INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

308–193

Rev. E

Supersedes C and PCN D

HIGH PRESSURE AIR-ASSISTED AIRLESS

Model AA 270 HS Spray Gun

4000 psi (280 bar) Maximum Working Fluid Pressure

100 psi (7 bar) Maximum Working Air Pressure

Part No. 224–887, Series A

The AA 270 HS Spray Gun was designed to spray at higher fluid pressures than the original AA2000 Spray

Gun to provide the additional power needed to atomize higher solids materials. The gun includes a spray tip of choice.

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 Patent No. 82–21202

Foreign Patents Pending

Table of Contents

Warnings

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

13

2

4

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Tip and Air Cap Selection Charts . . . . . . . . . .

14

16

18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .

19

19

19

20

20

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1991, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

WARNING

INJECTION HAZARD

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an 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 medical attention.

Do not point the spray gun at anyone or at any part of the body.

Do not put hand or fingers over the spray tip.

Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

Do not “blow back” fluid; this is not an air spray gun.

Always have the tip guard on the spray gun when spraying.

Check the gun diffuser operation weekly.

Be sure the gun trigger safety operates before spraying.

Lock the gun trigger safety when you stop spraying.

Follow the Pressure Relief Procedure on page 7 whenever you: are instructed to relieve pressure; stop spraying; clean, check, or service the equipment; or install or clean the spray tip.

Tighten all the fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

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.

WARNING

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

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 uncertain about usage, call your Graco distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check the equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 4000 psi (280 bar) maximum working pressure at 100 psi (7 bar) maximum incoming air pressure .

D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180 _ F (82 _ C) or below –40 _ F (–40 _ C).

D Do not use the hoses to pull the equipment.

D Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or bends near the couplings.

D 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.

D Wear hearing protection when operating this equipment.

D Comply with all applicable local, state and national fire, electrical and other safety regulations.

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.

D Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

D 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 balance and fall, resulting in serious injury.

Installation

C

A

D

C B T

L

J

V

Q

F

R

X

K

H

P

S

N

W

KEY

A Air Line Filter

B Air Line Lubricator

C* Bleed-type Air Shutoff Valve

D Pump Air Regulator

E* Fluid Drain Valve

F Fluid Shutoff Valve

G Fluid Filter

Fig. 1

Typical Installation

M

G

E

H* Grounded Fluid Hose

J Pump

K Air Line

L Air Pressure Regulator

M Pump Fluid Inlet

N In-line Fluid Filter

P Pattern Adjustment Valve Knob

Q* Fluid Pressure Regulator

The typical installation shown in Fig. 1 is only a guide for selecting and installing air-assisted airless spray systems. It is not an actual system design. Contact your Graco distributor for assistance in designing a system to meet your needs.

The Graco fluid pump Model 218–335 is designed for use in high pressure air-assisted airless systems. It has a maximum working pressure of 4050 psi (283 bar). See instruction manual 307–013 for information on this pump.

E

0790

R Pressure Gauge

S Trigger Safety

T Pump Runaway Valve

V* Pump Ground Wire

W Gun Fluid Connector

X Air Shutoff Valve

*Equipment required for safe operation of the system. Must be purchased separately .

Ventilate the Spray Booth

WARNING

TOXIC FLUID HAZARD

To prevent hazardous concentrations of 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 requirements.

4 308-193

Connect the Air Line

Installation

Connect the Fluid Line

1. 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.

2. Install an air pressure regulator (L) on the gun air supply line to control the air pressure to the gun.

3. Install an air pressure regulator (D) on the pump air supply line to control air pressure to the pump.

4. 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.

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,

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 sufficient.

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 (280 bar).

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 unexpectedly, which could result in serious injury.

NOTE: The gun air inlet has a 1/4–18 npsm (R1/4–19) compound male thread that is compatible with NPSM and BSP female swivel connectors.

5. 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).

6. Connect the air hose (K) from the air supply to the gun air inlet.

1. 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.

2. 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 regulating the air pressure to the pump.

