Graco Inc. 218-745 Paint Sprayer User Manual
Contents
1. 16b 16c 17t ert PART NO 218 744 218 111 217 591 107 106 180 070 107 107 110 916 218 041 177 156 106 555 178 504 179 387 222 256 222 255 222 013 183 749 183 750 176 936 105 673 179 388 179 790 181 825 181 824 181 299 218 996 176 930 176 968 180 739 20 923 105 667 108 045 179 412 176 921 186 127 107 207 180 928 180 927 176 941 106 901 108 173 156 454 181 179 179 791 178 131 106 262 181 384 PARTS LIST DESCRIPTION BODY gun POWER CARTRIDGE Includes items 2a amp 5 ALTERNATOR turbine Includes items 2b amp 2c O RING buna N PLUG REGULATOR disc SCREW 1 4 20 POWER SUPPLY ES 75 KV Includes items 5a 5b amp 5c O RING Viton O RING fluorocarbon SPRING compression GASKET housing FLUID NEEDLE ASSY Includes items 9a 9g PACKING ASSY needle NEEDLE fluid Includes items 9c amp 9d NUT adjusting NUT locking NUT packing SPRING compression INSULATOR needle LABEL warning WASHER ELECTRODE color coded black NOZZLE fluid 1 2 mm 0 047 See manual 307 803 for other available fluid nozzles AIR CAP ASSEMBLY Includes items 16a 16b amp 16c RING retaining NUT retaining AIR CAP See manual 307 803 for other available air caps STUD resistor color coded black O RING Viton standard color coded green O RING polyethylene optional color coded white BARREL gun Includes i2. 5 to press the cushion into the barrel as it will not adhere properly 4 Insert the new power cartridge in the gun body 1 NOTE See Fig 18 for proper alignment of the power cartridge 2 in the gun body 1 5 Install the gasket 6 in the gun body 1 6 Install the barrel on the gun body as described under Barrel Removal KEY 1 Gun Body 2 Power Cartridge Fig 18 SERVICE Turbine Alternator Removal 1 Remove power cartridge from the gun body as described under Power Cartridge Replacement Carefully twist the turbine alternator 2a counter clockwise and pull it off the power supply 5 until just disengaged from the coupling Then continue to slowly pull the turbine alternator away from the power supply disconnecting the 3 wire connector HH See Fig 19 Using an ohmmeter test the coil in the turbine alter nator 2a Measure the resistance between the two outer terminals of the 3 wire connector HH The resistance should be 3 to 5 ohms If the reading var ies from this value replace the alternator Measure the resistance between each outer termi nal of the 3 wire connector HH and the turbine al ternator housing 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 5 See Fig 19 Us ing asmall screwdriver push the connector onto the prongs until seated Slide the
3. Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 307 712 7 85 Revised 9 90 32 307 712
4. 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 HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS The air hose supplies air to the spray gun Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed The turbine generates power which is converted by the power cartridge to supply high voltage current to the gun s ionizing electrode The pump supplies fluid to the hose and gun where the fluid is electrostatically charged as it passes the elec trode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all sur faces 307 712 5 TYPICAL INSTALLATION A B Power Supplv Must Be Interlocked With Sprav Booth Exhaust Fan o7 Main Air Line CHAN NON HAZARDOUS AREA Air Line Lubricator Air Regulator KEY A Air Supply Shut off Valve bleed type Pump B Air amp Water Separator Fluid Filter c Drain Valve D E F G Ball Valve H J K The Typical Installation shown above is only a guide for selecting and installing electrostatic air spray systems lt is not an actual system design The particular type and size system for your operation must be custom designed for your needs For assistance in designing a system contact your Graco representative WARNING Installing and servicing this equipment requires ac
5. LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LI ABILITIES BASED ON NEGLIGENCE OR STRICT LIABILITY EVERY FORM OF LIABILITY FOR DIRECT SPECIAL OR CON SEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED IN NO CASE SHALL GRACOS LIABILITY EX CEED THE AMOUNT OF THE PURCHASE PRICE ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO 2 YEARS OF THE DATE OF SALE EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with rea sonable assistance in making any claim for breach of these warranties IMPORTANT PHONE NUMBERS TO PLACE AN ORDER contact your Graco distribu tor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free FOR TECHNICAL ASSISTANCE service repair infor mation or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free
6. at the pump outlet WARNING The fluid drain valve H is required in your system to assist in relieving fluid pressure in the displace ment pump hose and gun triggering the gun to relieve pressure may not be sufficient Install a drain valve close to pump s fluid outlet The drain valve reduces the risk of property damage or seri ous bodily injury including splashing in the eyes or on skin and contamination from hazardous fluids 4 Connect the fluid line to the gun fluid inlet CAUTION Do not use metal fittings at the gun barrel For cir culation systems use plastic fittings 307 712 7 INSTALLATION Check the Electrical Grounding WARNING Proper electrical grounding of every part of your system is essential For your safety read the warn ing section FIRE OR EXPLOSION HAZARD on page 5 Ground the system as explained there Then check your system as explained below 1 Shut off all air lines to the gun 2 Shut off the fluid supply to the gun 3 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose a With the electrically conductive air hose BB connected and properly grounded use a megohmmeter AA shown in ACCESSORIES section to measure the resistance between the gun body Y and a true earth ground Z Use an applied voltage of 500 volts minimum to 1000 volts maximum See Fig 1 b If the resistance is greater than 2 megohms ch
7. breach of this warranty Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment proven defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tam pering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of 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 material or workmanship repairs will be made at a rea sonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND
8. cess to parts which may cause electric shock or other serious bodily injury if work is not performed properly Do not install or service this equipment unless you are trained and qualified Be sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class 1 Group D Divisions 1 and 2 Hazardous Location Warning Signs A warning sign in English and one in Spanish is supplied with the gun Mount warning signs in the spray area where they can easily be seen and read by all operators This sign is also available in French and German See the ACCESSORIES section to order 6 307 712 Pump Ground Wire Air Filter 40 micron Electric Box K FEE HAZARDOUS AREA Pe ee ede Fluid Regulator ES Automatic Gun Normally Closed 3 Way Air Solenoid Valve or 3 Way Manual Valve Q Exhaust Hose uzr Ventilate the Spray Booth WARNING To prevent hazardous concentrations of toxic and or flammable vapors spray only in a properly ven tilated spray booth Never operate the spray gun unless 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 Check and follow all of the National State and Lo cal codes regarding air exhaust velocity require ments Check and follow all local safety and fire codes and OSHA
