Graco PRO 4500sc Instructions Manual

Electrostatic air spray gun

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Instructions-parts list manual (40 pages)

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INSTRUCTIONS-PARTS LIST

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INSTRUCTIONS

Model PRO 4500sc

Electrostatic Air Spray Gun

85 kV, MANUAL GUN

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

For use with Class , Group D paint spray materials

Part No. 956–623, Series B

Air Spray Gun with four-finger trigger

With 0.059 in. (1.5 mm) spray nozzle

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

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

Graco Inc. is registered to I.S. EN ISO 9001

308–489

Rev. C

Supersedes B

Table of Contents

Troubleshooting

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Summary of Contents for Graco PRO 4500sc

Page 1 Air Spray Gun with four-finger trigger With 0.059 in. (1.5 mm) spray nozzle 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...
Page 2 308–489...
Page 3: Table Of Contents
....... . The Graco Warranty and Disclaimers ..
Page 4: Warnings
WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
Page 5 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.
Page 6: Installation
Required for safe operation. Must pur - Air Line Lubricator Air Hose Ground Wire chase separately . See Accessories. Air Pressure Regulator Graco Electrically Conductive Air Hose NOTE: Solenoid V alve (B) is not offered Pump Electrostatic Spray Gun as a Graco accessory.
Page 7: Installing The System
Use Only Graco Electrically Con- ductive Air Supply Hose. Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class , Group D 1.
Page 8: Connect The Exhaust Tube
3. Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air 3. Install a fluid filter (K) and drain valve (U) at the Hose and connecting the air hose ground wire to a pump outlet.
Page 9: Check The Electrical Grounding
Installation Check the Electrical Grounding a. If using a black or grey air hose, use a me- (See Fig. 2) gohmmeter (AA) to measure the resistance. Use an applied voltage of 500 minimum to WARNING 1000 volts maximum. The resistance should not exceed 2 megohms.
Page 10 Notes 308–489...
Page 11: Operation
Operation Pressure Relief Procedure Operating Checklist WARNING ____ 1. All the operators are properly trained to safely operate an electrostatic air spray PRESSURIZED EQUIPMENT HAZARD system as instructed in this manual. The system pressure must be manually relieved to prevent the system from starting or spraying acci- dentally.
Page 12: Selecting A Fluid Nozzle And Air Cap
307–803 or COMPONENT RUPTURE HAZARD consult your authorized Graco distributor to select the To reduce the risk of component rupture, appropriate fluid nozzle and air cap. Install the air cap...
Page 13 Operation Operating the Spray Gun (continued) Air Hose Dynamic pressure at air hose inlet Length required for full voltage ft. (m) psi (bar, MPa) 1. Follow the Operating Checklist on page 11. 15 (4.6) 45 to 50 (3.1 to 3.5, 0.31 to 0.35) 25 (7.6) 50 to 55 (3.5 to 3.8, 0.35 to 0.38) 2.
Page 14: Shutdown
NOTE: A Gun Washer Kit, P/N 236–681, is available the electrostatic effect. Fluid in the power supply for use with a Graco Gun Washer. See Accessories. cavity can reduce the alternator life. 8. Place the gun in its hanging bracket, with the Immersing the gun in fluid is not recom- nozzle pointing down as shown in Fig.
Page 15: Clean The Air Cap And Fluid Nozzle
Maintenance Clean the Air Cap and Fluid Nozzle WARNING CAUTION PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop Do not use metal tools to clean the air cap or spray spraying and whenever you are instructed to tip holes as this could scratch them, and make sure relieve the pressure.
Page 16: Troubleshooting
Troubleshooting WARNING WARNING ELECTRIC SHOCK HAZARD PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Installing and servicing this equipment Relief Procedure on page 11 before checking or requires access to parts which may cause an electric shock or other serious servicing any part of the system and whenever you injury if the work is not performed properly.
Page 17: Gun Operation Troubleshooting
Troubleshooting Gun Operation Troubleshooting Fluid leakage from the fluid packing The needle packings or shaft are worn. Replace the packings or shaft; see page area Air leakage from the front of the gun The air valve is not seating properly. Clean and service the air valve;...
Page 18: Electrical Troubleshooting
Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap-around The ES ON-OFF lever is in the OFF (O) Turn the lever to ON (1). position.* The distance between the gun and work- Adjust the spraying distance to 8 to 12 inches piece is incorrect.
Page 19: Electrical Troubleshooting With Svr
Troubleshooting Electrical Troubleshooting with SVR NOTE: Additional gun troubleshooting can be done using the Remote Spraying Voltage Readout ( SVR ) . See Accessories to order the SVR and the RF transmitting power supply. Problem Cause Solution Lower than normal voltage output Insufficient air pressure to the turbine Increase the air pressure to the gun.
Page 20: Electrical Tests
