Hitachi 308640 User's Manual
Contents
1. Co _ E QO 3 8 ep F Z ai or ra M G aA a eT E E 05986 KEY H Grounded Fluid Hose R Pressure Gauge ae J Pump S Trigger Safety A AirLine Filter K AirLine T Pump Runaway Valve B AirLine Lubricator Ve PpP G dWi i L Air Pressure Regulator ump Ground vvire C Bleed type Air Shutoff Valve W Gun Fluid Connector D Pump Air Regulator M Pump Fluid Inlet X Air Shutoff Valve E Fluid Drain Valve N In line Fluid Filter F Fluid Shutoff Valve P Pattern Adjustment Valve Knob Equipment required for safe operation of the G Fluid Filter Q Fluid Pressure Regulator system Must be purchased separately Fig 1 Typical Installation Ventilate the Spray Booth The typical installation shown in Fig 1 is only a guide WARNING for selecting and installing air assisted spray sys2. RA INSTRUCTIONS 4 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture malfunction or start unexpectedly and result in serious injury This equipment is for professional use only Read all instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain about usage call your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component This equip ment has a 4000 psi 28 MPa 280 bar maximum working pressure at 100 psi 0 7 MPa 7 bar maximum incoming air pressure Route the hoses away from the traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not use the hoses to pull the equipment Use only Graco approved hoses Do not remove hose spring guards which help protect the hose from rupture caused by kinks or bends near the couplings Use fluids or solvents that are compatible with the equipment wetted parts See the Technical Data section of all the equipment manuals Read the fluid and solvent manufacturer s warnings Wear hearing protection when operating this equipment Comply with all applicable local
3. Included with Gun 238402 238883 and 241070 only Gasket 18 must be replaced if diffuser seat 15 is removed or replaced to avoid fluid leakage VAN Included with Gun 238852 only 18 308640 Parts Use Only Genuine Graco Parts and Accessories Part No 238402 238852 238883 and 241070 Ref Ref No PartNo Description Qty No PartNo Description Qty 1 238750 BODY gun 1 354 172479 TAG instruction not shown 1 106917 ADAPTER air Included with Gun A Replacement Warning labels tags and cards are 238402 238883 and 241070 only 1 available at no cost 113367 COUPLING air quick disconnect Included with Gun 238852 only 1 Repair Kits a AE e a a KitNo and Includes 5 2174 VALVE rn adjustment Includes tems Saandsb 0 q Peseription Ret No PartNo Desaroton 5a 168110 O RING nitrile rubber L 224949 168110 O Ring 5b 105456 e RETAINER clip 1 Gun Repair 105456 Retainer 6 106903 SPRING compression air valve 1 Kit 106903 Spring 7 178408 CAP valve air 1 938754 Needle 8 203953 CAP PONEN hex hd 10 24 x 111516 O Ring nn aa 111517 Backup Ring 10 238754 NEEDLE fluid Included with Gun ra g 238402 238852 and 241070 only 238427 Diffuser seat Includes replaceable items 10a 10b 1 178422 Gasket 238 55 NEEDLE fluid hi flow Included 187521 Gasket with Gun 238883 only Includes 105452 U Cup replaceable items 10a and 10b 1 217487 Valve pa ae Ce Zoro 11 238248 TIP GUARD i iar nee ne 12 107079 O RING PTFE 1 AS PACKUP
4. and air separator 16 part no 238402 238852 238883 and 241070 guns only See Fig 8 Trigger the gun to back the fluid needle ball off the seat Remove the diffuser seat 15 Remove the trigger 3 and trigger extension pieces 19 See the Parts Drawing page 18 To remove the fluid needle cartridge 10 slide the notch of the packing tool 34 around the small diameter of the trigger guide A and pull the cartridge toward the front of the gun Remove the fluid gasket 18 If the fluid needle cartridge was removed for cleaning remove the external o ring 10a and backup ring 10b Clean the needle cartridge thoroughly with a compatible solvent and a soft brush Install a new o ring 10a and backup ring 10b Lubricate the o ring 10a and backup ring 10b of the new or cleaned needle cartridge with light weight oil Insert the fluid needle cartridge into the front end of the gun body Use the packing tool 34 to pull back on the cartridge until it snaps into place the cartridge must be bottomed out in the gun body insert If the cartridge is seated properly the needle cartridge washer B will be visibly seated flat through the back end of the gun body insert Insert a new gasket 18 Install the gun trigger and trigger extension pieces Lubricate the diffuser seat 15 thread Trigger the gun while screwing the diffuser seat back into the gun Torque the diffuser seat to 90 to 100 in lb 10
5. 238754 item 10 on page 19 Use with diffuser seat 238427 only 210501 Plastic Needle Kit 240679 4000 psi 28 MPa 280 bar Maximum Working Pressure Includes Plastic Ball Tipped Needle Assembly 240678 diffuser seat and gasket For use with acid catalyzed finishes and for light viscosity fluids Use with diffuser seat 224855 only Not recommended for use with AA RAC tips Bleed type Master Air Valve 300 psi 2 1 MPa 21 bar Maximum Working Pressure Relieves air trapped in the air line between the pump air inlet and this valve when closed 107141 3 4 npt m x f inlet amp outlet ESS 107142 1 2 npt m x f inlet amp outlet SS SY Air Line Quick disconnect 113367 Consists of 113410 Coupling female quick disconnect 113368 Coupling male quick disconnect Brush 101892 For cleaning the gun Fluid Swivel Connector 189018 5800 psi 40 MPa 400 bar Maximum Working Pressure To ease movement of the gun and fluid hose 1 4 18 npsm Air Whip Hoses 100 psi 0 7 MPa 7 bar Maximum Working Pressure To ease movement of the gun and hose 1 4 18 npsm polyurethane with SST braid 238759 3 ft 0 92 m hose 236873 6 ft 1 83 m hose Air Cap Verification Kit 239897 For air cap 239898 only to determine air pressure behind the air cap Do not use for actual spraying To be compliant atomizing air pressure must not exceed 10 psi 70 kPa 0 7 bar Conversion Kits Kits to convert from a gun with standard
