastomer
. SHAFT, valve
. PLATE, retaining
. WASHER
. PIN
. KNOB
VALVE, air, atomizing; includes
23a-23d
. HOUSING, valve
. SHAFT
. O-RING; Viton ®
. RING, retaining
VALVE, exhaust; includes 24a
. O-RING; fluoroelastomer
VALVE, adjustment, fluid
ROD, packing; includes 26a-26h
. O-RING; fluoroelastomer
. SEAL
. SPREADER, packing; uhmwpe
. PACKING, rod; acetal
. NUT, packing
. HOUSING, packing
. SPACER, packing; Delrin ®
. ROD, packing
RING, retaining; includes 27a
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
54 309293D
Parts
Ref.
No.
Part No.
Description
36
37
38
39
40
27a* 198307
28
29
276695
276867
30 276698
35*** 245496
41
42
43
47
48
55
107460
276741
185103
110231
116553
244915
179791
180060
197967
198058
197624
. PACKING, u-cup
HOOK
NEEDLE, electrode; black
TRIGGER
SWIVEL, air; 1/4 npsm(m); left-hand threads
WRENCH, ball end; 4 mm
MULTI-TOOL
TUBE, exhaust
CLAMP
GREASE, dielectric, tube (not shown)
COVER, gun; box of 10 (not shown)
TAG, warning (not shown); replacement available at no cost
SIGN, warning (not shown); replacement available at no cost
PLUG
SCREW, cap, socket hd
SPRING, grounding
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
101 245252 HOSE, shielded waterborne fluid;
Qty
1
102
103
104
107
108
246431
198663
190863
185547
15B932
197954
105 185548
106 198643
102982
198640
HOSE, unshielded waterborne fluid; includes 102-108
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
. HOUSING, ferrule (shielded hose 245252)
HOUSING, ferrule (unshielded hose 246431)
. BRACKET, fluid fitting
. NUT
. FITTING, barrel
. O-RING
. FITTING, seal
1
1
1
1
1
1
1
1
1
1
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Included in Swivel Repair Kit 244834.
Replacement Warning labels, signs, tags, and cards are available at no cost.
309293D 55
Parts
Part No. 244582 60 kV Electrostatic Gun, Series A (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
0
KV
µα
100 %
LO
ES
HI
25 (Ref)
27a*
9
27 ti1253a
*18a
18b
53 (Ref)
51 (Ref)
22
20
18
7
7a
7b
See page 57 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
59
19
19a*
19e
11
16
*10
17
28
53
52
51 54
21
15
21a*
11
23c*
25
29
26
36
55
*6
8
*24a
30
4
37
108
107
106
101
105
104
103
102
23d
23a
24
23b
47
35***
39
38
TI1687A
56 309293D
Parts
Ref. No. 19: Alternator
19b
19b
19a*
TI1481a
20a
Ref. No. 20: Fan Adjustment Valve
20d
20b*
20c
19e
19d 19c
Ref. No. 22: ES ON/OFF Valve
22c
22b*
22e
22d
22f
22a*
48
22g
TI1488A
Ref. No. 26: Packing Rod
26c**
26g**
26d**
26b**
26e
26h
26f
26a**
TI1487A ti1601a
309293D 57
58
Parts
Part No. 244582 60 kV Electrostatic Gun, Series A (items 4-59)
Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)
Ref.
No.
Part No.
Description
4
6*
7
7a
7b
8
9
15
16
17
18
18a*
111261
111507
197369
197477
10* 197517
11 197518
18b 197624
19
19a*
19b
19c
19d
19e
20
20a
185111
188749
197266
185116
244394
245293
244542
103337
244555
110073
223688
244577
111745
198821
244556
101021
SPRING, compression
PACKING, u-cup, air valve; uhmwpe
NOZZLE; 1.5 mm orifice; includes
7a and 7b
. O-RING, conductive
. O-RING; fluoroelastomer
SCREW, trigger
AIR CAP
GASKET, barrel
SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)
SPRING, compression
BARREL, gun
HANDLE, gun; includes item 28
POWER SUPPLY, 60 kV; includes
18a-18d
. O-RING; Viton ®
. SPRING, compression
TURBINE, alternator; includes
19a-19e
. O-RING; Viton ®
. BEARING KIT; includes front and rear bearings and fan
. COIL
. RING, retaining
. PAD, pressure
VALVE, adjustment, fan; includes
20a-20d
. RING, retaining
Qty
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
2
1
23a 197594
23b 197591
23c* 168518
23d 101021
24 244560
24a* 106555
25
26
244593
244521
26a** 111316
26b** 116905
26c** 178409
26d** 178763
26e 197641
Ref.
