Repair. Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun

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Repair. Graco 3A4798F, Pro Xp Waterborne Auto Air Spray Gun | Manualzz

Repair

Prepare the Gun for Service

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

Remove the Gun from the

Manifold

See F IGURE 18.

1. Holding the gun firmly in hand, loosen the two screws (21) from the back and bottom of the mani fold.

The screws (21) should stay on the manifold.

2. Remove the gun from the manifold and take it to the service area.

The 5 o-rings (18) should stay on the gun.

To reduce the risk of injury, follow the Pressure

Relief Procedure

before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.

• Check all possible remedies in

Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to plastic parts.

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

• Only use genuine Graco parts. Do not mix or use parts from other Pro Gun models.

1. Flush and clean the gun, page 23.

2. Relieve the pressure. Follow Pressure Relief Pro cedure, page 19.

3. Remove the gun from the manifold, page 31.

4. Remove the gun from the work site. Repair area must be clean.

18

18

21

Rear Manifold

21

Bottom Manifold

F IG . 18. Remove Gun from Manifold

Repair

3A4798F 31

Repair

Install the Gun on the Manifold

See F IGURE 18.

1. Make sure the five o-rings (17) are in place on the gun. Inspect the parts for damage and replace them as needed.

2. Secure the gun to the manifold by tightening the two screws (19).

Air Cap and Nozzle

Replacement

1. Follow the steps in

Prepare the Gun for Service , page 31.

2. Remove the retaining ring (24) and air cap (25). See

F IGURE 19.

3. Point the gun up while removing the fluid nozzle (4) assembly with the multi-tool (48).

24

24a

25

48

4

4a

4b

3

The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of fire and explosion or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never oper ate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine

Graco part.

NOTE: Use non-silicone grease, Part No. 111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the conductive contact ring (4a). Excessive grease can mix with paint and blemish the finish on the workpiece.

4. Make sure the electrode needle (3) is finger-tight.

5. Make sure the conductive contact ring (4a) and the small o-ring (4b) are in place on the nozzle (4).

Lightly lubricate the small o-ring (4b).

6. Install the fluid nozzle (4) with the multi-tool (48).

Tighten until the fluid nozzle seats in the gun barrel

(1/8 to 1/4 turn past hand tight).

7. Place the shroud onto the gun. Optionally, secure with a screw.

8. Carefully install the air cap (25). Be sure to insert the electrode (3) through the center hole of the air cap. Rotate the air cap to the desired position.

9. Make sure the u-cup (24a) is in place on the retain ing ring (24). The lips must face forward. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

10. Install the gun onto the manifold. See

Install the

Gun on the Manifold .

F IG . 19. Air Cap and Nozzle Replacement

32 3A4798F

Repair

Electrode Replacement

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap and nozzle. See page 32, steps

1–3.

3. Unscrew the electrode (3) with the multi-tool (48).

F IGURE 20.

4. Apply low-strength (purple) thread sealant or equiv alent to the replacement electrode and packing rod threads. Install the electrode finger-tight. Do not over tighten.

5. Install the fluid nozzle. See page 32, steps 5 and 6.

6. Install the air cap. See page 32, steps 7 and 8.

7. Install the gun onto the manifold. See Install the

Gun on the Manifold , page 32.

Charging Probe Pin

Replacement

1. Remove the charging probe from the gun.

2. With a flathead screwdriver, unscrew the pin from the charging probe.

3. Inspect the threads for damage. Replace the probe if it is damaged.

4. Clean the threads on the charging probe.

5. Apply low-strength thread sealant (purple Loctite® or equivalent) to the new pin threads. NOTE: Loc tite® is a registered trademark of the Loctite Cor poration.

6. Install the pin finger-tight.

7. Clean off any excess thread sealant.

48

WL

F IG . 20. Electrode Replacement

NOTICE

To avoid equipment damage, use only the 26A416

Electrode Needle. Alternate electrodes are not accept able for use and do not fit the packing rod threads.

F

IG

. 21. Charging Probe Pin Replacement

3A4798F 33

Repair

Fluid Packing Rod Removal

You may replace the packing rod as an assembly, as

described below, or as individual parts (see page 35).

