Graco 3A0149E User Manual

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Page 1

Instructions - Parts List

Model G15

TI6553A

Model G40

TI6844A

TI7204B

Model G40 w/RAC tip

3A0149E

G15/G40 Spray Gun

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 3 for model information including maximum working pressure.

II 2 G

Page 2

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flush Before Using Equipment . . . . . . . . . . . . . . 8

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8

Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 8

Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8

Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . 8

Reverse-A-Clean

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressure Relief Procedure . . . . . . . . . . . . . . . . 10

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How the Air-Assisted Spray Gun Operates . . . . 11

Spray Pattern Adjustment . . . . . . . . . . . . . . . . . 11

HVLP Operation . . . . . . . . . . . . . . . . . . . . . . . . 12

Fluid Application . . . . . . . . . . . . . . . . . . . . . . . . 12

Daily Gun Care, Flushing, and Cleaning . . . . . . . 13

General System Maintenance . . . . . . . . . . . . . . 14

Fluid Filter Maintenance . . . . . . . . . . . . . . . . . . 14

Flushing and Cleaning . . . . . . . . . . . . . . . . . . . 14

Reverse-A-Clean

(RAC) Tip Assembly . . . . . . . 9

(RAC) Tip . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fan Valve Replacement . . . . . . . . . . . . . . . . . . . 20

Complete Gun Packing Repair . . . . . . . . . . . . . 20

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 32

Spray Tips, for use with G15/G40 Air Cap . . . . . 32

RAC SwitchTips, for use with

G40 RAC Air Cap . . . . . . . . . . . . . . . . . . . . 33

RAC SwitchTips, for use with

G40 RAC Air Cap, Continued . . . . . . . . . . . 34

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Part Interchangeability Guide . . . . . . . . . . . . . . 37

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Page 3

Models

Part Series

24C853 A

24C854 A

24C855 A

24C856 A

24C857 A

Maximum Working

Air Pressure

psi (MPa, bar)

100 (0.7, 7.0) 1500 (10.5, 105)

100 (0.7, 7.0) 4000 (28, 280)

Maximum Working

Fluid Pressure

psi (MPa, bar) Description Includes:

G15 Medium Pressure Air-Assisted Spray Gun, Carbide Seat and Ball

G15 Medium Pressure Air-Assisted Spray Gun, Plastic Seat, SST Ball

G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and Ball

G40 High Pressure, High Flow Air-Assisted Spray Gun, Carbide Seat and Ball

G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and

Ball, Reverse-A-Clean

(RAC) Tip

24C866

Air Cap

with pin

249180 Air Cap

without

24C921

RAC

Air Cap

3A0149E 3

Page 4

Warnings

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.

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Page 5

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

3A0149E 5

Page 6

Installation

TI6554A

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.

FIG. 1: Typical Installation (Model G15 Shown)

Key:

A Air Line Filter B Air Shutoff Valve C Gun Air Pressure Regulator DAir Line ESpray Gun F Electrically Conductive Fluid Hose G Gun Air Supply Hose

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Page 7

Installation

TI6556A

TI4838A

TI6846A

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. See F

IG. 1.

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 F

IG. 4. If desired, install a fluid swivel connector

(189018) at the gun inlet for best maneuverability. See Accessories, page 35.

IG. 2

6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See F

IG. 3.

FIG. 4

3. Connect the other end of the fluid hose (F) to the pump fluid outlet.

IG. 3

3A0149E 7

Page 8

Setup

TI6847A

Slot

Tip locating tab

Horizontal air cap position (standard)

Vertical air cap position

TI6558A

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

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.

IG. 5. When relocating

FIG. 5

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. See F

IG. 6. For the G15 air cap, the alignment pin will

stop the rotation in the proper orientation.

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.

8 3A0149E

IG. 6

Tighten the air cap retaining ring (6) firmly by hand to ensure a good seal between the tip gasket and the diffuser (5).

Page 9

Reverse-A-Clean® (RAC) Tip Assembly

TI7196A

TI7197A

TI7198A

TI7199A

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.

IG. 7

Insert the SwitchTip.

Screw the RAC tip assembly onto the gun and tighten firmly by hand.

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

Insert the gasket seat.

IG. 9

3A0149E 9

Page 10

Operation

TI6555A

TI6581A TI6582A

ENGAGED

DISENGAGED

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

FIG. 11

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

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. See F

IG. 11.

IG. 12.

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.

10 3A0149E

IG. 12

Page 11

Operation

TI6559A

OPEN

no air

too little air correct amount

of air

TI0792A

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.

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

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.

3A0149E 11

x Pump Air Regulator

Setting

=Fluid

Pressure

IG. 14

Page 12

Operation

TI6561A

TI6562A

INCORRECT

CORRECT

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

12 3A0149E

Page 13

Daily Gun Care, Flushing, and Cleaning

TI6563A

TI6564A

TI4827A

TI6565A

Daily Gun Care, Flushing, and Cleaning

NOTICE

Methylene chloride with formic or propionic acid is not recommended as a flushing or cleaning solvent with this gun as it will damage aluminum and nylon components.

NOTICE

Do not use any cleaning method which may allow solvent into the gun air passages. Solvent left in gun air passages could result in a poor quality paint finish.

Do not point the gun up while cleaning it.

Do not immerse the gun in solvent.

Do not wipe the gun with a cloth soaked in solvent;

wring out the excess.

Do not use metal tools to clean the air cap holes

as this may scratch them; scratches can distort

the spray pattern.

3A0149E 13

Page 14

Daily Gun Care, Flushing, and Cleaning

TI6735A

TI6566A

TI6567A

TI6566A

General System Maintenance

1. Relieve the pressure, page 10.

2. Clean the fluid and air line filters daily.

3. Check for any fluid leakage from the gun and fluid hoses. Tighten fittings or replace equipment as needed.

4. Flush the gun before changing colors and whenever you are done operating the gun.

Fluid Filter Maintenance

1. Unscrew the fluid inlet fitting (18).

2. Remove and inspect the inline fluid filter (12). Clean or replace the filter as necessary.

Flushing and Cleaning

NOTE:

• Flush before changing colors, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

1. Relieve the pressure, page 10.

2. Remove the air cap retaining ring (6), air cap (21), and spray tip (33). Soak the spray tip in a compatible solvent.

3. Disconnect the fluid supply hose (F) and air supply hose (G) from the gun.

FIG. 17

4. Connect the solvent supply hose (T) to the gun.

IG. 16

NOTICE

The threads on the fluid inlet fitting for new model guns are slightly finer than the threads on the old model guns. The fluid inlet fittings are not inter- changeable. Use of an incorrect fitting will damage the threads.

