Selection Charts

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 Water- borne Enamels

Selection Charts

Proper Needle/Nozzle Selection

The spray gun's needle/nozzle kits range in size to pro- vide 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 MPa, 3.5 bar - 0.14 MPa. 14 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 thicker, abrasive fluids, hardened SST needle tips and nozzles are recommended.

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.

Compliant Guns

A compliant 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 compliant air cap consumes much less air than the HVLP air cap.

The Graco compliant guns have no restrictions on air cap pressures, but the gun inlet pressure must remain under 30 psi (0.21 MPa, 2.1 bar) to remain in compli- ance.

Automatic Gun Air Consumption

Manifold Inlet Pressure psi

Airspray Atom. Flow

HVLP Atom. Flow

Compliant Atom. Flow

Airspray Fan Flow

HVLP Fan Flow

Compliant Fan Air Flow

Installation

Installation

The Automatic XT spray guns were designed to produce the highest quality finish with today's fluids as well as the low V.O.C. (volatile organic compound) fluids of tomorrow.

This spray gun can spray most coatings or finishes cur- rently being used for automotive, industrial, aerospace, marine, wood, plastic and architectural 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 bar) air pressure.

Ventilate Spray Booth

Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

Check and follow all local safety and fire codes.

Configure Gun and Manifold

The gun is supplied with an internal fluid plug and seals (19, 20, 21). To use the gun in a circulating system, remove the internal plug. In a non-circulating system, leave the plug in place to minimize flush time.

Circulating System

1.Apply anti-seize lubricant to the threads and mating faces of the manifold (101) and the elbows (107), supplied unassembled.

2.Install the elbows (107) in both fluid ports of the manifold (101).

3.Connect the fluid supply line to one elbow and the fluid return line to the other. The manifold fluid ports are reversible.

4.Install the gun on the manifold, using the four screws (13). Start the threads of all four screws. Tighten the front two screws first, and then tighten the back two. Torque all four screws evenly to 65 in-lb (7.3 N???m).

Non-circulating System

1.See FIG. 3. See Apply anti-seize lubricant 222955 to the threads and mating faces of the manifold (101), plug (109), and elbow (107), supplied unassembled.

2.Install an elbow (107) in one fluid port of the mani- fold (101), and a plug (109) in the other port.

3.Install the internal plug (5) in the gun fluid port on the same side as the manifold plug.

4.Connect the fluid supply line to the fluid inlet elbow (107).

5.Install the gun on the manifold, using the four screws (13). Start the threads of all four screws. Tighten the front two screws first, and then tighten the back two. Torque all four screws evenly to 65 in-lb (7.3 N???m).

21

107

2 109

TI8587b

FIG. 3: Non-Circulating Setup Shown (cutaway view)

Install Air Fittings

1.Install the supplied 1/4 in. tube fitting into the cylin- der (CYL) air port.

2.Install 3/8 in. tube fittings into the atomization (ATOM) air port and the fan (FAN) air port.

CYL

ATOM

FIG. 4: Air Fittings

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.

Ground 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.

Ground Air Compressors and Hydraulic

Power Supplies

Ground the air compressors and hydraulic power sup- plies according to the manufacturer recommendations.

Ground 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. The resistance must be less than 1 megohm.

Installation

Ground Fluid Supply Container

Ground the fluid supply container according to local code.

Ground Object Being Sprayed

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

Ground Solvent Pails

Ground all solvent pails that are used when flushing 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 cardboard, which interrupts the grounding continuity.

Installation

Mount Gun

Reciprocating Arm Rod Mount

To mount the gun on a reciprocating arm rod [0.5 in. (13 mm) diameter maximum]:

1.Insert the mounting bar (A) through the hole in the manifold as shown in FIG. 5.

Use the 1/8 in. alignment pin (P) to assist in orient- ing the gun.

2.Secure the gun to the bar by tightening the mount- ing screw (B).

B

P

FIG. 5: Reciprocating Arm Mount

Stationary Support

To mount the gun on a stationary support (refer to FIG. 6 and Mounting Hole Layout, page 35):

1.Align the manifold with the alignment pins. Locate alignment pins and holes per the Mounting Hole Layout illustration, page 35.

2.Secure the gun to the support with two M5 x 0.8 capscrews (C). The screws must be long enough to engage the threaded holes in the gun manifold to a depth of 1/4 in. (6 mm).

C

TI8095 a

FIG. 6: Stationary Support Mount

Retrofit Adapter Plate

The retrofit adapter plate enables the manifold to be attached to a variety of bolt patterns.

