Graco 308438A Model 510 Airless Spray Gun Owner's Manual

INSTRUCTIONS–PARTS LIST 308–438 Rev. A This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE. Model 510 Airless Spray Gun 7400 psi (510 bar) Maximum Working Pressure Part No. 236–995 Includes a Heavy Duty 510 RAC IV Tip Guard and size 527 SwitchTip 03965 GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN COPYRIGHT 1994, GRACO INC. 55440–1441 Notes Table of Contents Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation/Operation . . . . . . . . . . . . . . . . . . . . . . 6 System Requirements . . . . . . . . . . . . . . . . . . . 6 How to Use the Gun Trigger Safety . . . . . . . . 6 Pressure Relief Procedure . . . . . . . . . . . . . . . . 7 How to Use the Gun . . . . . . . . . . . . . . . . . . . . . 7 How to Adjust the Spray Pattern . . . . . . . . . . . 7 Care of the Spray Tip and Tip Guard . . . . . . . 8 How to Flush the Gun . . . . . . . . . . . . . . . . . . . . 9 How to Check the Gun Diffuser Operation . 10 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . 16 The Graco Warranty and Disclaimers . . . . . . . 16 Symbols Warning Symbol WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions. Caution Symbol CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions. WARNING WARNING SKIN INJECTION HAZARD Spray from the gun, hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause can also cause serious injury. D If a skin injection injury occurs, get emergency medical care at once. Do not treat as a simple cut. Tell the doctor exactly what fluid was injected. D Give the doctor this information: Injection into the skin is a traumatic injury. Treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable. D Do not point the spray gun at anyone or any part of the body. D Do not put hand or fingers over the spray tip. D Do not stop or deflect fluid leaks with your hand, body, glove or rag. D Do not “blow back” fluid; this is not an air spray system. D Always have the tip guard and the trigger guard on the spray gun when spraying. D Check the gun diffuser operation weekly. Refer to the gun manual. D Be sure the gun trigger safety operates before spraying the gun. D Lock the gun trigger safety when you stop spraying. D Follow the Pressure Relief Procedure on page 6 if the spray tip clogs and before cleaning, checking or servicing the equipment. D Tighten all fluid connections before each use. D Check the hoses, tubes and couplings daily. Replace worn or damaged parts immediately. Permanently coupled hoses cannot be repaired. D Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C). FIRE AND EXPLOSION HAZARD Improper grounding, poor air ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. D Ground the equipment and the object being sprayed. See Ground the System on page 6. D If there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem. D Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid being sprayed. D Do not smoke in the spray area. D Extinguish all open flames or pilot lights in the spray area. D Do not turn on or off any light switch in the spray area. D Electrically disconnect all equipment in the spray area. D Keep the spray area free of debris, including solvent, rags and gasoline. D Do not operate a gasoline engine in the spray area. WARNING WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture, malfunction or start unexpectedly and result in 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 in doubt about this, call Graco Technical Assistance at 1–800–543–0339. D Do not alter or modify this equipment. D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not exceed the 7400 psi (510 bar) Maximum Working Pressure of the equipment, or the maximum working pressure of any accessory used with it. D Do not move or lift pressurized equipment. D Use fluids or solvents which are compatible with equipment wetted parts. Refer to the Technical Data section on page 16 and all equipment manuals. Read the fluid and solvent manufacturer’s warnings. D Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or bends at or close to the couplings. D Comply with all applicable local, state and national fire, electrical and other safety regulations. TOXIC FLUID HAZARD Improper handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury, even death, due to splashing in the eyes, ingestion, or bodily contamination. D Know the specific hazards of the fluid you are using. D Store hazardous fluid in an approved container. Dispose hazardous fluid according to all local, state and national guidelines. D Wear appropriate clothing, gloves, eyewear and respirator. RECOIL HAZARD Due to the very high fluid pressure 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. 