Graco Inc. PRO4000 manual

INSTRUCTIONS–P ARTS LIST 307–638 Rev . AE Supersedes AD This manual contains IMPORT ANT W ARNINGS AND INSTRUCTIONS READ AND RET AIN FOR REFERENCE Part Number 218–026, Series E With 1.2 mm (0.047 in.) fluid nozzle, part no. 218–996 U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774 U.K. Patent No. 2,140,327B; 2,142,559B; 2[...]

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 T ABLE OF CONTENTS T erms 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety W arnings 4, 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . How The Electrostatic Air Spray Gun W orks 5 . . . . Installation T ypical Installation 6 . . . . . . . . . . . . . . . . . . . . . . . [...]

4ą307-638 SAFETY W ARNINGS SERIOUS BODIL Y INJUR Y , EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERST AND ALL INSTRUCTION MANUALS, T AGS, AND W ARNING LABELS BEFORE OPERA TING EQUIPMENT . ELECTROST A TIC EQUIPMENT SHALL ONL Y BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULL Y CONVERS[...]

307-638ą5 FIRE OR EXPLOSION HAZARD To reduce the risk of fire, explosion, or electric shock, which may result from electrical discharge, it is essential that: S All parts of the electrostatic system are properly grounded. S All personnel in or close to the spray area are properly grounded. S All electrically conductive objects or devices in the sp[...]

 TYPICAL INST ALLA TION KEY A Main Air Supply Line B V entilation Fan Interlock Solenoid V alve C Main Air Supply Shutof f V alve (bleed–type) D Air & W ater Separator E Pump Air Supply Shutof f V alve (bleed–type) F Air Line Lubricator G Air Pressure Regulator H Pump J Pump Ground Wire K Fluid Filter L Fluid Supp[...]

 INST ALLA TION V entilate the Spray Booth W ARNING T o prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. Never operate the spray gun unless ventilation fans are operating. Check and follow all of the National, State and Local codes regarding air exhaust ve[...]

 INST ALLA TION Check the Electrical Grounding (See Fig 1) W ARNING Proper electrical grounding of every part of your system is essential. For your safety , read the warning section, FIRE OR EXPLOSION HAZARD , on page 5. Ground the system as explained there. Then check your system as explained below . 1. T urn the ES On?[...]

307-638ą9 OPERA TION W ARNING Pressure Relief Procedure To reduce the risk of serious bodily injury , including splashing in the eyes or on the skin, injury from moving parts or electric shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing f[...]

10ą307-638 OPERA TION Install the Fluid Nozzle and Air Cap W ARNING To reduce the risk of serious bodily injury , including splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Proce- dure on page 9 before installing, or removing the fluid nozzle/air cap assembly . 1. See Instruction Manual 307–803 for air ca[...]

307-638ą11 MAINTENANCE Daily Care and Cleaning W ARNING To reduce the risk of serious bodily injury , including splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Proce- dure W arning on page 9 when shutting of f the sys - tem, when you stop spraying and before checking, servicing, installing, cleaning or cha[...]

12ą307-638 MAINTENANCE Flush the Spray Gun W ARNING To reduce the risk of fire or explosion and serious bodily injury , the ES ON–OFF lever must be OFF before flushing. 1. Follow the Pressure Relief Procedure W arning on page 9. 2. Disconnect and plug the fluid line. 3. Connect the solvent supply to the gun. 4. Flush the gun with solvent until i[...]

  SPRA Y P A TTERN TROUBLESHOOTING CHART W ARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other serious bodily 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 seri[...]

14 307-638 GUN OPERA TION TROUBLESHOOTING CHART Misalignment between air cap and Remove and clean air cap and fluid nozzle fluid nozzle. as described in Maintenance Section under Clean the Air Cap and Fluid Nozzle , then reinstall them. PROBLEM CAUSE SOLUTION W orn needle packing. Replace packing assembly . See page 21. Air leakage from front of gu[...]

307-638 15 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION *ES ON–OFF lever in OFF position. T urn lever to ON. Improper distance between gun Adjust spraying distance to and workpiece. 203–305 mm (8–12 in.). Parts poorly grounded. Clean hangers, check for proper ground on conveyer or track. High booth exhaust velocity . Reduce within [...]

16 307-638 ELECTRICAL TESTS $! ,!-"+-)*! +" /$! .,-4 #0* %. %-!/(4 ""!/!  4 /$! +* %/%+* +" /$! !(!/-%( +),+*!*/. +*/%*!  %*6 .% ! /$! #0* $! !(!/-%( /!./. !(+2 * ! 0.!  /+[...]

307-638 17 ELECTRICAL TESTS T est Resistor Stud Resistance $(')  %$*)!+ '%  !$)% )  *$ ''" '/ #%+ %' )  &%,' (*&&"- )() $ !$() )  #[...]

18 307-638 SERVICE Gun Disassembly ăWARNINGĂ (-.&&#(! ( -,0##(! ."#- +/#*'(. ,+/#,- -- .) *,.- 1"#" '2 /- &.,# -")% ), ).", -,#)/- )#&2 #($/,2 #  ."[...]

