Page 3 - Warning Symbol; WARNING; Caution Symbol; CAUTION
308131 3 Table of Contents Symbols 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Sy...
Page 4 - FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD; TOXIC FLUID HAZARD
4 308131 WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition andresult in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the...
Page 5 - PRESSURIZED EQUIPMENT HAZARD; EQUIPMENT MISUSE HAZARD
308131 5 WARNING PRESSURIZED EQUIPMENT HAZARD Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skinand cause serious injury. Do not point the spray gun at anyone or any part of the body. Do not stop or deflect fluid leaks with your hand, body, glove, or r...
Page 6 - Installation; Hazardous Area
6 308131 Installation 0389 Non-Hazardous Area Hazardous Area KEY A Main Air Supply Line B* Ventilation Fan Interlock Solenoid ValveC* Main Air Supply Shutoff Valve (bleed-type)D Air & Water Separator E* Pump Air Supply Shutoff Valve (bleed-type) F Air Line Lubricator G Air Pressure Regulator H P...
Page 7 - Installing the System; Warning Signs; Connect the Air Line
308131 7 Installation Installing the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause electric shock or other seriousinjury if work is not performed properly. Do not install or service this equip-ment unless you a...
Page 8 - Connect the Exhaust Tube; Ground the System
8 308131 Installation Connect the Exhaust Tube Press the exhaust tube (provided) onto the barbedadapter on the bottom of the gun handle. Secure thetube with the clamp provided. Refer to page 34. Connect the Fluid Line (Refer to Fig. 1, page 6) 1. Before connecting the fluid line (N), blow it out wit...
Page 9 - Check the Electrical Grounding
308131 9 Installation Check the Electrical Grounding (See Fig. 2) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDMegohmmeter P/N 241079 (AA-see Fig.2) is not approved for use in a hazard-ous area. To reduce the risk of sparking,do not use the megohmmeter to checkelectrical grounding unless: The g...
Page 10 - Notes
Page 11 - Operation; Pressure Relief Procedure; Filter the Fluid
308131 11 Operation Pressure Relief Procedure WARNING PRESSURIZED EQUIPMENT HAZARDThe system pressure must be manually relieved toprevent the system from starting or spraying acci-dentally. To reduce the risk of an injury from electricshock, accidental spray from the gun, splashingfluid, or moving p...
Page 12 - Selecting a Fluid Nozzle and Air Cap; Operating the Spray Gun
12 308131 Operation 0369A Fig. 4 0365 20 1 26 45 43g 31 DD 43c Selecting a Fluid Nozzle and Air Cap WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 11 before removing orinstalling a fluid nozzle and/or air cap. The gun is supplied with...
Page 14 - Shutdown; Maintenance; Daily Care and Cleaning
14 308131 Operation Shutdown WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 11 whenever you stopspraying and whenever you are instructed torelieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc...
Page 15 - Clean the Air Cap and Fluid Nozzle; Flush the Spray Gun
308131 15 Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spraytip holes as this could scratch them, and make surethe electrode wire is not damaged. Scratches in theair cap or spray tip or a damaged electrode wire candistort the spray pattern. Eq...
Page 16 - Troubleshooting; Spray Pattern Troubleshooting
16 308131 Troubleshooting WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause an electric shock or other serious injury if the work is not performed properly. Do notinstall or service this equipment unless you aretrained and qualified. WARNING ...
Page 17 - Gun Operation Troubleshooting
308131 17 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packingarea The needle packings or shaft are worn. Replace the packings or shaft; see page26. Air leakage from the front of the gun The air valve is not seating properly. Clean and service the...
Page 18 - Electrical Troubleshooting
18 308131 Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap-around The ES ON-OFF lever is in the OFF (O)position.* Turn the lever to ON (1). The distance between the gun and work-piece is incorrect. Adjust the spraying distance to 8 to 12 inches(203 to 305 mm) The parts are...
Page 19 - Electrical Troubleshooting with SVR
308131 19 Troubleshooting Electrical Troubleshooting with SVR NOTE: Additional gun troubleshooting can be done using the Remote Spraying Voltage Readout (SVR ). See Accessories to order the SVR and the RF transmitting power supply. Problem Cause Solution Lower than normal voltage output Insufficient...
Page 20 - Electrical Tests; Test Gun Resistance
20 308131 Electrical Tests The performance and safety of the spray gun aredirectly affected by the condition of the electricalcomponents contained inside the gun. The electricaltests below can be used to determine the condition ofthe power supply (18) and the resistor stud (22) as wellas the continu...
Page 21 - Test Power Supply Resistance; Test Resistor Stud Resistance
308131 21 Electrical Tests Test Power Supply Resistance (See Fig. 9) Remove the power supply (18) from the gun. SeePower Supply Removal and Replacement, page 27. Remove the turbine alternator from the power supply.See Turbine Alternator Removal and Replacement,page 28. Measure the resistance from th...
Page 22 - Service; Prepare the Gun for Service
22 308131 Service Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts that may causeelectric shock or other serious injury if the work is not performed properly. Do not install orservice this equipment unless you are trained andqua...
Page 23 - Electrode Needle Replacement
308131 23 Service Air Cap/Nozzle/Resistor Stud Replacement(continued) 6. Trigger the gun while installing the fluid nozzle (21)and resistor stud (22) assembly with the multi-tool(62). Tighten until the fluid nozzle seats in the gunbarrel (1/8 to 1/4 turn past hand tight). 7. Install air cap assembly...
