Graco 307706J Model PRO AA4000 Owner's Manual

INSTRUCTIQNS-PARTS LIST
307-706
GRACO
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PROAA4000TM
MANUAL MID-RANGE ELECTROSTATIC
AIR-ASSISTED AIRLESS SPRAY GUN
66 bar (950 psij MAXIMUM WORKING FLUID PRESSURE
7bar (100 psi) MAXIMUM WORKING AIR PRESSURE
Part Number 218-668, Series B
With 0.279 mrn (0.01 1 in.) spray tip, part no,.219-411
US. Patent No. 4,290,091; 4.219.865; 4,386.739; 3,843,052;
4,462,061; 4,497,447; 4,554,622
U.K. Patent No. 2,140,3276; 2,111,4066; 2,142,5596; 2,147,158.
Italian Patent No. 1.1 11.380
West German Patent No. DE 22 09 896
Patented 1986,1987 Canada
Brevete 1986, 1987
French Patent No. 82 21202; 84 07942; 84
.
.
Approved
GRACO INC. P.O. Box I441 MINNEAPOLIS,
@COPYRIGHT.IW,
GRACO INC.
Rev J
Supersedes H
MN 55440-1444
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TABLE OF CONTENTS
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TERMS...
1
HOW THE ELECTROSTATIC AIR-ASSISTED
1
AIRLESS SPRAY GUN WORKS
WARNINGS
Fluid Injection Hazard
2
Equipment Misuse Hazard
3
Fire or Explosion Hazard
3
Grounding
3
Flushing and Cleaning Safety
3
Ventilate the Spray Booth
3
Hose Safety
3
INSTALLATION
4
Typical Installation Drawing
6
Ventilate the Spray Booth
5
Connect the Air Line
5
Check the Electrloal Grounding
6
Connect the Fluid Line
5
Warning Signs
OPERATION
Operatlon Checkllst
6
Filter the Fluld
6
Install the Spray Tip 8 Adjust the Spray Pettern.6
Spraying Operatlon
7
Cleaning
7
Flushing
7
I
SERVICE
8
Troubleshooting
Electrical Tests
10
Gun Repalr
12
Electrode Wlre Replacement
12
Ball Seat Housing b Reslstor Replacement
12
Gun Housing Removal
13
Gun Housing Reassembly
13
Fluld Needle Replacement
14
Power Cartridge Replacement
16
Turbine Alternator Removal
16
Fan Air Valve Replacement
16
Air Valve Replacement
16
ES ON-OFF Valve Replacement
17
Muffler, Check Valve and Inlet Filter
Replacement
17
PARTS DRAWING b LIST
18, 19
HOWTO ORDER REPLACEMENT PARTS
19
ACCESSORIES.
20
SPRAY TIP SELECTION CHART
21
TECHNICAL DATA
Back Cover
;.Back Cover
WARRANTY
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TERMS
Be sure you read and understand each of these terms
before reading the rest of the manual.
FOR YOUR SAFETY Alerts user to read the additional safety
warnings on the page indicated.
WARNING Alerts user to avoid or correct conditions which
could cause bodily injury.
FLUID INJECTION INJURY Aseriousinjury, which rnayappear to be a simple cut, caused by high pressure injection of
fluid directlv into the bodv.
,~
CAUTION Alerts user to avoid or correct conditions which
could cause damage to or destruction of equipment.
PRESSURE RELIEF PROCEDURE A safety procedure for
relieving air and fluid pressure in the system.
.
~~
~~~~~
ES ON-OFF VALVE An onloff switch located near the rear of
the gun, above the gun handle, which turns the electrostatic
power On Or Off.
. ....
HOW THE ELECTROSTATIC fES1 AIR-ASSISTED AIRLESS SPRAY GUN WORKS
This gun combines electrostatic air spray and airless
spraying concepts. The air has three functions: (1) to
drive the turbine, (2)to help atomize the paint "tails",
and (31 to help control the pattern size.
The turbine generates power which the power cartridge
converts to a high voltage current. The high voltage
current charges the gun's ionizing electrode.
Fluid is electrostatically charged as it passes the gun's
ionizing electrode. The charged fluid is attracted to the
grounded workpiece, wrapping around and evenly
coating all surfaces.
The spray tip shapes the fluid into a fan pattern, similar
to a conventional airless spray tip, but a t a lower
pressure. Air from the air cap further atomizes the fluid
and pushes the paint.tails into the pattern. The fan adjusting knob controls the width of the pattern.
Note that the air-assisted airless spray gun differs from
the conventional air spray gun in that increasing the
fan air reduces the pattern width. To increase the pattern width, less fan air or a larger size tip must be used.
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 INSTALLED AND
USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY
CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS
INSTRUCTION MANUAL.
FLUID INJECTION HAZARD
General Safety
Thisequipment generatesvery high fluid pressure. Spray from
the gun, leaks or ruptured components can inject. fluid
through your skin and into your body and cause exfremely
serious bodily injury, including the need for amputation. Also,
fluid injected or splashed into the eyes or on the skin can
cause serious damage.
NEVER point the spray gun at anyone or at any pari of the
body. NEVER put hand or fingers over the spray tip. NNER
try to "blow back" paint; this is NOT an air spray system.
Medical Alert-Alrlese Spray Wounds
If any fluid appears to penetrate yourskin. get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A
SIMPLE CUT. Tell the doctor exactly what fluid was injected.
Note to Physician: Injection in the skin is a traumatic injury.
It Is important to treat the injury surgically as soon as
possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings iniected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon mey be advisable.
Be sura equipment safety devices are operating properly
before each use.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection, injury from moving parts, splashing in the eyes or on the
skin, 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 changlng
spray tips, and whenever you stop spraying.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before
each use. 0; not remove or rnodii any pa!? of the gun; this
can cause a malfunction end result in serious bodily Injury.
4. Disengage the gun safety latch.
ALWAYS follow the Pressure Relief Procedure., at right,
before cleaning or removing the spray tip or servlcing any
system equipment.
NEVER try to stop or deflect leaks with your hand or body.
Safety Latch
Whenever you stop spraying, even for a moment. always set
the gun safety latch in the closed or "locked' position, making
the gun inoperative by depressing the safety latch on the lefl
or right of trigger, See the illustration below. Failureto set the
safety latch can result in accidental triggering of the gun.
To disengage the latch, push it toward the trigger and up.
S A F h LATCH
SAFETY LATCH
SHOWN IN CLOSED
SHOWN IN OPEN
I1
"
~~
OR " L O C K
POSITION
Diffuser
The gun diffuser breaks up spray and reduces the risk of fluid
injection when the spray tip is not installed. To check diffuser
operation, follow the Pressure Relief Procedure. at right,
and then remove the spray tip. Aim the gun into e grounded
metal pail. With the ES ON-OFF valve lever turned to OFF, and
using the lowest possible pressure, trigger the gun. If the fluid
emitted is not diffused into an irregular stream, replace the diffusar immediately.
Spray Tip Safety
'Use extreme caution when cleaning or changing spray tips. If
the spray tip clogs while spraying, engage the gun safety latch
immediately. ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it.
NEVER wipe off build-up around the spray tip until pressure is
fully relieved and the gun safety latch is angaged.
9
2n7.711~
I ..
I'
1. Engage the gun safety latch.
2. Turn the ES ON-OFF valve lever to OFF.
3. Turn off air and fluid supply to the gun.
5. Trigger the gun into a grounded metal waste Container to
relieve fluid pressure.
6. Engage the gun safety latch.
7. Open the pump drain valve, having a grounded metal waste
container ready to catch the drainage.
8. Leave the pump drain valve open until you are ready to
spray again.
If you suspect that the tip or hose is completely clogged, or
that pressure has not been fully relieved after following the
steps above, VERY SLOWLY loosen the air cap retainer or
hose end coupling and relieve pressure gradually, then loosen
completely. Now clear the tip or hose.
