Graco AA SPRAY GUN G40, AA SPRAY GUN G15 User Manual
Instructions - Parts List
AA Series Spray Gun
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.
311001F
Model G15
Model G40
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
TI6844A
TI6553A
Model G40 w/RAC tip
II 2 G
TI7204B
Models
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
Maximum
Working Air
Part
No. Series
288844 A 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure
287926 C 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure
249242 C 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted
249246 B 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure, High Flow
249238 B 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted
Pressure
psi (MPa, bar)
Maximum
Working Fluid
Pressure
psi (MPa, bar) Description Includes:
Air-Assisted Spray Gun, Plastic
Seat, SST Ball
Air-Assisted Spray Gun, Carbide
Seat and Ball
Spray Gun, Carbide Seat and Ball
Air-Assisted Spray Gun, Carbide
Seat and Ball
Spray Gun, Carbide Seat and Ball,
Reverse-A-Clean
®
(RAC) Tip
249596
Air Cap
249596
Air Cap
249180
Air Cap
249180
Air Cap
288465
RAC
Air Cap
2 311001F
Related Manuals
This manual is available in the following languages:
Manual Language
311001 English
311145 Chinese
311146 Danish
311147 Dutch
311148 Finnish
311149 French
311150 German
311151 Italian
311152 Japanese
311153 Korean
311154 Norwegian
311155 Polish
311156 Russian
311157 Spanish
311158 Swedish
Related Manuals
311001F 3
Warnings
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
Installation
Typical Installation
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.
D
B
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.
A
C
FIG. 1: Typical Installation (Model G15 Shown)
Key:
A Air Line Filter
B Air Shutoff Valve
C Gun Air Pressure Regulator
DAir Line
E
G
TI6554A
F
ESpray Gun
F Electrically Conductive Fluid Hose
G Gun Air Supply Hose
6 311001F
Installation
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.
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. 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
F
IG. 4. If desired, install a fluid swivel connector
(115898) at the gun inlet for best maneuverability.
See Accessories, page 33.
G
TI6556A
F
IG. 2
6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See F
IG. 3.
B
G
C
TI4838A
F
A
IG. 3
F
TI6846A
IG. 4
F
3. Connect the other end of the fluid hose (F) to the
pump fluid outlet.
311001F 7
Setup
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 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 F
Tighten the air cap retaining ring (6) firmly by hand to
ensure a good seal between the tip gasket and the diffuser (5).
IG. 5.
TI6558A
IG. 6
F
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 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 do not come standard with model
G40 guns (249242).
IG. 7. When relocating
Slot
Tip Locating Tab
F
IG. 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 F
IG. 6.
8 311001F
TI6847A
F
Horizontal
Air Cap Position
(standard)
Verti cal
Air Cap Position
IG. 7
TI6847A
Reverse-A-Clean® (RAC) Tip
Setup
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
F
IG. 8
Insert the SwitchTip.
TI7197A
IG. 9
F
Insert the gasket seat.
TI7198A
FIG. 10
Screw the RAC tip assembly onto the gun and tighten
firmly by hand.
TI7199A
F
IG. 11
311001F 9
Operation
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
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure. See
F
IG. 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 F
IG. 13.
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 F
IG. 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.
IG. 13
F
ENGAGED
TI6581A TI6582A
DISENGAGED
10 311001F
Operation
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.
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 F
sets the gun for its widest pattern.
OPEN
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 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. 15. Seven to 10 psi (4.9 to
IG. 14. This
CLOSE
TI6559A
IG. 14. 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.
311001F 11
x Pump Air Regulator Setting = Fluid
Pressure
F
IG. 15
no air
TI0792A
too little air correct amount
of air
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