Graco 309295N User Manual

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Page 1

Instructions/Parts List

Manual Electrostatic Air-Assisted

PRO™ Xs4 AA Spray Gun

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 0.24mJ

Smart Model

For Professional Use ONLY.

100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure 3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

309295N

See for page 2 Table of Contents and page 3 for List of Models.

U.S. Patent 7,226,004

Standard Model

ti1509a

ti1332b

Page 2

Table of Contents

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic AA Spray Gun Works . . . . 6

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 8

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 8

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 10

Connect the Exhaust Tube . . . . . . . . . . . . . . . . 10

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 11

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Check Electrical Grounding . . . . . . . . . . . . . . . . 13

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 14

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Low Voltage Adjustment (Smart Guns Only) . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 16

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 18

Test Power Supply Resistance . . . . . . . . . . . . . 19

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Spray Pattern Troubleshooting . . . . . . . . . . . . . 21

Gun Operation Troubleshooting . . . . . . . . . . . . . 22

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pressure Relief Procedure . . . . . . . . . . . . . . . . 24

Prepare the Gun for Service . . . . . . . . . . . . . . . 25

Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Tip Guard, Air Cap, Spray Tip, or Seat Housing

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 26

Electrode Replacement . . . . . . . . . . . . . . . . . . . 28

Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 29

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 29

Fluid Needle Replacement . . . . . . . . . . . . . . . . 30

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 31

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Supply Removal and Replacement . . . . 32

Turbine Alternator Removal and Replacement . 33

Atomizing Air Adjustment Valve Repair . . . . . . . 34

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 35

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 36

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 44

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 44

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 45

Miscellaneous Accessories . . . . . . . . . . . . . . . . 45

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

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Page 3

List of Models

Part No. Model Description

244572, Series C PRO Xs4 AA Manual Air-Assisted Spray Gun 309296/3W9296/

244573, Series C PRO Xs4 AA Manual Air-Assisted Spray Gun with smart display 309296/3W9296/

Operation

Manual

3Z9296

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Page 4

Warnings

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

WARNING

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 requirements 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.

• Interlock the gun air supply to prevent operation unless ventilating fans are on.

• Use and clean equipment only in well ventilated area.

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment. To comply 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 equip- ment 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.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

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Page 5

Warning

WARNING

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury.

• Fluid injected into the skin might look like just a cut, but is a serious injury. Get immediate

surgical treatment.

• Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the spray tip. Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Never spray without the tip guard in place.

• Lock the trigger safety when you stop spraying.

• Follow the Pressure Relief Procedure, page 24, when you stop spraying and before cleaning, checking, or repairing equipment.

• Check the hoses and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.

• Tighten all fluid connections before each use.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

• Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local, state, and national guidelines.

• Wear appropriate protective clothing, gloves, eyewear, and respirator.

Equipment Misuse Hazard

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

• This equipment is for professional use only.

• Read all manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.

• Do not alter or modify equipment. Use only genuine Graco parts and accessories.

• Check the equipment daily. Repair or replace worn or damaged parts immediately.

• Do not exceed the maximum working pressure of the lowest rated system component. Maximum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 bar).

• Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

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Page 6

Introduction

How the Electrostatic AA Spray Gun Works

WARNING

Skin Injection Hazard

Remember, this is not an air spray gun.

For your safety, read and follow all Warnings in this manual.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

As the gun is triggered, part of the regulated 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 electrode.

The regulated air that is directed to the air cap can be further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air flow to the air cap while maintaining sufficient air flow to the turbine.The atomizing air adjustment valve does not control pattern width. To change pattern width, a new tip size must be used.

The high working fluid pressure of this gun provides the power needed to atomize higher solids materials.

The gun’s internal power supply provides high voltage current. The fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off. Closing this valve does not affect turbine operation.

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Page 7

Introduction

Gun Overview

The electrostatic gun includes the following controls. See F

IG. 1.

• Air cap/tip guard and spray tip. Never spray with-

out the tip guard. See page 46 for spray tip sizes.

• Trigger safety lock. Prevents the gun from spray-

ing.

• Atomizing AIR adjustment valve. Adjusts atomiz-

ing air.

• ES ON/OFF valve. Turns electrostatics ON (I) or

OFF (0).

• ES INDICATOR (standard gun only). Green when

ES is ON (I).

• Voltage/current DISPLAY (smart models only).

Shows voltage (V) and current (A). Green=spray, yellow/red=see Troubleshooting, page 23.

• ES HI/LO switch (smart models only). Sets volt-

age to HI or LO (factory settings).

• LO voltage adjustment (smart models only).

Remove plug to adjust to four settings.

TRIGGER SAFETY LOCK

ES INDICATOR

ES ON/OFF

(I = ON,

0 = OFF)

TIP GUARD

AIR CAP

Standard Gun

I O

SPRAY TIP

ti1366a

AIR

ES HI/LO

ES ON/OFF

(I = ON,

0 = OFF)

ti1509a

100

μα

I O

Smart Gun

DISPLAY

AIR

ti1333a

Fig. 1. Gun Overview

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Page 8

Installation

Install the System

WARNING

Fire, Explosion, and Electric Shock Hazard

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.

