INSTRUCTIONS–PARTS LIST
308–084
Rev. H
This manual contains IMPORTANT
ARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Supersedes
G
W
Model PRO 4600SC
t
AUTOMATIC ELECTROSTATIC
AIR SPRAY GUN
100 psi (7 bar) MAXIMUM WORKING PRESSURE
U.S. Patent No. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774;
5,063,350; 5,073,709; 5,080,289; 5,093,625
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. Patent No. 2,147,158; 2,142,559B; 2,140,327B; 2,245,197B
French Patent No. 91 14488
Other Foreign Patents Pending
Part No. 224–224, Series A
Air Spray Gun, without shroud
(0.059 in. (1.5 mm) spray nozzle)
0432
Part No. 235–893, Series A
Air Spray Gun, with standard shroud
Part No. 235–894, Series A
Part No. 235–893 shown
Air Spray Gun, with slotted shroud
For use when the gun is mounted in
the front position; see Fig 3 , page 6
Part No. 224–094 Series A
Gun Manifold
Must order separately
.
0435
For use with Class
I
, Group D paint spray materials
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
E
COPYRIGHT 1991 GRACO INC.
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FIRE, EXPLOSION, OR ELECTROSTATIC SHOCK HAZARD
To reduce the risk of fire, explosion, or electrostatic shock,
which may result from electrical discharge, it is essential that:
6. All persons entering the spray area: shoes must have con
-
ductive soles, such as leather, or personal grounding straps
must be worn. Rubber or plastic soles are not conductive.
S
All parts of the electrostatic system are properly grounded.
7. The floor of the spray area must be electrically conductive
and grounded. Do not cover the floor with cardboard or any
non-conductive material which would interrupt grounding
continuity.
S All personnel in or close to the spray area are properly
grounded.
S All electrically conductive objects or devices in the spray area,
including paint containers, wash cans and tools, are properly
grounded.
8. Flammable liquids in the spray area must be kept in
approved, grounded containers. Do not store more than the
quantity needed for one shift.
When operating the electrostatic device, any ungrounded
objects in the spray area (such as people, containers, tools,
etc.) can become electrically charged. Arcing may occur if these
objects then come in contact or close to ground. Arcing of suffi-
cient energy levels can ignite the fluid being sprayed, fumes
from solvents, dust particles, and other flammable substances.
9. All solvent pails: use only grounded metal pails, which are
conductive. Do not place the pail on any non-conductive
surface, such as cardboard or paper, which would interrupt
grounding continuity
.
10. All air and fluid lines and electric cables must be properly
grounded.
This can cause a fire, explosion, or electrostatic shock and re
sult in serious bodily injury and property damage.
-
Flushing and Cleaning Safety
To reduce the risk of static sparking or splashing, always follow
the Pressure Relief Procedure on page 2 before flushing.
Static electricity can also be generated by the flow of
through the pump, hose, gun, and nozzle, but it is dissipated
through proper grounding as described in Grounding below
fluid
.
Be sure the turbine air (electrostatics) is OFF before flush
ing or cleaning any part of the spray system.
-
If you experience any arcing or feel even a slight shock, STOP
SPRAYING IMMEDIATELY. Check for proper grounding of the
entire system. Be sure you have corrected the problem before
starting to spray again.
Use the lowest possible pressure to flush. Trigger the gun into
grounded metal waste container
a
.
To flush or purge equipment, ALWAYS use solvents with a flash
point equal to or greater than that of the fluid being sprayed.
Grounding
The following are minimum requirements for grounding a basic
electrostatic system. Your system may include other equipment
or objects which must also be grounded. Always check your
local electrical code for detailed grounding instructions. Be sure
your system is connected to a true earth ground.
To clean the exterior of the equipment, ALWAYS use solvents
with a flash point of higher than 100_ F (38_ C).
ALWAYS remove all solvent from the system before reactivating
the spray gun.
1. Pump: ground by using a ground wire and clamp as
described in your separate pump instruction manual.
Use only non-sparking tools to clean residue from the booth and
hangers.
2. Air compressors and hydraulic power supplies: ground
according to the manufacturer
’s recommendations.
Ventilate the Spray Booth
To prevent hazardous concentrations of toxic and/or flammable
vapors, spray only in a properly ventilated spray booth.
3. Electrostatic Air Spray Gun: obtain grounding through con
-
nection to a properly grounded air supply hose. Use only the
Graco Electrically Conductive Air Supply Hose; see
ACCESSORIES section to order . Connect the air hose
ground wire to a true earth ground.
Check and follow all National, State and Local codes regarding
air exhaust velocity requirements. Check and follow all local
safety and fire codes and OSHA standard 1910.107.
4. Object being sprayed: keep the work piece hangers clean
and grounded at all times. Contact points must be sharp
points or knife edges.
NEVER operate the spray gun unless the ventilating fans are
operating.
5. All electrically conductive objects or devices in the spray
area, including paint containers and wash cans, must be
properly grounded.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards––particularly the
General Standards, Part 1910.107 and any other appropriate regulations––should be consulted in connection with the installation, operation, and
maintenance of electrostatic spray painting equipment.
308-084
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TABLE OF CONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
2
4
Service
Flush the Gun and Relieve Pressure
Remove Gun from Manifold & Mounting Bracket 18
Air Cap/Nozzle/Resistor Stud Replacement . . . . 19
Electrode Replacement . . . . . . . . . . . . . . . . . . . . . 20
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fluid Packing Rod Removal and Repair . . . . . . . 23
Power Supply Removal and Replacement . . . . . 25
Power Supply Adjustment . . . . . . . . . . . . . . . . . . . 25
Turbine Alternator Removal and Replacement 25
.
. . . . . . . . . 18
.
.
Typical Installation
Warning Signs
Ventilate the Spray Booth
Install the Gun Controls and Display Module
Install the Gun Mounting Bracket
Install the Gun and Manifold
Connect the Air, Fluid, and Fiber Optic Lines
Check the Electrical Grounding
.
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
5
5
6
6
6
6
6
8
8
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gun Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Gun Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Manifold Parts Drawing & List . . . . . . . . . . . . . . . . 30
PRO 4600HC Conversion Kit . . . . . . . . . . . . . . . . . 31
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Graco Phone Numbers . . . . . . . . . . . . . . Back Cover
.
Install the Fabric Cover
.
.
Operation
Operating Checklist
Selecting a Fluid Nozzle and Air Cap
Gun Functions
Activating the Fluid Trigger Only
Adjusting the Spray Pattern
Adjusting the Turbine Air Pressure
.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
9
9
9
9
9
.
.
.
.
.
.
.
.
. . . . . . . . . . . 10
Activating the Voltage Select (KV HI/LO)
.
. . . . . . 10
.
Maintenance
Daily Care and Cleaning
Clean the Air Cap and Fluid Nozzle
Check for Fluid Leakage
.
. . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . 12
.
.
.
Troubleshooting
TERMS
Spray Pattern Troubleshooting Chart
Gun Operation Troubleshooting Chart
Electrical Troubleshooting Chart
.
. . . . . . . . . 13
. . . . . . . . 14
. . . . . . . . . . . . . 15
WARNING: Alerts user to avoid or correct conditions that
.
could cause bodily harm.
.
CAUTION: Alerts user to avoid or correct conditions that
could cause damage to or destruction of
equipment.
Electrical Tests
Test Gun Resistance
.
. . . . . . . . . . . . . . . . . . . . . . . 16
Test Power Supply Resistance
Test Resistor Stud Resistance
.
.
. . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . 17
NOTE:
Identifies essential procedures or helpful
information.
4
308-084
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TYPICAL INSTALLATION
Hazardous Area
BASIC SYSTEM
Non-Hazardous Area
Grounded Turbine Air Hose (gray hose)
P/N 223–068/–074
Controls Cabinet
KV Hi/Lo Air Line (if low KV setting option is desired)
Gun Manifold
P/N 224–094
PRO 4600 Gun
P/N 224–224
(gun only, see
Shut-off device
Fan
Atom Air Lines
for fluid only
operation
Manual 308–084 for
gun/shroud P/N)
Trigger Module
P/N 235–768
Bleed valve or
3 way solenoid
Air Regulator
Cylinder Air Line
Recip. Mount Assy
.
