Graco Inc AirPro 313869B, AirPro TI14428A, AirPro TI14427A User Manual

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Instructions/Parts

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AirPro

EFX Automatic

313869B

Spray Gun

Conventional, HVLP, HiTEch, and LVMP automatic guns for small component finishing applications. For professional use only.

100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure 100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 2 for model information.

ENG

Guns with manifold

TI14428A

TI14427A

Guns without manifold

II 2 G c IIB T6

Models

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Selection Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Gun Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Proper Needle/Nozzle Selection . . . . . . . . . . . . . 6

Models With Manifolds . . . . . . . . . . . . . . . . . . . . 7

Models Without Manifolds . . . . . . . . . . . . . . . . . . 7

Air Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sample Pattern Sizes and Shapes . . . . . . . . . . . 8

Needle Assembly Identification . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ventilate Spray Booth . . . . . . . . . . . . . . . . . . . . 10

Configure Gun and Manifold . . . . . . . . . . . . . . . 10

Ground System . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mount Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Connect Air Line . . . . . . . . . . . . . . . . . . . . . . . . 13

Connect Fluid Hose . . . . . . . . . . . . . . . . . . . . . 15

Flush Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . 16

Position Air Cap . . . . . . . . . . . . . . . . . . . . . . . . 16

Adjust Spray Pattern . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Relief Procedure . . . . . . . . . . . . . . . . 18

Apply Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Daily Gun Care . . . . . . . . . . . . . . . . . . . . . . . . . 19

General System Maintenance . . . . . . . . . . . . . . 20

Clean and Flush Gun . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Mounting Hole Layouts . . . . . . . . . . . . . . . . . . . . . 30

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Spray Pattern Test Report . . . . . . . . . . . . . . . . . 35

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

Models

Orifice Size

Spray Type

Conventional Conventional Conventional Conventional Conventional HVLP HVLP HVLP HVLP HiTEch HiTEch HiTEch LV MP LV MP LV MP LV MP LV MP LV MP Air Brush Gun without needle,

nozzle, or air cap

* Needle tip and nozzle exit constructed from tungsten carbide.

in. (mm)

0.028 (0.7) 24B857 24B877

0.035 (0.9) 24B858 24B878

0.043 (1.1) 24B859 24B879

0.051 (1.3) 24B860 24B880

0.059 (1.5) 24B861* -----

0.020 (0.5) 24B862 -----

0.028 (0.7) 24B863 24B881

0.043 (1.1) 24B864 24B882

0.051 (1.3) 24B865 24B883

0.028 (0.7) 24B866 24B884

0.039 (1.0) 24B867* 24B885*

0.059 (1.5) 24B868* 24B886*

0.020 (0.5) 24B869 24B887

0.028 (0.7) 24B870 24B888

0.035 (0.9) 24B871 24B889

0.043 (1.1) 24B872 24B890

0.051 (1.3) 24B873 24B891

0.059 (1.5) 24B874* -----

0.028 (0.7) 24B875 24B892 N/A 24B876 24B893

Models with Manifold**

Models without Manifold

** Models with manifold have fully stainless steel fluid passages.

2 313869B

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

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.

313869B 3

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.

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 the Pressure Relief Procedure when you stop spraying and before clean-

ing, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immedi-

ately.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocar-

bon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact

your material supplier for compatibility.

4 313869B

Warnings

WARNING

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 MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to appli-

cable 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 sol-

vent manufacturer.

313869B 5

Selection Charts

TERMS Light Fluid: Up to 18 seconds with No. 2 Zahn

cup (20 centipoise) Medium Fluid:19 to 28 seconds with No. 2

Zahn cup (20-64 centipoise) Heavy Fluid: Greater than 28 seconds with

No. 2 Zahn cup (greater than 64 centipoise) --

2.8 Volatile Organic Compounds, High-solid Polyurethanes, Heavy Waterborne Enamels

Gun Selection

HVLP Guns

An HVLP gun is a high transfer efficiency gun that limits the air pressure at the air cap to 10 psi (0.07 MPa, 0.7 bar) maximum. In some areas, an HVLP gun is required for compliance with environmental standards. See the Air Cap chart, page 8, for maximum inlet pressure.

Proper Needle/Nozzle Selection

The spray gun's needle/nozzle kits range in size to provide different fluid flow rates. As a general guideline, use the fluid nozzle that will give the required flow with the needle fully triggered at a fluid pressure of 5–20 psi (0.035–0.14 MPa, 0.35–1.4 bar).

• For low flow rates or light viscosity fluid,

select the smaller nozzle sizes.

• For high flow rates or high viscosity fluid,

select the larger nozzle sizes.

• For abrasive fluids, the gun models with

tungsten carbide needle tip and nozzle are recommended.

Orifice Size

in. mm oz/min cc/min

Viscosity

Flow

LVMP Guns

An LVMP gun is a high transfer efficiency gun that has been tested to have a transfer efficiency greater than or equal to HVLP guns. In addition, the LVMP air cap consumes much less air than the HVLP air cap. Graco LVMP guns have no restrictions on air cap pressures.

