INSTRUCTIONS-PARTS LIST
308936
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
First choice when
quality counts.
Supersedes Rev. A
85 KV ELECTROSTATIC
Model PRO AA4500/UNICARB
Air-Assisted Spray 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-finger trigger
Rev. B
NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts 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
COPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
01944A
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.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
Ground 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.
Check the spray gun resistance daily. See Test Gun Resistance, page 25.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Provide 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.
When 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.
Use only non-sparking tools to clean residue from the booth and hangers.
Do not flush the system with the gun electrostatics turned on.
Do not turn on the gun electrostatics until all solvent is removed from the system.
Extinguish all open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not store any flammable fluids in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do 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.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
Wear appropriate protective clothing, gloves, eyewear, and respirator.
2 308936
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.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray gun at anyone or any part of the body.
Do not put hand or fingers over the spray tip.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard on the spray gun when spraying.
Check the gun diffuser operation weekly.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
INSTRUCTIONS
Tighten all the fluid connections before operating the equipment.
Check 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.
This equipment is for professional use only.
Read all the instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment 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.
Use 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.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull equipment.
Wear hearing protection when operating this equipment.
Comply 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. . . . . . . . . . . . . . . . . . . .
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-OFF Valve 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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
4 308936
Introduction
How the PRO AA4500/UNICARB
Electrostatic Air-Assisted Spray 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.
Tip Guard
(orange)
The ability of the PRO AA4500/UNICARB Electrostatic
Spray Gun to spray at higher fluid pressures, combined with the addition of CO
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 have airless 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.
2
from the UNICARB
ES Indicator
Light
Air Control
Valve
Air
Cap
(black)
Spray
Tip
(orange)
Retaining
Nut
Trigger Safety
Latch
01944A
ES ON-OFF
Lever
Back View of Gun
308936 5
ES HI-LO
Lever
01947
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.
Do not install or service this equip-
ment unless you are trained and
qualified.
Be sure your installation complies with National,
State and Local codes for the installation of
electrical apparatus in a Class I, Group D
Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
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-off valve ( P) on each gun air
supply line (Q) to shut off air to the gun(s).
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.
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 Pres-
sure of the spray gun.
6 308936
Installation
A
S
R
KEY
A* Bleed-type Air Shutoff Valve
B Air Line Filter
H Fluid Shutoff Valve
K Pressure Gauge
L* Grounded Braid Type Fluid Hose
with spring guards
M Gun Fluid Inlet (1/4 npsm)
HK
L
R
Y
N Gun Air Regulator
P Gun Air Shut-off Valve
Q* Graco Electrically Conductive
Air Supply Hose
(1/4 npsm x 1/4 npsm LH)
R* Fluid Drain Valve
S Fluid Filter
N
B
P
W
Q
X
W PRO AA4500/UNICARB Spray Gun
X Gun Air Inlet (1/4 npsm LH)
Y Shrouded/Vented Waste Container
* Equipment required for safe operation of
system. Must be purchased separately.
See ACCESSORIES.
M
WARNING
SIGN
01945B
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.
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.
2. Install a fluid regulator (J) on the fluid line to control fluid pressure to the gun.
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.
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.
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.
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.
8 308936
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-assisted
airless 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.
WARNING
INJECTION HAZARD
Be sure the wallet sized warning card
179960, provided with the gun, is avail-
able 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.
____ 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.
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.
Fig. 2
06445
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:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
1. Lock the spray gun trigger safety latch. See Fig. 3.
2. Turn the ES ON-OFF lever to OFF.
Trigger Safety
Latch Unlocked
3. Turn off the fluid supply to the gun.
4. Close the bleed-type master air valve (required in
system).
5. Close the air valve for the gun air supply line.
6. Unlock the gun trigger safety latch.
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.
Fig. 3
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 Con-
ductive Air Supply Hose.
NOTE: The Graco air hose and the gun have special
left-hand threads 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).
See Accessories to order the hose.
A. Connect the 1/4 npsm(f) left-hand end of the
Graco conductive air supply hose (A) to the gun air
fitting (17).
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
NOTE: To connect two or more air hoses, use air
adapter nipple 185493. See Accessories.
Continued on the next page.