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

WARNING

Flammable or Toxic Vapor Hazard

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.

FIG. 2. shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

8 309295N

NOTE: 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.

Page 9

Installation

AB*C*D

The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on.

ti1514b

Non-Hazardous Area Hazardous Area

Fig. 2. Typical Installation Key

A Main Air Supply Line B* Ventilation Fan Interlock Solenoid Valve C* Main Air Supply Shutoff Valve (bleed-type) D 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 Grounded Fluid Supply Line, with spring guards

O Gun Air Regulator P Gun Air Supply Line Shutoff Valve Q* Air Hose Ground Wire R* Graco Grounded Air Hose S Electrostatic Air-Assisted Spray Gun T Fluid Pressure Gauge U* Fluid Drain Valve VGun Air Inlet W Gun Fluid Inlet X Pump Runaway Valve * Required for safe operation. Must be purchased

separately. NOTE: Solenoid valve (B) is not offered as a Graco accessory.

309295N 9

Page 10

Installation

Connect the Air Line

WARNING

Electric Shock Hazard

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). The gun air inlet fitting has a left-hand thread. Connect the air supply hose ground wire (Q) to a true earth ground.

2. Install an air line filter/water separator (D) on the 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, O) on the pump and gun air supply lines to control air pressure to the pump and gun.

WARNING

Skin Injection Hazard

The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the pump after the air regula-

tor is shut off. Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including fluid injection and splashing fluid in the eyes or on the skin.

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.

5. Install an air shutoff valve ( P) on each gun air supply line to shut off air to the gun(s).

WARNING

Skin Injection Hazard

To reduce the risk of serious injury due to component rupture, including fluid injection, pump pressure must be limited by the pump air regulator. Do not rely on the gun fluid regulator to limit the fluid pressure to the gun.

The fluid supply pump must be prevented from producing a fluid pressure greater than the 3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure of the gun. For example, the air supply pressure to a 30:1 ratio pump must not exceed 100 psi (0.7 MPa, 7 bar).

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).

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Page 11

Installation

Connect the Fluid Line

1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

2. Install a fluid regulator (M) on the fluid line to control fluid pressure to the gun.

WARNING

Skin Injection Hazard

The fluid drain valve (U) is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun. Trig-

gering 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 fluid injection and splashing in the eyes or on the skin.

3. Install a drain valve (U) near the pump outlet.

4. Connect the fluid line to the 1/4 npsm gun fluid inlet (W).

5. Before running any paint through the spray gun, flush it out with a compatible solvent.

Filter the Fluid

Install a fluid filter (K) at the pump outlet to remove particles and sediment which could clog the spray tip.

The gun includes an inline fluid filter (1) for additional filtration.

Select a Spray Tip

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure, page 24, before removing or installing the spray tip, air cap, or tip guard.

The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart, page 46, as a guide for selecting the appropriate spray tip for your application.

Refer to the gun operation manual to install the spray tip.

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Page 12

Installation

Grounding

WARNING

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 glove, 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 conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

• Electrostatic Air-Assisted Spray Gun: ground the gun by connecting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 13.

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.

12 309295N

• 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.

Page 13

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F

IG. 3.) is not approved for use in a hazard-

ous 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).

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. 3.

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.

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

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.

I O

ti1340a

ti1337a

Fig. 3. Check Gun Grounding

309295N 13

Page 14

Installation

Check Fluid Resistivity

WARNING

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, 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-assisted spray system.

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 and adjust as necessary.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

14 309295N

Page 15

Operation

Refer to the gun operation manual (supplied) for Setup, Shutdown, and Daily Care procedures.

INSTRUCTIONS

Operation

Low Voltage Adjustment (Smart Guns Only)

The ES HI/LO switch enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set, but can be adjusted.

1. Set the ES HI/LO switch to LO.

2. Remove the LOW VOLTAGE adjustment plug (53). Set the desired voltage, using a small screwdriver to slide switches 1 and 2 ON or OFF, according to Table 1 . Also see F

IG. 4.

Table 1: Low Voltage Adjustment

12kV

ON ON 70 ON OFF 60 OFF ON 50 OFF OFF 40

100

Fig. 4. Low Voltage Adjustment Switches

μα

ti1529a

OFF

309295N 15

Page 16

Maintenance

Refer to the gun operation manual (supplied) for Daily Care and Cleaning procedures.

INSTRUCTIONS

Flush the Spray Gun

Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF before flushing the gun.

1. Turn the ES ON/OFF valve OFF.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure, page 24, whenever you are instructed to relieve the pressure.

2. Relieve the pressure.

I O

ti1337a

ti1341a

CAUTION

Flush the gun with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.

Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.

16 309295N

3. Remove and clean the air cap and the spray tip.

ti1334b

Continued on page 17.

