Graco Inc 3A0149C Users Manual G15/G40 Spray Gun, Instructions/Parts, English
3A0149C Graco G15 G40 Manual 3A0149C
2015-02-09
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Instructions - Parts List G15/G40 Spray Gun 3A0149C ENG A lightweight line of air-assisted spray guns for spraying and finishing a variety of paints and coatings, particularly in applications requiring uniform atomization and high transfer efficiency. For professional use only. Important Safety Instructions: Read all warnings and instructions in this manual. Save these instructions. See page 2 for model information including maximum working pressure. Model G15 Model G40 TI6553A Model G40 w/RAC tip TI6844A TI7204B II 2 G Models Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush Before Using Equipment . . . . . . . . . . . . . . Select a Spray Tip and Air Cap . . . . . . . . . . . . . . Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 2 3 4 6 6 6 6 7 7 8 8 8 8 8 8 Reverse-A-Clean® (RAC) Tip . . . . . . . . . . . . . . . 9 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 . . . . . . . . . . . . . . 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 Models Part 24C853 A 100 (0.7, 7.0) Maximum Working Fluid Pressure psi (MPa, bar) Description 1500 (10.5, 105) G15 Medium Pressure Air-Assisted Spray Gun, Carbide Seat and Ball G15 Medium Pressure Air-Assisted Spray Gun, Plastic Seat, SST Ball Includes: 24C866 Air Cap with pin 24C854 A 100 (0.7, 7.0) 1500 (10.5, 105) 24C855 A 100 (0.7, 7.0) 4000 (28, 280) G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and Ball 4000 (28, 280) G40 High Pressure, High Flow Air-Assisted Spray Gun, Carbide Seat and Ball 249180 Air Cap without pin 4000 (28, 280) G40 High Pressure Air-Assisted Spray Gun, Carbide Seat and Ball, Reverse-A-Clean® (RAC) Tip 24C921 RAC Air Cap 24C856 24C857 2 Series Maximum Working Air Pressure psi (MPa, bar) A A 100 (0.7, 7.0) 100 (0.7, 7.0) 3A0149C Related Manuals Related Manuals This manual is available in the following languages: Manual Language 3A0149A English 3A0283A French 3A0282A Spanish 3A0442 Chinese 3A0443 Japanese 3A0444 Korean 3A0149C 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 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. 4 3A0149C 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 3A0149C 5 Installation Installation Grounding 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 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. • 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. E D A G C B TI6554A F FIG. 1: Typical Installation (Model G15 Shown) Key: A B C D E F G 6 Air Line Filter Air Shutoff Valve Gun Air Pressure Regulator Air Line Spray Gun Electrically Conductive Fluid Hose Gun Air Supply Hose 3A0149C Installation Air Line Fluid 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 FIG. 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 FIG. 2. Before connecting the fluid line, blow it out with air and flush it with solvent. See Flushing and Cleaning, 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 FIG. 4. If desired, install a fluid swivel connector (189018) at the gun inlet for best maneuverability. See Accessories, page 35. F G TI6846A TI6556A FIG. 2 FIG. 4 6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See FIG. 3. 3. Connect the other end of the fluid hose (F) to the pump fluid outlet. B G C A TI4838A FIG. 3 3A0149C 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. Slot Horizontal air cap position (standard) 2. Relieve the pressure. See Pressure Relief Procedure, page 10. Vertical air cap position Tip locating tab Select a Spray Tip FIG. 5 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. Install a Spray Tip 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 FIG. 5. When relocating the pin use low-strength thread locker. Torque to 1.5-2.5 in-lb (0.2-0.3 N•m). DO NOT OVERTIGHTEN. TI6847A Install a spray tip in the air cap. Ensure that the tip locating tab is positioned in the slot of the air cap. See FIG. 