Instructions - Parts List
AA Series Spray Gun 311001F
For air-assisted spraying and finishing of paints and coatings.
Important Safety Instructions:
Read all warnings and instructions in this manual. Save these instructions.
See page 2 for List of Models and Table of Contents.
Model G15 |
TI6553A |
Model G40 |
TI6844A |
Model G40 w/RAC tip |
TI7204B |
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 |
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II 2 G |
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Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001 |
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Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flush Before Using Equipment . . . . . . . . . . . . . . 8
Select a Spray Tip and Air Cap . . . . . . . . . . . . . . 8
Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8
Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . 8
Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . 10
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How the Air-Assisted Spray Gun Operates . . . . 11
Spray Pattern Adjustment . . . . . . . . . . . . . . . . . 11
HVLP Operation . . . . . . . . . . . . . . . . . . . . . . . . 12
Fluid Application . . . . . . . . . . . . . . . . . . . . . . . . 12
Daily Gun Care, Flushing, and Cleaning . . . . . . . 13
General System Maintenance . . . . . . . . . . . . . . 14
Fluid Filter Maintenance . . . . . . . . . . . . . . . . . . 14
Flushing and Cleaning . . . . . . . . . . . . . . . . . . . 14
Reverse-A-Clean® (RAC) Tip . . . . . . . . . . . . . . 16
Clearing a clogged RAC tip . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Troubleshooting . . . . . . . . . . . . . . . . . . 18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Items Needed for Service . . . . . . . . . . . . . . . . . 20 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fan Valve Replacement . . . . . . . . . . . . . . . . . . . 20 Complete Gun Packing Repair . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20
Seat Repair 20 Needle Repair 21 Air Valve Repair 22
Fluid Tube Replacement 22
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 30
AAM Fine Finish Spray Tips 30
GG4 Industrial Spray Tips 30 LTX RAC Spray Tips 31
FFT Fine Finish RAC Spray Tips 32 WRX WideRAC Spray Tips 32
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36
Models
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Maximum |
Maximum |
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Working Air |
Working Fluid |
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Part |
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Pressure |
Pressure |
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No. |
Series |
psi (MPa, bar) |
psi (MPa, bar) |
Description |
Includes: |
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288844 |
A |
100 (0.7, 7.0) |
1500 (10.5, 105) |
G15 Medium Pressure |
249596 |
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Air-Assisted Spray Gun, Plastic |
Air Cap |
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Seat, SST Ball |
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287926 |
C |
100 (0.7, 7.0) |
1500 (10.5, 105) |
G15 Medium Pressure |
249596 |
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Air-Assisted Spray Gun, Carbide |
Air Cap |
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Seat and Ball |
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249242 |
C |
100 (0.7, 7.0) |
4000 (2.8, 280) |
G40 High Pressure Air-Assisted |
249180 |
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Spray Gun, Carbide Seat and Ball |
Air Cap |
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249246 |
B |
100 (0.7, 7.0) |
4000 (2.8, 280) |
G40 High Pressure, High Flow |
249180 |
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Air-Assisted Spray Gun, Carbide |
Air Cap |
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Seat and Ball |
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249238 |
B |
100 (0.7, 7.0) |
4000 (2.8, 280) |
G40 High Pressure Air-Assisted |
288465 |
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Spray Gun, Carbide Seat and Ball, |
RAC |
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Reverse-A-Clean® (RAC) Tip |
Air Cap |
2 |
311001F |
Related Manuals
This manual is available in the following languages:
Manual |
Language |
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311001 |
English |
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311145 |
Chinese |
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311146 |
Danish |
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311147 |
Dutch |
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311148 |
Finnish |
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311149 |
French |
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311150 |
German |
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311151 |
Italian |
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311152 |
Japanese |
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311153 |
Korean |
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311154 |
Norwegian |
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311155 |
Polish |
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311156 |
Russian |
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311157 |
Spanish |
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311158 |
Swedish |
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311001F |
3 |
Warnings
The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols that appear in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
•Ground all equipment in work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
•Keep a fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the spray tip.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Do not spray without tip guard and trigger guard installed.
•Engage trigger lock when not spraying.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.
•Do not alter or modify equipment.
