Graco Inc. 224-094 Paint Sprayer User Manual
Contents
1. _ lt contact ring Lubricate CAUTION DO NOT over tighten Capscrews Tighten to we 18 in lbs 2 Nem MAXIMUM about half turn past snug us ing wrench provided Torque Fitting to 25 35 in lbs 2 8 4 0 Nem Install into internal grooves in fitting Fits between flared tube and fitting Lubricate f i Stretch o ring to start s Pd it over fitting threads then thread it into place sae ex a O ar 8 oO OC Z 90 A ee g Apply PTFE paste O Install flush to ER endotrod Apply high strength red Loctite or OL equivalent to threads eC 0433 26 308 084 MANIFOLD SERVICE NOTES Concave side Press fit toward manifold Apply low strength Left hand purple Loctite or threads equivalent eg Torque to 25 in Ib BNem lt This end 8 5 8 9 215 225 mm from manifold surface when properly assembled ON Standard o ring is Viton Torque to Optional EPR o ring is 25 in lb provided with the man 2 8 Nem ifold for compatibility with ketone solvents Apply low strength purple Loctite or equivalent Press fit Tighten until 0434 hex bottoms against manifold lt i J Torque to Lubricate ot 25 in lb 2 8 Nem 0434 308 084 27 SPRAY GUN PARTS DRAWING See Detail A DUT 28 SAK D 3 f Pa 3b DETAIL A REF NO 3 Includes items 3a 3h X 0433 28 308 084 SPRAY GUN2. To adjust the low voltage setting use a small blade end screw driver to turn the potentiometer G clockwise to increase the voltage or counterclockwise to decrease it fully clockwise is 80 kV fully counterclockwise is 45 kV Turbine Alternator Removal and Replacement NOTE Replace turbine bearings after 2 000 hours of operation See your authorized Graco representative 1 Remove the power supply from the gun handle as described at left 2 Squeeze the two ends of the retaining ring 13 together and carefully pull the alternator 27 away from the power supply 40 until the wire connector F disengages See Fig 23 3 Use an ohmmeter to test the turbine alternator coil Measure the resistance between the two outer termi nals of the 3 wire connector F Resistance should be 3 to 5 ohms If the reading varies from this value replace the alternator 4 Connect the 3 wire connector to the 3 prongs in the power supply Push the alternator 27 onto the pow er supply 40 until the retaining ring 13 engages with the alternator 5 Install the power supply in the gun handle as described at left 308 084 25 SPRAY GUN SERVICE NOTES CAUTION Do not damage Needle Elec trode wire during assy or disassy Lubricate Tighten Resistor Stud into nozzle to 10 in Ibs 1 15 Nem a Lubricate 7 Tighten Nozzle 1 8 to 1 4 turn past hand tight ae see str ngth pur SE ro to threads it DO Lubricate rs G
3. 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 HOSE SAFETY TIGHTEN all fluid connections securely before each use NEVER use a damaged hose Before each use check the en tire 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 2 308 084 Fluid Compatibility BE SURE all fluids and solvents used are chemically compat ible with the Wetted Parts shown in the TECHNICAL DATA Always read and follow the fluid and solvent manufacturer s lit erature 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 electrostatic shock always follow this procedure when shutting off the sys tem when checking or servicing any part of the spray system when installing cleaning or changing fluid nozzles and when ever you stop spraying 1 Turn off all the air to the control module except the manifold air If the air pilot fluid regulator is used air pressure is need ed at the regulator air inlet to relieve pressure in the fluid line 2 Turn off the fluid supply to the gun 3 Trigger the gun into a grounded metal waste container to relieve fluid pressure
4. 0446 Fig 19 308 084 21 SERVICE Barrel Installation 1 Be sure the gaskets 23 amp 40a and spring 11 are in place See Fig 20 Replace if damaged Place the barrel 10 over the power supply 40 and onto the gun body 39 Make sure the fluid rod spring 11 is seated properly Tighten the three socket head cap screws 15 oppositely and evenly with the ball end wrench 46 Tighten the cap screws to 18 in lbs 2 N em MAXI MUM about a half turn past snug tighten DO NOT over CAUTION To avoid damaging the gun DO NOT over tighten the cap screws 15 Tighten the screws to 18 in lbs 2 Nem MAXIMUM about a half turn past snug using the wrench 46 supplied only KEY 10 Gun Barrel 11 Spring 15 Cap Screws 21 Fluid Tube Fitting 23 Gasket 25 Jam Nut 29 Actuator Arm 39 Gun body 40 Power Supply 40a Gasket Fig 20 22 308 084 4 5 Install the fluid tube back into the fluid fitting 21 Install the actuator arm 29 and jam nut 25 with the jam nut assembled flush to the end of the rod There should be about a 1 16 in gap between the ac tuator arm 29 and the nut on the fluid shaft When the gun is triggered the electrode needle should draw back 3 to 4 mm If necessary adjust the jam nuts to obtain these dimensions The jam nut must be tightened securely to prevent it from loosening during operation Test the gun resistance as instructed on page 16 0457 F
5. Fig 22 Fig 22 Generously apply the grease to the outside of the spacer If installing the complete fluid rod assembly go to step 10 on page 24 KEY ee E Nut 3 Fluid Packing Rod Assembly 3e 3f 3h 3a 3d E 11 3a Packing Housing 3b 3b Fluid Rod 3c Packing Nut PRS OA 3d Spacer TRT 3e Rod Packing 4 3f Fluid Packing oe 3g O Ring 11 Spring 03224 Fig 22 308 084 23 SERVICE Fluid Packing Rod Removal and Repair continued 8 10 Place the fluid packing 3f rod packing 3e and housing 3a on the fluid rod 3b as shown in Fig 22 Lightly tighten the packing nut 3c The packing nut is properly tightened when there is 2 Ibs 9 N of drag force when sliding the packing housing 3a assem bly along the shaft Tighten or loosen the packing nut as needed Lubricate the o ring 3h on the outside of the packing housing 3a 24 308 084 11 12 Install the fluid packing rod assembly 3 into the gun barrel Using the 9 mm hex nut driver 45 tighten the assembly until just snug then check the drag on the fluid rod Make sure the spring 11 is installed on the nut E as shown in Fig 22 Install the electrode nozzle and resistor stud assembly and the air cap assembly as described in Electrode Replacement Install the arm 29 and jam nut 25 with the jam nut assembled flush to the end of the rod See Fig 20 page 22 SERVICE F 3 wire Connector G Potentiometer 10 Gun Barrel 13 Reta
6. 25 Turbine Alternator Removal and Replacement 25 Service Notes 26 Gun Parts Drawing 28 Gun Parts List 29 Manifold Parts Drawing amp List 30 PRO 4600HC Conversion Kit 31 ACCeSSOres sit ii che ee hide BO tres 32 Technical Data 35 Warranty Back Cover Graco Phone Numbers Back Cover 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 TYPICAL INSTALLATION Non Hazardous Area Controls Cabinet BASIC SYSTEM Hazardous Area Grounded Turbine Air Hose gray hose P N 223 068 074 ve vo vo dE ri 15 4 KV Hi Lo Air Line if low KV setting option is desired I2 ni Gun Manifold de PIN 224 094 S wi 7 J PRO 4600 Gun gt 1 Shutofdevice Fan H PIN 224 224 gt 8 operation H Atom Air Lines H gun only see L BE A Pi EF Trigger Module m Manual 308 084 for gt gt mr un shroud P N Bleed val
