Page 1
INSTRUCTIONS-PARTS LIST OJ
OIlACO
This manual contains IMPORTANT
WARNINGS
READ
and INSTRUCTIONS
AND
RETAIN
FOR
REFERENCE
307-896
Rev.
A
AUTOMATIC
AIR
7 bar (100 psi)
Part Number 907-292
Spray Gun & 75 ft. High Voltage Cable
Part
Number
Spray Gun & 50 Ft. High Voltage Cable
Part Number 956-610
Spray Gun with 25 Ft. High Voltage Cable
HIGH-RANGE ELECTROSTATIC
SPRAY
MAXIMUM
956-112
GUN
WORKING PRESSURE
GRACO
INC.
P.O.
Box
1441
©COPYRIGHT
u.s.
PATENT
and 4,501,394
MINNEAPOLIS,
1988
GRACO INC.
NO.
4,241,880; 4,335,861;
MN
55440-1444
H003
Page 2
WARNINGS
HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS
INSTALLATION
Typlc.1
V.ntll.te
Conn.ct
Connect
Ch.ck
Mount
Connect
Connect
Conn.ct
OPERATION
Op.r.tlng
Fllt.r
Adju.t
CI
••
CI
•• n the
Flu.hlng
SERVICE
Spray
Gun
EI.ctrlc.1
Gun
EI.ctrod. R ••
fluid N ••
......................................................................
In.t.lI.tlon
the
the
the
the
Electrical Grounding
the
Spr.y
the
the
the
Ch.ckllat
the
fluid
the
Spr.y
nlng
........................................................................
Air
.................•.......................••.............................
Patt.rn
Op.r.tlon
Troubl
DI
•••••
dl.
.........................................................
Spr.y
Booth
High
Voltage
High
Volt.ge
Gun
Air
Une
High
Volt.ge
fluid
Une
................................................................
P.tt.rn
C.p
and
Troubl
Troubl
••
mbly
..........................................................
I.tor
R.mov.1
................................................
Power
Supply
Ca
...........................................
......................................................
........................................................
.....................................................
........................................................
fluid
••
hootlng
••
hootlng
R.pl.c.m.nt
....................................................
........................................
Control
.................................................
Tip
.........................................
Ch.rt
hootlng
Ch.rt
Ch.rt
.....................................
.....................................
...........................
....................................
................................
..............................
TABLE OF CONTENTS
..........
10
11
11
12
2
4
4
4
4
15
15
15
15
8
8
1
1
8
7
7
7
8
9
fluid
B.rr"
fluid
B.rrel R .....
R
..
lator
R
..
lator
Servicing
F.n
Air
AIR CAP CONSUMPTION
Air
Cape
Air
Cap A
PARTS DRAWING
PARTS LIST
HOW TO ORDER REPLACEMENT PARTS
ACCESSORIES
TECHNICAL
The
words Warning, Caution, and
tion within this manual.
WARNING: Alerts user
personal injury.
CAUTION: Alerts user
damage
NOTE:
WARNING
Needle Replacement
Remov"
Pecking
Valve Replacement
to or destruction
Identifies essential procedures or extra information.
.............................................................
Repl.cement
mbly
Tubel R ..
Tube Reg
the
.......................................................................
...
lator
......
Actuator
mbll
..........................................................
...........................................................
....................................................................
................................................................
DATA
.............................................
to
..............................................
.••••••••.•••••••••••••••••••••••••••••••••.••••.•.••••.•
to
............................................
Repl.cement
ng
......... ~ ....................................
.................................................... 14
............................................
.nd
FLUID
avoid or correct conditions that could
avoid or correct conditions that could
of
equipment.
..............................
np
FLOW RATE CHART
...........................
Not.
are
used
B.ck
to
classify informa-
12
12
12
13
13
13
14
11
11
11
11
17
17
18
Cover
cause
cause
SERIOUS
SHOCK
BODILY
CAN
INJURY,
OCCUR IF THE
FOLLOWED.
•
READ
TAGS,
AND
AND
UNDERSTAND
WARNING
MENT.
c!J
Instruction.
EQUIPMENT MISUSE
General
Any misuse
overpressurizing, modifying parts, using incompatible
chemicals
cause them to rupture and
explosion or property damage.
NEVER
body.
ALWAYS follow the Pre
right,
system equipment.
NEVER
NEVER
could cause
CHECK
worn or damaged parts immediately.
This gun
Never exceed the maximum working pressure
any other component or accessory used in the system.
point the spray gun at anyone or at any part
NEVER
befo~e
try
alter or modify any part
all
ELECTROSTATIC
PERSONNEL
QUIREMENTS
EQUIPMENT
WHO
SHALL
STATED
WITHIN
HAZARD
Safety
of
the spray equipment or acc8880ries, such
and fluids, or using worn
put hand or fingers over the spray tip.
cleaning or removing the fluid tip or servicing any
to
stop or deflect
it
to
malfunction.
spray equipment regularly and repair or replace
has
a maximum working pressure
result in serious bodily injury, fire,
..
ure
leaks
or
damaged parts, can
Relief
of
Procedure,
with your hand or body.
this equipment; doing
of
7 bar
(100
of
the gun or
to
BE FULLY
88
of
the
the
so
psi).
EXPLOSION, FIRE, OR ELECTRIC
PRECAUTIONS
ALL
INSTRUCTION
LABELS BEFORE
SHALL
ONLY
BE
CONVERSANT
THIS
INSTRUCTION
Pressure Relief
To reduce the risk
in the eyes, injury from moving parts or electric shock, always
this procedure when shutting
follow
checking or servicing any part
stalling, cleaning or changing fluid tips, and whenever you
stop spraying.
1.
Turn
2.
3.
4.
5.
off
Turn
off
Trigger the gun into a grounded metal waste container
relieve fluid pressure.
Open the pump drain valve, having a grounded metal waste
container ready
Leave
spray again.
Procedure
of
the high voltage power supply.
the air and fluid supply
the pump drain valve open until you are ready
BELOW
ARE
NOT
MANUALS,
OPERATING
USED BY
WITH
EQUIP-
TRAINED
THE RE-
MANUAL.
serious bodily injury, including splashing
off
of
the spray system, when in-
to
catch the drainage.
the system, when
to
the gun.
to
to
2
307-896
Page 3
Bleed· Type
Valve
These
reduce the risk
the
repairing the pump.
The bleed-type air
this
Required
two
eyes and injury from moving parts
valve and the pump after the air regulator
AIr
Shutoff
accessories are required in your system
of
serious bodily injury, including splashing in
shutoff
Valve and
valve relieves air trapped between
fluid
if
you are adjusting or
is
shut
to
off.
Drain
Trap-
help
pad
air can cause the pump
valve within easy reach
The fluid drain valve assists in
displacement pump, hose and gun; triggering the gun to
relieve pressure may not be sufficient.
to
cycle unexpectedly. Locate the
of
the pump.
relieving fluid pressure in the
All parts
grounded
Static electricity
through the pump and hose and the spray gun's
power
charged and sparking may occur. Sparks can ignite fumes
from
flammable substances, which can cause a fire
and
If you experience any sparking or feel even a slight shock,
STOP SPRA
ing
lem before starting
The minimum spraying distance from the gun tip
workpiece is
workpiece will cause sparking.
Grounding
The following are minimum requirements for grounding a
basic
equipment
check your local electrical code
tions.
ground.
1.
2.
3.
4.
5.
6.
7.
of
the electrostatic spray system must be properly
to
reduce the risk
is
created by the high velocity
supply. Ungrounded objects can become electrically
solvents, fluid being sprayed, dust particles and other
result in serious bodily injury and property damage.
YING
of
the entire system.
electrostatic system. Your system may include other
Be
sure your system is connected
Pump: ground by using a ground wire and clamp
described
Air
compressors: ground according
recommendations.
High voltage
located outside the spray
and
the manufacturer's recommendations.
High voltage cable: obtain grounding through connection
of
an
undamaged cable
supply.
All
electric cables going
perly grounded.
Spray gun: obtain grounding through connection
perly grounded high voltage cable.
Object being sprayed: keep the workpiece hangers clean
and grounded at all times. Contact points must be sharp
points or knife
IMMEDIA
to
spray again.
100
mm (4 in.). Holding the gun any closer
or
objects which must also be grounded. Always
in
your separate pump instruction manual.
power
edges.
of
static electricity discharge.
TEL
Y.
Be
sure you have corrected the prob-
supplies: must be properly grounded
Check
for
detailed grounding instruc-
to
area.
Ground according
to
a properly grounded power
to
the power supply must be pro-
flow
of
fluid
or
explosion
for
proper ground-
to
the
to
the
to
a true earth
the manufacturer's
to
pro-
as
to
8.
All
electrically conductive objects
area,
including paint containers and wash cans, must
properly grounded.
9.
All
persons entering the spray area: shoes must have con-
ductive
straps must be worn. Rubber or
ductive.
10.
The
and grounded. Do not cover the floor
any non-conductive
grounding continuity.
11.
Flammable liquids in the spray
approved, grounded containers. Do not store more than
the quantity needed for one shift.
