INSTRUCTIONS PARTS LIST Rev. D

Transcription

1 INSTRUCTIONS PARTS LIST Rev. D This manual contains IMPORTANT WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Supersedes B Model AS4000M MANUAL ELECTROSTATIC METALLIC AIR SPRAY GUN 100 psi (7 bar) MAXIMUM WORKING PRESSURE Part Number Series A With air cap and in. (1.2 mm) fluid nozzle. U.S. Patent No. 4,241,880, 4,335,851, and 4,721,255 Other U.S. and Foreign Patents Pending GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN COPYRIGHT 1988 GRACO INC.

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3 TABLE OF CONTENTS Terms How AS4000M Spray Gun Works Safety Warnings , 5 Installation Typical Installation Warning Signs Ventilate the Spray Booth Connect the High Voltage Cable Connect the Air Lines Connect the Fluid Line Check the Electrical Grounding Operation Operating Checklist Filter the Fluid Adjust the Spray Pattern Flush the Spray Gun Maintenance Daily Care and Cleaning Clean the Air Cap and Fluid Nozzle Service Spray Pattern Troubleshooting Chart Gun Operation Troubleshooting Chart Electrical Troubleshooting Chart , 15 Gun Disassembly Electrode Replacement Barrel Removal Fluid Packing Removal Fluid Packing Replacement Resistor Assembly Replacement Fan Air Valve Replacement Air Valve Replacement Resistor Stud or Contact Replacement Parts Drawing Parts List How to Order Replacement Parts Accessories , 25 Repair Kits Technical Data Warranty TERMS Back Cover Back Cover WARNING Alerts user to avoid or correct conditions that could cause bodily harm. CAUTION NOTE Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment. Identifies essential procedures or helpful information. HOW AS4000M SPRAY GUN WORKS A transformer supplies high voltage current through the cable to the gun s ionizing electrode, where the electrostatic field is developed. The pump supplies fluid through the hose and gun, where it is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded work piece, wrapping around it and coating all surfaces.

4 SAFETY WARNINGS SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL. EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in serious bodily injury, fire, explosion or property damage. NEVER point the spray gun at anyone or at any part of the body. NEVER put hand or fingers over the spray nozzle. ALWAYS follow the Pressure Relief Procedure, at right, before cleaning or removing the fluid nozzle or servicing any system equipment. NEVER try to stop or deflect leaks with your hand or body. NEVER alter or modify any part of this equipment; doing so could cause it to malfunction. CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately. System Pressure This gun has a maximum working pressure of 100 psi (7 bar). Never exceed the maximum working pressure of the gun or any other component or accessory used in the system. Fluid Compatibility BE SURE all fluids and solvents used are chemically compatible with the Wetted Parts shown in the TECHNICAL DATA on the back cover. Always read the fluid and solvent manufacturer s literature before using the fluid or solvent in this gun. Pressure Relief Procedure To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying. 1. Turn off the high voltage power supply. 2. Turn off the air and fluid supply to the gun. 3. Trigger the gun into a grounded metal waste container to relieve fluid pressure. 4. Open the pump drain valve, having a waste container ready to catch the drainage. 5. Leave the pump drain valve open until you are ready to spray again. HAZARDOUS FLUID HAZARD Improper handling of hazardous fluids or inhaling vapors can cause extremely serious bodily injury, even death, due to splashing in the eyes, ingestion, inhalation, or bodily contamination. Know what fluid you are pumping and its specific hazards. Store hazardous fluids in approved containers. Dispose of any waste fluid according to all Local, State and Federal regulations pertaining to the disposal of hazardous wastes. Observe all precautions when handling known or potentially hazardous fluids, including, but not limited to, the following. 1. Always wear appropriate, protective clothing and equipment, such as eye protection, respiratory protection, and gloves. 2. Provide for the safe piping and disposal of all exhaust air. 3. Provide proper ventilation in accordance with accepted industry standards and governmental regulations. Refer to Ventilate the Spray Booth, on page 5. HOSE SAFETY TIGHTEN all fluid connections securely before each use. NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose.

