This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
23:1
MONARK CARBON
STEEL, CART MOUNTED
ARTS LIST
308–457
Rev.
B
Supersedes A
AA200hs
Air-Assisted Airless
Spray Package
See the Data Sheet, 305–663, for application information.
2760 psi (190 bar) Maximum System Working Pressure
120 psi (8.3 bar) Maximum Air Inlet Pressure
Model 237–418, Series A
This
complete package includes a pump,
an AA200hs air-assisted airless–spray gun
with a 41
and fluid hoses,
air and fluid controls, and a fluid feed.
This manual provides the basic safety
operation information for the package. For your safety
also read the component manuals supplied with this
package before operating it.
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
WARNINGWARNING
INJECTION HAZARD
Spray
from the gun, hose leaks or ruptured components can inject fluid into your body and cause
extremely serious injury
can also cause can also cause serious injury
D
Fluid injected into the skin is a serious injury
ous injury
D
Do not point the spray gun at anyone or any part of the body
D
Do not put hand or fingers over the spray tip.
D
Do not stop or deflect fluid leaks with your hand, body
D
Do not “blow back” fluid; this is not an air spray system.
D
Always have the tip guard and the trigger guard on the spray gun when spraying.
D
Check the gun dif
D
Be sure the gun trigger safety operates before spraying the gun.
D
Lock the gun trigger safety when you stop spraying.
D
Follow the
checking or servicing the equipment.
. Get immediate medical attention.
Pressure relief procedure
, including the need for amputation. Splashing fluid in the eyes or on the skin
.
. The injury might look like just a cut, but it is a seri
.
, glove or rag.
fuser operation weekly
. Refer to the gun manual.
on page 8 if the spray tip clogs and before cleaning,
-
D T
ighten all fluid connections before each use.
D
Check the hoses, tubes and couplings daily
manently coupled hoses cannot be repaired.
D
Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and
hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to tempera
tures above 180
_F (82_
C) or below –40
. Replace worn or damaged parts immediately
_F (–40_C).
TOXIC FLUID HAZARD
Improper
even death, due to splashing in the eyes, ingestion, or bodily contamination.
D
D
D W
handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container
state and national guidelines.
ear appropriate clothing, gloves, eyewear and respirator
. Dispose hazardous fluid according to all local,
.
. Per
-
-
,
WARNINGWARNING
FIRE AND EXPLOSION HAZARD
Improper
and result in a fire or explosion and serious injury
D
D
D
D
D
D
D
D
D
grounding, poor air ventilation, open flames or sparks can cause a hazardous condition
.
Ground the equipment and the object being sprayed. See
If there is any static sparking while using the equipment,
and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid be
ing sprayed.
Do not smoke in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not turn on or of
Electrically disconnect all equipment in the spray area.
Keep the spray area free of debris, including solvent, rags and gasoline.
Do not operate a gasoline engine in the spray area.
f any light switch in the spray area.
Ground the system
stop spraying immediately
on 6.
. Identify
EQUIPMENT MISUSE HAZARD
Equipment
in serious injury
D
This equipment is for professional use only
misuse can cause the equipment to rupture, malfunction or start unexpectedly and result
.
.
-
Read all instruction manuals, tags, and labels before operating the equipment.
D
D
Use the equipment only for its intended purpose. If you are in doubt about this, call Graco T
cal Assistance at 1–800–543–0339.
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D
Check equipment daily
D
Do not exceed the
mum incoming air pressure
used with it.
D
Do not move or lift pressurized equipment.
D Use
D
D
D
fluids or solvents which are compatible with equipment
section
Fluid hoses must have spring guards on both ends to protect it from rupture caused by kinks or
bends at or close to the couplings.
Comply with all applicable local, state and national fire, electrical and other safety regulations.
Do not touch the heater during operation; it is very hot.
of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
. Repair or replace worn or damaged parts immediately
2760 psi (190 bar) maximum working pressure at 120 psi (8.3 bar) maxi
of the pump, or the maximum working pressure of any accessory
wetted parts. Refer to the Technical Data
.
MOVING PARTS HAZARD
Moving
amputate fingers.
parts, such as the air motor piston located behind the air motor plates, which can pinch or
echni-
-
D
Never operate the equipment with the air motor plates removed.
D
Keep clear of any moving parts when starting or operating the equipment.
Setup
I.Prepare the operator.
