Graco 307726G Model PRO AA5000 SPRAY GUN Owner's Manual

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TABLE OF CONTENTS
TERMS ........................................................... 1
HOW THE ELECTROSTATIC AIR-ASSISTED
AIRLESS SPRAY GUN WORKS
1
WARNINGS
Fluid Injection Hazard.....................................
2
Equipment Misuse Hazard...............................
2
Fire or Explosion Hazard..................................
3
Hose Safety
3
INSTALLATION
Typical Installation Drawing ............................
4
Warning Signs .................................................
4
Ventilate the Spray Booth................................
4
5
Mount the Gun ...............................................
Connect the Air Lines......................................
5
Connect the Fluid Line.....................................
5
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Check the Electrical Grounding
5
Installing the Optional Fan Air Adapter ..............6
OPERATION
Operation Checklist ........................................
6
Filter the Fluid................................................
6
Selecting a Spray Tip .......................................
6
Installing a Spray Tip .......................................
6
Adjust the Spray Pattern .................................
6
Spraying Operation .........................................
7
Cleaning ........................................................
7
Flushing ........................................................
8
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SERVICE
Spray Pattern Troubleshooting Chart ..............10
.Gun Operation Troubleshooting Chart .............11
Electrical Troubleshooting Chart .....................
12
Electrical Tests .............................................
14
Gun Repair.: ...............................................
..15
Electrode Wire Replacement ..........................
15
Ball Seat Housing b Resistor Replacement ...:..15
Gun Housing Removal...................................
16
Gun Housing Reassembly ..............................
16
Fluid Needle Replacement ..............................
17
Power Cartridge Replacement
17
Turbine Alternator Removal...........................
18
Fan Air Valve Replacement .............................
18
Piston Removal & Repair ...............................
18
Disc Regulator 0-Ring Replacement ................19
Muffler Replacement .....................................
19
PARTS DRAWING ..........................................
20
PARTS LIST...................................................
21
ACCESSORIES............................................
23
SPRAY TIP SELECTION CHART.......................
23
HOW TO ORDER REPLACEMENT PA R TS..........24
TECHNICAL DATA............................
Back Cover
WARRANTY .....................................
Back Cover
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TERMS
Be sure you read and understand each of these terms
before reading the rast 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 Aserious injury, which mayappear to be a simple cut, caused by high pressure injection of
CAUTION Alerts user to avoid or correct conditions which
could cause damage to or destruction of equipment.
PRESSURE RELIEF PROCEDURE
fluid directly into the body.
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A safety procedure for
relieving air and fluid pressure in the system.
HOW THE ELECTROSTATIC (ESI AIR-ASSISTED AIRLESS SPRAY GUN WORKS
This gun combines electrostatic air spray and airless
spraying concepts. The air has three functions: (11 to
drive the turbine, (21 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 charaed fluid is attracted to the
grounded workpiece, wrapping around and evenly
coating all surfaces.
The spray tip shapes the fluid into a fan pettern, similar
to a conventional airless spray tip, but at 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.
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SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC
SHOCK CAN~.
OCCUR IFTHE
PRECAUTIONS BELOW ARE NOT
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FOLLOWED.
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READ AND UNDERSTAND ALL INSTRUCTION MANUALS,
TAGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT.
ELECTROSTATIC
EQUIPMENT
SHALL ONLY
BE INSTALLED
A
ND .u.sE-D. .BY. TRAINE.D~~
~QUAL,.Fl~ED~.
PERSoRINEL
SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS
STATED WITHIN THIS INSTRUCTION MANUAL.
FLUID INJECTION HAZARD
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General Safety
This equipment generates high fluid pressure. Spray from the
gun, leaks or ruptured components may inject fluid through
your skin and into your body and cause sarious 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 part of the
body. NEVER put hand or fingers over the spray tip. NEVER
try to "blow back" paint; this is NOT an air spray system.
ALWAYS follow the Pressure Relief Procedure. at riaht.
before cleaning or removing the spray tip or servicing a n i
system equipment.
NEVER try to stop or deflect leaks with your hand or body.
Be sure equipment Safety devices are operating properly
before each use.
Diffuser
The gun diffuser (part of ball seat housing 218-686) breaks up
spray and reduces the risk of fluid injection when the spray tip
is not installed. To check diffuser operation, follow the
Pressure Rellef Procedure, at right, and then remove the
spray tip. Aim the gun into a grounded metal pail. With the
turbine air OFF, and using the lowest possible pressure, actuate the gun. If the fluid emitted is not diffused into an irregular stream, replace the bail seat housing 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.
Medical Alert- Airless Spray Wounds
Ifany fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE A T ONCE. DO NOT TREAT A S A
SIMPLE CUT. Tell the doctor exactlywhat fluid was injected.
Note to Physklan: lnjection in the skin is a traumatic injury. It Is Important t o treat the injury surglcelly as soon
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 resuit in fluid injection or other
serious bodily injury, fire, explosion or property damage.
NEVER alter or modify any part of this equipment: doing so
could cause it t o malfunction.
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately.
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as possible. Do n o t delay treatment to research toxicity.
Toxicity is a concern with some exotic coatings injected
directly into the blood stream. Consultation with a plastic
surgeon or reconstructive hand surgeon may be advisable.
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 parts or electric shock, always follow this procedure when
shutting off the system, when checking or servicing any Part
of spray system, when installing, cleaning or changing spray
tips, and whenever you stop spraying.
1. Turn off all the air to the gun except the cylinder (actuating] air.
2. Turn off the fluid supply to the gun.
3. Actuate the gun into a grounded metal waste container to
relieve fluid pressure.
4. Open the pump drain valve, having a waste container ready
t o catch the drainage.
5. Leave the pump drain valve open until you are ready to
spray again.
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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 Air Shutoff V a l v e and Fluid D r a i n
Valva R a a u i r e d
These two accessories are required in your system to help
reduce the risk of serious bodily injury, 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.
System Pressure
This gun has a maximum fluid working pressure of 66 bar
(950 psi). Never exceed the maximum working pressure of
the gun or any other component or accessory used insystem.
Readand followthefluidand solvent manufacturer's literature
regarding the use of protective clothing and equipment.
Fluid C o m p a t i b i l i t y
BE SURE that all fluid and solvent used are chemicallv 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 them in this sprayer.
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FIRE OR EXPLOSION HAZARD
Toreduce the riskoffire, explosion. orelectricshock, which may result
from electrical discharge, it is essential that:
7.
The floor of the spray area must be electrically conductive and
grounded.Donotcover1hefloorwithcardboardoranynon-conductive materialwhich would interrupt grounding continuity.
E.
Flammable liquidsin the spray area must be kept in approved,
grounded containers. Do not store more than the quantity
needed for one shift.
9.
Al1solventpails:use only grounded metal pails, which are conductive. Do not piace the pail on any non<onductive surface,
such as cardboard or paper, which would inter- rupt grounding
continuity.
All parts of the electrostatic system are properly grounded.
Allpersonneiinorclosetotothesprayareaareproperlygrounded.