IG. 18

14 3A0149E

Page 15

Daily Gun Care, Flushing, and Cleaning

TI6729A

TI6730A

TI4845A

TI6569A

5. Increase the pressure slowly. Point the gun down into a grounded metal container, and flush the gun with solvent until all traces of fluid are removed from the gun passages.

IG. 19

6. Turn off the solvent supply.

7. Relieve the pressure.

10. Dip the end of a soft-bristle brush into a compatible solvent. Do not continuously soak the brush's bristles with solvent and do not use a wire brush.

FIG. 21

11. With the gun pointed down, clean the front of the gun, using the soft-bristle brush and solvent.

8. Disconnect the solvent supply hose (T) from the gun.

IG. 20

NOTICE

Trigger the gun whenever you tighten or remove the diffuser (5). This keeps the needle ball away from the seating surface and prevents the seat from being damaged.

IG. 22

12. Scrub the air cap retaining ring (6), air cap (21), diffuser (5), and spray tip (33) with the soft-bristle brush. To clean out air cap holes, use a soft tool, such as a toothpick, to avoid damaging critical surfaces. Blow air through the spray tip to ensure the orifice is clean. Clean the air cap and spray tip daily, minimum. Some applications require more frequent cleaning.

9. If it is necessary to remove the diffuser (5) to clean, trigger the gun while you remove the diffuser with the gun tool (30).

3A0149E 15

Page 16

Daily Gun Care, Flushing, and Cleaning

TI6570A

TI6568A

TI6571A

TI6553A

ENGAGED

TI6581A

IG. 23

13. If the diffuser was removed, trigger the gun while you reinstall the diffuser (5) with the gun tool (30). Tighten the diffuser securely to obtain a good seal. Torque to 155-165 in-lb (18-19 N•m). When properly tightened, the flange will bottom out on the gun.

14. Install the air cap retaining ring (6), air cap (21), and spray tip (33).

16. After cleaning the gun, lubricate the following parts with lubricant 111265 weekly:

• Trigger pivot pin (A)

• Boss on both sides of the gun where the trigger

contacts the gun body (B)

• Fluid needle shaft, behind trigger (C)

FIG. 26

Reverse-A-Clean® (RAC) Tip

IG. 24

15. Dampen a soft cloth with solvent and wring-out the excess. Point the gun down and wipe off the outside of the gun.

NOTE: Do not soak the RAC tip seat gasket (33a) in solvent for extended periods of time or swelling may occur.

Clearing a clogged RAC tip

Release the trigger and engage the trigger lock.

IG. 27

IG. 25

16 3A0149E

Page 17

Daily Gun Care, Flushing, and Cleaning

TI7200A

DISENGAGED

TI6580A

TI7202A

TI6581A

ENGAGED

TI7201A

TI6582A

DISENGAGED

Rotate the SwitchTip.

IG. 28

Disengage the trigger lock.

Engage the trigger lock.

FIG. 31

Return the SwitchTip to its original position.

IG. 29

Trigger the gun into a pail to clear the clog.

Do not point gun at anyone or at any part of the body.

IG. 30

IG. 32

Disengage the trigger lock and continue spraying.

IG. 33

3A0149E 17

Page 18

Troubleshooting

Problem Cause Solution

NOTE:

• Check all possible remedies in the troubleshooting charts before disassembling the gun.

• Some improper patterns are caused by the improper balance between air and fluid.

Fluid leakage from back of fluid packing area.

Air leakage from gun. Air valve not seating properly. Clean or replace air valve (8). Fluid leakage from front of gun. Needle ball worn or damaged. Replace needle assembly (2) and seat (5c).

Fluid in air passages. Spray tip seal leaking. Tighten retaining ring (6) or replace spray tip

Slow fluid shut-off. Fluid buildup on fluid needle

No fluid output when triggered. Spray tip plugged. Clean spray tip. See page 14.

Worn packings or needle shaft. Replace needle assembly (2).

Worn seat assembly. Replace the seat (5c) and gasket (5b, carbide

models only). The gasket must be replaced whenever the seat assembly is removed.

Do not reverse the direction of the plastic seat (5c, model 24C854 gun only) if it is worn. The seat must be replaced it if is worn.

Fluid viscosity too low for proper seal with carbide seat.

Leaking around seat housing. Replace the gasket (5b, carbide models only).

Fluid inlet fitting leaking. Replace the fluid tube gasket (22). The gas-

components.

Fluid filter or fluid hose plugged. After tip removal (see above), very slowly

Install plastic seat (5c).

(33).

The gasket must be replaced whenever the seat assembly is removed.

ket must be replaced whenever the fluid tube connector is removed.

Remove and clean or replace the fluid needle assembly (2).

loosen the hose end coupling at the gun and relieve pressure gradually. Then loosen completely to clear the obstruction. Clean or replace filter (12).

18 3A0149E

Page 19

Troubleshooting

Problem Cause Solution

Fluttering or spitting spray. Insufficient fluid supply. Adjust fluid regulator or fill fluid supply tank.

Air in paint supply line. Check, tighten pump siphon hose connec-

tions, bleed air from paint line.

Attempting to “feather” (partially trigger the gun).

Cannot “feather” with an AA gun. Feather will cause drastic reduction of pressure at the tip, resulting in poor atomization and/or spitting.

Striping spray. Spray tip partially plugged. Clean or replace spray tip. See page 14.

Irregular pattern. Fluid build-up on spray tip, or

Clean or replace spray tip. See page 14.

spray tip partially plugged. On defective side of pattern, air

horn holes are partially or totally

Clean air horn holes with solvent and soft brush. See page 14.

plugged.

