INSTRUCTIONS–PARTS LIST 307–638 Rev. AE This manual contains IMPORTANT WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE Model PRO4000 MANUAL MID–RANGE ELECTROSTATIC AIR SPRAY GUN 7 bar (100 psi) MAXIMUM WORKING AIR and FLUID PRESSURE Part Number 218–026, Series E With 1.2 mm (0.047 in.) fluid nozzle, part no. 218–996 U.S. Patent No. 4,290,091; 4,219,865; 4,462,061; 4,497,447; 4,660,774 U.K. Patent No.
TABLE OF CONTENTS Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5 How The Electrostatic Air Spray Gun Works . . . . 5 Installation Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . . . Connect the Air Line . . . . .
SAFETY WARNINGS SERIOUS BODILY INJURY, EXPLOSION, FIRE, OR ELECTRIC SHOCK CAN OCCUR IF THE PRECAUTIONS BELOW ARE NOT FOLLOWED. READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNING LABELS BEFORE OPERATING EQUIPMENT. ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIED PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS STATED WITHIN THIS INSTRUCTION MANUAL.
FIRE OR EXPLOSION HAZARD To reduce the risk of fire, explosion, or electric shock, which may result from electrical discharge, it is essential that: S S S 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.
TYPICAL INSTALLATION M A T N B C D S O E H G W G P J X R K Q F WARNING SIGN L U V NON–HAZARDOUS AREA HAZARDOUS AREA Power Supply Must Be Interlocked With Spray Booth Exhaust Fan.
INSTALLATION Ventilate the Spray Booth WARNING 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. Check and follow all of the National, State and Local codes regarding air exhaust velocity requirements. Check and follow all local safety and fire codes and OSHA standard 1910–107(b)(5)(i).
INSTALLATION Check the Electrical Grounding (See Fig 1) WARNING Proper electrical grounding of every part of your system is essential. For your safety, read the warning section, FIRE OR EXPLOSION HAZARD, on page 5. Ground the system as explained there. Then check your system as explained below. KEY Y Z AA BB Gun Handle True Earth Ground Ohmmeter Grounded Air Hose Z AA 1. Turn the ES On–Off valve to OFF. See Fig 2 for the location of the valve lever. 2. Turn off the air and fluid supply to the gun.
OPERATION WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin, injury from moving parts or electric 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. Turn the ES ON–OFF Valve lever to OFF. 2. Turn off the air and fluid supply to the gun. 3.
OPERATION Install the Fluid Nozzle and Air Cap WARNING To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Procedure on page 9 before installing, or removing the fluid nozzle/air cap assembly. 1. See Instruction Manual 307–803 for air cap consumption and fluid nozzle flow rate information. The fluid output and pattern shape depends on the fluid nozzle size, fluid viscosity, and fluid pressure. 2.
MAINTENANCE Daily Care and Cleaning WARNING To reduce the risk of serious bodily injury, including splashing in the eyes or on the skin or electric shock, always follow the Pressure Relief Procedure Warning on page 9 when shutting off the system, when you stop spraying and before checking, servicing, installing, cleaning or changing any part in the system. CAUTION Clean all parts with a non–conductive solvent, compatible with the fluid being sprayed. Conductive solvents can cause the gun to malfunction.
MAINTENANCE Flush the Spray Gun WARNING To reduce the risk of fire or explosion and serious bodily injury, the ES ON–OFF lever must be OFF before flushing. 4. Flush the gun with solvent until it is clean. 5. Follow the Pressure Relief Procedure Warning, then disconnect the solvent supply. 6. Reconnect the fluid supply line. 1. Follow the Pressure Relief Procedure Warning on page 9. 7. Turn on the fluid and air supplies. 2. Disconnect and plug the fluid line. 8.
SPRAY PATTERN TROUBLESHOOTING CHART WARNING Installing and servicing this equipment requires access to parts which may cause electric 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.
GUN OPERATION TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Leakage from fluid packing nut. Worn needle packing. Replace packing assembly. See page 21. Air leakage from front of gun. Air valve not seating properly. Clean, service. See page 24. Air stem packing too tight. Loosen packing. See page 24. Fluid leakage from front of gun. Electrode worn or damaged. Replace electrode. See page 18. Worn fluid seat. Replace fluid nozzle and/or electrode. See page 18. Fluid packing too tight.