P/N 235–094
Fluid Supply
True
Earth
Ground
Fig
1
Controls Cabinet
SYSTEM OPTIONS
24V Power Supply
P/N 235–301
S Spraying
S Air Pilot Fluid Regulator
Voltage Monitor
Fiber Optic Cable
P/N 224–680/–686
Fiber Optic Cable
P/N 224–670/–676
Bulkhead
P/N 224–261
ES Display Module
P/N 224–117
Air Pressure
Control
Air Pilot Fluid Regula
tor
-
Fluid Supply
P/N 224–531
Non-Hazardous Area
Hazardous Area
01769
Fig
2
Installing the System
Warning Signs
Fig 1 , above, shows a typical Model 4600 system. Fig
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
Warning Sign is provided with the gun. Additional
English, French, German, and Spanish signs are avail-
2
shows some possible system options. For assistance
in designing a system that is customized for your applica
tion, contact your Graco representative.
-
able at no charge. See the ACCESSORIES section to or
-
der them.
308-084
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INSTALLATION
2.3 in.
(58 mm)
WARNING
Installing and servicing this equipment requires
access to parts which may cause electrostatic shock
or other serious bodily injury if work is not performed
properly.
PRO 4600 Gun
with Standard Shroud
P/N 235–893
D Do not install or service this equipment unless
you are trained and qualified.
12 in.
(304 mm)
D Be sure your installation complies with National,
State and Local codes for the installation of elec
-
trical apparatus in a Class
Location.
I, Group D Hazardous
BACK MOUNTING POSITION
01876
Fig
4
D Check and follow all local safety and fire codes,
NFPA 33, NEC 504 and 516, and OSHA standard
1910.107.
Install the Gun and Manifold (See Fig 5 )
1. Remove the air cap nut/air cap assembly and slide
the shroud off the gun.
Ventilate the Spray Booth
2. Connect the gun to the manifold by tightening the
three socket head cap screws; use the ball end
wrench (46), supplied. Make sure the o-ring is in
place on the manifold.
WARNING
To prevent hazardous concentrations of toxic and/or
flammable vapors, spray only in a properly venti-
lated spray booth. Never operate the spray gun
unless ventilation fans are operating.
3. Slide the gun and manifold along the dovetail until the
button head screw bottoms against the mounting
bracket.
Electrically interlock the gun air supply with the ventila-
tors to prevent gun operation without ventilating fans op
erating. Check and follow all National, State, and Local
codes regarding air exhaust velocity requirements.
-
4. Secure the gun to the mounting bracket with the but
ton head screw , using the ball end wrench (46).
Tighten the two mounting bracket setscrews.
-
High velocity air exhaust will decrease the operating effi-
ciency of the electrostatic system. The minimum allow-
able air exhaust velocity is 60 feet/minute (19 linear
meters/minute).
5. Slide the shroud onto the gun and secure it by tight
-
ening the air cap nut onto the gun barrel. Tighten the
nut just enough so that the air cap is snug but can still
be turned.
Install the Gun Mounting Bracket
Connect the Air, Fluid, and Optional Fiber
Attach the mounting bracket to the robot or reciprocator
.
Optic Lines (See Fig 6 )
See the ACCESSORIES section for the mounting brack
-
WARNING
et and mount extension options and refer to Fig 3 and
Fig 4 for mounting positions.
To reduce the risk of electrostatic shock or other
serious injury, the turbine air supply hose must be
electrically connected to a true earth ground. Use
Only Graco Electrically Conductive Air Supply
Hose and connect the hose ground wire to a true
earth ground.
2.3 in.
(58 mm)
PRO 4600 Gun
with Slotted Shroud
P/N 235–894
See the ACCESSORIES section to order Graco Electri
-
cally Conductive Air Supply Hose. This hose and the gun
have special left-hand threads to prevent connecting
another type of air supply hose to the gun turbine air inlet.
8.8 in.
(235 mm)
Connect the air, fluid, and optional fiber optic lines to the
gun manifold as shown in Fig 6 . Before connecting the
fluid line, blow it out with air and flush it with solvent. Use
solvent that is compatible with the fluid being sprayed.
01876
FRONT MOUNTING POSITION
Fig 3
6
308-084
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INSTALLATION
To ensure a dry, clean air supply to the gun, install an air
line filter and an air and water separator on the air lines.
Dirt and moisture can ruin the appearance of your fin-
ished workpiece and can cause the gun to malfunction. A
combination air filter/moisture separator is shown in the
ACCESSORIES section.
Socket Head
Cap Screws
Mounting
Plate
Dovetail
Manifold
O-Ring
Spray Gun
Set Screws
Shroud
Mounting
Block
Hex Head
Cap Screws
Button Head
Screw
Square Head
Set Screw
01877
BACK VIEW OF MANIFOLD
INSTALLED ON
M
OUNTING BRACKET
Air Cap/Air
Cap Nut
0453
Set Screw
Fig
5
Connect 4’ of
1/4” ID tube
Connect 1/4” OD tube between
fitting and control module
Connect Graco Fiber Optic
Cable (see Accessories)
Connect Graco Grounded Air Hose
between fitting & control module
(left-hand thread). Connect the
ground wire on the air hose to a true
earth ground.
TURBINE
F.O.
EXH
MAX WRP
AIR AND FLUID
Connect 3/8” OD tube between
fitting and control module
KV
HI/LO
Connect 3/8” OD tube between
fitting and control module
100 PSI (7 BAR)
ATOM
FAN
Connect a 1/4” npsm swivel
fitting paint line
Connect 1/4” OD tube between
fitting and control module
PAINT
CYL
Shroud Exhaust
1/4” OD x 4’ tube
(included with manifold)
0322
Fig
6
308-084
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INSTALLATION
Megohmmeter
See ACCESSORIES to order
Check the Electrical Grounding (See Fig 7 )
True Earth
Ground
WARNING
Proper electrical grounding of every part of your
system is essential. For your safety , read the
warning section,
FIRE, EXPLOSION,
OR
ELECTROSTATIC SHOCK HAZARD , on page
3. Ground the system as explained there. Then
check your system as explained below
.
1. Completely turn off the air and fluid supplies to the
gun.
2. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
Grounded
Air Hose
a. With the electrically conductive air hose con-
nected and properly grounded, use a
megohmmeter to measure the
resistance
between the gun manifold and a true earth
ground. Use an applied voltage of 500 minimum
to 1000 volts maximum.
Gun
Manifold
b. If the resistance is greater than 2 megohms*,
check the tightness of the ground connections,
and be sure the air supply hose ground wire is
connected to a true earth ground. If the resis-
tance is still greater than 2 megohms*, replace
the air supply hose.
0436
Fig 7
* If you are using the red colored hose, resis-
tance should not exceed 100 ohms.
2. Cut a small slit in the cover and route the two exhaust
Install the Fabric Cover (See Fig 8 )
tubes outside the robot arm or reciprocator. This en
ables you to monitor the exhaust tubes for the pres
-
-
1. Install a fabric cover over the front of the gun and
slide it back to cover the exposed tubing and hoses at
ence of any paint or solvent. See Check for Fluid
Leakage on page 12. Strap down the exhaust tubes
to prevent them from moving around.
the back of the manifold. See ACCESSORIES sec
tion.
-
Fabric Cover
Slit
Exhaust Tubes
Exhaust Tubes
0437
Fig
8
0438
8
308-084
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OPERATION
WARNING
Pressure Relief Procedure
7. Be sure all refuse is removed from the spray
booth.
To reduce the risk of serious bodily injury, including
splashing in the eyes or on the skin, injury from
moving parts or electrostatic shock, always follow
this procedure when shutting off the system, when
checking or servicing any part of the spray system,
when installing, cleaning or changing fluid nozzles,
and whenever you stop spraying.
8. Be sure all flammable liquids in the spray
booth are in approved, grounded containers.
9. Be sure all conductive objects in the spray
area are electrically grounded and the floor of
the spray area is electrically conductive and
grounded.
1. Turn off the air to the control module, except for
the manifold air. If the air pilot fluid regulator is
used, air pressure is needed at the regulator air
inlet to relieve pressure in the fluid line.
10. Be sure to check the manifold exhaust tubes
for the presence of any fluid as instructed in
Check for Fluid Leakage, page 12
.
Selecting a Fluid Nozzle and Air Cap
2. Turn off the fluid supply to the gun.
3. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.
This gun is supplied with fluid nozzle 185–158 (1.5 mm)
and air cap 177–033. If your application requires a differ-
ent nozzle and air cap combination, use instruction
manual 307–803 to select the appropriate fluid nozzle
and air cap.
