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INSTRUCTIONS-PARTS 'LIST
@
307-=
DRACO
Rev C
SUPERSEDES
This manual contains
AND RETAiN
IMPORTANT
FOR REFERENCE
B
Model PRO4000
MANUAL MID-RANGE ELECTROSTATIC
AIR SPRAY GUN
7 bar (1W MAXIMUM WORKING PRESSURE
Part Number 218026
With 217-453
Series B cap assembly and 1.2
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GRACO INC. P.O. B
O X
1441 MINNEAPOLIS, MN 55440-1444
@COPYRIGHT 1983 GRACO INC.
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TABLE OF CONTENTS
4
INSTALLATION
Air
..................................................
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Check the Electrical Grounding
4
5
5
5
5
OPERATION
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Clean the Air Cap and Fluid Tip..
7
SERVICE
Spray Pattern Troubleshooting Chart..
Gun Operation Troubleshooting Chart..
Electrical Troubleshooting Chart..
Electrical Tests
Gun Disassembly..
Electrode Replacement..
Fluid Packing Replacement..
Power Cartridge Replacement..
Turbine Alternator Removal..
Fan Air Valve Replacement..
PARTS DRAWING
PARTS LIST
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Fluid Adjusting Screw Replacement.,
ES On-Off Valve Removal and Repair..
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ACCESSORIES..
TECHNICAL DATA..
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. B a c k
8
9
.10
I 1
. I 2
. I 2
.12
13
.13
. I 4
. I 4
.I4
.I4
. I 5
.15
.15
17
.19
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5
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DEFINITION OF TERMS
WARNING: Alerts user to avoid or correct conditions that could cause personal injury.
CAUTION: Alerts ment. user to avoid or correct conditions that could cause damage to or destruction of equip-
NOTE: Identifies essential procedures or extra informa- tion.
ES ON-OFF VALVE: Identifies the air valve which controls the portion of incoming air that operates the turbine alternator located in the gun handle. The valve can be turned
(refer to Fig
3
ON
or OFF by moving the valve lever and Typical installation Drawing) to the appropriate position stamped on the gun handle.
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307-638
SHOCK CAN OCCUR IFTHE PRECAUTIONS BELOW ARE NOT
FOLLOWED.
TAGS, AND WARNING LABELS BEFORE OPERATING EQUIP-
MENT.
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QUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.
GROUNDING
ALL components of the spray system, including spray gun, fluid supply pump, and compressor, MUST be electrically connected to
a true earth ground. ALWAYS check all local electrical codes. USE ONLY GRACO
ELECTRICALLY CONDUCTIVE AIR SUPPLY HOSE
The
OBJECT BEING COATED AND ALL OTHER
spray area must be grounded. Work piece hangers must be grounded and kept clean: contact points must sharp points or knife edges. be
When flushing the spray gun, the container used to catch the excess fluid must be electrically conductive and grounded.
The
FLOOR'of
the spray area must be electrically con- ductive and grounded.
All
PERSONS
sonal grounding straps must be worn. Rubber and plastic handle.
soles
entering spray area must be grounded.
soles,
such as leather, or per- are ,not conductive. Operator must not wear gloves that msulate the hand from the spray gun
FLAMMABLE LIQUIDS
in the spray area must be kept in approved, grounded containers. Do not exceed the minimum quantity needed for one shift.
Spra only in a
ro
erl ventilated s ray booth.
VENTILATING FANS ARE OPERATING.
KEEP SPRAY AREA CLEAN AT ALL TIMES.
hangers. Remove all
Use refuse from spray area immediate- ly. Do not cover floor with cardboard or any non- conductive material.
FLAMMABLE LIQUIDS
in the spray area must be kept in approved, grounded containers. Do not exceed the minimum quantity needed for one shift.
CLEANING THE SYSTEM
~~~~~~~~~~~
To avoid serious bodily injury, fire, explosion, or electric shock, ALWAYS follow this pressure relief procedure before cleaning or servicing the spray system:
Turn "ES ON-OFF" valve lever to OFF. Turn ply to gun. Turn off off air sup- fluid supply pump and relieve fluid pressure in lines and pump. (See pump instruction manual.)
NEVER
use solvents having a flash point of less than
2l0C (7OOF) to clean gun. a flash point of less than 38OC (100OF) to clean the spray system. ALWAYS
NEVER
use solvents having remove all solvent from system before reactivating the spray gun.
When flushing, always turn the "ES ON-OFF" valve lever to OFF and turn off air supply to gun. Use the
LOWEST FLUID PRESSURE POSSIBLE, and use a
GROUNDED, METAL WASTE CONTAINER.
Clean the outside surfaces of the gun by wiping with a soft cloth dampened with a compatible solvent.
IMMERSE GUN IN ANY LIQUID.
NEVER
IMPORTANT
,
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards-particularly the General Standards, Part 1910.107 and any other appropriate regulations-should be con- sulted in connection with the installation. operation and maintenance of electrostatic spray painting equipment.
307-638
3
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HOWTHE ELECTROSTATIC AIR SPRAY GUN WORKS
~~~~~~~~~~~
The air hose supplies air to the spray gun. A portion of the air operates the turbine and the balance of the air is used to atomize the fluid being sprayed. The turbine generates power, which is converted by the power car- tridge, to supply high voltage current to the gun's ioniz- ing electrode.
The pump supplies fluid through the hose and gun, where it is electrostatically charged as it passes the elec- trode. The charged fluid is attracted to the grounded work piece, wrapping around and evenly coating all sur- faces.
INSTALLATIO
Air Supply To Gun Must Be Interlocked
4
307-638
KEY
A
C
Main Air Supply Line
Ventilation Fan Interlock Solenoid Valve
Main Air Supply Shutoff Valve (bleed type)
Air Et Water Separator
Pump Air Supply Shutoff Valve (bleed type)
Air Line Oiler
Air Pressure Regulator
H Pump
J Pump Ground Wire
K
Fluid Filter
The Typical Installation shown above is a guide for selecting and installing electrostatic air spray systems. It is not an actual system design. The particular type and size system for your operation must be custom design- ed for your needs.