To mount the gun using the retrofit adapter plate (kit 288197):

1.Mount adapter plate to manifold using the three screws provided with the kit (FIG. 7).

2.Bolt plate to mounting surface using four M5 x 0.8 capscrews. Refer to the Mounting Hole Layout, page 36.

TI8180a

FIG. 7: Retrofit Adapter Plate Mount

Connect Air Line

You must install an air pressure regulator (F) on each gun air line to control air pressure to the gun. See FIG. 8.

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 work- piece. See FIG. 8.

Install a bleed type air shutoff valve (E) on each gun air supply line, downstream of the gun air regu- lator, to shut off air to the gun.

1.For manifolds with a separate ATOM and FAN port, the gun cylinder, fan, and atomization air must be supplied and regulated separately. For the manual fan valve manifold, only one supply line is required for both atomization and fan air.

The gun atomizing and fan air inlets are 3/8 in. O.D. tubing. The cylinder air inlet accepts 1/4 in. (6.3

mm) O.D. tubing. Use 3/8 in. (9.5 mm) O.D. tubing for fan and atomization air to minimize excessive pressure drop in the hoses.

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

F

D

H

G

E

TI01990

FIG. 8: Connect Air Line

Connect Fluid Hose

Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent that is compat- ible with the fluid to be sprayed.

Install a fluid regulator (L) on the fluid line to control fluid pressure to the gun. See FIG. 9.

Install a fluid shutoff valve (M) to shut off the fluid supply to the gun. See FIG. 9.

Filter the fluid line of coarse particles and sediment to avoid clogging the fluid nozzle and causing fin- ishing defects.

1.Connect the fluid supply hose (J) to the gun fluid inlet (S) 1/4 npsm thread. See FIG. 10.

2.Connect the other end of the fluid hose (J) to a regu- lated fluid supply outlet (M). See FIG. 9.

3.In a circulating system, connect a grounded fluid return hose to the gun fluid outlet (T). See FIG. 10.

In a non-circulating system, remove the gun fluid outlet fitting (T) and plug the outlet port with the pipe plug supplied. See FIG. 10.

TI7016a

FIG. 9: Connect Fluid Hose

Setup

KEY

N Cylinder Air Inlet: accepts 1/4 in. (6.3 mm) O.D. tubing

P Atomization Air Inlet: 3/8 in, (9.5 mm) O.D. tubing

R Fan Air Inlet: 3/8 in. (9.5 mm) O.D, tubing

S Fluid Inlet: 1/4 npsm

T Fluid Outlet (circulating gun only): 1/4 npsm

Side Mounted Manifold Ports

N

FAN ATOM

CYL

TI8096a

RP

Bottom Mounted Manifold Ports

N

FIG. 10: Manifold Ports

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.

2.Perform Pressure Relief Procedure; see page 17.

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 hori- zontal spray pattern, use a needle nos pliers 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. 11.

TI8171a

Vertical Pattern

A

TI8170a

TI8172a Horizontal Pattern

FIG. 11: Position Air Cap

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.

The spray gun fluid flow is controlled by the fluid pres- sure regulator and the fluid control knob. Use the fluid pressure regulator to adjust the general fluid flow and the fluid control knob to make precise fluid flow adjust- ments.

CAUTION

Use caution when operating the fluid control valve near the closed position. The plastic needle tip may be damaged if forced too hard against the nozzle seat by the fluid control valve.

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.

L

TI7019a

FIG. 12: Fluid Pressure Regulator

Setup

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, this allows air to act on the fluid longer and improve the 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

HVLP and Compliant 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. 35 psi (25 kPa, 2.5 bar) inlet air yields 10 psi (70 kPa, 0.7 bar) at the air cap. To measure pressure at the air cap, use the accessory tapped air cap. See Accessories, page 33.

Compliant Guns: the maximum inlet pressure to the manifold is 30 psi atomizing air.

Setup

F

FIG. 13: Air Pressure Regulator

TI01997

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 con- tainer to relieve air and fluid pressure.

TI8174a

FIG. 14: Pressure Relief

Apply Fluid

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 actuation air is stopped, the fluid stops before the air flow stops. This helps ensure that the spray is atomized and prevents fluid buildup on the air cap and tip.

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. Keep the gun a consistent distance, 6 to 8 in. (150 to 200 mm), from the surface of the object being sprayed.

Operation

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 surface to be sprayed with 50% overlap.

Incorrect

TI8098a

Correct

TI8099a

FIG. 15: Correct Spray Method

Do not point the gun up while cleaning it.

Do not wipe the gun with a cloth soaked in solvent; ring out the excess.

