Graco G1200 Operation manual


INSTRUCTIONS–P ARTS LIST 308–008
Rev D
Supersedes C
This manual contains IMPORT ANT
W
ARNINGS AND INSTRUCTIONS
READ AND RET AIN FOR REFERENCE
Model G1200
HIGH EFFICIENCY
LOW PRESSURE
HVLP SPRA Y GUN
100 psi (7 bar) MAXIMUM WORKING FLUID PRESSURE
15 psi (1 bar) MAXIMUM WORKING AIR PRESSURE
See the Selection Chart on page 4 for complete spray
gun
assembly ordering numbers and descriptions.
TABLE OF CONTENTS
Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection Charts 4–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 11. . . . . . . . . . . . . . . . . . . . . . .
Service 12–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Flow 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Order Replacement Parts 17. . . . . . . . . . . . . .
Accessories 18–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data Back Cover . . . . . . . . . . . . . . . . . . . . . . .
Warranty Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1990 GRACO INC.

 
WARNINGS
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.
Read and understand all instruction manuals, tags,
and warning labels before operating equipment.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such
as over pressurizing, modifying parts, using incompatible
chemicals and fluids, or using worn or damaged parts,
can cause them to rupture and result in serious bodily
injury,
fire, explosion or property damage.
NEVER point the spray gun at anyone or at any part of
the
body . NEVER put hand or fingers over the spray noz -
zle.
ALWAYS
follow the Pressure Relief Procedure , at right,
before cleaning or removing the fluid nozzle or servicing
any system equipment.
NEVER try to stop or deflect leaks with your hand or
body.
NEVER
alter or modify any part of this equipment; doing
so could cause it to malfunction.
CHECK all spray equipment regularly and repair or
replace
worn or damaged parts immediately .
System Pressure
This gun has a MAXIMUM FLUID WORKING PRES-
SURE
of 100 psi (7 bar) and a MAXIMUM AIR WORK-
ING PRESSURE
of 15 psi (1 bar). Never exceed the
maximum
working pressure of the gun or any other com -
ponent
or accessory used in the system.
Fluid Compatibility
BE SURE all fluids and solvents used are chemically
compatible
with the “W etted Parts” shown in the TECH-
NICAL DATA on the back cover . Always read the fluid
and solvent manufacturer ’s literature before using the
fluid
or solvent in this gun.
Methylene Chloride is not recommended as a flushing or
cleaning solvent with this gun or any other device with
nylon or
aluminum components as it can damage these
parts.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
splashing
in the eyes or on the skin or injury from moving
parts, always follow this procedure when shutting of f the
system, when checking or servicing any part of the spray
system, when installing, cleaning or changing fluid noz-
zles,
and whenever you stop spraying.
1. T urn of f the air and fluid supply to the gun.
2. Trigger the gun into a grounded metal waste con-
tainer
to relieve air and fluid pressure.
HOSE SAFETY
TIGHTEN all fluid connections securely before each use.
NEVER use a damaged hose. Before each use, check
the
entire hose for cuts, leaks, abrasion, bulging cover , or
damage or movement of the hose couplings. If any of
these
conditions exist, replace the hose immediately .
HANDLE AND ROUTE HOSES CAREFULL Y. Do not
pull
on hoses to move equipment. Do not use fluids or sol -
vents which are not compatible with the inner tube and
cover
of the hose.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These stan -
dards––particularly the General Standards, Part 1910 and the Construction Standards, Part 1926––should be consulted.