L Fluid Supply Line Shutoff Valve
M Fluid Pressure Regulator
N Fluid Supply Line
0 Air Filter (5
P Air Supply Line Shutoff Valve (bleed type)
Q
Spray Gun Ground Wire
Grounded Air Supply Hose
S
U
Electrostatic Spray Gun
ES
"ON-OFF'' Valve Lever
Air Line Drain Valve
WARNING
access to parts which may cause electric shock or injury. Do not install or service this equipment unless you are qualified.
Be
sure your installation complies with National, trical apparatus in a Class
Hazardous Location.
1, Divisions 1 and 2
I
Ventilate t h e Spray Booth
WARNING
and/or flammable vapors, spray only in a properly ventilated spray booth. NEVER OPERATE THE
SPRAY GUN UNLESS VENTILATION FANS ARE
OPERATING.
Be sure to check National and State codes regarding the air exhaust velocity requirements.
NOTE:
High velocity exhaust will decrease operating efficiency of the electrostatic system. Air exhaust velocity of 31-46 linear meterslmin (100-l50ftlminl should besuffi- cient.
Check all local safety fire codes and OSHA
Connect the Air Line
It is very.important that you use an air filter-and air separator to insure a clean dry air supply to the gun. Dirt and moisture can ruin the appearance of your finished work piece, and can cause malfunction of the gun.
WARNING
To avoid risk of serious bodily injury, explosion, fire, or electric shock, the AIR SUPPLY HOSE must be electrically connected to a true earth ground. USE ONLY GRACO ELECTRICALLY
CONDUCTIVE AIR SUPPLY HOSE shown on page 20.
To prevent the use of any hose other than the air
nished with a special
left the gun's air inlet is fur- hand thread.
Connect air supply hose from the air supply to the spray gun's air inlet. Connect the air supply hose ground wire to a true earth ground. ing.
See Typical Installation Draw-
Install an air regulator pressure to the gun. in the air supply line to control air
Check t h e Electrical Grounding
The electrical grounding of the spray gun and air hose should be checked by a qualified electrician. The elec- trical grounding can be checked by following the pro- cedure below.
1. Turn the ES ON-OFF valve lever to OFF. valve lever.)
(See Fig 3 and Typical Installation Drawing for location of
2. Turn off air and fluid supply to gun.
3. Using a megohmmeter (VI, measure the resistance between the gun handle
(X)
and a true earth ground
(W) using an applied voltage of not less than 100 volts and not more than 1000 volts. Check your local codes.
See
Fig 1.
NOTE:
The resistance should be less than 2 megohms. If the resistance is greater than true earth ground. greater than
2 megohms, check ground connections for tightness, and also check to be sure the air supply hose ground wire is connected to a hose.
2
If the resistance is still megohms, replace air supply
Check to make sure that all components of the system
(i.e., pump, compressor, etc.) are properly grounded.
(Refer to separate instruction manual for each compo- nent of the system.)
Work piece hangers must be grounded and kept clean, contact points must be sharp points or knife edges.
Parts to be sprayed that are separated from ground true earth ground is absolutely essential.
lose
electrostatic wrap efficiency. Proper connection to a
I
Before installing the gun make sure spray area is prepared for electrostatic spraying. Electrostatic equip- ment in itself is safe because of the low current involv- ed. Metal objects in the spray area that are not well grounded accept and store electrical charge and can cause arcing, fire, or explosion.
To
soles r
All conductive objects within 6m (20ft) of the gun must be electrically grounded. The floor of the spray area must be electrically conductive and grounded.
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All warning signs supplied with the gun should be mounted in spray area where they can easily be seen by the operator.
I
Connect the Fluid Line
Before connecting fluid supply line, blow it out with air and flush with solvent. Be sure the solvent you use is compatible with the fluid being sprayed.
Connect the fluid supply line from the outlet of the pump to the inlet of the gun. Install a fluid regulator to
KEY
Megohrnrneter
W
X Gun
Ground
Handle
307-638
5
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To avoid serious bodily injury from explosion, fire, or electric shock, all persons entering the spray area must be grounded. Shoes with conductive soles, such as leather, or personal ground straps
2.
76 m m 13 in.)
SQUARE CUTOUT
soles
3. are not con- ductive. The operator must not wear gloves that insulate the hand from the spray gun handle. If gloves are worn, they must be altered as shown in
Figure
Fig
2
WARNING
andlor flammable vaDors. sDrav onlv in a oroDerlv ventilated spray booth. NEVER OPERATE 'THE
SPRAY GUN UNLESS VENTILATION FANS ARE
OPERATING.
Keep spray area clean at all times. Use only non- sparking tools to clean material residue from the booth and hangers. Remove all refuse from the booth immediately. Do not cover the floor with cardboard or any non-conductive material.
Keep all flammable liquids in approved, grounded containers. Only keep enough for one shift in the spray area.
1
Filter the material to remove coarse particles and sedi- ment before spraying.
Ad'ust t h e Spray Pattern
NdTE:
To turn on the electrostatic power supply, move the ES ON-OFF valve lever IY) to ON.
See
Figure 3.
SPRAY PATTERN ADJUSTMENTS
SHOULD BE MADE WITH THE ES ON-OFF
VALVE LEVER TURNED ON.
Set the air pressure at pressure at 0.25 bar (3
2.8 to
4
bar (40 psi) and the fluid psil. Follow the procedure below to establish the correct flow rate and degree of atomization.
Fluid Flow
Rate
1.
Choose the correct fluid tip for the application.