Page 17

Maintenance

4. Change the fluid source to solvent, or disconnect the fluid line and connect a solvent supply line to the gun.

ti1287a

5. Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.

ti1465a

6. Relieve the pressure. Lock the trigger.

ti1465a

7. Shut off or disconnect the solvent line.

8. Hang the gun from its hook, with the nozzle pointing down.

ti1349a

9. When ready to spray again, reconnect the fluid supply line. Follow the Setup procedure in the Gun Operation Manual.

309295N 17

Page 18

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18) and barrel (16), and electrical continuity between components.

CAUTION

The barrel resistor cartridge is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

Use megohmmeter Part No. 241079 (AA) with an applied voltage of 500 V. Connect the leads as shown.

WARNING

Fire, Explosion, and Electric Shock Hazard

Test Gun Resistance

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode needle tip (9b) and the air swivel (35); it should be 156-180 megohms. See F the next test. If in range, refer to Electrical Trouble- shootingon page 23 for other possible causes of poor performance.

IG. 5. If outside this range, go to

Megohmmeter Part No. 241079 (AA-see F

IG. 5.) is not approved for use in a hazard-

ous 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;

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

Fig. 5. Test Gun Resistance

TI1469A

18 309295N

Page 19

Electrical Tests

Test Power Supply Resistance

1. Remove the power supply (18), page 32.

2. Remove the turbine alternator (19) from the power supply, page 33.

3. Measure resistance from the power supply's ground strips (EE) to the spring (18b). See F

4. The resistance should be 135-150 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

5. If you still have problems, refer to Electrical Trou- bleshooting on page 23 for other possible causes of poor performance, or contact your Graco distributor.

IG. 6.

6. Be sure the spring (18b) is in place before reinstalling the power supply.

18b

Fig. 6. Test Power Supply Resistance

ti1599a

309295N 19

Page 20

Electrical Tests

Test Barrel Resistance

1. Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel.

2. Measure the resistance between the conductive rod (B) and the barrel contact ring (16a). See F The resistance should be 19-29 megohms. If the resistance is incorrect, make sure the metal contact (C) in the barrel and the barrel contact ring (16a) are clean and undamaged.

3. If the resistance is still outside the range, remove the barrel contact ring (16a) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the contact ring groove.

4. If the resistance is in range, replace the contact ring (16a) with a new one. Press the contact ring firmly into the groove on the front of the barrel.

IG. 7.

5. If the resistance is still outside the range, replace the barrel.

16a

Fig. 7. Test Barrel Resistance

ti1515b

WARNING

Fire, Explosion, and Electric Shock Hazard

The barrel contact ring (16a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring (16a) 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.

20 309295N

Page 21

Troubleshooting

WARNING

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 service this equipment unless you are trained and qualified.

Skin Injection Hazard

To reduce the risk of a fluid injection injury, always follow the Pressure Relief Proce- dure on page 24 whenever you are instructed to relieve the pressure.

NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

WARNING

Spray Pattern Troubleshooting

NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.

Problem Cause Solution

Fluttering or spitting spray. No fluid. Refill supply.

Air in fluid supply. Check fluid source. Refill.

Irregular pattern. Fluid buildup; partially plugged tip. Clean. See gun operation manual.

Worn/damaged tip or air cap holes. Clean or replace.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern. Air pressure too low. Open atomizing air adjustment valve.

Fluid buildup on air cap/tip guard. Air pressure too high. Decrease.

Air cap holes plugged. Clean. See gun operation manual.

Fluid pressure too low. Increase.

309295N 21

Page 22

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Excessive spray fog. Atomizing air pressure too high. Close atomizing air 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. Spray tip is too large. Use smaller tip. See page 46. Poorly mixed or filtered fluid. Remix or refilter fluid. Fluid too thick. Reduce viscosity.

Fluid leaks from the fluid packing area

Air leaks from the front of the gun Air valve (21) is not seating properly. Clean and service air valve; see

Fluid leakage from the front of the gun

Gun does not spray Low fluid supply. Add fluid if necessary.

Dirty air cap Damaged or plugged air cap (9). Clean air cap; see gun operation

Worn fluid needle packings or shaft. Replace fluid needle assembly (26);

see page 30.

page 35. Worn or damaged fluid needle ball. Replace fluid needle (26); see page

30. Worn fluid seat housing (2). Replace seat housing; see page 26. Loose spray tip (3). Tighten retaining ring (27); see page

26. Damaged tip seal (3a). Replace; see page 26.

Damaged spray tip (3). Replace; see page 26. Dirty or clogged spray tip (3). Clean; see gun operation manual. Damaged fluid needle (26). Replace; see page 30.

manual.

22 309295N

Page 23

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I).

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 velocity too high. Decrease fluid pressure or replace

worn tip. 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 Gun Resistance” on page

18. Low fluid resistivity. Check fluid resistivity. See page 14. Fluid leaks from the fluid needle (26)

packings and causes a short. Faulty turbine alternator (19). Be sure the plug is in place on the

The KV HI-LO lever is on LO. Check the lever position; replace if

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

ES ON/OFF valve OFF (0).* Turn ON (I).