4. Open the pump drain valve, having a waste
container ready to catch the drainage.
5. Leave the pump drain valve open until you are
ready to spray again.
Gun Functions
WARNING
The gun functions include the following:
If any fluid leakage from the gun is detected,
stop spraying IMMEDIATELY! Fluid leakage into
S
Fluid Trigger (only)
S Spray (properly timed on/off sequence
of fan air, atom air, and paint)
S Turbine Air
the gun shroud could cause fire or explosion and re
-
sult in serious bodily injury and property damage.
See Check for Fluid Leakage, page 12.
S Voltage Select
Activating the Fluid Trigger Only
Operating Checklist
To activate the fluid trigger alone, first relieve the air pres
-
Check the following list daily, before starting to operate the
system, to help ensure you of safe, efficient operation.
sure to the trigger module, then shut off the air supply to
the OM and FAN air lines. Apply 50 psi (3.5 bar) mini
mum air pressure to the CYL air supply line to activate the
gun’s fluid trigger
AT
-
1. Be sure all operators are properly trained to
safely operate an automatic electrostatic air
spray system.
.
Adjusting the Spray Pattern
2. Be sure all operators are trained how to prop
-
erly and completely relieve system pressure.
Follow the steps below to establish the correct fluid flow
and air flow
on yet.
.
DO NOT turn the turbine air (electrostatics)
3. Be sure the system is thoroughly grounded.
See FIRE, EXPLOSION OR ELECTRO-
STATIC SHOCK HAZARD on page 3, and
1. Adjust the fluid flow with the fluid line’ s pressure
regulator.
Check the Electrical Grounding
on
page 8.
4. Be sure the operator and all persons entering
2. Rotate the air cap for the desired spray pattern.
the spray area are properly grounded by wear
ing shoes with conductive soles or personal
grounding straps.
-
3. Use an air pressure regulator to adjust the degree of
atomization and pattern width. For the most efficien-
cy, always use the lowest air pressure possible.
5. Be sure ventilation fans are operating
properly.
NOTE: See the Spray Pattern Troubleshooting Chart
on page 13 to correct spray pattern problems.
6. Be sure the workpiece hangers are clean and
grounded. Contact points must be sharp
points or knife edges.
OPERATION continued on next page
308-084
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OPERATION
4. Check the gun electrostatics display module, if used,
Adjusting the Turbine Air Pressure
to see the voltage and current output levels.
WARNING
The fan and atomizing air MUST be on before
turning on the turbine air . Actuating the turbine
air without fan and atomizing air flow could damage
the gun and may create hazardous operating
conditions and result in serious injury and property
damage.
NOTE: The gun’s normal high voltage output is 60 to 70
kV. If a ball end high voltage measurement probe is used,
the gun voltage will rise to about 85 kV. This will happen
with all resistive electrostatic guns.
See the Electrical Troubleshooting Chart on page 15
to correct voltage problems.
1. Complete all the checks under the
Operating
Checklist on page 9.
Activating the Voltage Select (KV HI/LO)
To change the voltage to the lower setting, activate the
voltage select function (KV HI/LO). The lower voltage
setting is factory set to 60 kilovolts at zero microamperes.
To change this setting, see page 25.
2. Make sure the fan and atomizing air are on, then turn
the turbine air (electrostatics) on.
3. The turbine air pressure should be adjusted to 40 psi
(2.8 bar) at the gun manifold inlet when air is flowing.
The gun may be operated at a lower air pressure, but
some voltage loss could occur. Do not exceed 50 psi
(3.5 bar) air pressure as there is no added benefit
and turbine life could be reduced.
The valve used to activate the KV HI/LO switch must
bleed the air out of the line for the switch to draw back to
the high setting.
MAINTENANCE
WARNING
Daily Care and Cleaning
To reduce the risk of serious bodily injury, including
splashing in the eyes or on the skin or electrostatic
shock, always follow the Pressure Relief Proce-
dure Warning on page 9 when shutting of f the
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.
system, when you stop spraying and before check
-
ing, servicing, installing, cleaning or changing any
part in the system.
3. Clean the air cap and fluid nozzle daily , minimum.
Some applications require more frequent cleaning.
Replace the fluid nozzle and air cap if they are dam
aged. See Clean the Air Cap and Fluid Nozzle
-
CAUTION
.
Clean all parts with a non-conductive solvent,
compatible with the fluid being sprayed. Conduc-
tive solvents can cause the gun to malfunction.
4. Check the electrode wire. Straighten if bent, and
replace if broken or damaged. See Replacing the
Electrode Needle
.
Methylene chloride is not recommended as a
flushing or cleaning solvent with this gun as it will
damage nylon components.
5. Check for any fluid leakage from the gun and fluid
hoses. See Check for Fluid Leaks.
Immersing the gun in solvent is not recommended
6. Check all of the work hangers for material build-up;
as
a
cleaning method. Solvent left in gun passages
clean them if necessary
.
could result in a poor quality paint finish and may
draw current and reduce the electrostatic ef fect.
Solvent in the power supply cavity can reduce the
alternator life.
WARNING
To reduce the risk of fire, explosion, or electrostatic
shock, BE SURE the turbine air (electrostatics) is
off before flushing the gun or any part of the system.
7. Flush the fluid passages by alternating solvent and
air. Flush before changing colors and whenever you
are done operating the gun.
10 308-084
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MAINTENANCE
Clean the Air Cap and Fluid Nozzle
Equipment needed:
Soft bristle brush (supplied)
Solvent compatible with fluid being sprayed
Procedure:
1. Follow the Pressure Relief Procedure Warning on
page 9.
2. Remove the air cap assembly and gun shroud.
3. Clean the air cap, fluid nozzle, and front of the
gun, using the soft bristle brush and solvent. Point
the gun down while cleaning to prevent dirty sol
-
vent from running back into the air passages. See
Fig 9 .
Do not use metal tools to clean the air cap holes
as this may scratch them, and make sure the elec
-
trode wire is not damaged. Scratches in the air cap
holes or a damaged electrode wire can distort the
spray pattern.
4. Carefully reinstall the air cap assembly. Avoid bend
ing the electrode. Tighten the retaining nut until it is
snug, allowing the air cap to turn with resistance.
-
0439
Fig 9
MAINTENANCE continued on next page
308-084
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MAINTENANCE
Check for Fluid Leakage (See Fig 10 )
WARNING
During operation, periodically check the two manifold ex
haust tubes and both ends of the gun shroud for the pres
ence of fluid. Fluid in these areas would indicate fluid
leakage into the shroud.
-
-
If any fluid leakage from the gun is detected,
stop spraying IMMEDIATELY! Fluid leakage into
the gun shroud could cause fire or explosion and
result in serious bodily injury and property damage.
If fluid is seen in any of these areas, stop spraying
immediately! Follow the Pressure Relief Procedure on
page 9, then remove the gun for repair
.
Fabric Cover
Gun Shroud
Check for signs
of fluid leakage
where indicated
by arrows
Exhaust Tubes
0437
0438
Fig
10
12 308-084
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SPRAY PATTERN TROUBLESHOOTING CHART
WARNING
Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other seri
-
ous bodily injury if the work is not performed properly
.
Do not install or service this equipment unless you are trained
and qualified.
To reduce the risk of serious bodily injury, including splashing fluid or solvent in the eyes or on the skin, always follow
the Pressure Relief Procedure on page 9 before checking, adjusting, cleaning or repairing the gun or any part of
the system.
NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.
PROBLEM:
CAUSE
SOLUTION
IMPROPER SPRA
Y
PATTERN
Fluttering or spitting spray
Insufficient fluid supply
.
Adjust fluid regulator or fill fluid tank.
Loose fluid nozzle or damaged
fluid nozzle taper seat.
Tighten or replace fluid nozzle.
See page 19.
Dirt between fluid nozzle, taper
Clean. See page 11.
seat and body
.
Loose or cracked coupler at
fluid inlet.
T
ighten or repair
.
Loose fluid tube in tank.
Tighten.
Fluid build-up on air cap; partially
clogged horn holes. Full air pres-
sure from clean horn hole forces
fan pattern toward clogged end.
Clean with soft implement or
submerge in suitable solvent and
wipe clean. See page 11.
Bent electrode.
Straighten electrode
Damaged fluid nozzle or air
cap holes.