Bleed-Type Alr Shutoff Valve and Fluid Drain
Valve Required
These two accessories are required in your system to help
reduce the risk of serious bodily injuw, including splashing in
the eyes or on the skin and injury from moving parts if you are
adjusting or repairing the pump.
The bleed-type air shutoff valve relieves air trapped between
this valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly. Locate the
valve within easy reach of the pump.
The fluid drain valve assists in relieving fluid pressure in the
displacement pump, hose and gun; triggering the gun to
relieve pressure may not be sufficient.
i
!
1:;
!
:
EQUIPMENT MISUSE HAZARD
General Safety
Any misuseof the spray equipment or accessories, such as overpressurizing. modifyingparts, using incompatiblechemicals and fluids, or
using worn or damaged parts. can cause them to ruptureand result in
fluid Injection, fire, explosion or property damage.
NEVER alter or modify any part d this equipment; doing so could
cause it to malfunction.
CHECK ail spray equipment regularly and repair or replace wornor
damaged parts immediately.
System Pressure
This gun has a maximum fluid working pressure of 66 bar (950 psi).
Never exceedthe maximumworking pressure of the gun or any other
component or accessory used in system.
Readandfollowthe fluidand solvent manufacturer'sliteratureregarding the use of protective clothing and equipment.
Fluid Compatability
BE SURE that all fluid and Solvent used are chemically compatible
with the wetted parts shown in the Technical Data on the back cover.
Always read the fluid and solvent manufacturer'sliterature before using them in this sprayer.
FIRE OR EXPLOSION HAZARD
Toreducetheriskoffire,explosion,orelectricshock,whichmayresult
from electricaldischarge, it is essential that:
All parts of the electrostatic system are properly grounded.
Ailpersonnelinorclosetotothesprayareaareproperlygrounded.
All electrically conductive objects or devices in the spray area,including paint containers, wash cans and too1s;are
properly
grounded.
When operating the electrostatic device, any ungrounded objects in
the spray area (such as people, containers, tools, etc.) can become
electrically charged. Arcing may occur if these objects then come in
contact or clo6e to ground. Arcing ofsufficient energy levels can ignite
the fluid being sprayed, fumes from solvents, dustparticles, and other
flammablesubstances.This can causeafireor explosionand result In
serious bodily injury and property damage.
Static electricity can also be generated by the flow of fluid through the
pump, hose, gun, and nozzle. but it is dissipated through proper
grounding as described in Grounding below.
If you experience an arcin or feel even a slight, shock, STOP
SPRAYING IMMEDIA$ELY.8heckforproper roundlngoftheenttre
system. Be sure you have corrected the probyem before starting to
spray again.
Grounding
The following are minimumrequirementsfor grounding a basic electrostaticsystem. Yoursystem may include other equipmentorobjects
which must also be grounded. Always check your local electrical code
fordetalledgroundinginstructions. Be sure yoursystem ~sconnected
to a true earth ground.
1. Pump:ground by using a ground wire and clampasdescribedin
. your separate pump instruction manual.
2. Air compressors and -hydraulic power supplies: ground
according to the manufacturer's recommendations.
3. Electrosta1icSprayGun:obtaingroundingthroughconnectionto
a properly rounded air supply hose. Use only the Graco
Electrtcally tonductive Air Supply Hose; see ACCESSORIES
sectiontoorder.Connectthealrhosegroundwiret0atrueeaRh
ground.
4. Object beings rayed keep the work piece hangers clean and
grounded at a/times! Contact points must be sharp points or
knife edges.
5. All electrically conductive objeds or devicesin the spray area,
Including pamt containers and wash cans, must be properly
grounded.
'
6.
All Dersons enterino !he sway area: shoes must have
The floor of the spray area must be electrically conductive and
grounded. Do not cover the floor with cardboard or any
non-onductive material which would interrupt grounding
continuity.
8. Flammableliquids in the spray area must be kept in approved,
grounded containers. Do not store more than the quantity
needed for one shift.
9. All solvent pails: use only rounded metal pails, which are
conductive. Do not lace &e pail on any non<onductive
surface, such as carBboard or paper, whlch would inter- rupt
grounding continuity.
IO. A
ll air and fluid lines and electric cables must be properly
grounded.
Flushing and Cleaning Safety
To reduce the risk of nuid injection. static sparking or splashing,aiways follow the Pressure Relief Procedure on page 2.and remove
the spray tip before flushing.
Be surethe ES valve lever Is OFF before flushing or cleaningany
pari of the spray system.
Use the lowest possible pressure to flush. Trigger the gun into a
grounded metal waste container.
To flush orpurge equipment, ALWAYS use solventswith aflash point
equal to or greater than that of the fluid being sprayed.
To clean the exterior of the equipment, ALWAYS use solvents with a
flash point of higher than looo F (38' C).
ALWAYS remove all solvent from the system before reactivatingthe
spray gun.
Use only non-sparking tools to clean residue from the booth and
hangers.
7.
Ventilate the Spray Booth
To prevent nazardous concentrations of toxic andlor flammable va-
pors, spray only in a properly ventilated spray booth.
NEVER operate the spray gun unless the ventilating fans are
operating.
Checkandfollow all National, State and Local codes regardingairexhaustvelocity requirements. Check and foilowall local safely and fire
codes and OSHA standard 191C-l07(b)(5)(i).
HOSE SAFETY
HI hlypressurizedfluidcontained in the hosecanbeve dangerous.
if #e hose develops a leak, split or rupture due to any,%nd of wear,
damage or misuse, high pressure spray emitted from ttcan cause a
fluid injenion injury or other serious bodlly injury or property damage.
TIGHTEN all fluid connections securely before each use. High pressurefluidcandislodgeaioosecouplingorallowhighpressuresprayto
be emitted from the couolino.
. NEVER useadamagedhose. Beforeeachuse,checktheentire hose
hose couplin s If any of these conditions exist. replace the hose immediately. D 8 NOTtry to recouple high pressure hose or mend it with
tape or any other device. A repaired hose cannot contaln the hlgh
pressure fluid.
HANDLEANDR0UTEHOSESCAREFULLY.Donotpullonhosesto
move equipment. Do not use fluids or solvents whichare not compatible with the inner tube and cover of the hose.
forcuts,leaks,abraslon,bulgingcover,ordamageormovementofthe
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 instaiiation,operation,
and maintenance of electrostatic spray painting equipment.
307-7M
R
INSTALLATION
TYPICAL INSTALLATION
....
KEY
Main Air Supply Line
Ventilation Fan Interlock Solenoid Valve
C Main Air Supply Shutoff Valve (bleed-type)
D Air &Water Separator
E Pump Air Supply Shutoff Valve (bleed-type)
F Air Line Lubricator
0 Air Pressure Regulator
H Air-Assisted Airless Pump
J Pump Ground Wire
K Fluid Filter
L Fluid Supply Line Shutoff Valve
M Fluid Pressure Regulator
A
N
0
P
B
The Typical Installation shown above is only a guide for
selecting and installing equipment for an electrostatic
air-assisted airless spray system. It is not an actual
sVstem design. Contact your Graco representative for
customdesigned systems information.
Fluid Supply Line
Air Filter
Air Supply Line Shutoff Valve (bleed-type)
Spray Gun Ground Wire
R Grounded Air Supply Hose
S flectrostatic Spray Gun
T ES "ON-OFF'' Valve Lever
U Air Line Drain Valve
V Fluid Drain Valve
CC Gun Air Inlet
DD Gun Fluid Inlet
Q
The pump you use should have a maximum working
pressure of 66 bar (950 psi). If the pump you are using
has a higher maximum working pressure, you must use
a regulator to limit the pressure to 66 bar 1950 psi).
Graco's 1O:l Ratio Monark Pump, Part No. 217-523,
may be used in this system. See Accessories.
