AGXV-541 LVMP
AUTOMATIC SPRAY GUNS OPERATION MANUAL
Important：Read and follow all instructions and SAFETY PRECAUTIONS before using this equipment.
Retain for future reference.

DESCRIPTION
The AGXV-541 LVMP gun has been developed to provide high transfer efficiency. Compared to theconventional guns, it offers high atomization and high transfer efficiency with far less air consumption. LVMP
stands for Low Volume Medium Pressure, meaning Low Volume (Low Air Consumption) Medium Pressure(air atomization pressure is medium pressure).
This automatic gun is designed for mass production line or precision coatings that cannot be achieved withmanual guns, and to be used with an automatic system or a quasi-automatic system. Models andapplications are as follows.

MODEL
Example

AGXV

-

541

- 80□

-

□□□
Fluid Tip : DFW(1.6mm)，DFX(1.1mm)，FX(1.1mm)
GD(0.7mm)，G(0.7mm)

Basic part number
Air Caps:805,807，805MT

This gun may be used with chlorinated solvents. Aluminum is not used in fluid passages. If using chlorinatedsolvents, make sure all other fluid handling components are also compatible.
Chart 1
Air Cap
Marking

Part No.

Fluid Tip Size(mm)

Pattern Size
Shape

Typical Applications

805

AV-1239-805

DFW (1.6)
DFX (1.1)
GD (0.7)220mm (DFX),
Taper pattern

Most conventional materials
Waterborne & chlorinated solvents

807

AV-1239-807

DFW (1.6)
DFX (1.1)
GD (0.7)300mm (DFX),
Straight pattern

Most conventional materials
Waterborne & chlorinated solvents

807MT

AV-1239-805MT

FX (1.1)
G (0.7)180mm (FX),
Taper pattern

Most conventional materials
Waterborne & chlorinated solvents

Chart 2Air Cap
805，807

805MT

Tip Marking (mm)Part Number (Tip & Needle Lapped Set)

DFW (1.6)

AGX-4300-DFW

DFX (1.1)

AGX-4300-DFX

GD (0.7)

AGX-4300-GD

FX(1.1)

AGX-4300-FX

G (0.7)

AGX-4300-G－ 1 －SAFETY PRECAUTIONSThis manual contains important information that ALL users should know and understand BEFORE using thisequipment. This information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS.
To help you recognize this information, we use the following terms to draw your attention to certain
equipment labels and portions of this manual. Pay special attention to any label or information that is
highlighted by one of these terms:

WARNINGCAUTION
NOTE

Important information to alert you to a situation that might cause serious injury or loss of life if
instructions are not followed.
Important information that tells how to prevent damage to equipment.
Information that you should pay special attention to.

WARNING

The following hazards may occur during the normal use of this equipment. Please read the following
chart.
HAZARD

CAUSE
Solvents and coatings can behighly flammable or
combustible, especially whensprayed.

Inhaling Toxic
Substance

Certain materials may be
harmful if inhaled or if there iscontact with the skin.

Explosion Hazard –Incompatible
Materials

Halogenated hydrocarbon
Solvents- for example:
methylene chloride and1,1,1,-Trichloroethane are notchemically compatible with thealuminum that might be used inmany system components. The
chemical reaction caused bythese solvents reacting withaluminum can become violent
and lead to an equipment
explosion.
Improper operation or
maintenance may create ahazard.

Fire

General Safety

SAFEGUARDS
1. Adequate exhaust must be provided to keep the
air free of accumulations of flammable vapors.
2. Smoking must never be allowed in the sprayarea.
3. Fire extinguishing equipment must be present in
the spray area.
4. Static discharges must be prevented. Ground(earth) all conductive objects in the spray area,such as a cleaning solvent bucket, fire
extinguisher, etc.
5. When using solvents for cleaning:・Those used for equipment flushing must havea flash point equal to or greater than that of thecoating.
・Those used for general cleaning must haveflash points above 100°F (37.8°C).
1. Follow the requirements of the Material Safety
Data Sheet supplied by coating material
manufacturer.
2. Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
3. Use a mask or respirator whenever there is achance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
The AGXV spray gun can be used with thesesolvents.
However, aluminum is widely used in other spray
application equipment – such as material pumps,
cups, regulators, valves, etc. Check all otherequipment items before use of these solvents.
Read the label or data sheet for the material you
intend to spray. If in doubt as to where or not a
coating or cleaning material is compatible, contact
your material supplier.
Operators should be given adequate training in thesafe use and maintenance of the equipment (inaccordance with the requirements of NFPA-33,
Chapter 15 in U.S.). Users must comply with all
local and national codes of practice and insurancecompany requirements governing ventilation, fire
precautions, operation, maintenance andhousekeeping (in the U.S., these are OSHA
Sections 1910.94 and 1910.107 and NFPA-33).

