Graco UNICARB Pro AA4500 Operation manual

INSTRUCTIONS-PARTS LIST 308-294
@
J
0-0
Rev. C
This manual contains important
warnings and information.
Supersedes B
READ AND RETAIN FOR REFERENCE
lNsmxmw
85 W 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
Part No. 236-030, Series A
Spray Gun with basic power supply
Part No. 236-031, Series A
Spray Gun with full-featured power supply
For use with Class I, Group D
paint spray materials
@
U.S.PatenlNo.4,290,091;4,219,865;4,497.447:4,462.061:4,660,T14:5,063,350;5.080.289
Brevele 1986. 1987
U.K. Patent No. 2,147,158: 2,142,5598; 2,140,327-8
Other US. and Foreign Patents Pending
OlSUA
! Patented 1986,1987 Canada
GRACO INC. EO. BOX 1441 MINNEAPOLIS, MN 55440-1441
0 COPYRIGHT 1993 GRACO INC.

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.
FLUID INJECTION HAZARD
This eauioment ooerates at very high fluid Dressure. SDrav
General Safety
from the
bun, leaks or ruptured.componenk can inject fluid
through your skin and Into your body and cause extremely
serious injury, including the need for amputation. Also, fluid
serious damage.
injected or splashed into the eyes or on the skin can cause
Never point the spray gun at anyone or at any part
of the
body.
Never put hand or fingers over the spray
tip.
Never try to "blow back" paint: this is not an air spray gun.
Always have the tip guard in place on the spray gun when
spraying.
Always lock the trigger safety latch when you are not
spraying.
Always follow the Pressure Rellel Procedure, at right, before
cleaning or removing the spray tip or servicing any system
equipment.
Never try to stop or deflect leaks with your hand or body.
each
use.
Check operation of all equipment safety devices before
Medical Alert - Airless Spray Wounds
medlcal care at once. Do not treat as a slmple cut. Tell the
If any fluid appears to penetrate your skin, get emergency
doctor exactly what fluid was injected.
Note to Physlclan: Injection into the skln is a traumatic injury It
Is Important to treat the Injury surglcally as soon a8 posslble.
Do not delay treatment to research toxicity. Toxicity is a concern
with some exotic coatings Injected directly into the blood stream.
Consultation with a plastic surgeon or reconstructive hand surgeon
may he advisable.
Spray
Gun Safety Devices
Be sure all gun safety devices are operating properly before
each
use. Do not remove or modify any pari of the gun; this
can cause a malfunction and result
in serious Injury.
Trigger Safety Latch
Whenever you stop spraying, even for a moment, always set
the gun trigger safety latch in the locked position, making the
gun inoperative.
See Fig 3, page 10. Failure to lock the safety
latch can result in accidental triggering
of the gun.
2 308-294
Tip Guard
Always have the tip guard in place on the spray gun while
spraying. The tip guard
alerts you to the fluid injection hazard
and helps reduce,
but does not prevent, risk of accidentally
placing your fingers or any pari of your body close to the
spray tip.
Diffuser (part of seat housing, item 21 in Parts List)
The gun diffuser breaks up spray and reduces the risk of fluid
injection when the tip is not installed. Check diffuser operation
regularly. Follow the Pressure
Rellel Procedure, below, then
remove the spray tip. Aim thegun into
a grounded metal pail,
pressure, trigger the gun.
If the fluid coming from the gun is
holding the gun firmly to the pail. Using the lowest possible
not diffused into an irregular stream, replace the diffuser
immediately.
Spray
Tip Safety
Use extreme caution when cleaning or chanoina sorav tios.
If
the spray tip clogs while spraying, lock the trigger safety iatch
immediately. Always follow the Pressure
Rellel Procedure,
below, and then remove the spray tip to clean
it. Never wipe
off build-up around the spray tip or air cap until pressure is
fully relieved and the trigger safety latch is locked.
To reduce the risk of serious injury, including fluid injection.
Pressure Relief Procedure
splashing in the
eyes or on skin, or electrostatic shock, always
follow this procedure whenever the pump is shut
off, when
checking or servicing any part of system, when installing or
changing spray tips and whenever you stop spraying.
2. Turn the gun's ES ON-OFF lever to the OFF position.
1. Lock the spray gun trigger safety latch.
3. Shut off the power to the pump.
4. Close the bleed-type master air valve (required in system).
5. Close the air valve for the gun air supply line,
6. Unlock the gun trigger safety latch.
7. Trigger the gun into a grounded metal waste container to
8. Lock the gun trigger safety latch again.
9. Open the pump drain valve (required in system) to help
relieve fluid pressure in the displacement pump.
In addi-
tion, open the drain valve connected
to the fluid pressure
fluid pressure in the hose and gun. Triggering the
gun to
gauge (in a system with fluid regulation) to help relieve
ready to catch the drainage.
relieve pressure may not be sufficient. Have
a container
10. Leave the drain valve(s) open until you are ready to spray
again.
If you suspect that the spray tip or hose is completely
clogged or that pressure has
not been fully relieved alter lol-
lowing the steps above, very slowly loosen the hose end cou-
pling and relieve pressure gradually, then
loosen completely.
Now clear the tip or hose obstruction.
".
relieve fluid and air pressure.

