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
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire, explosion, or electric shock.
•Electrostatic equipment must be used only by trained, qualified personnel who understand
the requirements in this manual.
•Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all conductive objects in the spray area. See Grounding, page 12.
•Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying,
flushing, or cleaning the gun. Interlock the gun air supply to prevent operation unless ventilating fans are on. See Ventilate the Spray Booth on page 7.
•Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all solvent is removed from the system.
•If there is any static sparking while using the equipment, stop spraying immediately. Iden-
tify and correct the problem.
•Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
•Check gun resistance daily. See Test Gun Resistance on page 18.
•Use cleaning solvents with the highest possible flash point, preferably above ambient
temperature.
•Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the
spray area.
•Use only non-sparking tools to clean residue from the booth and hangers.
•Keep a 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.
4309292L
Symbols
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 dis-
tributor.
•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. Max-
imum 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 Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
•Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do
not expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).
•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, page 24, 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.
309292L5
Introduction
I O
Introduction
How the Electrostatic Air Spray
Gun Works
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge to supply high voltage current to the gun’s electrode.
The 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.
•Fan AIR adjustment valve. Adjusts fan size and
shape.
•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 (standard gun only). Green when
ES is ON (I).
•Voltage/current DISPLAY (smart models only).
Shows voltage (V) and current (A). Green=spray,
yellow/red=see Troubleshooting, page 23.
•ES HI/LO switch (smart models only). Sets volt-
age to HI or LO (factory settings).
•LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings.
ES INDICATOR
ES ON/OFF
RESTRICTOR
Standard ModelSmart Model
Fig. 1. Gun Overview
ES
I O
ti1266a
AIR
FLUID
ES HI/LO
ES ON/OFF
RESTRICTOR
LO
ES
I O
DISPLAY
LO VOLTAGE
100%
0
KV
μα
HI
ES
AIR
FLUID
ti1253a
6309292L
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, Group D or a Class II 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.
309292L7
Installation
ES ON/OFF valve: I is ON, 0 is OFF
A
ES
I O
M
O
B*C*D
S
L
*E
G
C
H
F
J*
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 AreaHazardous Area
Fig. 2. Typical Installation
Key
AMain Air Supply Line
B*Ventilation Fan Interlock Solenoid Valve
C*Main Air Supply Shutoff Valve (bleed-type)
DPump Air Line Filter/Water Separator
E*Pump Air Supply Shutoff Valve (bleed-type)
FAir Line Lubricator
GAir Pressure Regulator
HPump
J*Pump Ground Wire
KFluid Filter
LFluid Supply Line Shutoff Valve
MFluid Pressure Regulator
ti1498a
NFluid Supply Line
OGun Air Line Filter/Water Separator
PGun Air Supply Line Shutoff Valve
Q*Air Hose Ground Wire
R*Graco Grounded Air Hose
SElectrostatic Air Spray Gun
TAir Line Drain Valve
U*Fluid Drain Valve
VGun Air Inlet
WGun Fluid Inlet
*Required for safe operation. Must be purchased
separately. NOTE: Solenoid valve (B) is not
offered as a Graco accessory.
8309292L
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).
309292L9
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.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
before removing or installing a fluid nozzle
and/or air cap.
Table 1: Fluid Nozzles
Part No.Orifice Size
1972630.75 mm (.030 in.)
1972641.0 mm (.042 in.)
1972651.2 mm (.047 in.)
1972661.5 mm (.055 in.)
1972671.8 mm (.070 in.)
1972682.0 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.)
* Glass-reinforced acetal construction.
Filter the Fluid
Install a fluid filter (K) to remove particles and sediment
which could clog the spray nozzle.
Part No.
197477
Select a Fluid Nozzle and Air
Cap
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
Table 1 and Table 2 , and instruction manual 309419, or
consult with your Graco distributor. See Air Cap/Nozzle Replacement on page 26.
