Graco Inc. Pro AA4500 manual

308936 Rev . B Supersedes Rev . A First choice when quality counts.  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[...]

2 308936 W ARNING 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 man[...]

308936 3 W ARNING 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 ser[...]

4 308936 T able of Contents W arnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

308936 5 Introduction How the PRO AA4500/UNICARB Electrostatic Air-Assisted Spray Gun Operates W ARNING Remember , this is not an air spray gun; for your safety be sure to read and follow the W arnings 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 [...]

6 308936 Installation Installing the System W ARNING 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 y[...]

308936 7 Installation 01945B Fig. 1 KEY A* Bleed-type Air Shutoff V alve B Air Line Filter H Fluid Shutoff V alve K Pressure Gauge L* Grounded Braid T ype Fluid Hose with spring guards M Gun Fluid Inlet (1/4 npsm) N Gun Air Regulator P Gun Air Shut-of f V alve Q* Graco Electrically Conductive Air Supply Hose (1/4 npsm x 1/4 npsm LH) R* Fluid Drain [...]

8 308936 Installation Ground the System W ARNING 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, explo- sion, or electric sh[...]

308936 9 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 proper[...]

10 308936 Operation Pressure Relief Procedure W ARNING 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 . T o reduce the risk of an injury from injection, splashing fluid or electric shock,[...]

308936 11 Gun Setup 1. Complete the Operating Checklist and follow the W arnings on pages 9 and 10. 2. Connect the Graco air hose. W ARNING ELECTRIC SHOCK HAZARD T o 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 Supp[...]

12 308936 Gun Setup 3. Check the gun ’ s electrical grounding. W ARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Megohmmeter P/N 218979 (E) is not approved for use in a hazardous area. T o reduce the risk of sparking, do not use the megohmmeter to check electri- cal grounding unless:  The gun has been removed from the hazardous area;  Or [...]

308936 13 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 com- patible with the fluid to be sprayed. B. Connect the static-free fluid hose (F) to the 1/4 – 18 npsm gun fluid fitting (10). Fig. 5B 01993A F 10 NOTE: The PRO AA4500 spray gun has a 100 mesh[...]

14 308936 Gun Setup 10. Install the pre-orifice W ARNING T o 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-orific[...]

308936 15 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. T urn the ES ON-OFF lever (26) to ON. Fig. 12A-B 01947 26 ON 43 close C. Make sure the fluid supply is shut off. D. T rigger the gun and adjust the air pressure with the gun air regul[...]

16 308936 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 tempera- ture, and the percentage of CO 2 used. Follow the recommendations of your material and equipment supplier . 14. Using the Electrostatics T urn the ES ON-OFF lever (26) to ON. [...]

308936 17 Daily Gun Care, Flushing, and Cleaning W ARNING INJECTION HAZARD T o 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 W arning on page 10 when shutting off the system, when you stop spraying and before checking, servicing, ins[...]

18 308936 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 c[...]

308936 19 Daily Gun Care, Flushing, and Cleaning 6. Lock the trigger safety latch and turn off the solvent supply . 7. Follow the Pressure Relief Procedure W arning 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. 02341 02338 Fig. 8 F A 9. Unlock the trigger safety l[...]

20 308936 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. Fig. 13 – 14 02009 P 14 Q 15. Hang up the gun. Fig. 15 02010A CAUTION Alw[...]

308936 21 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. W ARNING ELECTRIC SHOCK HAZARD T o reduce the risk of electric shock or explosion, never operate the spray gun with a bent, damaged or missing elec- trod[...]

22 308936 Spray Pattern T roubleshooting W ARNING 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. T o reduce the risk of serious injury , including fluid injec[...]

308936 23 Gun Operation T roubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid needle area Fluid needle packings loose Fluid needle packing damaged Tighten packing nut; See page 33 Replace fluid needle; See page 34 Air leakage from front of gun Air valve not turned off Piston air valve not seating properly Turn of f air (43). See page 15 Clean,[...]

24 308936 Electrical T roubleshooting NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying V oltage Read- out ( SVR  ) . See Accessories to order the SVR. PROBLEM CAUSE SOLUTION Reduced fluid efficiency Improper distance between gun and work-piece Parts poorly grounded High booth exhaust velocity Flui[...]

308936 25 Electrical T ests 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 th[...]

26 308936 Electrical T ests T est 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 resi[...]

