Graco Inc UNICARB 308936, UNICARB 965722, UNICARB Pro AA4500 User Manual

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INSTRUCTIONS-PARTSLIST

308936

This manual contains important

Rev. B

Supersedes Rev. A

warnings and information.

READ AND KEEP FOR REFERENCE.

First choice when

quality counts.t

 

INSTRUCTIONS

 

85 KV ELECTROSTATIC

Model PRO AA4500t/UNICARBr

Air-AssistedSpray Gun

100 psi (7 bar, 0.7 MPa) Maximum Working Air Pressure

3000 psi (207 bar, 20.7 MPa) Maximum Working Fluid Pressure

For use with Class I, Group D paint spray materials

Part No. 965722, Series B

Spray Gun with basic power supply, 2-fingertrigger

01944A

NOTE: Any modification of genuine Graco parts or replacement of parts withnon-Gracoparts will void agency approvals.

U.S. Patent No. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774; 5,063,350; 5,080,289; 5,289,977

Patented 1986, 1987 Canada

Brevete 1986, 1987

U.K. Patent No. 2,147,158; 2,142,559B; 2,140,327–B

Other U.S. and Foreign Patents Pending

UNICARB IS A REGISTERED TRADEMARK OF UNION CARBIDE, DANBURY CT.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

ECOPYRIGHT 1999, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.

DElectrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.

DGround the equipment, personnel in or close to the spray area, the object being sprayed, and all

other electrically conductive objects in the spray area. See Ground the System on page 8.

DCheck the spray gun resistance daily. See Test Gun Resistance, page 25.

DIf there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.

DProvide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on. See

Ventilate the Spray Booth on page 6.

DWhen cleaning, flushing, or purging electrostatic equipment, use solvents that comply with your local regulations. For countries following the U.S. National Fire Protection Association (NFPA) 33

requirements, use solvents with a flash point higher than 100_ F (38_ C) or a solvent normally used in spray operations.For European Countries complying with EN 50053, use solvents with a flash point as high as possible and higher than the ambient temperatures.

DUse only non-sparkingtools to clean residue from the booth and hangers.

DDo not flush the system with the gun electrostatics turned on.

DDo not turn on the gun electrostatics until all solvent is removed from the system.

DExtinguish all open flames or pilot lights in the spray area.

DKeep the spray area free of debris, including solvent, rags, and gasoline.

DDo not store any flammable fluids in the spray area.

DDo not turn on or off any light switch in the spray area while operating or if fumes are present.

DDo not smoke in the spray area.

DDo not operate a gasoline engine in the spray area.

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

DStore hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local, state, and national guidelines.

DWear appropriate protective clothing, gloves, eyewear, and respirator.

2308936

WARNING

INJECTION HAZARD

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause a serious injury.

DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medical attention.

DDo not point the spray gun at anyone or any part of the body.

DDo not put hand or fingers over the spray tip.

DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.

DDo not “blow back” fluid; this is not an air spray system.

DAlways have the tip guard on the spray gun when spraying.

DCheck the gun diffuser operation weekly.

DBe sure the gun trigger safety operates before spraying.

DLock the gun trigger safety when you stop spraying.

DFollow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

DTighten all the fluid connections before operating the equipment.

DCheck the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result

in a serious injury.

INSTRUCTIONS

D This equipment is for professional use only.

DRead all the instruction manuals, tags, and labels before operating the equipment.

DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor.

DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.

DCheck the equipment daily. Repair or replace worn or damaged parts immediately.

DDo not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (7 bar, 0.7 MPa) maximum working air pressure and 3000 psi (207 bar, 20.7 MPa) maximum working fluid pressure.

DUse fluids that are compatible with the equipment wetted parts. See the Technical Data section of all the equipment manuals. Read the fluid manufacturer’s warnings.

DRoute the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180_F (82_C) or below –40_F(–40_C).

DDo not use the hoses to pull equipment.

DWear hearing protection when operating this equipment.

DComply with all applicable local, state, and national fire, electrical, and other safety regulations.

308936 3

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installing the System . . . . . . . . . . . . . . . . . . . . . . . . 6

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . 6

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . . . 6

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . . . . 7

Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10

Gun Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Daily Gun Care, Flushing, and Cleaning . . . . . . . 17

Spray Pattern Troubleshooting . . . . . . . . . . . . . . . . 22

Gun Operation Troubleshooting . . . . . . . . . . . . . . . 23

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . 24

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . 25

Test Power Supply Resistance . . . . . . . . . . . . . . . 26

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . . . 27

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prepare the Gun for Service . . . . . . . . . . . . . . . . . 28

Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pre-Orifice,Tip Guard, Air Cap, Spray Tip,

or Seat Housing Replacement . . . . . . . . . . . . . . 29

Electrode Replacement . . . . . . . . . . . . . . . . . . . . . 30

Fluid Tube Removal & Replacement . . . . . . . . . . 31

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . 31

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fluid Packing Adjustment . . . . . . . . . . . . . . . . . . . 33

Fluid Needle Assembly Removal . . . . . . . . . . . . . 34

Power Supply Removal and Replacement . . . . . 35

Power Supply Adjustment . . . . . . . . . . . . . . . . . . . 35

Turbine Alternator Removal and Replacement . 36

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ES ON-OFFValve Repair . . . . . . . . . . . . . . . . . . . 37

Air Control Valve Repair . . . . . . . . . . . . . . . . . . . . 38

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . . . 47

Pre-orifice Selection Chart . . . . . . . . . . . . . . . . . . . . 47

The Graco Warranty and Disclaimers . . . . . . . . . . 48

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 48

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions.

4308936

Introduction

How the PRO AA4500/UNICARB

Electrostatic Air-AssistedSpray Gun

Operates

WARNING

Remember, this is not an air spray gun; for your safety be sure to read and follow the Warnings on pages 2 to 3 and throughout the text of this instruction manual.

The spray tip shapes the fluid into a fan pattern.

As the gun is triggered, the regulated air is directed to the power cartridge turbine.

The air control valve does not control pattern width. To change pattern width, a new tip size must be used.

The ability of the PRO AA4500/UNICARB Electrostatic Spray Gun to spray at higher fluid pressures, combined with the addition of CO2 from the UNICARB process, provides the additional power needed to atomize higher solids materials.

The gun’s internal power cartridge provides high voltage current. The fluid is electrostatically charged as it passes the gun’s electrode. The charged fluid is attracted to the grounded object, wrapping around and evenly coating all surfaces.

NOTE: The gun’s air control valve must be completely turned off to haveairless atomization. Closing the air control valve does not effect the operation of the turbine.

Power Supply’s Adjustable Lower Voltage Setting

The gun’s lower voltage setting (LO) is adjustable. The LO setting can be adjusted from 45 to 80 kV; it is preset by the factory at 60 kV. See page 35 to change the setting. NOTE: The gun’s full (HI) voltage setting is 85 kV.

 

 

 

 

 

ES Indicator

 

 

 

 

 

 

Light

Air Control

Tip Guard

 

 

 

 

 

 

 

 

Valve

(orange)

 

 

 

 

 

 

 

 

 

Air

Spray

Retaining

 

ES ON-OFF

 

ES HI-LO

Cap

Tip

Nut

Trigger Safety

 

(black)

(orange)

 

Latch

Lever

 

Lever

 

 

 

 

 

 

 

01944A

 

Back View of Gun

01947

308936 5

Installation

Installing the System

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

DDo not install or service this equipment unless you are trained and qualified.

DBe sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class I, Group D Hazardous Location.

DComply with all applicable local, state, and national fire, electrical, and other safety regulations.

Fig. 1 shows a typical electrostatic UNICARB 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 distributor.

Warning Signs

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun. Additional English, French, German, and Spanish signs are available at no charge. See Accessories to order them.

Ventilate the Spray Booth

WARNING

FLAMMABLE OR TOXIC VAPOR HAZARD

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

Air Line Accessories (Refer to Fig. 1)

1.Install an air shut-offvalve ( P) on each gun air supply line (Q) to shut off air to the gun(s).

2.Install an air regulator (N) on the gun air supply line to control air pressure to the gun.

3.Install an air line filter (B) on the air supply line to ensure a dry, clean air supply to the gun. Dirt and moisture can cause the gun to malfunction.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of serious injury due to component rupture, supply pressure must be limited.