Conventional Guns

A conventional gun has excellent atomization and high production rates typically with some reduction in transfer efficiency.

HiTEch Guns

A HiTEch gun is a high transfer efficiency gun with excellent atomization. Graco HiTEch guns have no restrictions on air cap pressures.

0.020 0.5 light 0.2-1.7 5-50

0.028 0.7 light 0.3-3.4 10-100

0.035 0.9 light-medium 0.5-5.1 15-150

0.039 1.0 light-medium 0.7-6.8 20-200

0.043 1.1 light-medium 0.8-8.5 25-250

0.051 1.3 medium 1.2-11.8 35-350

0.059 1.5 medium 1.5-15.2 45-450

6 313869B

Selection Charts

Models With Manifolds

Includes: Orifice Size

Gun

Assembly

Part No. Type

24B857 Conventional 24D177 24C182 0.028 0.7 Stainless Steel Indexing Plastic 24B858 Conventional 24C198 24C182 0.035 0.9 Stainless Steel Indexing Plastic 24B859 Conventional 24C199 24C182 0.043 1.1 Stainless Steel Indexing Plastic 24B860 Conventional 24C200 24C182 0.051 1.3 Stainless Steel Indexing Plastic 24B861 Conventional 24D178 24C182 0.059 1.5 Carbide Indexing Plastic 24B862 HVLP 24D302 24C183 0.020 0.5 Stainless Steel Indexing Plastic 24B863 HVLP 24D179 24C183 0.028 0.7 Stainless Steel Indexing Plastic 24B864 HVLP 24D305 24C183 0.043 1.1 Stainless Steel Indexing Plastic 24B865 HVLP 24D306 24C183 0.051 1.3 Stainless Steel Indexing Plastic 24B866 HiTEch 24D303 24D703 0.028 0.7 Stainless Steel Ultra Precision Stainless Steel 24B867 HiTEch 24C221 24D703 0.039 1.0 Carbide Ultra Precision Stainless Steel 24B868 HiTEch 24C201 24D704 0.059 1.5 Carbide Ultra Precision Stainless Steel 24B869 LV MP 24D277 24C184 0.020 0.5 Stainless Steel Ultra Precision Plastic 24B870 LV MP 24D278 24C184 0.028 0.7 Stainless Steel Ultra Precision Plastic 24B871 LV MP 24D279 24C184 0.035 0.9 Stainless Steel Ultra Precision Plastic 24B872 LV MP 24D280 24C184 0.043 1.1 Stainless Steel Ultra Precision Plastic 24B873 LV MP 24D281 24C184 0.051 1.3 Stainless Steel Ultra Precision Plastic 24B874 LV MP 24D284 24C184 0.059 1.5 Carbide Ultra Precision Plastic 24B875 Air Brush 24C197 24D705 0.028 0.7 Stainless Steel Indexing Plastic 24B876 N/A N/A N/A N/A N/A N/A Indexing Plastic

Needle/

Nozzle Kit

Part No.

Air Cap with Pin Part No. in. mm

Construction

of Needle Tip/

Nozzle Exit

Fluid

Adjustment

Knob

Construction

of Fluid

Fitting

Models Without Manifolds

Includes: Orifice Size

Gun

Assembly

Part No. Type

24B877 Conventional 24D177 24C182 0.028 0.7 Stainless Steel Lock Ring Plastic 24B878 Conventional 24C198 24C182 0.035 0.9 Stainless Steel Lock Ring Plastic 24B879 Conventional 24C199 24C182 0.043 1.1 Stainless Steel Lock Ring Plastic 24B880 Conventional 24C200 24C182 0.051 1.3 Stainless Steel Lock Ring Plastic 24B881 HVLP 24D179 24C183 0.028 0.7 Stainless Steel Indexing Plastic 24B882 HVLP 24D305 24C183 0.043 1.1 Stainless Steel Indexing Plastic 24B883 HVLP 24D306 24C183 0.051 1.3 Stainless Steel Indexing Plastic 24B884 HiTEch 24D303 24D703 0.028 0.7 Stainless Steel Ultra Precision Stainless Steel 24B885 HiTEch 24C221 24D703 0.039 1.0 Carbide Ultra Precision Stainless Steel 24B886 HiTEch 24C201 24D704 0.059 1.5 Carbide Ultra Precision Stainless Steel 24B887 LV MP 24D277 24C184 0.020 0.5 Stainless Steel Indexing Plastic 24B888 LV MP 24D278 24C184 0.028 0.7 Stainless Steel Indexing Plastic 24B889 LV MP 24D279 24C184 0.035 0.9 Stainless Steel Indexing Plastic 24B890 LV MP 24D280 24C184 0.043 1.1 Stainless Steel Indexing Plastic 24B891 LV MP 24D281 24C184 0.051 1.3 Stainless Steel Indexing Plastic 24B892 Air Brush 24C197 24D705 0.028 0.7 Stainless Steel Indexing Plastic 24B893 N/A N/A N/A N/A N/A NA Indexing Plastic

Needle/

Nozzle Kit

Part No.

