Spray Tip Selection Guide: RAC Tip Codes, Orifice Size, and Fan Width

The spray tip is the most job-specific component of an airless sprayer setup. The wrong tip produces runs and drips (oversized orifice), dry spray and poor film build (undersized orifice), uneven application (wrong fan width for the spray distance), or excess overspray and waste (fan too wide). Understanding the tip code system allows you to select the correct tip for any coating and application type — and to recognise when a tip is worn out and needs replacement.

How the RAC Tip Code System Works

Graco's RAC (Reversible-A-Tip Cleaning) tip system, also used in equivalent form by Titan (TRU-Tip), encodes the fan width and orifice size in a three-digit number printed on the tip.

The code format: XYZ

• X (first digit): Half the fan width in inches. Multiply by 2 to get the actual fan width.
• YZ (last two digits): The orifice diameter in thousandths of an inch.

Example: 517

• First digit: 5 × 2 = 10-inch fan width
• Last two digits: 0.017-inch orifice

Example: 411

• First digit: 4 × 2 = 8-inch fan width
• Last two digits: 0.011-inch orifice

Example: 623

• First digit: 6 × 2 = 12-inch fan width
• Last two digits: 0.023-inch orifice

This system is consistent across all Graco RAC X, SwitchTip, and Titan TRU-Tip products. The actual fan width at the surface depends on spray distance — the fan width in the tip code is calibrated at 12 inches (30 cm) from the surface.

Orifice Size by Material

The orifice size determines flow rate — the volume of material delivered per minute at a given pressure. Heavier, thicker materials require a larger orifice to achieve adequate flow at reasonable pressure. Fine finishing materials require a smaller orifice to avoid excessive flow and runs.

Starting point: When in doubt, start with the smaller orifice in the range. You can always increase the orifice if the material is not flowing adequately. A tip that is too large wastes material through excessive flow and runs.

Fan Width Selection

Fan width is selected based on the width of the surface being sprayed and the spray distance.

Practical guideline:

• For wall and ceiling spray (standard room painting): 12" fan (codes 6XX) at 12" from the surface
• For fascia boards, trim, and narrow surfaces: 6"–8" fan (codes 3XX–4XX)
• For doors and cabinets (fine finish): 8"–10" fan (codes 4XX–5XX)
• For heavy-build floor coatings and wide surfaces: 12"–16" fan (codes 6XX–8XX)

Fan width vs spray distance: The fan widens as you move the gun further from the surface. At 18" distance, a 10" tip produces a roughly 15" fan — the relationship is approximately proportional. Increasing spray distance reduces film build per pass and can produce dry spray (material that atomises but partially dries before hitting the surface). Maintaining a consistent 10–12" spray distance is the standard for most architectural applications.

Overspray and fan width: A wider fan creates more overspray in the tail area (the edges of the fan pattern). On exterior work where overspray drift is a concern, reducing fan width and slowing the gun speed reduces overspray at the expense of production speed.

Standard Tip Selection by Job Type

Reversible Tips and Clearing Clogs

A RAC tip is reversible — rotating it 180° in the guard shifts the orifice to point backward. In the reverse position, spraying at full pressure forces material backward through the tip, clearing most clogs.

Clearing procedure:

1. Turn the tip to the reverse (clear) position — the arrow or "R" marking should face toward the operator.
2. Point the gun at a waste surface, not at the work area — the material that clears will be unatomised and will hit the surface in a blob.
3. Pull the trigger briefly at full pressure.
4. Return the tip to the forward position and resume spraying.

If reversing does not clear the clog, the obstruction is likely in the tip filter (the small mesh screen inside the tip guard) or the fluid filter. Relieve pressure, remove the tip and guard, and clean both filters.

Tip Wear and Replacement

Spray tips wear — the carbide orifice enlarges over time from material flow, particularly with abrasive coatings (elastomeric, textured materials, materials with heavy filler). A worn tip wastes material, reduces production quality, and costs money.

Signs of tip wear:

• Fan pattern becomes "tailed" — a heavier band appears at each edge of the fan instead of a uniform ellipse
• Higher pressure required to maintain the same spray quality
• Increased material consumption with no change in coverage area
• The spray pattern appears "stringy" at the tails

Orifice wear gauge: Some manufacturers provide a tip wear gauge. Alternatively, compare the orifice against the specification — an orifice that has worn from 0.015" to 0.018" delivers 44% more material per minute at the same pressure.

Replacement interval: A carbide tip lasts 40–100 gallons of material (depending on material abrasiveness). Track tip use and replace when the spray pattern degrades. New tips are inexpensive relative to the material waste and quality loss from a worn tip.

Tip Guard Safety

The tip guard protects the operator's hand from the high-pressure spray jet. Airless injection injuries — paint forced through the skin into tissue — are caused by contact with the jet from an unguarded tip or the side of a guarded tip. These injuries require immediate surgical treatment.

Rules:

• Never operate an airless sprayer without the tip guard in place
• Never place any body part in front of the tip during operation or when the gun is pressurised
• Always engage the gun safety latch when not actively spraying — a pressurised gun with a unlatched trigger is a risk in storage and transit
• Relieve system pressure completely before removing or replacing the tip

For airless sprayer pump maintenance, flushing, and troubleshooting, see our airless sprayer maintenance guide. For spray equipment selection (airless vs HVLP vs AAA), see our pro sprayer guide.

ProPainterTools allows you to record the tip code used for each coating on each project — building a reference for future jobs with the same material type and surface.

Frequently Asked Questions

Can I use a Graco RAC tip on a Titan gun and vice versa? Graco RAC tips and Titan TRU-Tips use the same thread size (7/8"-14 UNF) and are physically interchangeable. The tip code system is the same. However, the tip guard for each brand is specific — use the guard supplied with your gun, as the guard geometry differs and using the wrong guard can create a gap that exposes the spray jet.

What causes streaks or lines in the spray pattern? Streaks typically indicate a partial clog in the orifice. Reverse the tip to clear. If the streaks persist after clearing, the tip may have a nick or chip in the orifice edge — replace the tip.

Why does my fan pattern go oval instead of staying as a flat ellipse? If the fan pattern rotates from a horizontal ellipse to a vertical one (or vice versa), the tip orifice is partially clogged on one side. Reverse and clear the tip. If the oval shape persists, the tip orifice is worn asymmetrically and needs replacement.

What does "RAC X" or "RAC 5" mean? These are Graco's tip generations. RAC X is the current generation — a two-piece tip and guard design. RAC 5 is the previous generation. They use the same tip code system and the same thread, but the guards are not interchangeable between generations. The tip codes work exactly the same way regardless of generation.