Instructions - Parts List
AA Series Spray Gun
For air-assisted spraying and finishing of paints and coatings.
Important Safety Instructions:
Read all warnings and instructions in this manual. Save
these instructions.
See page 2 for List of Models and Table of Contents.
311001F
Model G15
Model G40
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
TI6844A
TI6553A
Model G40 w/RAC tip
II 2 G
TI7204B
Models
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flush Before Using Equipment . . . . . . . . . . . . . . 8
Select a Spray Tip and Air Cap . . . . . . . . . . . . . . 8
Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8
Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . 8
Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . 16
Clearing a clogged RAC tip . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Troubleshooting . . . . . . . . . . . . . . . . . . 18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Items Needed for Service . . . . . . . . . . . . . . . . . 20
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Valve Replacement . . . . . . . . . . . . . . . . . . . 20
Complete Gun Packing Repair . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20
Seat Repair 20
Needle Repair 21
Air Valve Repair 22
Fluid Tube Replacement 22
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 30
AAM Fine Finish Spray Tips 30
GG4 Industrial Spray Tips 30
LTX RAC Spray Tips 31
FFT Fine Finish RAC Spray Tips 32
WRX WideRAC Spray Tips 32
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36
Models
Maximum
Working Air
Part
No. Series
288844 A 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure
287926 C 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure
249242 C 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted
249246 B 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure, High Flow
249238 B 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted
Pressure
psi (MPa, bar)
Maximum
Working Fluid
Pressure
psi (MPa, bar) Description Includes:
Air-Assisted Spray Gun, Plastic
Seat, SST Ball
Air-Assisted Spray Gun, Carbide
Seat and Ball
Spray Gun, Carbide Seat and Ball
Air-Assisted Spray Gun, Carbide
Seat and Ball
Spray Gun, Carbide Seat and Ball,
Reverse-A-Clean
®
(RAC) Tip
249596
Air Cap
249596
Air Cap
249180
Air Cap
249180
Air Cap
288465
RAC
Air Cap
2 311001F
Related Manuals
This manual is available in the following languages:
Manual Language
311001 English
311145 Chinese
311146 Danish
311147 Dutch
311148 Finnish
311149 French
311150 German
311151 Italian
311152 Japanese
311153 Korean
311154 Norwegian
311155 Polish
311156 Russian
311157 Spanish
311158 Swedish
Related Manuals
311001F 3
Warnings
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 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 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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. 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.
• 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or overbend hoses or use hoses to pull equipment.
• Comply with all applicable safety regulations.
• Keep children and animals away from work area.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
4 311001F
Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
311001F 5
Installation
Installation
Typical Installation
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.
D
B
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.
A
C
FIG. 1: Typical Installation (Model G15 Shown)
Key:
A Air Line Filter
B Air Shutoff Valve
C Gun Air Pressure Regulator
DAir Line
E
G
TI6554A
F
ESpray Gun
F Electrically Conductive Fluid Hose
G Gun Air Supply Hose
6 311001F
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.
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.
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. 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.
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
(115898) at the gun inlet for best maneuverability.
See Accessories, page 33.
G
TI6556A
F
IG. 2
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.
311001F 7
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 and Air Cap
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 30. Contact your
Graco distributor for assistance in selecting an appropriate spray tip for your application.
Install a Spray Tip
Install a spray tip in the gun. Ensure that the tip locating
tab is positioned in the slot of the air cap. See F
Tighten the air cap retaining ring (6) firmly by hand to
ensure a good seal between the tip gasket and the diffuser (5).
IG. 5.
TI6558A
IG. 6
F
Air Cap Alignment Pin
Model G15 guns (288844) 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 do not come standard with model
G40 guns (249242).
IG. 7. When relocating
Slot
Tip Locating Tab
F
IG. 5
Position the Air Cap
The air cap and spray tip position determines 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.
8 311001F
TI6847A
F
Horizontal
Air Cap Position
(standard)
Verti cal
Air Cap Position
IG. 7
TI6847A
Reverse-A-Clean® (RAC) Tip
Setup
Model 249238 guns use a Reverse-A-Clean® (RAC) tip.
To assemble the RAC tip, insert the seat housing into
the air cap assembly.
TI7196A
F
IG. 8
Insert the SwitchTip.
TI7197A
IG. 9
F
Insert the gasket seat.
TI7198A
FIG. 10
Screw the RAC tip assembly onto the gun and tighten
firmly by hand.