Air Cap with Pin Part No. in. mm

Construction

of Needle Tip/

Nozzle Exit

Fluid

Adjustment

Knob

Construction

of Fluid

Fitting

313869B 7

Selection Charts

Air Caps

Nozzle Orifice Recommended

Gun/Manifold

Air Cap

Part No. Type

24C182 Conventional 0.028-0.059 0.7-1.5 43 (0.3, 3.0) Blue-Grey 24C183 HVLP 0.020-0.051 0.5-1.3 15 (0.1, 1.0)* Pewter 24D703 HiTEch 0.028-0.039 0.7-1.0 29 (0.2, 2.0) Black 24D704 HiTEch 0.059 1.5 29 (0.2, 2.0) Black 24C184 LVMP 0.020-0.059 0.5-1.5 43 (0.3, 3.0) Brown 24D705 Air Brush 0.028 0.7 29 (0.2, 2.0) Clear

* Maximum compliant HVLP inlet pressure.

Inlet Pressure

psi (MPa, bar) Air Cap Colorin. mm.

Sample Pattern Sizes and Shapes

Recommended

Nozzle

Air Cap

Part No. Type

24C182 Conventional 0.028 (0.7) 43 (0.3, 3.0) 2.7 (80) 6 (15) Taper 1.0-6.0 (25-152) 24C183 HVLP 0.028 (0.7) 15 (0.1, 1.0) 2.7 (80) 6 (15) Straight 1.0-6.5 (25-165) 24D703 HiTEch 0.028 (0.7) 29 (0.2, 2.0) 2.7 (80) 6 (15) Straight 1.0-6.5 (25-165) 24D704 HiTEch 0.059 (1.5) 29 (0.2, 2.0) 2.7 (80) 6 (15) Straight 1.0-6.5 (25-165) 24C184 LVMP 0.028 (0.7) 43 (0.3, 3.0) 2.7 (80) 6 (15) Straight 1.0-6.5 (25-165)

24D705 Air Brush 0.028 (0.7) 29 (0.2, 2.0) 1.0 (30)

Orifice

in. (mm)

Gun/Manifold

Inlet Pressure

psi (MPa, bar)

Fluid* Flow

Rate

oz/min (cc/min)

Spray

Distance

in (cm)

2 (5) 4 (10) 0.6 (15) 6 (15) 0.7 (19)

Pattern

Shape

Round

Pattern Size*

in. (mm)

0.5 (13)

* Fluid viscosity for these samples was 30 centipoise.

Needle Assembly Identification

Part Needle Assembly Size # of Grooves

24C190 0.5 mm 1 24C191 0.7 mm 2 24C192 0.9 mm 3 24C193 1.1 mm 4 24C194 1.3 mm 5

Grooves

ti14043a

8 313869B

Selection Charts

313869B 9

Installation

This spray gun can spray most coatings or finishes currently being used for small component plastic, wood and metal finishing applications, while easily operating from paint delivery systems, such as pressure pots or remote pumps for production line operation.

The air regulator must have a minimum air flow capacity of 30 scfm at 100 psi (0.7 MPa,

7.0 bar) air pressure.

Ventilate 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.

Configure Gun and Manifold

Guns with Manifold

See FIG. 1. The gun is shipped with a fluid plug (25). To use the gun in a circulating system, do not install the plug. In a non-circulating system, install the plug as shown to minimize flush time.

1. Connect the fluid supply line to one fluid port fitting and the fluid return line to the other. The manifold fluid ports are reversible.

2. Install the gun on the manifold, using the two screws. Torque the screws evenly to 50 in-lb (5.6 N•m).

Do not install when used in circulating systems.

• Check and follow all national, state, and

local codes regarding air exhaust velocity requirements.

• Check and follow all local safety and fire

codes.

TI14429A

FIG. 1: Guns with Manifold

10 313869B

Installation

Guns without Manifold

The gun is shipped ready for use in a circulating system, with a fitting installed in each fluid port. Connect the fluid supply line to one fluid inlet fitting (15) and the fluid return line to the other.

To use the gun in a non-circulating system, remove one fitting and replace with plug (33, shipped loose). Use the 3/16 allen wrench supplied to tighten the plug.

Install for use in a non-circulating system.

Use fitting (15) for use in a circulating system.

Pump/Fluid Supply

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.

Air Compressors and Hydraulic Power Supplies

Ground the air compressors and hydraulic power supplies according to the manufacturer recommendations.

Spray Gun

Ground the spray gun by mounting the manifold to a properly grounded reciprocator, robot, or stationary mount. Check the electrical resistance between the manifold and a true earth ground. Resistance must not exceed 1 megohm.

TI14430A

FIG. 2: Guns without Manifold

Ground System

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.

Fluid Supply Container

Ground the fluid supply container according to local code.

Object Being Sprayed

Ground the object that is being sprayed according to local code.

Solvent Pails

Ground all solvent pails that are used when flushing according to local code. Use only conductive metal pails placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.

