Graco PRO AA4000 User manual

INSTRUCTIONS–P ARTS LIST 307–706
Rev. R
Supersedes P
This manual contains IMPORT ANT
W
ARNINGS AND INSTRUCTIONS
READ AND RET AIN FOR REFERENCE
Part Number 218–668, Series B
With 0.279 mm (0.01 1 in.) spray tip, part no. 219–41 1
U.S. Patent No. 4,290,091; 4,219,865;4,386,739; 3,843,052;
4,462,061; 4,497,447; 4,554,622
U.K. Patent No. 2,140,327B; 2,1 1 1,406B; 2,142,559B; 2,147,158
Patented 1986, 1987 Canada
Brevete 1986, 1987
French Patent No. 82 21202; 84 07942; 84 10234
Italian Patent No. 1,1 11,380
W
est German Patent No. DE 22 09 896
Model PRO AA4000 
MANUAL MID-RANGE ELECTROST ATIC
AIR-ASSISTED AIRLESS SPRAY GUN
66 bar (950 psi) MAXIMUM WORKING FLUID PRESSURE
7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1984, GRACO INC.

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TABLE OF CONTENTS
Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How The Electrostatic Air-Assisted Airless
Spray Gun W orks 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety W arnings 4, 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
Typical
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Signs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilate the Spray Booth 7. . . . . . . . . . . . . . . . . . . . . . .
Connect the Air Line 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Electrical Grounding 7. . . . . . . . . . . . . . . . . .
Connect the Fluid Line 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Operation
Filter
the Fluid 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spraying Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Spray T ip and Air Cap 9. . . . . . . . . . . . . . . . .
Adjust the Spray Pattern 9. . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Daily Care and Cleaning 10. . . . . . . . . . . . . . . . . . . . . . .
Flush the Spray Gun 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Pattern T roubleshooting Chart 11. . . . . . . . . .
Gun Operation Troubleshooting Chart 12. . . . . . . . .
Electrical Troubleshooting Chart 13. . . . . . . . . . . . . .
Electrical Tests
T
est Gun Resistance 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Power Supply Resistance 14. . . . . . . . . . . . . . . . . .
Test Resistor Stud Resistance 15. . . . . . . . . . . . . . . . . .
Service
Gun
Disassembly 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Wire Replacement 16. . . . . . . . . . . . . . . . . . . .
Ball Seat Housing & Resistor Replacement 16. . . . . . .
Barrel Removal 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Reassembly 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Needle Replacement 18. . . . . . . . . . . . . . . . . . . . .
Check the Gun Safety Latch 18. . . . . . . . . . . . . . . . . . . .
Power Cartridge Replacement 19. . . . . . . . . . . . . . . . . .
Turbine Alternator Removal 20. . . . . . . . . . . . . . . . . . . . .
Fan Air V alve Replacement 21. . . . . . . . . . . . . . . . . . . . .
Air V alve Replacement 21. . . . . . . . . . . . . . . . . . . . . . . . .
ES ON-OFF V alve Removal and Repair 22. . . . . . . . . .
Muffler, Check V alve & Inlet Filter Replacement 22. . .
Repair Kits 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 26–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 29. . . . . . . . . . . . . . . . . . . . . . .
Spray T ip Selection Chart 30, 31 . . . . . . . . . . . . . . . . . .
Warranty Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMS
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.
NOTE: Identifies essential procedures or helpful information.
FLUID INJECTION INJURY: A serious injury, which may ap-
pear to be a simple cut, caused by high pressure injection of
fluid
directly into the body .
PRESSURE RELIEF PROCEDURE: A safety procedure for
relieving
air and fluid pressure in the system.
FOR YOUR SAFETY : Alerts user to read the additional safety
warnings on the page indicated.
ES ON-OFF VALVE: An on/of f switch located near the rear of
the
gun, above the gun handle, that turns the electrostatic pow -
er
on or of f.
HOW THE ELECTROST ATIC AIR-ASSISTED AIRLESS SPRA Y GUN WORKS
This gun combines electrostatic air spray and airless
spraying concepts. The air has three functions: (1) to
drive
the turbine, (2) to help atomize the paint “tails”, and
(3) to help control the pattern size.
The turbine generates power that the power cartridge
converts
to a high voltage current. The high voltage cur -
rent
charges the gun’ s ionizing electrode.
Fluid is electrostatically charged as it passes the gun’s
ionizing electrode. The charged fluid is attracted to the
grounded
work piece, wrapping around and evenly coat -
ing
all surfaces.
The spray tip shapes the fluid into a fan pattern, similar to
a conventional airless spray tip, but at a lower pressure.
Air from the air cap further atomizes the fluid and pushes
the paint tails into the pattern. The fan adjusting knob
controls
the width of the pattern.
Note that the air-assisted airless spray gun differs from
the
conventional air spray gun in that increasing the fan
air reduces the pattern width. To increase the pattern
width,
less fan air or a larger size tip must be used.