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 FIG. 6. For the G15 air cap, the alignment pin will stop the rotation in the proper orientation. The air cap alignment pin can be removed according to preference. Air cap alignment pins will not work with model G40 guns. NOTICE The alignment pin and retaining ring for current model guns are different from the earlier model guns. They are not interchangeable. Use of the incorrect pin will result in fluid leakage or loss of the alignment feature. Use of the wrong retaining ring will damage retaining ring and gun threads. See Part Interchangeability Guide, page 37. 8 TI6558A FIG. 6 Tighten the air cap retaining ring (6) firmly by hand to ensure a good seal between the tip gasket and the diffuser (5). 3A0149C Setup Reverse-A-Clean® (RAC) Tip Assembly Model 24C857 guns use a Reverse-A-Clean® (RAC) tip. Screw the RAC tip assembly onto the gun and tighten firmly by hand. To assemble the RAC tip, insert the seat housing into the air cap assembly. TI7199A TI7196A FIG. 10 FIG. 7 Insert the SwitchTip. 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. TI7197A FIG. 8 Insert the gasket seat. TI7198A FIG. 9 3A0149C 9 Operation Operation Be sure to read and follow the Warnings on pages 4 and 5 and throughout the text of this instruction manual. Keep the wallet sized warning card (222385), provided with the gun, with the operator of this equipment at all times. The card contains important treatment information should a skin injection injury occur. Additional cards are available at no charge from Graco. Pressure Relief Procedure TI6555A 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. 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 FIG. 12. 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. 1. Engage the trigger lock. See FIG. 12. 2. Shut off the pump. See your pump manual. Trigger Lock 3. Shut off the gun air supply. Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped. 4. Disengage the trigger lock. See FIG. 12. 5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. See FIG. 11. ENGAGED DISENGAGED TI6581A TI6582A FIG. 12 10 3A0149C 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. 4. Close off the pattern adjustment air by turning the knob clockwise (in) all the way. See FIG. 13. This sets the gun for its widest pattern. CLOSE OPEN 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. TI6559A 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 FIG. 14. Seven to 10 psi (4.9 to 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 FIG. 13. If 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.) 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 x Pump Air Regulator Ratio Setting = Fluid Pressure 2. Trigger the gun to check the atomization; do not be concerned about the pattern shape yet. TI0792A no air too little air correct amount of air FIG. 14 3. Slowly increase the fluid pressure, just to the point where a further increase in fluid pressure does not significantly improve fluid atomization. 3A0149C 11 Operation HVLP Operation NOTE: For HVLP operation, the atomization air must not exceed 10 psi. Use HVLP Verification Kit 24C788 to verify air psi. NOTE: There is no fan adjustment when using RAC tips and caps. 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. 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 FIG. 15. TI6561A INCORRECT TI6562A CORRECT FIG. 15 12 3A0149C Daily Gun Care, Flushing, and Cleaning 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. TI6563A Do not immerse the gun in solvent. TI6564A 3A0149C 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. TI6565A 13 Daily Gun Care, Flushing, and Cleaning General System Maintenance Flushing and Cleaning 1. Relieve the pressure, page 10. NOTE: 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 • • • 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. 1. Unscrew the fluid inlet fitting (18). 2. Remove the air cap retaining ring (6), air cap (21), and spray tip (33). Soak the spray tip in a compatible solvent. 