All electrically conductive objects or devices in the spray areahcluding paint containers. wash cans and tools, -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 close toground. Arcing of sufficient energyleveis can ignite
the fluid being sprayed, fumes from solvents. dustparticles. and other
fiammablesubstances. This cancauseafireor explosion and result in
serious bodily injury and property damage.
Static electricity can ais0 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 any arcing or feel even a slight shock, STOP
SPRAYINGIMMEDIATELY.Checkforpropergroundingofthe entire
system. Be sure you have corrected the problem betare starting io
spray again.
Grounding
The following are minimum requirements for grounding a basic electrostaticsystem. Yoursystemmay includeother equipmentor objects
which must also be grounded. Always check your local electrical code
fordetailedgrounding instructions. Besure your system is connected
to a true earth ground.
1.
2.
3.
4.
5.
6.
Pump:ground by using a ground wire and clampas describedin
your separate pump instruction manual.
Air compressors and hydraulic powersupplies: ground according to the manufacturer'srecommendations.
Electros1aticSprayGun:obtaingrounding through connection to
aproperiygrounded air supply hose. Use only theGraco Electrically Conductive Air Supply Hose: see ACCESSORIES section
to order. Connect the air hose ground wire to a true earthground.
Object being sprayed: keep the work piece hangers clean and
grounded at all times. Contact points must be sharp points or
knife edges.
All electrical/y conductive objects or devicesin the spray area,
including paint containers and wash cans, must be properiy
grounded.
Alipersonsenlering1hesprayarea:shoes must haveconductive
soles, such as leather, and personal grounding straps must be
worn. Rubber or plastic soles are not conductive.
10. All air and fluid lines and electric cables must be properiy
grounded.
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Flushing and Cleaning Safety
To reduce the risk of fluid injection, static sparking or splashing,always follow the Pressure Relief Procedure on page 2 and remove
the spray tip before flushing.
Be sure the turbine air (electrostatics) is OFF before flushing or
cleaning any part of the spray system.
Use the lowest possible pressure to flush. Trigger the gun into a
grounded metal waste container.
To flush orpurgeequipment, ALWAYS use solvents with aflash point
To clean the exterior of the equipment, ALWAYS use solvents with a
flash point of higher than 100' F (38O C).
ALWAYS remove all Solvent from the system before reactivatingthe
spray gun.
Use only non-sparking tools lo clean residue from the booth and
hangers.
Ventilate the Spray Booth
To prevent hazardous concentrations of toxic andlor flammable vapors, spray only in a properly ventilated spray booth.
NEVER operate the spray gun unless the ventilating fans are
operating.
Check and follow all National, State and Local codes regarding airexhaust velocity requirements. Check and follow all local safety and fire
codes and OSHA standard 1910-107(b)(5)(i).
forcuts. leaks, abrasion, bulgingcover, ordamageormovement ofthe
hose couplings. If any of these conditions exist. replace the hose immediately. DO NOT try lo recouple high pressure hose or mend it with
tape or any other device. A repaired hose cannot contain the high
pressure fluid.
HANDLEAND ROUTE HOSESCAREFULLY. Donotpullon hosesto
move equipment. Do not use fluids or solvents whichare not compatible with the inner tube and cover of the hose.
IMPORTANT
United States Government safety standards have been adopted under the OccupationalSafety 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
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equal to or greater than that of the fluid being sprayed.
HOSE SAFETY
Hi hlypressurizedfluidcontainedinthehosecanbeve dangerous.
If #e hose develops a leak, split or rupture due to any7ind of wear,
damage or misuse, high pressure spray emined from itcan cause a
fluid injection injury or other seriousbodily injury or property damage.
TIGHTEN ail fluid connections securely before each use. High pressurefluidcandislodgealoosecouplingorailowhighpressuresprayto
be emitted from the coupling.
NEVER use a damaged hose. Before each use, check the entire hose
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TYPICAL INSTALLATION
A
E
C
D
E
F
INSTALLATION
0
H
Air Supply Shutoff Valve (bleed-type1
Air b Water Separator
Ball Valve
Air Line Lubricator
Air Regulator
PUmD
J
K
L
Fluid Filter
Drain Valve
Grounding Wire
Air Filter 1 4 0 micron1
Fluid Regulator
The Typical Installation shown above is only a guide for
selecting and installing equipment for en electrostatic
air-assisted airless spray system. It is not an actual
system design. Contact your Graco representative for
custom-deaigned systems information.
P
D
ES Automatic Gun
Normally Closed, 3-Way Air Solenoid
Valve or 3-Way Manual Valve
Exhaust HOse
Ventilate the Spray Booth
1
To prevent hazardous concentratlons of toxlc
The pump you use should have a maximum working
pressure of 68 bar (950 psi). If the pump you are usi,ng
has a higher maximum working pressure, you must use
s regulator to limit the pressure to 66 bar (960 psi).
Graco's 101 Ratio Monark Pump, PER No. 217-523,
may be used in this system. See Accessories.
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electrically interlocked with ihe ventihtors to prevent operation of the power supply unless ventilating fans are running.
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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.
Warning Signa
A warning sign in Englishand one in Spanish is supplied
with the gun. Mount the signs in the spray area where
they can easily be Seen end read by all operators. This
sign is also available in French and German. See the Accessories aection on page 23.
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1910.107(b) (5) (i).
Check and follow all of the national, state and local
codes regarding air exhaust velocity requirements.
NOTE:
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High velocity air exhaust will decrease the
operating efficiency of the electrostatic
system. Air exhaust velocity of 31-46 linear
meterslminute (100-150 ftlmin) should be
sufficient.
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Mount the Gun
Mount the gun on a stationary support or on a
reciprocating arm. The mounting rod must be properly
grounded.
Mount the gun so the front of the gun is 254 to 300 mm
(10 to 12 in.) from the workpiece.
Connect the Air Lines (See Typical Installation)
-WARMING-"----r
To reduce the risk of electric shock or other
serious bodily injury, the Turblne Air Supply
Hose must be electrically connected to a true
earth ground. Use Only Graco Electrically Conductive Alr 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 on page 23 for ordering the,
hose.
1.
2.
Install an air filter (K)and an air and watecseparator
(B) on the main air line to ensure a dry, clean air
supply to the gun. Dirt and moisture can ruin the
appearance of your finished workpiece and can
cause the gun to malfunction.
Install an air line lubricator (Dl close to the pump.
3. Install a normally closed, 3-way air solenoid (P)or
manual valve on the turbine, cylinder and remote
fan (optional) air supply lines.
4.
5.
6.
Install an air regulator (E) on the pump, turbine,
atomizing, cylinder and remote fan (optional) air
supply lines to control air pressure to the pump and
gun.
Install a bleed-type air shutoff valve (A) on the main
air line and the pump, turbine, atomizing, cylinder
and remote fan (optional)air supply lines to shut off
air to the pump and gun. Sea Bleed-Type Air
Shutoff Valve end Fluid Drain Valve Required,
page 2.
'4. Connect the fluid line to the 318 npsm(rn) gun fluid
inlet.
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Do not use metal fittings at the gun barrel. For circulation systems, use plastic fittings.
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Check the Electrical Grounding
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Proper electrical grounding 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 and below.
