Instructions
Manual Electrostatic
PRO™ Xs Waterborne
Air Spray Gun
For use with conductive spray materials (waterborne and other materials
less than 1 megohm-cm). For professional use ONLY.
For use in Class I, Div. I hazardous locations using Group D spray materials.
#53
For use in Group II, Zone 1 areas using Group IIA spray materials.
II 2 G EEx 0.24 mJ
312900G
EN
247936 Standard Model
247937 Smart Model
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
Important Safety Instructions:
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
Smart Model
247937
Standard Model
247936
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How the Electrostatic Air Spray Gun Works . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11
Connect the Charging Probe . . . . . . . . . . . . . . 11
Connect the Exhaust Tube . . . . . . . . . . . . . . . . 12
Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 12
Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check Electrical Grounding . . . . . . . . . . . . . . . . 15
Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 16
Prepare to Paint . . . . . . . . . . . . . . . . . . . . . . . . 16
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . 22
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Test Total Gun Resistance . . . . . . . . . . . . . . . . 23
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 23
Test Charging Probe Resistance . . . . . . . . . . . . 23
Test Power Supply Resistance . . . . . . . . . . . . . 24
Test Barrel Resistance . . . . . . . . . . . . . . . . . . . 24
Spray Pattern Troubleshooting . . . . . . . . . . . . . . . 25
Gun Operation Troubleshooting . . . . . . . . . . . . . . 26
Gun Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prepare the Gun for Repair . . . . . . . . . . . . . . . . 27
Replace Air Cap/Nozzle . . . . . . . . . . . . . . . . . . 28
Replace Fluid Needle . . . . . . . . . . . . . . . . . . . . 28
Remove Fluid Packing . . . . . . . . . . . . . . . . . . . . 29
Repair Packing Rod . . . . . . . . . . . . . . . . . . . . . . 30
Remove Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove and Replace Power Supply . . . . . . . . . 32
Remove and Replace Turbine Alternator . . . . . . 33
Repair Fan Air Adjustment Valve . . . . . . . . . . . . 33
Repair Fluid Adjustment Valve . . . . . . . . . . . . . 34
Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove and Replace Atomizing Air
Restrictor Valve . . . . . . . . . . . . . . . . . . . . . . 35
Repair ES ON/OFF Valve . . . . . . . . . . . . . . . . . 35
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 41
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 41
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 42
Miscellaneous Accessories . . . . . . . . . . . . . . . . 42
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 312900G
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
WARNINGWARNINGWARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire
and explosion:
• Electrostatic equipment must be used only by trained, qualified personnel who understand the require-
ments of this manual.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See
Grounding instructions.
• Only use grounded Graco conductive air supply hoses.
• Check gun and hose resistance and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Interlock the gun air supply to prevent operation unless ventilating fans are on.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment. To com-
ply with EN50050 requirements, cleaning solvents must have a flash point at least 5°C above ambient
temperature.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until
you identify and correct the problem.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off air supply before servicing equipment.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
• Do not touch gun electrode when electrostatics are on.
• Do not expose to rain. Store indoors.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
312900G 3
Warnings
WARNING
WARNINGWARNINGWARNING
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 com-
ponent. See Technical Data in all equipment manuals.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and
follow the Pressure Relief Procedure in this manual when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-
turer’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.
• Always wear impervious gloves when spraying or cleaning equipment.
• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocya-
nate Conditions Section of this manual.
4 312900G
Overview
KEY
How the Electrostatic Air Spray Gun Works
Overview
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge to supply high voltage current to the gun’s external charging probe.
A Air swivel inlet page 6
B Fluid inlet page 6
C Turbine air exhaust page 6
D Air cap and nozzle page 6
E Fluid needle page 6
F Fluid adjustment page 7
G Fan air adjustment valve page 7
H Atomizing air restrictor valve page 7
I ES ON/OFF switch page 7
J ES indicator (247936 only) page 8
K Voltage/current display (247937 only) page 8
L ES HI/LO switch (247937 only) page 8
M LO voltage adjustment (247937 only) page 8
N External charging probe
The pump supplies fluid to the hose and gun, where the
fluid is atomized by the air cap and the atomized particles are electrostatically charged as they pass the
external charging probe. The charged fluid is attracted
to the grounded workpiece, wrapping around and
evenly coating all surfaces. The external charging
allows the fluid supply to remain grounded at all times
and therefore eliminate the need for an isolation system.
J
MAX FLUID WPR:
100 PSI (7bar, 0.7 Mpa)
MAX AIR WPR:
I
100 PSI (7bar, 0.7 Mpa)
To avoid shock or explosion
•Use properly grounded air hose
•Read instruction manual
I O
ES
F
G
N
Smart Model
247937
Standard Model
247936
ti12581
K
M
L
H
I
0
HI
LO
ES
I O
100
KV
Ma
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
%
F
G
E
D
A
ti12658
Smart Model
247937
ti12582
BC
312900G 5
Overview
A. Air swivel inlet. Left-hand thread.
B. Fluid inlet.
ti1254a
A
C. Turbine air exhaust.
D. Air cap and nozzle. See page 13 for sizes.
E. Fluid needle. Shuts off fluid flow and provides a
ground point.
B
C
E
ti1254a
ti1254a
ti1255a
D
ti1256a
6 312900G
F. Fluid adjustment valve. Adjusts fluid needle travel.
Use only in low flow conditions, to reduce needle
wear.
G. Fan air adjustment valve. Adjusts fan size and
shape.
0
LO
ES
I O
0
LO
ES
I O
KV
Ma
MAX FLUID
WPR: 100 PSI
HI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
KV
Ma
HI
ES
100
%
100
%
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
Overview
F
G
H. Atomizing air restrictor valve. Restricts atomizing
air flow. Replace with plug (included) if desired.
I. ES ON/OFF switch. Turns electrostatics ON (I) or
OFF (0).
ES
I O
H
100
%
0
KV
I
HI
LO
ES
I O
Ma
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
ti1257a
312900G 7
Overview
J. ES indicator (247936 only). Green when ES is ON
(I).
MAX FLUID WPR:
100 PSI (7bar, 0.7 Mpa)
MAX AIR WPR:
100 PSI (7bar, 0.7 Mpa)
To avoid shock or explosion
•Use properly grounded air hose
•Read instruction manual
I O
ES
J
ti12581
K. Voltage (247937 only). Shows voltage and
current.
Green/yellow=spray,
red=see Electrical Troubleshooting, page 22.
NOTE: Normal current draw for this model is higher
and the yellow current bar will be lit.
L. ES HI/LO switch (247937 only). Sets voltage to HI
or LO (factory settings).