ELECTRICAL TROUBLESHOOTING CHART PROBLEM Poor wrap–around. Operator gets mild shock. Operator gets mild shock when touching work piece. CAUSE SOLUTION *ES ON–OFF lever in OFF position. Turn lever to ON. Improper distance between gun and workpiece. Adjust spraying distance to 203–305 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.
ELECTRICAL TESTS $! ,!-"+-) * ! +" /$! .,- 4 #0* %. %-! /(4 ""! /! 4 /$! +* %/%+* +" /$! !(! /-% ( +),+*!*/. +*/ %*! %*6 .% ! /$! #0* $! !(! /-% ( /!./. !(+2 * ! 0.! /+ !/!-)%*! /$! +* %/%+* +" /$! ,+2!- .0,,(4 * /$! -!.%./+- ./0 . 2!(( . /$! +*/%*0%/4 +" /$! !(! /-%6 ( , /$ !/2!!* /$! +),+*!*/. KEY A 2 2a 12 !#+$))!/! 0* * (! %- %//%*# (! /-+ ! .! )!#+$))!/!- .!! ACCESSORIES * * ,,(%! 1+(/ #! +" 1+(/. /+ +),(!/! /$!.! !(! /-% ( /!./.
ELECTRICAL TESTS Test Resistor Stud Resistance $( ') %$ * )!+ '% !$)% ) *$ '' " ' / #%+ %' ) &%, ' (*&&"- ) () $ !$() ) # ) " %$) ) !$ ) '%$) % ) '' " ! (*' ) ' (!() $ ), $ ) %$ * )!+ '% $ ) *$ " )'% ' (!() $ ( %*" # % #( ) ' (!() $ !( %'' ) ' ' )% ) Electrical Troubleshooting Chart %' %) ' &%((!/ " *( ( % &%%' & ' %'# $ %' %$) ) ) $ ' () *) %'!.
SERVICE Gun Disassembly ăWARNINGĂ (-. &&#(! ( - ,0# #(! ."#- +/#*' (. , +/#, -- .) * ,.- 1"# " ' 2 /- & .,# -") % ), )." , - ,#)/- ) #&2 #($/,2 # ." 1),% #- (). * ,4 ),' *,)* ,&2 ) (). #(-. && ), - ,0# ."# +/#*' (. /(& -- 2)/ , ., #( ( +/ &# # )&&)1 ." Pressure Relief Procedure Warning, * ! ), - ,0# #(! ." !/( ), (2 * ,. ) ." -2-. ' #- )(( . ." &/# ")- ,)' ." !/( (-. && ." ( 1 & .,) 1#." ." 1, ( " -/**&# ) (). )0 ,.#!".
SERVICE Resistor Stud Replacement ăWARNINGĂ Old/New Style Resistor Stud and Electrode , ."!1 " 0%" .&/( ,# /- .(&+$ 3%& % ,1)! 1/" #&." ,. "4-),/&,+ 0%" ")" 0.,!" +! /01! 5,1 &+/0 )) ." ) ( %" ,)! /05)" ")" 0.,!" +! /01! &+ 0%" ".&"/ 1+/ 3"." 3%&0" *&4 ,)! /05)" - .0/ 3&0% +"3 /05)" - .0/ /&+$ 0%" 3."+ % /1--)&"! &+/0 )) 0%" ."/&/0,. /01! &+ 0%" #.,+0 ,# 0%" $1+ ..") &$%0"+ 1+0&) /+1$ +/0 )) 0%" ")" 0.,!" / !"/ .
SERVICE Barrel Removal KEY )- ,!1 .$! )/. . .$! ,,!' "'/% %)'!. !! %# /'' .$! "'/% ./ ! */. *" .$! "'/% %)'!. 19 20 30 59f /. '/% / ! +- ,!1 ,!) $ !(*0! .$! .,%##!, 2 ,!(*0%)# .$! - ,!1- ) -+ !,- ",*( .$! #/) !(*0! .$! %) % .*, '%#$.- ",*( .$! -* &!. $! +- ,!1- " -%)# .$! 1,!) $ " -/++'%! '**-!) ) ,!4 (*0! .$! .1* -* &!. $! +- ,!1- ",*( .$! #/) *' .$! #/) $ ) '! 1%.$ *)! $ ) ) +/'' -., %#$. /+ .
SERVICE 5. Carefully remove the fluid needle assembly (45) from the rear part of the gun barrel (18). See Fig 15. If the packing assembly (45a) or insulator (45g) are still in the barrel, insert the packing removal rod (59d) into the front of the barrel to gently push them out. Refer to Fig 16. NOTE: If the insulator (45g) is removed, be sure to install it so the insulator end with holes is facing the packing assembly (45a). 6. Wipe the internal surfaces of the barrel clean with a soft brush or cloth.