6. state and national fire electrical and other safety regulations FIRE AND EXPLOSION HAZARD Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury Ground the equipment and the object being sprayed See Ground the System on page 6 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being sprayed Extinguish all the open flames or pilot lights in the spray area Electrically disconnect all the equipment in the spray area Keep the spray area free of debris including solvent rags and gasoline Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not smoke in the spray area Do not operate a gasoline engine in the spray area If there is any static sparking while using the equipment stop spraying immediately Identify and correct the problem 308640 3 Installation 4 gt U lt PN x lt NE
7. 2 to 11 2 Nem Install the gun air separator part no 238402 238852 238883 and 241070 guns only spray tip air cap or RAC housing and tip guard or AA RAC assembly Service Part No 238402 Spray Gun shown SERVICE NOTES Gasket 18 must be replaced if diffuser seat 15 is removed FLUID or replaced to avoid fluid leakage Gasket 17 must be replaced if fluid connector 30 is removed or replaced to avoid fluid leakage Torque to 20 24 ft lb 27 32 Nem Lubricate threads Torque to 15 19 ft lb 20 26 Nem Apply anaerobic pipe sealant to threads Apply high strength sealant to threads Lubricate with light weight oll Thread nut to bottom thread of needle Do not lubricate Use tool 34 to pull needle cartridge until it bottoms in gun body front end insert If the gun has the AA RAC assembly tighten the air cap retaining ring until it bottoms out while holding the orange tip guard in the desired direction Torque to 90 100 in lb 10 2 11 2 Nem U cup lips face inward Torque to 23 27 ft lb 31 37 Nem gt See ee 05989 PEPPPPEP bP D 308640 17 Parts Part No 238402 238852 238883 and 241070 SERVICE NOTES See Fig 8 for additional information 05990A Hix Apply high strength sealant to threads Gasket 17 must be replaced if fluid connector 30 is removed or replaced to avoid fluid leakage A N Torque to 23 27 ft lb 31 37 Nem San
8. 242511 250 300 0 013 Fe 242313 0 330 E 8 10 242413 200 250 10 12 242513 250 300 12 14 242613 300 350 0 015 es 242315 0 381 A 200 8 10 242415 200 250 10 12 242515 250 300 12 14 242615 300 350 0 017 E Hes 242317 0 432 E 8 10 242417 200 250 10 12 242517 250 300 12 14 242617 300 350 0 019 iy 242319 0 483 E E 8 10 242419 200 250 10 12 242519 250 300 12 14 242619 300 350 0 021 7 7 A 242321 0 533 E E 8 10 242421 200 250 10 12 242521 250 300 12 14 242621 300 350 Continued on the next page Spray Tip Selection Charts AA Reverse A Clean AA RAC Spray Tips Orifice at 12 Medium Heavy Size 300mm Viscosity Viscosity PartNo 0 023 8 10 40 0 34 0 242423 0 584 200 250 1 2 0 97 12 14 242623 300 350 0 025 10 12 50 0 42 0 242525 0 635 250 300 1 5 1 2 12 14 300 350 Orifice at 12 Medium Heavy Size 300mm Viscosity Viscosity PartNo 0 027 8 10 58 5 50 0 242427 0 686 200 250 1 7 1 4 0 029 10 12 68 0 59 0 242529 0 737 250 300 1 9 1 7 0 031 10 12 78 0 69 0 242531 0 787 250 300 2 2 2 0 l 300 350 Fluid output at 600 psi 4 1 MPa 41 bar Dimensions 05985 Measurements inches mm Gun AA BB CC DD Part No 5 238852 238883 7 5 191 6 9 175 7 5 239001 7 8 198 6 9 175 7 5 191 241070 7 5 191
9. 6 9 175 7 5 191 Dimension DD is taken from the end of the tip guard to the end of the quick disconnect air line fitting t On part no 238852 Dimension CC is taken from the top of the gun to the bottom of the quick disconnect air line fitting ee ee Aer 308640 25 Technical Data Maximum Working Fluid Pressure 4000 psi 28 MPa 280 bar Maximum Working Air Pressure 100 psi 0 7 MPa 7 bar Maximum Working Fluid Temperature 120 F 49 C Weight less filter 1 33 Ib 0 59 Kg Fluid Inlet p2ebsvacecenegesseesee aces 1 4 18 npsm Air Inlet Part No 238402 238851 238883 239001 and 241070 Guns 1 4 18 npsm R1 4 19 compound male thread Part No 238852 Gun 1 4 18 npsm quick disconnect fitting Wetted Parts Stainless Steel Carbide Ultra High Molecular Weight Polyethyl ene CV75 PTFE Delrin Delrin is a registered trademark of the DuPont Company CV75 is a registered trademark of the International Seal Co Inc Air Cap Pressure vs Gun Inlet Air Pressure for 239898 Air Cap only NOTE Air Cap Verification Kit 239897 is available See page 27 psi MPa bar 100 0 7 7 0 80 0 56 5 6 60 0 42 4 2 40 0 28 2 8 AIR CAP PRESSURE 20 0 14 1 4 psi 0 20 40 60 80 100 MPa 0 14 0 28 0 42 0 56 0 7 bar 1 4 2 8 4 2 5 6 7 0 GUN INLET AIR PRESSURE 26 308640 Sound Data
