Graco PRO 247936, PRO 247937, PRO 312900C, PRO Xs 247936, PRO Xs 247937 Instructions Manual

Instructions

Manual Electrostatic

PRO™ Xs Waterborne Air Spray Gun

For use with conductive spray materials (waterborne and other materials less than 1 megohm-cm). For professional use ONLY.

For use in Class I, Div. I hazardous locations using Group D spray materials.

#53

For use in Group II, Zone 1 areas using Group IIA spray materials.

II 2 G EEx 0.24 mJ

312900C

ENG

247936 Standard Model 247937 Smart Model

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

Important Safety Instructions:

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

See page 2 for Table of Contents.

U.S. Patent Pending

Smart Model 247937

Standard Model 247936

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3

Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

How the Electrostatic Air Spray Gun Works . . . . 5

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

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

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

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9

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

Connect the Charging Probe . . . . . . . . . . . . . . 11

Connect the Exhaust Tube . . . . . . . . . . . . . . . . 12

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 12

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 13

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Electrical Grounding . . . . . . . . . . . . . . . . 15

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 16

Prepare to Paint . . . . . . . . . . . . . . . . . . . . . . . . 16

Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . 22

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Test Total Gun Resistance . . . . . . . . . . . . . . . . 23

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 23

Test Charging Probe Resistance . . . . . . . . . . . . 23

Test Power Supply Resistance . . . . . . . . . . . . . 24

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . 24

Spray Pattern Troubleshooting . . . . . . . . . . . . . . . 25

Gun Operation Troubleshooting . . . . . . . . . . . . . . 26

Gun Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Prepare the Gun for Repair . . . . . . . . . . . . . . . . 27

Replace Air Cap/Nozzle . . . . . . . . . . . . . . . . . . 28

Replace Fluid Needle . . . . . . . . . . . . . . . . . . . . 28

Remove Fluid Packing . . . . . . . . . . . . . . . . . . . . 29

Repair Packing Rod . . . . . . . . . . . . . . . . . . . . . . 30

Remove Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Install Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Remove and Replace Power Supply . . . . . . . . . 32

Remove and Replace Turbine Alternator . . . . . . 33

Repair Fan Air Adjustment Valve . . . . . . . . . . . . 33

Repair Fluid Adjustment Valve . . . . . . . . . . . . . 34

Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 34

Remove and Replace Atomizing

Air Restrictor Valve . . . . . . . . . . . . . . . . . . . 35

Repair ES ON/OFF Valve . . . . . . . . . . . . . . . . . 35

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 41

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 41

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 42

Miscellaneous Accessories . . . . . . . . . . . . . . . . 42

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44

2 312900C

Warnings

Warning Symbol

WARNING

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

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

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

ments of this manual.

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions.

• Only use grounded Graco conductive air supply hoses.

• Check gun and hose resistance and electrical grounding daily.

• Use and clean equipment only in well ventilated area.

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

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment.

• Always turn the electrostatics off when flushing, cleaning or servicing equipment.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until

you identify and correct the problem.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Keep work area free of debris, including solvent, rags and gasoline.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off air supply before servicing equipment.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

• Do not touch gun electrode when electrostatics are on.

• Do not expose to rain. Store indoors.

Notice

NOTICE

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

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

312900C 3

Warnings

WARNING

WARNINGWARNINGWARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com- ponent. See Technical Data in all equipment manuals.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-

turer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

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

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocya-

nate Conditions Section of this manual.

4 312900C

Overview

KEY

How the Electrostatic Air Spray Gun Works

Overview

The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s external charging probe.

A Air swivel inlet page 6 B Fluid inlet page 6 C Turbine air exhaust page 6 D Air cap and nozzle page 6 E Fluid needle page 6 F Fluid adjustment page 7 G Fan air adjustment valve page 7 H Atomizing air restrictor valve page 7 I ES ON/OFF switch page 7 J ES indicator (247936 only) page 8 K Voltage/current display (247937 only) page 8 L ES HI/LO switch (247937 only) page 8 M LO voltage adjustment (247937 only) page 8 N External charging probe

The pump supplies fluid to the hose and gun, where the fluid is atomized by the air cap and the atomized particles are electrostatically charged as they pass the external charging probe. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces. The external charging allows the fluid supply to remain grounded at all times and therefore eliminate the need for an isolation system.

MAX FLUID WPR:

100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR:

100 PSI (7bar, 0.7 Mpa)

To avoid shock or explosion

•Use properly grounded air hose

•Read instruction manual

I O

Smart Model

247937

Standard Model

247936

ti12581

I O

100

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

ti12658

Smart Model

247937

ti12582

312900C 5

Overview

A. Air swivel inlet. Left-hand thread.

B. Fluid inlet.

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C. Turbine air exhaust.

D. Air cap and nozzle. See page 13 for sizes.

E. Fluid needle. Shuts off fluid flow and provides a

ground point.

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ti1255a

6 312900C

ti1256a

F. Fluid adjustment valve. Adjusts fluid needle travel.

Use only in low flow conditions, to reduce needle wear.

G. Fan air adjustment valve. Adjusts fan size and

shape.

I O

MAX FLUID WPR: 100 PSI

(7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

100

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

Overview

H. Atomizing air restrictor valve. Restricts atomizing

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

I. ES ON/OFF switch. Turns electrostatics ON (I) or

OFF (0).

I O

100

I O

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

ti1257a

312900C 7

Overview

J. ES indicator (247936 only). Green when ES is ON

(I).