Pattern pushed to one side, same side of air cap gets dirty.

Air horn holes partially or totally plugged.

Clean air horn holes with solvent and soft brush or toothpick. See page 14.

Material build up on air cap. Air pressure setting too high. Reduce inlet air pressure. Seven to 10 psi

(4.9 to 7.0 kPa, 0.49 to 0.7 bar) air pressure when triggered is recommended.

3A0149E 19

Page 20

Repair

TI6576A

Torque to 90 in-lb (10.5 N•m).

TI6568A

Repair

Complete Gun Packing Repair

Disassembly

Repair Kits

NOTE:

• Seal Repair Kit 249422 is available. For best results, use all the new parts in the kit. Kit parts are marked with an asterisk, for example (7*).

• Plastic Seat Repair Kit 249424 and Carbide Seat Repair Kit 249456 are available and can be used with both Model G15 guns and Model G40 guns. For best results, use all new parts in the kit. Kit parts are marked with a symbol in the Parts list, for example (5c†).

• Plastic Seat Kit 249424 is intended for low pressure usage.

Fan Valve Replacement

1. Relieve the pressure, page 10.

2. Unscrew the fan valve packing nut (A) from the back of the gun body (1). Slide the fan valve assembly (4) out of the gun body. See F

3. Before reinstalling, turn the pattern adjustment valve (C) of the replacement fan valve assembly (4) completely counterclockwise to prevent damage to the seat (5c). Install the replacement fan valve assembly into the gun body (1). Screw the packing nut (A) into the gun body and torque to 90 in-lb (10.5 N•m).

IG. 34.

Seat Repair NOTE:

• See Repair Kits, page 20.

• Clean parts with a solvent that is compatible with the parts and the fluid being sprayed.

1. Relieve the pressure, page 10. Remove the fluid and air hoses from the gun.

2. Remove the air cap retaining ring (6), air cap (21), and spray tip (33). See F

FIG. 35

3. Trigger the gun to pull the needle housing off the seat while you unscrew the diffuser (5) from the gun body (1), using the gun tool (30).

IG. 35.

4. Inspect the o-rings (5e*, 5f*, and 5g*) in place. Carefully remove the o-rings from the diffuser housing (5a) and replace if necessary.

5. Remove the seat nut (5d), seat (5c) and seat gasket (5b, carbide models only) using a 7/32 in. hex wrench.

6. Inspect the seat (5c) and seat gasket (5b) and replace if necessary.

FIG. 34

20 3A0149E

Page 21

7. Reinstall the seat gasket (5b, carbide models only),

TI6572A

5g*

5f*

5e*

(carbide only)

TI6574A

14‡

13‡

3‡

TI6575A

2a*

seat (5c), and seat nut (5d). Torque to 45-50 in-lb. Be sure not to overtighten the nut.

NOTE:

• When reinstalling the carbide seat (5c), the tapered end of the seat (red side) must point toward the gun tip.

• The plastic seat (5c, model 24C854 guns), can be reinstalled in either direction. To avoid fluid leakage, do not reverse the direction of the plastic seat (5c) if it is worn. The seat must be replaced if it is worn.

Repair

FIG. 37

3. Remove the fluid needle assembly (2) from the front of the gun by using the nut driver tool (29). If the needle is bent or damaged, or the packing is worn or leaking, replace the entire needle assembly. If replacement is necessary, be sure to remove the o-ring (2a*) as it may stick inside the gun body. See F

IG. 38.

IG. 36

Needle Repair

1. Remove the diffuser, see Seat Repair, page 20.

IG. 38

2. Remove the trigger pivot pin nut (14‡), pivot pin (13‡), and trigger (3‡) using the gun tool (30) and nut driver (29). See F

IG. 37.

3A0149E 21

Page 22

Repair

TI6577B

TI6573A

22*

Air Valve Repair

1. Unscrew the spring cap (11) from the back of the gun body (1) using the gun tool (30). Remove the two springs (15 and 19) and the shaft (9).

2. Push the air valve assembly (8*) out the back of the gun. See F

IG. 39.

3. Inspect the u-cup (7*) in the gun body (1). If the u-cup is worn or leaking, carefully remove the u-cup from the front of the gun body, using a pick.

Fluid Tube Replacement

1. Remove the air inlet fitting (17) using the gun tool (30) and remove the screw (20) using a 3/16 in. hex wrench.

2. Unscrew the fluid inlet fitting (18). Remove and clean or replace the inline fluid filter (12).

3. Unscrew the fluid tube connector (C) from the gun’s fluid inlet. Carefully remove the gasket (22*).

IG. 39

FIG. 40

22 3A0149E

Page 23

Repair

3A0149E 23

Page 24

Repair

TI6578A

28*

Lubricate lightly.

Lips face out of gun body.

TI6575A

2†

2a*

Reassembly

NOTE: See Repair Kits, page 20.

1. Install the tube gasket (22*) in the gun. Handtighten the fluid tube connector (C) into the gun’s fluid inlet. Handtighten the air inlet fitting (17) and screw (20). Torque the fluid tube connector to 150-160 in-lb (17-18 N•m). Torque the air inlet fitting to 210-220 in-lb (24-25 N•m). Torque the fluid tube bracket screw to 50-60 in-lb (6-7 N•m). See F

2. Install the inline fluid filter (12) into the base of the fluid tube. Screw the fluid inlet fitting (18) into the base of the tube. Torque to 175-185 in-lb (20-21 N•m). See F

IG. 43.

3. Place the new u-cup (7*) on the seal installation tool (28*), with the u-cup lips facing the tool as shown in F

IG. 41. Push the u-cup into the back of the gun until

you feel a definite snap.

IG. 43.

8. Insert the fluid needle assembly (2) into the front of the gun. Use the nut driver (29) to screw the fluid needle assembly into the gun body (1) and torque to 50-60 in-lb (6-7 N•m). See F

IG. 42.