5 FIRE OR EXPLOSION HAZARD All parts of the electrostatic spray system must be properly grounded to reduce the risk of static electricity discharge. Static electricity is created by the high velocity flow of fluid through the pump and hose and the spray gun s power supply. Ungrounded objects can become electrically charged and sparking may occur. Sparks can ignite vapors from solvents, fluid being sprayed, dust particles and other flammable substances, which can cause a fire or explosion and result in serious bodily injury and property damage. If you experience any sparking 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. The minimum spraying distance from the gun nozzle to the work piece is 4 in. (100 mm). Holding the gun any closer to the work piece will cause sparking. Grounding The following are minimum requirements for grounding a basic electrostatic system. Your system may include other equipment or objects which must also be grounded. Always check your local electrical code for detailed grounding instructions. Be sure your system is connected to a true earth ground. 1. Pump: ground by using a ground wire and clamp as described in your separate pump instruction manual. 2. Air compressors: ground according to the manufacturer s recommendations. 3. High voltage power supplies: must be properly grounded and located outside the spray area. Ground according to the manufacturer s recommendations. 4. High voltage cable: obtain grounding through connection of an undamaged cable to a properly grounded power supply. 5. All electric cables going to the power supply must be properly grounded. 6. Spray gun: obtain grounding through connection to properly grounded high voltage cable. 7. Object being sprayed: keep the work piece hangers clean and grounded at all times. Contact points must be sharp points or knife edges. 8. All electrically conductive objects or devices in the spray area, including paint containers and wash cans, must be properly grounded. 9. All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive. The operator must not wear gloves which insulate the hand from the spray gun. See page 9 for how to modify the glove. 10. 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. 11. Flammable liquids in the spray area must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift. 12. 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. Flushing and Cleaning Safety To reduce the risk of static sparking or splashing, always follow the Pressure Relief Procedure on page 4 before flushing. Use the lowest possible pressure and use a grounded metal waste container. Be sure the high voltage power supply is OFF during flushing. NEVER use solvents having a flash point of less than 70 F (21C) to clean the gun. NEVER use solvents having a flash point of less than 100 F (38 C) to clean the spray system. ALWAYS remove all solvent from the system before reactivating the spray gun. Use only non sparking tools to clean residue from the booth and hangers. Ventilate the Spray Booth To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. The High Voltage Power Supply must be electrically interlocked with the ventilators to prevent operation of the Power Supply unless ventilating fans are operating. NEVER operate the spray gun unless the ventilating fans are operating. IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards particularly the General Standards, Part and any other appropriate regulations should be consulted in connection with the installation, operation, and maintenance of electrostatic spray painting equipment.

6 TYPICAL INSTALLATION Connection for 75 KV Power Supply WARNING SIGN NON HAZARDOUS AREA Power Supply Must Be Interlocked With Spray Booth Exhaust Fan. HAZARDOUS AREA A Air Supply Line B Air & Water Separator C Ball Valve D Air Line Lubricator E Air Regulator (bleed type) F Pump G Fluid Filter H J K L M N Remote Switch and Lights Wiring ON OFF (D.P. D.T.) Switch High Voltage Power Supply (located outside the spray/hazardous area) Remote Switch & Lights Air Filter (5 micron) High Voltage Cable O P Q R S T Fluid Regulator Fluid Line Electrostatic Gun Atomizing Air Line Air Supply Shutoff Valve (bleed type) Fluid Drain Valve The Typical Installation shown above is only a guide 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 Signs Mount warning signs in the spray area where they can easily be seen and read by all operators. See the AC CESSORIES section on page 25. WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class 1, Group D, Divisions 1 and 2 Hazardous Location.

7 INSTALLATION Ventilate the Spray Booth WARNING To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. The High Voltage Power Supply must be electrically interlocked with the ventilators to prevent operation of the power supply unless the ventilation fans are operating. NEVER OPERATE THE SPRAY GUN UNLESS VENTILATION FANS ARE OPERATING. Check and follow all of the National, State and Local codes regarding air exhaust velocity requirements. Check and follow all local safety and fire codes and OSHA standard (b)(5)(i). NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of ft/min (31 46 linear meters/minute) should be sufficient. Connect the High Voltage Cable (Refer to the Typical Installation Drawing) 1. Connect one end of the High Voltage Cable (N) to the gun (Q) in the spray booth area. 2. Insert the High Voltage Cable into the insulator tube of the gun and tighten the cable with the retaining nut. 3. Route the High Voltage cable (N) from the gun to the Power Supply (K). To avoid permanent indentations of the cable and cable failures caused by unnecessary stress to the cable, be sure to take the following precautions: a. Support the cable overhead to avoid people walking on it and vehicles driving over it. b. DO NOT clamp the cable too tightly at supports. c. Avoid sharp kinks and bends in the cable. 4. Lubricate the cable o rings with petroleum jelly. Attach the cable to the Power Supply. Connect the Air Lines (Refer to the Typical Installation Drawing) 1. Install an air line filter (M) to ensure a clean, dry air supply to the gun. Dirt and moisture in the air line can ruin the appearance of your finished work piece, and cause the Power Supply to malfunction. 2. Install an air line lubricator (D) as close to the pump (F) as possible. 3. Install a bleed type air regulator (E) on the pump and gun air supply lines to control air pressure to the pump and gun. 4. Install a bleed type air shutoff valve (S) on the main air line and each gun air supply line to shut off air to the gun(s). Install an additional bleed type valve on each pump air supply line. WARNING The bleed type air shutoff valve is required in your system to relieve air trapped between this valve and the pump after the valve is closed. Trapped air can cause the pump to cycle unexpectedly, which could result in serious bodily injury, including splashing in the eyes or on the skin and injury from moving parts. 5. Connect an air supply line to the 1/4 npt(m) IN port on the Power Supply air flow switch. 6. Connect an air line from the 1/4 npt(m) OUT port on the air flow switch to the gun s 1/4 npsm(m) air inlet. Connect the Fluid Line (Refer to the Typical Installation Drawing) 1. Before connecting the fluid line (P), blow it out with air, and flush it with solvent. Be sure the solvent you use is compatible with the fluid to be sprayed. 2. Connect the fluid line from the outlet of the pump to the 3/8 npsm(f) inlet of the gun. 3. Install a fluid filter (G) and drain valve (T) at the pump outlet. WARNING The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump s fluid outlet. The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on the skin and contamination from hazardous fluids. 4. Install a fluid regulator (O) to control the fluid pressure to the gun.

