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

INSTRUCTIONS-PARTS LIST
ORACo
This manual contains IMPORTANT
WARMINOS and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
307-726
Rev F
SUPERSEDES E
Model PROAA5O0OTM
AUTOMATIC MID-RANGE ELECTROSTATIC
'AIR-ASSISTED AIRLESS SPRAY GUN
66 bar (950 psi1 MAXIMUM WORKING FLUID PRESSURE
7 bar IlW psi) MAXIMUM WORKING AIR PRESSURE
'
Part Number 218-928, Series A
Includes a 219-411 0.279 mm (0.011 in.) spray tip
I
U.S. 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. 2,140,3278; 2,111,4068; 2,142,5598
Italian Patent No. 1,111,380
West German Patent No. DE 22 09 896
Patented 1986, Canada
Brevete 1986
and Other US. and Foreign Patents Pending
ggFJ
+ I &
Approved
GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55440.1444
@COPYRIGHT 1985 GRACO INC.
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TABLE OF CONTENTS
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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
Mount the Gun...............................................
5
Connect the Air Lines
5
Connect the Fluid Line
5
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 8 Resistor Replacement
15
Gun Housing Removal...................................
16
Gun Housing Reassembly ..............................
16
Fluid Needle Replacement
..17
Power Cartridge Replacement
17
Turbine Alternetor Removal...........................
18
Fan Air Valve Replacement .............................
18
Piston Removal 8 Repair ...............................
18
Disc Regulator 0-Ring Replacement
19
Muffler Replacement
19
PARTS DRAWING...........................................
PARTS LIST
21
ACCESSORIES
23
SPRAY TIP SELECTION CHART
23
HOWTO ORDER REPLACEMENTPARTS
24
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 A serious injury, which may appear to be a simple cut, caused by high pressure injection of
fluid directly into the body.
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.
HOW THE ELECTROSTATIC (ES) AIR-ASSISTED AIRLESS SPRAY GUN WORKS
This gun combines electrostatic air spray and airless
spraying concepts. The air has three functions: I l l 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
convefts 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 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.
307-726
1
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 EQUIPWIENT.
, .
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 Sefety
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 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 tha spray gun at anyone or at any part of the
body. NEVER put hand or fingers over the spray tip. NEVER
try t o "blow back" paint; this is NOT an air spray system.
ALWAYS follow the Pressure Relief Procedure. at rioht.
before cleaning
removing the spray tip or sericin9 -any
system equlpment.
or
NEVER try to stop or deflect leaks with your hand or body.
Be sure equipment !safety devices are operating properly
before each use.
DHuser
The gun diffuser (part of ball seat housing 218686) 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 a grounded metal pail. With the
turbine air OFF, and using the lowest possible pressure, actuate the gun. If the fluid emitted is not diffusad into an irregular stream, replace the ball 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 t o clean it.
NEVER wipe off build-up around the spray tip until pressure is
fdlv mlinved.
Medical Alert- Airless Spray Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE A T ONCE. DO NO1 TREAT A S A
SIMPLE CUT.Tell the doctor exactly what fluid was Injected.
Note to Physlclen: hjectiin in the skin is a treumtic h jury. It Is important to treat t h e Injury surgically 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 t o rupture and result 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.
2
307-726
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.r
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 t o the gun except the cylinder lactuatingl air.
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 B waste container ready
to catch the drainaae.
5. Leave the pump d k i n 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 Air Shutoff V a l v e a n d Fluid D r a i n
Valve Required
These Nvo accessories ara 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 muse 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 working pressure of 66 bar
(950 psil. Never exceed the maximum working pressure of the
gun or any other component or accessory used in the system.
Read and follow the fluid and Solvent manufacturer,s literature
regarding the use of protective clothing and equipment.
Fluid ~ ~ ~ ~ ~ ~ i b i l i ~ ~
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's literature before using them in this sprayer.
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FIRE OR EXPLOSION HAZARD
All 'parts of the electrostatic spray system must be properly
grounded to reduce the risk of static electricity discharge.
Static electricity is created by the high velocity flow of fluid
through the pump and hose and the spray gun's internal
power supply. Ungrounded objects can become electricaliy
charged and sparking may occur. Sparks can ignite fumes
from solvents, fluid being sprayed, dust particles and other
flammable substances, which can cause a fire or explosion
and result in serious bodily injury and property damage.
If you experience any sparking or feel even a slight shock,
STOP SPRAYING IMMEDIATEL Y. Check for proper grounding of the entire system. Be sure you have corrected the problem before starting t o spray again.
Grounding
Following are the minimum requirements for grounding a
basic electrostatic system. Your system may include other
equipment or objects which must also be grounded. Always
check your local electrical code for detailed grounding instructions. Be sure your system is connected to a true earth
ground.
1. Pump: ground by using a ground wire and clamp as
described in your separate pump instruction m-anual.
2. Air compressors and hydraulic power supplies: ground
according to the manufacturer's recommendations.
3. Pro AAWW gun: obtain grounding through connection
t o a properly grounded air supply hose. Use only the
GRACO GROUNDEDAIR SUPPLY HOSE; see pageZ3to
order. Connect the air hose ground wire t o a true earth
ground.
4. Fluidsupply container: according to local code.
5. Object being sprayed: keep workpiece hangers clean and
grounded at all times. Contact points must be sharp points
or knife edges.
6. All electrically conductive objects or devices, including
paint containers and wash cans in rhe spray area, must be
properly grounded.
7. A
llpersons entering rhe spray area: shoes must have con-
ductive soles. such as leather. or personal grounding straps
must be worn. Rubber or plastic soles are not conductive.