The assembly is pre-adjusted at the factory.

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap. See page 32, step 2. Remove

the gun shroud (26).

3. Remove the jam nut (16), actuator arm (15), and

adjustment nut (16). See F IGURE 25.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4. Remove the fluid nozzle (4) and electrode (3).

5. Remove the packing rod (2), using the multi-tool

(48). See F IGURE 22.

6. Check all parts for wear or damage and replace if necessary.

Before installing the packing rod, clean the internal sur face of the barrel (1) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are pres ent, replace the barrel.

48

1

16

WLD

F IG . 22. Fluid Packing Rod Removal

34 3A4798F

Packing Rod Repair

You may replace the packing rod as individual parts, as

described below, or as an assembly (see page 33). The

assembly is pre-adjusted at the factory.

Before installing the fluid packing rod into the gun bar rel, make sure the internal surfaces of the barrel are clean. Remove any residue with a soft brush or cloth.

Check the inside of the barrel for marks from high volt age arcing. If marks are present, replace the barrel.

1. Follow the steps in

Fluid Packing Rod Removal

,

page 34.

2. Place the packing nut (2f) and seal (2b‡) on the fluid rod (2e). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away from the packing nut.

3. Fill the inner cavity of the spacer (2h‡) with dielec tric grease (43). Place the spacer on the fluid rod

(2e) in the direction shown. Generously apply dielectric grease to the outside of the spacer.

4. Place the fluid packing (2c‡) on the packing rod (2e) with its lips facing the front of the rod. Install the needle packing (2d‡) with the male end toward the fluid packing, then install the housing (2g).

5. Lightly tighten the packing nut (2f). The packing nut is properly tightened when there is 3 lb (13.3N) of drag force when sliding the packing housing (2g) assembly along the rod. Tighten or loosen the packing nut as needed.

6. Install the o-ring (2a‡) on the outside of housing

(2g). Lubricate the o-ring with non-silicone grease,

Part No. 111265. Do not over-lubricate.

7. Install the spring (5) against the nut (2j) as shown.

8. Install the packing rod assembly (2) into the gun barrel. Using the multi-tool (48), tighten the assem bly until just snug.

9. Install the electrode. See Electrode Replacement

,

page 33, step 4.

10. Install the nozzle and air cap. See

Air Cap and

Nozzle Replacement , page 32, steps 5–8.

5

2k 2j

Repair

2e

2f

2b‡

2h‡

2c‡

2d‡

2g

2a‡

F IG . 23. Packing Rod

3A4798F 35

Repair

Piston Repair

1. Follow the steps in

Prepare the Gun for Service , page 31.

2. Remove the air cap. See page 32, step 2. Remove

the gun shroud (26).

3. Remove the jam nut (16), actuator arm (15), and

adjustment nut (16). See F IGURE 25.

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.

4. Remove piston cap (13) from the rear of the gun.

5. Push on the piston rod (11) to push the piston out the back of the gun.

6. Inspect the o-rings (11d, 11e, 11f, 11g) for damage.

See Table 3 and F IGURE 24.

7. Lubricate the o-rings (11d, 11e, 11f, 11g) with non-silicone grease, Part No. 111265. Do not over-lubricate.

8. Align the two stems (11c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.

9. Install spring (12) and piston cap (13).

10. Install and adjust the actuator arm, page 37.

11e

11f

11c

11d

11g

11e

11f

Atomizing Air Side

F IG . 24. Piston O-Rings

11b

11d

Fan Air Side

11a

WLD

WLD

11g

Table 3. Piston O-Rings

Description

Shaft O-Ring

(11g)

Function

Seals cylinder air along the piston rod (34b). Replace if air leaks along rod.

Front O-Ring

(11e)

Back O-Ring

(11f)

Piston

O-Ring (11d)

Air shutoff seal. Replace if air leaks from air cap when gun is de-trig gered.

Separates cylinder air from fan and atomizing air.

Replace if air leaks from small vent hole at back of manifold when gun is triggered.

O-rings included in air seal repair kit 24W390

36 3A4798F

Adjust the Actuator Arm

The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm with the shroud removed.

See F IGURE 25.