10. Gun with GG4 spray tip and 239781 air cap Fluid Air Pressure Pressure Pressuret Powert psi psi MPa bar MPa bar 4000 28 280 4000 28 280 Gun with GG4 spray tip and 239898 air cap Fluid Air Sound Sound Pressure Pressure Pressuret Powert psi psi dB A dB A MPa bar lak bar 600 4 1 41 2 1 0 21 4000 28 280 a 0 21 4000 100 28 280 0 7 7 82 0 i 85 0 Gun with 242 spray tip and 238701 air cap Fluid Air Sound Sound Pressure Pressure Pressuret Powert psi psi dB A dB A MPa bar Pe bar 600 85 8 4 1 41 2 1 0 21 4000 90 3 28 280 a 0 21 4000 100 94 4 28 280 0 7 7 T Sound pressure was measured at 1 meter from the unit Sound power was tested in accordance with ISO 9614 2 Accessories Use Only Genuine Graco Parts and Accessories Grounding Clamp and Wire 222011 12 ga 25 ft 7 6 m wire G4 High Pressure Ball Valves Viton Seals 5000 psi 35 MPa 350 bar Maximum Working Pressure Can be used as fluid drain valve 210657 1 2 npt m 210658 3 8 npt m 210659 3 8 x 1 4 npt m In line Fluid Filter 210500 5000 psi 35 MPa 350 bar Maximum Working Pressure 100 mesh Fits onto the gun s fluid connector 1 4 18 npsm Includes the parts shown below Yn 168517 aaa Filter 205264 164075 Ruby ball Needle Assembly 236678 Use to decrease wear with acid catalyzed finishes For use in place of the standard fluid needle part no
11. follow the Pressure Relief Proce dure on page 7 before removing or installing a spray tip Install a spray tip in the gun 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 for the desired spray pattern direction See Fig 3 NOTE If the gun has the AA RAC assembly hand tighten the air cap retaining ring while holding the orange tip guard in the desired direction If the retain ing ring is over tightened the spray tip will be difficult to rotate Vertical Spray Pattern Horizontal Spray Pattern 05991 Fig 3 Operation Adjust the Spray Pattern 5 Set the atomizing air pressure at about 10 psi 0 7 bar 70 kPa Check the spray pattern then adjust the air pressure until the tails are completely A WARNING atomized and pulled into the spray pattern See Fig 5 Do not exceed 100 psi 0 7 MPa 7 bar air RECOIL HAZARD pressure to the gun Due to the very high pressure fluid emitted a strong recoil action will occur when you trigger this gun If you are unprepared your hand could be forced back toward your body or you could lose your balance and fall resulting in serious injury For a narrower pattern turn the pattern adjustment valve knob clockwise If the pattern is still not narrow enough increase the air pressure to the gun slightly or use a different size tip NOTE Pattern adjustment is not available w
12. of the openings will cause paint to collect at that area RIGHT To avoid damage never hang the gun by the tip guard WRONG 0793A Fig 6 10 308640 Operation Clean the Spray Gun and System Daily A WARNING INJECTION HAZARD To reduce the risk of an injection injury or splashing fluid in the eyes or on the skin e Follow the Pressure Relief Procedure on page 7 before cleaning removing or installing a spray tip and whenever you are instructed to relieve pressure Do not wipe fluid buildup off the gun or spray tip until pressure is relieved 4 CAUTION To avoid damaging the gun e Never immerse the gun in solvent as this could damage packings and allow solvent in the air passages Do not use fluids containing halogenated hydrocarbons to clean the gun body as HHC is not compatible with aluminum Methylene Chloride is not recommended as a flushing or cleaning solvent with this gun or any device with nylon or aluminum components Do not use metal tools to clean holes in the air Cap or spray tip NOTE Clean the front of the tip frequently during the day to help reduce buildup AA RAC style tips require more frequent cleaning 1 Relieve the pressure as instructed on page 7 2 Clean the outside of the gun and the tip guard with a soft cloth dampened with compatible solvent 3 To avoid damaging the spray tip and air cap clean them with a compatible solvent and soft brush To clean th
13. 0 T o 100 150 6 150 200 8 10 200 250 10 12 250 300 00 Ta 100 ma 4 6 100 150 P ee i 50 200 8 10 200 250 10 12 250 300 12 14 300 350 Ta 150 ie a 55 500 8 10 200 250 10 12 250 300 12 14 300 350 14 16 350 400 308640 Pa i nes E E E GG4207 GG4307 GG4109 GG4209 GG4309 GG4409 GG4509 GG4111 GG4211 GG4311 GG4411 GG4511 GG4611 GG4213 GG4313 GG4413 GG4513 GG4613 GG4713 nii Orifice at 12 Medium Heavy Size 300mm Viscosity Viscosity 0 015 4 6 17 0 0 381 100 150 0 5 6 8 150 200 8 10 200 250 10 12 250 300 12 14 300 350 14 16 350 400 16 18 400 460 0 017 4 6 fa Hs 0 432 100 150 6 8 150 200 8 10 200 250 10 12 250 300 12 14 300 350 14 16 350 400 16 18 400 460 18 20 457 508 0 019 4 6 iy 0 483 100 150 6 8 150 200 8 10 200 250 10 12 250 300 12 14 300 350 14 16 350 400 16 18 400 460 18 20 457 508 Part No GG4215 GG4315 GG4415 GG4515 GG4615 GG4715 GG4815 GG4217 GG4317 GG4417 GG4517 GG4617 GG4717 GG4817 GG4917 GG4219 GG4319 GG4419 GG4519 GG4619 GG4719 GG4819 GG4919 ELLEELLE Spray Tip Selection Charts Standard Spray Tips for use with Air Cap 239781 Fan Width