8. The floor of rhe spray area must be electrically conductive
and grounded. Do not cover the floor with cardboard or
any non-conductive material which would interrupt
grounding continuity.
9. Flammableliquidsin thesprayarea must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.
10. Allsolventpails: use only grounded metal pails, which are
conductive. Do not place the pail on any non-conductive
surface, such as cardboard or paper, which would interrupt
grounding continuity.
Rushing and Cleaning Safety
To reduce the risk of a fluid injection injury, stetic sparking, or
splashing, always follow the Pressure Relief Procedure on
page 2 and remove the spray tip before flushing. Use lowest
possible pressure and use a grounded metal waste container.
Be sure the turbine air (electrostatics) is OFF during flushing.
NEVER use solvents having a flash point of l e s s than 21OC
(70°F) to clean the gun. NEVER use solvents having a flash
point of less than 38OC IIW°F) to clean the spray system.
ALWAYS remove all solvent from the system before reactivating the spray gun.
. ."... .
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_.:i.
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Use only non-sparking tools t o clean residue from the booth
and hangers.
Ventilate t h e Spray Booth
To prevent hazardous concentrations of toxic andlor flammable vapors, spray only in a properly ventilated spray booth.
NEVER operate the spray gun untess the ventilating fans are
operating.
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HOSE SAFETY
Pressurized fluid contained in the hose can be dangerous. If
the hose develops a leak, split or rupture due t o any kind of
wear, damage or misuse, the high pressure spray emitted from
it can cause a fluid injection injury or other serious bodily injury
or property damage.
TIGHTEN all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high
pressure spray to be emitted from the coupling.
exist, replace the hose immediately. DO NOT try t o recouple
high pressure hose or mend it with tape or any other device. A
repaired hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on
hoses t o move equipment. Do not use fluids or solvents which
are not compatible with the inner tube and cover of the hose.
DO NOT expose Graco hose to temperatures above 82%
(180OFI or below - 4 0 T (-40°F).
. ..
.
NEVER use a damaged hose. Before each use, check entire
hose for cuts, leaks, abrasion, bulging cover, or damage or
movement of the hose couplings. If any of these conditions
,.. .
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards-particularly the General Standards, Part 1910.107 and any other appropriate regulations-should be consulted in connection with the installation, operation and maintenance of electrostatic spray painting equipment.
307-726
3
TYPICAL INSTALLATION
INSTALLATION
The air supply to the gun must be electrically
interlocked with the spray booth exhaust fan.
..
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
I.‘
KEY
A
B
C
0
E
F
Air Supply Shutoff Valve [bleed-typal
Air & Water Separator
Ball Valve
Air Line Lubricator
Air Revulator
Purno
G
H
J
K
L
Fluid Filter
Drain Valve
Grounding Wire
Air Filter I 4 0 micranJ
Fluid Regulator
The Typical Installation shown above is only a guide for
selecting end installing equipment for an electrostatic
air-assisted airless spraw:system. It is not an actual
system design. Contact your Graco representative for
customdesigned systems information.
The pump you use should have a maximum working
pressure of 66 bar 9
I50 psi). If the pump you are usi,ng
has a higher maximum working pressure, you must use
a regulator to limit the pressure to 66 bar (950 psi).
Graco’s 1 0 1 Ratio Monark Pump, Pert No. 217-523,
may be used in this system. Sea Accessories.
I
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.
Wamlng Signs
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 awn and read by all operators. This
sign is also available in French and German. See the Accessories section on page 23.,
4
307-726
P
Q
ES Automatic Gun
Normally Closed, 3-Way Air Solenoid
Valve or %Way Manus1 Valve
Exhaust Hose
Ventilate the Spray Booth
WARNING-
To prevent hazardous concentrations of toxic
andlor flammable vapors, spray only in a properly
ventilated spray booth. NEVER OPERATE THE
SPRAY GUN UN.LESS VENTILATION FANS ARE
OPERATING. The air supply to the gun must be
electrically interlocked with the ventilators to prevent operation of the power supply unless ventilating fans are running.
WARNING
“---WARNN
IG
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.
N
1910.107(b) (5) (i).
Check and follow all of the national, state and local
codas regarding air exhaust velocity requirements.
NOTE:
High velocity air exhaust will decrease the
operating efficiency of the electrostatic
system. Air exhaust velocity of 31-46 linear
meterdminute (100-150 ft/minl should be
sufficient.
,.,
::.
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)
W
-l ARNN
IG-,
To reduce the risk of electric shock or other
serious bodily injury. the Turbine Alr Supply
Hose must be electrically connected to a true
earth ground. Use Only Graco Electrically Conductlve 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. Install an air filter (K)and an air and water separator
(B) on the main air line to ensure a dw.clean air
supply to the gun. Dirt and moisture can ruin the
appearance of your finished workpiece and can
cause the gun to malfunction.
4. Connect the fluid line to the 318 npsm(m) gun fluid
inlet.
CAUTION
Do not use metal fittings at the gun barrel. For circulation systems, use plastic fittings.
Check the Electrical Grounding
system is essential. For your safety, read the
warning section, FIRE OR EXPLOSION
HAZARD. on page 3. Then ground the system as
1. Shut off all eir spray lines to the gun.
2. Turn off fluid supply to the gun.
3. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
a.
2. Install an air line lubricator (D) close to the pump.
3.
Install a normally closed, 3-way air solenoid (PI or
manual valve on the turbine, cylinder and remote
fan (optional) air supply lines.
4.
Install an air regulator (El on the pump, turbine,
atomizing, cylinder and remote .fan (optional) air
supply lines to control air pressure to the pump and
gun.
5. 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. See Bleed-Type Air
Shutoff Valve and Fluid Drain Valve Required,
page 2.