9. 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 To reduce the risk of serious bodily injury including splashing fluid or solvent in the eyes or on the skin always follow the Pressure Relief Procedure Warning on page 9 before checking adjusting cleaning or repairing the gun or any part of the system Disconnect the fluid hose from the gun NOTE Check all possible remedies in the Troubleshooting Charts before disassembling the gun CAUSE SOLUTION PROBLEM IMPROPER SPRAY PATTERN Fluttering or spitting Streaks Insufficient fluid supply Loose fluid nozzle or damaged fluid nozzle taper seat Dirt between fluid nozzle taper seat and body Loose or cracked coupler at fluid inlet Loose fluid tube in cup or tank Fluid build up on air cap partially clogged horn holes Full air pressure from clean horn hole forces fan pattern toward clogged end Damaged fluid nozzle or air cap holes Fluid build up on the perimeter of fluid nozzle orifice or partially clogged fluid nozzle orifice Too high atomization air pressure Fluid too thin Not enough fluid pressure Low atomization air pressure Fluid too thick Too much fluid Last coat of fluid applied too wet Too much air pressure Insufficient air pressure Non uniform spray pattern Adjust fluid regulator or fill fluid tank Tighten o
10. standard 1910 107 b 5 i NOTE High velocity air exhaust will decrease the oper ating efficiency of the electrostatic system The minimum allowable air exhaust velocity is 19 lin ear meters minute 60 ft min INSTALLATION Mount the Gun Mount the gun on a stationary support or on a reciprocat ing 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 work piece Connect the Air Line Refer to the Typical Installation Drawing WARNING To reduce the risk of electric shock or other serious bodily injury the air supply hose must be electrically connected to a true earth ground Use Only Graco Electrically Conductive Air Supply Hose This hose and the gun have special threads which pre vent using any other type of hose with the gun See the ACCESSORIES section to order the hose 1 Install an air line filter K and an air and water sepa rator B on the main air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the ap pearance of your finished workpiece and can cause the gun to malfunction 2 Install an air line lubricator D close to the pump air inlet 3 Install a normally closed 3 way air solenoid P or manual valve on the turbine cylinder and remote fan air supply lines The remote fan line is optional 4 Install a bleed type air regulator E on the pump turbine atomizing cylinder a
11. turbine alternator 2a onto the power sup ply being sure to align the coupling between the power supply and the turbine alternator housing Then twist the turbine alternator clockwise to lock the coupling Install the power cartridge in the gun body as described under Power Cartridge Replacement KEY HH 3 wire Connector 2a 5 Alternator 2a Power Supply HH Fig 19 Fan Air Valve Replacement 1 Place a wrench on the flats of the valve housing 55 and remove it from the gun body 1 See Fig 20 2 Remove the retaining ring 46 3 Rotate the air adjusting screw 56 counterclock wise until it is disengaged from the valve housing threads Pull the adjusting screw out of the valve housing 55 4 Clean all the parts and inspect them for wear or damage If replacing the seal 47 unscrew it clock wise and remove it from the adjusting screw 5 Apply medium grade thread sealant to the small threads on the end of the adjusting screw 56 and install a new seal left hand thread 6 When reassembling the fan air valve lubricate the o ring 54 and the adjusting screw threads with petroleum jelly 7 After the retaining ring 46 is installed on the adjust ing screw 56 back the adjusting screw out of the valve housing 55 until it bottoms out against the re taining ring 8 Apply Teflon paste to the threads of the valve hous ing 55 and install it in the gun body 1 Torque the housing to 1
12. until the tolerance is correct 10 Install the entire fluid needle assembly 9 into the gun barrel from the back of the barrel 11 Firmly tighten the packing nut 9e down until it bot toms CAUTION When checking the fluid needle movement DO NOT move the needle out of the gun barrel more than 6 35 mm 1 4 in to avoid pulling the needle out of the packing area and damaging the pack ings 12 Install the barrel as described under Barrel Removal 13 Install the electrode as described under Electrode Replacement 14 Install the air cap assembly and fluid nozzle as described in To Clean or Change Air Cap and Fluid Nozzle 15 Trigger the gun to check the needle adjustment The air should come fully on before the fluid comes on Adjust the needle adjusting nut 9c until the proper lead and lag is achieved If the fluid comes on too soon remove the trigger and back the needle adjusting nut 9c out away from the barrel slightly If the fluid comes on too late tighten the needle adjusting nut 9c slightly turn towards barrel After adjustment is complete tighten the locking nut 9d against the adjusting nut 9c KEY 9 Fluid Needle Assembly 9c Needle Adjusting Nut 20 Gun Barrel 132 7 mm 5 2 in 9c Fig 15 KEY 9 Fluid Needle Assembly 9d 9a Needle Packing Assembly 9b Fluid Needle 9c Adjusting Nut 9d Locking Nut 9e Packing Nut 9f 9c 9f Spring 9g Insulator Fig 16 3
13. 07 712 21 SERVICE KEY 1 Gun Body 2a Alternator 2b O Ring 2c Plug 5 Power Supply 5a O Ring 5b O Ring 5c Spring 6 Gasket 20 Barrel 20 See NOTE after step 3 below NOTE The power cartridge 2 includes items 2a 2b 2a 2c and 5 Fig 17 Power Cartridge Replacement 1 Remove the barrel as described under Barrel Removal 2 Remove the gasket 6 from the gun body 1 See Fig 17 CAUTION The power cartridge is fragile Be careful when handling it to avoid damage 3 Grasp the power cartridge with your hand With a gentle side to side motion pull it free from the gun body 1 Then pull the power cartridge straight out of the body CAUTION DO NOT use solvents to clean the power car tridge cavity in the gun body 1 Solvent will dam age electrical components contained in the power cartridge Inspect the power cartridge cavity in the gun body for dirt or moisture Clean out the cavity with a clean dry rag if necessary Lightly lubricate the o rings 2b 5a 5b on the new power cartridge with petroleum jelly All the o rings and the compression spring 5c must be in place or the gun will malfunction 22 307 712 NOTE The cushion 20b is part of the gun barrel and should never need to be removed If it is removed push the cushion in adhesive side to ward the barrel with a rod until it is securely ad hered in the barrel DO NOT use the power sup ply
14. 1 1 4 Nem 10 12 in Ib KEV 1 Gun Bodv 46 Retaining Ring 47 Valve Seal 54 O Ring 55 Valve Housing 56 Adjusting Screw Apply Teflon paste Torque to 1 1 1 4 NSm 10 12 in Ib Fig 20 307 712 23 SERVICE Piston Removal and Repair 1 To disconnect the fluid hose 31 from the cover plate 41 screw the nut 34 off the adapter 35 See Fig 21 Note the position of the trigger adjusting nut 24 for reinstallation then screw it off the piston shaft Remove the screws 61 and lock washers 82 from the cover plate 41 Remove the cover plate 41 spring 38 and retainer cap 74 Unscrew and remove the air valve guide 26 and needle packing 27 from the gun body 1 Push on the end of the piston shaft and remove the piston assembly NOTE DO NOT remove the u cup packing 37 from the piston shaft except to replace it as removal will damage this packing Clean and inspect parts for wear or damage Re place parts as needed When reassembling the piston assembly lubricate the o rings 30 amp 79 and the u cup packing 42 on the piston with petroleum jelly Pack the spring 38 with petroleum jelly Apply Teflon tape to the air valve guide 26 KEY 1 Gun Body 34 Nut 24 Trigger Adjusting Nut 35 Adapter 26 Air Valve Guide 37 U Cup Packing 27 Needle Packing 38 Spring 30 Buna n O Ring 41 Cover Plate 31 Fluid Tube 24 Fig 21 24 307 712 8 Install the new packing 27 and