Electrical Tests The performance and safety of the spray gun are Measure the resistance between the end of the elec- directly affected by the condition of the electrical trode (20) and the air fitting (17). The resistance components contained inside the gun. The electrical should be between 329 to 401 megohms.
Page 21: Test Power Supply Resistance
(D) or operate the gun without the contact ring in place. Do not replace the resistor stud (22) with anything but a genuine Graco part. 0373 Fig. 10 04257 Fig. 9...
Page 22: Service
(D) or operate the gun without the contact Only use genuine Graco parts. Do not mix or use ring in place. Do not replace the resistor parts from other PRO Gun models. See page 33.
Page 23: Electrode Needle Replacement
Service Air Cap/Nozzle/Resistor Stud Replacement Electrode Needle Replacement (continued) 1. Prepare the gun for service as instructed on page 8. Trigger the gun while installing the fluid nozzle (21) and resistor stud (22) assembly with the multi-tool 2. Remove the air cap, nozzle and resistor stud as (62).
Page 24: Barrel Removal
Service Barrel Removal 1. Prepare the gun for service as instructed on page 2. Carefully loosen the nut (14) from the bracket/fluid fitting (16). Pull the tube (12) out of the fitting. Make sure both ferrules and the nut stay with the tube.
Page 25: Fluid Packing Removal
Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page 2. Remove the air cap assembly, fluid nozzle and resistor stud and electrode as instructed on page 3. Remove the trigger screws (4) and the trigger (13) far enough to remove the trigger (13).
Page 26: Fluid Packing Rod Repair
Service Fluid Packing Rod Repair 4. Lightly tighten the packing nut (28c). The packing nut is properly tightened when there is 2 lbs. (9 N) The fluid packing rod can be replaced as individual of drag force when sliding the packing housing parts or as an assembly.
Page 27: Power Supply Removal And Replacement
Service Apply a very light coat of lubricant Do not expose to solvents 04263 Fig. 18 Power Supply Removal and Replacement 5. Lubricate the o-ring (37a) and insert the power supply in the gun handle. NOTES: To avoid a loss in electrostatic performance, inspect the gun handle power supply cavity for dirt or mois- 6.
Page 28: Turbine Alternator Removal And Replacement
NOTE: Replace turbine bearings after 2000 hours of 3. Tighten the three socket head cap screws (5) operation. See your authorized Graco representative. oppositely and evenly to 18 in-lbs (2 N m) maxi- 1. Prepare the gun for service as instructed on page mum (about a half turn past snug) with the wrench (63) supplied.
Page 29: Fan Air Adjustment Valve Repair
Service Fan Air Adjustment Valve Repair DETAIL 1. Prepare the gun for service as instructed on page 2. Place a wrench on the flats of the valve housing and remove it from the handle. See Fig. 20. NOTE: The fan air valve (43) can be replaced as an assembly or as individual parts.
Page 30: Air Trigger Valve Repair
Service Air Trigger Valve Repair 6. Install the air valve shaft (39), with the o-ring (41), and spring (44), into the back of the gun handle 1. Prepare the gun for service as instructed on page (7). If the u-cup (42) was removed, install the air valve shaft (39) before installing the u-cup.
Page 31: Es On-Off Valve Repair
Service ES ON-OFF Valve Repair 7. Install the valve (38) with the regulator disc (46) and o-ring (36) into the gun handle. Install the 1. Prepare the gun for service as instructed on page spacer (32) on the valve. 2. Loosen the set screw (24) with the 2 mm hex key 8.
Page 32: Parts
Parts DETAIL A 0601 See Detail A *28g *28d *28f *28e *28h 29* 12 REF. Item 18 includes items 18a to 18e Item 28 includes items 28a to 28h Item 37 includes items 37a and 37b Item 43 includes items 43b to 43h REF 12 308–489...
Page 33 Ref. WARNING Part No. Description Qty. 28d* 186–069 SPACER, packing Some PRO 4500sc Gun replacement parts look similar to 28e* 178–763 PACKING, needle other PRO Gun parts but are not interchangeable! When 28f* 178–409 PACKING, fluid servicing, do not mix or use other PRO Gun parts! 28g* 111–504...
Page 34: Accessories
Accessories AIR LINE ACCESSORIES Air Swivel Fitting 236–129 100 psi (7 bar , 0.7 MPa) Maximum Working Pressure Conductive Air Supply Hose; black 100 psi (7 bar , 0.7 MPa) Maximum Working Pressure Replaces gun air inlet fitting (item 17 in Parts List); 1/4 npsm(m) left-hand thread FM Approved;...
Page 35: Miscellaneous Accessories
216–076 25 ft (8 m) Gun Washer Kit Part No. 236–681 216–077 50 ft (15 m) For use with a Graco Gun Washer to clean the PRO 216–078 75 ft (23 m) 3500 and PRO 4500 Electrostatic Spray Guns. 216–079 100 ft (30 m) 216–080...
Page 36: Technical Data
Technical Data Radio Frequency Transmitter Approval Category Data FCC ID: JHI1 Gun Weight 34.3 oz (974 g) This device complies with Part 15 of the FCC Rules. Gun Length 11.1 in (283 mm) Operation is subject to the following two conditions: 1.) This device may not cause harmful interference, Maximum Working 100 psi (7 bar, 0.7 MPa)
Page 37 Notes 308–489...
Page 38 Notes 308–489...
Page 39 Notes 308–489...
Page 40: The Graco Warranty And Disclaimers
Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven defective.

This manual is also suitable for:

956-623