4307-706
SAFETY W ARNINGS
SERIOUS BODIL Y INJUR Y , EXPLOSION, FIRE, OR ELECTROST A TIC SHOCK CAN
OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED.
READ
AND UNDERST AND ALL INSTRUCTION MANUALS, T AGS, AND W ARNING
LABELS BEFORE OPERATING EQUIPMENT.
ELECTROSTATIC EQUIPMENT SHALL ONLY BE INSTALLED AND USED BY
TRAINED,
QUALIFIED PERSONNEL WHO SHALL BE FULL Y CONVERSANT WITH
THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray from the gun,
leaks or ruptured components can inject fluid through your skin and into
your body and cause extremely serious bodily injury , including the need
for amputation. Also, fluid injected or splashed into the eyes or on the skin
can cause serious damage.
NEVER point the spray gun at anyone or at any part of the body .
NEVER put hand or fingers over the spray tip.
NEVER try to “blow back” paint; this is NOT an air spray system.
NEVER try to stop or deflect leaks with your hand or body .
ALWAYS
follow the Pressure Relief Procedure , at right, before cleaning
or removing the spray tip or servicing any system equipment.
BE SURE equipment safety devices are operating properly before each
use.
Medical Alert – Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL
CARE A T ONCE. DO NOT TREA T AS A SIMPLE CUT . T ell the doctor
exactly what fluid was injected.
Note to Physician: Injection into the skin is a traumatic injury . It
is important to treat the injury surgically as soon as possible. Do
not
delay treatment to research toxicity . T oxicity is a concern with some
exotic coatings injected directly into the blood stream. Consultation
with
a plastic surgeon or reconstructive hand surgeon may be advis -
able.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before each use.
DO NOT remove or modify any part of the gun; this can cause a malfunc -
tion
and result in serious bodily injury .
Safety Latch
Whenever you stop spraying, even for a moment, AL WAYS set the gun
safety latch in the closed or “locked” position, making the gun
inoperative.
Failure to set the safety latch can result in accidental trigger -
ing
of the gun.
Set the safety latch by depressing it on the left or right side of the trigger .
See
the illustration below . Disengage the latch by pushing it toward the
trigger and up.
Safety Latch
shown in closed
or “Lock” position
Safety Latch
shown in open or
“Spray” position
SPRAY
LOCK SPRAY
LOCK
Diffuser
The gun dif fuser , which is part of the ball seat housing, breaks up spray
and reduces the risk of fluid injection when the spray tip is not installed. T o
check
dif fuser operation, follow the Pressure Relief Procedure , below ,
then
remove the spray tip. Aim the gun into a grounded metal pail. With
the turbine air OFF , and using the lowest possible pressure, trigger the
gun. If the fluid emitted is not dif fused into an irregular stream, replace the
ball seat housing.
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If the spray
tip clogs while spraying, engage the gun safety latch immediately . Follow
the Pressure Relief Procedure, then remove the spray tip to clean it.
NEVER wipe of f build-up around the spray tip or remove the spray tip until
pressure is fully relieved and the gun safety latch is engaged.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid injection, splash -
ing
in the eyes or on the skin, injury from moving parts or electrostatic
shock, always follow this procedure when shutting of f the system, when
checking or servicing any part of the spray system, when installing,
cleaning
or changing spray tips, and whenever you stop spraying.
1. Engage the gun safety latch.
2. T urn the ES On–Off valve lever to OFF .
3. T
urn of f the air and fluid supply to the gun.
4. Disengage the gun safety latch.
5. Trigger the gun into a grounded metal waste container to relieve fluid
pressure.
6. Open
the pump drain valve, having a waste container ready to catch
the drainage.
7. Leave the pump drain valve open until you are ready to spray again.
If you suspect that the tip or hose is completely clogged, or that pressure
has been fully relieved after following the steps above, VER Y SLOWL Y
loosen the air cap retainer or hose end coupling and relieve pressure
gradually, then loosen completely . Now clear the tip or hose.
Bleed-Type Air Shutoff V alve and Fluid Drain V alve
These two accessories are required in your system to help reduce the
risk of serious bodily injury , including splashing in the eyes or on the skin
and injury from moving parts if you are adjusting or repairing the pump.
The bleed-type air shutoff valve relieves air trapped between this valve
and the pump after the air regulator is shut of f. T rapped air can cause the
pump to cycle unexpectedly . Locate the valve within easy reach of the
pump.
The
fluid drain valve assists in relieving fluid pressure in the displacement
pump, hose and gun; triggering the gun to relieve pressure may not be
sufficient.

