Graco Inc. 218-026 Paint Sprayer User Manual
Contents
1. 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 Ea 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 2 307 638 9 OPERATION 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 ai2. KEY 2 Key 37 Valve Lever 4 Regulator Disk 38 O Ring 35 Nut 39 Air Valve Wave Washer Px 38 LI 35 Torque to 0 225 Nem 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 80 Apply sealant to outside surface 70 Adapter Retainer 71 Screw 77 Ball 78 Valve Check Retainer 80 Muffler O 81 Spring 85 Bulkhead Retainer Fig 23 307 638 25 PARTS DRAWING Ref No 59 Tool Kit Includes items 59a 59h Screw in restrictors flush with surface of gun handle Power Cartridge Includes items 3a 3c amp 5 A a 16t 21 12t WARNING Ref 2 Old New Style Resistor Stud and Electrode To reduce the risk of sparking which could cause fire Ref 70 or explosion BE SURE the electrode and stud you install are black The old style electrode and st
3. 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 10 307 638 31 THE GRACO PRO4000 WARRANTY AND DISCLAIMERS WARRANTY Graco warrants the PRO4000 to be free from defects in material and workmanship 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 from the date of sale repair or replace any part of the equipment proven defective with the exception of defects in the internal power supply and alternator which will be repaired or replaced for thirty six months from the date 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 sh
4. Fig 9 307 638 17 SERVICE Gun Disassembly WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not per formed properly Do not install or service this equipment unless you are trained and qualified Follow the Pressure Relief Procedure Warning page 9 before servicing the gun or any part of the system Disconnect the fluid hose from the gun NOTE Check all Troubleshooting Charts before disassembling the gun possible remedies in the CAUTION If the plastic parts of the gun must be held se curely ALWAYS clamp them in padded vice jaws to prevent damage to the parts ALWAYS lubricate o rings and seals with petro leum jelly ALWAYS remove gun from worksite for service or repair Service or repair area must be clean Flush the gun as described under Flush the Spray Gun Follow the Pressure Relief Procedure Warning on page 9 Disconnect the air and fluid line from the gun Electrode Replacement 1 Remove the air cap assembly and fluid nozzle as de scribed in Clean the Air Cap and Fluid Nozzle 2 Unscrew and remove the electrode 12 with the wrench 59c supplied See Fig 10 If the needle shaft assembly 45 turns while trying to loosen the electrode hold the needle shaft assembly nut with a small wrench 18 307 638 3 Install the new electrode 12 with the wrench 59c suppli
5. 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 li
6. 307 638 19 SERVICE Barrel Removal 1 Unscrew the nut 19 at the barrel fluid inlet See Fig 12 2 Pull the fluid tube 20 out of the fluid inlet 3 Remove the trigger by removing the screws and spacers from the gun 4 Remove the ES indicator lights from the socket head capscrews 30 5 Using the wrench 59f supplied loosen and re move the two socket head capscrews 30 from the gun 6 Hold the gun handle 2 with one hand and pull straight up to remove the gun barrel 18 See Fig 13 CAUTION To avoid damaging the power cartridge always pull the gun barrel straight away If necessary gently move the gun barrel from side to side to free it from the gun handle NOTE The gasket 46 should be left in the gun handle 2 if the gasket is not to be replaced To install the barrel 18 follow the procedure below 1 Be sure the gasket 46 is in place Replace if dam aged Place the barrel over the power cartridge 3 and onto the gun handle 2 See Fig 13 2 Install the two socket head capscrews 30 and tighten with the wrench 59f supplied See Fig 12 3 Snap the ES indicator lights in place over the socket head capscrews 30 4 Insert the fluid tube 20 into the fluid inlet of the gun barrel and tighten the nut 19 5 Install the trigger with the screws and spacers Test the gun resistance as instructed on page 16 Fluid Needle Packing Replacement 1 Remove the air cap assembly
7. ES Indicator Lights Fig 2 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 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 Turn the ES ON OFF Valve lever to OFF Turn off the air and 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 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 Be sure all operators are properly trained to safely operate an electrostatic air spray system 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
8. OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid pack ing nut Air leakage from front of gun Fluid leakage from front of gun Orange Peel finish Excessive spray fog No fluid sprays from gun Equipment covered with fluid Dirty air cap 14 307 638 Worn needle packing Air valve not seating properly Air stem packing too tight Electrode worn or damaged Worn fluid seat Fluid packing too tight Loose fluid nozzle Fluid adjusting screw not set correctly 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 Exhaust air flow insufficient or not directed properly Improper distance between gun and work piece Misalignment between air cap and fluid nozzle Air Cap Fluid Nozzle Misaligned Replace packing assembly See page 21 Clean service See page 24 Loosen packing See page 24 Replace electrode See page 18 Replace fluid nozzle and or electrode See page 18 Adjust packing screw See page 20 Tighten fluid nozzle See page 10 Adjust screw Increase use least air pressure needed for good results Remix or refilter fluid Use proper thinner Reduce use least air pressure needed for good results Properly thin fluid Check add if necessa
9. Range 0 75 KV Paint Resistivity Range 7 megohm cms to infinity Alt Inlet sa oy 1 4 npsm m L H Fluid Inlet 0 cece eee 3 8 npsm m Wetted Parts Stainless Steel Polyethylene Nylon Acetal Viton PTFE Delrin Viton and Delrin are registered trademarks of the DuPont Co Loctite 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 6 digit Part Number Qty Part Description SERVICE INFORMATION Listed below by assembly changed are OLD and NEW parts Assembly Ref Changed Status No Part No 218 026 ADDED 18b 186 127 Cushion Spray Gun OLD 43 181 183 Trigger NEW 43 186 473 Trigger INTERCHANGEABILITY NOTE NEW parts replace OLD parts listed directly above them MISCELLANEOUS NOTES Revised the manual to update the gun handle drawings Name 307 638 29 ACCESSORIES Accessories must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES WARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system Lower rated components may not be able to wit
10. 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 tool
11. and fluid nozzle as de scribed in Clean the Air Cap and Fluid Nozzle 2 Remove the electrode as described under Electrode Replacement 3 Remove the gun barrel as described under Barrel Removal 4 Unscrew the packing nut 45e using the wrench 59b supplied See Fig 14 20 307 638 KEY 19 Nut 20 Fluid Tube 30 Capscrew 59f Wrench 59f 30 Fig 12 KEY 2 Gun Handle 3 Power Cartridge 18 Gun Barrel 46 Gasket wey tin D7 Fig 13 KEY 45e Packing Nut 59b 59b Wrench Fig 14 SERVICE 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
12. 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 System Pressure This gun has a maximum working air and fluid pressure of 7 bar 100 psi Never exceed the maximum working pressure of the gun or any other component or accessory used in the system HAZARDOUS FLUID HAZARD Improper handling of hazardous fluids or inhaling vapors can cause 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 HOSE SAFETY TIGHTEN all fluid connections securely before each use NEVER use a damaged hose Before each use check the entire hose for cuts leaks abrasion bulging cover or damage or movement of the hose couplings If any of these conditions exist replace the hose immediately 4 307 638 Fluid Compatibility BE SURE all flui
13. coupler at fluid inlet Loose fluid tube in cup or tank Fluid build up on air cap partially clogged horn holes Full air pressure from clean horn hole forces fan pattern toward clogged end Damaged fluid nozzle or air cap holes Fluid build up on the perimeter of fluid nozzle orifice or partially clogged fluid nozzle orifice Too high atomization air pressure Fluid too thin Not enough fluid pressure Low atomization air pressure Fluid too thick Too much fluid Last coat of fluid applied too wet Too much air pressure Insufficient air pressure Non uniform spray pattern CAUSE SOLUTION Adjust fluid regulator or fill fluid tank Tighten or replace fluid nozzle See page 10 Clean See page 11 Tighten or repair Tighten Clean with soft implement or submerge in suitable solvent and wipe clean See page 11 Replace damaged part See page 10 Remove obstruction Never use wire or hard instruments See page 11 Reduce air pressure or adjust air adjusting valve Regulate fluid viscosity Increase fluid pressure Increase air pressure Regulate fluid viscosity Reduce fluid flow Reduce fluid pressure on pressure feed guns and or adjust Apply drier finish with multiple strokes Use least air pressure necessary Increase air pressure Clean or replace air cap NOTE Some improper patterns are caused by the improper balance between air and fluid 307 638 13 GUN