15. CESSORIES WARNING When servicing use only genuine Graco replace ment parts Use of other parts or any alteration or modification of this equipment could result in serious injury fire explosion or property damage NOTE The Ref Nos shown in the kits below correspond to the reference numbers used in the parts list on page 27 For the best results use all the parts in the kit even if the old parts still look good Spray Gun Repair Kit 218 967 Includes Ref No Part No 2b 107 106 3 107 107 5a 177 156 5b 106 555 6 179 387 18 105 667 27 106 901 30 156 454 37 181 039 54 105 666 87 103 648 28 307 712 Description O RING buna n REGULATOR disc O RING Viton O RING Viton GASKET housing O RING Viton PACKING needle PTFE O RING buna n PACKING u cup UHMWPE O RING ethylene propylene O RING Viton Qty N a a Nl A A AS a Pp Resistor Stud and Electrode Kit 220 391 Includes Ref No Part No 12 181 825 14 181 824 17 220 923 18 105 667 66c 177 007 66h 183 107 Description WASHER Qty 1 ELECTRODE color coded black 1 STUD resistor color coded black O RING Viton WRENCH needle TOOL resistor stud ek TECHNICAL DATA Weight apea cates Beant Hea gua 0 87 Kg 1 90 Ib Gun Length 0005 310 mm 12 25 in Maximum Working Pressure 7 bar 100 psi Air Pressure Operating Range 0 7 bar 0 100 psi Fluid Pr
16. ER try to stop or deflect leaks with your hand or body NEVER alter or modify any part of this equipment doing so could cause it to malfunction CHECK all spray equipment regularly and repair or replace worn or dam aged parts immediately System Pressure This gun has a maximum working air and fluid pressure of 7 bar 100 psi Never exceed the maximum working pressure of the gun or any other component or accessory used in the system HAZARDOUS FLUID HAZARD Improper handling of hazardous fluids or inhaling vapors can cause ex tremely serious bodily injury even death due to splashing in the eyes ingestion inhalation or bodily contamination Be sure you know what fluid you are pumping and its specific hazards Observe all precautions when handling known or potentially hazardous fluids including but not limited to the following 1 Store hazardous fluids in approved containers HOSE SAFETY TIGHTEN all fluid connections securely before each use NEVER use a damaged hose Before each use check the entire hose for cuts leaks abrasion bulging cover or damage or movement of the hose couplings If any of these conditions exist replace the hose immediately 4 307 712 Fluid Compatibility BE SURE all fluids and solvents used are chemically compatible with the Wetted Parts shown in the TECHNICAL DATA Always read the fluid and solvent manufacturer s literature before using the fluid or solvent in this gun Pres
17. EY 9e Packing Nut 66b 66b Wrench 0 Fig 14 SERVICE 5 Carefully remove the fluid needle assembly 9 from the rear part of the gun barrel 20 See Fig 15 Ifthe packing assembly 9a or insulator 9g are still in the barrel insert the packing removal rod 66d into the front of the barrel to gently push them out Refer to Fig 16 NOTE Ifthe insulator 9g is removed be sure to install it so the insulator end with holes is facing the packing assembly 9a 6 Wipe the internal surfaces of the barrel clean with a soft brush or cloth CAUTION Clean all parts in non conductive solvent compat ible with the fluid being used such as xylol or min eral spirits Use of conductive solvents can cause the gun to malfunction 7 Remove the packing assembly 9a from the needle 9b NOTE If the position of the adjusting nut 9c is changed install the adjusting nut to the ap proximate dimension shown in Fig 15 Final ad justment will be made in step 15 If the spring 9f was removed reinstall it over the nut 9d 8 Install the new packing assembly 9a CAUTION Carefully screw needle 9b into new packing assembly 9a to avoid damaging the seals 9 Test the drag on the fluid needle It should be ap proximately 2 5 to 3 lbs use a small spring scale to measure If the adjustment is out of tolerance tighten or loosen the adjusting screw on the pack ing assembly 9a slightly and retest Continue to adjust
18. INSTRUCTIONS PARTS LIST 307 712 GRACO Rev P This manual contains IMPORTANT Supersedes N WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Model PRO 5000 AUTOMATIC MID RANGE ELECTROSTATIC AIR SPRAY GUN 7 bar 100 psi MAXIMUM WORKING AIR PRESSURE Part Number 218 745 Series B With 1 2 mm 0 047 in spray nozzle and part no 218 996 air cap assembly U S Patent No 4 290 091 4 219 865 4 462 061 4 497 447 4 660 774 4 554 622 U K Patent No 2 140 327B 2 142 559B 2 147 158 2 191 423 Patented 1986 1987 Canada Brevete 1986 1987 French Patent No 84 07942 84 10234 Italian Patent No 1 111 380 Japanese Patent No 86 07416 MMA Fi meu PUG mv BE Approved SR GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1985 GRACO INC 2 307 712 TABLE OF CONTENTS TOMS keee aasa A A 3 Electrical Tests Test Gun Resistance seen 16 Safety Warnings ees reese 4 5 Test Power Supply Resistance 16 How The Electrostatic Air Spray Gun Works 5 Test Resistor Stud Resistance 17 Installation Service Typical INStaHAtO Rs sco xiced ot eecarerededin ane wena au 6 Gun Disassembly ht casted A g a ratata ta l patata 18 Warning SIGNS 1 Libi pswaboma ji Beediaezjaet baad 6 Electrode Replacement 2 ssarisazzovazibazrena 18 Ventilate the Spray Booth 0000 0000 6 Resistor Stud Replacement 19 Moun
19. M5 x 0 8 x 12 RESTRICTOR color coded white O RING ethylene propylene HOUSING valve SCREW adjusting SCREW trigger SCREW mach pnh 6 32 SIGN warning English not shown SIGN warning Spanish not shown See ACCESSORIES to order French or German KIT tool Includes items 66a 66h BRUSH cleaning WRENCH packing nut WRENCH needle ROD packing removal WRENCH resistor stud WRENCH barrel WRENCH fluid nozzle TOOL resistor stud CAP retainer spring PLUG 3 8 18 npsm ELBOW male 905 MUFFLER TUBE polvethvlene O RING Viton HOUSING pin PIN locking LOCKWASHER internal O RING buna N O RING Viton ADAPTER 1 4 18 npsm LH O RING Viton VALVE air WASHER plain SCREW cap hex hd M6 x 10 long SPACER Included in Repair Kit 218 967 Extra warning tags and labels are supplied at no charge 178m AKpo2 p No ee ee ee Cee ee T Haaa paia Aa SC OC CCC T Included in Repair Kit 220 391 Read and follow the Old New Style Resistor Stud and Electrode Warning at left See HOW TO ORDER REPLACEMENT PARTS on page 29 When servicing use only genuine Graco replace ment parts Use of other parts or any alteration or modification of this equipment could cause it to malfunction which could result in serious injury fire explosion or property damage WARNING 307 712 27 KITS Repair Kits must be purchased separately Use only GENUINE GRACO PARTS AND AC
20. RE the electrode and stud you install are black The old style electrode and stud in the Series A Guns were white DO NOT mix old style parts with new style parts 1 Remove the air cap assembly and fluid nozzle as described in To Clean or Change Air Cap and Fluid Nozzle 2 Remove the electrode as described in Electrode Replacement 3 Using the wrench 59h supplied unscrew and remove the resistor stud 17 with the o ring 18 and washer 12 See Fig 11 To install the resistor stud 1 Lubricate the o ring 18 with petroleum jelly and install it on the resistor stud 17 2 Install the washer 12 in the gun barrel 3 Using the wrench supplied install the resistor stud in the front of the gun barrel Tighten until snug 4 Install the electrode as described in Electrode Re placement 5 Install the fluid nozzle and air cap assembly as described in To Clean or Change Air Cap and Fluid Nozzle KEY 12 Washer 17 Resistor Stud 18 O Ring 18 17 Fig 11 307 712 19 SERVICE Barrel Removal 1 Unscrew the nut 34 at the gun s fluid inlet adapter 35 See the PARTS DRAWING 2 Pull the fluid tube 31 out of the fluid adapter 35 3 Remove the trigger by removing the screws and spacers from the gun 4 Remove the ES indicator lights from the socket head cap screws 52 5 Using the wrench 66f supplied loosen and remove the two socket head cap screws 52 from the gun S
