XTR™ 5 and XTR™ 7 Airless Spray Gun
Instructions/Parts
See page 7 for model numbers.
Maximum Working Pressure:
XTR 5: 5000 psi (35 MPa, 345 bar)
XTR 7: 7250 psi (50 MPa, 500 bar)
For use with protective coating materials
English
IMPORTANT SAFETY INSTRUCTIONS. Refer to
your sprayer instruction manual for pressure relief, priming,
and spraying instructions. Keep these instructions.
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Refer back to these warnings. Additional product-specific warnings may be found throughout the body of this manual where applicable.
ti5045a
312145B
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but
it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or
servicing equipment.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths
(potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you
identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
Instructions
II 2 G c T6
WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment
manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material,
request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing
such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment
rupture, and result in death, serious injury, and property damage.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not
touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the
equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing
loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
2 312145B
Pressure Relief Procedure
Pressure Relief Procedure
Follow this Pressure Relief Procedure whenever you are
instructed to relieve pressure, stop spraying, check or service
equipment, or install or clean spray tip.
1. Engage trigger lock.
2. Shut off pump.
3. Disengage trigger lock.
4. Hold a metal part of the gun firmly to a grounded metal
pail. Trigger the gun to relieve pressure.
5. Engage trigger lock.
6. Open fluid drain valve (see System Requirements).
Leave drain valve open.
If pressure is not fully relieved:
• Spray tip is clogged. For RAC tip, see Cleaning
Tips/Clearing Clogs, page 4. For flat tip, slowly loosen tip
guard retaining nut to relieve pressure. Remove and clear
tip.
• Hose is clogged. Slowly loosen hose end coupling to
relieve pressure. Clean hose obstruction.
System Requirements
• Install a bleed-type master air valve on a pneumatic pump
air supply line to relieve air trapped between this valve
and pump after air regulator is shut off. Trapped air can
cause the pump to cycle unexpectedly.
• Install a fluid drain valve between the pump and gun to
relieve pressure in displacement pump, hose, and gun.
Triggering to relieve pressure may not be sufficient. See
Pressure Relief Procedure.
Gun Trigger Lock
To prevent injury when the gun is not in use, always engage
the gun’s trigger lock if unit is being shut down or left
unattended. A wallet-sized warning card with important
injection treatment information is included with the gun.
Additional cards are available at no charge. Provide a card to
all operators.
Tr i gg e r
Locked
(no spray)
Tr i gg e r
Unlocked
(spray)
ti5049b
ti5048b
Tip Installation
RAC Tip
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Insert housing (A)
through back of retaining
nut (B) and pull it forward.
Install metal seal (20a) in
housing (A), flat side first.
20a
B
A
Grounding
Check your local electrical code and pump/sprayer manual for
detailed grounding instructions.
• Spray gun: ground through connection to a grounded fluid
hose and pump/sprayer.
• Fluid hose: use only grounded hoses.
• Fluid supply container: follow local code.
• Object being sprayed: follow local code.
• Solvent flushing pails: follow local code. Use only conductive metal pails placed on a grounded surface. Do not
place pail on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
• To maintain grounding continuity when flushing or relieving pressure: hold metal part of gun firmly to side of a
grounded metal pail, then trigger gun.
3. Install tip cylinder (20c) so
small orifice (X) faces
front.
4. Insert tip guard (19) into
place. Insert screw (20d)
and tighten. Install white
gasket (20b) in housing.
Install assembled RAC
onto spray gun.
A
X
20c
20b20d
19
Flat Tip
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Insert tip (32) and gasket (30) into back of guard (31).
3. Install guard over end of gun.
30
32
31
ti10051a
312145B 3
Operation
Operation
1. Connect a grounded fluid hose.
2. Without spray tip, flush pump. Use lowest pressure
possible.
3. Prime. Refer to sprayer manual.
4. Follow Pressure Relief Procedure.
5. Install spray tip and tip guard.
6. RAC tips only: Be sure the arrow-shaped tip faces
forward.
7. Hold gun perpendicular and approximately 12 inches
(304 mm) from surface. Wear gloves if fluid temperature
exceeds 110°F (43°C).
8. Move gun first, then pull gun trigger to spray onto test
paper.
a. Adjust fluid pressure until spray is completely
atomized.
b. If adjusting pressure does not give a good spray pat-
tern, follow Pressure Relief Procedure, then try
another tip size.
9. Trigger gun full-open or full-close.
Adjusting Spray Pattern
The spray tip orifice and spray angle determine pattern
coverage and size. When you need more coverage, use a
larger spray tip rather than increasing fluid pressure.
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Loosen tip guard retaining nut.
3. Align guard horizontally to spray a horizontal pattern.
Align guard vertically to spray a vertical pattern.
4. Tighten nut.
Cleaning Tips/Clearing Clogs
Clean tip and tip guard at end of each work day.
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Clean spray tip as follows:
a. RAC tips: Rotate tip 180°. Disengage trigger lock.
Trigger gun into pail or onto ground to remove clog.
Engage trigger lock. Rotate tip 180° back to spray
position.
b. Flat tips: Remove tip and clean with a solvent-soaked
brush.
