Graco PRO AA4500 Instructions Manual
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Graco PRO AA4500 Instructions Manual

Graco PRO AA4500 Instructions Manual

Air-assisted airless spray gun
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INSTRUCTIONS–PARTS LIST
85 KV ELECTROSTATIC
Model PRO AA4500
Air-Assisted Airless Spray Gun
100 psi (7 bar) Maximum Working Air Pressure
3000 psi (207 bar) Maximum Working Fluid Pressure
For use with Class , Group D paint spray materials
Part No. 236–030, Series A
Spray Gun with basic power supply,
2-finger trigger
Part No. 236–031, Series A
Spray Gun with full-featured power supply,
2-finger trigger
Part No. 236–032, Series A
Spray Gun with basic power supply,
4-finger trigger
Part No. 236–033, Series A
Spray Gun with full-featured power supply,
4-finger trigger
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
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
COPYRIGHT 1993 GRACO INC.
308–294
Rev. J
Supersedes G
and PCN H
01944A

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  • Page 1 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 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 COPYRIGHT 1993 GRACO INC.
  • Page 2 WARNINGS High Pressure Spray Can Cause Serious Injury. For Professional Use Only. Serious injury, explosion, fire or electrostatic shock can occur if the precautions below are not followed. Read and understand all instruction manuals, tags, and warning labels before operating equipment. Electrical equipment shall only be installed, operated, and serviced by trained, qualified personnel who shall be fully conversant with the requirements stated within this instruction manual.
  • Page 3 3. Electrostatic Air Spray Gun: obtain grounding through ing the spray gun. connection to a properly grounded air supply hose. Use only the Graco Electrically Conductive Air Supply Hose; Use only non-sparking tools to clean residue from the booth see ACCESSORIES section to order. Connect the air and hangers.
  • Page 4 System Pressure age. The PRO AA4500 electrostatic spray gun has a 3000 psi (207 bar) Maximum Working Fluid Pressure and 100 psi (7 Only use genuine Graco replacement parts when servicing bar) Maximum Working Air Pressure .

  • Page 5: Table Of Contents

    ....Graco Phone Numbers ..... . .

  • Page 6: Introduction

    SVR. Part No. 236–030 and 236–032, The ability of the PRO AA4500 Electrostatic Spray Gun to spray at higher fluid pressures provides the with Basic Power Supply additional power needed to atomize higher solids The basic power supply provided with Gun P/N materials.

  • Page 7: Installation

    C* Pump Air Regulator with spring guards Pump Fluid Inlet Air Line Lubricator M Gun Fluid Inlet (1/4 npsm) W PRO AA4500 Spray Gun Pump Runaway Valve Gun Air Regulator Gun Air Inlet (1/4 npsm LH) Pump Gun Air Shut-off Valve...
  • Page 8 Installation Ventilate the Spray Booth WARNING To reduce the risk of serious injury due to compo- WARNING nent rupture, be sure that all spray equipment and To prevent hazardous concentrations of toxic and/ accessories added to the spray system are prop- or flammable vapors, spray only in a properly venti- erly rated to withstand the maximum working pres- lated spray booth.

  • Page 9: Operation

    Additional cards are available at no charge from Graco. 2. Be sure all operators are trained how to prop- erly and completely relieve system pressure, using the Pressure Relief Procedure on 3 in.
  • Page 10 Operation WARNING Pressure Relief Procedure To reduce the risk of serious injury, including fluid injection, splashing in the eyes or on skin, or elec- trostatic shock, always follow this procedure when- ever the pump is shut off, when checking or servic- ing any part of system, when installing or changing spray tips and whenever you stop spraying.