- FIRE, EXPLOSION OR ELECTROSTATIC SHOCK HAZARD -
which may result from electrical discharge, it is essential that:
To reduce the risk of fire, explosion, or electrostatic shock, 7. All electrically conductive objects or devices in the spray
area, including paint containers and wash cans, must be
All patis of the electrostatic system are properly grounded. properly grounded.
9 All personnel in or close lo the spray area are properly
grounded.
8. All persons entering the spray area: shoes must have con-
ductive soles, such as leather, or personal grounding
All electrically conductive objects or devices in the spray straps must be worn. Rubber or plastic soles are
not con-
area, including paint containers, wash cans and tools, are ductive. The operator must not wear gloves that insulate
properly grounded. tive or modified as shown
in Fig 2, page 9.
the hand from the spray gun. The gloves must be wnduc-
When operating the electrostatic device, any ungrounded 9. The floor of the spray area must be electrically conductive
objects
in the spray area.(such as people, containers, tools,
etc.) can become electrically charged. Arcing may occur
if
and grounded. Do not cover the floor with cardboard or
these objects then come in contact or close lo ground. Arcing any non-conductive material which would interrupt
grounding continuity.
of sufficient energy levels can ignite the fluid being sprayed,
fumes irom solvents, dust particles, and other flammable sub-
10. Flammable liquids in the spray area must be kept in
stances. This can cause a fire, explosion, or electrostatic
shock and result in serious injury and propetty damage.
approved, grounded containers.
Do not store more than
the quantity needed for one shift.
Static electricity can also be generated by the flow
of fluid 11.Allsolventpails: use only grounded metal pails, which are
through the pump, hose, gun,
and nozzle, but it is dissipated conductive.
Do not place the pail on any non-conductive
through proper grounding as described in Groundlng below. surface, such as cardboard or paper, which would inter-
rupt grounding continuity.
If you experience any arcing or feel even a slight shock, stop
spraying Immedlately. Check for proper grounding of the
entire system. Be sure you have corrected the problem before
starting to spray again.
Grounding
The following are minimum requirements for grounding a
basic electrostatic system. Your system may include other
equipment or objects which must also be grounded. Always
tions. Be sure your system is connected to a true earth
check your local electrical code
for detailed grounding instruc-
ground.
1. Pump: ground by using a ground wire and clamp as
described in your separate pump instruction manual.
2. Air compressors and hydraulic power supplies: ground
according to the manufacturer's recommendations.
3. Electrostatic Air Spray Gun: obtain grounding through
connection to a properly grounded air supply hose. Use
only the Graco Electrically Conductive Air Supply Hose;
see ACCESSORIES section to order. Connect the air
hose ground wire
lo a true earth ground.
4. Ailair andfluidlines must be properly grounded. Use only
grounded hoses
with a maximum of 500 feet (150 m)
combined hose length to ensure grounding continuity:
Refer
also to Hose Groundlng Continuity on page 4.
5. All electric cables must be properly grounded.
6. Object being sprayed: keep the workpiece hangers clean
and grounded at all times. Contact points must be sharp
points or knife edges.
Rushing and Cleaning Safety
To reduce the risk of fluid injection injury, static sparking or
splashing, always follow the Pressure Relief Procedure on
page
2 and remove the spray tip before flushing. Use the
lowest possible pressure to flush. Trigger the gun into a
grounded metal waste container.
Be sure
the ES ON-OFF lever Is OFF before flushlng or
cleanlng any part
of the spray system.
point equal to
or greater than that of the fluid being sprayed.
To
flush orpurge equipment, always use solvents with a flash
with a flash point of higher than
100' F (38" C).
To clean the exferior of the equipment, always use solvents
Always remove all solvent from the system before reactivating
the spray gun.
and hangers.
Use only non-sparking tools to clean residue from the booth
Ventilate
the Spray Booth
To prevent hazardous concentrations of toxic and/or flam-
mable vapors, spray only in a properly ventilated spray booth.
Check and follow all National, State and Local codes regard-
local safety and fire codes and OSHA standard 1910.107.
ing air exhaust velocity requirements. Check and follow all
Never operate the spray gun unless the ventilating fans are
operating.
308-294 3

