Installation

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . . 7

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Check the Electrical Grounding . . . . . . . . . . . . . . . . . . 8

Operation

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Spraying Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the Fluid Nozzle and Air Cap . . . . . . . . . . . . . . 10

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . 11 Clean the Air Cap and Fluid Nozzle . . . . . . . . . . . . . . 11 Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Spray Pattern Troubleshooting Chart . . . . . . . . . . 13

Gun Operation Troubleshooting Chart . . . . . . . . . 14

Electrical Troubleshooting Chart . . . . . . . . . . . . . . 15

Electrical Tests

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 16 Test Resistor Stud Resistance . . . . . . . . . . . . . . . . . . 17

Service

Gun Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . . 18

Resistor Stud Replacement . . . . . . . . . . . . . . . . . . . . . 19

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fluid Needle Packing Replacement . . . . . . . . . . . . . . 20

Power Cartridge Replacement . . . . . . . . . . . . . . . . . . 22

Turbine Alternator Removal . . . . . . . . . . . . . . . . . . . . . 23

Fan Air Valve Replacement . . . . . . . . . . . . . . . . . . . . . 24

Air Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 24

ES On??Off Valve Removal and Repair . . . . . . . . . . . 25

Fluid Adjusting Screw Replacement . . . . . . . . . . . . . 25

Muffler and Check Valve Replacement . . . . . . . . . . . 25

Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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.

ES ON-OFF VALVE: An on/off switch located near the rear of the gun, above the gun handle, that turns the electrostatic pow- er on or off.

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.

NEVER 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.

Fluid Compatibility

BE SURE all fluids and solvents used are chemically compatible with the ??WettedParts?? shown in the TECHNICAL DATA. Always read the fluid and solvent manufacturer's literature before using the fluid or solvent in this gun.

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 servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.Turn the ES On??Off valve lever to OFF.

2.Turn off the air and fluid supply to the gun.

3.Trigger the gun into a grounded metal waste container to relieve fluid pressure.

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.

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.

HAZARDOUS FLUID HAZARD

Improper handling of hazardous fluids or inhaling vapors can cause extremely 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.

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 re- garding the use of protective clothing and equipment such as eye pro- tection, 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 7.

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.

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 the risk of fire, explosion, or electric shock, which may result from electrical discharge, it is essential that:

SAll parts of the electrostatic system are properly grounded.

SAll personnel in or close to the spray area are properly grounded.

SAll 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 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 only 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. The operator must not wear gloves which insulate the hand from spray gun. The gloves must be conductive or modified as shown on page 9.

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??conductive 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 ES valve lever 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).

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.

The Typical Installation shown above is only 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 designed for your needs. For assistance in designing a system, contact your Graco representative.

Warning Signs

Mount warning signs in the spray area where they can easily be seen and read by all operators. See the ACCESSORIES section to order.

WARNING

Installing and servicing this equipment requires ac- 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.

Ventilate the Spray Booth

WARNING

To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. Never operate the spray gun unless ventilation fans are operating.

Check and follow all of the National, State and Local codes regarding air exhaust velocity requirements.

Check and follow all local safety and fire codes and OSHA standard 1910??107(b)(5)(i).

NOTE: High velocity air exhaust will decrease the oper- ating efficiency of the electrostatic system. Air exhaust velocity of 100??150 ft/min (31??46 linear meters/minute) should be sufficient.

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 electri- cally connected to a true earth ground. Use Only

Graco Electrically Conductive Air Supply Hose. This hose, and the gun, have special threads which prevent using any other type of hose with the gun. See the ACCESSORIES sec- tion to order the hose.

1.Connect the air supply hose (R) between the air sup- ply line and the gun's air inlet (W). The gun air inlet fitting has a left hand thread. Connect the air supply hose ground wire (Q) to a true earth ground.

2.Install an air line filter (O) and an air and water sepa- rator (D) on the air line to ensure a dry, clean air sup- ply to the gun. Dirt and moisture can ruin the appear- ance of your finished workpiece and can cause the gun to malfunction.

