Graco Inc. 235-894 manual

0432 For use with Class  , Group D paint spray materials 0435 Part No. 235–893 shown I NSTRUCTIONS–P ARTS LIST 308–084 This manual contains IMPORT ANT W ARNINGS AND INSTRUCTIONS READ AND RET AIN FOR REFERENCE Rev . H Supersedes G Model PRO 4600SC  AUT OMA TIC ELECTROST A TIC AIR SPRA Y GUN 100 psi (7 bar) MAXIMUM WORKING PRESSURE U.S. P[...]

  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 OPERA TING EQUIPMENT . ELECTROST A TIC EQUIPMENT SHALL ONL Y BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE[...]

308-084 3 FIRE, EXPLOSION, OR ELECTROST A TIC SHOCK HAZARD T o reduce the risk of fire, explosion, or electrostatic shock, which may result 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. S All electric[...]

  T ABLE OF CONTENTS W arnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T erms 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation T ypical Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . W arning Signs 5 . . . . . . . . . . . [...]

  TYPICAL INST ALLA TION Non-Hazardous Area Hazardous Area Fig 1 01769 Controls Cabinet    Shut-off device for fluid only operation Bleed valve or 3 way solenoid Air Regulator Fan Atom Air Lines Grounded T urbine Air Hose (gray[...]

6 308-084 INST ALLA TION W ARNING 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 L[...]

  INST ALLA TION 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- ished workpiece and can cause the gun to malfunction. A combination air filter/moisture separator is shown in the AC[...]

  INST ALLA TION Check the Electrical Grounding (See Fig 7 ) W ARNING Proper electrical grounding of every part of your system is essential. For your safety , read the warning section, FIRE, EXPLOSION, OR ELECTROST A TIC SHOCK HAZARD , on page 3. Ground the system as explained there. Then check your system as explained below[...]

  OPERA TION W ARNING 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 of f the system, when checking or servicing any part of the spray system, whe[...]

10 308-084 OPERA TION Adjusting the T urbine Air Pressure W ARNING 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. 1. Complete all the checks under[...]

308-084 1 1 MAINTENANCE 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 W arning 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 th[...]

12 308-084 MAINTENANCE Check for Fluid Leakage (See Fig 10 ) W ARNING If any fluid leakage from the gun is detected, stop spraying IMMEDIA TEL Y! Fluid leakage into the gun shroud could cause fire or explosion and result in serious bodily injury and property damage. During operation, periodically check the two manifold ex - haust tubes and both end[...]

308-084 1 3 SPRA Y P A TTERN TROUBLESHOOTING CHART W ARNING 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. To reduce the risk of[...]

14 308-084 GUN OPERA TION TROUBLESHOOTING CHART Worn fluid rod packings or fluid rod Replace fluid rod packings or rod. See page 23. Fluid rod worn or damaged Replace fluid rod. See page 23. W orn fluid seat Replace fluid nozzle and/or electrode. See page 19 and 20. Piston seal or o-ring damaged Replace seal and/or o-ring and lubricate. Loose resis[...]

308-084 1 5 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Improper distance between gun Adjust spraying distance to and workpiece 8 to 12 inches (203 to 305 mm). Parts poorly grounded Clean hangers, check for proper ground on conveyer or track. High booth exhaust velocity Reduce exhaust velocity within code limits. Atomizin[...]

  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 (40) and the resistor stud (2) as well as the continuity of the electrical path between the[...]

308-084 1 7 ELECTRICAL TESTS T est 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). Y ou may have to press down on the contact ring (D) in several places to get a good[...]

18 308-084 SERVICE W ARNING 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. NOTE: Check all possible remedies in the T roubleshooting Charts before[...]

308-084 1 9 SERVICE 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. Point the front end of the gun up while removing the fluid nozzle (1[...]

  SERVICE Electrode Replacement 1. Remove the air cap, nozzle and resistor stud as described in Air Cap/Nozzle/Resistor Stud 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 ba[...]

308-084 2 1 SERVICE 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 a[...]

  SERVICE Barrel Installation 1. Be sure the gaskets (23 & 40a) and spring (1 1) 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 (1 1) is seated properly . 3. T ighten the three socket head cap screws (15) opp[...]