(See
the Air Cap Consumption and Fluid Tip Flow Rate
Chart.) Both flow rate and viscosity must be con- sidered. A
1.2
with the gun. mm (0.047 in) fluid tip is furnished
2. Adjust the fluid flow by using the fluid pressure regulator installed in the fluid line.
3. For fine adjustment, use the adjustment knob located at the rear of the gun. See Figure 3.
(Z) the knob clockwise to reduce the amount of fluid being sprayed, and counterclockwise to increase the amount of fluid being sprayed.
Air
Flow
Adjustment
1.
Choose the correct size air cap for the type of fluid being sprayed and the pattern desired.
2. Use an air pressure regulator to adjust the degree of atomization. Always use the lowest air pressure possible to assure the most efficiency. (See the
Spray Pattern Troubleshooting Chart.)
NOTE:
A minimum of 40 psi at the air inlet of the gun is required to assure proper turbine operation.
3. Use the fan control valve (AA) to vary the shape of the spray pattern. Turn the fan control valve knob counterclockwise for a wide pattern and clockwise for a solid round pattern.
See
Fig 3.
NOTE:
When increasing to a wide flat pattern, it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.
When all adjustments of atomizing air, fluid pressure, and fan pattern are made, operation can begin.
When spraying, ES indicator lights (BB) should be
"ON", indicating full electrostatic charge.
KEY
AA Fan
BB
Y ES Valve
Z
ES
Adjusting Knob indicator Lights
Fluid Adjusting Knob i
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6 307-638
Daily Care and Cleaning
Establish a preventive maintenance program to keep your gun in good working condition. To maintain effi- ciency and avoid repairs, follow these steps:
1.
The gun handle must be grounded through the electrically conductive air supply hose. Periodically check the resistance between the gun handle and a true earth ground with a megohmmeter, using an applied voltage of not less than more than than
2
1000
100
volts and not volts. The resistance should
be
less megohms. If the resistance is more than
2
and be sure the air supply hose ground wire is con- nected to
a
true earth ground. If the resistance is still greater than hose.
2
megohms, replace air supply
2.
All containers within 6m grounded.
I20
ft) of the gun must be
3.
No loose
or ungrounded objects can be allowed the spray booth.
- in
4.
To maintain proper grounding of work pieces, check all work piece hangers for build-up of paint.
Clean hangers if necessary.
5. Check air cap and fluid tip of gun for damage.
Replace if necessary.
6. Straighten gun electrode ICC) if bent.
7. Clean fluid filter.
8. Check to see if the
ES
indicator lights
(BE)
work by noting if they are on when spraying. See Fig 3.
9. Clean the outside surfaces of the gun by wiping with a soft cloth dampened with a compatible vent.
sol-
Clean the Air Cap and Fluid Tip
CAUTION
Damaging electrode ICCI.or holes. in the air cap and fluid tip can result in distortion pattern. of the spray
Never use metal instruments to clean the holes in the air cap or fluid tip.
Avoid anv cleanina method that could result
NEVER lMMERSE GUN IN SOLVENT.
in getting solvent inio the passages of the gun.
Point the front of the gun down while cleaning to prevent dirty solvent from running back into air passages of gun. Clogged air passages cause poor atomization and excessive current demands.
Clean all parts in non-conductive solvent compati-
ble
with cause a the material being sprayed, such as Xylol
Use
of conductive solvents can malfunction of the smav aun.
Equipment needed:
Soft bristle brush.Isupplied)
Fluid tip wrench.Isupplied)
Solvent compatible with fluid being sprayed,
1.
Turn ES ON-OFF valve lever to OFF.
2.
Turn off air and fluid supply to gun.
3. Trigger gun to relieve air and fluid pressure trapped in lines.
4.
Remove air cap assembly
(14).
4.
5.
Squeeze gun trigger and remove the fluid tip the fluid tip wrench supplied. Make sure the front of
4.
with
6.
Use
a soft bristle brush supplied and solvent to clean air cap, fluid tip, and front part of gun.
7. Squeeze gun trigger and screw fluid tip back into gun. Tighten tip securely with wrench supplied.
Torque fluid tip to
1.1-1.4 NmI10-12
in-lbl. See Fig
4.
8.
Carefully reinstall air cap assembly. Avoid bending electrode ICC). Tighten retaining nut it is snug, allowing air cap to turn with resistance. If too tight, the spray pattern will be distorted.
Fig
4
Flush the Spray Gun
1.
Turn
ES
ON-OFF valve lever to OFF.
2.
Turn off air and fluid supply to gun.
3. Trigger gun to relieve air and fluid pressure trapped in lines.
4.
Disconnect and plug fluid supply line.
5. Connect solvent supply to gun.
6. Run solvent through the gun.
7. Disconnect solvent supply.
8. Reconnect fluid supply line.
9. Trigger gun until it is clear of solvent.
307-638
7
WARNING
Installing and servicing this equipment requires access to parts which may cause serious bodily injury or electric shock. Do not install or service this equipment unless you are qualified.
Before servicing the tip turn off air and or gun, and before disassembling the gun,
ALWAYS
fluid supply to gun, trigger the spray gun, and relieve the turn the
ES
ON-OFF valve lever to
OFF,
NOTE:
Check all possible remedies in Troubleshooting Charts before disassembling gun.
SPRAY PAlTERN TROUBLESHOOTING CHART
SOLUTION PROBLEM:
IMPROPER SPRAV
PAlTERN
Fluttering or
Spitting spray
CAUSE
Insufficient material suppTy
Dry or worn fluid needle packing or loose packing nut permits air to get into fluid passage
Loose fluid tip or damaged fluid tip.taper seat
Fill tank.
Lubricate or replace packing, tighten packing nut.
Tighten or replace fluid tip.
Dirt between fluid tip, taper seat and body
Loose or cracked coupler at fluid inlet
Loose material tube in cup or tank
Clean.
Tighten or repair.
Tighten.