6.
Connect the cylinder air line to the gun's cylinder air
inlet (marked CYL).
7.
Connect the atomizing air iine to the gun's atomizing air inlet (marked ATOM).
NOTE:
With the electrically conductive air hose connected (see Connect the Air Lines a t left) and
properly grounded, use a megohmmeter (see
ACCESSORIES on page 2 2 ) to measure the
resistance between the gun handle and a true
earth ground. Use an applied voltage of not less
than 500 minimum to loo0 volts maximum. See
Fig 1.
If the air hose is not grounded, you will get a
fakereading.
b. If the resistance is greater than 2 megohms,
check the tightness of the ground 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
rMEGOHMMETER
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.
Fig 1
3. Install e fluid filter ( G ) end 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.
307-726
6
i
Installing the Optional Remote Fan Air Adapter
NOTE:
3. Install the 90° elbow (part no. 108-234) in the
adapter.
See ACCESSORIES to order the Remote
Fan Air Adapter 181-053 and 90° Elbow
108-234.
4. Install the remote fan air line, solenoid valve, air
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.
5. Adjust the air pressure for the desired fan pattern.
regulator end shutoff valve as instructed in Connect the Air Lines, on page 5.
1.
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2. Apply PTFE tape to the threads of the remote
fan air adapter (part no. 181-053) and install it in the
gun body (1). Torque the adapter to 1.1-1.4 N m
(10-12 in-lb).
OPERATION
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.
Operating Checklist
Check the followina list dailv. before using the svstem; to
help ensure you ofsafe, efficient operatbn.
- 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.
-4.
- 5.
Be sure the system is thoroughly grounded. See
Fire or Explosion Hazard on page 3, and Check
the Electrical Grounding on page 5.
Be sure the operator and ell 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.
Be sure all conductive objects within 6 m (20ft)
of the gun are electrically grounded end the floor
of the spray area is electrically conductive and
grounded.
-6.
Be sure the ventilation fans are operating properly.
-7.
Keep the workpiece hengers clean. Contact
points must be sharp points or knife edges.
-8.
Be sure ell refuse is removed from the spray
booth.
-9.
Selecting e Spray Tip
This gun is supplied with Spray Tip 219-411. See Spray
Tip Selectlon Chart on page 23 for the description.
6
inetaillng a Spray Tip
Place the tip (10) in the air cap (9). 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)
flrmly to prevent leakage between the tip and ball seat
housing. See Fig 4. The air cap and spray tip position
deterrninea the direction of the spray pattern. See Fig 2.
"------------V\IARNING
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 sure
the electrode wire is properly installed in the gun
(see page 15) and is not bent or damaged before
operating 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 (950 psi) fluid pressure.
2. Close the fen adjusting knob IAA) by turning it fully
counterclockwise.
VERTICALSPRAY PAlTERN
HORIZONTALSPRAY P A H E R N
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.
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.:
3. Set,the atomizing air pressure to 3.1 bar ( 4 5 psi).
4. Complete the Operating Checklist to the left and
then 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 pulled into the spray pattern. Refer to Fig 3. For
a narrower pattern, try turning the fan adjusting
knob (AAI clockwise. If the pattern is still not narrow enough, increase the air line pressure slightly (if
you have a separate fan air line) or use a different
size tip.
NOTE:
rc
Be careful not to damage the electrode by jam-
down
gun.
ming itthe
into
an object when operating or setting
leaning
A remote fan air adapter is available to control
the fan air at the control booth. See ACCESSORIES.
NOAIR
TOO LI'ITLEAIR
Relief Procedure on page 2 when shutting off
the system, when you stop spraying and befora
checking, servicing, installing, cleaning or chang-
RIGHT AMOUNT
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.
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.
When spraying the ES indicator lights (BE)
should glow, indicating the electrostatic
charge. See Fig 4.
Clean the fluid filter (361 daily. See Fig 5.
a. Unscrew and remove the fluid connector (34).
b. Remove the filter (36) 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.
NOTE:
dampened in e compatible solvent.
Be careful not .to damage the electrode by catch-
ing the cloth on R when wipingc
off the gun.
I
Clean the spray tip /lo1 and air cap (91 daily,
minimum. Some applications require more frequent
cleaning. Replace the spray tip and air cap if they
are damaged.
a.
Fan Adjusting Knob
ES Indicator Lights
Elsctrcda Wim
Retaining Nut
Air Cap
Rule X^
Remove the air cap and spray tip,
b. Clean the tip and air cap with solvant and scrub
with a soft brush.
c.
AA
BE
QG
8
8
10
Reinstall the filter and connector. Do not overtighten the connector, which could distort the
filter.
2. Clean the outside of the gun daily with a soft cloth
3.
'W
WARNING
Use a soft brush or other soft tool, with an air
blow gun, to clean the air cap passages. Take
care not to scratch any surfaces. If the air cap
holes are plugged, a round toothpick can be usad 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 NOTsoak it in solventl A damaged resistor
will impair the electrical continuiw and could
result in electrical discharge, which could cause
serious bodily injury, fire, or explosion.
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7
4. Check the electrode wire IGG). See Fig 4.
Straighten if bent, end replace if broken or damaged. Sea Electrode Wire Replacement, page 15.
Flushing
5. Remove all loose or ungrounded objects from the
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.
CAUTION
Do not use metal tools to clean the air cap holes as
this may scratch them, and make sure the electrode wire is not damaged. Scratches in the air
cap holes or a damaged electrode wire can distort
the spray pattern.
