Instructions - Parts List
MANUAL ELECTROSTATIC
PRO™ Xs2
Air Spray Gun
For use in Class I, Div. I hazardous locations using Group D spray materials.
#53
For use in Group II, Zone 1 areas using Group IIA spray materials.
II 2 G EEx 0.24 mJ
For Professional Use ONLY.
309291P
ENG
Important Safety Instructions:
Read all warnings and instructions in this manual.
Save these instructions.
See page for 2 Table of Conte nts and List of Models.
Part No. 244399, Series C
See page 2 for Model 244399 information.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
US Patents 6758424 and 7,226,004
U.S. Patents 6758424 and 7,226,004
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Table of Contents
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How the Electrostatic Spray Gun Works . . . . . . . 5
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install the System . . . . . . . . . . . . . . . . . . . . . . . . 6
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 6
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . 8
Connect the Exhaust Tube . . . . . . . . . . . . . . . . . 8
Select a Fluid Nozzle and Air Cap . . . . . . . . . . . 9
Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 10
Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check Electrical Grounding . . . . . . . . . . . . . . . . 12
Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 13
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 15
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 17
Test Power Supply Resistance . . . . . . . . . . . . . 18
Test Electrode Resistance . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spray Pattern Troubleshooting . . . . . . . . . . . . . 20
Gun Operation Troubleshooting . . . . . . . . . . . . 21
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 22
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Relief Procedure . . . . . . . . . . . . . . . . 23
Prepare the Gun for Service . . . . . . . . . . . . . . . 24
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 25
Electrode Replacement . . . . . . . . . . . . . . . . . . . 26
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 27
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 28
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 29
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Supply Removal and Replacement . . . . 30
Turbine Alternator Removal and Replacement . 31
Fan Air Adjustment Valve Repair . . . . . . . . . . . . 32
Fluid Adjustment Valve Repair . . . . . . . . . . . . . 33
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 33
Atomizing Air Restrictor Valve Removal and
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 34
ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 35
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 39
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 39
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 39
Miscellaneous Accessories . . . . . . . . . . . . . . . . 40
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42
Model Information
Part No. Model
244399 PRO Xs2
2 309291P
Type of Coatings
Standard High Conductivity
XX
Operation Manual
309294/3W9294/3Z9294
Warnings
Warnings
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
WARNING
Fire, Explosion, and Electric Shock Hazard
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements of this manual.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See
Grounding instructions.
• Only use grounded Graco conductive air supply hoses.
• Check gun and hose resistance and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Interlock the gun air supply to prevent operation unless ventilating fans are on.
• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equip-
ment until you identify and correct the problem.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• Keep a working fire extinguisher in the work area.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instructions.
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.
309291P 3
Warnings
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.
• 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).
• Do not kink or overbend hoses or use hoses to pull equipment.
• 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 on page 23 when you stop spraying and before clean-
ing, checking, or repairing equipment.
• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
• Tighten all fluid connections before each use.
4 309291P
Introduction
Introduction
How the Electrostatic 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 pump supplies fluid to the hose and gun, where the
fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded
workpiece, wrapping around and evenly coating all surfaces.
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.
• Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
• ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
• ES INDICATOR. Green when ES is ON (I).
ES INDICATOR
ES ON/OFF
ES
I O
RESTRICTOR
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AIR
FLUID
• Fan AIR adjustment valve. Adjusts fan size and
shape.
Fig. 1 Gun Overview
309291P 5
Installation
Installation
Install the System
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
•Do not install or service this equipment
unless you are trained and qualified.
•Be sure your installation complies with
National, State and Local codes for the
installation of electrical apparatus in a
Class I, Div. I, Group D or a Group II,
Category 2G Hazardous Location.
•Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
FIG. 2. shows a typical electrostatic air spray system. It
is not an actual system design. For assistance in
designing a system to suit your particular needs, contact
your Graco distributor.
Warning Sign
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
Warning Sign is provided with the gun.
Ventilate the Spray Booth
WARNING
Flammable or Toxic Vapor Hazard
Provide fresh air ventilation to avoid the
buildup of flammable or toxic vapors when
spraying, flushing, or cleaning the gun. Do
not operate the gun unless ventilation fans
are operating.
Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans
operating. Check and follow all National, State, and
Local codes regarding air exhaust velocity requirements.
High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of
100 ft/min (31 linear meters/minute) should be sufficient.