－ 2 －HAZARD
Noise Levels – Ear
InjurySpraying solvent

CAUSE
A continuous A-weighted
sound pressure level of thisspray gun (spray pistol) may
exceed 85 dB(A) depending on
the air cap/ fluid head setup
being used.
Sound levels are measured
using an impulse sound level
meter and analyzer, when the
gun is being used in a normal
spraying application.
During cleaning and flushing,solvents can be forcefully
expelled from fluid and air
passages.
Some solvents can cause eye
injury.

SAFEGUARDS
Always wear ear protection when using the gun.
Details of actual noise levels produced by thevarious air cap / fluid head setups are available
upon request.

Wear eye protection.

Misuse:・All spray guns project particles at high velocity and must never be aimed t any part of body.
・Never exceed the recommended safe working pressure for any of the equipment used.
・The fitting of non-recommended or non-original accessories or spare parts may create hazardous
conditions.
・Before dismantling the equipment for cleaning or maintenance, all pressures, air and material, must be
isolated and released.
The disposal of waste materials must be carried out in an approved manner. Burning may generate toxic
fumes. The removal or waste solvents and coating materials should be carried out by an authorized local
waste disposal service.

SPECIFICATIONS
Maximum Inlet Pressure
Maximum Fluid Pressure
Cylinder Air Pressure
WeightMounting Stud Diameter
Hose Connections

0.69MPa (100 psi)
0.69MPa (100 psi)
Min. 0.34MPa (50 psi)
Max. 0.69MPa (100 psi)
without mounting stud 738g
with mounting stud 865g
3/4" (19 mm)- Fluid Inlet 3/8" NPS(M)- Cylinder Air 1/4" NPS(M)- Atomization Air 1/4" NPS(M)Note
For installations where 0.34MPa (50psi) cylinder air is not available, the inner (red) piston spring
can be removed which lowers the minimum cylinder air to approximately 0.26MPa (37psi).

－ 3 －INSTALLATIONFIGURE 1 DIMENSIONSFIGURE 2 TYPICAL INSTALLATION
Trigger/
Cylinder Air

Atomization Air

HFRL-511
Filter-Regulator

Fluid
Atomization Air

Reciculating Port

Trigger/
Cylinder Air

3 Way Hand Valve

Automatic Valve

Skip Spray Valve

Mount the gun with the stud (13) or on a 5/16"(7.9mm) dia. rod tightening adequately with the 1/4-28 X 1/4"
set screws (Ref. No. 24). See "ACCESSORIES" for mounting clamps.
Note
The air supplied to the gun should be clean air that removed any impurities. Also, the air hose shouldhave enough inner diameter depending on the length to supply necessary air. As CYL air is notconsumption air, large diameter of the tube is not necessary. When circulating the paint, remove theplug (6) and install the fluid nipple (9).

OPERATION
1.Mix, prepare and strain the coating material to be sprayed according to paint manufacturer’s instructions.
2.Turn on cylinder air at source of supply. Supply air should be a minimum of 0.34MPa (3.5 bar). For
consistent operation the pressure should be regulated. If 0.35MPa cylinder air pressure is not available,
the red inner spring (31) can be removed. This allows a minimum cylinder pressure of approximately
0.26MPa.
Note
If red inner spring (31) is removed, atomization pressure should not exceed 0.48MPa (will result in
gun not shutting off).
3.Turn needle adjustment knob (25) counterclockwise several turns. With the cylinder air on, turn theadjustment knob (25) clockwise until it contacts piston (19) (for maximum fluid flow). Back knob out 1/2
turn.