Do not use any cleaning method which may
allow solvent into the gun air passages. Clogged air passages cause poor atomization end excessive current demands. Point the gun down
while cleaning to prevent dirty solvent-from running back into the eir passsges. NEVER IMMERSE
THE GUN IN SOLVENT.
ARNING
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.
1. Be sure the turbine sir (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 fluid supply line.
7 . Actuate the gun until it is clean of solvent.
Clean all parts with e non-conductive solvent,
compatible with the fluid being sprayed. Conductive solvents cen cause the gun to malfunction.
I..!
8
307-726
307-726
9
SERVICE
WARNING
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious
bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained
and qualified.
WARNING
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 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 PATTERN TROUBLESHOOTING CHART
PROBLEM:
iMPR0PER
SPRAY PATTERN
Fluttering or spitting spray
A
Irregular pattern
Pattern pushed to one side, same
side of air cap gets dirty
10
307-726
CAUSE
SOLUTION
Insufficient fluid in tank.
Fill tank.
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.
Air to gun is too low.
Increase air.
Fluid pressure too low.
Increase fluid pressure.
I
I
GUN OPERATION TROUBLESHOOTING CHART
I
PROBLEM
I
Air leakage from front of gun.
Fluid leakage from front of gun.
”Orange Peel” finish.
Excessive spray fog.
No fluid sprays from gun.
Equipment covered with paint.
Gun still actuated after cylinder air
shut off.
I
I
CAUSE
SOLUTION
Piston Assembly (25, 24, 22, 5 9 ) not
seating properly.
Clean, service.
Worn or broken O-ring (59).
Replace O-ring (59).
Air stem packing (191 too tight.
Loosen packing (19).
Loose fluid tip (10).
Tighten retaining nut; hand torque firmly.
Fluid tip washer 11Oa) worn or missing
Replace washer (loa).
Loose or worn ball seat housing (11).
Tighten or replace ball seat housing (11).
Insufficient air pressure.
Increase, use least air pressure needed
for good results.
Using too large of a fluid tip (10).
Use a smaller size tip.
Paint Jiscosity 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 (10).
Clean fluid tip 110).
Damaged fluid tip (101.
Check, replace fluid tip (101.
Broken fluid needle shaft 114).
Replace needle (14).
not directed properly.
Booth exhaust air flow insufficient or
Check for proper CFM, check baffles
and direction of air flow.
Improper distance between gun and
work piece.
Adjust distance to
(E12 in.).
Worn or broken O-ring (22).
Replace O-ring 122).
. .
203-305 mm
.. .
See Electrical Troubleshooting on page 12.
. ..
307-726
11
~
ELECTRICAL TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Poor wrap-around.
*Turbine alternator IZa) not
operating (no audible whine).
Check air supply to turbine. Check
for din or moisture in turbine.
Improper distance between gun and
workpiece.
Adjust spraying distance to
203-305 mm la12 in.).
Parts poorly grounded.
Clean workpiece hangars. 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 pan of ball seat housing
(11)l
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 (101.
'Faulty turbine alternator b
Be sure plug (2c) is in place on
back of turbine alternator housing
Pa). Remove and test turbine alternator. See Service Section. Replace
turbine alternator if necessary.
3perator gets mild shock.
lperator gets mild shock when
ouching workpiece.
l .
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 (in
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.
!
*ES indicator lights not "ON"w h e n gun is triggered.
. .
i
307-726
13
I
1
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 (4) 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.
WARNING
If the resistance is outside the specified range, remove
the electrode wire (GG). See Electrode Wire Replacement page 15. Measure the resistance between the
conductive rod (FFI and the resistor (LL) in the outside
diameter of the ball seat housing (11).
~
1
I
~
~
i.
The resistance should be 20-30 megohms. I f ' 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 (11) must be replaced. See page 15.
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
L
E
F
MEGOHMMETER
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 (67). 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
meaohms. If the resistance is outside the .soecified
"
ranee, go to the next test. If the resistance IS correct,
refer to the ELECTRICAL TROU8LESHOOTlNG
CHART on page 12 for other possible causes of poor
performance.
.
~~
~
~~~
~
~
~
ne
GO Electrode Wire
1 Gun Body
61 Adapter
6
KN.
EE Connector Prong
2 Power Cartridge
b Turbine
4 Power Supply
4c Spring
MEGOHMMETER
Test Power Supply Resistance (See Fig 7)
Remove the power cartridge (2) from 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 (€E) in
the power supply to the spring ( 4 c ) on the other end of
the power supply. Insert the lead from the spring into
the hole closest to."E" on the meaohmmeter. Insert the
lead from lhe center prong into the second hole to the
right of "L" on the magohmmeter.
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, proceed to the next test.
Test Resistor Stud Resistance (See Fig 8 Et 9)
Insert a conductive rod (FF) into the gun barrel lremoved for the power supply test) and against the metal contact (AA) molded into the front of the barrel.
Measure the resistance beween 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.
MEGOHMMETER
KEY
AA
GO
FF
12
Metel Contact
Electrode Wire
Conductive Rod
Gun Housing
MEGOHMMETER
K N
FF Conductive Rod
LL Resiator
11 Ball Seat Housing
L
I
'.:
!
!
i
I
i~
Fig 9
j
~
!
14
307-726
Gun Repair
Ball Seat Housing b Resletor Replacement
(SeeFigs 10 8 11)
WARNING
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 pert of the gun or system.
Unscrew the retaining nut (8).Remove the air cap (9)
and spray tip (10).
Insert the special wrench (55f) in the front of the gun.
While triggering the gun, unscrew the ball seat housing
(1 1) end 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 reverse order of
disassembly. Torque the ball seer housing to 1.1 N.m
(10 in-lbl (snug); DO NOT OVERTIGHTEN.
