INSTRUCTIONS–PARTS LIST

This manual contains IMPORTANT

WARNINGS AND INSTRUCTIONS

READ AND RETAIN FOR REFERENCE

Model AS4000M

MANUAL ELECTROSTATIC METALLIC

AIR SPRAY GUN

100 psi (7 bar) MAXIMUM WORKING PRESSURE

Part Number 221–179 Series A

With 180–739 air cap and 0.047 in. (1.2 mm) fluid nozzle.

U.S. Patent No. 4,241,880, 4,335,851, and 4,721,255

Other U.S. and Foreign Patents Pending

307–860

Rev. D

Supersedes B

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1988 GRACO INC.

TABLE OF CONTENTS

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

How AS4000M Spray Gun Works . . . . . . . . . . . . . . . 3

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5

Installation

Typical Installation

Warning Signs

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . .

Connect the High Voltage Cable . . . . . . . . . . . . . . .

Connect the Air Lines

Connect the Fluid Line

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding . . . . . . . . . . . . . . . .

7

7

8

7

7

6

6

Operation

Operating Checklist

Filter the Fluid

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust the Spray Pattern

Flush the Spray Gun

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

10

10

9

9

Maintenance

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . .

Clean the Air Cap and Fluid Nozzle . . . . . . . . . . . .

11

11

Service

Spray Pattern Troubleshooting Chart

Gun Operation Troubleshooting Chart

. . . . . . . . . .

. . . . . . . . .

12

13

Electrical Troubleshooting Chart . . . . . . . . . . . 14, 15

Gun Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . .

16

16

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing Replacement . . . . . . . . . . . . . . . . . .

17

18

18

Resistor Assembly Replacement

Fan Air Valve Replacement

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

19

20

Air Valve Replacement . . . . . . . . . . . . . . . . . . . . . . .

Resistor Stud or Contact Replacement . . . . . . . . .

20

21

Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

How to Order Replacement Parts . . . . . . . . . . . . . . 23

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical Data . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

TERMS

WARNING Alerts user to avoid or correct conditions that could cause bodily harm.

CAUTION Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.

NOTE Identifies essential procedures or helpful information.

HOW AS4000M SPRAY GUN WORKS

A transformer supplies high voltage current through the cable to the gun’s ionizing electrode, where the electrostatic field is developed. The pump supplies fluid through the hose and gun, where it is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded work piece, wrapping around it and coating all surfaces.

307-860ą3

SAFETY WARNINGS

SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK

CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED.

READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS,

AND WARNING LABELS BEFORE OPERATING EQUIPMENT.

ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED,

QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH

THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in serious bodily injury, fire, explosion or property damage.

NEVER point the spray gun at anyone or at any part of the body. NEVER put hand or fingers over the spray nozzle.

ALWAYS follow the Pressure Relief Procedure, at right, before cleaning or removing the fluid nozzle or servicing any system equipment.

NEVER try to stop or deflect leaks with your hand or body.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately.

System Pressure

This gun has a maximum working pressure of 100 psi (7 bar). Never exceed the maximum working pressure of the gun or any other component or accessory used in the system.

HAZARDOUS FLUID HAZARD

Improper handling of hazardous fluids or inhaling vapors can cause extremely serious bodily injury, even death, due to splashing in the eyes, ingestion, inhalation, or bodily contamination. Know what fluid you are pumping and its specific hazards. Store hazardous fluids in approved containers. Dispose of any waste fluid according to all Local, State and

Federal regulations pertaining to the disposal of hazardous wastes. Observe all precautions when handling known or potentially hazardous fluids, including, but not limited to, the following.

HOSE SAFETY

TIGHTEN all fluid connections securely before each use.

NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately.

Fluid Compatibility

BE SURE all fluids and solvents used are chemically compatible with the

“Wetted Parts” shown in the TECHNICAL DATA on the back cover. Always read the fluid and solvent manufacturer’s literature before using the fluid or solvent in this gun.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.

Turn off the high voltage power supply.

2.

Turn off the air and fluid supply to the gun.

3.

Trigger the gun into a grounded metal waste container to relieve fluid pressure.

4.

Open the pump drain valve, having a waste container ready to catch the drainage.

5.

Leave the pump drain valve open until you are ready to spray again.

1. Always wear appropriate, protective clothing and equipment, such as eye protection, respiratory protection, and gloves.

2. Provide for the safe piping and disposal of all exhaust air.

3. Provide proper ventilation in accordance with accepted industry standards and governmental regulations. Refer to Ventilate the

Spray Booth, on page 5.

HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose.

4 307-860

FIRE OR EXPLOSION HAZARD

All parts of the electrostatic spray system must be properly grounded to reduce the risk of static electricity discharge. Static electricity is created by the high velocity flow of fluid through the pump and hose and the spray gun’s power supply. Ungrounded objects can become electrically charged and sparking may occur. Sparks can ignite vapors from solvents, fluid being sprayed, dust particles and other flammable substances, which can cause a fire or explosion and result in serious bodily injury and property damage.

8.

All electrically conductive objects or devices in the spray area, including paint containers and wash cans, must be properly grounded.

9.

All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn.

Rubber or plastic soles are not conductive. The operator must not wear gloves which insulate the hand from the spray gun. See page 9 for how to modify the glove.

If you experience any sparking or feel even a slight shock, STOP

SPRAYING IMMEDIATELY. Check for proper grounding of the entire system. Be sure you have corrected the problem before starting to spray again.

The minimum spraying distance from the gun nozzle to the work piece is

4 in. (100 mm). Holding the gun any closer to the work piece will cause sparking.

10.

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.

Grounding

The following are minimum requirements for grounding a basic electrostatic system. Your system may include other equipment or objects which must also be grounded. Always check your local electrical code for detailed grounding instructions. Be sure your system is connected to a true earth ground.

11.

Flammable liquids in the spray area must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.

12.

All solvent pails: use only grounded metal pails, which are conductive. Do not place the pail on any non–conductive surface, such as cardboard or paper, which would interrupt grounding continuity.

1.