313869B 11

Installation

Mount Gun

Reciprocating Arm Rod Mount

To mount the gun on a reciprocating arm rod [0.75 in. (19 mm) diameter maximum], insert the bar (A) through the hole in the manifold as shown in FIG. 3.

NOTE: Use the 1/8 in. alignment slot (P) to assist in orienting the gun.

Secure the gun to the bar by tightening the mounting screw (B).

FIG. 3: Reciprocating Arm Mount

TI14433A

Stationary Support

To mount the gun on a stationary support, refer to FIG. 4 and to the correct mounting hole layout for your gun, page 30 - 31.

1. Align the gun or manifold with the alignment pins. Locate alignment slot and holes per the mounting hole layout.

Guns with manifold

Guns without manifold

FIG. 4: Stationary Support Mount

TI14434A

TI14435A

2. Secure the gun to the support with two M8 x 1.25 capscrews (C). The screws must be long enough to engage the threaded holes to a depth of 1/4 in. (6 mm).

12 313869B

Setup

Connect Air Line

NOTE:

• If your regulated air source does not

have a filter, install an air filter (G) on each 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. 5.

• You must install a separate air pressure

regulator (F) on the CYL, FAN, and ATOM air lines to control air pressure to the gun. See FIG. 6 and FIG. 7.

• Install a bleed type air shutoff valve (E)

on each gun air supply line, downstream of the gun air regulator, to shut off air to the gun.

1. The gun cylinder, fan, and atomization air must be supplied and regulated separately. To regulate air remotely, use solenoids (see FIG. 6 and FIG. 7).

NOTE: The three air inlet fittings accept 6 mm OD tubing.

2. Connect each air hose (D) to a regulated air supply line (H).

FIG. 5: Connect Air Line

FED

ti01990a

313869B 13

Setup

Air regulator

ATOMIZING AIR

2-way solenoid valve

CYLINDER AIR

3-way solenoid valve

FAN AIR

FIG. 6: Remote Air Regulation using Solenoid (Guns with Manifold)

FAN AIR

CYLINDER AIR

2-way solenoid

TI14444A

valve

2-way solenoid valve

3-way solenoid valve

ATOMIZING AIR

TI14445A

2-way solenoid valve

FIG. 7: Remote Air Regulation using Solenoid (Guns without Manifold)

14 313869B

Setup

Connect Fluid Hose

NOTE:

• 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.

• Install a fluid regulator (L) on the fluid

line to control fluid pressure to the gun. See FIG. 8.

• Install a fluid shutoff valve (M) to shut off

the fluid supply to the gun.

• Filter the fluid line of coarse particles

and sediment to avoid clogging the fluid nozzle and causing finishing defects. Inline fluid filter 24B707 is available.

In a non-circulating system, remove the gun fluid outlet fitting (T) and plug the outlet port with the pipe plug (33) supplied for guns without manifold. Guns with manifold use plug 24C211 (25, see page 10).

KEY

N Cylinder Air Inlet: accepts 6 mm OD tubing P Atomization Air Inlet: 6 mm OD tubing R Fan Air Inlet: 6 mm OD tubing S Fluid Inlet: 6 mm OD tubing T Fluid Outlet (circulating gun only): 6 mm OD tubing

With Manifold

ti7016a

FIG. 8: Connect Fluid Hose.

1. Connect the fluid supply hose (J) to the gun fluid inlet (S), 6 mm OD tube fitting. See

IG. 9.

2. Connect the other end of the fluid hose (J) to a regulated fluid supply outlet (M).

3. In a circulating system, connect a grounded fluid return hose to the gun fluid outlet (T). See FIG. 9.

Without Manifold

T (or S)

FIG. 9: Air and Fluid Ports

S (or T)T (or S)

TI14436A

S (or T)

TI14437A

313869B 15

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 a grounded metal container. See Clean and Flush Gun, page 20.

2. Perform Pressure Relief Procedure, page 18.

Position Air Cap

Air caps are factory-set with the alignment pin (A) set to a vertical spray pattern. To change the air cap to a horizontal spray pattern, use a 1/16 in. hex wrench to unscrew the alignment pin (A) and relocate it to the horizontal spray pattern hole. 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. Refer to FIG. 10.

Adjust Spray Pattern

Do not exceed 100 psi (0.7 MPa, 7 bar) maximum fluid and air pressure. Higher pressures can cause parts to rupture and result in serious injury.

Use the fluid pressure regulator to adjust the spray gun fluid flow. All models are equipped with a fluid control knob to make precise fluid flow adjustments.

Follow these steps to establish the correct fluid flow and air flow:

1. To achieve desired flow, adjust the fluid flow using the fluid pressure regulator (L) installed in the gun fluid line. Typical industrial flow rates will vary with regulator pressures from 5 to 30 psi (34 to 210 kPa,

0.3 to 2.1 bar). If the fluid pressure is too low at the desired flow rate, install a smaller nozzle. If the fluid pressure is too high, install a larger nozzle.