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 the
eauipment unless vou are trained and aualified.
I
DO NOT OVERTIGHTEN the bail seat housing
(11). Excess torque will damagec
the housing.
I
1
ALWAYS remove the gun from the worksite for
or repair.
reDair erea must
I service
c A
u The
T service
l o or N
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.
..... .
I
. .
.....,..>
,.....
. . ..
KEY
11 Ball SeatHousing
E t Wrench
ALWAYS lubricate the O-rings end seals with petroleum jelly to prevent damage during installation.
1. Flush the gun. See page 8. Follow the Pressure
Relief Procedure Warning on page 10.
::2...
:.
2. Disconnect the fluid supply hose from the gun.
3. Disconnect the sir supply lines from the gun.
Electrode Wlre Replacement (See Fig 10)
Unscrew the retaining nut (8).Remove the air cap (9)
end spray tip (10).
Use a needle nose pliers to gently pull the electrode wire
(GGl out the beck of the spray 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 wire 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 kt (655).
. .
KEY
(10 Electrode W h
8 Retaining Nut
S Air Cap
10 Spray Tip
Fig 10
Fig 11
307-726
15
Gun Housing Removal (See Figs 12, 13, 14 8 151
Remove the retaining nut, air cap, and spray tip.
Unscrew the fluid tube connector (FF) at the bottom of
the fluid tube (371, then pull the tube out of the inlet.
If you are replacing the needle, insert the special wrench
(55fl in the front of the gun. Whiletriggering the gun, unscrew the ball seat housing (111and 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 (331
and trigger adjusting nut (15) from the gun.
Remove the ES indicator lights (43). Then, using the
wrench (55~).supplied, loosen and remove the two
socket heed capscrews (44) from the gun.
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 115)
to its previously noted position.
Reinstall the ball seat housing (see page 151, air cap,
spray tip and retaining nut.
... .
. ,
i
KEY
2 Power Cartridge
6 Gasket
12 Gun Housing
Hold the gun body (1) with one hand and pull the gun
housing (121 straight up to remove it.
!.
.,. ...
I- .;..
,
To avoid damaging the power cartridge (2).
always pull the gun housing (12) straight up. If
necessary, gently move the gun housing from side
r to side
C to free
A it from
U the
T gun 'handle.
O
N
1
Leave the gasket (51 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 Et 15)
If the needle assembly was removed, reinstall it as described on page 17. Be sure the gasket (5) is in place on the
gun body (11. Place the gun housing (121over the power
cartridge (21 and position it onto the gun body (1).
1:. .,
,. .. .
Fig 13
Install the two socket head capscrews ( 4 4 1 and tighten
with the wrench ( 5 5 ~ )Push
.
the ES indicator lights (43)
into place over the capscrews (441.
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).
KEY
/
86c Wrench
.. .
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.
Insert the narrow end of the pressing tool ( 5 5 d through
the front of the^ gun to push the needle back, then remove the nut (17) and the adjustment nut (14). 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. Than use the wrench ( 5 s ~to
) finish pushing it out.
Power Cartridge Replacement (See Fig 17)
CAUTION
The power cartridge (2)is fragile. Use care when
handling it to avoid damaging it.
DO NOT USE solvents to clean the power cartridge cavity in the gun body (1). Solvents will
damage the electrical components in the power
cartridge.
4a.
.
All O-rings (2b.
4b) and the compression spring
(44 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).
Fluid Tube
Grasp the power cartridge with your hand and use a
gentle rocking motion to free it from the gun body (1).
Then pull the power cartridge (2) straight out of the
handle.
. .
. ,,.
Be sure the power cartridge cavity in the gun body
may damage
electronic
I taminants
(1) C
is very A
clean
and
U dry.the
TMoisture
' and
Ocircuitry.
otherN
con- 1
Inspect the power cartridge cavity in the gun body (1)
for dirt and moisture. Clean the cavity with a clean, dry
rag, if necessary. Don't use solvent,
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 ( 5 5 d
into the front of the gun and press to seat the needle.
Reinstall the new adjustment nut (14). hex end first,
onto the needle. Use the pressing tool (5%) 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 (17) firmly
against the adjustment nut to "lock" them together.
Reassemble tha gun es described in Gun Housing
Reassembly on page 16.
17
r
Lightly lubricate the O-rings (2b. 4a, 4b) on the new
power cartridge with petroleum jelly.
Insert the new power cartridge (2)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
BOTTOM
OFTHREAD
Fig 17
307-726
17
..>:
.j.:
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 ohmmeter 218-979, test the coil in the turbine
alternator (2a).With the ohmmeter set at R x l 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 sdewdriver 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 (47).
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). Beck the adjusting screw out of the valve housing
(48)until it bottoms out against the retaining ring (38).
ApplyPTFE tape to threads of valve housing (48)and
install in the gun body (1). Torque the housing (48)to
1.1-1.4 N m (10-12 in-lb).
..
- '.
..
Piston Removal and Repair (See Fig 20)
Disconnect the fluid hose (37) from the cover plate (32)
by screwing the nut (FF) 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 ( 6 0 ) from the
cover plate (32). Remove the cover plate (32). spring
(27). and retainer cap (26).
..
.r...,~.'..:; ..
. .
KEY
38 Retainina R h o
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
2a Turbine Alternator
4 Power Supply
Unscrew and remove the air valve guide (18) and needle
packing 119) from the gun body (1).
Fig 18
Fan Air Valve Replacement ( S e e 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) clockwise until it is disengaged from the
valve housing threads. Pull the adjusting screw (47) out
of the valve housing (48).
Push on the end of the piston shaft, and remove the
piston assembly.