12.
All
conductive. Do not place the pail on any non-conductive
surface, such
rupt grounding continuity.
flushing
To reduce the risk
follow
remove the
pressure and use a grounded metal waste container.
Be
sure the high voltage power supply is
NEVER
(700F)
point
AL WAYS remove
tivating the spray gun.
Use
only non-sparking tools
and hangers.
Ventilate
To prevent hazardous concentrations
mable
The
High Voltage Power Supply
ed with the ventilators
ply unless ventilating
NEVER
operating.
soles, such
floor
of
the spray area must
solvent pails: use only grounded metal pails, which
and
Cleaning
the Pre
use
to clean the gun. NEVER
of
vapors, spray only in a properly ventilated spray booth.
operate the spray gun unless the ventilating fans
••
fluid tip before flushing.
solvents having a flash point
less
than 38°C
the
Spray
as
leather, or personal grounding
material which would interrupt
as
cardboard or paper, which would inter-
Safety
of
static sparking or splashing, always
ure
Renef
(1000F)
all
solvent from the system before reac-
to
Booth
to
prevent operation
fans
are
or
devices, in the spray
plastic soles
be
electrically conductive
area
Procedure
Use
OFF
use
solvents having a flash
to
clean the spray system.
clean residue from the booth
of
must
be electrically interlock-
operating.
are
with
cardboard or
must
be
on page 2, and
the lowest possible
during flushing.
of
less
than 21°C
toxic
and/or
of
the Power Sup-
not
con-
kept in
flam-
be
are
are
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
stallation, operation and maintenance
of
electrostatic spray painting equipment.
be
consulted in connection with the in-
307-896
3
Page 4
How
the
Electrostatic
Air
Spray
Gun
Works
A transformer supplies high voltage current through the
cable
to
trostatic field
through the hose and gun, where
the gun's ionizing electrode, where the elec-
is
developed. The pump supplies fluid
it
is
electrostatically
INSTALLATION
TYPICAL
INSTALLATION
p
G
charged
as
it
passes
fluid is attracted
around
it
and coating all surfaces.
the ionizing electrode. The charged
to
the grounded workpiece, wrapping
NON-HAZARDOUS AREA
KEY
A Air
B Air Line Filter
C Air Line Lubricator
D Pump
EON-OFF
F Electric Power Line
G Air
The Typical Installation shown above
H High
Supply Line
(D.P.-D.T.) Switch
Supply Shutoff Valve (Bleed-type)
Voltage Power Supply
J Air Regulator
K Air Filter
L Atomizing Air Line
M High Voltage Cable
N Fluid Line
o Remote Switch & Lights Wiring
P Normally Closed, 3-way Air Solenoid
Valve or 3-way Manual Valve
is
only a guide
(40
micron)
for
selecting and installing electrostatic air spray systems. It
is
not
an
actual system design. The particular type and
size
system for your operation must be custom designed
for your needs. For assistance in designing a system,
contact your Graco representative.
------WARNING-----
Installing and servicing this equipment requires ac-
cess
to
other serious
this equipment
Be
parts which may cause electric shock or
bodily injury. Do not install or service
unless you
sure your installation complies
are
qualified.
with
national,
state and local codes for the installation
trical
apparatus in a
Class
1,
Group
0;
Divisions 1
of
......
elec-
and 2 Hazardous Location.
WARNING
SIGN
H
HAZARDOUS AREA
Q Electrostatic Automatic Gun
R Fluid Regulator
S Remote Switch & Lights
T Relay
U Connection Between
V Cylinder
W Electrical Signal Required
EE
FF
Ventilate
the
Spray
..------WARNING
To prevent hazardous concentrations
and/or
ventilated spray booth. The High Voltage Power
Supply must be electrically interlocked with the
ventilators
ly unless the ventilation fans
OPERATE THE SPRAY GUN UNLESS VENTILATION FANS ARE OPERATING.
Check and follow
Local codes regarding air exhaust velocity
requirements.
Check and
OSHA standard 1910-107(b)(5)(i).
flammable vapors, spray only in a properly
to
prevent operation
follow all local safety and fire codes and
for
(CYU Air Line
Fluid Filter
Drain Valve
Booth
all
of
Electrical Signal
Relay
& Power Supply
to
Actuate Air
-------.
of
of
the power supp-
are
operating.
the National, State and
NEVER
toxic
Warning
Signs
Mount warning signs in the spray
easily
be
seen
and
read
cessories section on page
by all operators.
18.
4 307-896
area
where they can
See
the Ac-
NOTE: High velocity air exhaust will decrease the
operating efficiency
system. Air exhaust velocity
meters/minute (100-150
sufficient.
of
the electrostatic
of
31-46 linear
ft/min)
should
be
Page 5
Connect
The electrical connections
must
dance with
the
High
Voltage
be
performed by a qualified electrician, in accor-
all applicable local, state and national codes.
Power
to
Supply
the Power Supply (H)
z--~=-
Connect
Grease
Regreasing on page
Route the High Voltage Cable (M) from the gun
Power
Connect the High Voltage
To avoid permanent indentations
failures due to unnecessary stress
these steps:
1.
2.
3.
Check
...------WARNING
Proper electrical grounding
system
ing section,
page
Then check your system
1.
2. Shut
the
High
the resistor tube
Supply. Lubricate o-rings with petroleum jelly.
Support the cable overhead
walking
DO
Avoid sharp kinks and bends in the cable.
on
NOT clamp the cable too tightly at supports.
the
Electrical
Voltage
13.
it and vehicles driving over it.
Cable
as
described
Cable
to
Grounding
in
Resistor
the Power Supply.
of
the cable and cable
to
the cable, follow
to
keep
people from
(See
Fig
1)
Tube
to
the
-------.
of
is
essential. For your safety,
FIRE OR EXPLOSION
3.
Ground the system
Make sure the High Voltage Power Supply is properly grounded and located outside the spray area.
The
Power
can
grounded.
voltage circuit and
nected
precaution, attach a separate ground wire
case
to
the gun.
Supply
become
of
off
The
to a true
the High Voltage Power Supply.
the Power Supply and the air and fluid lines
case
charged
ground
must,
earth
every part
as
as
explained there.
explained below.
and
spray
if
the
case is
wire
is
without
ground.
of
read
the warn-
HAZARD,
gun
actuator
of
fail,
As
not
the high
be
an
part
your
on
well
con-
added
to
the
3. Have a qualified electrician check the electrical
grounding continuity
meter
(X)
to
tuator
of
The resistance should
measure resistance between the ac-
the gun
of
the spray gun.
(Y)
and a true earth ground
be
less
than
20
Use
an
ohms.
ohm-
(Z).
KEY
M High Voltage Cable
X Ohmmeter
Y Gun
Z Grounded Object
Fig 1
________________
Connect
Installation Drawing)
1.
2. Install
3.
4. Install
5.
the
Air
Lines (Refer
Install
an
supply
ruin the appearance
cause
(D)
Install a normally closed, 3-way air solenoid (P), or
hand valve in the air supply
supply
gun.
Install a bleed-type air shutoff valve
air line and each gun air supply line
the pump
type valve on each pump air supply line to relieve air
trapped between this valve and the pump after the
air regulator
Shutoff
warnings section, page
air line filter (B) to ensure a clean, dry air
to
the gun. Dirt and moisture in the line can
malfunction
an
air line lubricator
as
possible.
an
air regulator
lines
and/
Valve
of
to
control air pressure
or gun(s). Install
is
shut off.
and
to
the Typical
of
your finished piece, and
the Power Supply.
(C)
as
close
to
line (A).
(E)
on the pump and gun air
Fluid
See
Drain
3.
to
(G)
on the main
to
shut
an
additional bleed-
Bleed-Type
Valve
the pump
pump and
off
air
Required,
6. Connect the atomizing air line (U from the air line
the gun's 114 npt(f) atomizing air inlet. Refer
Typical
Installation drawing .
to
_
to
Air
to
the
...------WARNING
If the resistance is over
property grounded, and the
dous.
Check again that you have properly ground-
ed
your system components;
PLOSION
grounded through connection
properly grounded, high voltage cable (which
grounded through connection
grounded power supply), check for a grounding
problem with the cable and power supply first.
SURE you have corrected the problem before using the system.
Mount
Mount the gun
reciprocating arm. The mounting rod must
grounded.
Mount the gun head 254
the workpiece.
the
HAZARD,
Spray
Gun
(Q)
20
on page 3. Since the gun
on a stationary support or on a
to
-------,
ohms, the gun
system may be hazar-
see
FIRE OR EX-
to
an
undamaged,
to
a properly
be
300
mm
(10
to
12
is
not
is
is
BE
properly
in.) from
7. Connect the cylinder air line (V) from the solenoid
valve
to
the gun's
Adjust
If the gun is mounted
plug (11), adjust the air bleed valve
more atomizing air through the front
replace the plug
ping from the front
the
Air
1/4
npt(f) cylinder air inlet.
Bleed
Valve
above
(11), This helps prevent fluid from drip-
of
the gun onto the workpiece.
