Graco PRO AA4000 Instructions Manual

INSTRUCTIONS–P

This

manual contains IMPORT

ARNINGS AND INSTRUCTIONS

READ AND RET

AIN FOR REFERENCE

ARTS LIST

ANT

307–706

Rev. R

Supersedes

Model MANUAL MID-RANGE ELECTROST

AIR-ASSISTED

7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE

PRO AA4000



ATIC

AIRLESS SPRAY GUN

bar (950 psi) MAXIMUM WORKING FLUID PRESSURE

Part Number 218–668, Series B

With

0.279 mm (0.01

U.S.

Patent No. 4,290,091; 4,219,865;4,386,739; 3,843,052; 4,462,061; 4,497,447; 4,554,622 U.K. Patent No. 2,140,327B; 2,111,406B; 2,142,559B; 2,147,158 Patented 1986, 1987 Canada Brevete 1986, 1987 French Patent No. 82 21202; 84 07942; 84 10234 Italian Patent No. 1,1 W

est German Patent No. DE 22 09 896

1 in.) spray tip, part no. 219–41

11,380

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

 COPYRIGHT

1984, GRACO INC.



TABLE OF CONTENTS

Terms 3. How

Safety Warnings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Electrostatic Air-Assisted Airless

Spray Gun W

orks 3.

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation

Typical Warning Ventilate Connect Check Connect

Installation6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signs6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the Spray Booth7. . . . . . . . . . . . . . . . . . . . . . .

the Air Line7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

the Electrical Grounding7. . . . . . . . . . . . . . . . . .

the Fluid Line8. . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

the Fluid8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Spraying Operating Install Adjust

Operation8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checklist8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the Spray T

ip and Air Cap9. . . . . . . . . . . . . . . . .

the Spray Pattern9. . . . . . . . . . . . . . . . . . . . . . . .

Maintenance

Daily

Care and Cleaning

Flush

the Spray Gun

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

4, 5

10.

Test

Power Supply Resistance

Test

Resistor Stud Resistance

. . . . . . . . . . . . . . . . .

14.

15.

Service

Disassembly

Gun Electrode Ball Barrel Barrel Fluid Check Power Turbine Fan

Wire Replacement

Seat Housing & Resistor Replacement

Removal Reassembly

Needle Replacement

the Gun Safety Latch Cartridge Replacement

Alternator Removal

Air V

alve Replacement Air Valve Replacement ES

ON-OFF V

Muffler,

Repair Parts Parts List 25.

Check V

Kits

Drawing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 26–28

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

alve Removal and Repair

. . . . . . . . .

alve & Inlet Filter Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

16.

17.

18.

19.

20.

21.

22.

23.

24.

Spray

Pattern T

Gun Operation Troubleshooting Chart 12. Electrical Troubleshooting Chart 13.

roubleshooting Chart 11.

. . . . . . . . . . . . .

. . . . . . . . .

. . . . . . . .

Electrical Tests

est Gun Resistance

. . . . . . . . . . . . . . . . . . . . . . . . . .

14.

TERMS

WARNING:

cause

CAUTION: Alerts user to avoid or correct conditions that could

cause

NOTE: FLUID INJECTION INJURY: A serious injury, which may ap-

pear to be a simple cut, caused by high pressure injection of

directly into the body

fluid

HOW

This gun combines electrostatic air spray and airless spraying concepts. The air has three functions: (1) to drive (3)

to help control the pattern size.

The turbine generates power that the power cartridge converts rent

Fluid is electrostatically charged as it passes the gun’s ionizing electrode. The charged fluid is attracted to the grounded

all surfaces.

ing

Alerts user

bodily harm.

damage to or destruction of equipment.

Identifies essential procedures or helpful information.