The fluid supply system must be prevented from producing a fluid pressure greater than the 3000 psi (207 bar, 20.7 MPa) Maximum Working Pressure of the spray gun.

6308936

Installation

A

B

H

K

L

R

S

R

Y

KEY

A*

Bleed-typeAir Shutoff Valve

N

Gun Air Regulator

B

Air Line Filter

P

Gun Air Shut-offValve

H

Fluid Shutoff Valve

Q*

Graco Electrically Conductive

K

Pressure Gauge

 

Air Supply Hose

L*

Grounded Braid Type Fluid Hose

 

(1/4 npsm x 1/4 npsm LH)

 

with spring guards

R*

Fluid Drain Valve

M

Gun Fluid Inlet (1/4 npsm)

S

Fluid Filter

N W

P

Q

X M

WARNING

SIGN

01945B

WPRO AA4500/UNICARB Spray Gun

XGun Air Inlet (1/4 npsm LH)

YShrouded/Vented Waste Container

*Equipment required for safe operation of system. Must be purchased separately. See ACCESSORIES.

Fig. 1

Fluid Line Accessories (Refer to Fig. 1)

1.Install a fluid filter (S) and drain valve (R) at the pump outlet. Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip.

2.Install a fluid regulator (J) on the fluid line to control fluid pressure to the gun.

WARNING

INJECTION HAZARD

The fluid drain valve (R) is required in your system to assist in relieving fluid pressure in the supply system, hose and

gun; triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump’s fluid outlet. The drain valve reduces the risk of serious injury, including fluid injection and splashing in the eyes or on the skin.

308936 7

Installation

Ground the System

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

The following are minimum requirements for grounding a basic electrostatic system. Your system may include other equipment or objects which must be grounded.

Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

1.Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

2.Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer’s recommendations.

3.Electrostatic Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 12.

4.All air and fluid lines must be properly grounded. Use only grounded hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity.

5.All electric cables must be properly grounded.

6.All persons entering the spray area: their 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 that insulate the hand from the spray gun. The gloves must be conductive or modified as shown in Fig. 2, page 9.

7.Object being sprayed: keep the workpiece hangers clean and grounded at all times. Contact points must be sharp points or like knife edges.

8.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.

9.Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.

10.All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded.

8308936

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation.

____ 1. All the operators are properly trained to safely operate an electrostatic air-assistedairless spray system as instructed in this manual.

____ 2. All the operators are trained how to properly relieve pressure, using the Pressure Relief Procedure on page 10.

____ 3. The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded. See Ground the System, page 8.

____ 4. The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.

____ 5. The operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps.

____ 6. The operator is not wearing 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 the operator grounding through the gun.

____ 7. The condition of the electrical components of the spray gun has been checked as instructed in Electrical Tests, page 25.

____ 8. The ventilation fans are operating properly.

____ 9. The workpiece hangers are clean and grounded. Contact points must be sharp points or like knife edges.

____ 10. All the debris, including flammable liquids and rags, is removed from the spray area.

____ 11. All flammable liquids in the spray booth are in approved, grounded containers.

____ 12. All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.

WARNING

INJECTION HAZARD

Be sure the wallet sized warning card 179960, provided with the gun, is available and easily accessible, at all times,

for anyone operating or servicing this equipment. The card contains important information on what to do if an injection injury occurs. Additional cards are available at no charge from Graco.

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 they do not interfere with operator grounding through the gun.

06445

Fig. 2

308936 9

Operation

Pressure Relief Procedure

WARNING

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid

under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid or electric shock, follow the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor install or clean the spray tip.

1.Lock the spray gun trigger safety latch. See Fig. 3.

2.Turn the ES ON-OFFlever to OFF.

3.Turn off the fluid supply to the gun.

4.Close the bleed-typemaster air valve (required in system).

5.Close the air valve for the gun air supply line.

6. Unlock the gun trigger safety latch.

Fig. 3

7.Trigger the gun into a grounded, shrouded and vented metal waste container to relieve fluid and air pressure. This may take several minutes.

8.Lock the gun trigger safety latch again.

9.Open the fluid drain valve (required in system) to help relieve fluid pressure. In addition, open the drain valve connected to the fluid pressure gauge (in a system with fluid regulation) to help relieve fluid pressure in the hose and gun. Triggering the gun to relieve pressure may not be sufficient. Have a container ready to catch the drainage.

10.Leave the drain valve(s) open until you are ready to spray again.

11.If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above, very slowly loosen the hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose obstruction.

Trigger Safety

Latch Unlocked

Trigger Safety

Latch Locked

01988A

10 308936

Gun Setup

1.Complete the Operating Checklist and follow the Warnings on pages 9 and 10.

2.Connect the Graco air hose.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true

earth ground. Use Only Graco Electrically Conductive Air Supply Hose.

NOTE: The Graco air hose and the gun have specialleft-handthreads to prevent connecting another type of air supply hose to the gun air inlet and is available in lengths ranging from 6 to 100 feet (1.83 to 30.5 m). SeeAccessories to order the hose.

A.Connect the 1/4 npsm(f) left-handend of the Graco conductive air supply hose (A) to the gun air fitting (17).

17

A

Left-handthread

Fig. 2A

01989A

 

B.Connect the other end of the air supply hose (A) to a filtered and regulated air supply line (B).

C.Connect the air supply hose ground wire (C) to a true earth ground.

C

B

A

Fig. 2B-C

01990

NOTE: To connect two or more air hoses, use air adapter nipple 185493. SeeAccessories.

Continued on the next page.

308936 11

Gun Setup

3. Check the gun’s electrical grounding.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 218979 (E) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

D The gun has been removed from the hazardous area;

DOr all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, electric shock and result in serious injury and property damage.

A.Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

B.Turn the ES ON-OFFLever to OFF.

C.Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

D.Make sure the air hose (A) is connected and the hose ground wire is connected to a true earth ground.

E.Measure the resistance between the gun handle

(7) and a true earth ground (D).

a.If using a black or grey air hose, use a megohmmeter E) to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 2 megohms.

b.If using a red turbine air hose, use an ohmmeter to measure the resistance. Resistance should not exceed 100 ohms.

F.If the resistance is greater than the maximum reading specified above for your hose, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

A

7

D

E

01946A

Fig. 3D–E

4. Connect the gun exhaust tube.

Press the exhaust tube (56) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (57) provided.

56

57

01992A

Fig. 4

12 308936

Gun Setup

5. Connect the fluid hose.

A.Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

B.Connect the static-freefluid hose (F) to the1/4–18npsm gun fluid fitting (10).

6. Flush the spray gun.

Before running any paint through the spray gun, make sure the trigger safety latch is in the locked position, and the ES ON-OFF lever is turned to OFF, then remove the spray tip. Flush the gun out with a solvent that is compatible with the fluid to be sprayed, using the lowest possible pressure.

10

F

01993A

Fig. 5B

NOTE: The PRO AA4500 spray gun has a 100 meshin-linefluid inlet filter. A 60 mesh filter is also available. SeeAccessories.

C.Connect the other end of the fluid hose (F) to a grounded, filtered, and regulated fluid line (G).

G

Fig. 5C

F

01994A

 

 

 

 

7. Follow the Pressure Relief Procedure.

WARNING

INJECTION HAZARD

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Procedure on page 10before removing

or installing the spray tip, pre-orificeair cap or tip guard.

8. Select a spray tip.

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart on page 47, as a guide for selecting an appropriate spray tip for your application or consult your authorized Graco distributor. The orifice size of the spray tip is typically one or two sizes larger than the pre-orificesize selected below.

9. Select a pre-orifice

The fluid flow rate in UNICARB systems is controlled by the pre-orificesize, in conjuction with the fluid pressure. Use thepre-orificeselection chart on page 47 as a guide for selection.

308936 13

Gun Setup

10. Install the pre-orifice

WARNING

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 10 when you stop spraying and whenever you are instructed to relieve the pressure.

A.Place the spray tip seal (9a) on a flat surface.

B.Note that the hole through the pre-orifice(9b) is larger on one side than the other.

C.Place the pre-orifice(9b), with its larger hole facing up, on top of the tip seal (9a) hole.

D.Use a large, flat object to press the pre-orifice(9b) into the tip seal (9a).

PRESS DOWN with a large, flat

object

9b

9a

8799A

Fig. 10A–D

E.Turn over the tip seal and pre-orifice(9a, 9b) and insert them into the spray tip (9), wih thepre-orificeside facing down into the spray tip.