MAX FLUID WPR:

100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR:

100 PSI (7bar, 0.7 Mpa)

To avoid shock or explosion

•Use properly grounded air hose

•Read instruction manual

I O

ti12581

K. Voltage (247937 only). Shows voltage and

current. Green/yellow=spray, red=see Electrical Troubleshooting, page 22.

NOTE: Normal current draw for this model is higher and the yellow current bar will be lit.

L. ES HI/LO switch (247937 only). Sets voltage to HI

or LO (factory settings).

Voltage

Current

I O

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

100

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

100

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M. LO voltage adjustment (247937 only). Remove

plug to adjust to 4 settings.

8 312900C

I O

100

MAX FLUID WPR: 100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

ti12582

Installation

Install the System

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

• Do not install or service this equipment unless you

are trained and qualified.

• Be sure your installation complies with National,

State and Local codes for the installation of electrical apparatus in a Class I, Div. I, Group D or a Group II, Category 2G Hazardous Location.

• Comply with all applicable local, state, and

national fire, electrical, and other safety regulations.

FIG. 1. shows a typical electrostatic air spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Warning Sign

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun.

Ventilate the Spray Booth

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

312900C 9

Installation

c‡d

‡e

Fig. 1. Typical Installation

c‡

j‡

ES ON/OFF valve: I is ON, O is OFF

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b‡

‡r

u‡

q‡

ti1498ax

Key

a Main Air Supply Line b‡ Ventilation Fan Interlock Solenoid Valve c‡ Main Air Supply Shutoff Valve (bleed-type) d Pump Air Line Filter/Water Separator e‡ Pump Air Supply Shutoff Valve (bleed-type) f Air Line Lubricator g Air Pressure Regulator hPump j‡ Pump Ground Wire k Fluid Filter l Fluid Supply Line Shutoff Valve m Fluid Pressure Regulator n Fluid Supply Line o Gun Air Line Filter/Water Separator p Gun Air Supply Line Shutoff Valve (bleed-type) q‡ Air Hose Ground Wire

r‡ Graco Grounded Air Hose s Electrostatic Air Spray Gun t Air Line Drain Valve u‡ Fluid Drain Valve vGun Air Inlet w Gun Fluid Inlet ‡ These items are required for proper operation

and must be purchased separately. NOTE: Solenoid valve (b) is not offered as a Graco accessory.

10 312900C

Installation

Connect the Air Line

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco

Grounded Air Supply Hose.

1. Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet (V) (F

IG. 2). The gun air inlet fitting has a left-hand

thread. Connect the air supply hose ground wire (Q) to a true earth ground.

To air supply

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

Connect the Charging Probe

1. Apply dielectric grease to probe socket.

Probe Socket

ti12722

FIG. 3

2. Press electrode on in Connect/Disconnect position shown in F

3. Rotate electrode to spray position.

IG. 4.

Connect the Charging Electrode

ti1259

ti1259a

IG. 2

2. Install an air line filter/water separator (O) on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install a bleed-type air regulator (G) on the pump and gun air supply lines to control air pressure to the pump and gun.

4. Install a bleed-type air valve (E) on the pump air line to shut off air to the pump. Install an additional bleed-type air valve (C) on the main air line (A) to isolate the accessories for servicing.

The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin.

Connect/Disconnect

Position

IG. 4

Spray

Position

NOTICE

The external charging probe rotates easily. Do not press too hard when rotating it or it could be damaged.

NOTICE

For proper performance, do not operate electrostatics if the charging probe is not in spray position.

ti1933a

312900C 11

Installation

Connect the Exhaust Tube

Press the exhaust tube (38) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (39) (F

IG. 5).

Barbed adapter

ti1275a

IG. 5

Connect the Fluid Line

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

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

3. Install a fluid filter (K) and drain valve (U) at the pump outlet.

ti1277

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IG. 6

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

Filter the Fluid

Install a fluid filter (K) to remove particles and sediment that could clog the spray nozzle.

The fluid drain valve (U) is required in your system to assist in relieving fluid pressure in the displacement pump, hose, and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin.

4. Connect the fluid line to the 3/8 npsm gun fluid inlet (W) (F

IG. 6).

12 312900C

Installation

Select a Fluid Nozzle and Air Cap

The gun is supplied with Part No. 197266 Nozzle and 24A276 Air Cap. If you require a different size, refer to Table 1 and Table 2 , and instruction manual 309419, or consult with your Graco distributor. See Replace Air Cap/Nozzle on page 28.

A wide pattern kit (P/N 24A431) is included with the gun and if installed, will provide more fan air for wider spray patterns. (If pattern becomes split, use the fan air valve to reduce the amount of fan air.)

To reduce the risk of an injury, follow the Pressure Relief procedure on page 19 before removing or installing a fluid nozzle and/or air cap.

NOTE: Due to the larger needle diameter, use a nozzle one size larger than you would use with a standard Pro Xs gun (i.e., 1.5 mm = 1.2 mm flow area).

Table 1: Fluid Nozzles

Part No. Orifice Size

197265 1.2 mm (.047 in.) 197266 1.5 mm (.055 in.) 197267 1.8 mm (.070 in.) 249922* 1.2 mm (.047 in.) 249923* 1.5 mm (.055 in.) 249924* 1.8 mm (.070 in.)

* Glass-reinforced acetal construction.

Table 2: Air Caps

Pattern Shape

Part No.

