Page 2 - WARNING; FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD; TOXIC FLUID HAZARD
2 308936 WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition andresult in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the...
Page 3 - INJECTION HAZARD; EQUIPMENT MISUSE HAZARD
308936 3 WARNING INJECTION HAZARD Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause anextremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skincan also cause a serious injury. Fluid injected into the skin mi...
Page 4 - Warning Symbol; Caution Symbol; CAUTION
4 308936 Table of Contents Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6 . . ...
Page 5 - Introduction; Back View of Gun
308936 5 Introduction How the PRO AA4500/UNICARBElectrostatic Air-Assisted Spray GunOperates WARNING Remember, this is not an air spray gun; for yoursafety be sure to read and follow the Warnings onpages 2 to 3 and throughout the text of thisinstruction manual. The spray tip shapes the fluid into a ...
Page 6 - Installation; Installing the System; Warning Signs; Ventilate the Spray Booth; Air Line Accessories
6 308936 Installation Installing the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Installing and servicing this equipmentrequires access to parts which maycause electric shock or other seriousinjury if work is not performed properly. Do not install or service this equip-ment unless you ...
Page 7 - Fluid Line Accessories
308936 7 Installation 01945B Fig. 1 KEY A* Bleed-type Air Shutoff ValveB Air Line Filter H Fluid Shutoff Valve K Pressure Gauge L* Grounded Braid Type Fluid Hose with spring guards M Gun Fluid Inlet (1/4 npsm) N Gun Air Regulator P Gun Air Shut-off Valve Q* Graco Electrically Conductive Air Supply H...
Page 9 - Operation; Operating Checklist
308936 9 Operation Operating Checklist Check the following list daily, before starting to operatethe system, to help ensure safe, efficient operation. ____ 1. All the operators are properly trained tosafely operate an electrostatic air-assistedairless spray system as instructed in thismanual. ____ 2...
Page 11 - Gun Setup; Complete the Operating Checklist and
308936 11 Gun Setup 1. Complete the Operating Checklist and follow the Warnings on pages 9 and 10. 2. Connect the Graco air hose. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock orother serious injury, the air supply hosemust be electrically connected to a true earth ground. Use O...
Page 14 - Install the spray tip
14 308936 Gun Setup 10. Install the pre-orifice WARNING To reduce the risk of a serious injury, including fluidinjection, follow the Pressure Relief Procedure on page 10 when you stop spraying and whenever youare instructed to relieve the pressure. A. Place the spray tip seal (9a) on a flat surface....
Page 15 - Set the air pressure; Recommended Air Hose Inlet Pressure
308936 15 Gun Setup 12. Set the air pressure . A. Atomizing air is not used in the UNICARB process.Close the air control valve (43) by turning it fullyclockwise. B. Turn the ES ON-OFF lever (26) to ON. Fig. 12A-B 01947 26 ON 43close C. Make sure the fluid supply is shut off. D. Trigger the gun and a...
Page 16 - Setting the Atomization Fluid Pressure; to change
16 308936 Gun Setup 13. Setting the Atomization Fluid Pressure Atomization fluid pressure will vary based on the typeof fluid used, the flow rate desired, the fluid tempera-ture, and the percentage of CO 2 used. Follow the recommendations of your material and equipmentsupplier. 14. Using the Electro...
Page 18 - General System Maintenance; Follow the Pressure Relief Procedure; Make sure the air and coating supply is
18 308936 Daily Gun Care, Flushing, and Cleaning General System Maintenance 1. Clean the fluid and air line filters daily. 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 fluidhoses. Tighten fittings or replace equipment...
Page 20 - Wipe off the parts with a dry cloth. Be
20 308936 Daily Gun Care, Flushing, and Cleaning 13. Remove the bottom fluid tube fitting (P) and filter (14). Clean the filter in acompatible solvent. 14. Reinstall the filter and fitting. Do not over-tighten and make sure the topfluid tube fitting (Q) remains tightened. Fig. 13–14 02009 P 14 Q 15....