6 309291P
Installation
ES ON/OFF valve: I is ON, 0 is OFF
A
M
B*
*E
G
C*D
O
C
H
F
J*
L
ES
I O
S
V
G
*R
W
P
K
U*
The air supply to the
gun must be electrically interlocked with
the ventilators to pre-
Q*
vent the power supply
from operating without
T
ventilating fans on.
N
Non-Hazardous Hazardous Area
Fig. 2. Typical Installation
Key
A Main Air Supply Line
B* Ventilation Fan Interlock Solenoid Valve
C* Main Air Supply Shutoff Valve (bleed-type)
D Pump Air Line Filter/Water Separator
E* Pump Air Supply Shutoff Valve (bleed-type)
F Air Line Lubricator
G Air Pressure Regulator
HPump
J* Pump Ground Wire
K Fluid Filter
L Fluid Supply Line Shutoff Valve
M Fluid Pressure Regulator
TI1531a
N Fluid Supply Line
O Gun Air Line Filter/Water Separator
P Gun Air Supply Line Shutoff Valve
Q* Air Hose Ground Wire
R* Graco Grounded Air Hose
S Electrostatic Air Spray Gun
T Air Line Drain Valve
U* Fluid Drain Valve
VGun Air Inlet
W Gun Fluid Inlet
* Required for safe operation. Must be purchased
separately. NOTE: Solenoid valve (B) is not
offered as a Graco accessory.
309291P 7
Installation
Connect the Air Line
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
serious injury, the air supply hose must be
electrically connected to a true earth
ground. Use only Graco Grounded Air
Supply Hose.
1. Connect the Graco Grounded Air Supply Hose (R)
between the air supply line and the gun's air inlet
(V). The gun air inlet fitting has a left-hand thread.
Connect the air supply hose ground wire (Q) to a
true earth ground.
2. Install an air line filter/water separator (O) on the
gun air line to ensure a dry, clean air supply to the
gun. Dirt and moisture can ruin the appearance of
your finished workpiece and can cause the gun to
malfunction.
3. Install a bleed-type air regulator (G) on the pump
and gun air supply lines to control air pressure to the
pump and gun.
4. Install a bleed-type air valve (E) on the pump air line
to shut off air to the pump. Install an additional
bleed-type air valve (C) on the main air line (A) to
isolate the accessories for servicing.
WARNING
Pressurized Equipment Hazard
The bleed-type air valve (E) is required in
your system to relieve air trapped between
the valve and the pump after the air regulator is shut off. Trapped air can cause the
pump to cycle unexpectedly, which can
result in serious injury, including splashing
fluid in the eyes or on the skin.
5. Install an air shutoff valve ( P) on each gun air supply line to shut off air to the gun(s).
Connect the Exhaust Tube
Press the exhaust tube (38) onto the barbed adapter on
the bottom of the gun handle. Secure the tube with the
clamp (39).
8 309291P
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 23
before removing or installing a fluid nozzle
and/or air cap.
The gun is supplied with Part No. 197266 Nozzle and
24A376 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 25.
A wide pattern kit (P/N 24A431) is included with the gun
and if installed, will provide more fan air for wider spray
patterns. (If pattern becomes split, use the fan air valve
to reduce the amount of fan air.)
Table 1: Fluid Nozzles
Part No. Orifice Size
197263 0.75 mm (.030 in.)
197264 1.0 mm (.042 in.)
197265 1.2 mm (.047 in.)
197266 1.5 mm (.055 in.)
197267 1.8 mm (.070 in.)
197268† 2.0 mm (.080 in.)
249920* 0.75 mm (.030 in.)
249921* 1.0 mm (.042 in.)
249922* 1.2 mm (.047 in.)
249923* 1.5 mm (.055 in.)
249924* 1.8 mm (.070 in.)
249925*† 2.0 mm (.080 in.)
Table 2: Air Caps
Pattern Shape
Part No.
24A438
24A279
24A376*
24A274
24A439
24A275
*Also available in the following colors:
24A276 - blue
24A277 - red
24A278 - green
and Length in.
(mm)
Round end;
15-17 (381-432)
Round end;
14-16 (356-406)
Tapered end;
17-19 (432-483)
Tapered end;
12-14 (305-356)
Round end;
11-13 (279-330)
Tapered end;
14-16 (356-406)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Medium to high viscosity and
high solids.
Up to 15 oz/min (450 cc/min)
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Light to medium viscosity.
Up to 15 oz/min (450 cc/min)
Medium to high viscosity and
high solids.