No.
Part No.
Description
20b* 106560
20c 197566
20d 197567
21 244557
21a* 276733
22 244558
22a* 111516
22b* 113137
22c 198403
22d 198404
22e 198453
22f 198464
22g 276753
23 244559
. O-RING; fluorocarbon
. HOUSING, fan valve
. STEM, fan valve
VALVE, air; includes item 21a
. SEAL, fluoroelastomer
VALVE, electrostatics, ON/OFF; includes 22a-22g
. O-RING; CV75
. O-RING; fluoroelastomer
. SHAFT, valve
. PLATE, retaining
. WASHER
. PIN
. KNOB
VALVE, air, atomizing; includes
23a-23d
. HOUSING, valve
. SHAFT
. O-RING; Viton
®
. RING, retaining
VALVE, exhaust; includes 24a
. O-RING; fluoroelastomer
VALVE, adjustment, fluid
ROD, packing; includes 26a-26h
. O-RING; fluoroelastomer
. SEAL
. SPREADER, packing; uhmwpe
. PACKING, rod; acetal
. NUT, packing
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
309293D
Parts
Ref.
No.
Part No.
Description
26f 185495
26g** 186069
26h 244696
27 245790
27a* 198307
28
29
30
276695
276867
276698
35*** 245496
41
42
43
47
48
51
52
36
37
38
39
40
107460
276741
185103
110231
116553
244915
179791
180060
197967
198058
244627
111450
. HOUSING, packing
. SPACER, packing; Delrin
. ROD, packing
®
RING, retaining, air cap; includes item 27a
. PACKING, u-cup
HOOK
NEEDLE, electrode; black
TRIGGER
SWIVEL, air; 1/4 npsm(m); left-hand threads
WRENCH, ball end; 4 mm
MULTI-TOOL
TUBE, exhaust
CLAMP
GREASE, dielectric, tube (not shown)
COVER, gun; box of 10 (not shown)
TAG, warning (not shown); replacement available at no cost
SIGN, warning (not shown); replacement available at no cost
PLUG
SCREW, cap, socket hd
SWITCH, ES HI/LO
O-RING
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
53
54
55
276734
197910
197624
59 245265
101 245252
PLUG, LO voltage adjustment
SCREW, pivot
SPRING, grounding
CIRCUIT, flexible
HOSE, shielded waterborne fluid;
Qty
1
1
1
1
1
102
103
104
107
108
246431
198663
190863
185547
15B932
197954
105 185548
106 198643
102982
198640
HOSE, unshielded waterborne fluid; includes 102-108
. FERRULE (shielded hose
245252)
FERRULE (unshielded hose
246431)
. HOUSING, ferrule (shielded hose 245252)
HOUSING, ferrule (unshielded hose 246431)
. BRACKET, fluid fitting
. NUT
. FITTING, barrel
. O-RING
. FITTING, seal
1
1
1
1
1
1
1
1
1
1
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Included in Swivel Repair Kit 244834.
Replacement Warning labels, signs, tags, and cards are available at no cost.
Part No. 245897 Isolation Enclosure, Series A, with air and shielded wb fluid hoses, standard Xs3 gun (items
201-301)
309293D 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)
282 252
239
276
228
271
253
216
283
280
279
283
270
258
260
215 214
301
253
241
249
300
262
268
268
281
217
262
257
226
227
257 218
274
220 278
224
279
261 256
247
256
229
205
204
259
206
242
235
222
203
221
267
207
262
225 223
201
243
240
201a
275
268
263
213
Ref. only; not included
266
219
202
245
246
244
268
253
232
265
240
285
230
208
236
237
210
211
212
231
209
TI2138a
60 309293D
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
201 CABINET, enclosure; includes
201a
DOOR, cabinet 201a 15A947
202
203
116993
15A660
204 15A551
205 15A545
208
209 233501
CASTER, brake
PLATE
T-HANDLE, latch
STEM, handle, door
206 15A524 HOUSING, latch
207 113061 SWITCH, push, air
TUBE; 1/2 in. (13 mm) OD; polyethylene
PUMP, diaphragm; sst; see manual 309303
210
211
212
213 241005
214 104029
215
216
217 113060
218 116473
219
220
221
116989
111804
233824
162453
185547
SCREW, hex hd cap; 5/16-18 x
5.5 in. (140 mm)
WASHER, plain; 0.344 in. ID
NUT, lock; 5/16-18
COVER, pail
LUG, ground
VALVE, air
REGULATOR, air
GAUGE, air; 1/8 npt
VALVE, ball; 1/4 npt(fbe)
CART, enclosure
NIPPLE; 1/4 npt x 1/4 npsm
FERRULE, housing (233825)
Qty
1
1
1
1
1
A/R
1
4
1
1
2
1
1
1
1
1
1
2
2
1
1
1
15B932
222 198663
190863
223 101390
FERRULE, housing (246511)
FERRULE (233825)
FERRULE (246511)
WASHER, lock, internal tooth
1
1
1
1
Ref.