NOTE:
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 & 59) and the u-cup packing (24) on the
piston (25) with petroleum
Pack the spring (271
with petroleum jelly. Apply PTFE tape to the air valve
guide (18).
Clean all the parts and inspect them for wear or
damage. If replacing the seal (39). unscrew it clockwise
and remove from adjusting screw.
Install the new packing (19) and guide (18) in the gun
body (11, screw the guide in loosely.
Apply Loctite No. 609 to small threads on end of adjusting screw (47) and install a new seal (39)(left hand
thread).
guide must be boose to avoid damaging the
packing (19) when pushing the piston shaft
through the guide.
18
307-726
NOTE:
DO NOT fully tighten the guide (18) yet. The
If replacing the u-cup packing (241. slide it onto the
piston (251 so the lips of the packing.will face towards
the front of the gun when the piston is installed. Next
install the buna-N O-ring (22)and the Viton' 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 (261 into !he cover plate (32).Install the cover plate (32). spring (27) and retainer cap
(26) with the screws (311 and lockwashers 160).
Actuate the trigger, and tighten the air valve guide (18)
with e wrench.
Screw the trigger adjusting nut (15) onto the piston
shah to its previously noted position.
Connect the fluid hose (37) to the cover plate,
Disc Regulator 0-Ring Replacement (See Fig 211
Unscrew the turbine air line from the adapter (67).
Remove the capscrew (71) and washer (701 from the
gun body (1I. 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 (30).Clean and inspect parts
for wear or damage, and replace if necessary.
Clean and inspect the N o O-rings ( 6 8 1 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)50 its
beveled surface faces into the gun.
Scraw the adapter (67)into the air valve (69). and install
the air valve into the gun body (1).
Screw the capscrew (71). with the washer (70), into the
gun body.
Screw the turbine air line onto the adapter (67).
Muffler Replacement (See Fig 2 2 1
Remove the fan air valve assembly as instructed in Fan
Air Valve Replacement, page 18.
Remove the elbow (46)with the tuba (491.
Remove the muffler (21) with a hook, and replace with a
new muffler. Install the elbow (461.
Install the fan air valve assembly as instructed in Fan
Air Valve Replacement, page 18.
307-726
19
PARTS DRAWING
Rj13
~-
PARTS LIST
REF PART
NO. NO.
1
2
2a
2b
2c
3
4
4a
4b
4c
5
6
8
9
10
1Oa
11
12
12a
13
14
14a
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
an
DESCRIPTION
1
218-927 BODY, gun
218-111 POWER CARTRIDGE
Includes items 2a b 4
217-591 .ALTERNATOR, turbine
Includes items 2b b 2c
'107-106 .O-RING; buna-N
180-070 .PLUG
100.664 SCREW; 1/4-20
218-041 POWER SUPPLY, ES, 75 KV
Includes items
4b b 4c
'177-156 .O-RING; Viton"
*106-555 .O-RING; fluorocarbon
178.504
.. .._
. SPRING, compression
'179-387 GASKET, housing
LABEL, warning
*'179-790
218-695 NUT, retaining, air cap
220-535 AIR CAP
219-415 SPRAY TIP; 0.381 mm (0.0151
Includes item 1Oa. See page 23 for
other part numbers
-.
'164-769 .WASHER, non-metallic
220-613 HOUSING, ball seat; includes resistor
180-6E4 HOUSING, gun
176-921 .PLUG; M 3 x 0 . 5 ~ 6
*'179-791 TAG, warning (not shown)
218-697 NEEDLE, fluid ~'
Includes item 14a
176-938 .NUT, adjustment
160-927 NUT, adjustment, trigger
181-271
".
TRIGGER
105-689 NUT, mach. hex
176-941 GUIDE, valve, air
+106-901 PACKING, needle; PTFE
108-173 ELBOW, male
181-223 MUFFLER
156-454 O-RING; buna-N
107-208 NUT, ferrule; 5/8-20 UN-2B
'181-039 PACKING, u-cup; UHMW
aolvethvlene
" ,
218-989 PISTON, shaft
181-178 CAP, retainer, spring
108.221 SPRING, compression
'107.305
O-RING; Viton
181-599 PLUG; 3/8-18 npsm
1
1
2
4a.
32
34
35
36
205-264
180-728
1
1
1
1
1
1
1
1
Jla
38
39
42
43
44
"164-769
105-681
181-383
180-763
218-179
107-100
45
46
53
V03-557
181-594
180-714
180-713
054-134
180-060
55
220-614
1
1
1
1
1
1
1
47
48
49
!%a
55b
55c
55d
5%
5%
59
2
60
62
2
63
1
1
1
66
1
1
1
1
1
A I R CAPS
REGULATOR, disc
1
SCREW, mach. pnh; M 3 x 0 . 5 ~12
4
1
PLATE. cover
1
CONNECTOR, fluid
1
FILTER, tip, 0.005
RETAINER, filter
1
TUBE, fluid. nyion
Includes item
1
2
.WASHER. PTFE
1
RING, retaining, external
1
SEAL, valve
2
RESTRICTOR
2
LIGHT, indicator, ES
SCREW, cap, socket hd;
M5x0.8~12
2
1
O-RING; Viton; color coded green
1
ELBOW, male, 9oo
1
SCREW, adjusting
1
HOUSING, valve
178 mm
TUBE; polyethylene
SIGN, warnin English h o t shown)
See A C C E S S b S to MdM FIEllCh
1
or German
KIT, tool
1
Includes items &-Sf
1
.BRUSH. cleaning
1
.WRENCH
1
.WRENCH. barrel
1
.ELECTRODES, box of 10
1
.INSERT
1
.WRENCH, ball =at housing
1
O-RING; Viton
4
LOCKWASHER, internal
SIGN, warning, Spanish h o t shown1
See ACCESSORIES to order French
1
or German
2
SPACER
2
SCREW, trigger
1
O-RING; buna-N
O-RING:
Vitnn
1
-~
1
ADAPTER; 1/4-18 npsm, LH
2
O-RING; Viion
1
VALVE; air
1
WASHER; plain
1
SCREW, cap, hex hd; M6 x 10 long
*107-107
105330
180-924
180-706
220-225
1
1
1
1
~~
30
31
37
1
'
DESCRIPTION
1
1
1
Must be ordered separately. Restrictor Kit, part no.
below), must b e ordered and installed
when using t h e air caps.