10309292L
197478
197479
197480
197481
Table 2: Air Caps
Pattern Shape
and Length
in. (mm)
Round end;
15-17 (381-432)
Round end;
15-17 (381-432)
Tapered end;
13-15 (330-381)
Round end;
16-18 (406-457)
Tapered end;
17-19 (432-483)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Medium to high production.
Light to medium viscosity.
Low to medium production.
Light to medium viscosity.
Medium to high production.
Medium to high viscosity
and high solids.
Low to medium production.
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
Installation
244919 HC Conversion Kit
Part No. 244919 Conversion Kit converts PRO Xs3
standard coating guns (Part Nos. 244400 and 244579)
to high conductivity guns (244575 and 244576). For further instruction and parts, see manual 309453.
The kit is for use with fluids with low resistivity values.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure in your gun
manual before installing this kit.
1. Turn the ES ON/OFF valve OFF.
2. Flush and relieve the pressure.
3. Disconnect the fluid and air lines to the gun.
4. Remove the fluid tube and fittings.
9. Slide the tube case (1e) onto the barrel inlet, over
the o-ring (2b). The coiled tube (1a) will compress
slightly.
10. Insert the end of the coiled tube (1a) into the bracket
(3). Make sure the ferrules (1c, 1b) seat on the
bracket.
11. Secure the bracket by tightening the swivel (A).
Tighten the nut (1d). Reinstall the exhaust tube (B)
and clamp (C).
12. Reconnect the fluid and air lines to the gun.
5
2a
2b
2
1b
1c
1d
3
5. Remove the fluid inlet bracket.
6. Install the new bracket (3) from the kit loosely. See
F
IG. 3.
7. Place the spacer (5) in the barrel inlet. Apply Graco
dielectric grease (4) to the o-rings (2a, 2b) and to
both threads of the fluid fitting (2). Thread the fitting
into the barrel inlet.
8. Thread the nut (1d) onto the fitting (2). Make sure
the ferrules (1c and 1b) are on the tube (1a) and are
seated on the fitting (2) before tightening the nut
(1d).
1e
1a
1e
1e
FIG. 3: 244919 Conversion Kit
1e
A
B
C
1e
ti10674a
309292L11
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 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 13.
ti1259a
•Air compressors: ground the equipment according
to the manufacturer's recommendations.
•All air and fluid lines must be properly grounded.
Use only grounded hoses with a maximum of 100
feet (30.5 m) combined hose length to ensure
grounding continuity.
•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.
12309292L
Installation
Check Electrical Grounding
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).
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. 4.
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. 4. Check Gun Grounding
309292L13
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.
14309292L
Operation
Refer to the gun operation manual (supplied)
for Setup, Shutdown, and Daily Care procedures.
INSTRUCTIONS
Low Voltage Adjustment (Smart
Guns Only)
Operation
The ES HI/LO switch enables you to switch between full
voltage and a lower voltage output. The lower voltage is
factory set, but can be adjusted.
1. Set the ES HI/LO switch to LO.
2. Remove the LO VOLTAGE adjustment plug (53). Set
the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
Table 3 . Also see F
IG. 5.Fig. 5. Low Voltage Adjustment Switches
Table 3: Low Voltage Adjustment
60 kV Guns85 kV Guns
12kV12kV
ONON50ONON70
Factory
Setting
ONOFF40ONOFF60
OFFON35OFFON50
OFFOFF30OFFOFF40
OFF
ON
100%
0
KV
μα
12
53
ti1529a
309292L15
Maintenance
Maintenance
Refer to the gun operation manual (supplied)
for Daily Care and Cleaning procedures.
INSTRUCTIONS
Flush the Spray Gun
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
CAUTION
Flush the gun with a non-conductive, compatible
solvent. Conductive solvents can cause the gun to
malfunction.
Do not use methylene chloride as a flushing or
cleaning solvent with this gun as it will damage
nylon components.