(See
Fig
the workpiece, remove the
2)
(43)
to
of
the gun, then
allow slightly
11~'~
43
·~.~~1··~\/~
Fig 2
________________
~"""'
\UI)
:::
.......
,,~/
__
~'7
)
V
_
307-896 5
Page 6
Connect
An electrical signal
closed, 3-way air solenoid valve (P). The air solenoid
valve opens the cylinder air
the fluid needle, allowing the fluid
signal
relay (T). A set
to
Voltage
the
(W)
the 120
to
High
Voltage
is
required
that actuates the air solenoid valve actuates a
of
contacts from this relay
KV
Power Supply. This allows the High
be
turned on and
Control
to
actuate the normally
to
the actuator, which opens
to
spray. The same
is
connected
off
automatically.
KEY
13
88
Plug
O-Ring
Connect
Before connecting the fluid line
and flush
compatible with the fluid
Connect
the
and
assists
pump,
and
a
flUid
pressure
Color
Remove the plug
the gun barrel, and install a
cessories Section) in the gun barrel inlet.
the
Fluid Line
it
with
solvent.
the
fluid
line
1 /8
~ube
Fitting
and
(FF)
gun.
(R)
gun.
inlet
between
(13)
drain
valve
in
relieving fluid pressure
hose
~Iuid
Drain Valve Required,
regulator
to
the
Change/Circulating
(N),
blow
Be
sure the solvent you use is
to
be sprayed.
(PTFE)
at
from
the
of
the
gun.
Warnings
pump
System
1/4
Install a fluid
outlet.
and
(66)
npt(f) elbow
the
pump
See
Bleed-Type Air Shutoff Valve
and o-ring
it
outlet
of
The
in
the
displacement
Section.
gun
to
Option
from one side
out
the
drain
control
OPERATION
...------WARNING
For Your Safety, always follow the Pressure
Relief
the system, when you stop spraying, and before
checking, servicing, installing, cleaning or changing any part in the system.
Operating
Check the following list daily, before starting
the system,
operation.
_
_
_
_
_
_
_
Procedure
Checklist
to
1.
Be
sure
operate
2.
Be
and completely relieve system pressure.
3.
Be
FIRE OR EXPLOSION
Check
4.
Be
spray
5.
Be
6.
Be
grounded. Contact points must be sharp points
or knife edges.
7.
Be
all
an
sure all operators
sure the system
the
sure the operator and
area
sure ventilation fans
sure the workpiece hangers
sure
all
on page 2 when shutting
help assure you
operators
electrostatic air spray system.
is
Electrical
are
properly grounded.
refuse
is
-------.
of
safe, efficient
are
properly trained
are
trained
thoroughly grounded.
HAZARD
Grounding
all
are
removed from spray booth.
how
to
on page
on
persons entering the
operating properly.
are
with
air,
pump
to
filter
(EE)
valve
Install
fluid
(see
Ac-
off
to
operate
to
safely
properly
See
3,
page
and
5.
clean and
of
Fig 3
_______________
...------WARNING
Do not
fittings
plosion and cause serious bodily injury.
For color change, connect a fluid line
Remove the fluid tube assembly and install a flushing
valve
let. Connect the fluid flushing
Connect
For a circulating system, connect the fluid return line
the elbow.
Filter
Filter the fluid
which could clog the spray tip.
Adjust
This gun
viscosities and at various
to
establish the correct fluid
1.
2.
3.
4.
5.
6.
use
metal fittings at the gun head. Metal
can
cause sparking and result in fire or ex-
(see
Accessories Section) in the gun barrel fluid in-
an
air line
the
Fluid
the
Spray
can
Set the atomizing air pressure at 2 bar
fluid pressure at
Choose the correct fluid tip and air cap combination
for
your application. (See the Air
and Fluid Tip Flow Rate Chart), page
rate and viscosity must
(0.047 in.) fluid tip
Turn on the High Voltage Power Supply.
Adjust the fluid
regulator
Section).
For fine adjustment,
(39)
located at the rear
the knob
being sprayed, and
the amount being sprayed.
Use
an
for the desired degree
the lowest air pressure possible
air pressure regulator
to
actuate the flushing valve.
to
remove coarse particles and sediment
Pattern
atomize many fluids with different
installed in the fluid line. (See Accessories
clockwise to reduce the amount
flow
0.25 bar
is
furnished with the gun.
flow
use
counterclockwise to increase
-------.
to
the elbow.
line
to
the flushing valve.
rates. Follow these steps
flow
and air flow:
(3
to
4 psi).
be
considered. A 1.2 mm
by using the fluid pressure
the fluid adjusting screw
of
the gun.
to
of
atomization. Always
for
(30
Cap
Consumption
15.
See
Fig
adjust the pressure
most efficiency.
psi) and
Both
4.
of
_
flow
Turn
fluid
use
to
8.
Be
_
_
9.
sure all flammable liquids in the spray booth
are
in approved, grounded containers.
Be
sure all conductive objects within 6 m
of
the
gun-
of
the spray
grounded.
6 307-896
are
electrically grounded and the floor
area
is
electrically conductive and
(20
ft)
7.
Use
the fan valve
spray pattern.
counterclockwise
for
a solid, round pattern.
(57)
See
to
Fig
for
a wide pattern
change the shape
4.
Turn fan valve knob
and
clockwise
of
the
Page 7
39
KEY
39 Fluid Adjusting Screw
fi1
Fan
Valve Assembly
Clean
Equipment needed:
Procedure:
the
Air
Cap
and
Soft bristle brush (supplied).
Fluid tip wrench (supplied).
Solvent compatible
1.
Turn
off
the Power Supply.
with
Fluid
Tip
fluid being sprayed.
Fig 4
________________
NOTE:
Adjust the system's control device, so the gun starts
spraying just before meeting the workpiece, and stops
as
soon
See
Service section for additional information.
When
and fan pattern
ed
on and operation can begin.
Cleaning
~-----WARNING-----
For
Relief
system, when you stop spraying and before checking, servicing, installing, cleaning or changing any
part in the system.
1.
2.
3.
4.
5.
.....
-----CAUTION
Do not
this may scratch them, and make sure the elec-
trode wire
holes or a damaged electrode wire can distort the
spray pattern.
Do
allow
ed
cessive current demands. Point the gun
while cleaning
ning back into the air passages.
THE GUN
Clean
compatible
tive solvents can cause the gun
When increasing
may have
the gun
coverage over a large area.
as
it
has passed.
the
Spray
all adjustments
Your Safety. always follow the Pressure
Procedure
Clean
the fluid and air line filters daily.
Clean the outside
dampened
Clean
the air cap and fluid tip daily, minimum. Some
applications require more frequent cleaning.
Replace the fluid tip and air cap
See
Clean
Check the electrode resistor (55). Straighten
bent, and replace
page
11
for replacing the electrode resistor.
Check all
material; clean them,
to
Pattern
are
made, the high voltage can
in
a compatible solvent.
the
Air
of
the
to
to
maintain the same amount
Troubleshooting
of
on page 2 when shutting
of
it if
work
a wide, flat pattern, you
increase the supply
atomizing air, fluid pressure,
the gun daily
if
Cap
it
is
if
necessary.
and
they are damaged.
Fluid
broken or damaged.
hangers
Chart
with
Tip
for
of
a soft cloth
below.
build-up
--------.
use
metal tools
is
not damaged. Scratches in the air cap
not
use
any
solvent
air passages cause poor atomization and ex-
all parts
into
to
IN
SOLVENT.
with
to
clean the air cap holes
cleaning
the
prevent dirty solvent from run-
with
the fluid being sprayed. Conduc-
method
gun
air
a non··conductive solvent,
which
passages. Clogg-
NEVER
to
IMMERSE
malfunction.
fluid
be
off
the
it
may
down
_
in the
turn-
.....
if
it
See
as
to
of
is
of
2. Shut
3.
4.
5.
6.
7.
~~32
off
the fluid and air supply lines
Actuate the gun
trapped in the lines.
Note the position
See
Fig
spring tension on needle assembly.
Remove the air cap retaining nut
(32).
remove the fluid tip (30).
Use
to
Screw the fluid tip back into the gun. Tighten the tip
securely
to
4.
See
the soft
clean air cap, fluid tip, and front part
with
1.1
to
to
release
Turn the fluid adjusting screw
Fig
1.4 N·m
of
5.
With
br.c;tle
brush (83a) supplied and solvent
the wrench (83b). Torque the fluid tip
(10
55
{..
~
\
the air and fluid pressure
the fluid adjusting screw (39).
the wrench (83b) supplied,
to
12
in-Ib).
//
j
(J
to
the gun.
(27)
and air cap
of
See
Fig
KEY
27 Retaining
30 Fluid Tip
32 Air Cap
56
Electrode Resistor
~27
Fig 5
------------------
8.
Replace the retaining nut and air cap carefully
avoid bending the electrode wire. Tighten the
taining nut
with resistance.
will
be
9.
Reset the fluid adjusting screw
position. Measure the travel
trode. Full travel should
gun
Flushing
.....-----WARNING-----
For
Your Safety. always follow the Pressure
Relief
system, when you stop spraying and before checking, servicing, installing, cleaning or changing any
part
in
1.