8 INSTALLATION Check the Electrical Grounding (See Fig 1) WARNING Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE OR EXPLOSION HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below. Q Gun U True Earth Ground V Ohmmeter U V 1. Make sure the High Voltage Power Supply is pro perly grounded and located outside the spray area. The Power Supply case and spray gun actuator can become charged if the case is not well grounded. The ground wire is part of the high voltage circuit and must, without fail, be connected to a true earth ground. As an added precaution, attach a separate ground wire to the case of the High Voltage Power Supply. 2. Shut off the Power Supply and the air and fluid lines to the gun. 3. Have a qualified electrician check the electrical grounding continuity of the spray gun. Use an ohmmeter (V) to measure resistance between the handle of the gun (Q) and a true earth ground (U). The resistance should be less than 20 ohms. Q WARNING If the resistance is over 20 ohms, the gun is not properly grounded, and the system may be hazardous. Check again that you have properly grounded your system components; see FIRE OR EXPLOSION HAZARD, on page 5. Since the gun is grounded through connection to an undamaged, properly grounded, high voltage cable and power supply, check for a grounding problem with the cable and power supply first. BE SURE you have corrected the problem before using the system. Fig 1

9 OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying. 1. Turn off the high voltage power supply. 2. Turn off the air and fluid supply to the gun. 3. Trigger the gun into a grounded metal waste container to relieve fluid pressure. 4. Open the pump drain valve, having a waste container ready to catch the drainage. 5. Leave the pump drain valve open until you are ready to spray again. 3 in. (76 mm) Square Cutout or 2 Fingers of Glove Cutoff Operating Checklist Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation. Fig 2 Filter the Fluid Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle. Be sure all operators are properly trained to safely operate an electrostatic air spray system. Be sure all operators are trained how to properly and completely relieve system pressure. Be sure the system is thoroughly grounded. See FIRE OR EXPLOSION HAZARD on page 5, and Check the Electrical Grounding on page 8. Be sure the operator and all persons entering the spray area are properly grounded. Be sure ventilation fans are operating properly. Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges. Be sure all refuse is removed from the spray booth. Be sure all flammable liquids in the spray booth are in approved, grounded containers. Be sure all conductive objects within 20 ft (6 m) of the gun are electrically grounded and the floor of the spray area is electrically conductive and grounded. Be sure the operator s glove is modified, if used, so the operator s hand will not be insulated from the spray gun handle. See Fig 2.

10 OPERATION Adjust the Spray Pattern This gun can atomize many fluids with different viscosities and at various flow rates. Follow these steps to establish the correct fluid flow and air flow: 1. Set the atomizing air pressure at 30 psi (2 bar) and fluid pressure at 3 to 4 psi (0.25 bar). 2. Choose the correct fluid nozzle and air cap combination for your application. See Instruction Manual for the air cap consumption and fluid nozzle flow rate information. Both flow rate and viscosity must be considered. A in. (1.2 mm) fluid nozzle is furnished with the gun. 3. Adjust the fluid flow by using the fluid pressure regulator installed in the fluid line. (See the Accessories section.) 4. For fine adjustment, use the fluid adjusting screw (54) located at the rear of the gun. See Fig 3. Turn it clockwise to reduce the amount of fluid being sprayed, and counterclockwise to increase the amount being sprayed. 5. Use an air pressure regulator to adjust the pressure for the desired degree of atomization. Always use the lowest air pressure possible for the most efficiency. See the Spray Pattern Troubleshooting Chart in the Service Section. 6. Use the air adjusting screw (41) to change the shape of the spray pattern. Turn it counterclockwise for a wide pattern and clockwise for a solid, round pattern. NOTE: When increasing to a wide, flat pattern, you may have to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area. When all adjustments of atomizing air, fluid pressure, and fan pattern are made, the Power Supply can be turned on and operation can begin. (The spray pattern may need to be adjusted slightly after the Power Supply is turned on.) Flush the Spray Gun WARNING To reduce the risk of fire or explosion and serious bodily injury, the Power Supply MUST be turned OFF before flushing. 1. Turn off the Power Supply (K). Follow the Pressure Relief Procedure Warning on page Disconnect and plug the fluid line. 4. Connect the solvent supply to the gun. 5. Run solvent through the gun. 6. Disconnect the solvent supply. 7. Reconnect the fluid supply line. 8. Turn on the fluid and air supplies. 9. Trigger the gun until it is clean of solvent. 41 Air Adjusting Screw Assembly 54 Fluid Adjusting Screw Assembly Fig 3

