INSTRUCTIONS PARTS LIST

Transcription

1 INSTRUCTIONS PARTS LIST This manual contains IMPORTANT S AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Rev. R Supersedes P Model PRO AA4000 MANUAL MID-RANGE ELECTROSTATIC AIR-ASSISTED AIRLESS SPRAY GUN 66 bar (950 psi) MAXIMUM WORKING FLUID PRESSURE 7 bar (100 psi) MAXIMUM WORKING AIR PRESSURE Part Number , Series B With mm (0.011 in.) spray tip, part no U.S. Patent No. 4,290,091; 4,219,865;4,386,739; 3,843,052; 4,462,061; 4,497,447; 4,554,622 U.K. Patent No. 2,140,327B; 2,111,406B; 2,142,559B; 2,147,158 Patented 1986, 1987 Canada Brevete 1986, 1987 French Patent No ; ; Italian Patent No. 1,111,380 West German Patent No. DE GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN COPYRIGHT 1984, GRACO INC.

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3 Terms How The Electrostatic Air-Assisted Airless Spray Gun Works Safety Warnings , 5 Installation Typical Installation Warning Signs Ventilate the Spray Booth Connect the Air Line Check the Electrical Grounding Connect the Fluid Line Operation Filter the Fluid Spraying Operation Operating Checklist Install the Spray Tip and Air Cap Adjust the Spray Pattern Maintenance Daily Care and Cleaning Flush the Spray Gun TABLE OF CONTENTS Test Power Supply Resistance Test Resistor Stud Resistance Service Gun Disassembly Electrode Wire Replacement Ball Seat Housing & Resistor Replacement Barrel Removal Barrel Reassembly Fluid Needle Replacement Check the Gun Safety Latch Power Cartridge Replacement Turbine Alternator Removal Fan Air Valve Replacement Air Valve Replacement ES ON-OFF Valve Removal and Repair Muffler, Check Valve & Inlet Filter Replacement Repair Kits Parts Drawing Parts List Accessories Spray Pattern Troubleshooting Chart Gun Operation Troubleshooting Chart Electrical Troubleshooting Chart Technical Data Graco Phone Numbers Spray Tip Selection Chart , 31 Electrical Tests Test Gun Resistance Warranty Back Cover TERMS : 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. FLUID INJECTION INJURY: A serious injury, which may appear to be a simple cut, caused by high pressure injection of fluid directly into the body. PRESSURE RELIEF PROCEDURE: A safety procedure for relieving air and fluid pressure in the system. FOR YOUR SAFETY: Alerts user to read the additional safety warnings on the page indicated. ES ON-OFF VALVE: An on/off switch located near the rear of the gun, above the gun handle, that turns the electrostatic power on or off. HOW THE ELECTROSTATIC AIR-ASSISTED AIRLESS SPRAY GUN WORKS This gun combines electrostatic air spray and airless spraying concepts. The air has three functions: (1) to drive the turbine, (2) to help atomize the paint tails, and (3) to help control the pattern size. The turbine generates power that the power cartridge converts to a high voltage current. The high voltage current charges the gun s ionizing electrode. Fluid is electrostatically charged as it passes the gun s ionizing electrode. The charged fluid is attracted to the grounded work piece, wrapping around and evenly coating all surfaces. The spray tip shapes the fluid into a fan pattern, similar to a conventional airless spray tip, but at a lower pressure. Air from the air cap further atomizes the fluid and pushes the paint tails into the pattern. The fan adjusting knob controls the width of the pattern. Note that the air-assisted airless spray gun differs from the conventional air spray gun in that increasing the fan air reduces the pattern width. To increase the pattern width, less fan air or a larger size tip must be used.

4 SAFETY S SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTROSTATIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE INSTALLED AND USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL. FLUID INJECTION HAZARD General Safety This equipment generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage. 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 system. NEVER try to stop or deflect leaks with your hand or body. ALWAYS follow the Pressure Relief Procedure, at right, before cleaning or removing the spray tip or servicing any system equipment. BE SURE equipment safety devices are operating properly before each use. Medical Alert Airless Spray Wounds If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Note to Physician: Injection into the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. 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 be advisable. Spray Gun Safety Devices Be sure all gun safety devices are operating properly before each use. DO NOT remove or modify any part of the gun; this can cause a malfunction and result in serious bodily injury. Safety Latch Whenever you stop spraying, even for a moment, ALWAYS set the gun safety latch in the closed or locked position, making the gun inoperative. Failure to set the safety latch can result in accidental triggering of the gun. Set the safety latch by depressing it on the left or right side of the trigger. See the illustration below. Disengage the latch by pushing it toward the trigger and up. Safety Latch shown in closed or Lock position Safety Latch shown in open or Spray position Diffuser The gun diffuser, which is part of the ball seat housing, breaks up spray and reduces the risk of fluid injection when the spray tip is not installed. To check diffuser operation, follow the Pressure Relief Procedure, below, then remove the spray tip. Aim the gun into a grounded metal pail. With the turbine air OFF, and using the lowest possible pressure, trigger the gun. If the fluid emitted is not diffused into an irregular stream, replace the ball seat housing. Spray Tip Safety Use extreme caution when cleaning or changing spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately. Follow the Pressure Relief Procedure, then remove the spray tip to clean it. NEVER wipe off build-up around the spray tip or remove the spray tip until pressure is fully relieved and the gun safety latch is engaged. Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, injury from moving parts or electrostatic shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing spray tips, and whenever you stop spraying. 1. Engage the gun safety latch. 2. Turn the ES On Off valve lever to OFF. 3. Turn off the air and fluid supply to the gun. 4. Disengage the gun safety latch. 5. Trigger the gun into a grounded metal waste container to relieve fluid pressure. 6. Open the pump drain valve, having a waste container ready to catch the drainage. 7. Leave the pump drain valve open until you are ready to spray again. If you suspect that the tip or hose is completely clogged, or that pressure has been fully relieved after following the steps above, VERY SLOWLY loosen the air cap retainer or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose. Bleed-Type Air Shutoff Valve and Fluid Drain Valve These two accessories are required in your system to help reduce the risk of serious bodily injury, including splashing in the eyes or on the skin and injury from moving parts if you are adjusting or repairing the pump. The bleed-type air shutoff valve relieves air trapped between this valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly. Locate the valve within easy reach of the pump. SPRAY LOCK SPRAY LOCK The fluid drain valve assists in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient.