－ 4 －

Note
Due to close part tolerances, actuate gun on and off 7 or 8 times to "break-in" the packings. Do thiswith material supply off.
4.Adjust atomization air pressure to 0.2MPa (2 bar) or less. Always attempt to keep pressure as low as
possible to minimize overspray. The fluid pressure should be between 0.07MPa to 0.1MPa (0.7 to 1.0 bar).
5.Open hand valve and/or trip automatic valve if installed in system and observe spray pattern. Adjust air andfluid pressures until desired pattern is obtained. Control fluid pressure at source of supply. If desired
regulation is not practical at this point, restrict flow by turning adjustment knob (25) clockwise.
6.The width of the spray pattern is controlled by the adjusting valve (23) marked “FAN”. With the “FAN” valve
screwed fully clockwise, the spreader air will be closed off causing a round pattern. By gradually opening
this valve, the pattern changes to a fan spray. The width is determined by the amount the valve is opened.
Atomization air is adjusted by regulating the supply air to the gun. Adjustments to fan may be controlled
remotely by using the optional KK-4955 fan control adapter to replace the AGG-403 control valve (23). A
separate solenoid valve is required to control on/off function.
FIGURE 3 AIR CIRCUIT EXAMPLE WITH OPTIONAL KK-4955 REMOTE FAN CONTROLPREVENTIVE MAINTENANCEWARNING
Risk of Injury. Equipment and fluid may be under pressure.
Pressure in the system must be relieved before beginning the cleaning procedure and before
replacing any parts. Follow the procedures in the service literature provided with the system.

CLEANING
1.Relieve air pressure from pressure tank. Carefully follow instructions in the service bulletin sent with tank.
2.Replace material in container with a suitable solvent.
3.Re-pressurize system.
4.Trigger the gun and repeat the procedure until the gun and hose are thoroughly clean (solvent is clean
when it looks the same as when you first opened solvent container). A SolventSaver™ type hose and gun
cleaner which supplies a mixture of air and solvent can be used to most effectively clean the gun and hoseinternal passages. See "Accessories" on page 13. Wipe the exterior of the gun with a solvent dampened
cloth.
5.If a recirculating system is used, it may be necessary to fit a shut off valve in the return line to ensure thefluid tip and forward portion of the sprayhead passage are properly cleaned when flushed with solvent.
CAUTION
Do not totally submerge the gun in solvent. It is possible to wash solids into the air operating
sections of the gun which could damage piston "O" ring seals.
CAUTION
The air cap can be immersed in solvent for cleaning. If the orifices are clogged, use a broom straw or
toothpick to remove the obstruction. Never use a steel wire or hard instrument. This will damage theair cap and result in a distorted spray pattern.

－ 5 －REPLACEMENTPARTS REPLACEMENT• Adjustable Wrench or "C" Spanner• 1/2" Box Wrench or 1/2" Socket Spanner (Ref. 3)• 9/16" Open Wrench (Ref. 9) or 9/16" spanner• Long Neck Pliers (19) or long nose grips• Hex Wrench 1/8" for (Ref. 24)• Hex Wrench 3/16" for (Ref. 7)
Fluid needle (28) , Tip (3) and Needle Packings (11)
1. Relieve all air and fluid pressure in the system.
2. Remove retaining ring (1) & air cap (2).
3. Remove fluid tip (3).
CAUTION
To avoid serious gun damage, do not remove the fluid tip (nozzle) (3) from the spray gun (spray
piston) when the fluid inlet adapter (6 or 9) is removed. Doing so may allow the stainless steel
insert to break free from the aluminum body, which is non-repairable.
4. It is recommended that both the fluid tip (nozzle) (3) and the needle (28) be replaced at the same time.
The needle packings (11) should also be replaced when replacing the needle.
5. Remove adjusting knob (25), locknut(26) and needle spring(27).
6. Remove needle (28) with pliers.
7. Loosen four screws (7) and remove sprayhead (8).
8. Remove needle packings (11) and seal spring(12).
9. Slide onto the new needle (28), in this order, 1 packing (11), spring (12) and 1 packing (11). Be sure toorient the packings as shown (Figure 5).
10. Assemble sprayhead (8) with retaining screws (7).
11. Tighten screws (7) with a 3/16 hexagon key 30-40 in. lbs. (3.4 - 4.5 N-m) until the body is flush withsprayhead assembly.
12. Reassemble in reverse order.
Piston (19) , O-Rings (17 & 18) and Air Packing (20)
1. Remove the piston housing (29) by removing rear retaining screws (7).
2. Remove fluid needle (28).
3. Remove springs (30, 31 & 27) and piston (19). Care must be taken when removing the piston (19). Usea locking long nose pliers to extract the piston by clamping on the inner ring on the back of the piston.
4. Remove the air packing (20), "O" rings (17 & 18).
5. Wipe clean the bore of the cylinder. Replace the piston "O" rings (17 & 18) and lightly lubricate withclean petroleum jelly. See "LUBRICATION" section which follows.
6. To replace air packing (20) (inside of the piston), slide packing (20) over the needle (28) with thelead-in chamfer towards the fluid tip (nozzle) end of the needle. Insert the needle into the piston (19).
Hold the piston in your hand so that the tip end of the needle is protruding downward (protect theneedle from damage). Lightly tap the blunt end of the needle to drive the packing down into the piston.
The needle will stop inside the piston at a shoulder.
7. Fit complete assembly into gun.
8. Lubricate the outside of springs (30) and (31) (see "LUBRICATION" section), then re-install springs andpiston housing (29) and tighten down and torque mounting screws (7) 30-40 in. lbs. (3.4 to 4.5 N-m).
9. Lubricate the adjustment knob threads (25) after cleaning with SSL-10 Gun Lube. Loosen the locking
nut (26) before screwing the adjustment knob in.