No power. Repair/replace alternator turbine;

Gun too close to part. Should be 8-12 in. (200-300 mm).

Check fluid resistivity. See “Check Fluid Resistivity” on

Dirty gun. Clean. See Operation Manual.

ungrounded object. Gun not grounded. See “Check Electrical Grounding” on

Clean the needle cavity. Replace the fluid needle. See page 30.

back of the turbine alternator housing. Remove and test the turbine alternator. See page 33.

needed.

replace power supply. See page 32.

page 14.

See “Grounding” on page 12.

page 13 and “Test Gun Resistance” on page 18.

less. Clean workpiece hangers.

* ES indicator light is off when the gun is triggered.

309295N 23

Page 24

Repair

Pressure Relief Procedure

WARNING

Skin Injection Hazard

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high

pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or electric shock, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure

• stop spraying

• check or repair any of the system equipment

• or install or clean the spray tip.

4. Unlock the trigger.

ti1406a

5. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.

ti1341a

6. Lock the trigger.

ti1356a

7. Open the pump drain valve and all other fluid drain valves in the system, having a waste container ready to catch the drainage. Leave the drain valve(s) open until you are ready to spray again.

1. Turn the ES ON/OFF valve OFF.

I O

ti1337a

2. Lock the trigger.

ti1356a

3. Turn off the air bleed valves to the fluid source and to the gun.

ti1289a

ti1290a

8. 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.

24 309295N

Page 25

Repair

Prepare the Gun for Service

WARNING

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.

WARNING

Skin Injection Hazard

• Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models. Note that the air cap, spray tip, and tip guard for this gun are orange.

• Air Seal Repair Kit 244781 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (6*).

WARNING

Some PRO Xs4 AA Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When repairing, do not mix or use other

PRO Gun parts that may look similar, but have different part numbers! Use of parts other than

those specified in the PRO Xs4 AA Gun parts lists could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion, or property damage.

To reduce the risk of injury, follow the Pres- sure Relief Procedure on page 24 before checking or repairing any part of the system and whenever you are instructed to relieve the pressure.

NOTE:

• Check all possible remedies in Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to plastic parts.

• Lubricate the power supply o-ring (18a) and the plastic end of the fluid tube (14) with dielectric grease (40).

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

1. Flush the gun, page 16.

2. Relieve the pressure, page 24.

3. Disconnect the gun air and fluid lines.

4. Remove the gun from the worksite. Repair area must be clean.

Tools Needed

• 2 mm driver (supplied)

• 4 mm driver (supplied)

• Multi-Tool (supplied)

• adjustable wrench

• medium screwdriver

• snap ring pliers

309295N 25

Page 26

Repair

Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement

1. Prepare gun for service, page 25.

2. Remove the retaining ring (27), tip guard (4), air cap (9a), and spray tip (3). You may have to turn the air cap with the tip guard to remove it. See F

3. Replace the tip gasket (3a) if damaged.

27a

IG. 8.

CAUTION

The barrel resistor cartridge (B) is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

WARNING

Fire, Explosion, and Electric Shock Hazard

Fig. 8. Tip Guard, Air Cap, and Spray Tip Replacement

4. Trigger the gun and remove the seat housing (2) with the tool (37) provided. See F

IG. 9.

Fig. 9. Seat Housing Replacement

Continued on page 27.

26 309295N

Page 27

Repair

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tighten the seat housing. Over-tightening may result in improper fluid shut-off.

5. Trigger the gun and install the gray-colored seat housing (2). Tighten until snug, then 1/4 turn more.

CAUTION

To avoid damaging the tip guard (4), orientate the air cap (9a) before tightening the retaining ring (27). Do not turn the cap when the retaining ring is tight.

6. Assemble the spray tip (3), air cap (9a), and tip guard (4). Make sure the electrode (9b) is not damaged or missing. Install the air cap assembly with the retaining ring (27). The u-cup (27a) lips must face forward.

7. Test gun resistance, page 18.

309295N 27

Page 28

Repair

Electrode Replacement

WARNING

Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap.

1. Prepare the gun for service, page 25.

2. Remove the air cap assembly, page 26.

3. Pull the electrode (9b) out of the back of the air cap, using a needle-nose pliers.

4. Push the new electrode through the air cap hole. Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap. Press the electrode in place firmly with your fingers. See F

IG. 10.

5. Install the air cap assembly, page 26.

6. Test gun resistance, page 18.

Fig. 10. Electrode Replacement

02013

28 309295N

Page 29

Repair

Fluid Tube Replacement

1. Prepare the gun for service, page 25.

2. Disconnect the bottom fluid tube nut (C). See F

11.

3. Carefully unscrew the top fluid tube nut (D).

IG.