All
persons who operate the system should be trained
in the safe, efficient operation of all system compo
nents as well as the proper handling of the chemical
coating. At a minimum, all operators should
thoroughly read the safety
, installation and operation
sections of this manual and the component manuals.
II.Prepare the site.
1. Use
2.
3.
a minimum recommended 5
compressor for ef
ficient operation.
HP (3.7
Clear obstacles and debris that could hinder the
operator’
s movement.
Bring an air line from your compressed air supply
to the pump location. Be sure the air is dry and
filtered. Install a bleed–type master air valve (A)
upstream from the pump. Another master air valve
(14) is supplied with the package. When the
bleed–type master air valve is closed and the
pump air regulator (8a) is opened, the valve
relieves all air pressure to the system.
-
kW) air
4.
Have a grounded, metal waste–pail available to
use when draining the fluid filter
5. V
entilate the spray booth.
.
WARNING
T
o prevent hazardous concentrations of toxic and/
or flammable vapors, spray only in a properly venti
lated spray booth.
unless ventilation fans are operating.
Check and follow all of the national, state and local
codes
regarding air exhaust velocity requirements.
Never operate the spray gun
-
KEY
Components
A
B
A
B
C
D
E
C
you must supply:
Bleed-type master air valve
Required for pump; order
part no. 107–142, 1/4” npt(f)
Air filter
. Order part no.
106–149, 1/2 npt(f)
Air supply line
Grounded 5 gallon metal pail
Air line moisture trap
Components supplied with package:
1
23:1 Monark pump
3
Air-assisted airless spray gun
4
Spray tip
6
Gun fluid hose
7
Gun air hose
8a
Pump air regulator
8b
Gun air regulator
14
Bleed–type air valve
30
Pump ground wire
E
1
C30
3,4
6
8a
8b
7
14
D
Fig. 1
04072
Setup
III.Unpack the system.
1. In
addition to the assembled components, the air
and fluid hoses, gun and instruction manuals are
packaged separately in the main shipping con
tainer
. These are the manuals you should receive:
307–619
308–176
307–273
308–167
308–861
23:1 ratio Monark pump
Air-assisted airless spray gun
Fluid filter
Air regulator
Ball valve
IV.Connect the hoses and gun to the
system. See
1.
Connect the blue fluid hose (6) between the fluid
filter and the fluid inlet of the spray gun (3). These
are 1/4–18 npsm(f) swivel fittings.
Fig. 1.
V.Ground the system.
WARNING
-
To
reduce the risk of static sparking, ground the
pump and all other equipment used or located in
the spray area. Check your local electrical code for
detailed grounding instructions for your area and
type of equipment.
Also read
page 4
1.
Pump
connected to the air motor grounding lug. Connect
the clamp end of the ground wire to a true earth
ground.
2.
Air and fluid hoses
hoses with a maximum of 500 feet (150 m) com
bined hose length to ensure grounding continuity
3.
Air compressor
recommendations.
FIRE OR EXPLOSION HAZARD
.
: one end of the ground wire (30) is already
Ground all of this equipment.
on
: use only electrically conductive
: according to manufacturer’s
.
2.
Connect the red
regulator (8b) and the air inlet of the spray gun (3).
These are 1/4–18 npsm(f) swivel fittings.
3. V
erify that all fittings throughout the system are
tightened securely
air hose (7) between the gun air
.
4.
Fluid supply container:
5.
All solvent pails used when flushing
local code. Use only metal pails, which are con
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter
rupts the grounding continuity
according to local code.
, according to
.
-
-
6
308-457
System
Component Information
I.How to use the air–assisted airless
spray gun.
With
an air-assisted airless spray gun, the spray tip
shapes the fluid into a fan pattern. Air from the air cap
further atomizes the fluid and completes the atomiza
tion of the paint tails into the pattern to produce a more
uniform pattern.
The spray gun has a built-in lead and lag operation.
When triggered, the gun emits 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.
NOTE:
(R1/4–19) compound male threads that are compatible
with NPSM and BSP female swivel
connectors.
1.
The gun air and fluid inlets have 1/4–18 npsm
The fan pattern valve (E) can be used to reduce
the pattern by about 25% of the total pattern width.
As the valve is opened, the pattern will reduce
slightly
. The tip used designates the total width of
the spray pattern.
-
II.How to change the spray pattern
direction.
1. Relieve
2.
