Graco Inc. 308936 Paint Sprayer User Manual
Contents
1. WARNING SIGN 01945B KEY A Bleed type Air Shutoff Valve N Gun Air Regulator W PRO AA4500 UNICARB Spray Gun B Air Line Filter P Gun Air Shut off Valve X Gun Air Inlet 1 4 npsm LH H Fluid Shutoff Valve Q Graco Electrically Conductive Y Shrouded Vented Waste Container K Pressure Gauge Air Supply Hose L Grounded Braid Type Fluid Hose 1 4 npsm x 1 4 npsm LH Equipment required for safe operation of with spring guards R Fluid Drain Valve system Must be purchased separately M Gun Fluid Inlet 1 4 npsm S Fluid Filter See ACCESSORIES Fig 1 Fluid Line Accessories Refer to Fig 1 2 Install a fluid regulator J on the fluid line to con 1 Install a fluid filter S and drain valve R at the trol EE ihe gUn pump outlet Filtering the fluid will help remove coarse particles and sediment that could clog the spray tip A WARNING INJECTION HAZARD The fluid drain valve R is required in your system to assist in relieving fluid pressure in the supply system hose and gun triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including fluid injection and splashing in the eyes or on the skin 308936 7 Installation Ground the System A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD When operating the electrostatic device any ungrounded objects in the2. 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 resis tance 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 Ta performance or contact the nearest authorized service agency 18e NOTE Be sure the seal 18e is in place on the end of 18 the power supply before installing the power supply 0441 back into the gun Fig 5 26 308936 Electrical Tests Test Barrel Resistance See Fig 6 A WARNING Measure the resistance between the barrel contact FIRE EXPLOSION AND ring 3a and the metal contact pin E using a metal ELECTRIC SHOCK HAZARD rod D and megohmmeter as shown in Fig 6 Be The barrel contact ring 3a is a conduc careful not to damage or scratch the inner surfaces of tive contact ring not a sealing o ring To the barrel with the metal rod 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 The resistance should be 19 to 29 megohms If the resistance is incorrect make sure the metal contact pin E and the barrel c
3. 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 Fig 5 02005A 18 308936 Daily Gun Care Flushing and Cleaning 6 Lock the trigger safety latch and turn 11 Dip the end of a soft bristle brush into off the solvent supply a compatible solvent Then point the gun down and clean the front with the 7 Follow the Pressure Relief Procedure brush and solvent 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 Fig 8 9 Unlock the trigger safety latch and trig ger the gun into a grounded metal con tainer L to drain the fluid tube Fig 11 DE 12 Dampen a soft cloth with solvent and wring out the excess Point the gun down and wipe off the outside Fig 9 02006 02008 10 Lock the trigger safety latch Fig 12 308936 19 Daily Gun Care Flushing and Cleaning 13 Remove the bottom fluid tube fitting 16 Clean the retaining nut tip guard air P and filter 14 Clean the filter in a cap and fluid tip with a soft brush compatible solvent daily minimum Clean the parts with a soft brush and replace them if they are damaged Be careful not to bend dam 14 Reinstall the filter and fitting Do not age or dise
4. Fluid needle damaged Booth exhaust air flow too low or not directed properly Equipment covered with fluid Improper distance between gun and workpiece CO percentage too high Paint build up on air cap 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 SOLUTION 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 Properly thin fluid Check Add fluid if necessary Clean spray tip and pre orifice See page 20 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 CO 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
5. These parts are not shown in the parts drawing 23t 110099 O RING air valve cap PTFE 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 engm 223069 15 ft 5 m 223070 25 ft 8 m 223071 aen 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 sG ft 1 8 m 235069 15 ft 5m 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 44 308936 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
6. 150 6 8 150 200 sem 6 10 00 250 0 009 0 229 12 14 300 350 4 6 100 150 sem Jare 8 10 200 250 Feasts 10 2 80 200 seen 12 14 00 250 0 011 0 279 0 013 0 330 GG3213__ 4 6 100 150 GG3313 6 8 150 200 eases Jens m GG3513 10 12 250 300 GG3613 12 14 300 350 Gomm 46 100 150 eoo m E an GG3515 10 12 250 300 GG3615 12 14 300 350 4 6 100 150 GG3517 10 12 250 300 GG3617 12 14 300 350 0 015 0 381 0 017 0 432 Fan Width at 10 in 260 mm in mm in mm zo Orifice Size Gomm 6 8 150 200 0 019 0 483 E ae een kees een fewer 10 20 12 2 GG3421_ 8 10 200 250 0 021 0 533 RRE eer euer GG3721 14 16 350 400 6 eer kee GG3423_ 8 10 200 250 e io ose a0 eases beer ee re ooo ee kass aoa oa ees kees Case Tee GG3825 16 18 400 450 0 023 0 584 Pre orifice Selection Chart Orifice Size in mm ess es mme zez eme 0 010 0 254 308936 47 The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workman ship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for breach of this warranty Graco will for a period of twelve months or two thousand hours of operation from time of sale repair or replace any