5 EQUIPMENT MISUSE HAZARD General Safety Any misuse of the spray equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, electrostatic shock, fire, explosion or property damage. NEVER alter or modify any part of this equipment; doing so could cause it to malfunction. CHECK 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 clothing and equipment. System Pressure This gun has a maximum fluid working pressure of 66 bar (950 psi). Never exceed the maximum working pressure of the gun or any other component or accessory used in the system. Fluid Compatibility BE SURE all fluids and solvents used are chemically compatible with the Wetted Parts shown in the TECHNICAL DATA on page 29. Always read the fluid and solvent manufacturer s literature before using the fluid or solvent in this gun. FIRE, EXPLOSION, or ELECTROSTATIC SHOCK HAZARD To reduce the risk of fire, explosion, or electrostatic shock, which may result from electrical discharge, it is essential that: All parts of the electrostatic system are properly grounded. All personnel in or close to the spray area are properly grounded. All electrically conductive objects or devices in the spray area, including paint containers, wash cans and tools, are properly grounded. When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Arcing may occur if these objects then come in contact or close to ground. Arcing of sufficient energy levels can ignite the fluid being sprayed, fumes from solvents, dust particles, and other flammable substances. This can cause a fire or explosion and result in serious bodily injury and property damage. Static electricity can also be generated by the flow of fluid through the pump, hose, gun, and nozzle, but it is dissipated through proper grounding as described in Grounding below. If you experience any arcing or feel even a slight shock, STOP SPRAY- ING IMMEDIATELY. 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 check your local electrical code for detailed grounding instructions. Be sure your system is connected to a true earth 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 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 to a true earth ground. 4. Object being sprayed: keep the work piece hangers clean and grounded at all times. Contact points must be sharp points or knife edges. 5. All electrically conductive objects or devices in the spray area, including paint containers and wash cans, must be properly grounded. HOSE SAFETY Highly pressurized fluid contained in the hose can be very dangerous. If the hose develops leak, split or rupture, due to any kind of wear, damage or misuse, high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage. TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling. 6. All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive. The operator must not wear gloves which insulate the hand from spray gun. The gloves must be conductive or modified as shown on page The floor of the spray area must be electrically conductive and grounded. Do not cover the floor with cardboard or any non conductive material which would interrupt grounding continuity. 8. Flammable liquids in the spray area must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift. 9. All solvent pails: use only grounded metal pails, which are conductive. Do not place the pail on any non-conductive surface, such as cardboard or paper, which would interrupt grounding continuity. 10. All air and fluid lines and electric cables must be properly grounded. Flushing and Cleaning Safety To reduce the risk of static sparking or splashing, always follow the Pressure Relief Procedure on page 4 and remove the spray tip before flushing. Be sure the ES valve lever is OFF before flushing or cleaning any part of the spray system. Use the lowest possible pressure to flush. Trigger the gun into a grounded metal waste container. To flush or purge equipment, ALWAYS use solvents with a flash point equal to or greater than that of the fluid being sprayed. To clean the exterior of the equipment, ALWAYS use solvents with a flash point of higher than 38 C (100 F). ALWAYS remove all solvent from the system before reactivating the spray gun. Use only non-sparking tools to clean residue from the booth and hangers. Ventilate the Spray Booth To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. NEVER operate the spray gun unless the ventilating fans are operating. Check and follow all National, State and Local codes regarding air exhaust velocity requirements. Check and follow all local safety and fire codes and OSHA standard (b)(5)(i). NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot contain the high pressure fluid. HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids or solvents which are not compatible with the inner tube and cover of the hose. IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards particularly the General Standards, Part and any other appropriate regulations should be consulted in connection with the installation, operation, and maintenance of electrostatic spray painting equipment.

6 TYPICAL INSTALLATION A M T N S B* C* D E* H O G W G J* P R* X F K Q* V* L U SIGN NON HAZARDOUS AREA HAZARDOUS AREA Air Supply to Gun MUST Be Interlocked With Spray Booth Exhaust Fan. 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 Fluid Supply Line Shutoff Valve M Fluid Pressure Regulator N Fluid Supply Line O Air Filter (5 micron) P Air Supply Line Shutoff Valve *Equipment that must be installed for safe operation. Must be purchased separately. See ACCESSORIES. NOTE: Solenoid Valve (B) is not offered as a Graco accessory., Q* Air Hose Ground Wire R* Grounded Air Supply Hose S Electrostatic Spray Gun T ES On Off Valve Lever U Air Line Drain Valve V* Fluid Drain Valve W Gun Air Inlet X Gun Fluid Inlet The Typical Installation shown above is only a guide for selecting and installing an electrostatic air-assisted airless spray system. It is not an actual system design. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, contact your Graco representative. The pump you use should have a maximum working pressure of 66 bar (950 psi). If the pump you are using has a higher maximum working pressure, a regulator MUST be used to limit the pressure to 66 bar (950 psi). Graco s 10:1 Ratio Monark Pump, part no , may be used in this system. See ACCESSORIES. Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators. An English and a Spanish Warning Sign are provided with the gun. Additional English, French, German, and Spanish signs are available at no charge. See the ACCESSORIES section to order them. Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious bodily injury if work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Be sure your installation complies with National, State and Local codes for the installation of electrical apparatus in a Class 1, Group D, Divisions 1 and 2 Hazardous Location. Check and follow all local safety and fire codes, NFPA 33, NEC 504 and 516, and OSHA standard

7 INSTALLATION Ventilate the Spray Booth To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. Never operate the spray gun unless ventilation fans are operating. The air supply to the gun must be electrically interlocked with the ventilators to prevent operation of the power supply unless ventilating fans are running. Check and follow all the National, State and Local codes regarding air exhaust velocity requirements. NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 31 linear meters/minute (100 ft/min). Connect the Air Line (See Typical Installation) To reduce the risk of electrostatic shock or other serious bodily injury, the Air Supply Hose must be electrically connected to a true earth ground. Use only Graco Electrically Conductive Air Supply Hose. See ACCESSORIES. 1. Connect the air supply hose (R) between the air supply line and the gun s air inlet (W). The gun air inlet fitting has a left hand thread. Connect the air supply hose ground wire (Q) to a true earth ground. 2. Install an air line filter (O) and an air and water separator (D) on the air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction. 3. Install a bleed-type air regulator (G) on the pump and gun air supply lines to control air pressure to the pump and gun. Check the Electrical Grounding (See Fig 1) Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE, EXPLOSION, or ELEC- TROSTATIC SHOCK HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below. 1. Turn the ES On Off valve to OFF. See Fig 5 for the location of the valve lever. 2. Turn off the air and fluid supply to the gun. 3. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose. a. With the electrically conductive air hose (BB) connected (see Connect the Air Line) and properly grounded, use a megohmmeter (AA) to measure the resistance between the gun handle (Y) and a true earth ground (Z). Use an applied voltage of 500 volts minimum to 1000 volts maximum. See Fig 1. b. 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 resistance is still greater than 2 megohms, replace the air supply hose. Z AA BB 4. Install a bleed-type air shutoff valve (C) on the main air line and pump air line (E) to shut off air to the pump. Install an additional bleed-type valve on each pump air supply line to relieve air trapped between this valve and the pump after air regulator is shut off. The bleed type air shutoff valve 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 injury, including splashing in the eyes or on the skin and injury from moving parts. 5. Install an air line lubricator (F) as close to the pump (H) as possible. Y Y Gun Handle Z True Earth Ground AA Ohmmeter BB Grounded Air Hose Fig 1 6. Install an air shutoff valve (P) on each gun air supply line to shut off air to the gun(s).