307-7065
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as overpres -
surizing,
modifying parts, using incompatible chemicals and fluids, or us -
ing
worn or damaged parts, can cause them to rupture and result in fluid
injection, electrostatic shock, fire, explosion or property damage.
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 dam -
aged
parts immediately .
Read
and follow the fluid and solvent manufacturer ’ s literature regarding
the use of protective clothing and equipment.
System Pressure
This gun has a maximum fluid working pressure of 66 bar (950 psi). Never
exceed the maximum working pressure of the gun or any other compo -
nent
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 page 29. Always
read
the fluid and solvent manufacturer ’ s literature before using the fluid
or solvent in this gun.
FIRE, EXPLOSION, or ELECTROSTA TIC SHOCK HAZARD
To reduce the risk of fire, explosion, or electrostatic shock, which may re -
sult
from electrical discharge, it is essential that:
S All parts of the electrostatic system are properly grounded.
S All personnel in or close to the spray area are properly grounded.
SAll electrically conductive objects or devices in the spray area,
including paint containers, wash cans and tools, are properly
grounded.
When operating the electrostatic device, any ungrounded objects in the
spray area (such as people, containers, tools, etc.) can become electri -
cally
charged. Arcing may occur if these objects then come in contact or
close to ground. Arcing of sufficient energy levels can ignite the fluid
being
sprayed, fumes from solvents, dust particles, and other flammable
substances. This can cause a fire or explosion and result in serious bod -
ily
injury and property damage.
Static electricity can also be generated by the flow of fluid through the
pump, hose, gun, and nozzle, but it is dissipated through proper ground -
ing
as described in Grounding below .
If
you experience any arcing or feel even a slight shock, ST OP SPRA Y-
ING
IMMEDIA TELY . Check for proper grounding of the entire system. Be
sure you have corrected the problem before starting to spray again.
Grounding
The following are minimum requirements for grounding a basic electro -
static 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 and hydraulic power supplies: ground according to
the manufacturer ’ s recommendations.
3. Electrostatic Spray Gun: obtain grounding through connection 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.
4. Object being sprayed: keep the work piece hangers clean and
grounded
at all times. Contact points must be sharp points or knife
edges.
5.
All electrically conductive objects or devices in the spray area,
including paint containers and wash cans, must be properly
grounded.
6.
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 spray gun. The gloves
must
be conductive or modified as shown on page 8.
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 .
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.
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.
Flushing and Cleaning Safety
To reduce the risk of static sparking or splashing, always follow the Pres-
sure
Relief Procedure on page 4 and remove the spray tip before flush -
ing.
Be
sure the ES valve lever is OFF before flushing or cleaning any
part of the spray system.
Use the lowest possible pressure to flush. T rigger the gun into a grounded
metal waste container .
To flush or purge equipment, ALWAYS use solvents with a flash point
equal
to or greater than that of the fluid being sprayed.
To clean the exterior of the equipment, ALWA YS use solvents with a flash
point of higher than 38 _ C (100 _ F).
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. NEVER operate the spray
gun unless the ventilating fans are operating.
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(b)(5)(i).
HOSE SAFETY
Highly pressurized fluid contained in the hose can be very dangerous. If
the hose develops leak, split or rupture, due to any kind of wear , damage
or misuse, high pressure spray emitted from it can cause a fluid injection
injury or other serious bodily injury or property damage.
TIGHTEN all fluid connections securely before each use. High pressure
fluid can dislodge a loose coupling or allow high pressure spray to be
emitted
from the coupling.
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 .
DO
NOT try to recouple high pressure hose or mend it with tape or any
other device. A repaired hose cannot contain the high pressure fluid.
HANDLE AND ROUTE HOSES CAREFULL Y . 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.
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.

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TYPICAL INSTALLATION
KEY
AMain Air Supply Line
B* V entilation Fan Interlock Solenoid V alve
C* Main Air Supply Shutof f V alve (bleed–type)
D Air & W ater Separator
E* Pump Air Supply Shutof f V alve (bleed–type)
F Air Line Lubricator
G Air Pressure Regulator
HPump
J*
Pump Ground Wire
K Fluid Filter
L Fluid Supply Line Shutof f V alve
M
Fluid Pressure Regulator
N Fluid Supply Line
O Air Filter (5 micron)
P Air Supply Line
Shutof f V alve
Q*
Air Hose Ground Wire
R* Grounded Air Supply Hose
S Electrostatic Spray Gun
T ES On–Of f V alve Lever
U Air Line Drain V alve
V* Fluid Drain V alve
W Gun Air Inlet
X Gun Fluid Inlet
NON–HAZARDOUS AREA HAZARDOUS AREA
WARNING
SIGN
B* C* D O
AM
N
H
E*
G
F
V*
K
LU
Q*
R*
G
P
W
S
X
Air Supply to Gun MUST Be Interlocked
W ith Spray Booth Exhaust Fan.
T
J*
*Equipment that must be installed for safe operation. Must be
purchased separately . See ACCESSORIES. NOTE: Solenoid
V alve (B) is not offered as a Graco accessory .,
The Typical Installation shown above is only a guide for
selecting and installing an electrostatic air-assisted air-
less
spray system. 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.
The pump you use should have a maximum working
pressure of 66 bar (950 psi). If the pump you are using
has a higher maximum working pressure, a regulator
MUST be used to limit the pressure to 66 bar (950 psi).
Graco’s
10:1 Ratio Monark Pump, part no. 217–523, may
be used in this system. See ACCESSORIES.
Warning Signs
Mount warning signs in the spray area where they can
easily
be seen and read by all operators. An English and
a Spanish Warning Sign are provided with the gun.
Additional
English, French, German, and Spanish signs
are available at no charge. See the ACCESSORIES sec -
tion to order them.
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 electrical
apparatus in a Class 1, Group D, Divisions 1 and 2
Hazardous
Location.
Check and follow all local safety and fire codes,
NFPA 33, NEC 504 and 516, and OSHA standard
1910.107.

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INSTALLATION
Ventilate the Spray Booth
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. The air
supply to the gun must be electrically interlocked
with
the ventilators to prevent operation of the pow -
er
supply unless ventilating fans are running.
Check and follow all the National, State and Local
codes
regarding air exhaust velocity requirements.
NOTE: High velocity air exhaust will decrease the oper -
ating efficiency of the electrostatic system. The
minimum allowable air exhaust velocity is 31 lin -
ear
meters/minute (100 ft/min).
Connect the Air Line (See T ypical Installation)
WARNING
To reduce the risk of electrostatic 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. See ACCESSORIES.
1. Connect
the air supply hose (R) between the air
supply line and the gun’ s air inlet (W). The gun air in -
let
fitting has a left hand thread. Connect the air sup -
ply
hose ground wire (Q) to a true earth ground.
2. Install an air line filter (O) and an air and water
separator
(D) on the air line to ensure a dry , clean air
supply to the gun. Dirt and moisture can ruin the
appearance of your finished workpiece and can
cause
the gun to malfunction.
3. Install a bleed-type air regulator (G) 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 (C) on the
main
air line and pump air line (E) to shut of f air to the
pump. Install an additional bleed-type valve on each
pump air supply line to relieve air trapped between
this
valve and the pump after air regulator is shut of f.
WARNING
The
bleed–type air shutoff valve is required in your
system to relieve air trapped between this valve
and the pump after the air regulator is closed.
Trapped air can cause the pump to cycle unex-
pectedly, which could result in serious bodily in-
jury,
including splashing in the eyes or on the skin
and injury from moving parts.
5. Install an air line lubricator (F) as close to the
pump
(H) as possible.
6. Install an air shutoff valve (P) on each gun air
supply
line to shut of f air to the gun(s).
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, EXPLOSION, or ELEC-
TROSTATIC SHOCK HAZARD, on page 5.
Ground the system as explained there. Then
check
your system as explained below .
1. Turn
the ES On–Of f valve to OFF . See Fig 5 for
the location of the valve lever .
2. T
urn of f the air and fluid supply to the gun.
3. Have a qualified electrician check the electrical
grounding
continuity of the spray gun and air hose.
a. With the electrically conductive air hose (BB)
connected (see Connect the Air Line) and
properly
grounded, use a megohmmeter (AA) to
measure the resistance between the gun handle
(Y) and a true earth ground (Z). Use an applied
voltage
of 500 volts minimum to 1000 volts maxi-
mum
. See Fig 1.
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.
Fig 1
KEY
YGun Handle
ZT rue Earth Ground
AA Ohmmeter
BB Grounded Air Hose
Z
Y
AA
BB