Up to 15 oz/min (450 cc/min)
For use with 2.0 mm nozzle.
Light to medium viscosity and
high solids.
Aerospace coatings.
Up to 25 oz/min (750 cc/min).
* Glass-reinforced acetal construction.
† Air cap 24A439 must be used with a 2.0 mm (0.80 in.)
nozzle.
309291P 9
Installation
Connect the Fluid Line
1. Before connecting the fluid line (N), blow it out with
air and flush it with solvent. Use solvent which is
compatible with the fluid to be sprayed.
2. Install a fluid regulator (M) on the fluid line to control
fluid pressure to the gun.
3. Install a fluid filter (K) and drain valve (U) at the
pump outlet.
WARNING
Pressurized Equipment Hazard
The fluid drain valve (U) is required in your
system to assist in relieving fluid pressure in
the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may
not be sufficient. Install a drain valve close
to the pump's fluid outlet. The drain valve
reduces the risk of serious injury, including
splashing in the eyes or on the skin.
4. Connect the fluid line to the 3/8 npsm gun fluid inlet
(W).
5. Before running any paint through the spray gun,
flush it out with a compatible solvent.
Filter the Fluid
Install a fluid filter (K) to remove particles and sediment
which could clog the spray nozzle.
10 309291P
Installation
Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any
ungrounded objects in the spray area (people, containers, tools, etc.) can become
electrically charged. Improper grounding
can result in static sparking, which can
cause a fire, explosion, or electric shock.
Follow the grounding instructions below.
The following are minimum grounding requirements for
a basic electrostatic system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions. Your system must be connected to a true
earth ground.
• Pump: ground the pump by connecting a ground
wire and clamp as described in your separate pump
instruction manual.
• All persons entering the spray area: shoes must
have conductive soles, such as leather, or personal
grounding straps must be worn. Do not wear shoes
with non-conductive soles such as rubber or plastic.
If gloves are necessary, wear the conductive gloves
that are supplied with the gun. If non-Graco gloves
are worn, cut off fingers or palm area of glove, to
ensure your hand contacts the grounded gun handle.
• Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
• The floor of the spray area: must be electrically con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
• Electrostatic Air Spray Gun: ground the gun by con-
necting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground.
See Check Electrical Grounding, page 12.
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• Air compressors: ground the equipment according
to the manufacturer's recommendations.
• All air and fluid lines must be properly grounded.
Use only grounded hoses with a maximum of 100
feet (30.5 m) combined hose length to ensure
grounding continuity.
• Flammable liquids in the spray area: must be kept in
approved, grounded containers. Do not use plastic
containers. Do not store more than the quantity
needed for one shift.
• All electrically conductive objects or devices in the
spray area: including fluid containers and wash
cans, must be properly grounded.
309291P 11
Installation
Check Electrical Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
F
IG. 3.) is not approved for use in a hazard-
ous area. To reduce the risk of sparking, do
not use the megohmmeter to check electrical grounding unless:
•The gun has been removed from the hazardous area;
•Or all spraying devices in the hazardous
area are turned off, ventilation fans in the
hazardous area are operating, and there
are no flammable vapors in the area (such
as open solvent containers or fumes from
spraying).
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
4. Make sure the grounded air hose (R) is connected
and the hose ground wire is connected to a true
earth ground.
ti1259a
5. Measure the resistance between the gun handle
(BB) and a true earth ground (CC). Use an applied
voltage of 500 minimum to 1000 volts maximum.
The resistance should not exceed 1 megohm. See
F
IG. 3..
6. If the resistance is greater than 1 megohm, check
the tightness of the ground connections and be sure
the air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
BB
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.
AA
CC
ti1274a
Fig. 3. Check Gun Grounding
12 309291P
Installation
Check Fluid Resistivity
WARNING
Fire, Explosion, and Electric Shock Hazard
Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886
and Probe 722860 are not approved for use
in a hazardous area.
Failure to follow this warning could cause
fire, explosion, or electric shock and result
in serious injury and property damage.
Graco Part No. 722886 Resistance Meter and 722860
Probe are available as accessories to check that the
resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.
Follow the instructions included with the meter and
probe. Readings of 25 megohms-cm and above provide
the best electrostatic results.
Check Fluid Viscosity
To check fluid viscosity you will need:
• a viscosity cup
• a stopwatch.