•For professional use only.
•Use equipment only for its intended purpose. Call your Graco distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or overbend hoses or use hoses to pull equipment.
•Comply with all applicable safety regulations.
•Keep children and animals away from work area.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
4 |
311001F |
Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
•Hearing protection
311001F |
5 |
Installation
Typical Installation |
Grounding |
The typical installation shown in FIG. 1 is only a guide for selecting and installing air-assisted spray systems. Contact your Graco distributor for assistance in designing a system to meet your needs.
VENTILATE THE SPRAY BOOTH
To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. Do not 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.
Check your local electrical code and pump manual for detailed grounding instructions. Use only electrically conductive fluid hoses.
Ground the spray gun through connection to a properly grounded fluid supply hose and pump.
D
B
E
A G
C
TI6554A
FIG. 1: Typical Installation (Model G15 Shown) |
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F |
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Key: |
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A |
Air Line Filter |
E |
Spray Gun |
B |
Air Shutoff Valve |
F |
Electrically Conductive Fluid Hose |
C |
Gun Air Pressure Regulator |
G |
Gun Air Supply Hose |
D |
Air Line |
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6 |
311001F |
Air Line
1.Install an air filter (A) on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece. See FIG. 1.
2.Install an air pressure regulator (C) on the gun air line to control air pressure to the gun.
3.Install an air shutoff valve (B) on the gun air line and on the pump air line, to shut off air to the gun.
4.Use a 3/16 in. (5 mm) I.D. or larger air hose to minimize excessive pressure drop in the hose.
The gun air inlet has a 1/4-18 npsm (R1/4-19) compound male thread that is compatible with NPSM and BSP female swivel connectors.
5.Connect the air hose (G) to the 1/4 npsm gun air inlet. See FIG. 2.
Installation
Fluid Line
•Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.
•If better control of fluid pressure is needed, install a fluid regulator on the fluid line to better control fluid pressure to the gun.
1.Use a fluid filter to remove coarse particles and sediment, to avoid clogging the spray tip and causing finishing defects.
Guns are equipped with a built-in 100 mesh fluid filter to provide final filtering just before spraying.
2.Connect the fluid hose (F) to the gun fluid inlet. See FIG. 4. If desired, install a fluid swivel connector (115898) at the gun inlet for best maneuverability. See Accessories, page 33.
F
G
TI6846A
TI6556A
FIG. 4
FIG. 2
6.Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See FIG. 3.
B
G
C
A |
TI4838A |
FIG. 3
3.Connect the other end of the fluid hose (F) to the pump fluid outlet.
311001F |
7 |
Setup
Flush Before Using Equipment
1.The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flushing and Cleaning, page 14.
2.Relieve the pressure. See Pressure Relief Procedure, page 10.
Select a Spray Tip and Air Cap
The fluid flow and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. See Spray Tip Selection Chart, page 30. Contact your Graco distributor for assistance in selecting an appropriate spray tip for your application.
Install a Spray Tip
Install a spray tip in the gun. Ensure that the tip locating tab is positioned in the slot of the air cap. See FIG. 5. Tighten the air cap retaining ring (6) firmly by hand to ensure a good seal between the tip gasket and the diffuser (5).
Slot |
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Tip Locating Tab |
TI6847A |
FIG. 5
Position the Air Cap
The air cap and spray tip position determines the direction of the spray pattern.
Rotate the air cap (the spray tip rotates with it) as needed to achieve the desired spray pattern direction. See FIG. 6.
TI6558A
FIG. 6
Air Cap Alignment Pin
Model G15 guns (288844) use an air cap alignment pin to position the air cap. The standard location of the air cap alignment pin is the horizontal air cap position.
If you would like to change the spray pattern direction, use a needle nose pliers to unscrew the pin and relocate it to the desired position. See FIG. 7. When relocating the pin use low-strength thread locker. Torque to 1.5-2.5 in-lb (0.2-0.3 N•m). DO NOT OVERTIGHTEN.
The air cap alignment pin can be removed according to preference.
Air cap alignment pins do not come standard with model G40 guns (249242).