1. Turn the ES ON/OFF valve OFF.
ES
I O
ti1273a
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
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.
16309292L
ti1276a
5. Relieve the pressure.
ti1276a
6. Shut off or disconnect the solvent line.
Maintenance
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.
309292L17
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. 6.) 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 117-137
megohms for the PRO Xs3, and 156-180 megohms
for the PRO Xs4. If outside this range, go to the next
test. If in range, refer to Electrical Troubleshooting
on page 23 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. 6. Test Gun Resistance
18309292L
Electrical Tests
Test Power Supply Resistance
1. Remove the power supply (18), page 30.
2. Remove the turbine alternator (19) from the power
supply, page 31.
3. Measure resistance from the power supply's ground
strips (EE) to the spring (18b). See F
4. The resistance should be 95-105 megohms for the
PRO Xs3, and 135-150 megohms for the PRO Xs4.
If outside this range, replace the power supply. If in
range, proceed to the next test.
5. If you still have problems, refer to Electrical Trou-bleshooting on page 23 for other possible causes
of poor performance, or contact your Graco distributor.
IG. 7.
6. Be sure the spring (18b) is in place before reinstalling the power supply.
18b
EE
ti1599a
Fig. 7. Test Power Supply Resistance
309292L19
Electrical Tests
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. 8.
3. If in range, refer to Electrical Troubleshooting on
page 23 for other possible causes of poor performance, or contact your Graco distributor.
4. Remove the electrode (29), page 27. 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. 9.
5. Make sure the metal contact (C) in the barrel, the
nozzle contact ring (7a, F
IG. 10.), and the electrode
contact (E) are clean and undamaged.
C
29
B
ti1499a
F29E
Fig. 9. Electrode
ti1513a
Fig. 10. Nozzle Conductive O-Ring
ti1548a
7a
Fig. 8. Test Electrode Resistance
20309292L
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 24
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.
ProblemCauseSolution
Fluttering or spitting spray.No fluid.Refill supply.
Loose, dirty, damaged nozzle/seat.Clean or replace nozzle, page 26.
Air in fluid supply.Check fluid source. Refill.
Improper spray pattern.Damaged nozzle or air cap.Replace, page 26.
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 26.
309292L21
Troubleshooting
Gun Operation Troubleshooting
ProblemCauseSolution
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 gunAir valve (21) is not seating properly. Clean and service air valve; see
Fluid leakage from the front of the
gun
Gun does not sprayLow fluid supply.Add fluid if necessary.
Dirty air capMisaligned air cap (9) and fluid noz-
Worn packings or rod.Replace packings or rod; see page
29.
page 34.
Worn or damaged packing rod (26).Replace; see page 29
needle; see pages 26 to 27.
Loose fluid nozzle (7).Tighten; see page 26.
Damaged nozzle o-ring (7b).Replace; see page 26.
Damaged air cap (9).Replace; see page 26.
Dirty or clogged fluid nozzle (7).Clean; see page 26.
Damaged fluid nozzle (7).Replace; see page 26.
Damaged fluid adjustment valve (25). Replace; see page 34.
Clean fluid buildup off air cap and
zle (7).
fluid nozzle seat; see page 26.
22309292L
Troubleshooting
Electrical Troubleshooting
ProblemCauseSolution
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
18.
Low fluid resistivity.Check fluid resistivity, page 14.
Fluid leaks from the packing (26d)
and causes a short.
Faulty turbine alternator.Be sure the plug is in place on the
The KV HI-LO lever is on LO.Check the lever actuation; replace if
ES indicator or voltage/current display is not lit.
Voltage/current display stays red
(smart guns only).
Operator gets mild shock.Operator not grounded or is near
Operator gets shock from workpiece. Workpiece not grounded.Resistance must be 1 megohm or
ES ON/OFF valve OFF (0).*Turn ON (I).
No power.Replace power supply. See page 31.
