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Casio EX-ZR400 Camcorder User Manual

1. ES ON OFF Lever 1 is ON Ois OFF J Tl BY Cr a pe Ja F O O ja Lo Non Hazardous Area WARNING SIGN ae Hazardous Area The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on KEY Fig 1 6 Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve bleed type Air amp Water Separator Pump Air Supply Shutoff Valve bleed type Air Line Lubricator Air Pressure Regulator Pump Pump Ground Wire HOO3 308131 VOZSECrA 9p J Fluid Filter Fluid Supply Line Shutoff Valve Fluid Pressure Regulator Fluid Supply L
2. INSTRUCTIONS PARTS LIST This manual contains important warnings and information GRACO READ AND KEEP FOR REFERENCE INSTRUCTIONS Model PRO 4500sc Electrostatic Air Spray Gun 85 kV MANUAL GUN 100 psi 7 bar 0 7 MPa Maximum Working Pressure For use with Class Group D paint spray materials Part No 224200 Series B Air Spray Gun with two finger trigger With 0 059 in 1 5 mm spray nozzle Part No 224400 Series B Air Spray Gun with four finger trigger a AX With 0 059 in 1 5 mm spray nozzle HOO3 Part No 224200 shown Ke 308131 Rev R 0365 NOTE Any modification of genuine Graco parts or replacement of parts with non Graco parts will void agency approvals U S PATENT NO 4 290 091 4 219 865 4 497 447 4 462 061 4 660 774 5 063 350 5 080 289 D350 387 Patented 1986 1987 Canada Brevete 1986 1987 U K PATENT NO 2 147 158 2 142 559B 2 140 327B 2 245 197B Other U S and Foreign Patents Pending GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1991 GRACO INC Graco Inc is registered to I S EN ISO 9001 HOO3 2 308131 Table of Contents SymbolS 2 2 25455 ccanccundesdasetcaenebaeacene 3 Warnings 0 0 ccc eens 4 Installation 0 0 0 0 6 Installing the System 00 ee 7 Warning SIGNS 0 cece eee 7 Ventilate the Spray Booth 7 Connect the Air Line 0 0
3. Parts DETAIL A See Detail A TOS 28 T 33 HOOS 2 ltem 18 includes items 18a to 18f CJ Item 28 includes items 28a to 28h QD Item 37 includes items 37a and 37b Item 43 includes items 43b to 43h Item 45 includes items 45a to 45e D 22 ee 0366B 34 308131 Some PRO 4500sc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable When A WARNING servicing do not mix or use other PRO Gun parts Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun cause parts to leak or rupture or cause the gun to malfunction and result in serious injury fire explosion or property damage Part No 224200 Series B Electrostatic Air Spray Gun with two finger trigger Part No 224400 Series B Electrostatic Air Spray Gun with four finger trigger Ref No Part No 1 193033 2 176930 3 223940 4 186654 5 185096 6 185097 7 224851 8 187423 9 110077 10 186621 114c 179791 12 224367 224910 13 186791 189034 14 110079 15 185122 16 185104 236120 17 185105 18 236039 Series B 18at 186840 18b 185099 18c 185145 18f 192361 19t 106555 20 190933 21 185158 22 T 23T 24 25 HOO03 26 186839 28 224747 28a 185495 28b 223981 28C 185488 28d 186069 28e 178763 28f 178409 Description AIR CAP See Manual 307803 for available air caps RING retaining BARREL gun SCREW trigger SCREW cap relieved M5 x 0 8 HO
4. 3 1 to 3 4 50 to 55 345 to 379 3 4 to 3 7 60 to 65 410 to 444 4 1 to 4 4 68 to 73 465 to 501 4 5 to 5 0 75 to 80 514 to 550 5 1 to 5 5 100 30 5 7 Set the atomizing air valve 31 about 1 5 turns out for most applications The Atomizing Air Valve Adjustment chart shows the effect of the atomiz ing air valve adjustment on the air cap air flow 8 Adjust the pattern width with the fan air valve 43c Atomizing Air Valve Adjustment 100 90 se 80 70 O 60 LL 50 lt x o 40 30 20 lt 40 0 0 00 0 50 1 00 1 50 2 00 2 50 3 00 Fully Open Fully Closed Valve Turns Fine Adjustments of the Spray Gun To improve the atomization open the atomizing air valve further 31 If more atomizing air is needed beyond the fully open position of the valve increase the air hose inlet pressure Use the lowest air flow settings needed for accept able atomization The slower particle velocity will improve the electrostatic effect To reduce the atomization air and minimize any overspray turn the atomizing air valve in NOTE See the Spray Pattern Troubleshooting chart on page 16 to correct spray pattern problems 9 Turn the ES ON OFF lever to ON to begin spray ing with the electrostatics When spraying the ES indicator light DD should glow indicating the electrostatic charge NOTE To verify if you have enough air for fu
5. sparking or electric shock do not remove the resistor stud contact ring D or operate the gun without the contact ring in place Do not replace the resistor stud 22 with anything but a genuine Graco part 0442 Fig 10 308131 21 Service Air Cap Nozzle Resistor Stud Replacement Prepare the Gun for Service A WARNING requires access to parts that may cause ELECTRIC SHOCK HAZARD uly Installing and servicing this equipment electric shock or other serious injury if the work is not performed properly Do not install or service this equipment unless you are trained and qualified A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of injury follow the Pressure Relief Procedure on page 11 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure NOTE Check all possible remedies in Troubleshooting before disassembling the gun If the plastic parts of the gun must be held securely always clamp them in padded vice jaws to prevent damage to the parts Lightly lubricate o rings and seals with petroleum jelly Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other PRO Gun models See page 35 Flush the gun as instructed in Flush the Spray Gun page 15 Relieve the pressure Disconnect the air and fluid lines from the gun Remove t ge Un from the worksite for service or rvice or repair area must be
6. 17 in Parts List to provide an extended handle grip area Air Shutoff Valve 224754 150 psi 10 bar 1 0 MPa Maximum Working Pressure x Air Adapter Nipple 185493 For connecting two or more grounded gun air supply hoses 1 4 npt x 1 4 npsm left hand thread For turning air to gun off or on 1 4 nopsm m 1 4 nosm f left hand thread Quick Disconnect Swivel Coupling Assy 112534 Includes a quick disconnect coupling insert which replaces air inlet fitting 185105 and a swivel shut off coupling body left hand thread which connects to the grounded air hose Bleed type Master Air Valve 107141 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line Sk D between the paint pump air motor a a and this valve when closed 3 4 npt we Accessories FLUID LINE ACCESSORIES Fluid Hose Assemblies Nylon 225 psi 14 bar 1 4 MPa Maximum Working Pressure FM Approved 1 4 in 6 35 mm ID 3 8 npsm fbe 215637 215638 25 ft 8 m 50 ft 15 m Fluid Hose Assemblies Nylon 500 psi 35 bar 3 5 MPa Maximum Working Pressure FM Approved 1 4 in 6 85 mm ID 3 8 nposm fbe 216076 25 ft 8m 216077 50 ft 15 m 216079 100 ft 30 m Fluid Shutoff Drain Valve 500 psi 35 bar 3 5 MPa Maximum Working Pressure For turning fluid off or on to the gun and for relieving fluid line pressure at the pump 208630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids i MISCEL
7. OFF See Fig 4 page 12 for the location of the lever 3 Turn off the air and fluid supply to the gun The fluid hose must not have any fluid in it 4 Make sure the air hose R is connected and the hose ground wire is connected to a true earth BAT round j 5 Measure the resistance between the gun handle 0368B BB and a true earth ground CC Fig 2 HO03 308131 9 Notes HOO3 10 308131 Operation Pressure Relief Procedure A WARNING PRESSURIZED EQUIPMENT HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying acci dentally To reduce the risk of an injury from electric shock accidental spray from the gun splashing fluid or moving parts follow the Pressure Relief Procedure whenever you are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the fluid nozzle 1 Turn the ES ON OFF 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 con tainer ready to catch the drainage 5 Leave the pump drain valve open until you are ready to spray again Filter the Fluid Filter the fluid to remove coarse particles and sediment which could clog th