24A438

24A279

24A276*

24A274

24A439

24A275

*Also available in the following colors:

24A376 - gray 24A277 - red 24A278 - green

and Length in. (mm)

Round end; 15-17 (381-432)

Round end; 14-16 (356-406)

Tapered end; 17-19 (432-483)

Tapered end; 12-14 (305-356)

Round end; 11-13 (279-330)

Tapered end; 14-16 (356-406)

Recommended Fluids and Production Rates

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

Medium to high viscosity and high solids. Up to 15 oz/min (450 cc/min)

Light to medium viscosity. Up to 15 oz/min (450 cc/min)

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).

312900C 13

Installation

Grounding

Fire, Explosion, and Electric Shock Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

• Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

• All persons entering the spray area: shoes must

have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic. If gloves are necessary, wear the conductive gloves that are supplied with the gun. If non-Graco gloves are worn, cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun handle.

• Object being sprayed: keep the workpiece hangers

clean and grounded at all times. Resistance must not exceed 1 megohm.

• The floor of the spray area: must be electrically con-

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

• Electrostatic Air Spray Gun: ground the gun by con- necting the Graco Grounded Air Hose and connecting the air hose ground wire to a true earth ground. See Check Electrical Grounding, page 15.

ti1259a

• Air compressors: ground the equipment according to the manufacturer's recommendations.

• All air and fluid lines must be properly grounded. Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

• Flammable liquids in the spray area: must be kept in

approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.

• All electrically conductive objects or devices in the

spray area: including fluid containers and wash

cans, must be properly grounded.

14 312900C

Check Electrical Grounding

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous

area;

• Or all spraying devices in the hazardous area are

turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes

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

IG. 7.) is not

Installation

ti1274a

Fig. 7. Check Gun Grounding

Check Fluid Resistivity

1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

2. Turn the ES ON/OFF valve OFF.

3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4. Make sure the grounded air hose (R) is connected and the hose ground wire is connected to a true earth ground.

ti1259a

5. Measure the resistance between the gun handle (BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 1 megohm. See F

IG. 7.

Fire, Explosion, and Electric Shock Hazard

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area. Failure to follow this warning could cause fire, explosion, or electric shock and result in serious injury and property damage.

Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air spray system.

Follow the instructions included with the meter and probe. If the material is above 1 megohm-cm, then a Pro Xs3 HC gun may be a better option. The Pro Xs WB gun is intended to spray very conductive waterborne materials and other materials less than 1 megohm-cm.

6. If the resistance is greater than 1 megohm, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

312900C 15

Installation

Check Fluid Viscosity

To check fluid viscosity you will need:

• a viscosity cup

• a stopwatch.

1. Completely submerge the viscosity cup in the fluid. Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2. Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3. Record the fluid type, elapsed time, and size of the viscosity cup.

4. If the viscosity is too high or too low, contact the material supplier. Adjust as necessary.

Prepare to Paint

1. Position air cap.

4. Fully open atomizing air restrictor valve.

ti1272a

5. Check that ES ON/OFF switch is OFF (O).

MAX AIR WPR: 100 PSI

NOTE: This illustration shows the switch in the

(7bar, 0.7 Mpa)

I O

ON (I) position to view I and O indicators.

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6. Start pump. Adjust fluid regulator until stream from gun travels 8-12 in. (200-300 mm) before falling off. Typically, if fluid pressure is below 5 psi (.04 MPa,

0.4 bar) or above 20 psi (0.14 MPa, 1.4 bar), a change of nozzle size is recommended.

2. Fully open fan air adjustment valve.

3. Fully open fluid adjustment valve.

To avoid shock or explosion

•Use properly grounded air hose

•Read instruction manual

I O

To avoid shock or explosion

•Use properly grounded air hose

•Read instruction manual

I O

16 312900C

8-12 in.

(200-300 mm)

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Installation

7. Set gun air regulator to deliver minimum 40 psi (0.28 MPa, 2.8 bar) at gun when triggered, for maximum transfer efficiency. See table at right.

TI1281A

Air Hose* Length

ft (m)

Regulator Setting**

psi (MPa, bar)

15 (4.6) 50 (0.35, 3.5) 25 (7.6) 60 (0.42, 4.2)

50 (15.3) 75 (0.52, 5.2)

* 5/16 in. (8 mm) diameter/8 mm (5/16 in.) **Gun triggered

8. Spray test pattern. Check atomization. If over-atomization occurs at minimum pressure, adjust restrictor valve. If atomization is inadequate, increase air pressure.

10. Turn ES ON/OFF switch ON (I).

MAX FLUID WPR: 100 PSI

(7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

I O

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11. Check that ES indicator or display is lit. If not,

see Electrical Troubleshooting, page 22.

ES indicator

Standard Model 247936

ES display

Smart Model 247937

ti1282b

9. Adjust fan air adjustment valve: clockwise for a shorter pattern, counterclockwise for wider pattern.

12. Spray test piece. Examine edges for coverage. If

wrap is poor, see Spray Pattern Troubleshooting, page 25.

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312900C 17

ti1283

Installation

Flush

Fire, Explosion, and Electric Shock Hazard Read Fire and Explosion, and Electric Shock

Hazards, page 3. Follow steps 1-6 below to flush the

gun when using gun first time, changing colors, before fluid dries, at end of day, and before storing gun.

3. Change fluid source to solvent, or disconnect fluid

line and connect solvent supply line to gun.

NOTICE

This gun has nylon components which will be damaged if you use methylene chloride as a flushing or cleaning solvent.