3.Install a bleed??type air regulator (G) on the pump and gun air supply lines to control air pressure to the pump and gun.

4.Install a bleed??type air shutoff valve (C, E, P) on the main air line, the pump line, and each gun air supply line to shut off air to the pump and/or gun(s). Install an additional bleed??type valve on each pump air supply line to relieve air trapped between this valve and the pump after the air regulator is shut off.

WARNING

The bleed??type air shutoff valve 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 unex- pectedly, which could result in serious bodily in- jury, including splashing in the eyes or on the skin and injury from moving parts.

5.Install an air line lubricator (F) as close to the pump

(H) as possible.

Connect the Fluid Line (Refer to the Typical

Installation Drawing)

1.Before connecting the fluid line (N), 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 (M) on the fluid line to control fluid pressure to the gun.

3.Install a fluid filter (K) and drain valve (V) at the pump outlet.

WARNING

The fluid drain valve (V) 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 the pump's fluid oulet. The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on the skin and contamination from haz- ardous fluids.

4.Connect the fluid line to the 3/8??18.6(m) gun fluid in- let (X).

Check the Electrical Grounding (See Fig 1)

WARNING

Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE OR EXPLOSION HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below.

1.Turn the ES On??Off valve to OFF. See Fig 2 for the location of the valve lever.

2.Turn off the air and 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 (see Connect the Air Line, page 7) and properly grounded, use a megohmmeter

(AA)(shown in ACCESSORIES section) to measure the resistance between the gun handle

(Y)and a true earth ground (Z). Use an applied voltage of 500 minimum to 1000 volts maximum. See Fig 1.

b.If the resistance is greater than 2 megohms, check the tightness of the ground connections, and be sure the air supply hose ground wire is connected to a true earth ground. If the resis- tance is still greater than 2 megohms, replace the air supply hose.

KEY

YGun Handle

ZTrue Earth Ground

AAOhmmeter

BBGrounded Air Hose

Z

AA

BB

Y

Fig 1

KEY

YES Valve Lever

ZFluid Adjusting Knob

AAFan Adjusting Knob

BBES Indicator Lights

Y

BB

Z

AA

WARNING

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 servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying.

1.Turn the ES ON??OFF Valve lever to OFF.

2.Turn off the air and fluid supply to the gun.

3.Trigger 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.

Filter the Fluid

Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle.

3 in. (76 mm) Square Cutout

or

2 Fingers of Glove Cutoff

Fig 3

Operating Checklist

Check 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 electrostatic 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 on page 5, and Check the Electrical Grounding on 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.Operator must not wear gloves which insulate the hand from the spray gun. If worn, gloves must be conductive or modified as shown in Fig 3.

6.Be sure ventilation fans are operating properly.

7.Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges.

8.Be sure all refuse is removed from the spray booth.

9.Be sure all flammable liquids in spray booth are in approved, grounded containers.

10.Be sure all conductive objects within 20 ft (6 m) of the gun are electrically grounded and the floor of the spray area is electrically con- ductive and grounded.

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 buildup on the air cap.

When spraying, the ES indicator lights (BB) should glow, indicating the electrostatic charge. See Fig 2.

Install the 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 on page 9 before installing, or removing the fluid nozzle/air cap assembly.

1.See Instruction Manual 307??803 for air cap con- sumption and fluid nozzle flow rate information. The fluid output and pattern shape depends on the fluid nozzle size, fluid viscosity, and fluid pressure.

2.Remove the old air cap and fluid nozzle as instructed in Clean the Air Cap and Fluid Nozzle, steps 1 through 4.

3.Push the pin housing (83) into the slot (A) on the front of the gun until it bottoms out. See Fig 4.

4.Push the locking pin (84) into the housing (83).

5.Turn the locking pin (84) to the unlocked position, and screw the new fluid nozzle (13) onto the gun. See Fig 5.