CAUTION

Be careful not to damage the fluid tube assembly (14) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

4. Apply dielectric grease (40) to the entire length of the plastic extension on the end of the fluid tube (14).

5. Apply low strength thread sealant to the fluid tube nut threads.

Fluid Filter Removal

1. Prepare the gun for service, page 25.

2. Disconnect the bottom fluid tube nut (C).

3. Remove the fluid filter (1) from the fluid fitting. Clean or replace the filter, as needed. See F

NOTE: Replacement filters are available in 100 mesh (standard) or 60 mesh sizes. See page 45.

4. Install the fluid filter in the fluid fitting. Tighten the bottom nut (C) onto the fitting and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

IG. 12.

CAUTION

Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).

6. Install the fluid tube into the gun barrel and tighten the top nut (D) hand-tight, then 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do not overtighten the nut.

7. Make sure the fluid filter (1) is in place in the fluid fitting. Tighten the bottom nut (C) onto the fitting and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

Fig. 11. Fluid Tube Replacement

ti1524a

TI1521A

Fig. 12. Fluid Filter Removal

309295N 29

Page 30

Repair

Fluid Needle Replacement

1. Prepare the gun for service, page 25.

2. Remove the air cap assembly and seat housing, page 26.

3. Remove the barrel (16), page 31.

4. Remove the trigger screws (8) and trigger (30).

5. Remove the spring cap (45) and the spring (26a) from the barrel. See F

IG. 13.

6. Place the 2 mm driver (44) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

7. Using the u-shaped tool (37), pull back on the packing nut (N) to remove the fluid needle assembly. See F

IG. 14.

8. Install the fluid needle assembly in the gun barrel. Push in on the needle with the 2 mm driver (44) and tighten. See F

IG. 15.

26a

TI1618A

Fig. 13. Spring Cap and Springs

9. Install the spring (26a).

10. Install the spring cap (45), making sure the grounding spring (55) is in place.

11. Install the trigger (30) and screws (8).

12. Install the barrel (16), page 31.

CAUTION

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may result in improper fluid shutoff.

13. Install the seat housing and air cap, page 26.

14. Test gun resistance, page 18.

Fig. 14. Fluid Needle Removal

TI1526B

Fig. 15. Fluid Needle Replacement

30 309295N

Page 31

Repair

Barrel Removal

1. Prepare the gun for service, page 25.

2. Carefully loosen the nut (C) from the bracket fluid fitting (13). See F

3. Loosen the three screws (11).

IG. 16.

CAUTION

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.

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).

CAUTION

Do not over-tighten the screws (11).

4. Make sure the fluid filter (1) is in place in the fluid fitting. Tighten the bottom fluid tube nut (C) onto the bracket (13) fluid fitting and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

CAUTION

Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).

TI1516A

Fig. 16. Barrel Removal

Barrel Installation

1. Be sure the gasket (10*, FIG. 17.) and grounding spring (55, F holes are aligned properly. Replace if damaged.

IG. 13.) are in place and the gasket air

ti1517a

5. Test gun resistance, page 18.

*10

Fig. 17. Barrel Installation

TI1520B

309295N 31

Page 32

Repair

Power Supply Removal and Replacement

NOTE:

• 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 25.

2. Remove the barrel (16), page 31.

CAUTION

Be careful when handling the power supply (18) to avoid damaging it.

7. Connect the 3-wire connector (B). 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.

9. Lubricate the power supply o-ring (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 Models 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.

11. Install the barrel (16), page 31.

12. Test gun resistance, page 18.

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 Models only, disconnect the flexible circuit (59) from the socket at the top of the handle (17). See F

4. Disconnect the 3-wire connector (B) from the power supply. Slide the alternator up and off the power supply. Inspect the power supply and alternator for damage. On Smart Models only, disconnect the 6-pin flexible circuit (59) from the power supply.

5. Check the power supply resistance, page 19. Replace if necessary.

NOTE: Before installing the power supply, make sure the o-rings (18a*, 19a*), spring (18b), and pads (19e) are in place.

6. On Smart Models only, connect the 6-pin flexible cir- cuit (59) to the power supply.

IG. 18.

*10

*19a

19e

18b

*18a

Fig. 18. Power Supply and Turbine Alternator

ti1505c

32 309295N

Page 33

Repair

Turbine Alternator Removal and Replacement

NOTE: Replace turbine bearings after 2000 hours of

operation. Order Part No. 223688 Bearing Kit.

1. Prepare gun for service, page 25.

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 (B); 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.

309295N 33

Page 34

Repair

Atomizing Air Adjustment Valve Repair

1. Prepare the gun for service, page 25.

2. Place a wrench on the flats of the valve assembly (20) and unscrew it from the handle (17).

NOTE: 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).

IG. 19.

6. Clean all parts and inspect for wear or damage.

NOTE: Use non-silicone grease, Part No. 111265. Do not over-lubricate.

7. When reassembling the atomizing 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.

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

20b*

20c

20a

Fig. 19. Atomizing Air Adjustment Valve

TI1487A

34 309295N

Page 35

Repair

Air Valve Repair

1. Prepare the gun for service, page 25.

2. Remove the barrel, page 31.

3. Remove the air valve cap (25) from the handle (17). Remove the spring (15). See F

IG. 20.