1. Turn ES ON/OFF switch OFF (O).

ti12724_x2

2. Relieve pressure, page 19.

ti1934

ti1287a

4. Point gun into grounded metal pail. Flush until clean solvent flows from gun.

ti1934

5. Relieve pressure, page 19.

ti1934

18 312900C

6. Hang gun from hook. Nozzle must point down.

ti12718

Pressure Relief

Pressurized Equipment Hazard

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure

• stop spraying

• check or service any of the system equipment

1. Turn the ES ON/OFF valve OFF.

ti12724_x2

5. If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the nozzle or hose.

ti1298a

ti1298

Shutdown

Follow these steps at end of workshift and before cleaning, checking, or repairing equipment

1. Flush, page 18.

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

ti1289

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

ti1934

4. Open the pump drain valve, having a waste container ready to catch the drainage. Leave the pump drain valve open until you are ready to spray again.

ti1934

2. Hang gun from hook. Nozzle must point down.

ti12718

312900C 19

ti1290a

Maintenance

Clean Gun Daily

1. Flush, page 18.

2. a. Clean outside of gun with non-conductive,

compatible solvent. Point gun down. b. Use soft, damp cloth. c. Do not immerse gun.

ti1292a

ti1295a

4. Clean air cap, retaining ring, and nozzle with soft brush and non-conductive, compatible solvent.

ti1297a

5. Clean probe with soft brush and compatible solvent.

ti12716

6. Use toothpick or other soft tool to clean air cap holes. Do not use metal tools.

ti1293a

ti1294a

7. Reinstall air cap. Tighten securely.

3. Remove air cap.

ti1299a

ti1296

20 312900C

Daily System Care

Maintenance

1. Relieve pressure, page 19.

ti1934

2. Clean fluid and air filters.

3. Check for fluid leaks. Tighten all fittings.

5. Check movement of trigger (T) and valves (V). Lubricate if necessary.

ti12658

4. Clean workpiece hangers. Use non-sparking tools.

312900C 21

ti1291a

ti1300a

Electrical Troubleshooting

NOTE: Check all possible remedies in the Troubleshoot-

ing Chart before disassembling the gun.

Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.

Problem Cause Solution

Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I). (In general, a Pro Xs Waterborne gun

will have less wrap than a Pro Xs solventborne gun.)

ES indicator or voltage/current display is not lit.

Voltage/current display stays red (smart guns only).

Operator gets mild shock. Operator not grounded or is near

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

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

40 psi (0.28 MPa, 2.8 bar) needed at

gun for full voltage. Atomizing air pressure too high. Decrease. Fluid pressure too high. Decrease. Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm). Poorly grounded parts. Resistance must be 1 megohm or

less. Clean workpiece hangers. Faulty gun resistance. See Test Total Gun Resistance on

page 23. Faulty turbine alternator. Be sure the plug is in place on the

back of the power supply housing.

Remove and test the turbine alterna-

tor. See page 33. The KV HI-LO lever is on LO. Check the lever actuation; replace if

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

No power. Replace power supply. See page 32. Gun too close to part. Should be 8-12 in. (200-300 mm).

Dirty gun. Clean. See Maintenance on page

20.

See Grounding on page 14. ungrounded object.

Gun not grounded. See Check Electrical Grounding on

page 15 and Test Total Gun Resis-

tance on page 23.

less. Clean workpiece hangers.

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

22 312900C

Electrical Tests

Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18), barrel (16) and charging probe (31), and electrical continuity between components.

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

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see F through F

IG. 12.) is not approved for use in a hazard-

IG. 8.

ous areas. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous

area; or

• all spraying devices in the hazardous area are

turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes

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

Test Total Gun Resistance

Measure resistance between the charging probe tip (BB) and the air swivel (35) (see F 90-130 megohms. If outside this range, go to the next test. If in range, refer to Gun Repair on page 27 for other possible causes of poor performance.

IG. 8.); it should be

Test Gun Resistance

Measure resistance between the air swivel (35) and the charging probe socket (CC) (see F

IG. 9); it should be

70-95 megohms. If outside this range, check the power supply and barrel resistance. If in range, test the charging probe resistance.

ti13731

FIG. 9. Test Gun Resistance

Test Charging Probe Resistance

Measure resistance between the metal spring in the charging probe (DD) and the charging probe tip (BB) (see F

IG. 9); it should be 15-30 megohms. If outside this

range, replace the charging probe. If in range, inspect the spring and barrel socket for possible causes of poor continuity. Reassemble the charging probe and retest the gun resistance.

Fig. 8. Test Total Gun Resistance

312900C 23

ti1468ax

IG. 10. Test Charging Probe Resistance

ti13732

Electrical Tests

Test Power Supply Resistance

1. Remove the power supply (18), page 31.

2. Remove the turbine alternator (19) from the power supply, page 32.

3. Measure resistance from the power supply's ground strips (EE) to the conductive contact in the center of the power supply seal (FF). See F

4. The resistance should be 55-70 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

IG. 11.

Test Barrel Resistance

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

2. Measure the resistance between the conductive rod (GG) and the charging probe socket (CC). See F

12. The resistance should be 15-30 megohms.

3. If the resistance is outside the range, replace barrel.

4. If resistance is in range, reassemble the gun and test the gun resistance.

5. If you still have problems, refer to Gun Repair on page 27 for other possible causes of poor performance, or contact your Graco distributor.

IG.

Fig. 11. Test Power Supply Resistance

ti1599a

Fig. 12. Test Barrel Resistance

ti12821

24 312900C

Spray Pattern Troubleshooting

Electric Shock Hazard

Problem Cause Solution

Fluttering or spitting spray. No fluid. Refill supply.

Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 28.

Air in fluid supply. Check fluid source. Refill.