SERVICE KEY 2 3a 3b 3c 5 5a 5b 5c 18 18b 46 5a Gun Handle Alternator O–Ring Plug Power Supply O–Ring O–Ring Spring Barrel Cushion Gasket 5 5b 46 5c 18 3b 18b See NOTE after step 3, below. NOTE: The power cartridge (3) includes items 3a, 3b, 3c, and 5. 3c 2 3a Fig 17 Power Cartridge Replacement 1. Remove the barrel as described under Barrel Removal. 2. Remove the gasket (46) from the gun. See Fig 17. CAUTION The power cartridge is fragile. Be careful when handling it to avoid damage. 3.
SERVICE Turbine Alternator Removal 1. Remove power cartridge from the gun handle as described under Power Cartridge Replacement. 7. Install the power cartridge in the gun handle as described under Power Cartridge Replacement. KEY 2. Carefully twist the turbine alternator (3a) counterclockwise and pull it off the power supply (5) until just disengaged from the coupling. Then continue to slowly pull the turbine alternator away from the power supply, disconnecting the 3-wire connector (HH). See Fig 19.
SERVICE Fan Air Valve Replacement 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. 1. Using a screwdriver, remove the retainer (27), spring (26), and air valve (25). See Fig 21. 2. Remove the retaining ring (31). 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. 3.
SERVICE ES ON–OFF Valve Removal & Replacement Muffler and Check Valve Replacement 1. Loosen and remove the nut (35). Remove the lever (37) and washer (36). See Fig 22. Insert the hex head wrench into the hex end of the valve (39), and turn it to loosen and remove the valve. 1. Remove the screw (71), adapter retainer (70) and bulkhead retainer (85) from the gun handle. See Fig 23. 2. Clean and inspect parts for wear or damage. Replace if necessary.
PARTS DRAWING 4* Ref No 59, Tool Kit Includes items 59a–59h 59f *38 55 2 39 38* 59e 28 29* 76 *3b 59h 59d 59g 72 59c 27 23 73 36 74 37 33 32* 59a 34 *5a 40 31 24 Apply PTFE Tape 5 47* 2a 3a 63 5c Screw in restrictors flush with surface of gun handle *5b Ref No.
PARTS LIST REF NO. PART NO. DESCRIPTION 2 2a 3 218–014 179–400 218–111 3a 217–591 3b* 3c 4* 5 107–106 180–070 107–107 218–041 HANDLE, gun; Includes item 2a .ADAPTER POWER CARTRIDGE; Includes items 3a and 5 ALTERNATOR, turbine; Includes items 3b & 3c .O–RING, buna-n .PLUG REGULATOR, disc POWER SUPPLY; Includes items 5a–5c .O–RING; Viton .O–RING; Viton .
REPAIR KITS Repair Kits must be purchased separately. Use only GENUINE GRACO PARTS AND ACCESSORIES. WARNING When servicing use only genuine Graco replacement parts. Use of other parts or any alteration or modification of this equipment could result in serious injury, fire, explosion, or property damage. NOTE: The Ref. Nos. shown in the kits below correspond to the reference numbers used in the parts list on page 27. For the best results, use all the parts in the kit, even if the old parts still look good.
TECHNICAL DATA SERVICE INFORMATION 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 Operating Range: 0–7 bar (0–100 psi) Voltage Operating Range . . . . . . . . . . . . . . . . . . 0–75 KV Paint Resistivity Range . . . . 7 megohm cms to infinity Air Inlet . . . . . . . . . . . . .
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 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. The accessories in the box, below, are approved by Factory Mutual.
ACCESSORIES FILTER (AIR OR PAINT) 202–271 52 bar (750 psi)MAXIMUM WORKING PRESSURE With 250 micron (60 mesh) element, 3/8 npt(f) inlet, 3/8 npt(m) outlet SPRAY SYSTEM ACCESSORIES 218–118 ELECTROSTATIC SYSTEM Includes items: 218–026 Manual Electrostatic Air Spray Gun 218–103 Grounded Air Supply Hose (See page 30 for specifications) 216–077 Fluid Hose (See page 30 for specifications) 106–148 Air Filter 218–123 ELECTROSTATIC SYSTEM Includes items: 218–026 Manual Electrostatic Air Spray Gun 218–101 Grounded Ai
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 Graco distributor to the original purchaser for use.