8307-706
INSTALLATION
Connect the Fluid Line (See T ypical Installation)
1. Before connecting the fluid line (N), blow it out
with
air and flush it with solvent. Use solvent which is
compatible with the fluid to be sprayed.
2. Install a fluid regulator (M) on the fluid line to con -
trol
fluid pressure to the gun.
3. Install a fluid filter (K) and drain valve (V) at the
pump
outlet.
4. Connect fluid line to 1/4–18.6(m) gun fluid
inlet (X).
WARNING
The
fluid drain valve (V) 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. The drain valve
reduces
the risk of property damage or serious bod -
ily
injury , including splashing in the eyes or on skin.
Install a drain valve close to the pump’s fluid oulet.
OPERATION
WARNING
For your Safety, ALWAYS follow the Pressure
Relief
Procedure on page 4 when shutting of f the
system, when you stop spraying, and before
checking,
servicing, installing, cleaning or chaning
any part in the system.
Fig 2
3 in. (76 mm)
Square Cut Out
and Finger of
Glove Cut Off
NOTE: If gloves are worn, they must
be conductive or modified as shown
so as not to interfere with operator
grounding
through the gun.
Filter the Fluid
Filter the fluid to remove coarse particles and sediment
which
could clog the spray nozzle.
Spraying Operation
This gun has a built-in lead and lag operation. The gun
begins emitting air before the fluid is discharged. When
you
release the trigger , the fluid stops before the air flow
stops. This helps prevent fluid buildup on the air cap.
When spraying, the ES indicator lights (44) should glow ,
indicating
the electrostatic charge. See Fig 5.
CAUTION
Be careful not to damage the electrode by jam-
ming it into an object when operating or setting
down
the gun.
Operating Checklist
Check the following list daily, before starting to operate
the system, to help ensure you of safe, efficient
operation.
1. Be sure all operators are properly trained to
safely operate an air-assisted airless electro-
static
spray system.
2. Be sure all operators are trained how to prop -
erly
and completely relieve system pressure.
3. Be sure the system is thoroughly grounded.
See FIRE, EXPLOSION, or ELECTRIC
SHOCK HAZARD, page 5, and Check the
Electrical Grounding
, page 7.
4. Be sure the operator and all persons entering
the spray area are properly grounded by wear -
ing shoes with conductive soles or personal
grounding
straps.
5. Operator must not wear gloves which insulate
the hand from the spray gun. If worn, gloves
must be conductive or modified as shown in
Fig 2 so as not to interfere with operator
grounding
through the gun.
6. Be sure ventilation fans are operating
properly.
7. Be
sure the workpiece hangers are clean and
grounded. Contact points must be sharp
points
or knife edges.
8. Be sure all refuse is removed from the spray
booth.
9. Be sure all flammable liquids in spray booth
are in approved, grounded containers.
10. 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 con-
ductive
and grounded.

307-7069
OPERATION
Install the Spray Tip and Air Cap
WARNING
For
your safety , always follow the Pressure Relief
Procedure, on page 4, before installing, or remov -
ing
the spray tip or air cap.
1. See the SPRA Y TIP SELECTION CHART , page
30, to select the appropriate spray tip for your appli -
cation.
The fluid output and fan width depends on the
spray tip size, fluid viscosity , and fluid pressure.
2. Place the spray tip (13) in the air cap (12), align -
ing the tab of the tip with groove in the air cap. Be
careful
not to damage electrode wire (GG). See Fig
5.
3. Place the air cap assembly on the gun. Screw
the
retaining nut (1 1) firmly onto the gun to prevent
leakage between the tip and ball seat housing.
NOTE: The air cap and spray tip position determines the
direction of the spray pattern. See Fig 3.
WARNING
Operating
the gun without the electrode wire or with
a bent or damaged electrode wire will impair the
electrical
continuity of the gun. T o reduce the risk of
electrical discharge, which could cause serious in -
jury,
fire, or explosion, BE SURE the electrode wire
is properly installed in the gun (see page 16) and is
not bent or damaged before operating the gun.
Fig 3
VERTICAL SPRA Y P ATTERN HORIZONT AL SPRA Y P ATTERN
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow
and air flow . DO NOT turn the electrostatics on yet.
1. Set the fluid pressure at about 21 bar (300 psi),
using the fluid regulator .
2. Trigger the gun to check the atomization; don’t
be
concerned about the pattern shape yet.
3. Increase the fluid pressure just to the point that
any
further increase in fluid pressure does not signifi -
cantly
improve fluid atomization. DO NOT exceed 66
bar (950 psi) fluid pressure.
4. Be sure the fan adjusting knob (EE) is closed
(turned
fully counterclockwise ).
5. Set
the atomizing air pressure to 3.1 bar (45 psi).
6. First, complete all the checks under the Operat-
ing
Checklist on page 9. Then turn the ES ON-OFF
valve lever (T) to ON. See Fig 5.
Provide a 3.1 bar (45 psi) clean, dry, regulated air
supply to the gun to ensure full voltage from the
power supply. The gun may be operated at lower
turbine
air pressure, but may lose some electrostatic
effect. Do not operate the turbine at an air pressure
greater
than 3.1 bar (45 psi) as there is no benefit and
turbine life will be reduced.
7. Check the spray pattern, then adjust the air pres -
sure until all the tails are completely atomized and
pulled
into the spray pattern. Refer to Fig 4.
8. If a narrower pattern is desired, try turning the
fan adjusting knob (EE)
clockwise . If the pattern is
still
not narrow enough, increase the air line pressure
slightly or use a dif ferent size tip.
KEY
11 Retaining Nut
12 Air Cap
13 Spray T ip
44 ES Indicator Lights
T ES ON-OFF
V alve Lever
EE Fan Adjusting Knob
GG Electrode Wire
13
NO AIR T
OO LITTLE AIR
RIGHT AMOUNT
OF AIR
Fig 4
Fig 5
GG
12
11
Tab
44 T
EE