Pump: ground by using a ground wire and clamp as described in your separate pump instruction manual.

2.

Air compressors: ground according to the manufacturer’s recommendations.

Flushing and Cleaning Safety

To reduce the risk of static sparking or splashing, always follow the Pres-

sure Relief Procedure on page 4 before flushing. Use the lowest possible pressure and use a grounded metal waste container.

3.

High voltage power supplies: must be properly grounded and located outside the spray area. Ground according to the manufacturer’s recommendations.

Be sure the high voltage power supply is OFF during flushing.

NEVER use solvents having a flash point of less than 70

_

F (21

_

C) to clean the gun. NEVER use solvents having a flash point of less than 100

_

F (38

_

C) to clean the spray system. ALWAYS remove all solvent from the system before reactivating the spray gun.

4.

High voltage cable: obtain grounding through connection of an undamaged cable to a properly grounded power supply.

Use only non–sparking tools to clean residue from the booth and hangers.

5.

All electric cables going to the power supply must be properly grounded.

6.

Spray gun: obtain grounding through connection to properly grounded high voltage cable.

Ventilate the Spray Booth

To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth.

7.

Object being sprayed: keep the work piece hangers clean and grounded at all times. Contact points must be sharp points or knife edges.

The High Voltage Power Supply must be electrically interlocked with the ventilators to prevent operation of the Power Supply unless ventilating fans are operating.

NEVER operate the spray gun unless the ventilating fans are operating.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards––particularly the

General Standards, Part 1910.107 and any other appropriate regulations––should be consulted in connection with the installation, operation, and maintenance of electrostatic spray painting equipment.

Connection for 75 KV Power Supply

TYPICAL INSTALLATION

WARNING

SIGN

NON–HAZARDOUS AREA

Power Supply Must Be Interlocked

With Spray Booth Exhaust Fan.

KEY

A

B

C

D

E

F

G

Air Supply Line

Air & Water Separator

Ball Valve

Air Line Lubricator

Air Regulator (bleed–type)

Pump

Fluid Filter

H

J

K

Remote Switch and Lights Wiring

ON–OFF (D.P.–D.T.) Switch

High Voltage Power Supply

(located outside the spray/hazardous area)

Remote Switch & Lights L

M Air Filter (5 micron)

N High Voltage Cable

The Typical Installation shown above is only a guide for selecting and installing electrostatic air spray systems. It is not an actual system design. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, contact your Graco representative.

Warning Signs

Mount warning signs in the spray area where they can easily be seen and read by all operators. See the AC–

CESSORIES section on page 25.

HAZARDOUS AREA

O

P

Q

R

S

T

Fluid Regulator

Fluid Line

Electrostatic Gun

Atomizing Air Line

Air Supply Shutoff Valve

(bleed–type)

Fluid Drain Valve

WARNING

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

Be sure your installation complies with National,

State and Local codes for the installation of electrical apparatus in a Class 1, Group D, Divisions 1 and

2 Hazardous Location.

6ą307-860

Ventilate the Spray Booth

WARNING

To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. The High Voltage Power

Supply must be electrically interlocked with the ventilators to prevent operation of the power supply unless the ventilation fans are operating.

NEVER OPERATE THE SPRAY GUN UNLESS

VENTILATION FANS ARE OPERATING.

Check and follow all of the National, State and

Local codes regarding air exhaust velocity requirements.

Check and follow all local safety and fire codes and

OSHA standard 1910–107(b)(5)(i).

INSTALLATION

2.

Install an air line lubricator (D) as close to the pump

(F) as possible.

3.

Install a bleed–type air regulator (E) on the pump and gun air supply lines to control air pressure to the pump and gun.

4.

Install a bleed–type air shutoff valve (S) on the main air line and each gun air supply line to shut off air to the gun(s). Install an additional bleed–type valve on each pump air supply line.

WARNING

The bleed–type air shutoff valve is required in your system to relieve air trapped between this valve and the pump after the valve is closed. Trapped air can cause the pump to cycle unexpectedly, which could result in serious bodily injury, including splashing in the eyes or on the skin and injury from moving parts.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system.

Air exhaust velocity of 100–150 ft/min (31–46 linear meters/minute) should be sufficient.

Connect the High Voltage Cable

(Refer to the

Typical Installation Drawing)

1.

Connect one end of the High Voltage Cable (N) to the gun (Q) in the spray booth area.

2.

Insert the High Voltage Cable into the insulator tube of the gun and tighten the cable with the retaining nut.

3.

Route the High Voltage cable (N) from the gun to the

Power Supply (K). To avoid permanent indentations of the cable and cable failures caused by unnecessary stress to the cable, be sure to take the following precautions: a.

Support the cable overhead to avoid people walking on it and vehicles driving over it.

b.

DO NOT clamp the cable too tightly at supports.

c.

Avoid sharp kinks and bends in the cable.

4.

Lubricate the cable o–rings with petroleum jelly. Attach the cable to the Power Supply.

Connect the Air Lines

(Refer to the Typical

Installation Drawing)

1.

Install an air line filter (M) to ensure a clean, dry air supply to the gun. Dirt and moisture in the air line can ruin the appearance of your finished work piece, and cause the Power Supply to malfunction.

5.

Connect an air supply line to the 1/4 npt(m) IN port on the Power Supply air flow switch.

6.

Connect an air line from the 1/4 npt(m) OUT port on the air flow switch to the gun’s 1/4 npsm(m) air inlet.

Connect the Fluid Line

(Refer to the Typical

Installation Drawing)

1.

Before connecting the fluid line (P), blow it out with air, and flush it with solvent. Be sure the solvent you use is compatible with the fluid to be sprayed.

2.

Connect the fluid line from the outlet of the pump to the 3/8 npsm(f) inlet of the gun.

3.

Install a fluid filter (G) and drain valve (T) at the pump outlet.

WARNING

The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient.

Install a drain valve close to the pump’s fluid outlet.

The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on the skin and contamination from hazardous fluids.

4.

Install a fluid regulator (O) to control the fluid pressure to the gun.