8. alternator 37 onto the power supply 18 until the retaining ring 35 engages with the alternator 7 Install the power supply in the gun handle as described on page 27 16 Barrel Installation 1 Be sure the gaskets 34 amp 18a and spring 30 are in place See Fig 13 Replace if damaged Tighten to 18 in lbs 2 Nem maximum about half turn past 2 Place the barrel 3 over the power supply 18 and snug using wrench provided onto the gun handle 7 Make sure the fluid rod l 0381 Fi g 19 iim spring 30 is seated properly HO03 28 308131 Service Fan Air Adjustment Valve Repair 8 Reposition the KV HI LO lever 43g back onto the valve housing 43d in correct orientation Reinstall 1 Prepare the gun for service as instructed on page the retaining ring 43h into the groove on the valve housing DETAIL 2 Place a wrench on the flats of the valve housing 43d and remove it from the handle See Fig 20 NOTE The fan air valve 43 can be replaced as an assembly or as individual parts To disassemble the fan air valve 43f 43h 72 1 Rotate the adjustment knob 43c counterclock wise backing out until it stops Remove the retain ing ring 43h and back off the KV HI LO lever 43g from the valve housing 43d See Fig 20 Lubricate o rings 43e and top knob threads 43c with
9. nozzle and or electrode needle see pages 22 to 23 The resistor stud is loose Tighten the resistor stud see page 22 The fluid nozzle is loose Tighten the fluid nozzle see page 22 The resistor stud o ring is damaged Replace the o ring see page 22 Orange Peel finish The air pressure is insufficient for good Increase the air cap air pressure by open atomization ing the atomizing air valve more or in creasing the gun air inlet pressure use the least air pressure needed for good results The fluid is poorly mixed or filtered Remix or refilter the fluid An improper thinner is being used Use the proper thinner Excessive spray fog The air pressure is too high Reduce the air cap air pressure by closing the atomizing air valve more or decreas ing the gun air inlet pressure use the least air pressure needed for good results Do not reduce below minimum pressure needed for full voltage See page 13 The fluid is thinned too much Properly thin the fluid No fluid sprays from the gun The fluid supply is low Check the fluid supply add fluid if necessary The air cap is damaged Replace the air cap see page 22 The fluid nozzle is dirty or clogged Clean the fluid nozzle see page 15 The fluid nozzle is damaged Replace the fluid nozzle see page 22 The fluid adjustment valve is damaged Replace the o r
10. orifice The electrode is bent Straighten the electrode wire The fan air pressure is too high Reduce the fan air pressure The fluid is too thin Increase the fluid viscosity There is not enough fluid pressure Increase the fluid pressure The fan air pressure is too low The fluid is too thick There is too much fluid Increase the fan air pressure Reduce the fluid viscosity Reduce the fluid flow Reduce fluid pres sure on pressure feed guns and or adjust the fluid adjusting screw until proper pat tern is obtained Streaks The last coat of fluid is applied too wet Apply a drier finish using multiple strokes LEE There is too much air pressure Decrease the air pressure Eo The air pressure is insufficient Increase the air pressure The spray pattern is non uniform Clean or replace the air cap see page 15 or 22 6 1 308131 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packing The needle packings or shaft are worn Replace the packings or shaft see page area 26 Air leakage from the front of the gun The air valve is not seating properly Clean and service the air valve see page 30 The air valve o ring is sticking Lubricate the o ring see page 30 Fluid leakage from the front of the gun The needle is worn or damaged Replace the needle see page 26 The fluid seat is worn Replace the fluid
11. petroleum jelly 2 Using a standard wrench remove the valve hous Apply low strength purple Loctite or equiva 43 ing 43d from the gun lent to housing 43d threads Torque to Remove the retaining ring 43b a a 4 Rotate the adjustment knob 43c counterclock wise until it is disengaged from the valve housing threads 43d Pull the fan valve from the housing The KV HI LO lever 48g and the wave spring 43f can be removed if necessary 5 Clean all the parts and inspect them for wear or damage 6 When reassembling the fan air valve 43 lubricate the o rings 43e and the threads on the adjust ment knob 43c with petroleum jelly Reassemble the retaining ring 7 Apply low strength purple Loctite or equivalent thread sealant to the threads of the valve housing 43d Start the valve housing threads into the handle by turning the adjustment knob 43c Once the threads are started rotate the knob 43c fully counterclockwise Torque the valve housing 43d to 10 12 in lb 1 1 1 4 Nem Fig 20 HO03 308131 29 Service Fluid Adjustment Assembly Repair 1 Prepare the gun for service as instructed on page 2 Using a 14 mm socket wrench remove the fluid adjustment assembly 45 See Fig 21 3 Turn the stem 45a fully clockwise and remove the sleeve stop 45e 4 To completely disassemble the fluid adjustment assembly the sleeve stop 45e must be assembled back on to the stem 45a Turn th
12. tags and cards are available at no cost t Parts not shown 308131 35 Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose black 100 psi 7 bar 0 7 MPa Maximum Working Pressure FM Approved Color coded black 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 220444 s G ft 1 8 m 218100 15 ft 5m 218101 25 ft 8m 218102 36 ft 11 m 218103 50 ft 15m 220119 75 ft 23 m 220120 100 ft 30 5 m Conductive Air Supply Hose gray 100 psi 7 bar 0 7 MPa Maximum Working Pressure FM Approved Color coded gray More flexible than black hose 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 223068 6 ft 1 8 m 223069 15 ft 5 m 223070 25 ft 8 m 223071 36 ft 11 m 223072 50 ft 15m 223073 75 ft 23 m 223074 100 ft 30 5 m Conductive Air Supply Hose red 100 psi 7 bar 0 7 MPa Maximum Working Pressure Meets CENELEC EN 50 050 requirement for metallic ground path Color coded red Stainless steel braid ground path 0 315 in 8 mm ID 1 4 nosm f x 1 4 npsm f left hand thread 235068 6 ft 1 8 m 235069 15 ft 5 m 235070 25 ft 8 m 235071 36 ft 11 m 235072 50 ft 15 m 235073 75 ft 23 m 235074 100 ft 30 5 m HO03 36 308131 Air Swivel Fitting 236129 100 psi 7 bar 0 7 MPa Maximum Working Pressure Replaces standard fitting item 17 in Parts List 1 4 npsm m left hand thread Extended Air Fitting 189191 Replaces standard fitting item
13. 0 eae 7 Connect the Exhaust Tube 8 Connect the Fluid Line 05 8 Ground the System 0 e ee eee 8 Check the Electrical Grounding 9 Operation 0 0 0c eee 11 Pressure Relief Procedure 11 Filter the Fluld 0 0 eee 11 Operating Checklist 0008 11 Selecting a Fluid Nozzle and Air Cap 12 Operating the Spray Gun 12 SHULCOWI tai resa drach waked Sarath ba acd wae ee BA 14 Maintenance 0 0000 ccc 14 Daily Care and Cleaning 0 14 Clean the Air Cap and Fluid Nozzle 15 Flush the Spray Gun 0 00 e aes 15 Troubleshooting 0 0 0 e eee eae 16 Spray Pattern Troubleshooting 16 Gun Operation Troubleshooting 17 Electrical Troubleshooting 18 Electrical Troubleshooting with SVR 19 Electrical Tests 0 0 00 cece eee 20 Test Gun Resistance 00 eee 20 Test Power Supply Resistance 21 Test Resistor Stud Resistance 21 Service cai Fei asn dave death dee Peale dane ae ag dw deg 22 Prepare the Gun for Service 22 Air Cap Nozzle Resistor Stud Replacement 22 HO03 Electrode Needle Replacement 23 Barrel Removal 0 0 00 24 Fluid Packing Removal 0005 25 F