10    307-706
MAINTENANCE
Daily Care and Cleaning
CAUTION
Clean all parts with a non–conductive solvent,
compatible with the fluid being sprayed. Conduc-
tive
solvents can cause the gun to malfunction.
Methylene chloride is not recommended as a
flushing
or cleaning solvent with this gun as it will
damage nylon components.
Do not use any cleaning method which may
allow solvent into the gun air passages.
Immersing
the gun in solvent is not recommended
as a cleaning method. Solvent left in gun passages
could result in a poor quality paint finish and may
draw current and reduce the electrostatic effect.
Solvent
in the power supply cavity can reduce al -
ternator
life.
WARNING
For your safety, always follow the Pressure Re-
lief
Procedure on page 4 when shutting of f the sys -
tem,
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. Check all of the work hangers for build-up of
material;
clean them, if necessary .
3.
Clean the gun fluid filter (26) daily . See Fig 6.
a. Unscrew and remove the fluid inlet fitting (25).
b. Remove the filter (26) and clean thoroughly in a
compatible non-conductive solvent.
c. Reinstall the filter and inlet fitting. DO NOT over
tighten the inlet fitting as over tightening could
distort
the filter .
4. Clean
the outside of the gun daily with a soft cloth
dampened in a compatible solvent.
5. Clean the air cap and spray tip daily, minimum.
Some applications require more frequent cleaning.
Replace
spray tip and air cap if they are damaged.
a. Remove the air cap and spray tip.
b. Clean the tip and air cap with solvent and scrub
with a soft brush.
WARNING
To avoid damaging the ball seat housing resistor,
use a soft bristle brush dipped in solvent to clean;
DO
NOT soak it in solvent! A damaged resistor will
impair the electrical continuity and could result in
electrical discharge, which could cause serious
injury,
fire, or explosion.
c. Use a soft brush or other soft tool, with an air
blow gun, to clean air cap passages. Take care
not to scratch any surfaces. If air cap holes are
plugged, use a round toothpick to unplug the
holes.
CAUTION
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.
6. Check the electrode wire. Straighten if bent, and
replace if broken or damaged. See Electrode Wire
Replacement.
Fig 6
KEY
25 Fluid Inlet Fitting
26 Fluid Filter
25
26
Flush the Spray Gun
WARNING
To reduce the risk of electric shock, which could
result in serious injury, or the risk of fire or explo-
sion the ES On-Off lever (electrostatics) must be
OFF
before flushing.
For your safety, always follow the Pressure
Relief
Procedure on page 4 before flushing.
CAUTION
Methylene chloride is not recommended as a
flushing
or cleaning solvent with this gun as it will
damage nylon components.
1. Follow the Pressure Relief Procedure on page 4.
2. Disconnect and plug the fluid line.
3. Connect the solvent supply to the gun.
4. Flush the gun with solvent until it is clean.
5. Follow the Pressure Relief Procedure,then dis-
connect
the solvent supply .
6.
Reconnect the fluid supply line.
8. T rigger the gun until it is clear of solvent.

307-706 11
SPRAY PA TTERN 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.
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
fluid injection, 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 sys -
tem, when installing, cleaning or changing fluid noz-
zles,
and whenever you stop spraying.
1. Engage the gun safety latch.
2. T urn the ES ON–OFF V alve lever to OFF .
3. T
urn of f the air and fluid supply to the gun.
4. Disengage the gun safety latch.
5. Trigger the gun into a grounded metal waste con -
tainer
to relieve fluid pressure.
6. Engage the gun safety latch.
7. Open the pump drain valve, having a waste con-
tainer
ready to catch the drainage.
8. Leave the pump drain valve open until you are
ready
to spray again.
If you suspect that the tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above. VERY SLOWLY
loosen the air cap retainer or hose end coupling and
relieve pressure
gradually , then loosen completely.
Now
clear the tip or hose.
NOTE: Check all possible remedies in the T roubleshooting Charts before disassembling the gun.
PROBLEM: CAUSE SOLUTION
IMPROPER SPRA Y
PATTERN
Insuf ficient fluid supply . Adjust fluid regulator or fill fluid tank.
Loose or cracked coupler at fluid inlet. T ighten or repair .
Air in paint supply line Check, tighten siphon hose
connections, bleed air from paint line.
Fluid build-up or spray tip partially Clean spray tip.
plugged.
Air horn holes on defective side of Clean air horn holes with solvent
pattern partially or totally plugged. and soft brush.
Air horn holes partially or totally Clean air horn holes with solvent
plugged. and soft brush.
Insuf ficient air pressure. Increase air pressure.
Fluid pressure too low . Increase fluid pressure.
Fluttering or spitting
spray
Irregular pattern
Pattern pushed to one
side, same side of air
cap gets dirty
T ails in pattern

