Graco OR PRO TI1681A, PRO Xs3 Instructions-parts List Manual

Instructions/Parts List

ELECTROSTATIC, WATERBORNE, AIR SPRAY

WB100 Isolation System and
PRO™ Xs3 Spray Gun

Important Safety Instructions

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

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

For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the
following conditions for non-flammability:

309293J

FM Approved

• The fluid has a flash point above 140°F (60°C)

and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93. FM

• The fluid does not sustain burning when tested per

ASTM Standard D4206 Sustained Burn Test.

CE-EN 50059 Compliant

• Materials which cannot be ignited, in any mixture

with air, by an energy source of less than 500 mJ.

See page 3 for a List of Models

U.S. Patent No. 7,226,004

PRO Xs3
Smart Gun and
Fluid Hose

TI2139a

WB 100
Isolation Enclosure

TI1681A

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents

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

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How the Electrostatic Air Spray Gun Works . . . . 7

Spraying Waterborne Fluids Electrostatically . . . 7

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Requirements . . . . . . . . . . . . . . . . . . . . . 9

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 9

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 11

Ground the Cabinet . . . . . . . . . . . . . . . . . . . . . . 11

Connect the Waterborne Fluid Hose . . . . . . . . . 11

245895 Agitator Kit . . . . . . . . . . . . . . . . . . . . . . 14

245944 Fluid Regulator Kit . . . . . . . . . . . . . . . . 15

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Check Electrical Grounding . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 19

Fluid Voltage Discharge and

Grounding Procedure . . . . . . . . . . . . . . . . . 20

Pressure Relief Procedure . . . . . . . . . . . . . . . . 20

Fill the Fluid Supply . . . . . . . . . . . . . . . . . . . . . . 21

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Low Voltage Adjustment (Smart Guns Only) . . 25

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 26

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 27

Clean the Air Cap and Fluid Nozzle . . . . . . . . . 29

Grease Door Latch Threads . . . . . . . . . . . . . . . 29

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 30

Test Power Supply Resistance . . . . . . . . . . . . . 31

Test Electrode Resistance . . . . . . . . . . . . . . . . . 32

Test Ground Strip Resistance . . . . . . . . . . . . . . 33

Test Cylinder Resistance . . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Voltage Loss Troubleshooting . . . . . . . . . . . . . . 34

Spray Pattern Troubleshooting . . . . . . . . . . . . . 37

Gun Operation Troubleshooting . . . . . . . . . . . . . 38

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 39

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Prepare the Gun for Service . . . . . . . . . . . . . . . 41

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 42

Electrode Replacement . . . . . . . . . . . . . . . . . . . 43

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 44

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 45

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 46

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 46

Power Supply Removal and Replacement . . . . 47

Turbine Alternator Removal and Replacement . 48

Fan Air Adjustment Valve Repair . . . . . . . . . . . . 49

Fluid Adjustment Valve Repair . . . . . . . . . . . . . 50

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 50

Atomizing Air Restrictor Valve Removal and

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 51

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 51

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 65

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 65

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 66

Miscellaneous Accessories . . . . . . . . . . . . . . . . 66

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 70

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 70

2 309293J

List of Models

Part No. Gun Model Description

245897 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air

245898 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air

233825 Waterborne Isolation Enclosure without hoses and gun.

List of Models

FM Approved

spray gun, grounded air hose, and shielded waterborne fluid
hose

spray gun, grounded air hose, and shielded waterborne fluid
hose

244581,

Series B

245301, PRO Xs3 Part No. 244581 Gun, with 25 ft (7.6 m) waterborne fluid hose

244582,

Series B

245305 PRO Xs3 Part No. 244582 Gun, with 25 ft (7.6 m) waterborne fluid hose

245252 Shielded Waterborne Fluid Hose Assembly 25 ft (7.6 m)

PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings

PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings,

EN 50059 Compliant

244581,

Series B

244582,

Series B

246511 Waterborne Isolation Enclosure, without hoses and gun

246431 PRO Xs3 Unshielded Waterborne fluid hose assembly, 25 ft (7.6 m).

246592 PRO Xs3 Waterborne Isolation Enclosure with standard electrostatic air

PRO Xs3 Standard Electrostatic Air Spray Gun, for waterborne coatings.

PRO Xs3 Smart Electrostatic Air Spray Gun, for waterborne coatings.

spray gun, grounded air hose, and unshielded waterborne fluid
hose

246593 PRO Xs3 Waterborne Isolation Enclosure with smart electrostatic air

309293J 3

spray gun, grounded air hose, and unshielded waterborne fluid
hose

Symbols

Symbols

Warning Symbol

WARNING

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

WARNING

Electric Shock Hazard

Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous
condition and result in electric shock or other serious injury.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all conductive objects in the spray area. See Grounding, page 17.

• The gun must be connected to a voltage isolation system that will discharge the system volt­age when the gun is not in use.

• All components of the isolation system that are charged to high voltage must be contained
within an enclosure that prohibits personnel from making contact with the high voltage compo­nents before the system voltage is discharged.

Caution Symbol

CAUTION

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

• Follow the Fluid Voltage Discharge and Grounding Procedure on page 20 when instructed
to discharge the voltage; before cleaning, flushing, or servicing the system; before approach­ing the front of the gun; and before opening the safety enclosure for the isolated fluid supply.

• Do not touch the gun nozzle or come within 4 in. (102 mm) of the nozzle during gun operation
or for 30 seconds after operation stops, to allow the voltage to discharge through the bleed
resistor. Place the gun in the holster (accessory) during this 30 second period. Refer to Fluid

Voltage Discharge and Grounding Procedure, page 20.

• Electrically connect a metal part of the fluid supply unit to the bleed resistor.

• The gun air supply must be interlocked with the isolation system to shut off the air supply any-

time the isolation system enclosure is opened.

• Use only the red-colored Graco electrically conductive gun air hose with this gun. Do not use
black or grey-colored Graco air hoses.

• Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and
the spray gun. Do not splice hoses together.

• Do not enter a high voltage or hazardous area until all high voltage equipment has been dis­charged.

4 309293J

Warning

WARNING

Fire and Explosion Hazard

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition
and result in a fire or explosion.

• Electrostatic equipment must be used only by trained, qualified personnel who understand the

requirements in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all other electrically conductive objects in the spray area. See Grounding, page 17.

• Check gun resistance daily. See Test Gun Resistance on page 30.

• If there is any static sparking while using the equipment, stop spraying immediately. Identify

and correct the problem.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. See Ventilate the
Spray Booth on page 11.

• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front

cover of this manual.

• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable flu­ids, as defined on the front cover of this manual.

• Do not flush with the gun electrostatics turned on.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the

spray area.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

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.

309293J 5

Warning

WARNING

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 distribu-

tor.

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

• Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply

with this gun.

• 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. Maxi-

mum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).

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

ings.

• 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 regula-

tions.

Pressurized Equipment Hazard

Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause serious injury.

• Do not point the spray gun at anyone or at any part of the body.

• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure, page 20, when you stop spraying and before cleaning,

checking, or repairing equipment.

• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.

• Tighten all fluid connections before each use.

6 309293J

Introduction

Introduction

How the Electrostatic Air Spray
Gun Works

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 electrode.

The fluid source supplies fluid to the hose and gun. The
gun must be connected to a voltage isolation system to
maintain voltage at the gun. In an isolation system, the
entire fluid supply is electrostatically charged. The
charged fluid is attracted to the grounded workpiece,
wrapping around and evenly coating all surfaces.

Spraying Waterborne Fluids
Electrostatically

This electrostatic air spray gun is designed to spray only
waterborne fluids with a flash point above 140°F (60°C)
and a maximum organic solvent concentration of 20%,
by weight, per ASTM Standard D93. Also, the fluid must
not sustain burning when tested per ASTM Standard
D4206 Sustained Burn Test.

When connected to a voltage isolation system, all of the
fluid in the spray gun, fluid hose, and isolated fluid sup­ply is charged to high voltage, which means that the sys­tem has more electrical energy than a solvent-based
system. Therefore, only non-flammable fluids (as
defined on the front cover of this manual) can be
sprayed with the system or be used to clean, flush, or
purge the system.

Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards.
When the spray gun charges the isolated fluid to high
voltage, it is similar to charging a capacitor or a battery.
The system will store some of the energy while spraying
and retain some of that energy after the spray gun is
shut off. It is not safe to touch the front end of the gun
until the stored energy is discharged. The amount of
time it takes to discharge the energy depends on the
system design. Follow the Fluid Voltage Discharge
and Grounding Procedure on page 20 before
approaching the front of the gun.

CAUTION

The Graco warranty is void if the spray gun is con­nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.

309293J 7

Introduction

I O

Gun Overview

The electrostatic gun includes the following controls
(see F

IG. 1.).

• FLUID adjustment valve. Adjusts fluid rod travel.

Use only in low flow conditions, to reduce wear.

• Fan AIR adjustment valve. Adjusts fan size and

shape.

• Atomizing air RESTRICTOR valve. Restricts

atomizing air flow. Replace with plug (included) if
desired.

ES INDICATOR

ES ON/OFF

ES

I O

RESTRICTOR

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 Electrical Troubleshooting, page

39.

• 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. Page 21.

100%

LO

ES

I O

0

KV

μα

HI

ES

ES HI/LO

ES ON/OFF

RESTRICTOR

DISPLAY

LO VOLTAGE

AIR

Standard Model Smart Model

AIR CAP

ELECTRODE

Fig. 1. Gun Overview

ti1266a

FLUID TUBE

FLUID

FLUID

ti1253a

TRIGGER

AIR INLET

TI1681A

8 309293J

Installation

Installation

System Requirements

A safe, well designed voltage isolation system should
have the following features:

• All components of the isolation system that are

charged to high voltage must be contained within an
enclosure that prohibits persons from making con­tact with the high voltage components before the
system voltage is discharged.

