Page 4 - SAFETY WARNINGS; EQUIPMENT MISUSE HAZARD; General Safety; HAZARDOUS FLUID HAZARD
4ą307-638 SAFETY WARNINGS SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CANOCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNINGLABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIEDPER...
Page 5 - FIRE OR EXPLOSION HAZARD; Grounding; Flushing and Cleaning Safety; HOW THE ELECTROSTATIC AIR SPRAY GUN WORKS
307-638ą5 FIRE OR EXPLOSION HAZARD To reduce the risk of fire, explosion, or electric shock, which may resultfrom electrical discharge, it is essential that: S All parts of the electrostatic system are properly grounded. S All personnel in or close to the spray area are properly grounded. S All elec...
Page 6 - TYPICAL INSTALLATION; KEY; Warning Signs; WARNING
TYPICAL INSTALLATION KEY A Main Air Supply Line B Ventilation Fan Interlock Solenoid Valve C Main Air Supply Shutoff Valve (bleed–type) D Air & Water Separator E Pump Air Supply Shutoff Valve (bleed–type) F Air Line Lubricator G Air Pressure Regulator H Pump J Pump Ground Wire K Fluid Filter L F...
Page 7 - INSTALLATION; Ventilate the Spray Booth; Connect the Air Line; Connect the Fluid Line
INSTALLATION Ventilate the Spray Booth WARNING To prevent hazardous concentrations of toxicand/or flammable vapors, spray only in a properlyventilated spray booth. Never operate the spraygun unless ventilation fans are operating. Check and follow all of the National, State andLocal codes regarding a...
Page 8 - Check the Electrical Grounding; Turn off the air and fluid supply to the gun.; Fig 1; AA; Fig 2; BB
INSTALLATION Check the Electrical Grounding (See Fig 1) WARNING Proper electrical grounding of every part of yoursystem is essential. For your safety, read thewarning section, FIRE OR EXPLOSIONHAZARD, on page 5. Ground the system asexplained there. Then check your system asexplained below. 1. Turn t...
Page 9 - OPERATION; Filter the Fluid; Fig 3; Operating Checklist; Be sure all conductive objects within 20 ft; Spraying Operation
307-638ą9 OPERATION WARNING Pressure Relief ProcedureTo reduce the risk of serious bodily injury, includingsplashing in the eyes or on the skin, injury frommoving parts or electric shock, always follow thisprocedure when shutting off the system, whenchecking or servicing any part of the spray system...
Page 10 - Install the Fluid Nozzle and Air Cap; ES indicator light
10ą307-638 OPERATION Install the Fluid Nozzle and Air Cap WARNING To reduce the risk of serious bodily injury, includingsplashing in the eyes or on the skin or electricshock, always follow the Pressure Relief Proce-dure on page 9 before installing, or removing thefluid nozzle/air cap assembly. 1. Se...
Page 11 - MAINTENANCE; Daily Care and Cleaning; Clean the fluid and air line filters daily.; Clean the Air Cap and Fluid Nozzle; CAUTION; ing pin to the locked position.; Fig 6
307-638ą11 MAINTENANCE Daily Care and Cleaning WARNING To reduce the risk of serious bodily injury, includingsplashing in the eyes or on the skin or electricshock, always follow the Pressure Relief Proce-dure Warning on page 9 when shutting off the sys-tem, when you stop spraying and before checking...
Page 12 - Flush the Spray Gun
12ą307-638 MAINTENANCE Flush the Spray Gun WARNING To reduce the risk of fire or explosion and seriousbodily injury, the ES ON–OFF lever must be OFFbefore flushing. 1. Follow the Pressure Relief Procedure Warning onpage 9. 2. Disconnect and plug the fluid line. 3. Connect the solvent supply to the g...
Page 13 - SPRAY PATTERN TROUBLESHOOTING CHART
SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric shock or other seriousbodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained andqualified. To reduce the...
Page 14 - GUN OPERATION TROUBLESHOOTING CHART; PROBLEM; “Orange Peel” finish.