6.Turn the locking pin (84) to the locked position to lock the fluid nozzle (13) in place.

7.Carefully install air cap assembly. Avoid bending electrode (12). Tighten the retaining nut so it is snug, allowing the air cap to turn with resistance. If too tight, the spray pattern will be distorted.

Adjust the Spray Pattern

Follow these steps to establish the correct fluid flow and air flow. DO NOT turn the ES ON??OFF lever to 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, use the adjusting knob (Z) lo- cated at the rear of the gun. See Fig 2. Turn the knob clockwise to reduce the amount of fluid being sprayed and counterclockwise to increase the amount of fluid being sprayed.

3.Choose the correct size air cap for the type of fluid being sprayed and the pattern desired.

4.Be sure the fan adjusting knob (AA) is closed (turned fully clockwise).

5.Use an air pressure regulator to adjust the degree of atomization. Always use the lowest air pressure pos- sible for the most efficiency.

NOTE: A minimum of 2.8 bar (40 psi) air supply at the gun is required to ensure full voltage from the power supply. The gun may be operated at a lower air pressure/voltage if required, but may lose some electrostatic wrap.

6.First, complete all the checks under the Operating Checklist on page 9. Then turn the ES ON??OFF lever to ON. When spraying, the ES indicator light should glow, indicating the electrostatic charge.

7.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.

NOTE: See the Spray Pattern Troubleshooting Chart on page 13 to correct spray pattern problems.

KEY

A Slot

83 Pin Housing

13

Fig 5

Daily Care and Cleaning

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 Warning on page 9 when shutting off the sys- tem, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system.

CAUTION

Clean all parts with a non??conductive solvent, compatible with the fluid being sprayed. Conductive 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.

1.Clean the fluid and air line filters daily.

2.Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent.

3.Clean the air cap and fluid nozzle daily, minimum. Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are dam- aged. See Clean the Air Cap and Fluid Nozzle.

4.Check the electrode wire. Straighten if bent, and re- place if broken or damaged. See Electrode Needle Replacement.

5.Check all of the work hangers for build-up of material; clean them, if necessary.

Clean the Air Cap and Fluid Nozzle

CAUTION

Do not use metal tools to clean the air cap holes as this may scratch them, and make sure the elec- trode wire is not damaged. Scratches in the air cap holes or a damaged electrode wire can distort the spray pattern.

Equipment needed:

Soft bristle brush (supplied). Fluid nozzle wrench (supplied).

Solvent compatible with fluid being sprayed.

Procedure:

1.Follow the Pressure Relief Procedure Warning on page 9.

2.Remove the air cap assembly (14). See Fig 6.

3.Turn the locking pin (84) to the unlocked position.

4.Squeeze the gun trigger and remove the fluid nozzle with the fluid nozzle wrench (59g) supplied. Make sure the front of the gun is held down. See Fig 6.

5.Use the soft bristle brush (59a) supplied and solvent to clean the air cap, fluid nozzle, and front part of the gun.

6.Squeeze the gun trigger and screw the fluid nozzle back into gun. Tighten the nozzle securely with the wrench (59g) supplied. Torque the fluid nozzle to 1.1??1.4 NSm (10??12 in??lb). See Fig 6. Turn the lock- ing pin to the locked position.

7.Carefully reinstall the air cap assembly. Avoid bend- ing the electrode (12). Tighten the retaining nut so it is snug, allowing the air cap to turn with resistance. If too tight, the spray pattern will be distorted.

KEY

12Electrode

13Fluid Nozzle

14Air Cap Assembly 59g Wrench

14 12

13 Torque to 1.1??1.4 NSm (10??12 in??lb)

59g

Fig 6

Flush the Spray Gun

WARNING

To reduce the risk of fire or explosion and serious bodily injury, the ES ON??OFF lever must be OFF before flushing.

1.Follow the Pressure Relief Procedure Warning on page 9.

2.Disconnect and plug the fluid line.