8 INSTALLATION Connect the Fluid Line (See Typical Installation) 1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. 2. Install a fluid regulator (M) on the fluid line to control fluid pressure to the gun. 3. Install a fluid filter (K) and drain valve (V) at the pump outlet. The fluid drain valve (V) is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. The drain valve reduces the risk of property damage or serious bodily injury, including splashing in the eyes or on skin. Install a drain valve close to the pump s fluid oulet. 4. Connect fluid line to 1/4 18.6(m) gun fluid inlet (X). OPERATION For your Safety, ALWAYS follow the Pressure Relief Procedure on page 4 when shutting off the system, when you stop spraying, and before checking, servicing, installing, cleaning or chaning any part in the system. 3 in. (76 mm) Square Cut Out and Finger of Glove Cut Off NOTE: If gloves are worn, they must be conductive or modified as shown so as not to interfere with operator grounding through the gun. Operating Checklist Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation. 1. Be sure all operators are properly trained to safely operate an air-assisted airless electrostatic spray system. 2. Be sure all operators are trained how to properly and completely relieve system pressure. 3. Be sure the system is thoroughly grounded. See FIRE, EXPLOSION, or ELECTRIC SHOCK HAZARD, page 5, and Check the Electrical Grounding, page Be sure the operator and all persons entering the spray area are properly grounded by wearing shoes with conductive soles or personal grounding straps. Fig 2 Filter the Fluid Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle. Spraying Operation This gun has a built-in lead and lag operation. The gun begins emitting air before the fluid is discharged. When you release the trigger, the fluid stops before the air flow stops. This helps prevent fluid buildup on the air cap. When spraying, the ES indicator lights (44) should glow, indicating the electrostatic charge. See Fig 5. CAUTION Be careful not to damage the electrode by jamming it into an object when operating or setting down the gun. 5. 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 2 so as not to interfere with operator grounding through the gun. 6. Be sure ventilation fans are operating properly. 7. Be sure the workpiece hangers are clean and grounded. Contact points must be sharp points or knife edges. 8. Be sure all refuse is removed from the spray booth. 9. Be sure all flammable liquids in spray booth are in approved, grounded containers. 10. Be sure all conductive objects within 20 ft (6 m) of the gun are electrically grounded and the floor of the spray area is electrically conductive and grounded.

9 OPERATION Install the Spray Tip and Air Cap For your safety, always follow the Pressure Relief Procedure, on page 4, before installing, or removing the spray tip or air cap. 1. See the SPRAY TIP SELECTION CHART, page 30, to select the appropriate spray tip for your application. The fluid output and fan width depends on the spray tip size, fluid viscosity, and fluid pressure. 2. Place the spray tip (13) in the air cap (12), aligning the tab of the tip with groove in the air cap. Be careful not to damage electrode wire (GG). See Fig Place the air cap assembly on the gun. Screw the retaining nut (11) firmly onto the gun to prevent leakage between the tip and ball seat housing. NOTE: The air cap and spray tip position determines the direction of the spray pattern. See Fig First, complete all the checks under the Operating Checklist on page 9. Then turn the ES ON-OFF valve lever (T) to ON. See Fig 5. Provide a 3.1 bar (45 psi) clean, dry, regulated air supply to the gun to ensure full voltage from the power supply. The gun may be operated at lower turbine air pressure, but may lose some electrostatic effect. Do not operate the turbine at an air pressure greater than 3.1 bar (45 psi) as there is no benefit and turbine life will be reduced. 7. Check the spray pattern, then adjust the air pressure until all the tails are completely atomized and pulled into the spray pattern. Refer to Fig If a narrower pattern is desired, try turning the fan adjusting knob (EE) clockwise. If the pattern is still not narrow enough, increase the air line pressure slightly or use a different size tip. Operating the gun without the electrode wire or with a bent or damaged electrode wire will impair the electrical continuity of the gun. To reduce the risk of electrical discharge, which could cause serious injury, fire, or explosion, BE SURE the electrode wire is properly installed in the gun (see page 16) and is not bent or damaged before operating the gun. VERTICAL SPRAY PATTERN Fig 3 HORIZONTAL SPRAY PATTERN Adjust the Spray Pattern Follow the steps below to establish the correct fluid flow and air flow. DO NOT turn the electrostatics on yet. 1. Set the fluid pressure at about 21 bar (300 psi), using the fluid regulator. 2. Trigger the gun to check the atomization; don t be concerned about the pattern shape yet. 3. Increase the fluid pressure just to the point that any further increase in fluid pressure does not significantly improve fluid atomization. DO NOT exceed 66 bar (950 psi) fluid pressure. 4. Be sure the fan adjusting knob (EE) is closed (turned fully counterclockwise). NO AIR TOO LITTLE AIR RIGHT AMOUNT Fig 4 OF AIR 11 Retaining Nut T ES ON-OFF 12 Air Cap Valve Lever 13 Spray Tip EE Fan Adjusting Knob 44 ES Indicator Lights GG Electrode Wire GG 44 Tab 13 T EE 5. Set the atomizing air pressure to 3.1 bar (45 psi). Fig 5

10 MAINTENANCE Daily Care and Cleaning CAUTION Clean all parts with a non conductive solvent, compatible with the fluid being sprayed. Conductive solvents can cause the gun to malfunction. Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components. Do not use any cleaning method which may allow solvent into the gun air passages. Immersing the gun in solvent is not recommended as a cleaning method. 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 alternator life. For your safety, always follow the Pressure Relief Procedure on page 4 when shutting off the system, when you stop spraying, and before checking, servicing, installing, cleaning or changing any part in the system. 1. Clean the fluid and air line filters daily. 2. Check all of the work hangers for build-up of material; clean them, if necessary. 3. Clean the gun fluid filter (26) daily. See Fig 6. a. Unscrew and remove the fluid inlet fitting (25). b. Remove the filter (26) and clean thoroughly in a compatible non-conductive solvent. c. Reinstall the filter and inlet fitting. DO NOT over tighten the inlet fitting as over tightening could distort the filter. 4. Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent. 5. Clean the air cap and spray tip daily, minimum. Some applications require more frequent cleaning. Replace spray tip and air cap if they are damaged. a. Remove the air cap and spray tip. b. Clean the tip and air cap with solvent and scrub with a soft brush. To avoid damaging the ball seat housing resistor, use a soft bristle brush dipped in solvent to clean; DO NOT soak it in solvent! A damaged resistor will impair the electrical continuity and could result in electrical discharge, which could cause serious injury, fire, or explosion. c. Use a soft brush or other soft tool, with an air blow gun, to clean air cap passages. Take care not to scratch any surfaces. If air cap holes are plugged, use a round toothpick to unplug the holes. CAUTION 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 air cap holes or a damaged electrode wire can distort the spray pattern. 6. Check the electrode wire. Straighten if bent, and replace if broken or damaged. See Electrode Wire Replacement. 25 Fluid Inlet Fitting 26 Fluid Filter Fig 6 Flush the Spray Gun To reduce the risk of electric shock, which could result in serious injury, or the risk of fire or explosion the ES On-Off lever (electrostatics) must be OFF before flushing For your safety, always follow the Pressure Relief Procedure on page 4 before flushing. CAUTION Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components. 1. Follow the Pressure Relief Procedure on page Disconnect and plug the fluid line. 3. Connect the solvent supply to the gun. 4. Flush the gun with solvent until it is clean. 5. Follow the Pressure Relief Procedure, then disconnect the solvent supply. 6. Reconnect the fluid supply line. 8. Trigger the gun until it is clear of solvent.