9a, 9b

9

8799A

Fig. 10E

11. Install the spray tip

WARNING

To reduce the risk of a serious injury, including fluid injection, follow the Pressure Relief Procedure on page 10 when you stop spraying and whenever you are instructed to relieve the pressure.

A.Make sure there is no pressure in the system before removing or installing a spray tip. Relieve the system pressure.

B.Place the spray tip (9) in the air cap (1), aligning the tab of the tip with the groove in the air cap. Be careful not to bend the electrode wire (1a).

1

9

8800A

Fig. 11B

C.Install the spray tip (9) and air cap (1), tip guard (2), and retaining nut (8) onto the gun; tighten the retaining nut firmly.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, and electric shock, never operate the spray gun with a bent, damaged or missing electrode (1a).

1, 9

2

8

02088B

Fig. 11C

14 308936

Gun Setup

12. Set the air pressure.

A.Atomizing air is not used in the UNICARB process. Close the air control valve (43) by turning it fully clockwise.

B.Turn the ES ON-OFFlever (26) to ON.

26

43

close

ON

 

01947

Fig. 12A-B

C.Make sure the fluid supply is shut off.

D.Trigger the gun and adjust the air pressure with the gun air regulator (H); use the Recommended Air Hose Inlet Pressure chart, below, as a guide.

 

H

Fig. 12D

01997

 

Recommended Air Hose Inlet Pressure

 

Recommended Air

Air Hose Length

Hose Inlet Pressure

 

 

6 ft ((1.8 m)

40 psi (2.8 bar)

 

 

15 ft (5 m)

43 psi (3.0 bar)

 

 

25 ft (8 m)

45 psi (3.1 bar)

 

 

36 ft (11 m)

47 psi (3.2 bar)

 

 

50 ft (15 m)

50 psi (3.5 bar)

 

 

75 ft (23 m)

55 psi (3.8 bar)

 

 

100 ft (30.5 m)

60 psi (4.1 bar)

NOTE: Using higher than recommended air pressures can reduce the life of the turbine/alternator. Lower pressures can be used but may reduce electrostatic wrap.

E.Check the voltage output of the gun using a high voltage probe and meter.

NOTE: The gun’s normal high voltage reading is 60 to 70 KV. If a ball end high voltage probe is used, the gun voltage will rise to about 85 KV. This will happen with all resistive electrostatic guns.

308936 15

Gun Setup

13. Setting the Atomization Fluid Pressure

Atomization fluid pressure will vary based on the type of fluid used, the flow rate desired, the fluid temperature, and the percentage of CO2 used. Follow the recommendations of your material and equipment supplier.

14. Using the Electrostatics

Turn the ES ON-OFFlever (26) to ON. This will activate the electrostatics.

Some objects with deep crevices or internal features may be painted more efficiently with the electrostatics turned off or in the LO setting (see 15 below). Be sure to turn off the electrostatics any time you are flushing the gun (see page 18).

NOTE: When spraying, the ES indicator light (K) will glow, indicating the electrostatic charge.

15.Use the ES HI-LOlever (43g) to change to either full voltage (HI) or a lower voltage level (LO).

K

43g

HI 26

ON

01947

Fig. 14-15

The LO setting is factory set to 60 kV. This setting can be adjusted between 45 and 80 kV. See page 35 to adjust.

16 308936

Daily Gun Care, Flushing, and Cleaning

WARNING

INJECTION HAZARD

To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on the skin or electric shock,

always follow the Pressure Relief Procedure Warningon page 10 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system.

CAUTION

Clean all parts with a non-conductivesolvent, compatible with the fluid being sprayed. Conductive 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.

CAUTION

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 the alternator life. Do not use any cleaning method which may allow solvent into the gun air passages.

Do not point the gun up while cleaning it.

Do not wipe the gun with a cloth soaked in solvent; ring out the excess.

Do not immerse the gun in solvent.

02028

02027

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.

02000

02001A

308936 17

Daily Gun Care, Flushing, and Cleaning

General System Maintenance

1.Clean the fluid and air line filters daily.

2.Check all of the work hangers for material build-up;clean them if necessary.

3.Check for any fluid leakage from the gun and fluid hoses. Tighten fittings or replace equipment as needed.

4.Flush the gun before changing colors and whenever you are done operating the gun.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, or electric shock, be sure the ES ON-OFFlever is turned to OFF before flushing the gun.

1.Follow the Pressure Relief Procedure Warning on page 10.

2.Make sure the ES ON-OFFlever is turned to OFF and the trigger safety latch is locked before proceeding.

locked

ES

 

OFF

Fig. 2

02002A

 

3.Pointing the gun down, unscrew and remove the retaining nut (8), tip guard (2), air cap (1) and fluid tip (9).

You may have to turn the air cap with the tip guard to remove the air cap from the gun. Set these parts aside.

1 9

2

8

Fig. 3

02004A

 

4.Make sure the air and coating supply is turned off. Turn on the solvent supply.

01999A

Fig. 4

5. Flush the Spray Gun.

Unlock the trigger safety latch, point the gun down into a grounded metal container, and flush the gun with solvent until it is clean. Use the lowest possible fluid pressure when flushing.

Fig. 5

02005A

 

18 308936

Daily Gun Care, Flushing, and Cleaning

6.Lock the trigger safety latch and turn off the solvent supply.

7.Follow the Pressure Relief Procedure Warning on page 10.

8.Make sure the trigger safety latch is locked, then disconnect the solvent (F) and air (A) supply hoses from the gun.

F

A

02341

02338

Fig. 8

9.Unlock the trigger safety latch and trigger the gun into a grounded metal container (L) to drain the fluid tube.

L

11.Dip the end of a soft-bristlebrush into a compatible solvent. Then point the gun down and clean the front with the brush and solvent.

02007

01948

Fig. 11

12.Dampen a soft cloth with solvent and wring-outthe excess. Point the gun down and wipe off the outside.

Fig. 9

02006

 

 

 

10. Lock the trigger safety latch.

Fig. 12

02008

 

308936 19

Daily Gun Care, Flushing, and Cleaning

13.Remove the bottom fluid tube fitting

(P) and filter (14). Clean the filter in a compatible solvent.

14.Reinstall the filter and fitting. Do not over-tightenand make sure the top fluid tube fitting (Q) remains tightened.

Q

P

14

02009

Fig. 13–14

15. Hang up the gun.

Fig. 15

02010A

 

CAUTION

Always hang the gun with its nozzle pointing down to avoid having solvent run into the gun air passages. Solvent in the gun air passages can cause poor atomization and excessive current demands and can damage the gun.

16.Clean the retaining nut, tip guard, air cap and fluid tip with a soft brush daily, minimum.

Clean the parts with a soft brush and replace them if they are damaged. Be careful not to bend, damage, or disengage the electrode wire.

Fig. 16

02011

 

17.Wipe off the parts with a dry cloth. Be careful not to bend the electrode wire.

18.Check the electrode wire. Replace it if it is bent or damaged. See page 30.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing electrode.

20 308936

Daily Gun Care, Flushing, and Cleaning

19. Place the spray tip (9) in the air cap (1).

Align the tab of the tip with the groove in the air cap. Be careful not to bend the electrode wire.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing electrode.

1

9

8800A

 

Fig. 19

20.Install the spray tip (9) and air cap (1), tip guard (2), and retaining nut (8). Tighten the retaining nut firmly.

CAUTION

To avoid damaging the tip guard (2), orientate the air cap (1) before tightening the retaining nut (8). Do not turn the air cap when the retaining nut is tight.

1, 9

2

8

21. Hang up the gun until it is used again.

Fig. 21

02012B

 

CAUTION

Always hang the gun with its nozzle pointing down to avoid having solvent run into the gun air passages. Solvent in the gun air passages can cause poor atomization and excessive current demands and can damage the gun.

02088B

Fig. 20

308936 21

Spray Pattern Troubleshooting

WARNING

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious 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 serious injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin, or electric shock, always follow the Pressure Relief Procedure on page 10 before checking, adjusting, cleaning or repairing the gun or any part of the system.

NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.

NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.

PROBLEM:

CAUSE

SOLUTION

IMPROPER SPRAY

 

 

PATTERN

 

 

 

 

 

Fluttering or spitting spray

The fluid pressure or fluid supply is insuf-

Adjust the flluid/CO2 supply system.