21. agency If the resistance is outside the specified range remove the electrode 14 See Electrode Replacement Meas ure the resistance between the conductive rod FF and the resistor in the inside diameter of resistor stud 17 The resistance should be 20 to 30 megohms If the resis tance is correct the electrode wire is defective and must be replaced See Electrode Replacement If the resis tance is outside the specified range the resistor is defec tive and the resistor stud 17 must be replaced See Re sistor Stud Replacement If you still have problems refer to the Electrical Troubleshooting Chart for other possible causes of poor performance or contact the nearest authorized service agency KEY A Megohmmeter FF Conductive Rod GG Metal Contact 14 Electrode 20 Gun Barrel Fig 9 307 712 17 SERVICE Gun Disassembly 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 per formed properly Do not install or service this equipment unless you are trained and qualified Follow the Pressure Relief Procedure Warning page 9 before servicing the gun or any part of the system Disconnect the fluid hose from the gun NOTE Check all possible remedies in the Troubleshooting Charts before disassembling the gun CAUTION If the plastic parts of the gun must be held se curely ALWAYS cl
22. amp them in padded vice jaws to prevent damage to the parts ALWAYS lubricate o rings and seals with petro leum jelly ALWAYS remove gun from worksite for service or repair Service or repair area must be clean Flush the gun as described under Flush the Spray Gun Follow the Pressure Relief Procedure Warning on page 9 Disconnect the air and fluid line from the gun Gun Assembly Note Whenever you are tightening plastic parts where there is no torque specified in the instructions tighten the parts finger tight and then retighten with a wrench 1 4 to 1 2 turn Electrode Replacement 1 Remove the air cap assembly and fluid nozzle as de scribed in To Clean or Change Air Cap and Fluid Nozzle 18 307 712 2 Unscrew and remove the electrode 14 with the wrench 66c supplied See Fig 10 If the needle shaft assembly 9 turns while trying to loosen the elec trode hold the needle shaft assembly nut with a small wrench 3 Install the new electrode 14 with the wrench 66c Do not over tighten CAUTION To avoid damaging the plastic threads be very careful when installing the electrode 4 Reinstall fluid nozzle and air cap assembly as described in To Clean or Change Air Cap and Fluid Nozzle KEY 9 Fluid Needle Shaft Assembly 66c Wrench Fig 10 SERVICE Resistor Stud Replacement WARNING Old New Style Resistor Stud and Electrode To reduce the risk of sparking which could cause fire or explosion BE SU
23. ck the following list daily before starting to operate the system to help ensure you of safe efficient operation 1 Be sure all operators are properly trained to safely operate an automatic air spray system 2 Be sure all operators are trained how to prop erly and completely relieve system pressure 3 Be sure the system is thoroughly grounded See FIRE OR EXPLOSION HAZARD page 5 and Check the Electrical Grounding page 8 4 Be sure the operator and all persons entering the spray area are properly grounded by wear ing shoes with conductive soles or personal grounding straps 5 Be sure ventilation fans are operating prop 7 erly 6 Be sure the work piece hangers are clean and grounded Contact points must be sharp points or knife edges 7 Be sure all refuse is removed from the spray booth 8 Be sure all flammable liquids in the spray booth are in approved grounded containers 9 Be sure all conductive objects within 6 m 20 ft of the gun are electrically grounded and the floor of the spray area is electrically con ductive and grounded Filter the Fluid Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle WARNING Turn off the fluid supply to the gun Trigger the gun into a grounded metal waste con tainer to relieve fluid pressure Engage the gun safety latch Open the pump drain valve having a waste con tainer ready to catch the drainage L
24. e can distort the spray pattern DETAIL DETAIL Equipment needed Soft bristle brush supplied Fluid nozzle wrench supplied Solvent compatible with fluid being sprayed Unlocked ee Position Procedure Position 1 Follow the Pressure Relief Procedure Warning on 81 81 page 9 2 Remove the air cap assembly BB See Fig 6 3 Turn the locking pin 81 to the unlocked position Fig 5 4 Squeeze the gun trigger and remove the fluid nozzle KEY 15 with the fluid nozzle wrench 66g supplied cc Electrode Make sure the front of the gun is pointed down See 15 Fluid Nozzle Fig 6 16 Air Cap Assembly 66g Wrench 5 Use the soft bristle brush 66a supplied and solvent to clean the air cap fluid nozzle and front part of the gun CC 6 Squeeze the gun trigger and screw the fluid nozzle back into the gun Tighten the nozzle securely with the wrench 66g supplied Torque the fluid nozzle to 1 1 1 4 Nem 10 12 in lb See Fig 6 Turn the lock ing pin to the locked position 15 7 Carefully reinstall the air cap assembly Avoid bend Torque to ing the electrode CC doaa tnab 8 Tighten the retaining nut so it is snug If the nut is tight enough you will feel resistance when turning the air cap If too tight the spray pattern will be distorted 66g Fig 6 12 307 712 SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock
25. e from the power supply The gun may be operated at lower turbine air pressure but may lose some electro static effect Do not operate the turbine at an air pressure greater than 3 1 bar 45 psi as there is no benefit and turbine life will be reduced NOTE A remote fan air adapter is available to control the fan air at the control booth See ACCESSORIES See the Spray Pattern Troubleshooting Chart on page 13 to correct spray pattern problems Trigger Adjusting Nut ES Indicator Light Fan Adjusting Knob 56 Fig 4 MAINTENANCE Daily Care and Cleaning CAUTION Clean all parts with a non conductive solvent compatible with the fluid being sprayed Conduc tive solvents can cause the gun to malfunction Do not use any cleaning method which may al low solvent into the gun air passages Solvent left in the gun passages could result in a poor qual ity paint finish and may draw current and reduce the electrostatic effect Point the gun down while cleaning to prevent dirty solvent from running back into the air passages NEVER IMMERSE THE GUN IN SOLVENT WARNING For your safety always follow the Pressure Relief Procedure Warning on page 9 when shutting off the system when you stop spraying and before checking servicing installing cleaning or chang ing any part in the system Clean the fluid and air line filters daily Check all of the work hangers for build up of material clean them if necessary All lo
