INSTRUCTIONS-PARTS
LIST
308–044
This
manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Model H.E.L.P
. 1600
First
quality counts.
STAINLESS STEEL FLUID PASSAGES
High
Efficiency Low Pressure
Automatic Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Air Pressure*
65 psi (444 kPa, 4.5 bar) Maximum Operating Air Pressure**
* The
Maximum W
mum air pressure the gun was designed to operate
safely under
orking Air Pressure is the maxi
.
-
Rev. G
Supersedes F
choice when
**
The Maximum Operating Air Pressure is the maxi
mum inlet air pressure allowable to guarantee HVLP
compliance. If input pressures are maintained at or
below 65 psi (444 kPa, 4.5 bar), internal restrictors
will reduce this to 10 psi (70 kPa, 0.7 bar) maximum
air cap pressure.
Table
Warnings 2.
Installation 4
Operation 6
Maintenance 8
Troubleshooting 10
Service 12
Parts 14
Accessories 16
Dimensional
Technical
Air
Flow Charts
Warranty 20
Graco T
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Data
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oll-Free Phone Numbers
of Contents
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Drawing
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18.
18.
19.
20.
Part No. 110–863
Includes
0.070 in. (1.8 mm) fluid nozzle
GRACO INC. P.O. BOX 1441
MINNEAPOLIS, MN
COPYRIGHT
Graco
Inc. is registered to I.S. EN ISO 9001
1990, GRACO INC.
55440–1441
Symbols
Warning Symbol
WARNING
his
symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment
serious injury
D
This equipment is for professional use only
D
Read all instruction manuals, tags, and labels before operating the equipment.
D
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D
Check equipment daily
misuse can cause the equipment to rupture, malfunction or start unexpectedly and result in
.
. Repair or replace worn or damaged parts immediately
Caution Symbol
CAUTION
This
symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
.
.
D
Use this equipment only in low pressure, air spray systems.
D
Do not exceed the maximum working pressure of the lowest rated system component. This equip
ment has a
D
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180
D W
ear hearing protection when operating this equipment.
D
Use fluids or solvents that are compatible with equipment wetted parts. See the Technical Data
section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D
Methylene Chloride with formic or propionic acid is not recommended as a flushing or cleaning
solvent with this gun or any other device with nylon or aluminum components as it can damage
these parts.
D
Comply with all applicable local, state and national fire, electrical and other safety regulations.
100 psi (0.7 MPa, 7 bar) maximum working fluid and air pressure
_F (82_
C) or below –40
_F (–40_C).
.
-
2
308–044
WARNING
PRESSURIZED EQUIPMENT HAZARD
Spray
from the gun, hose leaks or ruptured components can splash fluid in the eyes or on the skin and
cause serious injury
Do not stop or deflect fluid leaks with your hand, body
Follow the
stop spraying; clean, check or service the equipment; and install or clean fluid nozzles.
Do not point the spray gun at anyone or at any part of the body
T
ighten all fluid connections before operating the equipment.
Check the hoses, tubes and couplings daily
Permanently coupled hoses cannot be repaired; replace the entire hose.
FIRE AND EXPLOSION HAZARD
Poor
air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or
explosion and serious injury
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
sprayed.
Extinguish all open flames or pilot lights in the spray area.
.
Pressure Relief Procedure
.
, glove or rag.
on page 6 when: you are instructed to relieve pressure;
.
. Replace worn, damaged or loose parts immediately
.
Electrically disconnect all equipment in the spray area.
Keep the spray area free of debris, including solvent, rags and gasoline.
Do not turn on or of
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
f any light switch in the spray area while operating or if fumes are present.
TOXIC FLUID HAZARD
Hazardous
skin, inhaled, or swallowed.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container
state and national guidelines.
Dress appropriately for your application. W
and respirator
fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
. Dispose of hazardous fluid according to all local,
ear the appropriate protective clothing, gloves, eyewear
.
,
308–044 3
Installation
H
A
J
G
N
D
C
M
L
K
Fig. 1
The
Model H.E.L.P
. 1600 High Ef
ficiency Low Pres
sure Spray Gun was designed to produce the highest
quality finish with today’
V
.O.C. (volatile organic compound) fluids of tomorrow
s fluids as well as the the Low
This spray gun can spray most coatings or finishes
currently being used for automotive refinish, industrial,
aerospace, marine, wood, plastic and architectural
applications, while easily operating from any paint
delivery system, including pressure pots of any size, or
remote pumps for production line operation.
.
E
B
KEY
A Conveyor
B Fluid
C
D
E
F
G
Line
Air Filter
3-way Air Solenoid V
Cylinder Air Supply Line
Atomizing Air Supply Line
Air Regulators
alve
H
J
K
L Pump
M
N
F
Sensing Device
Automatic Air Spray Gun
Fluid Pressure Regulator
Fluid Supply
Air Shut-of
f V
Ventilate the Spray Booth
WARNING
TOXIC
T
toxic and/or flammable vapors, spray
only in a properly ventilated spray booth.
Do not operate the spray gun unless ventilation fans are operating.