2. Remove and inspect the inline fluid filter (12). Clean or replace the filter as necessary. 3. Disconnect the fluid supply hose (F) and air supply hose (G) from the gun. G F TI6566A 18 TI6567A FIG. 17 4. Connect the solvent supply hose (T) to the gun. 12 TI6735A FIG. 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 interchangeable. Use of an incorrect fitting will damage the threads. T TI6566A FIG. 18 14 3A0149C Daily Gun Care, Flushing, and Cleaning 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. 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. TI4845A TI6729A FIG. 19 FIG. 21 11. With the gun pointed down, clean the front of the gun, using the soft-bristle brush and solvent. 6. Turn off the solvent supply. 7. Relieve the pressure. 8. Disconnect the solvent supply hose (T) from the gun. TI6569A FIG. 22 T TI6730A FIG. 20 NOTICE 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. 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). 3A0149C 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) A B TI6570A FIG. 23 C 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. TI6553A FIG. 26 14. Install the air cap retaining ring (6), air cap (21), and spray tip (33). Reverse-A-Clean® (RAC) Tip 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. TI6568A FIG. 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. TI6581A ENGAGED FIG. 27 TI6571A FIG. 25 16 3A0149C Daily Gun Care, Flushing, and Cleaning Engage the trigger lock. Rotate the SwitchTip. TI6581A ENGAGED TI7200A FIG. 31 FIG. 28 Return the SwitchTip to its original position. Disengage the trigger lock. TI7201A DISENGAGED TI6580A FIG. 29 Trigger the gun into a pail to clear the clog. FIG. 32 Disengage the trigger lock and continue spraying. Do not point gun at anyone or at any part of the body. TI6582A DISENGAGED FIG. 33 TI7202A FIG. 30 3A0149C 17 Troubleshooting Troubleshooting NOTE: • • Problem 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. Cause Solution Fluid leakage from back of fluid packing area. Worn packings or needle shaft. Replace needle assembly (2). 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). 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. Install plastic seat (5c). Spray tip seal leaking. Tighten retaining ring (6) or replace spray tip (33). Leaking around seat housing. Replace the gasket (5b, carbide models only). The gasket must be replaced whenever the seat assembly is removed. Fluid inlet fitting leaking. Replace the fluid tube gasket (22). The gasket must be replaced whenever the fluid tube connector is removed. Slow fluid shut-off. Fluid buildup on fluid needle components. Remove and clean or replace the fluid needle assembly (2). No fluid output when triggered. Spray tip plugged. Clean spray tip. See page 14. Fluid filter or fluid hose plugged. After tip removal (see above), very slowly loosen the hose end coupling at the gun and relieve pressure gradually. Then loosen completely to clear the obstruction. Clean or replace filter (12). Fluid in air passages. 18 3A0149C Troubleshooting Problem Fluttering or spitting spray. Cause Solution Insufficient fluid supply. Adjust fluid regulator or fill fluid supply tank. Air in paint supply line. Check, tighten pump siphon hose connections, 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 spray tip partially plugged. Clean or replace spray tip. See page 14. On defective side of pattern, air horn holes are partially or totally plugged. Clean air horn holes with solvent and soft brush. See page 14. 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. 3A0149C 19 Repair Repair Complete Gun Packing Repair Disassembly Repair Kits Seat Repair NOTE: 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. 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 FIG. 35. 6 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 FIG. 34. 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). 1 33 21 TI6568A 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). 