THE ELECTROST

the turbine, (2) to help

to avoid or correct conditions that could

ATIC AIR-ASSISTED AIRLESS SPRA

atomize the paint “tails”, and

to a high voltage current. The high voltage cur

charges the gun’

work piece,

s ionizing electrode.

wrapping around and evenly coat

Technical Graco Spray T Warranty Back

PRESSURE RELIEF PROCEDURE: A safety procedure for

relieving

FOR

warnings

ES ON-OFF VALVE:

gun,

the

on or of

Data

Phone Numbers

ip Selection Chart

air and fluid pressure in the system.

YOUR SAFETY: Alerts user to read

on the page indicated.

above the gun handle, that turns the electrostatic pow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

the additional safety

An on/of

f switch located near the rear of

Y GUN WORKS

The

spray tip shapes the fluid into a fan pattern, similar to

conventional airless spray tip, but at a lower pressure.

Air

from the air cap further atomizes the the paint tails into the pattern. The fan adjusting knob controls

Note that the air-assisted airless spray gun differs from the

the width of the pattern.

conventional air spray gun in that increasing

air reduces the pattern width. To increase the pattern

less fan air or a larger size tip must be used.

width,

fluid and pushes

29.

30, 31

Cover

the fan



SAFETY

ARNINGS

SERIOUS

BODIL

Y INJURY, EXPLOSION, FIRE, OR ELECTROSTATIC SHOCK CAN

OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ

UNDERST

AND ALL INSTRUCTION MANUALS, T

AGS, AND W

AND

LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE INSTALLED AND USED BY

TRAINED,

QUALIFIED

PERSONNEL WHO SHALL BE FULL

Y CONVERSANT WITH

THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.

FLUID

General

This leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury for

amputation. Also, fluid injected or splashed into the

can

cause serious damage. NEVER point the spray gun at anyone or at any part of the body NEVER put hand or fingers over the spray tip. NEVER try to “blow back” paint; this is NOT an air spray system. NEVER try to stop or deflect leaks with your hand or body ALWAYS

removing the spray tip or servicing any system equipment.

SURE equipment safety devices are operating properly before each

use.

Medical

any fluid appears

CARE AT

exactly

Note

not exotic coatings injected directly into the blood stream. Consultation with able.

Spray

sure all gun safety devices are operating properly before each use.

NOT remove or modify any part of the gun;

tion

and result in serious bodily injury

Safety

Whenever safety latch in the closed or “locked” position, making the gun inoperative. ing

of the gun.

Set

the safety latch by depressing it on the left or right side of the trigger See trigger

INJECTION HAZARD

Safety

equipment generates very high fluid

follow the

Pressure Relief Procedure

Alert – Airless Spray W

to penetrate your skin, get

ONCE. DO NOT TREA

what fluid was injected.

to Physician:

important to treat the injury surgically as soon as possible.

delay treatment to research toxicity

a plastic surgeon or reconstructive hand surgeon may be advis

Injection

Gun Safety Devices

Latch

you stop spraying, even for a moment, AL

Failure to set the safety latch can result in accidental

the illustration below

and up.

Safety

Latch shown in or

“Lock”

. Disengage the latch

closed

position

SPRAY LOCK

pressure. Spray from the gun,

, including the need

eyes or on the skin

, at right, before cleaning

ounds

T AS A SIMPLE CUT. T

into the skin is a traumatic injury

EMERGENCY MEDICAL

. T

oxicity is a concern with some

this can cause a malfunc

by pushing it toward the

ell the doctor

WAYS

set the gun

Safety Latch shown in

“Spray”

open

position

trigger

SPRAY LOCK

Diffuser

The

gun dif

fuser

and

reduces the risk of fluid injection when the spray tip is not installed. T

check

dif

then

remove the spray tip.

the

turbine air OFF

gun.

If the fluid emitted is not dif

ball

seat housing.

Spray T

Use

extreme caution when cleaning or changing spray tips. If the

tip

clogs while spraying, engage the gun safety latch immediately

the Pressure Relief Procedure, NEVER

pressure

Pressure

reduce the risk of serious bodily injury

ing

in the eyes or

shock,

always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning

Engage the gun safety latch.

