Instructions - Parts List
g
309295
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
)LUVW FKRLFH ZKHQ
TXDOLW\ FRXQWV
MANUAL ELECTROSTATIC
PRO™ Xs4 AA
Air-Assisted Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
3000 psi (21 MPa, 210 bar) Maximum Working Fluid Pressure
See page 3 for a List of Models
Smart Model
Rev. A
U.S. Patent Pending
For use with Class I Group D or Class II 2 G spray materials.
Standard Model
ti1509a
ti1332b
Graco Inc. P.O. Box 1441Minneapolis, MN 55440-1441
COPYRIGHT 2001, Graco Inc.
Graco Inc. is re
istered to I.S. EN ISO 9001
Table of Contents
List of Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
War ni ng Sy mb ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic AA Spray Gun Works. . . . . 7
Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . 9
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . . . . .11
Connect the Exhaust Tube . . . . . . . . . . . . . . . . . . . .11
Connect the Fluid Line . . . . . . . . . . . . . . . . . . . . . . 12
Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Select a Spray Tip. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check Electrical Grounding . . . . . . . . . . . . . . . . . . 14
Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . . . . 15
Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . . . . 15
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Voltage Adjustment (Smart Guns Only) . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tes t Gun Re s i s t a n c e . . . . . . . . . . . . . . . . . . . . . . . . . 19
Test Power Supply Resistance . . . . . . . . . . . . . . . . 20
Test Barrel Resistance . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Spray Pattern Troubleshooting . . . . . . . . . . . . . . . .22
Gun Operation Troubleshooting . . . . . . . . . . . . . . .23
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . .24
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . . .25
Prepare the Gun for Service . . . . . . . . . . . . . . . . . . .26
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Tip Guard, Air Cap, Spray Tip, or Seat Housing
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Electrode Replacement . . . . . . . . . . . . . . . . . . . . . . .29
Fluid Tube Replacement . . . . . . . . . . . . . . . . . . . . . .30
Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . .30
Fluid Needle Replacement . . . . . . . . . . . . . . . . . . . .31
Barrel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Barrel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Power Supply Removal and Replacement. . . . . . .33
Turbine Alternator Removal and Replacement. . .34
Atomizing Air Adjustment Valve Repair. . . . . . . .35
Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ES ON/OFF Valve Repair. . . . . . . . . . . . . . . . . . . . .37
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . . . .46
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . . . .46
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Miscellaneous Accessories . . . . . . . . . . . . . . . . . . . .47
Spray Tip Selection Chart. . . . . . . . . . . . . . . . . . . . . . . .48
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2 309295
List of Models
List of Models
Part No. Model Description
244572 PRO Xs4 AA Manual Air-Assisted Spray Gun 309296/
244573 PRO Xs4 AA Manual Air-Assisted Spray Gun with smart display 309296/
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Operation
Manual
3W9296/3Z9296
3W9296/3Z9296
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the
instructions.
309295 3
Warning
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 13.
•
Check gun resistance daily. See “Test Gun Resistance” on page 19.
•
If there is any static sparking while using the equipment, stop spraying immediately. Identify
and correct the problem.
•
Provide fresh air ventilation to avoid buildup of flammable or toxic vapors. Interlock the gun
air supply to prevent operation unless ventilating fans are on. See “Ventilate the Spray
Booth” on page 9.
•
Use solvents that comply with local regulations. Flash point should be higher than 100°F
(38°C).
•
Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all solvent is removed from the system.
•
Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the
spray area.
•
Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop
cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
•
Use only non-sparking tools to clean residue from the booth and hangers.
4 309295
Warning
WARNING
Fluid Injection Hazard
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on
the skin can also cause serious injury.
•
Fluid injected into the skin might look like just a cut, but is a serious injury. Get immediate
medical attention.
•
Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers
over the spray tip. Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
•
Never spray without the tip guard in place.
•
Lock the trigger safety when you stop spraying.
•
Follow the “Pressure Relief Procedure”, page 25, when you stop spraying and before cleaning, checking, or repairing equipment.
•
Check the hoses and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.
•
Tighten all fluid connections before each use.
Toxic Fluid Hazard
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on
the skin, swallowed, or inhaled.
•
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
•
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to
all local, state, and national guidelines.
•
Wear appropriate protective clothing, gloves, eyewear, and respirator.
309295 5
Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in a serious injury.
•
This equipment is for professional use only.
•
Read all manuals, tags, and labels before operating the equipment.
•
Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.
•
Do not alter or modify equipment. Use only genuine Graco parts and accessories.
•
Check the equipment daily. Repair or replace worn or damaged parts immediately.
•
Do not exceed the maximum working pressure of the lowest rated system component. Maximum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 bar).
•
Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-
ings.
•
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).
•
Wear hearing protection when operating this equipment.
•
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
6 309295
Introduction
Introduction
How the Electrostatic AA
Spray Gun Works
WARNING
Fluid Injection Hazard
Remember, this is not an air spray gun.
For your safety, read and follow all Warnings in this manual.
The air-assisted spray gun combines airless and air
spraying concepts. The spray tip shapes the fluid into a
fan pattern, as does a conventional airless spray tip. Air
from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.
As the gun is triggered, part of the regulated air operates the turbine and the rest of the air atomizes the fluid
being sprayed. The turbine generates power, which is
converted by the power cartridge to supply high voltage current to the gun’s electrode.
The regulated air that is directed to the air cap can be
further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air flow to
the air cap while maintaining sufficient air flow to the
turbine.The atomizing air adjustment valve does not
control pattern width. To change pattern width, a new
tip size must be used.
The high working fluid pressure of this gun provides
the power needed to atomize higher solids materials.
The gun’s internal power supply provides high voltage
current. The fluid is electrostatically charged as it passes
the electrode. The charged fluid is attracted to the
grounded workpiece, wrapping around and evenly
coating all surfaces.
NOTE:
atomizing air adjustment valve completely off. Closing
this valve does not affect turbine operation.
For airless atomization, if desired, turn the gun’s
309295 7
Gun Overview
Introduction
•
ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
The electrostatic gun includes the following controls
(see Fig. 1).
•
Air cap/tip guard and spray tip. Never spray without the tip guard. See page 48 for spray tip sizes.
•
Trigger safety lock. Prevents the gun from spraying.
•
Atomizing AIR adjustment valve. Adjusts atomizing air.
TIP GUARD
•
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 24.
•
ES HI/LO switch (smart models only). Sets voltage
to HI or LO (factory settings).
•
LO voltage adjustment (smart models only).
Remove plug to adjust to four settings.
TRIGGER SAFETY LOCK
ES INDICATOR
ES ON/OFF
(I = ON,
0 = OFF)
Fig. 1.
Gun Overview
AIR CAP
Standard Gun
ES
I O
SPRAY TIP
ti1366a
AIR
ES HI/LO
ES ON/OFF
(I = ON,
0 = OFF)
ti1509a
100%
0
KV
µα
HI
LO
ES
ES
I O
Smart Gun
DISPLAY
LO
AIR
ti1333a
8 309295
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.