14. 01 and 241070 Guns The gun air inlet has a 1 4 18 nosm R1 4 19 compound male thread that is compat ible with NPSM and BSP female swivel connectors Part No 238852 Gun The gun air inlet has a 1 4 18 npsm quick disconnect fitting Install an air shutoff valve X on each gun air supply line downstream of the gun air regulator to shut off air to the gun s Connect the air hose K from the air supply to the gun air inlet A WARNING INJECTION HAZARD To reduce the risk of property damage or serious injury including fluid injection which could be caused by component rupture or unrelieved fluid pressure Vea A fluid drain valve s E is required in your system to assist in relieving fluid pressure in the displacement pump hose and gun triggering the gun to relieve pressure may not be suffi cient A fluid pressure regulator Q must be installed in the system if the pump s maximum working pressure exceeds the gun s maximum fluid working pressure of 4000 psi 28 MPa 280 bar Install a fluid filter G and drain valve s E close to the pump s fluid outlet The drain valve assists in relieving fluid pressure in the displacement pump hose and gun See Fig 1 Install a fluid pressure regulator Q to control fluid pressure to the gun NOTE Some applications require fine tuned control of fluid pressure You can control fluid pressure more accurately with a fluid pressure regulator than by r
15. 1 239173 Hifluearseut 15 239172 DIFFUSER SEAT Included with Gun 178422 Cake aai 187521 Gasket 239173 DIFFUSER SEAT hi flow Included with Gun 239001 only 1 105452 U Cup 17 178422 GASKET fluid Delrin 217487 Valve 1 sent unassembled 2 239179 238755 Needle 18 187521 GASKET fluid acetal homopolymer Hi flow Fluid 111516 O Ring black 1 sent unassembled 2 Section 111517 Backup Ring E glia oe 230173 Diffuser seat needle 24 178765 NUT packing air i Aan ae 25 105452 U CUP PTFE 1 26 217487 VALVE air 1 Must be used with tips larger than 0 025 in 0 635 mm 29 238228 GUARD trigger 1 30 191026 CONNECTOR fluid 1 314 222385 WARNING CARD not shown 1 34 187737 TOOL needle assembly 1 354A 172479 TAG instruction not shown 1 A Replacement Warning labels tags and cards are available at no cost 308640 21 mm Spray Tip Selection Charts NOTE Part No 238755 Fluid Needle and 224855 Diffuser seat must be used with GG4 tips larger than 0 025 in 0 635 Standard Spray Tips for use with Air Cap 239781 FanWidth Lightto Orifice Size inches mm Fan Width at 12 300 mm ag mm a Medium Viscosity a oz min liters min Lightto Heavy Viscosity floz min liters min 3 Part No 0 007 2 4 4 0 GG4107 0 178 50 100 0 1 0 009 0 229 0 011 0 279 0 013 0 330 ME 22 4 6 100 150 1 HET Zzp TN 50 10
16. INSTRUCTIONS PARTS LIST Cs 308640 Rev J 9 This manual contains important GRACO warnings and information _ Supersedes G READ AND KEEP FOR REFERENCE FSI COICO WOEN includes Rev H quality counts INSTRUCTIONS HIGH PRESSURE AIR ASSISTED Model AA Plus Spray Gun 4000 psi 28 MPa 280 bar Maximum Working Fluid Pressure 100 psi 0 7 MPa 7 bar Maximum Working Air Pressure Part No 238402 Series A Spray Gun with standard spray tip tip guard air cap and 1 4 18 npsm R1 4 19 air line fitting Part No 238851 Series B Spray Gun with AA Reverse A Clean RAC assem bly and 1 4 18 npsm R1 4 19 air line fitting Part No 238852 Series A Spray Gun with standard spray tip tip guard air cap and quick disconnect air line fitting Part No 238883 Series A Hi Flow Spray Gun with Hi Flow fluid needle and diffuser seat and standard spray tip tip guard air cap and 1 4 18 nosm R1 4 19 air line fitting LAB Part No 239001 Series B Hi Flow Spray Gun with Hi Flow fluid needle and diffuser seat AA Reverse A Clean RAC assembly Ne apaa and 1 4 18 npsm R1 4 19 air line fitting Part No 238402 Spray Gun shown Part No 241070 Series A HVLP Spray Gun with standard spray tip HVLP air cap and 1 4 18 npsm R1 4 19 air line fitting U S Patent Nos 3 843 052 4 386 739 5 285 965 United Kingdom Patent No 2 111 406 B Patented 1984 Canada Brevete 1984 French
17. IRINO 13 239781 AIR CAP Included with Gun 238427 Diffuser seat 238402 238852 and 238883 only 1 178422 Gasket 239898 AIR CAP Included with Gun 187521 Gasket 241070 only 1 238739 168110 O Ring 14 GG4XXX SPRAY TIP Customer s choice Hi flow Gun 105456 Retainer See Chart on page 22 Includes Repair Kit 106903 Spring replacement gasket 183616 1 15 238427 DIFFUSER SEAT Included with Gun ao SECA 238402 238852 and 241070 only 1 111516 O Ring 224855 DIFFUSER SEAT hi flow Included 111517 Backup Ring with Gun 238883 only 1 107079 O Ring 16 178414 SEPARATOR air 1 224855 Diffuser seat 17 178422 GASKET fluid Delrin 178422 Gasket 1 sent unassembled 2 187521 Cakal 18 187521 GASKET fluid acetal homopolymer 105452 U Cup black 1 sent unassembled 2 19 224868 TRIGGER EXTENSION 2 Ued uae 29 187504 NUT needle 238738 2387955 Needle 24 178765 NUT packing air 1 Hi flow Fluid 111516 O Ring 25 105452 U CUP PTFE Se 111517 Backup Ring 26 217487 VALVE air 1 Lai 224855 Diffuser seat 29 238228 GUARD trigger 1 178422 Gasket 30 191026 CONNECTOR fluid 1 314 222385 WARNING CARD not shown 1 _ a 34 187737 TOOL needle assembly 1 Must be used with tips larger than 0 025 in 0 635 mm 308640 19 Parts Part No 238851 and 239001 14a SERVICE NOTES See Fig 8 for additional information TAN Apply high strength sealant to threads Torque to 23 27 ft lb 31 37 Nem A Gasket 18 must be replaced if diffuser seat 15 i