2. T

urn the ES On–Off valve lever to OFF

urn of

3. T

Disengage the gun safety latch.

5. Trigger

pressure.

6. Open

the

drainage.

7. Leave If you suspect

has

been fully relieved

loosen the air cap retainer or hose end coupling and relieve pressure

gradually,

Bleed-Type

These

two accessories are required in your system to help reduce

risk

of serious bodily injury

and

injury from moving parts if you are

The

bleed-type air shutoff valve

and

the pump after the air regulator is

pump

to cycle unexpectedly

pump. The

fluid drain valve

pump,

hose and gun; triggering the

sufficient.

, which is part of the ball seat housing, breaks up spray

fuser operation, follow the

Aim the gun into a

, and using the

Pressure Relief Procedure

lowest possible pressure, trigger the

fused into an irregular

ip Safety

then remove the spray tip to clean it.

wipe of

f build-up around the spray tip or remove the spray tip until

is fully relieved and the gun safety latch is engaged.

Relief Procedure

on the skin, injury from moving parts or electrostatic

or changing spray tips, and whenever you stop spraying.

f the air and fluid supply to the gun.

the gun into a

the pump

the pump drain valve open until you

that the tip or hose is completely clogged, or that pressure

then loosen completely

grounded

drain valve, having a waste container ready to catch

after following the steps above, VER

Air Shutoff V

, including splashing in the eyes or on the skin

. Locate the valve within easy reach of the

assists in relieving fluid pressure in the

, including fluid injection, splash

metal waste container to relieve

. Now clear the tip or hose.

alve and Fluid Drain V

adjusting or repairing the pump.

relieves air trapped between this valve

shut of

gun to relieve pressure may not be

ARNING

grounded

stream, replace the

are ready to spray again.

f. T

rapped air can cause the

, below

metal pail. With

spray

. Follow

Y SLOWL

alve

displacement

fluid

the

4307-706

EQUIPMENT MISUSE HAZARD

General

Any surizing, ing injection,

NEVER to

malfunction.

CHECK aged

Read the

Safety

misuse of the spray equipment or accessories, such as overpres

modifying parts,

worn or damaged parts, can cause them to rupture and result in fluid

electrostatic shock, fire, explosion or property damage.

alter or modify any part of this equipment; doing so

all spray equipment regularly and repair or replace worn or dam

parts immediately

and follow the fluid and solvent manufacturer’s literature regarding

use of protective clothing and equipment.

using incompatible chemicals and fluids, or us

could cause it

FIRE, EXPLOSION, or ELECTROSTA

reduce the risk of fire, explosion, or electrostatic shock, which may re

sult

from electrical discharge, it is essential that:

All parts of the electrostatic system are properly grounded.

All personnel in or close to the spray area are properly grounded.

S All electrically conductive objects or devices in the spray area,

including paint containers, wash cans and tools, are properly grounded.

When

operating the electrostatic device, any ungrounded objects in the

spray

area (such as people, containers, tools, etc.) can become

cally

charged. Arcing may occur if these objects then come in contact or close to ground. Arcing of sufficient energy levels can ignite the fluid being

sprayed, fumes from solvents, dust particles, and other flammable substances. ily

injury and property damage.

Static electricity can also be generated by the pump, ing

as described in

you

ING

sure

This can cause a fire or explosion and result in serious bod

hose, gun, and nozzle, but it is dissipated through proper

experience any arcing or feel even a slight shock, STOP SPRA

IMMEDIA

you have corrected the problem before starting to spray again.

Grounding

TELY

. Check for proper grounding of the entire system. Be

below

flow of fluid through the

Grounding

The

following are static system. Your system may include other equipment or objects which

must also be grounded. Always check your local electrical code for

detailed

grounding instructions. Be sure your systemis connected to a

true

earth ground.