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. Do
not operate the gun unless ventilation fans
are operating.
Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans
operating. Check and follow all National, State, and
Local codes regarding air exhaust velocity requirements.
Fig. 2 shows a typical electrostatic air-assisted spray
system. It is not an actual system design. For assistance
in designing a system to suit your particular needs, contact your Graco distributor.
309295 9
NOTE:
ating efficiency of the electrostatic system. Air exhaust
velocity of 100 ft/min (31 linear meters/minute) should
be sufficient.
High velocity air exhaust will decrease the oper-
Installation
AB*C*D
The air supply to the gun must be electrically
interlocked with the ventilators to prevent the power
supply from operating without ventilating fans on.
D
C
O
S
P
H
J*
Q*
V
L
M
W
T
*R
G
*E
N
X
F
K
U*
ti1514b
Non-Hazardous Area Hazardous Area
Fig. 2. Typical Installation
Key
A Main Air Supply Line
B* Ventilation Fan Interlock Solenoid Valve
C* Main Air Supply Shutoff Valve (bleed-type)
D Air Line Filter/Water Separator
E* Pump Air Supply Shutoff Valve (bleed-type)
F Air Line Lubricator
G Air Pressure Regulator
HPump
J* Pump Ground Wire
K Fluid Filter
L Fluid Supply Line Shutoff Valve
M Fluid Pressure Regulator
N Grounded Fluid Supply Line, with spring guards
O Gun Air Regulator
P Gun Air Supply Line Shutoff Valve
Q* Air Hose Ground Wire
R* Graco Grounded Air Hose
S Electrostatic Air-Assisted Spray Gun
T Fluid Pressure Gauge
U* Fluid Drain Valve
V Gun Air Inlet
W Gun Fluid Inlet
X Pump Runaway Valve
* Required for safe operation. Must be purchased
separately.
NOTE
: Solenoid valve (B) is not
offered as a Graco accessory.
10 309295
Installation
Connect the Air Line
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
serious injury, the air supply hose must be
electrically connected to a true earth
ground. Use only Graco Grounded Air
Supply Hose.
1. Connect the Graco Grounded Air Supply Hose (R)
between the air supply line and the gun's air inlet
(V). The gun air inlet fitting has a left-hand thread.
Connect the air supply hose ground wire (Q) to a
true earth ground.
2. Install an air line filter/water separator (D) on the
air line to ensure a dry, clean air supply to the gun.
Dirt and moisture can ruin the appearance of your
finished workpiece and can cause the gun to malfunction.
3. Install a bleed-type air regulator (G, O) on the
pump and gun air supply lines to control air pressure to the pump and gun.
WARNING
Fluid Injection Hazard
The bleed-type air valve (E) is required in
your system to relieve air trapped between
the valve and the pump after the air regula-
tor is shut off. Trapped air can cause the
pump to cycle unexpectedly, which can result in serious injury, including fluid injection and splashing
fluid in the eyes or on the skin.
4. Install a bleed-type air valve (E) on the pump air
line to shut off air to the pump. Install an additional
bleed-type air valve (C) on the main air line (A) to
isolate the accessories for servicing.
5. Install an air shutoff valve ( P) on each gun air supply line to shut off air to the gun(s).
WARNING
Fluid Injection Hazard
To reduce the risk of serious injury due to
component rupture, including fluid injection, pump pressure must be limited by the
pump air regulator. Do not rely on the gun
fluid regulator to limit the fluid pressure to
the gun.
The fluid supply pump must be prevented from producing a fluid pressure greater than the 3000 psi (21
MPa, 210 bar) Maximum Working Fluid Pressure of the
gun. For example, the air supply pressure to a 30:1
ratio pump must not exceed 100 psi (0.7 MPa, 7 bar).
Connect the Exhaust Tube
Press the exhaust tube (38) onto the barbed adapter on
the bottom of the gun handle. Secure the tube with the
clamp (39).
309295 11
Installation
Connect the Fluid Line
1. Before connecting the fluid line (N), blow it out
with air and flush it with solvent. Use solvent
which is compatible with the fluid to be sprayed.
2. Install a fluid regulator (M) on the fluid line to control fluid pressure to the gun.
WARNING
Fluid Injection Hazard
The fluid drain valve (U) is required in your
system to assist in relieving fluid pressure
in the displacement pump, hose and gun.
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 fluid injection and splashing in the eyes or on the skin.
3. Install a drain valve (U) near the pump outlet.
4. Connect the fluid line to the 1/4 npsm gun fluid
inlet (W).
5. Before running any paint through the spray gun,
flush it out with a compatible solvent.
Filter the Fluid
Install a fluid filter (K) at the pump outlet to remove
particles and sediment which could clog the spray tip.
The gun includes an inline fluid filter (1) for additional
filtration.
Select a Spray Tip
WARNING
Fluid Injection Hazard
To reduce the risk of a fluid injection injury,
always follow the “Pressure Relief Proce-
dure”, page 25, before removing or install-
ing the spray tip, air cap, or tip guard.
The fluid output and pattern width depend on the size
of the spray tip, the fluid viscosity, and the fluid pressure. Use the “Spray Tip Selection Chart”, page 48, as a
guide for selecting the appropriate spray tip for your
application.
Refer to the gun operation manual to install the spray
tip.
12 309295
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.
Installation
•
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 worn, cut off fingers or cut out palm
area, to ensure your hand contacts the grounded
gun handle.
•
Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Resistance must
not exceed 1 megohm.
•
The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
•
Electrostatic Air-Assisted Spray Gun: ground the gun
by connecting the Graco Grounded Air Hose and
connecting the air hose ground wire to a true earth
ground. See “Check Electrical Grounding”, page
14.
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.
309295 13
•
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.
Installation
Fig. 1
ti1259a
Check Electrical Grounding
WARNING
Fire, Explosion, and Electric Shock
Hazard
Megohmmeter Part No. 241079 (AA-see
Fig. 3) is not 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).
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.
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 Fig. 3.
6. If the resistance is greater than 1 megohm, check the
tightness of the ground connections and be sure the
air hose ground wire is connected to a true earth
ground. If the resistance is still too high, replace the
air hose.
BB
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
2. Turn the ES ON/OFF valve OFF.
ES
I O
AA
CC
ti1340a
ti1337a
Fig. 3. Check Gun Grounding
.
14 309295
Installation
Check Fluid Resistivity
WARNING
Fire, Explosion, and Electric Shock
Hazard
Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and
Probe 722860 are not approved for use in a
hazardous area.
Failure to follow this warning could cause
fire, explosion, electric shock and result in
serious injury and property damage.
Graco Part No. 722886 Resistance Meter and 722860
Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements
of an electrostatic air-assisted spray system.
Check Fluid Viscosity
To check fluid viscosity you will need:
•
a viscosity cup
•
a stopwatch.