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Clean with soft implement or submerge in suitable solvent and wipe clean.
Material build up on air cap; partially clogged horn holes. Full air pressure from clean horn hole forces fan pattern toward clogged end
Damaged fluid tip or air cap holes
Material build up on the perimeter of fluid tip orifice, or partially clogged fluid tip orifice
Too high atomization air pressure
Material too thin
Not enough material pressure
Low atomization air pressure
Material too thick
Too much material
Replace damaged part.
Remove obstruction. Never use a wire or hard instruments.
Reduce air pressure or adjust air adjusting valve.
Regulate material viscosity.
Increase material pressure.
Raise air pressure.
Regulate material viscosity.
Reduce material flow. Reduce material pressure on pressure feed guns andlor ad- just material adjusting screw until proper pattern is obtained.
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Streaks Last coat of material applied too wet
Too much air pressure
Insufficient air pressure
Non-uniform spray pattern
Apply drier finish with multiple strokes.
Use least air pressure necessary.
Increase air pressure.
Clean or replace air cap.
NOTE:
Some improper patterns are caused by the improper balance between air and material.
I
8 307-638
t-
GUN OPERATION TROUB
PROBLEM
Leakage from fluid packing nut.
Air leakage from front of gun.
Fluid leakage from front of gun.
“Orange Peel” finish.
SHOOTING
CHART
CAUSE
Loose packing nut.
Worn packing.
Air valve not seating properly.
Air stem packing too tight.
Electrode worn or damaged.
Worn fluid seat.
Fluid packing too tight.
Loose fluid tip.
Fluid adjusting screw (281 not set correctly.
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Material poorly mixed or filtered.
Improper thinner being used.
Too much air pressure. Excessive spray fog.
IEquipment covered with paint.
Fluid thinned too much
Fluid low.
Damaged air cap.
Dirty or clogged fluid tip,
Damaged fluid tip.
Exhaust air flow insufficient or not directed properly.
Improper distance between gun and work piece.
Misalignment between air cap and fluid tip
Air Cap
Aligned
Fluid Tip
Misaligned
SOLUTION
Tighten.
Replace.
Clean, service.
Loosen packing.
Replace.
Replace fluid tip andlor electrode.
Lubricate and adjust.
Tighten.
Adjust.
Increase, use least air pressure need- ed for good results.
Remix or refilter material.
Use proper thinner.
Reduce, use least air pressure needed for good results.
Properly thin fluid.
Check, add if necessary.
Replace air cap
Clean fluid tip.
Check, replace fluid tip.
Check for proper CFM, check baffles and direction of air flow.
Adjust distance to 20-30 rnm
(8-12 in.1.
Remove and clean air cap and fluid tion under Clean the Air Cap and
Fluid Tip (page finger tight. Using the wrench sup- plied, tighten fluid tip 114 turn (tor- que to 1.1-1.4 N m retaining nut until snug only: dlowing air cap to turn with resistance.
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307-638
9
-ECTRICAL TROUBLESHOOTI G CHART
PROBLEM
~
CAUSE
Poor wrap-around. *ES ON-OFF valve in OFF position.
'Turbine alternator not operating
Ino audible whine).
Improper distance between gun and workpiece.
Pans poorly grounded.
Operator gets mild shock.
High booth exhaust velocity.
Too high.atomizing air pressure.
*Too low-material resistivity.
'Faulty gun resistance.
'Faulty resistor stud resistance.
'Faulty power supply resistance.
'Faulty needle electrode assembly
'Faulty turbine alternator.
Operator not properly grounded
Gun not properly grounded.
Operator gets mild shock when touching workpiece.
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Workpiece not properly grounded.
*ES
indicator lights not
"ON" gun is triggered.
SOLUTION
Turn valve to ON.
Check air supply to gun.'Turn ES
ON-OFF valve to on. Check for dirt or moisture in turbine.
Adjust spraying distance to mm (8"-12).
20.30
Clean workpiece hangers. Check for proper ground on conveyor or track.
Reduce, within code limits.
Reduce air pressure.
Check material resistivity with paint meter and probe (refer to instruc- tion manual 307-263).
Check gun resistance. See page 11.
Check resistor stud resistance. See page 11.
Check power supply resistance. See page 11.
Replace needle electrode assembly.
Be sure plug 13cI is in place on back of turbine alternator housing;
Remove and test turbine alternator;
See Service Section: Replace tur- bine alternator if necessary.
Be sure floor is properly grounded,
Wear shoes with non-insulating soles. If gloves are worn, be sure to modify as described in Operation section.
Be sure Graco air supply hose is be- ing used and is properly grounded.
Clean workpiece hangers. Check for proper ground on conveyor or track.
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The performance of the spray gun is directly affected by the condition of the electrical components contained side the gun. The electrical tests below can be in- used to determine the condition of the power supply (5) and the resistor stud (16) as well as the continuity of the elec- trical path between the components.
L between volts. the
See
WARNING testing to prevent serious bodily injury resulting from explosion or fire caused by sparking.
'Test Gun Resistance
Using a megohmmeter
(DD),
end of gun electrode range, .proceed to the next test.
1 to the air inlet on the gun handle (-), using an applied voltage of
Fig 5. The resistance should be 65-130 megohms. If the resistance is outside the specified
If
( +
1000 the resistance is cor- rect, refer back to the Electrical Troubleshooting Chart for other possible causes of poor performance. -
Test Power Supply Resistance
Remove the power cartridge 13) from gun handle
, described under Power Cartridge Replacement.
(2)
., ,
Remove the turbine alternator (3a) from the power sup- ply (5) as described under Turbine Alternator
Disassembly.
Using a megohmmeter
(DD),
between the center prong (EE) in the power supply
(-1
to the contact spring (+)(5C) on the other end of the power supply, using an applied voltage of 1000 volts.