18. Light to Fan Width Light to Orifice at 12 Medium Heavy Orifice at 12 Medium Heavy Size 300mm Viscosity Jiscosity Part No Size 800mm Viscosity Viscosity PartNo 0 021 6 8 35 0 27 0 GG4321 0 029 8 10 ee 7 ae A GG4429 0 533 150 200 1 0 0 8 i 737 200 250 8 10 GG4421 12 14 GG4629 200 250 300 350 10 12 GG4521 0 031 8 10 7 a 5 GG4431 250 300 0 787 200 250 12 14 GG4621 12 14 GG4631 300 350 300 350 14 16 GG4721 18 20 GG4931 350 400 457 508 16 18 GG4821 0 033 12 14 a fs GG4633 400 460 0 838 300 350 18 20 GG4921 16 18 GG4833 457 508 400 460 0 023 8 10 a 34 0 GG4423 18 20 GG4933 0 584 200 250 0 97 457 508 10 12 GG4523 0 035 8 10 a 7 GG4435 250 300 0 889 200 250 12 14 GG4623 10 12 GG4535 300 350 250 300 14 16 GG4723 12 14 GG4635 350 400 300 350 16 18 GG4823 16 18 GG4835 400 460 400 460 18 20 GG4923 18 20 GG4935 457 508 457 508 0 025 8 10 A 7 GG4425 0 037 14 16 i GG4737 0 635 200 250 0 940 350 400 pe av i i GG4525 0 039 8 10 T n 0 GG4439 0 991 200 250 12 14 GG4625 4 300 350 l o a i i GG4539 14 16 GG4725 4 350 400 a pm GG4639 16 18 GG4825 4 ed E 400 460 0 027 a 7 7 7 GG4327 0 686 EET Fluid output at 600 psi 4 1 MPa 41 bar 8 10 GG4427 p psi 200 250 TET EEA Fluid output Q at other pressures P can be calcu
19. Patent No 82 21202 Patents Pending Foreign Patents Pending GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1996 GRACO INC Graco Inc is registered to I S EN ISO 9001 Table of Contents NV ANOS cscs oa sh e dessin Bap sed Parola Ges Sok Raves Bow Gok Baden aes 2 Spray Tip Selection Chart 000005 22 STAN ATO E 6 4 ee done est eee eee ae 4 AIr GAS oc deen atta x bop gredai eni ai edi eared i deb a 22 Operation 0 cee ene 7 DIMENSIONS 1 eee eens 25 General Troubleshooting 00 cee eaee 14 Technical Data ccf an ace 6 eet wees he ech ie ee ee ee 26 Spray Pattern Troubleshooting 15 ACCESSOVIES 1 ee tees 27 OGIVICE aparis poa a ih E ey OS 16 Warranty cee aueicndauedanetauneevetavecannsene 28 PONS fate esa oa ered Saree eee oe a ee a oe 18 Graco Phone Number 20000eeee 28 A WARNING INJECTION HAZARD Spray from the gun hose leaks or ruptured components can inject fluid into your body and cause an 2 extremely serious injury including the need for amputation Splashing fluid in the eyes or on the skin can also cause a Serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate medi cal attention e Do not point the spray gun at anyone or at any part of the body e Do not put hand or fingers over the spray tip e Do not stop or deflect fluid leaks with your hand body
20. avec les procedures concern es Graco Phone Manual Number Change Summary TO PLACE AN ORDER contact your Graco distribu Manual changed per ECO V4782 tor or call this number to identify the distributor closest to you 1 800 367 4023 Toll Free All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Sales Offices Minneapolis Detroit Foreign Offices Belgium England Korea France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 http www graco com PRINTED IN U S A 308640 April 1996 Revised December 1998 28 308640
21. e Keep the wallet sized warning card 179960 pro pressure may not be sufficient Have a container vided with the gun with the operator of this equip ready to catch the drainage ment at all times The card contains important g treatment information should an injection injury occur Additional cards are available at no charge from Graco Leave the drain valve s open until you are ready to spray again 9 If you suspect that the spray tip or hose is com pletely clogged or that pressure has not been fully relieved after following the steps above very Pressure Relief Procedure slowly loosen the hose end coupling and relieve pressure gradually then loosen the coupling completely Now clear the tip or hose obstruction A WARNING INJECTION HAZARD Ea 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 n pers check or service any of the system equipment ON SAFE Position or install or clean the spray tip 1 Lock the spray gun trigger safety to avoid acciden tally triggering the gun See Fig 2 Shut off the power to the pump l Trigger Safety Unlocked Close the bleed type mast
22. e air cap passages use a soft brush or other soft tool Dry the parts with an air blow gun 4 lf using an in line filter remove and clean it thoroughly in a compatible solvent 5 Clean the system s fluid filter and air line filter Check the Diffuser seat Operation Weekly A WARNING INJECTION HAZARD The gun diffuser seat breaks up spray when the gun is sprayed without the spray tip installed such as during flush ing This reduces the risk of an injection injury Check the diffuser seat operation weekly 1 Relieve the pressure as instructed on page 7 2 Remove the tip guard and spray tip 3 Start the pump and operate it at its lowest pres sure 4 Hold a metal part of the gun firmly against a grounded metal waste container and trigger the gun See Fig 7 If the fluid coming from the gun is not diffused into an irregular stream replace the diffuser seat immediately AN Va N A Vay us Ww A Lay D wa AN Maintain firm metal to metal contact between the gun and a grounded metal container Fig 7 05988 308640 11 Operation Flush the Gun Daily A WARNING INJECTION HAZARD To reduce the risk of a fluid injection injury follow the Pressure Relief Proce dure on page 7 before cleaning removing or installing a spray tip and whenever you are instructed to relieve pressure A WARNING To reduce the risk of serious injury including splashing fluid in t