Voltage
Current
L
LO
I O
0
HI
LO
ES
I O
0
KV
Ma
HI
ES
ES
KV
Ma
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
100
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
100
%
K
%
ti12582
ti12582
M. LO voltage adjustment (247937 only). Remove
plug to adjust to 4 settings.
8 312900G
0
LO
ES
I O
KV
Ma
HI
ES
100
%
MAX FLUID
WPR: 100 PSI
(7bar, 0.7 Mpa)
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
M
ti12582
Installation
Installation
Install the System
Installing and servicing this equipment requires
access to parts which may cause electric shock or
other serious injury if work is not performed properly.
• Do not install or service this equipment unless you
are trained and qualified.
• Be sure your installation complies with National,
State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D or a
Group II, Category 2G Hazardous Location.
• Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
FIG. 1. shows a typical electrostatic air spray system. It
is not an actual system design. For assistance in
designing a system to suit your particular needs, contact
your Graco distributor.
Warning Sign
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
Warning Sign is provided with the gun.
Ventilate the Spray Booth
Provide fresh air ventilation to avoid the buildup of
flammable or toxic vapors when spraying, flushing,
or cleaning the gun. Do not operate the gun unless
ventilation fans are operating.
Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans
operating. Check and follow all National, State, and
Local codes regarding air exhaust velocity requirements.
High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of
100 ft/min (31 linear meters/minute) should be sufficient.
312900G 9
Installation
a
c‡d
‡e
g
h
f
Fig. 1. Typical Installation
m
c‡
j‡
l
v
ES ON/OFF valve:
I is ON, O is OFF
ti12721
s
b‡
o
g
‡r
w
p
k
n
u‡
q‡
t
ti1498ax
Key
a Main Air Supply Line
b‡ Ventilation Fan Interlock Solenoid Valve
c‡ Main Air Supply Shutoff Valve (bleed-type)
d Pump Air Line Filter/Water Separator
e‡ Pump Air Supply Shutoff Valve (bleed-type)
f Air Line Lubricator
g Air Pressure Regulator
hPump
j‡ Pump Ground Wire
k Fluid Filter
l Fluid Supply Line Shutoff Valve
m Fluid Pressure Regulator
n Fluid Supply Line
o Gun Air Line Filter/Water Separator
p Gun Air Supply Line Shutoff Valve (bleed-type)
q‡ Air Hose Ground Wire
r‡ Graco Grounded Air Hose
s Electrostatic Air Spray Gun
t Air Line Drain Valve
u‡ Fluid Drain Valve
vGun Air Inlet
w Gun Fluid Inlet
‡ These items are required for proper operation
and must be purchased separately.
NOTE: Solenoid valve (b) is not offered as a
Graco accessory.
10 312900G
Installation
Connect the Air Line
To reduce the risk of electric shock or other serious
injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco
Grounded Air Supply Hose.
1. Connect the Graco Grounded Air Supply Hose (R)
between the air supply line and the gun's air inlet (V)
(F
IG. 2). The gun air inlet fitting has a left-hand
thread. Connect the air supply hose ground wire (Q)
to a true earth ground.
V
Q
To air supply
5. Install an air shutoff valve (P) on each gun air supply
line to shut off air to the gun(s).
Connect the Charging Probe
1. Apply dielectric grease to probe socket.
Probe
Socket
ti12722
FIG. 3
2. Press electrode on in Connect/Disconnect position
shown in F
3. Rotate electrode to spray position.
IG. 4.
Connect the Charging Electrode
R
ti1259
F
ti1259a
IG. 2
2. Install an air line filter/water separator (O) 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 and can cause the gun to
malfunction.
3. Install a bleed-type air regulator (G) on the pump
and gun air supply lines to control air pressure to the
pump and gun.
4. Install a bleed-type air valve (E) on the pump air line
to shut off air to the pump. Install an additional
bleed-type air valve (C) on the main air line (A) to
isolate the accessories for servicing.
The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the
pump after the air regulator is shut off. Trapped air
can cause the pump to cycle unexpectedly, which
can result in serious injury, including splashing fluid
in the eyes or on the skin.
Connect/Disconnect
Position
F
IG. 4
Spray
Position
NOTICE
The external charging probe rotates easily. Do not
press too hard when rotating it or it could be damaged.
NOTICE
For proper performance, do not operate electrostatics if the charging probe is not in spray position.
ti1933a
312900G 11
Installation
Connect the Exhaust Tube
Press the exhaust tube (38) onto the barbed adapter on
the bottom of the gun handle. Secure the tube with the
clamp (39) (F
IG. 5).
Barbed adapter
W
N
38
39
ti1275a
IG. 5
F
Connect the Fluid Line
1. Before connecting the fluid line (N), blow it out with
air and flush it with solvent. Use solvent compatible
with the fluid to be sprayed.
2. Install a fluid regulator (M) on the fluid line to control
fluid pressure to the gun.
3. Install a fluid filter (K) and drain valve (U) at the
pump outlet.
ti1277
F
ti1277a
IG. 6
5. Before running any paint through the spray gun,
flush it with a compatible solvent.
Filter the Fluid
Install a fluid filter (K) to remove particles and sediment
that could clog the spray nozzle.
The fluid drain valve (U) is required in your system to
assist in relieving fluid pressure in the displacement
pump, hose, and gun. Triggering the gun to relieve
pressure may not be sufficient. Install a drain valve
close to the pump's fluid outlet. The drain valve
reduces the risk of serious injury, including splashing
in the eyes or on the skin.
4. Connect the fluid line to the 3/8 npsm gun fluid inlet
(W) (F
IG. 6).
12 312900G
Installation
Select a Fluid Nozzle and Air Cap
The gun is supplied with Part No. 197266 Nozzle and
24A276 Air Cap. If you require a different size, refer to
Table 1 and Table 2 , and instruction manual 309419, or
consult with your Graco distributor. See Replace Air
Cap/Nozzle on page 28.
A wide pattern kit (P/N 24A431) is included with the gun
and if installed, will provide more fan air for wider spray
patterns. (If pattern becomes split, use the fan air valve
to reduce the amount of fan air.)
To reduce the risk of an injury, follow the Pressure
Relief procedure on page 19 before removing or
installing a fluid nozzle and/or air cap.
NOTE: Due to the larger needle diameter, use a nozzle
one size larger than you would use with a standard Pro
Xs gun (i.e., 1.5 mm = 1.2 mm flow area).
Table 1: Fluid Nozzles
Part No. Orifice Size
197265 1.2 mm (.047 in.)
197266 1.5 mm (.055 in.)
197267 1.8 mm (.070 in.)
249922* 1.2 mm (.047 in.)