3. RAC tips: If tip is still clogged:
a. Shut off sprayer and disconnect power source.
b. Open fluid drain valve (see System Requirements
on page 3) to relieve pressure.
c. Remove and clean spray tip.
Maintenance
Flushing
Flush pump and gun before fluid can dry in it. If available, use
flushing procedure provided in your pump or sprayer manual
instead of this procedure.
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Remove spray tip and guard from gun. Clean with solvent.
3. Put the pump intake in a grounded pail of compatible
solvent.
4. Start pump at its lowest pressure.
5. Disengage trigger lock, then trigger gun into the paint pail.
When solvent appears, release trigger.
6. Trigger gun into solvent pail. Circulate fluid until system is
thoroughly flushed.
7. Follow Pressure Relief Procedure. Engage trigger lock.
Cleaning/Replacing Filter
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Disconnect trigger guard
from gun body by pushing up
on guard hook and pulling it
out of notch.
3. The trigger guard beneath
the gun handle can then be
used as a wrench to loosen
the nut.
4. When alignment notches are
no longer engaged, use your
hand to twist handle and
remove it from gun head.
5. Remove filter.
6. Clean filter using a soft brush.
7. Replace filter.
8. Apply light coating of grease to threads and then attach.
9. Use trigger guard to tighten the nut.
10. Reattach the trigger guard to the gun.
Cleanup
Flush gun after each work shift and store in a dry location. Do
not leave the gun or any parts in water or cleaning solvents.
ti5052a
ti5054a
4 312145B
Repair
Repair
Disassembly
1. Follow Pressure Relief Procedure. Engage trigger lock.
2. Disconnect fluid hose. Remove RAC tip guard and
tip (19 and 20a-20d) or flat tip guard and tip (30, 31 and
32).
3. Using a wrench, remove the cap (4) with spring (5)
(releases spring tension on needle).
4. Remove the valve seat (10) and
gasket (9).
5. Holding the needle with tool (36)
remove the needle retainer (6).
6. Pull the needle (8) out.
7. Using a socket wrench, remove the
seal retainer (2) from the back of the
gun. Use a pick to remove the
gasket (3).
8. Clean and replace parts as needed.
If you need to remove the trigger
To avoid losing parts, be ready for two actuator pins (7) to
fall out of the gun body when the trigger (16) is removed.
XTR 7 Guns
1. Using a wrench, remove screw
(11b) from the pivot pin (11a).
2. Slide the pivot pin (11a) out of
the gun body, and remove the
trigger (16).
3. Before installing trigger, grease
the actuator pins (7) and the
pivot pin (11a).
XTR 5 Guns
1. Using a socket wrench, remove screw (12) from each side
of the gun body and remove trigger.
2. Before installing trigger, grease the actuator pins (7).
36
6
ti5187a
11b
7
11a
16
ti5190a
Assembly
1. Press a new gasket (3*) into the gun body. Lightly grease
the seal retainer (2*) and install. Torque to 48-72 in-lb (5-8
N•m).
2. Lightly grease and replace the needle (8*). Press the
needle through the seal retainer.
Caution
Use only tool (36) and fingers to tighten needle. Do not
overtighten or breakage may occur.
3. Apply light-strength Loctite™ to needle threads. Holding
the needle with tool (36*), install needle retainer (6).
Tighten until it bottoms out. Do not overtighten.
4. Lightly grease valve seat (10*) threads. Squeeze the
trigger to retract the needle and install gasket (9*) and
valve seat (10*). Torque valve seat to 26-32 ft-lb
(34-43 N•m).
5. Grease and install the spring (5) and cap (4). Tighten the
cap to 10-13 ft-lb (8-10 N•m).
Test Gun Before Using
1. Engage trigger lock. Connect fluid hose to gun.
2. Start and prime the pump.
3. Disengage the trigger lock and trigger the gun into a metal
waste container.
4. Release the trigger. The gun should immediately stop
spraying and there should be no leaks. If there is a
problem, follow Pressure Relief Procedure. Check
through Assembly procedure and correct problem.
5. Install tip and tip guard before regular use.
Technical Data
Maximum working pressure:
XTR 5 . . . . . . . . . . 5000 psi (35 MPa, 345 bar)
XTR 7 . . . . . . . . . . 7250 psi (50 MPa, 500 bar)
Fluid orifice . . . . . . . . . . . . . 0.090 in. (2.3 mm)
Fluid inlet . . . . . . . . . . . . . . . 1/4 npsm (m)
Max. fluid temperature. . . . . 160°F (71°C)
Sound pressure . . . . . . . . . . 84.3 dB(A)*
Sound power . . . . . . . . . . . . 95.7 dB(A)*
Wetted parts . . . . . . . . . . . . aluminum, stainless steel, acetal,
polyethylene, nylon, polypropylene, carbide, polyurethane, solvent-resistant o-rings.
*Results are maximum readings taken at 6000 psi (41 MPa,
414 bar), with HD519 tip, using water. Sound power level was
tested to ISO 9614-2.