Pump:

separate

Air

compressors and hydraulic power supplies:

the

manufacturer’s recommendations.

Electrostatic

properly grounded air

Conductive

Connect

Object being sprayed:

grounded

edges.

All electrically conductive objects or devices

including paint containers and wash cans, must be properly

grounded.

minimum

ground

by using a ground wire and clamp as described in your

pump instruction manual.

Spray Gun:

Air

the air hose ground wire to a true earth ground.

at all times. Contact points must be sharp points or knife

requirements for grounding a basic electro

ground according to

obtain grounding through connection to a

supply hose. Use only the Graco Electrically

Supply Hose; see

keep the work piece hangers clean and

ACCESSORIES

in the spray area,

electri

ground

Y-

section to order

System

This

exceed nent

Fluid

BE “Wetted Parts” shown in the TECHNICAL DATA on page 29. Always

read

Pressure

gun has a maximum fluid working pressure of 66 bar (950 psi). Never

the maximum working pressure of the

or accessory used in the system.

gun or any other compo

Compatibility

SURE all fluids and solvents used

the fluid and solvent manufacturer’s literature before using the

solvent in this gun.

are chemically compatible with the

TIC SHOCK HAZARD

All

persons entering the

soles,

such as leather

Rubber

or plastic soles are not conductive. The operator must not wear gloves which insulate the hand from spray gun. The gloves must

be conductive or modified as shown on page

The floor of the spray area

7. grounded. Do not cover the floor with cardboard or any non–conductive

Flammable liquids

8. grounded one

All solvent pails:

conductive. Do not place the pail on any non-conductive surface, such as cardboard or paper, which would interrupt grounding continuity.

10.

All

containers. Do not store more than the quantity needed for

shift.

air and fluid lines

spray area:

, or personal grounding straps must be worn.

must be electrically conductive and

material which would interrupt grounding

in the spray area must be kept in approved,

use only grounded metal pails, which are

and electric cables

shoes must have conductive

must be properly grounded.

Flushing and Cleaning Safety

reduce the risk of static sparking or splashing, always

sure

Relief Procedure

ing.

sure the ES valve lever is OFF before flushing or cleaning any

part

of the spray system.

Use

the lowest possible pressure to

metal

waste container

To flush or purge equipment,

equal

to or greater than that of the fluid being sprayed.

clean the exterior of the equipment,

point

of higher than 38

ALWAYS remove all solvent from the system before reactivating the spray

gun.

Use

only non-sparking tools to clean residue from the booth and

Ventilate

prevent hazardous concentrations spray gun

Check and follow all National, State and Local codes regarding air exhaust codes

the Spray Booth

only in a properly ventilated spray booth. NEVER operate the spray

unless the ventilating fans are operating.

velocity requirements. Check and follow

and OSHA standard 1910–107(b)(5)(i).

on page 4 and remove

_ C

flush. T

ALWAYS use solvents with a flash point

(100_ F).

the spray tip before flush

rigger the gun into a

ALWA

YS use solvents with a flash

of toxic and/or flammable vapors,

all local safety and fire

continuity

follow the

grounded

hangers.

fluid

Pres-

HOSE SAFETY

Highly

pressurized fluid contained in the hose can be very dangerous. If

the

hose develops leak, split or rupture, due to any kind of wear or misuse, high pressure spray emitted from it can cause a fluid injection injury

or other serious bodily injury or property damage.

TIGHTEN fluid can dislodge a loose coupling or allow high pressure spray to be emitted

United States Government safety standards have been adopted under the Occupational General Standards, Part 1910.107 and any other appropriate regulations––should be consulted in connection with the installation, operation, and maintenance of electrostatic spray painting equipment.

all fluid connections securely before each use. High pressure

from the coupling.