• A bleed resistor to drain off the system voltage when

the spray gun is not in use.

• The system should not have any severe arcing

occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the sys­tem components.

• The system must include a means for automatically

discharging the system voltage when anyone opens
the isolation enclosure.

CAUTION

Warning Sign

Mount the warning sign, Part No. 186118, in the spray
area where it can be seen and read by all operators.
Additional warning signs are available at no charge.

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 all

National, State and Local safety and fire
codes, NFPA 33, NEC 504 and 516, and
OSHA standard 1910.107.

The Graco warranty is void if the spray gun is con­nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.

FIG. 2. on page 10 shows a PRO Xs electrostatic water­borne air spray system. For assistance in designing a
system to suit your particular needs, contact your Graco
distributor.

309293J 9

Installation

B*

AA

BB

TI1896C

K*

Gun ES ON/OFF valve: I is ON, 0 is OFF

Q*

DE

M

A

C

B*

L

U

S

P*

X

N

G

W

J

R

V*

Y

T

F

Z

H

Fig. 2. Typical Installation: PRO Xs Waterborne System
Key

A Main Air Supply Line
B* Main Air Supply Shutoff Valve (bleed-type)
C Pump Air Pressure Gauge
D Pump Air Pressure Regulator
EkV Meter
FPump
G Pump Suction Hose
H Paint Container
J Bleed Resistor
K* Enclosure Safety Interlock
L Isolated Enclosure
M Gun Air Line Filter
N Gun Air Pressure Regulator
P* Graco Red Grounded Air Supply Hose
Q* Air Hose Ground Wire

TI1775C

R Graco Waterborne Fluid Hose
S Waterborne Electrostatic Air Spray Gun
T Grounding Rod
U Ground Terminal
V* Main Ground Wire
W Strain Relief/Ground Fitting
X Pump Air Supply Line
Y Grounding Cylinder
Z Pump Fluid Outlet Fitting
AA Isolated Enclosure Door
BB Enclosure T-Handle Locking Screw

* Required for safe operation. Must be purchased separately.

10 309293J

Installation

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors. Do not
operate the gun unless ventilation fans are
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. The minimum allow­able air exhaust velocity is 60 linear ft/min (18.3 linear
meters/minute).

Connect the Air Line

4. Connect the main air supply line (A) to the
bleed-type air valve (B). The bleed valve shuts off all
air to the system. Install an additional bleed-type air
valve (B) upstream of the air filter (M) to isolate the
filter for servicing.

WARNING

Pressurized Equipment Hazard

The bleed-type air valve (B) is required in
your system to relieve air trapped between

the valve and the fluid supply unit after the
air regulator (D) is shut off. Trapped air can cause the
fluid supply unit to cycle unexpectedly, which can
result in serious injury, including splashing fluid in the
eyes or on the skin.

Ground the Cabinet

Connect the main ground wire (V) to a true earth
ground.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other
serious injury, you must use the red-colored
Graco Electrically Conductive Air Hose for

the gun air supply hose, and you must con­nect the hose ground wire to a true earth ground. Do
not use the black or grey-colored Graco air hoses.

1. Install an air line filter/water separator (M) on the
main air supply 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.

2. Install a bleed-type air regulator (N) on the gun air
line (P).

3. Connect the red-colored Graco Grounded Air Sup­ply Hose (P) between the gun air regulator (N) and
the gun's air inlet. The gun air inlet fitting has a
left-hand thread. Connect the air supply hose
ground wire (Q) to a true earth ground.

Connect the Waterborne Fluid
Hose

Always use a Graco waterborne fluid hose between the
voltage isolation system fluid outlet and the gun fluid
inlet. See F
sists of an inner PTFE tube (T) and an abrasion-resis­tant outer jacket (J). Shielded hose 245252 also has a
conductive layer (C), The conductive layer is connected
to ground at the gun fitting bracket (104).

Before connecting the waterborne fluid hose to the gun,
blow it out with air and flush with water to remove con­taminants. Flush the gun before using it.

IG. 3.. The waterborne fluid hose (101) con-

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, install
only one continuous Graco waterborne
hose between the isolated fluid supply and
the gun. Do not splice hoses together.

309293J 11

Installation

1. Remove the gun air inlet fitting (35). See FIG. 3..

Shielded Hose 245252

C

A

16

104

108

107

35

106

105

38

103

102

101

39

TI2155A

Fig. 3. Connect the Fluid Hose

In a shielded hose system, if a hose failure occurs
where high voltage arcs through the inner tube, voltage
will be discharged to ground through the conductive
hose layer. When properly installed, the conductive hose
layer is grounded through its connection to the grounded
enclosure.

2. For the fluid hose to fit properly, it must be stripped
and assembled to the dimensions in F

IG. 4.. Push

the inner tube (T) into the fitting (F) until the tube
bottoms. A new Graco waterborne fluid hose comes
fully assembled to these dimensions.

B

J

T

F

A

A 7.40 in. (188 mm)
B 2.0 in. (50 mm)

Fig. 4. Waterborne Hose Dimensions (At Gun)

Unshielded
Hose 246431

T

C

J

A

A 1.25 in (32 mm)

TI2742A

Fig. 5.

3. Generously apply dielectric grease (40) to the o-ring
(107) and the threads of the fitting (106). Pull the fit­ting back 1-1/2 in. (38 mm) and apply grease to the
exposed PTFE hose to fill the area between the
hose and the fitting. Make sure the barrel inlet is
clean and dry, then screw the fitting into the fluid
inlet of the gun barrel (16). See F

IG. 3..

4. Loosen the strain relief nut (102) so the bracket can
move freely on the hose.

CAUTION

Be careful not to cut into the inner tube (T) of the
hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.

12 309293J

5. Align the bracket (104) holes with the air inlet and
exhaust outlet. Secure with the air inlet fitting (35).
Tighten the strain relief nut (102) to secure the hose.

6. Check that the nut (105) is tightened securely to the
ferrule housing (103).

7. Press the exhaust tube (38) onto the barbed
adapter (A). Secure with the clamp (39).

8. Connect the other end of the hose to the isolated
fluid supply as follows:

a. Graco WB100 Enclosure: Slide hose through

the strain relief fitting (W). Ensure conductive
layer (C) has passed through fitting. Tighten to
55 in-lb (6.2 N•m). Pull back on hose to check it
is secure. Comply with the requirements in
Warning at right. See F

IG. 6. and FIG. 7..

See Warning below.

Installation

C

W

J

Shielded

C

Hose 245252

T

J

B

A

A 14.5 in. (368 mm)
B 0.75 in. (19 mm)

TI2166A

Fig. 6. Waterborne Hose Dimensions (At Graco
WB100 Enclosure)

C

See Warning at right.

W

J

T

Z

L

T

Z

L

TI2744

A

Fig. 9. Unshielded fluid connection

WARNING

Electric Shock Hazard

For Shielded hose systems:
Conductive hose layer (C) must be
grounded through its connection to the iso-

lation system’s grounded enclosure (L) or
grounded safety fence. To maintain grounding conti­nuity, the conductive hose layer (C) must be engaged
in the ferrule when the strain relief nut is tightened.
Failure to properly install the hose in the strain relief
could result in an electric shock.

TI1897A

b. Non-Graco Isolated Enclosure: Connect hose

as instructed in the isolation system manual,
and comply with the requirements in the Warn-

Fig. 7. Shielded Fluid Hose Connection at Graco

ing at right. Refer to F

IG. 10..

WB100

Unshielded
Hose 246431

T

C

J

NOTE: Ground layer (C) of hose must
be grounded at isolation system.

J

T

L

A

Fig. 8.

309293J 13

A 12.0 in (305 mm)

TI2743A

C (see note above)

TI1966A

Fig. 10. Shielded Fluid Hose Connection at Non-Gra­co Isolated Enclosure

Installation

c. Connect the end of the tube (T) to the pump

fluid outlet fitting (Z).

CAUTION

The Graco warranty is void if the spray gun is con­nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.

CAUTION

Factory Mutual approval is valid only when this gun is
used with Factory Mutual approved voltage isolation
systems.

245895 Agitator Kit

7. Assemble the other parts of the kit as shown.
Secure the agitator with the setscrew (408).

8. Return the system to service.

Connect to elbow (282)
inside control box (258)

407

401

406

403

408

404

402

Install tube A2 here

To add an agitator to the Graco isolation system, order
Part No. 245895. See page 67 for the kit parts list.

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

3. Open the isolated enclosure door.

4. Remove the back of the control box (258).

5. Remove tube (A2) from elbow (282) at the air mani­fold; see the tubing diagram on page 64. Install the
Y fitting (402) into the elbow. Install tubes (A2) and
(407) into the Y fitting. See F
tor tube (407) into the cabinet.

6. Replace the back of the control box (258).

IG. 11.. Route the agita-

406 (Ref)

TI2137A

Fig. 11. 245895 Agitator Kit

14 309293J

Installation

245944 Fluid Regulator Kit

To add a fluid regulator to the Graco isolation system,
order Part No. 245944. See page 68 for the kit parts list.

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

3. Open the isolated enclosure door.

4. Remove the 1/4 OD tube (A1) from the pump air
inlet; see the tubing diagram on page 64.

5. Remove the waterborne fluid hose from the pump
fluid outlet fitting (231) and remove the fitting.

6. Unscrew the two pump mounting screws (S, F

12.) and remove the pump from the isolation enclo­sure.

7. Remove the back of the control box (258).

IG.

12. Connect tube (A1) to the air inlet of fluid regulator
(504). Connect tube (507) to the pump air inlet.

13. Connect the waterborne fluid hose to the fluid regu­lator outlet fitting (501).

14. Return the system to service.

The cabinet air regulator and gauge (216, 217) will now
operate the air piloted fluid regulator (504). The pump
will now operate at the inlet air pressure.