307-860ą7

INSTALLATION

Check the Electrical Grounding

(See Fig 1)

WARNING

Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE OR EXPLOSION

HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below.

KEY

Q

U

V

Gun

True Earth Ground

Ohmmeter

1.

Make sure the High Voltage Power Supply is pro– perly grounded and located outside the spray area.

The Power Supply case and spray gun actuator can become charged if the case is not well grounded. The ground wire is part of the high voltage circuit and must, without fail, be connected to a true earth ground. As an added precaution, attach a separate ground wire to the case of the High Voltage Power

Supply.

2.

Shut off the Power Supply and the air and fluid lines to the gun.

3.

Have a qualified electrician check the electrical grounding continuity of the spray gun. Use an ohmmeter (V) to measure resistance between the handle of the gun (Q) and a true earth ground (U). The resistance should be less than 20 ohms.

WARNING

If the resistance is over 20 ohms, the gun is not properly grounded, and the system may be hazardous. Check again that you have properly grounded your system components; see FIRE OR

EXPLOSION HAZARD, on page 5. Since the gun is grounded through connection to an undamaged, properly grounded, high voltage cable and power supply, check for a grounding problem with the cable and power supply first. BE SURE you have corrected the problem before using the system.

Fig 1

Q

U

V

8ą307-860

OPERATION

WARNING

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.

Turn off the high voltage power supply.

2.

Turn off the air and fluid supply to the gun.

3.

Trigger the gun into a grounded metal waste container to relieve fluid pressure.

4.

Open the pump drain valve, having a waste container ready to catch the drainage.

5.

Leave the pump drain valve open until you are ready to spray again.

3 in. (76 mm)

Square Cutout or

2 Fingers of

Glove Cutoff

Fig 2

Filter the Fluid

Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle.

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

Be sure all operators are properly trained to safely operate an electrostatic air spray system.

Be sure all operators are trained how to properly and completely relieve system pressure.

Be sure the system is thoroughly grounded.

See FIRE OR EXPLOSION HAZARD on page

5, and Check the Electrical Grounding on page 8.

Be sure the operator and all persons entering the spray area are properly grounded.

Be sure ventilation fans are operating properly.

Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges.

Be sure all refuse is removed from the spray booth.

Be sure all flammable liquids in the spray booth are in approved, grounded containers.

Be sure all conductive objects within 20 ft (6 m) of the gun are electrically grounded and the floor of the spray area is electrically conductive and grounded.

Be sure the operator’s glove is modified, if used, so the operator’s hand will not be insulated from the spray gun handle. See Fig 2.

307-860ą9

Adjust the Spray Pattern

This gun can atomize many fluids with different viscosities and at various flow rates. Follow these steps to establish the correct fluid flow and air flow:

1.

Set the atomizing air pressure at 30 psi (2 bar) and fluid pressure at 3 to 4 psi (0.25 bar).

2.

Choose the correct fluid nozzle and air cap combination for your application. See Instruction Manual

307–803 for the air cap consumption and fluid nozzle flow rate information. Both flow rate and viscosity must be considered. A 0.047 in. (1.2 mm) fluid nozzle is furnished with the gun.

3.

Adjust the fluid flow by using the fluid pressure regulator installed in the fluid line. (See the Accessories section.)

4.

For fine adjustment, use the fluid adjusting screw

(54) located at the rear of the gun. See Fig 3. Turn it clockwise to reduce the amount of fluid being sprayed, and counterclockwise to increase the amount being sprayed.

5.

Use an air pressure regulator to adjust the pressure for the desired degree of atomization. Always use the lowest air pressure possible for the most efficiency.

See the Spray Pattern Troubleshooting Chart in the Service Section.

6.

Use the air adjusting screw (41) to change the shape of the spray pattern. Turn it counterclockwise for a wide pattern and clockwise for a solid, round pattern.

OPERATION

NOTE: When increasing to a wide, flat pattern, you may have to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.

When all adjustments of atomizing air, fluid pressure, and fan pattern are made, the Power Supply can be turned on and operation can begin. (The spray pattern may need to be adjusted slightly after the Power Supply is turned on.)

Flush the Spray Gun

WARNING

To reduce the risk of fire or explosion and serious bodily injury, the Power Supply MUST be turned

OFF before flushing.

1.

Turn off the Power Supply (K). Follow the Pressure

Relief Procedure Warning on page 9.

3.

Disconnect and plug the fluid line.

4.

Connect the solvent supply to the gun.

5.

Run solvent through the gun.

6.

Disconnect the solvent supply.

7.

Reconnect the fluid supply line.

8.

Turn on the fluid and air supplies.

9.

Trigger the gun until it is clean of solvent.

KEY

41 Air Adjusting Screw Assembly

54 Fluid Adjusting Screw Assembly

41

Fig 3

54

Daily Care and Cleaning

For Your Safety, always follow the Pressure Relief Pro-

cedure on page 9 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system.

1.

Clean the fluid and air line filters daily.

2.

Clean the outside of the gun daily with a soft cloth, dampened in a compatible solvent.

3.

Clean the air cap and fluid nozzle daily, minimum.

Some applications require more frequent cleaning.

Replace the fluid nozzle and air cap if they are damaged. See Clean the Air Cap and Fluid

Nozzle, below.

4.

Check the electrode (56). Straighten it if bent, and replace it if broken or damaged. See page 16 for replacing the electrode.

5.

Check all of the work hangers for build–up of material; clean them, if necessary.

CAUTION

Do not use metal tools to clean the air cap holes as this may scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap holes or a damaged electrode wire can distort the spray pattern.

Do not use any cleaning method which may al-

low solvent into the gun air passages. Clogged air passages cause poor atomization and excessive current demands. Point the gun down while cleaning to prevent dirty solvent from running back into the air passages. NEVER IMMERSE THE

GUN IN SOLVENT.

Clean all parts with a non–conductive solvent, compatible with the fluid being sprayed.

Conductive solvents can cause the gun to malfunction.

Clean the Air Cap and Fluid Nozzle

Equipment needed:

Soft bristle brush (supplied).