249923* 1.5 mm (.055 in.)
249924* 1.8 mm (.070 in.)
* Glass-reinforced acetal construction.
Table 2: Air Caps
Pattern Shape
Part No.
24A438
24A279
24A276*
24A274
24A439
24A275
*Also available in the following colors:
24A376 - gray
24A277 - red
24A278 - green
and Length in.
(mm)
Round end;
15-17 (381-432)
Round end;
14-16 (356-406)
Tapered end;
17-19 (432-483)
Tapered end;
12-14 (305-356)
Round end;
11-13 (279-330)
Tapered end;
14-16 (356-406)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Medium to high viscosity and
high solids.
Up to 15 oz/min (450 cc/min)
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Medium to high viscosity and
high solids.
Up to 15 oz/min (450 cc/min)
For use with 2.0 mm nozzle.
Light to medium viscosity and
high solids.
Aerospace coatings.
Up to 25 oz/min (750 cc/min).
312900G 13
Installation
Grounding
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any ungrounded
objects in the spray area (people, containers, tools,
etc.) can become electrically charged. Improper
grounding can result in static sparking, which can
cause a fire, explosion, or electric shock. Follow the
grounding instructions below.
The following are minimum grounding requirements for
a basic electrostatic system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions. Your system must be connected to a true
earth ground.
• Pump: ground the pump by connecting a ground
wire and clamp as described in your separate pump
instruction manual.
• All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are necessary, wear the conductive gloves
that are supplied with the gun. If non-Graco gloves
are worn, cut off fingers or palm area of gloves to
ensure your hand contacts the grounded gun handle.
• Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
• The floor of the spray area: must be electrically con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
• Electrostatic Air Spray Gun: ground the gun by con-
necting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground.
See Check Electrical Grounding, page 15.
ti1259a
• Air compressors: ground the equipment according
to the manufacturer's recommendations.
• All air and fluid lines must be properly grounded.
Use only grounded hoses with a maximum of 100
feet (30.5 m) combined hose length to ensure
grounding continuity.
• Flammable liquids in the spray area: must be kept in
approved, grounded containers. Do not use plastic
containers. Do not store more than the quantity
needed for one shift.
• All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.
14 312900G
Check Electrical Grounding
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see F
approved for use in a hazardous area. To reduce the
risk of sparking, do not use the megohmmeter to
check electrical grounding unless:
• The gun has been removed from the hazardous
area;
• Or all spraying devices in the hazardous area are
turned off, ventilation fans in the hazardous area are
operating, and there are no flammable vapors in the
area (such as open solvent containers or fumes
from spraying).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury
and property damage.
IG. 7.) is not
Installation
BB
AA
CC
ti1274a
Fig. 7. Check Gun Grounding
Check Fluid Resistivity
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
2. Turn the ES ON/OFF valve OFF.
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
4. Make sure the grounded air hose (R) is connected
and the hose ground wire is connected to a true
earth ground.
ti1259a
5. Measure the resistance between the gun handle
(BB) and a true earth ground (CC). Use an applied
voltage of 500 minimum to 1000 volts maximum.
The resistance should not exceed 1 megohm. See
F
IG. 7.
Fire, Explosion, and Electric Shock Hazard
Check the fluid resistivity in a non-hazardous area
only. Resistance Meter 722886 and Probe 722860 are
not approved for use in a hazardous area.
Failure to follow this warning could cause fire, explosion, or electric shock and result in serious injury and
property damage.
Graco Part No. 722886 Resistance Meter and 722860
Probe are available as accessories to check that the
resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.
Follow the instructions included with the meter and
probe. If the material is above 1 megohm-cm, then a Pro
Xs3 HC gun may be a better option. The Pro Xs WB gun
is intended to spray very conductive waterborne materials and other materials less than 1 megohm-cm.
6. If the resistance is greater than 1 megohm, check
the tightness of the ground connections and be sure
the air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
312900G 15
Installation
Check Fluid Viscosity
To check fluid viscosity you will need:
• a viscosity cup
• a stopwatch.
1. Completely submerge the viscosity cup in the fluid.
Lift the cup out quickly, starting the stopwatch as
soon as the cup is completely removed.
2. Watch the stream of fluid coming from the bottom of
the cup. As soon as there is a break in the stream,
shut off the stopwatch.
3. Record the fluid type, elapsed time, and size of the
viscosity cup.
4. If the viscosity is too high or too low, contact the
material supplier. Adjust as necessary.
Prepare to Paint
1. Position air cap.
4. Fully open atomizing air restrictor valve.
ti1272a
5. Check that ES ON/OFF switch is OFF (O).
LO
ES
MAX AIR
WPR: 100 PSI
NOTE: This illustration
shows the switch in the
(7bar, 0.7 Mpa)
ES
I O
ON (I) position to view
I and O indicators.
ti12723
6. Start pump. Adjust fluid regulator until stream from
gun travels 8-12 in. (200-300 mm) before falling off.
Typically, if fluid pressure is below 5 psi (.04 MPa,
0.4 bar) or above 20 psi (0.14 MPa, 1.4 bar), a
change of nozzle size is recommended.
2. Fully open fan air adjustment valve.
3. Fully open fluid adjustment valve.
To avoid shock or explosion
•Use properly grounded air hose
•Read instruction manual
I O
To avoid shock or explosion
•Use properly grounded air hose
•Read instruction manual
ES
I O
ES
8-12 in.
(200-300 mm)
ti12684
16 312900G
Installation
a
7. Set gun air regulator to deliver minimum 40 psi (0.28
MPa, 2.8 bar) at gun when triggered, for maximum
transfer efficiency. See table at right.
TI1281A
Air Hose* Length
ft (m)
Regulator Setting**
psi (MPa, bar)
15 (4.6) 50 (0.35, 3.5)
25 (7.6) 60 (0.42, 4.2)
50 (15.3) 75 (0.52, 5.2)
* 5/16 in. (8 mm) diameter/8 mm (5/16 in.)
**Gun triggered
8. Spray test pattern. Check atomization. If over-atomization occurs at minimum pressure, adjust restrictor
valve. If atomization is inadequate, increase air
pressure.
10. Turn ES ON/OFF switch ON (I).
MAX FLUID
WPR: 100 PSI
HI
(7bar, 0.7 Mpa)
LO
ES
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
I O
ti12732
11. Check that ES indicator or display is lit. If not,
see Electrical Troubleshooting, page 22.
ES
indicator
Standard Model
247936
ES
display
Smart Model
247937
ti1282b
9. Adjust fan air adjustment valve: clockwise for a
shorter pattern, counterclockwise for wider pattern.