12    307-706
GUN OPERA TION TROUBLESHOOTING CHART
PROBLEM CAUSE SOLUTION
Air leakage from front of
gun.
Fluid leakage from
front of gun.
Air valve not seating properly . Clean, service. See page 21.
Air stem packing too tight. Loosen packing. See page 21.
T oo much air pressure. Reduce,use least air pressure
needed for good results.
Fluid thinned too much. Properly thin fluid.
Excessive spray fog.
Loose or worn fluid seat. T ighten or replace fluid seat and/or
electrode. See page 16.
Loose spray tip. T ighten spray tip.
Insuf ficient air pressure. Increase, use least air pressure
needed for good results.
Using too large of a spray tip. Use a smaller size spray tip.
Fluid poorly mixed or filtered. Remix or refilter fluid.
Improper thinner being used. Use proper thinner .
“Orange Peel” finish.
No fluid sprays from
gun.
Fluid low . Check, add if necessary .
Broken fluid needle shaft. Replace needle.
Dirty or clogged spray tip. Clean spray tip. See page 10.
Damaged spray tip. Check, replace spray tip. See page 9.
Exhaust air flow insuf ficient or not directed Check for proper CFM, check baf fles,
properly. and direction of air flow .
Improper distance between gun and Adjust distance to 203–305 mm
work piece. (8–12 in.).
Equipment covered
with fluid.

307-706 13
ELECTRICAL TROUBLESHOOTING CHART
PROBLEM CAUSE SOLUTION
*ES
ON–OFF lever in OFF position. T urn lever to ON.
*T urbine alternator not operating Check if ES ON–OFF lever is ON.
Check air supply to gun. Check for
dirt or moisture in turbine. See
page 23.
Improper distance between gun Adjust spraying distance to
and work piece. 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.
*Fluid resistivity too low . Check fluid resistivity with paint
meter and probe.
*Faulty gun resistance. Check gun resistance. See page 14.
*Faulty resistor stud resistance. Check resistor stud resistance.
See page 15.
*Faulty power supply resistance. Check power supply resistance.
See page14.
*Damaged electrode wire. Replace electrode wire.
See page 16.
*Faulty turbine alternator . Be sure plug is in place on back of
turbine alternator housing.Remove
and test turbine alternator . See
page 20.
Poor wrap–around.
Operator gets mild
shock.
Operator not properly grounded Be sure floor is properly grounded.
or is in contact with ungrounded W ear shoes with conductive soles
object. or wear personal grounding straps.
Be sure operator is not in contact
with or carrying any metallic items
which could build up electrical
charge. If worn, a glove must be
conductive or modified as shown
on page 8.
Gun not properly grounded. See Check the Electrical Grounding,
page 7. Be sure Graco air supply hose
is being used and is properly grounded.
Operator gets mild
shock when touching
work piece.
W ork piece not properly Clean work piece hangers. Check
grounded. for proper ground on conveyor or
track.
*ES indicator light not on when gun is triggered.

    
ELECTRICAL TESTS
The performance of the spray gun is directly af fected 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 (3) and the
ball
housing and resistor (14) as well as the continuity of
the electrical path between components.
Use megohmmeter 218–979 (see ACCESSORIES ) and
an applied voltage of 500 volts to complete these electri -
cal
tests. Connect the leads as shown.
WARNING
To
reduce the risk of sparking, which could cause
fire or explosion and result in serious bodily injury ,
including electrostatic shock, DO NOT use the
megohmmeter in the hazardous area. Remove
the
gun from the hazardous area before testing it.
Test Gun Resistance
NOTE: Check the resistance with the gun triggered and
with the trigger released.
Measure the resistance between the end of the electrode
wire (GG) and the gun air fitting (32a). See Fig 7. The re -
sistance
should be between 1 15–152 megohms. If the re -
sistance is outside the specified range, go to the next
test. If the resistance is correct, refer to the Electrical
Troubleshooting Chart on page 13 for other possible
causes
of poor performance.
Test Power Supply Resistance
Remove the power cartridge (1) from the gun handle
(32).
See Power Cartridge Replacement .
Remove the turbine alternator (1a) from the power sup-
ply (3). See T urbine Alternator Removal .
Measure
the resistance from the center prong (HH) in the
power supply to the contact spring (3b) on the other end
of the power supply . See Fig 8.
The resistance should be 95–122 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 .
Fig 7
KEY
32 Gun Handle
32a Air Inlet Fitting
AMegohmmeter
GG Electrode
Fig 8
KEY
3b Contact Pin
AMegohmmeter
HH Center Connector Prong
32a
GG
A
A
3b 3
HH
32