Gun too close to part.Should be 8-12 in. (200-300 mm).
Check fluid resistivity.See Check Fluid Resistivity on
Dirty gun.Clean. See Operation Manual.
ungrounded object.
Gun not grounded.See Check Electrical Grounding on
Clean the packing rod cavity.
Replace the packing rod. See page
29.
back of the power supply housing.
Remove and test the turbine alternator. See page 32.
needed.
page 14.
See Grounding on page 12.
page 13 and Test Gun Resistance
on page 18.
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
309292L23
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 Pro-
cedure 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
2. Turn off the air bleed valves to the fluid source and
to the gun.
ti1289a
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.
ti1273a
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.
t
24309292L
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.
Repair
•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), some pack-
ing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
•Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
WARNING
Pressurized Equipment Hazard
To reduce the risk of injury, follow the Pressure Relief Procedure on page 24 before
checking or servicing any part of the system
and whenever you are instructed to relieve
the pressure.
•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 16.
2. Relieve the pressure, page 24.
3. Disconnect the gun air and fluid lines.
4. Remove the gun from the worksite. Repair area
must be clean.
309292L25
Repair
Air Cap/Nozzle Replacement
WARNING
CAUTION
Hold the front end of the gun up and trigger the gun
while removing the nozzle to help drain the gun and
prevent any paint or solvent left in the gun from
entering the air passages.
1. Prepare gun for service, page 25.
2. Remove the retaining ring (27) and air cap (9). See
F
IG. 11..
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 27).
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. 11. Air Cap/Nozzle Replacement
7a
7b
ti1501a
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 18.
26309292L
Electrode Replacement
1. Prepare the gun for service, page 25.
2. Remove the air cap and nozzle, page 26.
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
turning, F
IG. 12.
CAUTION
To avoid damaging the plastic threads, be very
careful when installing the electrode.
Repair
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 26.
6. Test gun resistance, page 18.
ti1502a
Fig. 12. Electrode Replacement
309292L27
Repair
Fluid Packing Removal
1. Prepare the gun for service, page 25.
2. Remove the air cap and fluid nozzle, page 26.
3. Remove the electrode, page 27.
4. Loosen the trigger screws (8) and trigger (30). See
F
IG. 13..
5. Remove the packing rod (26), using the multi-tool
(37).
CAUTION
37
30
Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause
the gun to malfunction.
6. Check all parts for wear or damage and replace if
necessary.
8
TI1549A
Fig. 13. Fluid Packing Removal
28309292L
Repair
4
Packing Rod Repair
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.
Before installing the fluid packing rod into the gun barrel,
make sure the internal surfaces of the barrel are clean.
Remove any residue with a soft brush or cloth. Check
the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.
To assemble the individual parts:
1. Place the packing nut (26e) and seal (26b**) on the
fluid rod (26h). Flats on the packing nut must face
the back of the fluid rod. The seal o-ring must face
away from the packing nut. See F
2. Fill the inner cavity of the spacer (26g**) with dielectric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
IG. 14..
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 27.
10. Install the nozzle and air cap, page 26.
11. Test gun resistance, page 18.
3. Place the rod packing (26d**), packing spreader
(26c**), and housing (26f) on the packing rod (26h) .
26e
**26b
**26g
**26d
**26c
26f
**26a
E
TI1489A
26h
Fig. 14. Packing Rod
309292L29
Repair
Barrel Removal
1. Prepare the gun for service, page 25.
2. Carefully loosen the nut (32 or 50d) 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).
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. 15..
16
Barrel Installation
1. Be sure the gasket (10*) and grounding spring (55)
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).
IG. 16..
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 18.
*10
18
11
ti1503a
17
Fig. 15. Barrel Removal
16
55
ti1506a
Fig. 16. Barrel Installation
ti1504a
30309292L
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 25.
2. Remove the barrel (16), page 30.
CAUTION
Be careful when handling the power supply (18) to
avoid damaging it.
