Graco Inc 288046, 311052E, 288217 User Manual
Instructions - Parts
Automatic G40 Air-Assisted
Spray Guns
For air-assisted spraying of paints and coatings. For professional use only.
Approved for use in explosive atmospheres.
4000 psi (28 MPa, 280 bar) Maximum Working Fluid Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure
See page 3 for model information.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
311052E
ENG
Part No. 288046 Spray Gun shown
mounted on Part No. 288217 Manifold
TI8087b
II 2 G c T6
Related Manuals
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ventilate Spray Booth . . . . . . . . . . . . . . . . . . . . . 6
Configure Gun and Manifold . . . . . . . . . . . . . . . . 6
Install Air Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mount Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connect Air Line . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Fluid Line . . . . . . . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flush Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . 11
Select a Spray Tip and Air Cap . . . . . . . . . . . . . 11
Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 11
Position the Air Cap . . . . . . . . . . . . . . . . . . . . . 11
Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
Adjust Spray Pattern . . . . . . . . . . . . . . . . . . . . . 12
Apply Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Daily Gun Care . . . . . . . . . . . . . . . . . . . . . . . . . 14
General System Maintenance . . . . . . . . . . . . . . 15
Flushing and Cleaning . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Troubleshooting . . . . . . . . . . . . . . . . . . 17
Spray Pattern Troubleshooting . . . . . . . . . . . . . 19
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diffuser Seat Replacement . . . . . . . . . . . . . . . . 23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AAP Series Tip and Air Cap Selection Charts . . . 31
LTX Series RAC Tip Selection Charts . . . . . . . . . 32
RAC Switch Tips . . . . . . . . . . . . . . . . . . . . . . . . 33
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . 37
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
Related Manuals
The Automatic Air-Assisted Airless Spray Guns manual is available in the following languages. See the following
chart for specific language and part number.
Manual Language
Manual Language
311052
311651
311652
311653
311654
311655
311656
311657
English
Chinese
Danish
Dutch
Finnish
French
German
Italian
311658
311659
311660
311661
311662
311663
311664
Japanese
Korean
Norwegian
Polish
Russian
Spanish
Swedish
2 311052E
Models
A manifold is required for each gun to be installed.
Refer to the Parts section for manifold information.
Models
G40 Standard Spray Gun, 288046, Series A
• High pressure spray gun with Carbide ball and Carbide seat.
• Includes AAP series tip of choice.
G40 Plastic Seat Spray Gun, 288044, Series B
• Medium pressure spray gun with SST ball and plastic seat; for acid catalyzed or thin fluids.
• Best results when used with non-abrasive fluids at
pressures below 1500 psi (10.5 MPa,105 bar).
• Includes AAP series tip of choice.
G40 RAC Spray Gun, 288053, Series A
• High pressure spray gun with AA Reverse-A-Clean
(RAC) assembly; and Carbide ball and Carbide
Seat.
• Includes LTX Series RAC tip of choice.
311052E 3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• 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. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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 the 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 working fire extinguisher in the work area.
4 311052E
Warnings
WARNING
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
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
311052E 5
Installation
Installation
Ventilate Spray Booth
Check and follow all National, State, and Local
codes regarding air exhaust velocity requirements.
Check and follow all local safety and fire codes.
Configure Gun and Manifold
The gun is supplied with an internal fluid plug and seals
(5, 6, 7). To use the gun in a circulating system, remove
the internal plug. In a non-circulating system, leave the
plug in place to minimize flush time.
Circulating System
1. Apply anti-seize lubricant 222955 to the threads and
mating faces of the manifold (101) and the elbows
(107), supplied unassembled.
2. Install the elbows (107) in both fluid ports of the
manifold (101).
3. Connect the fluid supply line to one elbow and the
fluid return line to the other. The manifold fluid ports
are reversible.
4. Install the gun on the manifold, using the four
screws (17). Start the threads of all four screws, and
tighten the front two screws first, and then tighten
the back two screws to 65 in-lb (7.3 N•m).
Non-circulating System
1. See FIG. 1. Apply anti-seize lubricant 222955 to the
threads and mating faces of the manifold (101), plug
(109), and elbow (107), supplied unassembled.
2. Install an elbow (107) in one fluid port of the manifold (101), and a plug (109) in the other port.
3. Install the internal plug (5) in the gun fluid port on
the same side as the manifold plug.
4. Connect the fluid supply line to the manifold elbow
(107).
5. Install the gun on the manifold, using the four
screws (17). Start the threads of all four screws, and
tighten the front two screws first, and then tighten
the back two screws to 65 in-lb (7.3 N•m).
1
Remove when used in circulating systems.
2
Replace with a reducing nipple (107) when used in
circulating systems.
3
Install optional filter in fluid inlet port. See Accessories,
page 34.