220-493 lsee
aTy
REF PART
NO. NO.
64
65
67
68
69
70
71
177-128
107-400
104-282
105796
." ."
181-598
103-648
181-597
102-782
105408
"Included in Repair Kit 220.115.
**Extra warning tags end labels are supplied at no'charge.
See page 24 for "How To Order Replacement Parts':
Part No. Description
Fine finish air cap (no pattern control)
High solids air cap
220-536
220-537
High Air Flow R e s t r i c t o r Kit 220-493
Must be purchased separately. Includes:
Ref No. P a r t No.
100
179-994
101
107-414
102
100-172
Description
RESTRICTOR
SPRING, compression
BALL: 3/16" diameter
Qty
2
2
2
R e p a i r Kit 220-115
Must be purchased separately.
Includes:
Ref No.
2b
4a
~-
/
4b
5
1Oa
19
22
24
28
30
37a
45
59
Qty.
2
1
1
2
1
1
2
1
1
1
2
1
1
307-726
21
~~
~~
I
,
I
ACCESSORIES (Must be purchased separately)
The accessories in this section have not been
tested by Factory Mutual.
W
-I ARR
N
IIG-
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.
AIR LINE FILTER
17.5 bar 1250 psi, MAXIMUM WORKING PRESSURE
106-148 3/8 npt(f)
106-149 1/2 nptlf)
AIR LINE LUBRICATOR
17.5 bar (250psil MAXIMUM WORKING PRESSURE
214-847 3/8 npt(f)
214-848 .1/2 npt(f)
PARTS TO CONVERT STANDARD .FLUID
PRESSURE REGULATOR 206-661
TO 70 bar (1000 psi) WORKING PRESSURE
~
HIGH VOLUME AIR REGULATOR 206-199
0-9 bar (0-125 psi) Regulated Pressure
14 bar (200 psi) Steel Pressure Gauge.
See instruction manual 306-972.
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.)
-.
PAINT RESISTANCE METER 722-888
Used with 722-860 measure resistance of paint. See instruction manual 307-263. (Not for use in hazardous
areas.)
101 MONARK PUMP 217-523
66 bar (950psil MAXIMUM WORKING PRESSURE
~
~
~~~~
COMPRESSION SPRING 501-511
.FLUID PRESSURE GAUGE 101-696
0-70 bar (0-loo0
psi) range
MEGOHMMETER 218-979
500 Volt output; 0.01-Zoo0megohms
(Not for use in hazardous areas.)
UNIVERSAL GUN MOUNTING ROD 590-236
RECIP. GUN'MOUNTING BRACKET -973
NOTE: All safety barriers and interlocks are to be
supplied by the customer.
STATIONARY GUN MOUNTING STAND 722-562
WALL BRACKET 206-220
STATIONARY GUN MOUNTING BRACKET724344
CART 208-210
SWAY AIR VALVE 722-502
PUMP SUCTION HOSE 214-980
CONTROL PANEL 218-394
For one or two gun operation. Includes cabinet
mounted air regulator, air filter, three-way triggering
valve and sir atomizing gauge. See manual 307-673.
PAIL SUCTION TUBE 165-767
DRUM SUCTION TUBE 206-286
FLUID FILTERS
207 bar (3KW psil MAXIMUM WORKING PRESSURE
214570 with aluminum bowl and support.
216-029 with carbon steel bowl and support.
STAINLESS STEEL SCREENS
167-024
167-025
167-028
167-027
595 micron (30 mesh)
250 micron ( 6 0 mesh)
149 micron (100 mesh)
74 micron (200mesh)
FILTER DRAIN VALVE 210-859
350 bar l5oyM psil MAXIMUM WORKING PRESSURE
FLUID SHUTOFF VALVE 210851
350 bar I s b w psil MAXIMUM WORKING PRESSURE
FLUID PRESSURE REGULATOR 217-576
70bar ll(xx, psil MAXIMUM WORKING PRESSURE
AIR PRESSURE REGULATOR 104-267
20 bar 13LM psi, MAXIMUM WORKING PRESSURE
AIR PRESSUREGAUGE 101-180
0-14 bar 10-200 psi) range
22
307-726
ELECTRODE WIRES 218-751
Box of 10 replacement electrode wires for the spray tip.
REMOTE FAN AIR ADAPTER 181-053
1/8-27 nDt(f)
To contioI.fan pattern from the control booth.
.... ...
Must also order:
106234 SOo Elbow; 1/8 npt(m)
REMOTE SWITCH Et SIGNAL LIGHT 728-386
ELECTROSTATIC SYSTEM 231437
Includes items:
218-928 Automatic Electrostatic AirlAirless S ray Gun
218-101 Grounded Air Supply Hose, 25 ft ( l e e page
23 for specifications)
214-698 Static Free Fluid Hose, 25 ft. (See page 23 for
specifications)
106-148 Air Filter, 3/8 npt
ELECTROSTATIC SYSTEM 231-038
Includes items:
218-928 Automatic Electrostatic AirlAirIess Spray Gun
218-103 Grounded Air Supply Hose, 50 ft. (See page
23 for specifications)
214-697 Static Free Fluid Hose, 50 ft (See page 23 for
specifications)
106-148 Air Filter, 3/8 npt
.
i
r
ACCESSORIES (Must be purchased separately)
The accessories in this section have 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.