Turn
2. Disconnect and plug the fluid supply
3.
Connect the solvent supply
4.
Run
5.
Disconnect the solvent supply.
6.
Reconnect the fluid supply line.
7.
Trigger the gun until
so
it
is
snug, allowing the air cap to turn
If
it
is
too tight, the spray pattern
distorted.
be
2.5 mm (0.10 in.). The
is
now
ready for spraying.
Procedure
the system.
off
the high voltage power supply.
solvent through the gun.
on page 2 when shutting
to
it
is
clean
(39)
of
to its original
the resistor elec-
line.
the gun.
of
solvent.
to
relieve
the gun.
5.
Nut
off
the
to
re-
......
307-896
7
Page 8
SERVICE
~----------------------------VVARNING----------------------------~
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious
bodily injury.
Do
not install or service this equipment unless you
are
qualified.
Before servicing the tip or gun, and before disassembling the gun,
cedure on page
NOTE:
SPRAY PATTERN TROUBLESHOOTING
PROBLEM:
IMPROPER SPRAY
PATTERN CAUSE
Fluttering or
Spitting spray
Check
IKlCJ~
c::
e
2.
all
of
:?
~
Disconnect the fluid hose from the gun.
the possible remedies in the Troubleshooting Charts before disassembling the gun.
CHART
Insufficient
Leak in the
Dry or worn fluid needle packing or loose packing
nut permits air
Loose fluid tip or damage fluid tip taper seat.
Dirt between
Fluid build
holes. Full air pressure from clean horn hole
forces fan panern toward clogged end
Damaged
Fluid build up on the perimeter
or
partially clogged fluid tip orifice
Too high atomization air pressure
fluid supply
fluid line Tighten or repair
to
get into fluid passage.
fluid tip, taper seat and body. Clean.
up on air cap; partially clogged horn
fluid tip
or
air cap holes
of
fluid tip orifice,
ALWAYS
follow the Pressure Relief Pro-
SOLUTION
Adjust fluid regulator or fill tank.
Lubricate or
packing nut.
Tighten or replace fluid tip.
Clean
suitable solvent and wipe clean.
Replace
Remove obstruction.
hard instruments.
Reduce air pressure or adjust air adjusting
valve.
replace packing, tighten
with
soft brush or submerge in
damaged part.
Never
use
a wire or
~
<!>
Fluid too thin
Not enough
Low atomization air pressure
Fluid too thick
Too much fluid
0
Streaks
NOTE: Some improper patterns
Last coat
;8.
':':
Too much air pressure
.:,:';:-
i
Insufficient air pressure
Non-uniform spray pattern
fluid pressure
of
fluid applied
are
caused by the improper balance between air and fluid.
too
wet
Regulate
Increase fluid pressure.
Raise
Regulate fluid viscosity.
Reduce fluid
on pressure feed guns
adjusting screw
obtained.
Apply drier finish with multiple strokes.
Use
Increase air pressure.
Clean or replace air cap.
fluid viscosity.
air pressure.
flow, reduce fluid pressure
least air pressure necessary.
and/or
until proper pattern
adjust fluid
is
8 307-896
Page 9
GUN OPERATION TROUBLESHOOTING CHART
PROBLEM
Leakage from fluid packing nut.
Air
leakage from front
Fluid leakage from front
Fluid leaks from rear needle packing
nut or drain
"Orange Peel" finish. Insufficient air pressure.
hole.
of
gun. Air valve not seating properly. Clean, service.
of
gun.
CAUSE
Loose packing nut (23). Tighten.
Worn needle packing
Air
bleed valve is open. Check, adjust or close
Resistor electrode worn or damaged.
Worn
fluid seat.
Fluid packing
Loose
Adjusting screw
Cylinder air going into gun not completely
shut off.
Worn
needle packing (4).
Worn needle shaft
Paint viscosity
(4)
fluid tip
(4).
too tight.
(30).
(39)
not set correctly.
(61).
too
high. Thin paint or
SOLUTION
Replace.
See
Fig
2.
Replace.
Replace
electrode.
Lubricate and adjust.
Tighten.
Adjust.
Turn
Replace packing.
Replace worn needle shaft.
Increase,
ed
fluid tip
off
cylinder air.
use
for good results.
least air pressure need-
use
as
and/or
resistor
larger fluid nozzle.
required.
Excessive spray fog.
No fluid sprays from gun.
Equipment covered
Dirty air cap.
with
fluid.
Fluid poorly
Improper thinner being used.
Too much air pressure. Reduce,
Fluid
Fluid low.
Damaged air cap. Replace air cap.
Dirty or clogged
Damaged
Air
valve not actuating. Check cylinder air, fluid needle pack-
Damaged
Exhaust air
properly.
Equipment closer
being sprayed.
Misalignment between air cap and
Aligned
mixed or filtered. Remix or refilter fluid.
Use
proper thinner.
use
for good
thinned too much. Properly thin fluid.
Check, add if necessary.
fluid tip.
fluid tip. Check, replace fluid tip.
fluid needle. Replace.
flow
insufficient or not directed
to
ionizing tip than object Mount gun closer
fluid tip.
Aircap1
Fluid Tip •
Misaligned
Clean
ing (4), and
necessary.
Check for proper CFM, check
and direction of air
Remove and clean air cap and
tip
as
tion under
Air
Cap
Reinstall fluid tip finger tight. Using
the wrench supplied, tighten fluid tip
114
turn (torque to 1.1-1.4
(10-12 in-Ib)). Set locking pin
ed
position. Reinstall air cap being
sure
to
snug only; allowing air cap
with resistance.
least air pressure needed
results.
fluid tip.
needle. Replace parts
described in the Operation Sec-
To
Clean
and
Fluid
tighten retaining nut until
flow.
to
Tip
target.
or
Change
(page
N'm
to
to
as
baffles
fluid
the
7).
lock-
turn
307-896 9
Page 10
ELECTRICAL TROUBLESHOOTING
CHART
PROBLEM
Poor wrap-around. Parts poorly grounded.
CAUSE SOLUTION
High exhaust velocity.
High fluid pressure.
Fluid viscosity.
Low or no electrostatic voltage.
Faulty gun resistance.
Improper distance between gun and Adjust spraying distance
workpiece.
Too high atomizing air pressure. Reduce air pressure.
low fluid resistivity.
Too
Faulty power supply resistance. Check power supply resistance.
Clean
hangers, check for proper
ground on conveyer or track.
Reduce within code
Reduce pressure.
Check
supplier for proper fluid for
electrostatic spray.
See
below.
Check; resistance
megohms ±
resistor electrode
of
the High Voltage Cable, where
connects to the Power Supply.
resistance
of
resistor
203-305
Check
meter and probe (refer to instruction
manual
page
20
is
(62).
mm
fluid resistivity with paint
307-263).
12.
limits.
should
be
from the
of
gun to the end
lower check resistance
(8-12
in.).
end
to
450
of
the
If
See
it
Faulty needle electrode assembly. Replace needle electrode assembly.
Supply
is
Low or no electrostatic Power
wrap. turned
Fuse
on
inside
Supply
Power
Power
line voltage is incorrect. Adjust for correct voltage.
Low or no electrostatic Faulty High Voltage Power
wrap. (Spraying voltage
light
does not come on).
Low or no electrostatic
wrap. (Spraying voltage
light comes on then goes
off).
Low or no electrostatic
wrap. (Spraying voltage
light
is
on all
of
the time).
Continued on page
11.
Gun
held too close to part being Increase distance between part
painted. gun.
is
Fluid
Electrical short in the High Voltage Replace the High Voltage Cable.
Cable.
Electrical short in gun. Take gun apart and visually check the
Faulty High Voltage Power Supply.
Faulty resistor in the resistor
trode
Resistor
connection
gun body.
too conductive.
assembly.
of
off. Line Power Switch
of
High Voltage Replace fuse.
is
blown.
Supply.
elec-
gun not making a good
with
contact inside
of
See
instruction manual included with
High Voltage Power
Lower conductivity
resistor
the
needle well in the gun barrel for
and/or
dirt
replace parts
See
instruction manual included with
High
Replace the resistor electrode
assembly.
See
in this manual.
is
OFF,
should
ON.
Supply.
of
fluid.
holder, the resistor well and
damage.
Voltage Power Supply.
Resistor Assembly Replacement
as
required.
Clean
and
be
and
10 307-896
High Voltage
good contact
Cable insulation punctured.
Cable not making
with
resistor
of
gun.
Replace
Replace cable.
conductive spring
as
required.
Page 11
ELECTRICAL TROUBLESHOOTING
CHART
PROBLEM
Low
or
wrap.
light is on
Continued from page
Spraying
when gun
Operator gets mild shock.
Operator gets mild shock
when touching workpiece.
Gun
.....
no electrostatic
(Spraying voltage
all
of
the time).
voltage stays on
is
not
actuated.
Disassembly
-----WARNING------
10.
CAUSE
Spring at transformer end
not
making good contact.