3. Grasp the power supply (18) with your hand. With a
gentle side to side motion, free the power supply/alternator assembly from the gun handle (17),
then carefully pull it straight out. On Smart Models only, disconnect the flexible circuit (59) from the
socket at the top of the handle (17). See F
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alternator for damage. On Smart Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.
IG. 17..
8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
9. Lubricate the power supply o-ring (18a*) with dielectric grease (40).
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Models only, con-
nect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
11. Install the barrel (16), page 30.
12. Test gun resistance, page 18.
17
10*
19a*
19
19e
5. Check the power supply resistance, page 19.
Replace if necessary.
Before installing the power supply, make sure the
o-rings (18a*, 19a*), spring (18b), and pads (19e)
are in place.
6. On Smart Models only, connect the 6-pin flexible cir-
cuit (59) to the power supply.
7. Connect the 3-wire connector (GG). Slide the alternator (19) down onto the power supply (18).
59
ti1505c
GG
18
*18a18b
Fig. 17. Power Supply
309292L31
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 25.
2. Remove the power supply/alternator assembly,
page 31.
3. Disconnect the alternator from the power supply,
page 31.
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 31.
Fluid Tube Removal and
Replacement (PRO Xs4 Guns
Only)
1. Remove the nut (32) from the bracket (13).
2. Loosen the fitting (1) to remove the fluid tube (14)
from the barrel (16).
3. Apply dielectric grease (40) to the threads of the fitting (1), the o-ring (5), and the sleeve (S) of the fluid
tube (14).
4. Slide the fitting (1) onto the fluid tube (14) and
thread the fitting into the barrel (16).
5. With the ferrules (31) seated to the bracket (13),
screw the nut (32) onto the bracket.
5
S
1
14
7. Install the power supply/alternator assembly, page
31.
Fig. 18. PRO Xs4 Fluid Tube
32
31
TI1490A
32309292L
Repair
Fan Air Adjustment Valve Repair
1. Prepare the gun for service, page 25.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
You may replace the valve as an assembly (go to
step 9) or as individual parts (steps 3-9).
3. Remove the retaining ring (20a). See F
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
5. Remove the o-ring (20b).
IG. 19..
6. Clean all parts and inspect for wear or damage.
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. 19. Fan Air Adjustment Valve
20b*
309292L33
Repair
Fluid Adjustment Valve Repair
1. Prepare the gun for service, page 25.
2. Remove the fluid adjustment valve (25). It can only
be replaced as a complete assembly. See F
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
Fig. 20. Fluid Adjustment Valve
IG. 20..
25
ti1507a
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 30.
Air Valve Repair
1. Prepare the gun for service, page 25.
2. Remove the barrel, page 30.
3. Remove the fluid adjustment valve (25) from the
handle (17). Remove the spring (15). See FIG. 21..
CAUTION
Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause
the gun to malfunction.
*6
Fig. 21. Air Valve
17
ti1512a
21
15
25
34309292L
Repair
Atomizing Air Restrictor Valve
Removal and Replacement
1. Prepare the gun for service, page 25.
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 (47).
4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
ES ON/OFF Valve Repair
1. Prepare the gun for service, page 25.
2. Loosen the screw (48). Remove the valve.
3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-rings can be pushed into the gun air passage
and blemish the finish on the workpiece.
4. Clean and inspect parts for damage. Replace if necessary.
The protrusion on the retainer plate (22d) must point
upward.
23d
ti1508a
Fig. 22. Atomizing Air Restrictor Valve
23c*
23a
47
23b
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. 23. ES ON/OFF Valve
22f
22g
48
309292L35
Parts
Parts
Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55)
Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55)
Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55)
See page 37 for detail views of the fluid tube assemblies, alternator
(19), fan adjustment valve (20), ES ON/OFF valve (22), and packing
rod (26).
