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INSTRUCTIONS–PARTS LIST
308–084
Rev. H
This manual contains IMPORTANT
Supersedes G
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
Model PRO 4600SC
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 , Group D paint spray materials
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1991 GRACO INC.
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Table of Contents
Troubleshooting
Related Manuals for Graco PRO 224-094
Summary of Contents for Graco PRO 224-094
- Page 1 INSTRUCTIONS–PARTS LIST 308–084 Rev. H This manual contains IMPORTANT Supersedes G WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Model PRO 4600SC 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;...
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Page 2: Warnings
SERIOUS BODILY INJUR Y, EXPLOSION, FIRE, OR ELECTROST ATIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, T AGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULL Y CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL. - Page 3 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: All parts of the electrostatic system are properly grounded. All personnel in or close to the spray area are properly grounded.
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Page 4: Table Of Contents
Warnings ........Terms ........Installation Typical Installation . -
Page 5: Typical Installation
Non-Hazardous Area Controls Cabinet Shut-off device for fluid only Atom Air Lines operation Air Regulator Bleed valve or 3 way solenoid Cylinder Air Line True Earth Ground Fig 1 Controls Cabinet 24V Power Supply Fiber Optic Cable P/N 235–301 P/N 224–680/–686 ES Display Module P/N 224–117 Air Pressure... -
Page 6: Ventilate The Spray Booth
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. 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 elec- trical apparatus in a Class , Group D Hazardous Location. - Page 7 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- Spray Gun Shroud Air Cap/Air Cap Nut Fig 5 Connect 4’...
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Page 8: Check The Electrical Grounding
Check the Electrical Grounding (See Fig 7 ) WARNING Proper electrical grounding of every part of your system is essential. For your safety warning section, FIRE, EXPLOSION, ELECTROSTATIC SHOCK HAZARD , on page 3. Ground the system as explained there. Then check your system as explained below. -
Page 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 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. -
Page 10: Adjusting The Turbine Air Pressure
Adjusting the Turbine Air Pressure 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. -
Page 11: Clean The Air Cap And Fluid Nozzle
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. -
Page 12: Check For Fluid Leakage
Check for Fluid Leakage (See Fig 10 ) WARNING 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. 0437 MAINTENANCE During operation, periodically check the two manifold ex-... -
Page 13: Spray Pattern Troubleshooting Chart
SPRAY PATTERN TROUBLESHOOTING CHART 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. -
Page 14: Gun Operation Troubleshooting Chart
GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE Leakage from fluid Worn fluid rod packings or fluid rod packing area Fluid leakage from front Fluid rod worn or damaged of gun Worn fluid seat Piston seal or o-ring damaged Loose resistor stud Loose fluid nozzle Damaged resistor stud o-ring “Orange Peel”... -
Page 15: Electrical Troubleshooting Chart
ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE Poor wrap-around Improper distance between gun and workpiece Parts poorly grounded High booth exhaust velocity Atomizing air pressure too high Fluid pressure too high Improper fluid viscosity Fluid resistivity too low No or low voltage output Turbine alternator not operating Faulty gun resistance Fluid leaks from fluid rod packing... -
Page 16: Electrical Tests
The performance of the spray gun is directly affected by 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. -
Page 17: Test Resistor Stud Resistance
Test Resistor Stud Resistance (See Fig 13 ) 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. -
Page 18: Service
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 equipment unless you are trained and qualified. NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun. -
Page 19: Air Cap/Nozzle/Resistor Stud Replacement
Air Cap/Nozzle/Resistor Stud Replacement CAUTION 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. 1. -