308936 27 Electrical T ests T est Barrel Resistance (See Fig. 6) Measure the resistance between the barrel contact ring (3a) and the metal contact pin (E), using a metal rod (D) and megohmmeter as shown in Fig. 6. Be careful not to damage or scratch the inner surfaces of the barrel with the metal rod. The resistance should be 19 to 29 megohms. If t[...]

28 308936 Service Prepare the Gun for Service W ARNING 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. W ARNING INJECTION HAZARD T o [...]

308936 29 Service Pre-Orifice, Tip Guard, Air Cap, Spray T ip, or Seat Housing Replacement 1. Prepare the gun for service as instructed on page 28. 2. Remove the retaining nut (8), tip guard, (2), air cap (1), and spray tip (9). See Fig. 7. Y ou may have to turn the air cap with the tip guard to remove the air cap from the gun. 3. Replace the tip g[...]

30 308936 Service Electrode Replacement W ARNING ELECTRIC SHOCK HAZARD T o 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 Fi[...]

308936 31 Service Fluid T ube Removal & Replacement T o 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)[...]

32 308936 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[...]

308936 33 Service Fluid Packing Adjustment If fluid leaks from the fluid needle area, the fluid pack- ings may be loose. T ighten 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. Y ou may have t[...]

34 308936 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. Y ou may have to turn the air cap with the tip guard to remove the air cap from the gun. 3. T rigger the gun and remove the seat housing (21) wi[...]

308936 35 Service Fig. 16 7 35 37a 37b 18a 18 37 F 3 18b 18c 18d 18e 01953A Power Supply Removal and Replacement NOTES: a. T o 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 wil[...]

36 308936 Service T urbine 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) tog[...]

308936 37 Service ES ON-OFF V alve Repair 1. Prepare the gun for service as instructed on page 28. 2. Loosen the set screw (24) with the 2 mm hex key (63), supplied. Remove the lever (26) from the valve. See Fig. 18. W ARNING MOVING P ARTS HAZARD T o reduce the risk of eye injury , be sure to wear safety glasses when removing or installing the reta[...]

38 308936 Service Air Control V alve Repair NOTE: The air control valve (43) can be replaced as an assembly or as individual parts. T o 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 [...]

308936 39 Service Air V alve 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 solv[...]

40 308936 Notes[...]

308936 41 T echnical Data Category Data Gun Weight 35 oz (1 kg) Gun Length 1 1.4 in (290 mm) Maximum Air Working Pressure 100 psi (7 bar , 0.7 MPa) Maximum Fluid Working Pressure 3000 psi (207 bar , 20.7 MPa) T ypical Noise Level at 40 psi (2.8 bar , 0.28 MPa)* Sound Pressure  86 Db(A) Sound Power  88.9 Db(A) Maximum Noise Level at 100 psi (7[...]

1 2 3 4 5 6 7 8 9 14 12 REF 12 13 15 16 17 18a 18e 18 18b 18d 18c 19 21 23 24 26 28 30 31 32 19 33 34 35 36 37 37a 37b 38 39 40 41 42 43b 43d 43f 43g 43h 43e 43c 44 45 46 47 3a 9a 56 57 1a 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 in[...]

308936 43 Parts W ARNING 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 ma[...]

44 308936 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 (1 1 m) 21[...]

308936 45 Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES High Pressure Ball V alves 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), [...]

46 308936 Accessories Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Grounding Clamp and Wire 22201 1 0189 12 ga, 25 ft (7.6 m) wire Megohmmeter 218979 500 V olt output; 0.01 – 2000 megohms; Not for use in Hazardous areas Remote Spraying V oltage Readout (SVR  ) 224388 (Requires Gun Power Supply change to 224100; see be[...]

308936 47 Spray Tip Selection Chart Part N o. Fan Width at 10 in. (260 mm) in. (mm) Orifice Size in. (mm) GG3107 2 – 4 (50 – 100) 0.007 (0.178) GG3207 4 – 6 (100 – 150) GG3307 6 – 8 (150 – 200) GG3209 4 – 6 (100 – 150) 0.009 (0.229) GG3309 6 – 8 (150 – 200) GG3409 8 – 10 (200 – 250) GG3609 12 – 14 (300 – 350) GG321 1 4 ?[...]

48 308936 The Graco W arranty and Disclaimers W ARRANTY Graco war ran ts al l eq uip men t 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 fo r breach of this warranty , Graco will, f[...]