GROUNDED AIR SUPPLY HOSE, Polyurethane
7bar IlW mil MAXIMUM WORKING PRESSURE
6.35 mm~(O.25in.) ID, 1/4 npsm(fbe)
220-444 1 rn (4 f t l lona
218-100 5 m i15 f t ) ionlg
218-101 8 m (25 f t ) long
218-102 1 1 m (36f t ) long
218-103 15 rn ( 5 0 f t ) long
220-119 23 m (75f t ) long
220-120 30.5 m (100 f t ) long
WARNING SIGNS
180-060Warning Sign
180-061.Warning Sign
180-062 Warning Sign
180-063 Warning Sign
~
Part
No.
~~~~
ID
~~~~
Length
I
_.=... ._
Inches
Medium
"Heavy
Orifice
Fan Width Viscosity Viscosity
Size
at 300 mm literslmir
mm (in1
I12 in.)
If1 ozlmin
219-207
219-307
219407
150-200 (6-8)
200-250 (6-101
219-311
219-411
219-511
200-250 18-10]
250-300 (10-121
219-213
219-313
219413
219-513
219-613
__
0.5
117.0)
0.432
0.7
(22.0)
(0.0171
219-417
219-517
219-617
121.01
(27.0)
300-350 112-14)
350-400(14-16)
400-460 116-18)
134.0)
219-421
219-521
219-621
219-721
219-821
219-523
219-623
219-723
219-823
'Fluid Output a t 41 bar ( 6 0 0 psi),
The fluid output ((1) a t other pressures (P) can be calculated
0 = (0.041) KIT)
I
P
.: ,
.. ..
219-419
219-519
219-619
219-719
219-425
219-525
219-625
219-725
219-825
by this formula:
... . ..,
:
219-315
219-415
219-515
219-615
Thread
Size
1/4 npsmlf)
114 nptlmxfl
114 npsm(f)
114 npsmlf)
114 npsm(f1
1/4 npsmrf)
1/4 npsmlf)
114 npsm(f)x
114 n p t W
114 npsm(f)
1/4 npsm(f)
114 npsmrf)
. .: .
. . ..
200-250 (8-101
0.381
(0.015)
(English)
(French)
(German)
(Spanish)
STATIC FREE FLUID HOSE
Nylon Tube, Urethane Cover
207 bar 1 3 d w psi) MAXIMUM WORKING PRESSURE
~~~~
SPRAY TIP SELECTION CHART
).
Where QT = Fluid output (flozlminl 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 (0.025 inl.
307-726
23
..,
SERVICE INFORMATION
HOW TO ORDER REPLACEMENT PARTS
Updated manual to add FMS and CSA approval information to cover and added 0.178 mm lO:W7 in.) orifice
spray tips.
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 pam from your nearest Graco distributor.
6 digit
PART
NUMBER
QTY
PART DESCRIPTION
I
. ..
i
TECHNICAL DATA
Weight : O B 7 Kg 1l.W Ib)
Gun length :310 mm 112.25 in.)
Operating voltage range :0-75 Kv
Operating fluid pressure: 0-68 bar ( 0 - 9 5 0 psi)
Operating air pressure :0-7 bar 10-100 psi)
Fluid inlet: 318 npsmlm)
Air inlets: Turbine-1/4 npsm(rn) L.H.
Atomizing & Cylinder-114 nptlm)
Wetted parts: Stainless Steel, Acetal, UHMW
Polyethylene, N on, Carbide,
Tefon' , Delrin
2
TFE and Delrin' ara registered trademarks of the
Company.
Loctite'
is a registered Uedemark 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 defect8in material and wckmanshi m the data of sale
by an authorized Graw dim'butor to the original purchaser for use. As purchaser's sole remedy for breach of this warranty, Graco will, for a
period of twehre months from the date of %le. repair or replace.anypan oftha equipment proven defective. This warranty applies only when the
equipment is installed, opereted and maintained in accordance wit6 Graco's writtan racornmandatiorm.
This warramv does not cover, and,Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication,
abraslon, wrroslon, Inadequate or Improper maintenance, negligence, accident, tampering, or substitution of non-Gram component
Nw
parts.
shall Graco be liable for malfunction, damage or Wear caused by tha inmmpatibiliw with Graco equipment of B t ~ c t u r ~ accessories.
s,
equipmant or materials not supplied by Gram, or the improper design, manufacture, installation. operation or rnaintananca of mcturas. acequipment or materials not supplied by Graco.
cessories.
Thii warranty is conditioned upon the prepaid return of tha equipment claimed to be defactiva for examination by Graw to verify the claimed
defect. If the claimed defect is verified, Graw will repair or replaca free of charge any defective paw. The equipment will,be returned to the
original purchaser transpartation prepaid. If inspection of the equipment does not disclose any defect in inaterial or workmnship, repairs will be
made at a reasonable charge. which char~esmay include the the c m o of parts, labor and transporntion.
Factory Blanches:Atlanta, Dallea, Detroit. Los Angeles, West Caldwell IN.J.l
Subsidiary end Affiliate Companies:Canada: England: Switzerland: France: Germany: Hong Kong: Japan
GRACO INC.
P. 0. Box 1441
MINNEAPOLIS, MN 55440-1444
PRINTED IN U.S.A. 307-728 885 Revised 1 2 a
i

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