Connect to
elbow (282)
inside control
box (258)

506

507

Connect

waterborne

fluid hose here

501

504

Tube A1

502

8. Remove tube (A2) from elbow (282) at the air mani­fold; see page 64. Install the Y fitting (506) in the
elbow. Install tubes (A2) and (507) into the Y fitting.
Route the tube (507) into the cabinet.

9. Replace the back of the control box (258).

10. Assemble the fluid regulator kit as shown in F

IG. 12..

11. Reinstall the pump in the isolation enclosure. Use
the two mounting holes to the left of the holes used
previously, to allow clearance for the fluid regulator.

Connect

tube A2

here

Fig. 12. Fluid Regulator Kit

505

503

S

TI2149A

309293J 15

Installation

Select a Fluid Nozzle and Air
Cap

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
before removing or installing a fluid nozzle
and/or air cap.

The gun is supplied with Part No. 197266 Nozzle and
197477 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 Air Cap/Nozzle

Replacement on page 42.

Table 1: Fluid Nozzles

Part No.

197263 0.75 (.030) 197266 1.5 (.055)
197264 1.0 (.042) 197267 1.8 (.070)
197265 1.2 (.047) 197268 2.0 (.080)

Size,
mm (in.)

Part No.

Size,
mm (in.)

Table 2: Air Caps

Part No.

197477

197478

197479

197480

197481

Pattern Shape
and Length
in. (mm)

Round end;
15-17 (381-432)

Round end;
15-17 (381-432)

Tapered end;
13-15 (330-381)

Round end;
16-18 (406-457)

Tapered end;
17-19 (432-483)

Recommended Fluids and
Production Rates

Light to medium viscosity.
Medium to high production.

Light to medium viscosity.
Low to medium production.

Light to medium viscosity.
Medium to high production.

Medium to high viscosity
and high solids.
Low to medium production.

Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.

16 309293J

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 waterborne 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.

• Voltage Isolation System: electrically connect to a

true earth ground, as instructed in the voltage isola­tion system manual.

• 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 red-colored Graco Grounded Air Hose
and connecting the air hose ground wire to a true
earth ground. See Check Electrical Grounding,
page 18.

ti1259a

• Graco Waterborne Fluid Hose: the hose is grounded
through the conductive layer. Install the hose as
instructed on page 11.

• 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.

• All solvent pails: use only grounded metal pails,

which are conductive. Do not use plastic containers.
Do not place the pail on a non-conductive surface
such as paper or cardboard. Do not store more than
the quantity needed for one shift.

• All electrically conductive objects or devices in the

spray area: including fluid containers, tools, and

wash cans, must be properly grounded.

309293J 17

Installation

Check Electrical Grounding

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.

ES

I O

ti1273a

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 red-colored grounded air hose (R) is
connected and the hose ground wire is connected to
a true earth ground.

ti1259a

5. Using an ohmmeter (AA), measure the resistance
between the gun handle (BB) and a true earth
ground (CC). The resistance should not exceed 100
ohms. See F

IG. 13..

BB

AA

CC

TI2161A

Fig. 13. Check Gun Grounding

7. Using an ohmmeter (AA), measure the resistance
between the cabinet ground lug (214) and a true
earth ground (CC). See F

IG. 14.. The resistance

must be less than 100 ohms.

6. If the resistance is greater than 100 ohms, 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.

214

AA

CC

TI2163A

Fig. 14. Check Cabinet Grounding

18 309293J

Operation

Operation

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.

Ventilation fans are operating properly.

All operators are properly trained to safely
operate an electrostatic waterborne air spray
system as instructed in this manual.

All operators are trained in the Pressure
Relief Procedure on page 20.

The electrostatics are turned off and properly
grounded according to the.Fluid Voltage Dis-
charge and Grounding Procedure on page
20 before any person enters the safety enclo­sure, before cleaning, and before performing
any maintenance or repair.

The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Grounding
on page 17.

Fluid Hose is in good condition with no cuts or
abrasions of the PTFE layer. Replace hose if
damaged.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags,
is removed from the spray area.

Only fluids with a flash point above 140°F
(60°C) and a maximum organic solvent con­centration of 20%, by weight, may be in the
spray area.

All conductive objects in the spray area are
electrically grounded and the floor of the spray
area is electrically conductive and grounded.

309293J 19

Operation

Fluid Voltage Discharge and
Grounding Procedure

WARNING

Electric Shock Hazard

The fluid supply is charged with high volt­age until the voltage is discharged. Contact
with the charged components of the isola­tion system or spray gun electrode will

cause an electric shock. To avoid an electric shock,
follow the Fluid Voltage Discharge and Grounding

Procedure:

• whenever you are instructed to discharge the

voltage

• before cleaning, flushing, or servicing the system

equipment

Pressure Relief Procedure

WARNING

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

• or install or clean the fluid nozzle.

• before approaching the front of the gun

• or before opening the safety enclosure for the

isolated fluid supply.

1. Turn the ES ON/OFF valve OFF and wait 30 sec­onds.

ES

I O

ti1273a

2. Remove the door T-handle locking screw. This will
shut off the air to the gun and trigger the grounding
cylinder to discharge any remaining electrical
charge.

3. Use the grounding rod to touch the pump and sup­ply pail. If you see any arcs, see Electrical Trouble-
shooting on page 39.

1. Turn the ES ON/OFF valve OFF.

ES

I O

ti1273a

2. Follow the Fluid Voltage Discharge and Ground-
ing Procedure at left.

3. Turn off the main air supply valve (B).

ti1289a

4. Trigger the gun into a grounded metal waste con­tainer to relieve the air and fluid pressure.

ti1276a

20 309293J

5. Relieve fluid pressure in the fluid supply unit as
instructed in your fluid supply unit manual.

Fill the Fluid Supply

Operation

1. Discharge the system voltage (page 20).

2. Relieve the pressure (page 20).

ti1276a

3. Open the isolated enclosure door.

4. Remove the pail cover from the pail, holding a rag
over the suction tube strainer to prevent any fluid
from dripping into the isolated enclosure. Place the
cover and suction tube outside the enclosure.

5. Remove the supply pail from the enclosure.

CAUTION

Be sure to wipe up all fluid spills in the isolated enclo­sure. Fluid can create a conductive path and cause
the system to short out.

6. Clean up any fluid spills in the enclosure, using a
soft cloth and a non-flammable, compatible solvent.

7. Fill the supply pail with fluid and return it to the
enclosure. Clean up any spills.

8. Reinstall the pail cover, holding a rag over the suc­tion tube strainer to prevent fluid spills while you
place the pump suction tube in the pail.

WARNING

Fire and Explosion Hazard

To reduce the risk of fire and explosion, only
use this equipment with fluids that meet at
least one of the following conditions for
non-flammability:.

• The fluid has a flash point above 140°F (60°C)

and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.

• The fluid does not sustain burning when tested

per ASTM Standard D4206 Sustained Burn Test.

WARNING

Electric Shock Hazard

Contact with the charged components of
the spray gun will cause an electric shock.
Do not touch the gun nozzle or electrode or

come within 4 in. (102 mm) of the front of the gun
during operation or until performing the Fluid Voltage
Discharge and Grounding Procedure on page 20.

Follow the Fluid Voltage Discharge and Grounding
Procedure on page 20 when you stop spraying and
whenever you are instructed to discharge the voltage.

9. Close the isolated enclosure door and fasten
securely with the T-handle locking screw.

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow
and air flow.

309293J 21

WARNING

Component Rupture Hazard

To reduce the risk of component rupture,
which can cause serious injury, do not

exceed the maximum working pressure of
the lowest rated system component. This equipment
has a 100 psi (0.7 MPa, 7 bar) maximum working air
and fluid pressure.

Operation

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
whenever you are instructed to relieve the
pressure.

4. Fully open the fan air adjustment valve.

LO

I O

100

%

0

KV

μα

HI

ES

ES

ti1269a

1. Make sure the ES ON/OFF valve is OFF.

ES

I O

ti1273a

2. Turn on the main air supply valve (B).

3. Position the air cap by loosening the air cap retain­ing ring, and rotating the air cap for a vertical or hor­izontal spray pattern. Tighten the retaining ring until
the air cap is held firmly in place; you should not be
able to rotate the air cap horns by hand.

Vertical Pattern

5. Fully open the fluid adjustment valve.

0

KV

μα

HI

LO

ES

ES

I O

6. Fully open the atomizing air restrictor valve.

7. Make sure the ES ON/OFF valve is OFF.

100%

ti1267a

ti1272a

Horizontal Pattern

22 309293J

ES

I O

ti1273a

Operation

8. Adjust the pump air regulator to start the fluid supply
unit. Adjust the fluid flow with the air pressure regu­lator until the stream from the 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. Refer to instruction manual
309419 to set the fluid pressure for various fluid
flows, according to the size of the fluid nozzle being
used.

8-12 in. (200-300 mm)

TI1760A

9. Set the gun air regulator to deliver a minimum 40 psi
(0.28 MPa, 2.8 bar) at the gun when triggered, for
maximum transfer efficiency. See Table 3 .

10. Spray a test pattern. Check the atomization. If over­atomization occurs at minimum pressure, adjust the
air atomizing restrictor valve. If atomization is inade­quate, increase the air pressure.

ti1282a

11. Adjust the fan air adjustment valve: clockwise for a
rounder pattern, counterclockwise for a wider pat­tern.

TI1281A

Table 3: Air Regulator Settings

Air Hose Length

ft (m)

(5/16 in. [8 mm] diameter)

15 (4.6) 50 (0.35, 3.5)

25 (7.6) 60 (0.42, 4.2)

50 (15.3) 75 (0.52, 5.2)

• For the most efficiency, always use the lowest air

pressure possible.

• When increasing to a wide, flat pattern, it may be

necessary to increase the supply of fluid to the gun
to maintain the same amount of coverage over a
large area.