14. disc 1 O RING Viton 1 O RING Viton 1 O RING Viton 1 O RING Viton 1 O RING Viton 1 O RING Viton 2 GASKET housing 1 PACKING needle PTFE 1 Resistor Stud and Electrode Kit 220 391 Description Qty ELECTRODE color coded black 1 STUD resistor color coded black O RING Viton WRENCH needle TOOL resistor stud WASHER er oe oe Description Qty RETAINER adapter SCREW machine pnh M5 x 12 BALL SST 3 8 dia RETAINER valve check MUFFLER SPRING compression h b h b b h Includes Ref No Part No 12 181 824 16 220 923 17 105 667 59c 177 007 59h 183 107 75 181 825 Muffler Kit 218 682 Includes Ref No Part No 70 181 380 71 180 624 77 101 435 78 180 621 80 180 623 81 108 046 85 180 143 28 307 638 RETAINER bulkhead Low Air Flow Restrictor Kit 223 830 For reducing atomizing air flow Includes Ref No PartNo Description Qty 100 179 994 RESTRICTOR 101 107 414 SPRING compression 102 100 172 BALL 3 16 diameter NNN MUST also order Air Cap 220 535 Optional Air Cap 220 535 MUST be used with Low Air Flow Restrictor Kit 223 830 above Must order separately TECHNICAL DATA Weight mereen aosa ak Melee Bede i 0 87 Kg 1 90 Ib Gun Length aaas 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
15. from haz ardous fluids 4 Connect the fluid line to the 3 8 18 6 m gun fluid in let X 307 638 7 INSTALLATION 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 Turn the ES On Off valve to OFF See Fig 2 for the location of the valve lever Turn off the air and fluid supply to the gun 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 8 307 638 KEY Y Gun Handle Z True Earth Ground AA Ohmmeter BB Grounded Air Hose AA y AR ER h Fig 1 KEY Y ES Valve Lever Z Fluid Adjusting Knob AA Fan Adjusting Knob BB
16. 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 t
17. side to side motion pull it free from the gun handle 2 Then pull the power cartridge straight out 5 Install the gasket 46 in the gun handle 2 of the handle 6 Install the barrel on the handle as described under CAUTION Barrel Removal 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 2 Gun Handle 3 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 Fig 18 22 307 638 SERVICE Turbine Alternator Removal 1 Remove power cartridge from the gun handle as described under Power Cartridge Replacement Carefully twist the turbine alternator 8a counter clockwise and pull it off the power supply 5 until just disengaged from the coupling Then continue to slowly pull the turbine alternator away from the power supply disconnecting the 3 wire connector HH See Fig 19 Using an ohmmeter test the coil in the turbine alter nator 8a 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 Mea
18. 2 15 m 50 ft 223 073 23 m 75 ft 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 30 307 638 HIGH VOLUME AIR REGULATOR 206 199 0 9 bar 0 125 psi Regulated Pressure 14 bar 200 psi Steel Pressure Gauge 1 2 npt f inlet and outlet AIR FILTER amp MOISTURE SEPARATOR 106 148 17 5 bar 250 psi MAXIMUM WORKING PRESSURE For cleaning and drying air in air spray system 20 micron element 5 oz bowl capacity 3 8 npt f inlet and outlet ACCESSORIES FILTER AIR OR PAINT 202 271 52 bar 750 psi MAXIMUM WORKING PRESSURE With 250 micron 60 mesh element 3 8 npt f inlet 3 8 npt m outlet SPRAY SYSTEM ACCESSORIES 218 118 ELECTROSTATIC SYSTEM Includes items 218 026 Manual Electrostatic Air Spray Gun 218 103 Grounded Air Supply Hose See page 30 for specifications 216 077 Fluid Hose See page 30 for specifications 106 148 Air Filter 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 ELECTROST
19. ATIC 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
20. INER bulkhead REF NO PARTNO DESCRIPTION QTY REF 2 218 014 HANDLE gun Includes item 2a 1 NO PARTNO DESCRIPTION QTY 2a 179 400 ADAPTER 1 40 181 383 SEAL valve 1 3 218 111 POWER CARTRIDGE Includes 41 177 128 SPACER 2 items 3a and 5 1 42 107 400 SCREW trigger 2 3a 217 591 ALTERNATOR turbine Includes 43 186 473 TRIGGER 1 items 3b amp 3c 1 45 222 256 FLUID NEEDLE ASSY Includes 3b 107 106 O RING buna n 2 items 45a 45g 1 3c 180 070 PLUG l 1 45a 222 255 PACKING ASSY needle 1 4 107 107 REGULATOR disc 1 45b 222 013 NEEDLE fluid Includes item 5 218 041 POWER SUPPLY Includes 45c amp 45d 1 items 5a 5c 1 45c 183 749 NUT adjusting 1 5a 177 156 O RING Viton 1 45d 183 750 NUT locking 1 5b 106 555 O RING Viton 1 45e 176 936 NUT packing 1 5c 178 504 SPRING compression 1 45f 105 673 SPRING compression 1 12T 181 824 ELECTRODE color coded black 1 45g 179 388 INSULATOR needle 1 13 181 299 NOZZLE fluid See manual 46 179 387 GASKET housing 1 307 803 for available nozzles 1 47 106 901 PACKING needle PTFE 1 14 218 996 AIR CAP ASSEMBLY See manual 52 179 790 LABEL warning 1 307 803 for available air cap 53 179 791 TAG warning not shown 1 assys Includes items 14a 14c 1 55 104 765 PLUG screw 1 14a 176 930 RING retaining 1 58 107 207 FITTING male 1 14b 176 968 NUT retaining 1 59 220 388 TOOL KIT Includes item 59a 59h 1 14c 180 739 AIR CAP See manual 307 803 59a 105 749 BRUSH cleaning 1 for a