3. Install a fluid shutoff valve (F) to shut off the fluid supply to the gun.

NOTE: The gun fluid fitting (W) has a 1/4–18 npsm

(R1/4–19) compound male thread that is compatible with NPSM and BSP female connectors.

4. Install an in-line fluid filter (N) on the gun fluid fitting (W) to avoid clogging the spray tip with particles from the fluid.

5. Connect the grounded fluid hose (H) to the gun fluid fitting (W) or optional in-line filter (N).

6. Install an in-line fluid filter (N) on the gun fluid fitting (W) to avoid clogging the spray tip with particles from the fluid.

308-193 5

Ground the System

Installation

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.

3.

Air , fluid, and hydraulic hoses connected to the pump : Use only grounded hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity. Check the electrical resistance of your air and fluid hoses at least once a week. If the resistance exceeds the recommended limits, replace the hose immediately.

4.

Spray gun: Ground the gun by connecting it to a properly grounded fluid hose and pump.

5.

Fluid supply container: Ground it according to local code.

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.

6.

Object being sprayed: Ground it according to local code.

1.

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.

7.

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 cardboard, which interrupts the grounding continuity.

2.

Air compressors and hydraulic power supplies: Ground them according to the manufacturer recommendations.

8.

To maintain grounding continuity when flushing or relieving pressure: Always hold a metal part of the gun firmly to the side of a grounded metal pail, then trigger the gun.

6 308-193

Safety

WARNING

Keep the wallet sized warning card 179–960, provided with the gun, with the operator of this equipment at all times. The card contains important treatment information should an injection injury occur. Additional cards are available at no charge from Graco.

Pressure Relief Procedure

WARNING

Operation

INJECTION HAZARD

Remember, this is not an air spray gun.

For your safety be sure to read and follow the Warnings on pages 2 and 3 and throughout the text of this instruction manual.

5. Hold a metal part of the gun firmly to the side of a grounded metal waste container and trigger the gun to relieve the fluid pressure.

6. Lock the gun trigger safety again.

7. Open the pump drain valve (required in the system) to help relieve fluid pressure in the displacement pump. In addition, open the drain valve connected to the fluid pressure gauge (in a system with fluid regulation) to help relieve fluid pressure in the hose and gun. Triggering the gun to relieve pressure may not be sufficient. Have a container ready to catch the drainage.

8. Leave the drain valve(s) open until you are ready to spray again.

9. If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above , very slowly loosen the hose end coupling and relieve pressure gradually, then loosen the coupling completely. Now clear the tip or hose obstruction.

INJECTION HAZARD

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, stop spraying, check or service any of the system equipment, or install or clean the spray tip.

Trigger Safety

Unlocked or in OFF

SAFE Position

1. Lock the spray gun trigger safety to avoid accidentally triggering the gun. See Fig. 2.

2. Shut off the power to the pump.

3. Close the bleed-type master air valve (required in the system).

4. Unlock the gun trigger safety.

Fig. 2

Trigger Safety Locked or in ON SAFE Position

0795A

308-193 7

How the Air-Assisted Airless

Spray Gun Operates

Operation

The air-assisted airless 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 pattern adjustment valve controls the width of the pattern.

Note that the air-assisted airless 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.

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 pressure. Use the Spray Tip and Air Cap Selection

Charts , on page 18, as a guide for selecting an appropriate spray tip and air cap for your application.

Install a Spray Tip

WARNING

INJECTION HAZARD

To reduce the risk of a fluid injection injury, follow the Pressure Relief Procedure 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.

The ability of the AA 270 HS Spray Gun to spray at higher fluid pressures than the standard AA2000 Spray

Gun provides the additional power needed to atomize higher solids materials.

Rotate the air cap (the spray tip rotates with it) as needed for the desired spray pattern direction. See

Fig. 3.

Vertical Spray Pattern Horizontal Spray Pattern

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.

Fig. 3

Adjust the Spray Pattern

WARNING

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 balance and fall, resulting in serious injury.

WARNING

Operation

5. Set the atomizing air pressure at about 10 psi (0.7

bar). Check the spray pattern, then adjust the air pressure until the tails are completely atomized and pulled into the spray pattern. See Fig. 5. Do not exceed 100 psi (7 bar) air pressure to the gun.

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: For some spray tips, when the line air pressure to the gun is increased to a certain level, the spray pattern will become round. This is the smallest pattern width. Further increases in air pressure will force the pattern to turn from horizontal to vertical or from vertical to horizontal.

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 (280 bar) or the maximum working pressure of the lowest rated component in the system.

Pattern

Adjustment

Knob

0795A

1. Set the fluid pressure with the fluid regulator.

Fig. 4

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 significantly improve fluid atomization.

4. Close the pattern adjustment valve by turning the knob (see Fig. 4) counterclockwise all the way.

This sets the gun for its widest pattern.

No Air

Fig. 5

Too Little Air Right Amount of Air

0792

Operation

Apply the Fluid

When applying the fluid, keep the gun a consistent distance, 8 to 10 inches (200 to 250 mm), from the surface of the object being sprayed. Always hold the gun at a right angle from the surface. Do not make an arc with the gun as it causes an uneven coat of fluid.

See Fig. 6.

CAUTION

Openings in the tip guard reduce paint buildup on the guard while spraying. Damage to the sharp edges of the openings will cause paint to collect at that area.

To avoid damage, never hang the gun by the tip guard.

RIGHT

Fig. 6

WRONG

0793A

Operation

Clean the Spray Gun and System Daily

4. If using an in-line filter, remove and clean it thoroughly in a compatible solvent.

WARNING

INJECTION HAZARD

To reduce the risk of an injection injury or splashing fluid in the eyes or on the skin:

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.

5. Clean the system’s fluid filter and air line filter.

Check the Diffuser-seat Operation Weekly

WARNING

INJECTION HAZARD

The gun diffuser-seat breaks up spray when the gun is sprayed without the spray tip installed, such as during flushing. This reduces the risk of an injection injury.

Check the diffuser-seat operation weekly.

CAUTION

To avoid damaging the gun:

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 outside of the gun 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.

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 pressure.

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.

1

NOTE: Clean the front of the tip frequently during the day to help reduce buildup.

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 the air cap passages, use a soft brush or other soft tool, with an air blow gun.

ÄÄÄÄ

ÄÄÄÄ

ÄÄÄÄ

1

Fig. 7

Maintain firm metal-to-metal contact between the gun and a grounded metal container.

0794A

Operation

1. Relieve the pressure as instructed on page 7.

Flush the Gun Daily

WARNING

INJECTION HAZARD

To reduce the risk of a fluid injection injury, follow the Pressure Relief Procedure on page 7 before cleaning, removing, or installing a spray tip and whenever you are instructed to relieve pressure.

2. Disconnect the atomizing air hose and the fluid supply line.

3. Remove the tip guard and spray tip. Clean the parts.

4. Connect a compatible solvent supply to 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:

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.

If it is available, the flushing procedure provided in the pump or sprayer manual should be used instead of this procedure.

5. Start the pump and operate it at its lowest pressure.

6. 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.

7. Relieve the pressure as instructed on page 7.

8. Disconnect the solvent supply.

NOTE: If 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 14 to remove the needle cartridge.

Troubleshooting

WARNING

INJECTION HAZARD

To reduce the risk of a fluid injection injury, follow the Pressure Relief Procedure on page 7 before checking or servicing any of the system equipment and whenever you are instructed to relieve pressure.

NOTE:

Check all possible remedies in the troubleshooting charts before disassembling the gun.

Some improper patterns are caused by the improper balance between air and fluid.

General Troubleshooting

Problem

Fluid leakage from back of fluid needle

Air leakage from front of gun

Fluid leakage from front of gun

Cause

Worn packings or needle shaft

Air valve not seating properly

Fluid needle worn or damaged

Solution

Replace external needle packings or entire fluid needle cartridge. See page 14.

Clean/service air valve. See page 14.

Replace fluid needle cartridge. See page 14.

Worn diffuser-seat housing Replace the diffuser-seat and gasket.

The gasket must be replaced whenever the diffuser-seat is removed.

See page 14.

Tighten or replace fluid tip.

Fluid tip seal leaking

Leaking around diffuser-seat housing Replace the diffuser-seat gasket. The gasket must be replaced whenever the diffuser-seat is removed. See page 14.

Fluid inlet fitting leaking Replace the fluid fitting gasket. The gasket must be replaced whenever the fluid fitting is removed. See page 15.

Spray Pattern Troubleshooting

Problem

Fluttering or spitting spray

Cause

Insufficient fluid supply

Air in paint supply line

Solution

Adjust fluid regulator or fill fluid supply tank.

Check, tighten siphon hose connections, bleed air from paint line.

Irregular pattern

Pattern pushed to one side, same side of air cap gets dirty

Fluid build-up or spray tip partially plugged

On defective side of pattern, air horn holes are partially or totally plugged

Air horn holes partially or totally plugged

Clean spray tip. See page 11.

Clean air horn holes with solvent and soft brush. See page 11.

Clean air horn holes with solvent and soft brush. See page 11.

WARNING

INJECTION HAZARD

To reduce the risk of a fluid injection injury, follow the Pressure Relief Procedure on page 7 before checking or servicing any of the system equipment and whenever you are instructed to relieve pressure.

Service

Fluid Needle Cartridge Service

Follow the procedure below to remove the fluid needle cartridge for cleaning or to replace the fluid needle cartridge when there is leakage from the back of it.

1. Relieve the pressure as instructed on page 7.

2. Remove the air cap retainer (11), air cap (13), spray tip (14), and air separator (16). See Fig. 8.

NOTE:

D Follow the Service Notes in Fig. 8 when reassembling the gun. Also refer to the parts drawing on page 16 for parts not shown in Fig. 8.

3. Trigger the gun to back the fluid needle ball off the seat. Remove the diffuser-seat (15).

4. Remove the trigger (3) and trigger extension pieces (19). See the Parts Drawing, page 16.

D Gun Repair Kit 224–949 is available. See page 17.

The reference numbers with asterisks in the service procedures are included with the kit.

5. 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.

Air Valve Service

1. Relieve the pressure as instructed on page 7.

6. Remove the fluid gasket (18).

2. Remove the trigger (3) and valve cap (7). See the parts drawing and Fig. 8.

3. Unscrew the needle nut (23) while holding the flats of the air valve (26) stem with a long nose pliers.

7. 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*).

CAUTION

To avoid leakage, be careful not to scratch the air valve stem.

4. Remove the spring (6) and air valve (26*).

5. 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.

6. 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.

7. For best air valve life, lubricate the external air valve shaft with light oil after each day’s use.

8. Lubricate the o-ring (10a) and backup ring (10b) of the new or cleaned needle cartridge with lightweight oil.

9. 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.

10. Insert a new gasket (18*).

11. Install the gun trigger and trigger extension pieces.

12. Trigger the gun while screwing the diffuser-seat

(15*) back into the gun. Torque the diffuser-seat to

23 to 27 ft-lbs (31 to 37 N S m).

13. Install the gun air separator, spray tip, air cap and air cap retainer.

14 308-193

Service

12 5a

11 4

5

11 4 7

7 10

14

13 12

16

11

13

3 9 15

18 1

FLUID

24

B

A

10b 12

10a 12

23 6

17 2

5 9

30

25

26

8

6

10 4 AIR

2

5

6

3

4

SERVICE NOTES:

1

2

Gasket (18) must be replaced if diffuser-seat (15) is removed or replaced to avoid fluid leakage

Gasket (17) must be replaced if fluid connector (30) is removed or replaced to avoid fluid leakage

Lubricate threads

Apply anaerobic pipe sealant to threads

Apply high strength sealant to threads

Thread nut to bottom thread of needle

7

8

9

10

11

12

13

Use tool (34) to pull needle cartridge until it bottoms in gun body front end insert.

U-cup lips face inward

Torque to 23–27 ft-lb (31–37 N m)

Torque to 20–24 ft-lb (27–32 N m)

Torque to 15–19 ft-lb (20–26 N m)

Lubricate with light-weight oil

Do not lubricate

Fig. 8

308-193 15

11

13

14

*12

16

*10

*10a

*10b

23

15*

3

18*

4

*17

30

29

Parts

8

1

*5b

*5a

5

26*

6*

7

9

25*

24

19

3

19

2

34

2 1

SERVICE NOTES (See Fig. 8 for additional information):

1

2

3

4

Lubricate threads

Torque to 23–27 ft-lb (31–37 N m)

Gasket (18) must be replaced if diffuser-seat (15) is removed or replaced to avoid fluid leakage.

Gasket (17) must be replaced if fluid connector (30) is removed or replaced to avoid fluid leakage.

0799A

16 308-193

Parts

Use Only Genuine Graco Parts and Accessories

Ref.

No.

Part No.

Description Qty.

3

4

1

2

235–381 BODY, gun

106–917 ADAPTER, air

187–503 TRIGGER, gun

206–946 SAFETY LATCH, trigger

5

8

217–489 VALVE, pattern adjustment;

Includes items 5a & 5b

178–408 CAP, valve, air

203–953 CAP SCREW, hex hd, 10-24 x

1

5a* 168–110 S O-RING, nitrile rubber

5b* 105–456 S RETAINER, clip

6*

1

1

106–903 SPRING, compression, air valve 1

7 1

1

1 9

0.375” long

187–562 PIN, pivot

10* 224–947 NEEDLE, fluid; Includes replaceable items 10a & 10b

10a* 111–516 S O-RING; CV75

10b* 111–517 S RING, backup;

11 235–080 GUARD, tip

PTFE

12* 107–079 O-RING,

13 222–608 AIR CAP

PTFE

14 r

182–XXX SPRAY TIP; Customer’s choice.

See Chart on page 18 .

1

1

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description Qty.

15* 236–679 DIFFUSER-SEAT

16 178–414 SEPARATOR, air

17* 178–422 GASKET, fluid, Delrin r ;

1 sent unassembled

18* 187–521 GASKET, fluid; acetal homopolymer

2

1

1

(black), 1 sent unassembled 2

19

23

224–868 TRIGGER EXTENSION

187–504 NUT, needle

24 178–765 NUT, packing, air

25* 105–452 U-CUP, PTFE

26* 217–487 VALVE, air

29 218–566 GUARD, trigger

30 180–547 CONNECTOR, fluid

31 Y 222–385 WARNING CARD (not shown)

34 187–737 TOOL, needle assembly

35 Y 172–479 TAG, instruction (not shown)

1

1

1

1

1

1

1

1

2

1

* These parts are included in Repair Kit 224–949, which must be purchased separately.

Y Replacement W arning and Instruction tags and instruction are available at no cost.

308-193 17

Spray Tip and Air Cap Selection Charts

Orifice

Size inches

(mm)

0.007

(0.178)

0.009

(0.229)

0.011

(0.279)

0.013

(0.330)

0.015

(0.381)

0.017

(0.432)

0.019

(0.483)

0.021

(0.533)

0.023

(0.584)

0.025

(0.635)

STANDARD SPRAY TIPS

Inches (mm)

Fan Width at 12”

(300 mm)

*Light to

Medium

Viscosity

fl oz/min

(liters/min)

*Heavy

Viscosity fl oz/min

(liters/min)

4–6 (100–150)

6–8 (150–200)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

6–8 (150–200)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

14–16 (350–400)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

14–16 (350–400)

16–18 (400–460)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

14–16 (350–400)

16–18 (400–460)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

14–16 (350–400)

16–18 (400–460)

2–4 (50–100) 4.0

4–6 (100–150) (0.1)

6–8 (150–200)

8–10 (200–250)

4–6 (100–150) 7.0

6–8 (150–200) (0.2)

8–10(200–250)

4–6 (100–150)

6–8 (150–200)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

10.0

(0.3)

13.0

(0.4)

4–6 (100–150)

6–8 (150–200)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

4–6 (100–150)

6–8 (150–200)

8–10 (200–250)

10–12 (250–300)

12–14 (300–350)

17.0

(0.5)

22.0 17.0

(0.7)

28.0 21.0

(0.8)

35.0

(1.0)

40.0 34.0

(1.2)

50.0 42.0

(1.5)

(0.5)

(0.6)

27.0

(0.8)

(0.97)

(1.2)

Part

No.