Page 24 - Barrel Removal
24 308131 Service Barrel Removal 1. Prepare the gun for service as instructed on page22. 2. Carefully loosen the nut (14) from the bracket/fluidfitting (16). Pull the tube (12) out of the fitting.Make sure both ferrules and the nut stay with thetube. See Fig. 14. 3. Using the wrench (63) supplied, l...
Page 25 - Fluid Packing Removal
308131 25 Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page22. 2. Remove the air cap assembly, fluid nozzle andresistor stud and electrode as instructed on page23. 3. Loosen the trigger screws (4) far enough to re-move the trigger (13). 4. Remove the needle assembly ...
Page 26 - Fluid Packing Rod Repair
26 308131 Service Fluid Packing Rod Repair The fluid packing rod can be replaced as individualparts or as an assembly. The overall assembly ispre-adjusted at the factory. NOTE: Before installing the fluid packing rod into thegun barrel, make sure the internal surfaces of thebarrel are clean. Remove ...
Page 27 - Power Supply Removal and Replacement; Power Supply Adjustment
308131 27 Service Fig. 18 7 35 37a 37b 18a 18 37 F 3 18b 18c 18f G Apply a very light coat of lubricant Do not expose to solvents 0384B B Power Supply Removal and Replacement NOTES: To avoid a loss in electrostatic performance, inspectthe gun handle power supply cavity for dirt or mois-ture. Clean t...
Page 28 - Barrel Installation
28 308131 Service Turbine Alternator Removal and Replacement NOTE: Replace turbine bearings after 2000 hours ofoperation. See your authorized Graco representative. 1. Prepare the gun for service as instructed on page22. 2. Remove the power supply from the gun handle asinstructed on page 27. 3. Squee...
Page 29 - Fan Air Adjustment Valve Repair
308131 29 Service Fan Air Adjustment Valve Repair 1. Prepare the gun for service as instructed on page22. 2. Place a wrench on the flats of the valve housingand remove it from the handle. See Fig. 20. NOTE: The fan air valve (43) can be replaced as anassembly or as individual parts. To disassemble t...
Page 30 - Fluid Adjustment Assembly Repair
30 308131 Service Fluid Adjustment Assembly Repair 1. Prepare the gun for service as instructed on page22. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45). See Fig. 21. 3. Turn the stem (45a) fully clockwise and removethe sleeve stop (45e). 4. To completely disassemble the f...
Page 31 - Air Trigger Valve Repair
308131 31 Service Air Trigger Valve Repair 1. Prepare the gun for service as instructed on page22. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45), o-ring (23) and spring(44). See Fig. 21. CAUTION Clean all parts in non-conductive solvent compatiblewith the fluid being used,...
Page 32 - ES ON-OFF Valve Repair
32 308131 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page22. 2. Loosen the set screw (24) with the 2 mm hex key(69) provided. Remove the lever (26) from thevalve. See Fig. 23. WARNING MOVING PARTS HAZARDTo reduce the risk of eye injury, be sureto wear safety glass...
Page 34 - Parts; DETAIL A
34 308131 Parts 28c 28a *28d *28e *28h DETAIL A 1, 75 8 2 22 21 *25 See Detail A 28b 20 43b 43d 43f 43c 43e 43h 43g 5 3 34 18a 18b 18c 18f 35 37b 37a REF. 12 14 9* 66 67 17 16 33 19 15 41 39 44 45c 46 38 36 47 32 26 24 30 REF.40 42 10 29* 12 45d 45b 45a 6 4 13 31 19 7 23 49 0601 *28f *28g 45e 12 16 ...
Page 36 - Accessories; AIR LINE ACCESSORIES
36 308131 Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID;1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 6 ft (1.8 m) 218100 15 ft (5 m) 218101 25 ft (8 m) 218102 36 ft (11 m) 2...
Page 37 - FLUID LINE ACCESSORIES
308131 37 Accessories FLUID LINE ACCESSORIES Fluid Hose Assemblies (Nylon)225 psi (14 bar, 1.4 MPa) Maximum Working Pressure FM Approved; 1/4 in. (6.35 mm) ID, 3/8 npsm(fbe) 215637 25 ft (8 m) 215638 50 ft (15 m) Fluid Hose Assemblies (Nylon)500 psi (35 bar, 3.5 MPa) Maximum Working Pressure FM Appr...
Page 38 - GUN SYSTEMS
38 308131 Accessories GUN SYSTEMS Gun System 224637 With 36 ft (11 m) conductive air hose. Includes: Part No. Description Qty 224200 PRO 4500sc ES Spray Gun 1 223071 Conductive Air Hose, 36 ft (11 m) 1 206199 Air Regulator with Gauge 1 106149 Air Filter 1 158491 Hex Nipple 1 158212 Bushing 1 164672 ...
Page 39 - Technical Data; Manual Change Summary
308131 39 Technical Data Category Data Gun Weight 34.3 oz (974 g) Gun Length 11.1 in (283 mm) Maximum WorkingPressure 100 psi (7 bar, 0.7 MPa) Air PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Fluid PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Voltage Output 0–85 kV Short Circuit ...