1. Completely submerge the viscosity cup in the fluid.
Lift the cup out quickly, starting the stopwatch as
soon as the cup is completely removed.
2. Watch the stream of fluid coming from the bottom
of the cup. As soon as there is a break in the stream,
shut off the stopwatch.
3. Record the fluid type, elapsed time, and size of the
viscosity cup.
4. If the viscosity is too high or too low, contact the
material supplier and adjust as necessary.
Follow the instructions included with the meter and
probe. Readings of 25 megohms-cm and above provide
the best electrostatic results.
309295 15
Fig. 1
INSTRUCTIONS
Operation
Operation
Refer to the gun operation manual (supplied)
for Setup, Shutdown, and Daily Care
procedures.
Low Voltage Adjustment
(Smart Guns Only)
The ES HI/LO switch enables you to switch between
full voltage and a lower voltage output. The lower voltage is factory set, but can be adjusted.
1. Set the ES HI/LO switch to LO.
2. Remove the LOW VOLTAGE adjustment plug (53).
Set the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
Table 1 . Also see Fig. 4.
Table 1: Low Voltage Adjustment
12kV
Fac tory
Setting
Fig. 4. Low Voltage Adjustment Switches
.
ON ON 70
ON OFF 60
OFF ON 50
OFF OFF 40
100%
0
KV
µα
53
ti1529a
OFF
ON
12
16 309295
INSTRUCTIONS
Maintenance
Maintenance
Refer to the gun operation manual (supplied)
for Daily Care and Cleaning procedures.
Flush the Spray Gun
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
WARNING
Fire, Explosion, and Electric Shock
Hazard
To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
1. Turn the ES ON/OFF valve OFF.
WARNING
Fluid Injection Hazard
To reduce the risk of a fluid injection injury,
always follow the “Pressure Relief Proce-
dure”, page 25, whenever you are
instructed to relieve the pressure.
2. Relieve the pressure.
ES
I O
ti1337a
ti1341a
CAUTION
Flush the gun with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.
Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon
components.
309295 17
3. Remove and clean the air cap and the spray tip.
ti1334b
Continued on page 18.
Maintenance
4. Change the fluid source to solvent, or disconnect
the fluid line and connect a solvent supply line to
the gun.
ti1287a
5. Point the gun into a grounded metal pail. Flush
until clean solvent flows from the gun.
ti1465a
6. Relieve the pressure. Lock the trigger.
ti1465a
7. Shut off or disconnect the solvent line.
8. Hang the gun from its hook, with the nozzle pointing down.
ti1349a
9. When ready to spray again, reconnect the fluid supply line. Follow the Setup procedure in the Gun
Operation Manual.
18 309295
Electrical Tests
Fig. 1
Electrical Tests
Electrical components inside the gun affect performance
and safety. The following procedures test the condition
of the power supply (18) and barrel (16), and electrical
continuity between components.
CAUTION
The barrel resistor cartridge is part of the barrel and
is not replaceable. To avoid destroying the gun barrel,
do not attempt to remove the barrel resistor.
Use megohmmeter Part No. 241079 (AA) with an
applied voltage of 500 V. Connect the leads as shown.
WARNING
Fire, Explosion, and Electric Shock
Hazard
Test Gun Resistance
1. Flush and dry the fluid passage.
2. Measure resistance between the electrode needle
tip (9b) and the air swivel (35); it should be 156-180
megohms. See Fig. 5. If outside this range, go to the
next test. If in range, refer to “Electrical Trouble-
shooting”on page 24 for other possible causes of
poor performance.
AA
Megohmmeter Part No. 241079 (AA-see
Fig. 5) is not 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.
9b
Fig. 5. Test Gun Resistance
.
35
TI1469A
309295 19
Test Power Supply
Fig. 1
Resistance
1. Remove the power supply (18), page 33.
2. Remove the turbine alternator (19) from the power
supply, page 34.
3. Measure resistance from the power supply's ground
strips (EE) to the spring (18b). See Fig. 6.
Electrical Tests
4. The resistance should be 135-150 megohms. If outside this range, replace the power supply. If in
range, proceed to the next test.
5. If you still have problems, refer to “Electrical Trou-
bleshooting” on page 24 for other possible causes
of poor performance, or contact your Graco distributor.
6. Be sure the spring (18b) is in place before reinstalling the power supply.
18b
Fig. 6. Test Power Supply Resistance
.
EE
ti1599a
20 309295
Electrical Tests
Fig. 1
ti1515b
Test Barrel Resistance
1. Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the
metal contact (C) in the front of the barrel.
2. Measure the resistance between the conductive rod
(B) and the barrel contact ring (16a). See Fig. 7. The
resistance should be 19-29 megohms. If the resistance is incorrect, make sure the metal contact (C) in
the barrel and the barrel contact ring (16a) are
clean and undamaged.
3. If the resistance is still outside the range, remove the
barrel contact ring (16a) and measure the resistance
between the conductive rod (B) and the wire lead at
the bottom of the contact ring groove.
4. If the resistance is in range, replace the contact ring
(16a) with a new one. Press the contact ring firmly
into the groove on the front of the barrel.
5. If the resistance is still outside the range, replace the
barrel.
16a
Fig. 7. Test Barrel Resistance
.
C
B
WARNING
Fire, Explosion, and Electric Shock
Hazard
The barrel contact ring (16a) is a conductive
contact ring, not a sealing o-ring. To reduce
the risk of sparking or electric shock, do not
remove the barrel contact ring (16a) except
to replace it and never operate the gun
without the contact ring in place. Do not
replace the contact ring with anything but a
genuine Graco part.
309295 21
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 service this equipment unless you are trained and qualified.
Fluid Injection Hazard
To reduce the risk of a fluid injection injury,
always follow the “Pressure Relief Proce-
dure” on page 25 whenever you are
instructed to relieve the pressure.
NOTE:
ing Chart before disassembling the gun.
Check all possible remedies in the Troubleshoot-
WARNING
Spray Pattern Troubleshooting
NOTE:
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem Cause Solution
Fluttering or spitting spray. No fluid. Refill supply.
Air in fluid supply. Check fluid source. Refill.
Irregular pattern. Fluid buildup; partially plugged tip. Clean. See gun operation manual.
Worn/damaged tip or air cap holes. Clean or replace.
Pattern pushed to one side; air cap
gets dirty.
Tails in pattern. Air pressure too low. Open atomizing air adjustment valve.
Fluid buildup on air cap/tip guard. Air pressure too high. Decrease.
22 309295
Air cap holes plugged. Clean. See gun operation manual.
Fluid pressure too low. Increase.
Fluid pressure too low. Increase.
Troubleshooting
Gun Operation Troubleshooting
Problem Cause Solution
Excessive spray fog. Atomizing air pressure too high. Close atomizing air valve some, or
decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8
bar) needed at gun for full voltage.
Fluid too thin. Increase viscosity.