  • Page 11: Gun Setup

    A. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose, NOTE: The Graco air hose and the gun have special using the accessory Graco megohmmeter (E). Use left-hand threads to prevent connecting another type of...
  • Page 12 The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pres- NOTE: The PRO AA4500 spray gun has a 100 mesh sure. Use the Spray Tip Selection Chart on page 43, in-line fluid inlet filter.
  • Page 13 Gun Setup 9. Install the spray tip. 10. Set the air pressure A. Close the air control valve (43) by turning it fully A. With the pressure relieved, trigger safety latch clockwise. locked, and ES ON-OFF lever OFF, place the spray tip (9) in the air cap (1), aligning the tab of B.
  • Page 14 Gun Setup 11. Set the atomization fluid pressure. B. Set the fluid pressure with the fluid regulator (J), based on the Starting Fluid Pressure in the Atom- NOTE: Atomization fluid pressure will vary based on ization Chart at left for the type of fluid you are the viscosity of the fluid, the flow rate desired, and oth- spraying.
  • Page 15 Gun Setup 11 Set the atomization fluid pressure. 12. Turn the ES ON-OFF lever (26) to ON. (continued) 13. Use the ES HI-LO lever (43g) to change G. Continue to increase the fluid pressure by the increments shown in the chart until the particle to either full voltage (HI) or a lower volt- size no longer reduces in size;...

  • Page 16: Daily Gun Care, Flushing, And Cleaning

    Daily Gun Care, Flushing, and Cleaning WARNING CAUTION To reduce the risk of serious injury, including fluid Clean all parts with a non-conductive solvent, com- injection, splashing in the eyes or on the skin or patible with the fluid being sprayed. Conductive electrostatic shock, always follow the Pressure solvents can cause the gun to malfunction.
  • Page 17 Daily Gun Care, Flushing, and Cleaning 1. Follow the Pressure Relief Procedure 4. Make sure the air and coating supply is Warning on page 10. turned off. Turn on the solvent supply. 2. Make sure the ES ON-OFF lever is turned to OFF and the trigger safety latch is locked before proceeding.
  • Page 18 Daily Gun Care, Flushing, and Cleaning 8. Make sure the trigger safety latch is 11. Dip the end of a soft-bristle brush into locked, then disconnect the solvent a compatible solvent. Then point the and air supply hoses from the gun. gun down and clean the front with the brush and solvent.
  • Page 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 dai- compatible solvent. ly, minimum.
  • Page 20 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. WARNING To reduce the risk of electrostatic shock or explo- sion, never operate the spray gun with a bent,...

  • Page 21: Spray Pattern Troubleshooting

    Spray Pattern Troubleshooting WARNING Installing and servicing this equipment requires access to parts which may cause electrostatic 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.

  • Page 22: Gun Operation Troubleshooting

    Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid needle Fluid needle packings loose Tighten packing nut; See page 33 area Fluid needle packing damaged Replace fluid needle; See page 33 Air leakage from front of gun Air valve not seating properly Clean, Service;...

  • Page 23: Electrical Troubleshooting

    Electrical Troubleshooting NOTE: Additional gun troubleshooting can be done on Gun Part No. 236–031 using the Remote Spraying Voltage Read- out ( SVR ) . See ACCESSORIES to order the SVR. PROBLEM CAUSE SOLUTION Poor wrap-around KV HI-LO lever on low Check lever position *ES ON-OFF lever in OFF position Turn lever to ON...
  • Page 24 Electrical Troubleshooting PROBLEM CAUSE SOLUTION Lower than normal voltage Faulty gun resistance Check gun resistance; See page 25 output Insufficient air to the turbine Increase air pressure to the gun alternator Faulty turbine alternator Replace turbine alternator; See page 35 Improper distance between gun and Adjust spraying distance to 8 to 12 workpiece...

  • Page 25: Electrical Tests

    Electrical Tests The performance of the spray gun is 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 continu- ity of the electrical path between the components.

  • Page 26: Test Barrel Resistance

    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 contact ring (3a) are clean.

  • Page 27: Service

    PRO Gun parts that may look similar, but have different part numbers! Use of parts other 9 mm Driver (included with gun) than those specified in the PRO AA4500 Gun parts Adjustable Wrench list on page 39 could alter the grounding continuity...

  • Page 28: Air Cap, Spray Tip, Or Seat Housing Replacement

    Do not remove the barrel contact ring from the bar- rel 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. 02004A Fig.

  • Page 29: Electrode Replacement

    Service Electrode Replacement WARNING To reduce the risk of fire, explosion, or electrostatic shock, do not operate the spray gun without the electrode installed in the air cap. 1. 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.