1. Shut off all air spray lines to the gun.
2. Turn off fluid supply to the gun.
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3. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
a. With the electrically conductive air hose connected (see Connect the Air Lines at left) and
properly grounded, use a megohmrneter (see
ACCESSORIES on page 22) to measure the
resistance between the gun handle and a true
earth ground. Use an applied voltage of not
less than 500 volts minimum to 1000 volts
maximum. See Fig 1.
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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.
TRUE EARTH GROUND
Connect the cylinder air line to the gun's cylinder air
inlet (marked CYL).
rMEGOHMMETER
7. Connect the atomizing air line to the gun's atomizing air inlet (marked ATOM).
8. Connect the turbine air supply line to the gun's
1/4-18 npsm (LH) air inlet (marked ES). Connect
the hose's ground wire to a true earth ground.
9. A remote fan air adapter is available to control the
fan air at the control booth. See Installing the Optional Remote Fan Air Adapter, on page 6.
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 (L) on the fluid line to control
fluid pressure to the gun.
3. Install a fluid filter (GI and drain valve (H) 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 3.
Fig 1
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Installing the Optional Remote Fen Air Adapter
NOTE:
See ACCESSORIES to order the Remote
Fan Air Adapter 181-053 and 90° Elbow
108-234.
1. Place a wrench on the flats of the valve housing (48)
and remove the fan air valve assembly from the gun
body (1). See Fig 19, page 18.
3. Install the
adaDter.
4.
90°
elbow (part no. 108-234) in the
Install the remote fan air line, solenoid valve, air
regulator and shutoff valve as instructed in Connect the AIr Lines. on page 5.
5. Adjust the air pressure for the desired fan pattern.
2. Apply PTFE tape to the threads of the remote
fan air adapter (part no. 181-0531 and install it in the
gun body (1). Torque the adapter to 1.1-1.4 N.m
(1012 in-lb).
WARNING
1
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 of the system.
Operating Checklist
Check the following list daily, before using the system, to
help ensure you of safe, efficient operation.
- 1.
Be sure all operators are properly trained in the
safe operation of an air-assisted airless electrostatic spray system.
-2.
Be sure all operators have been trained on how
to properly and completely relieve system
pressure.
-3.
Be sure the system is thoroughly grounded. See
Fire or Explosion Hazard on page 3, and Check
the Electrical Grounding on page 5.
- 4.
Be sure the operator and all persons entering the
spray area are grounded. Shoes with conductive
soles, such as leather, or personal grounding
straps must be worn. Rubber or plastic soles are
not conductive.
-5.
Be sure all conductive objects within 6 m (21) ft)
of the gun are electrically grounded and the floor
of the spray area is electrically conductive and
grounded.
- 6.
Be sure the ventilation fans are operating properly.
-7.
Keep the workpiece hangers clean. Contact
points muSt be sharp points or knife edges.
-8.
Be sure all refuse is removed from the spray
booth.
The fluid output and fan width depend on the spray tip
size, fluid viscosity and fluid pressure. If your application requires a different tip, use the Spray Tip Selection Chart to select the appropriate spray tip.
Installing a Spray Tip
Place the tip (10) in the air cap 19).aligning the tab of
the tip with the groove in the air cap. Be careful not to
damage the electrode wire (GG).Place the air cap
assembly on the gun and screw on the retaining nut (8)
firmly to prevent leakage between the tip and ball seat
housing. See Fig 4. The air cap and spray tip position
determines the direction of the spray pattern. See Fig 2.
“-----------IAIARNING
Operating the gun without the electrode wire or
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 sura
the electrode wire is properly installed in the gun
(see page 15) and is not bent or damaged before
operatinrt the gun.
Adjust the Spray Pattern
1. Adjust the fluid pressure. Turn on the fluid to about
21 bar (300 psi). Trigger the gun to check the
atomization; 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 (950psi) fluid pressure.
2. Close the fen adjusting knob (AA) by turning it fully
counterclockwise.
VERTICAL SPRAV P A T E R N
HORIZONTALSPRAV PAlTERN
- 9. Be sure all flammable liquids in the spray booth
are in approved, grounded containers.
Filter the Fluid
Filter the fluid to be sprayed to remove coarse particles
and sediment which could clog the spray tip. See Fig 5.
Selecting a Spray Tip
This aun is SUDDlied with SDrav Ti0 219-411. See Sorav
Tlp Selection ‘Chart on page 23’for the descriptibn. .
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Fig 2
3. %,the atomizing air pressure to 3.1 bar (46 psi).
4. Complete the Operating Chackllst to the left and
than turn the turbine air on.
NOTE:
A minimum of 2.8 bar (40 psi) air supplv is
required at the gun to ensure full voltage
from the power supply. The fan and
atomization air can be adjusted as your application requires.
5. Check the spray pattern, then adjust the air
pressure until all the tails are completely atomized
and pullad into the spray pattern. Refer to Fig 3. For
a narrower pattern, try turning the fan adjusting
knob (AA) clockwise. Ifthe pattern is still not narrow enough, increase the air line pressure slightly (if
you have a separate fan air line) or use e different
size tip.
NOTE:
A remote fan air adapter is available to control
the fan air at the control booth. See ACCESSORIES.
CAUTION
the electrode by jamming it into an object when operating or setting
down the gun.
Cleaning
I-WARNING”----------~
For Your Safety, always follow the Pressure
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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.
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Fig 3
NO AIR
TOO LITTLE AIR
RIGHT AMOUNT
OF AIR
Spraying Operation
This gun has a built-in lead and lag operation. The gun
begins emitting air before the fluid is discharged and the
fluid stops before the air flow stops. This helps prevent
fluid buildup on the air cap and assures the fluid is
atomized.
Fig 5
1. Clean the fluid filter 1361 daily. See Fig 5.
8 . Unscrew and remove the fluid connector (34).
b. Remove the filter (38)and clean thoroughly in a
compatible non-conductive solvent.
Adjust the system‘s control device, if it is automatic, so
the gun starts spraying just before meeting the workpiece, and stops as soon as the workpiece has passed.
c.
See the Spray Pattern Troubleshooting Chart in the
Service section for additional information.
When all adjustments of atomizing air, fluid pressure,
and fan pattern are made, operation can begin.
NOTE:
When spra.ying the ES indicator lights IBB)
should glow, indicating the electrostatic
charge. See Fig 4.
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2.
Reinstall the filter and connector. Do not overtighten the connector, which could distort the
filter.
Clean the outside of the gun daily with a soft cloth
dampened in a compatible solvent.
CAUTION
the electrode by catching the cloth on it when wiping off the gun.
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3. Clean the spray
tip f10) and air cap (9) daily,
minimum. Some applications require more frequent
cleaning; Replace the 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.
c.
Use s soh brush or other soft tool, with an air
blow gun, to clean the air cap peasages. Take
care not to scratch any surfaces. If the air cap
holes sra plugged, s round toothpick can be used to unplug the holes, without damaging the
air cap.
WARNING
To avoid damaging the bal seat housing resistor,
use a soft bristle brush dipped in solvent to clean
it; DO NOT soak it in solvent1A damaged resistor
will impair the electrical continuity and could
result in electrical discharge. which could cause
serioua bodily injury, fire, or explosion.