Replace damaged part. See
page 19.
Fluid build-up on the perimeter
of fluid nozzle orifice, or partially
clogged fluid nozzle orifice
Remove obstruction. Never use
wire or hard instruments. See
page 11.
Bent electrode.
Straighten electrode
Too high fan air pressure.
Reduce air pressure or adjust fan
air adjusting valve.
Fluid too thin.
Regulate fluid viscosity.
Not enough fluid pressure
Low fan air pressure
Fluid too thick
Increase fluid pressure.
Increase air pressure.
Regulate fluid viscosity
.
T
oo much fluid.
Last coat of fluid applied too wet.
oo much air pressure.
Reduce fluid flow
.
Apply drier finish with multiple
strokes.
Streaks
T
Use least air pressure necessary
.
Insufficient air pressure.
Increase air pressure.
Non-uniform spray pattern.
Clean or replace air cap. See
page 11.
NOTE: Some improper patterns are caused by the improper balance between air and fluid.
308-084
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GUN OPERATION TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Leakage from fluid
packing area
Worn fluid rod packings or fluid rod
Replace fluid rod packings or rod.
See page 23.
Fluid leakage from front
of gun
Fluid rod worn or damaged
Replace fluid rod. See page 23.
Worn fluid seat
Replace fluid nozzle and/or
electrode. See page 19 and 20.
Piston seal or o-ring damaged
Replace seal and/or o-ring and
lubricate.
Loose resistor stud
Tighten resistor stud. See page 19.
Loose fluid nozzle
Tighten fluid nozzle. See page 19.
Damaged resistor stud o-ring
Replace o-ring. See page 19.
“Orange Peel” finish
Insufficient air pressure
Increase air pressure, use least air
pressure needed for good results.
Fluid poorly mixed or filtered
Improper thinner being used
Remix or refilter fluid.
Use proper thinner
.
Excessive spray fog
Too much air pressure
Reduce air pressure, use least air
pressure needed for good results.
Fluid thinned too much
Properly thin fluid.
Fluid low
Check, add fluid if necessary.
No fluid sprays from gun
Damaged air cap
Replace air cap.
Dirty or clogged fluid nozzle
Damaged fluid nozzle
Piston not actuating
Clean fluid nozzle. See page 11.
Replace fluid nozzle. See page 19.
Check cylinder (CYL) air
.
Actuator arm out of position
Check actuator arm (29) and
nuts (25, 7). See page 21.
Equipment covered
with fluid
Exhaust air flow insufficient
or not directed properly
Check for proper CFM; check
baffles and direction of air flow
.
Improper distance between gun
and workpiece
Adjust spraying distance to
8 to 12 inches (203 to 305 mm).
Dirty air cap
Misalignment between air cap
and fluid nozzle
Remove and clean air cap and fluid
nozzle. See page 11. Then reinstall
them.
Air Cap
Or replace fluid nozzle and air cap.
See page 19.
Fluid Nozzle
ALIGNED
MISALIGNED
14 308-084
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ELECTRICAL TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
Poor wrap-around
Improper distance between gun
and workpiece
Adjust spraying distance to
8 to 12 inches (203 to 305 mm).
Parts poorly grounded
Clean hangers, check for proper
ground on conveyer or track.
High booth exhaust velocity
Reduce exhaust velocity within
code limits.
Atomizing air pressure too high
Fluid pressure too high
Reduce atomizing air pressure.
Reduce fluid pressure.
Improper fluid viscosity
Check supplier for proper fluid for
electrostatic spray
.
Fluid resistivity too low
No or low voltage output
Check fluid resistivity with paint
meter and probe.
Check possible causes listed below
.
Turbine alternator not operating
Check air supply to gun.
Faulty gun resistance
Check gun resistance. See page 16.
Fluid leaks from fluid rod packing
and causes short
Clean fluid rod cavity, replace packing.
See page 23.
Faulty turbine alternator
Be sure plug is in place on back of
turbine alternator housing. Remove
and test turbine alternator. See page 25.
KV HI-LO switch stuck on low
Check switch actuation; replace if
needed.
Operator gets shock
Operator not properly grounded
or is near an ungrounded object
Be sure floor is properly grounded.
W
ear shoes with conductive soles
or wear personal grounding straps.
Be sure operator is not in contact
with or carrying any metallic items
which could build up electrical charge.
Gun not properly grounded
See Check the Electrical Grounding.
Operator gets shock
when touching workpiece
W
orkpiece not properly
Clean workpiece hangers. Check for
proper ground on conveyor or track.
grounded
Damaged fiber optic cable or
connection
Check cables and connections.
Replace if damaged.
No or low voltage output
reading on gun display
module
See other causes under Problem
“Poor wrap-around”, above.
–
308-084
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ELECTRICAL TESTS
The performance of the spray gun is directly affected by
KEY
A
Megohmmeter
the condition of the electrical components contained
inside the gun. The electrical tests below can be used to
determine the condition of the power supply (40) and the
resistor stud (2) as well as the continuity of the electrical
path between the components.
A
28 Electrode
39 Gun Body
Use megohmmeter 218–979 (see ACCESSORIES) and
an applied voltage of 500 volts to complete these electri
-
cal tests. Connect the leads as shown.
Remove the gun from the manifold and bracket, as
instructed on page 18, before performing the electrical
tests.
39
WARNING
To reduce the risk of sparking, which could cause
fire, explosion, or electrostatic shock and result in
serious bodily injury, do not use the megohmmeter
in the hazardous area. Remove the gun from the
hazardous area before testing it.
Test Gun Resistance (See Fig 11 )
28
Measure the resistance between the end of the electrode
(28) and the gun body (39). The resistance should be
between 329 to 401 megohms. If the resistance is out-
side the specified range, go to the next test. If the
0440
Fig 1
1
KEY
resistance is correct, refer to the
Electrical
A
Megohmmeter
Troubleshooting Chart on page 15 for other possible
causes of poor performance.
EE Ground Contact Point
40 Power Supply
40d Seal
A
Test Power Supply Resistance (See Fig
12 )
Remove the power supply (40) from the gun body (39).
See page 25.
Measure the resistance from the power supply’s ground
contact point (EE) to the contact inside of the power sup
ply seal (40d) [the conductive rubber contact may be
slightly recessed into the seal]. See Fig 12 .
-
The resistance should be 297 to 363 megohms. If the
resistance is outside the specified range, the power sup
-
ply is defective and must be replaced. If the resistance of
the power supply is correct, proceed to the next test.
If you still have problems, refer to the
Electrical
Troubleshooting Chart for other possible causes of
poor performance, or contact the nearest authorized
service agency
.
EE
40d
40
0441
Fig 12
16 308-084
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ELECTRICAL TESTS
KEY
D
E
Test Resistor Stud Resistance
(See Fig 13 )
Resistor Stud Contact Ring
Needle Contact Ring
Remove the resistor stud. See Air Cap/Nozzle/Resistor
Stud Replacement. Check the resistance between the
black resistor stud ring contact (D) and the needle con-
tact ring (E). You may have to press down on the contact
ring (D) in several places to get a good reading.
The resistance should be 21 to 29 megohms. If the
resistance is correct, make sure the metal contact in the
gun barrel and the needle contact ring (E) are clean. If the
resistance is outside the specified range, the resistor is
defective and the resistor stud (2) must be replaced. See
D
E
Air Cap/Nozzle/Resistor Stud Replacement
.
0442
Fig 13
WARNING
The resistor stud contact ring (D) is a conductive
contact ring, NOT a sealing o-ring. To reduce the
risk of sparking, which could cause fire, explosion,
or electrostatic shock and result in serious injury ,
DO NOT remove the resistor stud contact ring (D)
from the resistor stud or operate the gun without
the contact ring in place. DO NOT replace the re-
sistor stud with anything but a genuine Graco part.
308-084
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SERVICE
WARNING
WARNING
Installing and servicing this equipment requires
access to parts which may cause electrostatic
shock or other serious bodily injury if the work is not
performed properly. Do not install or service this
equipment unless you are trained and qualified.
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
splashing in the eyes or on the skin, injury from
moving parts or electrostatic shock, always follow
this procedure when shutting off the system, when
checking or servicing any part of the spray system,
when installing, cleaning or changing fluid nozzles,
and whenever you stop spraying.
NOTE: Check all possible remedies in the
Troubleshooting Charts before disassembling the gun.