“Orange Peel” finish. Atomizing air pressure too low. Open atomizing air valve more or
increase gun air inlet pressure; use
lowest air pressure necessary.
Spray tip is too large. Use smaller tip. See page 48.
Poorly mixed or filtered fluid. Remix or refilter fluid.
Fluid too thick. Reduce viscosity.
Fluid leaks from the fluid packing
area
Air leaks from the front of the gun Air valve (21) is not seating properly. Clean and service air valve; see
Fluid leakage from the front of the
gun
Gun does not spray Low fluid supply. Add fluid if necessary.
Dirty air cap Damaged or plugged air cap (9). Clean air cap; see gun operation
Worn fluid needle packings or shaft. Replace fluid needle assembly (26);
see page 31.
page 36.
Worn or damaged fluid needle ball. Replace fluid needle (26); see page
31.
Worn fluid seat housing (2). Replace seat housing; see page 27.
Loose spray tip (3). Tighten retaining ring (27); see page
27.
Damaged tip seal (3a). Replace; see page 27.
Damaged spray tip (3). Replace; see page 27.
Dirty or clogged spray tip (3). Clean; see gun operation manual.
Damaged fluid needle (26). Replace; see page 31.
manual.
309295 23
Troubleshooting
Electrical Troubleshooting
Problem Cause Solution
Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I).
Gun air pressure too low. Check air pressure to gun; minimum
40 psi (0.28 MPa, 2.8 bar) needed at
gun for full voltage.
Atomizing air pressure too high. Decrease.
Fluid velocity too high. Decrease fluid pressure or replace
worn tip.
Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).
Poorly grounded parts. Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance. See “Test Gun Resistance” on page
19.
Low fluid resistivity. Check fluid resistivity. See page 15.
Fluid leaks from the fluid needle (26)
packings and causes a short.
Faulty turbine alternator (19). Be sure the plug is in place on the
The KV HI-LO lever is on LO. Check the lever position; replace if
ES indicator or voltage/current display is not lit.
Voltage/current display stays red
(smart guns only).
Operator gets mild shock. Operator not grounded or is near
Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or
ES ON/OFF valve OFF (0).* Turn ON (I).
No power. Repair/replace alternator turbine;
Gun too close to part. Should be 8-12 in. (200-300 mm).
Check fluid resistivity. See “Check Fluid Resistivity” on
Dirty gun. Clean. See Operation Manual.
ungrounded object.
Gun not grounded. See “Check Electrical Grounding” on
Clean the needle cavity. Replace the
fluid needle. See page 31.
back of the turbine alternator housing. Remove and test the turbine
alternator. See page 34.
needed.
replace power supply. See page 33.
page 15.
See “Grounding” on page 13.
page 14 and “Test Gun Resistance”
on page 19.
less. Clean workpiece hangers.
* ES indicator light is off when the gun is triggered.
24 309295
Repair
ti1289a
ti1290a
t
Repair
Pressure Relief Procedure
WARNING
Fluid Injection Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. Fluid under high
pressure can be injected through the skin
and cause serious injury. To reduce the risk of an
injury from injection, splashing fluid, or electric
shock, follow the Pressure Relief Procedure whenever you:
•
are instructed to relieve the pressure
•
stop spraying
•
check or repair any of the system equipment
3. Turn off the air bleed valves to the fluid source and
to the gun.
4. Unlock the trigger.
ti1406a
5. Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
ti1341a
6. Lock the trigger.
•
or install or clean the spray tip.
1. Turn the ES ON/OFF valve OFF.
2. Lock the trigger.
ES
I O
ti1356a
7. Open the pump drain valve and all other fluid
drain valves in the system, having a waste container
ready to catch the drainage. Leave the drain
valve(s) open until you are ready to spray again.
ti1337a
ti1356a
8. If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end
coupling. Now clear the nozzle or hose.
309295 25
Prepare the Gun for Service
WARNING
Electric Shock Hazard
Installing and repairing this equipment
requires access to parts that may cause elec-
tric shock or other serious injury if the work
is not performed properly. Do not install or service
this equipment unless you are trained and qualified.
WARNING
Repair
•
Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
WARNING
Some PRO Xs4 AA Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When repairing, do not mix or use other PRO
Gun parts that may look similar, but have different
part numbers! Use of parts other than those specified
in the PRO Xs4 AA Gun parts lists could alter the
grounding continuity of the gun, cause parts to leak
or rupture, or cause the gun to malfunction and
result in serious injury, fire, explosion, or property
damage.
Fluid Injection Hazard
To reduce the risk of injury, follow the
“Pressure Relief Procedure” on page 25
before checking or repairing any part of the
system and whenever you are instructed to
relieve the pressure.
NOTE:
•
Check all possible remedies in “Troubleshooting”
before disassembling the gun.
•
Use a vise with padded jaws to prevent damage to
plastic parts.
•
Lubricate the power supply o-ring (18a) and the
plastic end of the fluid tube (14) with dielectric
grease (40).
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
1. Flush the gun, page 17.
2. Relieve the pressure, page 25.
3. Disconnect the gun air and fluid lines.
4. Remove the gun from the worksite. Repair area
must be clean.
Tools Needed
•
2 mm driver (supplied)
•
4 mm driver (supplied)
•
9 mm driver (supplied)
•
adjustable wrench
•
medium screwdriver
•
snap ring pliers
•
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models. Note that the air
cap, spray tip, and tip guard for this gun are orange.
26 309295
needle-nose pliers
Tip Guard, Air Cap, Spray
Fig. 1
Fig. 1
Repair
Tip, or Seat Housing
Replacement
1. Prepare gun for service, page 26.
2. Remove the retaining ring (27), tip guard (4), air cap
(9a), and spray tip (3). You may have to turn the air
cap with the tip guard to remove it. See Fig. 8.
3. Replace the tip gasket (3a) if damaged.
3a
3
9a
4
27a
27
ti1522a
B
CAUTION
The barrel resistor cartridge (B) is part of the barrel
and is not replaceable. To avoid destroying the gun
barrel, do not attempt to remove the barrel resistor.
WARNING
Fire, Explosion, and Electric Shock
Hazard
The barrel contact ring (16a) is a conductive
contact ring, not a sealing o-ring. To reduce
the risk of sparking or electric shock, do not
remove the barrel contact ring (16a) except
to replace it and never operate the gun
without the contact ring in place. Do not
replace the contact ring with anything but a
genuine Graco part.
2
Fig. 8. Tip Guard, Air Cap, and Spray Tip Replacement
.
4. Trigger the gun and remove the seat housing (2)
with the tool (37) provided. See Fig. 9.
ti1523a
Fig. 9. Seat Housing Replacement
.
Continued on page 28.
309295 27
Repair
CAUTION
To avoid damaging the seat housing and gun barrel,
never over-tighten the seat housing. Over-tightening
may result in improper fluid shut-off.
5. Trigger the gun and install the gray-colored seat
housing (2). Tighten until snug, then 1/4 turn more.