 
ELECTRICAL TESTS
Test Resistor Stud Resistance
Insert a conductive rod (JJ) into the gun barrel (removed
for the power supply test) and against the metal contact
(KK) in the front of the barrel. See Fig 9.
Measure the resistance between the conductive rod (JJ)
and the gun electrode (GG). The resistance should be
20–30
megohms. If the resistance is correct, refer to the
Electrical Troubleshooting Chart for other possible
causes of poor performance, or contact the nearest
authorized
service agency .
If the resistance is outside the specified range, remove
the electrode wire (GG). See Electrode W
ire Replace -
ment. Measure the resistance between the conductive
rod (JJ) and the resistor (LL) in the outside diameter of
ball
seat housing (14). See Fig 10.
The resistance should be 20–30 megohms. If the resis-
tance
is correct, the electrode wire is defective and must
be replaced. See Electrode Wire Replacement. If the
resistance is outside the specified range, the resistor is
defective and the ball seat housing (14) must be
replaced. See Ball Seat Housing & Resistor
Replacement.
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 .
KEY
9Gun Barrel
AMegohmmeter
JJ
Conductive Rod
KK Metal Contact
GG Electrode
Fig 9
A
KK
GG
9
JJ
Fig 10
A
14
JJ
LL KEY
14 Ball Seat Housing
AMegohmmeter
JJ Conductive Rod
LL Resistor

16    307-706
SERVICE
Gun DisassemblyWARNING
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.
Follow the Pressure Relief Procedure Warning,
page
1 1, 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 petro-
leum
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.
Follow the Pressure Relief Procedure Warning on
page
1 1. Disconnect the air and fluid line from the gun.
Fig 1 1
KEY
11 Retaining Nut
12 Air Cap
13 Spray T ip
GG Electrode Wire
GG
11
12 13
Electrode Wire Replacement
1. Unscrew the retaining nut (11). Remove the air
cap
(12) and spray tip (13). See Fig 1 1.
2. Use
a needle nose pliers to gently pull the elec -
trode
wire (GG) out the back of the spray tip.
3. Install the long end of the new wire in the hole
closest
to the tab of the tip. See Fig 1 1. Push the wire
in, aligning the short end of the wire with the other
hole
in the tip. Pull on the front of the wire to seat it.
NOTE: A box of ten electrodes is included in the tool
kit (63).
Ball Seat Housing & Resistor Replacement
1. Unscrew the retaining nut (11) . Remove the air
cap (12) and spray tip (13). See Fig 1 1.
2. Insert
the special wrench (63d) in the front of the
gun. While triggering the gun, unscrew the ball seat
housing (14) and remove it. See Fig 12.
3. If you are replacing the fluid needle assembly , do
not reassemble the gun.
If no further service is required, install the new hous -
ing in the reverse order of disassembly. Torque the
ball seat housing to 1.1 Nm (10 in-lb)
(snug) ; DO
NOT
OVER TIGHTEN.
CAUTION
DO NOT over tighten the ball seat housing (14).
Excess
torque will damage the housing.
Fig 12
KEY
14 Ball Seat Housing
63d Wrench
63d
14
T orque to
1.1 N m
(10 in-lb)
63d
14

307-706 17
SERVICE
Barrel Removal
1. Remove the retaining nut, air cap, and spray tip.
2. Unscrew the fluid tube connector (FF) at the bot -
tom
of the fluid tube (20), then pull the tube out of the
inlet. See Fig 13.
3. If you are replacing the needle, insert the special
wrench (63d) in the front of the gun. While triggering
the gun, unscrew the ball seat housing (14) and
remove
it. See Fig 12.
4. Remove the trigger screws, spacers, and trigger .
5. Remove the ES indicator lights. Using the
wrench (63f) supplied, loosen and remove the two
socket head cap screws (45) from the gun. See Fig
13.
6. Hold
the gun handle (32) with one hand and pull
the gun barrel (9) straight up to remove it. See Fig 14.
CAUTION
To avoid damaging the power cartridge, always
pull
the gun barrel straight up. If necessary , gently
move the gun barrel from side to side to free it from
the gun handle.
NOTE: The gasket (4) should be left in the gun handle
(32)
if the gasket is not to be replaced.
Barrel Reassembly
1. If the needle assembly was removed, reinstall it
as described on page 18.
2. Be sure the gasket (4) is in place. Replace if
damaged.
Place the barrel over the power cartridge
(1) and onto the gun handle (32). See Fig 14.
3. Install the two socket head cap screws (45) and
tighten with the wrench (63f) supplied. See Fig 13.
Snap
the ES indicator lights in place over the socket
head cap screws.
4. Insert the fluid tube (20) into the fluid inlet of the
gun barrel, making sure the washer (20a) is in place,
and tighten the fluid tube connector (FF). See Fig 13.
5. If the ball seat housing (14) was removed , insert
the pressing tool (63c) [see Fig 15] in the front of the
gun and gently push the needle back before sliding
the trigger into place and installing the screws and
spacers.
Then remove the tool and reinstall the ball
seat housing (see page 16).
6. Install the air cap, spray tip, and retaining nut.
Test
the gun resistance as instructed on page 14.
Fig 13
Fig 14
KEY
20 Fluid T ube
20a Washer
45 Cap Screw
63f Wrench
FF Fluid T ube Connector
FF
63f
45
20a
KEY
1 Power Cartridge
4Gasket
9 Gun Barrel
32 Gun Handle
32
9
3
Fig 15
20
4
19
77
63c
44
Torque to
1.1–1.4 N m
(10–12 in-lb)
KEY
19 Trigger
44 ES Indicator Lights
63c Pressing T ool
77 Screw