For spray guns equipped with the fluid control knob, you can make flow rate changes at the spray gun. Rotate the fluid control knob clockwise to reduce the flow.

ti8171a

Vertical Pattern

Horizontal Pattern

ti8170a

ti8172a

FIG. 10: Position Air Cap

16 313869B

ti7019a

FIG. 11: Fluid Pressure Regulator

NOTE: A larger fluid nozzle at a reduced fluid

pressure will maintain the same flow rate, but the fluid stream (velocity) will slow down. When air is applied, the lower velocity allows the air to act on the fluid longer, which improves atomization.

2. Using the air pressure regulator (F), set the fan and atomizing air supply pressure per Table 1. Use these suggested settings as a starting point.

Table 1: Suggested Starting Settings

Spray

Type

Conven-

tional

HVLP 15 (0.1, 1.0) 15 (0.1, 1.0)

HiTEch 29 (0.2, 2.0) 29 (0.2, 2.0)

LVMP 43 (0.3, 3.0) 43 (0.3, 3.0)

Air Brush NA 29 (0.2, 2.0)

Fan Air

psi (MPa, bar)

43 (0.3, 3.0) 43 (0.3, 3.0)

Atomizing Air

psi (MPa, bar)

Setup

NOTE: HVLP Gun Limits

HVLP Guns: local laws may limit the maximum pressure to 10 psi (70 kPa, 0.7 bar) at the air cap for compliance. See the table on page 8 for maximum HVLP manifold inlet pressures. To measure pressure at the air cap, use the appropriate HVLP Pressure Verification Kit.

ti01997

FIG. 12: Air Pressure Regulator

3. Test the spray pattern atomization while keeping the gun a consistent distance, about 6 to 8 inches (150 to 200 mm), from the test piece.

Check the atomization quality. Increase the gun atomizing air supply pressure with the air pressure regulator in 5 psi (34 kPa, 0.3 bar) increments until you obtain the desired atomization.

NOTE: For the best transfer efficiency, use the lowest setting needed to achieve desired finish quality.

4. If the spray pattern is too wide or split, reduce the fan air pressure.

NOTE: Reducing the fan air pressure to 0 psi (or fully closing the fan adjustment valve) will produce a round pattern.

To further control the spray pattern, use an alternate air cap. For a list of available air caps, see page 8.

313869B 17

Operation

Pressure Relief Procedure

1. Turn off all bleed type air valves and all other air and fluid supplies to the gun.

2. Trigger the gun into a grounded metal waste container to relieve fluid pressure.

ti8174a

FIG. 13: Pressure Relief

To achieve best results when applying fluid:

• Keep gun perpendicular and 6 to 8 in.

(150 to 200 mm) from object being sprayed.

• Use smooth, parallel strokes across sur-

face to be sprayed with 50% overlap.

Incorrect

TI14439A

Apply Fluid

The gun does not have an air shutoff. The air should be activated before the fluid to ensure full atomization of fluid and prevent buildup on the air cap.

Adjust the system control device, if it is automatic, so the gun starts spraying just before meeting the part and stops as soon as the part has passed.

Correct

TI14438A

FIG. 14: Correct Spray Method

18 313869B

Daily Gun Care

NOTICE

Methylene chloride with formic or propionic acid is not recommended as a flushing or cleaning solvent with this gun as it will damage aluminum and nylon components.

NOTICE

Solvent left in gun air passages could result in a poor quality paint finish. Do not use any cleaning method which may allow solvent into the gun air passages.

Do not wipe the gun with a cloth soaked

Do not point the gun up while cleaning it.

in solvent; wring out the excess.

Operation

ti8100a

ti4827a

Do not use metal tools to clean the air cap holes as this may scratch them;

Do not immerse the gun in solvent.

ti8101a

313869B 19

scratches can distort the spray pattern.

ti8175a

Operation

General System Maintenance

• Follow the Pressure Relief Procedure,

page 18.

• Clean the fluid and air line filters daily.

• Check for any fluid leakage from the gun

and fluid hoses. Tighten fittings or replace equipment as needed.

• Flush the gun before changing colors and

whenever you are done operating the gun.

Clean and Flush Gun

1. Follow the Pressure Relief Procedure, page 18.

2. Shut off the gun fan and atomizing air.

3. Supply a compatible solvent to the gun fluid inlet.

4. Point the gun down into a grounded metal container, and flush the gun with solvent until all traces of paint are removed from the gun passages.

9. Dip the end of a soft-bristle brush into a compatible solvent. Do not continuously soak the brush's bristles with solvent and do not use a wire brush.

ti4845a

FIG. 15: Use solvent-dipped soft-bristle brush

10.With the gun pointed down, clean the front of the gun, using the soft-bristle brush and solvent.

11.Scrub the air cap retaining ring, air cap, and fluid nozzle with the soft-bristle brush (see FIG. 16). To clean out air cap holes, use a soft implement, such as a toothpick, to avoid damaging critical surfaces. Clean the air cap and fluid nozzle daily, minimum. Some applications require more frequent cleaning.

5. Follow the Pressure Relief Procedure,

page 18.