 

ficient.

Check; tighten the siphon hose connections;

 

 

 

There is air in the fluid supply line.

bleed the air from the fluid line.

 

The CO2 percentage is fluctuating or is

Check fluid/CO2 supply system.

 

too high.

Check temperature control system

 

The fluid temperature is fluctuating.

 

 

 

 

 

Irregular pattern

There is fluid buildup on the spray tip or

Clean the spray tip and pre-orifice;see

 

the spray tip or pre-orificeis partially

page 20.

 

plugged.

 

 

The spray tip or pre-orificeis damaged or

Replace the damaged or worn part; see

 

worn.

page 29.

 

 

 

Tails in pattern

The CO2 percentage is too low.

Increase the CO2 percentage.

 

The fluid pressure is too low.

Increase the fluid pressure with the gun fluid

 

 

regulator.*

 

The temperature is too low

Increase fluid temperature.

 

 

 

Excessive paint buildup on the

The fluid pressure is too low.

Increase the fluid pressure with the gun fluid

air cap and tip guard

 

regulator.*

 

 

 

* Use the least fluid pressure needed for good results.

22 308936

Gun Operation Troubleshooting

PROBLEM

CAUSE

SOLUTION

 

 

 

Leakage from fluid needle area

Fluid needle packings loose

Tighten packing nut; See page 33

 

Fluid needle packing damaged

Replace fluid needle; See page 34

 

 

 

Air leakage from front of gun

Air valve not turned off

Turn off air (43). See page 15

 

Piston air valve not seating properly

Clean, Service; See page 39

 

 

 

Fluid leakage from front of gun

Fluid needle worn

Replace fluid needle; See page 34

 

Fluid seat loose or worn

Tighten or replace fluid seat

 

Spray tip loose

Tighten retaining nut

 

Tip seal damaged

Replace tip seal; See page 29

 

 

 

“Orange Peel” finish

CO2 percentage is too low

Increase CO2 percentage

 

Fluid pressure too low

Increase fluid pressure with gun fluid regulator*

 

Spray tip or pre-orificetoo large

Use a smaller size spray tip or pre-orifice;

 

Fluid poorly mixed or filtered

See page 47

 

Remix or refilter fluid

 

Improper thinner being used

 

Use proper thinner

 

 

 

 

 

Excessive spray fog

Fluid thinned too much

Properly thin fluid

 

 

 

No fluid sprays from gun

Fluid supply low

Check; Add fluid if necessary

 

Spray tip or pre-orificeis dirty or clogged

Clean spray tip and pre-orifice;See page 20

 

Spray tip damaged

Check; Replace spray tip; See page 29

 

Fluid needle damaged

Replace fluid needle; See page 34

 

 

 

Equipment covered with fluid

Booth exhaust air flow too low or not

Check for proper CFM; Check baffles and

 

directed properly

direction of air flow

 

Improper distance between gun and

Adjust spraying distance to 8 to 12 inches

 

workpiece

(203 to 305 mm)

 

 

 

Paint build-upon air cap

CO2 percentage too high

Reduce CO2 percentage

 

Air cap dirty

Clean air cap; See page 20

 

 

 

Fluid doesn’t shut off properly

Seat housing over-tightened

Replace seat housing; See page 29

 

Fluid leakage buildup on fluid needle

Replace fluid needle; See page 34

 

Fluid packings too tight

Adjust fluid packings; See page 34

 

 

 

* Use the least fluid pressure needed for good results.

308936 23

Electrical Troubleshooting

NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying Voltage Readout (SVRt). SeeAccessories to order the SVR.

PROBLEM

CAUSE

SOLUTION

 

 

 

Reduced fluid efficiency

Improper distance between gun and

Adjust spraying distance to 8 to 12 inches

 

work-piece

(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

 

Fluid pressure too high

Reduce fluid pressure at fluid supply

 

Improper fluid viscosity

Check supplier for proper fluid for electro-

 

 

static spray

 

Fluid resistivity too low

Check fluid resistivity with paint meter and

 

 

probe

 

No or low voltage output

Check possible causes listed below

 

Turbine alternator not operating

Check air supply to turbine inlet; See page 15

 

Faulty gun resistance

Check gun resistance; See page 25

 

Fluid leaks from needle packing and

Clean needle cavity; Replace fluid needle;

 

causes short

See page 34

 

Faulty turbine alternator

Be sure plug is in place on back of turbine

 

 

alternator housing; Remove and test turbine

 

 

alternator; See page 36

 

kV switch stuck on low

Check switch actuation; replace if needed

 

 

 

Operator gets shock

Operator not properly grounded or is

Be sure floor is properly grounded; Wear

 

near an ungrounded object

shoes with conductive soles 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

 

Gun not properly grounded

worn, a glove must be conductive or modified

 

as shown on page 9

 

 

 

 

See Check the Electrical Grounding,

 

 

page 12

 

 

 

Operator gets shock when

Workpiece not properly grounded.

Clean workpiece hangers; Check for proper

touching workpiece

 

ground on conveyor or track

 

 

 

No or low voltage output reading

Damaged fiber optic cable or

Check cables and connections; replace if

on gun display module

connection

damaged

 

 

See other causes under Problem

 

 

Reduced fluid efficiency, above

 

 

 

NOTE: If using an ES Display Module, see its instruction manual, No. 308265, for further troubleshooting.

24 308936

Electrical Tests

The performance and safety of the spray gun are 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 (18) and the barrel resistor cartridge as well as the continuity of the electrical path between the components.

CAUTION

The barrel resistor cartridge is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor cartridge.

Use megohmmeter P/N 218979 (A) and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 218979 (A-seeFig. 4) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to do the electrical tests unless:

D The gun has been removed from the hazardous area;

DOr all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, electric shock and result in serious injury and property damage.

Test Gun Resistance (See Fig. 4)

NOTE: The fluid passage must be flushed and dried to get an accurate reading.

Measure the resistance between the end of the electrode (1a) and the air fitting (17). The resistance should be between 329 to 401 megohms. If the resistance is outside the specified range, go to the next test. If the resistance is correct, refer to Electrical Troubleshooting on page 24 for other possible causes of poor performance.

A

1a

17

 

01949

Fig. 4

308936 25

Electrical Tests

Test Power Supply Resistance (See Fig. 5)

Remove the power supply (18) from the gun. See page 35.

Measure the resistance from the power supply’s ground contact point (EE) to the contact inside of the power supply seal (18e) [the conductive rubber contact may be slightly recessed into the seal]. See Fig. 5.

The resistance should be 297 to 363 megohms. If the resistance is outside the specified range, the power supply 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 Electrical Troubleshooting for other possible causes of poor performance, or contact the nearest authorized service agency.

NOTE: Be sure the seal (18e) is in place on the end of the power supply before installing the power supply back into the gun.

A

EE

18e

18

0441

Fig. 5

26 308936

Electrical Tests

Test Barrel Resistance (See Fig. 6)

Measure the resistance between the barrel contact ring (3a) and the metal contact pin (E), using a metal rod (D) and megohmmeter as shown in Fig. 6. Be careful not to damage or scratch the inner surfaces of the barrel with the metal rod.

The resistance should be 19 to 29 megohms. If the resistance is incorrect, make sure the metal contact pin (E) and the barrel contact ring (3a) are clean.

If the resistance is still outside the specified range:

1.Remove the barrel contact ring (3a) with a small pick. There is a wire lead in the groove that the contact ring was removed from.

2.With the metal rod (D) still inside the barrel as shown in Fig. 6, measure the resistance between the wire lead and the metal rod.

3.If the resistance is still outside the specified range, the gun barrel needs to be replaced.

If the resistance is correct, install a new contact ring (3a) and press it firmly into the groove on the front of the barrel.

Be sure the contact ring is in place before operating the gun.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

The barrel contact ring (3a) is a conductive contact ring, not a sealingo-ring.To reduce the risk of sparking or electric shock,do not remove the barrel contact ring from the barrel except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

 

E

3a

D

 

 

Wire lead in groove behind contact ring

01957

Fig. 6

308936 27

Service

Prepare the Gun for Service

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts that may cause electric shock or other serious injury if

the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. gun.

WARNING

INJECTION HAZARD

To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on the skin or electric shock,

always follow the Pressure Relief Procedure Warningon page 10 before checking or servicing any part in the system and whenever you are instructed to relieve the pressure.