__~~ ~
EQUIPMENT MISUSE HAZARD
Any misuse of the spray equipment or accessories. such as
General Safety
over pressurizing, modifying parts, using improper replace-
worn or damaged parts, can cause them to rupture and result
ment parts, using incompatible chemicals and fluids,
or using
in serious injury, including fluid injection and splashing fluid in
the eyes or
on the skin, or in Rre, explosion or property dam-
age.
Only use genuine Graco replacement parts when selvicing
the gun. Do not mix or use other
PRO Gun parts that may look
similar, but have different part numbers1 .
could cause it to malfunction.
Never alter or modify any part
of this equipment; doing so
Check the gun and all spray equipment regularly and repair or
replace worn or damaged parts immediately.
Read and follow the fluid and solvent manufacturer's literature
regarding the use
of protective eyewear, gloves, clothing, res-
pirator and other equipment.
Fluid Compatibility
Be sure all fluids and solvents used are chemically compatible
with the 'Wetted Parts" shown in the
TECHNICAL DATA on
:he back cover. Ways read the fluid and solvent manufac-
turer's literature before using fluid or solvent in this gun.
System Pressure
The PRO AA4500 electrostatic spray gun has a 3000 psi (207
Maximum Working Air Pressure. Never exceed these pres-
bar) Maximum Working
Fluid Pressure and 100 psi (7 bar)
suresl
The high pressure fluid supply pump must be limited
so that it
is not capable of producing a fluid pressure greater than the
maximum working fluid pressure
of the spray gun or any
other system component.
the spray system are properly rated to withstand maximum
Be sure that
all spray equipment and accessories added to
working pressure of any component or accessory used in the
working pressure
of your system. Do not exceed maximum
system.
HOSE SAFETY
High pressure fluid in the hoses can be vely dangerous. If the
hose develops
a leak, split or rupture due to any kind of wear,
damage or misuse, the high pressure spray coming from
it
can cause a fluid injection injuly or other serious injury or
property damage.
The spring guards help protect the hose from kinks or bends
All fluid spray hoses must have a spring guard on both endsl
at or close to the coupling which can result in hose rupture.
Tlghten all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high
pressure spray to come out
of the coupling.
entire hose for cuts, leaks, abrasion, bulging cover, or dam-
Never use a damaged hose. Before each use, check the
age or movement
of the hose couplings. If any of these condi-
tions exist, replace the hose immediately. Do not try to
device.
A repaired hose cannot contain the high pressure
recouple high pressure hose or mend
it with tape or any other
fluid.
Handle and route hoses carefully. Do not pull on hoses to
move equipmentiDo not use fluids
or solvents which are not
compatible with the inner tube and cover
of the hose. Do not
expose Graco hose to temperatures above
180° F (82' C) or
below -40' F (-40' C).
Hose Grounding Continuity
Proper hose grounding continuity is essential
to maintaining a
grounded spray system. Check the electrical resistance
of
your air and fluid hoses at least once a week. If your fluid hose
does not have
atag on it which specifies the maximum electri-
cal resistance, contact the hose supplier or manufacturer for
the maximum resistance limits, Use a resistance meter in the
appropriate range
for your hose to check the resistance. If the
resistance exceeds the recommended limits, replace
it imme-
diately. An ungrounded or poorly grounded hose can make
your system hazardous.
Also read FIRE, EXPLOSION, OR
ELECTROSTATIC SHOCK HAZARD on page 2.
IMPORTANT
United States Government safely standards have been adopted under the Occupational Safety and Health Act. These standards--parUcularly
the General Standards, Pari 1910.107 and any other appropriate regulalions--should be consulted in connection with the installation, operation,
and maintenance
of electrostatic spray painting equipment.
4 308-294

Table of Contents
Warnings ..................................... 2
Terms ........................................ 5
Introduction .................................. 6
Installation .................................... 7
Operation ..................................... 9
Gun Setup ................................... 11
Daily Gun Care. Flushing. and Cleaning ........ 16
Spray Pattern Troubleshooting ................ 21
Gun Operation Troubleshooting ............... 22
Electrical Troubleshooting .................... 23
Electrical Tests
Test Gun Resistance
......................... 25
Test Power Supply Resistance ................ 25
Test Barrel Resistance ....................... 26
Service
Read This Page Before Selvicing the Gun
...... 27
Air Cap. Spray Tip. or Seat Housing
Replacement
............................... 28
Fluid Tube Removal and Replacement 30
Electrode Replacement 29
Fluid Filter Removal ......................... 30
Barrel Removal ............................. 31
Barrel Installation ........................... 32
Fluid Packing Adjustment .................... 33
......................
.........
Fluid Needle Removal ....................... 33
Power Supply Removal & Replacement ........ 34
Power Supply Adjustment.
Turbine Alternator Removal &Replacement 35
Gun Part No
236-031 Only 1 34
ES ON-OFF Valve Repair ..................... 35
Fan Air Adjustment Valve Repair .............. 36
Air Valve Repair .............................. 37
. ........ ........
....
Parts ........................................ 30
Accessories ................................. 40
Graco Phone Numbers
....................... 42
Spray Tip Selection Chart ..................... 43
Technical Data ....................... Back Cover
Warranty
............................ Back Cover
Terms
WARNING: Alerts user to avoid or correct conditions
that could cause bodily harm
.
CAUTION: Alerts user to avoid or correct conditions
that could cause damage
to or destruction
of equipment
.
NOTE: Identifies essential procedures or helpful
information
.
308-294 5