CAUTION

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 the rubber sealing surface and replace the air valve if damaged.

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 air valve cap (25). Torque to 15-25 in-lb (1.7-2.8 N•m).

8. Install the barrel, page 31.

CAUTION

When removing the air valve (21) be careful not to damage the seat area. The rubber seal is not removable.

ti1527a

Fig. 20. Air Valve

309295N 35

Page 36

Repair

ES ON/OFF Valve Repair

1. Prepare the gun for service, page 25.

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.

CAUTION

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.

NOTE: 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).

22g

22d

22e

22b*

22c

22a*

TI1488A

Fig. 21. ES ON/OFF Valve

22f

36 309295N

Page 37

Parts

Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50)

See page 38 for detail views of the alternator (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22).

Parts

16a

I O

ti1366a

*18a

18b

26a

19e

*10

19a*

21***

24a*

14 (Ref)

38 39

ti1511C

27a*

309295N 37

Page 38

Parts

Ref. No. 20: Atomizing Air Adjustment ValveRef. No. 19: Alternator

19b

19d

19c

Ref. No. 22: ES ON/OFF Valve

22d

22e

22b*

22c

19e

22f

19a*

TI1481a

22g

20a

20c

20b*

20d

TI1487A

22a*

TI1488A

38 309295N

Page 39

Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50)

Parts

Ref. No.

1 205264 FILTER, fluid, inline 1

2 245280 HOUSING, seat 1

3 GG3XXX SPRAY TIP (customer’s choice);

3a 183459 . SEAL, spray tip 1

4 276767 TIP GUARD 1

6* 188749 PACKING, u-cup, air valve;

8 197369 SCREW, trigger 2

9 245276 AIR CAP ASSEMBLY; includes

9a 198679 . AIR CAP 1

9b 244917 . ELECTRODE (kit of 5) 1

10* 197517 GASKET, barrel 1

11 197518 SCREW; socket-hd; 10-24 x 3/4

13 15M680 BRACKET, inlet, fluid 1

14 244713 TUBE, fluid 1

15 185116 SPRING, compression 1

16 244531 BARREL, gun; includes item 16a 1

16a 197486 . O-RING; conductive 1

17 245286 HANDLE, gun (includes item 28) 1

18 244541 POWER SUPPLY, 85 kV; includes

18a* 103337 . O-RING; fluoroelastomer 1

18b 197624 . SPRING, compression 1

19 244555 TURBINE, alternator; includes

19a* 110073 . O-RING; fluoroelastomer 1

19b 223688 . BEARING KIT; includes front

19c 244577 . COIL 1

19d 111745 . RING, retaining 1

19e 198821 . PAD, pressure 2

Part No. Description Qty

includes item 3a

UHMWPE

items 9a and 9b

in. (19 mm)

items 18a-18b

items 19a-19e

and rear bearings and fan

Ref. No.

20 244556 VALVE, adjustment, atomizing air;

20a 101021 . RING, retaining 1

20b* 106560 . O-RING; fluorocarbon 1

20c 197566 . HOUSING, valve 1

20d 197567 . STEM, valve 1

21*** 244557 VALVE, air; 1

22 244558 VALVE, electrostatics, ON/OFF;

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

22g 276753 . KNOB 1

24 249323 VALVE, exhaust; includes item

24a* 112085 . O-RING; fluorocarbon 1

25 197966 CAP, air valve 1

26 244714 NEEDLE, fluid; includes item 26a 1

26a 112691 . SPRING, compression 1

27 244927 RING, retaining, air cap; includes

27a* 198307 . PACKING, u-cup 1

28 276695 HOOK 1

30 276698 TRIGGER 1

35 185105 FITTING, air; left-hand threads 1

36 107460 WRENCH, ball end; 4 mm 1

37 276741 MULTI-TOOL 1

38 185103 TUBE, exhaust 1

39 110231 CLAMP 1

40 116553 GREASE, dielectric, tube (not

Part No. Description Qty

includes items 20a-20d

includes items 22a-22g

24a

item 27a

shown)

309295N 39

Page 40

Parts

Ref. No.

41 244915 COVER, gun; box of 10 (not

42 179791 TAG, warning (not shown);

43 180060 SIGN, warning (not shown);

44 112080 TOOL, needle; 2 mm 1

45 198516 CAP, spring

47 197967 PLUG 1

Part No. Description Qty

shown)

replacement available at no cost

Ref. No.

48 198058 SCREW, cap, socket hd 1

49 222385 CARD, warning (not shown);

50 188774 TAG, warning (not shown);

Part No. Description Qty

replacement available at no cost

* Included in Air Seal Repair Kit 244781.

*** Rubber seal is not removable.

Replacement Warning labels, signs, tags, and cards are available at no cost.

40 309295N

Page 41

Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59)

I O

Parts

16a

μα

I O

53 (Ref)

100

adjustment valve (20), and ES ON/OFF valve (22).