23. egulating the air pressure to the pump 3 Install a fluid shutoff valve F to shut off the fluid supply to the gun Install an in line fluid filter N on the gun fluid fitting W to avoid clogging the spray tip with particles from the fluid Connect the grounded fluid hose H to the gun fluid fitting W or optional in line filter N 308640 5 Installation Ground the System A WARNING FIRE AND EXPLOSION HAZARD Improper grounding could cause static sparking which could cause a fire or explosion To reduce the risk of property damage or serious injury follow the grounding instructions below The following grounding instructions are minimum requirements for a system Your system may include other equipment or objects which 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 l 6 Pump 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 sup plies Ground them according to the manufacturer recommendations 308640 3 Air fluid and hydraulic hoses connected to the pump Use only electrically conductive hoses with a maximum of 500 feet 150 m combined hose length to ensure grounding continuity Check the electrical resistance of
24. er air valve required in or in OFF SAFE Position the system 05987 4 Unlock the gun trigger safety Fig 2 308640 7 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 slightly adjusted by the pattern adjustment valve Note that 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 less pattern air or a larger size tip must be used 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 Select a Spray Tip and Air Cap The fluid output and pattern width depend on the size of the spray tip the fluid viscosity and the fluid pres sure Use the Spray Tip Selection Chart on page 22 as a guide for selecting an appropriate spray tip for your application 8 308640 Install a Spray Tip A WARNING INJECTION HAZARD To reduce the risk of a fluid injection injury
25. glove or rag e Do not blow back fluid this is not an air spray gun e Always have the tip guard on the spray gun when spraying e Check the gun diffuser operation weekly Be sure the gun trigger safety operates before spraying e Lock the gun trigger safety when you stop spraying Follow the Pressure Relief Procedure on page 7 whenever you are instructed to relieve pres sure stop spraying clean check or service the equipment or install or clean the spray tip Tighten all the fluid connections before operating the equipment e Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire hose TOXIC FLUID HAZARD Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin swallowed or inhaled Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Wear the appropriate protective clothing gloves eyewear and respirator RECOIL HAZARD Due to the very high pressure fluid emitted a strong recoil action will occur when you trigger this gun If you are unprepared your hand could be forced back toward your body or you could lose your bal ance and fall resulting in serious injury 2 308640
26. he eyes or on the skin or static electric discharge when flushing Be sure the entire system including flushing pails are properly grounded Remove the tip guard and spray tip Maintain metal to metal contact between the gun and a grounded metal waste container See Fig 7 page 11 Use the lowest possible pressure NOTE Flush the pump and gun before the fluid can dry in it e lf itis available the flushing procedure provided in the pump or sprayer manual should be used instead of this procedure 12 308640 1 Relieve the pressure as instructed on page 7 2 Disconnect the atomizing air hose and the fluid supply line 3 Remove the tip guard or AA RAC assembly 11 air cap or RAC housing 13 and spray tip 14 Refer to the parts drawing for your gun model page 18 or 20 4 Clean the parts 5 Connect a compatible solvent supply to the gun 6 Start the pump and operate it at its lowest pres sure 7 Hold a metal part of the gun firmly against a grounded metal waste container and trigger the gun until all the paint is removed from the gun passages 8 Relieve the pressure as instructed on page 7 9 Disconnect the solvent supply NOTE f the gun is being used with plural component materials remove the needle cartridge and thoroughly clean it with a soft brush to ensure that the material does not cure in the spring area and make the gun inoperable See page 16 to remove the needle car tridge No
27. ith guns with the AA RAC assembly as the air separa tor part no 178414 must be removed when the A WARNING RAC assembly is installed INJECTION HAZARD To reduce the risk of component rupture and serious injury including injection do not exceed the gun s maximum fluid working pressure of 4000 psi 28 MPa 280 bar or the maximum working pressure of the lowest rated component in the system Pattern Adjustment A Knob 0789A 1 Set the fluid pressure with the fluid regulator Do Fig 4 not turn on the air supply yet 2 Trigger the gun to check the atomization do not be concerned about the pattern shape yet 3 Increase the fluid pressure just to the point where a further increase in fluid pressure does not signifi cantly improve fluid atomization 4 Close the pattern adjustment valve by turning the No Air Too Little Air Right Amount knob see Fig 4 counterclockwise all the way l of Air n This sets the gun for its widest pattern e 308640 9 Operation Apply the Fluid When applying the fluid keep the gun a consistent distance about 8 to 12 inches 200 to 300 mm from the surface of the object being sprayed Always hold V the gun at a right angle from the surface Do not make an arc with the gun as it causes an uneven coat of a Vad K fluid See Fig 6 j j A CAUTION Openings in the tip guard reduce paint buildup on the guard while spraying Damage to the sharp edges
