Binks AA4000 Air Assisted Airless Spray Gun Operation and
Contents
1. WIRE AND BALL ASSEMBLY AND SEAT REPLACEMENT Refer to assembly drawing on page 7 to locate numbered 5 Remove the AA4000 needle packing cartridge 8 items 6 Carefully install new AA4000 needle packing 1 Engage the trigger safety cartridge 8 2 Shut off fluid pump and disconnect its air or power 7 Remove fluid seat 4 and o ring supply 8 Install new fluid seat 4 and o ring 3 Release pressure from the entire fluid system from 9 Reinstall trigger 20 trigger stud 13 and trigger the pump to the spray gun screw 12 4 Remove tip guard assembly 1 air cap 2 and spray 10 Reinstall air cap 2 spray tip 3 and tip guard tip 3 Remove trigger 20 by removing the trigger assembly 1 stud 13 and the trigger screw 12 AIR VALVE REPLACEMENT 1 Engage the trigger safety 4 Remove trigger 20 by removing the trigger stud 2 Shut off fluid pump and disconnect its air or power 13 and the trigger screw 12 supply 5 Remove air valve assembly 21 3 Release pressure from the entire fluid system from 6 Replace air valve assembly 21 the pump to the spray gun 7 Reinstall trigger 20 trigger stud 13 and trigger screw 12 PARTS LIST When ordering please specify Part No Not all part numbers are available for purchasing ITEM PART ITEM PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 544983 TIP GUARD ASSEMBLY 1 13 54 4938 TRIGGER STUD 1 2 54 4978 AA4 A2. AWARNING HIGH PRESSURE SPRAY AND HOSE LEAKS FLAMMABLE EXPLOSIVE AND TOXIC VAPORS HIGH PRESSURE CAN CAUSE SERIOUS INJURY IF EQUIPMENT IS INSTALLED OR USED INCOR RECTLY READ UNDERSTAND AND OBSERVE ALL WARNINGS AND INSTRUCTIONS IN THIS MANUAL OPERATE EQUIPMENT ONLY AFTER ALL INSTRUCTIONS ARE CLEARLY UNDERSTOOD In this part sheet the words WARNING CAUTION and NOTE are used to emphasize important safety information as follows A WARNING Hazards or unsafe practices which could result in severe personal injury death or substantial property damage A CAUTION Hazards or unsafe practices which could result in minor personal injury product or property damage Important installation operation or maintenance information INJECTION HAZARD Spray from the gun hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury including poisoning or the need for amputation Splashing fluid in eyes or on skin can also cause a serious injury e Fluid injected into the skin might look like just a cut but is a serious injury and should be treated as such GET IMMEDIATE MEDICAL ATTENTION INFORM THE PHYSICIAN WHAT TYPE OF MATERIAL WAS INJECTED e Do not point the spray gun at anyone or any part of the body e Do not put fingers or hand over the spray tip e Do not stop or detect fluid leaks with a rag hand body or glove e Do not use a rag to blow back fluid THIS IS
3. tainer Use only compatible solvents that are identified as approved for cleaning and wash off use 4 Place the gun trigger safety switch in the locked position 5 Remove the fluid tip and place it in a closed solvent container 6 Adjust the pump air supply regulator to its lowest level counter clockwise 7 Place the gun trigger safety switch in the unlocked position 8 Turn on the air supply to the pump and close the bypass priming valve 11 so equipped 9 Slowly adjust the pump air supply regulator until the pump begins to cycle 10 Trigger the gun into a closed container until the fluid runs clear continued A WARNING Failure to reduce pump air supply pressure or to use a closed container can result in material bounce back Material bounce back can cause injury and damage During cleaning the gun may only be sprayed into a closed container never flush the gun into the air or spray booth K BINKS CLEANING Continued 11 Using a rag dampened with solvent wipe the exteri clearly labeled as approved for cleaning and wash off or surface of the gun Additionally some solvents are operations If the operator has any question on prohibited from being used for cleaning The opera selecting appropriate cleaning solvents the operator tor must take care to use only approved cleaning sol should consult a supervisor or plant environmental vents for equipment cleaning These materials are staff