308-438 5 Installation/Operation System Requirements Pressure Relief Procedure WARNING Keep the wallet-sized warning card provided with this gun with the operator at all times. The card contains important treatment information should an injection injury occur. Additional cards are available at no charge from Graco Inc. WARNING The equipment must have a bleed-type master air valve (pneumatic pumps only) and a pressure drain valve. These accessories help reduce the risk of serious injury from fluid injection, splashing in the eyes or on the skin, or moving parts, when adjusting or repairing the pump or gun. WARNING To reduce the risk of serious injury, including fluid injection, splashing fluid or solvent in the eyes or on the skin, follow this procedure when you are instructed to relieve pressure, when you stop spraying, shut off the pump, check or service any system equipment, or install, clean or change spray tips. 1. Lock the gun trigger safety. 2. Shut off the power to the pump. Open the bleed– type master air valve (pneumatic pumps only). 3. Unlock the gun trigger safety. 1. The bleed-type master air valve relieves air trapped between this valve and the pneumatic pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly. 2. The pressure drain valve assists in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. 3. Strain the fluid you are spraying if it contains particles which could clog the spray tip. Ground the System WARNING To reduce the risk of static sparking, ground the pump and all other equipment used or located in the spray area. Check your local electrical code for detailed grounding instructions for your area and type of equipment. Also follow the grounding instructions provided in your pump or sprayer manual. The gun obtains grounding through connection to a properly grounded fluid hose and pump or sprayer. Also read FIRE OR EXPLOSION HAZARD on page 4. 4. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. 5. Lock the gun trigger safety. 6. Open the drain valve, having a container ready to catch the drainage. Leave the drain valve open until you are ready to spray again. If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually. Clean the tip or hose obstruction. Gun trigger safety shown locked Gun trigger safety shown unlocked How to Use the Gun Trigger Safety 1. To lock the gun trigger safety, turn the safety to a right angle with the gun body. See Fig. 1. 2. To unlock the gun trigger safety, push the safety out and turn it parallel with the gun body. See Fig. 1. 6 308-438 Fig. 1 03966 Installation/Operation How to Operate the Gun WARNING RECOIL HAZARD Due to the very high pressure emitted, a strong recoil action will occur when you trigger the 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. WARNING To reduce the risk of component rupture, and serious injury, including fluid injection, do not exceed the gun’s 7400 psi (510 bar) Maximum Working Pressure or the maximum working pressure of lowest rated component in the system. 5. Start the pump. Trigger the gun onto test paper. Adjust the fluid pressure until the spray is completely atomized. Use the lowest pressure necessary to get the desired results. Higher pressure may not improve the spray pattern and will cause premature tip and pump wear. 6. If adjusting the pressure does not give a good spray pattern, relieve pressure and then try another tip size. 7. Use a full-open, full-close trigger action. Hold the gun about 14 in. (350 mm) from and at right angles to the work surface. Don’t swing the gun in an arc. Practice to find the best length and speed of stroke. How to Adjust the Spray Pattern 1. To adjust the spray pattern direction, relieve pressure. Loosen the tip guard retaining nut (B). Turn the tip guard/tip groove horizontally (C) for a horizontal pattern and vertically (A) for a vertical pattern. Tighten the nut. See Fig. 3. 