7. 37a and insert the power supply in the gun handle Install the barrel on the handle as instructed on page 36 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 Remove the power supply from the gun handle as instructed on page 35 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 connec tor F disengages See Fig 16 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 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 Connect the 3 wire connector to the 3 prongs in the power supply Push the alternator 3
8. 7 Follow the Pressure Relief Procedure A 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 pres sure 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 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 308936 13 Gun Setup 10 Install the pre orifice A 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 orific
9. Voltage Read out SVR See Accessories to order the SVR PROBLEM Reduced fluid efficiency Improper distance between gun and 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 Operator gets shock Operator not properly grounded or is near an ungrounded object Gun not properly grounded Operator gets shock when Workpiece not properly grounded touching workpiece No or low voltage output reading Damaged fiber optic cable or on gun display module connection CAUSE SOLUTION 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 electro static 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 Be sure floor is properl
10. 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 9m 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 Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES GUN 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 PTFE seals Fluid Swivel Fitting 189018 5800 psi 400 bar 40 MPa Maximum Working Pr
11. not wipe the gun with a cloth soaked in solvent ring out the excess 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 Do not immerse the gun in solvent 02001A 308936 17 Daily Gun Care Flushing and Cleaning General System Maintenance 1 Clean the fluid and air line filters daily 2 Check all of the work hangers for material build up clean them if necessary 3 Check for any fluid leakage from the gun and fluid hoses Tighten fittings or replace equipment as needed 4 Flush the gun before changing colors and when ever you are done operating the gun Fig 3 02004A A WARNING ELECTRIC SHOCK HAZARD 4 Make sure the air and coating supply is To reduce the risk of fire explosion or turned off Turn on the solvent supply 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 2 Make sure the ES ON OFF lever is turned to OFF and the trigger safety latch is locked before proceeding 01999A Fig 4 5 Flush the Spray Gun Unlock the trigger safety latch point the gun down into a grounded metal container and flush the gun with solvent until it is clean Use the lowest pos sible fluid pressure when flushing Fig 2 02002A
12. 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 instal lation 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 materi als 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 a
13. s snug and then tighten it 1 8 turn more A 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 02016 Fig 15 Service 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 T 01953A 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 neces sary Also make sure the gaskets pads 18a 18d are in place See Fig 16 Lubricate the o ring
14. spray area such as people containers tools etc can become electrically charged Improper grounding can result in static sparking which can cause a fire explo sion or electric shock Follow the grounding instructions below The following are minimum requirements for grounding a basic electrostatic system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground 1 Pump ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual 2 Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations 3 Electrostatic Spray Gun ground the gun by con necting 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 8 308936 4 10 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 All electric cables must be properly grounded 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 in
15. 39 ES ON OFF LEVER 28 235798 FLUID NEEDLE ASSY 30 112691 SPRING compression 31 185079 PLUG 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 32 185119 SPACER ES valve malfunction and result in serious injury fire explosion or 33 185112 FITTING barb property damage 34t 185113 GASKET manifold polyethylene 35 185114 RETAINER RING alternator 36 113746 O RING ES valve CV75 37 222319 TURBINE ALTERNATOR e ee Ce Cee Ces Cees Cree Coes Cree Cee 40 185115 PACKING NUT 4it 111508 O RING air valve fluoroelastomer 42t 105452 U CUP air valve PTFE Part No 965722 Series B Includes items 37a amp 37b 1 Includes items 1 8 10 67 37at 110073 e O RING Viton 1 37b 185124 e CUSHION 1 Ref 38 185118 ES VALVE 1 No PartNo Description Qty 39 224194 AIR VALVE SHAFT ASSY 1 1 1 241250 AIR CAP amp ELECTRODE ASSY Includes item 1a oa 43 223978 AIR CONTROL VALVE ASSY ta SES EE Includes items 43b 43h 1 4 1 H 2 188479 TIP GUARD 1 3b 05681 RETAINING RING 1 P 43c 191806 e KNOB adjustment 1 3 235827 BARREL gun Includes item 3a 1 43d 186837 e HOUSING 1 3a 111261 e CONTACT RING barrel 1 i 43et 168518 e O RING Viton 2 4 186654 SCREW