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. 4 C 1 1 A Torque to 90 in-lb (10.5 N•m). 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. TI6576A FIG. 34 20 3A0149C Repair 7. Reinstall the seat gasket (5b, carbide models only), 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. 13‡ 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. 3‡ 1 14‡ FIG. 37 5g* 5c 5a 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 FIG. 38. 5e* 5d 5f* TI6574A 5b (carbide only) 1 30 29 TI6572A 2a* FIG. 36 2 Needle Repair TI6575A 1. Remove the diffuser, see Seat Repair, page 20. FIG. 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 FIG. 37. 3A0149C 21 Repair Air Valve Repair Fluid Tube Replacement 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). 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. Push the air valve assembly (8*) out the back of the gun. See FIG. 39. 2. Unscrew the fluid inlet fitting (18). Remove and clean or replace the inline fluid filter (12). 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. 3. Unscrew the fluid tube connector (C) from the gun’s fluid inlet. Carefully remove the gasket (22*). 7* 15 8* 1 11 22* 19 17 C 9 20 18 TI6577B FIG. 39 12 TI6573A FIG. 40 22 3A0149C Repair 3A0149C 23 Repair 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 FIG. 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 FIG. 42. 1 29 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 FIG. 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 FIG. 41. Push the u-cup into the back of the gun until you feel a definite snap. 8 3 3 Lubricate lightly. 8 Lips face out of gun body. 7* 28* TI6578A 2a* 2† TI6575A 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 FIG. 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). 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. FIG. 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 FIG. 43. 11. Attach the retaining ring (6), air cap (21), and spray tip (33). 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). 24 3A0149C Repair 6 6 4 12 21a (G15 only) 6 5b✖ (carbide only) 5c†✖ *5g 5d†✖ 11 *5f 5a *5e 15 *6a (G40 only) *6a 33 6 (G40 only) 11 4 21 *7 *6b 3 8 10 *8 13 3 *2a 19 3 7 6 (G15 only) 3 9 2 9 *22 1a 1 1 3 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 210-220 in-lb (24-25 N•m). 11 Torque to 45-50 in-lb (5-6 N•m). 3 18 12 Use low-strength thread locker. 13 (24C853, 24C854, and 24C855) 13 Torque to 175-185 in-lb (20-21 N•m). 14 5 17 10 16 (24C856 & 24C857) 12 12 (24C853, 24C854, and 24C855) 9 20 16 (24C853, 24C854 and 24C855 only) TI6579D FIG. 43 3A0149C 25 Parts Parts Part No. 24C853 and 24C854, G15 Gun Part No. 24C855, G40 Gun Part No. 24C856, G40 Gun, High Flow 5b✖ (carbide only) *5g 5c†✖ 5d†✖ *5f 5a 21a (G15 only) *6a (G40 only) *5e 15 ◆*6a 6 (G40 only) ◆*6b 33 4 21 *7 *8 13‡ 11 19 *2a 9 6 (G15 only) 2 *22 1a 3‡ 1 14‡ 17 12 (24C853, 24C854, and 24C855 only) 16 (24C856 only) 20 16 (24C853, 24C854, and 24C855 only) 29 30 28* 18 (24C853, 24C854, and 24C855 only) TI6579D 26 3A0149C Parts Part No. 24C854, G15 Gun with Plastic Seat Part No. 24C853, G15 Gun with Carbide Seat Ref. No. 1 1a 2 Part No. Description Qty. BODY, gun 1 249423 STOP, trigger 1 24B790 NEEDLE, assy; 3/32 ball; sst 1 includes items 2a (24C854 only) and 9 24B789 NEEDLE, assy; 3/32 ball; carbide 1 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 1 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 1 6b 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 1 for fitting with JIC threads 3A0149C Ref. No. 19 20 21 21a 22*✓ 28* 29 30 31▲ 32▲ 33 33a Part No. Description Qty. 119767 SPRING, compression (24C854 1 only) 115141 SPRING, compression (24C853 1 only) 119996 SCREW, cap, socket hd; 1/4-20 x 1 3/8 in. (10 mm) 24C866 AIR CAP, includes item 21a 1 24D627 PIN, air cap; indexing 1 (package of 3) 115133 GASKET, tube, acetal 1 TOOL, installation; seal 1 117642 TOOL, nut driver 1 15F446 TOOL, gun 1 222385 CARD, warning (not shown) 1 172479 TAG, warning (not shown) 1 SPRAY TIP, customer’s choice 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 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. 