21. INSTRUCTIONS PARTS LIST gt 307 638 GRACO Rev AE This manual contains IMPORTANT Supersedes AD WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Model PRO4000 MANUAL MID RANGE ELECTROSTATIC AIR SPRAY GUN 7 bar 100 psi MAXIMUM WORKING AIR and FLUID PRESSURE Part Number 218 026 Series E With 1 2 mm 0 047 in fluid nozzle part no 218 996 U S Patent No 4 290 091 4 219 865 4 462 061 4 497 447 4 660 774 U K Patent No 2 140 327B 2 142 559B 2 147 158 2 191 423 Patented 1986 1987 Canada Brevete 1986 1987 French Patent No 84 07942 84 10234 Japanese Patent No 86 07416 Ea Approved SP GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1984 GRACO INC 2 307 638 TABLE OF CONTENTS TEMS eens eet eek ee ed we A Ee eo 3 Electrical Tests Test Gun Resistance 0 000 c cee eee ee 16 Safety Warnings e esse eee 4 5 Test Power Supply Resistance 16 How The Electrostatic Air Spray Gun Works 5 Test Resistor Stud Resistance 17 Installation Service Typical Installation o on onc eei nr Galend dats 6 Gun Disassembly tc iadasinlvereduneta niece 18 Warning SIGNS aceite sto oles actos at otek ee 6 Electrode Replacement i002 since nity eeeens s 18 Ventilate the Spray Booth 00 000 7 Resistor Stud Replacement 19 Connect the Air Line 0 cece cee eee 7 Barrel Rem
22. OSHA standard 1910 107 b 5 i IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act These standards particularly the General Standards Part 1910 107 and any other appropriate regulations should be consulted in connection with the installation operation and maintenance of electrostatic spray painting equipment HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS The air hose supplies air to the spray gun Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed The turbine generates power which is converted by the power cartridge to supply high voltage current to the gun s ionizing electrode The pump supplies fluid to the hose and gun where the fluid is electrostatically charged as it passes the elec trode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all sur faces 307 638 5 TYPICAL INSTALLATION NON HAZARDOUS AREA Power Supply Must Be Interlocked With Spray Booth Exhaust Fan HAZARDOUS AREA KEY A Main Air Supply Line J Pump Ground Wire Q Spray Gun Ground Wire B Ventilation Fan Interlock Solenoid Valve K Fluid Filter R Grounded Air Supply Hose C Main Air Supply Shutoff Valve bleed type L Fluid Supply Line Shutoff Valve S Electrostatic Spray Gun D Air amp Water Separator M Fluid Pressure Regulator T ES On Off Valve Lever E Pump Air Supply Shutoff Valve bleed ty
23. RY FORM OF LIABILITY FOR DIRECT SPECIAL OR CONSEQUENTIAL DAMAGES 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 RESPECT TO ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties IMPORTANT PHONE NUMBERS TO PLACE AN ORDER contact your Graco distribu tor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free FOR TECHNICAL ASSISTANCE service repair infor mation or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 307 638 3 83 Revised 5 90 32 307 638
24. all not be liable for any malfunction damage or wear caused by faulty installation misap plication 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 equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Graco to verify the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in 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 IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRAC TUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON NEGLIGENCE OR STRICT LIABILITY EVE
25. ds and solvents used are chemically compatible with the Wetted Parts shown in the TECHNICAL DATA Always read the fluid and solvent manufacturer s literature before using the fluid or solvent in this gun 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 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 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 inne