16. 7 onto the power supply 18 until the retaining ring 35 engages with the alternator Install the power supply in the gun handle as instructed on page 35 Barrel Installation 1 36 Be sure the gaskets 84 A 18a and spring 30 are in place See Fig 17 Replace if damaged Place the barrel 3 over the power supply 18 and onto the gun handle 7 Make sure the fluid nee dle spring 30 is seated properly 308936 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 Nem maximum about a half turn past snug Do not over tighten A 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 i Tighten to 18 in lbs 2 Nem maximum about half turn past snug using wrench provided 01952A Fig 17 Service ES ON OFF Valve Repair A CAUTION 1 Prepare the gun for service as instructed on page Be sure the regulator disk 46 is installed correctly 28 A missing or incorrectly installed regulator disc can cause severe damage to the turbine alternator 2 Loosen the set screw 24 with the 2 m
17. ECO V6786 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Sales Offices Minneapolis Detroit Foreign Offices Belgium Korea Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com PRINTED IN U S A 308936 March 1999 Revised September 1999 48 308936
18. INSTRUCTIONS PARTS LIST d 308936 e RB This manual contains important GRACO Rev B Le warnings and information Supersedes Rev A READ AND KEEP FOR REFERENCE First choice when quality counts INSTRUCTIONS 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 A x Spray Gun with basic power supply d 2 finger trigger NIVA e Z A SS A CA oe Wi Ep APPROVED Ge 2 AN A Z WO sg R S 01944A 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 Pe Graco Inc is registered to I S EN ISO 9001 HOO3 2 AA 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 e Electrostatic e
19. Pliers e Needle Nose Pliers Service A CAUTION Pre Orifice Tip Guard Air Cap Spray Tip or Seat Housing Replacement 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 Prepare the gun for service as instructed on page 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 7 Make sure the electrode is not bent damaged or missing from the air cap A WARNING Repl the ti ket if E Sy Replace ihe Np gasket 9a ir damaged ELECTRIC SHOCK HAZARD l To reduce the risk of electric shock or 4 Trigger the gun and remove the seat housing 21 explosion never operate the spray gun with the 9 mm driver 64 supplied See Fig 8 with a bent damaged or missing elec trode 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 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD The barrel contact ring 3a is a conduc tive 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 t
20. and blemish the finish on the workpiece A Bevelled side of disk 46 faces toward valve 38 2 Lubricate o rings with petroleum jelly 6 Install the regulator disk 46 in the valve 38 with its bevelled side facing in toward the valve Fig 18 Ee 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 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 tur
21. ard 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 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 8 EQUIPMENT MISUSE HAZARD J les Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in a serious injury INSTRUCTIONS Gea 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 wi
22. ay tip or pre orifice is partially plugged The spray tip or pre orifice is damaged or worn The CO percentage is too low The fluid pressure is too low The temperature is too low The fluid pressure is too low Use the least fluid pressure needed for good results 22 308936 SOLUTION Adjust the flluid CO supply system Check tighten the siphon hose connections bleed the air from the fluid line Check fluid CO supply system 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 CO percentage Increase the fluid pressure with the gun fluid regulator Increase fluid temperature Increase the fluid pressure with the gun fluid regulator Gun Operation Troubleshooting PROBLEM CAUSE 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 CO 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 No fluid sprays from gun Fluid supply low Spray tip or pre orifice is dirty or clogged Spray tip damaged
23. cedure on page 10 3 The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Ground the System page 8 4 The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators 5 The operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps 6 The operator is not wearing gloves which insulate the hand from the spray gun If worn gloves must be conductive or modified as shown in Fig 2 so as not to interfere with NOTE If gloves are worn they must be conductive or the operator grounding through the gun modified as shown so they do not interfere with operator grounding through the gun 1 3in 76 mm square cut out and finger of glove cut off 7 The condition of the electrical components of the spray gun has been checked as Fig 2 instructed in Electrical Tests page 25 06445 The ventilation fans are operating properly 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 a