7. 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 3 Read and follow the fluid and solvent manufacturer s litera ture 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 EXPLOSION OR ELECTROSTATIC SHOCK HAZARD To reduce the risk of fire explosion or electrostatic shock which may result from electrical discharge it is essential that e All parts of the electrostatic system are properly grounded e All personnel in or close to the spray area are properly grounded e All electrically conductive objects or devices in the spray area including 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 electrically charged Arcing may occur if these objects then come in contact or close to ground Arcing of suffi cient energy levels c
8. 6 Connect the Air Fluid and Fiber Optic Lines 6 Check the Electrical Grounding 8 Install the Fabric Cover 8 Operation Operating Checklist 9 Selecting a Fluid Nozzle and Air Cap 9 GUN FUNCHIONS ec 2er td dense tirent ees 9 Activating the Fluid Trigger Only 9 Adjusting the Spray Pattern 9 Adjusting the Turbine Air Pressure 10 Activating the Voltage Select KV HI LO 10 Maintenance Daily Care and Cleaning 10 Clean the Air Cap and Fluid Nozzle 11 Check for Fluid Leakage 12 Troubleshooting 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 4 308 084 Service Flush the Gun and Relieve Pressure 18 Remove Gun from Manifold amp Mounting Bracket 18 Air Cap Nozzle Resistor Stud Replacement 19 Electrode Replacement 20 Barrel Removal 21 Barrel Installation 22 Fluid Packing Rod Removal and Repair 23 Power Supply Removal and Replacement 25 Power Supply Adjustment
9. Misalignment between air cap and fluid nozzle 5 Air Cap o o Fluid Nozzle ALIGNED MISALIGNED Replace fluid rod See page 23 Replace fluid nozzle and or electrode See page 19 and 20 Replace seal and or o ring and lubricate Tighten resistor stud See page 19 Tighten fluid nozzle See page 19 Replace o ring See page 19 Increase air pressure use least air pressure needed for good results Remix or refilter fluid Use proper thinner Reduce air pressure use least air pressure needed for good results Properly thin fluid Check add fluid if necessary Replace air cap Clean fluid nozzle See page 11 Replace fluid nozzle See page 19 Check cylinder CYL air Check actuator arm 29 and nuts 25 7 See page 21 Check for proper CFM check baffles and direction of air flow Adjust spraying distance to 8 to 12 inches 203 to 305 mm Remove and clean air cap and fluid nozzle See page 11 Then reinstall them Or replace fluid nozzle and air cap See page 19 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Poor wrap around Improper distance between gun Adjust spraying distance to and workpiece 8 to 12 inches 203 to 305 mm Parts poorly grounded Clean hangers check for proper ground on conveyer or track High booth exhaust velocity Reduce exhaust velocity within code limits Atomizing air pressure too high Reduce atomizing air pressure Fluid pressure too high
10. Replace damaged part See page 19 Remove obstruction Never use wire or hard instruments See page 11 Straighten electrode Reduce air pressure or adjust fan air adjusting valve Regulate fluid viscosity Increase fluid pressure Increase air pressure Regulate fluid viscosity Reduce fluid flow Apply drier finish with multiple strokes Use least air pressure necessary Increase air pressure Clean or replace air cap See page 11 NOTE Some improper patterns are caused by the improper balance between air and fluid 308 084 13 GUN OPERATION TROUBLESHOOTING CHART Fluid leakage from front of gun Orange Peel finish Excessive spray fog No fluid sprays from gun Equipment covered with fluid Dirty air cap 14 308 084 PROBLEM CAUSE SOLUTION Leakage from fluid Worn fluid rod packings or fluid rod Replace fluid rod packings or rod packing area See page 23 Fluid rod worn or damaged Worn fluid seat Piston seal or o ring damaged Loose resistor stud Loose fluid nozzle Damaged resistor stud o ring Insufficient air pressure Fluid poorly mixed 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 Piston not actuating Actuator arm out of position Exhaust air flow insufficient or not directed properly Improper distance between gun and workpiece
11. at all times Contact points must be sharp points or knife edges 5 All electrically conductive objects or devices inthe spray area including paint containers and wash cans must be properly grounded 6 All persons entering the spray area shoes must have con ductive soles such as leather or personal grounding straps must be worn Rubber or plastic soles are not conductive 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 Pressure Relief Procedure on page 2 before flushing Be sure the turbine air electrostatics is OFF before flush ing 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
12. electrode not shown 48 187 421 WRENCH nozzle not shown 49 180 060 SIGN warning English not shown 50 187 343 COVER gun not shown 51 110 088 WRENCH allen 8 mm 52 105 749 BRUSH ee ee ee ee AQ A The replacements for these parts are available in Fluid Seal Repair Kit 237 786 Purchase the kit separately Additional warning tags and signs available at no charge French German and Spanish warning signs are also avail able See ACCESSORIES section T The replacements for these parts are available in Air Seal Repair Kit 224 636 Purchase the kit separately WARNING When servicing use only genuine Graco replacement parts Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in serious injury fire explosion electrostatic shock or property damage 308 084 29 MANIFOLD PARTS DRAWING 0434 MANIFOLD PARTS LIST Part No 224 094 Gun Manifold Includes items 101 124 REF NO 101 103 104 106 107 108 109 110 111 112 113 114 115 116 117 117a 117b 117c 117d 117e 30 308 084 PART NO 111 224 106 167 110 078 186 846 186 820 183 822 105 668 186 844 186 845 105 796 186 779 107 107 111 157 111 237 224 143 186 809 186 808 186 810 111 165 224 577 DESCRIPTION QTY LENSE 1 O RING perfluoroelastomer 2 FITTING tube for 3 8 OD tube 2 BO
13. in k amp 8 in k fs mm Fig 3 FRONT MOUNTING POSITION _ 76 6 308 084 2 3 in 58 mm rx PRO 4600 Gun re SAH with Standard Shroud oul P N 235 893 J gt 6 12 in e 304 mm Fig 4 BACK MOUNTING POSITION 6 Install the Gun and Manifold See Fig 5 1 Remove the air cap nut air cap assembly and slide the shroud off the gun 2 Connect the gun to the manifold by tightening the three socket head cap screws use the ball end wrench 46 supplied Make sure the o ring is in place on the manifold 3 Slide the gun and manifold along the dovetail until the button head screw bottoms against the mounting bracket 4 Secure the gun to the mounting bracket with the but ton head screw using the ball end wrench 46 Tighten the two mounting bracket setscrews 5 Slide the shroud onto the gun and secure it by tight ening the air cap nut onto the gun barrel Tighten the nut just enough so that the air cap is snug but can still be turned Connect the Air Fluid and Optional Fiber Optic Lines See Fig 6 WARNING To reduce the risk of electrostatic shock or other serious injury the turbine air supply hose must be electrically connected to a true earth ground Use Only Graco Electrically Conductive Air Supply Hose and connect the hose ground wire to a true earth ground See the ACCESSORIES section to or