1. Install the adjustment nut (16b), actuator arm (15), and jam nut (16a) onto the piston rod (11b).

2. Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (15) and the fluid packing rod nut (E). This allows the atomizing air to actuate before the fluid.

3. Tighten the adjustment nut (16b) against the actua tor arm (15). Check that the 0.125 in. (3 mm) gap has been maintained. In addition, there should be 3 mm of electrode needle travel when the gun is trig gered. Adjust the jam nut position to obtain these dimensions. Tighten the jam nut (16a).

4. Test gun resistance, page 25.

5. Install the gun shroud (26) and air cap (25). See

page 32.

6. Install the gun onto the manifold. See page 32.

0.125 in. (3 mm) gap

Barrel Removal

1. Follow the steps in Prepare the Gun for Service

,

page 31.

2. Remove the air cap. See page 32, step 2.

3. Remove the gun shroud (26).

4. Carefully loosen the fluid fitting nut (35). Pull the tube (39) out of the fitting (32). Make sure both fer rules (33, 34) and the nut stay with the tube. See

F IGURE 26.

5. Remove the adjustment nuts (16a) and actuator

arm (15). See F IGURE 25.

6. Loosen the two screws (19). See F IGURE 26.

NOTICE

To avoid damaging the power supply, pull the gun bar rel (1) straight away from the gun body (10). If neces sary, gently move the gun barrel from side to side to free it from the gun body.

7. Hold the gun body (10) with one hand and pull the

barrel (1) straight off the body. See F

IGURE

26.

1

Repair

WLD

16a 15 16b 11b E

F

IG

. 25. Actuator Arm Adjustment

10

32

19

F IG . 26. Barrel Removal

WLD

39

33, 34

35

3A4798F 37

Repair

38

Barrel Installation

1. Verify the gasket (9) and grounding spring (6) are in place and the gasket air holes are aligned properly.

Replace the gasket if damaged.

2. Make sure the spring (7a) is in place on the tip of

the power supply (7). See F IGURE 27. Liberally apply

dielectric grease to the tip of the power supply.

Place the barrel (1) over the power supply and onto the gun body (10).

3. Tighten the two barrel screws (19) oppositely and evenly (about 1/4 turn past snug or 20

2.3 Nm). Do not over-tighten.

 5 in-lbs or

NOTICE

To avoid damaging the gun barrel, do not over-tighten the screws (19).

4. Assemble the fluid tube (39) into the fluid fitting (32).

Ensure that the ferrules (33, 34) are in place and tighten the nut (35).

5. Install and adjust the actuator arm (15), jam nut

(16a), and adjustment nut (16b). See

Adjust the

Actuator Arm , page 37.

6. Follow the steps in Test Total Gun Resistance

,

page 25.

7. Install the gun shroud (26) and air cap, page 32.

8. Install the gun onto the manifold. See Install the

Gun on the Manifold , page 32.

19

10

7

9

7a

35

33, 34

16a

15

16b

6

1

Power Supply Removal and

Replacement

• Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag.

• Do not expose gasket (9) to solvents. Replace gasket if damaged.

1. Follow the steps in Prepare the Gun for Service , page 31.

2. Follow the steps in Barrel Removal , page 37.

NOTICE

Be careful when handling the power supply (7) to avoid damaging it.

3. Grasp the power supply (7) with your hand. With a gentle side to side motion, free the power sup ply/turbine assembly from the gun body (10), then carefully pull it straight out.

Smart models only: disconnect the flexible circuit

(30) from the socket at the top of the gun body.

4. Inspect the power supply and turbine for damage.

5. To separate the power supply (7) from the turbine

(8), disconnect the 3-wire ribbon connector (PC) from the power supply.

Smart models only: Disconnect the 6–pin flexible circuit (30) from the power supply. Slide the turbine up and off the power supply.

6. Follow the steps in Test Gun Resistance with

Probe Removed , page 26. Replace the power sup

-

ply if necessary. To repair the turbine, see Turbine

Removal and Replacement , page 39.

NOTICE

To prevent damage to the cable and possible inter ruption of the ground continuity, bend the turbine’s

3–wire ribbon cable (PC) upward and back, so the bend faces the power supply and the connector is at the top.