4. Max static air pressure at regulator with 25 of hose to inlet 20 p s i Max Dynamic Gun Inlet Air Pressure 15 p s i Gun Body Forged Aluminum Alloy Fluid Path Stainless Steel and Tungsten Carbide K BINKS SPRAY PATTERN TROUBLESHOOTING Fluttering Spray Pattern Air in paint supply line Attempting to feather Partially trigger gun Striping Spray Fingers Irregular Pattern partially plugged On defective side of pattern air horn holes are plugged Pattern pushed to one side same side of air cap gets dirty holes are plugged Insufficient fluid supply Carbide tip partially plugged Fluid builds up on carbide tip or tip On defective side of pattern air horn Adjust fluid regulator or fill fluid supply tanks Check and tighten pump siphon hose connections bleed air from paint line Cannot feather with an AA4000 gun Clean or replace carbide tip assembly Clean carbide tip Clean air horn holes with solvent and a soft brush Clean air horn holes with solvent and a soft brush or toothpick AIR ASSISTED AIRLESS SPRAY GUN MAINTENANCE AND CLEANING Maintenance of air assisted airless spray guns includes 1 fluid tip wear and replacement 2 lubrication and 3 cleaning of the gun FLUID TIP Operating an air assisted airless spray gun with a worn fluid tip will result in increased usage of spraying materi al and therefore HAP emissions For example an i
5. Ww Ww wW Ww w NNNNNNN U71 U1 U1 01 01 0101 W UW Ww W Ww Ww w CG eed OARNO OARA NO 8 00 CONBRNG OO ARNO APPLICATION CHART AA2 Optional 54 4980 Thin to Medium Materials ACCESSORIES AA4 Standard 54 4978 Medium to Hvy Materials HOSES ACCESSORIES Cont 71 4990 15 Polyurethane Air Tubing ASM w fittings FLUID REGULATORS a ad a a 845011 Less Gauge 1000 to 3000 PSI regulated range 71 4331 4747 Tubing ASM w fittings 845013 Less Gauge 2000 to 5000 PSI regulated range 71 8087 15 3 16 High Pressure Fluid Hose Assembly 71 8088 25 3 16 High Pressure Fluid Hose Assembly FITTINGS 54 4975 1 8 NPT Male x 3 8 O D Push In Tube Fitting optional 54 4976 1 4 NPT Female x 3 8 O D Push In Tube Fitting optional FLUID FILTERS 103 1241 100 Mesh Inline Filter 4000 PSI working pressure 54 3655 100 Mesh Element Gun Mounted Filter 5800 PSI w p 54 5010 100 Mesh Screen Gun Mounted Filter 4000 PSI w p 54 4725 100 Mesh Element Gun Mounted Filter 4000 PSI w p REPLACEMENT FILTERS 54 1835 Replacement filters for 54 3655 and 54 4725 54 5012 K10 Replacement filter for 54 5010 CLEANING KIT 54 4994 Cleaning Kit Includes one standard stiff nylon pipe cleaning brush full s
6. AA4000 AIR ASSISTED AIRLESS SPRAY GUN x I1 2 GX HVLP R oo PSI 275 BA MAX FLUID 40 7 BAR 100 PS MAX AIR 1 WARNING The following instructions provide the necessary information for the proper operation and preventive maintenance of the Binks AA4000 Air Assisted Airless Spray Gun Please read and understand all information in this document in order to get the maximum performance from your new AA4000 spray gun In the AA4000 spray gun the paint or other material to be sprayed is preatom ized and forced through the carbide tip by the typical 1 500 3 800 psi fluid pressure with capabilities up to 4 000 psi 275 bar As a result of the preatom izing the final shaping air supplied by the air cap produces an exceptionally fine and even spray pattern The result of this spray pattern is an even finish that lends itself to products that need an exceptionally fine finish with reduced overspray and VOC emissions SPECIFICATIONS Maximum Fluid Pressure 4000 psi 275 bar Maximum Air Pressure 100 psi 6 8 bar Gun Body Forged Aluminum Fluid Path Stainless Steel Fluid Shut Off Type Tungsten Carbide Seat standard UHMW Seat optional Fluid Inlet Size 1 4 NPS m Thread Air Inlet Size 1 8 NPT m x 1 4 NPS m D M Nipple Product shown is covered by U S patent No 6 276 616 Foreign patents are issued or pending Gun Weight 16 02 Replaces Part Part Sheet Sheet 77 2776R 8 77 2776R 9
7. Actual starting pressure points may be higher or lower than 1600 psi and depend on the setup including the type of pump used the type of material sprayed and the spray gun itself 4 Using the control knob on the gun air regulator set the air pressure at zero 5 To test the spraying pattern spray a piece of wood or cardboard with a fast pass about one foot away from the piece The results of the test will allow you to determine the uniformity of the particle size and spraying pattern 6 Ifthe spraying pattern develops tails or is not uniform gradually increase the air pressure as necessary to develop a uniform spraying pattern Typically 10 psi air pressure is adequate since the air is used to shape the patterns rather than for atomization of the