Improper spray pattern. Damaged nozzle or air cap. Replace, page 28.

Fluid buildup on air cap or nozzle. See Maintenance on page 20.

Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure

Relief procedure on page 19 whenever you are

instructed to relieve the pressure.

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

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

Fan air pressure too high. Decrease.

Fluid too thin. Increase viscosity. Fluid pressure too low. Increase. Fan air pressure too low. Increase.

Fluid too thick. Reduce viscosity. Too much fluid. Decrease flow.

Streaks. Did not apply 50% overlap. Overlap strokes 50%.

Dirty or damaged air cap. Clean or replace, page 28.

312900C 25

Gun Operation Troubleshooting

Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed prop-

Pressurized Equipment Hazard To reduce the risk of an injury, follow the Pressure

Relief procedure on page 19 whenever you are

instructed to relieve the pressure. erly. Do not install or repair this equipment unless you are trained and qualified.

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

Problem Cause Solution

Excessive spray fog. Atomizing air pressure too high. Close restrictor valve some, or

decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.

Fluid too thin. Increase viscosity.

“Orange Peel” finish. Atomizing air pressure too low. Open atomizing air valve more or

increase gun air inlet pressure; use

lowest air pressure necessary. Poorly mixed or filtered fluid. Remix or refilter fluid. Fluid too thick. Reduce viscosity.

Fluid leaks from the fluid packing area

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

30.

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

page 34.

Fluid leakage from the front of the

Worn or damaged packing rod (26). Replace; see page 30

gun

Worn fluid seat. Replace fluid nozzle and/or needle;

see page 28. Loose fluid nozzle (7). Tighten; see page 28. Damaged nozzle o-ring (7b). Replace; see page 28.

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

Damaged air cap (9). Replace; see page 28. Dirty or clogged fluid nozzle (7). Clean; see page 28. Damaged fluid nozzle (7). Replace; see page 28. Damaged fluid adjustment valve (25). Replace; see page 34.

Dirty air cap Misaligned air cap (9) and fluid

nozzle (7).

Clean fluid buildup off air cap and

fluid nozzle seat; see page 28.

26 312900C

Gun Repair

Prepare the Gun for Repair

Electric Shock Hazard

Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

Pressurized Equipment Hazard

• To reduce the risk of injury, follow the Pressure Relief procedure on page 19 before checking or

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

• Check all possible remedies in Gun Operation Troubleshooting before disassembling the gun.

• Use a vise with padded jaws to prevent damage to

plastic parts.

• Lubricate the power supply seal (18a), some packing rod parts (26), and certain fluid fittings with dielectric grease (40), as specified in the text.

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

• Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.

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

• Fluid Seal Repair Kit 244911 is available. The kit must be purchased separately. Kit parts are marked with a double asterisk, for example (5†).

1. Flush the gun, page 18.

2. Relieve the pressure, page 19.

3. Disconnect the gun air and fluid lines.

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

312900C 27

Gun Repair

Replace Air Cap/Nozzle

NOTICE

Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages.

1. Prepare gun for repair page 27.

2. Remove probe.

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

IG. 13.

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

29 7b

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

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

Make sure the fluid needle (29) is finger- tight (page

28).

6. Trigger gun while installing the fluid nozzle (7) with the multi-tool (37). Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).

7. Install the air cap (9) and retaining ring (27). Make sure the u-cup (27a*) is in place with the lips facing forward.

Replace Fluid Needle

1. Prepare the gun for repair page 27.

ti12726

27a*

Fig. 13. Replace Air Cap/Nozzle

Fire, Explosion, and Electric Shock Hazard

The nozzle contact ring (7a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (7a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

2. Remove the air cap and nozzle, page 28.

3. Unscrew the fluid needle (29). Hold the packing rod end (26) to prevent it from turning, F

4. Apply low-strength (purple) Loctite

IG. 13.

or equivalent thread sealant to the fluid needle and packing rod threads. Install the fluid needle finger-tight. Do not overtighten.

5. Install the fluid nozzle and air cap, page 28.

28 312900C

Remove Fluid Packing

1. Prepare the gun for repair, page 27.

2. Remove the air cap and fluid nozzle, page 28.

3. Remove the fluid needle, page 28.

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

IG. 14.

Gun Repair

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

NOTICE

Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

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

TI1549A

Fig. 14. Remove Fluid Packing

312900C 29

Gun Repair

Repair Packing Rod

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 (26g) and seal (26f†) on the fluid rod (26a). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away from the packing nut. See F

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

IG. 15.

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

5. Install the o-ring (26h†) on the outside of housing (26f). Lubricate the o-ring with non-silicone grease, Part No. 111265. Do not over-lubricate.

6. Install the spring (4) against the nut (E) as shown.

7. Install the packing rod assembly (26) into the gun barrel. Using the multi-tool (37), tighten the assembly until just snug.

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

9. Install the fluid needle page 28.

10. Install the nozzle and air cap, page 28.

11. Install the probe.

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

26g

26f†

26e†

26d

†

26c†

26b

26h†

Fig. 15. Packing Rod

26a

ti12719

30 312900C

Gun Repair

Remove Barrel

1. Prepare the gun for repair, page 27.

2. Carefully loosen the nut (54) from the bracket fluid fitting (13). Pull the tube (14 or 50a) out of the fitting. Make sure both ferrules and the nut stay with the tube.

3. Loosen the three screws (11).

NOTICE

To avoid damaging the power supply (18), pull the gun barrel straight away from the gun handle. If necessary, gently move the gun barrel from side to side to free it from the gun handle.

4. Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle. See F

IG. 16.

Install Barrel

1. Be sure the gasket (10*) and grounding spring (53) are in place. Make sure the air holes are aligned properly. Replace if damaged. See F

2. Place the barrel (16) over the power supply (18) and onto the gun handle (17).

3. Tighten the three screws (11) oppositely and evenly (about a half turn past snug).

NOTICE

Do not over-tighten the screws (11).

4. Assemble the fluid tube (14) into the bracket fitting (13). Ensure that the ferrules are in place. Tighten the nut (54).

5. Test gun resistance, page 23.

*10

IG. 17.

ti1503a

Fig. 16. Remove Barrel

ti1504a

ti12830

Fig. 17. Install Barrel

312900C 31

Gun Repair

Remove and Replace Power Supply

• Inspect the gun handle power supply cavity for dirt

or moisture. Clean with a clean, dry rag.

• Do not expose gasket (10) to solvents.

1. Prepare gun for service, page 27.

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

NOTICE

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

3. Grasp the power supply (18) with your hand. With a gentle side to side motion, free the power supply/alternator assembly from the gun handle (17), then carefully pull it straight out. On Smart Model only, disconnect the flexible circuit (59) from the socket at the top of the handle (17). See F

IG. 18.

11. Install the barrel (16), page 31. Ensure the ground spring (53) is in place.

12. Test gun resistance, page 23.

10*

19a*

19e

ti1505cx

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

5. Check the power supply resistance, page 24. Replace if necessary.

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

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

8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate. Ensure the alternator pads (19e) are in place.

9. Lubricate the power supply seal (18a) with dielectric grease (40).

10. Insert the power supply/alternator assembly in the gun handle (17). Make sure the ground strips make contact with the handle. On Smart Model only, con- nect the flexible circuit (59) to the socket at the top of the handle. Push the 6-pin connector into the socket to ensure it is properly connected.

18a

FIG. 18. Power Supply

32 312900C

Gun Repair

Remove and Replace Turbine Alternator

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

1. Prepare gun for repair, page 27.

2. Remove the power supply/alternator assembly, page 32.

3. Disconnect the alternator from the power supply, page 32.

4. Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be

2.5-3.5 ohms. If outside this range, replace the alternator coil.

5. Follow the bearing replacement procedure in the bearing kit manual 308034.

6. Install the alternator on the power supply, page 32.

7. Install the power supply/alternator assembly, page

32.

Repair Fan Air Adjustment Valve

1. Prepare the gun for service, page 27.

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

You may replace the valve as an assembly (go to step 9) or as individual parts (steps 3-9).

3. Remove the retaining ring (20a). See F

4. Turn the valve stem (20d) counterclockwise until it comes free from the valve housing (20c).

5. Remove the o-ring (20b).

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

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

7. When reassembling the fan air valve (20), lightly lubricate the valve threads and screw the stem (20d) fully into the housing (20c) until bottomed. Install the o-ring (20b*), lubricate, and unscrew the valve stem until the o-ring enters the housing.

IG. 19.

20a

8. Reassemble the retaining ring (20a). Unscrew the valve stem from the housing until it is stopped by the retaining ring.

9. Screw the valve assembly (20) into the gun handle, using a wrench on the flats of the housing. Torque to 15-25 in-lb (1.7-2.8 N•m).

20d

TI1487A

20b*

20c

Fig. 19. Fan Air Adjustment Valve

312900C 33

Gun Repair

Repair Fluid Adjustment Valve

1. Prepare the gun for repair, page 27.

2. Remove the fluid adjustment valve (25). It can only be replaced as a complete assembly. See F

3. Screw the valve (25) into the gun handle. Torque to 15-25 in-lb (1.7-2.8 N•m).

Fig. 20. Fluid Adjustment Valve

IG. 20..

ti11931

5. Inspect the u-cup (6*). Do not remove the u-cup unless damaged. If removed, install the new one with its lips facing into the gun handle (17).

6. Install the air valve (21) and spring (15) into the gun handle (17).

7. Install the fluid adjustment valve (25). Torque to 15-25 in-lb (1.7-2.8 N•m).

8. Install the barrel, page 31.

ti12717

Fig. 21. Air Valve

Repair Air Valve

1. Prepare the gun for service, page 27.

2. Remove the barrel, page 31.

3. Remove the fluid adjustment valve (25) from the handle (17). Remove the spring (15). See FIG. 21.

NOTICE

Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

4. Remove the air valve (21) with a pliers. Inspect the rubber sealing surface and replace the air valve if damaged.

NOTICE

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

34 312900C

Gun Repair

Remove and Replace Atomizing Air Restrictor Valve

1. Prepare the gun for repair, page 27.

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

IG. 22.

3. Install a new atomizing air restrictor valve (23), or disassemble and replace parts individually. The valve protrusion must be oriented to clear the air valve (21) shaft.

If the atomizing air restrictor valve is not desired, install the supplied plug (2).

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

Repair ES ON/OFF Valve

1. Prepare the gun for repair, page 27.

2. Loosen the screw (48). Remove the valve.

3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

NOTICE

Do not over-lubricate parts. Excessive lubricant on the o-rings can be pushed into the gun air passage and blemish the finish on the workpiece.

4. Clean and inspect parts for damage. Replace if necessary.

The protrusion on the retainer plate (22d) must point upward.

5. Reinstall the valve. Torque the screw (48) to 15-25 in-lb (1.7-2.8 N•m).

23d

ti1508a

Fig. 22. Atomizing Air Restrictor Valve

23c*

23a

23b

22b*

22c

22a*

Fig. 23. ES ON/OFF Valve

22e

22d

22g

22f

ti12720

312900C 35

Parts

Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model)

See page 38 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26).