12. Spray test piece. Examine edges for coverage. If
wrap is poor, see Spray Pattern Troubleshooting,
page 25.
ti1285b
ti1283
312900G 17
Installation
Flush
Fire, Explosion, and Electric Shock Hazard
Read Fire and Explosion, and Electric Shock
Hazards, page 3. Follow steps 1-6 below to flush the
gun when using gun first time, changing colors, before
fluid dries, at end of day, and before storing gun.
3. Change fluid source to solvent, or disconnect fluid
line and connect solvent supply line to gun.
NOTICE
This gun has nylon components which will be damaged if you use methylene chloride as a flushing or
cleaning solvent.
1. Turn ES ON/OFF switch OFF (O).
ti12724_x2
2. Relieve pressure, page 19.
ti1934
ti1287a
4. Point gun into grounded metal pail. Flush until clean
solvent flows from gun.
ti1934
5. Relieve pressure, page 19.
ti1934
6. Hang gun from hook. Nozzle must point down.
ti12718
18 312900G
Pressure Relief
Pressure Relief
Pressurized Equipment Hazard
The system pressure must be manually relieved to
prevent the system from starting or spraying accidentally. To reduce the risk of an injury from electric shock,
accidental spray from the gun, 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
1. Turn the ES ON/OFF valve OFF.
ti12724_x2
5. If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end
coupling. Now clear the nozzle or hose.
ti1298a
ti1298
Shutdown
Follow these steps at end of workshift and before cleaning, checking, or repairing equipment
1. Flush, page 18.
2. Turn off the air bleed valves to the fluid source and
to the gun.
ti1289
3. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
ti1934
4. Open the pump drain valve, having a waste container ready to catch the drainage. Leave the pump
drain valve open until you are ready to spray again.
ti1934
2. Hang gun from hook. Nozzle must point down.
ti12718
ti1290a
312900G 19
Maintenance
Maintenance
Clean Gun Daily
1. Flush, page 18.
2.
a. Clean outside of gun with non-conductive,
compatible solvent. Point gun down.
b. Use soft, damp cloth.
c. Do not immerse gun.
ti1292a
ti1295a
4. Clean air cap, retaining ring, and nozzle with soft
brush and non-conductive, compatible solvent.
ti1297a
5. Clean probe with soft brush and compatible solvent.
ti12716
6. Use toothpick or other soft tool to clean air cap
holes. Do not use metal tools.
ti1293a
ti1294a
7. Reinstall air cap. Tighten securely.
3. Remove air cap.
ti1299a
ti1296
20 312900G
Daily System Care
Maintenance
1. Relieve pressure, page 19.
ti1934
2. Clean fluid and air filters.
3. Check for fluid leaks. Tighten all fittings.
5. Check movement of trigger (T) and valves (V).
Lubricate if necessary.
T
V
ti12658
ti1291a
4. Clean workpiece hangers. Use non-sparking tools.
ti1300a
312900G 21
Electrical Troubleshooting
Electrical Troubleshooting
NOTE: Check all possible remedies in the Troubleshoot-
ing Chart before disassembling the gun.
Electric Shock Hazard
Installing and servicing this equipment requires
access to parts which may cause an electric shock or
other serious injury if the work is not performed properly. Do not install or repair this equipment unless you
are trained and qualified.
Problem Cause Solution
Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I).
(In general, a Pro Xs Waterborne gun
will have less wrap than a Pro Xs
solventborne gun.)
ES indicator or voltage/current display is not lit.
Voltage/current display stays red
(smart guns only).
Operator gets mild shock. Operator not grounded or is near
Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or
Gun air pressure too low. Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.
Atomizing air pressure too high. Decrease.
Fluid pressure too high. Decrease.
Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).
Poorly grounded parts. Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance. See Test Total Gun Resistance on
page 23.
Faulty turbine alternator. Be sure the plug is in place on the
back of the power supply housing.
Remove and test the turbine alterna-
tor. See page 33.
The KV HI-LO lever is on LO. Check the lever actuation; replace if
needed.
ES ON/OFF valve OFF (0).* Turn ON (I).
No power. Replace power supply. See page 32.
Gun too close to part. Should be 8-12 in. (200-300 mm).
Dirty gun. Clean. See Maintenance on page
20.
See Grounding on page 14.
ungrounded object.
Gun not grounded. See Check Electrical Grounding on
page 15 and Test Total Gun Resis-
tance on page 23.
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
22 312900G
Electrical Tests
Electrical Tests
Electrical components inside the gun affect performance
and safety. The following procedures test the condition
of the power supply (18), barrel (16) and charging probe
(31), and electrical continuity between components.
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see F
through F
IG. 12.) is not approved for use in a hazard-
IG. 8.
ous areas. To reduce the risk of sparking, do not use
the megohmmeter to check electrical grounding
unless:
• The gun has been removed from the hazardous
area;
or
• all spraying devices in the hazardous area are
turned off, ventilation fans in the hazardous area are
operating, and there are no flammable vapors in the
area (such as open solvent containers or fumes
from spraying).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury
and property damage.
Test Total Gun Resistance
Measure resistance between the charging probe tip
(BB) and the air swivel (35) (see F
90-130 megohms. If outside this range, go to the next
test. If in range, refer to Gun Repair on page 27 for
other possible causes of poor performance.
IG. 8.); it should be
Test Gun Resistance
Measure resistance between the air swivel (35) and the
charging probe socket (CC) (see F
IG. 9); it should be
70-95 megohms. If outside this range, check the power
supply and barrel resistance. If in range, test the charging probe resistance.
AA
35
CC
ti13731
FIG. 9. Test Gun Resistance
Test Charging Probe Resistance
Measure resistance between the metal spring in the
charging probe (DD) and the charging probe tip (BB)
(see F
IG. 9); it should be 15-30 megohms. If outside this
range, replace the charging probe. If in range, inspect
the spring and barrel socket for possible causes of poor
continuity. Reassemble the charging probe and retest
the gun resistance.
AA
AA
BB
BB
35
ti1468ax
IG. 10. Test Charging Probe Resistance
F
DD
ti13732
Fig. 8. Test Total Gun Resistance
312900G 23
Electrical Tests
Test Power Supply Resistance
1. Remove the power supply (18), page 31.
2. Remove the turbine alternator (19) from the power
supply, page 32.
3. Measure resistance from the power supply's ground
strips (EE) to the conductive contact in the center of
the power supply seal (FF). See F
4. The resistance should be 55-70 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
AA
IG. 11.
Test Barrel Resistance
1. Insert a conductive rod (GG) into the gun barrel
(removed for the power supply test) and against the
metal contact (HH) in the front of the barrel.