Electrical short in gun. Take gun apart and visually check the
Faulty High Voltage Power
Gun actuating device
not
Operator
is
in contact
object.
not
Gun
Workpiece
properly grounded
with
properly grounded.
not
properly grounded.
Installing and servicing this equipment requires access
to
other serious
this equipment
Turn
relieve
the
Follow the Pressure Relief
parts which may cause electric shock or
bodily injury. Do not install or service
unless you are qualified.
off
the High Voltage Power Supply and
all
of the pressures trapped in the gun and
lines before servicing any part
Procedure
of
the system.
on page
2.
NOTE: Check all possible remedies in Trouble-
shooting Charts before disassembling gun.
.....
----------CAUTION--------
If
the plastic parts
ly ,
ALWAYS
prevent damage
ALWAYS
lubricate the o-rings and seals
petroleum jelly.
ALWAYS
remove the gun from worksite
vice or repair. Service
To disconnect the gun from the High
Supply and the fluid supply:
of
the gun must
be
held secure-
clamp them in padded vise jaws
to
the parts.
with
for
or
repair
area
must
be
clean.
Voltage Power
to
ser-
SOLUTION
of
Supply.
is
faulty.
ungrounded
6.
cable
or
Disconnect High Voltage Cable from Power Supply .
Stretch spring.
resistor holder, the resistor well and
needle well
Clean and replace parts required.
See
High Voltage Power Supply.
Check actuating device, replace
faulty.
Be
sure floor
Wear shoes
soles.
tact
metalic items which could build-up
electric charge.
Be
sure Graco air supply hose
ing used and
Clean workpiece hangers. Check
proper ground on conveyor
7. Take the gun and cable assembly
for repair.
NOTE: Because
High
of
Voltage Cable resistor tube
dielectric grease. The High Voltage Cable
should
not
be
replacement or regreasing
Electrode
Resistor
Replacement
Remove the air cap and fluid tip
Operation Section under
Tip. Remove the electrode resistor
(83d)
supplied. Install new electrode resistor
wrench. Do not overtighten .
r-------CAUTION
To avoid damaging the plastic threads,
careful when installing the electrode.
Install
the air cap and fluid tip
tion Section under
KEY
83d
Wrench
Clean
83d
for
dirt
and/or
damage.
instruction manual included
is
properly grounded.
with
Be
sure operator
with
or carrying (in clothing) any
non-insulating
is
is
properly grounded.
to
the workbench
not
in con-
is
or
track.
with
if
be-
for
the high operating voltage, the
is
filled with
removed from the gun, unless
is
necessary.
(See
Fig
6)
as
Clean
described in the
the
Air
Cap
(55)
with
and
Fluid
the wrench
with
the
------..
be
very
as
described in the Opera-
the
Air
Cap
and
Fluid
Tip.
1. Turn
2. Turn
3. Shut
off
the high voltage at the Power Supply.
off
the line voltage input
off
the fluid pump and actuate the gun
to
the Power Supply.
relieve the pressure.
4.
Disconnect the fluid hose and air lines from the gun.
5.
Flush the gun
with
a compatible solvent.
to
Fig 6
________________
307-896
_
11
Page 12
Fluid Needle
Remove the air cap and fluid tip
Operation
Tip. Turn the cylinder air off. Remove the electrode
resistor (55). Note the position
(39),
and remove adjusting screw, retaining nut (35),
spring
removing the four screws (12). Loosen the
ing nut
With a long nose pliers pull out the needle assembly (64)
from the back
(63) and washer
(23) half a turn, using the wrench
Removal
Section under Clean
of
the actuator.
(See
(68).
Figs
7 and
8)
as
described in the
the
Air
Cap
of
the adjusting screw
Remove plate
needle pack-
(83c)
and
Fluid
(37),
supplied.
by
Install the electrode resistor
supplied.
described
Cap
Apply air
ing nut
until there
the fluid needle packing (4) or resistor tube (48) have
If
to
be
dielectric grease
Regreasing, Regreasing
Disassembled.
See
Fig
6. Install the air cap and fluid tip
in
and
the Operation Section under Clean
Fluid
Tip.
to
cylinder air port
(23) with the wrench
is
light packing resistance on the needle.
replaced, the resistor tube must
as
(55)
with the wrench (83d)
of
the gun. Adjust the pack-
(83c)
supplied (See
described in
with
be
Resistor
Barrel/Resistor Tube
the
Fig
refilled with
as
Air
8)
Tube
~~~39
~~35
68 KEY
12
Screw
35
Retaining
37
Plate
39
Adjusting Screw
63
Spring
68
Washer
KEY
23
Packing
83c Wrench
Fig 8
Fluid Needle
The fluid needle assembly (64)
with retaining nuts
these nuts
sion shown in
Before replacing the needle assembly, thoroughly
lubricate
installing into gun.
KEY
34
Retaining Nuts
64
Fluid Needle Assy.
Nut
Replacement
are
with petroleum jelly. Twist the needle when
(34) set for the correct length.
moved, reset them
Fig
9.
is
sent from the factory
to
the proper dimen-
Nut
If
Barrel Removal
Remove the fluid needle
Removal.
Loosen the barrel nut
Pull
the gun barrel forward
not
to
lose the gasket (24).
Fig
10
_______________________________
(28)
'0.
as
described
using wrench
off
resistor tube.
See
Fig
28
in
Fluid Needle
(83b)
12.
KEY
28 Barrel
39
Adjusting Screw
83b Wrench
supplied.
Be
careful
Nut
_
Fluid
F:1:';i:~~~
I
Fig 9
________________
Install the plate (37) with the four screws (12). Install the
adjusting screw
washer
tion.
12
(68). Set adjusting screw
See
307-896
Fig
(39),
7.
64
retaining nut (35), spring (63) and
(39)
to
its original posi-
~
I
_
Packing
Remove the gun barrel (60)
Removal.
Remove the packing nut (23) from the rear
using the wrench (83c) supplied.
Remove the insulator
Place
the barrel on the bench in a vertical position with
the back
(83e) supplied in the front
out the
needle packing
Replacement
(44)
of
the barrel touching the bench. Insert the rod
(4)
as
described in Barrel
from the gun barrel.
of
the barrel and gently tap
and supports
See
of
the barrel
Figs 8 and
(20,
29).
11.
Page 13
KEY
4 Packing
20
SupPOrt
23
Packing Nut
28
Barrel Nut
29
Support
44
Insulator
60
Gun
earrel
~
~n
Fig
11
________________
66
O-Ring
67
O-Ring
n
Fitting
20~
6I~
29
,
i»®1'
~66
28~~
~~~
~,~
~
c:/'/
To remove the resistor tube (48),
hand, pushing
while pulling
\
other hand.
Push
the new resistor tube
the gun body. The resistor tube should protrude
190
mm (7.5 in.) from the front
Screw the retainer
the retainer
Place
the o-ring (8) into insert (53). Install the larger
bored end
resistor tube (48).
resistor tube.
Regrease the gun
_
Regreasing, Regreasing
Disassembled.
it
from the back
it
from the front
(48)
(52)
to
20
of
the insert into the retainer
back into the gun body. Torque
to
27
N·m
Slide the o-rings (6) in place over the
as
described in
lift up on
of
the gun body (56),
of
the gun body with your
back
in
of
the gun body (56).
(15
to
20 ft-Ib).
with
Barrell Resistor Tube
it
from the front
(52)
and over the
Resistor
with
one
of
Tube
Check
them
...------CAUTION
Place
packing
Barrel
Make sure the three o-rings
ing supports
Insert the needle shaft assembly into the barrel and
tighten packing nut
See
Assemble
rel
Install the
Fluid Needle Replacement
all
of
if
the parts for wear or damage and replace
necessary.
-------.
Use extreme care when handling the packing
because
tra pac kings on hand.
Clean
ble
spirits.
gun
Figs 8 and
nut
it
is
very brittle. You may want
all parts in non-conductive solvent compati-
to
the fluid being used, such
Use
of
to
malfunction.
packing nut (23), insulator tube (44), support (20),
(4)
Reassembly
the barrel
(28)
needle
conductive solvents can cause the
and support
(20, 29).
11.
with
the wrench (83b) supplied. See Fig
into
(29)
See
Fig
(23)
with
Pull the needle back
to
the actuator, tightening the bar-
the
gun
as
over needle shaft.
(66,
67)
11.
wrench (83c) supplied.
as
described
to
keep ex-
Xylol or mineral
are in place
out
of
the barrel.
in
in
(4)
pack-
10.
KEY
6 O-Ring
8 O-Ring
22
Retaining Ring
24
Gasket
28
Barrel
48
52
53
58
58
60
62
Fig
Resistor
Nut
Resistor Tube
Retainer
Insert
Gun
Body
Spring
Gun
Barrel
Resistor
12
________________
Tube
Regreasing
62\48~1
58"
L
~.
TORQUE TO
(See
20-27
(16-20
Fig
ft-Ib)
NOTE: Service Kit 217-114 (supplied
contains
resistor tube.
all items needed
~
6~O
52~\{)
7j"'-
N.m '
/
It::)
i.
r
_
12)
with
the gun)
to
regrease the
Resistor
Remove the barrel from the gun body
Barrel
(52)
tainer, packing (8), and insert (53),
replace
replace it.