WARNING
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious
bodily injury. 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 I, Group D, Divisions 1 and 2 Hazardous Location.
4
307-706
Ventilate the Spray Booth
WARNING
To prevent hazardous concentrations of toxic
and/or flammable vapors, spray only in a properly
ventilated spray booth. NEVER operate the
spray gun unless the ventilation fans are
operating.
1. The operator must not wear gloves which insulate
the hand from the spray gun. Gloves must be conductive or modifed as shown in Fig 1.
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.
Check and follow OSHA standard 1910-107(b)(5)(i).
NOTE:
High velocity exhaust will decrease the
operating efficiency of the electrostatic
system. Air exhaust velocity of 31-46 linear
meterslminute (100-153 ftlmin) should be
sufficient.
2.
a. With the air hose connected and properly
grounded, use a megohmmeter (AA) to
measure the resistance between the gun
handle (BB) and a true earth ground (PP),
using an applied voltage of 500 volts minimum
to 1000 volts maximum. See Fig 2.
"
Connect the Air Line (See Typical Installation)
WARNING
To reduce the risk of electric shock or other
serious bodily injury, the Air Supply Hose must
be electrically connected to a true earth ground.
Use Only Graco Electrically Conductive Air
Supply Hose. This hose and the gun have special
threads which prevent using any other type of
hose with the gun. See the Accessories section
for ordering the hose.
1. Connect the air supply hose (13) between the air
supply line and the gun's air inlet ICC). Connect the
ground wire to a true earth ground.
2. Install an air filter (0)
and an air and water separator
(D)on the air line to ensure a dry, clean air supply to
the gun. Dirt and moisture can ruin the amearance
of your finished workpiece and can cause the gun
to malfunction.
3. Also install an air regulator. (GI on the pump and
gun air supply lines to control air pressure to the
pump and gun.
4.
Install an air line lubricator (F) close to the pump.
5. Install e bleed-type air shutoff valve IC, E 8 P) on
the main air line and the pump and gun air supply
lines to shut off air to the pump and gun. See
Bleed-type Air Shutoff Valve and Fluid Drain
Valve Required, page 2.
Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
b. If the resistance is greater than 2 megohms,
check the tightness of the connections, and be
sure the air supply hose ground wire is connected to a true earth ground. If the resistance
is still greater than 2 megohms, replace the air
supply hose.
Connect the Fluid Line (See Typical Installation)
1. Blow out the fluid line with air and flush it with solvent before connecting it to the gun. Use solvent
which is compatible with the fluid to be sprayed.
2. Install a fluid regulator (MI on the fluid line to control fluid pressure to the gun.
3. Install a fluid filter (K) and drain valve IV) at the
pump outlet. The drain valve assists in relieving
fluid pressure in the displacement pump, hose and
gun. See Bleed-Type Air Shutoff Valve and
Fluid Drain Valve Required, page 2.
4.
Connect the fluid line to the 114-18.6(rn) gun fluid
inlet (DD).
Warning Signs
An English and a Spanish warning sign is supplied with
the gun. Mount these signs in the spray erea where they
can easily be seen and read by all operators. This sign is
also available in French and German. See the Accessories section on page 21.
ppdg
4
w I-.
Check the Electrical Grounding
WARNING
'A
of every part of your
system is essential. For your safety, read the
warning section FIRE OR EXPLOSION
HAZARD on page 3. Then ground the system as
explained in that section.
KEY
AA
BB
PP
Megohmmeter
Gun Handle
True Earth C
,-AA
WARNING
OPERATION
VERTICALSPRAY PATTERN
HORIZONTALSPRAY PATTERN
Relief Procedure on page 2 when shutting off
the system, when you stop spraying, and before
checking, servicing, installing, cleaning or changOperating Checklist
Check the following list daily, before starting to operate
the system, to help assure you of safe efficient
operation.
I
Be sure all operators are properly trained in the
safe operation of an air-assisted airless electrostatic spray system.
-1.
2.
Be sure all operators have been trained on how
-3.
-4.
to properly and completely relieve system
pressure.
"
611
Be sure system is thorou hl grounded. See
FIRE OR EXPLOSION H 2 RD, page3; and
Check the Electrical Grounding, page 5.
Be sure the operator and all persons entering
spray area are properly grounded and operator is not wearing gloves which insulate the
hand from spray gun. If worn, gloves must be
conductive or modified as shown in Fig 1.
-5.
Be sure ventilation fans aro operating properly.
-6.
Be sure the workpiece hangers are clean. Contact paints must be sharp points or knife edges.
-7.
Be sure all refuse is removed from the spray
booth.
-8.
Be sure all flammable liquids in the spray booth
are in approved, grounded containers.
NO AIR
Fig 4
TOOLITTLE AIR
RIGHTAMOUNT
OF AIR
Filter the Fluid
Filter the fluid to be sprayed to remove coarse particles
and sediment which could clog h e spray tip.
Install the Spray Tlp
e Adjust the Spray Pattern
1. Select the appropriate spray tip for your application
from the Spray Tip Selection Chart on page 21. The
fluid output and fan width depend on the size of the
spray tip, the fluid viscosity, and the fluid pressure.
2. Place the tip (13) in the air cap (12), aligning the tab
of the tip with the groove in the air cap. Be careful
not to damage the electrode wire (GGI. Place the
air cap assembly on the gun. Screw on the retaining
nut 111) flrmly to prevent leakage between the tip
and ball seat housing (14). See Fig 5. The air cap
and spray tip position determines the direction of
the spray pattern. See Fig 3.
WARNING
1 Operating the gun without the electrode wire or
1 with a bent or damaged electrode wire will impair
the electrical continuity of the gun. To reduce the
risk of electrical discharge, which could cause
serious bodily injury, fire, or explosion, be sure
the electrode wire is properly installed in the gun
(see page 12) and is not bent or damaged before
operating the gun.
Fig 5
3. Adjust the fluid pressure. Turn on the fluid to about
21 bar (300 psi]. Trigger the gun to check the
atomlzation; don't be concerned about the pattern shape yet. Increase the fluid pressure just to
the point that any further increase in fluid pressure
does not significantly improve fluid atomization.
DO NOT exceed 66 bar (950 psi) fluid pressure.
4. Turn the ES ON-OFF valve lever (TI to
Fig 5.
ON. See
5. Be sure the fan adjusting knob (€E) is fully closed
(turned all the way counterclockwise).
6. Set the atomizing air pressure to 3.1 bar (45 psi).
NOTE:
A minimum of 2.8 bar (40psi) air pressure to
the gun is required to drive the turbine fast
enough for maximum electrostatic effect.
3. Clean the spray tip and air cap daily, minimum.
Some applications require more frequent cleaning.
Replace spray tip and air cap if they are damaged.
a. Remove the air cap and spray tip.
b. Clean the tip and air cap with solvent and scrub
with a soft brush.
7 . Check the spray pattern. then adjust the air
pressure until all the tails are completely atomized
and pulled into the spray pattern. Refer to Fig 4.
For a narrower pattern, try turning the fen adjusting
knob (EE) clockwise. If the pattern is still not narrow enough, increase the air line pressure slightly or
use a different size tip.
c.
Spraying Operation
This gun has a built-in lead and lag operation. The gun
begins emitting air before the fluid is discharged. When
you release the trigger, the fluid stops before the air
flow stops. This helps prevent fluid buildup on the air
cap and assures the fluid is atomized.
Cleaning
blow gun, to clean the air cap passages. Take
care not to scratch any surfaces. If the air cap
holes ere plugged, a round toothpick can be used to unplug the holes, without damaging the
air cap.
WARNING
To avoid damaging the ball seat housing resistor,
use a soft bristle brush dipped in solvent to clean
it; DO NOT soak it in solvent1 A damaged resistor
wil impair the electrical continuity and could
result in electrical discharge, which could cause
serious bodilv iniurv. fire, or exdosion.
