Graco AKA 420 User manual

Continued on pages 1 to 11

Pneumatically operated automatic spray gun for airless atomization of liquid materials.

The original manufacturer’s nameplate is located

on the spray gun. Please compare the

specifications and complete if necessary.

Read and understand the operator manual and

the safety instructions before taking into

operation

In this manual important information is marked with

the following symbols.

Information affecting your safety

Important operational direction

Keep user information for future reference

CONTENTS OF THE USER INFORMATION

Page

OPERATING INSTRUCTIONS

CORRECT USE 2

FUNCTIONAL DIAGRAM 2

PRODUCT DESCRIPTION 3

SUITABILITY, MATERIAL 3

TECHNICAL DATA 4

Key

Data

Material in contact with the fluid

Dimensions, Connection thread

Mounting the gun

LIST OF TOOLS 6

START-UP 7

IMPORTANT INFORMATION CONCERNING START-UP AND OPERATION 8

OPERATION 8

MAINTENANCE AND INSPECTION, REPAIR 8

TORQUE MOMENTS 9

TROUBLESHOOTING 9

FOOTNOTE 10

REPAIR PARTS SET 10

ACCESSORIES 11

Includes:

TEST CERTIFICATE (final inspection)

DECLARATION OF CONFORMITY

Replacement for issue of 02.97

SPRAY GUN A KA 420

Subject to change

Part nbr. 7990 022001

Prepared 28.10.99 Stengele

Approved 12.11.99 Kuhn

Issued 10.99

B.2.30.95-B

*5$&2 6000330E, Rev.A

USER INFORMATION

- OPERATING INSTRUCTIONS -

B.2.30.95-B- 2 -

CORRECT USE

The spray gun A KA 420 is exclusively manufactured for normal use in surface technology

(for spraying coating substances) or for similar work.

Any other purpose above and beyond this, is considered as incorrect use. We are not liable for any

damage or injury resulting from this; the user will bear sole liability in such cases.

Correct use includes observing operating, maintenance and inspection conditions and regulations

laid down by us.

The spray gun A KA 420 may only be installed, maintained and repaired by personnel familiar with,

and trained to recognize the inherent dangers.

The relevant accident prevention regulations as well as safety and medical rules must be respected.

Unilateral changes to the spray gun will cause us to waive our responsibility for any damage or injury

caused.

The user is responsible for correct attachment/installation.

FUNCTIONAL DIAGRAM

Operating air

(control air)

A Automatic spray gun

B 3/2-way valve

C Air pressure regulator

D Pressure gauge

Coating substance

Fig. 1

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PRODUCT DESCRIPTION

The spray gun A KA 420 is operated pneumatically.

When switched on, the control air 1opens the fluid valve 2.

When switched off, the fluid valve is closed by the pressure spring 3.

The parts in contact with the fluid are suitable for water-based paints (stainless steel).

The needle 4is completely made of hardened steel.

The valve seat (diffuser) 5and the gun body 6are designed in such a way that a filter element 7of varying

mesh size can be incorporated, and that an additional filter element does not obstruct the flow of fluid through

the spray gun.

The spray gun is fixed centrally at the rear end 8.

The union nut 9belongs to the spray gun.

Fan jet nozzles, pre-atomizer, filter elements and connections should be specified separately by the operator.

COMPATIBILITY, MATERIAL

FLUID Compatibility

Neutral

Corrosive

Abrasive

Acidic

Inflammable 1)

highly suitable

suitable under

certain conditions

suitable under

certain conditions

highly suitable

1) Hazard classes AI, AII, AIII: the spray gun

should be properly grounded.

Please consult us when processing highly

abrasive and aggressive materials.

Fig. 2

switched air

%%

- 4 -

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

Kinematic viscosity in

mm2/s Compatibility

up to 500

500 to 750

over 750

highly suitable

suitable

suitable under certain conditions

(application must be tested)

Solids content Compatibility

low

low to 1 %

medium 1 to 6 %

over 6%

over 50%

highly suitable

suitable

suitable under certain conditions

not suitable

TECHNICAL DATA

KEY TO DESIGNATION

Spray gun A KA 420 - 0

DATA

Spray gun AKA 420 (basic version) Part nbr.: 79331 006002

Fluid inlet pressure max. permissible 420 bar

Fluid temperature max. perm. 80 °C

Operating air pressure max. perm. 5 bar

Recommended switching frequency 160 Strokes/min

Mesh size of the filter elements 0.08 0.18 0.30

Weight of the spray gun without accessories 450 g

Without nozzles

Fluid inlet pressure

Conventional Airless

Automatic

%%

MATERIALS IN CONTACT WITH THE FLUID

Pos. Description Material

Gun body

Valve seat (diffuser)

Needle

Seat

Profile sealing ring

Spacer

Grooved ring

Filter element

SST 1.4305

Hardened steel

POM

SST

Materials that contain chlorinated hydrocarbons such as trichloro-ethane or methylene chloride

react with aluminum to form metal-organic compounds.

These compounds are explosive and extremely caustic.

– The use is not permissible

GROUNDING, CONNECTION THREAD

Nominal diameter of the pressure air hose preferred DN 6; hose length < 1.5 m DN 4.

Fig. 3

Air pressure connection G 1/8, 7 deep

Thread M 10 for gun

fastening, 10 deep

Fig. 4

for positioning pin

Fluid connection G 1/4, 9 deep, on both sides

B.2.30.95-B- 6 -

MOUNTING THE GUN

- centrally at the rear end

LIST OF TOOLS

Tools for the spray gun in its basic version

Allen Screw

DIN 911

Open-end spanner

DIN 895

Spanner

DIN 3116

Drift

Part nbr.

