INSTRUCTIONS–PARTS LIST
308–386
Rev. A
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
Refer to your gun instruction manual
308–294 for complete warnings and
instructions for safe operation.
PRO AA4500 Round Spray Conversion Kit
Part No. 236–902
For use with the PRO AA4500 Electrostatic Air-Assisted Airless Spray Gun only.
This kit changes the gun from the standard fan pattern spray to round pattern spray.
Installation
To help reduce spray tip clogging:
WARNING
Pressure Relief Procedure
To reduce the risk of serious injury, including fluid
injection and splashing in the eyes or on skin, or electrostatic shock, relieve all pressure in the system, as
instructed below, before installing the kit; checking or
servicing any part of the system; cleaning, installing, or
changing spray tips; and whenever you stop spraying.
1. Lock the spray gun trigger safety latch.
2. Turn the gun’s ES ON-OFF lever to the OFF position.
3. Shut off the power to the pump.
4. Close the bleed-type master air valve (required in
system).
5. Close the air valve for the gun air supply line.
6. Unlock the gun trigger safety latch.
7. Trigger the gun into a grounded metal waste container to relieve fluid and air pressure.
8. Lock the gun trigger safety latch again.
9. Open the pump drain valve (required in system) to
help relieve fluid pressure in the displacement pump.
In addition, open the drain valve connected to the
fluid pressure gauge (in a system with fluid regulation)
to help relieve fluid pressure in the hose and gun.
Triggering the gun to relieve pressure may not be
sufficient. Have a container ready to catch the drainage.
10. Leave the drain valve(s) open until you are ready to
spray again.
If you suspect that the spray tip or hose is completely
clogged or that pressure has not been fully relieved after
following the steps above, very slowly loosen the hose
end coupling and relieve pressure gradually, then loosen
completely. Now clear the tip or hose obstruction.
GRACO INC.
Install the 100 mesh in-line fluid filter, P/N 210–500, ahead
of the gun. See page 4 to order the filter.
Remove the gun fluid filter, P/N 205–264, and clean or
replace it. See gun manual 308–294 to remove the filter.
To install the kit:
1.
Flush the fluid passages as instructed in gun manual
308–294.
2.
Follow the Pressure Relief Procedure Warning, at left.
3.
Remove the retaining ring (A), tip guard (B), air cap (C)
and tip assembly (D). See Fig. 1.
C D
B
A
Fig. 1
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1994, GRACO INC.
02004A
55440–1441
Installing or Replacing the Electrode
Installation
4.
Install the kit diffuser/seal assembly (1), air cap/electrode
assembly (2), and cover (3) onto the gun. Tighten the
cover firmly. See Fig. 2. Be careful not to cross-thread
the cover onto the barrel.
If the electrode (2a) needs to be replaced or re-installed, insert the two ends of the electrode into the two small air cap
(2) holes until both electrode ends protrude through the front
of the air cap. Refer to Fig. 2, at left, and the Parts drawing,
page 4.
WARNING
Operation
To reduce the risk of electrostatic shock or explosion,
make sure the electrode is in place. Never operate the
spray gun with a bent, damaged or missing electrode.
WARNING
This equipment operates at 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 injury, including the need for
amputation. Also, fluid injected or splashed into the eyes
or on the skin can cause serious damage.
Be sure the electrode (2a) is in place in the air cap (2).
1
2
Never point the spray gun at anyone or at any part of
the body.
3
Never put hand or fingers over the spray tip.
4
Never try to “blow back” paint; this is not an air spray
gun.
Always lock the trigger safety latch when you are not
spraying.
2a
Always follow the Pressure Relief Procedure Warning, on the cover, before checking or servicing any
part of the system; cleaning or removing the spray tip;
and whenever you stop spraying.
Fig. 2
5.
Install the spray tip (4) and tighten it, using the wrench
(5) provided. See Fig. 3. When tightening, only grip the
end of the wrench with your fingers; do not grip the
wrench cross-arms (E).
Never try to stop or deflect leaks with your hand or
body.
Check operation of all equipment safety devices before each use.
See the gun instruction manual 308–294 for complete
warnings and instructions for safe operation.
CAUTION
Over tightening the spray tip (4) can damage the tip and
cause poor spray performance.
ES
OFF
Only grip the end of the wrench with your fingers;
do not grip the wrench cross-arms (E)
Air
Control
closed
5
Fig. 4
E
Fig. 3
01998
1.
Adjust the air hose inlet pressure according to the
instructions in the gun instruction manual 308–294.
2.
Turn the ES ON-OFF lever OFF and close the air control
knob. See Fig. 4.
Operation
3.
Atomization fluid pressure will vary based on the viscosity of the fluid, the flow rate desired, and other characteristics of your system. To adjust the fluid pressure to
achieve the desired flow rate:
a.
Use a starting fluid pressure of about 300 psi (21
bar) for light viscosity fluids (about 20 centipoise) or
about 600 psi (42 bar) for medium viscosity fluids
(about 42 centipoise).
b.
Spray quickly across a test surface (quick-pass),
holding the gun 12 inches (305 mm) from the surface. Note the atomization (particle size).
c.
4.
5.
Increase the fluid pressure by 100 psi (7 bar) increments and spray test patterns until the atomization
does not improve significantly (particle size no
longer reduces); do not exceed the gun’s Maximum
Fluid Pressure of 3000 psi (207 bar).