FIG. 42

9. Install the trigger (3), pivot pin (13), and nut (14). Use low strength thread locker and be sure that the brass piece of the fluid needle assembly (2) is behind the trigger. See F

IG. 43. Lubricate both sides

of the pivot pin where the trigger contacts the pin and lubricate the boss on both sides of the gun where the trigger contacts the gun body. Torque the nut to 20-30 in-lb (2-3 N•m).

IG. 41

4. Lubricate the front end of the air valve assembly (8*). Gently slide the air valve assembly into the back of the gun, passing through the u-cup (7*), as far as it will go. Be careful not to damage the u-cup. See F

IG. 43.

5. Carefully insert the thinner end of the shaft (9) into the air valve (8*).

6. Install the two springs (15 and 19). Screw the spring cap (11) into the back of the gun body. Torque to 210-220 in-lb (24-25 N•m).

7. Lightly lubricate the needle assembly o-rings and shaft where the packing slides. Be sure that the o-ring (2a*) is in place in the gun body (1).

10. Trigger the gun to pull the needle back while you screw the diffuser assembly (5) into the gun body (1) using the gun tool (30). Torque to 155-165 in-lb (18-19 N•m). When properly tightened, the flange will bottom out on the gun.

11. Attach the retaining ring (6), air cap (21), and spray tip (33).

24 3A0149E

Page 25

6 (G15 only)

*22

*6b

*5e

*5f

*5g

5b✖ (carbide only)

5c†✖

5d†✖

*2a

TI6579D

6 (G40 only)

*6a

Torque to 150-160 in-lb (17-18 N•m).

Lubricate lightly.

Torque to 155-165 in-lb (18-19 N•m).

Torque to 20-30 in-lb (2-3 N•m).

Do not lubricate diffuser o-rings.

Brass part must be behind trigger.

Lips face out of gun body.

Torque to 50-60 in-lb (6-7 N•m).

Torque to 210-220 in-lb (24-25 N•m).

Torque to 45-50 in-lb (5-6 N•m).

Use low-strength thread locker.

Torque to 175-185 in-lb (20-21 N•m).

789

21a (G15 only)

(24C853, 24C854 and

(24C856 &

24C857)

24C855 only)

(24C853, 24C854, and 24C855)

*6a (G40 only)

Repair

FIG. 43

3A0149E 25

Page 26

Parts

3‡

6 (G15 only)

13‡

14‡

*22

◆*6b

*5e

*5f

*5g

5b✖ (carbide only)

5c†✖

5d†✖

*2a

6 (G40 only)

◆*6a

21a (G15 only)

TI6579D

28*

(24C856 only)

(24C853, 24C854, and 24C855 only)

*6a (G40 only)

Parts

Part No. 24C853 and 24C854, G15 Gun

Part No. 24C855, G40 Gun

Part No. 24C856, G40 Gun, High Flow

26 3A0149E

Page 27

Part No. 24C854, G15 Gun with Plastic Seat Part No. 24C853, G15 Gun with Carbide Seat

Parts

Ref. No. Part No. Description Qty.

1BODY, gun 1 1a 249423 STOP, trigger 1 2 24B790 NEEDLE, assy; 3/32 ball; sst

includes items 2a (24C854 only) and 9

24B789 NEEDLE, assy; 3/32 ball; carbide

includes items 2a (24C853 only)

and 9 2a*✓ 110004 PACKING, o-ring; PTFE 1 3‡ TRIGGER, gun 1 4 249135 VALVE, fan, assy 1 5 249132 DIFFUSER, assy (24C854 only) 1

249133 DIFFUSER, assy (24C853 only) 1 5a DIFFUSER, housing 1 5b✖ 288619 GASKET, seat; nylon (24C853

only) 5c† SEAT; plastic (24C854 only) 1 5c✖ SEAT; carbide (24C853 only) 1 5d†✖ NUT, seat 1 5e* 111116 PACKING, o-ring, seat; PTFE 1 5f*✓ 109450 PACKING, o-ring; PTFE 1 5g*✓ 111457 PACKING, o-ring; PTFE 1 6 24D438 RING, retaining; includes 6a and 6b1

6a*◆✓ 109213 PACKING, o-ring; PTFE 1 6b*◆✓ 15G320 WASHER; PTFE 1 7*✓ 188493 PACKING, u-cup; UHMWPE 1 8* VALVE, air, assy 1 9 16A529 SHAFT, fluid spring 1 11 15F195 CAP, spring 1 12 224453 FILTER, tip (pkg of 5) 1 13‡ 15F739 PIN, pivot 1 14‡ 15F740 PIN, pivot, nut 1 15 114069 SPRING, compression 1 16 24D436 TUBE, assy.; includes item 22 1 17 15F202 FITTING, air inlet 1 18 24D437 FITTING, hose; see Accessories

for fitting with JIC threads

Ref. No. Part No. Description Qty.

19 119767 SPRING, compression (24C854

20 119996 SCREW, cap, socket hd; 1/4-20 x

21 24C866 AIR CAP, includes item 21a 1 21a 24D627 PIN, air cap; indexing

22*✓ 115133 GASKET, tube, acetal 1 28* TOOL, installation; seal 1 29 117642 TOOL, nut driver 1 30 15F446 TOOL, gun 1 31▲ 222385 CARD, warning (not shown) 1 32▲ 172479 TAG, warning (not shown) 1

33 SPRAY TIP, customer’s choice 33a 183616 GASKET, tip (not shown) 1

▲ Replacement Danger and Warning labels, tags, and

* Included in Seal Repair Kit 249422 (purchase

† Included in Plastic Seat Repair Kit 249424

✖ Included in Carbide Seat Repair Kit 249456

‡ Included in Trigger Repair Kit 249585

◆ Included in Air Cap Seal Kit 253032

✓ Not for sale separately.

115141 SPRING, compression (24C853

cards are available at no cost.

separately).

(purchase separately).

only)

3/8 in. (10 mm)

(package of 3)

3A0149E 27

Page 28

Parts

Part No. 24C855, G40 Gun with Standard Tip Part No. 24C856, G40 Gun, High Flow

Ref. No. Part No. Description Qty.