24. e 02015 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 A 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 clock wise until just snug then 1 4 to 1 2 turn tighter 9 Install the trigger 13 and tighten the trigger screws 4 34 308936 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
25. e 9b into the tip seal 9a PRESS DOWN with a large flat object i See EE 2 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 oN 9a 9b 8799A Fig 10A D 8799A Fig 10E 11 Install the spray tip A 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 14 308936 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 8800A Fig 11B C Install the spray tip 9 and air cap 1 tip guard 2 and retaining nut 8 onto the gun tighten the retaining nut firmly A 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 02088B Fig 11C 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 01947 Fig 12A B C Ma
26. e or toxic vapors Do x not operate the gun unless ventilation gh fans are operating Electrically interlock the gun air supply with the ventila tors 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 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 A 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 Installation P DER
27. e the u cup unless it is dam aged f 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 10 NI Fig 20 Install the air valve shaft with the o ring 41 into the back of the gun handle 7 If removed install the u cup with its lips facing into the gun handle Tighten the air valve packing nut 40 until it bot toms Install the spring 44 o ring 23 and air valve cap 45 Tighten the air valve packing nut 40 40 42 2 Lubricate o rings with petroleum jelly Do not remove u cup 42 unless damaged Install with lips facing into handle 02014A 308936 39 Notes 40 308936 Technical Data 35 oz 1 kg 11 4 in 290 mm 100 psi 7 bar 0 7 MPa 3000 psi 207 bar 20 7 MPa Sound Pressure t 86 Db A Sound Power 88 9 Db A Category Gun Weight Gun Length 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 120 mA Output Paint Resistivity 3 megohm cm to infinity Range Air Inlet 1 4 npsm m left hand 1 4 npsm m Fluid Inlet Wetted Parts Stainless Steel Nylon PEEK Ultra High Molecular Weight Polyethylene Tungsten Carbide Glass Filled Nylon Viton is a registered tradema
28. essure Connects to gun fluid inlet fitting 188691 1 4 nosm m x 1 4 npsm f 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 i 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 C gt Megohmmeter 218979 500 Volt output 0 01 2000 megohms Not for u
29. he Fig 7 contact ring with anything but a genuine Graco part 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 A 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 retain 02085 ing nut firmly Fig 8 308936 29 Service Electrode Replacement 30 A 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 Prepare the gun for service as instructed on page 28 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 Pull the electrode 1a out of the backside of the air cap with a needle nose pliers 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 308936 5 Assemble the spray tip air cap and tip guard Then install them on the gun
30. he 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 Air Spray Retaining Cap Tip Nut black orange Latch Trigger Safety The ability of the PRO AA4500 UNICARB Electrostatic Spray Gun to spray at higher fluid pressures com bined with the addition of CO from the UNICARB process provides the additional power needed to atomize higher solids materials The gun s internal power cartridge provides high voltage current The fluid is electrostatically charged as it passes the gun s electrode The charged fluid is attracted to the grounded object wrapping around and evenly coating all surfaces NOTE The gun s air control valve must be completely turned off to 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 ES Indicator Light Air Control Valve WARNING To avoid shock or explosion use
31. ice A CAUTION Fluid Packing Adjustment If fluid leaks from the fluid needle area the fluid pack ings may be loose Tighten the packings following the procedure below 1 Prepare the gun for service as instructed on page 28 2 Remove the retaining nut 8 tip guard 2 air cap 1 and spray tip 9 See Fig 7 page 29 You may have to turn the air cap with the tip guard to remove the air cap from the gun 3 Trigger the gun and remove the seat housing 21 with the 9 mm driver 64 supplied See Fig 8 page 29 NOTE The seat housing 21 must be removed before adjusting the fluid packings 4 Remove the barrel as instructed on page 32 5 Place the 2 mm driver 58 supplied in the back of the fluid needle assembly Push the tool in and turn it clockwise slightly to tighten the packings See Fig 14 6 Assemble the barrel as instructed on page 36 7 Trigger the gun and install the seat housing 21 with the 9 mm driver 64 Tighten the seat housing until it s snug and then tighten it 1 8 turn more 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 EN To tighten packings 2 To remove needl