Air Regulator Setting

psi (MPa, bar)

(with gun triggered)

WARNING

Electric Shock Hazard

When the ES ON/OFF switch is turned ON,
the fluid supply is charged with high voltage
until the voltage is discharged. Contact with

the charged components of the spray gun
will cause an electric shock. Do not touch the gun
nozzle or electrode or come within 4 in. (102 mm) of
the front of the gun during operation.

12. Turn the ES ON/OFF switch ON (I).

ES

I O

ti1283a

ti1284a

309293J 23

Operation

I O

13. Check that the ES indicator or display is lit, or check
that the kV indicator on the isolated enclosure reads
45-55 kV. If not, see Electrical Troubleshooting on
page 39 for possible problems.

100%

0

KV

μα

ES

I O

ti1266a

LO

HI

ES

ES

I O

ti1253a

14. Check the kV meter on the isolated enclosure;
45-55 kV is normal.

15. Spray a test piece. Examine the edges for coverage.

If wrap is poor, see Spray Pattern Troubleshoot-
ing on page 37.

ti1285a

16. When you finish spraying, perform the Shutdown

procedure on page 25.

24 309293J

Operation

Shutdown

1. Discharge the system voltage (page 20).

2. Flush the spray gun. See page 26.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the
Pressure Relief Procedure on whenever
you are instructed to relieve the pressure.

3. Relieve the pressure (page 20).

ti1276a

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 LO VOLTAGE adjustment plug (53). Set
the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
Table 4 . Also see F

0

KV

μα

100%

IG. 15..

OFF

ON

12

53

ti1529a

ti1276a

4. Hang the gun from its hook or place it in the acces­sory holster, with the nozzle pointing down. Be sure
to keep the gun from grounding out.

ti1288a

Fig. 15. Low Voltage Adjustment Switches

Table 4: Low Voltage Adjustment

12kV

ON ON 50

Factory Setting >ON OFF 40

OFF ON 35
OFF OFF 30

309293J 25

Maintenance

Maintenance

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.

Follow the Fluid Voltage Discharge and
Grounding Procedure on page 20 before
flushing.

Only flush, purge, or clean the gun with fluids that
meet at least one of the following conditions for
non-flammability:

1. Turn the ES ON/OFF valve OFF and wait 30 sec­onds for the voltage to bleed off.

ES

I O

ti1273a

2. Discharge the system voltage (page 20).

3. Relieve the pressure (page 20).

ti1276a

4. Change the fluid source to solvent.

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

• The fluid has a flash point above 140°F (60°C)

and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.

• The fluid does not sustain burning when tested

per ASTM Standard D4206 Sustained Burn Test.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 20
whenever you are instructed to relieve the
pressure.

ti1276a

6. Relieve the pressure.

ti1276a

7. Open the isolated enclosure door. Leave the flush­ing fluid in the system until you are ready to spray
again.

8. Hang the gun from its hook, with the nozzle pointing
down. Be sure to keep the gun from grounding out.

ti1288a

9. Before using the system electrostatically again,
make sure no flammable vapors are present.

26 309293J

Daily Care and Cleaning

Maintenance

CAUTION

• Clean the outside of the gun daily with a soft cloth

dampened with a non-flammable solvent, as
defined on page 26.

• Check for fluid leaks. Tighten all fittings.

• Clean the air cap and fluid nozzle daily, minimum.

See page 29. Some applications require more fre­quent cleaning.

• Fluid in the air passages could cause the gun to

malfunction and could draw current and reduce the
electrostatic effect. Fluid in the power supply cavity
can reduce the alternator life. Do not use any
cleaning method which could allow fluid into the
gun air passages.

• Hang the gun with its nozzle pointing down when it

is not being used.

• Clean the workpiece hangers with non-sparking

tools.

• Clean the fluid and air line filters daily.

Do not immerse the gun in fluid.

ti1294a

• Check the movement of the trigger and valves.

Lubricate if necessary.

Do not point the gun up while cleaning it. Do not wipe the gun with a cloth that is heavily satu-

rated; wring out the excess fluid.

ti1295a

309293J 27

ti1293a

Maintenance

• Inspect the cabinet and clean up any spilled paint.

Conductive paint residue allowed to contact
grounded parts may short out the electrostatics.

• Keep the inside of the cabinet clean, for proper

operation.

• Visually inspect the ground strip (240) for damage.

Replace if needed. Measure the resistance weekly.
See page 33.

CAUTION

240

28 309293J

Maintenance

Clean the Air Cap and Fluid
Nozzle

Equipment Needed

• soft bristle brush

• non-flammable solvent

Procedure

1. Turn the ES ON/OFF valve OFF. Wait 30 seconds.

ES

I O

ti1273a

2. Discharge the system voltage (page 20).

3. Relieve the pressure (page 20).

5. Clean the air cap (9) with the soft bristle brush and
non-flammable solvent or submerge the air cap in
solvent and wipe it clean.

6. With the gun pointing down, clean the fluid nozzle
(7) and the front of the gun with a soft brush damp­ened with non-flammable solvent.

If it appears that there is paint inside the fluid nozzle (7)
air passages, remove the gun from the line for servicing.

7. Carefully install the air cap (9). Be sure to insert the
electrode (29) through the center hole of the air cap.
Rotate the air cap to the desired position.

8. Tighten the retaining ring (27) until the air cap is
held firmly in place; you should not be able to rotate
the air cap horns by hand.

9. Test gun resistance, page 30.

7

29

9

ti1276a

4. Remove the retaining ring (27) and air cap (9). See
F

IG. 16..

CAUTION

Do not use metal tools to clean the
air cap or fluid nozzle holes as this
could scratch them, and make sure
the electrode is not damaged.
Scratches in the air cap or nozzle or
a damaged electrode can distort the
spray pattern.

27

ti1297a

Fig. 16. Clean Air Cap and Fluid Nozzle

Grease Door Latch Threads

Inspect the door T-handle locking screw regularly, to
ensure the threads are well greased. Apply silicone-free
grease to the threads when necessary.

309293J 29

Electrical Tests

Electrical Tests

Electrical components inside the gun affect performance
and safety. The following procedures test the condition
of the power supply (18) and electrode (29), and electri­cal continuity between components.

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

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see
F

IG. 17.) is not approved for use in a haz-

ardous 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;

Test Gun Resistance

1. Prepare the gun for service as instructed on page

41.

2. Measure resistance between the electrode needle
tip (29) and the air swivel (35); it should be 117-137
megohms. If outside this range, go to the next test. If
you still have problems, refer to Voltage Loss Trou-
bleshooting on page 34 for other possible causes
of poor performance, or contact your Graco distribu­tor.

AA

29

• 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.

35

TI1688B

Fig. 17. Test Gun Resistance

30 309293J

Test Power Supply Resistance

1. Prepare the gun for service as instructed on page

41.

2. Remove the power supply (18), page 46.

3. Remove the turbine alternator (19) from the power
supply, page 47.

Electrical Tests

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

IG. 18..

5. The resistance should be 95-105 megohms. If out­side this range, replace the power supply. If in
range, proceed to the next test.

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

18b

Fig. 18. Test Power Supply Resistance

EE

ti1599a

309293J 31

Electrical Tests

Test Electrode Resistance

1. Prepare the gun for service as instructed on page

41.

2. 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.

3. Measure the resistance between the conductive rod
(B) and the electrode (29). The resistance should be
20-30 megohms. See F

IG. 19..

F29E

4. If in range, refer to Electrical Troubleshooting on
page 39 for other possible causes of poor perfor­mance, or contact your Graco distributor.

5. Remove the electrode (29), page 43. Measure the
resistance between the contact (E) and the elec­trode wire (F). The resistance should be 20-30
megohms. If out of range, replace the electrode.
See F

IG. 20..

6. Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, F

IG. 21.), and the electrode

contact (E) are clean and undamaged.

C

29

B

ti1499a

Fig. 20. Electrode

ti1513a

Fig. 21. Nozzle Conductive O-Ring

ti1548a

7a

Fig. 19. Test Electrode Resistance

32 309293J

Electrical Tests

Test Ground Strip Resistance

See FIG. 22.. Using an ohmmeter, measure the resis­tance between the latch housing (206) and the ground
lug (214). The ground strip is grounded through the cart
back to the ground lug. Resistance must be less than
100 ohms. If greater than 100 ohms, replace the ground
strip (240).

206

Test Cylinder Resistance

See FIG. 23.. Remove the enclosure door. Using an
ohmmeter, measure the resistance from the pump (209)
to the ground lug (214). Resistance must be less than
100 ohms. If greater than 100 ohms, replace the
grounding cylinder.

209

214

214

Fig. 22. Test Ground Strip Resistance

TI2165A

TI2164A

Fig. 23. Test Cylinder Resistance

309293J 33

Troubleshooting

Troubleshooting

WARNING

A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage isolation sys­tem, since all of the system components are electrically
connected through the conductive, waterborne fluid.

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.

Follow the Fluid Voltage Discharge and Grounding
Procedure on page 20 before checking or servicing
the system and whenever you are instructed to dis­charge the voltage.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 20

before checking or servicing any part of the

system and whenever you are instructed to

relieve the pressure.

Before troubleshooting or servicing the voltage isolation
system itself, you need to determine which component
in the system is most likely causing a problem. Possible
causes include the following:

Spray Gun

• Fluid leakage

• Dielectric breakdown at the fluid hose connection or

fluid packings

• Not enough air pressure for the turbine

• Faulty power supply

• Excessive overspray on gun surfaces

• Fluid in the air passages

Waterborne Fluid Hose

• Dielectric failure of hose (pin-hole leak through

PTFE layer)

• Air gap in the fluid column between the gun and iso-

lated fluid supply, causing a low voltage reading on
the isolation system voltage meter.