NOTE:

DCheck all possible remedies in Troubleshooting before disassembling the gun.

DIf the plastic parts of the gun must be held securely, always clamp them in padded vice jaws to prevent damage to the parts.

DLightly lubricate o-ringsand seals with petroleum jelly. Do notover-lubricate.

DOnly use genuine Graco parts. Do not mix or use parts from other PRO Gun models. Note that the air cap, spray tip, and tip guard for this gun are orange.

WARNING

Some PRO AA4500 Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts that may look similar, but have different part numbers! Use of parts other than those specified in the PRO AA4500 Gun parts list on page 43 could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or property damage.

1.Flush the gun as instructed on page 18.

2.Relieve the pressure.

3.Disconnect the air and fluid lines from the gun.

4.Remove the spray gun from the worksite for service or repair. Service or repair area must be clean.

Tools Needed

D2 mm Driver (included with gun)

D4 mm Driver (included with gun)

D9 mm Driver (included with gun)

DAdjustable Wrench

DMedium Screw Driver

DSnap Ring Pliers

DNeedle Nose Pliers

28 308936

Service

Pre-Orifice,Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement

1.Prepare the gun for service as instructed on page 28.

2.Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

3.Replace the tip gasket (9a) if damaged.

4.Trigger the gun and remove the seat housing (21) with the 9 mm driver (64), supplied. See Fig. 8.

CAUTION

The barrel resistor cartridge (B) is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor cartridge.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

The barrel contact ring (3a) is a conductive contact ring, not a sealingo-ring.To reduce the risk of sparking or electric shock,do not remove the barrel contact ring from the barrel except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

5.Trigger the gun and install the seat housing (21) with the 9 mm driver (64). Tighten the seat housing until it’s snug and then tighten it 1/4 turn more.

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tightenthe seat housing.Over-tighteningmay result in improper fluidshut-off.

6.Assemble the spray tip (9), air cap (1), and tip guard (2). Then install them on the gun, securing them with the retaining nut (8). Tighten the retaining nut firmly.

CAUTION

To avoid damaging the tip guard (2), orientate the air cap (1) before tightening the retaining nut (8). Do not turn the air cap when the retaining nut is tight.

7.Make sure the electrode is not bent, damaged or missing from the air cap.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing electrode.

8. Test the gun resistance as instructed on page 25.

9 9a

1

2

8

02004A

Fig. 7

21

64

B

02035

Fig. 8

308936 29

Service

Electrode Replacement

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap.

1.Prepare the gun for service as instructed on page 28.

2.Remove the retaining nut (8), tip guard, (2), air cap

(1) and spray tip (9). See Fig. 7. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

3.Pull the electrode (1a) out of the backside of the air cap with a needle nose pliers.

4.Push the new electrode through the air cap hole. Place firm finger pressure on the electrode wire (1a) on the backside of the air cap, and make sure the short end (BB) of the electrode engages into the hole (CC) as shown in Fig. 9.

5.Assemble the spray tip, air cap, and tip guard. Then install them on the gun, securing them with the retaining nut. Tighten the retaining nut firmly.

6.Test the gun resistance as instructed on page 25.

1a 1

CC BB

8804A

Fig. 9

30 308936

Service

Fluid Tube Removal & Replacement

To remove the fluid tube assembly (12) for cleaning or replacement:

1.Prepare the gun for service as instructed on page 28.

2.Disconnect the bottom fluid tube nut (C). See Fig. 10.

3.Carefully unscrew the top fluid tube nut (D).

CAUTION

Be careful not to damage the fluid tube assembly (12) when cleaning or installing it, especially the sealing surface (E). See Fig. 11. If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

4.Apply grease, part no. 217115, to the entire length of the plastic extension on the end of the fluid tube (12). See Accessories to order the grease.

5.Apply a low strength thread sealer (such as purple Loctiter) to the fluid tube nut (D) threads.

6.Install the fluid tube into the gun barrel by tightening the top fluid tube nut (D) hand-tight,then turn it 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do notover-tightenit.

7.Make sure the fluid filter (14) is in place in the fluid fitting (10). Then tighten the bottom fluid tube nut

(C) onto the fluid fitting; make sure the top fluid tube nut (D) remains tightened.

Fluid Filter Removal

1.Prepare the gun for service as instructed on page 28.

2.Disconnect the bottom fluid tube nut (C). See Fig. 10.

3.Remove the fluid filter (14) from the fluid fitting (10). Clean or replace the filter, as needed.

4.Install the fluid filter back into the fluid fitting (10) and tighten the bottom fluid tube nut (C) onto the fluid fitting; make sure the top fluid tube nut (D) remains tightened.

10

D

C

14

02009

Fig. 10

Apply grease 217115

Apply low strength thread sealer

12

E

D

C

Fig. 11

2079

308936 31

Service

Barrel Removal

1.Prepare the gun for service as instructed on page 28.

2.Disconnect the bottom fluid tube nut (C). See Fig. 12.

NOTE: 2-fingertrigger guns only

It should not be necessary to remove the fluid fitting (10) from the bracket. If you must remove it, remove the two setscrews in the bracket that hold it in place. Apply a low strength (purple) Loctiter to setscrews before re-installingthem.

3.Loosen the three cap screws (5), using the 4 mm driver (55), supplied.

4. Hold the gun handle (7) with one hand and pull the

18

 

barrel (3) straight away from the handle to remove

7

it. See Fig. 13.

 

 

Fig. 13

CAUTION

 

To avoid damaging the power supply (18), always pull the gun barrel straight away. If necessary, gently move the gun barrel from side to side to free it from the gun handle.

10 C

55

5

01950

Fig. 12

3

01951A

32 308936

Service

Fluid Packing Adjustment

If fluid leaks from the fluid needle area, the fluid packings may be loose. Tighten the packings, following the procedure below.

1.Prepare the gun for service as instructed on page 28.

2.Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7, page 29. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

3.Trigger the gun and remove the seat housing (21) with the 9 mm driver (64), supplied. See Fig. 8, page 29.

NOTE: The seat housing (21) must be removed before adjusting the fluid packings.

4.Remove the barrel as instructed on page 32.

5.Place the 2 mm driver (58), supplied, in the back of the fluid needle assembly. Push the tool in and turn it clockwise, slightly, to tighten the packings. See Fig. 14.

6.Assemble the barrel as instructed on page 36.

7.Trigger the gun and install the seat housing (21) with the 9 mm driver (64). Tighten the seat housing until it’s snug and then tighten it 1/8 turn more.

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tightenthe seat housing.Over-tighteningmay result in improper fluidshut-off.

8.Assemble the spray tip, air cap, and tip guard. Then install them on the gun, securing them with the retaining nut. Tighten the retaining nut firmly.

9.Test the gun resistance as instructed on page 25.

To tighten packings

To remove needle

58

02015

Fig. 14

308936 33

Service

Fluid Needle Assembly Removal

1.Prepare the gun for service as instructed on page 28.

2.Remove the retaining nut (8), tip guard, (2), air cap

(1) and spray tip (9). See Fig. 7, page 29. You may have to turn the air cap with the tip guard to remove the air cap from the gun.

3.Trigger the gun and remove the seat housing (21) with the 9 mm driver (64). See Fig. 8, page 29.

4.Remove the barrel as instructed on page 32.

5.Remove the trigger screws (4) and trigger (13).

6.Place the 2 mm driver (58) in the back of the fluid needle assembly (28). See Fig. 14. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

7.Insert the 2 mm driver (58) into the front of the gun and push the fluid needle assembly (28) out the back of the gun body.

CAUTION

To avoid damaging the needle assembly, be sure the needle is completely unthreaded before pushing it out of the barrel.

8.Install the fluid needle assembly (28) into the gun barrel. See Fig. 15. Push in on the needle with the 2 mm driver (58) and tighten the assembly clockwise until just snug, then 1/4 to 1/2 turn tighter.

9.Install the trigger (13) and tighten the trigger screws (4).

10.Assemble the barrel as instructed on page 36.

11.Trigger the gun and install the seat housing (21) with the 9 mm driver (64). Tighten the seat housing until it’s snug and then tighten it 1/8 turn more.

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tightenthe seat housing.Over-tighteningmay result in improper fluidshut-off.