Introduction
How the PRO AA4500 Electrostatic
Air-Assisted Airless Spray Gun Operates
WARNING
safety be sure to read and follow the Warnings on
Remember, this
is not an air spray gun; for your
pages
2 to 4 and throughout the text of this
instruction manual.
The air-assisted airless spray gun combines airless
fluid into a fan pattern, as does a conventional airless
and air spraying concepts. The spray tip shapes the
spray tip. Air from the air cap further atomizes the
fluid and completes the atomization of the paint tails
into the pattern
to produce a more uniform pattern.
As the gun is triggered, the regulated air is directed to
the air cap for the air-assist function and air is also
directed
to the power cartridge turbine.
The regulated air that
is directed to the air cap can be
further controlled using the gun’s air control valve.
This valve can be used
to restrict air flow to the air
cap while maintaining sufficient air flow to the turbine.
To change pattern width, a new tip
size must be used.
The air control valve does not control pattern width.
The ability of the
PRO AA4500 Electrostatic Spray
Gun
to spray at higher fluid pressures provides the
additional power needed to atomize higher solids
materials.
The gun’s internal power cartridge provides high volt-
age current. The fluid
is electrostatically charged as it
passes the gun’s electrode. The charged fluid is
attracted to the grounded object, wrapping around
and evenly coating all surfaces.
NOTE The gun’s air control valve can be completely
turned
off to have airless atomization if desired. Clos-
ing the air control valve does not effect the operation
of the turbine.
Power Supply’s Adjustable Lower Voltage Setting
The gun’s lower voltage setting
(LO) is adjustable.
The
LO setting can be adjusted from 45 to 80 kV; it is
the setting. NOTE The gun’s full (HI) voltage setting
preset by the factory at
60 kV. See page 34 to change
is 05 kV.
This full-featured power supply includes a radio fre-
Model
236-031, with Full-Featured Power Supply
quency
(RF) transmitter. The transmitter sends a sig-
nal to a hand held spray voltage readout monitor,
called an
SVR. The SVR readout is the actual spray
voltage. A jumper pin is provided with the
SVR and
the gun will transmit a signal. See ACCESSORIES to
must be installed
in the gun’s power supply before
order the
SVR.
Model 236-030, with Basic Power Supply
The basic power supply provided with Gun Model
236-030 does not include the RF transmitter
capability.
ES lndlcator
Llght
I Alr Control
ES ON-OFF
Lever
ES HI-LO
Lever
Back View of Gun ow

Installation
A
a
KEY
019151
A' Bleed-type Air Shutoff Valve
K Pressure Gauge R' Fluid Drain Valve
B Air Une Filter
L* Grounded Fluid Hose
C' Pump Air Regulator
with spring guards
S Fhid Fdter
D Air Une Lubricator
T Pump Fluld Inlet
E Pump Runaway Vake
GO Pump Ground Wlre
F Pump P Gun Air Shut4 Valve
H Fluid Shutoff Valve
J* fluid Pressure Regulator
M Gun Fluid Inlet (114 npsm)
W PRO AA4500 Spray Gun
N Gun Air Regulator
X Gun Air Inlel(1/4 npsm LH)
a* Gram Eiecirically Conductive Equjpment required
for safe operation of
Air Supply Hose
(1/4 npsm x 1/4 npsm LH)
system. Must be purchased separately.
See ACCESSORIES.
The typical installation shown in Fig. 1 is only a guide
for selecting and installing electrostatic air-assisted
airless spray systems.
It is not an actual system
design. The particular type and size system for your
operation must be custom designed for your needs.
Graco representative.
For assistance
in designing a system, contact your
Warning Signs
can easily be seen and read by all operators. An
Mount warning signs in the spray area where they
English Warning Sign is provided with the gun. Addi-
tional English, French, German, and Spanish signs
them.
are available at no charge. See Accessories to order
WARNING
access to parts which may cause electrostatic
Installing and servicing this equipment requires
formed properly.
shock or other serious injury if work is not per-
* Do not install or service this equipment unless
you are trained and qualified.
Be sure your installation complies with
tion of electrical apparatus
in a Class I, Group
National, State and Local codes
for the installa-
D Hazardous Location.
Check and follow all local safety and fire codes,
NFPA
33, NEC 504 and 51 6, and OSHA stan-
dard
1910.107.
300-294 7