7
3
6
101
5
2
1
109
107
TI8587b
FIG. 1: Non-Circulating Setup Shown (cutaway view)
6 311052E
Installation
Install Air Fittings
1. Install the supplied 1/4 in. tube fitting into the cylinder (CYL) air port.
2. Install 3/8 in. tube fittings into the atomization
(ATOM) air port and the fan (FAN) air port.
CYL
ATOM
TI8211a
F
IG. 2: Air Fittings
FAN
Ground System
Ground Air, Fluid, and Hydraulic Hoses
Connected To Pump
Use only electrically conductive hoses with a maximum
of 100 ft (30.5 m) combined hose length to ensure
grounding continuity. Check the electrical resistance of
your air and fluid hoses at least once a week. If the total
resistance to ground exceeds 25 megohms, replace the
hose immediately.
Use a meter that is capable of measuring resistance at this level.
Ground Spray Gun
Ground the spray gun by mounting it to a grounded
reciprocator and by connecting it to a properly grounded
fluid hose and pump.
Ground Fluid Supply Container
Ground the fluid supply container according to local
code.
The following grounding instructions are minimum
requirements for a system. Your system may include
other equipment or objects that must be grounded.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Your
system must be connected to a true earth ground.
Ground Pump
Ground the pump by connecting a ground wire and
clamp between the fluid supply and a true earth ground
as instructed in your separate pump instruction manual.
Ground Air Compressors and Hydraulic
Power Supplies
Ground air compressors and hydraulic power supplies
according to the manufacturer recommendations.
Ground Object Being Sprayed
Ground the object that is being sprayed according to
local code.
Ground Solvent Pails
Ground all solvent pails that are used when flushing
according to local code. Use only metal pails, which are
conductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which interrupts
the grounding continuity.
311052E 7
Installation
Mount Gun
Reciprocating Arm Rod Mount
To mount the gun on a reciprocating arm rod [0.5 in. (13
mm) diameter maximum]:
1. Insert the mounting bar (A) through the hole in the
manifold as shown in F
Use the 1/8 in. alignment pin (P) to assist in orienting the gun.
2. Secure the gun to the bar by tightening the mounting screw (B).
P
A
F
IG. 3: Reciprocating Arm Mount
IG. 3.
B
TI8120a
2. Secure the gun to the support with two M5 x 0.8
capscrews (S). The screws must be long enough to
engage the threaded holes in the gun manifold to a
depth of 1/4 in. (6 mm).
TI8121a
S
IG. 4: Stationary Support Mount
F
Retrofit Adapter Plate
The retrofit adapter plate enables the manifold to be
attached to a variety of bolt patterns.
To mount the gun using the retrofit adapter plate (kit
288197):
1. Mount adapter plate to manifold using the three
screws provided with the kit (F
IG. 5).
Stationary Support
To mount the gun on a stationary support (refer to FIG.
4. and to Mounting Hole Layout, page 37):
1. Align the manifold with the alignment pins. Locate
alignment pins and holes per the Mounting Hole
Layout illustration, page 37.
2. Bolt plate to mounting surface using four M5 x 0.8
capscrews. Refer to the Mounting Hole Layout,
page 37.
F
IG. 5: Retrofit Adapter Plate
TI8180a
8 311052E
Connect Air Line
Installation
1. Install an air/water separator and an air line filter to
ensure a clean, dry air supply to the gun. Dirt and
moisture in the line can ruin the appearance of your
finished piece.
2. Install an air pressure regulator on each gun air supply line.
3. For manifolds with separate fan and atomization
ports, the gun cylinder, fan, and atomization air must
be supplied and regulated separately. For manual
valve manifolds, only one supply line is required for
both atomization and fan air.
A minimum of 50 psi (0.34 MPa, 3.4 bar) air pressure must be supplied to the cylinder for proper
operation. Set the atomization air as needed for
complete atomization of the entire pattern. The tip
size is the primary controller of the pattern size.
Use the fan air only as needed to slightly adjust the
pattern size.
4. Install a bleed-type master air shutoff valve on the
main air line. Install an additional bleed-type valve
on each pump air supply line, downstream of the
pump air regulator, to relieve air trapped between
this valve and the pump after the 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 injury.
5. Install a bleed-type air shutoff valve on each gun air
supply line, downstream of the gun air regulator, to
shut off air to the gun.
6. For manifolds with separate fan and atomization
ports, connect a separate air supply line to the gun
atomizing air inlet (D) and cylinder air inlet (C). Connect an air supply line to the fan air inlet (E) if
desired. See F
valve, only one supply line is required for both atomization and fan air.
IG. 6. For manifolds with a manual fan
The gun atomizing and fan air inlets are 3/8 in. (9.5
mm) O.D. tubing compatible. The cylinder air inlet
accepts 1/4 in. (6.3 mm) O.D. tubing.
311052E 9
Installation
Connect Fluid Line
Before connecting the fluid line, blow it out with air
and flush it with solvent. Use solvent that is compatible with the fluid to be sprayed.
A fluid drain valve(s) 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.