3.Connect the solvent supply to the gun.

4.Flush the gun with solvent until it is clean.

5.Follow the Pressure Relief Procedure Warning, then disconnect the solvent supply.

6.Reconnect the fluid supply line.

7.Turn on the fluid and air supplies.

8.Trigger the gun until it is clear of solvent.

Gun??? Disassembly

3??? Install??? the??? new??? electrode??? ??????2?????? with??? the??? wrench??? ???59c??? supplied?????? Do??? not??? overtighten???

4.R!mov!??? t$!??? ES??? %n %??????tor??? l%#$ts??? "rom??? t$!??? so???k!t $!??? ??? ??????ps???r!ws??? ???30???.

???. Us%n#??? t$!??? wr!n???$??? ??????9"?????? suppl%! ?????? loos!n??? ???n ??? r!4 mov!??? t$!??? two??? so???k!t??? $!??? ??? ??????ps???r!ws??? ???30?????? "rom??? t$! #un.

???.Hol ??? t$!??? #un??? $???n l!??? ???2?????? w%t$??? on!??? $???n ??? ???n ??? pull str???%#$t??? up??? to??? r!mov!??? t$!??? #un??? ??????rr!l??? ???18???.??? S!!??? F%# 13.

CAUTION

To??? ???vo% ??? ???m???#%n#??? t$!??? pow!r??? ??????rtr% #!?????? ???lw???ys pull??? t$!??? #un??? ??????rr!l??? str???%#$t??? ???w???y.??? I"??? n!???!ss???ry??? #!ntly??? mov!??? t$!??? #un??? ??????rr!l??? "rom??? s% !??? to??? s% !??? to "r!!??? %t??? "rom??? t$!??? #un??? $???n l!.

Fig??? 12

NOTE: T$!??? #???sk!t??? ???4????????? s$oul ??? ???!??? l!"t??? %n??? t$!??? #un??? $???n l!

???9"

30

???2?????? %"??? t$!??? #???sk!t??? %s??? not??? to??? ???!??? r!pl??????! .

KEY

2.Inst???ll??? t$!??? two??? so???k!t??? $!??? ??? ??????ps???r!ws??? ???30?????? ???n t%#$t!n??? w%t$??? t$!??? wr!n???$??? ??????9"?????? suppl%! .??? S!!??? F%#???12.

3.Sn???p??? t$!??? ES??? %n %??????tor??? l%#$ts??? %n??? pl??????!??? ov!r??? t$!??? so???k!t $!??? ??? ??????ps???r!ws??? ???30???.

???.Inst???ll??? t$!??? tr%##!r??? w%t$??? t$!??? s???r!ws??? ???n ??? sp??????!rs.??? T!st t$!??? #un??? r!s%st???n???!??? ???s??? %nstru???t! ??? on??? p???#!??? 1???.

Fig??? 13

Fluid??? Needle??? Packing??? Replacement

18

3

4???

5.Carefully remove the fluid needle assembly (45) from the rear part of the gun barrel (18). See Fig 15. If the packing assembly (45a) or insulator (45g) are still in the barrel, insert the packing removal rod (59d) into the front of the barrel to gently push them out. Refer to Fig 16.

NOTE: If the insulator (45g) is removed, be sure to install it so the insulator end with holes is facing the packing assembly (45a).

6.Wipe the internal surfaces of the barrel clean with a soft brush or cloth.

CAUTION

Clean all parts in non??conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

7.Remove the packing assembly (45a) from the needle (45b).

NOTE: If the position of the adjusting nut (45c) is changed, install the adjusting nut to the approxi- mate dimension shown in Fig 15. (Final adjust- ment will be made in step 15.) If the spring (45f) was removed, reinstall it over the nut (45d).

8. Install the new packing assembly (45a).

CAUTION

Carefully screw needle (45b) into new packing assembly (45a) to avoid damaging the seals.