I O
25 (Ref)
22
ES
20
19e
19a*
19
18
ti1266a
18b
28
17
25
15
21***
11
*18a
11
23c*
23a
47
23b
29
26
16
4
55
*10
*6
8
23d
24a*
24
30
35
13
9
27a*
27
36309292L
37
36
38
39
ti1480b
7b
7a
7
Parts
Ref. No. 20: Fan Adjustment ValveRef. No. 19: Alternator
19b
19b
19d
19c
Ref. No. 22: ES ON/OFF Valve
22f
22d
22e
22b*
22c
22a*
TI1488A
19e
48
19a*
TI1481a
22g
26a**
20b*
20c
20a
Ref. No. 26: Packing Rod
26b**
26g**
26d**
26c**
26f
26e
20d
26h
TI1487A
ti1601a
Fluid Tube: Model 244400Fluid Tube: Model 244575Fluid Tube: Model 244401
5**
1
31
32
14
32
31**
ti1492a
309292L37
49
50c
5**
50b
49a
49b
50d
50e
50a
50f
50b
5
1
14
**3132
50c50d
TI1490A
Parts
Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55)
Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55)
Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55)
Ref.
Part No. DescriptionQty
Ref.
Part No. DescriptionQty
No.
1110078FITTING, tube, fluid; used on 2444001
198587FITTING, tube, fluid; used on 2444011
4185111SPRING, compression1
5**185120SPACER, fluid; nylon; used on
244400 and 244575
102982O-RING; used on 2444011
6*188749PACKING, u-cup, air valve;
UHMWPE
7197266NOZZLE; 1.5 mm orifice; includes 7a
and 7b
7a111261. O-RING, conductive1
7b111507. O-RING; fluoroelastomer1
8197369SCREW, trigger2
9197477AIR CAP1
10*197517GASKET, barrel1
11197518SCREW; socket-hd; 10-24 x 3/4 in.
(19 mm)
1315M678BRACKET, inlet, fluid; used on
244400 and 244401
15M679BRACKET, inlet, fluid; used on
244575
No.
18244540POWER SUPPLY, 60 kV; used on
244541POWER SUPPLY, 85 kV; used on
18a* 103337. O-RING; fluoroelastomer1
1
18b197624. SPRING, compression1
19244555TURBINE, alternator; includes
1
19a* 110073. O-RING; fluoroelastomer1
1
19b223688. BEARING KIT; includes front and
19c244577. COIL1
19d111745. RING, retaining1
19e198821. PAD, pressure2
20244556VALVE, adjustment, fan; includes
20a101021. RING, retaining1
3
20b* 106560. O-RING; fluorocarbon1
1
20c197566. HOUSING, fan valve1
20d197567. STEM, fan valve1
1
21*** 244557VALVE, air; 1
1
244400 and 244575; includes
18a-18d
1
244401; includes 18a-18b
1
19a-19e
1
rear bearings and fan
1
20a-20d
14197588TUBE, fluid; used on 2444001
244574TUBE, fluid; used on 2444011
15185116SPRING, compression1
16244395BARREL, gun; used on 244400 and
244575
244394BARREL, gun; used on 2444011
17245290HANDLE, gun; (includes item 28)
used on 244400
289277HANDLE, gun; (includes item 28)
used on 244575
245285HANDLE, gun; (includes item 28)
used on 244401
38309292L
22244558VALVE, electrostatics, ON/OFF;
includes 22a-22g
22a* 111516. O-RING; CV751
22b* 113137. O-RING; fluoroelastomer1
1
22c198403. SHAFT, valve1
22d198404. PLATE, retaining1
22e198453. WASHER1
1
22f198464. PIN1
22g276753. KNOB1
1
1
Parts
Ref.
Part No. DescriptionQty
No.