6. Disconnect the solvent supply.

7. Remove the air cap retaining ring and air cap.

NOTICE

Trigger the gun whenever you tighten or remove the nozzle. This keeps the needle

IG. 16: Clean air cap, ring and fluid nozzle

ti8176a

seat away from the nozzle seating surface and prevents the seat from being dam-

12.Install the air cap retaining ring and air cap.

aged.

13.Dampen a soft cloth with solvent and wring

8. Clean the air cap retaining ring, air cap, and fluid nozzle with solvent.

20 313869B

out the excess. Point the gun down and wipe off the outside of the gun.

Operation

313869B 21

Troubleshooting

Problem Cause Solution

Spray Pattern Normal pattern. No action necessary.

Right

Spray Pattern Dirty or damaged air cap or

fluid nozzle.

Wrong

Heavy top or bottom

Spray Pattern Fan pressure too high for vis-

cosity of material being sprayed.

Wrong

Split pattern

Rotate air cap (5) 180°.

If pattern follows air cap, problem is in air cap. Clean and inspect. If pattern is not corrected, replace air cap.

If pattern does not follow the air cap, the problem is with the

fluid nozzle (4). Clean and inspect the nozzle. If the pattern is not corrected, replace nozzle.

Reduce fan air pressure and increase material viscosity.

Spray Pattern Dirty or distorted air horn

holes.

Clean and inspect air cap (5). If pattern is not corrected, replace air cap.

Wrong

22 313869B

Troubleshooting

Problem Cause Solution

Gun spitting. Air getting into paint stream. Check if fluid source is empty

and fill.

Tighten fluid nozzle (4).

Check fluid nozzle o-ring (3) for damage.

Check fluid nozzle (4) for damage.

Will not spray. Fluid control valve (11) turned

too far clockwise.

Adjust fluid control valve (11) counterclockwise.

Fluid source empty. Refill.

Excessive air blowing back. Loose fluid nozzle (4). Tighten fluid nozzle (4).

Damaged fluid nozzle seal (3). Replace seal (3).

Gun fluid pressure is too high with gun triggered (cannot

Using needle/nozzle kit with too small orifice.

Use needle/nozzle kit with larger orifice.

achieve desired flow rate). Using a low fluid pressure set-

ting, the fluid flow is too high,

Using needle/nozzle kit with too large orifice.

Use needle/nozzle kit with

smaller orifice. making it necessary to restrict needle travel to reduce fluid flow.

Fluid system will not operate at low enough pressure [below 10 psi (70 kPa, 0.7 bar)].

Fluid flow is fluttering while spraying.

There is no fluid regulator, or air regulator is not sensitive enough at low pressure.

Add low pressure fluid regula-

tor, or add more sensitive low

pressure air regulator.

Fluid source empty. Refill.

313869B 23

Service

screws (16) and remove the gun from the manifold.

NOTE: Numbers in parenthesis in the text refer to the reference numbers in the figures and in the parts list.

Disassembly

1. Follow the Pressure Relief Procedure,

page 18.

2. Remove gun for service:

a. With Manifold: Use the 4 mm allen

wrench supplied to unscrew the two

Torque to 155-165 in-lb (18-19 N•m).

Torque to 80 in-lb (9.0 N•m).

b. Without Manifold: Disconnect the air

and fluid hoses. Remove the gun from the mounting arm.

3. Remove the air cap retaining ring (21) and air cap (5).

4. Remove the fluid adjustment knob (11) and spring (10).

5. Pull the piston (7) and fluid needle (6) out of the back of the gun.

FIG. 17

24 313869B

ti14946a

Service

6. Use a 1/16 hex wrench to loosen the fluid needle set screw (7a). Remove the needle (6) from the piston (7).

7. Check the fluid needle (6) for damage or excessive wear. Replace the needle if necessary.

NOTICE

The needle and tip are permanently bonded. To prevent damage to the needle, do not try to separate.

8. Use the 10 mm hex nut driver to remove the fluid packing nut (2).

9. Use the 10 mm wrench to remove the nozzle (4).

Reassembly

1. Lightly grease the new nozzle (4), which includes o-ring (3). Use the 10 mm wrench to install the nozzle. Torque to 155-165 in-lb (18-19 N•m).

2. Install the new air cap assembly (5, includes air cap, o-ring, washer, and alignment pin) and the retaining ring (21).

Torque to 4.5 to 5.5 in-lb (0.5 to 0.6 N•m).

FIG. 18

ti14944a

NOTICE

To avoid damage, the nozzle (4) must be installed before the needle (6).

5. Grease the needle shaft and piston o-ring. Push the needle/piston assembly into the gun as far as possible. Insert spring (10).

6. Turn counterclockwise to fully open the fluid adjustment knob (11). Install the knob hand-tight.

NOTE: If you have an ultra-precision fluid adjustment knob, loosen the set screw to adjust the position of the hash markings for convenient reading.

NOTE: Be sure to move the alignment pin if you want a horizontal spray pattern. See Posi- tion Air Cap, page 16.