14. 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 40 and the resistor stud 2 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 Remove the gun from the manifold and bracket as instructed on page 18 before performing the electrical tests WARNING To reduce the risk of sparking which could cause fire explosion or electrostatic shock 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 See Fig 11 Measure the resistance between the end of the electrode 28 and the gun body 39 The resistance should be between 329 to 401 megohms If the resistance is out side 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 Resistance See Fig 12 Remove the power supply 40 from the gun body 39 See page 25 Measure the resistance from the power supply s ground contact point EE to the contact inside of the power sup ply seal 40d the conductive rubber conta
15. 2 50 ft 15m 235 073 75 ft 23 m 235 074 100 ft 30 5 m Air Adapter Nipple 185 493 For connecting two or more grounded gun air supply hoses 1 4 npt x 1 4 npsm left hand thread 32 308 084 Air Filter amp Moisture Separator 106 148 250 psi 17 5 bar 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 High Volume Air Regulator 206 199 0 125 psi 0 9 bar Regulated Pressure 200 psi 14 bar Steel Pressure Gauge For regulating air to the gun 1 2 npt f inlet and outlet Air Shut off Valve 224 754 150 psi 10 bar MAXIMUM WORKING PRESSURE For turning air to gun off or on 1 4 npsm m LH x 1 4 npsm f LH Bleed type Master Air Valve 107 141 300 psi 21 bar MAXIMUM WORKING PRESSURE Relieves air trapped in the air line between the paint pump air motor and this valve when closed 3 4 npt Filter Air or Paint 202 271 750 psi 52 bar MAXIMUM WORKING PRESSURE With 60 mesh 250 micron element 3 8 npt f inlet 3 8 npt m outlet Fluid Drain Valve 500 psi 35 bar MAXIMUM WORKING PRESSURE For relieving fluid line pressure 208 630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids 210 071 3 8 npt m x 3 8 npt f stainless steel and PTFE for corrosive fluids ACCESSORIES Accessories must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES GUN MOUNTING ACCESSORIES Gun Mount Asse
16. AIR AND FLUID Connect 3 8 OD tube between fitting and control module Connect 3 8 OD tube between 100Psi 7BAR KV fitting and control module ATOM ATION READ INSTRUCTIONS Connect 1 4 OD tube between fitting and control module Connect a 1 4 npsm swivel fitting paint line Shroud Exhaust 1 4 OD x 4 tube included with manifold 0322 Fig 6 308 084 7 INSTALLATION Check the Electrical Grounding See Fig 7 WARNING Proper electrical grounding of every part of your system is essential For your safety read the warning section FIRE EXPLOSION OR ELECTROSTATIC SHOCK HAZARD on page 3 Ground the system as explained there Then check your system as explained below 1 Completely turn off the air and fluid supplies to the gun 2 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose a With the electrically conductive air hose con nected and properly grounded use a megohmmeter to measure the resistance between the gun manifold and a true earth ground Use an applied voltage of 500 minimum to 1000 volts maximum b Ifthe 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 If you are using the red colored hose resis tance sh
17. INSTRUCTIONS PARTS LIST 308 084 This manual contains IMPORTANT GRACO Rev H WARNINGS AND INSTRUCTIONS Supersedes G READ AND RETAIN FOR REFERENCE Model PRO 4600SC AUTOMATIC ELECTROSTATIC AIR SPRAY GUN 100 psi 7 bar MAXIMUM WORKING PRESSURE U S Patent No 4 290 091 4 219 865 4 497 447 4 462 061 4 660 774 5 063 350 5 073 709 5 080 289 5 093 625 Patented 1986 1987 Canada Brevete 1986 1987 U K Patent No 2 147 158 2 142 559B 2 140 327B 2 245 197B French Patent No 91 14488 Other Foreign Patents Pending Part No 224 224 Series A Air Spray Gun without shroud 0 059 in 1 5 mm spray nozzle Part No 235 893 Series A Air Spray Gun with standard shroud Part No 235 894 Series A Air Spray Gun with slotted shroud For use when the gun is mounted in the front position see Fig 3 page 6 Part No 235 893 shown Part No 224 094 Series A Gun Manifold Must order separately 0435 Approved For use with Class 1 Group D paint spray materials GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1991 GRACO INC WARNINGS SERIOUS BODILY INJURY EXPLOSION FIRE OR ELECTROST ATIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED READ AND UNDERSTAND ALL INSTRUCTION MANUALS T AGS AND WARNING LABELS BEFORE OPERATING EQUIPMENT ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED QUALIFIED PERSONNEL WHO SHALL BE FULL Y CONVERSANT WITH THE REQUIREMENTS STATED WI
18. LT manifold M5 x 0 8 3 MANIFOLD 1 SLEEVE o ring 4 O RING Viton 4 FITTING flow washer M16 x 1 5 LH 1 FITTING turbine 1 4 18 npsm LH 1 O RING Viton 1 FITTING fiber optic cable 7 16 20 1 DISK regulator 1 FITTING tube for 1 4 OD tube 1 FITTING barb 1 SWITCH voltage Includes items 17a 17h CYLINDER PISTON FITTING plug FITTING male MAGNET ee ee ee ee REF NO PART NO DESCRIPTION QTY 117f 111 208 SPRING compression 117g 111 295 SET SCREW cup point 4 40 117h 111 294 PACKING u cup UHMWPE 118 185 819 FITTING fluid 1 4 npsm 121 186 847 SLEEVE o ring 122 111 180 O RING Viton 123 111 333 O RING EPR 124 224 548 TUBE The replacements for these parts are available in Fluid Seal Repair Kit 237 786 Purchase the kit separately T The replacements for these parts are available in Air Seal Repair Kit 224 636 Purchase the kit separately WARNING When servicing use only genuine Graco replacement parts Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in serious injury fire explo sion electrostatic shock or property damage PRO 4600HC CONVERSION KIT Part No 237 301 PRO 4600HC Conversion Kit To convert the PRO 4600SC spray gun to the PRO 4600HC spray gun The gun longer 20 in 508 mm fluid tube used by the HC provides increased spraying voltage when sp
19. PARTS LIST Part No 224 224 Automatic Electrostatic Air Spray Gun without shroud Includes items 1 17 19 52 Part No 235 893 Series A Air Spray Gun with standard shroud Includes items 1 52 REF NO PART NO 1 186 762 2 223 977 3 224 747 3a 185 495 3b 223 981 3c 185 488 3d 186 069 3e 178 763 3f 178 409 3g 111 504 3h 111 316 4 186 763 5 141 177 6 186 764 7 102 025 8 100 518 9 176 930 10 223 940 11 185 111 12 110 492 13 185 114 14 185 158 15 185 096 16 177 033 17 _ 181 039 186 770 18 188 699 19 186 958 20 186 765 21 187 319 21a 111 285 21b 111 286 22 186 818 23t 185 113 24 181 178 25 101 324 27 222 319 27at 110 073 27b 185 124 28 185 107 29 186 766 30 102 982 31 111 507 32 111 182 36t 111 450 DESCRIPTION PISTON valve STUD resistor PACKING ROD ASSY Includes items 3a 3h HOUSING packing ROD fluid eNUT packing SPACER packing PACKING rod PACKING fluid O RING fluoroelastomer O RING fluoroelastomer COVER piston CAP SCREW button hd 1 4 20 x 0 5 RING air cap NUT hex 1 4 20 SCREW mach pnh 6 32 x 3 8 RING retaining BARREL gun SPRING compression O RING PTFE RING retainer alternator QTY ss BR om om om A So om So Om oO Oo NOZZLE fluid See Manual 307 803 for available nozzles SCREW cap relieved M5 x 0 8 AIR CAP See Manual 307 803 for available air caps PACKING u cup UHMWPE SHRO