1. Completely submerge the viscosity cup in the fluid.
Lift the cup out quickly, starting the stopwatch as
soon as the cup is completely removed.
2. Watch the stream of fluid coming from the bottom of
the cup. As soon as there is a break in the stream,
shut off the stopwatch.
3. Record the fluid type, elapsed time, and size of the
viscosity cup.
4. If the viscosity is too high or too low, contact the
material supplier. Adjust as necessary.
309291P 13
Operation
Operation
Refer to the gun operation manual
(supplied) for Setup, Shutdown, and
Daily Care procedures.
INSTRUCTIONS
14 309291P
Maintenance
INSTRUCTIONS
Flush the Spray Gun
Maintenance
Refer to the gun operation manual
(supplied) for Daily Care and Cleaning
procedures.
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.
CAUTION
Flush the gun with a non-conductive, compatible
solvent. Conductive solvents can cause the gun to
malfunction.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 23
whenever you are instructed to relieve the
pressure.
2. Relieve the pressure.
ti1276a
3. Change the fluid source to solvent, or disconnect
the fluid line and connect a solvent supply line to the
gun.
4. Point the gun into a grounded metal pail. Flush until
clean solvent flows from the gun.
Do not use methylene chloride as a flushing or
cleaning solvent with this gun as it will damage
nylon components.
1. Turn the ES ON/OFF valve OFF.
309291P 15
ES
I O
ti1276a
5. Relieve the pressure.
ti1276a
ti1273a
Maintenance
6. Shut off or disconnect the solvent line.
7. Hang the gun from its hook, with the nozzle pointing
down.
ti1288a
8. When ready to spray again, reconnect the fluid supply line. Follow the Setup procedure in the Operation Manual.
16 309291P
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. 4.) is not approved for use in a hazard-
ous area. To reduce the risk of sparking, do
not use the megohmmeter to check electrical grounding unless:
•The gun has been removed from the hazardous area;
•Or all spraying devices in the hazardous
area are turned off, ventilation fans in the
hazardous area are operating, and there
are no flammable vapors in the area (such
as open solvent containers or fumes from
spraying).
Test Gun Resistance
1. Flush and dry the fluid passage.
2. Measure resistance between the electrode needle
tip (29) and the air swivel (35); it should be 101-121
megohms. If outside this range, go to the next test. If
in range, refer to Electrical Troubleshooting on
page 22, for other possible causes of poor performance.
AA
29
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
35
TI1468A
Fig. 4. Test Gun Resistance
309291P 17
Electrical Tests
Test Power Supply Resistance
1. Remove the power supply (18), page 29.
2. Remove the turbine alternator (19) from the power
supply, page 30.
3. Measure resistance from the power supply's ground
strips (EE) to the spring (18b). See F
IG. 5..
4. The resistance should be 75-85 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
5. If you still have problems, refer to Electrical Trou-
bleshooting on page 22 for other possible causes
of poor performance, or contact your Graco distributor.
6. Be sure the spring (18b) is in place before reinstalling the power supply.
18b
ti1500a
EE
Fig. 5. Test Power Supply Resistance
18 309291P
Test Electrode Resistance
1. Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the
metal contact (C) in the front of the barrel.
2. Measure the resistance between the conductive rod
(B) and the electrode (29). The resistance should be
20-30 megohms. See F
IG. 6..
Electrical Tests
3. If in range, refer to Electrical Troubleshooting on
page 22 for other possible causes of poor performance, or contact your Graco distributor.
4. Remove the electrode (29), page 26. 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. 7..
5. Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, F
IG. 8.), and the electrode
contact (E) are clean and undamaged.
C
29
B
ti1499a
F29E
ti1548a
Fig. 7. Electrode
7a
ti1513a
Fig. 8. Nozzle Conductive O-Ring
Fig. 6. Test Electrode Resistance
309291P 19
Troubleshooting
Troubleshooting
WARNING
Electric Shock Hazard
Installing and servicing this equipment
requires access to parts which may cause
an electric shock or other serious injury if
the work is not performed properly. Do not install or
repair this equipment unless you are trained and
qualified.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 23
whenever you are instructed to relieve the
pressure.
Check all possible remedies in the Troubleshooting
Chart before disassembling the gun.
WARNING
Spray Pattern Troubleshooting
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 25.
Air in fluid supply. Check fluid source. Refill.
Improper spray pattern. Damaged nozzle or air cap. Replace, page 25.
Fluid buildup on air cap or nozzle. Clean. See Operation Manual.