28. lated by this 250 300 formula Q 0 041 QT VP 12 14 GG4627 Where QT Fluid output fl oz min from the above table for 300 350 the selected orifice size 16 18 GG4827 NOTE Other tips are available on special work order Allow 4 400 460 to 6 weeks for delivery 308640 23 Spray Tip Selection Charts Standard Sealer Tips for use with Air Cap 239781 NOTE Part No 238755 Fluid Needle and 224855 Diffuser seat must be used with GG4 tips larger than 0 025 in 0 635 mm Light to Orifice Medium Heavy Viscosity floz min liters min Size Viscosity inches floz min mm liters min Fluid output at 600 psi 4 1 MPa 41 bar AA Reverse A Clean AA RAC Spray Tips Fluid Seat Housing 193000 AA RAC 192096 Tip Guard Air Cap Assy 238701 Tip Cylinder full soray position ss 8027A NOTE e AA RAC Tips 242XXX feature a 1 piece plastic fluid seat 193000 Do not use in combination with parts from previous generations of AA RAC Tips AARXXX e The air separator item 16 must be removed when using the AA RAC e AA RAC Conversion Kits are available See page 27 24 308640 AA Reverse A Clean AA RAC Spray Tips Fan Width Light to a T Orifice at 12 Medium Heavy Size 300 mm Viscosity Viscosity Part No inches Inches floz min floz min mm mm liters min liters min 0 011 10 0 242311 0 279 TE 0 3 8 10 242411 200 250 10 12
29. r incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement
30. s removed or replaced to avoid fluid leakage A N Gasket 17 must be replaced if fluid connector 30 is removed or replaced to avoid fluid leakage 06759B 20 308640 Parts Use Only Genuine Graco Parts and Accessories Part No 238851 and 239001 Repair Kits ng Part No Description Qt See ee p y Description eee oe eee pm eno OR 3 276429 TRIGGER gun a Repair 105456 mOran 5 217489 VALVE pattern adjustment 106903 Spring Includes items 5a and 5b 1 238754 Needle 5a 168110 O RING nitrile rubber 1 111516 O Ring 5b 105456 e RETAINER clip 1 111517 Backup Ring 6 106903 SPRING compression air valve 1 239172 Diffuser seat 7 178408 CAP valve air 1 178422 Gaskel 8 203953 CAP SCREW hex hd 10 24 x 187521 Gaskel 0 375 long 1 187562 PIN pivot 1 nies ae 10 238754 NEEDLE fluid Included with Gun 238851 only Includes replaceable 239178 238754 Needle items 10a and 10b Fluid Section 111516 O Ring 238755 NEEDLE fluid hi flow Included with Repair Kit 111517 Backup Ring Gun 239001 only Includes 239172 Diffuser seat replaceable items 10a and 10b 1 178422 Gasket 10a 111516 e O RING CV75 1 187521 Gasket 10b 111517 e RING backup PTFE 1 11 238701 AA RAC TIP GUARD RE mony ang AIR CAP ASSY 1 ieee a 105456 Retainer 13 192096 RAC HOUSING 1 E 106903 Spring 14 242XXX AA RAC SPRAY TIP Customer s 238755 Needle choice See Chart on page 24 111516 O Ring Includes item 14a 1 111517 Backup Ring 14a 193000 eFLUID SEAT
31. spray tip tip guard and air cap to a gun with the AA RAC assem bly See parts list and drawing below for parts included with kit 240462 Use with gun part no 238402 and 238852 to convert to gun part no 238851 240463 Use with gun part no 238883 to convert to gun part no 239001 Ref No Part No Description Qty 1 238701 AA RAC AIR CAP ASSEMBLY 1 2 192096 RAC HOUSING 1 3 242XXX TIP CYLINDER tip of choice Includes item 3a 1 3a 193000 e FLUID SEAT 1 4 239172 DIFFUSER SEAT Included with Kit 240462 only 1 239173 DIFFUSER SEAT hi flow Included with Kit 240463 only 1 3 187521 GASKET fluid acetal homopolymer black 1 06765B 308640 27 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship onthe date of sale by an authorized Graco distributor to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadeq
32. tems Fe ee oe on rece g TOXIC FLUID HAZARD 7 7 d SY To prevent hazardous concentrations of i IA toxic and or flammable vapors spray only in a properly ventilated spray booth Never operate the spray gun unless ventilation fans are operating Check and follow all of the National State and Local codes regarding air exhaust velocity require ments 4 308640 Installation Connect the Fluid Line Connect the Air Line k Install an air line filter A to ensure a clean dry air supply to the gun Dirt and moisture in the line can ruin the appearance of your finished piece See Fig 1 Install an air pressure regulator L on the gun air supply line to control the air pressure to the gun Install an air pressure regulator D on the pump air supply line to control air pressure to the pump Install a bleed type air shutoff valve C on the main air line and on the pump air line downstream of the pump air regulator to shut off air to the pump Install an additional bleed type valve on each pump air supply line to relieve air trapped between this valve and the pump after the air regulator is shut off A WARNING The bleed type air shutoff valve is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed Trapped air can cause the pump to cycle unexpect edly which could result in serious injury NOTE 5 Part No 238402 238851 238883 2390