See
Fig 6. The resistance should be 65-130 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 next test. is correct, proceed to the
Test Resistor Stud Resistance
Insert a
(GG) conductive rod IFF) into the gun barrel (remov- ed for power supply test) and against the metal contact molded into the front of the barrel. See
Using a megohmmeter (DD), measure the resistance between conductive rod (FF) and gun electrode 112). using an applied voltage of 50-100 volts. The resistance should be 20-30 megohms. If the resistance is correct, refer back to the Electrical Troubleshooting Chart for other possible causes of poor performance or contact the nearest authorized service agency.
If the resistance is outside the specified range, remove electrode 112) as described under Electrode Replace- ment in the Service section and measure the resistance between conductive rod and the resistor in the in- side diameter of resistor stud (16). The resistance electrode (12) is defective and must be replaced. If the resistance is still outside the specified range, resistor stud 116) is defective and must be replaced,
KEY
2
DD
Gun
Gun
Handle
Electrode
KEY
5
Megohmmeter
Prong
Fig 6
5c
KEY
12
18 Gun Barrel
DD
FF
GG
Gun Electrode
Metal Contact
Fig
7
12 f
DD
L 1 8
FF
Gun Disassembly icing this equipment requires rts which may cause serious bodily ic shock.
Do
in- not install or service the nless you are qualified.
ALWAYS turn the ES ON-OFF valve lever to OFF, turn off air and fluid supply to gun, trigger the
NOTE:
Check a l l possible remedies
Troubleshooting Charts before disassembl- ing gun.
CAUTION
ALWAYS remove gun from work site for service or repair. Service or repair area must be kept clean.
If the plastic parts of the gun must be held secure- ly, ALWAYS clamp them in padded vice jaws30 prevent damage to the parts.
ALWAYS lubricate rings and seals with petroleum jelly to prevent damage during installation.
Flush gun as described under Flush~the Spray Gun in the Operation Section.
Disconnect the fluid supply hose from the gun.
Disconnect the air supply line from the gun.
Electrode Replacement
Remove air cap assembly (1'4) and fluid tip (13) as described in Operation Section under Clean the Air Cap and Fluid Tip.
Unscrew plied. and remove electrode
(12)
with wrench sup-
See Fig 8. Hold nut of needle shaft assembly with a small wrench if needle shaft assembly (45) turns while trying to loosen electrode.
Install new electrode (12) with wrench supplied. overtighten.
Do
not
CAUTION
When installing electrode, extreme care should be taken to avoid damaging the plastic threads.
Reinstall fluid tip (13) and air cap assembly (14) as described in Operation Section under Clean the Air Cap and Fluid Tip.
Resistor Stud and Fluid Tip.
Replacement
Remove air cap assembly (14) and fluid tip (13) as described in Operation Section under Clean the Air Cap
Remove electrode (12) as described under Electrode
Replacement.
Using the wrench washer (751.
See
I!%)
Fig
9.
supplied, unscrew and remove resistor stud (16) with O-ring (17). spring (11) and
KEY
45 Fluid Needle Shaft
5% Wrench
Assembly
To install resistor stud:
Lubricate O-ring (17) with petroleum jelly and install on resistor stud (16).
Install washer (75) in gun barrel.
Install spring (111 in resistor stud (16).
Apply Loctite"
No.
271 to threads of resistor stud and using wrench supplied, reinstall resistor stud in front of gun barrel (18). Tighten until snug. Reinstall electrode
(12) as described under Electrode Replacement.
Reinstall fluid tip (13) and air cap assembly (14) as described in Operation Section under Clean the Air Cap and Fluid Tip.
." .
11
16
17
75
Spring
Resistor Stud
0-Ring
Washer
17
16 j.
.
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12
307-638
Barrel Removal
Unscrew nut (19) at
barrel'U81 fluid inlet. See Fig 10.
Pull fluid tube of fluid inlet.
Remove trigger (43) by removing screws spacers
(411
from gun.
(42)
and
Remove ES indicator lights head capscrews (301. t64) from heads of socket two
(59f) supplied, loosen and remove socket head capscrews (30) from gun.
Hold gun handle
(2)
with one hand and pull straight up
to remove gun barrel (18). See Fig 11.
CAUTION
5% Wrench
19
20
30
Nut
Fluid Tube
Screw
\ Y
59f
30
Fig 10
KEY
18
Gun Handle
Gun Barrel
NOTE:
Gasket (46) should be left in gun han-dle
(2)
if it is not to be replaced.
To reinstall barrel
118).
follow the procedure below:
NOTE:
Be sure gasket (461 is in place. Replace if damaged.
Place barrel over power cartridge dle
12).
(31
and onto gun han-
Install two socket head capscrews (30) and
Snap
ES
capscrews indicator lights
(30). in place over socket head
Insert fluid tube tighten nut (19).
Reinstall trigger (43) with screws
(42)
and spacers (41).
Fluid
Packing Removal
Remove air cap assembly (141 and fluid tip (13) as described in Operation Section under Clean the Air Cap and Fluid Tip.
Remove electrode
Replacement.
(12) as described under Electrode
Remove gun barrel (18) as described under Barrel
Removal.
Slightly loosen packing nut (6) using the wrench (59b)
CarefUlly remove fluid needle assembly part of gun barrel (18).
(45)
from rear
Remove packing nut (6) at the rear of barrel using the wrench supplied.
NOTE:
The nut is glued to needle shaft assembly
(45). and should not be removed. If nut is removed, it will have to be reassembled to needle shaft assembly with LoctiteO No.
271
to the proper dimension. See Fig 13.
Turn barrel (18) over and allow insulator 17) to drop out.
Place barrel on bench in a vertical position with tip of barrel up. Insert the rod, supplied, in the front of the
Fig 11
!i9b
Packing Nut
Packing Nut Wrench
Fig 12
KEY
45 Fluid Needle Assembly
I
Fig 13
L 1 3 2 . 7 mm 15.2in.l barrel and gently tap out four packing supports
18).
two needie packings (9) and
NOTE:
The needle packings49) are very fragile and must be handled with care.