14. 4400 only GASKET manifold polyethylene RING retainer alternator O RING CV75 ALTERNATOR turbine Includes items 37a amp 37b O RING Viton e CUSHION VALVE electrostatic SHAFT ASSY air valve NUT packing O RING trigger valve fluoroelastomer U CUP PTFE VALVE ASSY fan air Includes items 43b 43h e RING retaining e KNOB fan air adjustment e HOUSING valve O RING Viton e SPRING wave e LEVER voltage adjustment e RING external retaining SPRING compression air valve VALVE ASSY fluid adjustment Includes items 45a 45e e STEM fluid adjustment e O RING CV 75 e KNOB e SLEEVE guide e STOP sleeve REGULATOR disc RING retaining GASKET air cap nut TOOL multi WRENCH barrel TUBE exhaust polyurethane CLAMP exhaust tube TOOL hex key allen wrench 2 mm SIGN warning English See Accessories for additional signs Qty it St St N i st tl a ee ee ee ee oo Md Se ee ee ee ee ee ee a ca aa a a oo a ee a a a ce Ca a aa aa s COVER gun Order Part No 218374 for package of 10 BRACKET gun hanging PLUG optional to install in place of item 31 TAB four finger 224400 only SCREW mach 4 40 x 0 25 224400 only These parts are included in Fluid Seal Repair Kit 224634 which may be purchased separately t These parts are included in Air Seal Repair Kit 224633 which may be purchased separately A Replacement Danger and Warning labels signs
15. AEA PRO 40g lt 2 D O q m 22 i Torque to 10 in Ibs 1 12 Nem Apply low strength purple Loctite or equivalent to fluid rod Fia 12 on threads F 0378 g Fig 13 308131 23 Service Barrel Removal 1 Prepare the gun for service as instructed on page 22 2 Carefully loosen the nut 14 from the bracket fluid fitting 16 Pull the tube 12 out of the fitting Make sure both ferrules and the nut stay with the tube See Fig 14 3 Using the wrench 63 supplied loosen the three socket head cap screws 5 4 Hold the gun handle 7 with one hand and pull the barrel 3 straight away from the handle to remove it See Fig 15 4 CAUTION To avoid damaging the power supply 18 pull the gun barrel straight away from the gun handle If necessary gently move the gun barrel from side to side to free it from the gun handle Fig 15 80 Fi g 14 maaaa i Ii i 24 308131 Service Fluid Packing Removal 1 Prepare the gun for service as instructed on page 2 Remove the air cap assembly fluid nozzle and resistor stud and electrode as instructed on page 23 3 Loosen the trigger screws 4 far enough to re move the trigger 13 4 Remove the needle assembly 28 using the multi tool 62 See Fig 16 4 CAUTION Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral spirits Use of condu
16. Booth A WARNING qr LAMMABLE OR TOXIC d APOR HAZARD rovide fresh air ventilation to avoid the A WARNING PRESSURIZED EQUIPMENT HAZARD 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 unexpect edly which could result in serious injury including splashing in the eyes or on the skin HO03 _ Jildup of flammable or toxic vapors Do not operate the gun unless ventilation IA fans are operating 5 Install an air line lubricator F as close to the Electrically interlock the gun air supply with the ventila pump H as possible tors to prevent gun operation without ventilating fans operating Check and follow all National State and 6 Install an air shutoff valve P on each gun air Local codes regarding air exhaust velocity supply line to shut off air to the gun s requirements 308131 7 Installation Connect the Exhaust Tube Press the exhaust tube provided onto the barbed adapter on the bottom of the gun handle Secure the tube with the clamp provided Refer to page 34 Connect the Fluid Line Refer to Fig 1 page 6 1 Before connecting the fluid line N blow it out with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed 2 Install a fluid regulator M on the fluid line to control fluid pressure to the gun 3 In
17. HOCK HAZARD To reduce the risk of fire explosion or electric shock turn the ES ON OFF lever OFF before flushing the gun A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve the pressure Relieve the pressure Disconnect and plug the fluid line Connect the solvent supply to the gun Flush the gun with compatible solvent into a grounded container until it is clean Relieve the pressure Disconnect and plug the solvent line Trigger the gun into a grounded container to drain out the solvent remaining in the gun Place the gun in its hanging bracket with the nozzle pointing down as shown in Fig 6 until it is used again When ready to spray again reconnect the fluid supply line 10 Turn on the fluid and air supplies 11 Make sure the ES ON OFF lever is OFF 12 Trigger the gun until it is clear of solvent 0370 308131 15 Fig 7 Troubleshooting A WARNING ELECTRIC SHOCK HAZARD ul Installing and servicing this equipment A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure requires access to parts which may cause an electric shock or other serious injury if the wor
18. LANEOUS ACCESSORIES Grounding Clamp and Wire 222011 12 ga 25 ft 7 6 m wire C Nee Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in Hazardous areas HO03 Paint Resistance Meter 722886 Used with 722860 Paint Probe to measure resistance of paint Not for use in Hazardous areas Paint Probe 722860 Used with 722886 Paint Resistance Meter to measure resistance of paint Not for use in Hazardous areas Safety Warning Signs FM Approved Available at no charge from Graco Must be ordered separately 180060 Warning Sign English GUN ACCESSORIES Gun Washer Kit Part No 236681 For use with a Graco Gun Washer to clean the PRO 3500 and PRO 4500 Electrostatic Spray Guns Snap Ring Pliers 110090 For removing the ES ON OFF Valve Retaining Ring item 47 in Parts List ES ON OFF Valve Conversion Kit 223976 FM Approved Converts the ES ON OFF Valve to a constant on setting A ball valve is included for com plete air shut off at the gun Push Pull Pattern Adjustment Valve 224720 FM Approved Pattern adjustment valve that allows quick adjustment of the pattern width between two adjustable settings Four Finger Trigger Conversion Kit 224884 FM Approved Converts gun from a two finger to a four finger trigger Gun Power Supply with RF Transmitter 224100 Power supply with transmitter capability for spraying voltage readout SVR 308131 37 Accessories Gun System 224640 GUN SYSTEMS G
19. OK HANDLE gun NUT air cap FERRULES fluid tube FITTING fluid tube TAG warning TUBE ASSY fluid 224200 only TUBE ASSY fluid 224400 only TRIGGER 224200 only TRIGGER 224400 only NUT fluid tube MUFFLER flame arrestor BRACKET gun fitting 224200 only BRACKET gun fitting 224400 only FITTING air POWER SUPPLY ASSY 85 KV Includes items 18a 18f e GASKET power supply e PAD e PAD e PAD O RING Viton NEEDLE electrode NOZZLE fluid See Manual 307803 for available nozzles STUD resistor O RING PTFE SET SCREW lever M4 x 0 7 O RING fluoroelastomer LEVER ES valve PACKING ROD ASSY Includes items 28a 28h e HOUSING packing e ROD fluid e NUT packing e SPACER packing e PACKING needle e PACKING fluid Qty i b b b d b d d d d d d d M CGO O ee b h h A M N a N e h ee ee ee ee ee 2 Part No 111504 111316 102982 185111 238927 185119 185112 188878 185113 185114 113746 222319 110073 185124 185118 224194 185115 111508 105452 223978 105681 191806 186837 168518 111221 224196 111510 185116 238895 186826 111516 186822 191794 191795 107107 110082 186848 191744 107460 185103 110231 110086 180060 180209 235300 185079 189023 112324 Description e O RING fluoroelastomer e O RING fluoroelastomer O RING Viton SPRING compression VALVE atomizing air SPACER lever ADAPTER 224200 only ADAPTER 22
20. ale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors 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 In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Phone Number TO PLACE AN ORDER contact your Graco distributor or call this number to identify th
21. all the trigger 13 and tighten the trigger 2 Fill the entire inner cavity of the spacer 28d with screws 4 petroleum jelly Place the spacer on the fluid rod 28b in the direction shown in Fig 17 Generously 9 Install the electrode needle nozzle and resistor apply petroleum jelly to the outside of the spacer stud assembly and the air cap assembly as 3 Place the fluid packing 28f needle packing 28e instructed on page 23 and housing 28a on the fluid rod 28b as shown in Fig 17 10 Test the gun resistance as instructed on page 20 28f 28h 28a 28d 28e 28gb g 28c Wi E 30 U 28 Item 30 is not included with the Packing Needle Assy 28 Apply a very light coat of lubricant Fill entire inner spacer cavity with petroleum jelly and generously lubricate outside of spacer 4 Tighten packil 3 9 N of drag force Fig 17 T 0383 HO03 26 308131 Service Apply a very light coat of lubricant Do not expose to solvents Fig 18 Power Supply Removal and Replacement NOTES e To avoid a loss in electrostatic performance inspect the gun handle power supply cavity for dirt or mois ture Clean the cavity with a clean dry rag e Do not expose seal B or gasket 18a to solvents as solvent will damage them 1 Prepare the gun for service as instructed on pag