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 25.
20 309291P
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
28.
page 33.
Worn or damaged packing rod (26). Replace; see page 28
Worn fluid seat. Replace fluid nozzle and/or electrode
needle; see pages 25 to 26.
Loose fluid nozzle (7). Tighten; see page 25.
Damaged nozzle o-ring (7b). Replace; see page 25.
Damaged air cap (9). Replace; see page 25.
Dirty or clogged fluid nozzle (7). Clean; see page 25.
Damaged fluid nozzle (7). Replace; see page 25.
Damaged fluid adjustment valve (25). Replace; see page 33.
Clean fluid buildup off air cap and
zle (7).
fluid nozzle seat; see page 25.
309291P 21
Troubleshooting
Electrical Troubleshooting
Problem Cause Solution
Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I).
Gun air pressure too low. Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.
Atomizing air pressure too high. Decrease.
Fluid pressure too high. Decrease.
Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).
Poorly grounded parts. Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance. See Test Gun Resistance on page
17.
Low fluid resistivity. Check fluid resistivity, page 13.
Fluid leaks from the packing (26d)
and causes a short.
Faulty turbine alternator. Be sure the plug is in place on the
ES indicator or voltage/current display is not lit.
Operator gets mild shock. Operator not grounded or is near
Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or
ES ON/OFF valve OFF (0).* Turn ON (I).
No power. Replace power supply. See page 30.
ungrounded object.
Gun not grounded. See Check Electrical Grounding on
Clean the packing rod cavity.
Replace the packing rod. See page
28.
back of the turbine alternator housing. Remove and test the turbine
alternator. See page 31.
See Grounding on page 11.
page 12 and Test Gun Resistance
on page 17.
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
22 309291P
Repair
Repair
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.
1. Turn the ES ON/OFF valve OFF.
ES
I O
3. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
ti1276a
4. Open the pump drain valve, having a waste container ready to catch the drainage. Leave the pump
drain valve open until you are ready to spray again.
ti1290a
5. If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end
coupling. Now clear the nozzle or hose.
ti1273a
2. Turn off the air bleed valves to the fluid source and
to the gun.
ti1289a
t
309291P 23
Repair
Prepare the Gun for Service
WARNING
Electric Shock Hazard
Installing and repairing this equipment
requires access to parts that may cause
electric shock or other serious injury if the
work is not performed properly. Do not install or service this equipment unless you are trained and qualified.
WARNING
Pressurized Equipment Hazard
To reduce the risk of injury, follow the Pres-
sure Relief Procedure on page 23 before
checking or servicing any part of the system
and whenever you are instructed to relieve the pressure.
• Check all possible remedies in Troubleshooting
before disassembling the gun.
• Use a vise with padded jaws to prevent damage to
plastic parts.
• Lubricate the power supply o-ring (18a) and some
packing rod parts (26) with dielectric grease (40), as
specified in the text.
• Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
• Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
• Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
• Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are marked
with a double asterisk, for example (5**).
1. Flush the gun, page 15.
2. Relieve the pressure, page 23.
3. Disconnect the gun air and fluid lines.
4. Remove the gun from worksite. Repair area must be
clean.
24 309291P
Air Cap/Nozzle Replacement
Repair
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 24.
2. Remove the retaining ring (27) and air cap (9). See
F
IG. 9..
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
26).
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. 9. Air Cap/Nozzle Replacement
7b
ti1501a
7a
37
7
6. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
7. Test gun resistance, page 17.
309291P 25
Repair
Electrode Replacement
1. Prepare the gun for service, page 24.
2. Remove the air cap and nozzle, page 25.
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
turning. See F
IG. 10..
CAUTION
To avoid damaging the plastic threads, be very
careful when installing the electrode.
37
4. Apply low-strength (purple) Loctite
®
or equivalent
thread sealant to the electrode and packing rod
threads. Install the electrode finger-tight. Do not
overtighten.
5. Install the fluid nozzle and air cap, page 25.
6. Test gun resistance, page 17.
ti1502a
Fig. 10. Electrode Replacement
26 309291P
Fluid Packing Removal
1. Prepare the gun for service, page 24.
2. Remove the air cap and fluid nozzle, page 25.
3. Remove the electrode, page 26.
4. Remove the trigger screws (8) and trigger (30). See
F
IG. 11.
5. Remove the packing rod (26), using the multi-tool
(37).
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.
Repair
37
30
8
6. Check all parts for wear or damage and replace if
necessary.