14 307-638 GUN OPERATION TROUBLESHOOTING CHART Misalignment between air cap and Remove and clean air cap and fluid nozzle fluid nozzle. as described in Maintenance Section under Clean the Air Cap and Fluid Nozzle, then reinstall them. PROBLEM CAUSE SOLUTION Worn needle packing. Replace packing assem...
Page 15 - ELECTRICAL TROUBLESHOOTING CHART; *ES indicator light not on when gun is triggered.
307-638 15 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION *ES ON–OFF lever in OFF position. Turn lever to ON. Improper distance between gun Adjust spraying distance to and workpiece. 203–305 mm (8–12 in.). Parts poorly grounded. Clean hangers, check for properground on conveyer or track. Hi...
Page 16 - ELECTRICAL TESTS; Test Gun Resistance
16 307-638 ELECTRICAL TESTS $! ,!-"+-)*! +" /$! .,-4 #0* %. %-!/(4 ""!/! 4 /$! +* %/%+* +" /$! !(!/-%( +),+*!*/. +*/%*! %*6 .% ! /$! #0* $! !(!/-%( /!./. !(+2 * ! 0.! /+ !/!-)%*! /$! +* %/%+* +" /$! ,+2!- .0,,(4 * /$! -!.%./+- ./0 . 2!(( . /$! +*/%*0%/4 +" /$! !(!/-%6 ( ,...
Page 17 - Test Resistor Stud Resistance
307-638 17 ELECTRICAL TESTS Test Resistor Stud Resistance $(') %$*)!+ '% !$)% ) *$ ''" '/ #%+ %' ) &%,' (*&&"- )() $ !$() ) #)" %$)) !$ ) '%$) % ) ''" ! (*' ) '(!()$ ),$ ) %$*)!+ '% $ ) *$ ")'% '(!()$ ( %*" #% #( ) '(!()$ !( %'') '' )% ) Electrical Troubleshooting...
Page 18 - SERVICE; Gun Disassembly
18 307-638 SERVICE Gun Disassembly ăWARNINGĂ (-.&&#(! ( -,0##(! ."#- +/#*'(. ,+/#,- -- .) *,.- 1"#" '2 /- &.,# -")% ), ).", -,#)/- )#&2 #($/,2 # ." 1),% #- (). *,4 ),' *,)*,&2 ) (). #(-.&& ), -,0# ."#- +/#*'(. /(&-- 2)/ , .,#( ( +/&# # ...
Page 19 - Resistor Stud Replacement
307-638 19 SERVICE Resistor Stud Replacement ăWARNINGĂ Old/New Style Resistor Stud and Electrode , ."!1 " 0%" .&/( ,# /-.(&+$ 3%& % ,1)! 1/" #&." ,. "4-),/&,+ 0%" ")" 0.,!" +! /01! 5,1 &+/0)) ." ) ( %" ,)! /05)" ")" ...
Page 20 - Barrel Removal
20 307-638 SERVICE Barrel Removal )-,!1 .$! )/. . .$! ,,!' "'/% %)'!. !! %# /'' .$! "'/% ./! */. *" .$! "'/% %)'!. !(*0! .$! .,%##!, 2 ,!(*0%)# .$! -,!1- ) -+!,- ",*( .$! #/) !(*0! .$! %) %.*, '%#$.- ",*( .$! -*&!. $! +-,!1- -%)# .$! 1,!)$ " -/++'%! '**-!) ) ,!4 (*0! ...
Page 21 - Install the air cap assembly and fluid nozzle as; described in Clean the Air Cap and Fluid Nozzle.; Trigger the gun to check the needle adjustment. The
307-638 21 SERVICE 5. Carefully remove the fluid needle assembly (45) fromthe rear part of the gun barrel (18). See Fig 15. If thepacking assembly (45a) or insulator (45g) are still inthe barrel, insert the packing removal rod (59d) intothe front of the barrel to gently push them out. Referto Fig 16...
Page 22 - Power Cartridge Replacement; Insert the new power cartridge in the gun handle.; NOTE: See Fig 18 for proper alignment of the power car-
SERVICE Fig 17 KEY 2 Gun Handle 3a Alternator 3b O–Ring 3c Plug 5 Power Supply 5a O–Ring 5b O–Ring 5c Spring 18 Barrel 18b Cushion 46 Gasket 18 46 5c 5b 5a 3a 3c 3b 2 5 NOTE: The power cartridge (3) includes items 3a, 3b,3c, and 5. 18b See NOTE afterstep 3, below. Power Cartridge Replacement 1. Remo...