22. and the gun s air inlet V The gun air inlet fitting has a Comply with all applicable local state and left hand thread Connect the air supply hose national fire electrical and other safety regula ground wire to a true earth ground tions 2 Install an air line filter O and an air and water separator D on the air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction Fig 1 shows a typical electrostatic air soray system lt is not an actual system design The particular type and size system for your operation must be custom designed for your needs For assistance in designing a system contact your Graco distributor l 3 Install a bleed type air regulator G on the pump i i and gun air supply lines to control air pressure to Warning Signs the pump and gun Mount warning signs in the spray area where they can A 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 Accessories to order them Install a bleed type air shutoff valve on the main air line C and the pump air line E to shut off air to the pump 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 Ventilate the Spray
23. bels before operating the equipment Use the equipment only for its intended purpose If you are uncertain about usage call your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component This equip ment has a 100 psi 7 bar 0 7 MPa maximum working air and fluid pressure Use fluids that are compatible with the equipment wetted parts See the Technical Data section of all the equipment manuals Read the fluid manufacturer s warnings Route the hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not use the hoses to pull equipment Wear hearing protection when operating this equipment Comply with all applicable local state and national fire electrical and other safety regulations HOO3 308131 5 Installation A
24. clean HO03 22 308131 4 CAUTION Hold the front end of the gun up and trigger the gun while removing the nozzle and resistor stud to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages 1 Prepare the gun for service as instructed at left 2 Remove the air cap assembly Point front end of the gun up and squeeze the trigger while removing the fluid nozzle resistor stud 21 22 assembly with the multi tool 62 See Fig 11 page 23 NOTE 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 3 Unscrew and remove the resistor stud 22 with the multi tool 62 See Fig 12 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD The resistor stud contact ring D is a conductive contact ring not a sealing o ring See Fig 11 To reduce the risk of sparking or electric shock do not remove the resistor stud contact ring D except to replace it and never operate the gun without the contact ring in place Do not replace the contact ring with anything but a genuine Graco part To install the resistor stud 4 Lightly lubricate the o ring 25 with petroleum jelly and install it on the resistor stud 22 5 Using the multi tool 62 install the resistor stud 22 in the fluid nozzle 21 Tighten to 10 in lb 1 12 Nem NOTE Make sure the electrode needle 20 is tight ene
25. cm to infinityx Range 1 4 nosm m left hand Fluid Inlet 3 8 npsm m Typical Noise Level Sound Pressure tT 91 Db A at 40 psi 2 8 bar Sound Power 90 7 Db A 0 28 MPa Maximum Noise Level at 100 psi Db A 7 bar 0 7 MPa Sound Power 105 3 Db A Wetted Parts Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Ceramic Epoxy Fluoroelastomer PEEK Music Wire Polyethylene Sound Pressure f 100 5 Radio Frequency Transmitter Approval only applies when accessory power supply 224100 is installed FCC ID JHI1 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation Changes or modification to this equipment not ex pressly approved by the party responsible for com pliance could void the user s authority to operate this equipment This equipment complies with DOC GRR II 6 4 En conformite avec MDC RGR II 6 4 Noise levels measured with a 40 psi 2 8 bar air supply at the gun air inlet and typical gun air flow settings Noise levels measured with a 100 psi 7 bar air supply at the gun air inlet and maximum gun air flow settings T Sound pressure was measured per Cagi Pneurop 1969 Sound power was measured per ISO 3744 1981 This is the allowable paint
26. colors and whenev er you are done operating the gun See page 15 NOTE A Gun Washer Kit P N 236681 is available for use with a Graco Gun Washer See Accessories 8 Place the gun in its hanging bracket with the nozzle pointing down as shown in Fig 6 until it is used again im 03683 Fig 6 Maintenance Clean the Air Cap and Fluid Nozzle 4 CAUTION Do not use metal tools to clean the air cap or spray tip holes as this could scratch them and make sure the electrode wire is not damaged Scratches in the air Cap or spray tip or a damaged electrode wire can distort the spray pattern Equipment needed e Soft bristle brush e Compatible solvent Procedure A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying before installing or cleaning the fluid nozzle and whenever you are instructed to relieve the pressure 1 Relieve the pressure 2 Remove the air cap assembly 3 With the front of the gun pointed down clean the air cap fluid nozzle and front of the gun using a soft bristle brush and compatible solvent See Fig re 4 Carefully re install the air cap assembly Avoid bending the electrode Tighten the retaining nut until it is snug allowing the air cap to turn with racictancea esistance as instructed on page 20 HOO3 Flush the Spray Gun A WARNING ELECTRIC S
27. ctive solvents can cause the gun to malfunction 5 Check all the parts for wear or damage and replace if necessary 0382A Fig 16 HOO3 308131 25 Service Fluid Packing Rod Repair 4 Lightly tighten the packing nut 28c The packing nut is properly tightened when there is 2 lbs 9 N The fluid packing rod can be replaced as individual of drag force when sliding the packing housing parts or as an assembly The overall assembly is 28a assembly along the shaft Tighten or loosen pre adjusted at the factory the packing nut as needed NOTE Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arcing If the marks are present replace 6 Make sure the spring 30 is installed against the the barrel nut E as shown in Fig 17 5 Install the o ring 28h on the outside of housing 28a and lubricate the o ring If the parts are purchased separately assemble them as instructed below and as shown in Fig 17 7 Install the fluid packing rod assembly 28 into the gun barrel Using the multi tool 62 tighten the assembly until just snug then check the drag on 1 Place the packing nut 28c and o ring 28g on the l the fluid rod fluid rod 28b Flats on the packing nut must be facing toward the back of the fluid rod 8 Inst
28. d properly as shown in Fig 13 Continued on the next page Service Air Cap Nozzle Resistor Stud Replacement Electrode Needle Replacement continued 1 Prepare the gun for service as instructed on page 6 Trigger the gun while installing the fluid nozzle 21 and resistor stud 22 assembly with the multi tool 9 62 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight Remove the air cap nozzle and resistor stud as instructed on page 22 3 Unscrew and remove the electrode needle 20 7 Install air cap assembly 1 8 49 and retaining with the multi tool 62 Hold the fluid rod end to ring 2 Test gun resistance as instructed on page prevent it from turning See Fig 13 20 4 CAUTION Be careful not to damage the contact wire when removing the electrode from the gun 4 Apply low strength purple Loctite or equivalent thread sealant to the electrode needle and fluid rod threads Install the electrode needle finger tight Do not over tighten it 4 CAUTION To avoid damaging the plastic threads or contact wire be very careful when installing the electrode 5 Install the fluid nozzle resistor stud and air cap assembly as instructed at left 6 Test the gun resistance as instructed on page 20 20 Apply a very light coat of lubricant Tighten 1 8 to 1 4 turn past hand tight J 05154A i ay o A Y KI _ a A K