308-0083
TYPICAL INSTALLATION
Air Filter 106–149
(See ACCESSORIES)
1/2 npt(f)
Filter inlet & outlet
3/8 npt(m)
System air inlet
3/4–11.5 NH*
System air outlet
3/4” ID Air Hose
(See ACCESSORIES)
MODEL G1200
SPRA
Y GUN
(See Chart, page 4)
Quick-
Disconnect
Gun Air Hose
Connection
Flexible Hose
(See ACCESSORIES)
3/4–11.5 NH*
Swivel Fitting
1500 System
223–293
Air Pressure Relief V alve
(Set at 15 psi [1.05 bar])
Fluid Inlet
3/8 npsm
(R3/8–19)
*NH – standard garden hose fitting
The Model G1200 High Efficiency Low Pressure Spray
Gun was designed to produce the highest quality finish
with
today’ s fluids as well as the the Low V .O.C. (volatile
organic
compound) fluids of tomorrow .
This spray gun can spray most coatings or finishes cur-
rently
being used for automotive refinish, industrial, aero -
space, marine, wood, plastic and architectural applica-
tions, while easily operating from any paint delivery sys -
tem, including pressure pots of any size, or remote
pumps
for production line operation.
The Model G1200 Spray Gun typically utilizes 10 psi (0.7
bar) air pressure with high air volume to produce high
quality
paint finishes.
One air source is the High Ef ficiency Low Pressure 1500
System. This system accurately converts standard air
line pressure down to the 10 psi (0.7 bar) required to meet
all new regulations. Another air source is the High Effi-
ciency Low pressure 8000 System. This system is a
stand-alone
powered air supply , which is capable of sup -
plying
full, consistent air pressure to four guns.
NOTE: Although the 1500 and 8000 Systems can have
an output air pressure of 15 psi (1.05 bar), for
proper
operation,10 psi (0.7 bar) or lower output
air pressure is recommended.
Installation of one of the Air Hose Assemblies listed in the
ACCESSORIES section is required to minimize the air
pressure drop in the hose while still maintaining good
hose flexibility. This combination produces the best
atomization
with high transfer ef ficiency.

4 308-008
SELECTION CHARTS
CHART 1: GUN ASSEMBLIES AVAILABLE
The following complete gun assemblies are standard non-bleeder-type guns , with trigger-actuated air shut-of f
valves.
Includes:
Complete
Gun Assy.
Part No.
Gun Body
Assy.
Part No.
Needle/Nozzle/Air Cap
Kit Part No. Orifice Size
Material Usage
(See TERMS below)
223–252 223–300 223–232 0.055”
(1.397 mm)
Light to Medium Fluids or
Low
Fluid Flow (5–8 oz/min)
223–253 223–300 223–233 0.070”
(1.778 mm)
Medium to Heavy Fluids
or Medium Fluid Flow (6–10
oz/min)
223–254 223–300 223–234 0.086”
(2.184 mm)
Heavy Fluids or Medium
Fluid
Flow (6–10 oz/min)
The following complete gun assemblies are bleeder-type guns , which include the Air V alve Filler 187–137 (see Parts
Drawing and List, pages 12 and 13). The bleeder-type gun allows air to bleed through the gun at all times, regardless of
the trigger position.
Includes:
Complete
Bleeder
Gun Assy.
Part No.
Gun Body
Assy.
Part No.
Needle/Nozzle/Air Cap
Kit Part No. Orifice Size
Material Usage
(See TERMS below)
224–609 224–606 223–232 0.055”
(1.397 mm)
Light to Medium Fluids or
Low
Fluid Flow (5–8 oz/min)
224–610 224–606 223–233 0.070”
(1.778 mm)
Medium to Heavy Fluids
or Medium Fluid Flow (6–10
oz/min)
224–611 224–606 223–234 0.086”
(2.184 mm)
Heavy Fluids or Medium
Fluid
Flow (6–10 oz/min)
TERMS:
Light Fluid: 15 to 20 seconds (No. 2 Zahn cup) -- Auto, Furniture, Appliances,
Fine Finish Metallics, T
op Coats, Lacquer , Enamel Primer .
Medium Fluid:
20 to 25 seconds (No. 2 Zahn cup) -- Contact Adhesive, Latex, Maintenance
Paints, T extures, Primers, Epoxies, V inyls, High Flow High V iscosity.
Heavy Fluid:
+25 seconds (No. 2 Zahn cup) -- 2.8 V olatile Organic Compounds,
High-solid Polyurethanes, Heavy W aterborne Enamels