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the water­borne gun is 45-55 kV. The system voltage is lower due
to spraying current demands and voltage isolation sys­tem losses.

34 309293J

Voltage Isolation System

• Fluid leakage

• Dirty interior

Troubleshooting

Visual Check

First, check the system for any visible faults or errors to
help isolate whether the spray gun, fluid hose or voltage
isolation system has failed. A voltage probe and meter,
part no. 236003, is helpful for diagnosing voltage prob­lems and is required for some of the troubleshooting
tests that follow.

1. Check that all of the air and fluid tubes and hoses
are properly connected.

2. Check that the voltage isolation system valves and
controls are properly set for operation.

3. Check that the interior of the isolated enclosure is
clean.

4. Check that the spray gun and voltage isolation sys­tem have sufficient air pressure.

5. Check that the gun ES ON/OFF valve is in the ON
position and that the gun ES indicator light is on. If
the ES indicator light is not on, remove the spray
gun for service and complete the electrical tests on
pages 30- 32.

6. Check that the voltage isolation system's enclosure
door is closed and that any safety interlocks are
engaged and working properly.

10. Inspect the entire system for any visible fluid leak­age and repair any fluid leaks that are found. Pay
special attention to the following areas:

• Packing area of the spray gun

• Fluid hose: check for leakage or any bulges in the

outer cover, which may indicate an internal leak

• Internal voltage isolation system components

Tests

If you still have no voltage, separate the spray gun and
hose from the voltage isolation system and check
whether the gun and hose alone will hold voltage with
the following test.

1. Flush the system with water and leave the lines
filled with water.

2. Discharge the system voltage (page 20).

3. Relieve the pressure (page 20).

4. Disconnect the fluid hose from the voltage isolation
system.

Avoid allowing any water to leak out of the fluid hose as
that could cause a significant air gap in the fluid column
up to the gun electrode, which can break the conductiv­ity path and conceal a potential failure area.

7. Make sure the voltage isolation system is in the “iso­late” mode, where it is isolating the fluid voltage
from ground.

8. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the volt­age isolation system and the spray gun. An air gap
in the fluid hose can break the electrical continuity
between the spray gun and the isolated fluid supply
and cause a low voltage reading on a voltage meter
connected to the isolated fluid supply.

9. Check the spray gun cover and barrel for accumu­lated overspray. Excessive overspray can create a
conductive path back to the grounded gun handle.
Install a new gun cover and clean the exterior of the
gun.

5. Position the end of the hose as far as possible away
from any grounded surface. The end of the hose
must be at least 1 ft. (0.3 m) from any ground. Make
sure that no one is within 3 ft. (0.9 m) of the end of
the hose.

6. Turn the ES ON/OFF valve to ON and trigger the
gun just enough to turn on the air to the gun but not
the fluid. Measure the voltage at the gun electrode
with a voltage probe and meter.

7. Discharge the system voltage by waiting 30 sec­onds and then touching the gun electrode with a
grounded rod.

8. If the meter reading is 45 to 55 kV, the gun and fluid
hose are okay, and the problem is in the voltage iso­lation system.

If the reading is below 45 kV, the problem is in the
gun or fluid hose.

309293J 35

Troubleshooting

9. Flush the fluid hose and gun with enough air to dry
out the fluid passages.

10. Turn the ES ON/OFF valve to ON and trigger the
gun. Measure the voltage at the gun electrode with
a voltage probe and meter.

11. If the meter reading is 45-55 kV, the gun power sup­ply is okay, and there is probably a dielectric break­down somewhere in the fluid hose or gun. Continue
with step 12.

If the reading is below 45 kV, do the electrical tests
on page 30 to check the gun and power supply
resistance. If those tests show the gun and power
supply are okay, continue with step 12.

12. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the compo­nent that is failing.

• Fluid hose

Check for leakage or any bulges in the outer cover,
which may indicate a pin-hole leak through the
PTFE layer. Disconnect the fluid hose from the gun,
and look for signs of fluid contamination on the out­side of the PTFE portion of the fluid tube.

Inspect the end of the hose connected to the volt­age isolation system. Look for cuts or nicks.

Make sure the hose is properly stripped (see step 2
on page 12). Restrip or replace the hose.

• Fluid packings

Remove the packing assembly from the gun as
instructed on page 44, and look for signs of fluid
leakage or any blackened areas, which would indi­cate arcing is occurring along the packing rod.

• Fluid hose connection joint to the spray gun

A breakdown at the fluid hose connection joint
would be caused by fluid leaking past the o-ring
seals on the end of the hose. Remove the hose at
the gun connection and look for signs of fluid leak­age along the PTFE tube.

13. Before reassembling the gun, clean and dry the gun
fluid inlet tube. Repack the inner spacer of the fluid
packing rod with dielectric grease and reassemble
the gun.

14. Reconnect the fluid hose.

15. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.

36 309293J

Spray Pattern Troubleshooting

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

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.

Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 42.

Air in fluid supply. Check fluid source. Refill.

Improper spray pattern. Damaged nozzle or air cap. Replace, page 42.

Fluid buildup on air cap or nozzle. Clean. See page 29.

Troubleshooting

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 42.

309293J 37

Troubleshooting

Gun Operation Troubleshooting

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

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 Misaligned air cap (9) and fluid noz-

Worn packings or rod. Replace packings or rod; see page

45.

page 50.
Worn or damaged packing rod (26). Replace; see page 45

Worn fluid seat. Replace fluid nozzle and/or electrode

needle; see pages 42 to 43.
Loose fluid nozzle (7). Tighten; see page 42.
Damaged nozzle o-ring (7b). Replace; see page 42.

Damaged air cap (9). Replace; see page 42.
Dirty or clogged fluid nozzle (7). Clean; see page 42.
Damaged fluid nozzle (7). Replace; see page 42.
Damaged fluid adjustment valve (25). Replace; see page 50.

Clean fluid buildup off air cap and
zle (7).

fluid nozzle seat; see page 29.

38 309293J

Electrical Troubleshooting

Problem Cause Solution

Voltage still present at gun after fol­lowing the Fluid Voltage Discharge

and Grounding Procedure

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

ES ON/OFF valve is not turned OFF. Turn OFF.

Did not wait long enough for voltage
to discharge.

Air pocket in fluid line leaves fluid
near gun isolated.

Voltage isolation system failed. Service voltage isolation system.
Grounding cylinder not operating. Check resistance of grounding cylin-

Gun air pressure too low. Check air pressure to gun; minimum

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

Faulty gun resistance. See Test Gun Resistance on page

Fluid leaks from the packing (26d)
and causes a short.

Faulty turbine alternator. Be sure the plug is in place on the

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

Spilled paint, dried paint, or other
contaminants inside WB100 enclo­sure, causing a short circuit.

Wait longer before touching electrode
with grounded rod. Check for bleed
resistor failure.

Determine cause and correct. Purge
air from fluid line.

der, page 33. Replace if needed.

40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.

less. Clean workpiece hangers.

30.
Clean the packing rod cavity.

Replace the packing rod. See page

45.

back of the turbine alternator hous­ing. Remove and test the turbine
alternator. See page 48.

needed.
Clean interior of enclosure.

Troubleshooting

309293J 39

Troubleshooting

Problem Cause Solution

ES indicator or voltage/current dis-

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

play is not lit.

No power. Replace power supply. See page 47.

Voltage/current display stays red

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

(smart guns only).

Check fluid resistivity. See Operation on page 19.
Dirty gun. Clean. See page 27.

Operator gets mild shock. Operator not grounded or is near

See Grounding on page 17.
ungrounded object.

Gun not grounded. See Check Electrical Grounding on

page 18 and Test Gun Resistance

on page 30.

Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or

less. Clean workpiece hangers.

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

40 309293J

Repair

Prepare the Gun for Service

WARNING

Repair

• Check all possible remedies in Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to

plastic parts.

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of a fire, explosion, or
electric shock:

• Follow the Fluid Voltage Discharge and
Grounding Procedure on page 20 and

be sure the ES ON/OFF valve is OFF
before flushing, checking, or servicing
the system and whenever you are
instructed to discharge the voltage.

• Clean all parts with a non-flammable
fluid as defined on the front cover of this
manual.

• Do not service this equipment unless you
are trained and qualified.

• Do not touch the gun nozzle or come
within 4 in. (102 mm) of the nozzle during
gun operation or until you perform the

Fluid Voltage Discharge and Ground­ing Procedure on page 20.

• Lubricate the power supply o-ring (18a), some pack-

ing 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 (26a**).

1. Follow the Fluid Voltage Discharge and Ground-
ing Procedure on page 20.

2. Flush the gun, page 26.

WARNING

Pressurized Equipment Hazard

To reduce the risk of injury, follow the Pres­sure Relief Procedure on page 20 before

checking or servicing any part of the system
and whenever you are instructed to relieve the pres­sure.

309293J 41

3. Blow the fluid lines dry with air.

4. Relieve the pressure, page 20.

5. Disconnect the gun air and fluid lines at the isolation
system.

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

Repair

Air Cap/Nozzle Replacement

WARNING

CAUTION

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 service, page 41.

2. Remove the retaining ring (27) and air cap (9). See

IG. 24..

F

3. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).

27

27a*

9

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.

Use non-silicone grease, Part No. 111265, on the small
o-ring (7b). Do not over-lubricate. Do not lubricate the
contact ring (7a).

4. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).

Make sure the electrode needle (29) is finger- tight
(page 43).

5. 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).

Fig. 24. Air Cap/Nozzle Replacement

7a

7b

ti1501a

6. Install the air cap (9) and retaining ring (27). Make

37

7

sure the u-cup (27a*) is in place with the lips facing
forward.

7. Test gun resistance, page 30.

42 309293J

Electrode Replacement

1. Prepare the gun for service, page 41.

2. Remove the air cap and nozzle, page 42.

3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
turning, F

IG. 25..