29. e 22 2 Remove the barrel as instructed on page 24 4 CAUTION Be careful when handling the power cartridge to avoid damaging it 3 Grasp the power supply 18 with your hand With a gentle side to side motion pull the power supply T the gun handle 7 then pull it straight PER 18 4 e power supply for any physical damage HO03 power supply electrical resistance as instructed on page 21 If needed replace the power supply Before installing the power supply inspect the seal 18e for any damage or swelling replace it if necessary Make sure the gaskets pads 18a 18f are in place 0384B 5 Lubricate the o ring 37a and insert the power supply in the gun handle 6 Install the barrel on the handle as instructed on page 28 7 Test the gun resistance as instructed on page 20 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 The power supply may be equipped with either a potentiometer or a two position jumper pin If you have the jumper pin style place the pin in either the 45 kV or 60 kV position If you have the potentiometer style follow the directions below To adjust the low voltage setting use a small blade end screw driver to turn the potentiometer G clock wise to increase the voltage or counterclockwise to decrease th
30. e stem until the sleeve is protruding about 0 4 inches 10 mm 5 To remove the sleeve 45d hold the cap 45c and turn the sleeve stop 45e counterclockwise with a wrench 6 Remove the stem 45a and o ring 45b 7 Repair or replace any damaged parts Lubricate the o ring 45b with petroleum jelly 8 Carefully apply low strength purple Loctite or equivalent thread sealant to the sleeve 45d external threads Turn the sleeve in with the sleeve stop 45e until it bottoms out then back it out 1 8 turn 4 CAUTION Do not allow Loctite to get onto the stem 45a during assembly or the stem will not turn after assembly 9 Place the fluid adjustment assembly on the work bench with its threaded end facing down and allow the Loctite to cure over night 10 After the Loctite has cured install the fluid adjustment assembly into the gun Tighten the adjustment knob 45c with the 14 mm socket wrench HO03 30 308131 DETAIL 40 42 Lubricate o rings with petroleum jelly Carefully apply low strength purple Loctite or equivalent to sleeve 45d external thread Turn sleeve in with sleeve stop 45e until it bottoms out then back out 1 8 turn Allow Loctite to cure overnight Do not remove u cup 42 unless damaged Install with lips facing into handle Tighten packing nut 40 until it bottoms 0387A Fig 21 Service Air Trigger Valve Repair Atomizing Air Valve Removal and Rep
31. e the power supply is defective and must be replaced If the resis tance of the power supply is correct proceed to the next test If you still have problems refer to Electrical Troubleshooting for other possible causes of poor performance or contact the nearest authorized service agency NOTE Be sure the seal B is in place on the end of the power supply before installing the power supply back into the gun T10378 Test Resistor Stud Resistance See Fig 10 Remove the resistor stud 22 See Air Cap Nozzle Resistor Stud Replacement page 22 Check the resistance between the black resistor stud contact ring D and the needle contact 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 stud 2 must be replaced See Air Cap Nozzle Resistor Stud Replacement A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD The resistor stud contact ring D is a conductive contact ring not a sealing o ring See Fig 10 To reduce the risk of
32. e distributor closest to you 1 800 367 4023 Toll Free HOO3 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Sales Offices Minneapolis Detroit International Offices Belgium Korea Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN U S A 308131 July 1991 Revised September 2000 40 308131
33. e spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded 308131 11 Operation fs To avoid shock or lon use properly ground Pree For safe operation read Instructions La a ZA lt I 4 Ye 0 2 y o 8 b 439 31 9 E A 20 0369A Fig 4 Selecting a Fluid Nozzle and Air Cap Operating the Spray Gun A WARNING A WARNING PRESSURIZED EQUIPMENT HAZARD PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve pressure To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 before removing or installing a fluid nozzle and or air cap The gun is sur ese h a 0 059 in 1 5 mm fluid nozzle P N 1 A1 air cap P N 193033 If your A WARNING application rex ferent nozzle and air cap combination tion manual 307803 or consult COMPONENT RUPTURE HAZARD your authorize 4O03_ _istributor to select the ap To reduce the risk of component rupture propriate fluid nozzle and air cap Install the air cap uH ikea which can cause serious injury do not and fluid nozzle into the gun barrel as instructed in Air exceed the maximum working pressure Cap Nozzle Resistor Stud Replacement pa
34. e spray nozzle HO03 l 31n 6 mm square cut out and finger of glove cut off NOTE If gloves are worn they must be conductive or modified as shown so they do not interfere with operator grounding through the gun 06445 Fig 3 Operating Checklist Check the following list daily before starting to operate the system to help ensure safe efficient operation 1 All the operators are properly trained to safely operate an electrostatic air spray system as instructed in this manual 2 All the operators are trained how to properly relieve pressure as instructed at left 3 The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Ground the System page 8 4 The operator is not wearing gloves which insulate the hand from the spray gun If worn gloves must be conductive or modified as shown in Fig 3 so as not to interfere with the operator grounding through the gun 5 The condition of the electrical components of the spray gun has been checked as instructed in Electrical Tests page 20 6 The ventilation fans are operating properly 7 The workpiece hangers are clean and grounded Contact points must be sharp points or like knife edges 8 All the debris including flammable liquids and rags is removed from the spray area 9 All flammable liquids in the spray booth are in approved grounded containers 10 All conductive objects in th
35. e voltage fully clockwise is 80 kV fully counterclockwise is 45 kV 308131 27 Service Turbine Alternator Removal and 3 Tighten the three socket head cap screws 5 Replacement oppositely and evenly to 18 in lbs 2 Nem maxi mum about a half turn past snug with the wrench NOTE Replace turbine bearings after 2000 hours of 63 supplied operation See your authorized Graco representative 1 Prepare the gun for service as instructed on page 22 A CAUTION 2 Remove the power supply from the gun handle as To avoid damaging the gun do not over tighten the instructed on page 27 cap screws 9 3 Squeeze the two ends of the retaining ring 35 4 Assemble the fluid tube 12 back into the fluid together and carefully pull the alternator 37 away fitting 16 from the power supply 18 until the 3 wire connec tor F disengages See Fig 18 page 27 5 Test the gun resistance as instructed on page 20 4 Use an ohmmeter to test the turbine alternator coil Measure the resistance between the two outer terminals of the 3 wire connector F The resist ance should be 3 to 5 ohms If the reading varies from this value replace the alternator 5 Measure the resistance between each outer terminal of the 3 wire connector and the turbine alternator housing The resistance should be infinite If the resistance is not infinite replace the alternator 6 Connect the 3 wire connector to the 3 prongs in the power supply Push the