51 (Ref)

See page 42 for detail views of the alternator (19), atomizing air

21***

ti1253a

*18a

18b

26a

19e

19a*

*10

24a*

14 (Ref)

ti1510d

27a*

309295N 41

Page 42

Parts

Ref. No. 20: Atomizing Air Adjustment ValveRef. No. 19: Alternator

19b

19d

19c

Ref. No. 22: ES ON/OFF Valve

22f

22d

22e

22b*

22c

19a*

19e

TI1481a

22g

20a

20c

20b*

20d

TI1487A

22a*

TI1488A

Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59)

Ref. No.

1 205264 FILTER, fluid, inline 1

2 245280 HOUSING, seat 1

3 GG3XXX SPRAY TIP (customer’s choice);

3a 183459 . SEAL, spray tip 1

4 276767 TIP GUARD 1

6* 188749 PACKING, u-cup, air valve;

8 197369 SCREW, trigger 2

9 245276 AIR CAP ASSEMBLY 1

9a 198679 . AIR CAP 1

Part No. Description Qty

includes item 3a

UHMWPE

Ref. No.

9b 244917 . ELECTRODE (kit of 5) 1

10* 197517 GASKET, barrel 1

11 197518 SCREW; socket-hd; 10-24 x 3/4

13 15M680 BRACKET, inlet, fluid 1

14 244713 TUBE, fluid 1

15 185116 SPRING, compression 1

16 244531 BARREL, gun; includes item 16a 1

16a 197486 . O-RING; conductive 1

17 245288 HANDLE, gun (includes item 28) 1

Part No. Description Qty

in. (19 mm)

42 309295N

Page 43

Parts

Ref. No.

18 244541 POWER SUPPLY, 85 kV; includes

18a* 103337 . O-RING; fluoroelastomer 1

18b 197624 . SPRING, compression 1

19 244555 TURBINE, alternator; includes

19a* 110073 . O-RING; fluoroelastomer 1

19b 223688 . BEARING KIT; includes front

19c 244577 . COIL 1

19d 111745 . RING, retaining 1

19e 198821 . PAD, pressure 2

20 244556 VALVE, adjustment, atomizing air;

20a 101021 . RING, retaining 1

20b* 106560 . O-RING; fluorocarbon 1

Part No. Description Qty

items 18a-18b

items 19a-19e

and rear bearings and fan

includes items 20a-20d

Ref. No.

27a* 198307 . PACKING, u-cup 1

28 276695 HOOK 1

30 276698 TRIGGER 1

35 185105 FITTING, air; left-hand threads 1

36 107460 WRENCH, ball end; 4 mm 1

37 276741 MULTI-TOOL 1

38 185103 TUBE, exhaust 1

39 110231 CLAMP 1

40 116553 GREASE, dielectric, tube (not

41 244915 COVER, gun; box of 10 (not

42 179791 TAG, warning (not shown);

43 180060 SIGN, warning (not shown);

Part No. Description Qty

shown)

replacement available at no cost

20c 197566 . HOUSING, valve 1

20d 197567 . STEM, valve 1

21*** 244557 VALVE, air 1

22 244558 VALVE, electrostatics, ON/OFF;

includes items 22a-22g

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

22g 276753 . KNOB 1

24 249323 VALVE, exhaust; includes item

24a

24a* 112085 . O-RING; fluorocarbon 1

25 197966 CAP, air valve 1

26 244714 NEEDLE, fluid; includes item 26a 1

26a 112691 . SPRING, compression 1

27 244927 RING, retaining, air cap; includes

item 27a

44 112080 TOOL, needle; 2 mm 1

45 198516 CAP, spring

47 197967 PLUG 1

48 198058 SCREW, cap, socket hd 1

49 222385 CARD, warning (not shown);

replacement available at no cost

50 188774 TAG, warning (not shown);

replacement available at no cost

51 244627 SWITCH, ES HI/LO 1

52 111450 O-RING 1

53 276734 PLUG, LO voltage adjustment 1

54 197910 SCREW, pivot 1

55 197624 SPRING, grounding 1

59 245265 CIRCUIT, flexible 1

* Included in Air Seal Repair Kit 244781.

*** Rubber seal is not removable.

Replacement Warning labels, signs, tags, and cards are available at no cost.

309295N 43

Page 44

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)

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

Nylon Fluid Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

223540 1/4 in. (6 mm) ID x 25 ft (7.6 m), 1/4 npsm 223541 1/4 in. (6 mm) ID x 50 ft (15.2 m), 1/4 npsm

Grounded Air Whip Hose

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.188 in. (5 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) left-hand threads

236130 3 ft (0.9 m) 236131 6 ft (1.8 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.

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.

Fluid Whip Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

0.125 in. (3 mm) ID; 1/4 npsm(f) x 1/4 npt(m)

236134 3 ft (0.9 m) 236135 6 ft (1.8 m)

Fluid Shutoff/Drain Valve

5000 psi (350 bar, 35 MPa) Maximum Working Pressure

For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.