2. Measure the resistance between the conductive rod
(GG) and the charging probe socket (CC). See F
12. The resistance should be 15-30 megohms.
3. If the resistance is outside the range, replace barrel.
4. If resistance is in range, reassemble the gun and
test the gun resistance.
5. If you still have problems, refer to Gun Repair on
page 27 for other possible causes of poor performance, or contact your Graco distributor.
IG.
AA
FF
Fig. 11. Test Power Supply Resistance
EE
ti1599a
HH
GG
CC
Fig. 12. Test Barrel Resistance
ti12821
24 312900G
Spray Pattern Troubleshooting
Spray Pattern Troubleshooting
Electric Shock Hazard
Installing and servicing this equipment requires
access to parts which may cause an electric shock or
other serious injury if the work is not performed properly. Do not install or repair this equipment unless you
are trained and qualified.
Problem Cause Solution
Fluttering or spitting spray. No fluid. Refill supply.
Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 28.
Air in fluid supply. Check fluid source. Refill.
Improper spray pattern. Damaged nozzle or air cap. Replace, page 28.
Fluid buildup on air cap or nozzle. See Maintenance on page 20.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the Pressure
Relief procedure on page 19 whenever you are
instructed to relieve the pressure.
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
NOTE: Some spray pattern problems are caused by the
improper balance between air and fluid.
Fan air pressure too high. Decrease.
Fluid too thin. Increase viscosity.
Fluid pressure too low. Increase.
Fan air pressure too low. Increase.
Fluid too thick. Reduce viscosity.
Too much fluid. Decrease flow.
Streaks. Did not apply 50% overlap. Overlap strokes 50%.
Dirty or damaged air cap. Clean or replace, page 28.
312900G 25
Gun Operation Troubleshooting
Gun Operation Troubleshooting
Electric Shock Hazard
Installing and servicing this equipment requires
access to parts which may cause an electric shock or
other serious injury if the work is not performed prop-
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the Pressure
Relief procedure on page 19 whenever you are
instructed to relieve the pressure.
erly. Do not install or repair this equipment unless you
are trained and qualified.
NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun
.
Problem Cause Solution
Excessive spray fog. Atomizing air pressure too high. Close restrictor valve some, or
decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8
bar) needed at gun for full voltage.
Fluid too thin. Increase viscosity.
“Orange Peel” finish. Atomizing air pressure too low. Open atomizing air valve more or
increase gun air inlet pressure; use
lowest air pressure necessary.
Poorly mixed or filtered fluid. Remix or refilter fluid.
Fluid too thick. Reduce viscosity.
Fluid leaks from the fluid packing
area
Worn packings or rod. Replace packings or rod; see page
30.
Air leaks from the front of the gun Air valve (21) is not seating properly. Clean and service air valve; see
page 34.
Fluid leakage from the front of the
Worn or damaged packing rod (26). Replace; see page 30
gun
Worn fluid seat. Replace fluid nozzle and/or needle;
see page 28.
Loose fluid nozzle (7). Tighten; see page 28.
Damaged nozzle o-ring (7b). Replace; see page 28.
Gun does not spray Low fluid supply. Add fluid if necessary.
Damaged air cap (9). Replace; see page 28.
Dirty or clogged fluid nozzle (7). Clean; see page 28.
Damaged fluid nozzle (7). Replace; see page 28.
Damaged fluid adjustment valve (25). Replace; see page 34.
Dirty air cap Misaligned air cap (9) and fluid
nozzle (7).
Clean fluid buildup off air cap and
fluid nozzle seat; see page 28.
26 312900G
Gun Repair
Gun Repair
Prepare the Gun for Repair
Electric Shock Hazard
Installing and repairing this equipment requires access
to parts that may cause electric shock or other serious
injury if the work is not performed properly. Do not
install or service this equipment unless you are trained
and qualified.
Pressurized Equipment Hazard
• To reduce the risk of injury, follow the Pressure
Relief procedure on page 19 before checking or
servicing any part of the system and whenever you
are instructed to relieve the pressure.
• Check all possible remedies in Gun Operation
Troubleshooting before disassembling the gun.
• Use a vise with padded jaws to prevent damage to
plastic parts.
• Lubricate the power supply seal (18a), some packing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
• Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
• Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
• Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
• Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are marked
with a double asterisk, for example (5†).
1. Flush the gun, page 18.
2. Relieve the pressure, page 19.
3. Disconnect the gun air and fluid lines.
4. Remove the gun from the worksite. Repair area
must be clean.
312900G 27
Gun Repair
Replace Air Cap/Nozzle
NOTICE
Hold the front end of the gun up and trigger the
gun while removing the nozzle to help drain the
gun and prevent any paint or solvent left in the gun
from entering the air passages.
1. Prepare gun for repair page 27.
2. Remove probe.
3. Remove the retaining ring (27) and air cap (9). See
F
IG. 13.
4. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).
29
7b
26
Use non-silicone grease, Part No. 111265, on the
small o-ring (7b). Do not over-lubricate. Do not lubricate the contact ring (7a).
5. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).
Make sure the fluid needle (29) is finger- tight (page
28).
6. Trigger gun while installing the fluid nozzle (7) with
the multi-tool (37). Tighten until the fluid nozzle
seats in the gun barrel (1/8 to 1/4 turn past
hand-tight).
7. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
Replace Fluid Needle
1. Prepare the gun for repair page 27.
7a
7
9
37
27a*
27
Fig. 13. Replace Air Cap/Nozzle
Fire, Explosion, and Electric Shock Hazard
The nozzle contact ring (7a) is a conductive contact
ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact
ring (7a) except to replace it and never operate the
gun without the contact ring in place. Do not replace
the contact ring with anything but a genuine Graco
part.
ti12726
2. Remove the air cap and nozzle, page 28.
3. Unscrew the fluid needle (29). Hold the packing rod
end (26) to prevent it from turning, F
4. Apply low-strength (purple) Loctite
thread sealant to the fluid needle and packing rod
threads. Install the fluid needle finger-tight. Do not
overtighten.
5. Install the fluid nozzle and air cap, page 28.
IG. 13.
®
or equivalent
28 312900G
Remove Fluid Packing
1. Prepare the gun for repair, page 27.
2. Remove the air cap and fluid nozzle, page 28.
3. Remove the fluid needle, page 28.
4. Loosen the trigger screws (8) and trigger (30). See
F
IG. 14.
Gun Repair
37
5. Remove the packing rod (26), using the multi-tool
(37).
NOTICE
Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause
the gun to malfunction.
6. Check all parts for wear or damage and replace if
necessary.