01990
Left-hand thread
Fig. 2A
17
A
01989A
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:
The gun has been removed from the
hazardous area;
Or 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.
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
A. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
B. Turn the ES ON-OFF Lever 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 me-
gohmmeter E) to measure the resistance. Use
an applied voltage of 500 minimum to 1000
volts maximum. The resistance should not
exceed 2 megohms.
E
Fig. 3D–E
01946A
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
b. If using a red turbine air hose, use an ohmme-
ter to measure the resistance. Resistance
should not exceed 100 ohms.
12 308936
Fig. 4
57
01992A
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-free fluid hose (F) to the 1/4–18
npsm gun fluid fitting (10).
10
F
Fig. 5B
NOTE: The PRO AA4500 spray gun has a 100 mesh
in-line fluid inlet filter. A 60 mesh filter is also available.
See Accessories.
C. Connect the other end of the fluid hose (F) to a
grounded, filtered, and regulated fluid line (G).
01993A
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.
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 10 before removing
or installing the spray tip, pre-orifice air 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-orifice size
selected below.
Fig. 5C
G
9. Select a pre-orifice
The fluid flow rate in UNICARB systems is controlled
by the pre-orifice size, in conjuction with the fluid
pressure. Use the pre-orifice selection chart on page
47 as a guide for selection.
F
01994A
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
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
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.
8800A
Fig. 10A–D
E. Turn over the tip seal and pre-orifice (9a, 9b) and
insert them into the spray tip (9), wih the pre-orifice
side facing down into the spray tip.
9a, 9b
9
Fig. 10E
8799A
8799A
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.
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-OFF lever (26) to ON.
26
ON
Fig. 12A-B
C. Make sure the fluid supply is shut off.
43
close
01947
H
Fig. 12D
01997
Recommended Air Hose Inlet Pressure
Recommended Air
Air Hose Length
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.
Hose Inlet Pressure
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.
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 CO
recommendations of your material and equipment
supplier.
2
used. Follow the
14.Using the Electrostatics
Turn the ES ON-OFF lever (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-LO lever (43g) to change
to either full voltage (HI) or a lower voltage level (LO).
K
43g
26
ON
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.
HI
01947
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
Warning on page 10 when shutting off the system,
when you stop spraying and before checking,
servicing, installing, cleaning or changing any part
in the system.
Clean all parts with a non-conductive solvent, 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
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.
0202702028
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
A
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-OFF
lever is turned to OFF before flushing
the gun.
1. Follow the Pressure Relief Procedure
Warning on page 10.
9
1
2
8
Fig. 3
02004A
4. Make sure the air and coating supply is
turned off. Turn on the solvent supply.
2. Make sure the ES ON-OFF lever is
turned to OFF and the trigger safety
latch is locked before proceeding.
locked
Fig. 2
ES
OFF
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.
02002
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
01999A
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
11. Dip the end of a soft-bristle brush into
a compatible solvent. Then point the
gun down and clean the front with the
brush and solvent.
02007
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
Fig. 9
02006
Fig. 11
01948
12.Dampen a soft cloth with solvent and
wring-out the excess. Point the gun
down and wipe off the outside.
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-tighten and make sure the top
fluid tube fitting (Q) remains tightened.
Q
P
14
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. 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.
02009
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
Fig. 19
9
20.Install the spray tip (9) and air cap (1),
tip guard (2), and retaining nut (8).
Tighten the retaining nut firmly.
8800A
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.
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
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-
ficient.
There is air in the fluid supply line.
The CO
too high.
The fluid temperature is fluctuating.
Irregular pattern There is fluid buildup on the spray tip or
the spray tip or pre-orifice is partially
plugged.
The spray tip or pre-orifice is damaged or
worn.
Tails in pattern The CO2 percentage is too low.
The fluid pressure is too low.
The temperature is too low
Excessive paint buildup on the
air cap and tip guard
The fluid pressure is too low. Increase the fluid pressure with the gun fluid
2
percentage is fluctuating or is
Adjust the flluid/CO2 supply system.
Check; tighten the siphon hose connections;
bleed the air from the fluid line.
Check fluid/CO
Check temperature control system
Clean the spray tip and pre-orifice; see
page 20.
Replace the damaged or worn part; see
page 29.
Increase the CO2 percentage.