Installation
Ventilate the Spray Booth
WARNING
To prevent hazardous concentrations of toxic and/
or fiammable vapors, spray only in a properly ven-
tilated spray booth. Never operate the spray gun
unless ventilation fans are operating.
Electrically interlock the gun air supply with the venti-
lators to prevent gun operation without ventilating
fans operating. Check and follow all National, State,
and Local codes regarding air exhaust velocity
requirements.
NOTE High velocity air exhaust will decrease the
operating efficiency of the electrostatic system. Air
exhaust~velocity of 100 Wmin (31 linear meters/min-
Ute) should be sufficient.
Air Line Accessories (Refer to Fig. 1)
1. Install an air shut-off valve
( P) on each gun air
supply line
(0) to shut off air to the gun(s).
2. Install an air regulator (N) on the gun air supply
line to control air pressure to the gun.
3. Install an air line filter (8) on the air supply line to
ensure a dry, clean air supply to the gun. Dirt and
work-piece and can cause the gun to malfunction.
moisture can ruin the appearance of your finished
4. Install a bleed-type air regulator (C) on the pump
air supply line to control air pressure to
the pump.
WARNING
To reduce the risk of serious injury due to compo-
nent rupture, pump pressure
must be limited by
the pump air regulator. Do not rely on the gun fluid
regulator to limit the fluid pressure to the gun.
The fluid supply pump must be prevented from
producing a fluid pressure greater than the 3000
psi
(207 bar) Maximum Working Pressure of the
spray gun. For example,
the air supply pressure to
a 30:l pump must not exceed 100 psi (7 bar).
WARNING
To reduce the risk of serious injuly due to compo-
accessories added to the spray system are prop-
nent rupture, be sure that all spray equipment and
eriy rated to withstand the maximum working
pressure
of your system.
5. Install a bleed-type air shutoff valve (A) on the
to the pump. Install an additional bleed-type valve
main air line and the pump air
line to shut off air
trapped between this valve and the pump after
on each pump air supply line to relieve air
the air regulator
is shut off.
WARNING
The bleed-type air shutoff valve (A) is required in
your system to relieve air trapped between this
valve and the pump after the air regulator is
closed. Trapped air can cause the pump to cycle
unexpectedly, which could result in serious bodily
skin and injury from moving
parts.
injury, including splashing in the eyes or on the
6. Install an air line lubricator (D) as close to the
pump
(F) as possible.
Fluid Line Accessories (Referto Fig. 1)
1. Install a fluid filter (S) and drain valve (R) at the
pump outlet. Filtering the fluid will help remove
coarse particles and sediment that could clog the
spray tip.
WARNING
The fluid drain valve (R) is required in your system
to assist in relieving fiuid pressure in the dispiace-
ment pump, hose and gun; triggering the gun to
relieve pressure may not be sufficient. Install
a
drain valve close to the pump’s fluid outlet. The
drain valve reduces the risk of property damage or
serious bodily injury, including splashing in the
ardous fluids.
eyes or on the skin and contamination from haz-
2. Install a fluid regulator (J) on the fluid line to con.
trol fluid pressure to the gun.
8 308-294

Operation
Operating Checklist
Check the following list daily, before starting to oper-
ate the system, to help ensure safe, efficient opera-
Be sure all operators are properly trained to
safely operate an electrostatic air-assisted
airless spray system.
Be sure all operators are trained how to prop-
erly and completely relieve system pressure,
using the Pressure Relief Procedure on
page
10.
See FIRE, EXPLOSION
OR ELECTRO-
Be sure the system
is thoroughly grounded.
STATIC SHOCK
HAZARD on page 3, and
Check the Electrical Grounding on
page
11.
Be sure the warning sign provided with the
gun
is mounted in the spray area where it can
be easily seen and read by all operators.
the spray are; are properly grounded by
Be sure the operator and all persons entering
wearing shoes with conductive soles or per-
sonal grounding straps.
.WARNING
The wallet sized warning card 179-960, provided
with the gun, should be available and easily
accessible at all times for anyone operating or
servicing this equipment. The card contains im-
portant Information on what to do
If a fluid injec-
tion injury occurs. Additional cards are available at
no charge
from Graco.
Square Cut Out
3 In. (76 mm)
and Flnger of
Glove Cut Off
thev must be conductive or
NOTE:
If gloves are worn,
Operator must not wear gloves which insulate
the hand from the spray gun.
If worn, gloves
must be conductive or modified as shown in
Fig.
Fig. 2 so as not to interfere with operator
grounding through the gun.
mobified as shown
so as
not to interfere with operator
grounding through the gun.
Be sure ventilation fans are operating
properly.
and grounded. Contact points must be sharp
Be sure the work-piece hangers are. clean
points or knife edges.
Be sure all refuse and non-essential equip-
ment
is removed from the spray booth.
-10. Be sure all flammable liquids in the spray
booth are in approved, grounded containers.
- 11. Be sure all electrically conductive objects in
the spray area, including paint containers
and wash cans, are properly grounded and
the floor of the spray area is electrically con-
ductive and grounded.
308-294 9