26. ed Do not overtighten CAUTION To avoid damaging the plastic threads be very careful when installing the electrode 4 Reinstall fluid nozzle and air cap assembly as described in Clean the Air Cap and Fluid Nozzle KEY 45 Fluid Needle Shaft Assembly 59c Wrench 59c Fig 10 SERVICE Resistor Stud Replacement WARNING Old New Style Resistor Stud and Electrode To reduce the risk of sparking which could cause fire or explosion BE 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 1 Remove the air cap assembly and fluid nozzle as de scribed in Clean the Air Cap and Fluid Nozzle 2 Remove the electrode as described in Electrode Replacement 3 Using the wrench 59h supplied unscrew and re move the resistor stud 16 with the o ring 17 and washer 75 See Fig 11 To install the resistor stud 1 Lubricate the o ring 17 with petroleum jelly and install it on the resistor stud 16 2 Install the washer 75 in the gun barrel 3 Using the wrench supplied install the resistor stud in the front of the gun barrel Tighten until snug 4 Install the electrode as described in Electrode Re placement 5 Install the fluid nozzle and air cap assembly as described in Clean the Air Cap and Fluid Nozzle KEY 16 Resistor Stud 17 O Ring 75 Washer 17 16 Fig 11
27. he 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 Fig 15 KEY 45 Fluid Needle Assembly 45a Needle Packing Assembly 45b Fluid Needle 45c Adjusting Nut 45d Locking Nut 45e Packing Nut 45f 45f Spring 45g Insulator Fig 16 307 638 21 SERVICE 2 Gun Handle 3a Alternator 3b O Ring 3c Plug 5 Power Supply 5a O Ring 5b O Ring 5c Spring 18 Barrel 18b Cushion 18 46 Gasket See NOTE after step 3 below NOTE The power cartridge 3 includes items 3a 3b 3c and 5 Power Cartridge Replacement 1 Remove the barrel as described under Barrel NOTE The cushion 18b is part of the gun barrel and Removal should never be removed If it ever is removed push the cushion adhesive side in toward the 2 Remove the gasket 46 from the gun See Fig 17 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 CAUTION The power cartridge is fragile Be careful when here propery handling it to avoid damage 4 Insert the new power cartridge in the gun handle 3 Grasp the power cartridge with your hand With a NOTE S A anieele Ure ii gentle
28. hstand the pressure developed by the pump and may rupture causing serious bodily injury or property damage The accessories in the box below are approved by Factory Mutual GROUNDED AIR SUPPLY HOSE 7 bar 100 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 1 4 nosm fbe 220 444 1 2m 4 ft 218 100 5m 15 it 218 101 8m 25 ft 218 102 11 m 86 ft 218 103 15m 50 ft 23 m 75 ft 220 120 30 5 m 100 ft FLUID HOSE ASSEMBLIES Nylon 14 bar 225 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 3 8 npsm fbe 215 637 8m 25 ft 215 638 15 m 50 ft 215 639 75 ft 23 m 215 640 100 ft 30 5 m 215 641 150 ft 46 m 220 119 FLUID HOSE ASSEMBLIES Nylon 35 bar 500 psi MAXIMUM WORKING PRESSURE 6 35 mm 0 25 in ID 3 8 npsm fbe 216 076 8m 25 ft 216 077 15m 50 ft 216 078 23m 75 ft 216 079 30m 100 ft 216 080 46 m 150 ft WARNING SIGNS Available from Graco at no extra charge Must be ordered separately 180 060 Warning Sign English 180 061 Warning Sign French 180 062 Warning Sign German 180 063 Warning Sign Spanish ACCESSORIES The accessories below and on page 31 have not been tested by Factory Mutual AIR LINE ACCESSORIES GROUNDED AIR SUPPLY HOSE 7 bar 100 psi MAXIMUM WORKING PRESSURE 8 mm 0 315 in ID 1 4 nposm fbe Color coded gray More flexible than black hose 223 068 1 2m 4 ft 223 069 5m 15 ft 223 070 8m 25 ft 223 071 11 m 36 ft 223 07
29. n handle 2 and tighten with a screwdriver Reinstall the trigger with the screws and spacers 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 Gun Handle Guide Air Valve Assembly Spring Retainer Packing Fig 21 SERVICE ES ON OFF Valve Removal amp 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 Nem 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
30. ne 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
31. olvent until it is clean To reduce the risk of fire or explosion and serious 5 Follow the P Relief P d Warnin bodily injury the ES ON OFF lever must be OFF a y TONOW MIF eee Ole Tenens T TOCECUTE vka 9 before flushing then disconnect the solvent supply 6 Reconnect the fluid supply line 1 Follow the Pressure Relief Procedure Warning on page 9 7 Turn on the fluid and air supplies 2 Disconnect and plug the fluid line 8 Trigger the gun until it is clear of solvent 3 Connect the solvent supply to the gun 12 307 638 SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly Do not install or service this equipment unless you are trained and qualified To reduce the risk of serious bodily injury including splashing fluid or solvent in the eyes or on the skin always follow the Pressure Relief Procedure Warning on page 9 before checking adjusting cleaning or repairing the gun or any part of the system Disconnect the fluid hose from the gun NOTE Check all possible remedies in the Troubleshooting Charts before disassembling the gun PROBLEM IMPROPER SPRAY PATTERN Fluttering or spitting Streaks Insufficient fluid supply Loose fluid nozzle or damaged fluid nozzle taper seat Dirt between fluid nozzle taper seat and body Loose or cracked