30
8
TI1549A
Fig. 14. Remove Fluid Packing
312900G 29
Gun Repair
4
Repair Packing Rod
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory for proper air lead and lag. The gun begins emitting air before the fluid is discharged and the fluid stops
before the air flow stops.
To adjust the lead/lag air flow:
1. Remove the spring (4) from the nut (E).
2. Use a hex wrench to hold the end of the packing
rod. Turn the nut (E) out to increase the lead/lag
time for the air flow. The recommended adjustment
is one half turn and not more than one full turn.
3. Apply thread-locking adhesive to fix the nut in the
new position.
Before installing the fluid packing rod into the gun
barrel, make sure the internal surfaces of the barrel
are clean. Remove any residue with a soft brush or
cloth. Check the inside of the barrel for marks from
high voltage arcing. If marks are present, replace
the barrel.
To assemble the individual parts:
1. Place the packing nut (26g) and seal (26f†) on the
fluid rod (26a). Flats on the packing nut must face
the back of the fluid rod. The seal o-ring must face
away from the packing nut. See F
IG. 15.
2. Fill the inner cavity of the spacer (26e†) with dielectric grease (40). Place the spacer on the fluid rod
(26a) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
3. Place the rod packing (26d†), packing spreader
(26c†), and housing (26b) on the packing rod (26h).
4. Lightly tighten the packing nut (26g). The packing
nut is properly tightened when there is 3 lb (13.3 N)
of drag force when sliding the packing housing (26b)
assembly along the rod. Tighten or loosen the packing nut as needed.
5. Install the o-ring (26h†) on the outside of housing
(26f). Lubricate the o-ring with non-silicone grease,
Part No. 111265. Do not over-lubricate.
6. Install the spring (4) against the nut (E) as shown.
7. Install the packing rod assembly (26) into the gun
barrel. Using the multi-tool (37), tighten the assembly until just snug.
8. Install the trigger (30) and screws (8).
9. Install the fluid needle page 28.
10. Install the nozzle and air cap, page 28.
11. Install the probe.
E
26a
26g
26f†
26e†
26d
†
26c†
26b
26h†
ti12719
Fig. 15. Packing Rod
30 312900G
Gun Repair
Remove Barrel
1. Prepare the gun for repair, page 27.
2. Carefully loosen the nut (54) from the bracket fluid
fitting (13). Pull the tube (14 or 50a) out of the fitting.
Make sure both ferrules and the nut stay with the
tube.
3. Loosen the three screws (11).
NOTICE
To avoid damaging the power supply (18), pull the
gun barrel straight away from the gun handle. If
necessary, gently move the gun barrel from side to
side to free it from the gun handle.
4. Hold the gun handle (17) with one hand and pull the
barrel (16) straight off the handle. See F
32
14
54
55
13
11
IG. 16.
16
Install Barrel
1. Be sure the gasket (10*) and grounding spring (53)
are in place. Make sure the air holes are aligned
properly. Replace if damaged. See F
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
NOTICE
Do not over-tighten the screws (11).
4. Assemble the fluid tube (14) into the bracket fitting
(13). Ensure that the ferrules are in place. Tighten
the nut (54).
5. Test gun resistance, page 23.
18
*10
IG. 17.
ti1503a
17
Fig. 16. Remove Barrel
ti1504a
11
16
53
ti12830
Fig. 17. Install Barrel
312900G 31
Gun Repair
Remove and Replace Power Supply
• Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
• Do not expose gasket (10) to solvents.
1. Prepare gun for service, page 27.
2. Remove the barrel (16), page 31.
NOTICE
Be careful when handling the power supply (18) to
avoid damaging it.
3. Grasp the power supply (18) with your hand. With a
gentle side to side motion, free the power supply/alternator assembly from the gun handle (17),
then carefully pull it straight out. On Smart Model
only, disconnect the flexible circuit (59) from the
socket at the top of the handle (17). See F
IG. 18.
11. Install the barrel (16), page 31. Ensure the ground
spring (53) is in place.
12. Test gun resistance, page 23.
17
10*
19a*
19
19e
53
59
ti1505cx
GG
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alternator for damage. On Smart Model only, disconnect
the 6-pin flexible circuit (59) from the power supply.
5. Check the power supply resistance, page 24.
Replace if necessary.
6. On Smart Model only, connect the 6-pin flexible cir-
cuit (59) to the power supply.
7. Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate. Ensure the alternator pads (19e) are in place.
9. Lubricate the power supply seal (18a) with dielectric
grease (40).
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Model only, con-
nect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
18a
18
FIG. 18. Power Supply
32 312900G
Gun Repair
Remove and Replace Turbine Alternator
Replace turbine alternator bearings after 2000 hours
of operation. Order Part No. 223688 Bearing Kit.
1. Prepare gun for repair, page 27.
2. Remove the power supply/alternator assembly,
page 32.
3. Disconnect the alternator from the power supply,
page 32.
4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be
2.5-3.5 ohms. If outside this range, replace the alternator coil.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
6. Install the alternator on the power supply, page 32.
7. Install the power supply/alternator assembly, page
32.
Repair Fan Air Adjustment Valve
1. Prepare the gun for service, page 27.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
You may replace the valve as an assembly (go to
step 9) or as individual parts (steps 3-9).
3. Remove the retaining ring (20a). See F
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
5. Remove the o-ring (20b).
6. Clean all parts and inspect for wear or damage.
Use non-silicone grease, Part No. 111265. Do not
over-lubricate.
7. When reassembling the fan air valve (20), lightly
lubricate the valve threads and screw the stem (20d)
fully into the housing (20c) until bottomed. Install the
o-ring (20b*), lubricate, and unscrew the valve stem
until the o-ring enters the housing.
IG. 19.
20a
8. Reassemble the retaining ring (20a). Unscrew the
valve stem from the housing until it is stopped by the
retaining ring.
9. Screw the valve assembly (20) into the gun handle,
using a wrench on the flats of the housing. Torque to
15-25 in-lb (1.7-2.8 N•m).
20d
TI1487A
20b*
20c
Fig. 19. Fan Air Adjustment Valve
312900G 33
Gun Repair
Repair Fluid Adjustment Valve
1. Prepare the gun for repair, page 27.
2. Remove the fluid adjustment valve (25). It can only
be replaced as a complete assembly. See F
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
Fig. 20. Fluid Adjustment Valve
IG. 20..
25
ti11931
5. Inspect the u-cup (6*). Do not remove the u-cup
unless damaged. If removed, install the new one
with its lips facing into the gun handle (17).
6. Install the air valve (21) and spring (15) into the gun
handle (17).
7. Install the fluid adjustment valve (25). Torque to
15-25 in-lb (1.7-2.8 N•m).