coating 7 Ifthe quality of spray is acceptable begin spraying If the spraying rate is too slow to keep up with the production line speed or if the quantity of material sprayed is inadequate for acceptable coverage gradu ally increase the fluid pressure 10 50 psi increments using the fluid regulator control knob However note that as the fluid pressure increases more air is needed to eliminate the tails Consistency in spraying can be increased across spray gun operators and similar spraying jobs by developing pressure standardization charts Repeat step 6 until the required material coverage and spraying speed are achieved If the maximum fluid pressure is reached before the req
8. D PRESSURE DO NOT EXCEED THE FLUID PRESSURE RATING e Route all hoses away from all sharp edges moving parts hot surfaces and high traffic areas e Do not use hoses to pull the equipment e Use only Binks approved hoses Do not remove spring guards from hoses these are on the hoses to prevent rupture from kinking at the connectors e Use only solvents compatible with hoses and wetted parts of the equipment used Comply with all applicable local state and national fire electrical and other safety regulations Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in fire or explosion and cause serious injury FIRE AND EXPLOSION HAZARD Ground the equipment and object being sprayed Provide fresh air ventilation to avoid the build up of flammable fumes from the material being sprayed or from solvent Extinguish all open flames or pilot lights in spray area e Electrically disconnect all equipment in the spray area e Keep the spray area free from all debris including solvent rags e If there is any static sparking while using the equipment STOP SPRAYING IMMEDIATELY Identify and correct problem NOISE LEVELS The A weighted sound level of spray guns may exceed 85 dB A depending on the setup being used It is recommended that ear protection is worn at all times when spraying The Spray Gun models listed in the following declaration of conformity may be used i
9. IR CAP Standard 1 14 FLAT PLUG Not Sold Separately 54 4980 AA2 AIR CAP Optional 1 15 54 4947 FLUID TUBE BRACKET SPACER 1 3 113 OXXXX CARBIDE TIP ASSEMBLY 1 16 54 4943 FLUID TUBE BRACKET 1 See Tip Selection Chart pg 8 17 5449754 PUSH IN TUBE FITTING 1 4 54 4960 FLUID SEAT Tungsten Carbide 1 1 8 NPT m x 3 8 O D Standard or UHMW Optional 54 4926 18 20 6718 BUTTON HEAD CAP SCREW 1 4A 20 6037m O RING ret re ee ee aan 1 19 4 4 FLUID INLET FITTING EEES ETETE 1 5 54 4906 FLUID TUBE ASSEMBLY 1 20 54 4937 66 1 6 GUN HEAD a 1 21 54 4909 AIR VALVE ASSEMBLY L a eenn 1 7 54 4923 FRONT HEAD GASKET 1 22 71 28 D M NIPPLE 1 8 54 4963 NEEDLE PACKING CARTRIDGE 1 1 8 NPT m x 1 4 NPS m 4 000 PSI Maximum 23 54 4725 FILTER ASSEMBLY 100 Mesh 1 9 GUN BODY Not Sold Separately 10 54 4925 FLUID INLET NUT 1 Also available 20 6750 K10 Kit of 10 O rings for AA 4 Air Cap Available as part of Repair Kit 54 4993 11 94 4977 FAN CONTROL ASSEMBLY 1 E Also available 20 6037 K10 Kit of 10 O rings 12 94 4939 TRIGGER SCREW 1 A Alternate Push In Tube Fitting 17 is included in gun package Alternate Fluid Inlet Fitting 19 order separately K BINKS AA4000 AIR ASSISTED AIRLESS SPRAY GUN Altern
10. NOT AN AIR SPRAY GUN e Engage the gun safety when not spraying ALWAYS RELIEVE THE PRESSURE WHENEVER WORKING ON THE SPRAY GUN Tighten all fluid connections before operating equipment Check all hoses tubes and couplings daily Replace all worn damaged or loose parts immediately Hazardous fluids or toxic fumes can cause serious injury or death if splashed on skin or in the eyes swallowed or inhaled TOXIC FLUID HAZARD Know the specific hazards of the fluid you are using This information is on the MSDS for the material being used Read all fluid manufacturer s warnings Store hazardous fluids in approved containers only Dispose of all hazardous fluids in accordance with all state local and national guidelines Wear the appropriate protective clothing gloves eyewear and respirator Equipment misuse can cause the equipment to fail malfunction or start unex pectedly and result in serious injury EQUIPMENT MISUSE HAZARD e This equipment is for professional use only Read and understand all instructional manuals tags and labels before operat ing equipment e Use the equipment only for its intended purpose If you are unsure about its purpose call your local Binks distributor e Do not alter or modify this equipment Use only genuine Binks parts e Do not exceed the maximum working pressure of the lowest rated system component THE MAXIMUM RATING OF THE AA4000 IS 4000 PSI 275 BAR FLUI