F IG . 27. Barrel Installation

39

37

7. Connect the 3-wire ribbon connector (PC) to the power supply.

Smart models only: Connect the 6–pin flexible cir cuit (30) to the power supply.

3A4798F

Repair

Tuck the ribbon forward, under the power supply.

Slide the turbine (8) down onto the power supply

(7).

8. Insert the power supply/turbine assembly in the gun body (10). Make sure the ground strips (EE) make contact with the gun body.

Smart models only: Align the connector of the

6–pin flexible circuit (30) with the socket (CS) at the

top of the gun body. See F

IGURE

28.

Push the connector securely into the socket as you slide the power supply/turbine assembly into the gun body.

CS 30

Turbine Removal and

Replacement

NOTE: Replace turbine bearings after 2000 hours of operation. Order Part No. 24N706 Bearing Kit. Parts included in the kit are marked with a symbol (

).

1. Follow the steps in Prepare the Gun for Service , page 31.

2. Remove the power supply/turbine assembly and disconnect the turbine. See

Power Supply

Removal and Replacement , page 38.

3. Measure resistance between the two outer termi nals of the 3-wire connector (PC); it should be

2.0–6.0 ohms. If outside this range, replace the tur bine coil (8a).

4. Using a flat blade screwdriver, pry the clip (8h

) off the housing (8d). Remove the cap (8f

), using a thin blade or screwdriver.

5. If necessary, rotate the fan (8e) so its blades clear the four bearing tabs (T) of the housing (8d).

8e

T

F IG . 28. Connect Flexible Circuit

9. Make sure the gasket (8), ground spring (6), and power supply spring (7a) are in place. Assemble the

barrel (1) to the body (10). See Barrel Installation , page 38.

10. Follow the steps in Test Total Gun Resistance

,

page 25.

10

CS

9 

8

PC

WLE

F IG . 30. Fan Orientation

P

EE

WLD

F IG . 29. Power Supply

3A4798F

7

30

7a

39

Repair

6. Push the fan and coil assembly (8a) out the front of the housing (8d).

8b2  M 8a 8g 8f

WLE

PC 8h 

8d 8b1

 S

F IG . 31. Turbine Cross-Section.

NOTICE

To prevent damage to the turbine do not scratch or damage the magnet (M) or shaft (S). Do not pinch or damage the 3–wire connector (PC) when disassem bling and reassembling the bearings.

7. Hold the coil assembly (8a) on a workbench with the fan end facing up. Using a wide blade screw driver, pry the fan (8e

) off the shaft (S).

8. Remove the top bearing (8b2

).

9. Remove the bottom bearing (8b1

).

10. Install the new bottom bearing (8b1

) on the long end of the shaft (S). The flatter side of the bearing must face away from the magnet (M). Install in the coil (8a) so the bearing blades are flush with the surface of the coil.

11. Press the new top bearing (8b2

) onto the short end of the shaft so the bearing blades are flush with the surface of the coil (8a). The flatter side of the bearing must face away from the coil.

12. Hold the coil assembly (8a) on a workbench with the fan end facing up. Press the fan (8e

) onto the long end of the shaft (S).The fan blades must be ori -

ented as shown in F

IGURE

30.

13. Carefully press the coil assembly (8a) into the front of the housing (8d

) while aligning the pin on the coil with the slot in the housing. The 3–wire connec tor (PC) must be positioned below the wider notch

(W) of the housing tabs.

14. Rotate the fan (8e

) so its blades clear the four bearing tabs (T) at the back of the housing. Ensure that the blades of the bottom bearing (8b1

) align with the tabs.

15. Seat the coil fully into the housing (8d

). Secure with the clip (8h

),ensuring that its tabs engage the slots in the housing.

16. Ensure that the o-ring (8g) is in place. Install the cap

(8f

).

17. Install the turbine on the power supply, and install both parts in the gun body. See

Power Supply

Removal and Replacement , page 38.

40

F IG . 32. Turbine

8f

8e

8g*

8d

W

8b1

Slot

S

8c

M

8a

8b2

Pin

WLE

PC

8h

3A4798F

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