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4. Check the electrode wire IGGI. See Fig 4.
Straighten if bent, and replace if broken or damaged. See Electrode Wire Replacement, page 15.
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For Your Safety, always follow the Pressure
Relief Procedure on page 2 when shutting off
5. Remove all loose or ungrounded objects from the
the system, when you stop spraying and before
checking, servicing, installing, cleaning or changing any part in the system.
spray booth.
6. Check all of the work hangers for build-up of
material; clean them, if necessary.
7. Clean the fluid filter and air line filter.
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
allow solvent into the gun air passages. Clogged air passages cause poor atomization and eucessive 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.
8
307-726
1. Be sure the turbine air (electrostatics) is OFF during
flushing.
2. Disconnect and plug the fluid supply line.
3. Connect the solvent supply to the gun.
4.
Run solvent through the gun.
5. Disconnect the solvent supply.
6. Reconnect the fiuid supply line.
7. Actuate the gun until it is clean of solvent.
I
f
I
SERVICE
." .""
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. 00 not install or service this equipment unless you are trained
and qualified.
WARMING
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 this procedure before servicing any part of the gun or system.
1. Turn off all the air to the gun except the
cylinder (actuating) air.
2. Turn off the fluid supply to the gun.
3. Actuate the gun into a grounded metal waste
container to relieve fluid pressure.
NOTE:
4. Open the pump drain valve, having a grounded
metal waste container ready to catch the
drainage.
5. 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
I
I
-
PROBLEM:
.
.. ....
~~
"
IMPROPER
SPRAY PAlTERN
CAUSE
SOLUTION
Fluttering or spitting spray
Insufficient fluid in tank.
Fill tank.
Irregular pattern
Fluid build up or spray tip partially plugged.
Clean spray tip.
Air horn holes on defective side
of pattern partially or totally
plugged.
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.
Pattern pushed to one side, same
side of air cap gets dirty
Air to gun is too low.
Fluid pressure too low.
I
Increase air.
Increase fluid pressure.
~~
GUN OPERATION TROUBLESHOOTING CHART
CAUSE
SOLUTION
Piston Assembly 125, 24, 22, 59) not
seating properly.
Clean, service.
Worn or broken O-ring 159):
Replace O-ring 1 5 9 ) .
Air stem packing 119) too tight.
Loosen packing 119).
Loose fluid tip (101.
Tighten retaining nut; hand torque firmly.
Fluid tip washer (loa) worn or missing
Replace washer (loa).
Loose or worn ball seat housing (111.
Tighten or replace ball seat housing 1111.
Insufficient air pressure.
Increase, use least air pressure needed
for good results.
Using io0 large of a fluid tip (10).
Use a smaller size tip.
Paint viscosity too
. . high.
Thin paint or use larger fluid tip.
Fluid poorly'mixed or filtered.
Remix or refilter fluid.
Improper thinner being used.
Use proper thinner.
Too much air pressure.
Reduce, use least air pressure needed
for good results.
Fluid thinned too much.
Properly thin fluid.
Fluid low.
Check, add fluid if necessary.
Dirty or clogged fluid tip 110).
Clean fluid tip 110).
Damaged fluid tip (10).
Check, replace fluid tip 110).
Broken fluid needle shaft 114).
Replace needle 114).
Booth 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.
4djust distance to 203-305 mm
E-12 in.).
Worn or broken O-ring 122).
Replace O-ring 1221.
...
See Electrical Troubleshooting on page 12.
. ..
ELECTRICAL TROUBLESHOOTING CHART
I
PROBLEM
CAUSE
Poor wramaround.
*Turbine alternator f 2 a ) not
operating fno audible whine).
Check air supply to turbine. Check
for dirt or moisture in turbine.
Improper distance between gun and
workpiece.
Adjust spraying distance to
203.305 mm 18-12 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 (refer to instruction manual 307-263).
-.
'Faulty gun resistance.
Check gun resistance. See page 11.
"Faulty resistor stud resistance.
[Resistor part of ball seat housing
Check resistor stud resistance. See
page 11,.
*Faulty power supply (4) resistance.
Check power supply resistance. See
page 11.
'Faulty spray tip assembly (10).
Replace spray tip assembly (10).
(11)l
"Faulty turbine alternator
Dperator gets mild shock.
3peretor gets mild shock when
touching workpiece.
"ES indicator lights not
SOLUTION
f2al.
Be sure plug f2c) is in place on
back of turbine alternator housing
(2a). Remove and test turbine alternator. See Service Section. Replace
turbine alternator if necessary.
Operator not properly grounded or
is close to ungrounded object.
Be sure floor is properly grounded.
Wear shoes with non-insulating
soles. Be sure operator is not in
contact with or carrying fin
clothing) any metalic items which
could build-up electric charge.
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.
"ON"when gun is triggered.
i
I'
I2
307-726
~~
~
ELECTRICAL TESTS
The performance of the spray gun is directly affected by
the condition of the electrical components contained inside the gun. The electrical tests below can be used to
determine the condition of the power supply 14) and the
ball seat housing and resistor (11) as well as the continuity of the electrical path between the components.
Use megohmmeter 218-979 (see ACCESSORIES) and
an applied voltage of 500 volts to complete these electrical tests.
If the resistance is outside the specified range, remove
the electrode wire (GGI. See Electrode Wire Replacement page 15. Measure the resistance betwean the
conductive rod (FF) and the resistor (LL) in the outside
diameter of the ball seat housing (11).
The resistance should be 20-30 megohms. If the
resistance is correct, the electrode wire (GGI is defective and must be replaced. If the resistance is still outside the specified range, the resistor is defective and the
ball seat housing (11) must be replaced. See page 15.
j:
.....
MEGOHMMETER
\
I
Test Gun Resistance (See Fig 6 )
NOTE: Check the resistance with the gun triggered
and untriggered.
Measure the gun resistance between the end of the gun
electrode wire and the air inlet adapter (671. 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 115-152
megohms. If the resistance is outside the specified
range, go to the next test. If the resistance is correct,
refer to the ELECTRICAL TROUBLESHOOTING
CHART on page 12 for other possible causes of poor
performance.
1 . .
i
...
j.;:
GO Electrode wire
1 Gun Body
67 Adapter
Fig 6
MEOOHMMETER
KEY
EE Connector Prong
2 Power Canridge
2a Turbine
4 Power
4c Spring
:.
..
Test Power Supply Resistance (See Fig 7)
Remove the power cartridge (21from gun body (1). See
Power Cartridge Replacement on page 17.
Remove the turbine alternator (2a)from the power supply (4). See Turbine Alternator Removal on page 18.
Measure the resistance from the center prong IEE) in
the power supply to the spring (4c) on the other end of
the power supply. Insert the lead from the spring into
the hole closest to "E" on the megohmmeter. Insert the
lead from the center prong into the second hole to the
right of "L" on the megohmmetar.
The resistance should be 95-122 megohms. If the
resistance is outside the specified range, the power supply is defective and must be replaced. If the resistance
of the power supply is correct, proceedto the next test.