General System Maintenance

???Perform Pressure Relief Procedure, page 17.

???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.Perform Pressure Relief Procedure, page 17.

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.

5.Perform Pressure Relief Procedure, page 17.

6.Disconnect the solvent supply.

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

CAUTION

Trigger the gun or remove the piston cap whenever you tighten or remove the nozzle. This keeps the nee- dle seat away from the nozzle seating surface and prevents the seat from being damaged.

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

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

Daily Gun Care

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. 17). 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.

TI8176a

FIG. 17:

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

13.Dampen a soft cloth with solvent and wring-out the excess. Point the gun down and wipe off the outside of the gun.

Service

Items Needed for Service

???1/16 in. Hex Wrench - provided

???3 mm Hex Wrench

???Adjustable Wrench

???4 mm Hex Wrench

???Pliers

???Lubricant part no. 111265; see Accessories, page 33, to order

???Compatible Solvent

Service

5.Using a 1/16 in. hex wrench loosen the fluid needle set screw (30). Remove the needle stop (29).

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

7.Check the fluid needle (5) for damage or excessive wear. Replace the needle tip (5a) or the entire nee- dle if necessary.

8.Remove nozzle (23). Check nozzle and o-ring (36) for damage. You may need to use a pick to remove o-ring from housing (2).

Replace Fluid Packings and Air

Seals

Air Section Repair Kit 288171 and Fluid Section Repair Kit 288135 are available. Purchase the kits separately.

1.Perform Pressure Relief Procedure, page 17.

2.Unscrew the four screws (13) and remove the gun from the manifold.

3.Remove the air cap retainer (25) and air cap (24). See FIG. 18.

36

TI8198a

FIG. 19

9.Remove the piston. Using a pliers, pull the piston (3) out of the piston housing (1). See FIG. 20.

10.Unscrew the two screws (14) and separate the fluid housing (2) and the piston housing (1). Remove gasket (12) only if it needs to be replaced. See FIG. 20.

14

23

24, 25

FIG. 18

4

13

TI8102a

2

14

1

TI8173a

FIG. 20

4.Remove the piston cap (4) from the piston housing

(1). Remove the springs (6, 7).

11.Remove the packing nut (16) with a wrench.

12.Remove the fluid packing (17) from the nut (16). Discard the old fluid packing.

13. Remove all o-rings from the piston (3) and stems

(T). Check that the stems are solidly in place. If they are loose, replace the entire piston assembly (3).

14. Perform the following applicable step:

a. Non-circulating guns: Remove the fluid outlet port plug (19), and gasket (22) from the fluid housing (2). Remove the o-ring (21) and backup (20) from the plug.

1 2

11* 3

16 8

25

23 1 2

24

17 3

5

5a9

36

TI8199a

Alternate Fluid Control Shown

FIG. 21

b.Circulating guns: Remove the gasket (22) from the fluid housing (2).

15.Clean all parts and replace any worn parts. When assembling, lubricate the threads with anti-seize lubricant.

7

29

30 6 7

9 3

3 3

Cutaway View:

Part No. 249388 Gun Shown

SERVICE NOTES:

1Torque to 35-45 in-lb (4.0-5.1 N???m)

2Lubricate threads with anti-seize lubricant

3Lubricate with light-weight oil

4 Tighten cap (4) until it bottoms out

6 Apply semi-permanent anaerobic sealant

8Torque to 95-105 in-lb (10.7-11.8 N???m)

9Apply semi-permanent anaerobic sealant to two threads at end of needle shaft.

Reassembly

1.Non-circulating guns only: Lubricate the backup ring (20???) and o-ring (21???) and install them on the fluid outlet port plug (19). Install the plug in the fluid out- let port of the fluid housing (2). See FIG. 22.

2.All guns: Reinstall the gasket (22) in the fluid hous- ing (2).

3.Install the o-rings (8*, 9*) on the piston (3). Install the two o-rings (10*, 11*) on each of the piston stems (T). Lubricate all the o-rings, the piston, and the piston stems.

4.Remove the protective paper from the sticky side of the gasket (12*) and adhere the gasket to the bot- tom of the piston housing (1), making sure the three holes in the gasket are properly aligned with the matching holes in the housing.

5.Lubricate the new fluid packing (17???) and insert it into the packing nut (16). Insert the packing nut into the fluid housing (2) and torque to 95-105 in-lb (10.7-11.8 N???m).