11 MAINTENANCE Daily Care and Cleaning For Your Safety, always follow the Pressure Relief Procedure on page 9 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system. 1. Clean the fluid and air line filters daily. 2. Clean the outside of the gun daily with a soft cloth, dampened in a compatible solvent. 3. Clean the air cap and fluid nozzle daily, minimum. Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See Clean the Air Cap and Fluid Nozzle, below. 4. Check the electrode (56). Straighten it if bent, and replace it if broken or damaged. See page 16 for replacing the electrode. 5. Check all of the work hangers for build up of material; clean them, if necessary. CAUTION Do not use metal tools to clean the air cap holes as this may scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap holes or a damaged electrode wire can distort the spray pattern. 4. Use the soft bristle brush (77a), supplied, and solvent to clean the air cap, fluid nozzle, and front part of the gun. 5. Squeeze the gun trigger and screw the fluid nozzle back into the gun finger tight. Torque the fluid nozzle to in lb ( N.m) (about 1/4 of a turn) with the wrench (77b) supplied. 6. Replace the retaining nut and air cap carefully to avoid bending the electrode wire (56). Tighten the retaining nut so it is snug, allowing the air cap to turn with resistance. If it is too tight, the spray pattern will be distorted. 17 Air Cap 19 Fluid Nozzle 47 Retaining Nut 56 Electrode 77b Wrench Do not use any cleaning method which may allow solvent into the gun air passages. Clogged air passages cause poor atomization and excessive current demands. Point the gun down while cleaning to prevent dirty solvent from running back into the air passages. NEVER IMMERSE THE GUN IN SOLVENT. Clean all parts with a non conductive solvent, compatible with the fluid being sprayed. Conductive solvents can cause the gun to malfunction. Clean the Air Cap and Fluid Nozzle Equipment needed: Soft bristle brush (supplied). Fluid nozzle wrench (supplied). Solvent compatible with fluid being sprayed. Procedure: 1. Turn off the Power Supply. Follow the Pressure Relief Procedure Warning on page 9. 77b 2. Remove the retaining nut (47) and air cap (17). See Fig 4. Fig 4 3. Squeeze the gun trigger and remove the fluid nozzle (19) with the fluid nozzle wrench (77b) supplied. Make sure the front of the gun is held down. See Fig 4.

12 SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. To reduce the risk of serious bodily injury, including splashing fluid or solvent in the eyes or on the skin, always follow the Pressure Relief Procedure on page 9 before checking, adjusting, cleaning or repairing the gun or any part of the system. Disconnect the fluid hose from the gun. NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun. PROBLEM: CAUSE SOLUTION IMPROPER SPRAY PATTERN Fluttering or spitting spray Streaks Insufficient fluid supply. Dry or worn fluid needle packing or loose packing nut permits air to get into fluid passage. Loose fluid nozzle or damaged fluid nozzle taper seat. Dirt between fluid nozzle, taper seat and body. Loose or cracked coupler at fluid inlet. Loose fluid tube in cup or tank. Fluid build up on air cap; partially clogged horn holes. Full air pres sure from clean horn hole forces fan pattern toward clogged end. Damaged fluid nozzle or air cap holes. Fluid build up on the perimeter of fluid nozzle orifice, or partially clogged fluid nozzle orifice Too high atomization air pressure. Fluid too thin. Not enough fluid pressure Low atomization air pressure Fluid too thick Too much fluid. Last coat of fluid applied too wet. Too much air pressure. Insufficient air pressure. Non uniform spray pattern. Adjust fluid regulator or fill fluid tank. Lubricate or replace packing, tighten packing nut. Tighten or replace fluid nozzle. Clean. Tighten or repair. Tighten. Clean with soft implement or submerge in suitable solvent and wipe clean. Replace damaged part. Remove obstruction. Never use wire or hard instruments. Reduce air pressure or adjust air adjusting valve. Regulate fluid viscosity. Increase fluid pressure. Raise air pressure. Regulate fluid viscosity. Reduce fluid flow. Reduce fluid pressure on pressure feed guns and/or adjust fluid adjusting screw until proper pattern is obtained. Apply drier finish with multiple strokes. Use least air pressure necessary. Increase air pressure. Clean or replace air cap. NOTE: Some improper patterns are caused by the improper balance between air and fluid.

13 GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid packing nut. Air leakage from front of gun. Fluid leakage from front of gun. Orange Peel finish. Excessive spray fog. No fluid sprays from gun. Equipment covered with fluid. Equipment covered with fluid. Loose packing nut (27). Worn needle packing (6). Air valve not seating properly. Air stem packing too tight. Electrode (56) worn or damaged. Worn fluid seat. Fluid packing (6) too tight. Loose fluid nozzle (19). Fluid adjusting screw (54) not set correctly. Insufficient air pressure. Fluid poorly mixed or filtered. Improper thinner being used. Too much air pressure. Fluid thinned too much. Fluid low. Damaged air cap (17). Dirty or clogged fluid nozzle (19). Damaged fluid nozzle (19). Exhaust air flow insufficient or not directed properly. Equipment closer to ionizing nozzle than object being sprayed. Misalignment between air cap and fluid nozzle. Tighten. Replace needle packing. Clean, service. Loosen packing. Replace electrode. Replace fluid nozzle (19) and/or electrode (56). Lubricate packing and adjust packing nut (27). Tighten fluid nozzle. Adjust screw. Increase, use least air pressure needed for good results. Remix or refilter fluid. Use proper thinner. Reduce,use least air pressure needed for good results. Properly thin fluid. Check, add if necessary. Replace air cap. Clean fluid nozzle. Check, replace fluid nozzle. Check for proper CFM, check baffles and direction of air flow. Mount gun closer to target. Remove and clean air cap and fluid nozzle as described in Maintenance Section under Clean the Air Cap and Fluid Nozzle, then reinstall them.