－ 6 －Plug (6) or Fluid Insert (9)WARNING
Halogenated Hydrocarbon solvents can chemically react with aluminum. A risk of explosion or
severe corrosion will occur. The following assembly step must be carefully performed.
If replacing AGX-415 inlet fitting, or if it should loosen, follow the assembly procedures below, and refer toFigure 4.
1. If installing a used fitting (9), clean paint and thread sealant from the fitting threads and gun body.
2. Screw the jam nut all the way onto the fitting. Then apply a medium strength thread sealant (i.e. Loctite
242 blue, or equal) to the first few threads of the fitting (9).
3. Install the AGX-415 fitting (9) into the spray gun and tighten to a maximum of 12 ft. lbs. (16.3 N-m)
torque. (Do not overtighten, damage may occur.)
4. Tighten the jam nut to 16 ft. lbs. (21.7 N-m) torque using a thin 9/16" open end wrench.
Figure 4

LUBRICATION
The piston O-rings (17 and 18) must be lubricated when the piston (19) is removed. Lightly lubricate withclean petroleum jelly. Do not use silicone-based lubricants. Petroleum jelly is effective as a lubricant up to
approximately 110°F (43°C). Above 110°F (43°C), petroleum jelly will become "liquid" and will not lubricate
the O-rings adequately. If the ambient temperature adjacent to the spray gun exceeds 110°F (43°C), use
Parker O-Lube or suitable high temperature grease. This allows the spray gun to be used in temperatures up
to 150°F (65° C) continuous without lubrication degradation.
Lubricate the outside of the larger piston spring (30 and 31) and needle spring (27) with a light coating of
non-silicone grease.
Note
Due to close part tolerances, after repairing the gun, actuate the gun on and off 7 or 8 times to"break-in" the air packing (20). Do this with the material supply off.

－ 7 －Figure 5 GUN ASSEMBLY

Item No.

Replacement Part No.

Description

Ind. Parts Req’d.

1

MBC-368

Retaining Ring

1

2

See Chart 1

Air Cap

1

3

See Chart 2

Fluid Tip (nozzle)

1

4

AV-1-K5

Gasket1

5

AGHV-403

Baffle16AGX-6-K3

Fluid Outlet Plug (Kit of 3)

1

7

SSF-3156-K4

Mounting Screw (Kit of 4)

8

8

AGXV-400

Sprayhead Assembly19AGX-415
AGX-5-1/4

Inlet Fitting and Jam Nut G3/8
Inlet Fitting and Jam Nut G1/4

1
1 (optional)

10

---

"O" Ring, Buna-N

2

11

AGX-7-K10

Needle Packing (Kit of 10)

2

－ 8 －

Item No.
12

Replacement Part No.

Description

Ind. Parts Req’d.