CAUTION
To avoid damaging the tip guard (4), orientate the air
cap (9a) before tightening the retaining ring (27). Do
not turn the cap when the retaining ring is tight.
6. Assemble the spray tip (3), air cap (9a), and tip
guard (4). Make sure the electrode (9b) is not damaged or missing. Install the air cap assembly with
the retaining ring (27). The u-cup (27a) lips must
face forward.
7. Test gun resistance, page 19.
28 309295
Repair
Fig. 1
Electrode Replacement
WARNING
Electric Shock Hazard
To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun
without the electrode installed in the air
cap.
1. Prepare the gun for service, page 26.
2. Remove the air cap assembly, page 27.
3. Pull the electrode (9b) out of the back of the air cap,
using a needle-nose pliers.
4. Push the new electrode through the air cap hole.
Make sure the short end (BB) of the electrode
engages the hole (CC) in the back of the air cap.
Press the electrode in place firmly with your fingers.
See Fig. 10.
5. Install the air cap assembly, page 27.
6. Test gun resistance, page 19.
9b
CC
BB
Fig. 10. Electrode Replacement
.
02013
309295 29
Repair
Fig. 1
Fig. 1
Fluid Tube Replacement
1. Prepare the gun for service, page 26.
2. Disconnect the bottom fluid tube nut (C). See Fig.
11.
3. Carefully unscrew the top fluid tube nut (D).
CAUTION
Be careful not to damage the fluid tube assembly (14)
when cleaning or installing it, especially the sealing
surface (E). If the sealing surface is damaged, the
entire fluid tube assembly must be replaced.
4. Apply dielectric grease (40) to the entire length of
the plastic extension on the end of the fluid tube
(14).
5. Apply low strength thread sealant to the fluid tube
nut threads.
Fluid Filter Removal
1. Prepare the gun for service, page 26.
2. Disconnect the bottom fluid tube nut (C).
3. Remove the fluid filter (1) from the fluid fitting.
Clean or replace the filter, as needed. See Fig. 12.
NOTE:
(standard) or 60 mesh sizes. See page 47.
4. Install the fluid filter in the fluid fitting. Tighten the
Replacement filters are available in 100 mesh
bottom nut (C) onto the fitting and torque to 20-30
in-lb (2.3-3.4 N•m). Make sure the top nut remains
tight.
CAUTION
Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).
6. Install the fluid tube into the gun barrel and tighten
the top nut (D) hand-tight, then 1/4 to 1/2 turn
with a wrench. There will be a gap between the nut
and barrel. Do not overtighten the nut.
7. Make sure the fluid filter (1) is in place in the fluid
fitting. Tighten the bottom nut (C) onto the fitting
and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure
the top nut remains tight.
C
E
D
Fig. 11. Fluid Tube Replacement
.
1
ti1524a
TI1521A
14
C
1
Fig. 12. Fluid Filter Removal
.
30 309295
Fluid Needle Replacement
Fig. 1
Fig. 1
TI1526B
Repair
1. Prepare the gun for service, page 26.
2. Remove the air cap assembly and seat housing,
page 27.
3. Remove the barrel (16), page 32.
4. Remove the trigger screws (8) and trigger (30).
5. Remove the spring cap (45) and the spring (26a)
from the barrel. See Fig. 13.
6. Place the 2 mm driver (44) in the back of the fluid
needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.
7. Insert the tool in the front of the gun and push the
fluid needle assembly out the back of the barrel.
CAUTION
CAUTION
To avoid damaging the seat housing and gun barrel,
never overtighten the seat housing. Overtightening
may result in improper fluid shutoff.
13. Install the seat housing and air cap, page 27.
14. Test gun resistance, page 19.
55
45
26a
8
30
TI1618A
Fig. 13. Spring Cap and Springs
.
To avoid damaging the needle assembly, be sure the
needle is completely unthreaded before pushing it
out of the barrel.
8. Install the fluid needle assembly in the gun barrel.
Push in on the needle with the tool (44) and tighten.
See Fig. 14.
9. Install the spring (26a).
10. Install the spring cap (45), making sure the grounding spring (55) is in place.
11. Install the trigger (30) and screws (8).
12. Install the barrel (16), page 32.
8
30
Fig. 14. Fluid Needle Replacement
.
309295 31
Repair
Fig. 1
Fig. 1
Barrel Removal
1. Prepare the gun for service, page 26.
2. Carefully loosen the nut (C) from the bracket fluid
fitting (13). See Fig. 15.
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.
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
CAUTION
Do not over-tighten the screws (11).
4. Make sure the fluid filter (1) is in place in the fluid
fitting. Tighten the bottom fluid tube nut (C) onto
the bracket (13) fluid fitting and torque to 20-30 inlb (2.3-3.4 N•m). Make sure the top nut remains
tight.
CAUTION
C
13
11
TI1516A
17
Fig. 15. Barrel Removal
.
Barrel Installation
16
ti1517a
Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).
5. Test gun resistance, page 19.
17
18
*10
11
16
13
TI1520B
14
Fig. 16. Barrel Installation
.
1
C
1. Be sure the gasket (10*, Fig. 16) and grounding
spring (55, Fig. 13) are in place and the gasket air
holes are aligned properly. Replace if damaged.
32 309295
Repair
Fig. 1
18
19
*18a
*10
*19a
59
B
17
19e
18b
Power Supply Removal and
Replacement
NOTE:
•
Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
•
Do not expose gasket (10) to solvents.
1. Prepare gun for service, page 26.
2. Remove the barrel (16), page 32.
CAUTION
Be careful when handling the power supply (18) to
avoid damaging it.
7. Connect the 3-wire connector (B). Slide the alternator (19) down onto the power supply (18).
8. Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
9. Lubricate the power supply o-ring (18a*) with
dielectric grease (40).
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Models only, connect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
11. Install the barrel (16), page 32.
12. Test gun resistance, page 19.
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 Fig. 17.
4. Disconnect the 3-wire connector (B) from the power
supply. Slide the alternator up and off the power
supply. Inspect the power supply and alternator for
damage. On Smart Models only, disconnect the 6-pin
flexible circuit (59) from the power supply.
5. Check the power supply resistance, page 20.
Replace if necessary.
NOTE:
the o-rings (18a*, 19a*), spring (18b), and pads (19e) are
in place.
6. On Smart Models only, connect the 6-pin flexible cir-
Before installing the power supply, make sure
cuit (59) to the power supply.
ti1505c
Fig. 17. Power Supply and Turbine Alternator
.
309295 33
Repair
Turbine Alternator Removal
and Replacement
NOTE:
operation. Order Part No. 223688 Bearing Kit.
1. Prepare gun for service, page 26.
2. Remove the power supply/alternator assembly,
3. Disconnect the alternator from the power supply,
Replace turbine bearings after 2000 hours of
page 33.
page 33.