FLUID HAZARD
o prevent hazardous concentrations of
alve
04863
If input air pressures are maintained at or below 65 psi
(444 kPa, 4.5 bar), internal restrictors in the Model
H.E.L.P
. 1600 Spray Gun will reduce the air line pres
sure to 10 psi (70 kPa, 0.7 bar) maximum air cap
pressure, which is required to meet all new regulations.
The illustration shown above is only a guide to the
equipment needed for an automatic spraying system.
For assistance in designing a system to meet your
needs, contact your Graco representative.
4 308–044
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.
Mount the Gun
Mount
the gun on a 0.50 in. (12 mm) diameter rod
mounting fixture that allows adjustment of the spray
pattern direction and the distance from the workpiece.
Connect the Fluid Line
1. Before
2.
connecting the fluid line (B), blow it out with
air and flush it with solvent. Use solvent which is
compatible with the fluid to be sprayed.
Install a fluid regulator (K) on the fluid line (B) to
control fluid pressure to the gun.
Installation
3.
Connect an atomizing air supply line (F) to the
1/4–18 npsm (R 1/4–19) gun air inlet marked
ATOM.
Install separate air regulators (G) to control atom
4.
izing air and cylinder air
-
.
3.
Connect the fluid line to the 3/8–18 npsm
(R 3/8–19) gun fluid inlet.
Connect the Air Lines
1. Install
2.
an air filter (C) to provide a clean, dry air
supply to the gun. Dirt and moisture in the air line
can af
fect the appearance of your finished work
piece.
Install a normally closed, 3-way air solenoid valve
(D) and air shut-of
supply line (E). Connect an air hose from the air
shut-of
air inlet marked CYL.
f valve to the 1/4–18 npsm (R 1/4–19) gun
f valve (N) in the cylinder air
Recommended Hose Sizes
(General Purpose)
Fluid Hose
Length
-
Needed
0–35 ft.
(0–11 m)
35–100 ft.
(11–30 m)
100–200 ft.
(30–60 m)
ID Length Needed ID
3/8 in.
1/2 in.
3/4 in.
Air Hose
0–100 ft.
(0–30 m)
100–200 ft.
(30–60 m)
5/16
in.
3/8 in.
308–044 5
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED
The system pressure must be manually relieved to
prevent the system from starting or spraying acci
dentally. T
dental spray from the gun, splashing fluid, or
moving parts, follow the
dure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray nozzle.
1. T
urn of
2. T
rigger the gun into a grounded metal waste
container to relieve system pressures.
Filter the Fluid
Strain
or filter the paint to remove coarse particles and
sediment, then check the viscosity of your fluid. This
gun is best suited for light to medium fluids.
Light Fluid: 19 to 24 seconds (No. 2 Zahn cup). Auto,
furniture,
quer,
Medium
tact
ers,
Heavy
polyurethanes,
appliances, fine finish metallics, top coats, lac
enamel primer
Fluid:
adhesive, latex, maintenance paints, textures,
epoxies, vinyls, high flow high viscosity
Fluid:
Adjusting the Spray Pattern
The
desired pattern, volume of fluid output and degree
of atomization can easily be obtained by regulating the
fan adjustment valve (5) and the fluid adjustment
knob (6). See Fig. 2.
EQUIPMENT HAZARD
o reduce the risk of an injury from acci
Pressure Relief Proce
f the air and fluid supply to the gun.
.
22 to 41 seconds
2.8 V
olatile organic compounds, high-solid
heavy waterborne enamels
(No. 2 Zahn cup). Con
.
-
-
-
prim
NOTE:
Accessories.
Adjust the Pattern Size
T
urn the fan adjustment valve (5) out (counterclock
wise) to make the spray pattern wider
NOTE:
10 to 1
flow and 10 in. (254 mm) target distance with 65 psi
(444 kPa, 4.5 bar) inlet air pressure. (Measurements
taken using a 23 sec. zahn #2 viscosity fluid.) The
pattern length will vary with the fluid flow
fluid viscosity
Adjust the Fluid Output Volume
T
urn the fluid adjustment knob (6) out all the way
(counterclockwise). Then adjust the air pressure at the
pressure feed tank until the desired fluid flow is ob
tained. For the final adjustment, turn the fluid adjust
ment knob in (clockwise) to reduce the volume of fluid
output and obtain the desired results.
NOTE:
way
T
est Spray Pattern
Hold the gun about 6 to 8 inches (150 to 200 mm)
away from the surface of the test piece. Adjust the air
pressure to the gun until proper atomization is
achieved. Use the lowest possible air pressure to
obtain the desired results.
-
-
Continuous Spraying
Leave the fan and fluid adjustment valves in the full
open positions. This provides maximum fluid flow and
prevents premature wear on the fluid nozzle. Use
separate regulators to control the air and fluid flow to
the gun.
Short-term Operations
The pattern size may be reduced by turning in the fan
and fluid adjustment valves.
A Remote Fan V
The pattern width at the widest adjustment is
1 in. (254 to 279 mm) at 350 grams/min. fluid
, and other factors.
If the fluid adjustment knob is turned in all the
, the gun will emit only air
alve Kit is available. See
.
, air pressure,
.
-
-
-
6 308–044
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