8. Install the barrel, page 31.
25
15
21
17
*6
ti12717
Fig. 21. Air Valve
Repair Air Valve
1. Prepare the gun for service, page 27.
2. Remove the barrel, page 31.
3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See FIG. 21.
NOTICE
Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause
the gun to malfunction.
4. Remove the air valve (21) with a pliers. Inspect the
rubber sealing surface and replace the air valve if
damaged.
NOTICE
When removing the air valve (21) be careful not to
damage the seat area.The rubber seal is not
removable.
34 312900G
Gun Repair
Remove and Replace Atomizing Air Restrictor Valve
1. Prepare the gun for repair, page 27.
2. Remove the atomizing air restrictor valve (23).
Inspect the o-ring (23c*). Replace if necessary. See
F
IG. 22.
3. Install a new atomizing air restrictor valve (23), or
disassemble and replace parts individually. The
valve protrusion must be oriented to clear the air
valve (21) shaft.
If the atomizing air restrictor valve is not desired,
install the supplied plug (2).
4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
Repair ES ON/OFF Valve
1. Prepare the gun for repair, page 27.
2. Loosen the screw (48). Remove the valve.
3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
NOTICE
Do not over-lubricate parts. Excessive lubricant on
the o-rings can be pushed into the gun air passage
and blemish the finish on the workpiece.
4. Clean and inspect parts for damage. Replace if necessary.
The protrusion on the retainer plate (22d) must point
upward.
5. Reinstall the valve. Torque the screw (48) to 15-25
in-lb (1.7-2.8 N•m).
23d
ti1508a
Fig. 22. Atomizing Air Restrictor Valve
23c*
23a
23b
2
22b*
22c
22a*
Fig. 23. ES ON/OFF Valve
22e
22d
22g
22f
ti12720
312900G 35
Parts
Parts
Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model)
See page 38 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
11
1
1
Maximum torque 10 in-lb (1.1 N•m)
7
9
27a*
27
7b
26
31
60
4
8
16
1
30
10*
53
8
1
22
Ref. No. 37: Multi-tool
18a
18
7a
29
14
19
54
32
55
24a*
24
23
6*
2
17
3
20
25
15
21
13
35
ti11932
36 312900G
Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model)
See page 38 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
Parts
1
Maximum torque 10 in-lb (1.1 N•m)
7
9
27a*
27
7b
18
7a
26
29
31
59
60
4
19
16
1
11
1
8
53
10*
1
8
30
58
56
5
22
57
6*
3
20
25
15
21
Ref. No. 37: Multi-tool
18a
14
54
32
55
24a*
24
23
2
17
13
35
ti12659
312900G 37
Parts
Ref. No. 20: Fan Adjustment ValveRef. No. 19: Alternator
19b
19b
19d
19c
Ref. No. 22: ES ON/OFF Valve
22d
22e
22b*
22c
22a*
19a*
19e
TI1481a
22g
22f
20c
20a
Ref. No. 26: Packing Rod
26e†
26d†
26c†
26b
20b*
26f†
20d
TI1487A
26a
26g
ti12719
Ref. No. 37: Multi-tool
ti12720
26h†
247936 (Standard Model) controls
MAX FLUID WPR:
100 PSI (7bar, 0.7 Mpa)
MAX AIR WPR:
100 PSI (7bar, 0.7 Mpa)
To avoid shock or explosion
•Use properly grounded air hose
•Read instruction manual
I O
ES
247937 (Smart Model) controls
100
%
0
KV
Ma
MAX FLUID
WPR: 100 PSI
HI
(7bar, 0.7 Mpa)
LO
ES
MAX AIR
WPR: 100 PSI
(7bar, 0.7 Mpa)
ES
I O
38 312900G
Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model)
Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model)
Parts
Ref.
No.
1 111157 FITTING, tube, fluid 1
2 197967 PLUG, handle 1
3 198058 SCREW, cap, socket head 1
4 185111 SPRING, compression 1
5 111450 PACKING, o-ring (247937 only) 1
6* 188749 PACKING, u-cup, air valve;
7 197266 NOZZLE; 1.5 mm orifice; includes
7a 111261 . O-RING, conductive 1
7b 111507 . O-RING; fluoroelastomer 1
8 24A445 SCREW, trigger 2
9 24A276 AIR CAP 1
10* 197517 GASKET, barrel 1
11 197518 SCREW; socket-hd; 10-24 x 3/4 in.
13 24A336 BRACKET, inlet, fluid 1
14 24A334 TUBE, fluid 1
Part No. Description Qty
UHMWPE
7a and 7b
(19 mm)
Ref.
No.
20 244556 VALVE, adjustment, fan; includes
20a 101021 . RING, retaining 1
20b* 106560 . O-RING; fluorocarbon 1
20c 197566 . HOUSING, fan valve 1
20d 197567 . STEM, fan valve 1
1
21
22 244558 VALVE, electrostatics, ON/OFF;
1
22a* 111516 . O-RING; CV75 1
22b* 113137 . O-RING; fluoroelastomer 1
22c 198403 . SHAFT, valve 1
22d 198404 . PLATE, retaining 1
22e 198453 . WASHER 1
22f 198464 . PIN 1
3
22g 249185 . KNOB 1
23 244559 VALVE, air restrictor; includes
Part No. Description Qty
20a-20d
244557 VALVE, air; 1
❖
includes 22a-22g
23a-23d
1
1
1
15 185116 SPRING, compression 1
16 24A329 BODY, gun; ES; includes 16a-16e 1
17 24A596 HANDLE, smart (247937) 1
24A595 HANDLE, standard (247936) 1
18 24A332 POWER SUPPLY, 60 kV 1
18a 256267 . SEAL 1
19 244555 TURBINE, alternator; includes
19a-19e
19a* 110073 . O-RING; fluoroelastomer 1
19b 223688 . BEARING KIT; includes front and
rear bearings and fan
19c 244577 . COIL 1
19d 111745 . RING, retaining 1
19e 198821 . PAD, pressure 2
23a 197594 . HOUSING, valve 1
23b 197591 . SHAFT 1
23c* 111504 . O-RING; fluoroelastomer 2
23d 101021 . RING, retaining 1
24 249323 VALVE, exhaust; includes 24a 1
24a* 112085 . O-RING; fluorocarbon 1
25 244593 VALVE, adjustment, fluid 1
1
1
312900G 39
Parts
Ref.
No.
