A lightweight line of air-assisted spray guns for spraying and finishing a variety of paints
and coatings, particularly in applications requiring uniform atomization and high transfer
efficiency. For professional use only.
Important Safety Instructions:
Read all warnings and instructions in this manual. Save these
instructions. See page 2 for model information including maximum working pressure.
The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment.
Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols that
appear in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not spray without tip guard and trigger guard installed.
•Engage trigger lock when not spraying.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the spray tip.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
43A0149C
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
3A0149C5
Installation
Installation
Typical Installation
NOTE: The typical installation shown in FIG. 1 is only a
guide for selecting and installing air-assisted spray systems. Contact your Graco distributor for assistance in
designing a system to meet your needs.
Ventilate the Spray Booth
•To prevent hazardous concentrations of toxic
and/or flammable vapors, spray only in a properly
ventilated spray booth. Do not 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.
Grounding
•Check your local electrical code and pump manual for detailed grounding instructions. Use only
electrically conductive fluid hoses.
•Ground the spray gun through connection to a
properly grounded fluid supply hose and pump.
D
A
C
B
FIG. 1: Typical Installation (Model G15 Shown)
Key:
AAir Line Filter
BAir Shutoff Valve
CGun Air Pressure Regulator
DAir Line
ESpray Gun
FElectrically Conductive Fluid Hose
GGun Air Supply Hose
E
G
TI6554A
F
63A0149C
Installation
Air Line
1. Install an air filter (A) on the gun air line to ensure a
dry, clean air supply to the gun. Dirt and moisture
can ruin the appearance of your finished workpiece.
IG. 1.
See F
2. Install an air pressure regulator (C) on the gun air
line to control air pressure to the gun.
3. Install an air shutoff valve (B) on the gun air line and
on the pump air line, to shut off air to the gun.
4. Use a 3/16 in. (5 mm) I.D. or larger air hose to minimize excessive pressure drop in the hose.
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. Connect the air hose (G) to the 1/4 npsm gun air
inlet. See F
IG. 2.
Fluid Line
•Before connecting the fluid line, blow it out with air
and flush it with solvent. See Flushing and Clean-ing, page 14. Use solvent which is compatible with
the fluid to be sprayed.
•If better control of fluid pressure is needed, install a
fluid regulator on the fluid line to better control fluid
pressure to the gun.
1. Use a fluid filter to remove coarse particles and sediment, to avoid clogging the spray tip and causing
finishing defects.
NOTE: Guns are equipped with a built-in 100 mesh fluid
filter to provide final filtering just before spraying.
2. Connect the fluid hose (F) to the gun fluid inlet. See
IG. 4. If desired, install a fluid swivel connector
F
(189018) at the gun inlet for best maneuverability.
See Accessories, page 35.
G
TI6556A
IG. 2
F
6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See F
IG. 3.
B
G
C
TI4838A
F
A
IG. 3
F
TI6846A
IG. 4
F
3. Connect the other end of the fluid hose (F) to the
pump fluid outlet.
3A0149C7
Setup
Setup
Flush Before Using Equipment
1. The equipment was tested with lightweight oil, which
is left in the fluid passages to protect parts. To avoid
contaminating your fluid with oil, flush the equipment
with a compatible solvent before using the equipment. See Flushing and Cleaning, page 14.
2. Relieve the pressure. See Pressure Relief Proce-
dure, page 10.
Select a Spray Tip
FIG. 5
Slot
Tip locating tab
Horizontal air
cap position
(standard)
Vertical air
cap position
TI6847A
The fluid flow and pattern width depend on the size of
the spray tip, the fluid viscosity, and the fluid pressure.
See Spray Tip Selection Chart, page 32. Contact your
Graco distributor for assistance in selecting an appropriate spray tip for your application.
Air Cap Alignment Pin
Model G15 guns use an air cap alignment pin to position
the air cap. The standard location of the air cap alignment pin is the horizontal air cap position.
If you would like to change the spray pattern direction,
use a needle nose pliers to unscrew the pin and relocate
it to the desired position. See F
the pin use low-strength thread locker. Torque to 1.5-2.5
in-lb (0.2-0.3 N•m). DO NOT OVERTIGHTEN.
The air cap alignment pin can be removed according to
preference. Air cap alignment pins will not work with
model G40 guns.
NOTICE
The alignment pin and retaining ring for current model
guns are different from the earlier model guns. They are not interchangeable. Use of the incorrect pin will
result in fluid leakage or loss of the alignment feature.
Use of the wrong retaining ring will damage retaining
ring and gun threads. See Part Interchangeability Guide, page 37.
IG. 5. When relocating
Install a Spray Tip
Install a spray tip in the air cap. Ensure that the tip locating tab is positioned in the slot of the air cap. See F
IG. 5.
Position the Air Cap
Assemble the air cap to the gun. The air cap and spray
tip position determine the direction of the spray pattern.