.-------CAUTION
Clean all parts in non-conductive solvent compatible
mineral spirits. Use
cause the gun
Remove spring
and replace if necessary. Check resistance
(62)
should have
Tube/Resistor
Removal.
and remove retainer from gun body. Remove re-
as
Place a wrench on the flats
necessary.
Replacement
If
insert
(53)
(See
as
described
Inspect for damage,
has burn marks,
------
with
the fluid being used, such
(58)
using a megohmmeter. The resistor electrode
25
± 5 megohms resistance.
of
to
malfunction.
and o-rings (6). Inspect
conductive solvents can
as
Xylol or
for
of
Fig
of
retainer
damage
resistor
12)
(55)
in
Regreasing With Barrel I Resistor Tube Disassembled
Remove the resistor
Screw the grease fitting (82c) into the resistor end
resistor tube (48). Using the grease gun
tric grease (82b), fill the resistor tube until the grease
comes
grease fitting.
To
tainer
from being pushed
tainer. The, face the
front
the resistor tube.
Thoroughly wipe
contaminate the
to
out
of
the end
install the resistor, first, cover the open end
(52)
with
of
the gun barrel (60), and push the resistor into
fluid passages
(62)
from the resistor tube (48).
(82a)
of
the retainer (52), Remove the
your
thumb
out
plug end
off
fluid
of
the gun. (Continued on page 14).
to
prevent too much grease
of
the resistor tube
of
the resistor toward the
any excess grease. Grease may
to
be sprayed
if
allowed to seep in-
of
and dielec-
of
the re-
(48)
and re-
the
307-896
13
Page 14
Replace the barrel
Reassemble the electrode resistor
air cap
Fluid
(32)
Tip
in the Operation Section.
as
described in Barrel
as
described in Clean
(55),
Reas.embly.
fluid tip
the
Air
(30),
Cap
and
and
Remove the housing (38), and spring
housing
the gun body
all
(65). Remove housing (65). Piston parts from
(56) will come out with the housing.
parts with compatible solvent and replace
(17)
from the
Clean
if
worn.
NOTE:
Reassemble the High Voltage Cable
should come out from the threads and bleed hole in the
cable swivel
off
the excess grease.
When the
system resistance through the gun and cable should
450 ± 25 megohms.
Regreasing With Only the High Voltage Cable Removed
If only the High Voltage Cable
the gun
retainer
Attach the grease gun
grease tube (82e).
end
resistor tube cavity,
of
the resistor (62).
Slowly fill the tube with dielectric grease (82b). As
grease fills the cavity, the grease tube will back out
the insert (53), Continue filling until the grease tube
comes
Carefully
taminate the
the fluid passages
NOTE:
Reassemble the High Voltage
should come out from the threads and bleed hole in the
cable swivel
off
the excess grease.
When the
system resistance through the gun and cable should
450
Servicing
Remove the needle
Replacement.
lockwashers (71).
If
the gun is
(52) opening
if
the resistor tube
cable
can
be
(52).
of
the insert (53) and retainer
all
the way out and the entire cavity
wipe
off
fluid
If the gun
(52) opening
if
the resistor tube
cable
±25
megohms.
the
Actuator
to
be stored, cover the retainer
to
prevent contamination.
is
is
assembled with the gun, the total
is
greased by back filling through the
(82a)
Insert the grease tube into the open
until contact
any excess grease.
to
be
sprayed
of
the gun.
is
to
to
is
assembled with the gun, the total
as
Remove the four screws (9) and
removed from the gun,
to
the lubricant fitting
be
stored, cover the retainer
prevent contamination.
Cable
is
(See
Fig
described in Fluid
to
the gun.
properly filled. Wipe
(52),
is
made with the back
Grease
if
allowed
to
the gun.
properly filled. Wipe
13)
Grease
of
through the
is
may con-
to
seep
Grease
Needle
be
the
of
full.
into
be
~
17
16
65
8
c
~
~
\
Fig
J
13
________________
68~'
38~®,,,.,,~,
\
~
..
../~
,.'
'),-;::
,,~~:"
,~'"
~~i
~~
~-
"-~:
, 9 Screw
;:)
""II',
'.
6;
,
14
/
\...71
40
~~
~~
'Xl
35 39
9
KEY
8 O-Ring
14
U-C~pPacking
18
O-Ring
17 Spring
35
Retaining
38
Housing
39
A.djusting Screw
40
Piston
63
Spring
66
Housing
88
Washer
71
Lockwasher
Nut
NOTE:
When
parts with
piston.
the o-ring
housing together, and push the piston into the front
housing
front housing. Remove the rear housing
spring (17). Then
front housing.
shown in
Assemble the remainder
Needle
KEY
AA
BB
CC Adjusting Screw
DO O-Ring
BB~
To inspect the o-ring
must be tapped lightly through the center
hole
of
the housing (65) with a small punch.
reassembling the actuator, lightly coat all the
petroleum jelly. Slide the u-cup (14) onto the
Install the piston into the rear housing
(16)
onto the piston. Put the front and rear
(65) using a dowel rod through the hole in the
install the rear housing back onto the
Fig
Replacement.
Housing
Retaining Ring
TORQUE TO
Reassemble the remaining parts
13.
of
the gun
AA
20-27
N'm
(15-20 ft-Ib)
(16),
the piston
as
described in Fluid
~"'\'\'''~
~
Fig 14
Fan
Place
housing (AA) and remove
the retaining ring
counterclockwise removing it from valve housing (AA).
Clean
if necessary.
When reassembling the fan air valve assembly (57),
petroleum jelly
of
After the retaining ring
justing screw (CC), back the adjusting screw out
housing (AA)
ring
Apply Loctite® pipe sealant
ing (AA). Torque the housing (AA)
_
________________
Air
Valve
a wrench on the flats
all
the adjusting screw (CC).
(BB).
(14
to
20 ft-Ib) when replacing into the gun body (56).
Replacement
(BB).
parts, inspect for wear or damage, and replace
See
Fig
to
lubricate o-ring
until
it
bottoms out against the retaining
of
fan valve assembly (57)
it
from the handle. Remove
Rotate the adjusting screw
14.
(DO)
and the threads
(BB)
is
reinstalled on the ad-
to
the threads
to
(38),
to
install the
of
the hous-
20
to
Place
of
27
(40)
as
_
(CC)
use
the
N·m
14 307-896
Page 15
AIR CAP CONSUMPTION
AND
FLUID TIP FLOW RATE CHART
___
Dm
__
WMmmlHS1i~gt*i]rn1Jm1~n:;;;%bWiitHfWJ
NOTE:
This
is
only a guide for selecting
an
air cap and fluid tip combination for your application. ALL TIPS AND
CAPS ARE INTERCHANGEABLE. Contact your Graco representative for further information.
RECOMMENDED
Air
Cap
Air
TYPE
OF
AND
FLUID
VISCOSITY
Low
Production
Stains
Primers
Sealers 181-299
lacquers (0.047)
15
to
22
(No.2
Medium Production
Primers
Lacquers
Enamels
Sealers (0.047)
19
(No.2
High Production
Metallics
Lacquers
Enamels
19
(No.2
seconds
Zahn cup)
to
30 seconds
Zahn cup)
to
30 seconds
Zahn cup)
Part
Number
177-037
1n-848
177-034
177-848 0.34 Round end
180-739-
180-740
Consumption
m3/min
(CFM
at
at
30
0.20
(7.0)
0.34
(12.1)
0.24
(8.5)
(12.1)
0.27
(9.2)
0.27 Round end 181-298 1.0
(9.2)
2.1
psn
AIR
CAP
Pattern Shape
bar
and Length
254
mm
Round end 181-298
279
(11
Round end 181-298
356
(14
Round end (0.040)
330
(1350
356
(14
Round end
381
(15
457
(18
AND
at
(10
in.)
to
330
mm
to
13
in.)
to
406
mm
to
16
in.)
to
381
mm
15
in.)
to
406
mm
to
16
in.)
to
432
mm
to
17
in.) 181-299-
to
508
mm
to
20
in.)
FLUID TIP
Fluid
T1p
Part
Number
181-298
181-299
181-300 1.5
181-298 1.0
181-298
181-300 1.5
COMBINATIONS
ID
mm
(In.)
1.0
(0.040)
1.2
1.0
(0.040)
1.0
1.2
(0.060)
(0.040)
1.0
(0.040)
1.2
(0.047)
(0.060)
(0.040)
Flow
Rate
ml/min
(oz/min)
In
to
(6
to
18)
356
to
(12
to
In
to
(6
to
18)
In
to
(6
to
18)
355
to
(12
to
591
to
1182
(20
to
In
to
(6
to
18)
In
to
(6
to
to
355
(12
to
591
to
(20
to
In
to
(6
to
532
710
24)
532
532
710
24)
40)
532
532
18)
710
24)
1182
40)
532
18)
Low
Volume-High Solid 177-848
Lacquers
Enamels
Epoxies 181-300
Urethanes
Over 28 seconds
(No.2
Zahn cup)
Heevy
end
Lacquers
Enamels
Epoxies
Urethanes
Over 28 seconds
(No.4
• Air cap and fluid tip combination supplied
Air
Caps
The following air caps
High Solid
Zahn cup)
can
be
with
ordered
177-038 0.28
177-039 0.29 Tapered end
gun.
as
accessories: Air cap assemblies include a pre-assembled retaining
0.34 Round end
(12.1)
(10.0)
(10.2)
Air
356
to
406
(14
to
16
Tapered end
381
to
432
(15
to
17
356
to
406
(14
to
Cap
Assemblies
16
mm
in.)
mm
in.)
mm
in.)
ring (part no. 176-930), retaining nut (part no. 176-968),
Part
No.
and air cap.