Operation
Pressure Relief Procedure
WARNING
To reduce the risk of serious injury, including fluid
trostatic shock, always follow this procedure
injection, splashing in the eyes or on skin, or elec-
whenever the pump
is shut off, when checking or
servicing any part of system, when installing or
changing spray tips and whenever you stop
spraying.
I
1. Lock the spray gun trigger safety latch. See
Fig. 3.
2. Turn the gun’s ES ON-OFF lever to the OFF
3. Shut off the power to the pump.
4. Close the bleed-type master air valve
5. Close the ailvalve for the gun air supply line.
6. Unlock the gun trigger safety latch.
7. Trigger the gun into a grounded metal waste
container to relieve fluid and air pressure.
8. Lock the gun trigger safety latch again.
9. Open the pump drain valve (required in sys-
tem) to help relieve fluid pressure in the dis-
valve connected to the fluid pressure gauge
placement pump. In addition, open the drain
(in a system with fluid regulation) to help
relieve fluid pressure in the hose and gun.
Triggering the gun to relieve pressure may not
the drainage.
be sufficient. Have a container ready to catch
ready to spray again.
position.
(required in system).
10. Leave the drain valve(s) open until you are
If you suspect that the spray tip or hose is com-
pletely clogged or that pressure has not been fully
relieved after following the steps above,
very slow-
ly loosen the hose end coupling and relieve
pres-
sure gradually, then loosen completely. Now clear
the tip or hose obstruction.
Trigger Safety
Latch Unlocked
Trigger Safety
Latch Locked
Fig. 3
OlQ88A
10 308-294

Gun Setup
1. Complete the Operating Checklist and
follow the Warnings on pages
9 and 10.
2. Connect the Graco air hose.
serious injury, the air supply hose must be electri-
NOTE
The Gram air hose and the gun have special
left-hand threads to prevent connecting another type
of air supply hose to the gun air inlet and
is available
in lengths ranging from
6 to 100 feet (1.83 to 30.5 m).
See Accessories to order the hose.
A. Connect the
1/4 nosmm left-hand end of the
. ..
~ ~
Graco conductive air supply hose (A) to the gun
air fitting (17).
Fig. 2A
01am
B. Connect the other end of the air supply hose (A)
to a filtered and regulated air supply line (6).
C. Connect the air supply hose ground wire (C) to a
true earth ground.
Fig. 2B-C
OlQSl
NOTE: To connect two or more air hoses, use air
adapter nipple 185-493. See Accessories.
3. Check the gun's electrical grounding.
WARNING
Proper electrical grounding of every part of your
system
is essential. For your safety, read the warn-
ing section, FIRE, EXPLOSION,
OR ELECTRO-
STATIC SHOCK HAZARD, on page 3. Ground the
system as explained there. Then check the gun as
explained below.
A. Have a qualified electrician check the electrical
grounding continuity
of the spray gun and air
hose, using the accessory Graco megohmmeter
(E). Use an applied voltage of 500 minimum to
1000 volts maximum.
B. With the fluid and air supply turned off and the
gun's
ES ON-OFF Lever turned to OFF, set the
the resistance between the gun handle
(7) and a
megohmmeter to the
"20M" scale and measure
true earth ground
(D).
A
E
Fig. 38
01w
C. If the resistance is greater than 2 megohms*,
check the tightness of the ground connections,
and be sure the air supply hose ground wire
is
connected to a true earth ground. If the resis-
tance
is still greater than 2 megohms*, replace
the air supply hose.
* If you are using the red colored conductive air
hose, resistance should
not exceed 100 ohms.
308-294 11

Gun Setup
4. Connect the gun exhaust tube. C. Connect the other end of the fluid hose (F) to a
Press the exhaust tube
(56) onto the barbed adapter grounded, filtered, and regulated fluid line
(G).
on the bottom of the gun handle. Secure the tube
with the clamp
(57) provided.
n
Fig. 5C
F
01w
6. Flush the spray gun.
5. Connect the fluid hose.
A. Before connecting the fluid line, blow it out with Before running any paint through the spray
gun, make
sure the trigger safety latch
is in the locked position,
air and flush
it with solvent. Use solvent which is
and the ES ON-OFF lever is turned to OFF, then
compatible with the fluid to be sprayed. remove the spray tip. Flush the gun
out with a solvent
that is compatible with the fluid to be sprayed, using
8. Connect the static-free fluid hose (F) to the the lowest possible pressure.
1/4-18 npsm (R1/4-19) gun fluid fitting (IO).
7. Follow the Pressure Relief Procedure.
WARNING
follow the Pressure Relief Procedure on page 10
before removing or installing the spray tip, air cap
or tip guard.
F
8. Select a spray tip.
Fig. 58 The fluid output and pattern width depend on the size
NOTE The PRO AA4500 spray gun has a 100 mesh
of the spray tip, the fluid viscosity, and the fluid pres-
sure. Use the Spray Tip Selection Chart on page
43,
in-line fluid inlet filter. A 60 mesh filter is also available.
See Accessories.
as a guide for selecting an appropriate spray tip for
your application.
OIBau
12 308-294