26 24A331 NEEDLE; includes 26a-26h 1
26a
26b
26c
26d
26e†
26f
26g
26h†
27 244927 RING, retaining; includes 27a 1
27a* 198307 . PACKING, u-cup 1
29
30 24A335 TRIGGER 1
31
32 111285 FERRULE, back 1
35 24N626 SWIVEL, air; 1/4 npsm(m) ;
36 107460 WRENCH, ball end; 4 mm 1
Part No. Description Qty
24A330 . NEEDLE, assembly 1
185495 . HOUSING, packing 1
178763 . PACKING, needle 1
†
178409 . PACKING, fluid 1
†
186069 . SPACER, packing 1
116905 . SEAL 1
†
197641 . NUT, packing 1
111316 . PACKING, o-ring 1
24A338 NEEDLE, electrode 1
24A328 PROBE, external charging 2
left-hand threads
Ref.
No.
42▲ 179791 TAG, warning (not shown); replace-
43▲ 180060 SIGN, warning (not shown);
53 197624 SPRING, compression 1
54 112644 NUT, swagelock 1
55 111286 FERRULE, front 1
56 197910 SCREW, pivot, ES HI/LO (247937
57 276734 PLUG, KV adjust (247937 only) 1
58 244627 SWITCH, ES HI/LO (247937 only) 1
59 245265 CIRCUIT, flexible (247937 only) 1
60 248130 O-RING (pack of 6) 1
61 24A431 KIT, wide pattern (not shown) 1
Part No. Description Qty
ment available at no cost
replacement available at no cost
only)
* Included in Air Seal Repair Kit 244781.
† Included in Fluid Seal Repair Kit 244911.
❖ Rubber seal is not removable.
1
▲Replacement Warning labels, signs, tags, and cards
are available at no cost.
1
1
1
37 276741 MULTI-TOOL 1
38 185103 TUBE, exhaust (not shown) 1
39 110231 CLAMP (not shown) 1
40 116553 GREASE, dielectric, tube (not
shown)
41 244915 COVER, gun; box of 10 (not shown) 1
1
40 312900G
Accessories
Accessories
Air Line Accessories
AirFlex™ Flexible Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread
244963 6 ft (1.8 m)
244964 15 ft (4.6 m)
244965 25 ft (7.6 m)
244966 36 ft (11 m)
244967 50 ft (15 m)
244968 75 ft (23 m)
244969 100 ft (30.5 m)
Standard Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread
223068 6 ft (1.8 m)
223069 15 ft (4.6 m)
223070 25 ft (7.6 m)
223071 36 ft (11 m)
223072 50 ft (15 m)
223073 75 ft (23 m)
223074 100 ft (30.5 m)
High Flow Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.375 in. (10 mm) ID; 3/8 npsm(f) x 1/4 npsm(f) left-hand
thread
24A225 50 ft (15.2 m)
24A226 75 ft (22.9 m)
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve
and the pump air motor when closed.
Air Line Quick Disconnect
112534 Swiveling quick disconnect replaces stan-
dard air inlet swivel.
Air Hose Adapter Nipple
185493 Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
Non-Swivel Air Inlet Fitting
185105 Replaces standard swivel. Left-hand thread.
Extended Air Inlet Fitting
189191 Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
Fluid Line Accessories
Fluid Hose
225 psi (14 bar, 1.4 MPa) Maximum Working Pressure
FM Approved; nylon; 3/8 npsm(fbe)
215637 1/4 in. (6 mm) ID x 25 ft (7.6 m)
215638 1/4 in. (6 mm) ID x 50 ft (15.2 m)
Fluid Shutoff/Drain Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving fluid
line pressure at the pump.
208630 1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
Fluid Swivel
5800 psi (405 bar, 40 MPa) Maximum Working Pressure
115898 1/4 npsm(m) x 1/4 npsm(f)
107141 3/4 npt
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
312900G 41
Accessories
Gun Accessories
Gun Repair Kits
244781 Air Seal Repair Kit
244911 Fluid Seal Repair Kit
Push/Pull Fan Air Valve
244912 For quick change of fan size.
ES Always On Kit
244913 Replaces inlet fitting with ball valve to shut
off air during flushing. Converts ES ON/OFF
valve to always ON condition.
Handle Grips
245263 Medium Grip
245264 Large Grip
Gun Washer Kit
245270 Use to convert Graco gun washers so they
can clean PRO Xs3 and PRO Xs4 air spray
guns.
Miscellaneous Accessories
Ground Wire and Clamp
222011 For grounding pump and other components
and equipment in the spray area.
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079 500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Paint Resistance Meter
722886 Use with 722860 Paint Probe to measure
resistance of paint.
Not for use in hazardous areas.
Paint Probe
722860 Use with 722886 Paint Resistance Meter to
measure resistance of paint.
Not for use in hazardous areas.
Safety Warning Signs
Pressure Cups
Includes air regulators for gun atomization air and supply air to pressure cup.
244731 1 Quart (0.95 Liter)
244732 2 Quart (1.90 Liter)
Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
Alternator Bearing Kit
223688 To repair the turbine alternator.
Cleaning Brush
105749 For cleaning air cap and fluid nozzle.
180060 English Warning Sign. FM Approved. Avail-
able at no charge from Graco.
Electrostatic Conductive Gloves (box of 12)
117823 Small
117824 Medium
117825 Large
42 312900G
Technical Data
Technical Data
Category Data
Maximum Working Fluid Pressure.................................... 100 psi (0.7 MPa, 7 bar)
Maximum Working Air Pressure ........................................ 100 psi (0.7 MPa, 7 bar)
Maximum Fluid Operating Temperature ............................ 120°F (49°C)
Maximum voltage output ................................................... 60kV
Sound Pressure (measured per ISO Standard 9216) ....... at 40 psi (0.28 MPa, 2.8 bar); 90.4 dB(A)
at 100 psi (0.7 MPa 7 bar): 105.4 dB(A)
Sound Pressure (measured 1 m from gun) ....................... at 40 psi (0.28 MPa, 2.8 bar); 87 dB(A)
at 100 psi (0.7 MPa 7 bar): 199 dB(A)
Air inlet fitting, left-hand thread.......................................... 1/4 npsm
Fluid inlet fitting ................................................................. 3/8-18 npsm (R 3/8-19) compound thread
Gun Weight........................................................................ 247936: 22.4 oz (634 g)
247937: 25.1 oz (712 g)
Gun Length (with probe).................................................... 10.6 in. (24.6 cm)
Paint Resistivity ................................................................. <1 megohm-cm
Wetted Parts...................................................................... Polyethylene, Stainless Steel; Nylon, Acetal, PTFE,
UHMWPE, Fluoroelastomer, PEEK, Nickel Plate
312900G 43
Graco Warranty
Graco warrants all equipment 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 or two thousand hours of operation from the date of sale, repair or replace any
part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal
power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of
operation from the date of sale. 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
procedures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 312900
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised December 2013
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