2. The spray tip orifice and spray angle determines the coverage and size of pattern. When more coverage is needed, use a larger spray tip rather than increasing fluid pressure. CAUTION A 8 30 Fig. 2 03967 1. Connect a grounded fluid hose (A) to the gun inlet. See Fig. 2. Openings in the tip guard reduce paint buildup on the guard while spraying. Damage to the sharp edges of the openings causes paint to collect at that area. Never hang the gun by the tip guard. B A C 2. With no tip installed, start the pump. Flush the pump according to the instructions supplied with it. Use the lowest pressure possible. Be sure you have a firm footing and hold the gun securely. Prime the system with the material. 3. Relieve pressure. 4. Install the SwitchTip (8) and tip guard (30). Follow the instructions in the manual, supplied. See Fig. 2. 03968 Fig. 3 308-438 7 Installation/Operation Care of the Spray Tip and Tip Guard If the spray tip clogs while spraying 1. Stop spraying immediately. WARNING To reduce the risk of fluid injection or splashing in the eyes or on the skin, do not hold a hand, body or rag in front of the spray tip when cleaning or checking a clogged tip. Point the gun toward the ground or into a waste container when checking to see if the spray tip is cleared. Do not try to “blow back” paint; this is not an air spray gun. Do not wipe fluid buildup off the gun or spray tip until pressure is relieved. 2. Lock the gun trigger safety. Rotate the RAC IV tip handle back 180_. See Fig. 4. 3. Unlock the gun trigger safety. Trigger the gun into a pail or onto the ground to remove the clog. 4. Lock the gun trigger safety. Rotate the tip handle to the spraying position. See Fig. 4. 5. If the tip is still clogged, engage the gun trigger safety, shut off the sprayer and disconnect the power source, and open the pressure drain valve to relieve pressure. Clean the spray tip as shown in manual 307–848, supplied with the RAC IV. CAUTION Never soak the entire gun in solvent. Prolonged exposure to solvent can ruin the packings. Spraying position shown. Turn handle 180_ and trigger gun to clear clog. Cleaning during the day 1. Relieve pressure. 2. Clean the front of the tip frequently during the day to help reduce buildup. Also clean the tip and tip guard at the end of each work day. Use a solventsoaked brush to clean the spray tip. Fig. 4 03965 Installation/Operation How to Flush the Gun WARNING To reduce the risk of serious injury, including splashing fluid in the eyes or on the skin, or static electric discharge when flushing: D Be sure the entire system, including flushing pails, are properly grounded. D Remove the tip guard and spray tip. D Maintain metal to metal contact between the gun and the flushing pail. D Use the lowest possible pressure. Always flush the pump and gun before the fluid being sprayed can dry in it. NOTE: If it is available, the flushing procedure provided in your pump or sprayer manual should be used instead of this procedure. 1. Relieve pressure. 2. Remove the tip guard and spray tip. Soak and clean the parts. 3. Put the pump intake in a grounded pail of compatible solvent. 4. Start the pump at its lowest pressure. ÄÄÄ ÄÄÄ 5. Trigger the gun into the original pail. When solvent appears, release the trigger. 6. Now trigger the gun into the solvent pail. Circulate the fluid until the system is thoroughly flushed. 7. Relieve pressure. 308-438 9 Installation/Operation How to Check the Gun Diffuser Operation 1. Relieve pressure. The Standard Needle and Seat Kit, 237–398, has the number 090 stamped on the needle and seat. The seat does have a diffuser. 2. Remove the tip guard and spray tip. The optional Non–diffused Needle and Seat Kit, 237–260, has the number 125 stamped on the needle and seat. The seat does not have a diffuser. WARNING The diffuser, located in the valve seat, creates an irregular spray pattern when the gun is sprayed without a tip guard, such as during cleaning. This reduces the risk of an injection injury. 