When spraying, the ES indicetor lights &I) should
glow, indicating electrostatic charge. See Fig 5.
Be careful not to damage the electrode by jamming it into an object .when operating or setting
Use a soft brush or other soft tool, with an air
4.
-
Check the electrode wire. Straighten it if it is bent,
and replace it if it is broken or damaged. See page
12 for replacing the electrode wire.
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.
WARNING
For Your Safety, always follow the Pressure
Relief Procedure on page 2 when shutting off
the system, when you stop spraying and before
checking, servicing, installing, cleaning or changing any part in the system.
. ..
Do n o t use any cleaning method whlch may
allow 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
which is compatible with the fluid being sprayed.
Conductive solvents can cause the gun to
malfunction.
Flushing
WARNING
For Your Safety, always follow the Pressure
Relief Procedure on page 2 when shutting off
the system, when you stop spraying and before
checking, servicing, installing, cleaning or chang-
1. Clean the fluid filter (26) daily. See Fig 6.
a. Unscrew and remove the fluid inlet fitting (251.
b. Remove the filter (26) and clean thoroughly in a
compatible non-conductive solvent.
c.
1.
Be sure the ES valve lever is turned OFF during
flushing.
2. Disconnect and plug the fluid supply line.
Reinstall the filter and inlet fitting. Do not overtighten the inlet fitting, which could distort the
filter.
3. Connect the solvent supply to the gun, and run sol-
2. Clean the outside of the gun daily with a sofl cloth
dampened in a compatible solvent.
4. Disconnect the solvent supply, and reconnect the
fluid supply line.
vent through the gun.
Icn
5. Trigger the gun until it is clean of solvent.
Be careful not to damage the electrode by catching the cloth on it when wiping off the gun.
WARNING
Installing and servicing.this equipment requires access to parts which may cause electric shock or other serious
bodily injury. Do not install or service this equipment unless you are trained and qualified.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on
the skin, or injury from moving pans or electric
shock, always follow this procedure before servicing any part of the gun or system.
WARNING
1. Engage the gun safety latch.
2. Turn the ES ON-OFF valve lever to OFF.
3. Turn off air and fluid supply to the gun. -.
4. Disengage the gun safety latch.
5. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.
NOTE:
6. Engage the gun safety latch.
7. Open the pump drain valve, having a grounded
metal waste container ready to catch the
drainage.
0. Leave the pump drain valve open until you are
ready to spray again.
If you suspect that the tip or hose is completely
clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the air cap retainer or hose end coupling and relieve pressure gradually, then loosen
completely. Now clear the tip or hose.
Check all possible remedies in the Troubleshooting Charts before disassembling gun.
SPRAY PAlTERN TROUBLESHOOTING CHART
PROBLEM:
IMPROPER
SPRAY PATTERN
CAUSE
SOLUTION
Fluttering or spitting spray
Insufficient fluid supply
Adjust fluid regulator or fill fluid
container.
Check, tighten siphon hose
connections, bleed air from
paint line.
Irregular pattern
Pattern pushed to one side, same
side of air cap gets dirty
I
Fluid build up or spray tip partially plugged
Clean spray tip.
Air horn holes on defective side
of pattern partially or totally
Clean air horn holes with solvent and soft brush.
Air horn holes partially or totally
plugged
Clean air horn holes with solvent and soft brush.
Increase air.
Increase fluid pressure.
8
307-706
I
I
! :'
GUN OPERATION TROUBLESHOOTING CHART
Fluid leakage from front of gun.
CAUSE
SOLUTION
Air valve not seating properly.
Clean, service.
Air stem packing too tight.
Loosen packing.
Loose or worn fluid seat.
Tighten or replace fluid seat andlor
electrode.
Loose fluid tip.
Tighten.
Insufficient air pressure.
Increase, use least air pressure needed for good results.
Using too large of a fluid tip.
Use a smaller size fluid tip.
Fluid pooriy mixed or filtered:
Remix or refilter fluid.
Improper thinner being used.
Use proper thinner.
Too m i c h air pressure.
Reduce, use least air pressure needed
for good results.
Fluid thinned too much.
Properly thin fluid.
Fluid low.
Check. add if necessary.
Broken fluid needle shaft.
Replace needle.
Dirty or clogged fluid tip.
Clean fluid tip.
Damaged fluid tip.
Check. replace fluid tip.
Exhaust air flow insufficient or not directed
properly.
Check for proper CFM, check baffles
and direction of air flow.
Improper distance between gun and work
piece.
(8-12 in.).
..
i
No fluid sprays from gun.
I
"
Equipment covered with paint.
Adjust distance to 203-305 mm
307-706
9
ELECTRICAL TROUBLESHOOTING C H A R T
PROBLEM
CAUSE
SOLUTION
Poor wrap-around.
*ES ON-OFF valve in OFF position.
Turn valve to ON.
*Turbine alternator not operating
(no audible whine).
Check air supply to gun. Turn ES
ON-OFF valve to on. Check for dirt
or moisture in turbine.
Improper distance between gun and
workpiece.
Adjust spraying distance to 203-305
mm 1812 in.).
Parts poorly grounded.
Clean workpiece hangers. Check for
proper ground on conveyor or
track.
High booth exhaust velocity.
Reduce, within code limits.
Too high atomizing air pressure.
Reduce air pressure.
'Too low-fluid resistivity.
Check fluid resistivity with paint
meter and probe lrefer to instruction manual 307-2631.
"Faulty gun resistance.
Check gun resistance. See Electrical Tests, below.
'Faultv resistor stud resistance.
Check resistor stud resistance. See
Electrical Tests, below.
"Faulty power supply resistance,
Check power supply resistance. See
Electrical Tests, below.
"Faulty needle electrode assembly.
Replace needle electrode assembly.
*Faulty turbine alternator.
Be sure plug is in place on back of
turbine alternator housing; Remove
and test turbine alternator; See Service Section; Replace turbine alternator if necessary.
Operator not properly grounded.
Be sure floor is properly grounded.
Wear shoes with non-insulating
soles. If gloves are worn, be sure to
modify as described in Operation
section.
Operator gets mild shock.
Operator gets mild shock when
touching workpiece.
Gun not properly grounded.
Be sure Graco air supply hose is being used and is properly grounded.
Workpiece not properly grounded.
Clean workpiece hangers. Check for
proper ground on conveyor or
track.
is triggered.
ELECTRICAL TESTS
The performance of the spray gun is directly affected by
t h e condition of the electrical components contained inside the gun. The electrical tests on page 11 can b e used
to determine t h e condition of the power supply (3)and
the ball seat housing and resistor (14), as well as the
continuity of the electrical path between the com-
ponents.
Use megohmmeter 218-979 (see ACCESSORIES) and
an applied voltage of 500 volts t o complete these electrical tests.
10
307-7n6
WARNING
To reduce the risk of serious bodily injury resulting
from explosion or fire caused by sparking, do not
use megohmmeter in the hazardous area; remove
Electrical Tests continued on page 11.
I.. .
j'
..
.:,
..
."
..~
:.:
:.:.-
.:, ..
NOTE:
Be sure to read the information on page 10
under Electrical Test before conducting
any of the tests below.
MEGOHMMETER
Test the Gun Resistance (See Fig 7)
NOTE: Check the resistance with the gun triggered
and untriggered.
Measure the gun resistance between the end of the gun
electrode wire (GG) and the air inlet fitting (37~).Insert
the lead from the electrode wire into the hole closest to
" E on the megohmmeter. Insert the lead from the air
inlet into the second hole to the right of "L" on the
megohmmeter. The resistance should be between
115152 megohms. If the resistance is outside the
specified range, go to the next test. If the resistance is
correct, refer to the ELECTRICAL TROUBLESHOOTING CHART on page 10 for other possible causes of
poor performance.
Test the Power Supply Resistance (See Fig 8)
Remove the power cartridge (1) from the gun handle
(32). See page 15.