Page 23 - Turbine Alternator Removal; HH
SERVICE Turbine Alternator Removal 1. Remove power cartridge from the gun handle asdescribed under Power Cartridge Replacement. 2. Carefully twist the turbine alternator (3a) counter-clockwise and pull it off the power supply (5) until justdisengaged from the coupling. Then continue toslowly pull th...
Page 24 - Fan Air Valve Replacement
24 307-638 SERVICE Fan Air Valve Replacement 1. Place a wrench on the flats of the valve housing (33)and remove it from the handle (2). See Fig 20. 2. Remove the retaining ring (31). 3. Rotate the air adjusting screw (34) counterclockwise until it is disengaged from the valve housing threads.Pull th...
Page 25 - ES ON–OFF Valve Removal & Replacement
307-638 25 SERVICE ES ON–OFF Valve Removal & Replacement 1. Loosen and remove the nut (35). Remove the lever(37) and washer (36). See Fig 22. Insert the hex headwrench into the hex end of the valve (39), and turn itto loosen and remove the valve. 2. Clean and inspect parts for wear or damage. Re...
Page 26 - PARTS DRAWING
PARTS DRAWING Old/New Style Resistor Stud and ElectrodeTo reduce the risk of sparking, which could cause fireor explosion, BE SURE the electrode and stud youinstall are black. The old style electrode and stud inthe Series A–D Guns were white. DO NOT mix oldstyle parts with new style parts. *38 4* 39...
Page 27 - PARTS LIST
PARTS LIST REF NO. PART NO. DESCRIPTION QTY 2 218–014 HANDLE, gun; Includes item 2a 1 2a 179–400 .ADAPTER 1 3 218–111 POWER CARTRIDGE; Includes items 3a and 5 1 3a 217–591 ALTERNATOR, turbine; Includes items 3b & 3c 1 3b* 107–106 .O–RING, buna-n 2 3c 180–070 .PLUG 1 4* 107–107 REGULATOR, disc 1 ...
Page 28 - REPAIR KITS; WASHER
REPAIR KITS Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING When servicing use only genuine Graco replace-ment parts. Use of other parts or any alteration ormodification of this equipment could result in seriousinjury, fire, explosion, or property dama...
Page 29 - TECHNICAL DATA; SERVICE INFORMATION
TECHNICAL DATA Weight 0.87 Kg (1.90 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . Gun Length 310 mm (12.25 in.) . . . . . . . . . . . . . . . . . . . . . Maximum Working Pressure 7 bar (100 psi) . . . . . . . . . . Air Pressure Operating Range: 0–7 bar (0–100 psi) Fluid Pressure Operatin...
Page 30 - The accessories in the box, below, are approved by Factory Mutual.; ACCESSORIES; AIR LINE ACCESSORIES
ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component inyour system. Lower rated components may not be able to withstand the pressure develop...
Page 31 - SPRAY SYSTEM ACCESSORIES; NOTE: The installation of this kit will void the CSA and; MISCELLANEOUS ACCESSORIES
ACCESSORIES FILTER (AIR OR PAINT) 202–271 52 bar (750 psi)MAXIMUM WORKING PRESSUREWith 250 micron (60 mesh) element,3/8 npt(f) inlet, 3/8 npt(m) outlet SPRAY SYSTEM ACCESSORIES 218–118 ELECTROSTATIC SYSTEMIncludes items: 218–026 Manual Electrostatic Air Spray Gun 218–103 Grounded Air Supply Hose (Se...
Page 32 - THE GRACO PRO4000 WARRANTY AND DISCLAIMERS; WARRANTY; IMPORTANT PHONE NUMBERS
THE GRACO PRO4000 WARRANTY AND DISCLAIMERS WARRANTY Graco warrants the PRO4000 to be free from defects in material and workmanship on the date of sale by an authorized Gracodistributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period...