14 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Poor wrap around. Low or no electrostatic wrap. Parts poorly grounded. High exhaust velocity. High fluid pressure. Fluid viscosity. Low or no electrostatic voltage. Clean hangers, check for proper ground on conveyer or track. Reduce within code limits. Reduce pressure. Check supplier for proper fluid for electrostatic spray. See below. Faulty gun resistance. Check; resistance should be 250 megohms +20 from the end of the gun electrode (56) to the end of the High Voltage Cable, where it connects to the Power Supply. If resistance is lower, check resistance of resistor (12) and electrode (56). Improper distance between gun and workpiece. Too high atomizing air pressure. Too low fluid resistivity. Faulty Power Supply resistance. Faulty needle electrode assembly. Power Supply is off. Fuse on inside of Power Supply is blown. Power line voltage is incorrect. Adjust spraying distance to 8 12 in. ( mm). Reduce air pressure. Check fluid resistivity with paint meter and probe (refer to Instruction Manual ). Check Power Supply resistance. See instruction manual included with power supply. Replace needle electrode assembly. Line Power Switch is OFF, should be turned ON. Replace fuse. Adjust for correct voltage. Low or no electrostatic wrap. (Spraying voltage light comes on, then goes off). Gun held too close to part being painted. Fluid is too conductive. Electrical short in the High Voltage Cable. Electrical short in gun. Faulty Power Supply. Increase distance between part and gun. Lower conductivity of fluid or adjust Time Delay Relay setting on Power Supply. See PS7500M Power Supply Manual Replace the High Voltage Cable. Take gun apart and visually check the resistor housing (40), resistor well and needle well in the gun barrel (36) for dirt and/or damage. Clean and replace parts as required. See instruction manual included with Power Supply. Continued on next page.

15 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Low or no electrostatic wrap. (Spraying voltage light does not come on). Low or no electrostatic wrap. (Spraying voltage light is on all the time). Spraying voltage stays on when gun trigger is released. Operator gets mild shock when touching work piece. Faulty Power Supply. Air flow switch is stuck or sluggish. Faulty resistor stud (71). Resistor (12) not making a good connection with contact inside of gun body. High Voltage Cable not making good contact with resistor (58a). Cable insulation punctured. Spring at transformer end of cable not making good contact. Electrical short in High Voltage Cable. Electrical short in gun. Faulty Power Supply. Air flow switch in Power Supply not working or sluggish return. Work piece not properly grounded. Operator not properly grounded or is in contact with ungrounded object. Gun not properly grounded. See instruction manual included with Power Supply. Replace or repair air flow switch. Replace the resistor stud. See Resistor Assembly Replace ment, in the Service Section. Replace conductive spring (58c) as required. Replace cable. Stretch spring. Replace the High Voltage Cable. Take gun apart and visually check the resistor housing (58b), resistor well and needle well in the gun barrel (36) for dirt and/or damage. Clean and replace parts as required. See instruction manual included with Power Supply. Check switch, replace if faulty. Clean work piece hangers. Check for proper ground on conveyor or track. Be sure floor is properly grounded. Wear shoes with non insulating soles. Be sure operator is not in contact with or carrying any metallic items which could build up electrical charge. If a glove is worn, modify it as shown on page 9. Be sure high voltage cable is undamaged and power supply is properly grounded. See Check the Electrical Grounding in the Installation Section.

16 SERVICE Gun Disassembly WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Follow the Pressure Relief Procedure, page 9, before servicing the gun or any part of the system. Disconnect the fluid hose from the gun. NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun. CAUTION If the plastic parts of the gun must be held securely, ALWAYS clamp them in padded vice jaws to prevent damage to the parts. ALWAYS lubricate o rings and seals with petroleum jelly. ALWAYS remove gun from worksite for service or repair. Service or repair area must be clean. Flush the gun as described under Flush the Spray Gun in the Operation Section. Follow the Pressure Relief Procedure Warning on page 9. Disconnect the air and fluid line from the gun. Disconnect the High Voltage Cable from the gun and cover the cable to prevent contamination. The High Voltage Cable can stay at the worksite when you service the gun. Electrode Replacement Remove the air cap (17) and fluid nozzle (19) as described in the Maintenance Section under Clean the Air Cap and Fluid Nozzle. Remove the electrode (56*) with the wrench (77d*) supplied. See Fig 5. Hold the needle shaft assembly (55) nut with a small wrench if the needle turns. Install the new electrode assembly with the wrench. Do not over tighten. CAUTION To avoid damaging the plastic threads, be very careful when installing the electrode. Install the air cap and fluid nozzle as described in the Maintenance Section under Clean the Air Cap and Fluid Nozzle. The barrel retaining ring (26) and the retaining nut (48) do not have to be removed. If they must be replaced, lift one end of the retaining ring out of its groove and spiral it off the end of the barrel. Then remove the retaining nut. Spiral the new retaining ring back over the barrel. 77d Wrench *77d NOTE: Parts included with a repair kit are marked with an asterisk, for example, (77d*). Fig 5