9.Test the drag on the fluid needle. It should be approxi- mately 2.5??3 lbs (use a small spring scale to meas- ure). If the adjustment is out of tolerance, tighten or loosen the adjusting screw on the packing assembly (45a) slightly and retest. Continue to adjust until the tolerance is correct.

10.Install the entire fluid needle assembly (45) into the gun barrel, from the back of the barrel.

11.Firmly tighten the packing nut (45e) 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 Clean the 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 (45c) until the proper lead and lag is achieved.

If the fluid comes on too soon, remove the trigger and back the needle adjusting nut (45c) out (away from the barrel) slightly.

If the fluid comes on too late, tighten the needle adjusting nut (45c) slightly (turn towards barrel).

After adjustment is complete, tighten the locking nut (45d) against the adjusting nut (45c).

KEY

18 Gun Barrel

45 Fluid Needle Assembly

45c Needle Adjusting Nut

132.7 mm

(5.2 in.)

45c 45

18

Fig 15

KEY

45a

Fig 16

KEY

18b

See NOTE after step 3, below.

NOTE: The power cartridge (3) includes items 3a, 3b, 3c, and 5.

Fig 17

5a

3b

3c 2 3a

Power Cartridge Replacement

1.Remove the barrel as described under Barrel Removal.

2.Remove the gasket (46) from the gun. 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 handle (2). Then pull the power cartridge straight out of the handle.

CAUTION

DO NOT use solvents to clean the power cartridge cavity in the gun handle (2). Solvent will damage electrical components contained in the power cartridge.

Inspect the power cartridge cavity in the handle for dirt or moisture. Clean out the cavity with a clean, dry rag if necessary.

Lightly lubricate the o??rings (3b, 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.

NOTE: The cushion (18b) is part of the gun barrel and should never be removed. If it ever is removed, push the cushion, adhesive side in toward the barrel, with a rod until it is securely adhered in the barrel. DO NOT use the power supply (5) to press the cushion into the barrel as it will not ad- here properly.

4. Insert the new power cartridge in the gun handle.

NOTE: See Fig 18 for proper alignment of the power car- tridge (3) in the gun handle (2).

5.Install the gasket (46) in the gun handle (2).

6.Install the barrel on the handle as described under

Barrel Removal.

KEY

3

Fig 18

Turbine Alternator Removal

1.Remove power cartridge from the gun handle as described under Power Cartridge Replacement.

2.Carefully twist the turbine alternator (3a) 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.

3.Using an ohmmeter, test the coil in the turbine alter- nator (3a). Measure the resistance between the two outer terminals of the 3-wire connector (HH). The re- sistance should be 3??5 ohms. If the reading varies from this value, replace the alternator.

4.Measure the resistance between each outer terminal of the 3-wire connector (HH) and the turbine alterna- tor housing. The resistance should be infinite. If the resistance is not infinite, replace the alternator.

5.Partially connect the 3-wire connector (HH) onto the prongs inside the power supply (5). See Fig 19. Us- ing a small screwdriver, push the connector onto the prongs until seated.

6.Slide the turbine alternator (3a) 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.

7.Install the power cartridge in the gun handle as de- scribed under Power Cartridge Replacement.

KEY

5

Fig 19

Fan Air Valve Replacement

1.Place a wrench on the flats of the valve housing (33) and remove it from the handle (2). See Fig 20.

2.Remove the retaining ring (31).

3.Rotate the air adjusting screw (34) counterclockwise until it is disengaged from the valve housing threads. Pull the adjusting screw (34) out of the valve hous- ing (33).

4.Clean all the parts and inspect them for wear or dam- age. If replacing the seal (40), unscrew it clockwise and remove it from the adjusting screw.

5.Apply medium grade thread sealant to the small threads on the end of the adjusting screw (34) and install a new seal (left hand thread).

6.When reassembling the fan air valve, lubricate the o?? ring (32) and the adjusting screw threads with petro- leum jelly.