CAUTION

To avoid damaging the plastic threads, be very care­ful when installing the electrode.

®

4. Apply low-strength (purple) Loctite
thread sealant to the electrode and packing rod
threads. Install the electrode finger-tight. Do not
overtighten.

or equivalent

Repair

37

5. Install the fluid nozzle and air cap, page 42.

6. Test gun resistance, page 30.

TI1682a

Fig. 25. Electrode Replacement

309293J 43

Repair

Fluid Packing Removal

1. Prepare the gun for service, page 41.

2. Remove the air cap and fluid nozzle, page 42.

3. Remove the electrode, page 43.

4. Loosen the trigger screws (8) and trigger (30). See
F

IG. 26..

5. Remove the packing rod (26), using the multi-tool
(37).

37

30

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.

6. Check all parts for wear or damage and replace if
necessary.

8

TI1683A

Fig. 26. Fluid Packing Removal

44 309293J

Repair

4

Packing Rod Repair

You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.

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 (26e) and seal (26b**) on the
fluid rod (26h). 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

2. Fill the inner cavity of the spacer (26g**) with dielec­tric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.

IG. 27..

4. Lightly tighten the packing nut (26e). The packing
nut is properly tightened when there is 3 lb (13.3 N)
of drag force when sliding the packing housing (26f)
assembly along the rod. Tighten or loosen the pack­ing nut as needed.

5. Install the o-ring (26a**) 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 electrode, page 43.

10. Install the nozzle and air cap, page 42.

11. Test gun resistance, page 30.

3. Place the packing spreader (26c**), rod packing
(26d**), and housing (26f) on the packing rod (26h).

26e

**26b

**26g

**26c

**26d

26f

**26a

E

TI1489A

26h

Fig. 27. Packing Rod

309293J 45

Repair

Barrel Removal

1. Prepare the gun for service, page 41.

2. Remove the air inlet fitting (35) and take the bracket
(104) off the gun handle (17).

3. Loosen the three screws (11).

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. See F

IG. 28..

5. Apply dielectric grease (40) to the exposed inner
tube of the fluid hose (101).

6. Check that the nut (105) is tight on the ferrule hous­ing (103).

7. Test gun resistance, page 30.

104

11

16

35

17

TI1690A

Barrel Installation

1. Be sure the gasket (10*) and grounding spring (55)
are in place. Make sure the gasket 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).

IG. 29..

CAUTION

Do not over-tighten the screws (11).

4. Position the bracket (104) on the gun handle (17)
and secure with the air inlet fitting (35).

Fig. 28. Barrel Removal

18

11

16

101

105

Fig. 29. Barrel Installation

17

TI1691A

*10

55

35

104

TI1692A

46 309293J

Repair

Power Supply Removal and
Replacement

• 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 41.

2. Remove the barrel (16), page 46.

CAUTION

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

IG. 30..

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, con­nect 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 46.

12. Test gun resistance, page 30.

17

10*

19a*

19

19e

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 Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.

5. Check the power supply resistance, page 31.
Replace if necessary.

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.

7. Connect the 3-wire connector (GG). Slide the alter­nator (19) down onto the power supply (18).

59

ti1505c

GG

18

*18a 18b

Fig. 30. Power Supply

309293J 47

Repair

Turbine Alternator Removal and
Replacement

Replace turbine alternator bearings after 2000 hours of
operation. Order Part No. 223688 Bearing Kit.

1. Prepare gun for service, page 41.

2. Remove the power supply/alternator assembly,
page 47.

3. Disconnect the alternator from the power supply,
page 47.

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 47.

7. Install the power supply/alternator assembly, page

47.

48 309293J

Repair

Fan Air Adjustment Valve Repair

1. Prepare the gun for service, page 41.

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).

IG. 31..

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.

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

20c

20a

Fig. 31. Fan Air Adjustment Valve

20b*

309293J 49

Repair

Fluid Adjustment Valve Repair

1. Prepare the gun for service, page 41.

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).

IG. 32..

25

4. Remove the air valve (21) with a pliers. Inspect the
seal (21a*) and replace if damaged. Be sure the
seal is pressed securely onto the valve so the outer
cone is flats.

CAUTION

When removing the air valve (21) be careful not to
damage the seat area.

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 46.

TI1684A

Fig. 32. Fluid Adjustment Valve

Air Valve Repair

1. Prepare the gun for service, page 41.

2. Remove the barrel, page 46.

3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See FIG. 33..

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.

*6

Fig. 33. Air Valve

TI1685A

17

21a*

21

15

25

50 309293J

Repair

Atomizing Air Restrictor Valve
Removal and Replacement

1. Prepare the gun for service, page 41.

2. Remove the atomizing air restrictor valve (23).
Inspect the o-ring (23c*). Replace if necessary. See
F

IG. 34..

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 (47).

4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).

23c*

47

23a

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.

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

22b*

22e

22d

22f

23d

TI1686A

Fig. 34. Atomizing Air Restrictor Valve

ES ON/OFF Valve Repair

1. Prepare the gun for service, page 41.

22c

22a*

23b

48

TI1488A

Fig. 35. ES ON/OFF Valve

309293J 51

Parts

Parts

Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)

Part No. 245301 60 kV Electrostatic Gun with Shielded waterborne fluid hose, Series A (items 4-55, 101-108)

See page 53 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).

I O

25 (Ref)

27

ES

27a*

ti1266a

*18a

22

20

19e

19a*

19

18

28

25

18b

17

15

21

7b

7a

7

9

16

11

*10

21a*

11

23c*

55

*6

8

*24a

23d

23a

24

47

23b

30

4

35***

36

26

29

52 309293J

37

108

107

106

101

105

104

38

103

102

39

TI1679A

Parts

Ref. No. 20: Fan Adjustment ValveRef. No. 19: Alternator

19b

19b

19d

19c

Ref. No. 22: ES ON/OFF Valve

22f

22d

22e

22b*

22c

22a*

TI1488A

19e

48

19a*

22g

TI1481a

20c

20a

Ref. No. 26: Packing Rod

26c**

26d**

26f

26a**

20b*

26g**

26b**

26e

20d

26h

TI1487A

ti1601a

309293J 53

Parts

Part No. 244581 60 kV Electrostatic Gun, Series B (items 4-55)

Part No. 245301 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-55, 101-108)

Ref.

Part No. Description Qty

No.

Ref.

Part No. Description Qty

No.

4 185111 SPRING, compression 1

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

uhmwpe

7 197266 NOZZLE; 1.5 mm orifice; includes

7a and 7b

7a 111261 . O-RING, conductive 1

7b 111507 . O-RING; fluoroelastomer 1

8 197369 SCREW, trigger 2

9 197477 AIR CAP 1

10* 197517 GASKET, barrel 1

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

in. (19 mm)

15 185116 SPRING, compression 1

16 244394 BARREL, gun 1

17 245292 HANDLE, gun; includes item 28 1

18 244542 POWER SUPPLY, 60 kV; includes

18a-18d

18a* 103337 . O-RING; fluoroelastomer 1

18b 197624 . SPRING, compression 1

19 244555 TURBINE, alternator; includes

19a-19e

20d 197567 . STEM, fan valve 1

21 244557 VALVE, air 1

21a* 276733 SEAL, fluoroelastomer 1

1

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 276753 . KNOB 1

23 244559 VALVE, air, atomizing; includes

23a 197594 . HOUSING, valve 1

23b 197591 . SHAFT 1

1

23c* 168518 . O-RING; fluoroelastomer 2

23d 101021 . RING, retaining 1

24 249323 VALVE, exhaust; includes 24a 1

24a* 112085 . O-RING; fluorocarbon 1

1

25 244593 VALVE, adjustment, fluid 1

includes 22a-22g

23a-23d

1

1

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

20 244556 VALVE, adjustment, fan; includes

20a-20d

20a 101021 . RING, retaining 1

20b* 106560 . O-RING; fluorocarbon 1

20c 197566 . HOUSING, fan valve 1

54 309293J

26 244521 ROD, packing; includes 26a-26h 1

26a** 111316 . O-RING; fluoroelastomer 1

1

26b** 116905 . SEAL 1

26c** 178409 . SPREADER, packing; uhmwpe 1

26d** 178763 . PACKING, rod; acetal 1

26e 197641 . NUT, packing 1

1

26f 185495 . HOUSING, packing 1

26g** 186069 . SPACER, packing; acetal 1

26h 244696 . ROD, packing 1

27 245790 RING, retaining; includes 27a 1

Parts

Ref.

Part No. Description Qty

No.

27a* 198307 . PACKING, u-cup 1

28 276695 HOOK 1

29 276867 NEEDLE, electrode; black 1

30 276698 TRIGGER 1

35*** 245496 SWIVEL, air; 1/4 npsm(m);

left-hand threads

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

shown)

41 244915 COVER, gun; box of 10 (not

shown)

42 179791 TAG, warning (not shown);

replacement available at no cost

43 180060 SIGN, warning (not shown);

replacement available at no cost

Ref.

Part No. Description Qty

No.

101 245252

246431

102 198663

1

1

1

1

190863

103 185547

15B932

104 197954 . BRACKET, fluid fitting 1

105 185548 . NUT 1

106 198643 . FITTING, barrel 1

107 102982 . O-RING 1

108 198640 . FITTING, seal 1

HOSE, shielded waterborne fluid;

HOSE, unshielded waterborne
fluid; includes 102-108

. FERRULE (shielded hose

245252)
FERRULE (unshielded hose

246431)

. HOUSING, ferrule (shielded

hose 245252)
HOUSING, ferrule (unshielded
hose 246431)

* Included in Air Seal Repair Kit 244781.