1 BODY, gun 1 1a 249423 STOP, trigger 1 2 24B789 NEEDLE, assy; 3/32 ball; carbide

includes items 2a and 9 2a*✓ 110004 PACKING, o-ring; PTFE 1 3‡ TRIGGER, gun 1 4 249135 VALVE, fan, assy 1 5 249133 DIFFUSER, assy 1 5a DIFFUSER, housing 1 5b✖ 288619 GASKET, seat; nylon 1 5c✖ SEAT; carbide 1 5d✖ NUT, seat 1 5e* 111116 PACKING, o-ring, seat; PTFE 1 5f*✓ 109450 PACKING, o-ring; PTFE 1 5g*✓ 111457 PACKING, o-ring; PTFE 1 6 24D439 TIP GUARD, includes items 6a

and 6b (24C855 & 24C856 only) 6a*◆✓ 109213 PACKING, o-ring; PTFE 2 6b*◆✓ 15G320 WASHER; PTFE 1 7*✓ 188493 PACKING, u-cup; UHMWPE 1 8* VALVE, air, assy 1 9 16A529 SHAFT, fluid spring 1 11 15F195 CAP, spring 1 12 224453 FILTER, tip (pkg of 5, 24C855

only) 13‡ 15F739 PIN, pivot 1 14‡ 15F740 PIN, pivot, nut 1 15 114069 SPRING, compression 1 16 24D436 TUBE, assy, includes item 22

(24C855 only)

249317 TUBE, assy (24C856 only) 1

17 15F202 FITTING, air inlet 1

Ref. No. Part No. Description Qty.

18 24D437 FITTING, hose (24C855 only);

see Accessories for fitting with

19 115141 SPRING, compression 1 20 119996 SCREW, cap, socket hd; 1/4-20 x

21 249180 AIR CAP 1 22*✓ 115133 GASKET, tube, acetal 1 28* TOOL, installation; seal 1 29 117642 TOOL, nut driver 1 30 15F446 TOOL, gun 1 31▲ 222385 CARD, warning (not shown) 1 32▲ 172479 TAG, warning (not shown) 1 33 SPRAY TIP, customer’s choice 33a 183616 GASKET, tip (not shown) 1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

* Included in Seal Repair Kit 249422 (purchase

separately).

✖ Included in Carbide Seat Repair Kit 249456

(purchase separately).

‡ Included in Trigger Repair Kit 249585

(purchase separately).

◆ Included in Air Cap Seal Kit 253032 (purchase separately).

✓ Not for sale separately.

JIC threads.

3/8 in. (10 mm) (24C855 only)

28 3A0149E

Page 29

Parts

3A0149E 29

Page 30

Parts

3‡

★4

★5a

13‡

14‡

*22

★*5f

★*5g

★✖5b

*2a

TI7203B

28*

33a

★35

★6

★*6a

5c✖★

5d✖★

TI6580A

Part No. 24C857, G40 Gun with RAC Tip

30 3A0149E

Page 31

Part No. 24C857, G40 Gun with RAC Tip

Parts

Ref. No.Part No. Description Qty.

1 BODY, gun 1 1a 249423 STOP, trigger 1 2 24B789 NEEDLE, assy; 3/32 ball; carbide

includes items 2a and 9 2a*✓ 110004 PACKING, o-ring; PTFE 1 3‡ TRIGGER, gun 1 4★ 15G713 NUT, air plug 1 5★ 249877 DIFFUSER, assy, RAC 1 5a★ DIFFUSER, housing 1 5b✖★ 288619 GASKET, seat; nylon 1 5c✖★ SEAT; carbide 1 5d✖★ NUT, seat 1 5e*★✓ 111116 PACKING, o-ring, seat; PTFE 1 5f*★✓ 109450 PACKING, o-ring; PTFE 1 5g*★✓ 111457 PACKING, o-ring; PTFE 1 6★ 24C921 TIP GUARD/AIR CAP ASSY,

includes item 35 6a*★✓ 109213 PACKING, o-ring, PTFE 1 7*✓ 188493 PACKING, u-cup; UHMWPE 1 8* VALVE, air, assy 1 9 16A529 SHAFT, fluid spring 1 11 15F195 CAP, spring 1 13‡ 15F739 PIN, pivot 1 14‡ 15F740 PIN, pivot, nut 1 15 114069 SPRING, compression 1 16 249317 TUBE, assy 1 17 15F202 FITTING, air inlet 1 19 115141 SPRING, compression 1 20 119996 SCREW, cap, socket hd; 1/4-20 x

3/8 in. (10 mm)

Ref. No.Part No. Description Qty.

22*✓ 115133 GASKET, tube, acetal 1 28* TOOL, installation; seal 1 29 117642 TOOL, nut driver 1

30 15F446 TOOL, gun 1 31▲ 222385 CARD, warning (not shown) 1 32▲ 172479 TAG, warning (not shown) 1 33 SPRAY TIP, customer’s choice,

see tip selection chart page 32, includes item 33a

33a 246453 RAC GASKET, standard, black 1

248936 RAC GASKET, solvent resistant,

orange

35★ 15F442 HOUSING, cylinder 1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

* Parts included in Seal Repair Kit 249422 (purchase

separately).

✖ Parts included in Carbide Seat Repair Kit 249456

(purchase separately).

‡ Parts included in Trigger Repair Kit 249585 (pur-

chase separately).

★ Parts included in RAC Conversion Kit 24C791 (pur-

chase separately).

✓ Not for sale separately.

3A0149E 31

Page 32

Spray Tip Selection Chart

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

Spray Tip Selection Chart

Spray Tips, for use with G15/G40 Air Cap

AAM Fine Finish Spray Tips

Recommended for high finish quality applications at low and medium pressures. Order desired tip, Part No. AAMxxx, where xxx = 3-digit number from matrix below.

GG4 Industrial Spray Tips

Recommended for high wear applications at high pressures. Order desired tip, Part No. GG4xxx, where xxx = 3-digit number from matrix below.

NOTE:

• All tips in the Spray Tip Selection Chart below can be used with Model G40 guns. Use tips in the gray shaded area of the chart with Model G40 guns only.

• Do not use tips in the gray shaded area of the chart with Model G15 guns.