27 Parts Part No. 24C855, G40 Gun with Standard Tip Part No. 24C856, G40 Gun, High Flow Ref. No. 1 1a 2 Part No. Description Qty. BODY, gun 1 249423 STOP, trigger 1 24B789 NEEDLE, assy; 3/32 ball; carbide 1 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 1 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 1 only) 13‡ 15F739 PIN, pivot 1 14‡ 15F740 PIN, pivot, nut 1 15 114069 SPRING, compression 1 16 24D436 TUBE, assy, includes item 22 1 (24C855 only) 249317 TUBE, assy (24C856 only) 1 17 15F202 FITTING, air inlet 1 28 Ref. No. 18 19 20 21 22*✓ 28* 29 30 31▲ 32▲ 33 33a Part No. Description Qty. 24D437 FITTING, hose (24C855 only); 1 see Accessories for fitting with JIC threads. 115141 SPRING, compression 1 119996 SCREW, cap, socket hd; 1/4-20 x 1 3/8 in. (10 mm) (24C855 only) 249180 AIR CAP 1 115133 GASKET, tube, acetal 1 TOOL, installation; seal 1 117642 TOOL, nut driver 1 15F446 TOOL, gun 1 222385 CARD, warning (not shown) 1 172479 TAG, warning (not shown) 1 SPRAY TIP, customer’s choice 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. 3A0149C Parts 3A0149C 29 Parts Part No. 24C857, G40 Gun with RAC Tip ★✖5b 5c✖★ ★*5g 5d✖★ ★*5f 15 11 ★4 ★5a *8 *7 13‡ ★35 33a ★*6a 19 ★6 *2a 9 2 1a 1 33 *22 3‡ 14‡ 17 16 TI7203B 20 29 30 28* TI6580A 30 3A0149C Parts Part No. 24C857, G40 Gun with RAC Tip Ref. No. Part No. 1 1a 249423 2 24B789 2a*✓ 3‡ 4★ 5★ 5a★ 5b✖★ 5c✖★ 5d✖★ 5e*★✓ 5f*★✓ 5g*★✓ 6★ 6a*★✓ 7*✓ 8* 9 11 13‡ 14‡ 15 16 17 19 20 3A0149C 110004 15G713 249877 288619 111116 109450 111457 24C921 109213 188493 16A529 15F195 15F739 15F740 114069 249317 15F202 115141 119996 Description Qty. BODY, gun 1 STOP, trigger 1 NEEDLE, assy; 3/32 ball; carbide 1 includes items 2a and 9 PACKING, o-ring; PTFE 1 TRIGGER, gun 1 NUT, air plug 1 DIFFUSER, assy, RAC 1 DIFFUSER, housing 1 GASKET, seat; nylon 1 SEAT; carbide 1 NUT, seat 1 PACKING, o-ring, seat; PTFE 1 PACKING, o-ring; PTFE 1 PACKING, o-ring; PTFE 1 TIP GUARD/AIR CAP ASSY, 1 includes item 35 PACKING, o-ring, PTFE 1 PACKING, u-cup; UHMWPE 1 VALVE, air, assy 1 SHAFT, fluid spring 1 CAP, spring 1 PIN, pivot 1 PIN, pivot, nut 1 SPRING, compression 1 TUBE, assy 1 FITTING, air inlet 1 SPRING, compression 1 SCREW, cap, socket hd; 1/4-20 x 1 3/8 in. (10 mm) Ref. No. Part No. 22*✓ 115133 28* 29 117642 30 15F446 31▲ 222385 32▲ 172479 33 33a 35★ Description Qty. GASKET, tube, acetal 1 TOOL, installation; seal 1 TOOL, nut driver 1 TOOL, gun 1 CARD, warning (not shown) 1 TAG, warning (not shown) 1 SPRAY TIP, customer’s choice, 1 see tip selection chart page 32, includes item 33a 246453 RAC GASKET, standard, black 1 248936 RAC GASKET, solvent resistant, orange 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 (purchase separately). ★ Parts included in RAC Conversion Kit 24C791 (purchase separately). ✓ Not for sale separately. 31 Spray Tip Selection Chart 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. • * Fluid Output fl oz/min (lpm) 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. Maximum Pattern Width at 12 in. (305 mm) in. (mm) Orifice Size in. (mm) at 600 psi (4.1 MPa, 41 bar) at 1000 psi (7.0 MPa, 70 bar) 2 to 4 4 to 6 6 to 8 8 to 10 10 to 12 12 to 14 14 to 16 16 to 18 18 to 20 (100) (150) (200) (250) (300) (350) (400) (450) (500) † 0.007 (0.178) † 0.009 (0.229) † 0.011 (0.279) 0.013 (0.330) 0.015 (0.381) 0.017 (0.432) 0.019 (0.483) 0.021 (0.533) ‡ 0.023 (0.584) ‡ 0.025 (0.635) ‡ 0.027 (0.686) ‡ 0.029 (0.737) ‡ 0.031 (0.787) ‡ 0.033 (0.838) ‡ 0.035 (0.889) ‡ 0.037 (0.940) ‡ 0.039 (0.991) 4.0 (0.1) 7.0 (0.2) 9.5 (0.28) 12.0 (0.35) 16.0 (0.47) 20.0 (0.59) 28.0 (0.8) 35.0 (1.0) 40.0 (1.2) 50.0 (1.5) 58.5 (1.7) 68.0 (1.9) 78.0 (2.2) 88.0 (2.5) 98.0 (2.8) 108.0 (3.1) 118.0 (3.4) 5.2 (0.15) 9.1 (0.27) 12.5 (0.37) 16.0 (0.47) 21.0 (0.62) 26.5 (0.78) 36.3 (1.09) 45.4 (1.36) 51.9 (1.56) 64.8 (1.94) 75.8 (2.27) 88.2 (2.65) 101.1 (3.03) 114.1 (3.42) 127.1 (3.81) 140.0 (4.20) 153.0 (4.59) ★107 207 109 209 111 211 213 215 217 219 * Spray Tip 307 309 311 313 315 317 319 321 409 411 413 415 417 419 421 423 425 509 511 513 515 517 519 521 523 527 431 ❄711 713 715 717 719 721 723 725 815 817 819 821 825 827 917 919 921 923 ★925 ★833 435 737 539 639 839 Tips are tested in water. Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) P where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size. † These tip sizes include a 150 mesh tip filter. ★ GG4 tips only. ‡ Do not use these tips with Model G15 guns. ❄ AAM tips only. 32 611 613 615 617 619 621 623 625 627 629 631 633 3A0149C Spray Tip Selection Chart 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) 0.011 (0.279) 0.013 (0.330) 0.015 (0.381) 0.017 (0.432) * Maximum Pattern Width at 12 in. (305 mm) in. (mm) at 600 psi at 1000 psi (4.1 MPa, 41 bar) (7.0 MPa, 70 bar) 9.5 (0.28) 12.0 (0.35) 16.0 (0.47) 20.0 (0.59) 12.5 (0.37) 16.0 (0.47) 21.0 (0.62) 26.5 (0.78) 6 to 8 (200) 8 to 10 (250) 310 312 410 412 414 416 10 to 12 (300) 12 to 14 (350) Spray Tip 510 512 514 516 610 612 614 616 Tips are tested in water. Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) P where QT = fluid output (fl oz/min) at 600 psi from the above table for the selected orifice size. 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. NOTE: 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, where xxx = 3-digit number from matrix below. ❖ Maximum Pattern Width at 12 in. (305 mm) in. (mm) * Fluid Output, 2 to 4 4 to 6 6 to 8 8 to 10 10 to 12 12 to 14 at 2000 psi (100) (150) (200) (250) (300) (350) Orifice Size in. (14.0 MPa, 140 bar) (mm) fl oz/min (lpm) Spray Tip 0.009 (0.229) 0.011 (0.279) 0.013 (0.330) 0.015 (0.381) 0.017 (0.432) 0.019 (0.483) 0.021 (0.533) 0.023 (0.584) 0.025 (0.635) 0.027 (0.686) 0.029 (0.737) 0.031 (0.787) 0.033 (0.838) 0.035 (0.889) * 11.2 (0.33) 16.6 (0.49) 23.3 (0.69) 30.8 (0.91) 39.5 (1.17) 49.7 (1.47) 60.5 (1.79) 72.7 (2.15) 85.9 (2.54) 100.0 (2.96) 115.6 (3.42) 131.8 (3.90) 149.4 (4.42) 168.4 (4.98) 109 111 115 209 211 213 215 217 219 221 231 309 311 313 315 317 319 321 323 325 327 329 331 235 335 225 227 409 411 413 415 417 419 421 423 425 427 429 431 433 435 509 511 513 515 517 519 521 523 525 527 529 531 533 535 611 613 615 617 619 621 623 625 627 629 631 633 635 14 to 16 16 to 18 18 to 20 (400) (450) (500) 721 723 817 819 821 827 729 735 831 833 835 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. 3A0149C 33 Spray Tip Selection Chart 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) * Fluid Output at Orifice Size in. 2000 psi (14.0 MPa, 140 bar) (mm) fl oz/min (lpm) 0.008 (0.203) 0.010 (0.254) 0.012 (0.305) 0.014 (0.356) 8.8 (0.26) 13.9 (0.41) 19.9 (0.59) 27.0 (0.80) 4 to 6 (150) 6 to 8 (200) 208 210 212 214 308 310 312 314 8 to 10 (250) 10 to 12 (300) 12 to 14 (350) 510 512 514 612 614 Spray Tip 410 412 414 WRX WideRAC Spray Tips Order desired tip, Part No. WRxxxx, where xxxx = 4-digit number from matrix below. Orifice Size in. (mm) 0.021 (0.533) 0.023 (0.584) 0.025 (0.635) 0.027 (0.686) 0.029 (0.737) 0.031 (0.787) 0.033 (0.838) 0.035 (0.889) 0.037 (0.940) 0.039 (0.991) * * Fluid Output at 2000 psi (14.0 MPa, 140 bar) fl oz/min (lpm) 60.5 (1.79) 72.7 (2.15) 85.9 (2.54) 100.0 (2.96) 115.6 (3.42) 131.8 (3.90) 149.4 (4.42) 168.3 (4.98) 187.9 (5.56) 208.9 (6.18) ❖ Maximum Pattern Width at 12 in. (305 mm) 24 in. (610 mm) Spray Tip 1221 1223 1225 1227 1229 1231 1233 1235 1237 1239 Tips are tested in water. Fluid output (Q) at other pressures (P) can be calculated by this formula: Q = (0.041) (QT) P where QT = fluid output (fl oz/min) from the above table for the selected orifice size. ❖ Measured with NO airflow. Air assist will tend to reduce pattern lengths by 1 in. to 2 in. 34 3A0149C Accessories 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. Gun Lubricant 111265 One 4 oz. (113 g) tube sanitary (non-silicone) lubricant for fluid seals and wear areas. 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. 