23244559VALVE, air, atomizing; includes
23a-23d
23a197594. HOUSING, valve1
23b197591. SHAFT1
23c* 168518. O-RING; fluoroelastomer2
23d101021. RING, retaining1
24249323VALVE, exhaust; includes 24a1
24a* 112085. O-RING; fluorocarbon1
25244593VALVE, adjustment, fluid1
26244597ROD, packing; used on 244400 and
244575; includes 26a-26h
244521ROD, packing; used on 244401;
includes 26a-26h
26a**111316. O-RING; fluoroelastomer1
26b**116905. SEAL1
Ref.
Part No. DescriptionQty
No.
35244834SWIVEL, air; 1/4 npsm(m) ; left-hand
1
threads
36107460WRENCH, ball end; 4 mm1
37276741MULTI-TOOL1
38185103TUBE, exhaust1
39110231CLAMP1
40116553GREASE, dielectric, tube (not
shown)
41244915COVER, gun; box of 10 (not shown)1
42▲ 179791TAG, warning (not shown); replace-
1
43▲ 180060SIGN, warning (not shown); replace-
1
47197967PLUG1
48198058SCREW, cap, socket hd1
49245211FITTING, fluid; used on 244575;
ment available at no cost
ment available at no cost
includes 49a-49b
1
1
1
1
1
26c**178409. SPREADER, packing; UHMWPE1
26d**178763. PACKING, rod; acetal1
26e197641. NUT, packing1
26f185495. HOUSING, packing1
26g**186069. SPACER, packing; acetal1
26h244695. ROD, packing; used on 244400
and 244575
244696. ROD, packing; used on 2444011
27244927RING, retaining; includes 27a1
27a* 198307. PACKING, u-cup1
28276695HOOK1
29****276697NEEDLE, electrode1
30276698TRIGGER1
31** 110077FERRULE, tube, fluid; used on
244400 and 244401
32110079NUT, tube, fluid; used on 244400 and
244401
49a116768. O-RING1
49b110749. O-RING1
50244918TUBE, fluid; used on 244575;
includes 50a-50f
50a198302. TUBE, fluid, coiled1
50b111286. FERRULE, front2
50c111285. FERRULE, back2
50d112644. NUT2
1
50e198270. CASE, tube1
50f198271. CAP, end1
55197624SPRING, grounding1
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Rubber seal is not removable.
**** Optional replacement Electrode Needle 277060 is
1
available for abrasive materials.
▲ Replacement Warning labels, signs, tags, and cards
1
are available at no cost.
1
309292L39
Parts
I O
Part No. 244579 60 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59)
Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59)
0
HI
LO
ES
I O
25 (Ref)
53 (Ref)
100%
KV
μα
tor (19), fan adjustment valve (20), ES ON/OFF valve (22), and
packing rod (26).
51 (Ref)
See page 41 for detail views of the fluid tube assemblies, alterna-
59
2251
ES
20
19e
19
19a*
17
28
5253
54
25
15
21***
18
ti1253a
18b
11
*18a
11
23c*
23a
29
26
16
*10 *6
4
55
8
23d
24a*
24
30
47
23b
35
13
37
36
38
39
7b
7a
7
9
27a*
27
40309292L
Parts
Ref. No. 19: Alternator
19b
19b
19d
19c
Ref. No. 22: ES ON/OFF Valve
22f
22d
22e
22b*
22c
22a*
TI1488A
19a*
19e
48
TI1481a
22g
Ref. No. 20: Fan Adjustment Valve
20c
20a
Ref. No. 26: Packing Rod
26d**
26c**
26f
26a**
20b*
26g**
26b**
26e
20d
26h
TI1487A
ti1601a
Fluid Tube: Model 244579Fluid Tube: Model 244576Fluid Tube: Model 244580
5**
1
31
32
14
32
31**
ti1492a
309292L41
49
50c
50b
50d
5**
49a
49b
50e
50a
50f
50b
5
1
14
**3132
50c50d
TI1490A
Parts
Part No. 244579 60 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59)
Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Ref.
No.