308-084 2 3 SERVICE 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. Remove the air cap assembly , fluid nozzle and resis - tor stud and ele[...]

  SERVICE 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. (9 N) of drag force when sliding the packing housing [...]

308-084 2 5 SERVICE Fig 23 KEY F 3-wire Connector G Potentiometer 10 Gun Barrel 13 Retainer Ring 27 Alternator 27a O-Ring 27b Cushion 39 Gun Body 40 Power Supply 40a Gasket 40b Pad 40c Pad 40d Seal 40e Cushion 39 13 27a 27b 40a 40 27 F 10 40b 40c 40e G 40d 0450 Power Supply Removal and Replacement REP AIR NOTES: a. T o avoid a loss i[...]

  SPRA Y GUN SERVICE NOTES Lubricate Lubricate Apply high strength (red) Loctite or equivalent to threads. Lubricate Lubricate T ighten Resistor Stud into nozzle to 10 in-lbs (1.15 N  m) T ighten Nozzle 1/8 to 1/4 turn past hand tight T orque Fitting to 25–35 in-lbs (2.8–4.0 N  m) CAUTION: Do not damage Needle E[...]

308-084 2 7 MANIFOLD SERVICE NOTES 0434 0434 Press fit This end 8.5-8.9” (215-225 mm) from manifold surface when properly assembled Standard o-ring is V iton. Optional EPR o-ring is provided with the man - ifold for compatibility with ketone solvents. Must be clean Press fit T ighten until hex bottoms against manifold Left-hand thr[...]

  SPRA Y GUN P ARTS DRA WING DET AIL A 0433 See Detail A 3b 3 28 31 2 14 9 16 43 12 6 18 40e 40b 27a 27 27b 13 40c 40 40d 40a 23 22 42 15 10 36 30 19 25 29 REF 3 11 20 7 REF 19 21a 21b 5 21 39 36 17 1 4 8 32 24 41d 41j 41e 41g 41i 41b 41c 41h 41a 41f 41 REF NO. 3 Includes items 3a–3h 3a 3h 3c 3d 3e 0601 3f 3g[...]

 308-084 2 9 SPRA Y GUN P ARTS 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. 235–894, Series A Air Spray Gun, with slotted shroud Includes items 1–52 REF NO. P ART NO[...]

  MANIFOLD P ARTS DRA WING 0434 122 1 17d 1 17c 1 17h 1 17b 1 17g 1 17e 1 17f 11 8 11 0 11 4 111 11 6 106 104 104 11 3 11 5 107 108 109 101 121 11 2 124 103 MANIFOLD P ARTS LIST Part No. 224–094 Gun Manifold Includes items 101–124 REF NO. P ART NO. DESCRIPTION QTY 101 1 1 1–224 LENSE 1 103* 106–167 O-RING; perfluo[...]

308-084 3 1 PRO 4600HC CONVERSION KIT Part No. 237–301 PRO 4600HC Conversion Kit ; T o 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. The kit must be ordered separately . It incl[...]

  ACCESSORIES Accessories must be purchased separately . Use only GENUINE GRACO P ARTS 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. 0331 Grounded Air Supply Hose 100 psi (7 bar) MAXIMUM WORKING PR[...]

308-084 3 3 ACCESSORIES Accessories must be purchased separately . Use only GENUINE GRACO P ARTS AND ACCESSORIES. GUN MOUNTING ACCESSORIES Gun Mount Assembly 235–094 01875 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 [...]

  ACCESSORIES Accessories must be purchased separately . Use only GENUINE GRACO P ARTS AND ACCESSORIES. CABLE ACCESSORIES Fiber Optic Cables Fiber Optic Cable Assembly For connection between gun manifold and display module or between bulkhead connector and display module. PA R T NO. LENGTH 224–680 6 ft (1.8 m) 224–681[...]

   Safety W arning Signs Available at no charge from Graco. Must be ordered separately . PA R T NO. DESCRIPTION 180–060 W arning Sign (English) 180–061 W arning Sign (French) 180–062 W arning Sign (German) 180–063 W arning Sign (Spanish) Paint Resistance Meter 722–886 Used with 722–860 Paint Pro[...]

36 308-084 THE GRACO W ARRANTY AND DISCLAIMERS W ARRANTY 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 [...]