Do not use tips in the gray shaded area of the Spray Tip Selection Chart with Model G15 guns. G15 guns are not designed for use at high pressures. Failure to follow this warning can result in serious injury, including fluid injection and splashing in the eyes or on the skin.

* Fluid Output

fl oz/min (lpm)

at 600 psi

Orifice Size

in. (mm) † 0.007 (0.178) 4.0 (0.1) 5.2 (0.15) † 0.009 (0.229) 7.0 (0.2) 9.1 (0.27) † 0.011 (0.279) 9.5 (0.28) 12.5 (0.37)

0.013 (0.330) 12.0 (0.35) 16.0 (0.47)

0.015 (0.381) 16.0 (0.47) 21.0 (0.62)

0.017 (0.432) 20.0 (0.59) 26.5 (0.78)

0.019 (0.483) 28.0 (0.8) 36.3 (1.09)

0.021 (0.533) 35.0 (1.0) 45.4 (1.36) ‡ 0.023 (0.584) 40.0 (1.2) 51.9 (1.56) ‡ 0.025 (0.635) 50.0 (1.5) 64.8 (1.94) ‡ 0.027 (0.686) 58.5 (1.7) 75.8 (2.27) ‡ 0.029 (0.737) 68.0 (1.9) 88.2 (2.65) ‡ 0.031 (0.787) 78.0 (2.2) 101.1 (3.03) ‡ 0.033 (0.838) 88.0 (2.5) 114.1 (3.42) ‡ 0.035 (0.889) 98.0 (2.8) 127.1 (3.81) ‡ 0.037 (0.940) 108.0 (3.1) 140.0 (4.20) ‡ 0.039 (0.991) 118.0 (3.4) 153.0 (4.59)

(4.1 MPa, 41 bar)

at 1000 psi (7.0 MPa, 70 bar)

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

2 to 4

(100)

4 to 6

(150)

6 to 8

(200)

8 to 10

(250)

10 to 12

(300)

Spray Tip

12 to 14

(350)

14 to 16

(400)

★107 207 307

109 209 309 409 509 111 211 311 411 511 611 ❄711

213 313 413 513 613 713 215 315 415 515 615 715 815 217 317 417 517 617 717 817 917 219 319 419 519 619 719 819 919

321 421 521 621 721 821 921

423 523 623 723 923 425 625 725 825 ★925

527 627 827

629

431 631

633 ★833

435

737

539 639 839

16 to 18

(450)

18 to 20

(500)

* Tips are tested in water.

† These tip sizes include a 150 mesh tip filter. ‡ Do not use these tips with Model G15 guns.

32 3A0149E

★ GG4 tips only. ❄ AAM tips only.

Page 33

Spray Tip Selection Chart

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size.

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) from the above table for the selected orifice size.

AAF Fine Finish Pre-Orifice Spray Tips

Recommended for high finish quality applications at low and medium pressures. AAF tips have a pre-orifice that assists in atomizing sheer thinning materials, including lacquers.

Order desired tip, Part No. AAFxxx, where xxx = 3-digit number from matrix below.

* Fluid Output

fl oz/min (lpm)

Orifice Size

in. (mm)

0.009 (0.229) 7.0 (0.21) 8.5 (0.25)

0.011 (0.279) 9.5 (0.28) 12.5 (0.37)

0.013 (0.330) 12.0 (0.35) 16.0 (0.47)

0.015 (0.381) 16.0 (0.47) 21.0 (0.62)

0.017 (0.432) 20.0 (0.59) 26.5 (0.78)

at 600 psi

(4.1 MPa, 41 bar)

at 1000 psi

(7.0 MPa, 70 bar)

4 to 6

(150)

208 308 408 210 310 410 510 610 710 212 312 412 512 612 712

Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

6 to 8

(200)

8 to 10

(250)

Spray Tip

414 514 614 714 416 516 616 716

* Tips are tested in water.

RAC SwitchTips, for use with G40 RAC Air Cap

NOTE: All tips in the Spray Tip Selection Charts below

can be used with Model G40 guns equipped with RAC air cap 24C921.

LTX RAC Spray Tips Order desired tip, Part No. LTXxxx, where xxx = 3-digit number from matrix below.

NOTE: Tips are sometimes packaged with other promo-

tional parts intended for the airless market. Disregard extra parts.

10 to 12

(300)

12 to 14

(350)

14 to 16

(400)

❖ Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

Orifice Size in.

(mm)

* Fluid Output,

at 2000 psi

(14.0 MPa, 140 bar)

fl oz/min (lpm)

2 to 4

(100)

4 to 6

(150)

6 to 8

(200)

8 to 10

(250)

10 to 12

(300)

Spray Tip

12 to 14

(350)

14 to 16

(400)

16 to 18

(450)

0.009 (0.229) 11.2 (0.33) 109 209 309 409 509

0.011 (0.279) 16.6 (0.49) 111 211 311 411 511 611

0.013 (0.330) 23.3 (0.69) 213 313 413 513 613

0.015 (0.381) 30.8 (0.91) 115 215 315 415 515 615

0.017 (0.432) 39.5 (1.17) 217 317 417 517 617 817

0.019 (0.483) 49.7 (1.47) 219 319 419 519 619 819

0.021 (0.533) 60.5 (1.79) 221 321 421 521 621 721 821

0.023 (0.584) 72.7 (2.15) 323 423 523 623 723

0.025 (0.635) 85.9 (2.54) 225 325 425 525 625

0.027 (0.686) 100.0 (2.96) 227 327 427 527 627 827

0.029 (0.737) 115.6 (3.42) 329 429 529 629 729

0.031 (0.787) 131.8 (3.90) 231 331 431 531 631 831

0.033 (0.838) 149.4 (4.42) 433 533 633 833

0.035 (0.889) 168.4 (4.98) 235 335 435 535 635 735 835

* Tips are tested in water.

18 to 20

(500)

❖ Measured with NO airflow. Air assist will tend to reduce pattern lengths by 1 in. to 2 in.

3A0149E 33

Page 34

Spray Tip Selection Chart

Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) where QT = fluid output (fl oz/min) from the above table for the selected orifice size.