33. tes 308640 13 Troubleshooting NOTE A WARNING e Check all possible remedies in the troubleshooting charts before disassembling the gun eE TOARN Some improper patterns are caused by the To reduce the risk of a fluid injection PAPAT y injury follow the Pressure Relief Proce M prO pAr DAAC OEA E E dure on page 7 before checking or servicing any of the system equipment and when ever you are instructed to relieve pressure General Troubleshooting Problem Cause Solution Fluid leakage from back of fluid Worn packings or needle shaft Replace external needle packings or needle entire fluid needle cartridge See page 16 Air leakage from front of gun Air valve not seating properly Clean service air valve See page 16 Fluid leakage from front of gun Fluid needle worn or damaged Replace fluid needle cartridge See page 16 Worn diffuser seat housing Replace the diffuser seat and gasket The gasket must be replaced when ever the diffuser seat is removed See page 16 Fluid in air passages Fluid tip seal leaking Tighten or replace fluid tip Leaking around diffuser seat housing Replace the diffuser seat gasket The gasket must be replaced whenever the diffuser seat is removed See page 16 Fluid inlet fitting leaking Replace the fluid fitting gasket The gasket must be replaced whenever the fluid fitting is removed See page 17 Slow fluid shut off Fluid buildup on fluid needle cartridge Remo
34. uate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any othe
35. ve and clean or replace the components fluid needle cartridge See page 16 Diffuser seat is overtightened Remove diffuser seat and replace diffuser seat gasket Torque diffuser seat to 90 100 in lb 10 2 11 2 Nem 14 308640 Spray Pattern Troubleshooting Problem Fluttering or spitting spray i Cause Insufficient fluid supply Air in paint supply line Attempting to feather partially trig ger the gun Troubleshooting Solution Adjust fluid regulator or fill fluid supply tank Check tighten siphon hose connec tions bleed air from paint line Cannot feather with an AA gun Feathering will cause drastic reduc tion of pressure at the tip resulting in poor atomization and or spitting Irregular pattern Fluid build up or spray tip partially plugged On defective side of pattern air horn holes are partially or totally plugged Clean spray tip See page 11 Clean air horn holes with solvent and soft brush See page 11 Pattern pushed to one side same side of air cap gets dirty Air horn holes partially or totally plugged Clean air horn holes with solvent and soft brush See page 11 308640 15 a Service Fluid Needle Cartridge Service A WARNING INJECTION HAZARD To reduce the risk of a fluid injection injury follow the Pressure Relief Proce dure on page 7 before checking or servicing any of the system equipment and when e
36. ver you are instructed to relieve pressure NOTE Follow the Service Notes in Fig 8 when reassem bling the gun Refer to the parts drawing for your gun model page 18 or 20 for parts not shown in Fig 8 Repair Kits are available See page 19 or 21 for the kits for your gun model Air Valve Service i A CAUTION To avoid leakage be careful not to scratch the air valve stem 4 5 16 Relieve the pressure as instructed on page 7 Remove the trigger 3 and valve cap 7 See the parts drawing and Fig 8 Unscrew the needle nut 23 while holding the flats C of the air valve 26 stem with a long nose pliers Remove the spring 6 and air valve 26 If there is air leakage at the air valve 26 unscrew the packing nut 24 and carefully remove the u cup packing 25 Replace packing if worn or damaged When re installing be sure the u cup faces inward If leakage occurs internally or the front of the gun leaks air when it s not triggered clean and inspect the air valve and the spring for wear or damage Replace as needed For best air valve life lubricate the external air valve stem C with light oil after each day s use 308640 Follow the procedure below to remove the fluid needle cartridge for cleaning or for replacement 1 2 13 Relieve the pressure as instructed on page 7 Remove the tip guard or AA RAC assembly 11 air cap or RAC housing 13 spray tip 14
37. your air and fluid hoses at least once a week If the resistance exceeds the recommended limits replace the hose immediate ly Spray gun Ground the gun by connecting it to a properly grounded fluid hose and pump Fluid supply container Ground it according to local code Object being sprayed Ground it according to local code All solvent pails used when flushing Ground them according to local code Use only metal pails which are conductive Do not place the pail on a non conductive surface such as paper or card board which interrupts the grounding continuity To maintain grounding continuity when flush ing or relieving pressure Always hold a metal part of the gun firmly to the side of a grounded metal pail then trigger the gun Operation Safety 5 Hold a metal part of the gun firmly to the side of a A WARNING grounded metal waste container and trigger the gun to relieve the fluid pressure 6 Lock the gun trigger safety again INJECTION HAZARD 7 Open the pump drain valve required in the sys On Remember this is not an air spray gun tem to help relieve fluid pressure in the displace For your safety be sure to read and ment pump In addition open the drain valve follow the Warnings on pages 2 and 3 connected to the fluid pressure gauge in a system and throughout the text of this instruction manual with fluid regulation to help relieve fluid pressure in the hose and gun Triggering the gun to reliev
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