TI6847A
Horizontal
Air Cap Position
(standard)
Vertical
Air Cap Position
FIG. 7
8 |
311001F |
Reverse-A-Clean® (RAC) Tip
Model 249238 guns use a Reverse-A-Clean® (RAC) tip.
To assemble the RAC tip, insert the seat housing into the air cap assembly.
TI7196A
FIG. 8
Insert the SwitchTip.
TI7197A
FIG. 9
Setup
Insert the gasket seat.
TI7198A
FIG. 10
Screw the RAC tip assembly onto the gun and tighten firmly by hand.
TI7199A
FIG. 11
311001F |
9 |
Operation
Safety
SKIN INJECTION HAZARD
Remember, this is not an air spray gun. For your safety be sure to read and follow the Warnings on pages 4 and 5 and throughout the text of this instruction manual.
Keep the wallet sized warning card (222385), provided with the gun, with the operator of this equipment at all times. The card contains important treatment information should an injection injury occur. Additional cards are available at no charge from Graco.
Pressure Relief Procedure
SKIN INJECTION HAZARD
The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:
•are instructed to relieve the pressure,
•stop spraying,
•check or service any of the system equipment,
•or install or clean the spray tip.
Follow Pressure Relief Procedure on page 10 when you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read Warnings, page 4.
1.Engage the trigger lock. See FIG. 13.
2.Shut off the pump. See your pump manual.
3.Shut off the gun air supply.
4.Disengage the trigger lock. See FIG. 13.
5.Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. See FIG. 12.
TI6555A
FIG. 12
6.Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valve(s) open until you are ready to spray again.
7.Engage the trigger lock. See FIG. 13.
8.If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the tip guard retaining ring or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.
ENGAGED |
DISENGAGED |
TI6581A |
TI6582A |
FIG. 13
10 |
311001F |
How the Air-Assisted Spray Gun
Operates
The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the paint tails into the pattern to produce a more uniform pattern. The width of the pattern can be adjusted by the pattern adjustment valve.
The air-assisted spray gun differs from an air spray gun in that increasing the pattern air reduces the pattern width. To increase the pattern width, use less pattern air or a larger size tip.
The spray gun has a built-in lead and lag operation. When triggered, the gun begins emitting air before the fluid is discharged. When the trigger is released, the fluid stops before the air flow stops. This helps assure the spray is atomized and prevents fluid buildup on the air cap.
Spray Pattern Adjustment
SKIN INJECTION HAZARD
To reduce the risk of component rupture and serious injury, including injection, do not exceed the gun’s maximum fluid working pressure or the maximum working pressure of the lowest rated component in the system.
1.Do not turn on the gun air supply yet. Set the fluid pressure at a low starting pressure. If a fluid pressure regulator is installed, use it to make adjustments.
If your system does not have a fluid regulator, the fluid pressure is controlled by the air regulator supplying the pump, per the formula below:
Pump x Pump Air Regulator Setting = |
Fluid |
Ratio |
Pressure |
2.Trigger the gun to check the atomization; do not be concerned about the pattern shape yet.
Operation
3.Slowly increase the fluid pressure, just to the point where a further increase in fluid pressure does not significantly improve fluid atomization.
4.Close off the pattern adjustment air by turning the knob clockwise (in) all the way. See FIG. 14. This sets the gun for its widest pattern.
CLOSE
OPEN
TI6559A
FIG. 14
5.Set the atomizing air pressure at about 5 psi (3.5 kPa, 0.35 bar) when triggered. Check the spray pattern, then slowly increase the air pressure until the tails are completely atomized and pulled into the spray pattern. See FIG. 15. Seven to 10 psi (4.9 to 7.0 kPa, 0.49 to 0.7 bar) air pressure is typically enough to atomize the tails, especially for low viscosity materials. Setting the air pressure too high will cause material to build up on the air cap and decrease transfer efficiency. Do not exceed 100 psi (0.7 MPa, 7 bar) air pressure to the gun.
For a narrower pattern, turn the pattern adjustment valve knob counterclockwise (out). See FIG. 14. If the pattern is still not narrow enough, increase the air pressure to the gun slightly or use a different size tip. (Not available for RAC tip guns.)
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TI0792A |
no air |
too little air correct amount |
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of air |
FIG. 15
311001F |
11 |