Increase the fluid pressure with the gun fluid
regulator.*
Increase fluid temperature.
regulator.*
2
supply system.
* 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
Fluid needle packing damaged
Air leakage from front of gun Air valve not turned off
Piston air valve not seating properly
Fluid leakage from front of gun Fluid needle worn
Fluid seat loose or worn
Spray tip loose
Tip seal damaged
“Orange Peel” finish CO2 percentage is too low
Fluid pressure too low
Spray tip or pre-orifice too large
Fluid poorly mixed or filtered
Improper thinner being used
Excessive spray fog Fluid thinned too much Properly thin fluid
No fluid sprays from gun Fluid supply low
Spray tip or pre-orifice is dirty or clogged
Tighten packing nut; See page 33
Replace fluid needle; See page 34
Turn off air (43). See page 15
Clean, Service; See page 39
Replace fluid needle; See page 34
Tighten or replace fluid seat
Tighten retaining nut
Replace tip seal; See page 29
Increase CO2 percentage
Increase fluid pressure with gun fluid regulator*
Use a smaller size spray tip or pre-orifice;
See page 47
Remix or refilter fluid
Use proper thinner
Check; Add fluid if necessary
Clean spray tip and pre-orifice; See page 20
Spray tip damaged
Fluid needle damaged
Equipment covered with fluid Booth exhaust air flow too low or not
directed properly
Improper distance between gun and
workpiece
Paint build-up on air cap CO2 percentage too high
Air cap dirty
Fluid doesn’t shut off properly Seat housing over-tightened
Fluid leakage buildup on fluid needle
Fluid packings too tight
* Use the least fluid pressure needed for good results.
Check; Replace spray tip; See page 29
Replace fluid needle; See page 34
Check for proper CFM; Check baffles and
direction of air flow
Adjust spraying distance to 8 to 12 inches
(203 to 305 mm)
Reduce CO2 percentage
Clean air cap; See page 20
Replace seat housing; See page 29
Replace fluid needle; See page 34
Adjust fluid packings; See page 34
308936 23
Electrical Troubleshooting
NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying Voltage Read-
out (SVR). See Accessories to order the SVR.
PROBLEM
Reduced fluid efficiency Improper distance between gun and
CAUSE SOLUTION
work-piece
Parts poorly grounded
High booth exhaust velocity
Fluid pressure too high
Improper fluid viscosity
Fluid resistivity too low
No or low voltage output
Turbine alternator not operating
Faulty gun resistance
Fluid leaks from needle packing and
causes short
Faulty turbine alternator
kV switch stuck on low
Adjust spraying distance to 8 to 12 inches
(203 to 305 mm)
Clean hangers; Check for proper ground on
conveyer or track
Reduce exhaust velocity within code limits
Reduce fluid pressure at fluid supply
Check supplier for proper fluid for electrostatic spray
Check fluid resistivity with paint meter and
probe
Check possible causes listed below
Check air supply to turbine inlet; See page 15
Check gun resistance; See page 25
Clean needle cavity; Replace fluid needle;
See page 34
Be sure plug is in place on back of turbine
alternator housing; Remove and test turbine
alternator; See page 36
Check switch actuation; replace if needed
Operator gets shock Operator not properly grounded or is
near an ungrounded object
Gun not properly grounded
Operator gets shock when
touching workpiece
No or low voltage output reading
on gun display module
Workpiece not properly grounded. Clean workpiece hangers; Check for proper
Damaged fiber optic cable or
connection
Be sure floor is properly grounded; Wear
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
worn, a glove must be conductive or modified
as shown on page 9
See Check the Electrical Grounding,
page 12
ground on conveyor or track
Check cables and connections; replace if
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-see Fig.
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:
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
The gun has been removed from the
hazardous area;
Or 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.
1a
Fig. 4
17
01949
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.
Fig. 5
18e
A
EE
18
0441
26 308936
Electrical Tests
Test Barrel Resistance (See Fig. 6)
WARNING
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.
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
The barrel contact ring (3a) is a conductive contact ring, not a sealing o-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
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.
3a
Wire lead in groove behind
contact ring
Fig. 6
D
01957
308936 27
Prepare the Gun for Service
Service
WARNING
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
Warning on page 10 before checking or servicing
any part in the system and whenever you are
instructed to relieve the pressure.