26. e steps below to establish the correct fluid flow and air flow DO NOT turn the turbine air on yet 1 Adjust the fluid flow for the appropriate flow rate by using the fluid pressure regulator installed in the fluid line Check the fluid nozzle chart in manual 307 803 for the appropriate flow rate for the air cap Start with the lowest rate shown and increase it until you get the desired flow rate 2 For fine adjustment of how much fluid is sprayed tighten or loosen the trigger adjusting nut 24 See Fig 4 Turn the nut out to reduce the amount of fluid sprayed or turn it in to increase the amount 3 Close the fan adjusting knob 56 by turning it fully clockwise 4 Use an air pressure regulator to adjust the degree of atomization Always use the lowest air pressure pos sible for the most efficiency 5 Use the fan adjusting knob to change the shape of the spray pattern Turn the knob counterclockwise for a wide pattern and clockwise for a solid round pattern 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 6 First complete all the checks under the Operating Checklist on page 9 Then turn the turbine air on When spraying the ES indicator light 51 should glow indicating the electrostatic charge 10 307 712 NOTE Provide a 3 1 bar 45 psi clean dry regulated air supply to the gun to ensure full voltag
27. eave the pump drain valve open until you are ready to spray again Spraying Operation This gun has a built in lead and lag operation The gun begins emitting air before the fluid is discharged When you release the trigger the fluid stops before the air flow stops This helps prevent fluid build up on the air cap Adjust the system s control device if it is automatic so the gun starts spraying just before meeting the work piece and stops as soon as the work piece has passed When spraying the ES indicator lights BB should glow indicating the electrostatic charge See Fig 4 Selecting a Fluid Nozzle and Air Cap WARNING To reduce the risk of serious bodily injury including splashing in the eyes or on the skin or electric shock always follow the Pressure Relief Proce dure above before installing or removing the fluid nozzle air cap assembly This gun is supplied with fluid nozzle 181 299 and air cap 180 739 See Instruction Manual 307 803 for air cap consumption and fluid nozzle flow rate information The fluid output and pattern shape depends on the fluid nozzle size fluid viscosity and fluid pressure If your application requires a different nozzle and air cap combi nation use manual 307 803 to select the appropriate fluid nozzle and air cap To install a different fluid nozzle and air cap see To Clean or Change Air Cap and Fluid Nozzle page 12 307 712 9 OPERATION Adjust the Spray Pattern Follow th
28. eck the tightness of the ground connections and be sure the air supply hose ground wire is connected to a true earth ground If the resis tance is still greater than 2 megohms replace the air supply hose Installing Optional Remote Fan Air Adapter NOTE See ACCESSORIES to order the Remote Fan Air Adapter 181 053 and 90 Elbow 108 234 1 Place a wrench on the flats of the valve housing 55 and remove the fan air valve assembly from the gun body 1 See Fig 20 page 23 8 307 712 KEY Y Z Turbine Air Inlet True Earth Ground AA Ohmmeter BB Grounded Air Hose AA Fig 1 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 Nem 10 12 in Ib Install the 90 elbow part no 108 234 in the adapter Install the remote fan air line solenoid valve air regu lator and shut off valve as instructed in Connect the Air Lines on page 7 OPERATION Pressure Relief Procedure To reduce the risk of serious bodily injury including splashing in the eyes or on the skin injury from moving parts or electric shock always follow this procedure when shutting off the system when checking or serv icing any part of the spray system when installing cleaning or changing fluid nozzles and whenever you stop spraying 1 Turn off all the air to the gun except the cylinder actuating air Operating Checklist Che
29. ee Fig 12 6 Hold the gun body with one hand and pull straight up to remove the gun barrel 20 See Fig 13 CAUTION To avoid damaging the power cartridge always pull the gun barrel straight away If necessary gently move the gun barrel from side to side to free it from the gun body NOTE The gasket 6 should be left in the gun body if the gasket is not to be replaced To install the barrel 20 follow the procedure below 1 Be sure the gasket 6 is in place Replace if dam aged Place the barrel over the power cartridge 2 and onto the gun body See Fig 13 2 Install the two socket head cap screws 52 and tighten with the wrench 66f See Fig 12 3 Snap the ES indicator lights in place over the socket head cap screws 52 4 Insert the fluid tube 31 into the gun s fluid inlet adapter 35 and tighten the nut 34 5 Install the trigger with the screws and spacers Test the gun resistance as instructed on page 16 Fluid Needle Packing Replacement 1 Remove the air cap assembly and fluid nozzle as described in To Clean or Change Air Cap and Fluid Nozzle 2 Remove the electrode as described under Elec trode Replacement 3 Remove the gun barrel as described under Barrel Removal 4 Unscrew the packing nut 9e using the wrench 66b supplied See Fig 14 20 307 712 KEY 31 Fluid Tube 52 Cap Screw 66f Wrench Fig 12 KEY 2 Power Cartridge 6 Gasket 20 Gun Barrel Fig 13 K
30. essure Operating Range 0 7 bar 0 100 psi Voltage Operating Range 0 75 KV Paint Resistivity Range 7 megohm cms to infinity Air Inlet FUNDING i b See 1 4 npsm m L H Atomizing amp Cylinder 1 4 npt m Fluid Inlet 0 0 c eee eee eee 3 8 npsm m Wetted Parts Stainless Steel Polyethylene Nylon Acetal Viton Delrin Viton and Delrin are registered trademarks of the DuPont Co HOW TO ORDER REPLACEMENT PARTS 1 To be sure you receive the correct replacement parts kits or accessories always give all of the information requested in the chart below 2 Check the parts list to identify the correct part number do not use the ref no when ordering 3 Order all parts from nearest Graco distributor 6 digit Part Number Qty Part Description SERVICE INFORMATION Listed below by assembly changed are OLD and NEW parts Assembly Ref Changed Status No Part No 4 100 664 Screw 4 110 916 Screw Name 218 745 OLD Spray Gun NEW 307 712 29 ACCESSORIES Accessories must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES 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 The access
31. 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 manual 2 Air compressors and hydraulic power supplies ground according to the manufacturer s recommendations 3 Electrostatic Spray Gun obtain grounding through connection to a properly grounded air supply hose Use oy the Graco Electrically Conductive Air Supply Hose see ACCESSORIES section to order Connect the air hose ground wire to a true earth ground 4 Object being sprayed keep the work piece hangers clean and grounded at all times Contact points must be sharp points or knife edges 5 All electrically conductive objects or devices in the spray area including paint containers and wash cans must be properly grounded 6 All persons entering the spray area shoes must have conductive soles such as leather or personal grounding straps must be worn Rubber or plastic soles are not conductive 7 The floor of the 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 8 Flammable liquids in the spray area must be kept in approved grounded containers Do not store more than the quantity needed for one shift 9 All solvent pails use only grounded metal pails which are conductive Do not place the pail on any non c