210657 1/2 npt(m), Fluoroelastomer seals 210658 3/8 npt(m), Fluoroelastomer seals 210659 3/8 npt x 1/4 npt(m), Fluoroelastomer seals 214037 1/4 npt(m), PTFE seals

Fluid Swivel

5800 psi (405 bar, 40 MPa) Maximum Working Pressure

115898 1/4 npsm(m) x 1/4 npsm(f)

44 309295N

Page 45

Accessories

Gun Accessories

Gun Repair Kit

244781 Air Seal Repair Kit

Electrode Replacement Kit

244917 Includes five electrodes.

Inline Fluid Filters

238561 100 mesh filter. Set of three. 238563 60 mesh filter. Set of three.

Round Pattern Kit

Provides higher level of performance to electrostatic spraying.

245282 Includes tip of choice.

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

245271 Use to convert Graco gun washers so they

can clean PRO Xs4 air-assisted spray guns.

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.

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 Sign

180060 English Warning Sign. FM Approved. Avail-

able at no charge from Graco.

Instruction Signs

198310 English Setup Instructions. 198320 English Daily Care Instructions.

Electrostatic Conductive Gloves (box of 12)

117823 Small 117824 Medium 117825 Large

309295N 45

Page 46

Spray Tip Selection Chart

Fan Width at

Part No.

GG3107 2-4 (50-100) 0.007 (0.178)

GG3207 4-6 (100-150)

GG3307 6-8 (150-200)

GG3209 4-6 (100-150) 0.009 (0.229)

GG3309 6-8 (150-200)

GG3409 8-10 (200-250)

GG3211 4-6 (100-150) 0.011 (0.279)

GG3311 6-8 (150-200)

GG3411 8-10 (200-250)

GG3511 10-12 (250-300)

GG3611 12-14 (300-350)

GG3213 4-6 (100-150) 0.013 (0.330)

GG3313 6-8 (150-200)

GG3413 8-10 (200-250)

GG3513 10-12 (250-300)

GG3613 12-14 (300-350)

GG3215 4-6 (100-150) 0.015 (0.381)

GG3315 6-8 (150-200)

GG3415 8-10 (200-250)

GG3515 10-12 (250-300)

GG3615 12-14 (300-350)

10 in. (250 mm)

in. (mm)

Orifice Size

in. (mm)

Fan Width at

Part No.

GG3217 4-6 (100-150) 0.017 (0.432)

GG3317 6-8 (150-200)

GG3417 8-10 (200-250)

GG3517 10-12 (250-300)

GG3617 12-14 (300-350)

GG3717 14-16 (350-400)

GG3319 6-8 (150-200) 0.019 (0.483)

GG3419 8-10 (200-250)

GG3519 10-12 (250-300)

GG3619 12-14 (300-350)

GG3719 14-16 (350-400)

GG3421 8-10 (200-250) 0.021 (0.533)

GG3521 10-12 (250-300)

GG3621 12-14 (300-350)

GG3721 14-16 (350-400)

GG3821 16-18 (400-450)

GG3423 8-10 (200-250) 0.023 (0.584)

GG3523 10-12 (250-300)

GG3623 12-14 (300-350)

GG3723 14-16 (350-400)

GG3823 16-18 (400-450)

GG3425 8-10 (200-250) 0.025 (0.635)

10 in. (250 mm)

in. (mm)

Orifice Size

in. (mm)

GG3525 10-12 (250-300)

GG3625 12-14 (300-350)

GG3725 14-16 (350-400)

GG3825 16-18 (400-450)

46 309295N

Page 47

Technical Data

Category Data

Maximum Working Fluid Pressure 3000 psi (21 MPa, 210 bar)

Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar)

Minimum Air Pressure to Gun Inlet 40 psi (0.28 MPa, 2.8 bar)

Maximum Fluid Operating Temperature 120°F (48°C)

Paint Resistivity Range 3 megohm/cm to infinity

Short Circuit Current Output 125 microamperes

Voltage Output PRO Xs4 AA (244572): 85 kV

PRO Xs4 AA (244573): 40-85 kV

Sound Power (measured per ISO Standard 9216) at 40 psi (0.28 MPa, 2.8 bar): 88.9 dB(A)

at 100 psi (0.7 MPa, 7 bar): 99.7 dB(A)

Sound Pressure (measured 1 m from gun) at 40 psi (0.28 MPa, 2.8 bar): 86.0 dB(A)

at 100 psi (0.7 MPa, 7 bar): 95.0 dB(A)

Technical Data

Air inlet fitting, left-hand thread 1/4 npsm(m)

Fluid inlet fitting 1/4-18 npsm(m)

Gun Weight 29.1 oz (825 g)

Gun Length 11.4 in. (29 cm)

Wetted Parts Stainless Steel; Nylon, Acetal, Ultra-High Molecular

Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten Wire, Polyethylene

Loctite® is a registered trademark of the Loctite Corporation.

309295N 47

Page 48

Graco Standard 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.

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1-800-328-0211 Toll Free

612-623-6921

612-378-3505 Fax

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

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 309295

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised 10/2011