TI1549A
Fig. 11. Fluid Packing Removal
309291P 27
Repair
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. 12.
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 26.
10. Install the nozzle and air cap, page 25.
11. Test gun resistance, page 17.
3. Place the fluid packing (26c**), rod packing (26d**),
and housing (26f) on the packing rod (26h) .
**26b
**26g
**26c
**26d
26f
**26a
4
E
26h
TI1550A
26e
Fig. 12. Packing Rod
28 309291P
Repair
Barrel Removal
1. Prepare the gun for service, page 24.
2. Carefully loosen the nut (32) from the bracket fluid
fitting (13). Pull the tube (14) out of the fitting. Make
sure both ferrules and the nut stay with the tube.
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
14
32
13
11
IG. 13..
16
Barrel Installation
1. Be sure the gasket (10*) is in place. Make sure the
air holes are aligned properly. Replace if damaged.
See F
IG. 14..
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
CAUTION
Do not over-tighten the screws (11).
4. Assemble the fluid tube (14) into the bracket fitting
(13). Ensure that the ferrules are in place. Tighten
the nut (32).
5. Test gun resistance, page 17.
*10
18
11
ti1503a
17
Fig. 13. Barrel Removal
16
ti1535a
ti1504a
Fig. 14. Barrel Installation
309291P 29
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 24.
2. Remove the barrel (16), page 29.
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. See F
IG. 15..
7. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
8. Lubricate the power supply o-ring (18a*) with dielectric grease (40).
9. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle.
10. Install the barrel (16), page 29.
11. Test gun resistance, page 17.
*10
*19a
19
19e
GG
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alternator for damage.
5. Check the power supply resistance, page 18.
Replace if necessary.
Before installing the power supply, make sure the
o-rings (18a*, 19a*), spring (18b), and pads (19e) are in
place.
6. Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
ti1534a
18
16
18b
*18a
Fig. 15. Power Supply
30 309291P
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 24.
2. Remove the power supply/alternator assembly,
page 30.
3. Disconnect the alternator from the power supply,
page 30.
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 30.
7. Install the power supply/alternator assembly, page
30.
309291P 31
Repair
Fan Air Adjustment Valve Repair
1. Prepare the gun for service, page 24.
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. 16..
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. 16. Fan Air Adjustment Valve
20b*
32 309291P
Repair
Fluid Adjustment Valve Repair
1. Prepare the gun for service, page 24.
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).
TI1536A
IG. 17..
25
4. Remove the air valve (21) with a pliers. Inspect the
rubber sealing surface and replace the air valve if
damaged.
CAUTION
When removing the air valve (21) be careful not to
damage the seat area.The rubber seal is not
removable.
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 29.
Fig. 17. Fluid Adjustment Valve
Air Valve Repair
1. Prepare the gun for service, page 24.
2. Remove the barrel, page 29.
3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See FIG. 18..
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.
25
15
21
17
*6
TI1551A
Fig. 18. Air Valve
309291P 33
Repair
Atomizing Air Restrictor Valve
Removal and Replacement
1. Prepare the gun for service, page 24.
2. Remove the atomizing air restrictor valve (23).
Inspect the o-ring (23c*). Replace if necessary. See
F
IG. 19..
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 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*
23a
23d
TI1533A
Fig. 19. Atomizing Air Valve
47
23b
34 309291P
Repair
ES ON/OFF Valve Repair
1. Prepare the gun for service, page 24.
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).
22d
22e
22b*
22c
22a*
TI1488A
Fig. 20. ES ON/OFF Valve
22f
22g
48
309291P 35
Parts
Parts
Part No. 244399 20 kV Electrostatic Gun, Series C
See page 37 for detail views of the alternator (19), fan adjustment
valve (20), ES ON/OFF valve (22), and packing rod (26).
22
18
20
11
19e
19
19a*
I O
25 (Ref)
ES
ti1266a
18b
*18a
28
17
25
15
21***
11
23c*
23a
29
27
26
27a*
16
4
*10
*6
8
**5
30
23d
24a*
24
13
47
23b
35
1
**31
7b
32
7a
38
39
7
14
9
36
ti1496b
37
36 309291P
Parts
Ref. No. 20: Fan Adjustment ValveRef. No. 19: Alternator
19a*
19b
19b
19e
19d
19c
Ref. No. 22: ES ON/OFF Valve
22g
22f
22d
TI1481a
20b*
20c
20a
Ref. No. 26: Packing Rod
**26b
26c**
26d**
26f
20d
TI1487A
TI1497a
26e
26h
22c
TI1488A
22a*
22b*
22e
26g**
48
26a**
309291P 37
Parts
Ref.