TI7199A
F
IG. 11
311001F 9
Operation
Operation
Safety
SKIN INJECTION HAZARD
Remember, this is not an air spray gun. For your
safety 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 an injection injury occur.
Additional cards are available at no charge from
Graco.
Pressure Relief Procedure
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure. See
F
IG. 12.
TI6555A
FIG. 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
IG. 13.
SKIN INJECTION HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected
through the skin and cause serious injury. 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.
Follow Pressure Relief Procedure on page 10 when
you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read Warnings,
page 4.
1. Engage the trigger lock. See FIG. 13.
2. Shut off the pump. See your pump manual.
3. Shut off the gun air supply.
4. Disengage the trigger lock. See F
IG. 13.
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.
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.
IG. 13
F
ENGAGED
TI6581A TI6582A
DISENGAGED
10 311001F
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
SKIN INJECTION HAZARD
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.
3. Slowly increase the fluid pressure, just to the point
where a further increase in fluid pressure does not
significantly improve fluid atomization.
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. 14
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. 15. Seven to 10 psi (4.9 to
IG. 14. This
CLOSE
TI6559A
IG. 14. 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.
311001F 11
x Pump Air Regulator Setting = Fluid
Pressure
F
IG. 15
no air
TI0792A
too little air correct amount
of air
Operation
HVLP Operation
For HVLP operation, the atomization air must not
exceed 10 psi. Use HVLP Verification Kit 249140 to
verify air psi.
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. 16.
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.
F
IG. 16
INCORRECT
TI6561A
TI6562A
CORRECT
12 311001F
Daily Gun Care, Flushing, and Cleaning
Daily Gun Care, Flushing, and Cleaning
CAUTION
Methlyene chloride with formic or propionic acid is not
recommended as a flushing or cleaning solvent with
SKIN INJECTION HAZARD
Follow the Pressure Relief Procedure on page 10
before cleaning the gun.
CAUTION
Solvent left in gun air passages could result in a poor quality paint finish. Do not use any cleaning method which
may allow solvent into the gun air passages.
this gun as it will damage aluminum and nylon components.
Do not point the gun up while cleaning it.
Do not immerse the gun in solvent.
TI6563A
Do not wipe the gun with a cloth soaked in solvent;
wring out the excess.
TI4827A
Do not use metal tools to clean the air cap holes as this
may scratch them; scratches can distort the spray pattern.
TI6564A
311001F 13
TI6565A
Daily Gun Care, Flushing, and Cleaning
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
FIRE AND EXPLOSION HAZARD
Read Warnings, page 4. Follow Grounding
instructions, page 6.
• 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).
F
IG. 17
12
18
TI6735A
3. Disconnect the fluid supply hose (F) and air supply
hose (G) from the gun.
G
F
F
IG. 18
TI6566A
TI6567A
14 311001F
Daily Gun Care, Flushing, and Cleaning
4. Connect the solvent supply hose (T) to the gun.
T
TI6557A
F
IG. 19
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.
CAUTION
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.
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).
10. Dip the end of a soft-bristle brush into a compatible
solvent. Do not continuously soak the brush's bris-
tles with solvent and do not use a wire brush.
TI6729A
IG. 20
F
6. Turn off the solvent supply.
7. Relieve the pressure.
8. Disconnect the solvent supply hose (T) from the
gun.
T
TI6566A
F
IG. 21
TI4845A
F
IG. 22
11. With the gun pointed down, clean the front of the
gun, using the soft-bristle brush and solvent.
TI6569A
F
IG. 23
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.
311001F 15
Daily Gun Care, Flushing, and Cleaning
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)
TI6570A
F
IG. 24
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).
A
B
C
TI6553A
FIG. 27
Reverse-A-Clean® (RAC) Tip
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.
TI6568A
F
IG. 25
15. Dampen a soft cloth with solvent and wring-out the
excess. Point the gun down and wipe off the outside
of the gun.
F
IG. 28
TI6571A
F
IG. 26
16 311001F
ENGAGED
TI6581A
Daily Gun Care, Flushing, and Cleaning
Rotate the SwitchTip.
IG. 29
F
Disengage the trigger lock.
DISENGAGED
TI6582A
TI7200A
Engage the trigger lock.
ENGAGED
TI6581A
FIG. 32
Return the SwitchTip to its original position.
TI7201A
IG. 30
F
Trigger the gun into a pail to clear the clog.
SKIN INJECTION HAZARD
Do not point gun at anyone or at any part of the body.
TI7202A
IG. 31
F
IG. 33
F
Disengage the trigger lock and continue spraying.