3. Start the sprayer and adjust it to the lowest pressure. 4. Aim the gun into a grounded metal pail while holding it firmly to the pail. Trigger the gun. If the fluid emitted is not diffused into an irregular stream, replace the entire needle kit immediately. See Fig. 5. If you are using the optional Kit 237–260, you must take extra precautions to keep your hands and body away from the nozzle of the gun. Always have the tip guard in place during regular spraying operations. Check the diffuser operation weekly. The gun diffuser/ seat (2a) breaks up spray and reduces the risk of fluid injection when the tip is not installed. Perform the test below. If it fails, replace the entire Needle and Seat Kit. Diffuser/seats and needles are not sold separately; using old parts with new ones will result in leakage. 10 308-438 Irregular spray pattern ÄÄÄ ÄÄ ÄÄÄ ÄÄÄ ÄÄ ÄÄÄ 2a Fig. 5 Service WARNING To reduce the risk of serious injury from fluid injection or splashing, always follow the Pressure Relief Procedure on page 6 before servicing the gun. 2a 2b Repair Notes The needle and seat are available only as a kit which includes items 2a to 2e. The Standard Needle and Seat Kit, 237–398, has the number 090 stamped on the needle and seat. 03969 Fig. 7 3. Unscrew the valve seat (2a). Remove the gasket (2b). See Fig. 7. A Non–diffused Needle and Seat Kit, 237–260, has the number 125 stamped on the needle and seat. It is recommended only for use with mastics, sealers and other high viscosity materials which have fillers that cannot pass through the standard seat’s diffuser. 28 18 29 27 Use high quality, general purpose grease where grease is indicated. Disassembly NOTE: If replacing only the needle and seat, Step 4 and 5 are not required. However, removing them allows you to clean the gun more thoroughly. 25 03970 Fig. 8 1. Relieve pressure. 4. Remove one e–clip (27). Push out the pin (18). Remove the screw (29), pivot pin (28), and trigger (25). See Fig. 8. 21 30 A Fig. 6 03967 2. Disconnect the fluid hose (A). Remove the tip guard (30). Unscrew the spring screw (21) about 1/4 in. (7 mm) to release spring tension. See Fig. 6. 24 03971 Fig. 9 5. Remove the screws (24). See Fig. 9. 308-438 11 Service 1 2d 2c 22 2e Fig. 12 03974 15 8. Remove the needle (2c). Unscrew the seal retainer (2d). Remove the seal (2e). See Fig. 12. Fig. 10 03972 Cleaning 6. Loosen the setscrew (15). Pull the fluid housing (22) away from the gun body (1). See Fig. 10. Clean all parts and cavities thoroughly with a compatible solvent. Dry with a rag or compressed air. Replace any parts that are worn or damage. Reassembly 1 Torque to 20–25 ft–lb (27–34 N.m) 2 Lips of seal must face into housing 3 Grease inner cavity of housing 16 17 Fig. 11 03973 7. While supporting the spring guide (16) to prevent bending the needle, loosen the setscrews (17). Remove the spring guide (16). See Fig. 11. 12 308-438 Fig. 13 1 2d 2 2e 3 22 03975 1. Lightly grease the inner cavities of the fluid housing (22). Install the small seal (2e) so the lips face into the fluid housing cavity. Install the seal retainer (2d) and torque to 20–25 ft–lb (27–34 N.m). See Fig. 13. Service 1 2c 19 Grease this side 20 1 22 1 03676 Fig. 14 2. Lightly grease the small end of the needle (2c) and then guide it into the large end of the fluid housing (22). 1 Grease the threads 2 Torque to 20–25 ft–lb (27–34 N.m) 03979 Fig. 17 5. If the spring (19) was removed, grease the spring adjuster (20) and place the spring. Drop this assembly into the gun body (1). See Fig. 17. 2a 1 Torque to 30–40 in–lb (3.4–4.5 N.m) 2b 2 Fill cavity with petroleum jelly 1 22 22 03977 Fig. 15 3. Place the gasket (2b) on the valve seat (2a). Grease the threads of the valve seat (2a). Screw the valve seat into the fluid housing (22). Torque to 20–25 ft–lb (27–34 N.m). See Fig. 15. 15 Fig. 18 1 Seat against needle stem 2 Apply light strength Locktite; Torque alternately and evenly to 10–15 in–lb (1.1–1.7 N.m) 3 Fill cavity with petroleum jelly Fig. 16 2 03972 6. Push the fluid housing (22) onto the gun body (1) until fully seated. Tighten the setscrew (15) to 30–40 in–lb (3.4–4.5 N.m). Fill the setscrew cavity with petroleum jelly. See Fig. 18. 