308-0085
SELECTION CHARTS
SELECTING THE PROPER NEEDLE/NOZZLE/AIR CAP SET
The High Efficiency Low Pressure Spray Gun’s needle/
nozzle sets range in size to provide dif ferent fluid flow
rates.
Chart 2 shows the recommended combinations of
needle/nozzle kits and air caps.
Select from Charts 2, 3, and 4, using the following guide -
lines.
As a general guideline, use the fluid nozzle that will give
the required flow with the needle fully triggered at the low -
est
fluid pressure.
For low flow rates or light viscosity fluid, select the
smaller
nozzle sizes.
For high flow rates or high viscosity fluid, select the larger
nozzle sizes.
Some applications may benefit by using an air cap that is
one size larger then the needle/nozzle size that is being
used. In certain applications, this may improve atomiza -
tion, keep the air cap cleaner , and will decrease the pat -
tern
size. It will increase air flow , but also will decrease air
pressure at the air cap.
Using an air cap size that is smaller than the nozzle/
needle
size is not recommended.
NOTE: To help select the proper needle/nozzle size, a
fluid
pressure gauge may be connected tempo -
rarily to the gun fluid inlet to determine the fluid
pressure.
Selection Problems and Solutions
PROBLEM POSSIBLE
CAUSE
SOLUTION
Fluid pressure is too
high (greater than 10
psi [0.7 bar]) with
gun triggered
Using set with too
small orifice
Use needle/
nozzle/air cap
set with larger
orifice
Using a low pressure
setting, the fluid flow
is too high, making it
necessary to restrict
needle travel to
reduce fluid flow .
Using set with too
large orifice
Use needle/
nozzle/air cap
set with smaller
orifice
Fluid system will not
operate at low
enough fluid pres -
sure [below 10 psi
(0.7 bar)]
There’ s no fluid
regulator or air
regulator is not
sensitive enough
Add low pres -
sure fluid regu -
lator or add
more sensitive
air regulator on
pressure pot
CHART 2: NEEDLE/NOZZLE/AIR CAP KIT
Includes:
Needle/Nozzle/Air Cap
Kit Part No.
Standard Plastic
Needle & SST
Nozzle Kit Part No.
Air Cap*
Part No. Orifice Size
223–230 223–240 185–720 0.030” (0.762 mm)
223–231 223–241 185–721 0.042” (1.067 mm)
223–232 223–242 185–722 0.055” (1.397 mm)
223–233 223–243 185–723 0.070” (1.778 mm)
223–234 223–244 185–724 0.086” (2.184 mm)
223–235 223–245 185–725 0.110” (2.794 mm)
223–236 223–246 185–726 0.125” (3.175 mm)
*Approximate fan width for all air cap sizes 9 to 12 in. (229 to 305 mm).
Charts 3 and 4 are on the next page.

Optional SST
Needle/Nozzle
Matched Set
Part No.
CHART 4:
OPTIONAL SST
MATCHED SET
223–286
223–287
223–288
223–289
223–290
223–291
223–292
6 308-008
SELECTION CHARTS
CHART 3: STANDARD NEEDLE/NOZZLE KIT
Includes:
Standard Plastic
Needle & SST
Nozzle Kit Part No.
SST Fluid
Nozzle
Part No.
Standard Plastic
Fluid Needle
Part No. Orifice Size
223–240 185–700 185–710** 0.030”
(0.762 mm)
223–241 185–701 185–711 0.042”
(1.067 mm)
223–242 185–702 185–712 0.055”
(1.397 mm)
223–243 185–703 185–713 0.070”
(1.778 mm)
223–244 185–704 185–714 0.086”
(2.184 mm)
223–245 185–705 185–715 0.110”
(2.794 mm)
223–246 185–706 185–716 0.125”
(3.175 mm)
**Non-feathering

