Graco 3A0149E User Manual

Instructions - Parts List

Model G15

TI6553A

Model G40

TI6844A

TI7204B

Model G40 w/RAC tip

3A0149E

G15/G40 Spray Gun

A lightweight line of air-assisted spray guns for spraying and finishing a variety of paints and coatings, particularly in applications requiring uniform atomization and high transfer efficiency. For professional use only.

Important Safety Instructions:

Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information including maximum working pressure.

II 2 G

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flush Before Using Equipment . . . . . . . . . . . . . . 8

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8

Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 8

Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8

Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . 8

Reverse-A-Clean

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Assembly . . . . . . . 9

(RAC) Tip . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fan Valve Replacement . . . . . . . . . . . . . . . . . . . 20

Complete Gun Packing Repair . . . . . . . . . . . . . 20

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 32

Spray Tips, for use with G15/G40 Air Cap . . . . . 32

RAC SwitchTips, for use with

G40 RAC Air Cap . . . . . . . . . . . . . . . . . . . . 33

RAC SwitchTips, for use with

G40 RAC Air Cap, Continued . . . . . . . . . . . 34

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Part Interchangeability Guide . . . . . . . . . . . . . . 37

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40

2 3A0149E

Models

Part Series

24C853 A

24C854 A

24C855 A

24C856 A

24C857 A

Maximum Working

Air Pressure

psi (MPa, bar)

100 (0.7, 7.0) 1500 (10.5, 105)

100 (0.7, 7.0) 4000 (28, 280)

Maximum Working

Fluid Pressure

psi (MPa, bar) Description Includes:

G15 Medium Pressure Air-Assisted Spray Gun, Carbide Seat and Ball

G15 Medium Pressure Air-Assisted Spray Gun, Plastic Seat, SST Ball

G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and Ball

G40 High Pressure, High Flow Air-Assisted Spray Gun, Carbide Seat and Ball

G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and

Ball, Reverse-A-Clean

(RAC) Tip

24C866

Air Cap

with pin

249180 Air Cap

without

24C921

RAC

Air Cap

3A0149E 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 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.

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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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 the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

4 3A0149E

Warnings

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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• 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.

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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

3A0149E 5

Installation

TI6554A

Installation

Typical Installation

NOTE: 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.

Grounding

• 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.

FIG. 1: Typical Installation (Model G15 Shown)

Key:

A Air Line Filter B Air Shutoff Valve C Gun Air Pressure Regulator DAir Line ESpray Gun F Electrically Conductive Fluid Hose G Gun Air Supply Hose

6 3A0149E

Installation

TI6556A

TI4838A

TI6846A

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 F

IG. 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.

NOTE: 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 F

IG. 2.

Fluid Line

• Before connecting the fluid line, blow it out with air

and flush it with solvent. See Flushing and Clean- ing, page 14. 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.

NOTE: 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 F

IG. 4. If desired, install a fluid swivel connector

(189018) at the gun inlet for best maneuverability. See Accessories, page 35.

IG. 2

6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See F

IG. 3.

FIG. 4

3. Connect the other end of the fluid hose (F) to the pump fluid outlet.

IG. 3

3A0149E 7

Setup

TI6847A

Slot

Tip locating tab

Horizontal air cap position (standard)

Vertical air cap position

TI6558A

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 Proce-

dure, page 10.

Select a Spray Tip

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 32. Contact your Graco distributor for assistance in selecting an appropriate spray tip for your application.

Air Cap Alignment Pin

Model G15 guns 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 F 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 will not work with model G40 guns.

IG. 5. When relocating

FIG. 5

Install a Spray Tip

Install a spray tip in the air cap. Ensure that the tip locating tab is positioned in the slot of the air cap. See F

IG. 5.

Position the Air Cap

Assemble the air cap to the gun. The air cap and spray tip position determine 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. 6. For the G15 air cap, the alignment pin will

stop the rotation in the proper orientation.

NOTICE

The alignment pin and retaining ring for current model guns are different from the earlier model guns. They are not interchangeable. Use of the incorrect pin will result in fluid leakage or loss of the alignment feature. Use of the wrong retaining ring will damage retaining ring and gun threads. See Part Interchangeability Guide, page 37.

8 3A0149E

IG. 6

Tighten the air cap retaining ring (6) firmly by hand to ensure a good seal between the tip gasket and the diffuser (5).

Reverse-A-Clean® (RAC) Tip Assembly

TI7196A

TI7197A

TI7198A

TI7199A

Setup

Model 24C857 guns use a Reverse-A-Clean® (RAC) tip.

To assemble the RAC tip, insert the seat housing into the air cap assembly.

IG. 7

Insert the SwitchTip.

Screw the RAC tip assembly onto the gun and tighten firmly by hand.

FIG. 10

NOTICE

The RAC assembly for current model guns uses a different seat housing and has a coarser thread than the RAC assembly for earlier model guns. They are not interchangeable. Use of the incorrect RAC assembly will damage the threads. See

Part Interchangeability Guide, page 37.

IG. 8

Insert the gasket seat.

IG. 9

3A0149E 9

Operation

TI6555A

TI6581A TI6582A

ENGAGED

DISENGAGED

Operation

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 a skin injection injury occur. Additional cards are available at no charge from Graco.

Pressure Relief Procedure

FIG. 11

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

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.

1. Engage the trigger lock. See F

2. Shut off the pump. See your pump manual.

3. Shut off the gun air supply.

4. Disengage the trigger lock. See F

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. See F

IG. 11.

IG. 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 F

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.

IG. 12.

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.

10 3A0149E

IG. 12

Operation

TI6559A

OPEN

no air

too little air correct amount

of air

TI0792A

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

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.

4. Close off the pattern adjustment air by turning the knob clockwise (in) all the way. See F sets the gun for its widest pattern.

FIG. 13

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 F

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 F 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.)

IG. 14. Seven to 10 psi (4.9 to

IG. 13. This

IG. 13. If

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 Ratio

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.

3A0149E 11

x Pump Air Regulator

Setting

=Fluid

Pressure

IG. 14

Operation

TI6561A

TI6562A

INCORRECT

CORRECT

HVLP Operation

NOTE: For HVLP operation, the atomization air must not

exceed 10 psi. Use HVLP Verification Kit 24C788 to verify air psi.

NOTE: There is no fan adjustment when using RAC tips and caps.

Fluid Application

Always hold the gun at a right angle from the surface. Do not make an arc with the gun as it causes an uneven coat of fluid. See F

IG. 15.

1. To achieve the best results when applying fluid, keep the gun perpendicular to the surface and maintain a consistent distance of approximately 8 to 12 in. (200 to 300 mm) from the object being sprayed.

2. To obtain an even finish, use smooth, even strokes across the object being sprayed with 50% overlap.

3. Paint using parallel strokes. This spray gun applies all coatings evenly without cross coating.

IG. 15

12 3A0149E

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