12.Assemble the spray tip, air cap, and tip guard. Then install them on the gun, securing them with the retaining nut. Tighten the retaining nut firmly.

13.Test the gun resistance as instructed on page 25.

28

4

13

02016

Fig. 15

34 308936

Service

35

18d

18

18b

7

18a

18c

18e

F

37a

3

37b

37

01953A

Fig. 16

Power Supply Removal and Replacement

NOTES:

a.To avoid a loss in electrostatic performance, inspect the gun handle’s power supply cavity for dirt or moisture. Clean the cavity with a clean, dry rag.

4.Inspect the power supply for any physical damage. Check the electrical resistance as instructed on page 26. If needed, replace the power supply.

Before installing the power supply, inspect the seal (18e) for any damage or swelling; replace if necessary. Also, make sure the gaskets/pads (18a–18d)are in place. See Fig. 16.

b.Do not expose the seal (18e) or o-ring(37a) to solvents as it will damage them.

c.Be careful when handling the power supply to avoid damaging it.

1.Prepare the gun for service as instructed on page 28.

5.Lubricate the o-ring(37a) and insert the power supply in the gun handle.

6.Install the barrel on the handle as instructed on page 36.

7.Test the gun resistance as instructed on page 25.

2.Remove the barrel as instructed on page 32.

3.Grasp the power supply (18) with your hand. With a gentle side to side motion, pull the power supply free from the gun handle (7), then pull it straight out.

Power Supply Adjustment

The KV HI/LO switch, on the back of the gun manifold, enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set at 60 kV, but can be adjusted. Place the pin in either the 45 kV or 60 kV position.

308936 35

Service

Turbine Alternator Removal and

Replacement

NOTE: Replace turbine bearings after 2000 hours of operation. See your authorized Graco representative.

1.Prepare the gun for service as instructed on page 28.

2.Remove the power supply from the gun handle as instructed on page 35.

3.Squeeze the two ends of the retaining ring (35) together and carefully pull the alternator (37) away from the power supply (18) until the 3-wireconnector (F) disengages. See Fig. 16.

4.Use an ohmmeter to test the turbine alternator coil. Measure the resistance between the two outer terminals of the 3-wireconnector (F). Resistance should be 3 to 5 ohms. If the reading varies from this value, replace the alternator.

5.Measure the resistance between each outer terminal of the 3-wireconnector and the turbine alternator housing. The resistance should be infinite. If the resistance is not infinite, replace the alternator.

6.Connect the 3-wireconnector to the 3 prongs in the power supply. Push the alternator (37) onto the power supply (18) until the retaining ring (35) engages with the alternator.

7.Install the power supply in the gun handle as instructed on page 35.

Barrel Installation

1.Be sure the gaskets (34 & 18a) and spring (30) are in place. See Fig. 17. Replace if damaged.

2.Place the barrel (3) over the power supply (18) and onto the gun handle (7). Make sure the fluid needle spring (30) is seated properly.

3.Pressing the barrel and handle together, tighten the three cap screws (5) oppositely and evenly with the 4 mm driver (55). Tighten the cap screws to 18 in-lbs(2 NSm) maximum (about a half turn past snug). Do notover-tighten.

CAUTION

To avoid damaging the gun, do not over-tightenthe cap screws (5).

4.Make sure the fluid filter (14) is in place in the fluid fitting (10).

5.Tighten the bottom fluid tube nut (C) onto the fluid fitting (10); make sure the top fluid tube nut (D) remains tightened.

6.Test the gun resistance as instructed on page 25.

7

18a

18

34

5

3

30

14

D

10

 

12

 

C

 

Tighten to 18 in-lbs(2 NSm)maximum (about half turn past snug), using wrench provided.

01952A

Fig. 17

36 308936

Service

ES ON-OFFValve Repair

1.Prepare the gun for service as instructed on page 28.

2.Loosen the set screw (24) with the 2 mm hex key (63), supplied. Remove the lever (26) from the valve. See Fig. 18.

WARNING

MOVING PARTS HAZARD

To reduce the risk of eye injury, be sure

to wear safety glasses when removing or installing the retaining ring (47) as the

retaining ring could slip off the tool when compressed.

3.Use internal snap ring pliers to remove the retaining ring (47) from the handle. Align the holes in the retaining ring with the flat on the spacer (32) to ease assembly and disassembly.

4.Remove the valve body (38) from the handle; be careful not to drop the regulator disk (46) and spacer (32).

5.Clean and inspect the parts for damage. Replace if necessary. Lubricate the o-ring(36) with petroleum jelly.

CAUTION

Do not over-lubricateparts. Excessive lubricant on theo-ring(36) can be pushed into the gun air passage and blemish the finish on the workpiece.

6.Install the regulator disk (46) in the valve (38) with its bevelled side facing in toward the valve.

CAUTION

Be sure the regulator disk (46) is installed correctly. A missing or incorrectly installed regulator disc can cause severe damage to the turbine alternator.

7.Install the valve (38), with the regulator disc (46) and o-ring(36), into the gun handle as shown in Fig. 18. Install the spacer (32) on the valve.

8.Install the retaining ring (47) into the groove in the handle. Install the lever (26) and tighten the set screw (24).

WARNING

MOVING PARTS HAZARD

Make sure that the retaining ring (47) is

engaged in the groove in the gun handle when installing the ESON-OFFValve. If the retaining ring is missing or improperly installed,

the valve assembly can be propelled out of the gun when air pressure is applied and cause serious injury.

26

47

32

24

36

46

38

 

Bevelled side of disk (46) faces toward valve (38)

Lubricate o-ringswith petroleum jelly

01955B

Fig. 18

308936 37

Service

Air Control Valve Repair

NOTE: The air control valve (43) can be replaced as an assembly or as individual parts.

To disassemble the air control valve,

1.Prepare the gun for service as instructed on page 28.

2.Remove the retaining ring (43h). See Fig. 19.

3.Slide the KV HI-LOlever (43g) up, place a wrench on the flats of the valve housing and remove the air control valve assembly (43).

4.Remove the retaining ring (43b).

5.Rotate the adjustment knob (43c) counterclockwise until it is disengaged from the valve housing threads (43d). Pull the adjustment knob out of the valve housing. The KV HI-LOlever (43g) and the wave spring (43f) can be removed if necessary.

6.Clean all the parts and inspect them for wear or damage.

7.Reassemble the air control valve (43). Lubricate the o-rings(43e) and the adjustment knob threads (43c) with petroleum jelly. Install the retaining ring (43h).

8.Apply low strength (purple) Loctite or equivalent thread sealant to the threads of the valve housing (43d) and install the air control valve assembly (43) into the gun handle.

To start the valve housing (43d) threads into the handle, turn the adjustment knob (43c). Once the threads are started, turn the adjustment knob (43c) fully counterclockwise.

Torque the valve housing into the gun handle to 10 to 12 in-lb(1.1 to 1.4 NSm).

9.Install the retaining ring (43h) back into the groove in the valve housing (43d).

 

DETAIL

 

 

 

43b

43d

43g

 

43e

43f

43h

43c

0385A

 

 

 

 

 

Lubricate o-rings(43e) and top knob threads (43c) with petroleum jelly

Apply low strength (purple) Loctite or equivalent to housing (43d) threads; Torque to 10–12in-lb(1.1–1.4N.m)

43

01954B

Fig. 19

38 308936

Service

Air Valve Repair

1.Prepare the gun for service as instructed on page 28.

2.Using a screw driver, remove the air valve cap (45). See Fig. 20.

3.Remove the o-ring(23) and spring (44).

CAUTION

Clean all parts in non-conductivesolvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

4.Loosen the air valve packing nut (40) one full turn, then remove the air valve shaft (39).

CAUTION

When removing the air valve shaft (39) be careful not to damage the seat area.

5.Check the o-rings(41, 23) for damage and replace if necessary. Apply petroleum jelly to theo-rings.

6.Unscrew the packing nut (40) to check the u-cup(42). Do not remove theu-cupunless it is damaged.If the u-cup (42) is removed, be sure to install the air valve shaft (39) into the handle before installing the packing nut andu-cup.

7.Install the air valve shaft, with the o-ring(41) into the back of the gun handle (7).

8.If removed, install the u-cupwith its lips facing into the gun handle.

9.Tighten the air valve packing nut (40) until it bottoms.

10.Install the spring (44), o-ring(23) and air valve cap (45). Tighten the air valve packing nut (40).