32. ing any part in the system and whenever you are instructed to relieve the pressure NOTE e Check all possible remedies in Troubleshooting before disassembling the gun e If the plastic parts of the gun must be held securely always clamp them in padded vice jaws to prevent damage to the parts e Lightly lubricate o rings and seals with petroleum jelly Do not over lubricate e 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 28 308936 A WARNING Some PRO AA4500 Gun replacement parts look similar to other PRO Gun parts but are not inter changeable 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 e 2mm Driver included with gun e A mm Driver included with gun e 9mm Driver included with gun e Adjustable Wrench e Medium Screw Driver e Snap Ring
33. 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 01947 Fig 14 15 e the gun see page 18 The LO setting is factory set to 60 kV This setting can NOTE When spraying the ES indicator light K will be adjusted between 45 and 80 kV See page 35 to glow indicating the electrostatic charge adjust 16 308936 Daily Gun Care Flushing and Cleaning A WARNING INJECTION HAZARD Clean all parts with a non conductive solvent com DA To reduce the risk of serious injury patible with the fluid being sprayed Conductive including fluid injection splashing in the solvents can cause the gun to malfunction eyes or on the skin or electric shock always follow the Pressure Relief Procedure Methylene chloride is not recommended as a flush Warning on page 10 when shutting off the system ing or cleaning solvent with this gun as it will damage when you stop spraying and before checking nylon components servicing installing cleaning or changing any part in the system A CAUTION Solvent left in gun passages could result in a poor quality paint finish and may draw current and reduce the elec trostatic effect Solvent in the power supply cavity can reduce the alternator life Do not use any cleaning meth od which may allow solvent into the gun air passages Do not point the gun up while cleaning it Do
34. ke sure the fluid supply is shut off D Trigger the gun and adjust the air pressure with the gun air regulator H use the Recommended Air Hose Inlet Pressure chart below as a guide Fig 12D _ Recommended Air Hose Inlet Pressure ween LSZ Air Hose Length Hose Inlet Pressure 6 ft 1 8 m 15 ft 5 m 36 ft 11 m 50 ft 15 m 50 psi 3 5 bar 47 psi 3 2 bar 75 ft 23 m 100 ft 30 5 m 55 psi 3 8 bar 60 psi 4 1 bar NOTE Using higher than recommended air pressures can reduce the life of the turbine alternator Lower pressures can be used but may reduce electrostatic wrap E Check the voltage output of the gun using a high voltage probe and meter NOTE The gun s normal high voltage reading is 60 to 70 KV If a ball end high voltage probe is used the gun voltage will rise to about 85 KV This will happen with all resistive electrostatic guns 308936 15 Gun Setup 13 Setting the Atomization Fluid Pressure 15 Use the ES HI LO lever 43g to change Atomization fluid pressure will vary based on the type to either full voltage HI or a lower volt of fluid used the flow rate desired the fluid tempera age level LO ture and the percentage of CO used Follow the recommendations of your material and equipment supplier 14 Using the Electrostatics Turn the ES ON OFF lever 26 to ON This will acti vate the electrostatics Some objects with deep crevices or
35. king do not use the megohmmeter to do the electrical tests unless e The gun has been removed from the hazardous area e Orall 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 con tainers or fumes from spraying Failure to follow this warning could cause fire explosion electric shock and result in serious injury and property damage Test Gun Resistance See Fig 4 NOTE The fluid passage must be flushed and dried to get an accurate reading Measure the resistance between the end of the elec trode 1a and the air fitting 17 The resistance should be between 329 to 401 megohms If the resis tance 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 III la 01949 Fig 4 308936 25 Electrical Tests Test Power Supply Resistance See Fig 5 A 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
36. m hex key 63 supplied Remove the lever 26 from the valve See Fig 18 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 A WARNING handle Install the lever 26 and tighten the set screw 24 A 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 3 Use internal snap ring pliers to remove the retain the retaining ring is missing or improperly installed ing ring 47 from the handle Align the holes in the the valve assembly can be propelled out of the gun retaining ring with the flat on the spacer 32 to when air pressure is applied and cause serious ease assembly and disassembly Injury 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 com pressed 4 Remove the valve body 38 from the handle be careful not to drop the regulator disk 46 and spacer 32 5 Clean and inspect the parts for damage Replace if necessary Lubricate the o ring 36 with petroleum jelly A CAUTION Do not over lubricate parts Excessive lubricant on the o ring 36 can be pushed into the gun air pas sage