17 SERVICE Barrel Removal Remove the three nuts (81) and screws (80), then remove the shroud (79). See Fig 6. Disconnect the fluid hose nut (67) and collar (68) from the fitting (39). See Fig 7. Pull the tube (31) out of the fitting (39). NOTE: If the tube (31) needs to be replaced, be sure to wrap the new tube around the barrel (36) three times. Refer to Fig 6. Remove the trigger by removing the screws (33) and spacers (61) from the gun. 31 Fluid Tube 33 Screw 39 Adapter 48 Retaining Nut 61 Spacer 67 Fluid Hose Nut 68 Collar 77b Wrench 77b , 68 Loosen the retaining nut (48), using the wrench (77b) supplied. Hold the gun handle (57) with one hand and pull straight up to remove the gun barrel (36). See Fig 8. The barrel may slide off with heavy resistance. Pull the barrel straight up to avoid damaging the resistor housing (58b). 33, NOTE: The gasket (34) should be left in the gun handle if it is not being replaced. See the Parts Drawing on page 22 for the gasket location. Fig 7 79 Shroud 31 Fluid Tube 36 Gun Barrel 80 Screw 81 Nut 26 Retaining Ring 36 Gun Barrel 48 Retaining Nut 57 Gun Handle , Wrap around barrel 3 times 57 Fig 6 Fig 8

18 SERVICE Fluid Packing Removal Remove the electrode resistor as described in Electrode Replacement. Remove the barrel as described in Barrel Removal. Carefully remove the needle shaft assembly (55) from the rear of the barrel (36). See Fig 10. Remove the packing nut (27) at the rear of the barrel, using the wrench (77c) supplied. NOTE: The nut (55a) is secured with Loctite to the needle shaft assembly (55) and should not be removed. If the nut is removed, it will have to be reassembled to the needle shaft assembly with Loctite No. 271 to the proper dimension. See Fig 9 for the correct length. Slide the insulator (32) and support (23) off the needle shaft. Place barrel on a table top in a vertical position with the back of the barrel touching the table top. Insert the rod (77e), supplied, in the front of the barrel and gently tap out the needle packing (6*) and support (23). Check all the parts for wear or damage, replace them if necessary. CAUTION Use extreme care when handling the packing (6) because it is very brittle. You may want to keep extra packings on hand. 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. Fluid Packing Replacement Slide the packing nut (27) onto the fluid needle shaft (55). Then slide the insulator (32) onto the needle shaft. The holes in the one end of the insulator (32) must face toward the electrode end of the fluid needle shaft (55), as shown in Fig 10. Place the packing (6*) between the two supports (23), with the beveled side of the supports facing toward the packing. Slide the packing, with the supports, onto the fluid needle shaft (55). Place the spring (13) over the nut (55a). Slide the barrel over the resistor housing. With one hand, push the barrel up against the front part of the gun handle. Using the other hand, start and tighten the retaining nut (48). See Fig 11. Reassemble the needle electrode (56*), fluid nozzle (19) and air cap (17) as described in the Maintenance Section under Clean the Air Cap and Fluid Nozzle. 55 Needle Shaft Assy 55a Adjusting Nut Fig in. (44 mm + 1 ) in. (155.3 mm) 55a 6 Needle Packing 13 Spring 23 Support 27 Packing Nut 32 Insulator 36 Gun Barrel 55 Needle Shaft Assy 55a Nut Beveled Side Faces Packing (6) 55a Fig 10

19 SERVICE 48 Retaining Nut Slide the hook (50) forward and out of the gun channel. Pull the resistor housing (58b) up and forward to remove it from the gun handle (57) chamber. Remove the spring (11) from the end of the resistor. 48 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. Do not submerge the resistor in solvent. Check all parts for wear or damage, replace them if necessary. Place the new o rings (69, 10*) over the new resistor housing (58b) and lubricate them with petroleum jelly. Fig 11 Resistor Assembly Replacement Remove the trigger by removing the two screws (33) and spacers (61). See Fig 12. Remove the gun barrel as described in Barrel Removal. Remove the gasket (34) from the gun barrel (36) and replace if damaged. CAUTION All o rings and conductive springs must be in place or the gun will malfunction. Insert the resistor housing (58b) down through the top of the gun. Slide the hook (50) into place. Replace the barrel assembly by reversing the procedure described in Barrel Removal. 10 O Ring 11 Spring 33 Screws 50 Hook 57 Gun Handle 58 Resistor Assy. 58a Resistor 58b Resistor Housing 58c Spring 61 Spacers 69 O Ring 58b 58a 58c Spring inside resistor housing 57 Fig 12