NOTE:
Check all possible remedies in Troubleshooting
before disassembling the gun.
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
If the plastic parts of the gun must be held securely,
always clamp them in padded vice jaws to prevent
damage to the parts.
Lightly lubricate o-rings and seals with petroleum
jelly. Do not over-lubricate.
Only 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.
2 mm Driver (included with gun)
4 mm Driver (included with gun)
9 mm Driver (included with gun)
Adjustable Wrench
Medium Screw Driver
Snap Ring Pliers
Needle 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.
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.
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 sealing o-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.
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.
9a
9
1
2
8
Fig. 7
02004A
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-tighten the seat housing. Over-tightening
may result in improper fluid shut-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.
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
BBCC
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.
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
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
Loctite) 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 not over-tighten it.
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.
Fig. 10
Apply grease 217115
Apply low strength thread sealer
E
D
Fig. 11
02009
12
C
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-finger trigger 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) Loctite to setscrews
before re-installing them.
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
barrel (3) straight away from the handle to remove
it. See 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.
Fig. 13
3
18
7
01951A
10
Fig. 12
32 308936
C
5
55
01950
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.
CAUTION
To avoid damaging the seat housing and gun barrel,
never over-tighten the seat housing. Over-tightening
may result in improper fluid shut-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
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.
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.
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-tighten the seat housing. Over-tightening
may result in improper fluid shut-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.
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).
28
4
13
02016
Fig. 15
34 308936
18a
Service
35
18d
18
18b
7
18c
18e
F
3
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.
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.
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.
37a
37b
37
01953A
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.
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.
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-wire connector (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-wire connector (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-wire connector and the turbine
alternator housing. The resistance should be
infinite. If the resistance is not infinite, replace the
alternator.
6. Connect the 3-wire connector 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.
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 Nm) maximum (about a half turn
past snug). Do not over-tighten.
CAUTION
To avoid damaging the gun, do not over-tighten the
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
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.
36 308936
14
D
12
C
Tighten to 18 in-lbs (2 Nm) maximum (about half turn past
snug), using wrench provided.
Fig. 17
10
01952A
Service
ES ON-OFF Valve Repair
1. Prepare the gun for service as instructed on page
28.
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.
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).
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 ES ON-OFF Valve. 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
5. Clean and inspect the parts for damage. Replace if
necessary. Lubricate the o-ring (36) with petroleum
jelly.
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-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.
Bevelled side of disk (46) faces toward valve (38)
Lubricate o-rings with petroleum jelly
Fig. 18
46
24
36
38
01955B
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-LO lever (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) counterclock-
wise until it is disengaged from the valve housing
threads (43d). Pull the adjustment knob out of the
valve housing. The KV HI-LO lever (43g) and the
wave spring (43f) can be removed if necessary.
6. Clean all the parts and inspect them for wear or
damage.
DETAIL
43b
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 10–12 in-lb (1.1–1.4 N.m)
43d
43e
43f
43
43g
43h
43c
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 Nm).
9. Install the retaining ring (43h) back into the groove
in the valve housing (43d).
Fig. 19
01954B
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-conductive solvent 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
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-cup with 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).
45
23
44
39
41
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 the o-rings.
6. Unscrew the packing nut (40) to check the u-cup
(42). Do not remove the u-cup unless 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 and u-cup.
7
40, 42
Lubricate o-rings with 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
Working Pressure
Maximum Fluid
Working Pressure
Typical Noise Level
at 40 psi (2.8 bar,
0.28 MPa)*
Maximum Noise
Level at 100 psi
(7 bar, 0.7 MPa)**
Voltage Output 0–85 kV
Short Circuit Current
Output
Paint Resistivity
Range
Air Inlet 1/4 npsm(m) left-hand
Fluid Inlet 1/4 npsm(m)
Wetted Parts Stainless Steel, Nylon, PEEK,
Viton is a registered trademark of the DuPont Co.
is a registered trademark of the Loctite Corporation.
Loctite
* 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.