, damage

IMPORTANT

NEVER

use a damaged hose. Before each use, check the entire hose cuts, leaks, couplings. DO other

HANDLE move with

abrasion,

If any of

NOT try to recouple high pressure hose or mend it with tape or any

device. A repaired hose cannot contain the high pressure fluid.

AND

equipment. Do not use fluids or solvents which are not compatible

the inner tube and cover of the hose.

Safety and Health Act. These standards––particularly the

bulging cover

these conditions exist, replace the hose immediately

ROUTE HOSES CAREFULLY. Do not pull on hoses to

, or damage or movement of the hose

307-7065

for

TYPICAL INSTALLATION

B* C* D

NON–HAZARDOUS

AREA

WARNING

SIGN

HAZARDOUS AREA

Air

Supply to Gun MUST Be Interlocked

ith Spray Booth Exhaust Fan.

KEY

A Main B* V C* D E* F G H Pump

Air Supply Line

entilation Fan Interlock Solenoid V Main Air Supply Shutof Air & W

ater Separator Pump Air Supply Shutof Air Line Lubricator Air Pressure Regulator

alve

f V

alve (bleed–type)

f V

alve (bleed–type)

J* K L M N O P

The Typical Installation shown above is only a guide for selecting and installing an electrostatic air-assisted airless

spray system. It is not an actual system design.

The particular type and size system for your operation must be custom designed for your needs. For assistance in designing

a system, contact your Graco representative.

The pump you use should have a maximum working pressure of 66 bar (950 psi). If the pump you are using has a higher maximum working pressure, a regulator MUST be used to limit the pressure to 66 bar (950 psi). Graco’s be

10:1

Ratio Monark Pump, part no. 217–523, may

used in this system. See

ACCESSORIES.

Warning Signs

Mount warning signs in the spray area where they can easily

be seen and read by all operators. An English a Spanish Warning Sign are provided with the gun. Additional are tion

English, French, German,

available at no charge. See the

to order them.

and Spanish signs

ACCESSORIES

and

sec

*Equipment that must be installed for safe operation. Must be

purchased separately

alve (B) is not offered as a Graco accessory

Pump Ground Wire Fluid Filter Fluid Supply Line Shutof Fluid Pressure Regulator Fluid Supply Line Air Filter (5 micron) Air Supply Line Shutof

f V

alve

Installing and servicing this equipment requires access or

to parts which may cause electrostatic shock

other serious bodily injury if work is not performed

properly. Do not install or service this equipment

unless you are trained and qualified.

Be sure your installation complies with National, State

and Local codes for the apparatus in a Class 1, Group D, Divisions 1 and 2 Hazardous

Check and follow all local safety and fire codes, NFPA 33, NEC 504 and 516, and OSHA standard

1910.107.

f V

alve

Location.

. See ACCESSORIES. NOTE: Solenoid

Air Hose Ground Wire

Grounded Air Supply Hose

Electrostatic Spray Gun

ES On–Of

Air Line Drain V

Fluid Drain V

Gun Air Inlet

Gun Fluid Inlet

f V

alve Lever

alve

WARNING

installation of electrical



INSTALLATION

Ventilate the Spray Booth

WARNING

prevent hazardous concentrations of toxic

To flammable vapors, spray only in a properly ventilated spray booth. Never operate the spray gun unless ventilation fans are operating. The air supply to the gun must be electrically interlocked

the ventilators to prevent operation

with

supply unless ventilating fans are running.

er Check and follow all the National, State and Local

regarding air

codes

NOTE: High

velocity air exhaust will decrease the oper

exhaust velocity requirements.

ating efficiency of the electrostatic system. The

minimum

ear

Connect the Air Line (See T

allowable air exhaust velocity is 31 lin

meters/minute (100 ft/min).

ypical Installation)

WARNING

To reduce the risk of electrostatic shock or other

bodily

injury

serious electrically

connected to

, the Air Supply Hose must be

a true earth ground.

only Graco Electrically Conductive Air Supply Hose.

See

ACCESSORIES.