1110078FITTING, tube, fluid; used on 2445791
4185111SPRING, compression1
5**185120SPACER, fluid; nylon; used on
6*188749PACKING, u-cup, air valve; UHMWPE1
7197266NOZZLE; 1.5 mm orifice; includes 7a
7a111261. O-RING, conductive1
7b111507. O-RING; fluoroelastomer1
8197369SCREW, trigger2
9197477AIR CAP1
10*197517GASKET, barrel1
11197518SCREW; socket-hd; 10-24 x 3/4 in.
1315M678 BRACKET, inlet, fluid; used on
14197588TUBE, fluid; used on 2445791
15185116SPRING, compression1
16244395BARREL, gun; used on 244579 and
17245291HANDLE, gun; (includes item 28)
18244540POWER SUPPLY, 60 kV; used on
18a*103337. O-RING; fluoroelastomer1
18b197624. SPRING, compression1
19244555TURBINE, alternator; includes
Part No. DescriptionQty
198587FITTING, tube, fluid; used on 2445801
244579 and 244576
102982O-RING; used on 2445801
and 7b
(19 mm)
244579 and 244580
15M679 BRACKET, inlet, fluid; used on
244576
244574TUBE, fluid; used on 2445801
244576
244394BARREL, gun; used on 2445801
used on 244579
289278HANDLE, gun; (includes item 28)
used on 244576
245287HANDLE, gun; (includes item 28)
used on 244580
244579 and 244576; includes
18a-18d
244541POWER SUPPLY, 85 kV; used on
244580; includes 18a-18b
19a-19e
Ref.
No.
19a*110073. O-RING; fluoroelastomer1
19b223688. BEARING KIT; includes front and
19c244577. COIL1
1
19d111745. RING, retaining1
19e198821. PAD, pressure2
20244556VALVE, adjustment, fan; includes
1
20a101021. RING, retaining1
20b*106560. O-RING; fluorocarbon1
20c197566. HOUSING, fan valve1
20d197567. STEM, fan valve1
21***244557VALVE, air; 1
22244558VALVE, electrostatics, ON/OFF;
Electrostatic Conductive Gloves (box of 12)
117823Small
117824Medium
117825Large
309292L45
Technical Data
Technical Data
CategoryData
Maximum Working Fluid Pressure100 psi (0.7 MPa, 7 bar)
Maximum Working Air Pressure100 psi (0.7 MPa, 7 bar)
Minimum Air Pressure at Gun Inlet40 psi (0.28 MPa, 2.8 bar)
Maximum Fluid Operating Temperature120°F (48°C)
Paint Resistivity Range3 megohm/cm to infinity
Short Circuit Current Output125 microamperes
Voltage OutputPRO Xs3 (244400, 244575): 60 kV
PRO Xs3 (244579, 244576): 30-60 kV
PRO Xs4 (244401): 85 kV
PRO Xs4 (244580): 40-85 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 thread1/4 npsm(m)
Fluid inlet fitting3/8 npsm(m)
Gun WeightPRO Xs3: 25.1 oz (712 g)
PRO Xs4: 27.8 oz (788 g)
Gun LengthPRO Xs3: 9.7 in. (24.6 cm)
PRO Xs4: 11.1 in. (28.2 cm)
Wetted PartsStainless Steel; Nylon, Acetal, Ultra-High Molecular
Loctite® is a registered trademark of the Loctite Corporation.
46309292L
Technical Data
309292L47
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship
on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any
part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal
power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of
operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in
accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused
by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering,
or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the
incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper
design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.
The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose
any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no
other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or
property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within
two (2) years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying
equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach
of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal
proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les
parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et
procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les
procedures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
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
1-800-328-0211 Toll Free
612-623-6921
612-378-3505 Fax
This manual contains English. MM 309292
Graco Headquarters: Minneapolis
www.graco.com
10/2001, Revised 8/2007
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