3. Use the 10 mm hex nut driver to install new fluid packing nut (2, includes o-ring). Torque to 80 in-lb (9.0 N•m).

ti14947a

Set screw

4. Insert the new needle (6) in the piston (7).

FIG. 19

Apply medium-strength thread sealant to the setscrew (7a). Use the 1/16 hex wrench to torque the setscrew to 4.5 to 5.5 in-lb (0.5 to 0.6 N•m).

313869B 25

Parts

Guns with Manifold

Ultra-precision knob

Indexing knob

Lock ring

and cap

Guns without Manifold

ti14447a

ti14945a

ti14448a

26 313869B

Parts

Parts in Common Additional Parts for Models with Manifold

Ref. Part Description Qty.

1 ----- BODY 1 2 24C205 FLUID PACKING ASSEMBLY 1 3 111457 O-RING (included with Part 4) 1 4 See Table NOZZLE, fluid (includes Part 3) 1 5 See Table AIR CAP ASSEMBLY (includes

Parts 5a-5d) 5a ----- AIR CAP 1 5b✓ ----- O-RING 1 5c✓ ----- WASHER, UMHWPE 1 5d ----- PIN, alignment 1 6 See Table NEEDLE assembly 1 7 24C202 PISTON, needle stop (includes

Parts 7a and 7b) 7a ----- SCREW, set, 6-32 UNC x 1/16 in. 1 7b ----- O-RING 1 10 24C207 SPRING, compression 1 11

24D065 24C204 24C203

14 120538 FITTING, tube, air line,

24C213 24D046

21 289079 RETAINING RING, assembly

23 114141 TOOL, wrench, hex, 1/16, not

24 107157 TOOL, wrench, allen, 4 mm, not

26 101821 TOOL, wrench, allen, 3/16, not

31 24C210 TOOL, wrench, metric, not shown 1 32 24C209 TOOL, nut driver, hex, 10 mm,

33 100139 PLUG, pipe, not shown, shipped

KNOB, fluid adjustment

Ultra-Precision

Indexing

Lock ring and cap

1/8 npt x 6 mm

FITTING, tube, fluid line,

1/8 npt x 6 mm

Nylon

Stainless steel

(includes 5b and 5c)

shown

shown (Models without manifold)

not shown

loose (Models without

manifold)

Ref. Part Description Qty.

12 24C215 MANIFOLD, gun (includes Parts

13, 14, 15, 19, and 20) 13 106456† O-RING, PTFE, white 2 16 24C206 SCREW, mounting 2 17 24C208 ROD, mounting (includes Part 18) 1 18 ----- SCREW, cap, hex head 1 19 24C212 SCREW, set socket, M8 2 20 112319† O-RING, FX75, black 3 25 24C211 PLUG, manifold, not shown,

shipped loose

----- Not sold separately.

✓ Included in Air Cap Seal Kit 289791. See Repair Kits,

page 28.

† Included in Manifold O-Ring Kit 24D827. See Repair

Kits, page 28.

313869B 27

Repair Kits

Gun Part Number

With

Spray Type

Conventional 24B857 24B877 Conventional 24B858 24B878 Conventional 24B859 24B879 Conventional 24B860 24B880 Conventional 24B861* ----HVLP 24B862 ----HVLP 24B863 24B881 HVLP 24B864 24B882 HVLP 24B865 24B883 HiTEch 24B866 24B884 HiTEch 24B867* 24B885* HiTEch 24B868* 24B886* LV MP 24B869 24B887 LV MP 24B870 24B888 LV MP 24B871 24B889 LV MP 24B872 24B890 LV MP 24B873 24B891 LV MP 24B874* ----Air Brush 24B875 24B892

Manifold

Without

Manifold

Item 5

Air Cap

(Includes seals

and alignment

pin)

Nozzle Orifice

Size

in. (mm)

Needle/Nozzle

Kit

(Includes

Items 4 and 6)

Item 4

Nozzle

(includes

o-ring)

Item 6

Needle

Assembly

(includes

tip)

0.028 (0.7) 24D177 24D174 24C191

0.035 (0.9) 24C198 24C187 24C192

0.043 (1.1) 24C199 24C188 24C193

24C182

0.051 (1.3) 24C200 24C189 24C194

0.059 (1.5) 24D178 24D175 24C195

0.020 (0.5) 24D302 24D296 24C190

0.028 (0.7) 24D179 24D176 24C191

0.043 (1.1) 24D305 24D299 24C193

24C183

0.051 (1.3) 24D306 24D300 24C194

0.028 (0.7) 24D303 24D297 24C191

0.039 (1.0) 24C221 24C219 24C220

24D703

0.059 (1.5) 24C201 24D275 24C195 24D704

0.020 (0.5) 24D277 24D259 24C190

0.028 (0.7) 24D278 24D260 24C191

0.035 (0.9) 24D279 24D261 24C192

0.043 (1.1) 24D280 24D262 24C193

24C184

0.051 (1.3) 24D281 24D263 24C194

0.059 (1.5) 24D284 24D276 24C195

0.028 (0.7) 24C197 24C186 24C191 24D705

* Needle tip and nozzle exit constructed from tungsten carbide.