1. Connect supply

fitting has a left hand thread.

let

ply

hose ground wire (Q) to a true earth ground.

the air supply hose (R)

line and the gun’

s air inlet (W).

Connect the air sup

2. Install an air line filter (O) and an air and water separator

(D) on the air line to

ensure a dry supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause

the gun to malfunction.

and/or

of the pow

Use

between the air

The

gun air in

, clean air

Check the Electrical Grounding (See Fig 1)

WARNING

Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE, EXPLOSION, or ELEC- TROSTATIC SHOCK HAZARD, on page 5. Ground the system as explained there. Then

your system as explained below

check

1. Turn

the ES On–Of

the location of the valve lever

urn of

2. T

f the air and fluid supply to the gun.

3. Have a qualified electrician check the electrical

grounding

continuity of the spray gun and air hose.

a. With the electrically conductive air hose (BB)

connected (see Connect the Air Line) and properly measure

grounded, use a

the (Y) and a true earth ground (Z). Use an applied voltage

mum

of 500 volts

See Fig 1.

b. If the resistance is greater than 2 megohms,

check the tightness of the ground connections,

and be sure the air supply hose ground wire is connected to a true earth ground. If the resistance is still greater than 2 megohms, replace the

air supply hose.

f valve to OFF

megohmmeter (AA) to

resistance between the gun handle

minimum

to 1000 volts

. See Fig 5 for

maxi-

3. Install and pump

a bleed-type air regulator (G) on the pump

gun air supply lines to control air pressure to the

and gun.

4. Install a bleed-type air shutoff valve (C) on the main

air line and pump air line (E) to shut of

pump.

Install an additional bleed-type valve on pump air supply line to relieve air trapped between this

valve and the

pump after air regulator is shut of

WARNING

bleed–type air shutoff valve

The system to relieve air trapped between this valve and the pump after the air regulator is closed. Trapped air can cause the pump to cycle unexpectedly, which could result in serious bodily in-

including splashing in the eyes or on the skin

jury, and

injury from moving parts.

5. Install an air line lubricator (F) as close to the pump

(H) as possible.

6. Install an air shutoff valve (P) on each gun air supply

line to shut of

f air to the gun(s).

f air to the

each

is required in your

KEY

Y Gun Z T AA Ohmmeter BB

Handle

rue Earth Ground

Grounded Air Hose

Fig 1



INSTALLATION

Connect the Fluid Line (See T

ypical Installation)

1. Before connecting the fluid line (N), blow it out with

air and flush it with

compatible

2. Install

fluid pressure to the gun.

trol

with the fluid to be sprayed.

a fluid regulator (M) on the fluid line to con

solvent. Use solvent which is

3. Install a fluid filter (K) and drain valve (V) at the pump

outlet.

4. Connect fluid line to 1/4–18.6(m) gun fluid inlet (X).

OPERATION

WARNING

For your Safety,

Procedure

Relief

system, when you stop spraying, and before checking, any

Square Cut Out

servicing, installing,

part in the system.

in. (76 mm)

and Finger of

Glove Cut Off

ALWAYS follow the Pressure on page 4 when shutting off the

cleaning or chaning

NOTE:

If gloves are

conductive or modified as shown so as not to interfere with operator grounding

through the gun.

worn, they must

WARNING

The

fluid drain valve

assist

in relieving

(V) is required in your system to

fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. The drain valve

reduces ily Install

the risk of property damage or serious bod

injury

, including

splashing in the eyes or on skin.

a drain valve close to the pump’s fluid

Operating Checklist

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

1. Be sure all operators are properly trained to safely operate an air-assisted airless electro-

spray system.

static

2. Be

sure all operators are trained how to prop

and completely relieve system pressure.

erly

3. Be sure the system is thoroughly grounded. See FIRE, EXPLOSION, or ELECTRIC

SHOCK HAZARD, page 5, and Check the Electrical Grounding

, page 7.

oulet.