11. ate Alternate Do not overtighten for ease of filter replacement Adequate torque required is 5 6 ft Ibs SPRAY TIP SELECTION CHARTS HOW TO ORDER THE AA 4000 AIR PART NO ASSISTED AIRLESS SPRAY GUN 4000 0000 4 Standard AA4 Air Cap less Spray Tip Optional AA2 Air Cap order separately Spray Tip must be ordered separately Use this chart to determine orifice size and fan size required Note Listed Fan Widths based on 1000 PSI with water Actual results may vary depending on material viscosity 1 1 Uw UW Ww Ww www f Www U U WwW w www at ad LOUW 00 OO UO UO OQ OO FAN SIZE WIDTH 1 1 NN ooo0oo0o000 oo 1 0 ARNO 11 11 11 11 11 11 11 gzil I ONEN OO ARNO 1 1 i Scoooooo ooo0oo0o000 ooo0oo0oo000 COO OOP NOON ONBNOOSD HHRBNOAODA BNO me eed OOOOOOO OOOO000 OOO NNNNNNN f U7 U71 U1 U71 U1 0101 W UW
12. gns of a the tails the spraying defect is most likely due to the defective spray pattern emerge material temperature and or viscosity 1 Check the external portion of the fluid tip for material 5 If pattern pulsation or blinking occurs check the pres buildup If buildup has occurred secure the gun trig sure regulators all downstream regulators and the ger safety switch and clean the gun fluid tip with a pump These may require further adjustment or even non metal soft brush 1 repairs Tails Distorted 2 Ifthe spray pattern exhibits signs of tails at the top or Pattern bottom ends of the pattern increase the air pressure gradually until the tails disappear 3 If increasing air pressure does not dissipate the tails the fluid tip may be worn and may need to be replaced Another sign of the need to replace a worn Correct Hour tip is a gradual decline in spraying pattern width Pattern Glass Figure 3 GENERAL TROUBLESHOOTING Fluid leaking from the back Worn seal or needle shaft Replace needle packing cartridge 8 of seal cartridge assembly 8 Fluid leaking from the front Needle ball worn or damaged Replace needle packing cartridge 8 of the gun Worn seat assembly Replace fluid seat 4 Fluid in air passages Spray tip seal leaking Tighten retaining ring 1 Replace carbide tip assembly 3 Leaking around fluid seat Tighten or replace fluid seat 4 Slow fluid shut off Fluid buildup on cartridge assembly Clean o
13. ize nylon brush tip cleaner and Binks Gunners Mate lubricant REPAIR KIT 54 4993 Replacement Parts Kit Items Includes Items 4 4A 7 8 10 and 21 TEST GAUGES 54 4997 H V L P Test Gauge AA2 54 5022 4H V L P Test Gauge 4 Industrial Finishing Binks has authorized distributors throughout the world For technical Binks Worldwide Sales and Service Listing assistance or the distributor nearest you see listing below www binks com U S Canada Technical Service Office 195 Internationale Blvd Glendale Heights IL 60139 WARRANTY Toll Free Fax 1 888 246 5732 Za 77 2776R 9 Revisions P2 Replaced warnings An Illinois Tool Works Company 12 07 2007 Inc All rights reserved Printed in U S A
14. n some potentially explosive atmospheres ONLY when the special conditions for safe installation and operation have been followed as expressed in this user manual Part Sheet These models are approved to ATEX regulations 94 9 EC protection level II 2 G X Suitable for use in Zones 1 and 2 EC Declaration of Conformity Manuf By Industrial Finishing 195 Internationale Blvd Glendale Heights IL 60139 Type Series Model Manifold Mounted Automatic Spray Guns AA1500 AA4000 CE amp The equipment to which this document relates is in conformance with the following standards or other normative references EN ISO 12100 1 amp 2 2003 and BS EN 1953 1999 and thereby conform to the protection requirements of Council Directive 98 37 EC relating to Machinery Safety Directive and EN 13463 1 2001 Council Directive 94 9 EC relating to Equipment and Protective Systems for use in Potentially Explosive Atmospheres protection level Il 2 G X Approved By Date Chuck McCulloch Industrial Finishing 11 19 07 2 Industrial Finishing reserves the right to modify equipment specification without prior notice K BINKS SPRAY GUN SET UP 1 Connect your high pressure airless fluid hose to the gun fluid inlet and tighten securely 2 Connect your air hose to the gun air connection and tighten securely 3 Set the fluid pressure at the gun s lower end of the pressure range A typical starting fluid pressure is 1600 psi