Gun Setup
9.
A.
Install the spray tip. 1O.Set the air pressure.
With the pressure relieved, trigger safety latch
locked, and
ES ON-OFF lever OFF, place the clockwise.
spray tip (9) in the air cap
(l), aligning the tab of B. Turn the ES ON-OFF lever (26) to ON.
the tip with the groove in the air cap. Be careful
not
to bend the electrode wire.
A. Close the air control valve (43) by turning it fully
9 01885 C. Make sure the fluid SUDD~V is shut off.
Fig. 9A
6. Install the spray tip (9) and air cap (I), tip guard
(2), and retaining nut (8) onto the gun; tighten the
retaining nut firmly.
/wARN'NGl
To reduce the risk of electrostatic shock or explo-
sion, never operate the spray gun with a bent,
damaged or missing electrode.
.. .
D. Trigger the gun and adjust the air pressure with
the gun air regulator
(H); use the Recommended
Air
Hose Inlet Pressure chart, below, as a guide.
Fig.
1 OD
Recommended Air Hose Inlet Pressure
Air Hose Length Hose Inlet Pressure
Recommended
Air
6 ft ((1.8 m)
15ft(5 m)
30 psi (2.1 bar)
45 psi (3.1 bar)
75 ft (23 m)
40 psi (2.8 bar)
50 fl(15 m)
40 psi (2.8 bar)
36 it (11 m)
35 psi (2.4 bar)
25 ft(8 m)
35 psi (2.4 bar)
I 100 ft (30.5 m) 50 psi (3.5 bar)
NOTE Using higher than recommended air pres-
sures can reduce the life of the turbine/alternator.
Lower pressures can be used but may reduce electro-
static wrap.
308-294 13

11.Set the atomization fluid pressure.
NOTE: Atomization fluid pressure will vary based on
the viscosity
of the fluid, the flow rate desired, and
other characteristics of your system.
Atomization Chart
seconds in #2 (1 05 bar)
Zahn
CUD*
(1 4 bar)
L
Gun Setup
6. Set the fluid pressure with the fluid regulator (J),
based on the Starting Fluid Pressure in the Atom-
ization Chart at
left for the type of fluid you are
spraying.
25-40 se-
conds in #2
1000 psi
Zahn cup**
100 psi
Zahn cup***
(7 bar) (35 bar)
100 psi 500 psi
seconds in
#2
25 or less
(7 bar) (70 bar)
* Includes fluids with 60% volume solids or greater.
Examples:
high-buildhigh-solidsprotectiveurethanesand
epoxies
epoxies
Examples: alkyd enamels, some protective urethanes and
Examples: stains, lacquers, and decorative urethanes
A. Close the air control valve (43) by turning it
fully
clockwise and turn the ES ON-OFF lever (26) to
OFF.
** Includes fluids with 40 to 60% (medium) volume solids.
*** Includes fluids with 40% volume solids or less.
OFF
26
Fig. 11A 018811
J
Fig. 11B
..
01-
C. With the ES ON-OFF lever OFF and the air control
valve closed, spray a test pattern across
a piece
of paper, holding the gun 12 inches (305 mm)
from the surface.
Without being concerned about the presence of
"tails", note the particle size.
D. Increase the fluid pressure by the Fluid Pressure
lncrement shown
in the Atomization Chart for the
type of fluid you are spraying.
E. Spray another test pattern across a piece of
paper.
F. Without being concerned about the presence of
"tails", compare the particle size of the
two test
patterns.
A decrease in particle size indicates improved
atomization.
14 308-294

Gun Setup
11 Set the atomization fluid pressure.
0. Continue to increase the fluid pressure by the
(continued)
increments shown in the chart until the particle
size no longer reduces in size;
do not exceed the
gun’s
Maximum Fluid Pressure of 3000 psi (207-
bar).
When the particle size no longer reduces
in size,
the pattern is atomized at the lowest possible fluid
pressure, but
will still have tails.
H. To eliminate the tails, gradually open the air con-
trol valve, by turning it counterclockwise, until
there are no tails in the pattern.
No Air
n
Too Llltle Air Right Amount
of Air
0782
12.Turn the ES ON-OFF lever (26) to ON.
13.Use the ES HI-LO lever (439) to change to
either
full voltage (HI) or a lower voltage
level (LO).
n
4%
HI
26
ON
Fig. 12-13
01W7
The LO setting is factory set to 60 kV. This setting can
be adjusted between
45 and 80 kV. See page 34 to
adjust.
NOTE When spraying, the ES indicator light (K) will
glow, indicating the electrostatic charge.
308-294 15

