Graco ProComp HVLP 3800 User manual

Instructions – Parts List
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
HVLP 3800 and 4900
ProComptTurbine Sprayers
309242K
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
TI0875
4900 HVLP ProComp
120V AC 50/60 Hz
HVLP 3800 ProComptwith Three-Stage Turbine
Model 233423
6 psi (41 kPa, 0.4 bar) Maximum Working Pressure
HVLP 4900 ProComptwith Four-Stage Turbine
Model 233455
8 psi (55 kPa, 0.5 bar) Maximum Working Pressure
Model descriptions are in Turbine
Components Table on page 4.
Related Manuals
HVLP–Turbine Gun 309205. . . . . . . . . . . . .
Parts

2 309242
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 22. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 22. . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment. See Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DWhen flammable liquid is sprayed or used for flushing or cleaning the equipment, the turbine must
be placed at least 20 feet (6.1 m) away from areas where hazardous concentrations of flammable
vapors are likely to occur.
DUse additional air hose if necessary to ensure that the turbine is operated in a clean, dry, well-ven-
tilated area.
DNever place the turbine inside a spray booth! Use this equipment outdoors or in extremely well-
ventilated areas.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not operate a gasoline engine in the spray area.

309242 3
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before you operate the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest-rated system component.
HVLP 3800 ProComptturbine has a working pressure of 6 psi (0.4 bar, 41 kPa).
HVLP 4900 ProComptturbine has a working pressure of 8 psi (0.5 bar, 55 kPa).
DUse fluids and solvents that are compatible with the equipment wetted parts. See Specifications
on page 21 for wetted parts information.
DDo not use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the gun fluid nozzle.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DDo not “blow back” fluid; this is not an air spray system.
DFollow the Pressure Relief Procedure on page 10 if the fluid nozzle clogs and before you clean,
check, or service the equipment.
DTighten all fluid connections before you operate the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
DDo not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in the turbine spray system, which contains aluminum and/or galva-
nized-coated parts. Such use could result in a serious chemical reaction, with the possibility of
explosion, which could cause death, serious injury, and/or substantial property damage.

4 309242
General Information
HVLP ProComptTurbine Sprayers
The HVLP 3800 ProComptand the HVLP 4900
ProComptturbines, compressor and spray guns can
spray most coatings or finishes currently being used
for automotive refinish, industrial, aerospace, marine,
wood, plastic, and architectural applications.
To produce high-quality paint finishes, the spray gun
typically utilizes inbound air pressure of 6 psi (0.4 bar,
41 kPa) for the HVLP 3800 ProComptand 8 psi (0.5
bar, 55 kPa) for the HVLP 4900 ProCompt. A cone of
air, produced by the gun, carries and directs the paint
from the gun to the surface, minimizing overspray and
increasing transfer efficiency. This enables painters to
comply with new clean air laws that are designed to
reduce VOC (volatile organic compounds) emissions,
eases paint application by requiring fewer paint passes
to obtain coverage, and saves on both material and
clean-up time.
See HVLP–Turbine Gun manual 309205 for more
information on the operation and use of the turbine
spray gun.
Unpacking Turbine
Unpack the Graco Turbine Sprayer from the shipping
carton, and inspect for any possible shipping damage.
If there is any damage, call your distributor.
HVLP ProComptTurbine Configurations
Graco turbines come in the following basic configura-
tions:
DHVLP 3800 ProComptthree-stage turbine sprayer
DHVLP 4900 ProComptfour-stage turbine sprayer
HVLP 3800 and 4900 ProComptTurbine Components Table
System Model 2–qt Remote
Pressure Pot
30-ft (9 m) Turbine
Air Hose
30-ft (9 m) Com-
pressor Air Hose
Gun /
Fluid Set
Extra/Fluid
Sets
HVLP 3800
ProCompt
233423 287819 241413
240071
244118 non-
bleeder style
pressure–fed gun
with 244124 (#3)
244125 (#4)
244126 (#5)
HVLP 4900
ProCompt
233455 287819 241413
240071
244118 non-
bleeder style
pressure–fed gun
with 244124 (#3)
244123 (#2)
244125 (#4)
244126 (#5)
244127 (#6)