32. oval winnie odithe wash eins Lente ee 20 Connect the Fluid Line 00cc eee 7 Fluid Needle Packing Replacement 20 Check the Electrical Grounding 5 8 Power Cartridge Replacement 22 Turbine Alternator Removal 0 23 Operation Fan Air Valve Replacement 24 Filter the Fluid De seer eee e eee eee 9 Air Valve Replacement ceeeeeeeee 24 Operating Checklist aa a Te Naowap ene UR aC a clues iad dey endo heels 9 ES On Off Valve Removal and Repair Mle eee 25 Spraying Operation ON E EE 9 Fluid Adjusting Screw Replacement 25 Install the Fluid Nozzle and Air Cap 10 Muffler and Check Valve Replacement 25 Adjust the Spray Pattern anaana 10 Parts Drawing sec ncecdid oe hei panies Bake ees 26 Maintenance Daily Care and Cleaning 0000005 11 Parts EIST ENE EE EET EA AREE EET 27 Clean the Air Cap and Fluid Nozzle 11 aps Repair KiS oeieo eee ee pe eG Pa 28 Flush the Spray Gun 0 ccc e eee eee 12 p Technical Data 0 0 0 ccc cee 29 Spray Pattern Troubleshooting Chart 13 How To Order Replacement Parts 29 Gun Operation Troubleshooting Chart 14 p Accessories vnoerna d aes a 30 31 Electrical Troubleshooting Chart 15 Warranty de p ERORA ANER Mew bee Back Cover TERMS WARNING Alerts u
33. pe N Fluid Supply Line U Air Line Drain Valve F Air Line Lubricator oO Air Filter 5 micron Vv Fluid Drain Valve G Air Pressure Regulator P Air Supply Line W Gun Air Inlet H Pump Shutoff Valve bleed type Xx Gun Fluid Inlet The Typical Installation shown above is only a guide for WARNING 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 6 307 638 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 INSTALLATION 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
34. pt 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
35. r 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
36. r 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 All parts of the electrostatic system are properly grounded All personnel in or close to the spray area are properly grounded e All electrically conductive objects or devices in the spray area includ ing paint containers wash cans and tools are properly grounded When operating the electrostatic device any ungrounded objects in the spray area such as people containers tools etc can become electri cally charged Arcing may occur if these objects then come in contact or close to ground Arcing of sufficient energy levels can ignite the fluid be ing sprayed fumes from solvents dust particles and other flammable substances This can cause a fire or explosion and result in serious bod ily injury and property damage Static electricity can also be generated by the flow of fluid through the pump hose gun and nozzle but it is dissipated through proper ground ing as described in Grounding below If you experience any arcing or feel even a slight shock STOP SPRAY ING IMMEDIATELY Check for proper grounding of the entire system Be sure you have corrected the problem before starting to spray again Grounding The following are minimum requirements for grounding a basic electro static system Your system may include other equipment or object
37. ry Replace air cap See page 10 Clean fluid nozzle See page 11 Check replace fluid nozzle See page 10 Check for proper CFM check baffles and direction of air flow Adjust distance to 203 305 mm 8 12 in Remove and clean air cap and fluid nozzle as described in Maintenance Section under Clean the Air Cap and Fluid Nozzle then reinstall them ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE Poor wrap around ES ON OFF lever in OFF position Improper distance between gun and workpiece Parts poorly grounded High booth exhaust velocity Atomizing air pressure too high Fluid pressure too high Fluid viscosity Fluid resistivity too low Turbine alternator not operating no audible whine Faulty gun resistance Faulty resistor stud resistance Faulty power supply resistance Faulty needle electrode assembly Faulty turbine alternator Operator gets mild Operator not properly grounded shock or is in contact with ungrounded i object Gun not properly grounded Operator gets mild Work pios not properly shock when touching gees work piece ES indicator light not on when gun is triggered SOLUTION Turn lever to ON Adjust spraying distance to 203 305 mm 8 12 in Clean hangers check for proper ground on conveyer or track Reduce within code limits Reduce air pressure Reduce fluid pressure Check supplier for proper fluid for electrostatic spray Check fluid resi