Daily Gun Care, Flushing, and Cleaning
WARNING
To reduce the risk of serious injury, including fluid
injection, splashing in the eyes or on the skin or
electrostatic shock, always follow the Pressure
Relief Procedure Warning on page
10 when
shutting off the system, when you stop spraying
and before checking, servicing, installing, cleaning
or changing any part
in the system.
CAUTION
Clean all parts with a non-conductive solvent,
tive solvents can cause the gun
to malfunction.
compatible with the fluid being sprayed. Conduc-
Methylene chloride
is not recommended as a
flushing or cleaning solvent with this gun as it will
damage nylon components.
CAUTION
Solvent left in gun passages could result in a poor quality paint finish and may draw current and reduce the
electrostatic effect. Solvent in the power supply cavity can reduce the alternator life.
Do not use any cleaning
method which may allow solvent into the gun air passages.
..
Do not point the gun up while cleaning it.
Do not wipe the gun with a cloth soaked in
solvent; ring out the excess.
Do not immerse the gun in solvent.
Do not use metal tools to clean the air cap holes
as this may scratch them, and make sure the
electrode wire is not damaged. Scratches in the
tort the
air cap holes or a damaged electrode wire can dis-
General System Maintenance 4. Flush the gun before changing colors and when.
1. Clean the fluid and air line filters daily. ever you are done operating the gun.
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.
16 308-294
IWARNING1
To reduce the risk of fire, explosion, or electrostatic
shock, be sure the
ES ON-OFF lever is turned to OFF
before flushing the gun.

1.
2.
Daily Gun Care, Flushing, and Cleaning
Follow the Pressure Relief Procedure
Warning on page
IO.
Make sure the ES ON-OFF lever is
turned to OFF and the trigger safety
latch is locked before proceeding.
Fig. 2 02WU
3.
Pointing the gun down, unscrew and
remove the retaining nut
(8), tip guard
(2), air cap (1) and fluid tip (9).
You may have to turn the air cap with the tip
guard to remove the air cap from the gun. Set
these
parts aside.
Fig.
3 OZWA
4. Make sure the air and coating supply is
turned off. Turn on the solvent supply.
Fig. 4
0189SA
5. .Flush the Spray Gun.
Unlock the trigger safety latch, point the gun
the gun with solvent until it
is clean. Use the low-
down into a grounded metal container, and flush
est possible fluid pressure when flushing.
Fig.
5
OZ005A
6. Lock the trigger safety latch and turn
off the solvent supply.
7. Follow the Pressure Relief Procedure
Warning on page
IO.
308-294 17

Daily Gun Care, Flushing, and Cleaning
8. Make sure the trigger safety latch is
locked, then disconnect the solvent
and air supply hoses from the gun.
Fig. 8
9. Unlock the trigger safety latch and trig-
ger the gun into a grounded metal con-
tainer to drain the fluid tube.
Fig. 9 mMB
10. Lock the trigger safety latch.
11 .Dip the end of a soft-bristle brush into a
compatible solvent. Then point the gun
down and clean the front with the brush
and solvent.
02007
Fig. 11
01948
12.Dampen a soft cloth with solvent and
wring-out the excess. Point the gun
down and wipe
off the outside.
V
Fig. 12 02WB
18 308-294

Daily Gun Care, Flushing, and Cleaning
13.Remove the bottom fluid tube fitting (P)
and filter (14). Clean the filter in a com-
patible solvent.
14.Relnstall the filter
and fitting. Do not
over-tighten and make
sure the top
fluid tube fitting (a) remains tightened.
Fig. 13-14 02ma
15.Hang up the gun.
16.Clean the retaining nut, tip guard, air
Cap
and fluid tip with a soft brush daily,
minimum.
Clean the Parts with a soff brush and replace
them if they are damaged. Be careful not to bend,
damage,
or disengage the electrode wire.
Fig. 16
02011
17.Wipe off the parts with a dry cloth. Be
careful not to bend the electrode wire.
18.Check the electrode wire. Replace it if
it is bent or damaged. See page 29.
To reduce the risk of electrostatic shock or explo-
sion, never operate the spray gun with
a bent,
damaged or missing electrode.
308-294 19

Daily Gun Care, Flushing, and Cleaning
19.Place the spray tip (9) In the alr cap (1).
Align the tab of the tip with the groove in the air
cap. Be careful not to bend
the electrode wire.
WARNING
sion, never operate the spray gun with a bent,
damaged or missing electrode.
1
9
Fig. 19
01885
20.lnstall the spray tip (9) and air cap (l),
tip guard (2), and retaining nut (8).
Tighten the retalnlng nut firmly.
Fig. 20
moBBA
21.Hang up the gun until It is used agaln.
20 308-294