4. Measure resistance between the two outer terminals
of the 3-wire connector (B); it should be 2.5-3.5
ohms. If outside this range, replace the alternator
coil.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
6. Install the alternator on the power supply, page 33.
7. Install the power supply/alternator assembly, page
33.
34 309295
Repair
Atomizing Air Adjustment
Valve Repair
1. Prepare the gun for service, page 26.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
NOTE:
step 9) or as individual parts (steps 3-9).
3. Remove the retaining ring (20a). See Fig. 18.
4. Turn the valve stem (20d) counterclockwise until it
5. Remove the o-ring (20b).
You may replace the valve as an assembly (go to
comes free from the valve housing (20c).
6. Clean all parts and inspect for wear or damage.
NOTE:
over-lubricate.
7. When reassembling the atomizing air valve (20),
8. Reassemble the retaining ring (20a). Unscrew the
9. Screw the valve assembly (20) into the gun handle,
20d
Use non-silicone grease, Part No. 111265. Do not
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.
valve stem from the housing until it is stopped by
the retaining ring.
using a wrench on the flats of the housing. Torque
to 15-25 in-lb (1.7-2.8 N•m).
20b*
20c
20a
Fig. 18. Atomizing Air Adjustment Valve
TI1487A
309295 35
Repair
Fig. 1
Air Valve Repair
1. Prepare the gun for service, page 26.
2. Remove the barrel, page 32.
3. Remove the air valve cap (25) from the handle (17).
Remove the spring (15). See Fig. 19.
CAUTION
Clean all parts in non-conductive solvent compatible
with the fluid being used, such as xylol or mineral
spirits. Use of conductive solvents can cause the gun
to malfunction.
4. Remove the air valve (21) with a pliers. Inspect the
seal (21a) and replace if damaged. Be sure the seal is
pressed securely onto the valve so the outer cone is
flat.
5. Inspect the u-cup (6*). Do not remove the u-cup
unless damaged. If removed, install the new one
with its lips facing into the gun handle (17).
6. Install the air valve (21) and spring (15) into the gun
handle (17).
7. Install the air valve cap (25). Torque to 15-25 in-lb
(1.7-2.8 N•m).
8. Install the barrel, page 32.
25
15
21
21a*
*6
CAUTION
When removing the air valve (21) be careful not to
damage the seat area.
ti1527a
Fig. 19. Air Valve
.
36 309295
Repair
Fig. 1
ES ON/OFF Valve Repair
1. Prepare the gun for service, page 26.
2. Loosen the screw (48). Remove the valve.
3. Lubricate the o-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-rings can be pushed into the gun air passage
and blemish the finish on the workpiece.
4. Clean and inspect parts for damage. Replace if necessary.
NOTE:
point upward.
5. Reinstall the valve. Torque the screw (48) to 15-25
Fig. 20. ES ON/OFF Valve
The protrusion on the retainer plate (22d) must
in-lb (1.7-2.8 N•m).
22d
22e
22b*
22c
22a*
TI1488A
.
22f
22g
48
309295 37
Parts
Part No. 244572 85 kV Electrostatic Gun, Series A (items 1-50)
See page 39 for detail views of the alternator (19), atomizing
air adjustment valve (20), and ES ON/OFF valve (22).
Parts
I O
16a
22
ES
20
19e
19
19a*
18
ti1366a
18b
*10
28
17
25
15
21
21a*
11
*18a
45
26a
11
26
55
*6
47
24a*
24
13
16
14
8
30
35
14 (Ref)
3a
1
2
38
39
36
ti1511b
37
44
9b
3
9a
4
27a*
27
38 309295
Parts
Ref. No. 20: Atomizing Air Adjustment ValveRef. No. 19: Alternator
19b
19b
19d
19c
Ref. No. 22: ES ON/OFF Valve
22d
22e
22b*
22c
19e
22f
19a*
TI1481a
22g
20a
20c
20b*
20d
TI1487A
22a*
48
TI1488A
309295 39
Part No. 244572 85 kV Electrostatic Gun, Series A (items 1-50)
Parts
Ref.
No.
1 205264 FILTER, fluid, inline 1
2 245280 HOUSING, seat 1
3 GG3XXX SPRAY TIP (customer’s choice);
3a 183459 . SEAL, spray tip 1
4 276767 TIP GUARD 1
6* 188749 PACKING, u-cup, air valve;
8 197369 SCREW, trigger 2
9 245276 AIR CAP ASSEMBLY 1
9a 198679 . AIR CAP 1
9b 244917 . ELECTRODE (kit of 5) 1
10* 197517 GASKET, barrel 1
11 197518 SCREW; socket-hd; 10-24 x 3/4
13 197832 BRACKET, inlet, fluid 1
14 244713 TUBE, fluid 1
15 185116 SPRING, compression 1
16 244531 BARREL, gun; includes item 16a 1
16a 197486 . O-RING; conductive 1
17 245286 HANDLE, gun 1
18 244541 POWER SUPPLY, 85 kV; includes
18a* 103337 . O-RING; Viton
18b 197624 . SPRING, compression 1
19 244555 TURBINE, alternator; includes
19a* 110073 . O-RING; Viton
19b 223688 . BEARING KIT; includes front
Part No. Description Qty
includes item 3a
UHMWPE
in. (19 mm)
items 18a-18b
®
items 19a-19e
®
and rear bearings and fan
Ref.
No.
19c 244577 . COIL 1
19d 111745 . RING, retaining 1
19e 198821 . PAD, pressure 2
20 244556 VALVE, adjustment, atomizing air;
1
20a 101021 . RING, retaining 1
20b* 106560 . O-RING; fluorocarbon 1
20c 197566 . HOUSING, valve 1
1
20d 197567 . STEM, valve 1
21 244557 VALVE, air; includes item 21a 1
21a* 276733 . SEAL; fluoroelastomer 1
22 244558 VALVE, electrostatics, ON/OFF;
22a* 111516 . O-RING; CV75 1
22b* 113137 . O-RING; fluoroelastomer 1
3
22c 198403 . SHAFT, valve 1
22d 198404 . PLATE, retaining 1
22e 198453 . WASHER 1
22f 198464 . PIN 1
22g 276753 . KNOB 1
24 244560 VALVE, exhaust; includes item
24a* 106555 . O-RING; fluoroelastomer 1
1
25 197966 CAP, air valve 1
1
26 244714 NEEDLE, fluid; includes item 26a 1
26a 112691 . SPRING, compression 1
1
27 244927 RING, retaining, air cap; includes
1
27a* 198307 . PACKING, u-cup 1
1
28 276695 HOOK 1
30 276698 TRIGGER 1
Part No. Description Qty
includes items 20a-20d
includes items 22a-22g
24a
item 27a
1
1
1
1
35 185105 FITTING, air; left-hand threads 1
40 309295
Parts
Ref.
No.