CAUTION
Clean all parts in non-conductive solvent compati- ble with the material being sprayed, such as
Xylol" or mineral spirits. Use of conductive solvents can cause a malfunction of the spray
Check all parts for wear or damage and replace if necessary.
307-638
13
. .
...
.:..
. ,
, .
.: . .
KEY
3
Gun Handle
Power Cartridge
5 Power Supply
F1 Fluid Packing Replacement
Place packing nut (6) then insulator shaft (45). Refer to Parts Drawing. Then place one packing
(9)
(7)
between two supports onto fluid needle
(8)
(beveled faces fluid needle shaft (45). Repeat this procedure and install remaining packing shaft.
(9)
and supports
(8)
on fluid needle
If spring has been removed, reinstall over nut on fluid needle shaft.
See
Parts Drawing. Reinstall entire fluid needle shaft assembly into gun barrel 1181, from the back of the barrel. Thread packing nut (6) into barrel. Using the wrench supplied, tighten packing nut
16)
until it is just tight enough to prevent movement of the fluid needle shaft assembly by hand. Then unscrew packing nut (6) 118 turn.
Recheck movement of fluid needle shaft assembly (45).
Needle shaft should move with moderate resistance.
Reinstall barrel as described under Barrel Removal.
Install electrode (12) as described under EleEtrode
Replacement.
Install air cap assembly (14) and fluid tip (13) as describ- ed in Operation Section under Clean the Air Cap and
Fluid Tip.
Power Cartridge Replacement
Remove barrel (18) as described under Barrel Removal.
Remove gasket
Drawing.
(2). See
Parts
CAUTION
Power Cartridge is fragile. Care should be taken when handling to avoid damage.
Grasp power cartridge (31 by hand and with side to side motion, pull it a gentle free from gun handle
Then pull power cartridge straight out of handle.
(2).
CAUTION
DO
NOT use solvents to clean power cartridge cavity in electrical components contained tridge;
.- gun handle
. ..
(2).
Solvents will damage in power car-
~~
I
Inspect power cartridge cavity in handle necessary.
(2)
for dirt or moisture. Clean out cavity with clean, dry rag if
Lightly lubricate O-rings (3d,5a,5b) on new power cartridge with petroleum jelly.
I
I
All O-rings (3d,5a,5b) and conductive spring (5c)
C A U T l O N
Insert new power cartridge (3) in gun handle
(2).
NOTE:
See
(3) in gun handle (21.
1
Install gasket (46) gun handle 12).
Install barrel (18) on handle as described under Barrel
Removal.
Turbine Alternator Removal
Remove power cartridge (3) from gun handle described under Power Cartridge Replacement.
(2)
as
14
307-638
Fig 15
Carefully twist turbine alternator and pull it off of power supply
(HH).
See
(5)
counterclockwise until just disengaged from coupling. Then continue to slowly pull turbine alternator away from power supply, disconnecting
3-wire connector
Using an ohmmeter, test the coil in the turbine alter- nator (3a). Measure the resistance between the two outer terminals of 3-wire connector
(HH).
See
The resistance should be 3-5 ohms. If the reading varies from this value, replace coil.
Measure the resistance between each outer terminal of
3-wire connector (HH) ing. The resistance should be infinite (00). resistance varies from infinite, the coil is defective and must be replaced.
If the
Partially connect 3-wire connector side power supply (5). to
See
lock coupling.
IHH) onto prongs in-
Slide turbine alternator (3a) onto power supply, being sure to align coupling between power supply and the turbine alternator housing. Then twist turbine alternator clockwise
Install power cartridge (31 in gun handle under Power Cartridge Replacement.
as
described
Fan Air Valve Replacement
Place a wrench on the flats of valve housing remove from handle
(2).
See Fig 16.
(34) counterclockwise until disengaged from valve housing threads. Pull adjusting screw (34) out of valve housing (33).
Clean all parts and inspect for wear or damage. If seal
140) is to be replaced, unscrew CLOCKWISE and remove from adjusting screw. i j
I i i
.
.
.
.
..:.
. I.
. . i
.
. .
..,
.
.
. ~ .
Apply medium grade thread sealant to small threads on end of adjusting screw hand thread).
1 3 4 )
and install new seal 1 4 0 ) (left
When reassembling the fan air valve, lubricate O-ring
(32) and threads of adjusting screw jelly.
(34)
After retaining ring (31 is reinstalled on adjusting screw
(341. back the adjusting screw out of the valve housing
(33) until it bottoms out against the retaining ring (31).
Apply PTFE tape to threads of valve housing and install in handle
N.m 110-12 in-lbl.
(2).
(33)
Fluid Adjusting Screw Replacement
Remove retaining ring (23). Unscrew and remove old assembly from back of gun handle. Reverse this pro- cedure and install new assembly.
See
parts drawing.
Air
Valve
Replacement
Using a screwdriver, remove retainer (27). spring and air valve 125). See Fig 17.
- .
(26).
CAUTION
Clean all parts in non-conductive solvent compati- ble with the material being sprayed, such as
Use of conductive solvents can cause a malfunction of the spray
Unscrew and remove guide front of gun handle (2).
(24)
and packing (47) from
Install new packing (47) and guide (24) in front handle (2). of gun
Install new air valve (25) and spring handle (21.
(261
into back of gun
Apply PTFE retainer (27) in screwdriver. back of gun handle (2) tighten with
Tighten guide 124) into front of.gun handle 12). Squeeze trigger and tighten guide return when trigger is released. -Then loosen guide just enough so valve stem gered and released.
124) just until valve 125) will not returns freely when gun is trig-
ES
On-Off
Valve
Removal and Repair
Loosen and remove nut (35). Remove lever (37) and
Pushing on end of valve stem, force valve out of gun handle
(21.