Test Resistor Stud Resistance (See Fig 8 Et 91
Insert a conductive rod (FF) into the gun barrel (removed for the power supply test) and against the metal contact (AA) molded into the front of the barrel.
Measure the resistance between conductive rod (FF)
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 to the ELECTRICAL
TROUBLESHOOTING CHART on page 12 for other
possible causes of poor performance, or contact the
nearest authorized service agency.
4c
Fig 7
MEGOHMMETER
KEY
AA
GO
FF
12
"-
..
Metal Contact
Electrode Wire
Conductive Rod
Gun Housing
Fig 0
GG
'
MEGOHMMETER
KEY
FF
LL
11
Fig 9
L
12
r
Gun Repair
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 Relief Procedure Warning on page 10, before servicing
any part of the gun or system.
Installing and servicing this equipment requires
access to parts which may cause electric shock or
other serious bodily injury if the work is not per-
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 parts
with dirt.
If the plastic parts of the gun must be held securely, ALWAYS clamp them in padded vice jaws to
prevent damage to the parts.
Ball Seat Houslng 8 Realstor Replacement
(See Figs 10 8 111
Unscrew the retaining nut (81. Remove the air cap (9)
and spray tip (101.
Insert the special wrench ( 5 % ) in the front of the gun.
While triggering the gun, unscrew the ball seat housing
(11) and remove it.
If you are replacing the fluid needle assembly, do not
reassemble the gun. If no further service is required, install the new housing in the revems order of
disassembly. Torque the ball seat housing to 1.1 N m
(10 in-lbl (snug); DO NOT OVERTIGHTEN.
. .
.
Ic
DO NOT OVERTIGHTEN the ball seat housing
111). Excess torque will damage the housing.
... ..
KEY
11 Ball Seat Housing
66f Wrench
ALWAYS lubricate the O-rings and seals with petroleum jelly to prevent damage during installation.
l . Flush the gun. See page 8. Follow the Pressure
Relief Procedure Warning on page 10.
:.
..
2. Disconnect the fluid supply hose from the gun.
3. Disconnect the air supply lines from the gun.
Electrode Wire Replacement (See Fig 10)
Unscrew the retaining nut (8). Remove the air cap (9)
and spray tip (10).
Use a needle nose pliers to gently pull the electrode wire
(GGI out the back of the spray tip. Install the long end of
the new wire in the hole closeat to the tab of the tip. Push
?hewire in, aligning the short end of wip with the other
hole in the tip. Pull on the front of the wire to seat it. A
box of 10 electrodes is included in the tool kit (55).
Fig 10
I.
Fig 11
307-726
16
Gun Housing Removal (See Figs 12, 13, 14 8 15)
Remove the retaining nut, air cap, and spray tip.
Unscrew the fluid tube connector (FF) a t the bottom of
the fluid tube (37). then pull the tube out of the inlet.
If you are replacing the needle, insert the special wrench
(55f)in the front of the gun. While triggering the gun, unscrew the ball seat housing (11) and remove it. See Fig 11.
NOTE:
Before removing the trigger adjusting nut
(15). be sure to note its position for
reinstallation.
Remove the trigger (16) by removing the screws (33)
and trigger adjusting nut (15) from the gun.
Remove the ES indicator lights (43). Then, using the
wrench ( 5 5 ~ ) supplied,
.
loosen and remove the two
socket head capscrews (44)from the gun.
i
If the ball seat housing (11) was removed, insert the
pressing tool ( 5 5 e ) in the front of the gun and gently
push the needle back. Then slide the trigger (16) into
place and install the screws (33). Remove the tool.
Press the trigger and install the trigger adjusting nut (15)
to its previously noted position.
i
I
Reinstall the ball seat housing (see page 15). air cap,
spray tip and retaining nut.
KEY
2 Power Canridge
6 Gasket
12 Gun Housing
Hold the gun body (1) with one hand and pull the gun
housing (12) straight up to remove it.
-.
To avoid damaging the power cartridge (21,
always pull the gun housing (12) straight up. If
necessary, gently move the gun housing from side
T to side
C to free
A it from
U the
T gun 'handle.
O
N
1
Leave the gasket (5) in the gun body (1) if you are not
replacing it. Perform whatever service is necessary,
then reinstall the gun housing as follows.
Gun Housing Reassembly (See Fig 12, 13, 14 & 15)
If the needle assembly was removed, reinstallit as described on page 17. Be sure the gasket 15) is in place on the
gun body (1). Place the gun housing (12) over the power
cartridge 12) and position it onto the gun body (1).
i
Install the two socket head capscrews (44)and tighten
with the wrench 155~).Push the ES indicator lights (43)
into place over the capscrews ( 4 4 ) .
Insert the fluid tube (37) into the fluid inlet fitting. making sure the washer (37a) is in place, and tighTen the
fluid tube connector (FF).
6,j
KEY
Fig 12
16
307-726
I
I
i
Fig 14
~~
fluid Needle Replacement (See Fig 15 8 16)
Remove the gun housing (12) as instructed on page 16.
If the power cartridge (2) comes out, carefully press it
back into the handle.
Power Cartridge Replacement (See Fig 17)
CAUTION
The power cartridge 12) is fragile. Use care when
handling it to avoid damaging 'it.
Insert the narrow end of the pressing tool (55e)through
the front of the gun to push the needle back, then remove the nut (17) and the adjustment nut (Ma). Press
the needle assembly (14) out the front of the gun as far as
you can with a finger, or by pressing it against a flat surface. Then use the wrench I&c) to finish pushing it out.
KEY
FF
14
148
17
Connector
Needle Assembly
Adjustment Nut
Nut
fluid Tube
na Washer
66c Wrench
n
DO NOT USE solvents to clean the power .cartridge cavity in the gun body 11). Solvents will
damage the electrical components in the power
cartridge.
4a.
.
All O-rings (2b,
4b) and the compression spring
(4c) must be in place when reassembling the gun,
or it will malfunction.
Remove the gun housing (12).See page 16. Remove
the gasket (5) from the gun body ( 1 ) .
Grasp the power cartridge with your hand and use a
gentle rocking motion to free it from the gun body (11.
Then pull the power cartridge (2) straight out of the
handle.
Be sure the power cartridge cavity in the gun body
(1) is very clean and dry. Moisture and other conmay damage
the
I taminants
C
A
U
T electronic
I
Ocircuitry.
N
1
Fig 16
Remove the nut (14a) 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
into the front of the gun and press to seat the needle.
Reinstall the new adjustment nut ( 1 4 ) . hex end first,
onto the needle. Use the pressing tool (55e)to press on
the needle from the front of the gun, then screw the edjusting nut all the wey to the boffom of the threads.
Remove the tool. Screw the other nut (171 firmly
against the adjustment nut to "lock" them together.
Reassemble the gun as described in Gun Housing
Reassembly on page 16.
Inspect the power cartridge cavity in the gun body 11)
for dirt and moisture. Clean the cavity with a clean, dry
rag, if necessary. Don't use solvent.
4a.
4b) on the new
Lightly lubricate the O-rings (2b.
power cartridge with petroleum jelly.
Insert the new power cartridge (21 in the gun body. Fig
17 shows the alignment of the power cartridge in the
gun body.