11 SPRAY PATTERN TROUBLESHOOTING CHART Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, injury from moving parts or electrostatic shock, always follow this procedure when shutting off the system, when checking or servicing any part of the spray system, when installing, cleaning or changing fluid nozzles, and whenever you stop spraying. 1. Engage the gun safety latch. 2. Turn the ES ON OFF Valve lever to OFF. 3. Turn off the air and fluid supply to the gun. 4. Disengage the gun safety latch. 5. Trigger the gun into a grounded metal waste container to relieve fluid pressure. 6. Engage the gun safety latch. 7. Open the pump drain valve, having a waste container ready to catch the drainage. 8. Leave the pump drain valve open until you are ready to spray again. If you suspect that the tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above. VERY SLOWLY loosen the air cap retainer or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose. NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun. PROBLEM: CAUSE SOLUTION IMPROPER SPRAY PATTERN Fluttering or spitting spray Insufficient fluid supply. Loose or cracked coupler at fluid inlet. Air in paint supply line Adjust fluid regulator or fill fluid tank. Tighten or repair. Check, tighten siphon hose connections, bleed air from paint line. Irregular pattern Pattern pushed to one side, same side of air cap gets dirty Tails in pattern Fluid build-up or spray tip partially plugged. Air horn holes on defective side of pattern partially or totally plugged. Air horn holes partially or totally plugged. Insufficient air pressure. Fluid pressure too low. Clean spray tip. Clean air horn holes with solvent and soft brush. Clean air horn holes with solvent and soft brush. Increase air pressure. Increase fluid pressure.

12 GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Air leakage from front of gun. Air valve not seating properly. Clean, service. See page 21. Air stem packing too tight. Loosen packing. See page 21. Fluid leakage from front of gun. Orange Peel finish. Loose or worn fluid seat. Loose spray tip. Insufficient air pressure. Using too large of a spray tip. Fluid poorly mixed or filtered. Improper thinner being used. Tighten or replace fluid seat and/or electrode. See page 16. Tighten spray tip. Increase, use least air pressure needed for good results. Use a smaller size spray tip. Remix or refilter fluid. Use proper thinner. Excessive spray fog. Too much air pressure. Fluid thinned too much. Reduce,use least air pressure needed for good results. Properly thin fluid. No fluid sprays from gun. Fluid low. Check, add if necessary. Broken fluid needle shaft. Replace needle. Dirty or clogged spray tip. Clean spray tip. See page 10. Damaged spray tip. Check, replace spray tip. See page 9. Equipment covered with fluid. Exhaust air flow insufficient or not directed properly. Improper distance between gun and work piece. Check for proper CFM, check baffles, and direction of air flow. Adjust distance to mm (8 12 in.).

13 ELECTRICAL TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Poor wrap around. *ES ON OFF lever in OFF position. Turn lever to ON. *Turbine alternator not operating Check if ES ON OFF lever is ON. Check air supply to gun. Check for dirt or moisture in turbine. See page 23. Improper distance between gun Adjust spraying distance to and work piece mm (8 12 in.). Parts poorly grounded. Clean hangers, check for proper ground on conveyer or track. High booth exhaust velocity. Reduce within code limits. Atomizing air pressure too high. Reduce air pressure. *Fluid resistivity too low. Check fluid resistivity with paint meter and probe. *Faulty gun resistance. Check gun resistance. See page 14. *Faulty resistor stud resistance. Check resistor stud resistance. See page 15. *Faulty power supply resistance. Check power supply resistance. See page14. *Damaged electrode wire. Replace electrode wire. See page 16. *Faulty turbine alternator. Be sure plug is in place on back of turbine alternator housing.remove and test turbine alternator. See page 20. Operator gets mild shock. Operator gets mild shock when touching work piece. Operator not properly grounded or is in contact with ungrounded object. Gun not properly grounded. Work piece not properly grounded. Be sure floor is properly grounded. Wear shoes with conductive soles or wear personal grounding straps. Be sure operator is not in contact with or carrying any metallic items which could build up electrical charge. If worn, a glove must be conductive or modified as shown on page 8. See Check the Electrical Grounding, page 7. Be sure Graco air supply hose is being used and is properly grounded. Clean work piece hangers. Check for proper ground on conveyor or track. *ES indicator light not on when gun is triggered.

14 ELECTRICAL TESTS The performance of the spray gun is directly affected by the condition of the electrical components contained inside the gun. The electrical tests below can be used to determine the condition of the power supply (3) and the ball housing and resistor (14) as well as the continuity of the electrical path between components. Use megohmmeter (see ACCESSORIES) and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown. To reduce the risk of sparking, which could cause fire or explosion and result in serious bodily injury, including electrostatic shock, DO NOT use the megohmmeter in the hazardous area. Remove the gun from the hazardous area before testing it. 32 Gun Handle 32a Air Inlet Fitting A Megohmmeter GG Electrode A Test Gun Resistance NOTE: Check the resistance with the gun triggered and with the trigger released. Measure the resistance between the end of the electrode wire (GG) and the gun air fitting (32a). See Fig 7. The resistance should be between megohms. If the resistance is outside the specified range, go to the next test. If the resistance is correct, refer to the Electrical Troubleshooting Chart on page 13 for other possible causes of poor performance. GG 32 Test Power Supply Resistance Remove the power cartridge (1) from the gun handle (32). See Power Cartridge Replacement. Remove the turbine alternator (1a) from the power supply (3). See Turbine Alternator Removal. Fig 7 3b Contact Pin A Megohmmeter HH Center Connector Prong 32a A Measure the resistance from the center prong (HH) in the power supply to the contact spring (3b) on the other end of the power supply. See Fig 8. The resistance should be megohms. If the resistance is outside the specified range, the power supply is defective and must be replaced. If the resistance of the power supply is correct, proceed to the next test. If you still have problems, refer to the Electrical Troubleshooting Chart for other possible causes of poor performance, or contact the nearest authorized service agency. 3b Fig 8 3 HH

15 ELECTRICAL TESTS Test Resistor Stud Resistance Insert a conductive rod (JJ) into the gun barrel (removed for the power supply test) and against the metal contact (KK) in the front of the barrel. See Fig 9. Measure the resistance between the conductive rod (JJ) and the gun electrode (GG). The resistance should be megohms. If the resistance is correct, refer to the Electrical Troubleshooting Chart for other possible causes of poor performance, or contact the nearest authorized service agency. 9 Gun Barrel A Megohmmeter JJ Conductive Rod KK Metal Contact GG Electrode A If the resistance is outside the specified range, remove the electrode wire (GG). See Electrode Wire Replacement. Measure the resistance between the conductive rod (JJ) and the resistor (LL) in the outside diameter of ball seat housing (14). See Fig 10. The resistance should be megohms. If the resistance is correct, the electrode wire is defective and must be replaced. See Electrode Wire Replacement. If the resistance is outside the specified range, the resistor is defective and the ball seat housing (14) must be replaced. See Ball Seat Housing & Resistor Replacement. GG KK 9 JJ If you still have problems, refer to the Electrical Troubleshooting Chart for other possible causes of poor performance, or contact the nearest authorized service agency. Fig 9 A JJ 14 Fig 10 LL 14 Ball Seat Housing A Megohmmeter JJ Conductive Rod LL Resistor