DISENGAGED
TI6582A
IG. 34
F
311001F 17
Troubleshooting
Troubleshooting
• Check all possible remedies in the troubleshooting charts before disassembling the gun.
SKIN INJECTION HAZARD
Follow Pressure Relief Procedure on page 10.
Read warnings, page 4.
• Some improper patterns are caused by the
improper balance between air and fluid.
General Troubleshooting
Problem Cause Solution
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, model
G40 gun only). The gasket must be replaced
whenever the seat assembly is removed.
Do not reverse the direction of the plastic seat
(5c, model G15 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, model G40 gun
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).
only). 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 311001F
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.
311001F 19
Repair
Repair
Items Needed for Service
• Seal Installation Tool (28)-- provided
• Nut Driver Tool (29) -- provided
• Gun Tool (30) -- provided
•O-ring Pick
•7/32 in. Hex Wrench
•3/16 in. Hex Wrench
• Compatible Solvent
• Lubricant (part number 111265)
1
4
C
1
A
1
Torque to 90 in-lb
(10.5 N•m).
Repair Kits
• 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 (standard for
Model G15 guns) and Carbide Seat Kit 249456
(standard for Model G40 guns) are available.
For best results, use all new parts in the kit. Kit
parts are marked with a symbol, for example
(5c†).
• Plastic Seat Kit 249424 and Carbide Seat Kit
249456 can be used with both Model G15 guns
and Model G40 guns.
• 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
IG. 35.
TI6576A
F
IG. 35
Complete Gun Packing Repair
Disassembly
Seat Repair
• 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
6
IG. 36.
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).
F
IG. 36
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).
20 311001F
33
21
TI6568A
Repair
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†, model G40 gun only) using a 7/32 in. hex
wrench.
6. Inspect the seat (5c†) and seat gasket (5b†) and
replace if necessary.
7. Reinstall the seat gasket (5b†, model G40 gun
only), seat (5c†), and seat nut (5d†). Torque to
45-50 in-lb. Be sure not to overtighten the nut.
• When reinstalling the carbide seat (5c†), the
tapered end of the seat (red side) must point
toward the gun tip.
• The plastic seat (5c†), standard in model G15
guns (288844), can be reinstalled in either
direction. Do not reverse the direction of the
plastic seat if it is worn. The seat must be
replaced if it is worn.
Needle Repair
1. Remove the diffuser, see Seat Repair, page 20.
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. 38.
13‡
3‡
F
IG. 38
14‡
TI6574A
F
IG. 37
5e*
5a
30
5g*
5c†
5f*
1
5d†
5b†
(G40 only)
TI6572A
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. 39.
1
29
2a*
2
TI6575A
F
IG. 39
311001F 21
Repair
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), the shaft (9), and seat (10).
2. Push the air valve assembly (8*) out the back of the
gun. See F
IG. 40.
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.
15
1
8*
7*
11
19
10
9
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*).
22*
17
C
20
F
IG. 40
TI6577A
IG. 41
F
12
18
TI6573A
22 311001F
Repair
311001F 23
Repair
Reassembly
• 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 175-185
in-lb (20-21 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. 44.
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. 42. Push the u-cup into the back of the gun until
you feel a definite snap.
3
Lubricate lightly.
8
Lips face out of gun body.
7*
8
3
28*
IG. 42
F
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. 44.
5. Slide the seat (10) onto the shaft (9). Be sure that
the tapered end of the seat is toward the thicker end
of the shaft. Carefully insert the shaft (9) and seat
(10) in the air valve (8*).
IG. 44.
TI6578A
6. Install the two springs (15 and 19). Screw the spring
cap (11) into the back of the gun body. Torque to
175-185 in-lb (20-21 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).
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. 43.
1
29
2a*
2†
TI6575A
FIG. 43
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. 44. 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).
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 311001F
6 (G40 only)
12
21a (G15 only)
21
*6b
*6a
33
Repair
5b† (carbide only)
5c†
6
*5g
6
*5f
4
5a
6
*5e
5d†
11
15
11
13
4
3
*7
8
*8
13
6 (G15 only)
1
Torque to 150-160 in-lb (17-18 N•m).
3
Lubricate lightly.
4
Torque to 155-165 in-lb (18-19 N•m).
5
Torque to 20-30 in-lb (2-3 N•m).
6
Do not lubricate diffuser o-rings.
7
Brass part must be behind trigger.
8
Lips face out of gun body.
9
Torque to 50-60 in-lb (6-7 N•m).