Remove the turbine alternator (la) from the power
supply (3). See Fig 20, page 15.
Measure the resistance between the center prong IHH)
in the power supply and the contact spring (3b) on the
other end of the power supply. Insert the lead from the
spring into the hole closest to " E on the megohmmuter. Insert the lead from the center prong into the second hole to the right of "L" on the megohmmeter.
The resistance should be 95-122 megohms. If the
resistance is outside the specified range, the power supply 13)is defective and must be replaced. See page 15.
If the resistance of the power supply is correct, proceed
to the next test.
Test Resistance of Resistor (See Fig 9 8 10)
Insert a conductive rod (JJ) into the rear of the gun
housing 19) (which you removed in a previous test) and
press it against the contact (KK) which is molded into
the front of the gun housing.
KEY
32a
GO
Gun Handle
Air lniet Fitting
Electrode Wire
Fig 7
KEY
3b
Contact Pin
HH Center Prong
Fig 0
If the resistance is outside the specified range, remove
the electrode wire (GG). See Electrode Wire Replacement, page 12. Measure the resistance between the
conductive rod (JJ) and the resistor (LL) in the outside
diameter of the ball seat housing (14).
The resistance should be 20-30 megohms. If the
resistance is correct, the electrode wire (GG) is defective and must be replaced. If the resistance is still outside the specified range, the resistor is defective and the
ball seat housing (14) must be replaced. See page 12.
z
o
u
s
Electrode Wire
Conductive
Measure the resistance between the conductive rod
(JJ) and the gun electrode wire (GG). Insert the lead
from the electrode wire into the hole closest to "E" on
the megohmmeter. Insert the lead from the conductive
rod into the second hole to the right of "L" on the
megohmmeter.
The resistance should be 20-30 megohms. If the
resistance is correct, refer t o the Electrical
Troubleshooting Chart for other possible causes of poor
performance, or contact your nearest authorized servlce
agency.
MEGOHMMETER
KEY
8
Gun H
GO
JJ
MEGOHMMETER
GG
Fig 9
KEY
14
Ball Seat Housing
JJ
Conductive Rod
LL
Resistor
i
-Lh
7,
n
g
dE
I
307-706
11
r
Gun Repair
Ball Seat Houalng b Resistor Replacement
(See Fins 11 8 12)
Unscreh the retaining nut 111). Remove the air cap (12)
and spray tip 113).
ARNING
To reduce the risk of serious bodily injury, including fluid Injection, splashing in the eyes or on
the skin, or injury from moving parts or electric
shock, always follow the Pressure Rellef Procedure Warning on page 8. before servicing any
pert of the gun or system.
Insert the special wrench (63d)in the front of the gun.
While triggering the gun, unscrew the ball seat housing
114) and remove
it.
FWA
-
Installing and servicing this equipment requires
access to parts which may cause electric shock or
other serious bodily injury. Do not install or service
the equipment unless you are trained and
qualified.
CAUTION
ALWAYS remove the gun from the worksite for
service or repair. The service or repair area must
be kept clean to prevent contaminating the pads
with dirt.
If the plastic parts of the gun must be held secure-
ly, ALWAYS clamp them in padded vice jaws to
prevent damage to the parts.
ALWAYS lubricate the rings and seals with petroleum jelly to prevent damage during installation.
7
1.
Flush the gun. See page 7 . Follow the Pressure
Relief Procedure Warning on page 8.
2. Disconnect the fluid supply hose from the gun inlet
fitting (DD). See the Typical Installation page 4.
3. Disconnect the air supply line from the gun air inlet
fitting KC). See the Typical Installation page 4.
Fig 11
Electrode Wire Replacement (See Fia 111
Unscrew the retaining nut (11). Removetheair cap (12)
and spray tip (13).
Use a needle nose pliers to gently pull the electrode wire
IGG) out the back of the sprey tip. Install the long end of
the new wire in the hole closest to the tab of the tip. Push
the wire in, aligning the short end of the wire with the
other hole in the tip. Pull on the front of the wire to seat
A box of 10 electrodes is included in the tool kit 183).
it.
12
.?n7-7ffi
If you are replacing the fluid needle assembly, do not
reassemble the gun. If no further service is required, install the new housina in the reverse order of
disassembly. Torque thsball saet housing to 1.1 N m
110 in-lb) (snug); DO NOT OVERTIGHTEN.
CAUTION
DO NOT overtighten the ball seat housing (14).
Excess torque will damage the housing.
KEY
14
Ball Seat Housing
83d Wrench
Gun Housing Removal (See Figs 13, 14 8 15)
Remove the ring nut, air cap, and spray tip. Unscrew
the fluid tube connector IFF) at the bottom of the fluid
tube (20).then pull the tube out of the inlet.
KEY
1
4
9
32
Power cartridge
Gasket
Gun Housing
Gun Handle
lf you are replacing the needle, insert the special wrench
l a d ) in the front of the gun. Whiletriggering the gun, unand remove it. See Fig 12.
screw the ball seat housing (14)
.. ..
Remove the trigger screws (77). spacers (76) and the
trigger (19).Remove the ES indicator lights (44).Then,
using the wrench ( 6 3 f ) , supplied, loosen and remove
the two socket head capscrews (45)from the gun.
I.
rC
Hold the gun handle (32)with one hand and pull the gun
housing (9)straight up to remove it.
To avoid damaging the power cartridge (l),
always pull the gun housing (9)straight up. If
necessary, gently move the gun housing from side
to side to free it from the gun handle.
. ..
Leave the gasket (4) in the gun handle (32)if you are not
replacing it. Perform whatever service is necessary,
then reinstall the gun housing as.follows.
Gun Housing Reassembly (See Figs 13, 14 Et 15)
If the needle assembly was removed, reinstallit as described on page 14. Be sure the gasket (4)is in place on the
gun handle (32).Place the gun housing (9)over the power cartridge (1) and position it onto the gun handle (32).
Install the two socket head capscrews (45)and tighten
with the wrench (63f). Push the ES indicator lights (44)
into place over the capscrews (45).
Fig 14
KEY
19
Trigger
44
ES Indicator Lights
83c Pressing Tool
72
Screw
.,.
,. .
Insert the fluid tube (20)into the fluid inlet fitting, making sure the washer (20a) is in place, and tighten the
fluid tube connector IFF).
If the ball seat housing (14)was removed, insert the
pressing tool ( 6 3 ~ )in the front of the gun and gently
push the needle back. Then slide the trigger (19)into
place and install the spacers (76) and screws (77).
Remove the tool.
"---I\
Reinstall the ball seat housing (see page 12). air cap,
spray tip and ring nut.
,
FF
63f
45
KEY
20
Fluid Tube
2Q
Washer
45
Capscrew
651 Wrench
FF
Fluid Tube Connector
Fig 13
. .
Fig 15
307-7m
12
Fluid Needle Replacement (See Figs 16 Et 17)
Remove the gun housing (9) as instructed on D a m 13. If
the power supply (3) comes out, carefully press-it back
into the handle.
insert the narrow end of the pressing tool (63d through
the front of the gun to push the needle back, then remove the nut (21) and the adjustment nut (17a). Press
theneedleassembly(17)outthefrontofthegunasfaras
you can with a finger, or by pressing it against a flat surface. Then use the wrench (63f)to finish pushing it out.
Wf
FF
WARNING
For your safety, check to be sure the gun safety
latch works properly each time after you change
the needle. See FLUID INJECTION HAZARD,
page 2.
1. Engage the trigger safety latch to the right,
then try to trigger the gun. Look behind the
trigger to be sure it is not engaging the nut
(17a). Then engage the latch to the left and
check again. See Fig 18.
Wrench
Connector
TRIGGER MUST NOT
TOUCHNUT117alWHEN
SAFETY LATCH IS LOCKED
Fig 18
2. Disengage the trigger safety latch, and trigger
the gun gently to see if you can feel the "lead
and lag" operation, which means the air will
come on before the fluid does, and the fluid
shuts off before the air does.