No.
Part No.
Description
224 154636
225 185548
226 190410
227 116988
228 15A518
229 104267
230
231 114456
232
235
236
237
116315
15A682
116316
238 114958
239 222011
240 234018
241 110209
242 114051
243 210084
244
245
246
247
248
249
251
252
218798
107257
160430
WASHER, plain; 0.625 in. ID
NUT
RESISTOR, bleed
CYLINDER ROD
HOUSING, cylinder rod
REGULATOR, air
BUSHING; plastic; 3/4 x 1/2 npt
ELBOW, tube; 3/8 npt x 3/8 in. (10 mm) OD tube
ELBOW, tube; 3/8 npt x 1/2 in. (13 mm) OD tube
LABEL, warning
FITTING, tube; 1/2 npt x 1/2 in.
(13 mm) OD tube
STRAINER, 16 mesh; sst
STRAP, tie
GROUND WIRE, 25 ft (7.6 m)
STRIP, grounding; aluminum
NUT, regulator
WASHER, shim, latch
ROD, ground
SCREW, hex hd; 1/4-20 x 5/8 in.
(16 mm)
WASHER, plain; 1/4 in. (6 mm)
NUT, hex; 1/4-20
SCREW, thread forming
TUBE; 1/4 in (6 mm) OD; nylon
GAUGE, air
WIRE, 10 gauge; green with yellow stripe
CONNECTOR, swivel tee; 1/8 npt x 5/32 in. (4 mm) OD tube
Qty
1
1
1
1
1
16
1
3
1
16
16
1
A/R
1
A/R
1
1
1
1
1
1
1
1
2
1
1
309293D 61
Parts
Ref.
No.
Part No.
Description
253
256 162449
257
258
259
260
261
262
263
264
265
266
267
268
270
271
272
273
274
275
101874
116990
113983
237933
113336
116991
203953
155541
114261
NUT, hex; 10-32
NIPPLE, reducing; 1/2 npt x 1/4 npt
TERMINAL, ring
BOX, control
RING, retaining; 1/2 in. (13 mm)
METER, 0-90 kV
ADAPTER, 1/4 npt
SCREW, pan hd; 10-32 x 5/8 in.
(16 mm)
SCREW, pan hd; 10-32 x 1/4 in. (6 mm)
HOLDER, tie
SCREW, button hd; 10-24 x 1.5 in.
(38 mm)
SCREW, button hd; 10-32 x 1.0 in.
(25 mm)
NUT, hex; M5 x 0.8
WASHER, lock; no. 10
TEE, run, manifold
SCREW, hex hd cap with patch;
10-24 x 3/8 in. (10 mm)
WIRE, 14 gauge; red
WIRE, ground, 14 gauge; green with yellow stripe
UNION, swivel; 1/4 npt
TERMINAL, ring; no. 10
Qty
1
2
A/R
A/R
1
1
1
2
3
2
1
1
2
9
1
1
5
1
1
4
Ref.
No.
Part No.
Description
276 15A780 PLUG, hex hd
278 117314 BULKHEAD CONNECTOR; 1/4 npt
279 113319
280
281
282
283
CONNECTOR, tube; 1/4 npt x 3/8 in. (10 mm) OD tube
ELBOW, tube
FITTING, tube; 1/8 npt x 5/32 in.
(4 mm) tube
SWIVEL, tube; 1/4 npt x 1/4 in. (6 mm) OD tube
SWIVEL, tube; 1/8 npt x 5/32 in. (4 mm) OD tube
CLAMP 285 112791
286
300 235070
301 245301
301 245305
TUBE; 3/8 in. (10 mm) OD
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
GUN, air spray, standard, electrostatic, for waterborne coat-
Model 245897
GUN, air spray, smart, electrostatic, for waterborne coat-
Model 245898
Qty
2
4
2
1
A/R
1
1
1
1
1
1
1
Replacement Warning labels, signs, tags, and cards are available at no cost.
62 309293D
Parts
Tubing and Wiring Chart
Use the diagrams on page 64 to find the connection points for the tubing and wiring listed below.