37. more air hoses use air adapter nipple 185493 See Accessories Continued on the next page 308936 11 Gun Setup 3 Check the gun s electrical grounding F If the resistance is greater than the maximum reading specified above for your hose check the A WARNING 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 re place the air hose 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 electri cal grounding unless e 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 con tainers or fumes from spraying Failure to follow this warning could cause fire explosion electric shock and result in serious injury and property damage A Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 01946A Fig 3D E B Turn the ES ON OFF Lever to OFF 4 Connect the gun exhaust tube C Turn off the air and fluid supply to the gun The Press the exhaust tube 56 onto the barbed adapter fluid hose must not have any fluid in it on the bottom of the gun handle Secure the
38. n 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 Ib 1 1 to 1 4 Nem 9 Install the retaining ring 43h back into the groove in the valve housing 43d 38 308936 DETAIL 43f 43h 43c par 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 NI 43 J AN S A LK ROL A N Bee 01954B Fig 19 Service Air Valve Repair 1 Prepare the gun for service as instructed on page 28 Using a screw driver remove the air valve cap 45 See Fig 20 Remove the o ring 23 and spring 44 A 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 A CAUTION When removing the air valve shaft 39 be careful not to damage the seat area 5 Check the o rings 41 23 for damage and replace if necessary Apply petroleum jelly to the o rings Unscrew the packing nut 40 to check the u cup 42 Do not remov
39. ngage the electrode wire over tighten and make sure the top fluid tube fitting Q remains tightened 02009 Fig 13 14 15 Hang up the gun gt Fig 16 ozori 17 Wipe off the parts with a dry cloth Be careful not to bend the electrode wire Fi 15 02010A H TH 18 Check the electrode wire Replace it if it is bent or damaged See page 30 A CAUTION A WARNING Always hang the gun with its nozzle pointing down to ELECTRIC SHOCK HAZARD avoid having solvent run into the gun air passages To reduce the risk of electric shock or Solvent in the gun air passages can cause poor explosion never operate the spray gun atomization and excessive current demands and can with a bent damaged or missing elec damage the gun trode 20 308936 Daily Gun Care Flushing and Cleaning 19 Place the spray tip 9 in the air cap 1 21 Hang up the gun until it is used again Align the tab of the tip with the groove in the air cap Be careful not to bend the electrode wire A WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock or explosion never operate the spray gun with a bent damaged or missing elec trode im 02012B Fig 21 A 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 8800A Fig 19 damage
40. ontact ring 3a are clean If the resistance is still outside the specified range 1 Remove the barrel contact ring 8a 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 Se 3 If the resistance is still outside the specified range the gun barrel needs to be replaced 3a D If the resistance is correct install a new contact 1 ring 3a and press it firmly into the groove on the front of the barrel ae Wire lead in groove behind contact ring Be sure the contact ring is in place before operat ing the gun Fig 6 01957 308936 27 Service Prepare the Gun for Service A WARNING ELECTRIC SHOCK HAZARD ai Installing and servicing this equipment We 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 AA WARNING INJECTION HAZARD DA 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 servic
41. properly grounded air hose For safe operation read instructions ES ON OFF ES HI LO Lever Lever Back View of Gun 308936 5 Installation Ventilate the Spray Booth A WARNING FLAMMABLE OR TOXIC VAPOR HAZARD Installing the System A 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 e 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 regula tions Fig 1 shows a typical electrostatic UNICARB spray system It is not an actual system design The particu lar 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 6 308936 Provide fresh air ventilation to avoid the buildup of flammabl
42. quipment 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
43. re Orifice Tip Guard Air Cap Spray Tip or Seat Housing Replacement 29 Electrode Deplacement 30 Fluid Tube Removal amp Replacement 31 Fluid Filter Removal 00 0000 31 Barrel Removal 0 00000eeeeeeeee 32 4 308936 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 000 cece eee 41 PANIS o ooreet iia ka a vid a hoa Sue Ae 42 Accessories 44 Spray Tip Selection Chart 47 Pre orifice Selection Chart 47 The Graco Warranty and Disclaimers 48 Graco Phone Number 48 Symbols Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Caution Symbol A CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions Introduction How the PRO AA4500 UNICARB Electrostatic Air Assisted Spray Gun Operates A WARNING Remember this is not an air spray gun for your safety be sure to read and follow t