Fig 2

Filter the Fluid

Filter the fluid to remove coarse particles and sediment

could clog the spray nozzle.

which

Spraying Operation

This gun has a built-in lead and lag operation. The gun begins emitting air before the fluid is discharged. When

release the trigger

you stops.

This helps prevent fluid buildup on the air cap.

When

spraying, the ES indicator lights (44) should

indicating

the electrostatic charge. See Fig 5.

Be careful not to damage the electrode by jamming it into an object when operating or setting

the gun.

down

, the fluid

CAUTION

stops before the air flow

glow

4. Be

sure the operator and all persons entering

the

spray area are properly grounded by

wear

ing shoes with conductive soles or personal grounding

5. Operator

straps.

must not wear gloves which

insulate the hand from the spray gun. If worn, gloves must be conductive or modified as shown in Fig 2 so as not to interfere with operator grounding

through the gun.

6. Be sure ventilation fans are operating properly.

7. Be

sure the workpiece hangers

are clean and

grounded. Contact points must be sharp

or knife edges.

points

8. Be sure all refuse is removed from the spray booth.

9. Be sure all flammable liquids in spray booth are

in approved, grounded containers.

10. Be sure all conductive objects within 20 ft

of the gun are electrically grounded and

(6 m) the floor of the spray area is electrically conductive

and grounded.

8307-706

OPERATION

Install the Spray Tip and Air Cap

WARNING

your safety

For Procedure,

the spray tip or air cap.

ing

1. See the 30,

to select the appropriate spray tip cation. spray

tip size, fluid viscosity

2. Place ing the tab of the tip with groove in the air cap. Be careful

3. Place the air cap assembly on the gun. Screw the

retaining nut (1

leakage between the tip and ball seat housing.

NOTE: The

direction

Operating a bent or damaged electrode wire will impair the electrical electrical

fire, or explosion,

jury, is properly installed in the not

bent or damaged before operating the gun.

, always follow the

on page 4, before

SPRA

Y TIP SELECTION CHART

Pressure

Relief

installing, or remov

, page

for your appli

The fluid output and fan width

depends on the

, and fluid pressure.

the spray tip (13) in the air cap (12), align

not to damage electrode wire (GG). See Fig

firmly

onto the gun to prevent

air cap and spray tip position determines the

of the spray pattern. See Fig 3.

WARNING

the gun without the electrode

continuity of the gun. T discharge,

which could cause serious in

BE SURE

o reduce the risk of

gun

(see page 16) and is

wire or with

the electrode wire

6. First,

7. Check

complete all the checks under the

ing

Checklist

valve

lever (T) to ON. See Fig 5.

on page 9. Then turn the ES ON-OFF

Operat-

Provide a 3.1 bar (45 psi) clean, dry, regulated air supply to the gun to ensure full voltage from the power supply. The gun may be operated at lower turbine

air pressure,

but may lose some electrostatic effect. Do not operate the turbine at an air pressure greater turbine

than 3.1 bar (45 psi) as there is no benefit and

life will be reduced.

the spray pattern,

then adjust the air pres sure until all the tails are completely atomized and pulled

into the spray pattern. Refer to Fig 4.

If a narrower pattern is desired,

fan adjusting knob (EE) still

not narrow enough, increase the air line pressure

slightly

or use a dif

clockwise

ferent size tip.

try turning the

. If the pattern is

VERTICAL

SPRA

Y P

ATTERN HORIZONT

AL SPRA

Y P

ATTERN

Fig 3

Adjust the Spray Pattern

the steps

and

air flow. DO NOT

Set the fluid pressure at about 21

using the fluid regulator

2. Trigger the gun to check the atomization; don’t be

concerned about the pattern shape yet.

3. Increase the fluid pressure just to the point that any

further increase in fluid pressure does not signifi cantly bar

(950 psi) fluid pressure.