No. Part No. Description Qty
1 110078 FITTING, tube, fluid; includes one
each of items 31 and 32
4 185111 SPRING, compression 1
5** 185120 SPACER, fluid; nylon 1
6* 188749 PACKING, u-cup, air valve;
UHMWPE
7 197266 NOZZLE; 1.5 mm orifice; includes
items 7a and 7b
7a 111261 .O-RING, conductive 1
7b 111507 .O-RING; fluoroelastomer 1
8 197369 SCREW, trigger 2
9 24A376 AIR CAP 1
10* 197517 GASKET, barrel 1
11 197518 SCREW; socket-hd;
10-24 x 3/4 in. (19 mm)
13 15M678 BRACKET, inlet, fluid 1
14 197589 TUBE, fluid 1
15 185116 SPRING, compression 1
16 244396 BARREL, gun 1
17 245289 HANDLE, gun (includes item 28) 1
18 244539 POWER SUPPLY, 20 kV; includes
items 18a-18b
18a* 103337 .O-RING; fluoroelastomer 1
18b 197624 .SPRING, compression 1
19 244555 TURBINE, alternator; includes
items 19a-19e
19a* 110073 .O-RING; fluoroelastomer 1
19b 223688 .BEARING KIT; includes front and
rear bearings and fan
19c 244577 .COIL 1
19d 111745 .RING, retaining 1
19e 198821 .PAD, pressure 2
20 244556 VALVE, adjustment, fan; includes
items 20a-20d
20a 101021 .RING, retaining 1
20b* 106560 .O-RING; fluorocarbon 1
20c 197566 .HOUSING, fan valve 1
20d 197567 .STEM, fan valve 1
21*** 244557 VALVE, air 1
22 244558 VALVE, electrostatics, ON/OFF;
includes items 22a-22g
22a* 111516 .O-RING; CV75 1
22b* 113137 .O-RING; fluoroelastomer 1
22c 198403 .SHAFT, valve 1
22d 198404 .PLATE, retaining 1
22e 198453 .WASHER 1
22f 198464 .PIN 1
22g 276753 .KNOB 1
23 244559 VALVE, air, atomizing; includes
items 23a-23d
23a 197594 .HOUSING, valve 1
23b 197591 .SHAFT 1
Ref.
No. Part No. Description Qty
23c* 111504 .O-RING; fluoroelastomer 2
1
23d 101021 .RING, retaining 1
24 249323 VALVE, exhaust; includes item
24a
24a* 112085 .O-RING; fluorocarbon 1
1
25 244593 VALVE, adjustment, fluid 1
26 244598 ROD, packing; includes items
1
26a-26h
26a** 111316 .O-RING; fluoroelastomer 1
26b** 116905 .SEAL 1
26c** 178409 .PACKING, fluid; UHMWPE 1
26d** 178763 .PACKING, rod; acetal homopoly-
mer
26e 185488 .NUT, packing 1
3
26f 185495 .HOUSING, packing 1
26g** 186069 .SPACER, packing; acetal 1
26h 244694 .ROD, packing 1
27 244927 RING, retaining, air cap; includes
item 27a
27a* 198307 .PACKING, u-cup 1
28 276695 HOOK 1
1
29****276697 NEEDLE, electrode 1
30 276698 TRIGGER 1
31** 110077 FERRULE, tube, fluid 1
32 110079 NUT, tube, fluid 1
1
35 244834 SWIVEL, air; 1/4 npsm(m);
left-hand threads
36 107460 WRENCH, ball end 1
1
37 276741 MULTI-TOOL 1
38 185103 TUBE, exhaust 1
39 110231 CLAMP 1
40 116553 GREASE, dielectric, tube (not
1
41 244914 COVER, gun; box of 10 (not
shown)
shown)
42▲ 179791 TAG, warning (not shown) 1
43▲ 180060 SIGN, warning (not shown) 1
47 197967 PLUG 1
48 198058 SCREW, cap, socket hd 1
49 24A431 KIT, wide pattern (not shown) 1
1
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Rubber seal is not removable.
**** Optional replacement Electrode Needle 277007 is
1
available for abrasive materials.
▲ Replacement Warning labels, signs, tags, and cards
are available at no cost.