Install the gasket (5) in the gun body. Install the gun
housing in the body. See page 16.
KEY
1 Gun Body
2 Power Cartridge
f=l
Fig 17
KEY
14a Adjustment Nut
17
66s
307-726
17
Turbine Alternator Removal (See Fig 18)
Remove the power cartridge (2) from the gun body as
instructed under Power Cartridge Replacement.
Carefully twist the turbine alternator (2a) counterclockwise and pull it off the power supply, just until it is
disengaged from the coupling. Then continue to slowly
pull the turbine alternator away from the power supply,
disconnecting the 3-wire connector (HH).
Using an ohmmeter, test the coil in the turbine alternator (2a). With the ohmmeter set at R x 1 scale, measure
the resistance between the two outer terminals of the
3-wire connector (HH). 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
(2a).The resistance should be infinite. If the resistance
is not infinite, replace the alternator.
Partially connect the 3-wire connector (HH) onto the
prongs inside the power supply (4). Use a small screwdriver to push the connector onto the prongs until it is
seated. Slide the turbine alternator (2a) 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.
Remove the old O-ring (45) from the screw 147).
Lubricate the new O-ring and the threads of the screw
(47) with petroleum jelly. Install the screw in the air
valve housing (48)counterclockwise.
Install the retaining ring (38) on the adjusting screw
(47). Back the adjusting screw out of the valve housing
(48)until it bottoms out against the retaining ring (38).
Piston Removal and Repair (See Fig 20)
Disconnect the fluid hose (37) from the cover plate (32)
by screwing the nut IFF) off the connector (34).
Note the position of the trigger adjusting nut (15) for
reinstallation, then screw it off the piston shaft.
Remove the screws (31) and lockwashers (60)from the
cover plate (321. Remove the cover plate (32). spring
(27). and retainer cap (26).
KEY
38 Retaining Ring
39 Valve Seal
46 O-ring
48 Valve Housing
47 Adjusting Screw
Install the power cartridge (2) in the gun handle as instructed under Power Cartridge Replacement.
KEY
HH 3-Wire Connector
21, Turbine Alternator
4 Power Supply
Unscrew and remove the air valve guide (18)and needle
packing (19) from the gun body (1).
Push on the end of the piston shah, and remove the
piston assembly.
NOTE:
Fan Air Valve Replacement (See Fig 19)
Turn the fan adjusting knob fully clockwise.
Place a wrench on the flats of the valve housing (48)
and remove from body (1).
Remove the retaining ring (38).Rotate the air adjusting
screw (47) c/ockwise until it is disengaged from the
valve housing threads. Pull the adjusting screw (47) out
of the valve housing (48).
Clean all the parts and inspect them for wear or
damage. If replacing the seal (39),unscrew it clockwise
and remove from adjusting screw.
Apply Loctite" No. 609 to small threads on end of edjusting screw (47) and install a new seal (39)(left hand
thread).
18
307-726
DO NOT remove the u-cup packing (24)
from the piston shaft except to replace it as
removal will damage this packing.
Clean and inspect parts for wear or damage. Replace
parts as needed.
When reassembling the piston assembly, lubricate the
O-rings ( 2 2 b 5 3 ) and the u-cup packing (24) on the
piston (25) with petroleum jelly. Pack the spring (27)
with petroleum jelly. Apply PTFE tape to the air valve
guide (18).
Install the new packing (19) and guide (18) in the gun
body (1). screw the guide in loosely.
NOTE:
DO NOTfully tighten the guide (18) yet. The
guide must be loose to avoid damaging the
packing 119) when pushing the piston shaft
through the guide.
. . ,.
., ...
:',
: ., :
i
..
I:
~>
67
If replacing the u-cup packing (241, slide it.onto the
piston (26) so the lips of the packing will face.towards
the front of the gun when the piaton is installed. Next
install the buna-N O-ring (22)and the Won' O-ring (5.9)
on the piston.
Install the piston assembly into the gun body (1). being
careful not to damage the piston's lip seal.
Install the retainer cap (26) into !he cover plate (32).Install the cover plate (32). spring (27) and retainer cap
126) with the screws (31) and lockwashers 160).
30
.
.. ...
.. . ..
KEY
1 Gun Body
30 Disc Regulator
71
U7 Adapter
Actuate the trigger, and tighten the air valve guide (18)
with a wrench.
70 Washer
Screw the trigger adjusting nut (15) onto the piston
shafl to its previously noted position.
Fig 21
71
capSc.r.aw
-
Connect the fluid hose (37)to the cover plate.
:
..
Disc Regulator 0-Ring Replacement fSae Fig 21)
Unscrew the turbine air line from the adapter ( 6 7 1 .
Remove the capscrew (71) and washer (70) from the
gun body 11). Then pull out the adapter (67) with the air
valve (69).
Unscrew the adapter (67) from the air valve (69). and
remove the disk regulator (301. Clean and inspect parts
for wear or damage, and replace if necessary.
Clean and inspect the two O-rings (68)and one O-ring
(66)on the air valve. Replace if necessary. Lubricate the
O-rings with petroleum jelly.
Install the disc regulator (30)into the air valve (69)so i t s
beveled surface faces into the gun.
Screw the adapter (67) into the air valva
the air valve into the gun body ( I ) .
(a),
and install
Screw the capscrew (71). with the washer (70). into the
gun body.
Screw the turbine air line onto the adapter (67).
..
Fig 22
Muffler Replacement (See Fl 22)
Remove the fan air valve assemby as instructed in Fan
Air Valve Replacement. page 18.
Remove the elbow 146) with the tube (49).
Remove the muffler (211 with a hook, and replace with a
new muffler. Install the elbow (48).
Install the fan air valve assembly as instructed in Fan
Air Valve Replacement, page 18.
307-726
19
REF PART
NO. NO.
DESCRIPTION
1
2
218-927
218-111
2a
217-591
2b
2c
3
'107-106
180-070
100-664
218-041
4a
'177-156
'106-555
178-504
'179.387
"179-790
218-695
220-535
219-415
4
4b
4c
5
6
8
9
10
1Oa
11
12
12a
13
14
'183-459
220-613
220-963
176-921
"179-791
218-697
14a
15
16
17
18
19
176-938
180-927
20
21
22
23
24
1A1 -771
_.,
105-689
176-941
'106-901
108-173
181-223
* 156-454
107-208
"181-039
OTY
BODY, gun
POWER CARTRIDGE
Includes items 2a b 4
.ALTERNATOR, turbine
Includes items 2b b 2c
.O-RING; buna-N
.PLUG
SCREW; 1/4-20
POWER SUPPLY, ES, 75 KV
4b Et 4c
Includes items
.O-RING; Viton"
.O-RING; fluorocarbon
.SPRING, compression '
GASKET, housing
LABEL, warning
NUT, retaining, air cap
AIR CAP
SPRAY TIP; 0.381 mm (0.015')
Includes item o
la
.See page 23 for
other part numbers
.WASHER, non-metallic
HOUSING, ball seat; includes resistor
HOUSING, gun
.PLUG; M 3 x 0 . 5 ~ 6
TAG, warning lnot shown)
NEEDLE, fluid
Includes item 14a
.NUT, adjustment
NUT, adjustment, trigger
TRIGGER
NUT, mach, hex
GUIDE, valve, air
PACKING, needle; PTFE
ELBOW, male
MUFFLER
O-RING; buna-N
NUT, ferrule; 5/8-20 UN-28
PACKING, u-cup; UHMW
polyethylene
PISTON, shaft
CAP, retainer, spring
SPRING, compression
O-RING; Viton
PLUG; 3/8-18 npsm
1
1
1
2
1
1
4a.