309242 5
Component Identification and Function
B
E
G
A
D
C
H
F
Fig. 1
J
K
L
M
TI0876
ATurbine air outlet Connection for turbine air supply to HVLP–Turbine Gun (HVLP 4900
ProComptunits include quick connector)
BTurbine power switch ON/OFF switch for sprayer turbine
CStorage compartment Provides storage for fluid set components
DTurbine handle Folds flat for minimum storage space
ETurbine cover Houses air filter and provides dual air flow to motor and turbine
FAir filters (pre-filter and main) Provide filtered air for turbine spray gun and turbine motor
GTwo-speed switch Allows two-speed operation of turbine sprayer motor (used on HVLP
4900 ProComptunits)
HAir filter indicator light Indicates air filter performance and maintenance
JConnector and power cord Provides power for turbine sprayer (power cord provided with turbine)
KResettable circuit breaker Provides protection for turbine motor
LCompressor air outlet Connection for compressor air supply to 2–quart remote pressure pot
MCompressor power switch On/Off switch for compressor

6 309242
Setup
Grounding
WARNING
Improper installation or alteration of the grounding
plug will result in a risk of electric shock, fire, or
explosion that could cause serious injury or death.
This equipment requires a 120V AC, 60 Hz, 15A circuit
with a grounding receptacle. See Fig. 2.
Fig. 2
grounding prong
grounded outlets
Extension cord must be 3-wire, 12 AWG, 50 ft (15 m)
or shorter.
Do not alter the ground prong or use an adapter.
Setup/Use Options
HVLP Turbine Sprayers have a variety of user options.
See Fig. 3.
DSee HVLP–Turbine Gun manual 309205 for in-
formation on turbine spray gun setup and operation.
Prepare the Fluid
DAlways strain the fluid before you spray; this
includes color, reducer, and hardeners if used.
DWhen using a turbine spray system, use a slow-
er drying reducer or thinner to compensate for the
faster drying time caused by the warm air of the
turbine. Do not over reduce.
CAUTION
The performance of the turbine sprayer varies with
the viscosity of the material and the length of the
hose. Keep the hose short to prevent pressure drop.
Paint Reduction — Automotive Type Finishes
Reduce and catalyze all paint to manufacturer’s speci-
fications. To compensate for the faster drying time of
turbine systems, use a reducer that is one step slower
than what is used for conventional air spray.
Paint Reduction — Industrial or Domestic
Coatings
Reduce and catalyze all paint to manufacturer’s speci-
fications. If no reductions are given, first thoroughly
mix the fluid to be sprayed. Then gradually mix in the
proper reducer, testing the fluid until you have the
correct spraying consistency.
To test the consistency, remove the stir stick from the
thinned paint. When the paint stream running off the
stir stick breaks into droplets, the first few drops should
be about one second apart.

C
A
Fig. 3
B
X
A
G
Y
C
X
E
E
D
D
cup-over option
(see manual 309205)
cup setup for spray gun
HVLP 4900 ProCompt
Turbine
remote pressure pot setup for spray gun
TI0875
X
L
Z
309242 7
Setup
Connect the Fluid and Air Supply
See Fig. 3
DThe compressor provides the air supply for the
remote pressure pot.
DThe circled letters in Fig. 3 indicate hose line con-
nections.
1. Connect gun air supply hose (A) between turbine
air outlet (B) and gun air inlet (C). DO NOT use
wrench to tighten connections; hand tighten only.
The HVLP 4900 ProComptturbine uses a quick
connector at outlet (B). A wrench is not required
for hose connection.
2. If using a spray gun cup (D):
Connect the cup to the gun fluid inlet (E).
If using accessory remote pressure pot (F): Con-
nect fluid supply hose (G) between remote pres-
sure pot fluid outlet (H) and gun fluid inlet (E).
Connect pressure pot air hose (J) between pres-
sure pot air regulator inlet (K) and the compressor
air outlet (L).
Connect to Electric Supply
Plug turbine power cord into grounded outlet.
NOTE: Extension cord must be 3-wire, 12 AWG, 50 ft
(15 m) or shorter.
Z
Y
JK
H
G
F
4958C
to
compressor
2-quart remote pressure pot
ti7064a