Fig 16
Remove the nut (17a) from the new needle assembly,
then install the new needle assembly through the front of
the gun. Insert the narrow end of the pressing tool ( 6 3 ~ )
into the front of the gun and press to seat the needle.
Rainstall the new adjustment nut (17a). hex end first,
onto the needle. Use the pressing tool ( 6 3 ~to
) press on
the needle from the front of the gun, then screw the adjusting nut a// the way to the bottom of the threads.
Remove the tool. Screw the other nut (21) firmly
against the adjustment nut to ''lock'' them together.
3. If the gun fails either of these tests, remove the
trigger and the ball seat housing. Back the nuts
away from the bottom of the threads.
Reassemble and check tests 1 and 2 above.
Also check in front of the trigger to make sure
the needle still moves. If it fails any of these
tests now, the needle assembly is out of
tolerance and must be replaced.
Reassemble the gun. as described in Gun Housing
Reassembly on page 13.
KEY
17a Adjustment Nut
21
Nut
w c Pressing Tool
/17a
i
Fig 17
14 307-706
Power Cartridge Replacement (See Fig 19)
CAUTION
The power cartridge (1) is fragile. Use care when
handling it to avoid damaging it.
DO NOT USE solvents to'clean the power cartridge cavity in the gun handle (32).Solvents will
damage the electrical components in the power
cartridge.
All O-rings llb, 3a, 3c) and the conductive spring
(3b) must be in place when reassembling the gun,
or it will malfunction.
Remove the gun housing (9). See page 13. Remove the
gasket (4) from the gun handle (32).
Grasp the power cartridge with your hand and use a
gentle rocking motion to free it from the gun handle
(32). Then pull the power cartridge (1) straight out of
the handle.
_.
CAUTION
Be sure the power cartridge cavity in the handle
(32)is very clean and dry. Moisture and other contaminants may damage the electronic circuitry.
Inspect the power cartridge cavity in the handle 132) for
dirt and moisture. Clean the cavity with a clean, dry rag,
if necessary. Don't use solvent.
Turbine Alternator Removal (See Fig 2 0 )
Remove the power cartridge (1) from the gun handle as
instructed at left.
Carefully twist the turbine alternator ( l a ) counterclockwise and pull it off the power supply, just until it is
disengaged from the coupling 1").
Then continue to
slowly pull the turbine alternator away from the power
supply, disconnecting the 3-wire connector (NN).
Use an ohmmeter to test the coil in the turbine alternator (la). Measure the resistance between the two
outer terminals of the 3-wire connector (NN). The
resistance should be 3-5 ohms. If, the reading varies
from this value, replace the alternator.
,.
Measure the resistance between each outer terminal of
the 3-wire connector and the turbine alternator housing
(la). The resistance should be infinite. If the resistance
is not infinite, replace the alternator.
Partially connect the 3-wire connector (NN) onto the
prongs inside the power supply (3). Use a small screwdriver to push the connector onto the prongs until it is
seated. Slide the turbine alternator ( l a ) onto the power
supply, being .sure .to align the coupling between the
power supply and the turbine alternator housing. Then
twist the turbine alternator clockwise to lock the
coupling.
Install the power cartridge (1) in the gun handle as instructed at left.
Lightly lubricate the O-rings llb, 3a. 3c) 'on the new
power cartridge with petroleum jelly.
Insert the new power cartridge (1 in the gun handle. Fig
19 shows the alignment of the power cartridge in the
gun handle.
Install the gasket (4) in the gun handle. Install the gun
housing in the handle. See page 13.
.
.
MM Coupling
NN Connector
Fig 20
Fig 19
307-706
15
.. ..
..
.:.. ..
Fan Air Valve Replacement (See Fig 21)
Turn the fan adjusting knob (EE) fully clockwise.
Place a wrench on the flats of the air valve housing (47)
and remove it from the handle (32).
Remove the retaining ring (39).Rotate the air adjusting
screw (48) clockwise until it is disengaged from the
valve housing threads. Pull the adjusting screw out of
the valve housing.
Clean all pans and inspect for wear or damage. If
replacing the seal (401, unscrew it counterclockwise and
remove it from the adjusting screw.
Apply thread locking compound, such as Loctite@No.
609.
to the small threads on the end of the adjusting
screw (48)and install a new seal (40).Remember, the
screw has a left hand thread.
Remove the old O-ring (46) from the screw (48).
Lubricate the new O-ring and the threads of the screw
(48) with petroleum jelly. Screw the screw into the air
valve housing (47).
Install the retaining ring (391 on the adjusting screw
(48).Back the adjusting screw out of the valve housing
(47) until it bonoms out against the retaining ring (39).
Apply PTFE taDe to the threads of the valve housing
(47) and install in the gun handle (32).Torque the hou&
ing to 1.1-1.4 N.m (10-12 in-lb).
KEY
32
39
40
46
47
48
EE
Fig 21
KEY
32
52
63
64
66
68
Air Valva RaDlacement (See Fig 22)
Use a screwdriver to remove the retainer 157,.
( 5 5 ) and air valve (54).
67
spring
Gun Handle
Retaining Ring
Valve Seal
0-Ring
Air Valve Housing
Air Adiusting Screw
Fan Adjusting Knob
63b
Gun Handle
Guide
Packing
Air Valve
Spring
0-Ring
Retainer
Wrench
Use wrench ( a b ) to unscrew and remove guide ( 5 2 )
and packing ( 5 3 ) from the front of the gun handle (32).
I
1
Clean all pans in a non-conductive solvent which
is compatible with the fluid being sprayed, such as
xylol or mineral spirits. Using conductive solvents
can' cause the gun to malfunction.
~-
Apply PTFE tape to the threads of the guide (52). Install the packing and guide in the front of the gun
handle. Tighten the guide finger tight.
Install a new air valve ( 5 4 ) and spring (551 in the back of
the gun handle. Apply petroleum jelly to the threads of
the retainer 157) and the O-ring ( 5 6 ) . Install the retainer
in the back of the gun handle and tighten with a
screwdriver.
Tighten the guide into the front of the gun handle.
Squeeze the trigger and tighten the guide just until the
valve ( 5 4 ) will not return when the trigger is released.
Then loosen the guide just enough so the valve stem
returns freely when the gun is triggered and released.
16
307-706
Fig 22
ES ON-OFF Valve Removal and Repair (See Fig 2 3 )
Loosen and remove the nut (49).Remove the lever (51)
and the wave washer (50). Push on the end of the valve
stem to force the valve out of the gun handle. If the valve
is hard to remove, insert the hex head wrench ( 6 3 4 in the
hex end of the valve and turn to loosen the valve.
Clean and inspect parts for wear or damage, replacing
parts as necessary.
.
.....
..
Lubricate the O-rings (37) and valve 138) with petroleum
jelly. Install the regulator disc (2) in the valve so the
beveled face of the disc faces in toward the valve.
.
Install the valve with the regulator disc and O-rings into
the gun handle so the larger opening of the valve
cylinder faces toward the front of the gun handle.
Install the wave washer ( 5 0 ) . lever (51) and nut (49) on
the valve stem. Torque the nut to 0.225 N.m I2 in-lb).
,,...
,~
., . ..>
.
Muffler, Check Valve and Inlet Filter Replacement
(See Fig 24)
Unscrew and remove the fluid inlet fitting (25).
i
Remove the screw 122). Be'sure the flats of the adapter
(24) and the flats of the air inlet fitting (32a)are properly
aligned with the bracket (28). then remove the bracket
and bulkhead retainer (75) from the gun handle (32).
\\
Pull the muffler (33) out of the gun handle and install a
new muffler in its place.
Insert a 3.18 mm (0.125 in.) rod into the hole in the retainer (29)and pry the retainer out of the bracket (28).