70641 001002

SW 4 SW 27 A 20 Special tool

Tools for the spray gun accessories

Open-end spanner DIN 895

SW11 Air pressure connection (plug-in screw connection for DN 4)

SW12 Air pressure connection (plug-in screw connection for DN 4)

SW15 Fluid connection (angle)

Allen Screw DIN 941

SW6 Fluid connection (screw plug)

Position of the leakage hole

Positioning pin ø3

- on a bracket,

- on a reciprocating arm

- by means of a rod

- on a stationary support

Fig. 5

Fig. 6

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START-UP

Fasten spray gun

The threaded connection M 10 must be locked.

The leakage holes should point downwards.

Connect hoses and hose line(s)

Then check for tightness.

Install the in-line filter element

Automatic spray guns are delivered without filter elements.

Filter elements must be installed later (the choice of mesh size depends on spray tip used).

Before removing the valve seat (diffuser) the needle must be brought into the opened

position.

Switching on the control air (Pos. 1, page 3), does this.

Then - Screw out the valve seat (diffuser)

- Put the filter element 3 on to the valve seat (diffuser) 1

Note the mounting position of the profile sealing ring 2

- Install the valve seat (diffuser) with the filter element

The needle is in the opened position

Install the nozzles

- Put the nozzle in the union nut, align at the gun and tighten (pay attention to the tightening

torque).

Do not use any additional seals (The nozzle with pre-atomizer is self-sealing).

With older nozzles without pre-atomizers, a sealing washer should be installed instead of the

pre-atomizer.

Fig. 7

B.2.30.95-B- 8 -

IMPORTANT INFORMATION CONCERNING START-UP AND OPERATION

During prolonged operating pauses and/or during shutdown, no energy potential (fluid and/or

air pressure and/or electricity) should be present at the spray gun.

The working area of the spray gun must be protected.

The recommendations of the manufacturer of the fluid should be observed.

OPERATION

Do not exceed the specified technical data (page 4).

MAINTENANCE AND INSPECTION

- The automatic spray gun A KA 420 requires little maintenance.

• Flush thoroughly before operating pauses.

• Drain the condensed water every day from the filter or filter regulator if there is no automatic

water drainage in the compressed air supply to the spray gun.

• Regularly dismantle the filter element and thoroughly clean.

- The cleaning interval depends on the coating substance and must be determined by the

user.

• Check leakage behavior (air or material escaping from the leakage hole) at regular intervals –

e.g. once a week.

- The seals should be replaced if substantial amounts of air and fluid are escaping.

Loosen the sealing plug (cover) with spanner DIN 3116-A20.

By screwing in a tapping screw DIN 7981-ST4,2 the complete bearing bushing. 1and the

grooved ring 2can be simply removed.

The complete bearing bushing 1and the grooved ring 2are installed using the drift 3,

Part nbr. 70641 001002.

Fig. 8

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The parts should be lightly greased before assembly.

– We recommend “grease OKS 270” (Tube 100g, Part nbr. 70950 003001).

• The service life of the hose lines is adversely affected, and thus shortened, by surrounding

influences (oxygen in air, temperature, light, etc.), even if correctly handled.

It is recommended that they undergo regular visual checks and occasional checking of

performance.

As a precaution, the hose lines should be replaced by new ones at intervals set by the operator

(after 2 to 3 years).

NEVER dismantle a spray gun that is under pressure.

TIGHTENING TORQUE

Pos. Thread Material Tightening

torque

1 M24 x 1.5 X12CrMoS17 25 Nm

2 M 5 8.8 7 Nm

TROUBLESHOOTING

BREAKDOWN ANALYSIS

Component group Nature of defect Defect symptoms Possible cause Counter measure

Nozzle, filter

element Irregular fluid

delivery Change in the

spray pattern, no

application of fluid

Nozzle or pre-atomizer

obstructed, filter

element clogged up.

Clean nozzle, pre-

atomizer and filter

element

Sealing system

(needle seal, piston

seal)

Leakage at the

body of the gun Air or fluid escaping

from the leakage

holes

Seal(s) worn Replace seals

Air connections Spray gun does not

work No switching Air supply interrupted Check the plug

connection and air

hose

Fig. 9

B.2.30.95-B

- 10 -

FOOTNOTE

The spray gun is intended for attachment/installation to/in a machine for surface technology. The

start-up is prohibited until it has been established that the machine in/to, which the spray gun is to be

installed/attached, conforms to the provisions of the EU directive on machines in the version

93/44/EEC.

LIST OF REPAIR PARTS

Replacement part set, fluid valve Part nbr. 79978 040001

Pos. 10

Pos. 20

Pos. 30

1 off

Valve seat (diffuser) complete

Profile sealing ring

Needle complete

M 16 x 1 x 38.5

9.5 x 14 x 3.2

D 3 L 66.5

Repair kit

Pos. 40 1 off Union nut M 24 x 1.5 76089 080002

Replacement part set, seals Part nbr. 79978 041001

Pos. 10

Pos. 20

Pos. 30

Pos. 40

Pos. 50

Pos. 60

1 off

Spacer

Grooved ring

Seal

Bearing bushing complete

O-ring

Bearing

6 x 7.5 x 0.6

3 x 7.5 x 3.35

15 x 12 x 1.5

3.1 x 7.6 x 11

36 x 2.5B

4 x 1.55 x 118

Fig. 10

Fig. 11

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