308-0087
INSTALLATION
Ventilate the Spray Booth
WARNING
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.
Check
and follow all local safety and fire codes.
Connect the Air Line
1. Connect the flexible air hose between the atomizing
air hose and the gun’ s quick-disconnect air fitting.
Refer
to the System Drawing on page 3.
2. If using the High Efficiency Low Pressure Model
1500 Air Supply System,
install an air and water
separator (Part No. 106–149) on the air line to en-
sure a dry , clean air supply to the gun. Dirt and mois -
ture can ruin the appearance of your finished
workpiece.
See ACCESSORIES.
Connect the Fluid Line
1. Before connecting the fluid line, blow it out with air
and flush it with solvent. Use solvent which is com-
patible with the fluid to be sprayed.
2. Install a fluid regulator on the fluid line to control fluid
pressure to the gun.
3. Connect the fluid line to the gun fluid inlet (3/8–18
npsm
[R 3/8–19] compound thread).
Fig 1
Pattern Adjusting V alve
Fluid Adjusting Knob
Fluid
Nozzle
Fluid
Needle
Air Cap
Fluid Inlet
Air Inlet

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OPERATION
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
splashing in the eyes or on the skin or injury from
moving parts, always follow this procedure when
shutting
of f the system, when checking or servicing
any part of the spray system, when installing,
cleaning or changing fluid nozzles, and whenever
you
stop spraying.
1. T urn of f the air and fluid supply to the gun.
2. Trigger the gun into a grounded metal waste
container
to relieve fluid pressure.
Filter the Fluid
Filter the fluid to remove coarse particles and sediment
which
could clog the spray nozzle.
Select a Needle/Nozzle Set and Air Cap
Check the viscosity of your paint. Install the proper
needle/nozzle
set and air cap combination, selected from
the charts on pages 5 and 6.
CAUTION
Trigger the gun whenever you tighten or remove
the nozzle. This keeps the needle seat away from
the nozzle seating surface and prevents the seat
from
being scratched.
Position the Air Cap
Rotate the air cap as needed to achieve the desired spray
pattern direction. See Fig 2. T o create a round pattern,
turn
the pattern air of f.
Vertical Pattern
Horizontal Pattern
Fig 2
Adjust the Spray Pattern
Follow these steps to establish the correct fluid flow and
air flow:
1. Adjust the fluid flow by using the fluid pressure
regulator
installed in the fluid line.
2. The spray gun has a 15 psi (1 bar) maximum recom -
mended inlet air pressure. Using the air pressure
regulator, set the air line pressure according to the
fluid
manufacturer ’s recommendations for a high vol -
ume,
low pressure application. Local laws may limit
the air line maximum pressure to 10 psi (0.7 bar).
NOTE: The H.E.L.P . 1500 System is factory set to 10 psi
(0.7 bar) air pressure with 100 psi (7 bar) air pres -
sure at inlet. The pressure can be reduced by
adjusting
the air supply adjustment knobs.
3. Adjust the pattern size by turning the pattern adjust -
ing
valve OUT (counterclockwise) for a wider pattern
or IN (clockwise) for a narrower pattern.
4. T o adjust the volume of fluid output:
a. Turn the fluid adjusting knob out (counterclock-
wise)
until no restriction of the trigger movement
is felt. Refer to Fig 1.
b. Then adjust the air pressure at the pressure pot
or pump until the desired fluid flow is obtained.
WARNING
DO NOT exceed the gun’ s 100 psi (7 bar) maxi-
mum fluid pressure. Higher pressures can cause
parts
to rupture and result in serious bodily injury or
property damage.
c. For final adjustment, turn the fluid adjusting knob
in (clockwise) to reduce the volume of fluid out-
put
and obtain the desired results.
CAUTION
Restricting the trigger and fluid needle travel by
continuously spraying with the fluid adjusting knob
turned in (clockwise), will cause accelerated abra -
sive wear on the fluid needle and wear on the trig -
ger/air
valve shaft interface.
For the best results, adjust the fluid flow at the pres -
sure pot or pump or use a dif ferent size needle/
nozzle set and air cap combination. See the
SELECTION
CHAR TS on pages 5 and 6.
NOTE: If the fluid adjusting valve is turned in all the way
the gun will emit only air .
d. The fluid flow can be feathered by partially trig-
gering the fluid needle, except when using the
smallest needle/nozzle/air cap size. See the
charts
on pages 5 and 6.
5. For continuous spraying, leave the fluid adjusting
valve in the full open position. This provides maxi-
mum
fluid flow and prevents premature wear on the
fluid nozzle.
6. Test the spray pattern and atomization while holding
the gun about 6 to 8 inches (150 to 200 mm) from the
test piece. Adjust as needed.