100 psi (7 bar, 0.7 MPa)
3000 psi (207 bar,
20.7 MPa)
Sound Pressure 86 Db(A)
Sound Power 88.9 Db(A)
Sound Pressure 95 Db(A)
Sound Power 99.7 Db(A)
120 mA
3 megohm-cm to infinity
Ultra High Molecular Weight
Polyethylene, Tungsten
Carbide, Glass Filled Nylon
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) RGR II 6. (4).
308936 41
28
Parts
5
3
3a
21
9a
9b
9
1
2
1a
8
18d
18b
37b
35
18
18e
18a
18c
34
4
13
REF 12
37a
37
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
Item 45 includes items 45a to 45e
42 308936
30
42
40
43c
43e
43h
43g
31
19
43b
43f
43d
45
6
23
44
39
41
24
26
47
32
36
38
46
7
15
19
33
16
12
17
56
14
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
2 188479 TIP GUARD 1
3 235827 BARREL, gun; Includes item 3a 1
3a 111261
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
9a 626588 SEAL, spray tip 1
9b 5519XX PRE-ORIFICE, customer choice
11 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
18a
186840 GASKET 1
18b 185099 PAD 1
18c 185145
18d 185141 CUSHION 1
18e
186637 SEAL 1
19 106555 O-RING, plug & adapter; Viton 2
21 235797 SEAT HOUSING 1
110099 O-RING, air valve cap; PTFE 1
23
ELECTRODE; See pg. 45
to order kit of 5 electrodes 1
CONTACT RING, barrel 1
See pg. 47 to order 1
See pg. 47 to order 1
Includes items 18a–18e 1
PAD 1
Ref
No. Part No. Description Qty
24 110083 SET SCREW; M4 x 0.7 1
26 186839 ES ON-OFF LEVER 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 O-RING, Viton 1
37b 185124
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.
43b 105681
43c 191806
43d 186837
43e
168518 O-RING, Viton 2
43f 111221
43g 224196
43h 111510
44 185116 SPRING, compression, air valve 1
45 188486 AIR VALVE CAP 1
46 107107 DISC REGULATOR 1
47 110082 RETAINING RING 1
54 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
59 180060 WARNING SIGN, English
60 180209 GUN COVER; Order Part No. 218374
62 222385 WARNING CARD 1
64 110087 DRIVER, hex nut, 9 mm 1
67 235300 BRACKET, gun hanging 1
Replacement 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.
CUSHION 1
Includes items 43b–43h 1
RETAINING RING 1
KNOB, adjustment 1
HOUSING 1
SPRING. wave 1
LEVER, ES HI-LO 1
RETAINING RING, external 1
See Accessories for additional signs 1
for package of 10 1
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-hand thread
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-hand thread
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-hand thread
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)
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-hand x 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
Quick Disconnect/Swivel Coupling Assy. 112534
Includes a quick disconnect coupling insert, which
replaces air inlet fitting 185105, and a swivel shut-off
coupling body with left-hand thread 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-hand thread
Bleed-type Master 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), Viton seals
210658 3/8 npt(m), Viton seals
210659 3/8 x 1/4 npt(m), Viton seals
214037 1/4 npt(m), PTFEseals
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-grip area.
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-OFF Valve 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-off
at the gun
Push-Pull Pattern Adjustment Valve 224720
Pattern adjustment valve that allows quick adjustment
of the air cap air between two adjustable settings
Fluid Shut-off Spring 112876
For use with fluids that require higher shut-off force.
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; 0.01–2000 megohms;
Not for use in Hazardous areas
Remote Spraying Voltage Readout (SVR) 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 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
Gun Power Supply with RF Transmitter
224100
Power supply with transmitter capability for
spraying voltage readout (SVR).
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.
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)
10 in. (260 mm)
in. (mm)
Orifice Size
in. (mm)
Fan Width at
Part No.
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)
10 in. (260 mm)
in. (mm)
Orifice Size
in. (mm)
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)
Pre-orifice Selection Chart
Orifice Size
Part No.
551932 0.007 (0.178)
551933 0.008 (0.203)
551935 0.010 (0.254)
in. (mm)
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)
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–Graco component 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 any
non–contractual liabilities, 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-orifice offerings, 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.
Foreign Offices: Belgium, Korea, Hong Kong, Japan
Sales Offices: Minneapolis, Detroit
48 308936
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN U.S.A. 308936 March 1999 Revised September 1999
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