BE READY TO CATCH the ball (31) and sDrina (30)
which will come out when the retainer is removd.
Install a new ball and spring in the bracket (28). Snap
the retainer (29) back into the bracket (28).
Attach the bracket (28) and bulkhead retainer (75)to the
gun handle with the screw (22).
Install a new filter (26) in the adapter (24). Reinstall the
fluid fitting (251. There wi// be a small space between the
hexes of the fitting and adapter; do not overtighten
them.
:.,.
22
24
26
26
in
29
30
31
32
22a
33
76
FF
Adapter
Fluid Inlet Fitting
Fluid Filter
Bracket
Retainer
Spring
Ball
Gun Handle
Air Inlet Fining
Muffler
Bulkhead Retainer
Fluid Tube Connector
Fig 24
IU7-7clfi
'17
:
Part No. 218-668, Series B
Modal PROAA4000 Gun
ReDair Kit 2'18-752
Must be purchased separately
Includes:
Ref No.
lb
2
3a
3c
4
1%
r 37"
Qty
2
1
1
1
1
1
2
2
2oa
37
46
53
56
1
3b
%-APPLY LOCTITEQ
~I.~TOR~U
i.
\-I1
includes items 63a-63g
[
25 .-/
18
307-706
Part No. 218-668, Series B
REF
NO.
PART
NO.
1
218-111
la
lb
2
3
3a
3b
3c
4
5
9
11
12
13
13.3
14
17
17a
19
20
Ma
21
22
24
25
26
.a
29
30
31
32
32a
33
34
37
39
39
40
41
42
43
44
45
QN
DESCRIPTION
POWER CARTRIDGE
Includes items la Et 3
217-591 .ALTERNATOR
Includes replaceable itern l b
'107-106 ..O-RING; buna-N
'107-107 REGULATOR, disc
218441 POWER SUPPLY, ES I75 KVI
Includes replaceable item
3b. 3c
'106-555 .O-RING; fluorocarbon
17&504 SPRING
.- . .....'177-156 .O-RING; Viton"
* 179-387 GASKET, housing
.
179-790 LABEL, warning
220-963 HOUSING, gun
218-695 NUT, retaining, air cap
220-535 AIR CAP; See below for other air
caps
"219-411 SPRAY TIP, 0.279 rnrn (0.011'3;.
Includes item 13a; See page 21 for
other tips
"183-459 .WASHER
220-613 HOUSING, ball seat, includes resistor
"218-697
NEEDLE, fluid
Includes item 17a
176-938 .NUT, adjustment (front)
181-163 TRIGGER
218-713 TUBE, fluid
Includes item 20a
'164-769 .WASHER
105-689 NUT, mach, hex; M4 x 0.7
180-624 SCREW, rnach, cross pan head;
M 5 x 12
180-728 ADAPTER, filter
180-706 CONNECTOR, fluid
205-264 FILTER, tip
1 a 1 - m BRACKET
180-621 RETAINER
108446 SPRING, compression
101-435 BALL, bearing
218-716 HANDLE, gun
Includes item 32a
179-400 .FITTING, air inlet
180-623 MUFFLER
104-765 PLUG, pipe; hdls; 118-27 npt
'103-648 O-RING; Viton
161-326 VALVE, air
105681 RING, retaining, external
181-383 SEAL, valve; acetal
100-172 BALL; 3 / 1 6 diameter
107-414 SPRING, compression
180-763 RESTRICTOR
218-179 LIGHT, sensor
107-100 CAPSCREW, hex socket head;
M5 x 12
3a.
1
1
2
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
1
1
1
1
1
2
1
1
1
2
2
2
2
2
HOW TO ORDER REPLACEMENT PARTS
1. To be sure you receive the correct redacement Darts.
kit or acceisories, 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 orderlng.
3. Order all parts from your nearest Graco distributor.
I
I
6 digit
PART
NUMBER
an
PART DESCRIPTION
I
I
1
I
REF
NO.
46
47
PART
NO.
*103-557
180-713
180-714
181-328
102-268
181-327
180-735
*106-901
215890
107-029
-103-338
179-391
180-060
48
49
50
51
52
53
54
55
56
n
58
59
180-063
180-209
220614
62
63
ma
63b
63c
63d
63f
ms
75
76
77
78
105749
177-732
181095
183-107
107-460
218-751
180-143
177-128
107-400
179-791
aw
DESCRIPTION
O-RING: Viton
HOUSING, valve, air
SCREW, adjusting
NUT, cap; No. 10-32. nylon
WASHER, wave
LEVER, valve
GUIDE, s
O-RING; PTFE
air
VALVE.
.
_,
-~
SPRING, compression
O-RING; Viton
RETAINER, spring
SIGN, warning, English lnot shown)
See page 21 for other languages
SIGN, warning, Spanish h o t shown)
COVER, gun lnot shown)
KIT, tool
Includes items
.BRUSH, cleaning
.WRENCH
.TOOL, pressing
.WRENCH, ball seat housing
.WRENCH, barrel
.ELECTRODES, box of 10
RETAINER, bulkhead
SPACER
SCREW, trigger
TAG, warning lnot shown)
~~~~
~
63a-e
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
2
1
'Included in Repair Kit 218-752 [see page 181.
""Recommended "tool box" spare parts. Keep on hand to
reduce down time.
WARNING
AIR CAPS
Must b e ordered separately. Restrictor Kit, part no.
220-493 (see below), must b e ordered and installed
when using these air caps.
P a n No. Description
Fine finish air cap (no pattern control1
220-536
220-537 High solids air cap
High Air Flow R e s t r i c t o r Kit 220-493
Must be purchased separately. Includes:
Ref No. Part No. Description
100
~~~
101
102
179-994
RESTRICTOR
".
107-414 SPRING, compression
100-172 BALL; 3/16' diameter
Qty
-2
2
2
I
307-706
19
~~
ACCESSORIES (Must be purchased separately)
The accessories in this section have not been
tested by Factory Mutual.
1 0 1 MONARK PUMP 217-523
66 bar (950 psil MAXIMUM WORKING PRESSURE
WALL BRACKET 206-220
CART 208-210
PAINT RESISTANCE METER 722-886
Used with 722-860 measure resistance of paint. Sm
instruction manual 307-263. (Not for use in hazardous
areas.)
PUMP SUCTION HOSE 214-960
PAIL SUCTION TUBE 165767
DRUM SUCTION TUBE 206-266
FLUID FILTERS
207 bar (3dw psi) MAXIMUM WORKING PRESSURE
214-570 with aluminum bowl and support.
218-029 with carbon steel bowl and support. -.
167-024. 595 micron (30 mesh)
167&?5 250 micron'(60 mesh)
167-026 i49 micron (100 mesh)
167-027
74 micron (200 mesh)
FLUID SHUTOFF VALVE 210-657
350 bar /5(xx, psil MAXIMUM WORKING PRESSURE
FLUID PRESSURE REGULATOR 217-576
70 bar l l d w psil MAXIMUM WORKING PRESSURE
PARTS TO CONVERT STANDARD FLUID
PRESSURE REGULATOR 206-661
TO 70 bar (lOik-ps$ WORKiNGPRESSURE
.
COMPRESSION SPRlNG.501-511
*FLUID PRESSURE GAUGE '101-696
."
0-70 bar 10-1oOO psi) range
~
~~~
" ""
AIR PRESSURE REGULATOR 104-267
20 bar 13W psi) MAXIMUM WORKING PRESSURE
AIR LINE FILTER
17.5 bar 1250 psil MAXIMUM WORKING PRESSURE
106-148 3/8 npt(f)
106-149 1/2 nptlf)
FILTER DRAIN VALVE 210-659
350 bar (Sea, psil MAXIMUM WORKING PRESSURE
~"
PAINT PROBE 722-860
Used with 722-886 paint resistance meter to measure
resistance of paint. See instruction manual 307-263.
(Not for use in hazardous areas.)