1
1
m
35
35
37
37e
1
44
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
Part No. Description
220-536 Fine finish air cap (no pattern control)
220-537 High solids air cap
32
34
1
1
"
30
31
38
39
42
1
218-989
1
181-178
1
108-221
1
'107-305
1
181-599
1
29
AIR
CAPS
~~~.
.. Must be o r d e r e d separately. Restrictor Kit, part no.
220-493 (see below), must be ordered and installed
when using t h e air caps.
25
26
27
REF PART
NO. NO.
43
45
49
53
55
220-614
65a
105-749
177-732
48
55b
55c
55d
5%
55f
59
60
62
63
64
65
66
67
68
69
70
71
QTY
"107-107 REGULATOR, disc
105330 SCREW, mach, pnh; M 3 x 0 . 5 ~12
180-924 PLATE. cover
180-706 CONNECTOR, fluid
205264 FILTER, tip, 0.005
180-728 RETAINER, filter
220-225 TUBE, fluid, nylon
Includes item
-164-769 .WASHER, PTFE
105-681 RING, retaining, external
181-383 SEAL, valve
1eo-763 RESTRICTOR
218-179 LIGHT, indicator, ES
107-100 SCREW, cap, socket hd;
*103-557
181-594
180-714
180-713
054-134
180-060
46
47
DESCRIPTION
107-480
218-751
181095
183-107
'108298
108-340
180-063
177-128
107-400
104282
105796
181-598
103-848
181-597
102-782
105408
M5xO.8~12
*Included in Repair Kit 26 115.
**Extra warning tags and labels are supplied at no charge.
See page 24 for "How To Order Redacement Parts':
WARNING
Must b e purchased separately. Includes:
100
101
102
179-994
107-414
RESTRICTOR
~.
SPRING, compression
100-172 BALL; 3/16" diameter
~
QtY
2
2
2
~
1
1
1
2
1
1
2
2
2
O-RING; Viton; color coded green
1
ELBOW, male, 9oo
1
SCREW, adjusting
1
HOUSING, valve
1
178 mm
TUBE; polyethylene
SIGN, warning, English (not shown)
See ACCESSORIES to order French
or German
1
KIT, tool
Includes items 55a-55f
1
1
.BRUSH, cleaning
.WRENCH
1
.WRENCH. barrel
1
.ELECTRODES, box of 10
1
.INSERT
1
.WRENCH. ball seat housing
1
O-RING; Viton
1
4
LOCKWASHER, internal
SIGN, warning, Spanish lnot shown)
See ACCESSORIES t o order French
1
or German
SPACER
2
2
SCREW, trigger
1
O-RING; buna-N
O-RING; Viton
1
1
ADAPTER; 1/4-18 npsrn, LH
O-RING: Viton
2
VALVE; air
1
1
WASHER; plain
1
SCREW. cap, hex hd; M6 x 10 long
High Air Flow Restrictor Kit 220-493
Ref No. Part No. Description
1
4
1
1
Repair Kit 220-115
Must be purchased separately.
Includes:
Ref No.
2b
4a
4b
5
1Oa
19
22
ItY
(
2
1
1
2
1
i
24
2
1
37a
45
2
1
1
28
30
59
1
i
.. . ,
~
ACCESSORIES (Must be purchased separately)
The accessories in this section have not been
tested by.Factory Mutual.
WARNING
Never operate your equipment at a working
pressure rating that is higher than the lowest rated
component in your system. Lower rated components may not be able to withstand the
pressure developed by the pump and may rupture,
causing serious bodily injury or property damage.
HIGH VOLUME AIR REGULATOR 206-199
0-9 bar 10-125 psi) Regulated Pressure
14 bar (200psi) Steel Pressure Gauge.
See instruction manual 306-972.
PAINT PROBE 722-860
Used with 772-886 paint resistance meter to measure
resistance of paint. See instruction manual 307-263.
(Not for use in hazardous areas.)
-.
PAINT RESISTANCE METER 722-886
Used with 722-860measure resistance of paint. See instruction manual 307-263. (Not for use in hazardous
areas. )
AIR LINE FILTER
17,5 bar 1250psil MAXIMUM WORKING PRESSURE
106-148 3/8 npt(f)
106-149 1/2npt(f)
AIR LINE LUBRICATOR
17.5 bar (250psil MAXIMUM WORKING PRESSURE
214-8473/8 nptlf)
214-848 1/2nptlf)
PARTS TO CONVERT STANDARD FLUID
PRESSURE REGULATOR 206-661
TO 70 bar (lo00psi) WORKING PRESSURE
COMPRESSION SPRING 501-511
*FLUID PRESSURE GAUGE 101-696
0-70 bar ~O-loOOpsi) range
MEGOHMMETER 218-979
500 Volt output; 0.01-2oOOmegohms
(Not for use in hazardous areas.)
UNIVERSAL GUN MOUNTING ROD 590-236
RECIP. GUN MOUNTING BRACKET 725-973
NOTE: All safety barriers and interlocks are to be
supplied by the customer.
1O:l MONARK PUMP 217-523
66 bar 1950 psil MAXIMUM WORKING PRESSURE
STATIONARY GUN MOUNTING STAND 722-562
WALL BRACKET 206-220
STATIONARY GUN MOUNTING BRACKET724-344
CART 208-210
3-WAY AIR VALVE 722-502
PUMP SUCTION HOSE 214-960
PAIL SUCTION TUBE 165-767
DRUM SUCTION TUBE 206-266
FLUID FILTERS
207 bar ( 3 W psi) MAXIMUM WORKING PRESSURE
214-570 with aluminum bowl and support.
218-029 with carbon steel bowl and support.
STAINLESS STEEL SCREENS
167-024 595 micron (30 mesh)
167425 250 micron (60 mesh)
167-026 149 micron I 1 0 0 mesh)
167-027 74 micron 1200 mesh)
FILTER DRAIN VALVE 210-659
350 bar (5060 psi/ MAXIMUM WORKING PRESSURE
FLUID SHUTOFF VALVE 210-657
350 bar (5060 psi) MAXIMUM WORKING PRESSURE
FLUID PRESSURE REGULATOR 217676
70 bar l l W p s i l MAXIMUM WORKING PRESSURE
AIR PRESSURE REGULATOR 104-267
20 bar 131x,psil MAXIMUM WORKING PRESSURE
AIR PRESSURE GAUGE 101-180
0-14 bar 10-200 psi) range
COMPRESSION SPRING 105-673
For increased shut off forc
spraying plural component
22
307-726
CONTROL PANEL 218-394
For one or two gun operation. Includes cabinet
mounted air regulator, air filter, three-way triggering
valve and air atomizing gauge. See manual 307-673.