312145B 5
Parts
0
12
†
Parts
Ref Part Description Qty
1 15J771 BODY, gun, aluminum, (XTR 5 only) 1
15E178 BODY, gun, sst (XTR 7 only) 1
2* 245881 SEAL, retainer assembly 1
3* n/a GASKET (kit 248837 only, not sold sepa-
4 15K000 CAP, end (XTR 5 only) 1
15A864 CAP, end (XTR 7 only) 1
5 117350 SPRING, 1
6 15E088 RETAINER, needle 1
7 15E085 PIN, actuator 2
8* 248591 NEEDLE 1
9* 156766 GASKET 1
10* 245858 SEAT, valve 1
11a† 192272 PIN, pivot (XTR 7 only) 1
11b† 203953 SCREW, cap, hex-hd;
12† 117602 SCREW, shoulder, pan hd;
13 248952 HANDLE, includes trigger guard, swivel,
14a 276997 HANDLE SLEEVE, insulated, (see Tables 1
14b 15E083 HANDLE SLEEVE, 1 in. (25 mm), (see
15a 255275 HANDLE, includes trigger guard, swivel,
15b 255276 HANDLE, includes trigger guard, swivel,
16a† 287449 TRIGGER KIT, also includes 11a, 11b, and
16b† 287450 TRIGGER KIT, also includes 11a, 11b, and
16c† 287451 TRIGGER KIT, also includes 11a, 11b, and
21* 179733 SEAL, sleeve 1
24 n/a O-RING (kit 248952 only, not sold sepa-
26 287032 FILTER, 60 mesh, included with gun 1
287034 FILTER, 60 and 100 mesh combo
29▲ 222385 TAG, warning (not shown) 1
36* 194744 TOOL, repair, packing 1
rately)
10-24 x 3/8 in. (10 mm) [XTR7 only]
8-32 x 5/16 in. (8 mm) [XTR 5 only]
tube, and o-ring; see Tables 1 and 2
and 2)
Tables 1 and 2)
and tube, 1 in. (25 mm) OD, (XTR 5 only,
see Table 2)
and tube, 7/8 in. (23 mm) OD, (XTR 5 only,
see Table 2)
12, see Tables 1 and 2,
12, see Tables 1 and 2
12, see Tables 1 and 2
rately)
XTR 5 trigger attachment
12
†
1
11b
†
8*
1
9*
10*
7
3*
2*
21*
26
11a
6
†
1
16b
2
1
16a
16c
†
†
†
24
14b
1
1
1
14a
1
15a and 15b
1
1
1
‡
NOTE: Handles 15a and 15b are not pressure rated
(XTR 5 only
13
for use with the XTR 7. For an XTR 7, order handle 13
and sleeve 14a or 14b depending on your model (see
1
Table 1).
5
ti5192c
4
‡
)
▲ Replacement Danger and Warning labels, tags, and cards
are available at no cost.
* Parts included in Repair Kit 248837, purchased separately.
† Parts included in Trigger Kits 287449 (16a), 287450 (16b),
and 287451 (16c), purchased separately.
Ref Part Description Qty
19 245994 GUARD, RAC tip (see Tables 1 and 2) 1
Tip and Guard
20 GHDxxx SWITCH, RAC tip, 519 size included
(includes 20a - 20d, see Tables 1 and 2)
20a SEAL, fluid 1
20b GASKET 1
20c TIP, spray hd RAC 1
20d SCREW, machine, pan hd,
10-32 x 5/16 in. (8 mm)
30 166969 GASKET, (XTR501 and XTR701 only)
31 220251 GUARD, flat tip (XTR501 and XTR701 only) 1
32 163519 TIP, flat (XTR501 and XTR701 only) 1
19
RAC Tip
20d
20c
20a
20b
ti10050a
Flat Tip
3
32
31
ti10051a
6 312145B
1
1
Tip and Guard
Table 1: XTR 7 Models
XTR 7
Gun
Part No.
XTR700
XTR701
XTR702
XTR703
XTR704
XTR705
13 14a 14b 16a 16b 16c 19 20
✔✔✔ ✔
✔✔✔
✔✔ ✔✔✔
✔✔ ✔ ✔✔
✔✔✔ ✔✔
✔✔✔✔✔
Reference Numbers
Table 2: XTR 5 Models
XTR 5
Gun
Part No.
XTR500
XTR501
XTR502
XTR503
XTR504
XTR505
XTR506
XTR507
13 14a 14b 15a 15b 16a 16b 16c 19 20
✔✔ ✔✔✔
✔✔ ✔ ✔✔
Reference Numbers
✔✔ ✔
✔✔
✔✔ ✔✔
✔✔✔✔
Related Manuals
This manual is available in the following languages. Also see
www.graco.com for the latest translations.
Language Manual
Chinese 312293
Dutch 312138
English 312145
French 312294
German 312295
Italian 312549
Japanese 312296
Korean 312297
Portuguese 312136
Russian 312137
Spanish 312298
Swedish 312139
✔✔ ✔✔
✔✔✔✔
312145B 7
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is 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 from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. 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 procédures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
This manual contains English. MM 312145
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
312145B, 9/2007
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