Maximum torque 10 in-lb (1.1 N•m)

27a*

10*

Ref. No. 37: Multi-tool

18a

24a*

ti11932

36 312900C

Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model)

See page 38 for detail views of the alternator (19), fan adjustment valve (20), ES ON/OFF valve (22), and packing rod (26).

Parts

Maximum torque 10 in-lb (1.1 N•m)

27a*

10*

Ref. No. 37: Multi-tool

18a

24a*

ti12659

312900C 37

Parts

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

19b

19d

19c

Ref. No. 22: ES ON/OFF Valve

22d

22e

22b*

22c

22a*

19a*

19e

TI1481a

22g

22f

20c

20a

Ref. No. 26: Packing Rod

26e†

26d†

26c†

26b

20b*

26f†

20d

TI1487A

26a

26g

ti12719

Ref. No. 37: Multi-tool

ti12720

26h†

247936 (Standard Model) controls

MAX FLUID WPR:

100 PSI (7bar, 0.7 Mpa)

MAX AIR WPR:

100 PSI (7bar, 0.7 Mpa)

To avoid shock or explosion

•Use properly grounded air hose

•Read instruction manual

I O

247937 (Smart Model) controls

100

MAX FLUID WPR: 100 PSI

(7bar, 0.7 Mpa)

MAX AIR WPR: 100 PSI (7bar, 0.7 Mpa)

I O

38 312900C

Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model) Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model)

Parts

Ref. No.

1 111157 FITTING, tube, fluid 1

2 197967 PLUG, handle 1

3 198058 SCREW, cap, socket head 1

4 185111 SPRING, compression 1

5 111450 PACKING, o-ring (247937 only) 1

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

7 197266 NOZZLE; 1.5 mm orifice; includes

7a 111261 . O-RING, conductive 1

7b 111507 . O-RING; fluoroelastomer 1

8 24A445 SCREW, trigger 2

9 24A276 AIR CAP 1

10* 197517 GASKET, barrel 1

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

13 24A336 BRACKET, inlet, fluid 1

14 24A334 TUBE, fluid 1

Part No. Description Qty

UHMWPE

7a and 7b

(19 mm)

Ref. No.

20 244556 VALVE, adjustment, fan; includes

20a 101021 . RING, retaining 1

20b* 106560 . O-RING; fluorocarbon 1

20c 197566 . HOUSING, fan valve 1

20d 197567 . STEM, fan valve 1

22 244558 VALVE, electrostatics, ON/OFF;

22a* 111516 . O-RING; CV75 1

22b* 113137 . O-RING; fluoroelastomer 1

22c 198403 . SHAFT, valve 1

22d 198404 . PLATE, retaining 1

22e 198453 . WASHER 1

22f 198464 . PIN 1

22g 249185 . KNOB 1

23 244559 VALVE, air restrictor; includes

Part No. Description Qty

20a-20d

244557 VALVE, air; 1

❖

includes 22a-22g

23a-23d

15 185116 SPRING, compression 1

16 24A329 BODY, gun; ES; includes 16a-16e 1

17 24A596 HANDLE, smart (247937) 1

24A595 HANDLE, standard (247936) 1

18 24A332 POWER SUPPLY, 60 kV 1

18a 256267 . SEAL 1

19 244555 TURBINE, alternator; includes

19a-19e

19a* 110073 . O-RING; fluoroelastomer 1

19b 223688 . BEARING KIT; includes front and

rear bearings and fan

19c 244577 . COIL 1

19d 111745 . RING, retaining 1

19e 198821 . PAD, pressure 2

23a 197594 . HOUSING, valve 1

23b 197591 . SHAFT 1

23c* 111504 . O-RING; fluoroelastomer 2

23d 101021 . RING, retaining 1

24 249323 VALVE, exhaust; includes 24a 1

24a* 112085 . O-RING; fluorocarbon 1

25 244593 VALVE, adjustment, fluid 1

312900C 39

Parts

Ref. No.

26 24A331 NEEDLE; includes 26a-26h 1

26a

26b

26c

26d

26e†

26f

26g

26h†

27 244927 RING, retaining; includes 27a 1

27a* 198307 . PACKING, u-cup 1

30 24A335 TRIGGER 1

32 111285 FERRULE, back 1

35 244834 SWIVEL, air; 1/4 npsm(m) ;

36 107460 WRENCH, ball end; 4 mm 1

Part No. Description Qty

24A330 . NEEDLE, assembly 1

185495 . HOUSING, packing 1

178763 . PACKING, needle 1

†

178409 . PACKING, fluid 1

†

186069 . SPACER, packing 1

116905 . SEAL 1

†

197641 . NUT, packing 1

111316 . PACKING, o-ring 1

24A338 NEEDLE, electrode 1

24A328 PROBE, external charging 2

left-hand threads

Ref. No.

42▲ 179791 TAG, warning (not shown); replace-

43▲ 180060 SIGN, warning (not shown);

53 197624 SPRING, compression 1

54 112644 NUT, swagelock 1

55 111286 FERRULE, front 1

56 197910 SCREW, pivot, ES HI/LO (247937

57 276734 PLUG, KV adjust (247937 only) 1

58 244627 SWITCH, ES HI/LO (247937 only) 1

59 245265 CIRCUIT, flexible (247937 only) 1

60 248130 O-RING (pack of 6) 1

61 24A431 KIT, wide pattern (not shown) 1

Part No. Description Qty

ment available at no cost

replacement available at no cost

only)

* Included in Air Seal Repair Kit 244781.