1

** Included in Fluid Seal Repair Kit 244911.

1

1

1

1

1

1

47 197967 PLUG 1

48 198058 SCREW, cap, socket hd 1

55 197624 SPRING, grounding 1

*** Included in Swivel Repair Kit 244834.

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

309293J 55

Parts

I O

Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)

Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)

0

HI

LO

ES

I O

25 (Ref)

27

KV

μα

ES

100%

27a*

ti1253a

*18a

9

18b

53 (Ref)

51 (Ref)

22

18

7

20

See page 57 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).

59

19a*

19

28

51

19e

53

52

54

21

7a

7b

17

*10

16

11

21a*

23c*

55

*6

8

23d

23a

23b

25

15

11

47

*24a

4

30

24

35***

105

36

26

108

29

107

106

37

56 309293J

101

104

103

102

39

38

TI1687A

Parts

Ref. No. 19: Alternator

19b

19b

19d

19c

Ref. No. 22: ES ON/OFF Valve

22f

22d

22e

22b*

22c

22a*

TI1488A

19a*

19e

48

TI1481a

22g

Ref. No. 20: Fan Adjustment Valve

20c

20a

Ref. No. 26: Packing Rod

26c**

26d**

26f

26a**

20b*

26g**

26b**

26e

20d

26h

TI1487A

ti1601a

309293J 57

Parts

Part No. 244582 60 kV Electrostatic Gun, Series B (items 4-59)

Part No. 245305 60 kV Electrostatic Gun with waterborne fluid hose, Series A (items 4-59, 101-108)

Ref.

Part No. Description Qty

No.

Ref.

Part No. Description Qty

No.

4 185111 SPRING, compression 1

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

uhmwpe

7 197266 NOZZLE; 1.5 mm orifice; includes

7a and 7b

7a 111261 . O-RING, conductive 1

7b 111507 . O-RING; fluoroelastomer 1

8 197369 SCREW, trigger 2

9 197477 AIR CAP 1

10* 197517 GASKET, barrel 1

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

in. (19 mm)

15 185116 SPRING, compression 1

16 244394 BARREL, gun 1

17 245293 HANDLE, gun; includes item 28 1

18 244542 POWER SUPPLY, 60 kV; includes

18a-18d

18a* 103337 . O-RING; fluoroelastomer 1

18b 197624 . SPRING, compression 1

19 244555 TURBINE, alternator; includes

19a-19e

20b* 106560 . O-RING; fluorocarbon 1

20c 197566 . HOUSING, fan valve 1

20d 197567 . STEM, fan valve 1

1

21 244557 VALVE, air; includes item 21a 1

1

21a* 276733 . SEAL, fluoroelastomer 1

22 244558 VALVE, electrostatics, ON/OFF;

includes 22a-22g

22a* 111516 . O-RING; CV75 1

22b* 113137 . O-RING; fluoroelastomer 1

22c 198403 . SHAFT, valve 1

22d 198404 . PLATE, retaining 1

3

22e 198453 . WASHER 1

22f 198464 . PIN 1

22g 276753 . KNOB 1

23 244559 VALVE, air, atomizing; includes

23a-23d

1

23a 197594 . HOUSING, valve 1

23b 197591 . SHAFT 1

23c* 168518 . O-RING; fluoroelastomer 2

23d 101021 . RING, retaining 1

1

24 249323 VALVE, exhaust; includes 24a 1

1

1

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

20 244556 VALVE, adjustment, fan; includes

20a-20d

20a 101021 . RING, retaining 1

58 309293J

24a* 112085 . O-RING; fluorocarbon 1

25 244593 VALVE, adjustment, fluid 1

1

26 244521 ROD, packing; includes 26a-26h 1

26a** 111316 . O-RING; fluoroelastomer 1

26b** 116905 . SEAL 1

26c** 178409 . SPREADER, packing; uhmwpe 1

1

26d** 178763 . PACKING, rod; acetal 1

26e 197641 . NUT, packing 1

Parts

Ref.

Part No. Description Qty

No.

26f 185495 . HOUSING, packing 1

26g** 186069 . SPACER, packing; acetal 1

26h 244696 . ROD, packing 1

27 245790 RING, retaining, air cap; includes

item 27a

27a* 198307 . PACKING, u-cup 1

28 276695 HOOK 1

29 276867 NEEDLE, electrode; black 1

30 276698 TRIGGER 1

35*** 245496 SWIVEL, air; 1/4 npsm(m);

left-hand threads

36 107460 WRENCH, ball end; 4 mm 1

37 276741 MULTI-TOOL 1

38 185103 TUBE, exhaust 1

39 110231 CLAMP 1

Ref.

Part No. Description Qty

No.

53 276734 PLUG, LO voltage adjustment 1

54 197910 SCREW, pivot 1

55 197624 SPRING, grounding 1

59 245265 CIRCUIT, flexible 1

1

101 245252

246431

102 198663

190863

1

103 185547

15B932

104 197954 . BRACKET, fluid fitting 1

105 185548 . NUT 1

HOSE, shielded waterborne fluid;

HOSE, unshielded waterborne
fluid; includes 102-108

. FERRULE (shielded hose

245252)
FERRULE (unshielded hose

246431)

. HOUSING, ferrule (shielded

hose 245252)
HOUSING, ferrule (unshielded
hose 246431)

1

1

1

1

1

1

40 116553 GREASE, dielectric, tube (not

shown)

41 244915 COVER, gun; box of 10 (not

shown)

42 179791 TAG, warning (not shown);

replacement available at no cost

43 180060 SIGN, warning (not shown);

replacement available at no cost

47 197967 PLUG 1

48 198058 SCREW, cap, socket hd 1

51 244627 SWITCH, ES HI/LO 1

52 111450 O-RING 1

1

106 198643 . FITTING, barrel 1

107 102982 . O-RING 1

1

108 198640 . FITTING, seal 1

1

* Included in Air Seal Repair Kit 244781.

** Included in Fluid Seal Repair Kit 244911.

1

*** Included in Swivel Repair Kit 244834.

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

Part No. 245897 Isolation Enclosure, Series A, with air
and shielded wb fluid hoses, standard Xs3 gun (items
201-301)

309293J 59

Parts

Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, standard Xs3 gun (items 201-301)

Part No. 245898 Isolation Enclosure, Series A,
with air and wb fluid hoses, smart Xs3 gun (items 201-301)

Part No. 233825 Isolation Enclosure, Series A, for shielded hoses without hoses and gun (items 201-286)
Part No. 246511 Isolation Enclosure, Series A, for unshielded hoses without hoses and gun (items 201-286)

282

224

267

261

252

258

260

215

256

241

203

214

249

247

222
221

300

256

229

207

205

239

301

204
259

206
242

235

276
228

262

257

226

227

253

271

268

253

268

257

216

283

281
217

218
274

262

220

280

279

283

278

270

279

262

225

223

201

213

Ref. only;

not included

243

266

219

202

245

246

244

240

275

240

268
253

232

201a

268

265

208

263

236

285

230

237

210

231

209

211

212

TI2138a

60 309293J

Part No. 245897 Isolation Enclosure, Series A,
with air and wb fluid hose, standard Xs3 gun (items 201-301)

Part No. 245898 Isolation Enclosure, Series A,
with air and wb fluid hoses, smart Xs3 gun (items 201-301)

Part No. 233825 Isolation Enclosure, Series A, for shielded hoses without hoses and gun (items 201-286)

Ref.

Part No. Description Qty

Ref.

Part No. Description Qty

No.

201 CABINET, enclosure; includes

201a

201a 15A947 DOOR, cabinet 1

202 116993 CASTER, brake 4

203 15A660 PLATE 1

204 15A551 T-HANDLE, latch 1

205 15A545 STEM, handle, door 1

206 15A524 HOUSING, latch 1

207 113061 SWITCH, push, air 1

208 TUBE; 1/2 in. (13 mm) OD; poly-

ethylene

209 233501 PUMP, diaphragm; sst; see man-

ual 309303

210 SCREW, hex hd cap; 5/16-18 x

5.5 in. (140 mm)

211 WASHER, plain; 0.344 in. ID 2

212 NUT, lock; 5/16-18 2

213 241005 COVER, pail 1

214 104029 LUG, ground 1

215 116989 VALVE, air 1

216 111804 REGULATOR, air 1

217 113060 GAUGE, air; 1/8 npt 1

218 116473 VALVE, ball; 1/4 npt(fbe) 1

219 233824 CART, enclosure 1

220 162453 NIPPLE; 1/4 npt x 1/4 npsm 1

221 185547

FERRULE, housing (233825)

A/R

No.

224 154636 WASHER, plain; 0.625 in. ID 2

1

225 185548 NUT 1

226 190410 RESISTOR, bleed 1

227 116988 CYLINDER ROD 1

228 15A518 HOUSING, cylinder rod 1

229 104267 REGULATOR, air 1

230 BUSHING; plastic; 3/4 x 1/2 npt 1

231 114456 ELBOW, tube; 3/8 npt x 3/8 in. (10

mm) OD tube

232 116315 ELBOW, tube; 3/8 npt x 1/2 in. (13

mm) OD tube

235 15A682 LABEL, warning 1

1

236 116316 FITTING, tube; 1/2 npt x 1/2 in.

(13 mm) OD tube

2

237 218798 STRAINER, 16 mesh; sst 1

238 114958 STRAP, tie 3

239 222011 GROUND WIRE, 25 ft (7.6 m) 1

240 234018 STRIP, grounding; aluminum 1

241 110209 NUT, regulator 1

242 114051 WASHER, shim, latch 1

243 210084 ROD, ground 1

244 SCREW, hex hd; 1/4-20 x 5/8 in.

(16 mm)

245 WASHER, plain; 1/4 in. (6 mm) 16

246 NUT, hex; 1/4-20 16

247 107257 SCREW, thread forming 1

1

248 TUBE; 1/4 in (6 mm) OD; nylon A/R

Parts

1

1

1

16

15B932

222 198663

190863

223 101390 WASHER, lock, internal tooth 1

309293J 61

FERRULE, housing (246511)

FERRULE (233825)

FERRULE (246511)

249 160430 GAUGE, air 1

1

251 WIRE, 10 gauge; green with yel-

1

low stripe

1

252 CONNECTOR, swivel tee; 1/8 npt

x 5/32 in. (4 mm) OD tube

A/R

1

Parts

Ref.