1. Turn off the air to the control module, except for
the manifold air. If the air pilot fluid regulator is
used, air pressure is needed at the regulator air
inlet to relieve pressure in the fluid line.
2. Turn off the fluid supply to the gun.
3. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.
Flush the Gun and Relieve Pressure
WARNING
To reduce the risk of fire, explosion, or electrostatic
shock, BE SURE the turbine air (electrostatics) is
off before flushing the gun.
4. Open the pump drain valve, having a waste
container ready to catch the drainage.
5. Leave the pump drain valve open until you are
ready to spray again.
CAUTION
Methylene chloride is not recommended as a
flushing or cleaning solvent with this gun as it will
damage nylon components.
Remove the Gun from the Manifold and
the Mounting Bracket (See Fig 14 )
Before removing the gun for service, flush it by alternat
ing solvent and air. Then follow the Pressure Relief Pro
cedure, at right.
-
-
1. Remove the air cap/air cap nut assembly and the gun
shroud.
Service Notes:
2. Loosen the three socket head cap screws and the
button head screw, using the ball end wrench (46)
supplied.
S If the plastic parts of the gun must be held in a vise,
ONLY use padded vise jaws to avoid damaging parts.
S ALWAYS remove the gun from the worksite for service
or repair. The service or repair area must be clean.
3. Remove the gun from the manifold.
Socket Head
Cap Screws
Spray Gun
Shroud
Manifold
O-Ring
Air Cap/
Air Cap Nut
Button Head
Screw
01179
Fig 14
18 308-084
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SERVICE
KEY
D
2
Air Cap/Nozzle/Resistor Stud
Replacement
6, 16, 43
Contact Ring
Resistor Stud
CAUTION
6, 16,
43
9
12
14
28
31
48
Air Cap Assembly
Retaining Ring
O-Ring
Fluid Nozzle
Electrode
O-Ring
BE SURE to hold the front end of the gun up while
removing the nozzle and resistor stud. This helps
drain the gun and prevent any paint or solvent left
in the gun from entering the air passages.
12
9
1. Point the front end of the gun up while removing the
fluid nozzle (14) and resistor stud (2) assembly with
the nozzle wrench (48). This helps drain the gun and
prevent any paint or solvent left in the gun from
entering the air passages. See Fig 15 .
Nozzle
Wrench
28
14
If the resistor stud remains in the gun when the fluid
nozzle is removed, start the nozzle thread onto the
stud and pull the stud out.
2
D
48
2. Using an 8 mm hex key (A), unscrew and remove the
resistor stud (2). See Fig 16 .
31
WARNING
The resistor stud contact ring (D) is a conductive con
-
tact ring, NOT a sealing o-ring. To reduce the risk of
sparking, which could cause fire, explosion, or elec-
trostatic shock and result in serious injury, DO NOT
0443
Fig 15
remove the contact ring from the resistor stud or op
-
14
KEY
A
2
erate the gun without the contact ring in place. DO
NOT replace the resistor stud with anything but a
genuine Graco part.
Torque to
10 in-lbs
(1.12 NSm)
8 mm Hex Key
Resistor Stud
Fluid Nozzle
14
2
To install the resistor stud:
3. Lightly lubricate the o-ring (31) with petroleum jelly
and install it on the resistor stud (2).
4. Using an 8 mm hex key (A), install the resistor stud
(2) in the fluid nozzle (14). T
ighten to 10 in-lb
(1.12 NSm).
Make sure the electrode (28) is tightened properly ,
as shown in Fig 17 , page 20.
5. Install the fluid nozzle (14) and resistor stud (2)
assembly with the nozzle wrench (48). Tighten until
the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn
past hand-tight).
A
0444
Fig 16
6. Install the air cap assembly (6, 16, 43), o-ring (12),
and retaining ring (9). T
instructed on page 16.
est gun resistance as
308-084
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SERVICE
KEY
28
47
Electrode Replacement
Electrode
Electrode
1. Remove the air cap, nozzle and resistor stud as
Tool
described in
Air Cap/Nozzle/Resistor
Stud
Replacement.
2. Unscrew and remove the fluid needle/electrode (28)
with the electrode tool (47) provided. Be careful not
to damage the contact wire. See Fig 17 .
47
If the fluid rod turns, hold the back end of the fluid rod.
28
Apply low-strength
(purple) Loctite
or equivalent
3. Apply low-strength (purple) Loctite r or equivalent
thread sealant to the electrode and fluid rod threads.
Refer to SERVICE NOTES, page 25.
Hold the back end of the fluid rod to prevent it from
turning while installing the new electrode finger tight.
DO NOT over tighten the electrode.
CAUTION
To avoid damaging the plastic threads or contact
wire, be very careful when installing the electrode.
4. Install the fluid nozzle and resistor stud assembly .
Install the air cap assembly. Test the gun resistance
as instructed on page 16.
0445
Fig 17
20 308-084
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SERVICE
KEY
10
39
40
Barrel Removal
Gun Barrel
Gun Body
Power Supply
1. Carefully loosen the fluid fitting nut (21). Pull the tube
(19) out of the fitting. Make sure both ferrules and the
nut stay with the tube. See Fig 19 .
2. Remove the jam nut (25) and actuator arm (29).
NOTE: The fluid nozzle must be in place when removing
or installing the jam nut and actuator arm.
10
39
3. Using the ball end wrench (46), supplied, loosen the
three socket head cap screws (15). See Fig 20 .
4. Hold the gun body (39) with one hand and pull the
barrel (10) straight away from the body to remove it.
See Fig 18 .
CAUTION
40
To avoid damaging the power supply, always pull
the gun barrel straight away from the gun body. If
necessary, gently move the barrel from side to
side to free the power supply from the gun body
.
0447
Fig 18
KEY
7
Jam Nut
25
29
39
Jam Nut
Actuator Arm
Gun Body
10
19
21
Gun Barrel
Fluid Tube
Fluid Fitting Nut
39
10
19
21
25 29
7
0446
Fig 19
308-084
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SERVICE
4. Install the fluid tube back into the fluid fitting (21).
Barrel Installation
1. Be sure the gaskets (23 & 40a) and spring (11) are in
place. See Fig 20 . Replace if damaged.
5. Install the actuator arm (29) and jam nut (25), with the
jam nut assembled flush to the end of the rod.
2. Place the barrel (10) over the power supply (40) and
onto the gun body (39). Make sure the fluid rod spring
There should be about a 1/16 in. gap between the ac
-
tuator arm (29) and the nut on the fluid shaft. When
the gun is triggered, the electrode needle should
draw back 3 to 4 mm. If necessary , adjust the jam
nuts to obtain these dimensions.
(11) is seated properly
.
3. Tighten the three socket head cap screws (15)
oppositely and evenly with the ball end wrench (46).
Tighten the cap screws to 18 in-lbs (2 N Sm) MAXI-
MUM (about a half turn past snug). DO NOT over
tighten.
The jam nut must be tightened securely to prevent it
from loosening during operation.
6. Test the gun resistance as instructed on page 16.
CAUTION
To avoid damaging the gun, DO NOT over tighten
the cap screws (15). Tighten the screws to 18 in-
lbs (2 N Sm) MAXIMUM (about a half turn past
snug), using the wrench (46) supplied only
.
KEY
39
10
11
15
21
23
25
29
39
40
Gun Barrel
Spring
Cap Screws
Fluid Tube Fitting
Gasket
Jam Nut
Actuator Arm
Gun body
40a
40
23
Power Supply
15
40a Gasket
10
21
29
25
11
0457
Fig 20
22 308-084
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SERVICE
Fluid Packing Rod Removal and Repair
KEY
3
45
Fluid Packing Rod Assembly
Hex Nut Driver
NOTE: The fluid packing rod can be replaced as
individual parts or as an assembly . If the assembly is
purchased, it is pre-adjusted at the factory
.
1. Remove the jam nut (25) and arm (29). See Fig 20 .
2. Remove the air cap assembly, fluid nozzle and resis
-
tor stud and electrode as described in Electrode
Replacement.
45
3
3. Remove the fluid packing rod assembly (3), using the
9
mm hex nut driver (45). See Fig 21 .
CAUTION
Clean all parts in non-conductive
solvent
compatible with the fluid being used, such as xylol
or mineral spirits. Use of conductive solvents can
cause the gun to malfunction.
4. Check all the parts for wear or damage and replace if
necessary.