    
SERVICE
Fluid Needle Replacement
1. Remove the gun barrel (9) as instructed on page
17. If the power cartridge comes out, carefully press
it back into the handle.
2. Insert the narrow end of the pressing tool (63c)
through
the front of the gun to push the needle back,
then remove the nut (21) and the adjustment nut
(17a).
See Fig 17.
3. Press the needle assembly (17) out the front of
the
gun as far as you can with a finger , or by pressing
it against a flat surface. Then use the wrench (63f) to
finish pushing it out. See Fig 16.
4. Remove the nut (17a) from the new needle
assembly. Then install the new needle assembly
through
the front of the gun. Insert the narrow end of
the pressing tool (63c) into the front of the gun and
press
to seat the needle. See Fig 17.
5. Install the new adjustment nut (17a), hex end
first,
onto the needle.
6. Use the pressing tool (63c) to press on the
needle from the front of the gun, then screw the
adjusting nut (17a) all the way to the bottom of the
threads.
Remove the pressing tool.
7. Screw the other nut (21) firmly against the
adjustment
nut to lock them together .
8. Reassemble the gun as described in Barrel
Reassembly.
Fig 16
KEY
17 Needle Assembly
17a Adjustment Nut
21 Nut
63f Wrench
21
17a
17
63f
Fig 17
KEY
17a Adjustment Nut
21 Nut
63c
Pressing T ool
21
17a
63c
Bottom of
thread
Check the Gun Safety Latch
WARNING
Check
to be sure the gun safety latch works prop -
erly
each time after you change the needle. Safety
latch failure or improper use of the safety latch can
result in accidental gun triggering, which could
cause
fluid injection or splashing fluid into the eyes
or on skin and result in serious injury .
Fig 18
17a
Trigger MUST NOT
touch nut (17a) when
safety latch is locked.
SPRAY
LOCK
TEST 1
Engage the trigger safety latch to the right, then try to trig -
ger the gun. Look behind the trigger to be sure it is
not
engaging the nut (17a). Then engage the latch to the left
and check again. See Fig 18.
TEST 2
Disengage the trigger safety latch, and trigger the gun
gently
to see if you can feel the “lead and lag” operation,
which means the air will come on before the fluid does,
and
the fluid shuts of f before the air does.
If the gun fails either TEST 1 or 2:
Remove the trigger and the ball seat housing. Back the
nuts
(17a, 21) away from the bottom of the threads.
Reassemble
and check T ests 1 and 2 again. Also check
in front of the trigger to make sure the needle still moves.
If the trigger still fails any of these tests now , the needle
assembly (17) is out of tolerance and must be replaced.

 
SERVICE
Fig 19
KEY
1Power Cartridge
1a T urbine Alternator
1b O–Rings
1c Plug
3a O–Ring
3b Spring
3c O–Ring
4Gasket
9Barrel
9b Cushion
32
Gun Handle
9
NOTE: The power cartridge (1)
includes items 1a–1c,
and 3a–3c.
43b 3a
3c
1a 1c
1b
32
3
9b
See NOTE after
step 3, below .
Power Cartridge Replacement
1. Remove the barrel as described under Barrel
Removal.
2. Remove
the gasket (4) from the gun. See Fig 19.
CAUTION
The power cartridge is fragile. Be careful when
handling
it to avoid damage.
3. Grasp the power cartridge (1) with your hand.
With
a gentle side to side motion, pull it free from the
gun handle (32). Then pull the power cartridge
straight
out of the handle.
CAUTION
DO NOT use solvents to clean the power
cartridge
cavity in the gun handle (32). Solvent will
damage electrical components contained in the
power
cartridge.
Inspect the power cartridge cavity in the handle
for dirt or moisture. Clean out the cavity with a
clean, dry rag if necessary. Moisture and other
contaminants
may damage electronic circuitry .
All the o–rings (1b, 3a, 3c) and the compression
spring (3b) must be in place or the gun will
malfunction.
NOTE: The cushion (9b) is part of the gun barrel and
should never be removed. If it ever is removed,
push the cushion, adhesive side in toward the
barrel,
with a rod until it is securely adhered in the
barrel. DO NOT use the power supply (3) to
press the cushion into the barrel as it will not
adhere properly .
4. Lightly lubricate the o–rings (1b, 3a, 3c) on the
new power cartridge with petroleum jelly. Insert the
new
power cartridge in the gun handle.
NOTE: See Fig 20 for proper alignment of the power car -
tridge
(1) in the gun handle (32).
5. Install the gasket (4) in the gun handle (32).
6. Install the barrel on the handle as described
under
Barrel Removal .
Fig 20
KEY
1Power Cartridge
32 Gun Handle
32
1

    
SERVICE
Turbine Alternator Removal
1. Remove the power cartridge from the gun
handle as described under Power Cartridge
Replacement.
2. Carefully twist the turbine alternator (1a)
coun-
terclockwise
and pull it of f the power supply (3) until
just disengaged from the coupling (MM). Then con-
tinue to slowly pull the turbine alternator away from
the power supply, disconnecting the 3-wire
connec -
tor (NN). See Fig 21.
3. Using an ohmmeter , test the coil in the turbine al -
ternator (1a). Measure the resistance between the
two outer terminals of the 3-wire connector (NN).
The
resistance should be 3 to 5 ohms. If the reading
varies from this value, replace the alternator .
4. Measure
the resistance between each outer ter -
minal of the 3-wire connector (NN) and the turbine
alternator
housing (1a). The resistance should be in -
finite. If the resistance is not infinite, replace the
alternator.
5. Partially
connect the 3-wire connector (NN) onto
the prongs inside the power supply (3). See Fig 21.
Using a small screwdriver, push the connector onto
the
prongs until seated.
6. Slide the turbine alternator (1a) onto the power
supply,
being sure to align the coupling between the
power supply and the turbine alternator housing.
Then
twist the turbine alternator clockwise to lock the
coupling.
7. Install the power cartridge in the gun handle as
described
under Power Cartridge Replacement .
Fig 21
KEY
1a Alternator
3Power Supply
MM Coupling
NN 3–Wire Connector
3
NN
1a
MM