ELECTRODE WIRES 218-751
Box of 10 replacement electrode wires for the spray tip.
REMOTE FAN AIR ADAPTER 181-053
1/8-27 npt(f)
To control fan pattern from the control booth.
Must also order:
108-234 90° Elbow; 118 npt(m)
REMOTE SWITCH 8 SIGNAL LIGHT 728-386
ELECTROSTATIC SYSTEM 231-037
Includes
items:
.
218-928 Automatic Electrostatic Air/Airless S ray Gun
218-101 111)
Grounded
Air Supply Hose, 25 ft (gee page
X"
w IUI specifications)
214-698Static Free Fluid Hose, 25 ft. (See page 23 for
specificat:ions)
106-148 Air Filter, 318 npt
~~
~~
ELECTROSTATIC SYSTEM 231Includes items:
216-928 Automatic Electrostatic AirlAirless Spray Gun
218-103 Grounded Air SUDD~V
Hose, 50
(See Daae
. for specificationsi
214-697 Static Free Fluid Hose, 50 ft (See .DaQe
- Ufor
specifications)
106-148 Air Filter, 3/8 npt
.
ft.
ACCESSORIES (Must be purchased separately)
The accessories in this section heva been tested
by Factory Mutual.
WARMING
Never operate your equipment at a working
pressure rating that is higher than the lowest rated
component in your system. Lower rated components may not be able to withstand the
pressure developed by the pump and may rupture,
causing serious bodily injury or property damage.
'I
SPRAY TIP SELECTION CHART
~
~~
I
~~
'Light t o
Medium
"Heavy
Viscosity Viscosity
liters/rnin literslmin
Pari
If1 o d m i n ) (fl oz/min) Number
Inches
Orifice
Fan Width
Size
at 300 mm
mm (in)
(12 in.)
., .
GROUNDED AIR SUPPLY HOSE, Polyurethane
7bar llW psi1 MAXIMUM WORKING PRESSURE
6.35 mm (0.25in.) ID, 1 / 4 npsm(fbe1
220-444 1 m (4 h) long
218-100 5 m (15 f t ) lono
216-101 8 m i25 lone
218-102 11 m (36f t ) long
218-103 15 m ( 5 9 R) long
220-11923 m (75 f t ) long
220-12030.5 m l1W f t ) long
rti
,
.
.;..
.
..'.
WARNING SIGNS
180-080 Warning Sign (English).
180-061 Warning Sign (French)
180-062 Warning Sign (German)
180-063Warning Sign (Spanish)
STATIC FREE FLUID HOSE
Nylon Tube, Urethane Cover
ZV7 bar
psi1 MAXIMUM WORKING PRESSURE
Part
No..
ID
Length
214Mo 4.8 mm ( 3 / 1 6 ) 0.61 m (2 f t )
214701 4.8
214699 4.8
214698 4.8
214-697 4.8
214638 6.4
214-635 6.4
214-636 6.4
mm ( 3 / 1 6 )
mm (3/16")
mm 13/16)
mm (3/16")
mm (114")
mm (1/4")
mrn (114")
0.91 rn 13 ft)
1.8 m 16 ft)
7.6 m ( 2 5 ft)
15.2 m (50 f t )
0.36 rn (14 in.)
0.61 m 12 ft)
0.91 mrn (3 ft)
214629 6.4 mm (1/4") 4.6 rn 115 f t )
210-540 6.4 mm (1/4") 7.6 m ( 2 5 ft)
2lO-541 6.4 rnm 1114") 15.2 m ( 5 0 ft)
.
Thread
Size
114 npsm(f)
1/4 n p t h x f)
1/4 npsm(f)
1/4 npsrn(f1
1/4 npsm(f)
114 npsmlfl
1/4 npsm(f)
114 npsmlf)x
1/4 n p t h )
1/4 npsrn(f)
1/4 npsmlf)
1/4 npsm(f)
.. :
I
I
I
I
I
.
'Fluid Output at 41 bar ( 6 0 0 psij
The fluid output (Q) at other pressures (PI can be calculated
by this formula:
Q = (0.041) (QT) 1 r / p J ,
Where QT = Fluid output (fl oz/minl from the above table for
the selected orifice size.
NOTE: Other tips are available on special work order. Allow
4 to 6 weeks for delivery. Maximum orifice size is
0.635 mm (0.025in).
307-726
23
!
.
SERVICE INFORMATION
HOW TO ORDER REPLACEMENT PARTS
Listed below by the assembly changed are OLD and
NEW Darts.
1. To be sure you receive the correct replacement parts,
kit 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.
I
ASSEMBLY
CHANGED
II
218-920
Spray Gun
PART
REF PART
STATUS NO. NO.
OLD
NEW
10a
NEW
12
OLD
164-769
1831159
180-684.
220-963
NAME
I
Housin
Housinq
INTERCHANGEABILITY NOTE: NEW parts replace
1
6 digit
PART
NUMBER
QTY
PART DESCRIPTION
I
OLD parts listed directly above them.
ACCESSORIES NOTE: ADDED compression
spring 105673.
i
..::.
.
.. ..
24
307-726
.'
'
TECHNICAL DATA
Weight:0.87 Kg (1.90 Ib)
Gun length:310 mm (12.25 in.)
Operating voltage range :0-75 Kv
Operating fluid pressure :0-66bar (0-950psi)
Operating air pressure :0-7 bar (0-100 PSI)
Fluid inlet: 318 npsm(m)
Air inlets: Turbine-114 npsrn(m) L.H.
Atomizing B Cylinder--114 npt(m)
Wetted parts:Stainless Steel, Acetal, UHMW
Polyethylene, N Ion, Carbide,
Tefonm , Delrin
J
and Delrin"
Loctite" 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 euthorized Gram distributor to the original purchaser for use. As purchaser's sole remedy for breach of this warranty, Graw will, for a
period of twehre months from the date of sele. repair or replace-anypan of the equipment proven defective. This warranty applies onhl when the
equipment is instelled. operated end maintained in eccordance witH Graco's written recommendations.
This ywrnnty d"
not cover, and Greco shall ?ot be liable for. any maifunction, damage or wear caused by faulty installation. misapplication,
abraraon. wrroslon, Inadequate or unpmper malntenance, negligence, accident, tampering. or substitution of non-Graw component pans. Nor
shell Graco be liable for manunction. damage or weer caused by the incompatibility with Graw equipment of ~t~ct~r~p,
accessories, equipment or materials not supplied by Graco, or the improper design. manufacture, installation. operation or maintenance of m c t u r s , accessories, equipment or materials not supplied by Graco.
This warranty is condn'oned 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 pans. The equipment will be returned to the
original purchaser transponation 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 the costs of paw, labor and transpottation.
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASERS
T OLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER
WARRANTIES IEXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON-CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR
STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CONSEOUENTIAL DAMAGES OR LOSS IS MPRESSLY EXCLUDED AN0 DENIED. IN NO CASE SHALL GRACOS LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR
BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO 121 YEARS OF THE DATE OF SALE.
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 USA. 307-726 8-85 Revised 7 4 8

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