0448
Fig 21
Before installing the fluid packing rod assembly (3),
clean the internal surfaces of the barrel with a soft
brush or cloth. Check the inside of the barrel for
marks from high voltage arcing. If the marks are
present, replace the barrel.
6. Place the packing nut (3c) and o-ring (3g) on the fluid
rod (3b). The flats on the packing nut must be facing
toward the back of the fluid rod.
7. Fill the entire inner cavity of the spacer (3d) with the
dielectric grease included with the gun. Place the
spacer on the fluid rod (3b), in the direction shown in
Fig 22 . Generously apply the grease to the outside
5. If the parts are purchased separately , assemble
them as instructed in steps 6 to 9 and as shown in
Fig 22 .
of the spacer
.
If installing the complete fluid rod assembly , go to
step 10, on page 24.
(Item 11 not included with
Fluid Packing Rod Assembly)
KEY
E
Nut
3
Fluid Packing Rod
Assembly
Packing Housing
Fluid Rod
Packing Nut
Spacer
Rod Packing
Fluid Packing
O-Ring
E
11
3h
3f
3d
3a
3e
3g
3a
3b
3c
3d
3e
3f
3c
3b
3g
11
Spring
3
03224
Fig 22
308-084
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SERVICE
11. Install the fluid packing rod assembly (3) into the gun
Fluid Packing Rod Removal and Repair
(continued)
barrel. Using the 9 mm hex nut driver (45), tighten the
assembly until just snug, then check the drag on the
fluid rod.
8. Place the fluid packing (3f), rod packing (3e), and
housing (3a) on the fluid rod (3b) as shown in Fig 22 .
12. Make sure the spring (11) is installed on the nut (E) as
shown in Fig 22 .
9. Lightly tighten the packing nut (3c). The packing nut
is properly tightened when there is 2 lbs. (9 N) of drag
force when sliding the packing housing (3a) assem
bly along the shaft. Tighten or loosen the packing nut
as needed.
-
7. Install the electrode, nozzle and resistor stud
assembly and the air cap assembly as described in
Electrode Replacement
.
8. Install the arm (29) and jam nut (25), with the jam nut
assembled flush to the end of the rod. See Fig 20 ,
page 22.
10. Lubricate the o-ring (3h) on the outside of the packing
housing (3a).
24 308-084
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SERVICE
KEY
F
G
10
13
27
13
40
40e
3-wire Connector
Potentiometer
Gun Barrel
Retainer Ring
Alternator
40b
G
39
27a O-Ring
27b Cushion
39
40
Gun Body
Power Supply
40a
40a Gasket
40b Pad
40c
40c Pad
40d Seal
40e Cushion
40d
F
27a
27
10
27b
0450
Fig 23
Power Supply Removal and Replacement
Power Supply Adjustment
REPAIR NOTES:
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
a. To avoid a loss in electrostatic performance,
inspect the gun handle’s power supply cavity
for dirt or moisture. Clean the cavity with a
clean, dry rag.
,
but can be adjusted between 45 and 80 kV
.
To adjust the low voltage setting, use a small blade end
screw driver to turn the potentiometer (G), clockwise to
increase the voltage or counterclockwise to decrease it;
b. Do not expose the seal (40d) or o-ring (27a) to
solvents as solvents will damage them.
fully clockwise is 80 kV, fully counterclockwise is 45 kV
.
1. Remove the barrel as described in Barrel Removal
.
Turbine Alternator Removal and
Replacement
2. Grasp the power supply (40) with your hand. With a
gentle side-to-side motion, being careful not to dam
-
age the power supply, pull the power supply free from
the gun handle (39), then pull it straight out.
NOTE: Replace turbine bearings after 2,000 hours of
operation. See your authorized Graco representative.
3. Inspect the power supply for any physical damage.
Check the electrical resistance as instructed in Test
Power Supply Resistance. If needed, replace the
1. Remove the power supply from the gun handle as
described at left.
power supply
.
2. Squeeze the two ends of the retaining ring (13)
together and carefully pull the alternator (27) away
from the power supply (40) until the wire connector
(F) disengages. See Fig 23 .
Before installing the power supply, inspect the seal
(40d) for any damage or swelling; replace if neces-
sary. Also, make sure the gaskets/pads (40a–40e)
are in place.
3. Use an ohmmeter to test the turbine alternator coil.
Measure the resistance between the two outer termi
-
4. Lubricate the o-ring (27a) and insert the power sup
-
nals of the 3-wire connector (F). Resistance should
be 3 to 5 ohms. If the reading varies from this value,
ply in the gun handle.
replace the alternator
.
5. Install the barrel on the handle as described in Barrel
Installation.
4. Connect the 3-wire connector to the 3 prongs in the
power supply. Push the alternator (27) onto the pow
-
er supply (40) until the retaining ring (13) engages
with the alternator
.
5. Install the power supply in the gun handle as
described at left.
308-084
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SPRAY GUN SERVICE NOTES
CAUTION: Do not
damageNeedle Elec
-
trode wire during
Lubricate
assy. or disassy
.
Tighten Resistor
Stud into nozzle to
10 in-lbs (1.15 NSm)
Lubricate
T
ighten Nozzle 1/8 to 1/4
Apply low strength (pur-
ple) Loctite or
turn past hand tight
equivalent to threads
Lubricate
WARNING: DO
NOT remove
contact ring
Lubricate
CAUTION: DO NOT over
tighten Capscrews. Tighten to
18 in-lbs (2 N m) MAXIMUM
(about half turn past snug), us
S
-
ing wrench provided.
Torque Fitting to 25–35 in-lbs
(2.8–4.0 NSm)
Install into internal
grooves in fitting
Fits between
flared tube
and fitting
Lubricate
Stretch o-ring to start
it over fitting threads,
then thread it into
place
Lubricate
Apply PTFE paste
to threads
Install flush to
end of rod
Apply high strength
(red) Loctite or
equivalent to threads.
0433
26 308-084
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MANIFOLD SERVICE NOTES
Press fit
Concave side
toward manifold
Left-hand
threads
Apply low strength
(purple) Loctite or
equivalent
This end 8.5-8.9”
(215-225 mm) from
manifold surface when
properly assembled
Lubricate
T
orque to
25 in-lb
(2.8 NSm)
Must be
clean
Standard o-ring is Viton.
Optional EPR o-ring is
T
orque to
25 in-lb
provided with the man
-
(2.8 NSm)
ifold for compatibility with
ketone solvents.
Apply low strength
(purple) Loctite
or equivalent
Press fit
T
ighten until
hex bottoms
against manifold
0434
T
orque to
Lubricate
25 in-lb
0434
(2.8 NSm)
308-084
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SPRAY GUN PARTS DRAWING
DETAIL A
See Detail A
REF NO. 3
Includes items 3a–3h
3c
28
3g
3d
31
3f
3
3e
2
3b
3a
14
3h
9
0601
16
27a
43
27
12
40e
27b
6
13
40b
18
40c
15
40
10
40d
40a
23
24
32
22
42
8
4
1
36
17
30
11
19
36
41d
41j
REF
3
41f
20
39
29
41a
25
41h
41c
41b
41i
21
41g
41e
21b
5
7
21a
41
REF 19
0433
28 308-084
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SPRAY GUN PARTS LIST
Part No. 224–224 Automatic
Electrostatic Air Spray Gun, without shroud
Includes items 1–17, 19–52
Part No. 235–894, Series A
Air Spray Gun, with slotted shroud
Includes items 1–52
Part No. 235–893, Series A
Air Spray Gun, with standard shroud
Includes items 1–52
REF
REF
NO. PART NO.
DESCRIPTION
QTY
NO. PART NO.