20. Reduce fluid pressure Improper fluid viscosity Check supplier for proper fluid for electrostatic spray Fluid resistivity too low Check fluid resistivity with paint meter and probe No or low voltage output Check possible causes listed below Turbine alternator not operating Check air supply to gun Faulty gun resistance Check gun resistance See page 16 Fluid leaks from fluid rod packing Clean fluid rod cavity replace packing and causes short See page 23 Faulty turbine alternator Be sure plug is in place on back of turbine alternator housing Remove and test turbine alternator See page 25 KV HI LO switch stuck on low Check switch actuation replace if needed Operator gets shock Operator not properly grounded Be sure floor is properly grounded or is near an ungrounded object Wear shoes with conductive soles or wear personal grounding straps Be sure operator is not in contact with or carrying any metallic items which could build up electrical charge Gun not properly grounded See Check the Electrical Grounding Operator gets shock Workpiece not properly Clean workpiece hangers Check for when touching workpiece grounded proper ground on conveyor or track No or low voltage output Damaged fiber optic cable or Check cables and connections reading on gun display connection Replace if damaged module See other causes under Problem Poor wrap around above 308 084 15 ELECTRICAL TESTS The performance of
21. THIN THIS INSTRUCTION MANUAL EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories such as over pressurizing modifying parts using incompatible chemi cals and fluids or using worn or damaged parts can cause them to rupture and result in serious 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 spray 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 worn or damaged parts immediately replace System Pressure This gun has a maximum working air and fluid pressure of 100 psi 7 bar 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 extremely serious bodily injury even death due to splashing in the eyes ingestion inhalation or bodily contami nation 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 precautions
22. UD standard included with Part No 235 893 only SHROUD slotted included with Part No 235 894 only TUBE flared PTFE ROD actuator CONNECTOR male 1 8 npt for 1 4 OD tubing Includes items 21a amp 21b eFERRULE FERRULE FITTING fluid 5 8 20 GASKET manifold polyethylene CAP retainer spring NUT hex jam 1 4 20 ALTERNATOR turbine Includes items 27a amp 27b O RING Viton CUSHION NEEDLE electrode ARM actuator O RING PTFE O RING fluoroelastomer SPRING compression O RING fluoroelastomer Part No 235 894 Series A Air Spray Gun with slotted shroud Includes items 1 52 REF NO PART NO DESCRIPTION QTY 39 224 095 BODY gun 1 40 224 093 POWER SUPPLY ASSY 85 KV Includes items 40a 40e 40at 186 840 GASKET power supply 40b 185 099 PAD 40c 185 145 PAD 40dt 186 637 SEAL 40e 185 141 eCUSHION 41 224 340 CHECK VALVE ASSY Includes items 41a 41j 41a 187 264 eMUFFLER FLAME ARRESTOR 41b 108 046 BEARING ball 41c 101 435 BEARING ball 41d 186 980 eFITTING check valve 5 16 18 41e 186 981 eSCREW check valve M4 x 0 7 41f 186 982 BODY check valve 3 4 16 41g 186 983 eNUT check valve 3 4 16 41h 186 984 SEAT check valve 41i 186 985 VALVE check body 41j 103 337 O RING Viton 42 103 337 O RING Viton 43t 186 848 GASKET air cap nut 44 179 791 TAG warning not shown 45 110 087 DRIVER hex nut 9 mm not shown 46 107 460 WRENCH barrel not shown 47 185 123 WRENCH
23. 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 replace if broken or damaged See Replacing the Electrode Needle 5 Check for any fluid leakage from the gun and fluid hoses See Check for Fluid Leaks 6 Check all of the work hangers for material build up clean them if necessary WARNING To reduce the risk of fire explosion or electrostatic shock BE SURE the turbine air electrostatics is off before flushing the gun or any part of the system 7 Flush the fluid passages by alternating solvent and air Flush before changing colors and whenever you are done operating the gun MAINTENANCE Clean the Air Cap and Fluid Nozzle Equipment needed Soft bristle brush supplied Solvent compatible with fluid being sprayed Procedure 1 Follow the Pressure Relief Procedure Warning on page 9 2 Remove the air cap assembly and gun shroud 3 Clean the air cap fluid nozzle and front of the gun using the soft bristle brush and solvent Point the gun down while cleaning to prevent dirty sol vent from running back into the air passages See Fig9 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 wi
24. an ignite the fluid being sprayed fumes from solvents dust particles and other flammable substances This can cause a fire explosion or electrostatic shock and re sult in serious bodily 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 grounding as described in Grounding below If you experience any arcing or feel even a slight shock STOP SPRAYING 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 electrostatic system Your system may include other equipment or objects which must also be grounded Always check your local electrical code for detailed grounding instructions Be sure your system is connected to a true earth ground 1 Pump ground by using a ground wire and clamp as described in your separate pump instruction manual 2 Air compressors and hydraulic power supplies ground according to the manufacturer s recommendations 3 Electrostatic Air Spray Gun obtain grounding through con nection 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
25. ct may be slightly recessed into the seal See Fig 12 The resistance should be 297 to 363 megohms If the resistance is outside the specified range the power sup ply 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 16 308 084 KEY A Megohmmeter A 28 Electrode 39 Gun Body 39 c x li Sss pi 28 0440 Fig 11 KEY A Megohmmeter EE Ground Contact Point 40 Power Supply 40d Seal 40 0441 Fig 12 ELECTRICAL TESTS Test Resistor Stud Resistance See Fig 13 Remove the resistor stud See Air Cap Nozzle Resistor Stud Replacement Check the resistance between the black resistor stud ring contact D and the needle con tact ring E You may have to press down on the contact ring D in several places to get a good reading The resistance should be 21 to 29 megohms If the resistance is correct make sure the metal contact in the gun barrel and the needle contact ring E are clean If the resistance is outside the specified range the resistor is defective and the resistor st
26. ctrode 28 is tightened properly as shown in Fig 17 page 20 5 Install the fluid nozzle 14 and resistor stud 2 assembly with the nozzle wrench 48 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight 6 Install the air cap assembly 6 16 43 o ring 12 and retaining ring 9 T est gun resistance as instructed on page 16 KEY D Contact Ring 6 16 43 GS 2 Resistor Stud 6 16 43 Air Cap Assembly 12 9 Retaining Ring 12 O Ring 14 Fluid Nozzle 28 Electrode E 9 31 O Ring 48 Nozzle Wrench 7 gt 0443 14 Torque to KEY 10 in lbs A 8 mm Hex Key 1 12 Nem 2 Resistor Stud 14 Fluid Nozzle 0444 Fig 16 308 084 19 SERVICE Electrode Replacement 1 Remove the air cap nozzle and resistor stud as described in Air Cap Nozzle Resistor Stud Replacement 2 Unscrew and remove the fluid needle electrode 28 with the electrode tool 47 provided Be careful not to damage the contact wire See Fig 17 If the fluid rod turns hold the back end of the fluid rod 3 Apply low strength purple Loctite or equivalent thread sealant to the electrode and fluid rod threads Refer to SERVICE NOTES page 25 Hold the back end of the fluid rod to prevent it from turning while installing the new electrode finger tight DO NOT over tighten the electrode CAUTION To avoid damaging the plastic threads or contact wire be very careful wh