NOTE: See the Spray Tip Chart, page 3, for fluid flow
information. Refer to Spray Pattern Troubleshooting,
page 4, to correct spray pattern problems.
Use the gun‘s air control valve knob to adjust the air flow
to the air cap. Lower air flow will give a softer spray (less
velocity). Too little air may cause spitting.
Turn the ES ON-OFF lever to ON. The gun is now ready
to spray.
Tip Clogging
If the tip clogs, stop spraying immediately and follow the
Pressure Relief Procedure Warning on the front cover.
Remove the spray tip (4) with the wrench (5) provided. Use a
soft brush to clean the flow passages on the back side of the
tip plate and the front of the diffuser (1) with a compatible solvent (refer to Parts, page 4, for kit materials).
Flushing and Cleaning
WARNING
To reduce the risk of fire, explosion, or electrostatic shock,
be sure the ES ON-OFF lever is turned to OFF before
flushing or cleaning the gun or round spray kit parts.
1.
Follow the Pressure Relief Procedure Warning on the
front cover.
2.
Loosen the cover (3) and remove the round spray kit
parts (1, 2, 4). See Fig. 2.
Recommended Spraying Distance
The recommended spraying distance is 8 to 12 inches (203
to 305 mm), from the front of the gun to the object being
sprayed. Since the round pattern tip emits a very soft spray,
the electrostatic attraction of the floating particles is relatively
strong. To minimize having paint spray attracted to the gun
and operator, avoid spraying with the gun too far away from
the grounded object being sprayed.
NOTE: Use the wrench (5) provided to remove the spray
tip. See Fig. 3.
3.
Flush and clean the gun as instructed in manual
308–294.
4.
Use a soft brush to clean the round spray kit parts with a
compatible solvent (refer to Parts, page 4, for kit
materials).
Spray Tip Chart
Approximate Flow Rate for Light to Medium Viscosity Coatings (~20 to 40 centipoise)*
Part No.
Size No.
Flow at 300 psi (21 bar)
Flow at 600 psi (42 bar)
Flow at 1200 psi (84 bar)
236–836
4A
2.5 oz/min (73 cc/min)
4.1 oz/min (120 cc/min)
5.7 oz/min (170 cc/min)
236–837
6A
2.9 oz/min (86 cc/min)
5.1 oz/min (150 cc/min)
7.4 oz/min (220 cc/min)
236–838
7A
3.2 oz/min (95 cc/min)
5.4 oz/min (160 cc/min
7.8 oz/min (230 cc/min
236–839
5B
5.4 oz/min (160 cc/min)
7.8 oz/min (230 cc/min
11.0 oz/min (330 cc/min
236–840
7B
7.1 oz/min (210 cc/min)
9.1 oz/min (270 cc/min)
14.2 oz/min (420 cc/min)
236–841
9B
8.8 oz/min (260 cc/min)
11.8 oz/min (350 cc/min)
17.9 oz/min (530 cc/min)
236–842
11B
11.8 oz/min (350 cc/min)
16.2 oz/min (480 cc/min)
23.7 oz/min (700 cc/min)
* Flows based on white acrylic, enamel paint.
Spray Pattern
Troubleshooting
Problem
Possible Cause
Spray is too force- Air flow too high
ful (high velocity)
Spray tip worn
Diffuser worn
Fluid flow too high
Spray gun spitting
Air flow too low
Tip size too large
Tip clogging
Paint not properly
filtered
Tip size too small
Distorted spray
pattern (heavy to
one side)
Tip clogged
Worn or damaged
spray tip
Solution
Use gun air adjustment knob to
reduce air flow
Replace tip
Replace diffuser
Smaller spray tip
or lower pressure
Use gun air adjustment knob to
increase air flow
Try smaller size
tip
Parts
Part No. 236–902
PRO AA4500 Round Spray Conversion Kit
Ref.
No.
Part No.
Description
1
236–768
1a
2
183–459
236–769
2a
3
4
189–874
189–761
236–XXX
5
189–780
DIFFUSER/SEAL ASSY.
(stainless steel, ceramic, epoxy)
Includes item 1a
SEAL (UHMW polyethylene)
AIR CAP/ELECTRODE ASSY.
(acetal homopolymer)
Includes item 2a
ELECTRODE (stainless steel)
COVER (nylon)
SPRAY TIP (stainless steel, ceramic,
epoxy); customer choice; See
Spray Tip Chart, page 3
WRENCH
Clean or replace
gun filter; Install
line filter or clean/
replace line filter
Try larger tip size
Qty.
1
1
1
1
1
1
1
1a
1
2a
2
See above
Replace tip
4
3
5
Accessories
Fluid Filter 210–500
5000 psi (350 bar) Maximum Working Pressure
100 mesh in-line fluid filter. Fits onto the gun fluid connector
or the gun fluid whip hose.
1/4 npsm(f)
210–501
Graco Phone
Numbers
210–500
TO PLACE AN ORDER, contact your Graco distributor, or
call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
205–264
168–517
1/4 npt(m)
FOR TECHNICAL ASSISTANCE, service repair information
or assistance regarding the application of Graco equipment:
1–800–543–0339 Toll Free
Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC.
4
308-386
P.O. BOX 1441 MINNEAPOLIS, MN
PRINTED IN U.S.A.
308–386 7/94
55440–1441