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. Air Line Quick Disconnect 208536 Air Line Quick Disconnect Coupling 169967 Air Line Quick Disconnect Pin HVLP Verification Kit 24C788 Use to check air cap air pressure at various air supply air pressures. Do not use for actual spraying. 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. NOTE: To be HVLP compliant, the atomizing air pressure must not exceed 10 psi (70 kPa, 0.7 bar). 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. 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. G40 Gun Flush Box Insert 15G346 Insert for use with Gun Flush Box 244105 and G40 Spray Guns. 3A0149C 35 Accessories Plastic Seat Repair Kit 249424 Kit includes replacement plastic seat (pack of 10), and seat nut for Model G15 gun. Trigger Repair Kit 249585 Kit includes replacement trigger, pivot pins (qty. of 5), and pivot pin nuts (qty. of 5). 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. Trigger Stop Kit 249423 Kit includes replacement trigger stop and pin. 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. Unclogging Needle Kit 249598 Kit includes picks for unclogging gun tip. 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. 36 Ultimate Gun Cleaning Kit 15C161 Kit includes brushes and tools for gun maintenance. 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. 3A0149C Accessories Part Interchangeability Guide Description Part Number New Models Part Number, (24Cxxx) Older Models* 16A529 Interchangeable? 24D627 15F193 15F194 15G618 G15 retaining ring kit Includes retaining ring, PTFE o-ring, and PTFE washer 24D438 15F192 Yes 16A529 combines the fluid spring shaft and seat into a single part. Directly replaceable. No New pin is shorter to match the new gun body. 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. No See note below table. G40 retaining ring/tip guard kit Includes retaining ring with guard, PTFE o-ring, and PTFE washer 24D439 249256 No See note below table 15F442 15J770 No Works properly only with RAC Tip Guard/Air Cap Assembly 24C921 and is included in that kit. Seat will fit into older model assemblies, but spray performance may be affected. AA RAC guard kit Includes guard assembly (with retaining ring) and mating cylinder housing. 24C921 288465 No See note below table. Needle, carbide ball, G15 and G40 24B789 288559 Yes Directly replaceable. Needle, stainless steel ball, G15 24B790 288558 Yes Directly replaceable. HVLP verification kit 24C788 249140 No 24C791 287917 No 24C866 249596 24D436 249136 Fluid fitting, standard threads 24D437 15F186 Fluid fitting, JIC threads 24C356 NA Fluid spring shaft Locating pin RAC seat housing RAC gun conversion kit G15 air cap Fluid tube assembly See note below table. Can only be used on the new gun due to a different RAC guard. See note below table. No Uses new shorter locating pin. See note for Locating pin, this table. Yes The new fluid tube assembly will fit an older gun only if a new fluid fitting is purchased, 24D437 (standard threads) or 24C356 (JIC threads). No New fluid fittings have different threads that fit only the new fluid tube assembly (24D436). Any No 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. 3A0149C 37 Dimensions Dimensions Model G15 6.9 in. (17.5 cm) 8.0 in. (20.3 cm) 5.0 in. (12.7 cm) TI6583A 6.1 in. (15.5 cm) Model G40 6.9 in. (17.5 cm) 8.0 in. (20.3 cm) 5.8 in. (14.7 cm) 6.9 in. (17.5 cm) 38 TI6845A 3A0149C 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 . . . . . . . . . . . . . . . 110°F (43°C) 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 Polyethylene, Engineered Plastic, PTFE, Nylon, Fluoroelastomer * 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 Air Cap 12 10 10.6 8 Air Flow (SCFM) 8.6 6 6.4 5.8 4 4.2 4.6 3.8 2 0 2.6 0 10 20 30 40 50 Gun Inlet Pressure (PSI) Fan Valve Open 3A0149C Fan Valve Closed 39 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. 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 Copyright 2009, Graco Inc. is registered to ISO 9001 www.graco.com Revised 05/2010
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