16 SERVICE Gun Disassembly Installing and servicing this equipment requires access to parts which may cause electrostatic shock or other serious bodily injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified. Follow the Pressure Relief Procedure Warning, page 11, before servicing the gun or any part of the system. Disconnect the fluid hose from the gun. NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun. CAUTION If the plastic parts of the gun must be held securely, ALWAYS clamp them in padded vice jaws to prevent damage to the parts. ALWAYS lubricate o rings and seals with petroleum jelly. ALWAYS remove gun from worksite for service or repair. Service or repair area must be clean. NOTE: A box of ten electrodes is included in the tool kit (63). Ball Seat Housing & Resistor Replacement 1. Unscrew the retaining nut (11). Remove the air cap (12) and spray tip (13). See Fig Insert the special wrench (63d) in the front of the gun. While triggering the gun, unscrew the ball seat housing (14) and remove it. See Fig If you are replacing the fluid needle assembly, do not reassemble the gun. If no further service is required, install the new housing in the reverse order of disassembly. Torque the ball seat housing to 1.1 N m (10 in-lb) (snug); DO NOT OVER TIGHTEN. CAUTION DO NOT over tighten the ball seat housing (14). Excess torque will damage the housing. 14 Ball Seat Housing 63d Wrench Flush the gun as described under Flush the Spray Gun. Follow the Pressure Relief Procedure Warning on page 11. Disconnect the air and fluid line from the gun. 11 Retaining Nut 12 Air Cap 13 Spray Tip GG Electrode Wire 63d 14 Torque to 1.1 N m (10 in-lb) 63d GG 14 Fig Electrode Wire Replacement 1. Unscrew the retaining nut (11). Remove the air cap (12) and spray tip (13). See Fig Use a needle nose pliers to gently pull the electrode wire (GG) out the back of the spray tip. 3. Install the long end of the new wire in the hole closest to the tab of the tip. See Fig 11. Push the wire in, aligning the short end of the wire with the other hole in the tip. Pull on the front of the wire to seat it. Fig 12

17 SERVICE Barrel Removal 1. Remove the retaining nut, air cap, and spray tip. 2. Unscrew the fluid tube connector (FF) at the bottom of the fluid tube (20), then pull the tube out of the inlet. See Fig If you are replacing the needle, insert the special wrench (63d) in the front of the gun. While triggering the gun, unscrew the ball seat housing (14) and remove it. See Fig Remove the trigger screws, spacers, and trigger. 5. Remove the ES indicator lights. Using the wrench (63f) supplied, loosen and remove the two socket head cap screws (45) from the gun. See Fig Hold the gun handle (32) with one hand and pull the gun barrel (9) straight up to remove it. See Fig 14. CAUTION To avoid damaging the power cartridge, always pull the gun barrel straight up. If necessary, gently move the gun barrel from side to side to free it from the gun handle. NOTE: The gasket (4) should be left in the gun handle (32) if the gasket is not to be replaced. Barrel Reassembly 1. If the needle assembly was removed, reinstall it as described on page Fluid Tube 20a Washer 45 Cap Screw 63f Wrench FF Fluid Tube Connector Fig 13 FF 20a 1 Power Cartridge 4 Gasket 9 Gun Barrel 32 Gun Handle f Be sure the gasket (4) is in place. Replace if damaged. Place the barrel over the power cartridge (1) and onto the gun handle (32). See Fig Install the two socket head cap screws (45) and tighten with the wrench (63f) supplied. See Fig 13. Snap the ES indicator lights in place over the socket head cap screws. 4. Insert the fluid tube (20) into the fluid inlet of the gun barrel, making sure the washer (20a) is in place, and tighten the fluid tube connector (FF). See Fig If the ball seat housing (14) was removed, insert the pressing tool (63c) [see Fig 15] in the front of the gun and gently push the needle back before sliding the trigger into place and installing the screws and spacers. Then remove the tool and reinstall the ball seat housing (see page 16). 6. Install the air cap, spray tip, and retaining nut. Test the gun resistance as instructed on page 14. Fig Trigger 44 ES Indicator Lights 63c Pressing Tool 77 Screw Fig Torque to N m (10 12 in-lb) 63c

18 SERVICE Fluid Needle Replacement 1. Remove the gun barrel (9) as instructed on page 17. If the power cartridge comes out, carefully press it back into the handle. 2. Insert the narrow end of the pressing tool (63c) through the front of the gun to push the needle back, then remove the nut (21) and the adjustment nut (17a). See Fig Press the needle assembly (17) out the front of the gun as far as you can with a finger, or by pressing it against a flat surface. Then use the wrench (63f) to finish pushing it out. See Fig a Adjustment Nut 21 Nut 63c Pressing Tool 21 17a Bottom of thread 4. Remove the nut (17a) from the new needle assembly. Then install the new needle assembly through the front of the gun. Insert the narrow end of the pressing tool (63c) into the front of the gun and press to seat the needle. See Fig Install the new adjustment nut (17a), hex end first, onto the needle. 6. Use the pressing tool (63c) to press on the needle from the front of the gun, then screw the adjusting nut (17a) all the way to the bottom of the threads. Remove the pressing tool. 7. Screw the other nut (21) firmly against the adjustment nut to lock them together. 8. Reassemble the gun as described in Barrel Reassembly. 17 Needle Assembly 17a Adjustment Nut 21 Nut 63f Wrench Fig a 21 63f Fig 17 63c Check the Gun Safety Latch Check to be sure the gun safety latch works properly each time after you change the needle. Safety latch failure or improper use of the safety latch can result in accidental gun triggering, which could cause fluid injection or splashing fluid into the eyes or on skin and result in serious injury. Fig 18 Trigger MUST NOT touch nut (17a) when safety latch is locked. 17a SPRAY LOCK TEST 1 Engage the trigger safety latch to the right, then try to trigger the gun. Look behind the trigger to be sure it is not engaging the nut (17a). Then engage the latch to the left and check again. See Fig 18. TEST 2 Disengage the trigger safety latch, and trigger the gun gently to see if you can feel the lead and lag operation, which means the air will come on before the fluid does, and the fluid shuts off before the air does. If the gun fails either TEST 1 or 2: Remove the trigger and the ball seat housing. Back the nuts (17a, 21) away from the bottom of the threads. Reassemble and check Tests 1 and 2 again. Also check in front of the trigger to make sure the needle still moves. If the trigger still fails any of these tests now, the needle assembly (17) is out of tolerance and must be replaced.