Page 21 - Hang up the gun until it is used again.
308936 21 Daily Gun Care, Flushing, and Cleaning 19. Place the spray tip (9) in the air cap (1). Align the tab of the tip with the groove in the aircap. Be careful not to bend the electrode wire. WARNING ELECTRIC SHOCK HAZARD To reduce the risk of electric shock orexplosion, never operate the spray ...
Page 22 - Spray Pattern Troubleshooting
22 308936 Spray Pattern Troubleshooting WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other seriousinjury if the work is not performed properly. Do not install or service this equipment unless you are trained andqualified. To reduce the ri...
Page 23 - Gun Operation Troubleshooting
308936 23 Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Leakage from fluid needle area Fluid needle packings loose Fluid needle packing damaged Tighten packing nut; See page 33 Replace fluid needle; See page 34 Air leakage from front of gun Air valve not turned off Piston air valve not seatin...
Page 24 - Electrical Troubleshooting
24 308936 Electrical Troubleshooting NOTE: Additional gun troubleshooting can be done on Gun Part No. 236031 using the Remote Spraying Voltage Read- out ( SVR ) . See Accessories to order the SVR. PROBLEM CAUSE SOLUTION Reduced fluid efficiency Improper distance between gun andwork-piece Parts poorl...
Page 25 - Electrical Tests; Test Gun Resistance
308936 25 Electrical Tests The performance and safety of the spray gun aredirectly affected by the condition of the electricalcomponents contained inside the gun. The electricaltests below can be used to determine the condition ofthe power supply (18) and the barrel resistor cartridgeas well as the ...
Page 26 - Test Power Supply Resistance
26 308936 Electrical Tests Test Power Supply Resistance (See Fig. 5) Remove the power supply (18) from the gun. See page 35. Measure the resistance from the power supply’sground contact point (EE) to the contact inside of thepower supply seal (18e) [the conductive rubber contact may be slightly rece...
Page 27 - Test Barrel Resistance
308936 27 Electrical Tests Test Barrel Resistance (See Fig. 6) Measure the resistance between the barrel contactring (3a) and the metal contact pin (E), using a metalrod (D) and megohmmeter as shown in Fig. 6. Becareful not to damage or scratch the inner surfaces ofthe barrel with the metal rod. The...
Page 28 - Service; Prepare the Gun for Service; Tools Needed
28 308936 Service Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARD Installing and servicing this equipmentrequires access to parts that may causeelectric shock or other serious injury if the work is not performed properly. Do not install orservice this equipment unless you are trained andqu...
Page 30 - Electrode Replacement
30 308936 Service Electrode Replacement WARNING ELECTRIC SHOCK HAZARD To reduce the risk of fire, explosion, orelectric shock, do not operate the spraygun without the electrode installed in theair cap. 1. Prepare the gun for service as instructed on page28. 2. Remove the retaining nut (8), tip guard...
Page 31 - Fluid Tube Removal & Replacement; Fluid Filter Removal
308936 31 Service Fluid Tube Removal & Replacement To remove the fluid tube assembly (12) for cleaning orreplacement: 1. Prepare the gun for service as instructed on page28. 2. Disconnect the bottom fluid tube nut (C). SeeFig. 10. 3. Carefully unscrew the top fluid tube nut (D). CAUTION Be caref...
Page 32 - Barrel Removal
32 308936 Service Barrel Removal 1. Prepare the gun for service as instructed on page28. 2. Disconnect the bottom fluid tube nut (C). SeeFig. 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, removethe two setscre...
Page 33 - Fluid Packing Adjustment
308936 33 Service Fluid Packing Adjustment If fluid leaks from the fluid needle area, the fluid pack-ings may be loose. Tighten the packings, following theprocedure below. 1. Prepare the gun for service as instructed on page28. 2. Remove the retaining nut (8), tip guard, (2), air cap(1), and spray t...