27. der Graco Electri cally Conductive Air Supply Hose This hose and the gun have special left hand threads to prevent connecting another type of air supply hose to the gun turbine air inlet Connect the air fluid and optional fiber optic lines to the gun manifold as shown in Fig 6 Before connecting the fluid line blow it out with air and flush it with solvent Use solvent that is compatible with the fluid being sprayed INSTALLATION To ensure a dry clean air supply to the gun install an air ished workpiece and can cause the gun to malfunction A line filter and an air and water separator on the air lines combination air filter moisture separator is shown in the Dirt and moisture can ruin the appearance of your fin ACCESSORIES section Socket Head t Mounting Cap Screws Plate Manifold Dovetail O Ring Spray Gun Set Screws Shroud Mounting Block Hex Head oa Cap Screws x 2 fe LR _ Button Head Square Head a See Screw Set Screw 01877 BACK VIEW OF MANIFOLD INSTALLED ON MOUNTING BRACKET Air Cap Air Cap Nut Fig 5 Connect 4 of Connect 1 4 OD tube between 1 4 ID tube fitting and control module g TO AVOID SHOCK OR EXPLOSION USE PROPERLY GROUNDED AIR HOSE Connect Graco Fiber Optic Connect Graco Grounded Air Hose Cable see Accessories between fitting amp control module left hand thread Connect the ground wire on the air hose to a true earth ground MAX WRP
28. ds in the spray booth are in approved grounded containers 9 Be sure all conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded 10 Be sure to check the manifold exhaust tubes for the presence of any fluid as instructed in Check for Fluid Leakage page 12 Selecting a Fluid Nozzle and Air Cap This gun is supplied with fluid nozzle 185 158 1 5 mm and air cap 177 033 If your application requires a differ ent nozzle and air cap combination use instruction manual 307 803 to select the appropriate fluid nozzle and air cap Gun Functions The gun functions include the following e Fluid Trigger only e Spray properly timed on off sequence of fan air atom air and paint e Turbine Air e Voltage Select Activating the Fluid Trigger Only To activate the fluid trigger alone first relieve the air pres sure to the trigger module then shut off the air supply to the ATOM and FAN air lines Apply 50 psi 3 5 bar mini mum air pressure to the CYL air supply line to activate the gun s fluid trigger Adjusting the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow DO NOT turn the turbine air electrostatics on yet 1 Adjust the fluid flow with the fluid line regulator s pressure 2 Rotate the air cap for the desired spray pattern 3 Use an air pressure regulator to adjust the de
29. dur ing operation 10 Install the gun onto the manifold Refer to page 6 04673 Fig 25 04674 Fig 26 Fig 27 04672 308 084 31 ACCESSORIES Accessories must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES AIR AND FLUID LINE ACCESSORIES Air Pilot Paint Regulator 224 531 For controlling paint flow through the spray gun Connects to mount assembly 235 094 0331 Grounded Air Supply Hose 100 psi 7 bar MAXIMUM WORKING PRESSURE 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f LH Color coded black PART NO LENGTH 220 444 6 ft 1 8m 218 100 15 ft 5m 218 101 25 ft 8 m 218 102 36 ft 11 m 218 103 50 ft 15 m 220 119 75 ft 23 m 220 120 100 ft 30 5 m Grounded Air Supply Hose 100 psi 7 bar MAXIMUM WORKING PRESSURE 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f LH Color coded gray More flexible than black hose PART NO LENGTH 223 068 6 ft 1 8m 223 069 15 ft 5m 223 070 25 ft 8m 223 071 36 ft 11m 223 072 50ft 15m 223 073 75 ft 23 m 223 074 100 ft 30 5 m Grounded Air Supply Hose 100 psi 7 bar MAXIMUM WORKING PRESSURE 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f LH Color coded red Stainless steel braid ground path PART NO LENGTH 235 068 6 ft 1 8m 235 069 15 ft 5 m 235 070 25 ft 8m 235 071 36 ft 11m 235 07
30. e amp Meter 217 452 For direct measurement of gun output voltage SYSTEMS Gun Manifold and Mount System 235 303 Includes PART NO DESCRIPTION 224 224 PRO4600 Gun 224 094 Gun Manifold 235 094 Standard Gun Mount TECHNICAL DATA Weight gun amp manifold 43 oz 1207 g Maximum Working Pressure 100 psi 7 bar 0 100 psi 0 7 bar Fluid Pressure Operating Range 0 100 psi 0 7 bar Air Pressure Operating Range Voltage Output 0 85 kV Paint Resistivity Range 3 megohm cm to infinity Turbine Air Inlet 1 4 npsm m L H Wetted Parts Stainless Steel Nylon Acetal PTFE Kalrez Ultra High Molecular W eight Polyethylene Ceramic Chemraz Fluoro polymer Viton and Kalrez are registered trademarks of the DuPont Co Loctite is a registered trademark of the Loctite Corporation Chemraz is a registered trademark of the Green Tweed amp Co MANUAL CHANGE SUMMARY The following parts have been changed in this revision Assembly _ Part Ref Part No Name Changed Status No 224 635 Old 3 223 980 Packing Rod 224 224 New 3 224 747 Packing Rod 235 893 amp Added 51 110 088 Wrench 235 894 Spray Gun Added 52 105 749 Brush Miscellaneous Changes 1 Changed the Fluid Seal Repair Kit from part no 224 635 to part no 237 786 2 Added the PRO 4600HC Conv
31. e Voltage Select KV HI LO To change the voltage to the lower setting activate the voltage select function KV HI LO The lower voltage setting is factory set to 60 kilovolts at zero microamperes To change this setting see page 25 The valve used to activate the KV HI LO switch must bleed the air out of the line for the switch to draw back to the high setting MAINTENANCE WARNING To reduce the risk of serious bodily injury including splashing in the eyes or on the skin or electrostatic shock always follow the Pressure Relief Proce dure Warning on page 9 when shutting of fthe system when you stop spraying and before check ing 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 Conduc tive solvents can cause the gun to malfunction Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components Immersing the gun in solvent is not recommended as a cleaning method Solvent left in gun passages could result in a poor quality paint finish and may draw current and reduce the electrostatic ef fect Solvent in the power supply cavity can reduce the alternator life 10 308 084 Daily Care and Cleaning 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
