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AUTOMATIC MID-RANGE ELECTROSTATIC AIR SPRAY GUN 7bar (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. 2,140,327B; 2,142,559B; 2,147,158; 2,191,423 Patented 1986, 1987 Canada Brevete 1986, 1987 French Patent No. 84 07942; 84 10234 Italian Patent No. 1,111,380 Japanese Patent No. 86. 07416 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 . COPYRIGHT 1985, GRACO INC. . . TABLE OF CONTENTS Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 How The Electrostatic Air Spray Gun Works . . . . 5 Installation Typical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . . 6 Mount the Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connect the Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check the Electrical Grounding . . . . . . . . . . . . . . . . . . 8 Installing Optional Remote Fan Air Adapter . . . . . . . . 8 Operation Operating Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Spraying Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Selecting a Fluid Nozzle and Air Cap . . . . . . . . . . . . . 9 Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . 11 Flush the Spray Gun. . . . . . . . . . . . . . . . . . . . . . . . . . . 11 To Clean or Change Air Cap and Fluid Nozzle . . . . 12 Spray Pattern Troubleshooting Chart . . . . . . . . . . 13 Gun Operation Troubleshooting Chart . . . . . . . . . 14 Electrical Troubleshooting Chart . . . . . . . . . . . . . . 15 Electrical Tests Test Gun Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Test Power Supply Resistance . . . . . . . . . . . . . . . . . . 16 Test Resistor Stud Resistance . . . . . . . . . . . . . . . . . . 17 Service Gun Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . . . 18 Resistor Stud Replacement. . . . . . . . . . . . . . . . . . . . . 19 Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fluid Needle Packing Replacement. . . . . . . . . . . . . . 20 Power Cartridge Replacement . . . . . . . . . . . . . . . . . . 22 Turbine Alternator Removal. . . . . . . . . . . . . . . . . . . . . 23 Fan Air Valve Replacement. . . . . . . . . . . . . . . . . . . . . 23 Piston Removal and Repair. . . . . . . . . . . . . . . . . . . . . 24 Disc Regulator O-Ring Replacement . . . . . . . . . . . . . 25 Muffler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 How To Order Replacement Parts . . . . . . . . . . . . . . . 29 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. 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. . . 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. EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in serious bodily injury, fire, explosion or property damage. NEVER point the spray gun at anyone or at any part of the body. NEVER put h...