19 SERVICE 1 Power Cartridge 1a Turbine Alternator 1b O Rings 1c Plug 3a O Ring 3b Spring 3c O Ring 4 Gasket 9 Barrel 9b Cushion 32 Gun Handle 9 4 3b 3a 3 3c 1b 9b See NOTE after step 3, below. NOTE: The power cartridge (1) includes items 1a 1c, and 3a 3c. 1a 1c 32 Fig 19 Power Cartridge Replacement 1. Remove the barrel as described under Barrel Removal. 2. Remove the gasket (4) from the gun. See Fig 19. CAUTION The power cartridge is fragile. Be careful when handling it to avoid damage. 3. Grasp the power cartridge (1) with your hand. With a gentle side to side motion, pull it free from the gun handle (32). Then pull the power cartridge straight out of the handle. CAUTION DO NOT use solvents to clean the power cartridge cavity in the gun handle (32). Solvent will damage electrical components contained in the power cartridge. Inspect the power cartridge cavity in the handle for dirt or moisture. Clean out the cavity with a clean, dry rag if necessary. Moisture and other contaminants may damage electronic circuitry. NOTE: The cushion (9b) is part of the gun barrel and should never be removed. If it ever is removed, push the cushion, adhesive side in toward the barrel, with a rod until it is securely adhered in the barrel. DO NOT use the power supply (3) to press the cushion into the barrel as it will not adhere properly. 4. Lightly lubricate the o rings (1b, 3a, 3c) on the new power cartridge with petroleum jelly. Insert the new power cartridge in the gun handle. NOTE: See Fig 20 for proper alignment of the power cartridge (1) in the gun handle (32). 5. Install the gasket (4) in the gun handle (32). 6. Install the barrel on the handle as described under Barrel Removal. 1 Power Cartridge 32 Gun Handle 32 1 All the o rings (1b, 3a, 3c) and the compression spring (3b) must be in place or the gun will malfunction. Fig 20

20 SERVICE Turbine Alternator Removal 1. Remove the power cartridge from the gun handle as described under Power Cartridge Replacement. 2. Carefully twist the turbine alternator (1a) counterclockwise and pull it off the power supply (3) until just disengaged from the coupling (MM). Then continue to slowly pull the turbine alternator away from the power supply, disconnecting the 3-wire connector (NN). See Fig Using an ohmmeter, test the coil in the turbine alternator (1a). Measure the resistance between the two outer terminals of the 3-wire connector (NN). The resistance should be 3 to 5 ohms. If the reading varies from this value, replace the alternator. 4. Measure the resistance between each outer terminal of the 3-wire connector (NN) and the turbine alternator housing (1a). The resistance should be infinite. If the resistance is not infinite, replace the alternator. 6. Slide the turbine alternator (1a) onto the power supply, being sure to align the coupling between the power supply and the turbine alternator housing. Then twist the turbine alternator clockwise to lock the coupling. 7. Install the power cartridge in the gun handle as described under Power Cartridge Replacement. 1a Alternator 3 Power Supply MM Coupling NN 3 Wire Connector 3 MM NN 1a 5. Partially connect the 3-wire connector (NN) onto the prongs inside the power supply (3). See Fig 21. Using a small screwdriver, push the connector onto the prongs until seated. Fig 21

21 SERVICE Fan Air Valve Replacement 1. Turn the fan adjusting knob (48) fully clockwise. 2. Place a wrench on the flats of the air valve housing (47) and remove it from the handle (32). See Fig Remove the retaining ring (39). 4. Rotate the air adjusting screw (48) clockwise until it is disengaged from the valve housing threads. Pull the adjusting screw out of the valve housing (47). 5. Clean all the parts and inspect them for wear or damage. If replacing the seal (40), unscrew it counterclockwise and remove it from the adjusting screw. 6. Apply medium grade thread sealant to the small threads on the end of the adjusting screw (48) and install a new seal (40). (Remember the screw has a left hand thread.) 7. When reassembling the fan air valve, lubricate the o-ring (46) and the adjusting screw (48) threads with petroleum jelly. 8. After the retaining ring (39) is installed on the adjusting screw (48), back the adjusting screw out of the valve housing (47) until it bottoms out against the retaining ring. 9. Apply PTFE paste to the threads of the valve housing (47) and install it in the handle (32). Torque the housing to N m (10 12 in lb). 32 Gun Handle 39 Retaining Ring 40 Valve Seal 46 O-Ring 47 Air Valve Housing 48 Air Adjusting Screw 32 Air Valve Replacement 1. Using a screwdriver, remove the retainer (57), spring (55), and air valve (54). See Fig Remove the trigger by removing the screws and the spacers from the gun. 3. Using wrench (63b), unscrew and remove the guide (52) and packing (53) from the front of the gun handle (32). CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction. 4. Apply PTFE tape to the threads of the guide (52). Install the new packing (53) and guide in the front of the gun handle (32). Tighten the guide finger tight only. 5. Install the new air valve (54) and spring (55) into the back of the gun handle (32). 6. Apply petroleum jelly to the threads of the retainer (57) and the o-ring (56). Install the retainer in the back of the gun handle (32) and tighten with a screwdriver. 7. Reinstall the trigger with the screws and spacers. 8. Squeeze the trigger and tighten the guide (52) just until the valve (54) will not return when the trigger is released. Then loosen the guide just enough so the valve stem returns freely when the gun is triggered and released. 32 Gun Handle 52 Guide 53 Packing 54 Air Valve Assembly 55 Spring 56 O-Ring 57 Retainer Apply PTFE tape Torque to N m (10 12 in lb) Fig 22 Fig Apply PTFE tape 53

22 SERVICE ES ON OFF Valve Removal & Replacement 1. Loosen and remove the nut (49). Remove the lever (51) and washer (50). See Fig 24. Insert the hex head wrench (63e) into the hex end of the valve (38), and loosen and remove the valve. 2. Clean and inspect parts for wear or damage. Replace if necessary. Lubricate the o rings (37) and valve (38) with petroleum jelly. 3. Install the regulator disc (2) so that the beveled face of the disc faces into the valve (38). 4. Install the valve (38) with the regulator disc (2) and o rings (37) into the gun handle so that the larger opening of the valve cylinder faces toward the front of the gun handle. 5. Install the wave washer (50), lever (51), and nut (49) on the valve stem. Tighten the nut and torque it to N m (2 in lb). 2 Regulator Disk 37 O Ring 38 Air Valve Nut 50 Wave Washer 51 Valve Lever Torque to N m (2 in lb) Fig 24 Muffler, Check Valve, & Inlet Filter Replacement 1. Remove the fluid inlet fitting (25). See Fig Remove the screw (22). 3. Be sure the flats of the adapter (24) and the flats of the air inlet fitting (32a) are properly aligned with the bracket (28), then remove the bracket and bulkhead retainer (75) from the gun handle a 33 Apply sealant to outside surface 4. Pull the muffler (33) from the gun handle and replace with a new muffler. 5. Insert a 3.18 mm (0.125 in.) rod into one of the holes in the valve check retainer (29) and pry it out of the bracket (28). Be ready to catch the ball (31) and spring (30) as the valve check retainer (29) is removed. 6. Install a new ball (31) and spring (30) in the bracket (28). Snap the valve check retainer (29) back into place on the bracket. 7. Attach the bracket (28) and bulkhead retainer (75) to the gun handle with the screw (22). 8. Install a new filter (26) in the adapter (24) Screw 24 Adapter 25 Fluid Inlet Fitting 26 Fluid Filter 28 Bracket 29 Valve Check Retainer 30 Spring 31 Ball 32a Air Inlet Fitting 33 Muffler 75 Bulkhead Retainer Install the fluid fitting (25). There will be a small space between the hexes of the fitting and adapter; do not over tighten them. Fig 25

23 REPAIR KITS Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. When servicing use only genuine Graco replacement parts. Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in serious injury, fire, explosion, electrostatic shock, or property damage. NOTE: The Ref. Nos. shown in the kits below correspond to the reference numbers used in the parts list on page 25. For the best results, use all the parts in the kit, even if the old parts still look good. High Air Flow Restrictor Kit Use with standard air cap Includes: Ref No. Part No. Description Qty RESTRICTOR SPRING, compression BALL; 3/16 diameter 2 Low Air Flow Restrictor Kit * Includes: Ref No. Part No. Description Qty RESTRICTOR SPRING, compression BALL; 3/16 diameter 2 *MUST also order Air Cap Optional Air Cap MUST be used with Low Air Flow Restrictor Kit , at left. Must order separately. Spray Gun Repair Kit Includes: Ref No. Part No. Description Qty 1b O RING, buna N REGULATOR, disc 1 3a O RING, fluorocarbon 1 3c O RING, Viton GASKET, housing 1 13a WASHER, non-metallic 1 20a WASHER, PTFE O-RING, Viton O-RING, Viton O-RING, PTFE O-RING, Viton 1 MANUAL CHANGE SUMMARY The manual was changed from Rev. P to Rev. R to delete spray tip from the SPRAY TIP SELECTION CHART.