32. en installing the electrode 4 Install the fluid nozzle and resistor stud assembly Install the air cap assembly Test the gun resistance as instructed on page 16 20 308 084 KEY 28 Electrode 47 Electrode Tool 28 Apply low strength purple Loctite or equivalent 0445 Fig 17 SERVICE Barrel Removal KEY 1 Carefully loosen the fluid fitting nut 21 Pull the tube 39 Gun Body 19 out of the fitting Make sure both ferrules and the 40 Power Supply nut stay with the tube See Fig 19 2 Remove the jam nut 25 and actuator arm 29 NOTE The fluid nozzle must be in place when removing or installing the jam nut and actuator arm 3 Using the ball end wrench 46 supplied loosen the three socket head cap screws 15 See Fig 20 4 Hold the gun body 39 with one hand and pull the barrel 10 straight away from the body to remove it See Fig 18 CAUTION To avoid damaging the power supply always pull 40 the gun barrel straight away from the gun body If necessary gently move the barrel from side to side to free the power supply from the gun body Fig 18 samamm iIi KEY 7 Jam Nut 25 Jam Nut 10 Gun Barrel 29 Actuator Arm 19 Fluid Tube 39 Gun Body 39 21 Fluid Fitting Nut 10 25 29 7 19 21
33. ersion Kit part no 237 301 to the manual 308 084 35 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 workman ship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for breach of this warranty Graco will for a period of twelve months or two thousand hours of operation from time of sale repair or replace any part of the equipment proven defective However any deficiency in the barrel handle trigger hook internal power supply and alternator excluding turbine bearings will be repaired or replaced for thirty six months or six thousand hours of operation from time of sale 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 instal lation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering 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 e
34. ff the fluid supply to the gun Trigger the gun into a grounded metal waste container to relieve fluid pressure Open the pump drain valve having a waste container ready to catch the drainage Leave the pump drain valve open until you are ready to spray again WARNING If any fluid leakage from the gun is detected stop spraying IMMEDIATELY Fluid leakage into the gun shroud could cause fire or explosion and re sult in serious bodily injury and property damage See Check for Fluid Leakage page 12 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 automatic electrostatic air spray system 2 Besure all operators are trained how to prop erly and completely relieve system pressure 3 Be sure the system is thoroughly grounded See FIRE EXPLOSION OR ELECTRO STATIC SHOCK HAZARD on page 3 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 Be sure ventilation fans are operating properly 6 Be sure the workpiece hangers are clean and grounded Contact points must be sharp points or knife edges Be sure all refuse is removed from the spray booth 8 Be sure all flammable liqui
35. gree of atomization and pattern width For the most efficien cy always use the lowest air pressure possible NOTE See the Spray Pattern Troubleshooting Chart on page 13 to correct spray pattern problems OPERATION continued on next page 308 084 9 OPERATION Adjusting the Turbine Air Pressure WARNING The fan and atomizing air MUST be on before turning on the turbine air Actuating the turbine air without fan and atomizing air flow could damage the gun and may create hazardous operating conditions and result in serious injury and property damage 1 Complete all the checks under the Checklist on page 9 Operating 2 Make sure the fan and atomizing air are on then turn the turbine air electrostatics on 3 The turbine air pressure should be adjusted to 40 psi 2 8 bar at the gun manifold inlet when air is flowing The gun may be operated at a lower air pressure but some voltage loss could occur Do not exceed 50 psi 3 5 bar air pressure as there is no added benefit and turbine life could be reduced 4 Check the gun electrostatics display module if used to see the voltage and current output levels NOTE The gun s normal high voltage output is 60 to 70 kV If a ball end high voltage measurement probe is used the gun voltage will rise to about 85 kV This will happen with all resistive electrostatic guns See the Electrical Troubleshooting Chart on page 15 to correct voltage problems Activating th
36. iner Ring 27 Alternator 27a O Ring 27b Cushion 39 Gun Body 40 Power Supply 40a Gasket 40b Pad 40c Pad 40d Seal 40e Cushion Power Supply Removal and Replacement REPAIR NOTES a To avoid a loss in electrostatic performance inspect the gun handle s power supply cavity for dirt or moisture Clean the cavity with a clean dry rag b Do not expose the seal 40d or o ring 27a to solvents as solvents will damage them 1 Remove the barrel as described in Barrel Removal 2 Grasp the power supply 40 with your hand With a gentle side to side motion being careful not to dam age the power supply pull the power supply free from the gun handle 39 then pull it straight out 3 Inspect the power supply for any physical damage Check the electrical resistance as instructed in Test Power Supply Resistance If needed replace the power supply Before installing the power supply inspect the seal 40d for any damage or swelling replace if neces sary Also make sure the gaskets pads 40a 40e are in place 4 Lubricate the o ring 27a and insert the power sup ply in the gun handle 5 Install the barrel on the handle as described in Barrel Installation 0450 Power Supply Adjustment The KV HI LO switch on the back of the gun manifold enables you to switch between full voltage and a lower voltage output The lower voltage is factory set at 60 kV but can be adjusted between 45 and 80 kV
37. ld but not manufactured by Graco These items sold but not manu factured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties GRACO PHONE NUMBERS TO PLACE AN ORDER contact your Graco distributor FOR TECHNICAL ASSISTANCE service repair infor or call Graco 1 800 367 4023 Toll Free mation or answers about the application of Graco equip ment call 1 800 543 0339 Toll Free Sales Offices Atlanta Chicago Dallas Detroit Los Angeles Mt Arlington N J Foreign Offices Canada England Switzerland France Germany Hong Kong Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 084 June 1991 Revised January 1995 36 308 084
38. luid Packing Rod Removal and Repair NOTE The fluid packing rod can be replaced as 3 SERVICE KEY Fluid Packing Rod Assembly 45 Hex Nut Driver individual parts or as an assembly If the assembly is purchased it is pre adjusted at the factory 1 2 Remove the jam nut 25 and arm 29 See Fig 20 Remove the air cap assembly fluid nozzle and resis tor stud and electrode as described in Electrode Replacement Remove the fluid packing rod assembly 3 using the 9 mm hex nut driver 45 See Fig 21 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 4 Check all the parts for wear or damage and replace if necessary Fig 21 0448 Before installing the fluid packing rod assembly 3 clean the internal surfaces of the barrel with a soft 6 Place the packing nut 3c and o ring 3g on the fluid brush or cloth Check the inside of the barrel for rod 3b The flats on the packing nut must be facing marks from high voltage arcing If the marks are toward the back of the fluid rod present replace the barrel 7 Fill the entire inner cavity of the spacer 3d with the 5 Ifthe parts are purchased separately assemble dielectric grease included with the gun Place the them as instructed in steps 6 to 9 and as shown in spacer on the fluid rod 3b in the direction shown in