36. ge 22 of the lowest rated system component This equip ment has a 100 psi 7 bar 0 7 MPa maximum working air and fluid pressure Follow the steps on page 13 to establish the correct fluid flow and air flow Do not turn the ES ON OFF lever to ON yet 12 308131 Operation Operating the Spray Gun continued 1 Follow the Operating Checklist on page 11 2 To adjust the air cap for a vertical or horizontal spray pattern first make sure the pressure Is relieved Then loosen the air cap retaining nut and rotate the air cap as directed in Fig 5 Tighten the retaining nut until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand Horizontal Pattern 02020 Fig 5 3 Adjust the fluid flow by using the fluid line pressure regulator Refer to instruction manual 307803 to set the fluid pressure for various fluid flows ac cording to the size of the fluid nozzle being used 4 If necessary further adjust the fluid flow rate with the fluid adjustment knob 45 See Fig 4 5 Fully open the fan air valve 430 6 Set the air pressure with the air pressure regulator The following chart shows the air hose inlet pres sure required to get full voltage from the power supply To avoid shortening the turbine life do not exceed the recommended air pressures Air Hose Dynamic pressure at air hose inlet Length required for full voltage ft m psi kPa bar 45 to 50 314 to 345
37. ghten the set screw 24 A WARNING MOVING PARTS HAZARD Make sure that the retaining ring 47 is engaged in the groove in the gun handle when installing the ES ON OFF Valve If MOVING PARTS HAZARD AE To reduce the risk of eye injury be sure on to wear safety glasses when removing or installing the retaining ring 47 as the retaining ring could slip off the tool when com pressed 3 Use internal snap ring pliers to remove the retain the retaining ring is missing or improperly installed ing ring 47 from the handle Align the holes in the the valve assembly can be propelled out of the gun retaining ring with the flat on the spacer 32 to when air pressure is applied and cause serious ease assembly and disassembly Injury 4 Remove the valve body 38 from the handle be careful not to drop the regulator disk 46 and spacer 32 5 Clean and inspect the parts for damage Replace if necessary Lubricate the o ring 36 with petroleum jelly 4 CAUTION Do not over lubricate parts Excessive lubricant on the o ring 36 can be pushed into the gun air pas sage and blemish the finish on the workpiece Bevelled side of disk 46 faces toward valve 38 Lubricate o rings with petroleum jelly 6 Install the disk 46 in the valve 38 with 0388 its vale ng in toward the valve Fi g 23 meee HO03 32 308131 Notes 308131 33
38. heck the fluid resistivity with a paint meter and probe The turbine alternator is not operating Check if the ES ON OFF lever is ON 1 Check the air supply to the gun Check for dirt or moisture in the turbine See page 28 The gun resistance is faulty Check the gun resistance See page 20 Fluid leaks from the needle packing and causes a short Clean the needle cavity Replace the fluid needle See page 26 The turbine alternator is faulty Be sure the plug is in place on the back of the turbine alternator housing Remove and test the turbine alternator See page 28 The KV HI LO lever is on LO The operator is not properly grounded or is near an ungrounded object Check the lever actuation replace if needed Be sure the floor and the operator are properly grounded See Ground the System page 8 The gun is not properly grounded ES indicator light is not on when the gun is triggered 18 HOO3 308131 See Check the Electrical Grounding page 9 Operator gets a shock when The workpiece is not properly grounded Clean workpiece hangers Check for proper touching the workpiece grounding on the conveyor or track Troubleshooting Electrical Troubleshooting with SVR NOTE Additional gun troubleshooting can be done using the Remote Spraying Voltage Readout SVR See Accessories to order the SVR and the RF transmitting power supply Problem Cau
39. ine Air Filter 20 micron Air Supply Line Shutoff Valve Air Hose Ground Wire Graco Electrically Conductive Air Hose Electrostatic Spray Gun xs lt co 0389 Air Line Drain Valve Fluid Drain Valve Gun Air Inlet Gun Fluid Inlet Gun Exhaust Tube Required for safe operation Must pur chase separately See Accessories NOTE Solenoid Valve B is not offered as a Graco accessory Installation Installing the System NOTE High velocity air exhaust will decrease the op erating efficiency of the electrostatic system Air ex haust velocity of 100 ft min 31 linear meters minute A WARNING should be sufficient FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Connect the Air Line Refer to Fig 1 A WARNING ELECTRIC SHOCK HAZARD uly To reduce the risk of electric shock or e Do not install or service this equip ment unless you are trained and qualified other serious injury the air supply hose must be electrically connected to a true earth ground Use Only Graco Electrically Con ductive Air Supply Hose Be sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class Group D Hazardous Location 1 Connect the Graco Electrically Conductive Air Supply Hose R between the air supply line
40. ing see page 30 The equipment is covered with fluid The exhaust air flow is insufficient or not Check for the proper CFM check the directed properly baffles and direction of the air flow The distance between the gun and work piece is incorrect inches 203 to 305 mm The air cap is dirty The air cap and fluid nozzle are mis Check the air cap and fluid nozzle seat for aligned fluid buildup Adjust the spraying distance to 8 to 12 Clean or replace parts as needed see page 15 or 22 HO03 Fluid Nozzle ALIGNED MISALIGNED 308131 17 Troubleshooting Electrical Troubleshooting Problem Poor wrap around Operator gets a mild shock Cause The ES ON OFF lever is in the OFF O position Solution Turn the lever to ON 1 The distance between the gun and work piece is incorrect Adjust the spraying distance to 8 to 12 inches 203 to 305 mm The parts are poorly grounded Clean the workpiece hangers Check for proper grounding on the conveyer or track The booth exhaust velocity is too high Reduce exhaust velocity within code limits The atomizing air pressure is too high Reduce the atomizing air pressure The fluid pressure is too high Reduce the fluid pressure The fluid viscosity is not right for electros tatic spray Check with the supplier for proper fluid viscos ity for electrostatic spray The fluid resistivity is too low C
41. k 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 Chart before disassembling the gun Spray Pattern Troubleshooting NOTE Some spray pattern problems are caused by the improper balance between air and fluid Problem Cause Solution The fluid supply is insufficient Adjust the fluid regulator or fill the fluid supply Fluttering or spitting spray J The fluid nozzle is loose or the fluid noz zle taper seat is damaged Tighten or replace the fluid nozzle see page 22 There is dirt between the fluid nozzle taper seat and gun body Clean the parts see page 15 The coupler at the fluid inlet is loose or Tighten or repair the coupler cracked Loose fluid tube in tank Tighten Improper spray pattern There is fluid build up on the air cap Clean the air cap with a soft implement or partially clogged horn holes or full air submerge it in water and wipe it clean pressure from the clean horn hole forces see page 15 the fan pattern toward the clogged end The electrode is bent Straighten the electrode The fluid nozzle or air cap holes are dam Replace the damaged part see page 22 aged There is fluid buildup on the perimeter of Remove the obstruction never use wire the fluid nozzle orifice or a partially or hard instruments see page 15 clogged fluid nozzle