Clean and inspect parts for wear or damage. Replace if necessary.
Lubricate O-rings (38) and valve (39) with Lubriplate"
No. 630AA (Graco Part No. 070-2721. Install regulator disc (4) in valve (39) such that beveled face of regulator disc
(4)
faces in toward valve (39).
Install valve 139) with regulator disc 14) and O-rings 138) into gun handle
12)
such
(2).
Install spring washer (36). lever (37), and nut (35) on valve stem. Tighten nut 135) and torque to 0.225 N m in-lb).
12
KEY
Retaining Ring
32 Packing
Vitlve Housina
34 Adjusting
Valve Seal
Sc&w
Fig 18
307-638
15
..
:..
.. .
. .
,
.
.,
,:
.
..
.
:
. .
;:.,
,
. .
,.
. ..
.
.
, . .
.. .
PARTS
DRAWING
16
307-638
!
,.:. ,.: .
'':
REF PART
NO. NO.
DESCRIPTION
3a
3b
3c
5a
5c
218-014 HANDLE, gun
179-400 .ADAPTER
218-111 POWER CARTRIDGE
217-591
180-070
218-041
V77-156
176-926
'105-662
179-755
.ALTERNATOR, turbine
..PACKING, O-ring, NEOPRENE
..PLUG
.POWER SUPPLY
Includes items
..SPRING. compression
NUT, packing
ELECTRODE
5a-5c
SUPPORT, packing
PACKING, needle, PTFE
SPRING, compression
TIP, fluid (see page 211
AIR CAP ASSEMBLY
143
14b
176-968 .NUT. retaining
179-404 STUD, resistor
PACKING, O-ring, VlTON
Includes $ern 18a
1Ba
179-933 TUBE, fluid
21 178-131 COLLAR
22 106-262 NUT, tube, flareless
24
105-661 RING, retaining air
27
215-890 VALVE, air
179-391 RETAINER, spring
-~
Includes items 14a-14c (see page 21)
176-930 .RING, retaining
31
'168-110 PACKING, O-ring, VITON
105-681 RING, retaining
32 "105-666 PACKING, O-ring. EPR
179-399 HOUSING, valve
O N
71
72
73
75
59a
59b
59d
59f
59g
63
65
68
41
42
43
44
45
47
52
REF PART
NO. NO.
34 179-398
102-310
102-268
37
38
179-401
178-655
177-128
176-945
176-966
218-016
59
"106-901
179-790
179-791
104-765
107-207
218-050
105.749
177-73
177-007
179-803
107-158
107-157
177-004
179-994
218-179
180-060
180-061
180-062
180-063
180.143
107-400
100- 172
180-208
DESCRIPTION
SCREW, adjusting
NUT, hex
WASHER, wave
LEVER, valve
PACKING, O-ring, VITON
SEAL, valve
SPACER
TRIGGER
SPRING, compression
NEEDLE, fluid
GASKET, housing
LABEL, warning
PTFE
TAG, warning (not shown)
FITTING, male
TOOL KIT
.
Includes items 59a-59g
.BRUSH, cleaning
.WRENCH, nut, packing
.WRENCH, needle
.ROD, packing removal
.WRENCH. barrel
.WRENCH; tip, fluid
LIGHT, indicator, ES
SIGN. warning, English h o t shown)
SIGN, warning, French h o t shown)
SIGN. warning, German (not shown)
SIGN, warning, Spanish (not shown
ADAPTER, fluid
RETAINER, adapter
thd
BALL. steel; 3/16'dia
WASHER
O N
%eluded in Repair Kit 218.051.
Order parrs by name and series letter you of the assembly for
All
WARNING
218-050 TOOL KIT
No. 59; includes 59a-599)
218-051 REPAIR KIT
(Must be purchased separately)
Consists of:
3d
4
5a
5b
29
32
38
47
REF NO. QTY
1
1
1
1
1
1
1
1
307-638
17
ACCESSORIES(Must be purchased separately)
GROUNDED AIR SUPPLY HOSE
6.35 (0.25 1/4 NPSM (FEE)
218-100 5 m
218-102 11 m
218-103 15 m
(15 ft)
( 5 0
ftl
Air Supply Hose Assembly
Air Supply Hose Assembly
Air Supply
Hose
Assembly
Air Supply Hose Assembly
52
With
See
60 osil
PAINT) 202-271
MAXIMUM WORKING PRESSURE
~~ mesh element.
306-566.
HIGH VOLUME AIR REGULATOR
0-9
306-972.
206-193
125 psil Regulated Pressure psi) Steel Pressure Gauge.
See
instruction manual
AIR FILTER & MOSTURE SEPARATOR
17.5 bar
~250
Reuseable
-
. micron filter with drain cock for cleaning and drying air in air spray system.
106-148
A
PAINT RESISTANCE METER
Used with instruction manual areas.)
722-860
307-263.
722-886 to measure resistance of paint. See
(Not for use in hazardous
Used with 722-886 resistance of paint.
(Not for use in
722-860
See
instruction manual hazardous areas.)
307-263.
CONDUCTIVE (SOLVENT BASE) HOSE
See
instruction manual 307-627
KIT 217-496
For converting gun to handle conductive (solvent base) fluids.
CONDUCTIVE (WATER BASE) HOSE KIT fluids.
See
instruction manual 307-603
217-499
For converting gun to handle conductive (water base)
FLUID HOSE ASSEMBLIES (Nylon)
6.35 mm (0.25 ID, 3/8 NPSM (FEE)
215-637 8
215638
215-639
215640 30 m (25 m (75
Fluid
Fluid
Fluid Hose Assembly f t )
Hose
Hose
Assembly
Assembly
Fluid Hose Assembly
215641 46 m (150 ft) Fluid
Hose
Assembly
35 mm 10.25 in.)