32. guide 26 in the gun body 1 screw the guide in loosely NOTE DO NOT fully tighten the guide 26 yet The guide must be loose to avoid damaging the packing 27 when pushing the piston shaft through the guide If replacing the u cup packing 37 slide it onto the piston 42 so the lips of the packing will face to wards the front of the gun when the piston is in stalled Then install the buna n o ring 30 and Viton o ring 79 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 74 into the cover plate 41 Install the cover plate 41 spring 38 and retainer cap 74 with the screws 61 and lock washers 82 Actuate the trigger and tighten the air valve guide 26 with a wrench Screw the trigger adjusting nut 24 onto the piston shaft to its previously noted position Connect the fluid hose 31 to the adapter 35 Piston Screws Retainer Cap Viton O Ring Lock Washers 42 74 38 Pack with lubricant 30 SERVICE Disc Regulator O Ring Replacement 1 Unscrew the turbine air line from the adapter 86 See Fig 22 2 Remove the cap screw 90 and washer 89 from the gun body 1 3 Pull the adapter 86 with the air valve 88 out of the gun body 4 Unscrew the adapter 86 from the air valve 88 and remove the disk regulator 3 5 Clean and inspect parts f
33. he risk of fire explosion or electric shock which may result from electrical discharge it is essential that e All parts of the electrostatic system are properly grounded All personnel in or close to the spray area are properly grounded All electrically conductive objects or devices in the spray area includ ing paint containers wash cans and tools are properly grounded When operating the electrostatic device any ungrounded objects in the spray area such as people containers tools etc can become electri cally charged Arcing may occur if these objects then come in contact or close to ground Arcing of sufficient energy levels can ignite the fluid be ing sprayed fumes from solvents dust particles and other flammable substances This can cause a fire or explosion and result in serious bod ily injury and property damage Static electricity can also be generated by the flow of fluid through the pump hose gun and nozzle but it is dissipated through proper ground ing as described in Grounding below If you experience any arcing or feel even a slight shock STOP SPRAY ING IMMEDIATELY Check for proper grounding of the entire system Be sure you have corrected the problem before starting to spray again Grounding The following are minimum requirements for grounding a basic electro static system Your system may include other equipment or objects which must also be grounded Always check your local electrical code
34. ing Improper distance between gun and workpiece Parts poorly grounded High booth exhaust velocity Atomizing air pressure too high Fluid pressure too high Fluid viscosity Fluid resistivity too low Faulty gun resistance Faulty resistor stud resistance Faulty power supply resistance Faulty electrode Faulty turbine alternator Operator not properly grounded or is in contact with ungrounded object Gun not properly grounded Work piece not properly grounded ES indicator light not on when gun is triggered ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Check air supply to turbine Check for dirt or moisture in turbine See page 23 Adjust spraying distance to 203 305 mm 8 12 in Clean hangers check for proper ground on conveyer or track Reduce within code limits Reduce air pressure Reduce fluid pressure Check supplier for proper fluid for electrostatic spray Check fluid resistivity with paint meter and probe Check gun resistance See page 16 Check resistor stud resistance See page 17 Check power supply resistance See page16 Replace electrode See page 18 Be sure plug is in place on back of turbine alternator housing Remove and test turbine alternator See page 23 Be sure floor is properly grounded Wear shoes with conductive soles or wear personal grounding straps Be sure operator is not in contact with or carrying any metallic items which c
35. ing Chart 15 TERMS WARNING Alerts user to avoid or correct conditions that could cause bodily harm CAUTION Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment NOTE Identifies essential procedures or helpful information PRESSURE RELIEF PROCEDURE A safety procedure for re lieving air and fluid pressure in the system FOR YOUR SAFETY Alerts user to read the additional safety warnings on the page indicated 307 712 3 SAFETY WARNINGS SERIOUS BODILY INJURY EXPLOSION FIRE OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED READ AND UNDERSTAND ALL INSTRUCTION MANUALS TAGS AND WARNING LABELS BEFORE OPERATING EQUIPMENT ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories such as overpres surizing modifying parts using incompatible chemicals and fluids or us ing worn or damaged parts can cause them to rupture and result in seri ous bodily injury fire explosion or property damage NEVER point the spray gun at anyone or at any part of the body NEVER put hand or fingers over the fluid nozzle ALWAYS follow the Pressure Relief Procedure at right before cleaning or removing the fluid nozzle or servicing any system equipment NEV
36. nd remote fan option al 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 the pump line and each gun air supply line to shut off air to the pump and gun WARNING The bleed type air shutoff valve A is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed Trapped air can cause the pump to cycle unexpectedly which could result in serious bodily injury including splashing in the eyes or on the skin and injury from moving parts 6 Connect the cylinder air line to the gun s cylinder air inlet marked CYL 7 Connect the atomizing air line to the gun s atomizing air inlet marked ATOM 8 Connect the turbine air supply line to the gun s air in let marked ES The gun air inlet fitting has a left hand thread Connect the air supply hose 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 8 Connect the Fluid Line Refer to the Typical Installation Drawing 1 Before connecting the fluid line blow it out with air and flush it with solvent Use solvent which is com patible with the fluid to be sprayed 2 Install a fluid regulator L on the fluid line to control fluid pressure to the gun 3 Installa fluid filter G and drain valve H
37. onductive surface such as cardboard or paper which would interrupt grounding continuity 10 All air and fluid lines and electric cables must be properly grounded Flushing and Cleaning Safety To reduce the risk of static sparking or splashing always follow the Pres sure Relief Procedure on page 4 Be sure the turbine air electrostatics is OFF before flushing or cleaning any part of the spray system Use the lowest possible pressure to flush Trigger the gun into a grounded metal waste container To flush or purge equipment ALWAYS use solvents with a flash point equal to or greater than that of the fluid being sprayed To clean the exterior of the equipment ALWAYS use solvents with a flash point of higher than 38 C 100 F ALWAYS remove all solvent from the system before reactivating the spray gun Use only non sparking tools to clean residue from the booth and hangers Ventilate the Spray Booth To prevent hazardous concentrations of toxic and or flammable vapors spray only in a properly ventilated spray booth NEVER operate the spray gun unless the ventilating fans are operating Check and follow all National State and Local codes regarding air ex haust velocity requirements Check and follow all local safety and fire codes and OSHA standard 1910 107 b 5 i IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act These standards particularly the