36 107460 WRENCH, ball end; 4 mm 1
37 110087 DRIVER, hex nut; 9 mm 1
38 185103 TUBE, exhaust 1
39 110231 CLAMP 1
40 116553 GREASE, dielectric, tube (not
41 244915 COVER, gun; box of 10 (not
42 179791 TAG, warning (not shown);
43 180060 SIGN, warning (not shown);
Part No. Description Qty
shown)
shown)
replacement available at no cost
replacement available at no cost
Ref.
No.
44 112080 TOOL, needle; 2 mm 1
45 198516 CAP, spring
47 197967 PLUG 1
48 198058 SCREW, cap, socket hd 1
1
49 222385 CARD, warning (not shown);
1
50 188774 TAG, warning (not shown);
1
* Included in Air Seal Repair Kit 244781.
1
Replacement Warning labels, signs, tags, and cards are
Part No. Description Qty
replacement available at no cost
replacement available at no cost
available at no cost.
1
1
309295 41
Part No. 244573 85 kV Electrostatic Gun, Series A (items 1-59)
I O
Parts
0
LO
ES
I O
53 (Ref)
100%
KV
µα
adjustment valve (20), and ES ON/OFF valve (22).
51 (Ref)
See page 43 for detail views of the alternator (19), atomizing air
HI
22
ES
20
59
19e
19
19a*
17
18
ti1253a
18b
*10
*18a
28
53
52
51
21
54
25
15
11
45
26a
26
21a*
47
11
*6
55
24a*
24
16
14
8
30
13
35
16a
14 (Ref)
2
1
38
ti1510c
39
3a
36
37
9b
44
3
9a
4
27a*
27
42 309295
Parts
Ref. No. 20: Atomizing Air Adjustment ValveRef. No. 19: Alternator
19b
19b
19d
19c
Ref. No. 22: ES ON/OFF Valve
22d
22e
22b*
22c
19e
22f
19a*
TI1481a
22g
20a
20c
20b*
20d
TI1487A
22a*
48
TI1488A
309295 43
Part No. 244573 85 kV Electrostatic Gun, Series A (items 1-59)
Parts
Ref.
No.
1 205264 FILTER, fluid, inline 1
2 245280 HOUSING, seat 1
3 GG3XXX SPRAY TIP (customer’s choice);
3a 183459 . SEAL, spray tip 1
4 276767 TIP GUARD 1
6* 188749 PACKING, u-cup, air valve;
8 197369 SCREW, trigger 2
9 245276 AIR CAP ASSEMBLY 1
9a 198679 . AIR CAP 1
9b 244917 . ELECTRODE (kit of 5) 1
10* 197517 GASKET, barrel 1
11 197518 SCREW; socket-hd; 10-24 x 3/4
13 197832 BRACKET, inlet, fluid 1
14 244713 TUBE, fluid 1
15 185116 SPRING, compression 1
16 244531 BARREL, gun; includes item 16a 1
16a 197486 . O-RING; conductive 1
17 245288 HANDLE, gun 1
18 244541 POWER SUPPLY, 85 kV; includes
18a* 103337 . O-RING; Viton
18b 197624 . SPRING, compression 1
19 244555 TURBINE, alternator; includes
19a* 110073 . O-RING; Viton
19b 223688 . BEARING KIT; includes front
Part No. Description Qty
includes item 3a
UHMWPE
in. (19 mm)
items 18a-18b
®
items 19a-19e
®
and rear bearings and fan
Ref.
No.
19c 244577 . COIL 1
19d 111745 . RING, retaining 1
19e 198821 . PAD, pressure 2
20 244556 VALVE, adjustment, atomizing air;
1
20a 101021 . RING, retaining 1
20b* 106560 . O-RING; fluorocarbon 1
20c 197566 . HOUSING, valve 1
1
20d 197567 . STEM, valve 1
21 244557 VALVE, air; includes item 21a 1
21a* 276733 . SEAL; fluoroelastomer 1
22 244558 VALVE, electrostatics, ON/OFF;
22a* 111516 . O-RING; CV75 1
22b* 113137 . O-RING; fluoroelastomer 1
3
22c 198403 . SHAFT, valve 1
22d 198404 . PLATE, retaining 1
22e 198453 . WASHER 1
22f 198464 . PIN 1
22g 276753 . KNOB 1
24 244560 VALVE, exhaust; includes item
24a* 106555 . O-RING; fluoroelastomer 1
1
25 197966 CAP, air valve 1
1
26 244714 NEEDLE, fluid; includes item 26a 1
26a 112691 . SPRING, compression 1
1
27 244927 RING, retaining, air cap; includes
1
27a* 198307 . PACKING, u-cup 1
1
28 276695 HOOK 1
30 276698 TRIGGER 1
Part No. Description Qty
includes items 20a-20d
includes items 22a-22g
24a
item 27a
1
1
1
1
44 309295
Parts
Ref.
No.
35 185105 FITTING, air; left-hand threads 1
36 107460 WRENCH, ball end; 4 mm 1
37 110087 DRIVER, hex nut; 9 mm 1
38 185103 TUBE, exhaust 1
39 110231 CLAMP 1
40 116553 GREASE, dielectric, tube (not
41 244915 COVER, gun; box of 10 (not
42 179791 TAG, warning (not shown);
43 180060 SIGN, warning (not shown);
44 112080 TOOL, needle; 2 mm 1
45 198516 CAP, spring
Part No. Description Qty
shown)
shown)
replacement available at no cost
replacement available at no cost
Ref.
No.
47 197967 PLUG 1
48 198058 SCREW, cap, socket hd 1
49 222385 CARD, warning (not shown);
50 188774 TAG, warning (not shown);
1
51 244627 SWITCH, ES HI/LO 1
52 111450 O-RING 1
1
53 276734 PLUG, LO voltage adjustment 1
1
54 197910 SCREW, pivot 1
55 197624 SPRING, grounding 1
1
59 245265 CIRCUIT, flexible 1
Part No. Description Qty
replacement available at no cost
replacement available at no cost
* Included in Air Seal Repair Kit 244781.
Replacement Warning labels, signs, tags, and cards are
available at no cost.
1
1
309295 45
Accessories
PTFE
Accessories
Air Line Accessories
AirFlex™ Flexible Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread
244963 6 ft (1.8 m)
244964 15 ft (4.6 m)
244965 25 ft (7.6 m)
244966 36 ft (11 m)
244967 50 ft (15 m)
244968 75 ft (23 m)
244969 100 ft (30.5 m)
Standard Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand
thread
223068 6 ft (1.8 m)
223069 15 ft (4.6 m)
223070 25 ft (7.6 m)
223071 36 ft (11 m)
223072 50 ft (15 m)
223073 75 ft (23 m)
223074 100 ft (30.5 m)
Air Line Quick Disconnect
112534 Swiveling quick disconnect replaces stan-
dard air inlet swivel.
Air Hose Adapter Nipple
185493 Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
Non-Swivel Air Inlet Fitting
185105 Replaces standard swivel. Left-hand
thread.
Extended Air Inlet Fitting
189191 Replaces standard swivel to provide
extended handle grip area. Left-hand
thread.