Fluid nozzle wrench (supplied).

Solvent compatible with fluid being sprayed.

Procedure:

1.

Turn off the Power Supply. Follow the Pressure

Relief Procedure Warning on page 9.

2.

Remove the retaining nut (47) and air cap (17). See

Fig 4.

3.

Squeeze the gun trigger and remove the fluid nozzle

(19) with the fluid nozzle wrench (77b) supplied.

Make sure the front of the gun is held down. See Fig

4.

MAINTENANCE

4.

Use the soft bristle brush (77a), supplied, and solvent to clean the air cap, fluid nozzle, and front part of the gun.

5.

Squeeze the gun trigger and screw the fluid nozzle back into the gun finger tight. Torque the fluid nozzle to 10–12 in–lb (1.1–1.4 N.m) (about 1/4 of a turn) with the wrench (77b) supplied.

6.

Replace the retaining nut and air cap carefully to avoid bending the electrode wire (56). Tighten the retaining nut so it is snug, allowing the air cap to turn with resistance. If it is too tight, the spray pattern will be distorted.

KEY

17 Air Cap

19 Fluid Nozzle

47 Retaining Nut

56 Electrode

77b Wrench

17

19

56

47

Fig 4

77b

SPRAY PATTERN TROUBLESHOOTING CHART

WARNING

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

To reduce the risk of serious bodily injury, including splashing fluid or solvent in the eyes or on the skin, always follow the Pressure Relief Procedure on page 9 before checking, adjusting, cleaning or repairing the gun or any part of the system. Disconnect the fluid hose from the gun.

NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.

12

PROBLEM:

IMPROPER SPRAY

PATTERN

Fluttering or spitting spray

CAUSE

Insufficient fluid supply.

Dry or worn fluid needle packing or loose packing nut permits air to get into fluid passage.

Loose fluid nozzle or damaged fluid nozzle taper seat.

Dirt between fluid nozzle, taper seat and body.

Loose or cracked coupler at fluid inlet.

Loose fluid tube in cup or tank.

Fluid build–up on air cap; partially clogged horn holes. Full air pres– sure from clean horn hole forces fan pattern toward clogged end.

Damaged fluid nozzle or air cap holes.

Fluid build–up on the perimeter of fluid nozzle orifice, or partially clogged fluid nozzle orifice

Too high atomization air pressure.

SOLUTION

Adjust fluid regulator or fill fluid tank.

Lubricate or replace packing, tighten packing nut.

Tighten or replace fluid nozzle.

Clean.

Tighten or repair.

Tighten.

Clean with soft implement or submerge in suitable solvent and wipe clean.

Replace damaged part.

Remove obstruction. Never use wire or hard instruments.

Fluid too thin.

Not enough fluid pressure

Low atomization air pressure

Fluid too thick

Too much fluid.

Streaks Last coat of fluid applied too wet.

Too much air pressure.

Insufficient air pressure.

Non–uniform spray pattern.

NOTE: Some improper patterns are caused by the improper balance between air and fluid.

Reduce air pressure or adjust air adjusting valve.

Regulate fluid viscosity.

Increase fluid pressure.

Raise air pressure.

Regulate fluid viscosity.

Reduce fluid flow. Reduce fluid pressure on pressure feed guns and/or adjust fluid adjusting screw until proper pattern is obtained.

Apply drier finish with multiple strokes.

Use least air pressure necessary.

Increase air pressure.

Clean or replace air cap.

307-860

GUN OPERATION TROUBLESHOOTING CHART

PROBLEM

Leakage from fluid packing nut.

Air leakage from front of gun.

Fluid leakage from front of gun.

“Orange Peel” finish.

Excessive spray fog.

No fluid sprays from gun.

Equipment covered with fluid.

Equipment covered with fluid.

CAUSE

Loose packing nut (27).

Worn needle packing (6).

Air valve not seating properly.

Air stem packing too tight.

Electrode (56) worn or damaged.

Worn fluid seat.

Fluid packing (6) too tight.

Loose fluid nozzle (19).

Fluid adjusting screw (54) not set correctly.

Insufficient air pressure.

Fluid poorly mixed or filtered.

Improper thinner being used.

Too much air pressure.

Fluid thinned too much.

Fluid low.

Damaged air cap (17).

Dirty or clogged fluid nozzle (19).

Damaged fluid nozzle (19).

Exhaust air flow insufficient or not directed properly.

Equipment closer to ionizing nozzle than object being sprayed.

Misalignment between air cap and fluid nozzle.

SOLUTION

Tighten.

Replace needle packing.

Clean, service.

Loosen packing.

Replace electrode.

Replace fluid nozzle (19) and/or electrode (56).

Lubricate packing and adjust packing nut (27).

Tighten fluid nozzle.

Adjust screw.

Increase, use least air pressure needed for good results.

Remix or refilter fluid.

Use proper thinner.

Reduce,use least air pressure needed for good results.

Properly thin fluid.

Check, add if necessary.

Replace air cap.

Clean fluid nozzle.

Check, replace fluid nozzle.

Check for proper CFM, check baffles and direction of air flow.

Mount gun closer to target.

Remove and clean air cap and fluid nozzle as described in Maintenance

Section under Clean the Air Cap and

Fluid Nozzle, then reinstall them.

307-860 13

ELECTRICAL TROUBLESHOOTING CHART

PROBLEM

Poor wrap–around.

Low or no electrostatic wrap.

Low or no electrostatic wrap. (Spraying voltage light comes on, then goes off).

CAUSE

Parts poorly grounded.

High exhaust velocity.

High fluid pressure.

Fluid viscosity.

Low or no electrostatic voltage.

Faulty gun resistance.

Improper distance between gun and workpiece.

Too high atomizing air pressure.

Too low fluid resistivity.

Faulty Power Supply resistance.

Faulty needle electrode assembly.

Power Supply is off.

Fuse on inside of Power Supply is blown.

Power line voltage is incorrect.

Gun held too close to part being painted.

Fluid is too conductive.

Electrical short in the High

Voltage Cable.

Electrical short in gun.