38. s 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 ke
39. s 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 Nem 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 12 Electrode 13 Fluid Nozzle 14 Air Cap Assembly 59g Wrench 13 Torque to 1 1 1 4 Nem 10 12 in Ib a i 7 59g Fig 6 307 638 11 MAINTENANCE Flush the Spray Gun WARNING 4 Flush the gun with s
40. ser 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 307 638 3 SAFETY WARNINGS SERIOUS BODILY INJURY EXPLOSION FIRE OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED READ AND UNDERSTAND ALL INSTRUCTION MANUALS TAGS AND WARNING LABELS BEFORE OPERATING EQUIPMENT ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories such as overpres surizing modifying parts using incompatible chemicals and fluids or us ing worn or damaged parts can cause them to rupture and result in seri ous bodily injury fire explosion or property damage NEVER point the spray gun at anyone or at any part of the body NEVER put hand or fingers over the fluid nozzle ALWAYS follow the Pressure Relief Procedure at right
41. sparking which could cause fire or explosion and result in serious bodily injury DO NOT use the megohmmeter in the hazardous area Remove the gun from the hazardous area before testing it Test Gun Resistance NOTE Check the resistance with the gun triggered and untriggered Measure the resistance between the end of the elec trode 12 and the gun air fitting 2a See Fig 7 The re sistance should be between 115 152 megohms If the resistance is outside the specified range go to the next test If th e resistance is correct refer to the Electrical Troubleshooting Chart on page 15 for other possible causes of poor performance Test Power Supply Resistance Remove the power cartridge 3 from the gun handle 2 See Power Cartridge Replacement Remove the turbine alternator 8a from the power sup ply 5 See Turbine Alternator Removal Measure the resistance from the center prong EE in the power supply to the contact spring 5c on the other end of the power supply See Fig 8 The resistance should be 95 122 megohms If the re sistance 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 16 307 638 KEY A Megohmmeter 2 G
42. 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 10 307 638 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 Fig 4 KEY 13 Fluid Nozzle 14 Air Cap Assembly 84 Locking Pin DETAIL Unlocked Locked Se Bes Position Fig 5 MAINTENANCE Daily Care and Cleaning
43. stivity with paint meter and probe Check if ES ON OFF lever is ON Check air supply to gun Check for dirt or moisture in turbine See page 23 Check gun resistance See page 16 Check resistor stud resistance See page 17 Check power supply resistance See page16 Replace needle electrode assembly See page 18 Be sure plug is in place on back of turbine alternator housing Remove and test turbine alternator See page 23 Be sure floor is properly grounded Wear shoes with conductive soles and wear personal grounding straps Be sure operator is not in contact with or carrying any metalic items which could build up electrical charge If worn a glove must be conductive or modified as shown on page 9 See Check the Electrical Grounding page 8 Be sure Graco air supply hose Is being used and is properly grounded Clean work piece hangers Check for proper ground on conveyor or track 307 638 15 ELECTRICAL TESTS The performance of the spray gun is directly affected by the condition of the electrical components contained in side the gun The electrical tests below can be used to determine the condition of the power supply 5 and the resistor stud 16 as well as the continuity of the electri cal path between the components Use megohmmeter 218 979 see ACCESSORIES and an applied voltage of 500 volts to complete these electrical tests Connect the leads as shown WARNING To reduce the risk of
44. sure 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 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 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 HH 3 wire Connector 3a Alternator 3a 5 Power Supply Fig 19 307 638 23 SERVICE 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 Remove the retaining ring 31 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 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 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 When reassembling