Part No. Description Qty

No.

253 NUT, hex; 10-32 1

256 162449 NIPPLE, reducing; 1/2 npt x 1/4

npt

257 101874 TERMINAL, ring 5

258 116990 BOX, control 1

259 113983 RING, retaining; 1/2 in. (13 mm) 1

260 237933 METER, 0-90 kV 1

261 113336 ADAPTER, 1/4 npt 1

262 SCREW, pan hd; 10-32 x 5/8 in.

(16 mm)

263 SCREW, pan hd; 10-32 x 1/4 in. (6

mm)

264 HOLDER, tie 3

265 SCREW, button hd; 10-24 x 1.5 in.

(38 mm)

266 SCREW, button hd; 10-32 x 1.0 in.

(25 mm)

267 NUT, hex; M5 x 0.8 2

268 WASHER, lock; no. 10 9

270 116991 TEE, run, manifold 1

271 203953 SCREW, hex hd cap with patch;

10-24 x 3/8 in. (10 mm)

272 WIRE, 14 gauge; red A/R

273 WIRE, ground, 14 gauge; green

with yellow stripe

274 155541 UNION, swivel; 1/4 npt 1

275 114261 TERMINAL, ring; no. 10 1

A/R

Ref.

Part No. Description Qty

No.

276 15A780 PLUG, hex hd 1

278 117314 BULKHEAD CONNECTOR; 1/4

2

npt

279 113319 CONNECTOR, tube; 1/4 npt x 3/8

in. (10 mm) OD tube

280 ELBOW, tube 1

281 FITTING, tube; 1/8 npt x 5/32 in.

(4 mm) tube

282 SWIVEL, tube; 1/4 npt x 1/4 in. (6

4

283 SWIVEL, tube; 1/8 npt x 5/32 in. (4

1

285 112791 CLAMP 1

286 TUBE; 3/8 in. (10 mm) OD A/R

2

300 235070

mm) OD tube

mm) OD tube

HOSE, air, grounded; 0.315 in.
(8 mm) ID; 1/4 npsm(f) x 1/4

2

npsm(f) left-hand thread; red
cover with stainless steel braid
ground path; 25 ft (7.6 m) long

301 245301

GUN, air spray, standard, elec­trostatic, for waterborne coat­ings; see page 52; used on
Model 245897

1

301 245305

GUN, air spray, smart, electro­static, for waterborne coat­ings; see page 56; used on
Model 245898

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

1

2

1

4

2

1

1

1

62 309293J

Parts

Tubing and Wiring Chart

Use the diagrams on page 64 to find the connection
points for the tubing and wiring listed below.

Ref.
No.

Length
in. (mm)

Description

fold

interlock switch

gauge (2170

lock switch

resistor to meter

Code

A1 248 20 (508) 1/4 OD tube, regulator to pump
A2 248 9 (229) 1/4 OD tube, regulator (216) to mani-

B2 249 17 (432) 5/32 OD tube, manifold air to door

B3 249 20 (508) 5/32 OD tube, valve tee to cylinder
B4 249 5 (127) 5/32 OD tube, regulator (216) to

B5 249 22 (559) 5/32 OD tube, valve tee to door inter-

C1 272 9 (229) red 14 gauge wire from top of bleed

Ref.
No.

Length
in. (mm)

Description

internal box ground lug to cylinder
cap

external ground lug to cart

clamp, from external ground lug to
true earth ground

external ground lug to ground probe

cover with clamp

to ground on cylinder bracket

meter + to internal box ground lug

Code

C2 251 8 (204) green/yellow 14 gauge wire from

C3 273 34 (864) green/yellow 10 gauge wire from

C4 239 n/a green/yellow 25 ft ground wire with

C5 243 n/a green/yellow 10 gauge wire from

C6 226 n/a red wire from bleed resistor to pump
C7 272 16 (407) red 14 gauge wire from pump to pail

C8 272 12 (305) red 14 gauge wire from pump (209)

C9 251 n/a green/yellow 10 gauge wire from

E1 286 4 (102) 3/8 OD tube, bulkhead to manifold

309293J 63

Parts

Tubing and Wiring Diagrams

Detail of Control Box

C1

B3

C3, C4, C5

C9 A1 A2

B4

C2, C9

B5

A2

E1B2

TI2145A

C2
B3

C1

C6

C3

Detail of Door Interlock Switch

C8

A1

C6, C7, C8

B5

TI2144A

B2

TI2143A

64 309293J

Accessories

Accessories

Air Line Accessories

Grounded Air Hose (Red Cover)

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; red cover with stainless steel braid ground path.

235068 6 ft (1.8 m)
235069 15 ft (4.6 m)
235070 25 ft (7.6 m)
235071 36 ft (11 m)
235072 50 ft (15 m)
235073 75 ft (23 m)
235074 100 ft (30.5 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 fluid supply unit 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.

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

245252 Shielded Waterborne Fluid Hose

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

FM Approved; PTFE; 1/4 in. (6 mm) ID x 25 ft (7.6 m)

For FM approved systems

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 fluid supply unit.

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Air Line Quick Disconnect
112534 Swiveling quick disconnect replaces stan-

dard air inlet swivel.

309293J 65

208630 1/2 npt(m) x 3/8 npt(f); carbon steel and

PTFE; for non-corrosive fluids

246431 Unshielded Waterborne Fluid Hose

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

FM Approved; PTFE; 1/4 in. (6 mm) ID x 25 ft (7.6 m)

For compliance with EN 50059.

Accessories

Gun Accessories

Gun Repair Kits
244781 Air Seal Repair Kit

244911 Fluid Seal Repair Kit

Round Pattern Kits

Consists of fluid tip, diffuser and air cap.

245217 4-6 in. (102-152 mm) diameter
245219 8-10 in. (203-254 mm) diameter

Push/Pull Fan Air Valve
244912 For quick change of fan size.

Handle Grips
245263 Medium Grip

245264 Large Grip

Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone)

lubricant for fluid seals and wear areas.

Alternator Bearing Kit

Cleaning Brush
105749 For cleaning air cap and fluid nozzle.

Miscellaneous Accessories

Ground Wire and Clamp
222011 For grounding fluid supply unit 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.

Safety Warning Sign
186118 English Warning Sign. FM Approved. Avail-

able at no charge from Graco.

Electrostatic Conductive Gloves (box of 12)
117823 Small

117824 Medium
117825 Large

223688 To repair the turbine alternator.

66 309293J

Part No. 245895 Agitator Accessory Kit (items 401-407)

Accessories

401

406

403

408

404

406 (Ref)

407

402

Ref.

Part No. Description Qty

No.

401 112698 ELBOW, swivel, male; 1/8 npt(m) x

1/4 in. (6 mm) OD tube

402 114158 FITTING, adapter, Y; 1/4 in. (6

mm) OD tube; mxfxf

403 193315 COLLAR, mounting, agitator 1

404 193316 NUT, collar, agitator 1

405 197298 COVER, pail; 5 gal. (19 liter) 1

406 224571 AGITATOR; see manual 306565 1

407 purchase

locally

408 110272 SCREW, set, socket-hd; 1/4-20 x

TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)

1/4 in. (6 mm)

1

1

1

1

309293J 67

TI2137A

Accessories

Part No. 245944 Fluid Regulator Accessory Kit (items 501-507)

Ref.
No.

Part No. Description Qty

506

507

502

501

504

503

TI2149A

505

501 110078 FITTING, tube, fluid; 1/4 npt(m) x

3/8 in. (10 mm) OD tube

502 113070 NIPPLE, reducer; 3/8 npt x 1/4 npt 1

503 113576 PLUG; 1/4 npt 1

504 236281 REGULATOR, fluid; see manual

308325

505 C20350

506 114158 FITTING, adapter, Y; 1/4 in. (6

507 purchase

locally

ELBOW, 90°; 1/4 npt(f) x 1/4 in. (6
mm) OD tube

mm) OD tube; mxfxf

TUBE; nylon; 1/4 in. (6 mm) OD;
4 ft (1.22 m)

1

1

1

1

1

68 309293J

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)
Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar)
Maximum Fluid Operating Temperature 120°F (48°C)
Short Circuit Current Output 125 microamperes
Voltage Output Energy .35 J with fluid hose 246431 installed

244581, 245301: 60 kV
244582, 245305: 30-60 kV

Sound Power (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): 99 dB(A)
Gun Air Inlet Fitting, left-hand thread 1/4 npsm(m)
Gun Fluid Inlet Fitting custom inlet for Graco waterborne fluid hose
Gun Weight 27.8 oz (788 g)
Gun Length 11.1 in. (28.2 cm)
Isolation Enclosure Air Inlet Fitting 1/4 npt
Isolation Enclosure Fluid Inlet Fitting 3/8 in. OD tube fitting
Isolation Enclosure Weight 125 lb (56.3 kg)
Isolation Enclosure Height 44 in. (1118 mm)
Isolation Enclosure Width 24 in. (610 mm)
Isolation Enclosure Depth 29 in. (737 mm)
Wetted Parts Gun: Stainless Steel; Nylon, Acetal, Ultra-High Molecular

Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten

Wire, Polyethylene

Waterborne Fluid Hose: PTFE

Suction Tube: Polyethylene, Stainless Steel

Tri t on P um p: See manual 309303

Loctite® is a registered trademark of the Loctite Corporation.

309293J 69

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

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

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

This manual contains English. MM 309293

Graco Headquarters: Minneapolis

www.graco.com

309293 02/2002 Rev. 9/2007