7.After the retaining ring (31) is installed on the adjust- ing screw (34), back the adjusting screw out of the valve housing (33) until it bottoms out against the re- taining ring (31).

8.Apply PTFErpaste to the threads of the valve hous- ing (33) and install it in the handle (2). Torque the housing (33) to 1.1??1.4 NSm (10??12 in??lb).

Air Valve Replacement

1.Using a screwdriver, remove the retainer (27), spring (26), and air valve (25). See Fig 21.

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.

2.Remove the trigger by removing the screws and the spacers from the gun.

3.Unscrew and remove the guide (24) and packing (47) from the front of the gun handle (2).

4.Apply PTFE tape to the threads of the guide (24). In- stall the new packing (47) and guide (24) in the front of the gun handle (2). Tighten the guide (24) finger tight only.

5.Install the new air valve (25) and spring (26) into the back of the gun handle (2).

6.Apply PTFE tape to the threads of the retainer (27). Install the retainer (27) in the back of the gun handle

(2) and tighten with a screwdriver.

7.Reinstall the trigger with the screws and spacers.

8.Squeeze the trigger and tighten the guide (24) just until the valve (25) will not return when the trigger is released. Then loosen the guide just enough so the valve stem returns freely when the gun is triggered and released.

ES ON??OFF Valve Removal & Replacement

1.Loosen and remove the nut (35). Remove the lever (37) and washer (36). See Fig 22. Insert the hex head wrench into the hex end of the valve (39), and turn it to loosen and remove the valve.

2.Clean and inspect parts for wear or damage. Re- place if necessary. Lubricate the o??rings (38) and valve (39) with petroleum jelly.

3.Install the regulator disc (4) so that the beveled face of the disc faces into the valve (39).

4.Install the valve (39) with the regulator disc (4) and o??rings (38) into the gun handle (2) so that the larger opening of the valve cylinder faces toward the front of the gun handle (2).

5.Install the wave washer (36), lever (37), and nut (35) on the valve stem. Tighten the nut (35) and torque it to 0.225 NSm (2 in??lb).

Fluid Adjusting Screw Replacement

Remove the retaining ring (23) from the fluid adjusting screw (28). Refer to the Parts Drawing. Unscrew and re- move the fluid adjusting screw from the back of the gun handle. Install the new assembly.

KEY

36

37

35

Torque to 0.225 NSm (2 in??lb)

Fig 22

Muffler and Check Valve Replacement

1.Remove the screw (71), adapter retainer (70) and bulkhead retainer (85) from the gun handle. See Fig 23.

2.Pull the muffler (80) from the gun handle and replace with a new muffler.

3.Insert a 3.18 mm (0.125 in.) rod into one of the holes in the valve check retainer (78) and pry it out of the adapter retainer (70). Be ready to catch the ball (77) and spring (81).

4.Install a new ball (77) and spring (81) in the adapter retainer (70) and snap the valve check retainer (78) back into place on the adapter retainer.

5.Install the adapter retainer (70) and bulkhead retainer (85) on the gun handle using the screw (71).

71

80Muffler

81Spring

85 Bulkhead Retainer

85

Fig 23

75{ 18a 58 19

17{*

16{

12{

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 install are black. The old style electrode and stud in the Series A??D Guns were white. DO NOT mix old style parts with new style parts.

71**

21

Ref 2

Ref 70

Ref 85

69

Spray Gun Repair Kit 218??051

Includes:

Resistor Stud and Electrode Kit 220??391

Includes:

Muffler Kit 218??682

Includes:

Low Air Flow Restrictor Kit 223??830*

For reducing atomizing air flow.

Includes:

*MUST also order Air Cap 220??535.

102

101

100

Optional Air Cap 220??535

MUST be used with Low Air Flow Restrictor Kit 223??830, above. Must order separately.