† Included in Fluid Seal Repair Kit 244911.

❖ Rubber seal is not removable.

▲Replacement Warning labels, signs, tags, and cards

are available at no cost.

37 276741 MULTI-TOOL 1

38 185103 TUBE, exhaust (not shown) 1

39 110231 CLAMP (not shown) 1

40 116553 GREASE, dielectric, tube (not

shown)

41 197979 COVER, gun; box of 10 (not shown) 1

40 312900C

Accessories

Air Line Accessories

AirFlex™ Flexible Grounded Air Hose

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

244963 6 ft (1.8 m) 244964 15 ft (4.6 m) 244965 25 ft (7.6 m) 244966 36 ft (11 m) 244967 50 ft (15 m) 244968 75 ft (23 m) 244969 100 ft (30.5 m)

Standard Grounded Air Hose

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

223068 6 ft (1.8 m) 223069 15 ft (4.6 m) 223070 25 ft (7.6 m) 223071 36 ft (11 m) 223072 50 ft (15 m) 223073 75 ft (23 m) 223074 100 ft (30.5 m)

High Flow Grounded Air Hose

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

0.375 in. (10 mm) ID; 3/8 npsm(f) x 1/4 npsm(f) left-hand thread

24A225 50 ft (15.2 m) 24A226 75 ft (22.9 m)

Bleed-Type Master Air Valve

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between this valve and the pump air motor when closed.

Air Line Quick Disconnect 112534 Swiveling quick disconnect replaces stan-

dard air inlet swivel.

Air Hose Adapter Nipple 185493 Use to connect multiple air hoses. 1/4 npt x

1/4 npsm left-hand thread.

Non-Swivel Air Inlet Fitting 185105 Replaces standard swivel. Left-hand thread.

Extended Air Inlet Fitting 189191 Replaces standard swivel to provide

extended handle grip area. Left-hand thread.

Fluid Line Accessories

Fluid Hose

225 psi (14 bar, 1.4 MPa) Maximum Working Pressure

FM Approved; nylon; 3/8 npsm(fbe)

215637 1/4 in. (6 mm) ID x 25 ft (7.6 m) 215638 1/4 in. (6 mm) ID x 50 ft (15.2 m)

Fluid Shutoff/Drain Valve

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

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

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

PTFE; for non-corrosive fluids

Fluid Swivel

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

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

107141 3/4 npt

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off. 224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

312900C 41

Accessories

Gun Accessories

Gun Repair Kits 244781 Air Seal Repair Kit

244911 Fluid Seal Repair Kit

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

ES Always On Kit 244913 Replaces inlet fitting with ball valve to shut

off air during flushing. Converts ES ON/OFF valve to always ON condition.

Handle Grips 245263 Medium Grip

245264 Large Grip

Gun Washer Kit 245270 Use to convert Graco gun washers so they

can clean PRO Xs3 and PRO Xs4 air spray guns.

Miscellaneous Accessories

Ground Wire and Clamp 222011 For grounding pump and other components

and equipment in the spray area. 12 gauge, 25 ft (7.6 m).

Megohmmeter 241079 500 Volt output; 0.01-2000 megohms.

Not for use in hazardous areas.

Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure

resistance of paint.

Not for use in hazardous areas.

Paint Probe 722860 Use with 722886 Paint Resistance Meter to

measure resistance of paint.

Not for use in hazardous areas.

Safety Warning Signs

Pressure Cups

Includes air regulators for gun atomization air and supply air to pressure cup.

244731 1 Quart (0.95 Liter) 244732 2 Quart (1.90 Liter)

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

lubricant for fluid seals and wear areas.

Alternator Bearing Kit 223688 To repair the turbine alternator.

Cleaning Brush 105749 For cleaning air cap and fluid nozzle.

180060 English Warning Sign. FM Approved. Avail-

able at no charge from Graco.

Electrostatic Conductive Gloves (box of 12) 117823 Small

117824 Medium 117825 Large

42 312900C

Technical Data

Category Data

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

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

Maximum Fluid Operating Temperature ............................ 120°F (49°C)

Maximum voltage output ................................................... 60kV

Sound Pressure (measured per ISO Standard 9216) ....... at 40 psi (0.28 MPa, 2.8 bar); 90.4 dB(A)

at 100 psi (0.7 MPa 7 bar): 105.4 dB(A)

Sound Pressure (measured 1 m from gun) ....................... at 40 psi (0.28 MPa, 2.8 bar); 87 dB(A)

at 100 psi (0.7 MPa 7 bar): 199 dB(A)

Air inlet fitting, left-hand thread.......................................... 1/4 npsm

Fluid inlet fitting ................................................................. 3/8-18 npsm (R 3/8-19) compound thread

Gun Weight........................................................................ 247936: 22.4 oz (634 g)

247937: 25.1 oz (712 g)

Gun Length (with probe).................................................... 10.6 in. (24.6 cm)

Paint Resistivity ................................................................. <1 megohm-cm

Wetted Parts...................................................................... Polyethylene, Stainless Steel; Nylon, Acetal, PTFE,

UHMWPE, Fluoroelastomer, PEEK, Nickel Plate

312900C 43

Graco Warranty

Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco 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 312900

Graco Headquarters: Minneapolis

www.graco.com

Revised 10/2009

Graco PRO 247936, PRO 247937, PRO 312900C, PRO Xs 247936, PRO Xs 247937 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual