Graco 237-418 Operation manual

INSTRUCTIONS–P

ARTS LIST

308–457

Rev.

Supersedes A

23:1

MONARK CARBON

STEEL, CART MOUNTED

AA200hs

Air-Assisted Airless

Spray Package

See the Data Sheet, 305–663, for application information.

2760 psi (190 bar) Maximum System Working Pressure

120 psi (8.3 bar) Maximum Air Inlet Pressure

Model 237–418, Series A

This

complete package includes a pump,

an AA200hs air-assisted airless–spray gun

with a 41

1 spray tip

,a portable cart

, 25 ft. (7.6 m) air

and fluid hoses,

air and fluid controls, and a fluid feed.

IMPORTANT

This manual provides the basic safety

, installation and

operation information for the package. For your safety

also read the component manuals supplied with this

package before operating it.

GRACO INC. P.O. BOX 1441

MINNEAPOLIS, MN

55440–1441

COPYRIGHT

1994, GRACO INC.

This manual contains important

warnings and information.

READ AND RETAIN FOR REFERENCE

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Table

of Contents

Symbols 2.

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

Warnings 3

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

Setup 5

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

Ground

the system

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

System

Component Information

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

Operation 8

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

Pressure

relief procedure

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

Flushing 10

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

Parts 12

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

Technical

Data

16.

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

Warranty 16

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

Graco

Phone Numbers

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 SymbolCAUTION

This

symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

corresponding instructions.





WARNINGWARNING

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

Fluid injected into the skin is a serious injury

. The injury might look like just a cut, but it is a seri

ous injury

. Get immediate medical attention.

Do not point the spray gun at anyone or 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 system.

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

Check the gun dif

fuser operation weekly

. Refer to the gun manual.

Be sure the gun trigger safety operates before spraying the gun.

Lock the gun trigger safety when you stop spraying.

Follow the

Pressure relief procedure

on page 8 if the spray tip clogs and before cleaning,

checking or servicing the equipment.

ighten all fluid connections before each use.

Check the hoses, tubes and couplings daily

. Replace worn or damaged parts immediately

. Per

manently coupled hoses cannot be repaired.

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 tempera

tures above 180

_F (82_

C) or below –40

_F (–40_C).

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.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container

. Dispose hazardous fluid according to all local,

state and national guidelines.

ear appropriate clothing, gloves, eyewear and respirator



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

Ground the equipment and the object being sprayed. See

Ground the system

on 6.

If there is any static sparking while using the equipment,

stop spraying immediately

. Identify

and correct the problem.

Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid be

ing sprayed.

Do not smoke in the spray area.

Extinguish all open flames or pilot lights in the spray area.

Do not turn on or of

f any light switch in the spray area.

Electrically disconnect all equipment in the spray area.

Keep the spray area free of debris, including solvent, rags and gasoline.

Do not operate a gasoline engine in the spray area.

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 in doubt about this, call Graco T

echni-

cal Assistance at 1–800–543–0339.

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

Check equipment daily

. Repair or replace worn or damaged parts immediately

Do not exceed the

2760 psi (190 bar) maximum working pressure at 120 psi (8.3 bar) maxi

mum incoming air pressure

of the pump, or the maximum working pressure of any accessory

used with it.

Do not move or lift pressurized equipment.

DUse

fluids or solvents which are compatible with equipment

wetted parts. Refer to the

echnical Data

section

of all equipment manuals. Read the fluid and solvent manufacturer

’

s warnings.

Fluid hoses must have spring guards on both ends to protect it from rupture caused by kinks or

bends at or close to the couplings.

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

Do not touch the heater during operation; it is very hot.

MOVING

ARTS HAZARD

Moving

parts, such as the air motor piston located behind the air motor plates, which can pinch or

amputate fingers.

Never operate the equipment with the air motor plates removed.

Keep clear of any moving parts when starting or operating the equipment.

WARNINGWARNING

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Setup

I. Prepare the operator.

All

persons who operate the system should be trained

in the safe, efficient operation of all system compo

nents as well as the proper handling of the chemical

coating. At a minimum, all operators should

thoroughly read the safety

, installation and operation

sections of this manual and the component manuals.

II. Prepare the site.

1. Use

a minimum recommended 5

HP (3.7

kW) air

compressor for ef

ficient operation.

Clear obstacles and debris that could hinder the

operator’

s movement.

Bring an air line from your compressed air supply

to the pump location. Be sure the air is dry and

filtered. Install a bleed–type master air valve (A)

upstream from the pump. Another master air valve

(14) is supplied with the package. When the

bleed–type master air valve is closed and the

pump air regulator (8a) is opened, the valve

relieves all air pressure to the system.

Have a grounded, metal waste–pail available to

use when draining the fluid filter

5. V

entilate the spray booth.

WARNING

o prevent hazardous concentrations of toxic and/

or flammable vapors, spray only in a properly venti

lated 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.

Fig. 1

C30

8b 8a

04072

KEY

Components

you must supply:

Bleed-type master air valve

Required for pump; order

part no. 107–142, 1/4” npt(f)

Air filter

. Order part no.

106–149, 1/2 npt(f)

Air supply line

Grounded 5 gallon metal pail

Air line moisture trap

Components supplied with package:

23:1 Monark pump

Air-assisted airless spray gun

Spray tip

Gun fluid hose

Gun air hose

Pump air regulator

Gun air regulator

Bleed–type air valve

Pump ground wire

3,4

6308-457

Setup

III. Unpack the system.

1. In

addition to the assembled components, the air

and fluid hoses, gun and instruction manuals are

packaged separately in the main shipping con

tainer

. These are the manuals you should receive:

307–619

23:1 ratio Monark pump

308–176

Air-assisted airless spray gun

307–273

Fluid filter

308–167

Air regulator

308–861

Ball valve

IV. Connect the hoses and gun to the

system. See

Fig. 1.

Connect the blue fluid hose (6) between the fluid

filter and the fluid inlet of the spray gun (3). These

are 1/4–18 npsm(f) swivel fittings.

Connect the red

air hose (7) between the gun air

regulator (8b) and the air inlet of the spray gun (3).

These are 1/4–18 npsm(f) swivel fittings.

3. V

erify that all fittings throughout the system are

tightened securely

V. Ground the system.

WARNING

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.

Ground all of this equipment.

Also read

FIRE OR EXPLOSION HAZARD

page 4

Pump

: one end of the ground wire (30) is already

connected to the air motor grounding lug. Connect

the clamp end of the ground wire to a true earth

ground.

Air and fluid hoses

: use only electrically conductive

hoses with a maximum of 500 feet (150 m) com

bined hose length to ensure grounding continuity

Air compressor

: according to manufacturer

’

recommendations.

Fluid supply container:

according to local code.

All solvent pails used when flushing

, according to

local code. Use only metal pails, which are con

ductive. Do not place the pail on a non-conductive

surface, such as paper or cardboard, which inter

rupts the grounding continuity



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System

Component Information

I. How to use the air–assisted airless

spray gun.

With

an air-assisted airless spray gun, the spray tip

shapes the fluid into a fan pattern. Air from the air cap

further atomizes the fluid and completes the atomiza

tion of the paint tails into the pattern to produce a more

uniform pattern.

The spray gun has a built-in lead and lag operation.

When triggered, the gun emits 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.

NOTE:

The gun air and fluid inlets have 1/4–18 npsm

(R1/4–19) compound male threads that are compatible

with NPSM and BSP female swivel

connectors.

The fan pattern valve (E) can be used to reduce

the pattern by about 25% of the total pattern width.

As the valve is opened, the pattern will reduce

slightly

. The tip used designates the total width of

the spray pattern.

2. T

o unlock the gun trigger safety, turn the safety so

it is parallel with the trigger

. T

o lock the gun trigger

safety

, turn the safety to a right angle with the trig

ger

. See Fig. 2.

Fig. 2

UNLOCKED

gun trigger safety

LOCKED gun trigger safety

0795A

II. How to change the spray pattern

direction.

1. Relieve

the air and fluid pressure.

Install a spray tip in the gun. Rotate the air cap

(the spray tip rotates with it) to determine the

direction of the spray pattern. See Fig. 3.

Fig. 3

ertical Spray Pattern

Horizontal Spray Pattern

0791

III. How to adjust the air regulators.

See

Fig.

As you look at the system, the air regulator (8a) on the

left regulates air to the gun and the air regulator (8b)

on the right regulates air to the pump.

Always open air regulators slowly to prevent surg

ing during startup.

2. T

o open the regulator

, which allows air to flow

, turn

the T–handle IN (clockwise). T

urn the T–handle

OUT (counterclockwise) to close off the air flow

Be sure the jam nut under the T–handle does not

interfere with your adjustments. T

ighten the jam

nut to lock in the setting, if desired.

Fig. 4

8a 8b

CCW

04069



Operation

I. Pressure relief procedure

The

system remains pressurized until pressure is

manually relieved. To reduce the risk of serious

injury

, including skin injection from pressurized fluid

or accidental spray from the gun, or injury due to

splashing fluid in the eyes or on the skin, follow this

procedure whenever you:

are told to relieve pressure;

stop spraying;

check or service any system equipment;

install, clean or change spray tips.

WARNING

Lock the gun trigger safety

Close the bleed-type master air valves (A,14).

Close the air regulators (8a,8b).

Unlock the gun trigger safety

Hold the gun firmly against a grounded metal

waste pail. T

rigger the gun to relieve pressure.

Lock the gun trigger safety

Open the filter drain valve (26), having a container

ready to catch the drainage. Close the drain valve.

If you suspect that the spray tip or hose is completely

clogged or that pressure has not been fully relieved,

very slow loosen the tip retaining nut or hose end cou

pling and relieve pressure gradually

. Clean the tip or

hose obstruction.

II. Flush the pump before the first use.

Flush

with a solvent compatible to your fluid. Consult

the fluid manufacturer

’

s literature for recommenda

tions. See

Flushing

on page 10.

III. Prime the system.

See

Fig. 5.

Remove the air cap and spray tip from the gun.

Close the filter drain valve (26).

Put the suction tube into the fluid supply container

Make sure the air regulators (8a,8b) are closed.

Open the master air valves (A,14).

NOTE:

In the next steps, the pump will cycle quickly

until air is purged.

Slowly turn on the pump air regulator (8a) until the

pump cycles slowly

Hold a metal part of the gun firmly against and

aimed into the grounded metal waste pail. T

rigger

the gun while increasing pressure at the pump air

regulator (8a) just enough to purge the air and

storage solvent from the system. When new fluid

comes from the gun, release the trigger

. Lock the

gun trigger safety

Fig. 5

8b 8a

04072

KEY

A Bleed-type

master air valve

Air-assisted airless spray gun

Pump air regulator

Gun air regulator

Bleed–type air valve

Filter drain valve

308-457

Operation

IV. Set the fluid and air pressure.

1. Install

the spray tip and air cap on the gun.

Adjust the pump air pressure regulator until the

pressure shown on the fluid filter gauge is about

800 psi (56 bar). This should require approximately

35 psi (2.4 bar) air pressure to the pump.

3. T

est spray a pass or stationary horizontal pattern.

Hold the gun 10 to 12 in. (250 to 300 mm) from the

paper

. Stripes in the outer edges of the pass or

spots at the ends of the stationary pattern are

likely at this point.

NOTE:

If there are no stripes or spots, lower the

fluid pressure until they appear

before

turning on

the air to the gun.

Partially trigger the gun so only air is emitted. Set

the gun air regulator to 20 psi (1.4 bar).

Retest the spray pattern. T

rigger the gun and

adjust the gun’

s air control valve (C) to add air to

the aircap and to eliminate stripes or spots. If there

are no stripes or spots, you are ready to start

spraying.

If there are stripes or spots in the spray pattern,

raise the pump air pressure until you raise the fluid

outlet pressure by about 100 psi (6.9 bar) and try

again. Continue to raise the fluid pressure in

100

psi (6.9 bar) increments until the pattern is full

and clean. Do not exceed 120 psi (8.3 bar)

incoming air pressure or 2760 psi (190 bar) fluid

working pressure.

NOTE: Always use the lowest fluid and air pres

sure required for good atomization and spray pat

tern for maximum fluid ef

ficiency

. Air pressure over

approximately 30 psi (2.1 bar) will cause turbu

lence in the fan pattern, dirty air caps and slower

production capability

WARNING

This system has a maximum air working pressure

of 120 psi (8.3 bar) which produces a maximum

fluid working pressure of 2760 psi (190 bar). Higher

pressure can cause the system to rupture or mal

function and result in serious injury

V. You are now ready for production

spraying.

CAUTION

When

using catalyzed fluids, observe the pot life

as recommended by the fluid manufacturer

. Always

flush the system before the pot life has expired to

prevent dried fluid which may be dif

ficult to clean

out and may damage the system.

VI. When to shut down the system.

Shut

down the system at the end of the work shift and

before checking, adjusting, cleaning or repairing the

system. Always follow the

Pressure relief procedure

on page 8.

10 308-457

Flushing

I. When to flush.

DBefore

the first time use

When changing colors

Before fluid can dry or settle out in a dormant sys

tem (observe the recommended fluid pot life on cat

alyzed fluids)

Before storing the system

II. How to flush.

See

Fig. 6.

Relieve pressure. See page 8.

Remove the air cap and spray tip before flushing.

Unscrew the fluid filter (5) bowl. Remove the

screen. See manual 307–273. Reinstall the bowl

without the screen.

Put the suction tube into a grounded metal pail with

about 1/2 gallon (2 liters) of a compatible solvent.

Make sure the air regulators (8a,8b) are closed.

NOTE:

The gun air regulator (8b) always stays closed

during flushing.

Open the master air valves (A,14).

Slowly turn on the pump air regulator (8a) until the

pump cycles slowly

Hold a metal part of the gun firmly against the

grounded metal waste pail. T

rigger the gun. Slowly

increase the pump air regulator setting until the

fluid flows freely

. (Some air will spit from the gun

until the fluid arrives.)

Keeping the gun triggered, decrease the pump air

regulator (8a) pressure as much as possible

without stalling the pump, and pump out the

solvent until air comes through the gun.

10. Repeat

the procedure with clean solvent, if needed.

11. Release

the trigger and lock the gun trigger safety

12.

Close the master air valves (A,14). Fully close the

pump air regulator (8a).

13.

Open the drain valve (26), having a container

ready to catch the drainage.

14.

Remove the suction hose from the solvent and

place it in an empty container

15.

Clean the filter screen, air cap and spray tip sepa

rately

. Reinstall the filter screen.

16.

Thoroughly clean the inside and outside of the

suction tube

Fig. 6

8b 8a

04072

KEY

A Bleed-type

master air valve

Air-assisted airless spray gun

Fluid filter

Pump air regulator

Gun air regulator

Bleed–type air valve

Filter drain valve

14 5

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