182–215

182–315

182–415

182–515

182–615

182–217

182–317

182–417

182–517

182–617

182–319

182–419

182–519

182–619

182–719

182–421

182–521

182–621

182–721

182–821

182–107

182–207

182–307

182–407

182–209

182–309

182–409

182–211

182–311

182–411

182–511

182–611

182–213

182–313

182–413

182–513

182–613

182–423

182–523

182–623

182–723

182–823

182–425

182–525

182–625

182–725

182–825

*Fluid output at 600 psi (41 bar).

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) ( P ).

Where QT = Fluid output (fl oz/min) from the above table for the selected orifice size.

NOTE: Other tips are available on special work order. Allow 4 to 6 weeks for delivery.

Application

AIR CAPS

Tip Size

Used With inches (mm) smaller than

0.025 (0.635)

Air

Consumption

3–5 scfm Standard

High Efficiency Low

Pressure t smaller than

0.025 (0.635) 5–7 scfm

{ Air cap provided with spray gun.

Part No.

217–303

222–608 {

Dimensions

7.6 in.

(193 mm)

6.9 in.

(175 mm)

Technical Data

Maximum Working Fluid Pressure . 4000 psi (280 bar)

Maximum Working Air Pressure . . . . . . . 100 psi (7 bar)

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

Sound Pressure {

100 psi (7 bar) Air Pressure . . . . . . . . . . 97.6 dB(A)

30 psi (2.1 bar) Air Pressure

Sound Power }

100 psi (7 bar) Air Pressure

30 psi (21. bar) Air Pressure

Weight (less filter)

. . . . . . . . .

. . . . . . . . .

. . . . . . . .

. . . . . . . . . . . . . . . . .

90.8 dB(A)

112.8 dB(A)

106.0 dB(A)

1.35 lb (0.62 Kg)

Wetted Parts . . . . . . Stainless Steel, Carbide, Ultra

High Molecular Weight Polyethylene, CV75, PTFE r , Delrin r

PTFE r and Delrin r are registered trademarks of the

Company.

{ Sound pressure was measured per Cagi Pneurop, 1969.

} Sound power was measured per ISO–3744, 1981.

1/4–18 npsm

(R1/4–19)

Compound Thread

Accessories

Use Only Genuine Graco Parts and Accessories

Grounding Clamp and Wire 222–011

12 ga, 25 ft (7.6 m) wire

In-line Fluid Filter 210–500

5000 psi (350 bar) Maximum Working Pressure

100 mesh. Fits onto the gun’s fluid connector. 1/4–18 npsm.

Brush 101–892

For cleaning the gun.

High Pressure Ball Valves, Viton r Seals

5000 psi (350 bar) Maximum Working Pressure

Can be used as fluid drain valve.

210–657 1/2 npt(m)

210–658 3/8 npt(m)

210–659 3/8 x 1/4 npt(m)

210–501

168–517

Filter

164–075

205–264

Bleed-type Master Air Valve

300 psi (21 bar) Maximum Working Pressure

Relieves air trapped in the air line between the pump air inlet and this valve when closed.

107–141 3/4 npt(m x f) inlet & outlet

107–142 1/2 npt(m x f) inlet & outlet

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.

Graco Phone

Number

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

Manual Change

Summary

Assembly

Changed

224–887 spray gun

Part

Status

OLD

NEW

Ref.

No.

15

15

Part No.

224–948

236–679

Miscellaneous Changes:

1.

Updated manual to CE standards.

Name

Diffuser-seat

Diffuser-seat

2.

Added U.S. patent 5, 285,965.

3.

Added “do” and “do not” lubricate notes to Service section drawing.

Sales Offices: Atlanta, Chicago, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–193 December 1991, Revised November 1995