10
Torque to 125-135 in-lb (14-15 N•m).
11
Torque to 45-50 in-lb (5-6 N•m).
12
Use low strength thread locker.
13
Torque to 175-185 in-lb (20-21 N•m).
3
*2a
7
3
2
9
*22
1
16
(249238 &
249246 only)
9
16
(288844 & 249242 only)
3
20
18
(288844 & 249242 only)
3
10
(288844 torque only)
(249242 torque only)
13
3
10
9
1a
14
17
1
5
12
13
12
(288844 & 249242 only)
19
TI6579B
FIG. 44
311001F 25
Parts
*
Parts
Part No. 288844/G15 Gun
Part No. 249242/G40 Gun
Part No. 249246/G40 Gun, High Flow
21a (G15 only)
6 (G40 only)
◆*6a
33
*5e
5a
5b† (carbide only)
5c†
*5g
*5f
4
5d†
15
11
◆*6b
6 (G15 only)
21
*2a
2
*22
16
(249246 only)
16
(288844 & 249242 only)
3‡
20
13‡
*7
*8
10
9
1a
14‡
17
12
(288844 & 249242 only)
1
29
19
30
28
18
(288844 & 249242 only)
TI6579A
TI6579B
26 311001F
Parts
Part No. 288844/G15 Gun w/Plastic Seat
Part No. 287926/G15 Gun w/Carbide Seat
Ref.
No. Part No. Description Qty.
1 BODY, gun 1
1a 249423 STOP, trigger 1
2 288558 NEEDLE, assy; 3/32 ball; sst
includes item 2a (288844 only)
288559 NEEDLE, assy; 3/32 ball; carbide
includes item 2a (287926 only)
2a*✓ 110004 PACKING, o-ring; PTFE 1
3‡ TRIGGER, gun 1
4 249135 VALVE, fan, assy 1
5 249132 DIFFUSER, assy (288844 only) 1
249133 DIFFUSER, assy (287926 only) 1
5a DIFFUSER, housing 1
5b† 288619 GASKET, seat; nylon (287926 only) 1
5c† SEAT; plastic (288844 only) 1
SEAT; carbide (287926 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 15F192 RING, retaining 1
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 15F193 SHAFT, fluid spring 1
10 15F194 SEAT, 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 249136 TUBE, assy 1
17 15F202 FITTING, air inlet 1
18 15F186 FITTING, hose 1
19 119767 SPRING, compression (288844
only)
115141 SPRING, compression (287926
only)
20 119996 SCREW, cap, socket hd; 1/4-20 x
3/8 in. (10 mm)
21 249596 AIR CAP, includes item 21a 1
21a 15G618 PIN, air cap; indexing 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 Plastic Seat Repair Kit 249424 (purchase sep-
arately).
‡ Included in Trigger Repair Kit 249585 (purchase sepa-
rately).
◆ Included in Air Cap Seal Kit 253032 (purchase separately).
✓ Not for sale separately.
Part No. 249242/G40 Gun w/Standard Tip
Part No. 249246/G40 Gun, High Flow
Ref.
No. Part No. Description Qty.
1 BODY, gun 1
1a 249423 STOP, trigger 1
2 288559 NEEDLE, assy; 3/32 ball; carbide
1
2a*✓ 110004 PACKING, o-ring; PTFE 1
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 249256 TIP GUARD
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 15F193 SHAFT, fluid spring 1
10 15F194 SEAT, spring 1
11 15F195 CAP, spring 1
12 224453 FILTER, tip (pkg of 5) (249242 only) 1
13‡ 15F739 PIN, pivot 1
14‡ 15F740 PIN, pivot, nut 1
15 114069 SPRING, compression 1
16 249136 TUBE, assy (249242 only) 1
249317 TUBE, assy (249246 only) 1
17 15F202 FITTING, air inlet 1
18 15F186 FITTING, hose (249242 only) 1
19 115141 SPRING, compression 1
20 119996 SCREW, cap, socket hd; 1/4-20 x
1
21 249180 AIR CAP 1
1
22*✓ 115133 GASKET, tube, acetal 1
28* TOOL, installation; seal 1
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 sepa-
rately).
◆ Included in Air Cap Seal Kit 253032 (purchase separately).
✓ Not for sale separately.
includes item 2a
(249242 & 249246 only)
3/8 in. (10 mm) (249242 only)
1
1
1
311001F 27
Parts
Parts
Part No. 249238/G40 Gun w/RAC Tip
★6
★*6a
33
★35
33a
★5a
★*5f
2
★*5g
*22
★†5b
*2a
5c†★
5d†★
3‡
13‡
*7
★4
1a
14‡
17
*8
15
9
1
11
19
10
16
20
29
30
28*
TI7203B
28 311001F
Part No. 249238/G40 Gun w/RAC Tip
Ref.