---

Seal Spring

1

13

KK-4995

Gun Mounting Stud Kit(Includes items21, 22 & 24)

1

14

---

Body

1 (unsold good)15

PA-H-2008

Nipple G1/4 x 1/4 NPT

1

16

PA-H-1766

Nipple G1/4 x 1/8 NPT

1

17

---

O-Ring1

18---

O-Ring

1

19

AGX-9

Piston1

20---

Air Packing

1

21

---

Hex Head Cap Screw, 5/16-18 x 2-1/4

22

---

5/16 Lockwasher

23

AGG-403

Air Valve Assembly - Horn

1

24

---

1/4-28 x 1/4" Large Knurled
cup point set screw

2 (Commercial
products)

25

AGX-2-K3

Adjustment Knob (Kit of 3)12634215-122

Locknut

1

27

---

Needle Spring

1

28

See Chart 2

Fluid Needle Assembly129AGX-10

Piston Housing

1

30

---

Outer Piston Spring

1

31

---

Inner Piston Spring132

KK-5017

Abrasive Fluid Seal Kit (optional, includes
1
3 seals and 1 brass collar)*

Abrasive Fluid Seal (U.H.M.W. Poly.)
Torque Specifications
Ref. No.
Inch or Ft. Lbs.
3
20-25 ft. lbs.
730-40 in. lbs.
6,9
12 ft. lbs.
21
220 in. lbs.
24
30 in. lbs.

－ 9 －1 (Commercial
products)
1 (Commercial
products)

1N•m
27.0 - 24.0
3.4 - 4.5
16.3
21.5 - 24.9
3.4

SERVICE CHECKNormal spray pattern
The proper combination of fluid pressure, fan and atomization air pressure, and fluid tip size should
result in a pattern of this shape.
Proper gun adjustment will result in normal spray patterns, from round with the fan control valve (23)closed, to long and narrow with the valve open. Pattern width depends upon how much the valve is
opened, the type of air cap used and fluid flow rate.

ProblemWill not spray.

Cause
No pressure to gun.
Piston stops moving.
New air packing (20)Correction
Check air and material lines.
Check tightness of mounting screw (7).
Remove fluid needle (28) and lubricate
with petroleum jelly and reassemble.
A.
Gun not adjusted properly.
A.
Re-adjust. See “Operation Section”.
A, B. Material build up on the air cap A, B. Clean the air cap or fluid tip. Seeor fluid tip.
“Preventive Maintenance”.
Note
To determine where the material build up is, rotate the air cap 180°and test
spray. If the pattern stays in the same position, the condition is caused bymaterial build up on the fluid tip. If the pattern changes with air cap movement,
the buildup is in the air cap.
C, D. Wrong material or material too C, D. Adjust material pressure or thin
thick.
material.
D.
Insufficient material or atomizing D.
Increase material or reduce
air pressure too high.
atomizing air pressure.
1. Insufficient material in the tank or an 1. Fill tank or clear obstruction.
obstruction in the line.
2. Clean.
2. Gun material passage plugged.
3. Replace.
3. Worn packings (11).
4. Tighten or replace.
4. Loose or damaged Fluid Tip (3).
1. Needle packings (11) worn.
1. Replace.
2. Rough or worn fluid needle shaft
2. Replace tip (3) & needle (28).
(28).
1. Contamination (i.e. dried paint) in
1. Clean.
seating area of tip (3).
2. Worn or damaged fluid tip (3) or
2. Replace.
needle (28).
3. Piston springs (30) and/or (31)
3. Replace.
damaged or deformed.
Worn seals.
Replace valve. (23).

Improper spraypattern.

Jerky or fluttering spray

Fluid leaking fromneedle Needle
packings (11).
Dripping from Fluid
Tip (3).

Air Leakage fromControl Valve (23)ACCESSORIESPart No.
SSL-1042884-214-K5
KK-4955J
KK-5033-805
KK-5033-807
KK-5033-805MT
AGA-415
GC-100-K48
HD-505
QMGZ-5200

Gun Lube (60cc)
Cleaning Brush Kit of 5
Adapter for Pattern Control
Air Cap Test Kit (for AV-1239-805)
Air Cap Test Kit (for AV-1239-807)
Air Cap Test Kit (for AV-1239-805MT)
Universal Clamp (19Φ)
Gun Cover Kit of 48
Quick Cleaner (5)Solvent Saver (10)Description

DIVISION

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©2017 Carlisle Fluid Technologies.

2017-09-AGXV-LVMP－ 10 －