44. re 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 02009 Fig 10 A Apply grease 217115 Apply low strength thread sealer wes E D c Fig 41728079 NI NI 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 A 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 01950 Fig 12 32 308936 01951A Serv
45. rea is electrically conductive and grounded 308936 9 Operation Pressure Relief Procedure AA WARNING INJECTION HAZARD DA 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 Trigger Safety e are instructed to relieve the pressure Latch Unlocked e stop spraying e check or service any of the system equipment e or install or clean the spray tip Lock the spray gun trigger safety latch See Fig 3 Turn the ES ON OFF lever to OFF Turn off the fluid supply to the gun Po NM Close the bleed type master air valve required in system Trigger Safet Close the air valve for the gun air supply line tert Weise 01988A Unlock the gun trigger safety latch Fig 3 7 Trigger the gun into a grounded shrouded and vented metal waste container to relieve fluid and air pressure This may take several minutes 8 Lock the gun trigger safety latch again 9 Open the fluid drain valve required in system to help relieve fluid pressure In addition open the drain valve connected to the fluid pressure gauge in a system with fluid regulation to help relieve fluid pressure in the hose and gun Triggering the gun to relieve pressure may no
46. rk of the DuPont Co Loctite is a registered trademark of the Loctite Corporation Sound Pressure t 95 Db A Sound Power 99 7 Db A 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 t Sound pressure was measured per Cagi Pneurop 1969 Sound power was measured per ISO 3744 1981 Radio Frequency Transmitter Approval for Gun Part No 236031 and 236033 FCC ID JHI1 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation Changes or modification to this equipment not expressly approved by the party responsible for com pliance 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 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 37a Su 57 01956D 14 ey Parts Ref A WA R N l N G No PartNo Description Qty 24 110083 SET SCREW M4 x 0 7 26 1868
47. se in Hazardous areas 0189 Remote Spraying Voltage Readout SVR 224388 Requires Gun Power Supply change to 224100 see below For monitoring the gun voltage during operation Battery operated intrinsi cally safe Class I Group D hand held unit See Manual 308183 Sy SS Gun Power Supply with RF eg 224100 Power supply with transmitter capability for spraying voltage readout SVR 46 308936 Gun High Voltage Probe and Meter 236003 For direct measurement of gun output voltage Paint Resistance Meter 722886 Used with 722860 Paint Probe to measure resistance of paint Not for use in Hazardous areas Paint Probe 722860 Used with 722886 Paint Resistance Meter to measure resistance of paint Not for use in Hazardous areas Safety Warning Signs Available at no charge from Graco 180060 Warning Sign English 180061 Warning Sign French 180062 Warning Sign German 180063 Warning Sign Spanish Setup Instruction Poster 189062 Basic PRO AA4500 Gun operator setup instructions to hang in the spray booth area English on one side and Spanish on the other side Daily Gun Care Instruction Poster 189063 Basic PRO AA4500 daily gun care instructions to hang in the spray booth area English on one side and Spanish on the other side Spray Tip Selection Chart Fan Width at 10 in 260 mm Orifice Size in mm in mm GG3107 2 4 50 100 0 007 0 178 GG3207 4 6 100 150 GG3307 6 8 150 200 4 6 100
48. securing them with the retaining nut Tighten the retaining nut firmly 6 Test the gun resistance as instructed on page 25 la 1 CC BB 8804A Fig 9 Service Fluid Filter Removal Fluid Tube Removal amp 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 A 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 sur face is damaged the entire fluid tube assembly must be replaced 4 Apply grease part no 217115 to the entire length of the plastic extension on the end of the fluid tube 12 See Accessories to order the grease 5 Apply a low strength thread sealer such as purple Loctite to the fluid tube nut D threads 6 Install the fluid tube into the gun barrel by tighten ing 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 1 Prepa
49. sulate the hand from the spray gun The gloves must be conductive or modified as shown in Fig 2 page 9 Object being sprayed keep the workpiece hangers clean and grounded at all times Contact points must be sharp points or like knife edges 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 Flammable liquids in the spray area must be kept in approved grounded containers Do not store more than the quantity needed for one shift All electrically conductive objects or devices in the spray area including fluid containers and wash cans must be properly grounded Operation Operating Checklist Check the following list daily before starting to operate the system to help ensure safe efficient operation A WARNING 1 All the operators are properly trained to safely operate an electrostatic air assisted airless spray system as instructed in this INJECTION HAZARD Won 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 manual The card contains important information on what to 2 All the operators are trained how to properly do if an injection injury occurs Additional cards are relieve pressure using the Pressure Relief available at no charge from Graco Pro