Faulty Power Supply.

SOLUTION

Clean hangers, check for proper ground on conveyer or track.

Reduce within code limits.

Reduce pressure.

Check supplier for proper fluid for electrostatic spray.

See below.

Check; resistance should be 250 megohms +20 from the end of the gun electrode (56) to the end of the High Voltage Cable, where it connects to the Power Supply. If resistance is lower, check resistance of resistor (12) and electrode (56).

Adjust spraying distance to

8–12 in. (203–305 mm).

Reduce air pressure.

Check fluid resistivity with paint meter and probe (refer to Instruction

Manual 307–263).

Check Power Supply resistance. See instruction manual included with power supply.

Replace needle electrode assembly.

Line Power Switch is OFF, should be turned ON.

Replace fuse.

Adjust for correct voltage.

Increase distance between part and gun.

Lower conductivity of fluid or adjust

Time Delay Relay setting on Power

Supply. See PS7500M Power Supply

Manual 307–859.

Replace the High Voltage Cable.

Take gun apart and visually check the resistor housing (40), resistor well and needle well in the gun barrel (36) for dirt and/or damage. Clean and replace parts as required.

See instruction manual included with

Power Supply.

Continued on next page.

14 307-860

ELECTRICAL TROUBLESHOOTING CHART

PROBLEM

Low or no electrostatic wrap. (Spraying voltage light does not come on).

Low or no electrostatic wrap. (Spraying voltage light is on all the time).

Spraying voltage stays on when gun trigger is released.

Operator gets mild shock when touching work piece.

CAUSE

Faulty Power Supply.

Air flow switch is stuck or sluggish.

Faulty resistor stud (71).

Resistor (12) not making a good connection with contact inside of gun body.

High Voltage Cable not making good contact with resistor (58a).

Cable insulation punctured.

Spring at transformer end of cable not making good contact.

Electrical short in High Voltage

Cable.

Electrical short in gun.

Faulty Power Supply.

Air flow switch in Power Supply not working or sluggish return.

Work piece not properly grounded.

Operator not properly grounded or is in contact with ungrounded object.

Gun not properly grounded.

SOLUTION

See instruction manual included with

Power Supply.

Replace or repair air flow switch.

Replace the resistor stud.

See Resistor Assembly Replace–

ment, in the Service Section.

Replace conductive spring (58c) as required.

Replace cable.

Stretch spring.

Replace the High Voltage Cable.

Take gun apart and visually check the resistor housing (58b), resistor well and needle well in the gun barrel (36) for dirt and/or damage. Clean and replace parts as required.

See instruction manual included with

Power Supply.

Check switch, replace if faulty.

Clean work piece hangers. Check for proper ground on conveyor or track.

Be sure floor is properly grounded.

Wear shoes with non–insulating soles. Be sure operator is not in contact with or carrying any metallic items which could build up electrical charge. If a glove is worn, modify it as shown on page 9. Be sure high voltage cable is undamaged and power supply is properly grounded.

See Check the Electrical Grounding in the Installation Section.

307-860 15

Gun Disassembly

WARNING

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

Follow the Pressure Relief Procedure, page 9, before servicing the gun or any part of the system.

Disconnect the fluid hose from the gun.

SERVICE

Electrode Replacement

Remove the air cap (17) and fluid nozzle (19) as described in the Maintenance Section under Clean the Air

Cap and Fluid Nozzle.

Remove the electrode (56*) with the wrench (77d*) supplied. See Fig 5. Hold the needle shaft assembly (55) nut with a small wrench if the needle turns.

Install the new electrode assembly with the wrench. Do not over tighten.

CAUTION

To avoid damaging the plastic threads, be very careful when installing the electrode.

NOTE: Check all possible remedies in the

Troubleshooting Charts before disassembling the gun.

CAUTION

If the plastic parts of the gun must be held securely, ALWAYS clamp them in padded vice jaws to prevent damage to the parts.

ALWAYS lubricate o–rings and seals with petroleum jelly.

ALWAYS remove gun from worksite for service or repair. Service or repair area must be clean.

Install the air cap and fluid nozzle as described in the

Maintenance Section under Clean the Air Cap and

Fluid Nozzle.

The barrel retaining ring (26) and the retaining nut (48) do not have to be removed. If they must be replaced, lift one end of the retaining ring out of its groove and spiral it off the end of the barrel. Then remove the retaining nut. Spiral the new retaining ring back over the barrel.

KEY

77d Wrench Flush the gun as described under Flush the Spray Gun in the Operation Section. Follow the Pressure Relief

Procedure Warning on page 9. Disconnect the air and fluid line from the gun.

Disconnect the High Voltage Cable from the gun and cover the cable to prevent contamination. The High

Voltage Cable can stay at the worksite when you service the gun.

NOTE: Parts included with a repair kit are marked with an asterisk, for example, (77d*).

*77d

Fig 5

16 307-860

SERVICE

Barrel Removal

Remove the three nuts (81) and screws (80), then remove the shroud (79). See Fig 6.

Disconnect the fluid hose nut (67) and collar (68) from the fitting (39). See Fig 7.

Pull the tube (31) out of the fitting (39).

NOTE: If the tube (31) needs to be replaced, be sure to wrap the new tube around the barrel (36) three times. Refer to Fig 6.

Remove the trigger by removing the screws (33) and spacers (61) from the gun.

Loosen the retaining nut (48), using the wrench (77b) supplied.

Hold the gun handle (57) with one hand and pull straight up to remove the gun barrel (36). See Fig 8.

The barrel may slide off with heavy resistance. Pull the barrel straight up to avoid damaging the resistor housing

(58b).

NOTE: The gasket (34) should be left in the gun handle if it is not being replaced. See the Parts Drawing on page 22 for the gasket location.