39. mbly 235 094 Bracket for mounting to a 1 2 inch 12 7 mm rod with a slot for mount ing the air pilot fluid regulator 224 531 01875 Gun Mount Assembly 224 118 For mounting the PRO4600 gun to the GMF P150 robot Mount Extensions 224 255 259 For extending the mount length of Mount Assembly 224 118 Contact your Graco representative for avail able lengths Nylon Fabric Cover 187 343 Fabric cover to protect the manifold inlet tubing and fittings from paint buildup 187 343 0437 GUN CONTROL AND MONITORING ACCESSORIES For more information about gun controls and monitoring accessories contact your Graco representative Pneumatic Trigger Module 235 768 Provides pilot air valve control for atomizing air fan air and fluid trigger air gun functions Refer to manual 308 264 01768 ES Display Module 224 117 Receives fiber optic transmission from the PRO 4600SC Gun and displays the gun s output voltage and current Mounts in a standard 19 DIN Rack Refer to manual 308 265 D SN 2 VV OO 9 9 9 9 9 9 9 9 9 9 vv s0V0V0V0VVVLUVYUVUVUY A 0309 24 Volt Power Supply 235 301 Provides 24 volt power for up to 23 ES Display Modules 3 Las 01339 308 084 33 ACCESSORIES Accessories must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES CABLE ACCESSORIES Fiber Optic Cables Fiber Op
40. ng Button Head Screw 01179 SERVICE Air Cap Nozzle Resistor Stud Replacement CAUTION BE SURE to hold the front end of the gun up while removing the nozzle and resistor stud This helps drain the gun and prevent any paint or solvent left in the gun from entering the air passages 1 Point the front end of the gun up while removing the fluid nozzle 14 and resistor stud 2 assembly with the nozzle wrench 48 This helps drain the gun and prevent any paint or solvent left in the gun from entering the air passages See Fig 15 If the resistor stud remains in the gun when the fluid nozzle is removed start the nozzle thread onto the stud and pull the stud out 2 Using an 8 mm hex key A unscrew and remove the resistor stud 2 See Fig 16 WARNING The resistor stud contact ring D is a conductive con tact ring NOT a sealing o ring To reduce the risk of sparking which could cause fire explosion or elec trostatic shock and result in serious injury DO NOT remove the contact ring from the resistor stud or op erate the gun without the contact ring in place DO NOT replace the resistor stud with anything but a genuine Graco part To install the resistor stud 3 Lightly lubricate the o ring 31 with petroleum jelly and install it on the resistor stud 2 4 Using an 8 mm hex key A install the resistor stud 2 in the fluid nozzle 14 T ighten to 10 in lb 1 12 Nem Make sure the ele
41. odily injury including splashing fluid or solvent in the eyes or on the skin always follow the Pressure Relief Procedure on page 9 before checking adjusting cleaning or repairing the gun or any part of the system NOTE Check all possible remedies in the Troubleshooting Charts before disassembling the gun PROBLEM IMPROPER SPRAY PATTERN Fluttering or spitting spray l O 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 tank Fluid build up on air cap partially clogged horn holes Full air pres sure from clean horn hole forces fan pattern toward clogged end Bent electrode Damaged fluid nozzle or air cap holes Fluid build up on the perimeter of fluid nozzle orifice or partially clogged fluid nozzle orifice Bent electrode Too high fan air pressure Fluid too thin Not enough fluid pressure Low fan 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 CAUSE SOLUTION Adjust fluid regulator or fill fluid tank Tighten or replace fluid nozzle See page 19 Clean See page 11 Tighten or repair Tighten Clean with soft implement or submerge in suitable solvent and wipe clean See page 11 Straighten electrode
42. ould not exceed 100 ohms Install the Fabric Cover See Fig 8 1 Install a fabric cover over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold See ACCESSORIES sec tion a Megohmmeter See ACCESSORIES to order True Earth Ground Grounded Air Hose Gun Manifold 0436 Fig 7 2 Cuta small slit in the cover and route the two exhaust tubes outside the robot arm or reciprocator This en ables you to monitor the exhaust tubes for the pres ence of any paint or solvent See Check for Fluid Leakage on page 12 Strap down the exhaust tubes to prevent them from moving around E Fabric Cover Slit Exhaust Tubes 0437 Fig 8 8 308 084 Exhaust Tubes OPERATION 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 electrostatic 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 the air to the control module except for the manifold air If the air pilot fluid regulator is used air pressure is needed at the regulator air inlet to relieve pressure in the fluid line Turn o
43. plastic parts of the gun must be held in a vise ONLY use padded vise jaws to avoid damaging parts e ALWAYS remove the gun from the worksite for service or repair The service or repair area must be clean Spray Gun Shroud Air Cap Air Cap Nut 18 308 084 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 electrostatic 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 Turn off the air to the control module except for the manifold air If the air pilot fluid regulator is used air pressure is needed at the regulator air inlet to relieve pressure in the fluid line Turn off the fluid supply to the gun Trigger the gun into a grounded metal waste container to relieve fluid pressure Open the pump drain valve having a waste container ready to catch the drainage Leave the pump drain valve open until you are ready to spray again Remove the Gun from the Manifold and the Mounting Bracket See Fig 14 Remove the air cap air cap nut assembly and the gun shroud 2 Loosen the three socket head cap screws and the button head screw using the ball end wrench 46 supplied 3 Remove the gun from the manifold Socket Head Cap Screws Manifold O Ri
44. quipment or materi als 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 claim 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 reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warranties express or im plied including warranty of merchantability or warranty of fitness for a particular purpose and of any non contractual liabili ties including product liabilities based on negligence or strict liability Every form of liability for direct special or consequential dam ages or loss is expressly excluded and denied in no case shall Graco s liability exceed 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 re spect to accessories equipment materials or components so
45. ray ing highly conductive fluids The kit must be ordered separately It includes items 201 to 204 Ref No Part No Description Qty 201 237 299 COILED TUBE ASSY 1 202 112 644 NUT nylon for 1 4 O D tube 1 203 111 285 FERRULE nylon 1 204 111 286 FERRULE nylon 1 201 202 m awo 6 204 Fig 24 3933A Installing the PRO 4600HC Conversion Kit 1 2 Flush the gun with a compatible solvent Relieve system pressure as instructed in the Pres sure Relief Procedure on page 18 Remove the gun from the manifold as instructed on page 18 Remove the gun from the spray area Remove the PRO 4600SC gun s fluid tube fittings and o rings B See Fig 25 Clean the barrel fluid inlet A with compatible sol vent Inspect the barrel fluid inlet for damage and replace if needed Slide the coils of the tube assembly 201 over the front of the gun barrel until it is past the barrel fluid inlet A See Fig 26 and 27 Position the coiled tube assembly so its threaded inlet fitting C is aligned with the barrel fluid inlet A then tighten the fitting into the inlet as shown in Fig 27 Slide the nylon nut 202 and ferrules 203 amp 204 onto the coiled tube assembly 201 See Fig 24 Install the coiled tube assembly 201 into the fluid fitting and tighten the nut 202 See Fig 27 Make sure the entire tube is clear of the actuator arm D to avoid having the tube rub against it