307-638 19 SERVICE Resistor Stud Replacement ăWARNINGĂ Old/New Style Resistor Stud and Electrode  , ."!1 " 0%" .&/( ,# /-.(&+$ 3%& % ,1)! 1/" #&." ,. "4-),/&,+   0%" ")" 0.,!" [...]

20 307-638 SERVICE Barrel Removal  )-,!1 .$! )/.  . .$! ,,!' "'/%  %)'!. !! %#   /'' .$! "'/%  ./!  */. *" .$! "'/%  %)'!.  !(*0! .$! .,%[...]

307-638 21 SERVICE 5. Carefully remove the fluid needle assembly (45) from the rear part of the gun barrel (18). See Fig 15. If the packing assembly (45a) or insulator (45g) are still in the barrel, insert the packing removal rod (59d) into the front of the barrel to gently push them out. Refer to Fig 16. NOTE: If the insulator (45g) is removed, be[...]

  SERVICE Fig 17 KEY 2 Gun Handle 3a Alternator 3b O–Ring 3c Plug 5 Power Supply 5a O–Ring 5b O–Ring 5c Spring 18 Barrel 18b Cushion 46 Gasket 18 46 5c 5b 5a 3a 3c 3b 2 5 NOTE: The power cartridge (3) includes items 3a, 3b, 3c, and 5. 18b See NOTE after step 3, below . Power Cartridge Replacement 1. Remove the barre[...]

  SERVICE T urbine Alternator Removal 1. Remove power cartridge from the gun handle as described under Power Cartridge Replacement . 2. Carefully twist the turbine alternator (3a) counter- clockwise and pull it of f the power supply (5) until just disengaged from the coupling. Then continue to slowly pull the turbine alte[...]

24 307-638 SERVICE Fan Air V alve Replacement 1. Place a wrench on the flats of the valve housing (33) and remove it from the handle (2). See Fig 20. 2. Remove the retaining ring (31). 3. Rotate the air adjusting screw (34) counterclockwise until it is disengaged from the valve housing threads. Pull the adjusting screw (34) out of the valve hous- i[...]

307-638 25 SERVICE ES ON–OFF V alve Removal & Replacement 1. Loosen and remove the nut (35). Remove the lever (37) and washer (36). See Fig 22. Insert the hex head wrench into the hex end of the valve (39), and turn it to loosen and remove the valve. 2. Clean and inspect parts for wear or damage. Re- place if necessary . Lubricate the o–rin[...]

  P ARTS DRA WING Old/New Style Resistor Stud and Electrode To reduce the risk of sparking, which could cause fire or explosion, BE SURE the electrode and stud you install are black. The old style electrode and stud in the Series A–D Guns were white. DO NOT mix old style parts with new style parts. *38 4* 39 38* 2 29* 5[...]

  P ARTS LIST REF NO. P ART NO. DESCRIPTION QTY 2 218–014 HANDLE, gun; Includes item 2a 1 2a 179–400 .ADAPTER 1 3 218–1 1 1 POWER CAR TRIDGE; Includes items 3a and 5 1 3a 217–591 AL TERNA T OR, turbine; Includes items 3b & 3c 1 3b* 107–106 .O–RING, buna-n 2 3c 180–070 .PLUG 1 4* 107–107 REGULA T OR, di[...]

  REP AIR KITS Repair Kits must be purchased separately . Use only GENUINE GRACO P ARTS AND ACCESSORIES. W ARNING When servicing use only genuine Graco replace- ment parts. Use of other parts or any alteration or modification of this equipment could result in serious injury , fire, explosion, or property damage. NOTE: The[...]

  TECHNICAL DA TA Weight 0.87 Kg (1.90 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun Length 310 mm (12.25 in.) . . . . . . . . . . . . . . . . . . . . . Maximum W orking Pressure 7 bar (100 psi) . . . . . . . . . . Air Pressure Operating Range: 0–7 bar (0–100 psi) Fluid Pressure Operating Range: 0–7 [...]

  ACCESSORIES Accessories must be purchased separately . Use only GENUINE GRACO P ARTS AND ACCESSORIES. W ARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system. Lower rated components may not be able to withstand the pressure developed by the pump an[...]

  ACCESSORIES FIL TER (AIR OR P AINT) 202–271 52 bar (750 psi)MAXIMUM WORKING PRESSURE With 250 micron (60 mesh) element, 3/8 npt(f) inlet, 3/8 npt(m) outlet SPRA Y SYSTEM ACCESSORIES 218–1 18 ELECTROST A TIC SYSTEM Includes items: 218–026 Manual Electrostatic Air Spray Gun 218–103 Grounded Air Supply Hose (See pa[...]

  THE GRACO PRO4000 W ARRANTY AND DISCLAIMERS W ARRANTY Graco warrants the PRO4000 to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser ’ s sole remedy for breach of this warranty , Graco will, for a period of twelve mo[...]