4523

44

39

41

7

40, 42

Lubricate o-ringswith petroleum jelly

Do not remove u-cup(42) unless damaged. Install with lips facing into handle.

Fig. 20

02014A

308936 39

Notes

40 308936

Technical Data

Category

Data

 

 

 

 

 

 

Gun Weight

35 oz (1 kg)

 

 

 

 

 

 

Gun Length

11.4 in (290 mm)

 

 

 

 

Maximum Air

100 psi (7 bar, 0.7 MPa)

Working Pressure

 

 

 

 

 

 

Maximum Fluid

3000 psi (207 bar,

 

Working Pressure

20.7 MPa)

 

 

 

 

 

Typical Noise Level

Sound Pressure {

86 Db(A)

at 40 psi (2.8 bar,

Sound Power }

88.9 Db(A)

0.28 MPa)*

 

 

 

 

 

 

Maximum Noise

Sound Pressure {

95 Db(A)

Level at 100 psi

Sound Power }

99.7 Db(A)

(7 bar, 0.7 MPa)**

 

 

 

 

 

 

 

Voltage Output

0–85kV

 

 

 

 

 

 

Short Circuit Current

120 mA

 

 

Output

 

 

 

 

 

Paint Resistivity

3 megohm-cmto infinity

Range

 

 

 

 

 

Air Inlet

1/4 npsm(m) left-hand

 

 

 

 

Fluid Inlet

1/4 npsm(m)

 

 

 

 

Wetted Parts

Stainless Steel, Nylon, PEEK,

 

Ultra High Molecular Weight

 

Polyethylene, Tungsten

 

Carbide, Glass Filled Nylon

rVitonr is a registered trademark of the DuPont Co. Loctiter is a registered trademark of the Loctite Corporation.

*Noise levels measured with a 40 psi (2.8 bar) air supply at the gun air inlet and typical gun air flow settings.

**Noise levels measured with a 100 psi (7 bar) air supply at the gun air inlet and maximum gun air flow settings.

{ Sound pressure was measured per Cagi Pneurop, 1969.

}Sound power was measured per ISO–3744,1981.

Radio Frequency Transmitter Approval for Gun Part No. 236031 and 236033

FCC ID: JHI1

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1.) This device may not cause harmful interference, and

2.) This device must accept any interference received, including interference that may cause undesired operation.

Changes or modification to this equipment, not expressly approved by the party responsible for compliance, could void the user’s authority to operate this equipment.

This equipment complies with (DOC) GRR II 6. (4) En conformite avec (MDC) RGRII 6. (4).

308936 41

Parts

3

3a

21

9a

9b

9

1

2

1a 8

18d

18b

18

18e

18a

34

28

31

19

6

30

42

40

 

7

Item 1 includes item 1a

 

Item 3 includes item 3a

 

Item 18 includes items 18a to 18e

 

Item 37 includes items 37a and 37b

 

Item 43 includes items 43b to 43h

12

Item 45 includes items 45a to 45e

14

42 308936

5

4

13

REF 12

37a

37

37b

35

18c

43c

43e 43h

43g

43f

43d

43b

45 23

44

39

41

24 26

47

32

36

38

46

15

19

33

16

17

56

57 01956D

Parts

WARNING

Some PRO 4500sc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts!

Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or property damage.

Part No. 965722, Series B

Includes items 1–8,10–67

Ref

 

 

 

No.

Part No.

Description

Qty

1

241250

AIR CAP & ELECTRODE ASSY.;

 

 

 

Includes item 1a

1

1a

188676

S ELECTRODE; See pg. 45

 

 

 

to order kit of 5 electrodes

1

2

188479

TIP GUARD

1

3

235827

BARREL, gun; Includes item 3a

1

3a

111261

S CONTACT RING, barrel

1

4

186654

SCREW, trigger

2

5

185096

SCREW, cap, relieved; M5 x 0.8

3

6

185097

HOOK

1

7

235911

HANDLE

1

8

188480

RETAINING NUT, air cap

1

9

GG3XXX

SPRAY TIP, customer choice

 

 

 

See pg. 47 to order

1

9a

626588

SEAL, spray tip

1

9b

5519XX

PRE-ORIFICE,customer choice

 

 

 

See pg. 47 to order

1

11Y}

179791

WARNING TAG

1

12

235843

FLUID TUBE ASSY.

1

13

186791

TRIGGER

1

14

205264

FLUID FILTER

1

15

185122

MUFFLER (flame arrestor)

1

16

238160

BRACKET

1

17

185105

AIR FITTING

1

18

236039

POWER SUPPLY ASSY.; 85 KV

 

 

 

Includes items 18a–18e

1

18a{

186840

S GASKET

1

18b

185099

S PAD

1

18c

185145

S PAD

1

18d

185141

S CUSHION

1

18e{

186637

S SEAL

1

19{

106555

O-RING,plug & adapter; Vitonr

2

21

235797

SEAT HOUSING

1

23{

110099

O-RING,air valve cap; PTFEr

1

Ref

 

 

 

No.

Part No.

Description

Qty

24

110083

SET SCREW; M4 x 0.7

1

26

186839

ES ON-OFFLEVER

1

28

235798

FLUID NEEDLE ASSY.

1

30

112691

SPRING, compression

1

31

185079

PLUG

1

32

185119

SPACER, ES valve

1

33

185112

FITTING, barb

1

34{

185113

GASKET, manifold; polyethylene

1

35

185114

RETAINER RING, alternator

1

36

113746

O-RING,ES valve; CV75

1

37

222319

TURBINE ALTERNATOR;

 

 

 

Includes items 37a & 37b

1

37a{

110073

S O-RING,Viton

1

37b

185124

S CUSHION

1

38

185118

ES VALVE

1

39

224194

AIR VALVE SHAFT ASSY.

1

40

185115

PACKING NUT

1

41{

111508

O-RING,air valve; fluoroelastomer

1

42{

105452

U-CUP,air valve; PTFE

1

43

223978

AIR CONTROL VALVE ASSY.

 

 

 

Includes items 43b–43h

1

43b

105681

S RETAINING RING

1

43c

191806

S KNOB, adjustment

1

43d

186837

S HOUSING

1

43e{

168518

S O-RING,Viton

2

43f

111221

S SPRING. wave

1

43g

224196

S LEVER, ESHI-LO

1

43h

111510

S RETAINING RING, external

1

44

185116

SPRING, compression, air valve

1

45

188486

AIR VALVE CAP

1

46

107107

DISC REGULATOR

1

47

110082

RETAINING RING

1

54Y

188774

WARNING TAG

1

55}

107460

DRIVER, socket head; 4 mm

1

56

185103

EXHAUST TUBE; polyurethane

1

57

110231

CLAMP, exhaust tube

1

58}

112080

DRIVER, socket head, 2 mm

1

59Y}

180060

WARNING SIGN, English

 

 

 

See Accessories for additional signs

1

60}

180209

GUN COVER; Order Part No. 218374

 

 

for package of 10

1

62Y}

222385

WARNING CARD

1

64}

110087

DRIVER, hex nut, 9 mm

1

67}

235300

BRACKET, gun hanging

1

YReplacement Danger and Warning labels, tags and cards are available at no cost.

{These parts are included in Air Seal Repair Kit 224633, which may be purchased separately.

}These parts are not shown in the parts drawing.

308936 43

Accessories

Use Only Genuine Graco Parts and Accessories

AIR LINE ACCESSORIES

Conductive Air Supply Hose; black

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-handthread

220444

6 ft (1.8 m)

218100

15 ft (5 m)

218101

25 ft (8 m)

218102

36 ft (11 m)

218103

50 ft (15 m)

220119

75 ft (23 m)

220120

100 ft (30.5 m)

Conductive Air Supply Hose; gray

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

FM Approved; Color coded gray; More flexible than black hose; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-handthread

Flexible Conductive Air Whip Hose

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

Must be used with a full size Graco Conductive Air Supply Hose; Metallic ground path; 0.187 in. (4.5 mm) ID; 1/4 npsm(m) left-handx 1/4 npsm(f)left-hand

236130

3 ft (0.9 m)

236131

6 ft (1.8 m)

Air Swivel Fitting 236129

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

Replaces gun air inlet fitting 185105; 1/4 npsm(m) left-hand

Air Adapter Nipple 185493

For connecting two or more conductive gun air supply hoses; 1/4 npt x 1/4 npsm left-hand

223068

6 ft (1.8 m)

223069

15 ft (5 m)

223070

25 ft (8 m)

223071

36 ft (11 m)

223072

50 ft (15 m)

223073

75 ft (23 m)

223074

100 ft (30.5 m)

Conductive Air Supply Hose; red

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

Meets CENELEC EN 50 050 requirement for metallic ground path; Color coded red; Stainless steel braid ground path; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-handthread

Quick Disconnect/Swivel Coupling Assy. 112534

Includes a quick disconnect coupling insert, which replaces air inlet fitting 185105, and a swivel shut-offcoupling body withleft-handthread which connects to the conductive air hose.