Code
A1
A2
B2
B3
B4
B5
C1
Ref.
No.
Length in. (mm)
Description
248 20 (508) 1/4 OD tube, regulator to pump
248 9 (229) 1/4 OD tube, regulator (216) to manifold
249 17 (432) 5/32 OD tube, manifold air to door interlock switch
249 20 (508) 5/32 OD tube, valve tee to cylinder
249 5 (127) 5/32 OD tube, regulator (216) to gauge (2170
249 22 (559) 5/32 OD tube, valve tee to door interlock switch
272 9 (229) red 14 gauge wire from top of bleed resistor to meter
Code
C2
C3
C4
C5
C6
C7
C8
C9
E1
Ref.
No.
Length in. (mm)
Description
251 8 (204) green/yellow 14 gauge wire from internal box ground lug to cylinder cap
273 34 (864) green/yellow 10 gauge wire from
239 n/a external ground lug to cart green/yellow 25 ft ground wire with
243 n/a clamp, from external ground lug to true earth ground green/yellow 10 gauge wire from
226 n/a external ground lug to ground probe red wire from bleed resistor to pump
272 16 (407) red 14 gauge wire from pump to pail cover with clamp
272 12 (305) red 14 gauge wire from pump (209)
251 n/a to ground on cylinder bracket green/yellow 10 gauge wire from meter + to internal box ground lug
286 4 (102) 3/8 OD tube, bulkhead to manifold
309293D 63
Tubing and Wiring Diagrams
Detail of Control Box
C1
B3
C3, C4, C5
C9 A1 A2
B5
A2
C1
B4
C2, C9
B2 E1
TI2145A
C2
B3
C8
A1
C6, C7, C8
Detail of Door Interlock Switch
Parts
C6
C3
TI2143A
B5
B2
TI2144A
64 309293D
Accessories
Accessories
Air Line Accessories
Grounded Air Hose (Red Cover)
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.
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
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
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
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 Replaces standard swivel to provide extended handle grip area. Left-hand thread.
Fluid Line Accessories
245252 Shielded Waterborne Fluid Hose
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 FM approved systems
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
246431 Unshielded Waterborne Fluid Hose
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.
309293D 65
Accessories
Gun Accessories
Gun Repair Kits
244781
244911
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
Push/Pull Fan Air Valve
244912 For quick change of fan size.
Handle Grips
245263
245264
Medium Grip
Large Grip
Gun Valve Lubricant
111265 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 For cleaning air cap and fluid nozzle.
Miscellaneous Accessories
Ground Wire and Clamp
222011 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.
Safety Warning Sign
186118 English Warning Sign. FM Approved. Available at no charge from Graco.
Electrostatic Conductive Gloves (box of 12)
117823
117824
117825
Small
Medium
Large
66 309293D
Accessories
Part No. 245895 Agitator Accessory Kit (items 401-407)
407
402
401
406
403
408
404
Ref.
No.
Part No.
Description
401
402
112698
114158
403 193315
404 193316
405 197298
ELBOW, swivel, male; 1/8 npt(m) x
1/4 in. (6 mm) OD tube
FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf
COLLAR, mounting, agitator
NUT, collar, agitator
COVER, pail; 5 gal. (19 liter)
406 224571 AGITATOR; see manual 306565
407 purchase locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
408 110272 SCREW, set, socket-hd; 1/4-20 x
1/4 in. (6 mm)
Qty
1
1
1
1
1
1
1
1
406 (Ref)
TI2137A
309293D 67
Accessories
Part No. 245944 Fluid Regulator Accessory Kit (items 501-507)
506
507
502
501
504
503
505
TI2149A
Ref.
No.
Part No.
Description
501 110078
502 113070
FITTING, tube, fluid; 1/4 npt(m) x
3/8 in. (10 mm) OD tube
NIPPLE, reducer; 3/8 npt x 1/4 npt
503 113576 PLUG; 1/4 npt
504 236281 REGULATOR, fluid; see manual
308325
505 C20350 ELBOW, 90
°
; 1/4 npt(f) x 1/4 in. (6 mm) OD tube
506 114158 FITTING, adapter, Y; 1/4 in. (6 mm) OD tube; mxfxf
507 purchase locally
TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)
Qty
1
1
1
1
1
1
1
68 309293D
Technical Data
Technical Data
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
Viton® and Delrin®
Loctite® is a registered trademark of the Loctite Corporation.
309293D 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
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-367-4023 Toll Free
612-623-6921
612-378-3505 Fax
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.
Sales Office: Minneapolis
International Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com
PRINTED IN USA 309293 02/2002 Rev. 02/2004
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