AIR PRESSURE GAUGE 101-160
0-14 bar (0-200 psi) range
STAINLESS STEEL SCREENS
.
HIGH VOLUME AIR REGULATOR 206-199
0-9 bar (0-125 psi) Regulated Pressure
14 bar 1200 psi) Steel Pressure Gauge.
See instruction manual 306-972.
"_
230-987 ELECTROSTATIC SYSTEM
Includes items:
218-668 Manual E/S Air-Airless Spray Gun
218101 Grounded Air Supply Hose, 7.6 m 125')
214-698 Static Free Fluid Hose, 7.6 m 125')
106-148 Air Filter
AIR LINE LUBRICATOR
17.5 bar (250psil MAXIMUM WORKING PRESSURE
214847 318 npt(f)
214-848 112 npt(f)
ELECTRODE WIRES 218-751
Box of 10 replacement electrode wires for spray tip.
GUN COVERS 218-374
Package of 10 disposable gun covers.
MEGOHMMETER 21a979
500 volt output; 0.01-2000 megohms
COMPRESSION SPRING 105-673
For increased shut off force when
spraying plural component material
PROAA4000 1O:l MONARK CART SYSTEM 230-984
Includes system 230-987
PROAA4000 1O:l MONARK PAIL SYSTEM 230-985
Includes system 230-987
PROAA4000 1O:l MONARK WALL MOUNT
SYSTEM 230-988
".
Includes system 230-987
~
~~~~
_"
QUICK DISCONNECT COUPLING INSERT 109-187
1 / 4 18 npsm, left hand thread. Enables quick disconnect from air hose coupling body 109-188 (must order
separately).
SHUT-OFF COUPLING BODY 109-188
1/4-18 npsm, left hand thread. Enables quick disconnect from gun coupling insert 109-167 (must order
separately).
I1 .
1.'
.
"
ACCESSORIES (Must be purchased separately)
SPRAY TIP SELECTION CHART:;~~~~*:"::::.1
The accessories in this section have been tested
by Factory Mutual.
I
pressure rating that is higher than the lowest rated
component in your system. Lower rated components may not be able to withstand the
pressure developed by the pump and may rupture,
causing serious bodily iniurv or DroDertv damage.
I elinht tn I
I
1
Medium
*Heavy
Fan Width Viscosity viscosity
a t 300 mm literslmin liters1min
Part
112 in.)
If1oz/rninl If1 ozlmin) Number
"
Inches
, ...
GROUNDED AIR SUPPLY HOSE, Polyurethane
7 bar ( 1 0 0 psil MAXIMUM WORKING PRESSURE
6.35 mm (0.25 in.) ID, 1/4 npsm(fbe)
218-100 5 m (15 f t ) Air Supply Hose Assembly
218-101 8 m I 2 5 f t ) Air Supply Hose Assembly
218-102 11 m 136 f t ) Air Supply Hose Assembly
218-103 15 m ( 5 0 f t ) Air Supply Hose Assembly
220-119 23 m 175 f t ) Air Supply Hose Assembly
220-120 30.5 m (100 f t ) Air Supply Hose Acsembly
. .
..
AIR HOSE ADAPTER 185-493
For connecting two or more air supply hoses together.
1/4 npt(m) x 1/4 npsrn(m) left-hand.
WARNING SIGNS
Available from Graco at no extra charge.
Must be ordered separately.
180-060 Warning Sign (English)
180-061 Warning Sign (French)
180-062 Warning Sign (German)
180-063 Warning Sign (Spanish)
7
STATIC FREE FLUID HOSE
Nylon Tuba, Urethane Cover
207 bsr 1301y) psi) MAXIMUM WORKING PRESSURE
Part ID
NO.
Length
114 npsmlfl
114npt(rnxf)
114 npsmlf)
1 14 npsrnlf)
114 npsmlf)
114 npsm(f)
114 npsrn(f)
114 npsm(f)x
114 nptlml
1 14 npsmlf)
1 /4 npsmlfl
114 npsmlf)
.....
..
:
0.483
150-200 (881
(0.0191 200-250 18.101
250-300 (10-12)
300-350 (12-141
350-400 114-161
0.533 200-250 18.101
(0.0211 250-300 110-121
300-350 112-141
350-400 (14-16)
400-460 118181
0.6
0.8
(29.0)
(21.0)
1.0
(35.01
0.8
127.0)
219-319
219-419
219-519
219-619
219-719
219-421
219-521
219-621
219-721
219-821
300-350 112-141
35o-400 (14-161
400-460 (16181
219-623
219-723
219-823
219-425
300-350 112-14)
350-400 (14-161
400-460 (16-181
219-625
219-725
219-825
I
I
I
I
*Fluid Output at 41 bar 1600 psil.
The fluid output 1Q1 at other pressures IPI can be calculated
by this
(1 = [O.Wl) IQT) ( f l
).
Where QT = Fluid output If1ozlmjnl from the above table for
the selected orifice sue.
NOTE: Other tips are available on special work order. Allow
4 to 6 weeks for delivery. Maximum orifice Size is
0.635 rnrn 10.025 in).
I
Weight :
Gun Length :
Operating Voltage Range:
Operating Fluid Pressure :
Operating Air Pressure :
Fluid Inlet :
Air inlet :
Wetted parts :
0.87 Kg (1.90 Ib)
310 mm (12.25in.)
0-75 Kv
0-66 bar (0-950 psi)
0-7 bar (0-100 psi)
1/4-18.6 (m)
1/4 npsm(m) L.H.
Stainless Steel, Acetal,
UHMW Polyethylene,
Nylon, Carbide,
PTFE DelrinB
ACCESSORIES NOTE: Air Hose Adapter 185-493 added
to the Accessories page.
LoctiteB is a registered trademark of the Loctite
Corporation.
THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
~.~
~.~
r~
-,~
date of sale. This warranty applies only whgLthe~eauiomentisinstalled. oierated and mihiained in acdordance 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,
misap lication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitutionof
n n r d-r a"
c.
o c ~ m n n n e~.
nrt_
~ a r tNor
s .shall Graco be liablefor malfunction. damaoe
bvthe incomoatlbilitvwith Graco
..=. or wear caused
~~~~.~~
equipmentof structures, accessories. equipmentor materialsnot suppiiedby Graco, orthe improierdesign, manufahure. installation, operation or maintenance of structures, accessones. equipment or materials not supplled by Graco.
This warranty is conditionedupon the prepaid return of the equipment claimedto be defective for examination by Graco toverify
the claimeddefect. Ifthe claimeddefect is verified, Gracowill repair orreplace free of charge any defective parts.The equipment
will be returnedto the original purchasertransportationpre aid If inspection of the equipment does not disclose any defect in
materialor workmanship. repairs will be made at a reasonagle charge, which charges may includethecosts of parts. labor and
transportation.
~
~~
~~
~~
~
~~~~
~~
~
~~~
~
~
~
~
~~~
DISCLAIMERS AND LIMITATIONS
THETERMSOFTHlSWARRANTYCONSTlTUTEPURCHASER'SSOLEANDEXCLUSlVEREMEDYANDAREINLlEUOFANYOTHERWARRANTlES(EXPRESS
OR IMPLIED), INCLUDINGWARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON-CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES. BASED ON NEGLIGENCEOR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT. SPECIAL
ORCONSEOUENTlALDAMAGESORLOSSISEXPRESSLYEXCLUDEDANDDENlEO.INNOCASESHALLGRACOSLlABlLlTYEXCEE0THEAMOUNTOFTHE
PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANNMUST 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
These items sold, but not
manufactured by Gram (such as electric motor, switches, hose.etc.) are subject to the warranty, ifany, of their manufacturer,
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
RESPECT TO ACCESSORIES. EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTUREDBY GRACO.
Factory Branches: Atlanta, 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 55440-1444
PRINTED IN U.S.A. 307-706 12-84 Revised 3-89
I