ID,
(Nylon) bar (500
318 NPSM (FBE)
216-076
216-077
216-078
216-079
15
30 m m m
ftl
f t ) f t ) m (100
Fluid Hose Assembly
Fluid
Fluid f t )
Hose
Assembly
Assembly
Fluid Hose Assembly
216-080
46
m (150 ft) Fluid Hose Assembly
218-118 ELECTROSTATIC SYSTEM
Include items:
218-026 Manual Electrostatic Air Spray Gun
218-103 Grounded Air Supply
Hose
(See Chart in Ac- cessories for specifications)
215638 Fluid Hose
(See
Chart in Accessories for specifications)
106-148 Air Filter
180-060 Warning Sign (English)
180-061 Warning Sign (French)
180-062 Warning Sign (German)
180-063 Warning Sign (Spanish)
218-123 ELECTROSTATIC SYSTEM
Includes items:
218-026 Manual Electrostatic Air Spray Gun
Grounded Air Suoolv Hose (See Chart in Ac- cessories for specifications)
215-637 Fluid Hose
(See
Chart in Accessories for specifications)
106-148 Air Filter
180-060 Warning Sign (English)
180-061 Warning Sign (French)
180-062 Warning Sign (German)
180-063 Warning Sign (Spanish)
218-124 ELECTROSTATIC SYSTEM
Includes items:
218-026 Manual Electrostatic Air Spray Gun
218-102 Grounded Air Supply Hose
(See
Chart in Ac- cessories for specifications)
215-638 Fluid Hose
(See
Chart in Accessories for specifications)
106-148 Air Filter
180-060 Warning Sign (English)
180-061 Warning Sign (French)
180-062 Warning Sign (German)
180-063 Warning Sign (Spanish)
. . . .
. .. .
.,
.
.
..
. .. .
.:
18
307-638
I
Low Production
Stains
Primers
Sealers
to
INo.
22 seconds
Medium Production
Primers
Lacquers
Enamels
to 30 seconds
High Production
Metallics
Lacquers
Enamels
to
seconds
Zahn cupl
-
Air Cap
Part
Numbel m3/min
ICFM at 30 bar psi)
17.01
~
~ ~
AIR CAP
_ _
AND-FLUID T IP ~~ COMBINATIONS ~~
I
I
279 to 330 mm
~
..
I
176-975
176-976
176-975
115975
1.0
10.0401
.o
I
~~
Flow Rate iozlmin)
532
355 to to
710
177 to to
532
1n to 532
-
0.34
176-976
176-977
I
1.5
I0.WI
.o
I
355 to to
710 to 401 to a2
175975
mm
I
176-975
I
mm in.)
I
I
176.976.
176-977
176-975
356 to
406 mm
I
176-976
in.)
176-977
I
I
I
I
1.0
I
177 to
355 to to
532
181
710
1.5
I
I
591 to 1182
177 to 532 to 181
I
1.2
(0.0471
89 to 207
I
177 to 355
Low Volume-High SoGd
Lacquers
Enamels
Epoxies
Urethanes
Over
28 seconds
Heavy and High Solid
Enamels
Epoxies
Urethanes
Over
seconds
.
.. I I
406 mm
176-978
176-977
176-978
IO!&
1.5
I
1035 to 1479
120 to to 401
1035 to to 5 0 1
NOTE: All tips and caps are interchangeable.
Air Caps
The following air caps can be ordered as accessories:
Air Cap Assemblies
Air cap assemblies include ring (part no. and air cap. a retaining nut (part no. 176-968),
217-453
Includes Air Cap:
.
, .
. .
,
.. .
.
.
:.
.,,
.
.
. .
..
307-638 19
TECHNICAL DATA
Weight :
Gun length :
0.87
310
0-7
K g (1.90
mm
112.25
Ibl in.)
Operating voltage range
Operating fluid
Paint resistivity range
Fluid inlet
Air inlet
: 0-75 Kv
:
0-7 bar (0-100 bar (0-100 psil
: 7 megohm cms to infinity
:
:
318 npsm(m1
1/4 npsm(m1 psil
L.H.
SERVICE INFORMATION
Listed below by the assembly changed are OLD, NEW and ADDED parts,
1 ASSEMBLY PART
CHANGED STATUS
218-026
Gun
DELETED
ADDED
ADDED
(11
REF PART
NO. NO. NAME
179-994 Restrictor
74 180-208 Restrictor
75 180-235 Washer
SERVICE INFORMATION NOTE: Numbers in paren- theses indicate the quantity deleted.
I
.. -
.
.
.
i' !
THE
GRACO WARRANTY
Graco Inc. warrants ail equipment manufactured by it and bearing its name to be free from defects in material and workmanship under normal use and service. This warranty extends to the original purchaser for a period of 12 months from the date of purchase and applies only when the equipment is installed and operated in accordance with written factory recommendations. This warranty does not cover damage or wear which, in the reasonable judgment of Graco. arises from misusa, abrasion, corrosion, negligence, accident, substitution of non-Graco pans, faulty installation or tampering.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Graco to verify the claimed defect. If the claimed defect is verified. Graco will repair or replace free of charge, any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in workmanship or material. repairs will be made at a reasonable charge and return transponation will be charged.
EXCLUDED AND DENIED.
10
BY GRACO WARRANTY. Accessories or components of the warranty. if any. of their manufacturer. Graco will provide purcheser with reasonable assistance in making such claims. equipment sold
F a c t o y BranChes:Atlanta, Dallas, Datroit.
Subddlay and Affiliate
Los Angeles. West Caldweli IN.J.1
C o m p a n l e d h n a d a ; England; Switzerland: Francs: Germany: Hong Kong: Japan
GRACO INC. P.
0.
Box 1441 MINNEAPOLIS, MN 55440.1444
PRINTED IN U S A . 307-638 3-81 Revised 10-83
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