KEY

79 Shroud

31 Fluid Tube

36 Gun Barrel

80 Screw

81 Nut

KEY

31 Fluid Tube

33 Screw

39 Adapter

48 Retaining Nut

61 Spacer

67 Fluid Hose Nut

68 Collar

77b Wrench

Fig 7

77b

33, 61

KEY

26 Retaining Ring

36 Gun Barrel

48 Retaining Nut

57 Gun Handle

81

79

80

36

31

Wrap around barrel 3 times 57

Fig 6

Fig 8

48

31

67, 68

36

26, 48

39

307-860 17

Fluid Packing Removal

Remove the electrode resistor as described in Electrode

Replacement.

Remove the barrel as described in Barrel Removal.

Carefully remove the needle shaft assembly (55) from the rear of the barrel (36). See Fig 10.

Remove the packing nut (27) at the rear of the barrel, using the wrench (77c) supplied.

NOTE: The nut (55a) is secured with Loctite ) to the needle shaft assembly (55) and should not be removed. If the nut is removed, it will have to be reassembled to the needle shaft assembly with

Loctite No. 271 to the proper dimension. See Fig

9 for the correct length.

Slide the insulator (32) and support (23) off the needle shaft.

Place barrel on a table top in a vertical position with the back of the barrel touching the table top. Insert the rod

(77e), supplied, in the front of the barrel and gently tap out the needle packing (6*) and support (23). Check all the parts for wear or damage, replace them if necessary.

CAUTION

Use extreme care when handling the packing (6) because it is very brittle. You may want to keep extra packings on hand.

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.

SERVICE

Fluid Packing Replacement

Slide the packing nut (27) onto the fluid needle shaft (55).

Then slide the insulator (32) onto the needle shaft. The holes in the one end of the insulator (32) must face toward the electrode end of the fluid needle shaft (55), as shown in Fig 10.

Place the packing (6*) between the two supports (23), with the beveled side of the supports facing toward the packing. Slide the packing, with the supports, onto the fluid needle shaft (55).

Place the spring (13) over the nut (55a). Slide the barrel over the resistor housing. With one hand, push the barrel up against the front part of the gun handle. Using the other hand, start and tighten the retaining nut (48). See

Fig 11.

Reassemble the needle electrode (56*), fluid nozzle (19) and air cap (17) as described in the Maintenance Section under Clean the Air Cap and Fluid Nozzle.

KEY

55 Needle Shaft Assy

55a Adjusting Nut

55

Fig 9

1.76 in.

(44 mm + 1 )

0

6.1 in. (155.3 mm)

55a

KEY

6 Needle Packing

13 Spring

23 Support

27 Packing Nut

32 Insulator

36 Gun Barrel

55 Needle Shaft Assy

55a Nut

Beveled Side

Faces Packing (6)

55a

13

36

Fig 10

18 307-860

KEY

48 Retaining Nut

48

SERVICE

Slide the hook (50) forward and out of the gun channel.

Pull the resistor housing (58b) up and forward to remove it from the gun handle (57) chamber. Remove the spring

(11) from the end of the resistor.

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. Do not submerge the resistor in solvent.

Check all parts for wear or damage, replace them if necessary.

Place the new o–rings (69, 10*) over the new resistor housing (58b) and lubricate them with petroleum jelly.

CAUTION

All o–rings and conductive springs must be in place or the gun will malfunction.

Fig 11

Resistor Assembly Replacement

Remove the trigger by removing the two screws (33) and spacers (61). See Fig 12. Remove the gun barrel as described in Barrel Removal. Remove the gasket (34) from the gun barrel (36) and replace if damaged.

Insert the resistor housing (58b) down through the top of the gun. Slide the hook (50) into place.

Replace the barrel assembly by reversing the procedure described in Barrel Removal.

58c

Spring inside resistor housing

KEY

10 O–Ring

11 Spring

33 Screws

50 Hook

57 Gun Handle

58 Resistor Assy.

58a Resistor

58b Resistor Housing

58c Spring

61 Spacers

69 O–Ring

58b

58a

57

Fig 12

SERVICE

Fan Air Valve Replacement

Place a wrench on the valve housing (42) flats and remove the housing from the handle. See Fig 13.

Remove the retaining ring (14). Remove the air adjusting screw (41) from the valve housing (42), turning it counterclockwise.

Clean all parts, inspect for wear or damage, and replace if necessary.

Lubricate the o–ring and the threads of the air adjusting screw (41) with petroleum jelly.

Install the adjusting screw (41) into the valve housing

(42), turning it clockwise, and secure it with the retaining ring (14) .

Back the adjusting screw out of the valve housing (42) until it bottoms out against the retaining ring (14).

Apply Loctite ) pipe sealant to the threads of the housing

(42). Install the housing (42) into the gun handle, torquing it to 14–20 ft/lb (20–27 N.m).

Air Valve Replacement

Using a screwdriver, remove the retainer (29), spring

(62), and air valve stem (59) from the gun handle. See Fig

14. Replace parts as needed and install them back into the gun handle.

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.

Install the new packing (18*) and guide (30) into the front of the gun handle.

Tighten the guide (30) into the gun handle. Squeeze the trigger and adjust it until there is no movement, then back it off until it moves freely.

KEY

14 Retaining Ring

41 Air Adjusting Screw Assy

42 Valve Housing

42

Apply Loctite

Torque to 14–20 ft/lb

(20–27 N.m)

14

KEY

18 Packing

29 Retainer

30 Guide

59 Air Valve Stem

62 Spring

41

59

62

29

*18

30

Fig 14 Fig 13

Resistor Stud or Contact Replacement

WARNING

Old/New Style Resistor Stud and Electrode

To reduce the risk of sparking, which could cause fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and stud were white. DO NOT mix old style parts with new style parts.

SERVICE

Using the tool (77g*) supplied, reinstall the resistor stud in the front of the gun barrel (36). Tighten until snug.

Reinstall the electrode (56*) as described under

Electrode Replacement.

Reinstall the fluid nozzle (19) and air cap (17) as described in Clean the Air Cap and Fluid Nozzle.

KEY

9 O–Ring

36 Gun Barrel

71 Resistor Stud

74 Washer

78 Contact

Remove the air cap (17) and fluid nozzle (19) as described in the Maintenance Section under Clean the Air

Cap and Fluid Nozzle.

Remove the electrode (56*) as described under Elec-

trode Replacement.