RAC SwitchTips, for use with G40 RAC Air Cap, Continued

NOTE: All tips in the Spray Tip Selection Charts below

can be used with Model G40 guns equipped with RAC air cap 24C921.

FFT Fine Finish RAC Spray Tips Order desired tip, Part No. FFTxxx, where xxx = 3-digit number from matrix below.

❖ Maximum Pattern Width at 12 in. (305 mm)

in. (mm)

4 to 6

(150)

Orifice Size in.

(mm)

* Fluid Output at

2000 psi (14.0 MPa, 140 bar)

fl oz/min (lpm)

0.008 (0.203) 8.8 (0.26) 208 308

0.010 (0.254) 13.9 (0.41) 210 310 410 510

0.012 (0.305) 19.9 (0.59) 212 312 412 512 612

0.014 (0.356) 27.0 (0.80) 214 314 414 514 614

6 to 8

(200)

8 to 10

(250)

Spray Tip

10 to 12

(300)

12 to 14

(350)

WRX WideRAC Spray Tips Order desired tip, Part No. WRxxxx, where xxxx = 4-digit number from matrix below.

❖ Maximum Pattern Width at 12 in. (305 mm)

24 in. (610 mm)

Spray Tip

Orifice Size

in. (mm)

* Fluid Output at

2000 psi (14.0 MPa, 140 bar)

fl oz/min (lpm)

0.021 (0.533) 60.5 (1.79) 1221

0.023 (0.584) 72.7 (2.15) 1223

0.025 (0.635) 85.9 (2.54) 1225

0.027 (0.686) 100.0 (2.96) 1227

0.029 (0.737) 115.6 (3.42) 1229

0.031 (0.787) 131.8 (3.90) 1231

0.033 (0.838) 149.4 (4.42) 1233

0.035 (0.889) 168.3 (4.98) 1235

0.037 (0.940) 187.9 (5.56) 1237

0.039 (0.991) 208.9 (6.18) 1239

* Tips are tested in water.

❖ Measured with NO airflow. Air assist will tend to reduce pattern lengths by 1 in. to 2 in.

34 3A0149E

Page 35

Accessories

Use Only Genuine Graco Parts and Accessories

Accessories

Air Fitting and Tubing Kit 249473

Alternative-style connector for air inlet and hose. 3/8 in. to 1/4 npt(f) Push-To-Lock fitting, 25 ft (7.62 m) long, 3/8 in. (9.5 mm) ID, nylon tubing.

Air Hose 241811

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

1/4-18 npsm(fbe), 1/4 in. (6 mm) ID, 25 ft (7.62 m) long polyurethane tubing.

Air Line Quick Disconnect

208536 Air Line Quick Disconnect Coupling 169967 Air Line Quick Disconnect Pin

Fluid Filter Kits

224453 100 mesh (.005 gap spacing) replacement

fluid filters. Quantity. of 5.

238563 60 mesh (.009 gap spacing) replacement

fluid filters for coarser particle filtering to replace standard 100 mesh filters. Quantity of 3.

Fluid Hose 241812

3500 psi (24 MPa, 242 bar) Maximum Working Pressure

1/4-18 npsm(fbe), 3/16 in. (5 mm) ID, 25 ft (7.62 m) long, nylon tubing with polyurethane cover.

Fluid Swivel Connector 189018

5800 psi (40 MPa, 400 bar) Maximum Working Pressure

Connector to ease movement of the gun and fluid hose. 1/4-18 npsm. 17-4 PH SST wetted parts.

Gun Brush 101892

Use to clean the gun.

G15 Gun Flush Box Insert 15G093

Insert for use with Gun Flush Box 244105 and G15 Spray Guns.

G40 Gun Flush Box Insert 15G346

Insert for use with Gun Flush Box 244105 and G40 Spray Guns.

Gun Lubricant 111265

One 4 oz. (113 g) tube sanitary (non-silicone) lubricant for fluid seals and wear areas.

High Pressure Fluid Ball Valve 238694

5000 psi (35 MPa, 350 bar) Maximum Working Pressure

3/8 npt(mbe). SST wetted parts, PEEK seats, PTFE seals. Compatible with acid-catalyzed materials. Can be used as fluid drain valve.

HVLP Verification Kit 24C788

Use to check air cap air pressure at various air supply air pressures. Do not use for actual spraying.

NOTE: To be HVLP compliant, the atomizing air pressure must not exceed 10 psi (70 kPa, 0.7 bar).

RAC Gasket 246453

Pack of five standard replacement RAC gaskets (item 33a).

Acetal RAC Gasket 248936

Pack of five plastic (acetal) replacement RAC gaskets (item 33a).

G40 RAC Conversion Kit 24C791

Kit includes parts to convert a standard G40 gun to a RAC gun. LTX spray tip not included.

Air Cap Lacquer Kit 289080

Kit includes air cap optimized to spray lacquer.

Air Cap Seal Kit 253032

Pack of five seals and five o-rings for the air cap assy.

Seal Repair Kit 249422

Kit includes replacement o-rings, gasket, u-cup, air valve assembly, and seal installation tool.

3A0149E 35

Page 36

Accessories

Plastic Seat Repair Kit 249424

Kit includes replacement plastic seat (pack of 10), and seat nut for Model G15 gun.

SST Seat Repair Kit 287962

Kit includes assembled diffuser with SST seat for use with pigmented acid catalyzed materials. For use with gun 24C854 only.

Carbide Seat Repair Kit 249456

Kit includes replacement carbide seat, seat gasket, and seat nut for Model G40 gun. Kit also can be used with Model G15 guns.

Carbide Seat Gasket Kit 288619

Kit includes replacement nylon seat gaskets (qty. of ten) for Model G40 guns and G15 guns with a carbide seat.

Tip Filter Kit 241804

Replacement filters for spray tip orifice sizes 0.007,

0.009, and 0.011. Quantity of 10.

Trigger Repair Kit 249585

Kit includes replacement trigger, pivot pins (qty. of 5), and pivot pin nuts (qty. of 5).

Trigger Stop Kit 249423

Kit includes replacement trigger stop and pin.

Ultimate Gun Cleaning Kit 15C161

Kit includes brushes and tools for gun maintenance.