Page 34 - Fluid Needle Assembly Removal
34 308936 Service Fluid Needle Assembly Removal 1. Prepare the gun for service as instructed on page28. 2. Remove the retaining nut (8), tip guard, (2), air cap(1) and spray tip (9). See Fig. 7, page 29. You mayhave to turn the air cap with the tip guard toremove the air cap from the gun. 3. Trigger...
Page 35 - Power Supply Removal and Replacement; Power Supply Adjustment
308936 35 Service Fig. 16 7 35 37a 37b 18a 18 37 F 3 18b 18c 18d 18e 01953A Power Supply Removal and Replacement NOTES: a. To avoid a loss in electrostatic performance,inspect the gun handle’s power supply cavityfor dirt or moisture. Clean the cavity with aclean, dry rag. b. Do not expose the seal (...
Page 36 - Barrel Installation
36 308936 Service Turbine Alternator Removal and Replacement NOTE: Replace turbine bearings after 2000 hours of operation. See your authorized Graco representative. 1. Prepare the gun for service as instructed on page28. 2. Remove the power supply from the gun handle asinstructed on page 35. 3. Sque...
Page 37 - ES ON-OFF Valve Repair
308936 37 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page28. 2. Loosen the set screw (24) with the 2 mm hex key(63), supplied. Remove the lever (26) from thevalve. See Fig. 18. WARNING MOVING PARTS HAZARD To reduce the risk of eye injury, be sureto wear safety gla...
Page 38 - Air Control Valve Repair
38 308936 Service Air Control Valve Repair NOTE: The air control valve (43) can be replaced as an assembly or as individual parts. To disassemble the air control valve, 1. Prepare the gun for service as instructed on page28. 2. Remove the retaining ring (43h). See Fig. 19. 3. Slide the KV HI-LO leve...
Page 39 - Air Valve Repair
308936 39 Service Air Valve Repair 1. Prepare the gun for service as instructed on page28. 2. Using a screw driver, remove the air valve cap(45). See Fig. 20. 3. Remove the o-ring (23) and spring (44). CAUTION Clean all parts in non-conductive solvent compatiblewith the fluid being used, such as xyl...
Page 40 - Notes
Page 42 - Parts
1 2 3 4 5 6 7 8 9 14 12 REF 12 13 15 16 17 18a 18e 18 18b 18d 18c 19 21 23 24 26 28 30 31 32 19 33 34 35 36 37 37a 37b 38 39 40 41 42 43b 43d 43f 43g 43h 43e 43c 44 45 46 47 3a 9a 56 57 1a Item 1 includes item 1aItem 3 includes item 3aItem 18 includes items 18a to 18eItem 37 includes items 37a and 3...
Page 44 - Use Only Genuine Graco Parts and Accessories
44 308936 Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 6 ft (1.8 m) 218100 15 ft...
Page 45 - GUN ACCESSORIES
308936 45 Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES High Pressure Ball Valves 5000 psi (350 bar, 35 MPa) Maximum Working Pressure For turning fluid off or on to the gun and for relievingfluid line pressure at the pump 210657 1/2 npt(m), Viton seals 210658 3/8 np...
Page 47 - Spray Tip Selection Chart; Pre-orifice Selection Chart
308936 47 Spray Tip Selection Chart Part No. Fan Width at 10 in. (260 mm) in. (mm) Orifice Size in. (mm) GG3107 2–4 (50–100) 0.007 (0.178) GG3207 4–6 (100–150) GG3307 6–8 (150–200) GG3209 4–6 (100–150) 0.009 (0.229) GG3309 6–8 (150–200) GG3409 8–10 (200–250) GG3609 12–14 (300–350) GG3211 4–6 (100–15...
Page 48 - The Graco Warranty and Disclaimers; Graco Phone Number; Manual Change Summary
48 308936 The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workman-ship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedyfor brea...