45. the fan air valve lubricate the o ring 82 and the adjusting screw threads with petro leum jelly 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 Apply PTFE paste 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 Nem 10 12 in lb KEY 2 Gun Handle 2 31 Retaining Ring 32 O Ring 33 Valve Housing Adjusting Screw Valve Seal 33 Torque to 1 1 1 4 Nem 10 12 in Ib Fig 20 24 307 638 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 Remove the trigger by removing the screws and the spacers from the gun Unscrew and remove the guide 24 and packing 47 from the front of the gun handle 2 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 Install the new air valve 25 and spring 26 into the back of the gun handle 2 Apply PTFE tape to the threads of the retainer 27 Install the retainer 27 in the back of the gu
46. ud in Ref 85 the Series A D Guns were white DO NOT mix old D style parts with new style parts 69 26 307 638 PARTS LIST color coded white 18 179 412 BARREL gun Includes item 18a 18a 176 921 PLUG M3x0 5x6 18b 186 127 CUSHION 19 107 208 NUT ferrule 20 179 933 TUBE fluid 21 178 131 COLLAR 22 106 262 NUT tube flareless 23 105 661 RING retaining 24 176 941 GUIDE valve air 25 215 890 VALVE air 26 107 029 SPRING compression 27 179 391 RETAINER spring 28 218 150 SCREW adjusting fluid 29 168 110 O RING Viton 30 107 100 SCREW cap socket hd 31 105 681 RING retaining 32 103 557 O RING Viton 33 181 382 HOUSING valve 34 181 381 SCREW adjusting 35 181 328 NUT hex 36 102 268 WASHER wave 37 181 327 LEVER valve 38 103 648 O RING Viton 39 181 326 VALVE air 59g 177 004 WRENCH nozzle fluid 59ht 183 107 TOOL resistor stud 63 179 994 RESTRICTOR 64 218 179 LIGHT indicator ES 65 180 060 SIGN warning English not shown 69 181 384 ADAPTER fluid 70 181 380 RETAINER adapter 71 180 624 SCREW machine pnh M5 x 12 72 107 414 SPRING compression 73 100 172 BALL steel 3 16 dia 74 180 235 RESTRICTOR color coded black 75t 181 825 WASHER 103 338 O RING Viton 77 101 4385 BALL SST 3 8 dia 78 180 621 RETAINER valve check 80 180 623 MUFFLER 81 108 046 SPRING compression 82 180 209 COVER gun not shown 83 181 302 HOUSING pin 84 181 303 PIN locking 85 180 143 RETA
47. un Handle 2a Air Fitting 12 Electrode A Fig 7 KEY A Megohmmeter EE Connector Center Prong A 5 Power Supply 5c Contact Spring ELECTRICAL TESTS Test Resistor Stud Resistance Insert a conductive rod FF into the gun barrel re moved for the power supply test and against the metal contact GG in the front of the barrel See Fig 9 Measure the resistance between the conductive rod FF and the gun electrode 12 The resistance should be 20 30 megohms If the resistance is correct refer to the Electrical Troubleshooting Chart for other possi ble causes of poor performance or contact the nearest authorized service agency If the resistance is outside the specified range remove the electrode 12 See Electrode Replacement Meas ure the resistance between the conductive rod FF and the resistor in the inside diameter of resistor stud 16 The resistance should be 20 30 megohms If the resis tance is correct the electrode wire is defective and must be replaced See Electrode Replacement If the resis tance is outside the specified range the resistor is de fective and the resistor stud 16 must be replaced See Resistor Stud Replacement If you still have problems refer to the Electrical Troubleshooting Chart for other possible causes of poor performance or contact the nearest authorized service agency A Megohmmeter FF Conductive Rod GG Metal Contact 12 Electrode 18 Gun Barrel
48. vailable air caps 1 59b 177 732 WRENCH nut packing 1 16T 0 923 STUD resistor color code black 1 59ct 177 007 WRENCH needle 1 105 667 O RING Viton standard color 59d 179 803 ROD packing removal 1 17t coded green 1 59e 107 158 WRENCH stud resistor 1 108 045 O RING polyethylene optional 59f 107 460 WRENCH barrel 1 A 1 1 2 lt a Ce o o o a CO SOOO a O N M SO CO CR Included in Repair Kit 218 051 See page 28 Included in Repair Kit 218 682 See page 28 T Included in Repair Kit 220 391 See page 28 Read and follow the Old New Style Resistor Stud and Electrode Warning on page 26 po SA S SS SS S S PO KH AS SS SS St i i i i ts st y op 307 638 27 REPAIR KITS Repair Kits must be purchased separately Use only GENUINE GRACO PARTS AND ACCESSORIES WARNING When servicing use only genuine Graco replace ment parts Use of other parts or any alteration or modification of this equipment could result in serious injury fire explosion or property damage NOTE The Ref Nos shown in the kits below correspond to the reference numbers used in the parts list on page 27 For the best results use all the parts in the kit even if the old parts still look good Spray Gun Repair Kit 218 051 Includes Ref No Part No 3b 107 106 4 107 107 5a 177 156 5b 106 555 17 105 667 29 168 110 32 103 557 38 103 648 46 179 387 47 106 901 Description Qty O RING buna n 2 REGULATOR
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