Install a spray tip in the gun. Rotate the air cap
(the spray tip rotates with it) to determine the
direction of the spray pattern. See Fig. 3.
ertical Spray Pattern
V
Fig. 3
the air and fluid pressure.
Horizontal Spray Pattern
0791
III.How to adjust the air regulators.
See
Fig.
4.
As you look at the system, the air regulator (8a) on the
left regulates air to the gun and the air regulator (8b)
on the right regulates air to the pump.
1.
Always open air regulators slowly to prevent surg
ing during startup.
-
2. T
o unlock the gun trigger safety, turn the safety so
it is parallel with the trigger
safety
, turn the safety to a right angle with the trig
ger
. See Fig. 2.
1
UNLOCKED
2
LOCKED gun trigger safety
Fig. 2
gun trigger safety
. T
o lock the gun trigger
E
1
2
0795A
2. T
o open the regulator
the T–handle IN (clockwise). T
OUT (counterclockwise) to close off the air flow
-
Be sure the jam nut under the T–handle does not
interfere with your adjustments. T
nut to lock in the setting, if desired.
8b
8a
CCW
CW
Fig. 4
, which allows air to flow
urn the T–handle
ighten the jam
, turn
.
04069
Operation
I.Pressure relief procedure
WARNING
The
system remains pressurized until pressure is
manually relieved. To reduce the risk of serious
injury
, including skin injection from pressurized fluid
or accidental spray from the gun, or injury due to
splashing fluid in the eyes or on the skin, follow this
procedure whenever you:
D
are told to relieve pressure;
D
stop spraying;
D
check or service any system equipment;
D
install, clean or change spray tips.
1.
Lock the gun trigger safety
2.
Close the bleed-type master air valves (A,14).
3.
Close the air regulators (8a,8b).
4.
Unlock the gun trigger safety
5.
Hold the gun firmly against a grounded metal
waste pail. T
6.
Lock the gun trigger safety
7.
Open the filter drain valve (26), having a container
rigger the gun to relieve pressure.
ready to catch the drainage. Close the drain valve.
If you suspect that the spray tip or hose is completely
clogged or that pressure has not been fully relieved,
very slow loosen the tip retaining nut or hose end cou
pling and relieve pressure gradually
hose obstruction.
.
.
.
. Clean the tip or
II.Flush the pump before the first use.
Flush
with a solvent compatible to your fluid. Consult
the fluid manufacturer’s literature for recommenda
tions. See
Flushing
on page 10.
-
III.Prime the system.
See
Fig. 5.
1.
Remove the air cap and spray tip from the gun.
2.
Close the filter drain valve (26).
3.
Put the suction tube into the fluid supply container
Make sure the air regulators (8a,8b) are closed.
4.
5.
Open the master air valves (A,14).
NOTE:
In the next steps, the pump will cycle quickly
until air is purged.
6.
Slowly turn on the pump air regulator (8a) until the
pump cycles slowly
Hold a metal part of the gun firmly against and
7.
.
aimed into the grounded metal waste pail. T
the gun while increasing pressure at the pump air
regulator (8a) just enough to purge the air and
-
storage solvent from the system. When new fluid
comes from the gun, release the trigger
gun trigger safety
.
. Lock the
.
rigger
KEY
ABleed-type
3
Air-assisted airless spray gun
8a
Pump air regulator
8b
Gun air regulator
14
Bleed–type air valve
26
Filter drain valve
master air valve
Fig. 5
A
C
3
8a
8b
14
26
04072
Operation
IV.Set the fluid and air pressure.
1. Install
2.
3. T
4.
5.
6.
the spray tip and air cap on the gun.
Adjust the pump air pressure regulator until the
pressure shown on the fluid filter gauge is about
800 psi (56 bar). This should require approximately
35 psi (2.4 bar) air pressure to the pump.
est spray a pass or stationary horizontal pattern.
Hold the gun 10 to 12 in. (250 to 300 mm) from the
paper
. Stripes in the outer edges of the pass or
spots at the ends of the stationary pattern are
likely at this point.
NOTE:
fluid pressure until they appear
the air to the gun.
Partially trigger the gun so only air is emitted. Set
the gun air regulator to 20 psi (1.4 bar).
Retest the spray pattern. T
adjust the gun’
the aircap and to eliminate stripes or spots. If there
are no stripes or spots, you are ready to start
spraying.