DESCRIPTION
QTY
1
2
3
186–762
223–977
224–747
PISTON, valve
STUD, resistor
PACKING ROD ASSY
Includes items 3a–3h
SHOUSING, packing
SROD, fluid
SNUT, packing
SSPACER, packing
SPACKING, rod
1
1
39
40
224–095
224–093
BODY, gun
1
POWER SUPPLY ASSY; 85 KV
Includes items 40a–40e
SGASKET, power supply
SPAD
SPAD
SSEAL
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
40a{ 186–840
40b 185–099
40c 185–145
40d{ 186–637
40e 185–141
3a
3b
3c
3d*
3e*
3f*
3g*
3h*
4
5
6
7
8
185–495
223–981
185–488
186–069
178–763
178–409
111–504
111–316
186–763
111–177
186–764
102–025
100–518
176–930
223–940
185–111
SCUSHION
41
224–340
CHECK VALVE ASSY
Includes items 41a-41j
SMUFFLER/FLAME ARRESTOR
SBEARING, ball
SPACKING, fluid
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
SO-RING, fluoroelastomer
SO-RING, fluoroelastomer
COVER, piston
CAP SCREW, button hd; 1/4-20 x 0.5”
RING, air cap
NUT, hex; 1/4”-20
SCREW, mach, pnh; 6–32 x 3/8”
RING, retaining
41a 187–264
41b 108–046
41c 101–435
41d 186–980
41e 186–981
SBEARING, ball
SFITTING, check valve; 5/16-18
SSCREW, check valve; M4 x 0.7
SBODY, check valve; 3/4-16
SNUT, check valve; 3/4-16
SSEAT, check valve
SVALVE, check, body
SO-RING; Viton
O-RING; Viton
GASKET, air cap nut
TAG, warning (not shown)
DRIVER, hex nut; 9 mm (not shown)
WRENCH, barrel (not shown)
WRENCH, electrode (not shown)
WRENCH, nozzle (not shown)
SIGN, warning, English (not shown)
COVER, gun (not shown)
WRENCH, allen; 8 mm
41f
186–982
41g 186–983
41h 186–984
41i
41j
42*
43{ 186–848
44** 179–791
45
46
47
48
9
10
11
BARREL, gun
SPRING, compression
O-RING, PTFE r
186–985
103–337
103–337
12{ 110–492
13
14
1
1
185–114
185–158
RING, retainer, alternator
NOZZLE, fluid, See Manual 307–803
for available nozzles
SCREW, cap, relieved; M5 x 0.8
AIR CAP; See Manual 307–803 for
available air caps
PACKING, u-cup, UHMWPE
SHROUD, standard; included with
Part No. 235–893 only
SHROUD, slotted; included with
Part No. 235–894 only
TUBE, flared; PTFE
1
3
110–087
107–460
185–123
187–421
15
16
185–096
177–033
1
1
17{ 181–039
49** 180–060
186–770
50
51
52
187–343
110–088
105–749
1
18
188–699
BRUSH
1
1
1
19
20
21
186–958
186–765
187–319
ROD, actuator
* The replacements for these parts are available in Fluid Seal
Repair Kit 237–786. Purchase the kit separately
CONNECTOR, male; 1/8 npt; for 1/4”
OD tubing; Includes items 21a & 21b
SFERRULE
.
1
1
1
1
1
1
1
** Additional warning tags and signs available at no charge.
French, German, and Spanish warning signs are also avail
able. See ACCESSORIES section.
21a* 111–285
21b* 111–286
22
-
SFERRULE
186–818
FITTING, fluid; 5/8-20
GASKET, manifold; polyethylene
CAP, retainer, spring
NUT, hex, jam; 1/4”-20
ALTERNATOR, turbine
Includes items 27a & 27b
SO-RING, Vitonr
SCUSHION
NEEDLE, electrode
ARM, actuator
O-RING; PTFE
23{ 185–113
{ The replacements for these parts are available in Air Seal
24
25
27
181–178
101–324
222–319
Repair Kit 224–636. Purchase the kit separately
.
WARNING
1
1
1
1
1
When servicing use only genuine Graco replacement
parts. Use of other parts or any modification of the
gun could alter the grounding continuity of the gun or
cause parts to rupture and result in serious injury, fire,
explosion, electrostatic shock or property damage.
27a{ 110–073
27b 185–124
28
29
30*
31*
32
185–107
186–766
102–982
111–507
111–182
1
O-RING; fluoroelastomer
SPRING, compression
O-RING; fluoroelastomer
1
1
2
36{* 111–450
308-084
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MANIFOLD PARTS DRAWING
122
110
114
111
106
103
124
116
112
121
101
104
118
117f
117e
109
117g
117b
117h
108
107
113
117c
117d
104
115
0434
MANIFOLD PARTS LIST
Part No. 224–094 Gun Manifold
Includes items 101–124
REF
REF
NO.
P
ART NO.
DESCRIPTION
QTY
NO.
P
ART NO.
DESCRIPTION
SSPRING, compression
SSET SCREW, cup point; 4-40
SPACKING, u-cup; UHMWPE
FITTING, fluid; 1/4 npsm
SLEEVE, o-ring
O-RING; Viton
O-RING; EPR
TUBE
QTY
101 111–224
103* 106–167
104 110–078
106 186–846
107 186–820
108 183–822
109{ 105–668
110 186–844
LENSE
1
2
2
3
1
4
4
1
1
1
1
1
1
1
117f 111–208
117g 111–295
117h 111–294
118 185–819
121 186–847
122{ 111–180
123 111–333
124 224–548
1
1
1
1
1
1
1
1
O-RING; perfluoroelastomer
FITTING, tube; for 3/8” OD tube
BOLT, manifold; M5 x 0.8
MANIFOLD
SLEEVE, o-ring
O-RING; Vitonr
FITTING, flow-washer; M16 x 1.5 LH
FITTING, turbine; 1/4-18 npsm LH
O-RING, Viton
FITTING, fiber optic cable; 7/16-20
DISK, regulator
FITTING, tube; for 1/4” OD tube
FITTING, barb
SWITCH, voltage
111
186–845
112{ 105–796
113 186–779
114 107–107
115 111–157
116 111–237
117 224–143
*
The replacements for these parts are available in Fluid Seal
Repair Kit 237–786. Purchase the kit separately
.
{The replacements for these parts are available in Air Seal
Repair Kit 224–636. Purchase the kit separately
.
WARNING
Includes items 17a-17h
SCYLINDER
SPISTON
SFITTING, plug
SFITTING, male
1
1
1
1
1
1
When servicing use only genuine Graco replacement
parts. Use of other parts or any modification of the gun
could alter the grounding continuity of the gun or cause
parts to rupture and result in serious injury, fire, explo
sion, electrostatic shock, or property damage.
117a 186–809
117b 186–808
117c 186–810
117d 111–165
117e 224–577
-
SMAGNET
30 308-084
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PRO 4600HC CONVERSION KIT
Part No. 237–301
8. Slide the nylon nut (202) and ferrules (203 & 204)
onto the coiled tube assembly (201). See Fig. 24 .
PRO 4600HC Conversion Kit; To convert the PRO
4600SCt spray gun to the PRO 4600HC spray gun.
The longer 20 in. (508 mm) fluid tube used by the HC
gun provides increased spraying voltage when spray
ing highly conductive fluids. The kit must be ordered
separately. It includes items 201 to 204.
9. Install the coiled tube assembly (201) into the fluid
fitting and tighten the nut (202). See Fig. 27 .
Make sure the entire tube is clear of the actuator
-
arm (D) to avoid having the tube rub against it dur
ing operation.
-
Ref.
No.
Part No.
Description
Qty.
10. Install the gun onto the manifold. Refer to page 6.
201
202
203
204
237–299
112–644
111–285
111–286
COILED TUBE ASSY.
NUT; nylon; for 1/4” O.D. tube
FERRULE; nylon
1
1
1
1
FERRULE; nylon
201
B
A
04673
Fig. 25
202
203
204
201
3933A
Fig. 24
Installing the PRO 4600HC Conversion Kit
1. Flush the gun with a compatible solvent.
2. Relieve system pressure as instructed in the Pres-
sure Relief Procedure on page 18.
04674
3. Remove the gun from the manifold as instructed
on page 18. Remove the gun from the spray area.
Fig. 26
4. Remove the PRO 4600SC gun’s fluid tube, fittings,
and o-rings (B). See Fig. 25 .
5. Clean the barrel fluid inlet (A) with compatible sol
vent. Inspect the barrel fluid inlet for damage and
replace if needed.
-
6. Slide the coils of the tube assembly (201) over the
front of the gun barrel, until it is past the barrel fluid
inlet (A). See Fig. 26 and 27 .
A
C
D
201 202
7. Position the coiled tube assembly so its threaded
inlet fitting (C) is aligned with the barrel fluid inlet
(A), then tighten the fitting into the inlet as shown
in Fig. 27 .
04672
Fig. 27
308-084
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ACCESSORIES
Accessories must be purchased separately
.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
AIR AND FLUID LINE ACCESSORIES
Air Filter & Moisture Separator 106–148
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
For cleaning and drying air in air spray
system. 20 micron element, 5 oz. bowl
capacity, 3/8 npt(f) inlet and outlet
Air Pilot Paint Regulator 224–531
For controlling paint flow through the spray gun.