38. or filtered Improper thinner being used Too much air pressure Fluid thinned too much Fluid low Damaged air cap Dirty or clogged fluid nozzle Damaged fluid nozzle Air Valve not actuating Damaged fluid needle Exhaust air flow insufficient or not directed properly Improper distance between gun and work piece Misalignment between air cap and fluid nozzle Air Cap Fluid Nozzle Misaligned Clean service See page 24 Loosen packing See page 24 Replace electrode See page 18 Replace fluid nozzle and or electrode See page 18 Adjust packing screw See page 20 Tighten fluid nozzle See page 12 Adjust screw Increase use least air pressure needed for good results Remix or refilter fluid Use proper thinner Reduce use least air pressure needed for good results Properly thin fluid Check add if necessary Replace air cap See page 12 Clean fluid nozzle See page 12 Check replace fluid nozzle See page 12 Check cylinder air fluid needle packing and needle Replace parts as necessary See page 21 Replace See page 20 Check for proper CFM check baffles and direction of air flow Adjust distance to 203 305 mm 8 12 in Remove and clean air cap and fluid nozzle as described on page 12 then reinstall them Poor wrap around Operator gets mild shock Operator gets mild shock when touching work piece Turbine alternator not operat
39. or wear or damage and replace if necessary 6 Clean and inspect the two o rings 87 and one o ring 85 on the air valve Replace if necessary Lu bricate the o rings with petroleum jelly 7 Install the disc regulator 3 into the air valve 88 so its beveled surface faces into the gun 8 Screw the adapter 86 into the air valve 88 and install the air valve into the gun body 1 9 Screw the cap screw 90 with the washer 89 into the gun body 1 10 Screw the turbine air line onto the adapter 67 Muffler Replacement 1 Remove the fan air valve assembly as instructed in Fan Air Valve Replacement 2 Remove the elbow 76 with the tube 78 from the gun body 1 See Fig 23 3 With a hook remove the muffler 77 from the gun body and replace with a new muffler 4 Install the elbow 76 in the gun body 5 Install the fan air valve assembly as instructed in Fan Air Valve Replacement KEY 1 Gun Body 87 O Ring 3 Regulator Disk 88 Air Valve 85 O Ring 89 Washer 86 Adapter 90 Cap Screw Fig 22 KEY 1 Gun Body 76 Muffler 77 Elbow 78 Tube 1 78 Fig 23 307 712 25 PARTS DRAWING G8 9 e2 swell SOPNJOLJ abpuyey JOMOd Z ONJOH OG Apoq unb jo SIBJINS UHM USNIJ S10J9111S91 UI M9198 26 UJ9J EQQ SW SOPNJJUJ GS Wy 1001 99 ON Jou 307 712 REF NO e 2a 2b 2c 3 5a 5b 5c 9a 9b 9c 9d 9e 9f 9g jat 121 14t 15 16 16a
40. ories in the box below are approved by Factory Mutual WARNING SIGNS Available from Graco at no extra charge Must be ordered separately 180 060 180 061 180 062 180 063 GROUNDED AIR SUPPLY HOSE 7 bar 100 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 1 4 nosm fbe 220 444 1 2 m 4 ft 218 100 5m 15 ft 218 101 8m 25 ft 218 102 11 m 36 ft 218 103 15m 50 ft 220 119 23 m 75 ft 220 120 30 5 m 100 ft Warning Sign English Warning Sign French Warning Sign German Warning Sign Spanish FLUID HOSE ASSEMBLIES Nylon 35 bar 500 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 3 8 npsm fbe 216 076 8m 25 ft 216 077 15 m 50 ft 216 078 23 m 75 ft 216 079 30 m 100 ft 216 080 46 m 150 ft FLUID HOSE ASSEMBLIES Nylon 14 bar 225 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 3 8 npsm fbe 215 637 215 638 215 639 215 640 215 641 8 m 25 ft 15 m 50 ft 75 ft 23 m 100 ft 30 5 m 150 ft 46 m ACCESSORIES The accessories below and on page 31 have not been tested by Factory Mutual AIR LINE ACCESSORIES GROUNDED AIR SUPPLV HOSE 7 bar 100 psi MAXIMUM WORKING PRESSURE 8 mm 0 315 in ID 1 4 npsm fbe Color coded grav More flexible than black hose 223 068 1 2 m 4 ft 223 069 5m 15 ft 223 070 8m 25 ft 223 071 11 m 36 ft 223 072 15m 50 ft 223 073 23m 75 ft 223 074 30 5 m 100 ft AIR HOSE ADAPTER 185 493 For connecting two o
41. ose or ungrounded objects must be removed from the spray booth Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent 5 Flush the spray gun before changing fluids or colors and whenever you are done operating the gun See Flush the Spray Gun Check the electrode wire Straighten if bent and re place if broken or damaged See Electrode Replacement Clean the air cap and spray nozzle daily minimum some applications require more frequent cleaning Replace the spray nozzle and air cap if they are dam aged See To Clean or Change Air Cap and Fluid Nozzle Flush the Spray Gun WARNING To reduce the risk of fire or explosion and serious bodily injury the turbine air electrostatics must be off before flushing Follow the Pressure Relief Procedure Warning on page 9 Disconnect and plug the fluid line Connect the solvent supply to the gun Flush the gun with solvent until it is clean Follow the Pressure Relief Procedure Warning then disconnect the solvent supply Reconnect the fluid supply line Actuate the gun until it is clear of solvent 307 712 11 MAINTENANCE To Clean or Change Air Cap and Fluid Nozzle KEY 15 Fluid Nozzle BB CAUTION l BB Air Cap Assembly Do not use metal tools to clean the air cap holes as 81 Locking Pin this may scratch them and make sure the elec trode wire is not damaged Scratches in the air cap holes or a damaged electrode wir
42. ould build up electrical charge See Check the Electrical Grounding page 8 Be sure Graco electrically con ductive air supply hose is being used and is properly grounded Clean work piece hangers Check for proper ground on conveyor or track 307 712 15 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 5 and the resistor stud 17 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 electri cal tests Connect the leads as shown WARNING To reduce the risk of sparking which could cause fire or explosion and result in serious bodily injury DO NOT use the megohmmeter in the hazardous area Remove the gun from the hazardous area before testing it Test Gun Resistance NOTE Check the resistance with the gun triggered and untriggered Measure the resistance between the end of the electrode 14 and the gun air inlet adapter 86 See Fig 7 The re sistance should be between 115 to 152 megohms If the resistance is outside the specified range go to the next test If the resistance is correct refer to the Electrical Troubleshooting Chart on page 15 for other possible causes of poor performance Test Power Supply Resis
43. r more air supply hoses together 1 4 npt m x 1 4 npsm m left hand thread 3 WAY AIR VALVE 722 502 30 307 712 HIGH VOLUME AIR REGULATOR 206 199 0 9 bar 0 125 psi Regulated Pressure 14 bar 200 psi Steel Pressure Gauge 1 2 npt f inlet and outlet AIR FILTER amp MOISTURE SEPARATOR 106 148 17 5 bar 250 psi MAXIMUM WORKING PRESSURE For cleaning and drying air in air spray system 20 micron element 5 oz bowl capacity 3 8 npt f inlet and outlet ACCESSORIES FILTER AIR OR PAINT 202 271 52 bar 750 psi MAXIMUM WORKING PRESSURE With 250 micron 60 mesh element 3 8 npt f inlet 3 8 npt m outlet SPRAY SYSTEM ACCESSORIES ELECTROSTATIC SYSTEM 231 035 Includes items 218 745 Automatic Electrostatic Air Spray Gun 218 101 Grounded Air Supply Hose See page 30 for description 216 076 Fluid Hose See page 30 for descrip tion 106 148 Air Filter See page 30 for description ELECTROSTATIC SYSTEM 231 036 Includes items 218 745 Automatic Electrostatic Air Spray Gun 218 103 Grounded Air Supply Hose See and page 30 for description 216 077 Fluid Hose See page 30 for description 106 148 Air Filter See page 30 for description ISOLATION STAND Required for isolating the fluid supply from the ground when spraying conductive water base fluid 728 650 Isolation Stand 15 gal 57 liter maximum 727 212 Isolation Stand 55 gal 209 liter maxi mum 905 576 Same as 727 212 but includes bleed