Page 20: Electrode Replacement
Electrode Replacement 1. Remove the air cap, nozzle and resistor stud as described in Air Cap/Nozzle/Resistor 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 . If the fluid rod turns, hold the back end of the fluid rod. -
Page 21: Barrel Removal
Barrel Removal 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. -
Page 22: Barrel Installation
Barrel Installation 1. Be sure the gaskets (23 & 40a) and spring (11) are in place. See Fig 20 . Replace if damaged. 2. Place the barrel (10) over the power supply (40) and onto the gun body (39). Make sure the fluid rod spring (11) is seated properly. -
Page 23: Fluid Packing Rod Removal And Repair
Fluid Packing Rod Removal and Repair 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. -
Page 24: Fluid Packing Rod Removal And Repair
Fluid Packing Rod Removal and Repair (continued) 8. Place the fluid packing (3f), rod packing (3e), and housing (3a) on the fluid rod (3b) as shown in Fig 22 . 9. Lightly tighten the packing nut (3c). The packing nut is properly tightened when there is 2 lbs. -
Page 25: Power Supply Removal And Replacement
3-wire Connector Potentiometer Gun Barrel Retainer Ring Alternator 27a O-Ring 27b Cushion Gun Body Power Supply 40a Gasket 40b Pad 40c Pad 40d Seal 40e Cushion Fig 23 Power Supply Removal and Replacement REPAIR NOTES: a. To avoid a loss in electrostatic performance, inspect the gun handle’s power supply cavity for dirt or moisture. -
Page 26: Service Notes
Tighten Nozzle 1/8 to 1/4 turn past hand tight Lubricate CAUTION: DO NOT over tighten Capscrews. Tighten to 18 in-lbs (2 N m) MAXIMUM (about half turn past snug), us- ing wrench provided. Fits between flared tube and fitting Stretch o-ring to start it over fitting threads, then thread it into place... - Page 27 MANIFOLD SERVICE NOTES Concave side toward manifold Left-hand Apply low strength threads (purple) Loctite or equivalent Torque to 25 in-lb (2.8 N m) Torque to 25 in-lb (2.8 N m) Apply low strength (purple) Loctite or equivalent Lubricate Press fit Lubricate Must be clean...
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Page 28: Gun Parts Drawing
SPRAY GUN PARTS DRAWING DETAIL A REF NO. 3 Includes items 3a–3h 0601 36 30 REF 3 REF 19 See Detail A 0433... -
Page 29: Gun Parts List
Part No. 224–224 Automatic Electrostatic Air Spray Gun, without shroud Includes items 1–17, 19–52 Part No. 235–893, Series A Air Spray Gun, with standard shroud Includes items 1–52 PART NO. DESCRIPTION 186–762 PISTON, valve 223–977 STUD, resistor 224–747 PACKING ROD ASSY Includes items 3a–3h 185–495 HOUSING, packing... -
Page 30: Manifold Parts Drawing & List
117f 117e 117g 117b 117h 117c 117d Part No. 224–094 Gun Manifold Includes items 101–124 PART NO. DESCRIPTION 111–224 LENSE 103* 106–167 O-RING; perfluoroelastomer 110–078 FITTING, tube; for 3/8” OD tube 186–846 BOLT, manifold; M5 x 0.8 186–820 MANIFOLD 183–822 SLEEVE, o-ring 105–668 O-RING;... -
Page 31: Pro 4600Hc Conversion Kit
PRO 4600HC CONVERSION KIT Part No. 237–301 PRO 4600HC Conversion Kit; To convert the PRO 4600SC 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. -
Page 32: Accessories
Use only GENUINE GRACO PARTS AND ACCESSORIES. AIR AND FLUID LINE ACCESSORIES Air Pilot Paint Regulator 224–531 For controlling paint flow through the spray gun. Connects to mount assembly 235–094. Grounded Air Supply Hose 100 psi (7 bar) MAXIMUM WORKING PRESSURE 0.315 in. - Page 33 Use only GENUINE GRACO PARTS AND ACCESSORIES. GUN MOUNTING ACCESSORIES 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. Gun Mount Assembly 224–118 For mounting the PRO4600 gun to the GMF P150 robot.
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Page 34: Miscellaneous Accessories
Use only GENUINE GRACO PARTS AND ACCESSORIES. CABLE ACCESSORIES Fiber Optic Cables Fiber Optic Cable Assembly For connection between gun manifold and module or between bulkhead connector and display module. PART NO. LENGTH 224–680 6 ft (1.8 m) 224–681 15 ft (5 m) 224–682 25 ft (8 m) 224–683... -
Page 35: Technical Data
Safety Warning Signs Available at no charge from Graco. Must be ordered separately. PAR T NO. DESCRIPTION 180–060 Warning Sign (English) 180–061 Warning Sign (French) 180–062 Warning Sign (German) 180–063 Warning Sign (Spanish) Paint Resistance Meter 722–886 Used with 722–860 Paint Probe to measure resistance of paint. -
Page 36: Warranty
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.