24 PARTS DRAWING Part No , Series B Model PRO AA4000 Gun 37* 2* 38 37* * *3c 1a b* * 48 *3a 3b 9b * a Apply Loctite Torque to 3.4 N m (25 in-lb) 33 REF a* * a 29 9a 44 REF *20a Ref No 63, Tool Kit Includes items 63a 63g *20a 63c 63b 63g REF d 63f 63a 25

25 PARTS LIST REF NO. PART NO. DESCRIPTION QTY POWER CARTRIDGE; Includes items 1a and 3 1 1a ALTERNATOR, turbine; Includes item 1b 1 1b* O RING, buna N 2 2* REGULATOR, disc POWER SUPPLY; Includes items 3a. 3b, and 3c 1 3a* O RING, fluorocarbon 1 3b SPRING, compression 1 3c* O RING, Viton 1 4* GASKET, housing 1 5** LABEL, warning BARREL, gun; Includes item 9a 1 9a PLUG, M3 x 0.5 x 6 1 9b CUSHION NUT, retaining, air cap AIR CAP (see page 23 for optional low air flow air cap) SPRAY TIP, fluid; mm (0.011 ) Includes item 13a. See page 30 for other part numbers 1 13a* WASHER, non-metallic HOUSING, ball seat; (includes resistor) NEEDLE, fluid; Includes item 17a 1 17a NUT, adjustment TRIGGER TUBE, fluid, nylon; Includes item 20a 1 20a* WASHER, PTFE NUT, mach, hex; M4 x SCREW, mach, cross pan hd; M5 x RETAINER, filter CONNECTOR, fluid FILTER, tip, BRACKET RETAINER SPRING, compression BALL, bearing HANDLE, gun; Includes item 32a 1 32a FITTING, air inlet MUFFLER 1 REF NO. PART NO. DESCRIPTION QTY PLUG, pipe; hdls; 1/8 27 npt 1 37* O-RING; Viton VALVE, air RING, retaining, external SEAL, valve, acetal BALL; 3/16 dia SPRING, compression RESTRICTOR LIGHT, indicator, ES SCREW, cap, socket hd; M5 x 0.8 x * O-RING, Viton HOUSING, valve SCREW, adjusting NUT, cap; No , nylon WASHER, wave LEVER, valve GUIDE, stem 1 53* O-RING, PTFE VALVE, air SPRING, compression 1 56* O-RING, Viton RETAINER, spring 1 58** SIGN, warning, English (not shown) 1 59** SIGN, warning, Spanish (not shown) COVER, gun (not shown) TOOL KIT; Includes items 63a 63g 1 63a BRUSH, cleaning 1 63b WRENCH, nut, packing 1 63c TOOL, pressing 1 63d WRENCH, ball seat housing 1 63f WRENCH, barrel 1 63g ELECTRODES, box of RETAINER, bulkhead SPACER SCREW, trigger 2 78** TAG, warning (not shown) 1 *Included in Repair Kit See page 23. **Extra warning tags, labels, and signs are available at no charge from Graco. When servicing use only genuine Graco replacement parts. Use of other parts or any modification of the gun could alter the grounding continuity of the gun or cause parts to rupture and result in serious injury, fire, explosion, electrostatic shock, or property damage.

26 ACCESSORIES Accessories must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. NEVER operate your equipment at a working pressure rating that is higher than the lowest rated component in your system. Lower rated components may not be able to withstand the pressure developed by the pump and may rupture, causing serious bodily injury or property damage. AIR LINE ACCESSORIES Grounded Air Supply Hose FM Approved 7 bar (100 psi) MAXIMUM WORKING PRESSURE 8 mm (0.315 in.) ID; 1/4 npsm(f) x 1/4 npsm(f) LH; Color coded black Part No. Length m (6 ft) m (15 ft) m (25 ft) m (36 ft) m (50 ft) m (75 ft) m (100 ft) Grounded Air Supply Hose FM Approved 7 bar (100 psi) MAXIMUM WORKING PRESSURE 8 mm (0.315 in.) ID; 1/4 npsm(f) x 1/4 npsm(f) LH; Color coded gray; More flexible than black hose Part No. Length m (6 ft) m (15 ft) m (25 ft) m (36 ft) m (50 ft) m (75 ft) m (100 ft) Grounded Air Supply Hose 100 psi (7 bar) MAXIMUM WORKING PRESSURE 8 mm (0.315 in.) ID; 1/4 npsm(f) x 1/4 npsm(f) LH; Color coded red; Stainless steel braid ground path Part No. Length m (6 ft) m (15 ft) m (25 ft) m (36 ft) m (50 ft) m (75 ft) m (100 ft) Quick Disconnect Coupling Assy FM Approved Includes a quick disconnect coupling insert, which replaces air inlet fitting , and a shut-off coupling body (left-hand thread), which connects to the grounded air hose. Air Adapter Nipple For connecting two or more grounded gun air supply hoses. 1/4 npt x 1/4 npsm (left-hand thread) High Volume Air Regulator bar (0 125 psi) Regulated Pressure 14 bar (200 psi) Steel Pressure Gauge 1/2 npt(f) inlet and outlet Air Pressure Regulator bar (300 psi) MAXIMUM WORKING PRESSURE 1/2 npt(f) inlet and outlet Air Pressure Gauge bar (0 200 psi) Regulated Pressure Air Filter & Moisture Separator 17.5 bar (250 psi) MAXIMUM WORKING PRESSURE For cleaning and drying air in air spray system. 20 micron element, 5 oz. bowl capacity /8 npt(f) /2 npt(f) Air Line Lubricator 17.5 bar (250 psi) MAXIMUM WORKING PRESSURE /8 npt(f) /2 npt(f) Bleed-type Master Air Valve bar (300 psi) MAXIMUM WORKING PRESSURE Relieves air trapped in the air line between the paint pump air motor and this valve when closed. 3/4 npt