TECHNICAL DATA

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.87 Kg (1.90 lb) Gun Length . . . . . . . . . . . . . . . . . . . . . 310 mm (12.25 in.) Maximum Working Pressure . . . . . . . . . . 7 bar (100 psi) Air Pressure Operating Range: 0??7 bar (0??100 psi) Fluid Pressure Operating Range: 0??7 bar (0??100 psi) Voltage Operating Range . . . . . . . . . . . . . . . . . . 0??75 KV Paint Resistivity Range . . . . 7 megohm cms to infinity Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm(m) L.H. Fluid Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npsm(m) Wetted Parts . . . . . . Stainless Steel, Polyethylene,

Nylon, Acetal, Vitonr??? PTFE,r Delrinr

Vitonrr and Delrinr are registered trademarks of the DuPont Co.

Loctiter is a registered trademark of the Loctite Corporation.

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.

SERVICE INFORMATION

Listed below by assembly changed are OLD and NEW parts.

INTERCHANGEABILITY NOTE: NEW parts replace OLD parts listed directly above them.

MISCELLANEOUS NOTES: Revised the manual to update the gun handle drawings.

AIR LINE ACCESSORIES

GROUNDED AIR SUPPLY HOSE

7 bar (100 psi) MAXIMUM WORKING PRESSURE

8 mm (0.315 in.) ID; 1/4 npsm(fbe);

Color coded gray; More flexible than black hose

223??074 30.5 m (100 ft)

QUICK DISCONNECT COUPLING ASSY. 110??806

Includes a quick disconnect coupling insert, which replaces air inlet fitting 179??400, and a shut-off coupling body (left hand thread), which connects to the grounded air hose.

AIR HOSE ADAPTER 185??493

For connecting two or more air supply hoses together. 1/4 npt(m) x 1/4 npsm(m) left??hand thread.

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 & 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

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

218??118 ELECTROSTATIC SYSTEM

Includes items:

218??026 Manual Electrostatic Air Spray Gun 218??103 Grounded Air Supply Hose (See

218??123 ELECTROSTATIC SYSTEM

Includes items:

218??026 Manual Electrostatic Air Spray Gun 218??101 Grounded Air Supply Hose (See

and page 30 for specifications) 216??076 Fluid Hose (See page 30 for

specifications) 106??148 Air Filter

218??124 ELECTROSTATIC SYSTEM

Includes items:

218??026 Manual Electrostatic Air Spray Gun 218??102 Grounded Air Supply Hose (See

and page 30 for specifications) 216??077 Fluid Hose (See page 30 for

specifications) 106??148 Air Filter

PRO4000H GUN ELECTROSTATIC HIGH CONDUCTIVITY KIT 222??029

For converting the PRO4000 Gun to spray conductive (metallic) paints. Since there are so many variations in paint formulations, Graco recommends your specific ma- terial be tested for useability with this gun.

NOTE: The installation of this kit will void the CSA and FM approval on the PRO4000 Gun.

ISOLATION STAND 728??650

Required for isolating the fluid supply from the ground when spraying conductive water??base fluid.

CONDUCTIVE (WATER BASE) HOSE KIT 221??008

For converting gun to handle conductive (water base) flu- ids. See instruction manual 307??639.

NOTE: The installation of this kit will void the CSA and FM approval on the PRO4000 Gun.

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.

WATER BASE CONTROL BOX 218??619

7 bar (100 psi) MAXIMUM WORKING PRESSURE

110??115 Volt output; 50??60 Hz

Pneumatically operated control box used in a water base electrostatic system to automatically bleed the electro- static charge from the water base fluid supply when the gun is released or the safety fence is open.

Must also order the following:

221??008 Water Base Conductive Hose Kit 728??650 Isolation Stand

CONDUCTIVE (SOLVENT BASE) HOSE KIT 218??568

For converting gun to handle conductive (solvent base) fluids. See instruction manual 307??640.

NOTE: The installation of this kit will void the CSA and FM approval on the PRO4000 Gun.

MISCELLANEOUS ACCESSORIES

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

GUN COVER 180??209

Order Part No. 218??374 for package of 10.