Accessories

Kit 24C216, Fittings (1/4 inch)

Part Description Qty.

120388 FITTING, tube, air line,

1/8 npt x 1/4 T

111157 FITTING, tube, fluid line,

1/8 npt x 1/4 T

Kit 24D143, Robot Adapter Kit Fanuc Paint Mate 200

Compatible with and without manifold.

Kit 24D008, Inlet Air Needle Valve

Includes needle valve and 6mm tube fittings.

Kit 24D827, Manifold O-Rings

Part Description Qty.

106456 O-RING, PTFE, white 2 112319 O-RING, FX75, black 3

HVLP Pressure Verification Kit 24C214

For use in checking air cap atomizing and fan pattern air pressure at various supply air pressures. Not to be used for actual spraying.

Install the kit air cap on the gun. Turn on the air to the gun and read the air pressure on the gauge.

NOTE: To be “HVLP compliant,” the atomizing and fan pattern air pressure must not exceed 10 psi (70 kPa, 0.7 bar).

28 313869B

Dimensions

Guns with Manifold

Dimensions

1.3 in.

(33.0 mm)

FIG. 20

4.9 in. (124.5 mm) with Ultra-Precision knob

4.1 in. (104.1 mm) with indexing knob

3.5 in. (88.9 mm) with lock ring and cap

1.4 in.

(35.6 mm)

0.75 in. (19.1 mm) mounting hole

2.6 in.

(66.1 mm)

TI14440A

1.6 in.

(40.7 mm)

3.8 in.

(96.5 mm)

TI14436A

Guns without Manifold

4.9 in. (124.5 mm) with Ultra-Precision knob

4.1 in. (104.1 mm) with indexing knob

3.5 in. (88.9 mm) with lock ring and cap

2.2 in.

(55.9 mm)

TI14442A

3.5 in.

(88.9 mm)

TI14437A

1.6 in.

(40.6 mm)

FIG. 21

313869B 29

Mounting Hole Layouts

Guns with Manifold

0.95 in

(24.1 mm)

ti14700a

1.27 in

(32.3 mm)

0.86 in. (21.8 mm)

FIG. 22

0.43 in. (10.9 mm)

1.22 in. (31.0 mm)

1.4 in

(35.6 mm)

3 x M8 x 1.25

0.34 in. (8.6 mm) thru

0.13 in. (3.3 mm) slot

ti14441a

30 313869B

Guns without Manifold

0.95 in.

(24.1 mm)

Mounting Hole Layouts

1.76 in.

(44.7 mm)

M8 x 1.25 T

0.35 in. (8.9 mm) deep

0.13 slot

(3.3 mm)

FIG. 23

ti14701a

313869B 31

Technical Data

Maximum working fluid pressure . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Maximum working air pressure . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Maximum HVLP Inbound Air Pressure. . . . . . . . . . . . . . . . See chart on page 8.

Maximum Working Fluid Temperature . . . . . . . . . . . . . . . . 120° F (49° C)

Minimum Air Cylinder Actuation Pressure . . . . . . . . . . . . . 50 psi (0.34 MPa, 3.4 bar)

Weight

with manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with no manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted Parts

Models 24B857-24B860, 24B862-24B865,

24B869-24B873, 24B875 . . . . . . . . . . . . . . . . . . . . . . .

Model 24B866. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTFE, Stainless Steel, Ultra High

Models 24B867 and 24B868. . . . . . . . . . . . . . . . . . . . . PTFE, Stainless Steel, Ultra High

1.3 lb (575 g)

0.6 lb (275 g)

Nylon, PTFE, Stainless Steel, Ultra High Molecular Weight Polyethylene

Molecular Weight Polyethylene

Molecular Weight Polyethylene, tungsten carbide

Models 24B861 and 24B874. . . . . . . . . . . . . . . . . . . . . Nylon, PTFE, Stainless Steel, Ultra

High Molecular Weight Polyethylene, Tungsten Carbide

Models 24B877-24B883, 24B887-24B892 . . . . . . . . . . Anodized Aluminum, Nylon, Stain-

less Steel, Ultra High Molecular Weight Polyethylene

Models 24B885 and 24B886. . . . . . . . . . . . . . . . . . . . . Anodized Aluminum, Stainless Steel,

Tungsten Carbide, Ultra High Molecular Weight Polyethylene

Model 24B884. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anodized Aluminum, Stainless Steel,

Ultra High Molecular Weight Polyethylene

Triggering Speed

These values apply to a new gun with a 12 ft. (3.6 m), 1/4 in. (6.3 mm) OD cylinder air line and a

0.043 in. nozzle. These values will vary slightly with use and with variations in equipment.

Cylinder Air

Pressure

psi (kPa, bar)

Fluid Pressure

psi (kPa, bar)

Air Pressure

psi (kPa, bar)

msec to fully

open

msec to fully

50 (0.35, 3.5) 50 (0.35, 3.5) 100 (0.7, 7.0) 48 84

32 313869B