44. r replace fluid nozzle See page 12 Clean See page 12 Tighten or repair Tighten Clean with soft implement or submerge in suitable solvent and wipe clean See page 12 Replace damaged part See page 12 Remove obstruction Never use wire or hard instruments See page 12 Reduce air pressure or adjust air adjusting valve Regulate fluid viscosity Increase fluid pressure Increase air pressure Regulate fluid viscosity Reduce fluid flow Reduce fluid pressure on pressure feed guns and or adjust fluid adjusting screw until proper pattern is obtained Apply drier finish with multiple strokes Use least air pressure necessary Increase air pressure Clean or replace air cap See page 12 NOTE Some improper patterns are caused by the improper balance between air and fluid 307 712 13 GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid pack Worn needle packing Replace packing assembly ing nut See page 20 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 fluid Dirty air cap 14 307 712 Air valve not seating properly Air stem packing too tight Electrode worn or damaged Worn fluid seat Fluid packing too tight Loose fluid nozzle Cylinder air to gun not completely shut off Insufficient air pressure Fluid poorly mixed
45. resistor WATER BASE PACKING KIT 220 014 For converting packings to handle water base fluids NOTE The installation of this kit will void the CSA and FM approval on the PRO4000 Gun GUN MOUNTING ACCESSORIES UNIVERSAL GUN MOUNTING ROD 590 236 RECIPROCATING GUN MNTG BRACKET 725 973 Note All safety barriers and interlocks are to be supplied by the customer STATIONARY GUN MOUNTING STAND 722 562 STATIONARY GUN MOUNTING BRACKET 724 344 MISCELLANEOUS ACCESSORIES REMOTE FAN AIR ADAPTER 181 053 To control fan pattern from the control booth 1 8 27 npt f Must also order 108 234 90 Elbow 1 8 npt m REMOTE SWITCH amp SIGNAL LIGHT 728 386 CONTROL PANEL 218 394 For one or two gun operation Includes cabinet mounted air regulator air filter three way triggering valve and air atomizing gauge PAINT RESISTANCE METER 722 886 Used with 722 860 Paint Probe to measure resistance of paint Not for use in Hazardous areas PAINT PROBE 722 860 Used with 722 886 Paint Resistance Meter to measure resistance of paint Not for use in Hazardous areas MEGOHMMETER 218 979 500 Volt output 0 01 2000 megohms 307 712 31 THE GRACO WARRANTY AND DISCLAIMERS WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and work manship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for
46. sure Relief Procedure To reduce the risk of serious bodily injury including splashing in the eyes or on the skin injury from moving parts or electric shock always follow this procedure when shutting off the system when checking or servicing any part of the spray system when installing cleaning or changing fluid nozzles and whenever you stop spraying 1 Turn off all the air to the gun except the cylinder actuating air 2 Turn off the fluid supply to the gun 3 Actuate the gun into a grounded metal waste container to relieve fluid pressure 4 Open the pump drain valve having a waste container ready to catch the drainage 5 Leave the pump drain valve open until you are ready to spray again 2 Dispose of any waste fluid according to all Local State and Federal regulations pertaining to the disposal of hazardous wastes 3 Read and follow the fluid and solvent manufacturer s literature regarding the use of protective clothing and equipment such as eye protection respiratory protection and gloves 4 Provide for the safe piping and disposal of all exhaust air 5 Provide proper ventilation in accordance with accepted industry standards and governmental regulations Refer to Ventilate the Spray Booth on page 6 HANDLE AND ROUTE HOSES CAREFULLY Do not pull on hoses to move equipment Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose FIRE OR EXPLOSION HAZARD To reduce t
47. t the Gun 0 00 cece eee eee e eens 7 Barrel Removal LLL0 cece eee eee 20 Connect the Air Line 00 0 eee eee ee 7 Fluid Needle Packing Replacement 20 Connect the Fluid Line 0 002000 7 Power Cartridge Replacement 22 Check the Electrical Grounding 8 Turbine Alternator Removal 23 Installing Optional Remote Fan Air Adapter 8 Fan Air Valve Replacement 04 23 Piston Removal and Repair 24 Operation l Disc Regulator O Ring Replacement 25 Operating Checklist 0 0 c eee e eee eee 9 Muffler Replacement ceeceeeeveeees 25 Filter the Fluid 00 0 0 0 cece cece eee 9 l Spraying Operation si idi ke i a 9 Parts Drawing LL 000 r 26 Selecting a Fluid Nozzle and Air Cap 9 Parts List erinra ta eset tage ia oe aed ee 27 Adjust the Spray Pattern 00 00 0000 10 Kits orrena a E hw ashame 28 Maintenance Daily Care and Cleaning 00 2005 11 Technical Data 0 0 0 cece eee 29 Flush the Spray Gun Vi 11 To Clean or Change Air Cap and Fluid Nozzle 12 How To Order Replacement Parts 29 Spray Pattern Troubleshooting Chart 13 Accessories 0 ees 30 31 Gun Operation Troubleshooting Chart 14 Warranty 00 e a eee Back Cover Electrical Troubleshoot
48. tance Remove the power cartridge 2 from the gun body 1 See Power Cartridge Replacement Remove the turbine alternator 2a from the power sup ply 5 See Turbine Alternator Removal Measure the resistance from the center prong EE in the power supply to the contact spring 5c on the other end of the power supply See Fig 8 The resistance should be 95 to 122 megohms If the re sistance 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 If you still have problems refer to the Electrical Troubleshooting Chart for other possible causes of poor performance or contact the nearest authorized service agency 16 307 712 KEY A Megohmmeter 1 Gun Body 14 Electrode 86 Air Inlet Adapter Fig 7 KEY A Megohmmeter EE Connector Prong 2a Turbine Alternator 5 Power Supply 5c Contact Spring A ELECTRICAL TESTS Test Resistor Stud Resistance Insert a conductive rod FF into the gun barrel removed for the power supply test and against the metal contact GG in the front of the barrel See Fig 9 Measure the resistance between the conductive rod FF and the gun electrode 14 The resistance should be 20 to 30 megohms If the resistance is correct refer to the Electrical Troubleshooting Chart for other possible causes of poor performance or contact the nearest authorized service
49. tem 20a amp 20b PLUG M3 x 0 5 x 6 CUSHION FITTING male TRIGGER NUT adjusting trigger GUIDE valve air PACKING needle PTFE ELBOW male O RING buna N TUBE fluid TAG warning not shown COLLAR NUT tube flareless ADAPTER fluid WARNING Old New Style Resistor Stud and Electrode To reduce the risk of sparking which could cause fire or explosion BE SURE the electrode and stud you QTY pa cee ee eee A P eo oo ot oo AE S e Fe ae rene Caren CO Cons A A install are black The old style electrode and stud in the Series A Guns were white DO NOT mix old style parts with new style parts REF NO PART NO 36 107 208 37 181 039 38 108 221 41 180 924 42 218 989 46 105 681 47 181 383 50 180 235 51 218 179 52 107 100 53 179 994 54 105 666 55 181 382 56 181 381 60 107 400 61 100 205 62 180 060 65 180 063 66 220 388 66a 105 749 66b 177 732 66ct 177 007 66d 179 803 66e 107 158 66f 107 460 66g 177 004 66ht 183 107 74 181 178 75 181 599 76 181 594 77 181 223 78 054 134 79 108 298 80 181 302 81 181 303 82 108 340 84 104 282 85 105 796 86 181 598 87 103 648 88 181 597 89 102 782 90 105 408 91 177 128 DESCRIPTION NUT ferrule 5 8 20 UN 2B QTY 3 PACKING u cup UHMW polyethylene 1 SPRING compression PLATE cover PISTON shaft RING retaining external SEAL valve RESTRICTOR color coded black LIGHT indicator ES SCREW cap socket hd
Download Pdf Manuals
Related Search