No. Part No. Description Qty.
1 BODY, gun 1
1a 249423 STOP, trigger 1
2 288559 NEEDLE, assy; 3/32 ball; carbide
includes item 2a
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★ 288465 TIP GUARD/AIR CAP ASSY 1
6a*★✓ 109213 PACKING, o-ring, PTFE 1
7*✓ 188493 PACKING, u-cup; UHMWPE 1
8* VALVE, air, assy 1
9 15F193 SHAFT, fluid spring 1
10 15F194 SEAT, 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)
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 31,
includes item 33a
33a 246453 RAC GASKET, standard, black 1
248936 RAC GASKET, solvent resistant,
orange
35★ 15J770 HOUSING, cylinder 1
Parts
1
1
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 287917 (pur-
chase separately).
✓ Not for sale separately.
311001F 29
Spray Tip Selection Chart
Spray Tip Selection Chart
Spray Tips, for use with AA Series Air Cap
AAM Fine Finish Spray Tips
Recommended for high finish quality applications at low and medium pressures. Order desired tip
(Part No. AAMxxx) from matrix below.
GG4 Industrial Spray Tips
Recommended for high wear applications at high pressures. Order desired tip (Part No. GG4xxx) from matrix below.
• All tips in the Spray Tip Selection Chart below
can be used with Model G40 guns (249242).
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 (288844).
SKIN INJECTION HAZARD
Do not use tips in the gray shaded area of the Spray
Tip Selection Chart with Model G15 guns (288844).
Failure to follow this warning can result in serious
injury or amputation.
* Fluid Output, fl oz/min (lpm) Maximum Pattern Width at 12 in. (305 mm)
Orifice Size in.
(mm)
† 0.007 (0.178) 4.0 (0.1) 5.2 (0.15) ★107 207 307
† 0.009 (0.229) 7.0 (0.2) 9.1 (0.27) 109 209 309 409 509
† 0.011 (0.279) 10.0 (0.3) 13.0 (0.4) 111 211 311 411 511 611
0.013 (0.330) 13.0 (0.4) 16.9 (0.5) 213 313 413 513 613 713
0.015 (0.381) 17.0 (0.5) 22.0 (0.7) 215 315 415 515 615 715 815
0.017 (0.432) 22.0 (0.7) 28.5 (0.85) 217 317 417 517 617 717 817 917
0.019 (0.483) 28.0 (0.8) 36.3 (1.09) 219 319 419 519 619 719 819 919
0.021 (0.533) 35.0 (1.0) 45.4 (1.36) 321 421 521 621 721 821 921
‡ 0.023 (0.584) 40.0 (1.2) 51.9 (1.56) 423 523 623 723 923
‡ 0.025 (0.635) 50.0 (1.5) 64.8 (1.94) 425 625 725 825
‡ 0.027 (0.686) 58.5 (1.7) 75.8 (2.27) 527 627 827
‡ 0.029 (0.737) 68.0 (1.9) 88.2 (2.65) 629
‡ 0.031 (0.787) 78.0 (2.2) 101.1 (3.03) 431 631
‡ 0.033 (0.838) 88.0 (2.5) 114.1 (3.42) 633 ★833
‡ 0.035 (0.889) 98.0 (2.8) 127.1 (3.81) 435
‡ 0.037 (0.940) 108.0 (3.1) 140.0 (4.20) 737
‡ 0.039 (0.991) 118.0 (3.4) 153.0 (4.59) 539 639 839
at 600 psi
(4.1 MPa, 41 bar)
at 1000 psi
(7.0 MPa, 70 bar)
2 to 4
(100)
4 to 6
(150)
6 to 8
(200)
8 to 10
(250)
10 to 12
(300)
12 to 14
(350)
14 to 16
(400)
16 to 18
(450)
* Tips are tested in water.
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.
P
18 to 20
(500)
† These tip sizes include a 150 mesh tip filter.
‡ Do not use these tips with Model G15 guns (288844).
★ GG4 tips only.
30 311001F
RAC SwitchTips, for use with AA Series Air Cap
Spray Tip Selection Chart
All tips in the Spray Tip Selection Charts below can
be used with Model 249238 G40 guns equipped
with RAC air cap 288465.