Air Shutoff Valve 224754

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun off or on. 1/4 npsm(m) x 1/4 npsm(f) left-handthread

235068

6 ft (1.8 m)

235069

15 ft (5 m)

235070

25 ft (8 m)

235071

36 ft (11 m)

235072

50 ft (15 m)

235073

75 ft (23 m)

235074

100 ft (30.5 m)

Bleed-typeMaster Air Valve 107141

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between the paint pump air motor and this valve when closed. 3/4 npt

44 308936

Accessories

Use Only Genuine Graco Parts and Accessories

FLUID LINE ACCESSORIES

High Pressure Ball Valves

5000 psi (350 bar, 35 MPa) Maximum Working Pressure

For turning fluid off or on to the gun and for relieving fluid line pressure at the pump

210657 1/2 npt(m), Vitonr seals

210658 3/8 npt(m), Viton seals

210659 3/8 x 1/4 npt(m), Viton seals

214037 1/4 npt(m), PTFErseals

Fluid Swivel Fitting 189018

5800 psi (400 bar, 40 MPa) Maximum Working Pressure

Connects to gun fluid inlet fitting 188691; 1/4 npsm(m) x 1/4 npsm(f)

GUN ACCESSORIES

Electrostatic Gun Cleaning Kit 236659

Required when using Graco Gun Washers 112634, 112635, and 112636 to clean this gun.

Extended Air Fitting 189191

Replaces the standard air fitting (item 17 in parts list) to provide an extended handle-griparea.

Inline Fluid Filter 205265; 60 mesh

To replace the 100 mesh Filter 205264 that is included with the gun

Electrode Replacement Kit 236001

Includes five electrodes

Snap Ring Pliers 110090

For removing the ES ON-OFFValve Retaining Ring (item 47 in parts list)

Brush 105749

For cleaning the gun

Grease 217115

To grease the plastic extension on the fluid tube end.

ES ON/OFF Valve Conversion Kit 223976

Converts the ES ON/OFF Valve to a constant on setting; a ball valve is included for complete air shut-offat the gun

Push-PullPattern Adjustment Valve 224720

Pattern adjustment valve that allows quick adjustment of the air cap air between two adjustable settings

Fluid Shut-offSpring 112876

For use with fluids that require higher shut-offforce. Use in place of compression spring 112691 (item 30 in the parts list).

Gun Hanging Bracket 235300

308936 45

Accessories

Use Only Genuine Graco Parts and Accessories

MISCELLANEOUS ACCESSORIES

Grounding Clamp and Wire 222011

12 ga, 25 ft (7.6 m) wire

0189

Megohmmeter 218979

500 Volt output; 0.01–2000megohms;

Not for use in Hazardous areas

Remote Spraying Voltage Readout (SVRt) 224388

(Requires Gun Power Supply change to 224100; see below)

For monitoring the gun voltage during operation. Battery operated, intrinsically safe (Class I, Group D), handheld unit. See Manual 308183.

Gun Power Supply with RF Transmitter 224100

Power supply with transmitter capability for spraying voltage readout (SVR).

Gun High Voltage Probe and Meter 236003

For direct measurement of gun output voltage

Paint Resistance Meter 722886

Used with 722860 Paint Probe to measure resistance of paint; Not for use in Hazardous areas

Paint Probe 722860

Used with 722886 Paint Resistance Meter to measure resistance of paint; Not for use in

Hazardous areas

Safety Warning Signs

Available at no charge from Graco

180060 Warning Sign (English)

180061 Warning Sign (French)

180062 Warning Sign (German)

180063 Warning Sign (Spanish)

Setup Instruction Poster 189062

Basic PRO AA4500 Gun operator setup instructions to hang in the spray booth area; English on one side and Spanish on the other side

Daily Gun Care Instruction Poster 189063

Basic PRO AA4500 daily gun care instructions to hang in the spray booth area; English on one side and Spanish on the other side

46 308936

Spray Tip Selection Chart

 

Fan Width at

 

Part No.

10 in. (260 mm)

Orifice Size

 

in. (mm)

in. (mm)

 

 

 

GG3107

2–4(50–100)

0.007 (0.178)

 

 

 

GG3207

4–6(100–150)

 

 

 

 

GG3307

6–8(150–200)

 

 

 

 

GG3209

4–6(100–150)

0.009 (0.229)

 

 

 

GG3309

6–8(150–200)

 

 

 

 

GG3409

8–10(200–250)

 

 

 

 

GG3609

12–14(300–350)

 

 

 

 

GG3211

4–6(100–150)

0.011 (0.279)

 

 

 

GG3311

6–8(150–200)

 

 

 

 

GG3411

8–10(200–250)

 

 

 

 

GG3511

10–12(250–300)

 

 

 

 

GG3611

12–14(300–350)

 

 

 

 

GG3213

4–6(100–150)

0.013 (0.330)

 

 

 

GG3313

6–8(150–200)

 

 

 

 

GG3413

8–10(200–250)

 

 

 

 

GG3513

10–12(250–300)

 

 

 

 

GG3613

12–14(300–350)

 

 

 

 

GG3215

4–6(100–150)

0.015 (0.381)

 

 

 

GG3315

6–8(150–200)

 

 

 

 

GG3415

8–10(200–250)

 

 

 

 

GG3515

10–12(250–300)

 

 

 

 

GG3615

12–14(300–350)

 

 

 

 

GG3217

4–6(100–150)

0.017 (0.432)

 

 

 

GG3317

6–8(150–200)

 

 

 

 

GG3417

8–10(200–250)

 

 

 

 

GG3517

10–12(250–300)

 

 

 

 

GG3617

12–14(300–350)

 

 

 

 

 

Fan Width at

 

Part No.

10 in. (260 mm)

Orifice Size

 

in. (mm)

in. (mm)

 

 

 

GG3319

6–8(150–200)

0.019 (0.483)

 

 

 

GG3419

8–10(200–250)

 

 

 

 

GG3519

10–12(250–300)

 

 

 

 

GG3619

12–14(300–350)

 

 

 

 

GG3719

14–16(350–400)

 

 

 

 

GG3421

8–10(200–250)

0.021 (0.533)

 

 

 

GG3521

10–12(250–300)

 

 

 

 

GG3621

12–14(300–350)

 

 

 

 

GG3721

14–16(350–400)

 

 

 

 

GG3821

16–18(400–450)

 

 

 

 

GG3423

8–10(200–250)

0.023 (0.584)

 

 

 

GG3523

10–12(250–300)

 

 

 

 

GG3623

12–14(300–350)

 

 

 

 

GG3723

14–16(350–400)

 

 

 

 

GG3823

16–18(400–450)

 

 

 

 

GG3425

8–10(200–250)

0.025 (0.635)

 

 

 

GG3525

10–12(250–350)

 

 

 

 

GG3625

12–14(300–350)

 

 

 

 

GG3725

14–16(350–400)

 

 

 

 

GG3825

16–18(400–450)

 

 

 

 

 

Pre-orificeSelection Chart

 

 

 

Part No.

Orifice Size

 

in. (mm)

 

 

 

 

551932

0.007 (0.178)

 

 

 

 

551933

0.008 (0.203)

 

 

 

 

551935

0.010 (0.254)

 

 

 

 

308936 47

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 or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty six months or six thousand hours of operation from time of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Gracocomponent parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of anynon–contractualliabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. in no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose,with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call Graco:1–800–367–4023 Toll Free

Manual Change Summary

The manual was revised to remove 3 pre-orificeofferings, per ECO V6786.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Sales Offices: Minneapolis, Detroit

Foreign Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

www.graco.com

PRINTED IN U.S.A. 308936 March 1999 Revised September 1999

48 308936