Rotate the air cap (the spray tip rotates with it) as
needed to achieve the desired spray pattern direction.
IG. 6. For the G15 air cap, the alignment pin will
See F
stop the rotation in the proper orientation.
TI6558A
IG. 6
F
Tighten the air cap retaining ring (6) firmly by hand to
ensure a good seal between the tip gasket and the diffuser (5).
83A0149C
Reverse-A-Clean® (RAC) Tip Assembly
Setup
Model 24C857 guns use a Reverse-A-Clean® (RAC) tip.
To assemble the RAC tip, insert the seat housing into
the air cap assembly.
TI7196A
IG. 7
F
Insert the SwitchTip.
Screw the RAC tip assembly onto the gun and tighten
firmly by hand.
TI7199A
FIG. 10
NOTICE
The RAC assembly for current model guns uses a
different seat housing and has a coarser thread
than the RAC assembly for earlier model guns.
They are not interchangeable. Use of the incorrect RAC assembly will damage the threads. See
Part Interchangeability Guide, page 37.
IG. 8
F
Insert the gasket seat.
IG. 9
F
TI7197A
TI7198A
3A0149C9
Operation
Operation
Be sure to read and follow the Warnings on pages 4
and 5 and throughout the text of this instruction manual.
Keep the wallet sized warning card (222385), provided
with the gun, with the operator of this equipment at all
times. The card contains important treatment information should a skin injection injury occur. Additional cards
are available at no charge from Graco.
Pressure Relief Procedure
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.
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.
1. Engage the trigger lock. See F
2. Shut off the pump. See your pump manual.
3. Shut off the gun air supply.
4. Disengage the trigger lock. See F
IG. 12.
IG. 12.
TI6555A
FIG. 11
6. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to spray
again.
7. Engage the trigger lock. See F
8. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the tip
guard retaining ring or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
IG. 12.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure. See
IG. 11.
F
ENGAGED
TI6581ATI6582A
IG. 12
F
103A0149C
DISENGAGED
Operation
How the Air-Assisted Spray Gun
Operates
The air-assisted 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 width of the pattern
can be adjusted by the pattern adjustment valve.
The air-assisted spray gun differs from an air spray gun
in that increasing the pattern air reduces the pattern
width. To increase the pattern width, use less pattern air
or a larger size tip.
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.
Spray Pattern Adjustment
To reduce the risk of component rupture and serious
injury, including injection, do not exceed the gun’s maximum fluid working pressure or the maximum working
pressure of the lowest rated component in the system.
1. Do not turn on the gun air supply yet. Set the fluid
pressure at a low starting pressure. If a fluid pressure regulator is installed, use it to make adjustments.
4. Close off the pattern adjustment air by turning the
knob clockwise (in) all the way. See F
sets the gun for its widest pattern.
OPEN
FIG. 13
5. Set the atomizing air pressure at about 5 psi
(3.5 kPa, 0.35 bar) when triggered. Check the spray
pattern, then slowly increase the air pressure until
the tails are completely atomized and pulled into the
spray pattern. See F
7.0 kPa, 0.49 to 0.7 bar) air pressure is typically
enough to atomize the tails, especially for low viscosity materials. Setting the air pressure too high
will cause material to build up on the air cap and
decrease transfer efficiency. Do not exceed 100 psi
(0.7 MPa, 7 bar) air pressure to the gun.
For a narrower pattern, turn the pattern adjustment
valve knob counterclockwise (out). See F
the pattern is still not narrow enough, increase the
air pressure to the gun slightly or use a different size
tip. (Not available for RAC tip guns.)
IG. 14. Seven to 10 psi (4.9 to
IG. 13. This
CLOSE
TI6559A
IG. 13. If
If your system does not have a fluid regulator, the
fluid pressure is controlled by the air regulator supplying the pump, per the formula below:
Pump
Ratio
2. Trigger the gun to check the atomization; do not be
concerned about the pattern shape yet.
3. Slowly increase the fluid pressure, just to the point
where a further increase in fluid pressure does not
significantly improve fluid atomization.
3A0149C11
x Pump Air Regulator
Setting
=Fluid
Pressure
F
IG. 14
no air
TI0792A
too little aircorrect amount
of air
Operation
HVLP Operation
NOTE: For HVLP operation, the atomization air must not
exceed 10 psi. Use HVLP Verification Kit 24C788 to verify air psi.
NOTE: There is no fan adjustment when using RAC tips
and caps.
Fluid Application
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 F
IG. 15.
1. To achieve the best results when applying fluid,
keep the gun perpendicular to the surface and maintain a consistent distance of approximately 8 to 12
in. (200 to 300 mm) from the object being sprayed.
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.
IG. 15
F
INCORRECT
TI6561A
TI6562A
CORRECT
123A0149C
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