Tips are sometimes packaged with other promotional parts intended for the airless market. Disregard extra parts.
LTX RAC Spray Tips
Order desired tip (Part No. LTXxxx) from matrix below.
* Fluid Output, fl oz/min (lpm) ❖ Maximum Pattern Width at 12 in. (305 mm)
Orifice Size in.
(mm)
0.009 (0.229) 11.2 (0.33) 209 309
0.011 (0.279) 16.6 (0.49) 211 311 411 511
0.013 (0.330) 23.3 (0.69) 213 313 413 513
0.015 (0.381) 30.8 (0.91) 215 315 415 515 615
0.017 (0.432) 39.5 (1.17) 217 317 417 517 617
0.019 (0.483) 49.7 (1.47) 219 319 419 519 619
0.021 (0.533) 60.5 (1.79) 321 421 521 621 721
0.023 (0.584) 72.7 (2.15) 423 523 623
0.025 (0.635) 85.9 (2.54) 525 625
0.027 (0.686) 100.0 (2.96) 527 627 827
0.029 (0.737) 115.6 (3.42) 629
0.031 (0.787) 131.8 (3.90) 531 631
0.033 (0.838) 149.4 (4.42)
0.035 (0.889) 535 635
at 2000 psi
(14.0 MPa, 140 bar)
2 to 4
(100)
4 to 6
(150)
6 to 8
(200)
8 to 10
(250)
10 to 12
(300)
12 to 14
(350)
14 to 16
(400)
16 to 18
(450)
18 to 20
(500)
* Tips are tested in water.
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.
P
❖ Measured with NO airflow. Air assist will tend to reduce pattern lengths by 1 in. to 2 in.
311001F 31
Spray Tip Selection Chart
RAC SwitchTips, for use with AA Series Air Cap Continued
• All tips in the Spray Tip Selection Charts below
can be used with Model 249238 G40 guns
equipped with RAC air cap 288465.
FFT Fine Finish RAC Spray Tips
Order desired tip (Part No. FFTxxx) from matrix below.
* Fluid Output, fl oz/min (lpm) ❖ Maximum Pattern Width at 12 in. (305 mm)
Orifice Size in.
(mm)
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
WRX WideRAC Spray Tips
at 2000 psi
(14.0 MPa, 140 bar)
4 to 6
(150)
6 to 8
(200)
8 to 10
(250)
10 to 12
(300)
12 to 14
(350)
Order desired tip (Part No. WRXxxx) from matrix below.
❖ Maximum
* Fluid Output,
fl oz/min (lpm)
Orifice Size in.
(mm)
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
at 2000 psi
(14.0 MPa, 140 bar)
Pattern Width at
12 in. (305 mm)
24 in.
(610)
* Tips are tested in water.
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.
P
❖ Measured with NO airflow. Air assist will tend to reduce pattern lengths by 1 in. to 2 in.
32 311001F
Accessories
Use Only Genuine Graco Parts and 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 115898
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 AA
Series G15 Spray Guns.
G40 Gun Flush Box Insert 15G346
Insert for use with Gun Flush Box 244105 and AA
Series 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 249140
Use to check air cap air pressure at various air supply
air pressures. Do not use for actual spraying.
Accessories
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 287917
Kit includes parts to convert a standard G40 gun
(249242) 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.
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 288844 only.
Carbide Seat Repair Kit 249456
Kit includes replacement carbide seat, seat gasket, and
seat nut for Model G40 gun. Kit can also be used with
Model G15 guns, but is not standard.
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.
To be HVLP compliant, the atomizing air pressure
must not exceed 10 psi (70 kPa, 0.7 bar).
311001F 33
Technical Data
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,
Flouroelastomer
* 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.
Air Flow, Standard AA Series Air Cap
12
Air Flow
(SCFM)
10
8
6
4
2
4.2
2.6
8.6
6.4
4.6
3.8
10.6
5.8
0
10 20
Gun Inlet Pressure (PSI)
Fan Valve Open Fan Valve Closed
34 311001F
30 400
50
Dimensions
(17.5 cm)
8.0 in.
(20.3 cm)
Dimensions
Model G15
6.9 in.
5.0 in. (12.7 cm)
8.0 in.
(20.3 cm)
TI6583A
6.1 in. (15.5 cm)
Model G40
6.9 in.
(17.5 cm)
5.8 in. (14.7 cm)
TI6845A
6.9 in. (17.5 cm)
311001F 35
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
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.
This manual contains English. MM 311001
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
Printed in USA 311001F
5/2007
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