Connects to mount assembly 235–094.
High Volume Air Regulator 206–199
0331
0–125 psi (0–9 bar) Regulated Pressure
200 psi (14 bar) Steel Pressure Gauge
For regulating air to the gun.
Grounded Air Supply Hose
1/2 npt(f) inlet and outlet
100 psi (7 bar) MAXIMUM WORKING PRESSURE
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) LH;
Color coded black
PART NO. LENGTH
220–444
218–100
218–101
218–102
218–103
220–119
220–120
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Air Shut-off Valve 224–754
150 psi (10 bar) MAXIMUM WORKING PRESSURE
For turning air to gun off or on.
1/4 npsm(m) LH x 1/4 npsm(f) LH
Grounded Air Supply Hose
100 psi (7 bar) MAXIMUM WORKING PRESSURE
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) LH;
Color coded gray; More flexible than black hose
Bleed-type Master Air Valve 107–141
300 psi (21 bar) MAXIMUM WORKING PRESSURE
Relieves air trapped in the air line between the paint
pump air motor and this valve when closed. 3/4 npt
PART NO. LENGTH
223–068
223–069
223–070
223–071
223–072
223–073
223–074
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Filter (Air or Paint) 202–271
750 psi (52 bar) MAXIMUM WORKING PRESSURE
With 60 mesh (250 micron) element,
3/8 npt(f) inlet, 3/8 npt(m) outlet
Grounded Air Supply Hose
100 psi (7 bar) MAXIMUM WORKING PRESSURE
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) LH;
Color coded red; Stainless steel braid ground path
PART NO. LENGTH
235–068
235–069
235–070
235–071
235–072
235–073
235–074
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
Fluid Drain Valve
500 psi (35 bar) MAXIMUM WORKING PRESSURE
For relieving fluid line pressure
208–630 1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE;for non-corrosive fluids
210–071 3/8 npt(m) x 3/8 npt(f); stainless steel and
PTFE;for corrosive fluids
Air Adapter Nipple 185–493
For connecting two or more grounded gun air supply
hoses. 1/4 npt x 1/4 npsm (left hand thread)
32 308-084
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ACCESSORIES
Accessories must be purchased separately
.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
GUN MOUNTING ACCESSORIES
ES Display Module 224–117
Receives fiber optic transmission from the PRO 4600SC
Gun and displays the gun’s output voltage and current.
Mounts in a standard 19” DIN Rack. Refer to manual
308–265.
Gun Mount Assembly 235–094
Bracket for mounting to a 1/2 inch
(12.7 mm) rod, with a slot for mount
ing the air pilot fluid regulator
224–531.
-
01875
Gun Mount Assembly 224–118
For mounting the PRO4600 gun to the GMF P150 robot.
Mount Extensions 224–255/259
For extending the mount length of Mount Assembly
224–118. Contact your Graco representative for avail-
able lengths.
0309
Nylon Fabric Cover 187–343
Fabric cover to protect the manifold inlet tubing and
fittings from paint buildup.
24 Volt Power Supply 235–301
Provides 24 volt power for up to 23 ES Display Modules.
187–343
0437
GUN CONTROL AND MONITORING
ACCESSORIES
For
more information about gun controls and monitoring
01339
accessories contact your Graco representative.
Pneumatic Trigger Module 235–768
Provides pilot air valve control for atomizing air , fan air
and fluid trigger air gun functions. Refer to
308–264.
manual
01768
308-084
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ACCESSORIES
Accessories must be purchased separately
.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
CABLE ACCESSORIES
Bulkhead Connector 224–261
For connection between two fiber optic cables.
Fiber Optic Cables
Fiber Optic Cable Assembly
For connection between gun manifold and
display
module or between bulkhead connector and display
module.
PART NO. LENGTH
224–680
224–681
224–682
224–683
224–684
224–685
224–686
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
0185A
MISCELLANEOUS ACCESSORIES
Grounding Clamp and Wire 222–011
12 ga, 25 ft (7.6 m) wire
0189
0330
Megohmmeter 218–979
Fiber Optic Cable Extender
For connection between gun manifold and bulkhead con
nector.
PART NO. LENGTH
500
Volt output; 0.01–2000 megohms.
-
Not for use in Hazardous areas.
224–670
6 ft (1.8 m)
15 ft (5 m)
25 ft (8 m)
36 ft (11 m)
50 ft (15 m)
75 ft (23 m)
100 ft (30.5 m)
224–671
224–672
224–673
224–674
224–675
224–676
0184
34 308-084
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Safety Warning Signs
Available at no charge from Graco.
MANUAL CHANGE SUMMAR
Y
Must be ordered separately
.
The following parts have been changed in this revision:
PART NO. DESCRIPTION
180–060
180–061
180–062
180–063
W
W
W
W
arning Sign (English)
arning Sign (French)
arning Sign (German)
arning Sign (Spanish)
Assembly
Changed
Part
Status
Ref
No.
Part No. Name
224–635,
224–224,
235–893 &
235–894
Old
New
3
3
223–980 Packing Rod
224–747 Packing Rod
Added
Added
51
52
110–088 Wrench
105–749 Brush
Paint Resistance Meter 722–886
Used with 722–860 Paint Probe to measure resistance of
paint. Not for use in Hazardous areas.
Spray Gun
Miscellaneous Changes:
1. Changed the Fluid Seal Repair Kit from part no.
Paint Probe 722–860
224–635 to part no. 237–786.
Used with 722–886 Paint Resistance Meter to
measure resistance of paint. Not for use in
Hazardous areas.
2. Added the PRO 4600HC Conversion Kit, part no.
237–301 to the manual.
Gun High Voltage Probe & Meter 217–452
For direct measurement of gun output voltage.
SYSTEMS
Gun, Manifold, and Mount System 235–303
Includes:
PART NO. DESCRIPTION
224–224
224–094
235–094
PRO4600 Gun
Gun Manifold
Standard Gun Mount
TECHNICAL DATA
Weight (gun & manifold)
Maximum orking Pressure
Air Pressure Operating Range
Fluid Pressure Operating Range
Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . 0–85 kV
Paint Resistivity Range . . . . 3 megohm cm to infinity
Turbine Air Inlet . . . . . . . . . . . . . . . . . 1/4 npsm(m) L.H.
Wetted Parts . . . . . . Stainless Steel, Nylon, Acetal,
r, Kalrez r, Ultra High
.
. . . . . . . . . . . . . 43 oz (1207 g)
. . . . . . . . . 100 psi (7 bar)
. . 0–100 psi (0–7 bar)
0–100 psi (0–7 bar)
W
.
.
.
.
.
.
PTFE
Molecular W eight Polyethylene,
Ceramic, Chemraz r, Fluoro-
polymer
Vitonrr and Kalrezr are registered trademarks of the
DuPont Co.
Loctiter is a registered trademark of the Loctite Corporation.
Chemrazr is a registered trademark of the Green, Tweed, & Co.
308-084
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THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workman
ship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser s sole remedy
-
’
for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale,
repair or replace any part of the equipment proven defective. However, any deficiency in the barrel, handle, trigger, hook,
internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six
thousand hours of operation from time of sale. This warranty applies only when the equipment is installed, operated and
maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty instal
-
lation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the
incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the
improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materi
als not supplied by Graco.
-
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco
distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any
defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the
equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which
charges may include the costs of parts, labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser
plied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabili
ties, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential dam
’
s sole and exclusive remedy and are in lieu of any other warranties (express or im
-
-
-
ages or loss is expressly excluded and denied. in no case shall Graco’s liability exceed the amount of the purchase price. Any action
for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with re
spect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manu
factured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer
-
-
.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
GRACO PHONE NUMBERS
TO PLACE AN ORDER, contact your Graco distributor
or call Graco: 1–800–367–4023 Toll Free
,
FOR TECHNICAL ASSISTANCE, service repair infor-
mation or answers about the application of Graco equip
ment, call: 1–800–543–0339 Toll Free
-
Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Foreign Offices: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
GRACO INC. .O. BOX 1441 MINNEAPOLIS, MN 55440–1441
P
PRINTED IN U.S.A. 308–084 June 1991 Revised January 1995
36 308-084
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