Fluid Line Accessories
Nylon Fluid Hose
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
223540 1/4 in. (6 mm) ID x 25 ft (7.6 m), 1/4 npsm
223541 1/4 in. (6 mm) ID x 50 ft (15.2 m), 1/4 npsm
Grounded Air Whip Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.188 in. (5 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) lefthand threads
236130 3 ft (0.9 m)
236131 6 ft (1.8 m)
Fluid Whip Hose
3000 psi (210 bar, 21 MPa) Maximum Working Pressure
0.125 in. (3 mm) ID; 1/4 npsm(f) x 1/4 npt(m)
236134 3 ft (0.9 m)
236135 6 ft (1.8 m)
Fluid Shutoff/Drain Valve
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve
and the pump air motor when closed.
107141 3/4 npt
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754 1/4 npsm(m) x 1/4 npsm(f) left-hand
thread.
46 309295
5000 psi (350 bar, 35 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving
fluid line pressure at the pump.
210657 1/2 npt(m), Viton seals
210658 3/8 npt(m), Viton seals
210659 3/8 npt x 1/4 npt(m), Viton seals
214037 1/4 npt(m), seals
Fluid Swivel
5800 psi (405 bar, 40 MPa) Maximum Working Pressure
115898 1/4 npsm(m) x 1/4 npsm(f)
Accessories
Gun Accessories
Gun Repair Kit
244781 Air Seal Repair Kit
Electrode Replacement Kit
244917 Includes five electrodes.
Inline Fluid Filters
238561 100 mesh filter. Set of three.
238563 60 mesh filter. Set of three.
Round Pattern Kit
Provides higher level of performance to electrostatic
spraying.
245282 Includes tip of choice.
ES Always On Kit
244913 Replaces inlet fitting with ball valve to shut
off air during flushing. Converts ES ON/
OFF valve to always ON condition.
Alternator Bearing Kit
223688 To repair the turbine alternator.
Cleaning Brush
105749 For cleaning air cap and fluid nozzle.
Miscellaneous Accessories
Ground Wire and Clamp
222011 For grounding pump and other compo-
nents 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.
Handle Grips
245263 Medium Grip
245264 Large Grip
Gun Washer Kit
245271 Use to convert Graco gun washers so they
can clean PRO Xs4 air-assisted spray guns.
Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone)
lubricant for fluid seals and wear areas.
Paint Probe
722860 Use with 722886 Paint Resistance Meter to
measure resistance of paint.
Not for use in hazardous areas.
Safety Warning Sign
180060 English Warning Sign. FM Approved.
Available at no charge from Graco.
Instruction Signs
198310 English Setup Instructions.
198320 English Daily Care Instructions.
309295 47
Spray Tip Selection Chart
(
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
Spray Tip Selection Chart
Fan Width at
Part No.
GG3107 2-4
GG3207 4-6 (100-150
GG3307 6-8 (150-200
GG3209 4-6 (100-150
GG3309 6-8 (150-200
GG3409 8-10 (200-250
GG3211 4-6 (100-150
GG3311 6-8 (150-200
GG3411 8-10 (200-250
GG3511 10-12 (250-300
GG3611 12-14 (300-350
GG3213 4-6 (100-150
GG3313 6-8 (150-200
GG3413 8-10 (200-250
GG3513 10-12 (250-300
GG3613 12-14 (300-350
GG3215 4-6 (100-150
GG3315 6-8 (150-200
GG3415 8-10 (200-250
GG3515 10-12 (250-300
GG3615 12-14 (300-350
10 in. (250 mm)
in. (mm)
50-100
Orifice Size
in. (mm)
0.007 (0.178
0.009 (0.229
0.011 (0.279
0.013 (0.330
0.015 (0.381
Fan Width at
Part No.
GG3217 4-6 (100-150
GG3317 6-8 (150-200
GG3417 8-10 (200-250
GG3517 10-12 (250-300
GG3617 12-14 (300-350
GG3319 6-8 (150-200
GG3419 8-10 (200-250
GG3519 10-12 (250-300
GG3619 12-14 (300-350
GG3719 14-16 (350-400
GG3421 8-10 (200-250
GG3521 10-12 (250-300
GG3621 12-14 (300-350
GG3721 14-16 (350-400
GG3821 16-18 (400-450
GG3423 8-10 (200-250
GG3523 10-12 (250-300
GG3623 12-14 (300-350
GG3723 14-16 (350-400
GG3823 16-18 (400-450
GG3425 8-10 (200-250
GG3525 10-12 (250-300
10 in. (250 mm)
in. (mm)
Orifice Size
in. (mm)
0.017 (0.432
0.019 (0.483
0.021 (0.533
0.023 (0.584
0.025 (0.635
GG3625 12-14 (300-350
GG3725 14-16 (350-400
GG3825 16-18 (400-450
48 309295
Technical Data
y
g
y
PTFE
PTFE
Category Data
Maximum Working Fluid Pressure 3000 psi (21 MPa, 210 bar)
Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar)
Minimum Air Pressure to Gun Inlet 40 psi (0.28 MPa, 2.8 bar)
Maximum Fluid Operating Temperature 120°F (48°C)
Paint Resistivity Range 3 megohm/cm to infinity
Short Circuit Current Output 125 microamperes
Voltage Output PRO Xs4 AA (244572): 85 kV
PRO Xs4 AA (244573): 40-85 kV
Sound Power (measured per ISO Standard 9216) at 40 psi (0.28 MPa, 2.8 bar): 88.9 dB(A)
at 100 psi (0.7 MPa, 7 bar): 99.7 dB(A)
Sound Pressure (measured 1 m from gun) at 40 psi (0.28 MPa, 2.8 bar): 86.0 dB(A)
at 100 psi (0.7 MPa, 7 bar): 95.0 dB(A)
Technical Data
Air inlet fitting, left-hand thread 1/4 npsm(m)
Fluid inlet fitting 1/4-18 npsm(m)
Gun Weight 29.1 oz (825 g)
Gun Length 11.4 in. (29 cm)
Wetted Parts
and Viton®
Loctite® is a registered trademark of the Loctite Corporation.
Stainless Steel; N
ht Polyethylene, Fluoroelastomer, PEEK, Tung-
Wei
sten Wire, Pol
lon, Acetal, Ultra-High Molecular
ethylene
309295 49
Graco Standard Warranty
g
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 by an authorized Graco distributor 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 Phone Numbers
TO PLACE AN ORDER,
All written and visual data contained in this document reflects the latest product information available at the time of publication.
contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-367-4023 Toll Free
612-623-6921
612-378-3505 Fax
Graco reserves the right to make changes at any time without notice.
Sales Offices:
International Offices:
Minneapolis, Detroit
ium, Korea, Hong Kong, Japan
Bel
*5$&2 ,1& 32 %2; 0,11($32/,6 01
www.graco.com
PRINTED IN USA 309295 10/2001
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