27 ACCESSORIES FLUID LINE ACCESSORIES Fluid Hose Assemblies FM Approved 207 bar (3000 psi) MAXIMUM WORKING PRESSURE Nylon tube, Urethane Cover Part No. ID Length Thread Size mm (3/16 in) 0.61 m (2 ft) 1/4 npsm(f) mm (3/16 in) 0.91 m (3 ft) 1/4 npsm(m x f) mm (3/16 in) 1.8 m (6 ft) 1/4 npsm(f) mm (3/16 in) 7.6 m (25 ft) 1/4 npsm(f) mm (3/16 in) 15.2 m (50 ft) 1/4 npsm(f) mm (1/4 in) 0.4 m (14 in) 1/4 npsm(f) mm (1/4 in) 0.6 m (2 ft) 1/4 npsm(f) mm (1/4 in) 0.9 m (3 ft) 1/4 npsm(f) x 1/4 npt(m) mm (1/4 in) 4.6 m (15 ft) 1/4 npsm(f) mm (1/4 in) 7.6 m (25 ft) 1/4 npsm(f) mm (1/4 in) 15.2 m (50 ft) 1/4 npsm(f) Corrosion Resistant Fluid Hose bar (3000 psi) MAXIMUM WORKING PRESSURE PTFE tube, SST cover, SST couplings 6.4 mm (1/4 in.) ID, 483 mm (19 in.) long, 1/4 npsm(f) SST Fluid Pressure Regulator bar (1500 psi) MAXIMUM FLUID INLET PRESSURE bar ( psi) REGULATED PRESSURE SST Fluid Pressure Regulator bar ( psi) REGULATED PRESSURE To convert Standard Fluid Pressure Regulator to 70 bar (1000 psi) Maximum Working Pressure, order the following parts: Part No. Description Compression Spring Fluid Pressure Gauge 0 70 bar ( psi) range Fluid Filters 207 bar (3000 psi) MAXIMUM WORKING PRESSURE Part No. Description With aluminum bowl and support With carbon steel bowl and support Stainless Steel Screens Part No. Description micron (30 mesh) micron (60 mesh) micron (100 mesh micron (200 mesh) High Pressure Ball Valves 350 bar (5000 psi) MAXIMUM WORKING PRESSURE Install in outlets for individual fluid line control or install in bottom of filter bowl as fluid drain valve. Part No. Description /2 npt(m), Viton seals /8 npt(m), Viton seals /8 x 1/4 npt(m), Viton seals /4 npt(m), PTFE seals PUMP & SPRAY SYSTEM ACCESSORIES 10:1 Ratio Monark Pump bar (950 psi) MAXIMUM WORKING PRESSURE Pump Suction Hose Pail Suction Tube Drum Suction Tube Cart Wall Bracket Electrostatic System Includes items: Part No. Description Manual E/S Air-Assisted Airless Gun Grounded Air Supply Hose (See page 26 for specifications) Fluid Hose (See page 26 for specifications) Air Filter Pro AA :1 Ratio Monark Cart System Includes System , 10:1 Ratio Monark Pump, Cart, and additional accessories Pro AA :1 Ratio Monark Pail System Includes system , 10:1 Ratio Monark Pump, and additional accessories Pro AA :1 Ratio Monark Wall Mount System Includes system , 10:1 Ratio Monark Pump, Wall Bracket, and additional accessories

28 ACCESSORIES MISCELLANEOUS ACCESSORIES Paint Resistance Meter Used with Paint Probe to measure resistance of paint. Not for use in Hazardous areas. Compression Spring For increased shut-off force when spraying plural component materials Paint Probe Used with Paint Resistance Meter to measure resistance of paint. Not for use in Hazardous areas. Megohmmeter Volt output; megohms Not for use in Hazardous areas. Grounding Clamp And Wire ga, 25 ft (7.6 m) wire Gun Cover Package of 10 disposable gun covers. Electrode Wires Box of 10 replacement electrode wires for spray tip. Warning Signs FM Approved Available from Graco at no extra charge. Must be ordered separately. Part No. Description Warning Sign (English) Warning Sign (French) Warning Sign (German) Warning Sign (Spanish)

29 TECHNICAL DATA Weight Kg (1.90 lb) Gun Length mm (12.25 in.) Maximum Working Fluid Pressure bar (950 psi) Maximum Working Air Pressure bar (100 psi) Voltage Operating Range to 75 KV Air Inlet /4 npsm(m) L.H. Fluid Inlet / (m) Wetted Parts Stainless Steel, Acetal, UHMW Polyethylene, Nylon, Carbide, PTFE, Delrin Delrin and Viton are registered trademarks of the DuPont Co. GRACO PHONE NUMBERS TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: Toll Free FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Graco equipment: Toll Free Loctite is a registered trademark of the Loctite Corp. AIR FLOW CHART AIR FLOW WITH THE FAN ADJUSTMENT SET FOR THE WIDEST PATTERN AND THE TURBINE ON AIR CAP AIR CAP NOTES: Air Cap requires use of Standard Restrictor, part no Air Cap MUST be used with Low Air Flow Restrictor Kit, part no (see page 23). Air flow will increase if the fan adjustment valve is opened to temporarily reduce pattern size. Flows will reach 24 SCFM at 80 psi (5.6 bar) with Air Cap

30 SPRAY TIP SELECTION CHART Part Number Fan Width at 300 mm (12 in.) mm (in.) Orifice Size mm (in.) Light to Medium Viscosity* ml/min (fl oz/min) Heavy Viscosity liters/min ((fl oz/min) (2 4) (0.007) 100 (3.4) (4 6) (6 8) (4 6) (0.009) 200 (6.8) (6 8) (8 10) (4 6) (0.011) 300 (10.1) (6 8) (8 10) (10 12) (12 14) (4 6) (0.013) 400 (13.5) (6 8) (8 10) (10 12) (12 14) (4 6) (0.015) 500 (16.9) (6 8) (8 10) (10 12) (12 14) (4 6) (0.017) 700 (23.7) 500 (16.9) (6 8) (8 10) (10 12) (12 14)

31 SPRAY TIP SELECTION CHART Part Number Fan Width at 300 mm (12 in.) mm (in.) Orifice Size mm (in.) Light to Medium Viscosity* ml/min (fl oz/min) Heavy Viscosity* liters/min ((fl oz/min) (6 8) (0.019) 800 (27.0) 600 (20.3) (8 10) (10 12) (12 14) (14 16) (8 10) (0.021) 1000 (33.8) 800 (27.0) (10 12) (12 14) (14 16) (16 18) (8 10) (0.023) 1200 (40.6) 970 (32.8) (10 12) (12 14) (14 16) (16 18) (8 10) (0.025) 1500 (50.7) 1200 (40.6) (10 12) (12 14) (14 16) (16 18) *Fluid Output at 41 bar (600 psi). The fluid output (Q) at other pressures (P) can be calculated by this formula: Q= (0.041) (QT) ( P ) Where QT = Fluid output (fl oz/min) from the above table for the selected orifice size. NOTE: Other tips are available on special work order. Allow 4 to 6 weeks for delivery. The maximum orifice size is mm (0 025 in). Spray Tip Selection Chart continued on next page.

32 SPRAY TIP SELECTION CHART Round Pattern Kits Kit Spray Tip Tip Size Part No. Part No. in. (mm) (0.432) (0.279) (0.330) (0.381) (0.229) (not included) Kit (see chart) (included with tip) Spray Tip (see chart) 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 workmanship on the date of sale by an authorized 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 from the date of sale, repair or replace any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor and transportation. DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale. EQUIPMENT NOT COVERED BY GRACO WARRANTY Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.) Foreign Offices: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN PRINTED IN U.S.A Revised 1 93