Using the tool (77g*) supplied, unscrew and remove the resistor stud (71*) with the o–ring (9*) and washer (74*).

See Fig 15.

To replace the contact (78*), push the contact out the front of the gun barrel (36) with the rod (77e) supplied.

Press fit the contact into the gun body unti it bottoms out.

To install the resistor stud:

Lubricate the o–ring (9*) with petroleum jelly and install it on the resistor stud (71*).

Install the washer (74*) into the gun barrel.

*71

*74

*9

Fig 15

78*

36

307-860 21

[

[

Torque to

10–12 in/lb

1.1–1.4 N.m

PARTS DRAWING

WARNING

Old/New Style Resistor Stud and Electrode

To reduce the risk of sparking, which could cause fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and stud were white. DO NOT mix old style parts with new style parts.

58c

Spring inside resistor housing

58b

58a

Torque to

14.7–20 ft/lb

20–27 N.m

79

81

80 31

Wrap around barrel 3 times

70

[

*

[

[

Press fit into housing (36)

Tool Kit 220–389

Ref No. 77, Includes 77a–77g

77e

77b

[ 77g

77f

55a

[

77c

77d

[

77a

PARTS LIST

Model AS4000M

Electrostatic Metallic Air Spray Gun

Part No. 221–179, Series A

Includes items 2 to 81

REF

NO.

PART NO.

DESCRIPTION QTY

2

4

5

11

13

14

15*

17

18*

19

23

26

27 176–936

29 176–939

30

31

103–147

104–765

105–661

6* 105–662

9*

[

105–667

10* 105–668

177–233

105–673

105–681

168–110

180–739

106–901

181–299

176–926

176–930

176–941

183–905

37 176–955

39 181–384

41 215–926

PLUG, internal hex; 1/16 npt(f) 2

PLUG, internal hex; 1/8 npt(f) 3

RING, retaining

PACKING, needle,

O–RING, Viton r

O–RING, Viton r

PTFE

SPRING

SPRING, compression r

1

1

2

1

1

1

1

1

RING, retaining

O–RING, Viton r

AIR CAP (See Manual 307–803 for available air caps)

PACKING, needle, PTFE r

FLUID NOZZLE (See Manual

307–803 for available fluid

1

1 nozzles)

SUPPORT, packing

RING, retaining

NUT, packing, Delrin

RETAINER

GUIDE

TUBE, fluid, PTFE

ADAPTER, fluid r r

32 180–600

33 176–945

INSULATOR

SCREW

34 176–947 GASKET, housing, fiber

36 180–066 BARREL, gun

CONNECTOR, cable

AIR ADJUSTING SCREW

1

1

1

1

1

1

2

1

1

1

1

1

2

1

42

43

45

46

47

48

50

51

54

55 218–587

55a

176–961

176–962

176–962

176–966

176–969

176–969

176–973

177–000

215–646

180–599

HOUSING, valve

BRACKET, tube

ADAPTER, air

TRIGGER

NUT, retaining

NUT, retaining

HOOK

INSULATOR, cable

FLUID ADJUSTING SCREW

NEEDLE SHAFT ASSY

Includes item 55a

.NUT, adjusting

1

1

1

1

1

1

1

1

1

1

1

HOW TO ORDER REPLACEMENT PARTS

1.To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below.

2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering.

3. Order all parts from your nearest Graco distributor.

6 digit

Part

Number Qty Part Description

58a

58b

58c 106–375

59* 215–890

61 177–128

62 107–029

63 177–451

64 176–921

65 104–296

66 105–800

67 106–262

68 183–612

69 103–338

70 105–882

71

[

220–923

72 107–208

74* [ 181–825

75 176–898

76 180–209

77 220–389

REF

NO.

PART NO.

56

[

181–824

57 176–967

58 215–889

77a 105–749

77b 177–004

77c 177–732

77d

[

177–007

77e 179–803

77f 107–158

77g [ 183–107

78

[

181–827

79 183–629

80 108–972

81 108–973

DESCRIPTION QTY

ELECTRODE (color coded black) 1

HANDLE 2

RESISTOR ASSY

Includes items 58a–58c 1

.RESISTOR

.HOUSING, resistor

.SPRING, compression

AIR VALVE

1

1

1

1

SPACER

SPRING, compression

NUT, lock

PLUG, M3 x 0.5 x 6

RETAINER, adapter

SCREW, plug, M3 x 0.5 x 6

NUT

COLLAR

O–RING, Viton r

FITTING, male

1

1

1

1

1

1

1

2

1

1

STUD, resistor

(color coded black)

NUT, ferrule

WASHER

TAG, warning (not shown)

COVER, gun (not shown

KIT, tool

Includes items 77a–77g

.BRUSH, cleaning

.WRENCH, barrel nut/nozzle

.WRENCH, packing nut

.WRENCH, needle

.ROD, packing removal

.WRENCH, resistor stud

.TOOL, resistor stud

CONTACT

SHROUD

SCREW, mach,

NUT

1

1

1

1

2

1

1

3

1

1

1

1

3

1

1

1

1

* Included in Repair Kit 220–393. See page 25.

[

Included in Repair Kit 220–392. See page 25. Read and follow the Old/

New Style Resistor Stud and Electrode Warning, on page 22.

WARNING

When servicing use only genuine Graco replacement parts. Use of other parts could alter the grounding continuity of the gun, which could cause fire and explosion and result in property damage and serious bodily injury.

ACCESSORIES

FILTER (AIR OR PAINT) 202–271

750 psi (52 bar) MAXIMUM WORKING PRESSURE

With 60 mesh (250 micron) element,

3/8 npt(f) inlet, 3/8 npt(m) outlet

Accessories must be purchased separately.

Use only GENUINE GRACO PARTS AND ACCESSORIES.