50. t 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 ex press 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 ex ceed 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 pur pose 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
51. t 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 com pletely 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 10 308936 Gun Setup 1 Complete the Operating Checklist and follow the Warnings on pages 9 and 10 2 Connect the Graco air hose A 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 1 Left hand thread G 01989A Fig 2A 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 01990 Fig 2B C NOTE To connect two or
52. th 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 180 F 82 C or below 40 F 40 C 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 LEE 4 Introduction ee EEN eins aden RTE ENNEN EN 5 Installation Ne cad ee heer ed ER ekinaki keh 6 Installing the System 6 Warning Signs 00e cee eee eee 6 Ventilate the Spray Booth 6 Air Line Accessories 6 Fluid Line Accessories 22 00 05 7 Ground the System 8 Operation 9 Operating Checklist 9 Pressure Relief Procedure 10 Gun Setup eee eee eee eee 11 Daily Gun Care Flushing and Cleaning 17 Spray Pattern Troubleshooting 22 Gun Operation Troubleshooting 23 Electrical Troubleshooting 24 Electrical Tests 25 Test Gun Resistance 25 Test Power Supply Resistance 26 Test Barrel Resistance 2 005 27 E E ENEE EELER cake eae dd anes 28 Prepare the Gun for Service 28 Tools Needed 28 P
53. the gun 20 Install the spray tip 9 and air cap 1 tip guard 2 and retaining nut 8 Tighten the retaining nut firmly 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 02088B 308936 21 Spray Pattern Troubleshooting 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 clean ing 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 IMPROPER SPRAY PATTERN Fluttering or spitting spray Irregular pattern Tails in pattern Excessive paint buildup on the air cap and tip guard The fluid pressure or fluid supply is insuf ficient There is air in the fluid supply line The CO percentage is fluctuating or is too high The fluid temperature is fluctuating There is fluid buildup on the spray tip or the spr
54. 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 e Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings e Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines e Wear appropriate protective clothing gloves eyewear and respirator 308936 AA 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 gu
55. trigger 2 43f 111221 e SPRING wave 1 5 185096 SCREW cap relieved M5 x 0 8 3 6 185097 HOOK 1 43g 224196 e LEVER ES HI LO 1 7 235911 HANDLE 43h 111510 e RETAINING RING external 1 359 1 44 185116 SPRING compression air valve 1 8 188480 RETAINING NUT air cap 1 9 GG3XXX SPRAY TIP t hoi 45 188486 AIR VALVE CAP 1 S e S RES 46 107107 DISC REGULATOR 1 EE OGen 47 110082 RETAINING RING 1 9a 626588 SEAL spray tip 1 9b 5519XX PRE ORIFICE t hoi 54A 188774 WARNING TAG ox 3 pias ue OEP ence 55 107460 DRIVER socket head A mm 1 tat 179791 WARNING TAG 56 185103 EXHAUST TUBE polyurethane 1 12 235843 FLUID TUBE ASSY 1 57 110231 CLAMP exhaust tube 1 13 186791 TRIGGER i 58t 112080 DRIVER socket head 2 mm 1 14 205264 FLUID FILTER 59At 180060 WARNING SIGN English 15 185122 MUFFLER fi t 1 See Accessories for additional signs 1 flame arrestor ent 180209 GUN COVER Order Part No 218374 16 238160 BRACKET 1 17 185105 AIR FITTING 1 Tor package of TO 1 f 62At 222385 WARNING CARD 1 18 gt 11296099 SE a SDE 83 KV 64 110087 DRIVER hex nut 9 mm 1 18at 186840 GASKET 67 235300 BRACKET gun hanging 1 18b 185099 PAD 1 A Replacement Danger and Warning labels tags and cards 18c 185145 PAD 1 are available at no cost 18d 185141 e CUSHION 1 18et 186637 e SEAL 1 t These parts are included in Air Seal Repair Kit 224633 19t 106555 O RING plug amp adapter Viton 2 which may be purchased separately 21 235797 SEAT HOUSING 1
56. tube with the clamp 57 provided 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 Ifusing 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 b If using a red turbine air hose use an ohmme ter to measure the resistance Resistance should not exceed 100 ohms Fig 4 01992A 12 308936 Gun Setup Connect the fluid hose A Before connecting the fluid line blow it out with air and flush it with solvent Use solvent which is com patible with the fluid to be sprayed G i B Connect the static free fluid hose F to the 1 4 18 npsm gun fluid fitting 10 01993A 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 toa grounded filtered and regulated fluid line G Fig 5C 01994A 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
57. y 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 Clean workpiece hangers Check for proper 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 A 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 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Megohmmeter P N 218979 A see Fig 4 is not approved for use in a hazard ous area To reduce the risk of spar
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