OPERATION
Apply the Fluid
1. To achieve the best results when applying fluid, keep
the gun perpendicular to the surface and maintain a
consistent distance of approximately 6 to 8 inches
(150
to 200 mm) from the object being sprayed. See
Fig 3.
2. To obtain an even finish, use smooth, even strokes
across
the object being sprayed with 50% overlap.
3. Paint using parallel strokes. This spray gun applies
all
coatings evenly without cross coating.
NOTE: To eliminate the need to shut of f the air pressure
at the air supply , install One-way Shut-of f V alve
110–367 in the gun’ s quick disconnect. See
ACCESSORIES.
If the one-way shut-of f valve is installed in the
gun
line, allow for a 0.5 psi (0.035 bar) air pres -
sure
drop to the gun, due to increased restriction
of the air line.
WRONG RIGHT
6–8 in.
(150–200 mm)
90
Fig 3

10 308-008
MAINTENANCE
Daily Care and Cleaning
WARNING
Pressure
Relief Procedure
To reduce the risk of serious bodily injury , including
splashing in the eyes or on the skin or injury from
moving parts, always follow this procedure when
shutting
of f the system, when checking or servicing
any part of the spray system, when installing,
cleaning or changing fluid nozzles, and whenever
you
stop spraying.
1. T urn of f the air and fluid supply to the gun.
2. Trigger the gun into a grounded metal waste
container
to relieve fluid pressure.
CAUTION
Clean all parts with a solvent compatible with the
fluid
being sprayed and compatible with gun wetted
parts. See the T echnical Data on the back page.
Methylene Chloride is not recommended as a flush -
ing or cleaning solvent with this gun or any other
device
with nylon or aluminum components as it can
damage these parts.
To avoid getting solvent in the gun air passages,
NEVER
immerse the gun in solvent.
Hold the front of the gun down when brushing it
clean
with solvent to prevent dirty solvent from get -
ting
into the air passages.
1. After operation, flush the gun with a compatible sol -
vent
until all traces of paint are removed from the gun
passages. Follow the Pressure Relief Procedure
Warning,
above, before proceeding.
2. Wipe the outside of the gun clean with a solvent
dampened
cloth.
CAUTION
Trigger
the gun whenever you tighten or remove the
nozzle. This keeps the needle seat away from the
nozzle seating surface and prevents the seat from
being
scratched.
3. Trigger the gun and remove the air cap and fluid
nozzle
from the gun. Soak them in solvent and scrub
them with the fine, bristled brush. See ACCESSO-
RIES
to order brush.
4. To clean out air cap holes, use a soft implement, such
as a toothpick, to avoid damaging critical surfaces.
Clean the air cap and fluid nozzle daily , minimum.
(Some
applications require more frequent cleaning.)
NOTE: If the fluid shaft is removed from the gun with
dried paint (fluid) still on the needle tip end,
replace
the fluid seal as instructed on page 10.
5. Lubricate the gun daily , after cleaning it, at the points
marked in Fig 4. Periodically lubricate the fluid
needle spring (16) with lubricant 1 11–265 (see AC-
CESSORIES to order).
Fig 4
Lubricate
Lubricate