INSTRUCTIONS–PARTS LIST 307–712 Rev P This manual contains IMPORTANT WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Model PRO 5000 AUTOMATIC MID-RANGE ELECTROSTATIC AIR SPRAY GUN 7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE Part Number 218–745, Series B With 1.2 mm (0.047 in.) spray nozzle and part no. 218–996 air cap assembly U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774; 4,554,622 U.K. Patent No.
TABLE OF CONTENTS Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 How The Electrostatic Air Spray Gun Works . . . . 5 Installation Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . . Mount the Gun . . . . . . . . .
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.
FIRE OR EXPLOSION HAZARD To reduce the risk of fire, explosion, or electric shock, which may result from electrical discharge, it is essential that: S S S All parts of the electrostatic system are properly grounded. All personnel in or close to the spray area are properly grounded. All electrically conductive objects or devices in the spray area, including paint containers, wash cans and tools, are properly grounded.
TYPICAL INSTALLATION A B Power Supply Must Be Interlocked With Spray Booth Exhaust Fan. Electric Box K Main Air Line P E Fluid Line J Cyl. Air E A Atom. Air WARNING SIGN Turbine Air Opt.
INSTALLATION Mount the Gun Mount the gun on a stationary support or on a reciprocating arm. The mounting rod must be properly grounded. Mount the gun so the front of the gun is 254 to 300 mm (10 to 12 in.) from the work piece. Connect the Air Line (Refer to the Typical Installation Drawing) WARNING To reduce the risk of electric shock or other serious bodily injury, the air supply hose must be electrically connected to a true earth ground. Use Only Graco Electrically Conductive Air Supply Hose.
INSTALLATION Check the Electrical Grounding 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. KEY Y Z AA BB Turbine Air Inlet True Earth Ground Ohmmeter Grounded Air Hose AA Z 1. Shut off all air lines to the gun. 2. Shut off the fluid supply to the gun. 3.
OPERATION WARNING Pressure Relief Procedure 2. To reduce the risk of serious bodily injury, including 3. 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 serv4. icing any part of the spray system, when installing, 5. cleaning or changing fluid nozzles, and whenever you stop spraying. 1. Turn off all the air to the gun except the cylinder (actuating) air. Turn off the fluid supply to the gun.
OPERATION Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow. DO NOT turn the turbine air on yet. 1. Adjust the fluid flow for the appropriate flow rate by using the fluid pressure regulator installed in the fluid line. Check the fluid nozzle chart in manual 307–803 for the appropriate flow rate for the air cap. Start with the lowest rate shown and increase it until you get the desired flow rate. NOTE: Provide a 3.
MAINTENANCE Daily Care and Cleaning CAUTION Clean all parts with a non–conductive solvent, compatible with the fluid being sprayed. Conductive solvents can cause the gun to malfunction. Do not use any cleaning method which may allow solvent into the gun air passages. Solvent left in the gun passages could result in a poor quality paint finish and may draw current and reduce the electrostatic effect. Point the gun down while cleaning to prevent dirty solvent from running back into the air passages.
MAINTENANCE To Clean or Change Air Cap and Fluid Nozzle 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. KEY 15 BB 81 Fluid Nozzle Air Cap Assembly Locking Pin BB DETAIL DETAIL Equipment needed: Soft bristle brush (supplied). Fluid nozzle wrench (supplied). Solvent compatible with fluid being sprayed.
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.
GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid pack- Worn needle packing. ing nut. Replace packing assembly. See page 20. Air leakage from front of gun. Air valve not seating properly. Clean, service. See page 24. Air stem packing too tight. Loosen packing. See page 24. Fluid leakage from front of gun. Electrode worn or damaged. Replace electrode. See page 18. Worn fluid seat. Replace fluid nozzle and/or electrode. See page 18. Fluid packing too tight.
ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Poor wrap–around. *Turbine alternator not operating. Check air supply to turbine. Check for dirt or moisture in turbine. See page 23. Improper distance between gun and workpiece. Adjust spraying distance to 203–305 mm (8–12 in.). Parts poorly grounded. Clean hangers, check for proper ground on conveyer or track. High booth exhaust velocity. Reduce within code limits. Atomizing air pressure too high. Reduce air pressure.
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 (5) and the resistor stud (17) as well as the continuity of the electrical path between the components.
ELECTRICAL TESTS Test Resistor Stud Resistance Insert a conductive rod (FF) into the gun barrel (removed for the power supply test) and against the metal contact (GG) in the front of the barrel. See Fig 9. KEY A FF GG 14 20 Megohmmeter Conductive Rod Metal Contact Electrode Gun Barrel A Measure the resistance between the conductive rod (FF) and the gun electrode (14). The resistance should be 20 to 30 megohms.
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. 2. Unscrew and remove the electrode (14) with the wrench (66c) supplied. See Fig 10. If the needle shaft assembly (9) turns while trying to loosen the electrode, hold the needle shaft assembly nut with a small wrench. 3.
SERVICE Resistor Stud 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 in the Series A Guns were white. DO NOT mix old style parts with new style parts. 1. Remove the air cap assembly and fluid nozzle as described in To Clean or Change Air Cap and Fluid Nozzle. 3.
SERVICE Barrel Removal 1. Unscrew the nut (34) at the gun’s fluid inlet adapter (35). See the PARTS DRAWING. KEY 31 52 66f Fluid Tube Cap Screw Wrench 2. Pull the fluid tube (31) out of the fluid adapter (35). 3. Remove the trigger by removing the screws and spacers from the gun. 66f 4. Remove the ES indicator lights from the socket head cap screws (52). 31 52 5. Using the wrench (66f) supplied, loosen and remove the two socket head cap screws (52) from the gun. See Fig 12. 6.
SERVICE !1%&4,,8 1%-/5% 3(% &,4)$ .%%$,% !22%-",8 &1/3(% 1%!1 0!13 /& 3(% '4. "!11%, %% )' & 3(% 0!#+).' !22%-",8 ! /1 ).24,!3/1 ' !1% 23),, ). 3(% "!11%, ).2%13 3(% 0!#+).' 1%-/5!, 1/$ $ ).3/ 3(% &1/.3 /& 3(% "!11%, 3/ '%.3,8 042( 3(%- /43 %&%1 3/ )' NOTE: & 3(% ).24,!3/1 ' )2 1%-/5%$ "% 241% 3/ ).23!,, )3 2/ 3(% ).24,!3/1 %.$ 6)3( (/,%2 )2 &!#).' 3(% 0!#+).' !22%-",8 ! .23!,, 3(% !)1 #!0 !22%-",8 !.$ &,4)$ ./99,% !2 $%2#1)"%$ ).
SERVICE KEY 1 2a 2b 2c 5 5a 5b 5c 6 20 2, -"5 *1#/, 1-/ ',% *2% -4#/ 2..*5 ',% ',% ./',% 0)#1 //#* ! ## NOTE $1#/ 01#. #*-4 NOTE: &# .-4#/ ! /1/'"%# ',!*2"#0 '1#+0 ! ," ! Fig 17 Power Cartridge Replacement #+-3# 1&# Removal //#* 0 "#0!/' #" 2,"#/ Barrel #+-3# 1&# % 0)#1 $/-+ 1&# %2, -"5 ## '% CAUTION &# .-4#/ ! /1/'"%# '0 $/ %'*# # ! /#$2* 4&#, & ,"*',% '1 1- 3-'" " + %# / 0. 1&# .
SERVICE Turbine Alternator Removal Fan Air Valve Replacement &.07& 108&3 $"353*%(& '30. 5)& (6/ #0%9 "4 %&4$3*#&% 6/%&3 Power Cartridge Replacement -"$& " 83&/$) 0/ 5)& '-"54 0' 5)& 7"-7& )064*/( "/% 3&.07& *5 '30. 5)& (6/ #0%9 && *( "3&'6--9 58*45 5)& 563#*/& "-5&3/"503 " "/% 16-- *5 0'' 5)& 108&3 4611-9 6/5*+645 %*4&/("(&% '30. 5)& $061-*/( )&/ $0/5*/6& 50 4-08-9 16-- 5)& 563#*/& "-5&3/"503 "8"9 '30.