A fluid pressure regulator must be installed in the
system if the pump's maximum working pressure
exceeds the gun's maximum fluid working pressure
(see the front cover).
1. Install a fluid filter and drain valve(s) close to the
pump's fluid outlet.
G (or F)
FAN
C
F (or G)
ATO M
CYL
TI8113a
2. Install a fluid pressure regulator to control fluid pressure to the gun.
Some applications require fine-tuned control of fluid
pressure. You can control fluid pressure more accurately with a fluid pressure regulator than by regulating the air pressure to the pump.
3. Install a fluid shutoff valve to shut off the fluid supply
to the gun.
4. Install an in-line fluid filter on the gun fluid inlet (F) to
avoid clogging the spray tip with particles from the
fluid. See F
IG. 6.
5. In a circulating system, connect a grounded fluid
supply hose to the gun fluid fitting. Connect a
grounded return hose to the other port.
In a non-circulating system, remove the gun fluid
outlet fitting (G) and plug the outlet port with the
pipe plug (109) supplied.
KEY
Cylinder Air Inlet: accepts 1/4 in. (6.3 mm) O.D. tubing
C
D
Atomization Air Inlet: 1/4-18.6 npsm
E
Fan Air Inlet: 1/4-18.6 npsm
F
Fluid Inlet: 1/4-18 nptf or #5 JIC (1/2-20 unf)
G
Fluid Outlet (circulating gun only): 1/4-18 nptf or #5 JIC
(1/2-20 unf)
F
IG. 6: Side Mounted Manifold Ports
E
D
10 311052E
Setup
Setup
Flush Spray Gun
Before running any paint through the spray gun:
1. Flush the gun with a solvent that is compatible with
the fluid to be sprayed, using the lowest possible
fluid pressure and grounded metal container.
2. Perform Pressure Relief Procedure; see page 12.
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 page 31 and page 32 for spray tip selection charts.
Contact your Graco distributor for assistance in selecting an appropriate spray tip for your application.
Install a Spray Tip
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 F
IG. 8.
TI6558A
F
IG. 8
Air Cap Alignment Pin
Air caps are factory-set with an air cap alignment pin to
position the air cap. The standard location of the air cap
alignment pin is the vertical spray pattern.
1. Perform Pressure Relief Procedure, page 12.
2. Install a spray tip in the gun.
3. Align tip locating tab with slot on the air cap. See
F
IG. 7.
4. Tighten the air cap retaining ring (8) firmly by hand
to ensure a good seal between the tip gasket and
the diffuser (10).
Slot
Tip Locating Tab
FIG. 7
TI6847A
To change the spray pattern direction, use a needle
nose pliers to unscrew the pin and relocate it to the
desired position. See F
use low-strength thread locker. Torque to 1.5-2.5 in-lb
(0.2-0.3 N•m). Do not overtighten.
IG. 9
F
IG. 9. When relocating the pin
Horizontal
Air Cap Position
(standard)
Verti cal
Air Cap Position
TI6847A
311052E 11
Operation
Operation
Pressure Relief Procedure
1. Turn off the air and fluid supply to the gun.
2. Close the bleed-type master air valve (required in
the system).
3. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
TI8174a
Adjust Spray Pattern
The air-assisted spray gun combines airless and air
spray 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 fan air can be used if necessary to slightly adjust
the pattern size.
Air-assisted spray guns differ from air spray guns in
that increasing the fan air reduces the pattern
width. To increase the pattern width, use less fan
air or a larger size tip.
1. Set the fluid pressure at 300 psi (2.1 MPa, 21 bar)
with the fluid regulator.
FIG. 10: Pressure Relief
4. Open the pump drain valve (required in the system)
to 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 relieve fluid pressure in the hose and gun.
Have a container ready to catch the drainage.
5. Leave the drain valve(s) open until you are ready to
spray again.
6. If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully
relieved, very slowly loosen the hose end coupling
and relieve pressure gradually, then loosen the coupling completely. Clear the tip or hose obstruction.
For a narrower pattern, supply air to the gun fan air inlet
(or open the fan adjustment valve on manifold 288223).
The tip size is the primary controller of the pattern size.
Use the fan air only as needed to slightly adjust the pattern size.
2. Trigger the gun to check the atomization; do not be
concerned about the pattern shape yet.
3. Slowly Increase the fluid pressure just to the point
where a further increase in fluid pressure does not
significantly improve fluid atomization.
4. Turn on the atomizing air and set the air pressure at
about 10 psi (70 kPa, 0.7 bar). Check the spray pattern, and then adjust the air pressure until the tails
are completely atomized and pulled into the spray
pattern. See F
MPa, 7 bar) air pressure to the gun.
For HVLP operation do not exceed 10 psi at the air
cap. Use HVLP verification kit 249140 to measure
the atomization pressure at the air cap.
IG. 11. Do not exceed 100 psi (0.7
12 311052E
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