1n-034
1n-036
1n-037
1n-039
180-739
180-740
Part
No.
217-454
217-455
217-456
217-457
218-996
220-386
181-299
181-299 1.2
181-300 1.5
181-301 1.8
181-300 1.5
181-301 1.8
1.2
(0.047)
1.5
(0.060)
(0.047)
(0.060)
(0.070)
(0.060)
(0.070)
Includes
1n-034
177-036
1n-037
1n-039
180-739
180-740
Air
89
In
(6
355 to
(12
591
(20
1035
(35
591
(20
1035
(35
Cap:
to
207
(3
to
7)
to
355
to
12)
710
to
24)
to
1182
to
40)
to
1479
to
50)
to
1182
to
40)
to
1479
to
50)
307-896
15
Page 16
-0
J>
:u
en
....
c
53
:u
~
Z
~
G)
••....
>;
..•
x
~.~
.:
I
l~
I
.
.';'
,
~
t:
~··
~
I
I
~,·~
tm.
f,::::.;
}.;
216-642
Kit
Tool
I;
I
Includes 83a-83f)
r.....
(Ref No. 83;
~I
83e
218-988
Kit
2
Qty.
No.
4
Ref
72*
1
3
6
7
2
8
2
10
1
14
1
16
1
20
1
24
1
29
1
58
4
66
1
67
1
60
72
Repair
Must be ordered separately.
Consists of:
a;
~
......
I
Q)
<0
0)
Page 17
REF
PART
NO. NO.
4 *105-662
6 *103-338
7 *105-668
8 *105-796
9
105-797
10
*105-798
11
104-765
12 105-800
13 105-801
14 *598-706
15
106-144
16 *155-685
17
170-253
18 **172-045
20 *177-918
22
176-930
23 176-936
24 *178-271
27 176-968
28 176-969
29 *177-919
30 181-299
31
177-785
32
180-739
34 177-197
35 177-198
37
177-203
38 177-204
39 177-205
40
681-332
42 181-541
43
177-209
44 177-212
48 177-436
50 176-939
51
101-343
177-529
52
53
177-530
DESCRIPTION OTY
PACKING,
O-RING; Viton
O-RING: Viton
O-RING: Viton
SCREW, pnh; M4 x 0.7 x 45
O-RING; Viton (Part of Ref No. 64)
PLUG, pipe
SCREW, filh; M3 x 0.5 x 6
PLUG, pipe (Part of Ref No.
PACKING, u-cup; UHMWPE 1
SETSCREW; M10 x 1.5 x 16 1
O-RING
SPRING, compression 1
LABEL, warning 1
SUPPORT, packing
RING, retaining
NUT, packing
GASKET, housing
NUT, retaining, air cap 1
NUT, barrel
SUPPORT, packing
FLUID TIP; 1.2 mm (0.47"); other
fluid tips available, see page 15
PLATE, designation, MAX WPR
AIR CAP, Other Air Caps Available
See Page 15
NUT, retaining (Part of Ref No. 64)
NUT, retaining
PLATE
HOUSING, retaining
ADJUSTING SCREW
PISTON, valve
SHAFT, actuator (Part of Ref No. 64)
VAL VE, bleed
INSULATOR 1
TUBE, resistor
PLUG; M12 x 1.25
SCREW, drive; 3/16" long
RETAINER, sleeve
INSERT 1
needle;
PTFE
60)
1
3
1
2
4
2
1
4
2
1
1
1
1
1
1
1
2
1
1
,
1
1
1
1
1
1
4
1
REF
PART
DESCRIPTION OTY
NO. NO.
55
56 215-951
57
58
60 216-068 BARREL, gun; Includes items 13 & 66
61
62 216-112
63 724-391
64 220-215
65 217-066 HOUS lNG, valve
66 *106-167
67
68
70 177-839 SPACER
71
72
75
77
79
80 162-453 NIPPLE; 1/4 npsm(f) x 1/4 npt(m)
81
215-864
215-952 FAN VALVE ASSY.
*727-566
220-214
*106-174
102-360 WASHER, flat; 3/16
157-021 LOCKWASHER; int. tooth 3/16
*177-200 GASKET
103-147 PLUG, pipe
597-427
**176-898
722-615 FITTING, hose;
RESISTOR, electrode
BODY, gun
SPRING, compression
NEEDLE ASSY (Part of Ref No. 64)
RESISTOR, primary
SPRING
NEEDLE ASSEMBL Y
Includes
O-RING; Kalrez (Qty 2, part of Ref No.
60)
O-RING; Kalrez
FITTING
TAG, warning (not shown)
((not shown)
items 10,
114
34,42 & 61
npsm(f) x
1/4 npt(m) (not shown)
82 217-114
82a 728-224
82b
82c
82d 177-927 .
82e
83 215-642
83a
83b
83c
83d
83e
83f
··Extra warning labels
217-115 :LUBRICANT, can, 3.5 oz.
100-054 .FITTING, lubricant
217-505 .GREASE TUBE
105-749
177-004 .WRENCH, fluid tip
177-732 .WRENCH, packing nut
177-007 .WRENCH, needle
179-803
107-158 .WRENCH, resistor stud
-Supplied in Repair Kit 218988
KIT, service (not shown)
Includes items 82a and 82e
.GREASEGUN
TOOL, packing removal
KIT, tool
Includes items 83a to 83f
.BRUSH,
.ROD,
and
cleaning
packing removal
tags are supplied
at
no
charge.
WARNING
When
ment
grounding
servicing,
parts.
Use
continuity
use
of
only
other
of
the
original
parts
gun.
Graco
could
replace-
alter
the
4
1
1
1
4
1
1
1
1
2
2
1
1
2
1
1
1
HOW
1.
2.
TO ORDER REPLACEMENT
To
be
sure
you
kit
or
accessories,
requested
Check
the
in
the
parts
receive
list
always
chart
to
the
correct
give
below.
identify
the
all
correct
do not use the ref. no. when ordering.
3.
Order
all parts
6 digit
PART
NUMBER
from
your
OTY
nearest
PART DESCRIPTION
PARTS_*~
replacement
of
the
information
part
Graco
distributor.
307-896 17
parts,
number;
Page 18
...------WARNING------,
Never operate
pressure rating
component in
ponents may
pressure developed
causing serious bodily injury or property damage.
HIGH
VOLTAGE POWER SUPPLY 956-155
115
VAC,
50/60
Hz.
Contact your Graco distributor for information.
HIGH
VOLTAGE CABLES
FOR
POWER SUPPLY 956-155
217-413 8 m (25
217-414
217-415
217-416
217-417
15 m (50
23
30 m (100
46
m (75
m (150
ft)
ft)
ft)
Cable
Cable
Cable
tt)
tt)
Cable
Cable
your
that
is higher than the lowest rated
your
system. Lower rated com-
not
be able
by
the pump and may rupture,
SAFETY
172-049172-771172-149-
equipment
at
a working
to
withstand the
WARNING
English
Spanish
French
SIGN
172-1&O-German
/
GROUNDED
217-089
12
bar (175 psi)
0.31
10,
AIR
HOSE
14
bar (225 psi)
6.35
mm
216-630 8 m (25
216-631
AIR
MAXIMUM
with
1/4
npsm(fbe)
ASSEMBLIES,
MAXIMUM
(0.25 in.) 10,
tt)
15
m (50
tt)Air
HOSE
ASSEMBLY,
1/4
npsm(fbe)
Air
Hose Assembly
Hose Assembly
Buna-N
WORKING PRESSURE
15
m (50
tt)
Nylon
WORKING PRESSURE
O-RINGY
106-791
The
accessories
FLUSHING DUMP VALVE 907-517
HIGH
VOLTAGE POWER SUPPLY
ANALOG CONTROL -
11
() V AC
50/60
Contact your Graco distributor for information.
STATIONARY
STATIONARY
3-WAY
AIR
on
Hz.
GUN
GUN
VALVE
this
section
956111
MOUNTING
BRACKET
722-602
of
the
STAND
724-344
page
722-562
have
FLUID
14
6.35
not
been
ELBOW,
Male,
UNIVERSAL
RECIPROCAL
HOSE
bar (225 psi)
mm
(0.25 in.) 10,
215-837
216-838
8 m (25
15
tested
Nylon
1/4-18
ASSEMBLIES,
MAXIMUM
tt)
m (50
by
Fluid Hose Assembly
tt)
Factory
108-173
nptf,
5/8-20
GUN
BRACKET
GUN
BRACKET
Nylon
WORKING PRESSURE
1/4
npsm(fbe)
Ruid Hose Assembly
Mutural.