  • Page 30: Fluid Tube Removal And Replacement

    Service Fluid Tube Removal & Replacement Fluid Filter Removal 1. Disconnect the bottom fluid tube nut (C). See To remove the fluid tube assembly (12) for cleaning or Fig. 10. replacement: 2. Remove the fluid filter (14) from the fluid fitting (10).

  • Page 31: Barrel Removal

    Service Barrel Removal 1. 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 be- fore re-installing them.

  • Page 32: Barrel Installation

    Service Barrel Installation 4. Make sure the fluid filter (14) is in place in the fluid fitting (10). 1. Be sure the gaskets (34 & 18a) and spring (30) are in place. See Fig. 14. Replace if damaged. 5. Tighten the bottom fluid tube nut (C) onto the fluid fitting (10);...

  • Page 33: Fluid Packing Adjustment

    Service Fluid Packing Adjustment Fluid Needle Assembly Removal 1. Remove the retaining nut (8), tip guard, (2), air cap If fluid leaks from the fluid needle area, the fluid pack- (1) and spray tip (9). See Fig. 7, page 28. You may ings may be loose.

  • Page 34: Power Supply Removal & Replacement

    Service 01953A Fig. 17 Power Supply Removal and Replacement 3. Inspect the power supply for any physical damage. Check the electrical resistance as instructed on page 25. If needed, replace the power supply. NOTES: a. To avoid a loss in electrostatic performance, Before installing the power supply, inspect the seal inspect the gun handle’s power supply cavity (18e) for any damage or swelling;...

  • Page 35: Turbine Alternator Removal & Replacement

    Replacement jelly. NOTE: Replace turbine bearings after 2000 hours of operation. See your authorized Graco representative. 5. Install the regulator disk (46) in the valve (38) with its bevelled side facing in toward the valve. 1. Remove the power supply from the gun handle as described on page 34.
  • Page 36 Service Air Control Valve Repair To start the valve housing (43d) threads into the handle, turn the adjusting screw (43c). Once the threads are started, turn the adjusting screw (43c) NOTE: The air control valve (43) can be replaced as fully counterclockwise.

  • Page 37: Air Valve Repair

    Service Air Valve Repair 7. If removed, install the u-cup with its lips facing into the gun handle. 1. Using a screw driver, remove the air valve cap (45). See Fig. 20. 8. Tighten the air valve packing nut (40). 2.

  • Page 38: Parts

    Parts REF 12 ITEM 18 Includes 18a–18e 236–032 & 236–033 parts 236–030 & 236–031 only. See parts for 236–032 & 236–033 above. 01956B...
  • Page 39 FLUID NEEDLE ASSY. numbers! Use of parts other than those specified in the 112–691 SPRING, compression PRO AA4500 Gun parts list below could alter the ground- 185–079 PLUG ing continuity of the gun, cause parts to leak or rupture, or 185–119...

  • Page 40: Accessories

    3/4 npt Flexible Conductive Air Whip Hose 100 psi (7 bar) Maximum Working Pressure Must be used with a full size Graco Conductive Air Supply Hose; Metallic ground path; 0.187 in. (4.5 mm) ID; 1/4 npsm(m) left-hand x 1/4 npsm(f) left-hand 236–130...
  • Page 41 Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES Flexible Nylon Static-free Fluid Whip Hose 3000 psi (207 bar) Maximum Working Pressure Fluid Filter 214–570 0.125 in. (3.2 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) 3000 psi (207 bar) Maximum Working Pressure 236–134...

  • Page 42: Graco Phone Numbers

    (Class , Group D), hand-held unit; see Manual 308–183 Daily Gun Care Instruction Poster 189–063 Basic PRO AA4500 daily gun care instructions to hang in the spray booth area; English on one side and Span- ish on the other side...

  • Page 43: Spray Tip Selection Chart

    Spray Tip Selection Chart Fan Width at Fan Width at Part No. 10 in. (260 mm) Orifice Size Part No. 10 in. (260 mm) Orifice Size in. (mm) in. (mm) in. (mm) in. (mm) GG3–107 GG3–319 2–4 (50–100) 0.007 (0.178) 6–8 (150–200) 0.019 (0.483) GG3–207...

  • Page 44: Technical Data

    Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equip- ment proven defective.

This manual is also suitable for:

236-030236-031236-032236-033

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