If there are stripes or spots in the spray pattern,
raise the pump air pressure until you raise the fluid
outlet pressure by about 100 psi (6.9 bar) and try
again. Continue to raise the fluid pressure in
100
and clean. Do not exceed 120 psi (8.3 bar)
incoming air pressure or 2760 psi (190 bar) fluid
working pressure.
If there are no stripes or spots, lower the
before
turning on
rigger the gun and
s air control valve (C) to add air to
psi (6.9 bar) increments until the pattern is full
V.You are now ready for production
spraying.
CAUTION
When
using catalyzed fluids, observe the pot life
as recommended by the fluid manufacturer
flush the system before the pot life has expired to
prevent dried fluid which may be dif
out and may damage the system.
ficult to clean
VI.When to shut down the system.
Shut
down the system at the end of the work shift and
before checking, adjusting, cleaning or repairing the
system. Always follow the
on page 8.
Pressure relief procedure
. Always
NOTE: Always use the lowest fluid and air pres
sure required for good atomization and spray pat
tern for maximum fluid ef
approximately 30 psi (2.1 bar) will cause turbu
lence in the fan pattern, dirty air caps and slower
production capability
.
ficiency
. Air pressure over
-
WARNING
This system has a maximum air working pressure
of 120 psi (8.3 bar) which produces a maximum
fluid working pressure of 2760 psi (190 bar). Higher
pressure can cause the system to rupture or mal
function and result in serious injury
.
-
-
-
308-457
9
I.When to flush.
D Before
D
D
D
the first time use
When changing colors
Before fluid can dry or settle out in a dormant sys
tem (observe the recommended fluid pot life on cat
alyzed fluids)
Before storing the system
II.How to flush.
See
Fig. 6.
1.
Relieve pressure. See page 8.
2.
Remove the air cap and spray tip before flushing.
3.
Unscrew the fluid filter (5) bowl. Remove the
screen. See manual 307–273. Reinstall the bowl
without the screen.
4.
Put the suction tube into a grounded metal pail with
about 1/2 gallon (2 liters) of a compatible solvent.
5.
Make sure the air regulators (8a,8b) are closed.
NOTE:
during flushing.
6.
The gun air regulator (8b) always stays closed
Open the master air valves (A,14).
Flushing
7.
Slowly turn on the pump air regulator (8a) until the
pump cycles slowly
8.
Hold a metal part of the gun firmly against the
-
-
grounded metal waste pail. T
increase the pump air regulator setting until the
fluid flows freely
until the fluid arrives.)
9.
Keeping the gun triggered, decrease the pump air
regulator (8a) pressure as much as possible
without stalling the pump, and pump out the
solvent until air comes through the gun.
10. Repeat
11. Release
12.
Close the master air valves (A,14). Fully close the
pump air regulator (8a).
13.
Open the drain valve (26), having a container
ready to catch the drainage.
14.
Remove the suction hose from the solvent and
place it in an empty container
15.
Clean the filter screen, air cap and spray tip sepa
rately
16.
Thoroughly clean the inside and outside of the
suction tube
inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco
, any malfunction, damage or wear caused by faulty installation, misap
wear caused by the incompatibility with Graco equipment of
If inspection of the equipment does not disclose any defect in fluid or
, Graco
-
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or
implied),
ties, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential
damages
action
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with
respect
tured
purchaser
TO
utor
closest to you:
including warranty of merchantability or warranty of fitness for a particular purpose
or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price. Any
for breach of warranty must be brought within two (2) years of the date of sale.
to accessories, equipment, fluids, or components sold
by Graco (such as electric motor
with reasonable assistance in making any claim for breach of these warranties.
PLACE AN ORDER
, or call this number to identify the distributor
1–800–367–4023 T
Foreign Offices:
, contact your Graco distrib
Sales
, switches, hose, etc.) are subject to the
Graco
oll Free
Offices:
Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Canada, England, Korea, Switzerland, France, Germany
Phone Numbers
GRACO INC.P.O. BOX 1441
PRINTED
IN U.S.A.
308–457September,
but not manufactured by Graco. These items sold, but not manufac
-
warranty
, if any
FOR TECHNICAL ASSIST
information or assistance regarding the application of
Graco equipment:
MINNEAPOLIS, MN
1994, Revised November
, and of any non–contractual liabili
, of their manufacturer
ANCE,
1–800–543–0339 T
, Hong Kong, Japan
. Graco will provide
service repair
oll Free
55440–1441
, 1994
-
-
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