42. lacement 1 Prepare the gun for service as instructed on page p 22 1 Prepare the gun for service as instructed on page 2 Using a14 mm socket wrench remove the fluid adjustment assembly 45 o ring 23 and spring 2 Remove the fan air valve 43 See Fig 22 44 See Fig 21 A CAUTION 4 CAUTION Clean all parts in non conductive solvent compatible To avoid damaging the atomizing air valve 31 the fan air valve 43 must be removed before removing the atomizing air valve with the fluid being used such as xylol or mineral spirits Use of conductive solvents can cause the gun to malfunction 3 Remove the atomizing air valve 31 from the gun handle Inspect the o ring 19 and replace if 3 Loosen the air valve packing nut 40 one full turn necessary Remove the air valve shaft 39 with a pliers n 93 p 4 Install a new atomizing air valve 31 A CAUTION 5 Apply low strength purple Loctite or equivalent thread sealant to the fan air valve 43 housing When removing the air valve shaft 39 be careful not threads Start the valve housing threads into the to damage the seat area handle by turning the fan air valve knob Once the threads are started rotate the knob 43c fully counterclockwise Torque the valve housing 43d to 10 12 in lb 1 1 1 4 Nem 4 Check the o rings 41 23 for damage and replace if necessary Apply petroleum jelly to the o rings 4 CAUTION Do not over lubricate
43. ll voltage the Remote Spraying Voltage Readout SVR moni tor can be used See Accessories Watch the SVR display while increasing the air pressure to see if more air will increase the voltage 10 Use the ES HI LO lever 43g to change to either full voltage HI or a lower voltage level LO The lower voltage setting is factory set to 60 kilovolts at zero microamperes To change this setting see page 2 4 CAUTION Always hang the gun with its nozzle pointing down when it is not being used to avoid having fluid run into the gun air passages Fluid in the gun air pas sages Can cause poor atomization and excessive current demands and damage the gun Operation Shutdown 1 Relieve the pressure 2 Flush and clean the equipment Follow the instruc A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve pressure tion in Maintenance Maintenance Daily Care and Cleaning A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 when you stop spraying before cleaning or flushing the spray gun and whenever you are instructed to relieve the pressure A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD To reduce the risk of fire explosion or electric shock turn the ES ON OFF lever OFF befo
44. luid Packing Rod Repair 26 Power Supply Removal and Replacement 27 Power Supply Adjustment 27 Turbine Alternator Removal and Replacement 28 Barrel Installation 0 0 0 0 c cee eee 28 Fan Air Adjustment Valve Repair 29 Fluid Adjustment Assembly Repair 30 Air Trigger Valve Repair 06 31 Atomizing Air Valve Removal and Replacement 31 ES ON OFF Valve Repair 05 32 PAWNS ce occa eae 62 depp on cieece ee Ga edna eae eee 34 Accessories 0 ccc ees 36 Technical Data anaana c cee eee 39 The Graco Warranty and Disclaimers 40 Graco Phone Number 5 40 Symbols Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions 308131 3 4 4 WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in a fire explosion or electric shock e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements stated in this instruction manual Ground the equipment personnel in or close to the s
45. malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of s
46. nect the leads as shown j A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Megohmmeter P N 241079 A see Fig 8 is not approved for use in a hazard ous area To reduce the risk of sparking do not use the megohmmeter to do the electrical tests unless e The gun has been removed from the hazardous area e Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent con tainers or fumes from spraying Failure to follow this warning could cause fire explosion electric shock and result in serious injury and property damage Test Gun Resistance See Fig 8 sae NOTE The fluid passage must be flushed and dried to Fig 8 get an accurate reading HO03 20 308131 Electrical Tests Test Power Supply Resistance See Fig 9 Remove the power supply 18 from the gun See Power Supply Removal and Replacement page 27 Remove the turbine alternator from the power supply See Turbine Alternator Removal and Replacement page 28 Measure the resistance from the power supply s ground contact point EE to the contact inside of the power supply seal B the conductive rubber contact may be slightly recessed into the seall The resistance should be 297 to 363 megohms If the resistance is outside the specified rang
47. ound the equipment according to the manufac turer s recommendations 3 Electrostatic Air Soray Gun ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground Check the electrical grounding of the gun as instructed on page 9 4 All air and fluid lines must be properly grounded Use only grounded hoses with a maximum of 500 feet 150 m combined hose length to ensure grounding continuity 5 All electric cables must be properly grounded 6 All persons entering the spray area their 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 that insulate the hand from the spray gun The gloves must be conductive or modified as shown in Fig 3 page 11 7 Object being sprayed keep the workpiece hangers clean and grounded at all times Contact points must be sharp points or like knife edges 8 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 9 Flammable liquids in the spray area must be kept in approved grounded containers Do not store more than the quantity needed for one shift 10 All electrically conductive objects or devices in the spray area including fluid containers and wash cans must be
48. oxic fumes can cause a serious injury or death if splashed in the eyes or on the skin swallowed or inhaled Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings amm Zzardous fluid in an approved container Dispose of the hazardous fluid according to all qp te and national guidelines propriate protective clothing gloves eyewear and respirator HOO3 308131 A WARNING PRESSURIZED EQUIPMENT HAZARD Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury Do not point the spray gun at anyone or any part of the body Do not stop or deflect fluid leaks with your hand body glove or rag Follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve the pressure stop spraying clean check or service the equipment and install or clean the fluid nozzle Tighten all the fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire hose EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury INSTRUCTIONS ia This equipment is for professional use only Read all the instruction manuals tags and la
49. parts Excessive lubricant on the o ring 41 and air valve shaft 39 can be pushed into the gun air passage and blemish the finish on the workpiece 5 Unscrew the packing nut 40 to check the u cup 42 Do not remove the u cup unless it is dam aged 6 Install the air valve shaft 39 with the o ring 41 and spring 44 into the back of the gun handle 7 If the u cup 42 was removed install the air valve shaft 39 before installing the u cup Install Pe with its lips facing into the gun handle T f fluid adjustment assembly 45 with the Apply low strength purple Loctite or equivalent to fan air valve HO03 Tighten the adjustment knob 45c with housing threads Torque to 10 12 in Ib 1 1 1 4 N m the 14 mm socket wrench Tighten the air valve saan packing nut 40 until it bottoms Fig 22 308131 31 Service ES ON OFF Valve Repair A CAUTION 1 Prepare the gun for service as instructed on page Be sure the regulator disk 46 is installed correctly 22 A missing or incorrectly installed regulator disc can cause severe damage to the power supply 2 Loosen the set screw 24 with the 2 mm hex key 69 provided Remove the lever 26 from the valve See Fig 23 7 Install the valve 38 with the regulator disc 46 and o ring 36 into the gun handle Install the spacer 32 on the valve 8 Install the retaining ring 47 into the groove in the A WARNING handle Install the lever 26 and ti