46. re can distort the spray pattern 4 Carefully reinstall the air cap assembly Avoid bend ing the electrode Tighten the retaining nut until it is snug allowing the air cap to turn with resistance 0439 Fig 9 MAINTENANCE continued on next page 308 084 11 MAINTENANCE Check for Fluid Leakage See Fig 10 WARNING During operation periodically check the two manifold ex If any fluid leakage from the gun is detected haust tubes and both ends of the gun shroud for the pres stop spraying IMMEDIATELY Fluid leakage into ence of fluid Fluid in these areas would indicate fluid the gun shroud could cause fire or explosion and leakage into the shroud result in serious bodily injury and property damage If fluid is seen in any of these areas stop spraying immediately Follow the Pressure Relief Procedure on page 9 then remove the gun for repair Fabric Cover Gun Shroud Check for signs of fluid leakage where indicated by arrows Exhaust Tubes 0437 0438 12 308 084 SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other seri ous 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 b
47. t performed properly e 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 elec trical apparatus in a Class I Group D Hazardous Location Check and follow all local safety and fire codes NFPA 33 NEC 504 and 516 and OSHA standard 1910 107 Ventilate the Spray Booth WARNING To prevent hazardous concentrations of toxic and or flammable vapors spray only in a properly venti lated spray booth Never operate the spray gun unless ventilation fans are operating Electrically interlock the gun air supply with the ventila tors to prevent gun operation without ventilating fans op erating Check and follow all National State and Local codes regarding air exhaust velocity requirements High velocity air exhaust will decrease the operating effi ciency of the electrostatic system The minimum allow able air exhaust velocity is 60 feet minute 19 linear meters minute Install the Gun Mounting Bracket Attach the mounting bracket to the robot or reciprocator See the ACCESSORIES section for the mounting brack et and mount extension options and refer to Fig 3 and Fig 4 for mounting positions 2 3 in 58 mm i Hi PRO 4600 Gun m a A with Slotted Shroud JE tu PIN 235 894 dl if I 7
48. the fluid being sprayed To clean the exterior of the equipment ALWAYS use solvents with a flash point of higher than 100 F 38 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 Check and follow all National State and Local codes regarding air exhaust velocity requirements Check and follow all local safety and fire codes and OSHA standard 1910 107 NEVER operate the spray gun unless the ventilating fans are operating IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act These standards particularly the General Standards Part 1910 107 and any other appropriate regulations should be consulted in connection with the installation operation and maintenance of electrostatic spray painting equipment 308 084 3 TABLE OF CONTENTS Warnings 11 244400 02 Pour une 2 Terms 2520 8 agate tek mn ER rene the 4 Installation Typical Installation 5 Warning Signs 5 Ventilate the Spray Booth 6 Install the Gun Controls and Display Module 6 Install the Gun Mounting Bracket 6 Install the Gun and Manifold
49. tic Cable Assembly For connection between gun manifold and display module or between bulkhead connector and display module PART NO _LENGTH 224 680 224 681 224 682 224 683 224 684 224 685 224 686 6 ft 1 8 m 15 ft 5 m 25 ft 8 36 ft 11 50 ft 15 75 ft 23 100 ft 3 m m m m 0 5 m a 0330 Fiber Optic Cable Extender For connection between gun manifold and bulkhead con nector PART NO LENGTH 224 670 224 671 224 672 224 673 224 674 224 675 224 676 34 308 084 6 ft 1 8 m 15 ft 5 m 25 ft 8 36 ft 11 50 ft 15 75 ft 23 100 ft 3 m m m m 0 5 m 0184 Bulkhead Connector 224 261 For connection between two fiber optic cables SP A MISCELLANEOUS ACCESSORIES 0185A Grounding Clamp and Wire 222 011 12 ga 25 ft 7 6 m wire Megohmmeter 218 979 500 Volt output 0 01 2000 megohms Not for use in Hazardous areas 0189 Safety Warning Signs Available at no charge from Graco Must be ordered separately PART NO DESCRIPTION 180 060 Warning Sign English 180 061 Warning Sign French 180 062 Warning Sign German 180 063 Warning Sign Spanish 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 Gun High Voltage Prob
50. ud 2 must be replaced See Air Cap Nozzle Resistor Stud Replacement WARNING The resistor stud contact ring D is a conductive contact ring NOT a sealing o ring To reduce the risk of sparking which could cause fire explosion or electrostatic shock and result in serious injury DO NOT remove the resistor stud contact ring D from the resistor stud or operate the gun without the contact ring in place DO NOT replace the re sistor stud with anything but a genuine Graco part KEY D Resistor Stud Contact Ring E Needle Contact Ring 0442 Fig 13 308 084 17 SERVICE WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious bodily injury if the work is not performed properly Do not install or service this equipment unless you are trained and qualified NOTE Check all possible remedies in the Troubleshooting Charts before disassembling the gun Flush the Gun and Relieve Pressure WARNING To reduce the risk of fire explosion or electrostatic shock BE SURE the turbine air electrostatics is off before flushing the gun CAUTION Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components Before removing the gun for service flush it by alternat ing solvent and air Then follow the Pressure Relief Pro cedure at right Service Notes e If the
51. ve or Air Regulator J PIN 235 768 H 2 3 way solenoid we C 3 Cylinder Air Line is i us Recip Mount Assy Re de ec fie a Ree 7 Fluid Supply True Earth Fig 1 Controls Cabinet 24V Power Supply P N 235 301 Tp Fiber Optic Cable P N 224 680 686 Bulkhead ES Display Module P N 224 261 I f P N 224 117 i I Li Air Pressure Control Non Hazardous Area Fig 2 Installing the System Fig 1 above shows a typical Model 4600 system Fig 2 shows some possible system options For assistance in designing a system that is customized for your applica tion contact your Graco representative Fiber Optic Cable P N 224 670 676 P N 235 094 SYSTEM OPTIONS e Spraying Voltage Monitor e Air Pilot Fluid Regulator Air Pilot Fluid Regula tor P N 224 531 01769 Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun Additional English French German and Spanish signs are avail able at no charge See the ACCESSORIES section to or der them 308 084 5 INSTALLATION WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious bodily injury if work is no
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