SERVICE Piston Removal and Repair 8. Install the new packing (27) and guide (26) in the gun body (1); screw the guide in loosely. 1. To disconnect the fluid hose (31) from the cover plate (41), screw the nut (34) off the adapter (35). See Fig 21. NOTE: DO NOT fully tighten the guide (26) yet. The guide must be loose to avoid damaging the packing (27) when pushing the piston shaft through the guide. 2.
SERVICE Disc Regulator OĆRing Replacement 04%3'8 5*' 563$+0' #+3 .+0' (31/ 5*' #'3 '' +) '/17' 5*' %#2 4%3'8 #0& 8#4*'3 (31/ 5*' )60 $1&9 KEY 1 3 85 86 60 1&9 ')6.#513 +4 +0) '3 : +0) +3 !#.7' "#4*'3 #2 %3'8 6.. 5*' #'3 8+5* 5*' #+3 7#.7' 165 1( 5*' )60 $1&9 87 88 89 90 04%3'8 5*' #'3 (31/ 5*' #+3 7#.7' #0& 3'/17' 5*' &+4- 3')6.#513 .'#0 #0& +042'%5 2#354 (13 8'#3 13 &#/#)' #0& 3'2.
16b 5c 20b 5b 16c Includes items 2a–2c & 5 16a Ref No.
PARTS LIST REF NO. PART NO. DESCRIPTION 1 2 218–744 218–111 2a 217–591 2b* 2c 3* 4 5 107–106 180–070 107–107 110–916 218–041 5a* 5b* 5c 6* 9 177–156 106–555 178–504 179–387 222–256 9a 9b 9c 9d 9e 9f 9g 11** 12 14 15 222–255 222–013 183–749 183–750 176–936 105–673 179–388 179–790 181–825 181–824 181–299 16 218–996 16a 16b 16c 176–930 176–968 180–739 17 220–923 105–667 1 BODY, gun POWER CARTRIDGE Includes items 2a & 5 1 .ALTERNATOR, turbine Includes items 2b & 2c 1 ..O–RING; buna–N 2 ..
KITS Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING When servicing use only genuine Graco replacement parts. Use of other parts or any alteration or modification of this equipment could result in serious injury, fire, explosion, or property damage. NOTE: The Ref. Nos. shown in the kits below correspond to the reference numbers used in the parts list on page 27. For the best results, use all the parts in the kit, even if the old parts still look good.
TECHNICAL DATA SERVICE INFORMATION Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.87 Kg (1.90 lb) Gun Length . . . . . . . . . . . . . . . . . . . . . 310 mm (12.25 in.) Maximum Working Pressure . . . . . . . . . . 7 bar (100 psi) Air Pressure Operating Range . . . 0–7 bar (0–100 psi) Fluid Pressure Operating Range . 0–7 bar (0–100 psi) Voltage Operating Range . . . . . . . . . . . . . . . . . . 0–75 KV Paint Resistivity Range . . . . 7 megohm cms to infinity Air Inlet Turbine . . . . . .
ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system. Lower rated components may not be able to withstand the pressure developed by the pump and may rupture, causing serious bodily injury or property damage. The accessories in the box, below, are approved by Factory Mutual. WARNING SIGNS Available from Graco at no extra charge.
ACCESSORIES FILTER (AIR OR PAINT) 202–271 52 bar (750 psi)MAXIMUM WORKING PRESSURE With 250 micron (60 mesh) element, 3/8 npt(f) inlet, 3/8 npt(m) outlet GUN MOUNTING ACCESSORIES UNIVERSAL GUN MOUNTING ROD 590–236 RECIPROCATING GUN MNTG. BRACKET 725–973 Note: All safety barriers and interlocks are to be supplied by the customer.
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 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.