50. pray area the object being sprayed and all other electrically conductive objects in the spray area See Ground the System on page 8 Check the spray gun resistance daily See Test Gun Resistance page 20 If there is any static sparking while using the equipment stop spraying immediately Identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on See Ventilate the Spray Booth on page 7 When flushing or purging electrostatic equipment use solvents with a flash point equal to or greater than that of the fluid being sprayed To clean the exterior of the electrostatic equipment use solvents with a flash point higher than 100 F 38 C Use only non sparking tools to clean residue from the booth and hangers Do not flush the system with the gun electrostatics turned on Do not turn on the gun electrostatics until all solvent is removed from the system Extinguish all open flames or pilot lights in the spray area Keep the spray area free of debris including solvent rags and gasoline Do not store any flammable fluids in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not smoke in the spray area Do not operate a gasoline engine in the spray area TOXIC FLUID HAZARD Hazardous fluids or t
51. properly grounded Installation Check the Electrical Grounding See Fig 2 a If using a black or grey air hose use a me gohmmeter AA to measure the resistance Use an applied voltage of 500 minimum to A WARNING 1000 volts maximum The resistance should not exceed 2 megohms FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD b fusing a red turbine air hose use an ohmme Megonmmeter P N 241079 AA see Fig ter to measure the resistance Resistance 2 is not approved for use in a hazard should not exceed 100 ohms ous area To reduce the risk of sparking do not use the megohmmeter to check 6 If the resistance is greater than the maximum electrical grounding unless reading specified above for your hose check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground If the resistance is still too high Or all spraying devices in the hazardous area replace the air hose are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent con tainers or fumes from spraying BB e The gun has been removed from the hazardous area Failure to follow this warning could cause fire explosion electric shock and result in serious injury and property damage oy AQ Cam ys 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 2 Turn the ES ON OFF Lever to
52. re flushing the gun 4 CAUTION Fluid left in gun air passages could result in a poor quality paint finish and may draw current and reduce the electrostatic effect Fluid in the power supply cavity can reduce the alternator life Immersing the gun in fluid is not recom mended Do n cleaning method which may allow WT to the gun air passages Point own while cleaning to prevent fluid woo3 n9 into the air passages See Fig Hang the gun with its nozzle pointing down when it is not being used as shown in Fig 6 Clean all parts with a non conductive compatible solvent Conductive solvents can cause the gun to malfunction Methylene chloride is not recommended as a flush ing or cleaning solvent with this gun as it will damage nylon components 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 See page 15 Some applications require more frequent cleaning Replace the fluid nozzle and air cap if they are damaged See page 22 4 Check the electrode wire Straighten it if it is bent and replace it if it is broken or damaged See page 23 5 Check for fluid leakage from the gun and fluid hoses Tighten fittings or replace equipment as needed 6 Check all of the work hangers for build up of material clean them if necessary 7 Flush the gun before changing
53. resistivity range for this gun Note that electrostatic effect may drop off below about 25 megohm cm Viton and Kalrez are registered trademarks of the DuPont Co Loctite is a registered trademark of the Loctite Corporation ChemrazZ is a registered trademark of the Green Tweed amp Co Eveready Energizer is a registered trademark of the Eveready Battery Co Inc Manual Change Summary This manual has been changed per ECO s V6099 V5645 V5457 V4871 and V389201 HO03 308131 39 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name 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 With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for
54. se Solution Lower than normal voltage output Insufficient air pressure to the turbine Increase the air pressure to the gun alternator Faulty turbine alternator Replace the turbine alternator See page 28 Improper distance between gun and Adjust the spraying distance to 8 12 in workpiece 203 305 mm Fluid resistivity is too low Check the fluid resistivity with a paint meter and probe Dirty gun Clean the gun See page 14 Higher than normal voltage out Faulty gun resistance Check the gun resistance See page 20 put Fluid resistivity higher than normal Check the fluid resistivity with a paint meter and probe HOO3 308131 19 Electrical Tests The performance and safety of the spray gun are Measure the resistance between the end of the elec directly affected by the condition of the electrical trode 20 and the air fitting 17 The resistance components contained inside the gun The electrical should be between 329 to 401 megohms If the resis tests below can be used to determine the condition of tance is outside the specified range go to the next the power supply 18 and the resistor stud 22 as well test If the resistance is correct refer to Electrical as the continuity of the electrical path between the Troubleshooting on page 18 for other possible components causes of poor performance Use megohmmeter P N 241079 A and an applied voltage of 500 volts to complete these electrical tests Con
55. stall a fluid filter K and drain valve U at the pump outlet A WARNING PRESSURIZED EQUIPMENT HAZARD The fluid drain valve U 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 outlet The drain valve reduces the risk of serious injury including splashing in the eyes or on the skin 4 Connect the fluid line to the 3 8 18 6 m gun fluid inlet W 5 Before running any paint through the spray gun flush it out with a compatible solvent Ground the System A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD When operating the electrostatic device any ungrounded objects in the spray a aS people containers tools e T come electrically charged Ir ounding can result in static S Woo3 ich can cause a fire explo sion or electric shock Follow the grounding instructions below 8 308131 The following are minimum grounding requirements for a basic electrostatic system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground 1 Pump ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual 2 Air compressors and hydraulic power supplies gr
56. un System 224637 With 36 ft 11 m conductive air hose Includes Part No Description Qty 224200 PRO 4500sc ES Spray Gun 1 223071 Conductive Air Hose 36 ft 11 m 1 206199 Air Regulator with Gauge 1 106149 Air Filter 1 158491 Hex Nipple 1 158212 Bushing 1 164672 Hex Red Nipple 1 Gun System 224638 With 50 ft 15 25 m conductive air hose Includes Part No Description Qty 224200 PRO 4500sc ES Spray Gun 1 223072 Conductive Air Hose 50 ft 15 25 m 1 206199 Air Regulator with Gauge 1 106149 Air Filter 1 158491 Hex Nipple 1 158212 Bushing 1 164672 Hex Red Nipple 1 HO03 38 308131 Part No 224200 223070 206199 106149 158491 158212 164672 Includes Part No 224200 223070 216076 106148 With 25 ft 7 6 m conductive air hose Includes Description PRO 4500sc ES Spray Gun Conductive Air Hose 25 ft 7 6 m Air Regulator with Gauge Air Filter Hex Nipple Bushing Hex Red Nipple Gun System 224639 Description PRO 4500sc ES Spray Gun Conductive Air Hose 25 ft 7 6 m Fluid Hose 25 ft 7 6 m Air Filter Qty Qty Technical Data Category Data Gun Weight 34 3 oz 974 g Gun Length 11 1 in 283 mm Maximum Working 100 psi 7 bar 0 7 MPa Pressure 0 100 psi 0 7 bar 0 0 7 MPa Air Pressure Operating Range Fluid Pressure 0 100 psi 0 7 bar Operating Range 0 0 7 MPa Voltage Output 0 85 kV Short Circuit Current 120 mA Output Paint Resistivity 3 megohm

Casio EX-ZR400 Camcorder User Manual

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