1
1
1
1
1
1
1
38 309291P
Accessories
Accessories
Air Line Accessories
AirFlex™ Flexible Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread. Use for maximum flexibility.
244963 6 ft (1.8 m)
244964 15 ft (4.6 m)
244965 25 ft (7.6 m)
244966 36 ft (11 m)
244967 50 ft (15 m)
244968 75 ft (23 m)
244969 100 ft (30.5 m)
Standard Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread
223068 6 ft (1.8 m)
223069 15 ft (4.6 m)
223070 25 ft (7.6 m)
223071 36 ft (11 m)
223072 50 ft (15 m)
223073 75 ft (23 m)
223074 100 ft (30.5 m)
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve
and the pump air motor when closed.
107141 3/4 npt
Air Line Quick Disconnect
112534 Swiveling quick disconnect replaces stan-
dard air inlet swivel.
Air Hose Adapter Nipple
185493 Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
Non-Swivel Air Inlet Fitting
185105 Replaces standard swivel. Left-hand thread.
Extended Air Inlet Fitting
189191 Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
Fluid Line Accessories
Fluid Hose
225 psi (14 bar, 1.4 MPa) Maximum Working Pressure
FM Approved; nylon; 3/8 npsm(fbe)
215637 1/4 in. (6 mm) ID x 25 ft (7.6 m)
215638 1/4 in. (6 mm) ID x 50 ft (15.2 m)
Fluid Shutoff/Drain Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving
fluid line pressure at the pump.
208630 1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
309291P 39
Fluid Swivel
5800 psi (405 bar, 40 MPa) Maximum Working Pressure
115898 1/4 npsm(m) x 1/4 npsm(f)
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
Adjustable Round Pattern Kit
277851 Slow velocity, bell shaped spray pattern for
excellent transfer efficiency. Pattern is
adjustable from 6-12 in.
Push/Pull Fan Air Valve
244912 For quick change of fan size.
ES Always On Kit
244913 Replaces inlet fitting with ball valve to shut
off air during flushing. Converts ES ON/OFF
valve to always ON condition.
Handle Grips
245263 Medium Grip
245264 Large Grip
Gun Washer Kit
245270 Use to convert Graco gun washers so they
can clean PRO Xs2 air spray guns.
Pressure Cups
Includes air regulators for gun atomization air and supply air to pressure cup.
244731 1 Quart (0.95 Liter)
244732 2 Quart (1.90 Liter)
Abrasive Material Electrode Needle
277007 Optional replacement Electrode Needle is
available for abrasive materials.
Miscellaneous Accessories
Ground Wire and Clamp
222011 For grounding pump and other components
and equipment in the spray area.
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079 500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Paint Resistance Meter
722886 Use with 722860 Paint Probe to measure
resistance of paint.
Not for use in hazardous areas.
Paint Probe
722860 Use with 722886 Paint Resistance Meter to
measure resistance of paint.
Not for use in hazardous areas.
Safety Warning Signs
180060 English Warning Sign. FM Approved. Avail-
able at no charge from Graco.
Instruction Signs
198309 English Setup Instructions.
198319 English Daily Care Instructions.
Electrostatic Conductive Gloves (box of 12)
117823 Small
117824 Medium
117825 Large
Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
Alternator Bearing Kit
223688 To repair the turbine alternator.
Cleaning Brush
105749 For cleaning air cap and fluid nozzle.
40 309291P
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)
Paint Resistivity Range 3 megohm-cm to infinity
Short Circuit Current Output 125 microamperes
Voltage Output 20 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)
Air inlet fitting, left-hand thread 1/4 npsm(m)
Fluid inlet fitting 3/8 npsm(m)
Gun Weight 23.5 oz (668 g)
Gun Length 8.6 in. (21.8 cm)
Wetted Parts Stainless Steel, Nylon, Acetal, Ultra-High Molecular
Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten
Wire, Polyethylene
Loctite® is a registered trademark of the Loctite Corporation.
309291P 41
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship
on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any
part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal
power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of
operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in
accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused
by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering,
or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the
incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper
design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.
The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose
any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no
other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or
property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within
two (2) years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying
equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach
of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal
proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les
parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et
procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les
procedures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-328-0211Toll 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
Copyright 2001, Graco Inc. is registered to ISO 9001
This manual contains English. MM 309291
Graco Headquarters: Minneapolis
www.graco.com
Revised 10/2009
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