8 309242
Setup
Fill the Cup or Remote Pressure Pot
Spray Gun Cup
WARNING
The spray gun cup is pressurized by the gun’s air
supply. To reduce the risk of serious injury from
pressurized fluid or accidental spray from the gun,
always turn off the air supply to the gun before you
remove the spray gun cup.
Only fill the cup 3/4 full to help keep the air pressure
tube clean, then install the cover. The under-cup cover
has a latch (H) to secure it to the cup. The over-cup (J)
has threads that keep the lid in place when tightened in
place on the cup.
Fig. 4
02845
HJ
Accessory Remote Pressure Pot
WARNING
The accessory remote pressure pots remain pres-
surized until pressure is manually relieved. To
reduce the risk of serious injury from pressurized
fluid or accidental spray from the gun, always
relieve pressure in the pressure pot before you
loosen or remove the cover.
1. Relieve pressure from remote pressure pot as
follows (see Fig. 5):
a. Turn off air supply to pressure pot.
b. Turn pressure relief knob (133). Wait until
pressure is completely relieved before you
remove cover. Close knob.
Fig. 5
2 quart
2. Remove pressure pot cover and fill. Secure cover.
NOTE: Lightly coat the cover threads with petroleum
jelly.
CAUTION
If the 2-quart remote pressure pot is accidentally
tipped over or held at too great of an angle, fluid may
leak into the air regulator and cause damage. Take
precautions to avoid this. If fluid does get into the
regulator, clean it immediately.
NOTE: Always spray with the least amount of pot
pressure required to provide the desired spray pattern
and rate of application, typically 10 psi. Spraying at
pot pressures higher than necessary wastes paint and
can result in an orange peel finish.

309242 9
Setup
Prepare Surface to be Sprayed
To get proper adhesion, make sure surface is com-
pletely clean.
Operating Turbine
WARNING
Sparks can be expected in the normal operation of
the turbine motor. These sparks can ignite fumes
from flammable liquids, dust particles, and other
flammable substances in the spray area. This can
cause serious injury and property damage. Be sure
to follow the precautions below:
DWhen flammable liquid is sprayed or used for
flushing or cleaning equipment, the turbine must
be placed at least 20 feet (6.1 m) away from
areas where hazardous concentrations of
flammable vapors are likely to occur.
DUse additional air hose if necessary to ensure
that the turbine is operated in a clean, dry, well
ventilated area.
DNever place the turbine inside a spray booth!
Use this equipment outdoors or in extremely
well ventilated areas.
DAvoid all ignition sources such as: static elec-
tricity from plastic drop cloths, open flames like
pilot lights, hot objects like cigarettes, arcs from
connecting or disconnecting power cords, and
turning light switches on and off. Extinguish or
remove all sources of ignition.
1. Turn turbine ON a few minutes before spraying to
allow warm-up.
NOTE: When the turbine is not in use for an extended
period of time, turn it off. The turbine does not shut off
automatically.
2. Be sure turbine filter is clean before operating. See
page 11 to check and clean filter.
NOTE: To adjust the spray gun pattern see the turbine
gun manual.
HVLP ProComptCompressor Cold
Weather Operation
The HVLP ProComptuses a diaphragm compressor.
A new diaphragm may be stiff in cold weather. If cold
enough, the diaphragm is too stiff to allow the com-
pressor motor to start (the unit hums). If this occurs,
follow these steps:
1. Turn compressor OFF. Turn turbine ON and allow
to warm up for a few minutes.
2. Turn compressor ON. If compressor does not
start, proceed to step 3.
3. Turn turbine and compressor OFF.
4. Unplug turbine from power source.
5. Loosen four thumbscrews (16), remove filter
retainer (15), prefilter (22), and main filter (21).
See Fig. 7.
6. Hand spin cooling fan on compressor for a few
revolutions.
7. Reinstall filters and filter retainer.
8. Plug in turbine.
9. Turn turbine and compressor ON. If necessary,
repeat steps 3–9 above.

10 309242
Shutdown
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of a serious
injury from pressurized fluid, accidental spray from
the gun, or splashing fluid, follow the Pressure
Relief Procedure whenever you:
DAre instructed to relieve the pressure
DStop spraying
DCheck or service any of the system equipment
DInstall or clean the fluid nozzles
1. Turn off air supply to gun.
2. Turn off turbine sprayer.
WARNING
The turbine hose outlet may be hot. Carefully check
the hose end before you remove the hose.
3. If using remote pressure pot, relieve pressure by
following the pressure relief procedure on page 8.
NOTE: Elevate spray gun and pull trigger. This will
allow fluid in fluid hose to drain back into remote
pressure pot.
4. If using a spray gun cup, unlatch cup cover;
loosen or remove cup from cover to relieve cup
pressure.
5. Clean spray gun and cup as instructed in the
HVLP–Turbine Gun manual 309205.