16 1 3 17 2 3 03978 4. Install the spring guide (16) and seat it against the needle. Loosely thread both setscrews (17) into the spring guide, then alternately and evenly tighten the setscrews to 10–15 in-lb (1.1–1.6 N.m). Fill the setscrew cavities with petroleum jelly. 24 Fig. 19 7. Install the screws (24). See Fig. 19. 308-438 03971 13 Service Test the Gun Before Regular Use 28 A B,16 18 29 1. Lock the gun trigger safety. Connect a hose to the gun. Start and prime the pump. 2. Release the gun trigger safety. Trigger the gun into a waste container. Release the trigger to be sure the gun immediately stops spraying and that there are no leaks. 27 3. If the gun has a diffuser, check the diffuser using the procedure on page 10. 25 4. Install the tip guard before regular use. See Fig. 22. 03970 Fig. 20 8. Position the trigger (25) on the gun body. Insert the pivot pin (28) into the top hole (A) and secure with the screw (29) on the other side. Place an e–clip (27) on one end of the trigger pin (18). Slide the pin through lower trigger holes and through the hole (B) in the spring guide (16) (turn the spring guide to align, as needed). Install the other e–clip (27). See Fig. 20. Turn in until screw stops Fig. 21 21 Fig. 22 03980 9. If it was removed, install the spring tension screw (21) at the rear of the gun. Then, turn the screw in until it stops. See Fig. 21. 14 308-438 03965 Parts Part No. 236–995, Series A Model 510 Airless Spray Gun 28 21 15 20 27 16 19 18 2e 29 2d 22 1 2b 2c 27 17 2a 30 25 24 8 Ref. No. Part No. 1 2 2a 2b 2c 2d 2e 8 15 16 17 18 19 20 21 22 24 25 237–502 237–398 Description GUN BODY NEEDLE AND SEAT KIT (parts not sold separately) stamped with the number 090 [fluid orifice size is 0.090 (2.3 mm)] .VALVE SEAT .GASKET .NEEDLE .SEAL RETAINER .SEAL GHD–527 SwitchTip, size 527 102–207 SETSCREW, 1/4–20 189–960 SPRING GUIDE 112–729 SETSCREW, soc hd 189–958 TRIGGER PIN 112–727 SPRING 189–990 SPRING ADJUSTER 110–637 ADJUSTING SCREW 236–985 FLUID HOUSING 107–091 SCREW, 1/4–20 189–974 GUN TRIGGER 03964 Qty. 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 Ref. No. Part No. 27 28 29 30 112–410 187–965 203–953 237–162 34Y 35Y 187–346 222–385 Description Qty. E–CLIP PIVOT PIN SCREW, hex washer hd, 10–24 HEAVY DUTY 510 RAC TIP GUARD WARNING SHEET not shown WARNING CARD not shown 2 1 1 1 1 1 Y Replacement Danger and Warning labels, tags and cards are available at no cost. Optional Non–Diffused Needle and Seat Kit 237–260 Use in place of Ref. No. 2, above. Stamped with the number 125 [fluid orifice size is 0.125 in. (3.2 mm)] Recommended only for use with mastics, sealers and other high viscosity materials which have fillers that cannot pass through the standard seat’s diffuser. Technical Data Maximum working pressure . . . . . . . 7400 psi (510 bar) Fluid orifice size . . . . . . . . . . . . . . . . . 0.090 in. (2.3 mm) Inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm (m) Fluid tube inside diameter . . . . . . . . . . 0.245” (6.2 mm) Wetted parts . . . . . . . . . . . . . . . . . . . . . Tungsten carbide, 17–4ph passivated stainless steel, polypropylene, polyethylene Dimensions Graco Phone Numbers TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: 1–800–367–4023 Toll Free FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Graco equipment: 1–800–543–0339 Toll Free Weight includes tip and tip guard . . . . . . . . . 25.7 oz (729 gr) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25” (210 mm) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0” (203 mm) The Graco Warranty and Disclaimers WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of 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 claim. 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. DISCLAIMERS AND LIMITATIONS The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale. EQUIPMENT NOT COVERED BY GRACO WARRANTY Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, 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. Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.) Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN PRINTED IN U.S.A. 308–438 9/94 55440–1441
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