20 SERVICE Fan Air Valve Replacement Place a wrench on the valve housing (42) flats and remove the housing from the handle. See Fig 13. Remove the retaining ring (14). Remove the air adjusting screw (41) from the valve housing (42), turning it counterclockwise. Clean all parts, inspect for wear or damage, and replace if necessary. Lubricate the o ring and the threads of the air adjusting screw (41) with petroleum jelly. Install the adjusting screw (41) into the valve housing (42), turning it clockwise, and secure it with the retaining ring (14). Back the adjusting screw out of the valve housing (42) until it bottoms out against the retaining ring (14). Air Valve Replacement Using a screwdriver, remove the retainer (29), spring (62), and air valve stem (59) from the gun handle. See Fig 14. Replace parts as needed and install them back into the gun handle. 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. Install the new packing (18*) and guide (30) into the front of the gun handle. Tighten the guide (30) into the gun handle. Squeeze the trigger and adjust it until there is no movement, then back it off until it moves freely. Apply Loctite pipe sealant to the threads of the housing (42). Install the housing (42) into the gun handle, torquing it to ft/lb (20 27 N.m). 14 Retaining Ring 41 Air Adjusting Screw Assy 42 Valve Housing 42 Apply Loctite Torque to ft/lb (20 27 N.m) Packing 29 Retainer 30 Guide 59 Air Valve Stem 62 Spring *18 30 Fig 14 Fig 13

21 SERVICE Resistor Stud or Contact Replacement WARNING Old/New Style Resistor Stud and Electrode To reduce the risk of sparking, which could cause fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and stud were white. DO NOT mix old style parts with new style parts. Remove the air cap (17) and fluid nozzle (19) as described in the Maintenance Section under Clean the Air Cap and Fluid Nozzle. Remove the electrode (56*) as described under Electrode Replacement. Using the tool (77g*) supplied, reinstall the resistor stud in the front of the gun barrel (36). Tighten until snug. Reinstall the electrode (56*) as described under Electrode Replacement. Reinstall the fluid nozzle (19) and air cap (17) as described in Clean the Air Cap and Fluid Nozzle. 9 O Ring 36 Gun Barrel 71 Resistor Stud 74 Washer 78 Contact Using the tool (77g*) supplied, unscrew and remove the resistor stud (71*) with the o ring (9*) and washer (74*). See Fig 15. To replace the contact (78*), push the contact out the front of the gun barrel (36) with the rod (77e) supplied. Press fit the contact into the gun body unti it bottoms out. *71 *74 *9 78* 36 To install the resistor stud: Lubricate the o ring (9*) with petroleum jelly and install it on the resistor stud (71*). Fig 15 Install the washer (74*) into the gun barrel.

22 PARTS DRAWING WARNING Old/New Style Resistor Stud and Electrode To reduce the risk of sparking, which could cause fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and stud were white. DO NOT mix old style parts with new style parts. Torque to in/lb N.m 58b 58a 58c Spring inside resistor housing Torque to ft/lb N.m Wrap around barrel 3 times * 70 55a Press fit into housing (36) Tool Kit Ref No. 77, Includes 77a 77g 77g 77b 77f 77e 77c 77d 77a

23 PARTS LIST Model AS4000M Electrostatic Metallic Air Spray Gun Part No , Series A Includes items 2 to 81 REF NO. PART NO. DESCRIPTION QTY PLUG, internal hex; 1/16 npt(f) PLUG, internal hex; 1/8 npt(f) RING, retaining 1 6* PACKING, needle, PTFE 1 9* O RING, Viton 2 10* O RING, Viton SPRING SPRING, compression RING, retaining 1 15* O RING, Viton AIR CAP (See Manual for available air caps) 1 18* PACKING, needle, PTFE FLUID NOZZLE (See Manual for available fluid nozzles) SUPPORT, packing RING, retaining NUT, packing, Delrin RETAINER GUIDE TUBE, fluid, PTFE INSULATOR SCREW GASKET, housing, fiber BARREL, gun CONNECTOR, cable ADAPTER, fluid AIR ADJUSTING SCREW HOUSING, valve BRACKET, tube ADAPTER, air TRIGGER NUT, retaining NUT, retaining HOOK INSULATOR, cable FLUID ADJUSTING SCREW NEEDLE SHAFT ASSY Includes item 55a 1 55a NUT, adjusting 1 HOW TO ORDER REPLACEMENT PARTS 1.To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below. 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. 3. Order all parts from your nearest Graco distributor. 6 digit Part Number Qty Part Description REF NO. PART NO. DESCRIPTION QTY ELECTRODE (color coded black) HANDLE RESISTOR ASSY Includes items 58a 58c 1 58a.RESISTOR 1 58b.HOUSING, resistor 1 58c SPRING, compression 1 59* AIR VALVE SPACER SPRING, compression NUT, lock PLUG, M3 x 0.5 x RETAINER, adapter SCREW, plug, M3 x 0.5 x NUT COLLAR O RING, Viton FITTING, male STUD, resistor (color coded black) NUT, ferrule 1 74* WASHER TAG, warning (not shown) COVER, gun (not shown KIT, tool Includes items 77a 77g 1 77a BRUSH, cleaning 1 77b WRENCH, barrel nut/nozzle 1 77c WRENCH, packing nut 1 77d WRENCH, needle 1 77e ROD, packing removal 1 77f WRENCH, resistor stud 1 77g TOOL, resistor stud CONTACT SHROUD SCREW, mach, NUT 3 *Included in Repair Kit See page 25. Included in Repair Kit See page 25. Read and follow the Old/ New Style Resistor Stud and Electrode Warning, on page 22. WARNING When servicing use only genuine Graco replacement parts. Use of other parts could alter the grounding continuity of the gun, which could cause fire and explosion and result in property damage and serious bodily injury.