15. ncrease in the diameter of a tip from 0 015 inch to 0 021 inch due to wear can result in up to a 100 percent increase in material consumption and cost To prevent waste in spraying material and non value adding costs a maintenance schedule that includes fluid tip inspection and replacement must be established LUBRICATION Proper lubrication is essential for optimum spray gun per formance Lubrication allows the equipment to operate easily and correctly The spray gun should be lubricated after each cleaning The points that need lubrication dur ing the maintenance of air assisted airless spray guns include 1 the fluid needle packing 2 trigger pivot point Gun lube is used to lubricate the fluid needle pack ing and trigger pivot point A CAUTION Never immerse the entire gun in solvent or thinners Some gun parts will lose their lubricative film and wear more quickly Additionally solvents may carry impurities throughout the gun body and allow them to clog small air and fluid passages CLEANING The following steps summarize the procedure for clean ing air assisted airless spray guns 1 Turn off the atomizing air supply to the gun 2 Turn off air supply to the pump and relieve fluid pressure This may be accomplished by opening the bypass priming valve 11 so equipped 3 Place the siphon suction tube into a solvent con tainer If pump is directly immersed in material remove the pump and immerse it in a solvent con
16. r replace cartridge assembly 8 No fluid output when triggered Tip orifice plugged Turn off fluid supply Relieve pressure into a closed grounded container Engage trigger safety Remove tip guard assembly 1 and air cap 2 and the carbide tip 3 Clean or replace carbide tip assembly 3 Collet on needle has slipped Turn off fluid supply Relieve pressure into a closed grounded container Remove trigger 20 Remove needle packing cartridge 8 Loosen collet and move until the needle is flush with the rear of the collet Tighten collet Fluid filter or fluid hose plugged Turn off fluid supply Relieve pressure into a closed grounded container Turn off air supply to pump and relieve fluid pressure with bypass valve Engage trigger safety Very slowly loosen the hose connection at the gun to relieve any pressure in hose Remove hose and clear obstruction IMPORTANT REGULATORY NOTE The AA 4000 Air Assisted H V L P hand spray gun combines the proven efficiency of the Binks compliant spray guns with air assisted atomization to yield a reliable carefully engineered compliant spray gun With 25 of 5 16 I D air hose and regulator set at only 20 p s i the compliant air cap registers 10 p s i of atomization air to shape and soften the spray pattern The AA 4000 air assisted H V L P gun operates at high transfer efficiencies and fully complies with all govern ment regulations for H V L P spray guns Max Fluid Input 4000 p s i
17. uired material coverage and spraying speed are achieved you may need to switch to a larger fluid tip TYPICAL HOOK UP Oil and Water Extractor Figure 1 Fan pattern adjustment turn knob counterclockwise to increase pattern clockwise to decrease pattern Fig 2 Fan Control Knob Figure 2 FLUID TIP SELECTION Factors to consider in selecting a fluid tip for an air assisted airless spray gun include 1 the size of the parts being sprayed 2 the production line speed 3 the material flow rate and film thickness 4 the viscosity of the material applied 5 the type of material applied and 6 the quality of atomization of the coating required The selection of a fluid tip necessary to perform a specif ic spraying job is best determined through a combination of experimentation and expert advice from your material and equipment suppliers FLUID HOSES Air assisted airless spray guns operate at fluid pressures higher than operating pressures of air spray guns As a result when operating an air assisted airless spray gun it is critical to select the appropriate fluid hose that is rated for the pressure range at which the airless gun is operated K BINKS TROUBLESHOOTING DEFECTIVE SPRAY PATTERNS The following procedure summarizes the steps that an 4 If cleaning or replacing the fluid tip does not dissipate operator must immediately take when the first si
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