6.Align the gasket (15*) as shown in the exploded view in FIG. 22. Place the gasket on the piston hous- ing (1), then install the fluid housing (2) onto the pis- ton housing. Torque the two screws (14) to 30 in-lb (3.4 N???m).

a.Insert the piston (3) into the piston housing (1).

b.Ensure nozzle sealing o-ring (36) is installed in fluid housing (2).

7.To avoid galling of the fluid nozzle seat in the fluid housing, apply a thin film of lubricant to the threads. Install the nozzle into the fluid housing. Torque the nozzle securely to 60 in-lb (6.8 N???m).

If you are replacing the needle tip (5a), apply semi-permanent anaerobic sealant to two threads at the end of the needle shaft. Assemble the needle tip to the shaft and hand tighten. Allow adequate time for the sealant to cure before installing the needle assembly into the gun.

8.Lubricate and install the needle (5) into the back of the gun assembly. Push it straight in through the pis- ton.

9.Install the needle stop (29) on the needle. Coat the setscrew (30) with semi-permanent anaerobic seal-

Service

ant and install the screw into the needle stop. Torque to 4-5 in-lb (0.45-0.56 N???m). Pull on the nee- dle to make sure it seats fully.

10.Install the springs (6, 7).

11.Lubricate the threads of the piston housing (1). Screw the cap (4) onto the housing until it bottoms out.

12.Install the air cap (24) and air cap retainer (25).

13.Reinstall the gun on the manifold using the four screws (13). Start the threads of all four screws. Tighten the front two screws first, and then tighten the back two. Torque all four screws evenly to 65 in-lb (7.3 N???m).

12*

SERVICE NOTES:

1Torque to 35-45 in-lb (4.0-5.1 N???m)

2Lubricate threads with anti-seize lubricant

3Lubricate with light-weight oil

4Tighten cap (4) until it bottoms out

6Apply semi-permanent anaerobic sealant

7Torque to 4-5 in-lb (0.45-0.57 N???m)

8Torque to 95-105 in-lb (10.7-11.8 N???m)

TI8086a

Exploded View:

Part No. 249369 Gun Shown

Parts

Parts

???See spray gun assemblies table (page 28) for part number.

??? Included in Fluid Seal Repair Kit 288135.

* Included in Air Seal Repair Kit 288171.

??? Not shown.

Part No. 288221

Manifold with bottom fluid ports

??? Not shown.

Parts

2Apply anti-seize lubricant (222955) to threads and mating faces of manifold (101) and any fittings and/or plugs used in fluid ports.

101

103

107 2

FIG. 23: Manifold with Bottom Fluid Ports

Parts

Part No. 288217

North America Manifold with side fluid ports

Part No. 288218

International Manifold with side fluid ports

??? Not shown.

??? Part No. 288217 only.

??? Part No. 288218 only.

2Apply anti-seize lubricant (222955) to threads and mating faces of manifold (101) and any fittings and/or plugs used in fluid ports.

107

107 2

101

103

TI8148b

FIG. 24: Manifold with Side Fluid Ports

Parts

Part No. 288160

Rear Port Manifold, North America

Part No. 288211

Rear Port Manifold, International

??? Part No. 288160 only.

??? Part No. 288211 only.

1Apply sealant to threads and mating faces of manifold (101) and any fittings and/or plugs used in fluid ports.

2Torque to 30-42 in-lb (3.4-4.7 N???m).

3Torque to 110-130 in-lb (12.3- 14.7 N???m).

113

112 1

101

110

111 1

TI8200a

FIG. 26:

Cleaning Brush 105749

For use in cleaning gun.

Lubricant 111265

One 4 oz. (113 gram) tube sanitary (non-silicone) lubri- cant for fluid seals and wear areas.

Fluid Hose Parts Breakdown

Part No. Description

239629 FITTING, assy, swivel

061345 TUBING, 1000 ft. (305 m) roll

Alternate Nozzle Sizes

Retrofit Adapter Plate 288197

The retrofit adapter plate enables the manifold to be attached to a variety of bolt patterns.

HVLP Pressure Verification Kit

For use in checking air cap atomizing or pattern air pres- sure 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, then trigger the gun and read the air pressure on the gauge.

To be ???HVLP compliant???, the atomizing air pressure must not exceed 10 psi (70 kPa, 0.7 bar).

TI7637a

FIG. 27: HVLP Pressure Verification Kit

Fluid Control Knob Repair Kit 288138

Includes spring, ball, and retaining clip.

0.187 in. (4.8 mm)

2.125 in.

(54 mm)

1.750 in.

1.375 in. (44.5 mm)

(35 mm)

Two 0.128 diameter x 0.31 in. (7.8 mm) holes Use 1/8 in. pin for alignment