BUNA–N AIR HOSE ASSEMBLIES

180 psi (13 bar) MAXIMUM WORKING PRESSURE

0.25 in. (6.35 mm) ID, 1/4 npsm(fbe)

216–069 25 ft (8 m)

216–070 50 ft (15 m)

216–071 75 ft (23 m)

216–072 100 ft (30 m)

216–073 150 ft (46 m)

HIGH VOLUME AIR REGULATOR 206–199

0–125 psi (0–9 bar) Regulated Pressure

200 psi (14 bar) Steel Pressure Gauge

1/2 npt(f) inlet and outlet

AIR FILTER & MOISTURE SEPARATOR 106–148

250 psi (17.5 bar) MAXIMUM WORKING PRESSURE

For cleaning and drying air in air spray system.

20 micron element, 5 oz. bowl capacity,

3/8 npt(f) inlet and outlet

NYLON AIR HOSE ASSEMBLIES

225 psi (15.75 bar) MAXIMUM WORKING PRESSURE

0.25 in. (6.35 mm) ID, 1/4 npsm(fbe)

215–630 25 ft (8 m)

215–631 50 ft (15 m)

215–632 75 ft (23 m)

215–633 100 ft (30 m)

215–634 150 ft (46 m)

NYLON FLUID HOSE ASSEMBLIES

225 psi (15.75 bar) MAXIMUM WORKING PRESSURE

0.25 in. (6.35 mm) ID, 3/8 npsm(fbe)

215–637 25 ft (8 m)

215–638 50 ft (15 m)

NYLON FLUID HOSE ASSEMBLIES

500 psi (35 bar) MAXIMUM WORKING PRESSURE

0.25 in. (6.35 mm) ID, 3/8 npsm(fbe)

216–076 25 ft (8 m)

216–077 50 ft (15 m)

216–078 75 ft (23 m)

216–079 100 ft (30 m)

216–080 150 ft (46 m)

75 KV METALLIC POWER SUPPLY 221–180

For use with Electrostatic Metallic Air Spray Gun. Not for use in Hazardous areas.

HIGH VOLTAGE CABLES FOR 75 KV

POWER SUPPLY

217–306 25 ft (8 m)

217–307 50 ft (15 m)

217–308 75 ft (23 m)

217–309 100 ft (30 m)

217–310 150 ft (46 m)

GUN, POWER SUPPLY AND HOSE KITS

Each kit contains: Air Spray Gun 221–179, 75 KV

Power Supply 221–180, and a length of buna–N Air

Hose with fittings. The air hose lengths vary by part number, as indicated below.

222–425 25 ft (8 m)

222–426 50 ft (15 m)

222–427 75 ft (23 m)

222–428 100 ft (30 m)

222–429 150 ft (46 m)

24 307-860

ACCESSORIES

Accessories must be purchased separately.

Use only GENUINE GRACO PARTS AND ACCESSORIES.

REMOTE SWITCH & SIGNAL LIGHT 728–386 PAINT RESISTANCE METER 722–886

Used with 722–860 Paint Probe to measure resistance of paint. Not for use in Hazardous areas.

PAINT PROBE 722–860

Used with 722–886 Paint Resistance Meter to measure resistance of paint. Not for use in Hazardous areas.

SAFETY WARNING SIGNS

172–049 English

172–771 Spanish

172–149 French

172–150 German

REPAIR KITS

Repair Kits must be purchased separately.

Use only GENUINE GRACO PARTS AND ACCESSORIES.

NOTE: The Ref. No. shown in the kits below correspond to the reference numbers used in the parts lists on page 23. For the best results, use all the parts in the kit, even if the old parts still look good.

Gun Repair Kit 221–087

Includes:

Ref

No.

Part No.

6

9

105–662

105–667

10 105–668

15 168–110

18 106–901

59 215–890

74 181–825

Description

PACKING, needle, PTFE

O–RING, Viton

O–RING, Viton

O–RING, Viton

PACKING, needle, PTFE

AIR VALVE ASSY

WASHER

Qty

1

1

1

1

1

2

1

Resistor Stud and Electrode Kit 220–392

Includes:

Ref

No.

Part No.

9 105–667

56 181–824

71 220–923

74 181–825

77d 177–007

77g 183–107

78 181–827

Description Qty

O–RING, Viton 2

ELECTRODE (color coded black) 1

STUD, resistor (color coded black)

WASHER

WRENCH, needle

TOOL, resistor stud

CONTACT

1

1

1

1

1

307-860 25

SERVICE INFORMATION

Listed below by the assembly changed are OLD and

NEW parts.

Assembly

Changed Status

221–179 OLD

Air Spray NEW

Gun OLD

NEW

Ref

No. Part No.

Name

280–209 Cover

76 180–209 Cover

181–286 Wrench

77d 177–007 Wrench

INTERCHANGEABILITY NOTE: NEW parts replace the OLD parts listed directly above them.

ACCESSORIES NOTE: Added Gun, Power Supply and Hose Kits 222–425 through 222–429.

TECHNICAL DATA

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Length

1.95 lb (0.89 Kg)

. . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30 cm)

Maximum Working Pressure . . . . . . . . . .

Air Pressure Operating Range . . .

100 psi (7 bar)

0–100 psi (0–7 bar)

Fluid Pressure Operating Range . 0–100 psi (0–7 bar)

Voltage Operating Range

Paint Resistivity Range

. . . . . . . . . . . . . . . . . .

. . . .

0–75 KV

7 Megohm cms to infinity

High Voltage Connector

Air Inlet

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M18 x 1.5(m)

1/4 npsm(m)

Fluid Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted Parts . . . . . .

3/8 npsm(m)

Stainless Steel, Polyolefin, Nylon,

Acetal, Viton r

, Delrin r

, PTFE r

Viton r , Delrin r , and PTFE r are registered trademarks

Loctite r is a registered trademark of the Loctite

Corporation.

THE GRACO WARRANTY AND DISCLAIMERS

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective.

This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Graco to verify 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.

DISCLAIMERS AND LIMITATIONS

THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES (EXPRESS

OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON–CONTRAC-

TUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR

CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACO’S LIABILITY EXCEED THE AMOUNT OF THE

PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO (2) YEARS OF THE DATE OF SALE.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH

RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.

These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)

Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 307–860 2–88 Revised 4–89