Unclogging Needle Kit 249598

Kit includes picks for unclogging gun tip.

Fan Valve Fine Adjustment Kit 289499

Kit includes a replacement fan valve assembly with more adjustment accuracy.

Fluid Fitting Kit 24C356, JIC Threads

Kit includes a 1/2-20 JIC threaded fluid inlet fitting.

36 3A0149E

Page 37

Part Interchangeability Guide

Part Number

Description

Fluid spring shaft

Locating pin

G15 retaining ring kit

Includes retaining ring,

PTFE o-ring, and PTFE

washer

G40 retaining ring/tip

guard kit

Includes retaining ring

with guard, PTFE o-ring,

and PTFE washer

RAC seat housing

AA RAC guard kit

Includes guard assembly

(with retaining ring) and

mating cylinder housing.

Needle, carbide ball,

G15 and G40

Needle, stainless steel

ball, G15

HVLP verification kit

RAC gun conversion kit

G15 air cap

Fluid tube assembly

Fluid fitting,

standard threads

Fluid fitting,

JIC threads

New Models

(24Cxxx)

16A529 15F193

24D627 15G618 No New pin is shorter to match the new gun body.

24D438 15F192 No See note below table.

24D439 249256 No See note below table

15F442 15J770 No Works properly only with RAC Tip Guard/Air Cap

24C921 288465 No See note below table.

24B789 288559 Yes Directly replaceable.

24B790 288558 Yes Directly replaceable.

24C788 249140 No See note below table. 24C791 287917 No Can only be used on the new gun due to a differ-

24C866 249596 No Uses new shorter locating pin. See note for

24D436 249136 Yes The new fluid tube assembly will fit an older gun

24D437 15F186 No

24C356 NA No

Part Number,

Older Models* Interchangeable?

15F194

Accessories

Yes 16A529 combines the fluid spring shaft and seat

into a single part. Directly replaceable.

Using a new pin/air cap combo on an old model gun results in loss of the alignment feature. Using an old pin/air cap combo on a new model gun causes leakage due to improper fit.

Assembly 24C921 and is included in that kit. Seat will fit into older model assemblies, but spray performance may be affected.

ent RAC guard. See note below table.

Locating pin, this table.

only if a new fluid fitting is purchased, 24D437 (standard threads) or 24C356 (JIC threads).

New fluid fittings have different threads that fit only the new fluid tube assembly (24D436). Any interchange will damage the threads.

NOTE: The new retaining ring is black and has coarse threads, while the old retaining ring is silver and has fine

threads. Any interchange will damage the threads on the ring and gun body.

* Older model part numbers include 288xxx, 287xxx, 249xxx.

3A0149E 37

Page 38

Dimensions

6.1 in. (15.5 cm)

8.0 in.

(20.3 cm)

6.9 in.

(17.5 cm)

5.0 in. (12.7 cm)

Model G15

TI6583A

6.9 in. (17.5 cm)

5.8 in. (14.7 cm)

8.0 in.

(20.3 cm)

6.9 in.

(17.5 cm)

Model G40

TI6845A

Dimensions

38 3A0149E

Page 39

Technical Data

Air Flow, Standard Air Cap

Gun Inlet Pressure (PSI)

10 20

30 400

Air Flow

(SCFM)

4.2

6.4

8.6

10.6

5.8

4.6

3.8

2.6

Fan Valve Open Fan Valve Closed

Technical Data

Category Data

Maximum Working Fluid Pressure . . . . . . . . . . . . . . . . . . Model G15: 1500 psi (10 MPa, 105 bar)

Model G40: 4000 psi (28 MPa, 280 bar)

Maximum Working Air Pressure . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Maximum Gun Inlet Air Pressure for HVLP Operation . . . 14 psi (0.098 MPa, 0.98 bar)

Maximum Working Fluid Temperature . . . . . . . . . . . . . . .

Fluid Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4-18 npsm

Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4-18 npsm (R1/4-19) compound male thread

Gun Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 oz (450 grams)

*Sound Pressure at 20 psi (140 kPa, 1.4 bar) . . . . . . . . . 66.9 dB(A)

*Sound Pressure at 100 psi (0.7 kPa, 7 bar) . . . . . . . . . . 80.0 dB(A)

*Sound Power at 20 psi (140 kPa, 1.4 bar) . . . . . . . . . . . 76.8 dB(A)

*Sound Power at 100 psi (0.7 kPa, 7 bar) . . . . . . . . . . . . 89.9 dB(A)

Wetted Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless Steel, Carbide, Ultra High Molecular Weight

110

°F (43°C)

Polyethylene, Engineered Plastic, PTFE, Nylon, Fluoro-

elastomer

* All readings were taken with the fan valve fully closed (full fan size), at 20 psi (140 kPa, 1.4 bar) and 100 psi (0.7

kPa, 7 bar), and at the assumed operator position. Sound Power was tested to ISO 9614-2.

3A0149E 39

Page 40

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A0149

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revision E, March 2014

Graco 3A0149E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Warnings

Installation

Typical Installation

Ventilate the Spray Booth

Grounding

Air Line

Fluid Line

Setup

Flush Before Using Equipment

Select a Spray Tip

Air Cap Alignment Pin

Install a Spray Tip

Position the Air Cap

Reverse-A-Clean® (RAC) Tip Assembly

Operation

Pressure Relief Procedure

Trigger Lock

How the Air-Assisted Spray Gun Operates

Spray Pattern Adjustment

HVLP Operation

Fluid Application

Daily Gun Care, Flushing, and Cleaning

General System Maintenance

Fluid Filter Maintenance

Flushing and Cleaning

Reverse-A-Clean® (RAC) Tip

Troubleshooting

Repair

Complete Gun Packing Repair

Repair Kits

Fan Valve Replacement

Parts

Spray Tip Selection Chart

Spray Tips, for use with G15/G40 Air Cap

RAC SwitchTips, for use with G40 RAC Air Cap

RAC SwitchTips, for use with G40 RAC Air Cap, Continued

Accessories

Part Interchangeability Guide

Dimensions

Technical Data

Graco Standard Warranty

Graco Information