24 ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. FILTER (AIR OR PAINT) psi (52 bar) MAXIMUM WORKING PRESSURE With 60 mesh (250 micron) element, 3/8 npt(f) inlet, 3/8 npt(m) outlet HIGH VOLUME AIR REGULATOR psi (0 9 bar) Regulated Pressure 200 psi (14 bar) Steel Pressure Gauge 1/2 npt(f) inlet and outlet BUNA N AIR HOSE ASSEMBLIES 180 psi (13 bar) MAXIMUM WORKING PRESSURE 0.25 in. (6.35 mm) ID, 1/4 npsm(fbe) ft (8 m) ft (15 m) ft (23 m) ft (30 m) ft (46 m) NYLON FLUID HOSE ASSEMBLIES 225 psi (15.75 bar) MAXIMUM WORKING PRESSURE 0.25 in. (6.35 mm) ID, 3/8 npsm(fbe) ft (8 m) ft (15 m) NYLON FLUID HOSE ASSEMBLIES 500 psi (35 bar) MAXIMUM WORKING PRESSURE 0.25 in. (6.35 mm) ID, 3/8 npsm(fbe) AIR FILTER & MOISTURE SEPARATOR 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 ft (8 m) ft (15 m) ft (23 m) ft (30 m) ft (46 m) 75 KV METALLIC POWER SUPPLY For use with Electrostatic Metallic Air Spray Gun. Not for use in Hazardous areas. HIGH VOLTAGE CABLES FOR 75 KV POWER SUPPLY NYLON AIR HOSE ASSEMBLIES 225 psi (15.75 bar) MAXIMUM WORKING PRESSURE 0.25 in. (6.35 mm) ID, 1/4 npsm(fbe) ft (8 m) ft (15 m) ft (23 m) ft (30 m) ft (46 m) ft (8 m) ft (15 m) ft (23 m) ft (30 m) ft (46 m) GUN, POWER SUPPLY AND HOSE KITS Each kit contains: Air Spray Gun , 75 KV Power Supply , and a length of buna N Air Hose with fittings. The air hose lengths vary by part number, as indicated below ft (8 m) ft (15 m) ft (23 m) ft (30 m) ft (46 m)

25 ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. REMOTE SWITCH & SIGNAL LIGHT PAINT RESISTANCE METER Used with Paint Probe to measure resistance of paint. Not for use in Hazardous areas. PAINT PROBE Used with Paint Resistance Meter to measure resistance of paint. Not for use in Hazardous areas. SAFETY WARNING SIGNS English Spanish French German REPAIR KITS Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. NOTE: The Ref. No. shown in the kits below correspond to the reference numbers used in the parts lists on page 23. For the best results, use all the parts in the kit, even if the old parts still look good. Gun Repair Kit Includes: Ref No. Part No. Description Qty PACKING, needle, PTFE O RING, Viton O RING, Viton O RING, Viton PACKING, needle, PTFE AIR VALVE ASSY WASHER 1 Resistor Stud and Electrode Kit Includes: Ref No. Part No. Description Qty O RING, Viton ELECTRODE (color coded black) STUD, resistor (color coded black) WASHER 1 77d WRENCH, needle 1 77g TOOL, resistor stud CONTACT 1

26 SERVICE INFORMATION Listed below by the assembly changed are OLD and NEW parts. Assembly Ref Changed Status No. Part No. Name OLD Cover Air Spray NEW Cover Gun OLD Wrench NEW 77d Wrench INTERCHANGEABILITY NOTE: NEW parts replace the OLD parts listed directly above them. ACCESSORIES NOTE: Added Gun, Power Supply and Hose Kits through

27

28 Weight lb (0.89 Kg) Gun Length in. (30 cm) Maximum Working Pressure psi (7 bar) Air Pressure Operating Range psi (0 7 bar) Fluid Pressure Operating Range psi (0 7 bar) Voltage Operating Range KV Paint Resistivity Range Megohm cms to infinity High Voltage Connector M18 x 1.5(m) Air Inlet /4 npsm(m) TECHNICAL DATA Fluid Inlet /8 npsm(m) Wetted Parts Stainless Steel, Polyolefin, Nylon, Acetal, Viton, Delrin, PTFE Viton, Delrin, and PTFE are registered trademarks Loctite is a registered trademark of the Loctite Corporation. WARRANTY THE GRACO WARRANTY AND DISCLAIMERS Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective. 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 installation, 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 materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Graco to verify the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation. DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NON CONTRAC- TUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACO S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO (2) YEARS OF THE DATE OF SALE. EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.) Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN PRINTED IN U.S.A Revised 4 89