590-236
725-973
18
307-896
NOTE: All safety barriers and interlocks are
supplied by the customer.
to
be
Page 19
ACCESSO
The
accesaori
A I ES
..
(Must
on
this
be
purchased
page
have
separately)
not
been
nmMmtW*iimim::ti/@Mm:N?HM1mtJM:Wt:tiIrl:i::fil:·::
tested
by
Factory
Mutual.
••
·:~:
@Wi.{<:\·/?::)i·
STRAINER
52 bar (750 psi)
With
60
See
instruction manual 306-655.
HIGH
(AIR
or
PAINT)
MAXIMUM
mesh filter element.
3/8
VOLUME
AIR
REGULATOR 206-199
202-271
WORKING PRESSURE
~~
npt
INLET
0-9 bar (0-125 psi) Regulated Pressure
14
bar
(200
psi) Steel Pressure Gauge
1/2
npt
~I
FILTER
12.6
With
1/4
micron filter and a
instruction manual 306-273.
AIR
17.5
and
bar
1/2
npt
MOISTURE
(180
psi)
npt(f) inlet,
regulated outlets.
LINE FILTERS
bar
(250
psi)
MAXIMUM
MAXIMUM
(2)
100
micron mesh inlet strainer.
WORKING PRESSURE
1/4
npt(m) outlets, and
With
a porous bronze
WORKING PRESSURE
SEPARATOR 202-680
(-,
Reusable 40 micron filter with drain cock
and drying air in spray systems.
108-148
108-149
3/8
npt(f) inlet and outlet.
1/2
npt(f) inlet and outlet.
~
3/8npt~
~~~::
OUTLET
,
-,~
\~
.~
"'-/
for
cleaning
'-..
1/2npt
(2)
50
See
FILTER-REGULATOR
14
bar (200
With
a porous bronze
1/2
npt(f) inlet,
psi)
MAXIMUM
40
ASSEMBLY
WORKING PRESSURE
1/4
npt(m) regulated outlets.
micron filter and a
217-07&
100
micron mesh
With
inlet strainer. See instruction manual 307-476.
STAINLESS STEEL FLUID PRESSURE REGULATORS
17
bar
(250
psi)
0.3-6.8
1/4
let,
bar
(5-100
psi)
npt air inlet (Model 214-980 only),
3/8
npt
fluid outlet and
MAXIMUM
WORKING PRESSURE
REGULA
TED
PRESSURE
3/8
1/4
npt gauge port.
npsm fluid in-
SPRING OPERATED FLUID REGULATORS
214-896
214-708 With 6.8 bar
Without
pressure gauge and mounting tube.
(100 psi) pressure gauge and
gauge mounting tube.
214-971
AIR OPERATED FLUID REGULATOR
214-980 1 bar (15 psi)
906-800 0-60
906-800 EXTENDED LIFE REGULATOR
AIR
17.5 bar (250
See
214-847
214-848
214-849
PAINT
Used with 722-860
With 6.8 bar
and stainless
PRESSURE
psi FLUID REGULATOR
LINE
LUBRICATORS
psi)
(100
psi) chrome plated gauge
steel gauge mounting tube.
MAXIMUM INBOUND AIR
MAXIMUM
WORKING PRESSURE
instruction manual 307-316.
3/8
npt
1/2
3/4
inlet and outlet.
npt
inlet and outlet.
npt
inlet and outlet.
RESISTANCE METER 722-886
to
measure resistivity.
See
instruc-
tion manual 307-263.
REMOTE
SWITCH & SIGNAL
LIGHT
728-386
PAINT
Used with 722-886 resistivity meter.
PROBE 722-860
See
instruction
manual 307-263.
BLEED-TYPE
21
bar
(300
psi)
MASTER
MAXIMUM
AIR
VALVE
(REQUIRED)
WORKING PRESSURE
Relieves air trapped in the air line between the pump air
inlet and this valve when closed.
107-141
107-142
3/4
npt(m x f) inlet and outlet
1/2
npt(m x
f)
inlet and outlet
307-896
19
Page 20
I
17
cm
(6.7
in.'
-n
cm
t--I:
---33~~·5in.)
....
·-------------(13
In.'-------------I
1--------------------(17.3
44
em
in.'
,I
1/4
NPT
AIR
121
OPPOSITE
INLETS
12.5
em
SIDE~
16
in.1
TECHNICAL
Operating voltage range
Maximum air working pressure
Maximum
Minimum air
THE GRACO
WARRANTY
Graco warrants all equipment manufactured
by
an
authorized Graco distributor
period
of
twelve
months
equipment is installed, operated and maintained in accordance
This warranty does
abrasion, corrosion, inadequate
shall Graco be liable
ment or materials
cessories, equipment
This warranty is conditioned
defect.
If
the
original purchaser transportation prepaid.
made
DISCLAIMERS
THE TERMS
WARRANTIES (EXPRESS
TICULAR PURPOSE,
STRICT LIABILITY. EVERY FORM
CLUDED
BREACH OF
EQUIPMENT
GRACO MAKES NO
TICULAR PURPOSE,
TURED BY GRACO. These items sold,
ty,
if
claimed defect
at
a reasonable charge,
OF
AND
DENIED. IN NO CASE
WARRANTY
NOT
any,
of
their manufacturer. Graco will provide purchaser
from
not
cover, and Graco shall
for
malfunction, damage
not
supplied
or
material.
AND
LIMITATIONS
THIS
WARRANTY
AND
COVERED
WARRANTY,
WITH
to
the original purchaser
the
date
of
sale, repair
or
improper maintenance, negligence, accident, tampering,
by
Graco,
not
supplied
upon
the prepaid return
is
verified, Graco will repair
which
OR
IMPLIED), INCLUDING
OF
ANY
MUST
RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS,
If
inspection
charges may include
CONSTITUTE PURCHASER'S SOLE
NON-CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE
OF
LIABILITY
SHALL
BE
BROUGHT
BY
GRACO
AND
DISCLAIMS
but
not
fluid working pressure
cylinder operating pressure
Atomizing air inlet
Cylinder
Weight
(with 50-foot cable)
Paint resistivity range
WARRANTY
by
it
and bearing its name
not
be liable for, any malfunction, damage
or
wear caused
or
the improper design, manufacture, installation, operation
by
Graco.
FOR
GRACO'S LIABILITY EXCEED THE
WITHIN
WARRANTY
manufactured
for
or
replace any part
of
the equipment claimed
or
replace free
of
the equipment does
the the
WARRANTY
DIRECT, SPECIAL
TWO
ALL
IMPLIED WARRANTIES OF
DATA
0-120
KV
10.4 bar
7 bar
3.5 bar (50 psi)
Fluid inlet
air inlet
(gun only)
to
use.
As
purchaser's sole remedy
of
with
Graco's written recommendations.
by
the incompatibility
of
costs
of
OF
(2)
YEARS
by
Graco (such
with
reasonable assistance in making any claim
3/8
1/4
1/4
8
1.3 kg (2.85
7 Megohm CM
AND
DISCLAIMERS
be free from defects in material and workmanship on
the equipment proven defective. This warranty applies
to
be
charge any defective parts. The equipment will be returned
not
disclose any
parts, labor and transportation.
AND
EXCLUSIVE REMEDY
MERCHANTABILITY
OR
CONSEQUENTIAL
AMOUNT
OF
THE DATE OF SALE.
as
electric motor, switches, hose, etc.), are subject
(150
(100
psi)
npsm(m)
npt(f)
npt(f)
kg
(17
Ib 9 oz)
or
wear caused
or
substitution
with
Graco equipment
defective
for
defect
OF THE PURCHASE PRICE.
MERCHANTABILITY
OR
COMPONENTS SOLO
psi)
Ib)
to
infinity
the
for
breach
of
this warranty, Graco will,
by
faulty installation, misapplication,
of
non-Graco component parts.
of
structures, accessories, equip-
or
maintenance
examination by Graco
in material or workmanship, repairs will be
AND
OR
WARRANTY
DAMAGES
ARE IN LIEU
OR
for
to
OF
FITNESS
LOSS IS EXPRESSLY EX-
AND
FITNESS
BUT
breach
date
only
of
structures, ac-
verify
the
OF
ANY
FOR
ANY
ACTION
FOR
NOT
MANUFAC-
to
of
the warran-
these warranties.
of
when
claimed
to
OTHER
A PAR-
A PAR-
sale
for
the
Nor
the
OR
FOR
a
Sub.ldlary
Factory
and
GRACO
Affiliate
INC.
Branch
Companl
P.
••
:Atlanta,
O.
PRINTED
••
Box
Dalla.,
:Canada;
1441
IN
U.S.A.
Detroit,
England;
Lo.
Angele.,
Switzerland;
MINNEAPOLIS,
307-896
3/88
We.t
France;
MN
Caldwell
Germany;
55440-1444
(N.J.'
Hong
Kong;
Japan
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