4. Be sure the fan adjusting knob (EE) is closed (turned

below to establish the correct fluid flow

turn the electrostatics on yet.

bar (300 psi),

improve fluid atomization. DO NOT exceed 66

fully

counterclockwise

NO AIR

Fig

KEY

11 Retaining 12

Air Cap

Spray T

ES Indicator Lights

Nut

OO LITTLE AIR

Tab

RIGHT AMOUNT

ES ON-OFF V

alve Lever

Fan Adjusting Knob

Electrode Wire

OF AIR

5. Set

the atomizing

air pressure to 3.1 bar (45 psi).

Fig 5

307-7069

MAINTENANCE

Daily Care and Cleaning

CAUTION

Clean all parts with a non–conductive solvent, compatible with the fluid being sprayed. Conductive

solvents can cause the gun to malfunction.

Methylene chloride

flushing

or cleaning solvent with this gun as it will

damage nylon components.

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

Immersing

the gun as a cleaning method. Solvent left in gun passages could

result in a poor quality paint finish and may draw current and reduce the electrostatic effect. Solvent ternator

in the power supply cavity can

life.

For your safety,

Procedure

lief

when you stop spraying, and before checking,

tem, servicing, in

the system.

installing, cleaning or

is not recommended as a

in solvent is not recommended

reduce al

WARNING

always follow the Pressure Re-

on page 4 when shutting of

f the

changing any part

sys

c. Use a soft brush or other soft tool, with an air

blow gun, to clean air cap passages. Take care not to scratch any surfaces. If air cap holes are plugged, use a round toothpick to unplug the holes.

CAUTION

not use metal tools to clean the air cap holes as

this may scratch them, and make sure the elec-

wire is not damaged. Scratches in

trode holes

or a damaged electrode wire can distort the

spray

pattern.

6. Check

the electrode wire. Straighten

the air cap

if bent, and

replace if broken or damaged. See Electrode Wire

Replacement.

KEY

25 Fluid 26

Inlet Fitting

Fluid Filter

Clean the fluid and air line filters daily

2. Check all of the work hangers for build-up of material;

3. a. b. Remove

c. Reinstall

clean them, if necessary

Clean the gun fluid filter (26) daily

. See Fig 6.

Unscrew and remove the fluid inlet fitting (25).

the filter (26) and clean thoroughly in a

compatible

non-conductive solvent.

the filter and inlet fitting. DO NOT over tighten the inlet fitting as over tightening could distort

4. Clean dampened

the filter

the outside of the gun daily with a soft cloth

in a compatible solvent.

5. Clean the air cap and spray tip daily, minimum. Some applications require more frequent cleaning. Replace

a. b. Clean

spray tip and air cap if they are damaged.

Remove the air cap and spray tip.

the tip and air

with

a soft brush.

cap with solvent and scrub

Fig

Flush the Spray Gun

WARNING

To reduce the risk of electric shock, which could result in serious injury, or the risk of fire or explosion the ES On-Off lever (electrostatics) must be

before flushing.

OFF

For your safety,

Procedure

Relief

Methylene chloride

flushing

or cleaning solvent with this gun as it will

damage nylon components.

Follow the

Disconnect and plug the fluid line.

Connect the solvent supply to the gun.

Pressure Relief Procedure

always follow the Pressure

on page 4 before flushing.

CAUTION

is not recommended as a

on page 4.

WARNING

To avoid damaging the ball seat housing resistor, use a soft bristle brush dipped in solvent to clean;

NOT

soak it in solvent! A damaged resistor will impair the electrical continuity and could result in electrical discharge, which could cause serious

fire, or explosion.

injury,

10    307-706

Flush the gun with solvent until it is clean.

5. Follow the Pressure Relief Procedure, then disconnect

Reconnect the fluid supply line.

8. T

the solvent supply

rigger the gun until it is clear of solvent.

+ 22 hidden pages

Graco PRO AA4000 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual