Graco Inc. PRO 244572 User's Manual
Contents
1. Ref No 19 Alternator Ref No 20 Atomizing Air Adjustment Valve 19d 19c Ref No 22 ES ON OFF Valve Part No 244573 85 kV Electrostatic Gun Series C items 1 59 Ref No 1 2 3 3a 6 9a 42 pop N ET p A Part No 205264 245280 GG3XXX 183459 276767 188749 197369 245276 198679 22d 221 22e Description Qty FILTER fluid inline 1 HOUSING seat 1 SPRAY TIP customer s choice 1 includes item 3a SEAL spray tip 1 TIP GUARD 1 PACKING u cup air valve 1 UHMWPE SCREW trigger 2 AIR CAP ASSEMBLY 1 AIR CAP 1 Ref No 9b 10 13 14 15 16 16a 17 Part No 244917 197517 197518 15M680 244713 185116 244531 197486 245288 Description ELECTRODE kit of 5 GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm BRACKET inlet fluid TUBE fluid SPRING compression BARREL gun includes item 16a O RING conductive HANDLE gun includes item 28 Qty 309295L Ref No 18 18a 18b 19 19a 19b 19c 19d 19e 20 20a 20b 20c 20d p1 22 22a 22b 22c 22d 22e 22f 22g 24 24a 25 26 26a 27 Part No 244541 103337 197624 244555 110073 223688 244577 111745 198821 244556 101021 106560 197566 197567 244557 244558 111516 113137 198403 198404 198453 198464 276753 249323 112085 197966 244714 112691 244927 309295L Description POWER SUPPLY 85 kV2. ti1514b Hazardous Area Gun Air Regulator Gun Air Supply Line Shutoff Valve Air Hose Ground Wire Graco Grounded Air Hose Electrostatic Air Assisted Spray Gun Fluid Pressure Gauge Fluid Drain Valve Gun Air Inlet Gun Fluid Inlet Pump Runaway Valve Required for safe operation Must be purchased separately NOTE Solenoid valve B is not offered as a Graco accessory Installation Connect the Air Line A WARNING Electric Shock Hazard Y To reduce the risk of electric shock or other uly serious injury the air supply hose must be w 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 fin ished workpiece and can cause the gun to malfunc tion WARNING Skin 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 pro ducing a fluid pressure
3. 244577 111745 198821 309295L Description FILTER fluid inline HOUSING seat SPRAY TIP customer s choice includes item 3a SEAL spray tip TIP GUARD PACKING u cup air valve UHMWPE SCREW trigger AIR CAP ASSEMBLY includes items 9a and 9b AIR CAP ELECTRODE kit of 5 GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm BRACKET inlet fluid TUBE fluid SPRING compression BARREL gun includes item 16a O RING conductive HANDLE gun includes item 28 POWER SUPPLY 85 kV includes items 18a 18b O RING fluoroelastomer SPRING compression TURBINE alternator includes items 19a 19e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure Qty Ref No 20 20a 20b 20c 20d p4 22 22a 22b 22c 22d 22e 22f 22g 24 24a 25 26 26a 27 27a 28 30 35 36 37 38 39 40 Part No 244556 101021 106560 197566 197567 244557 244558 111516 113137 198403 198404 198453 198464 276753 249323 112085 197966 244714 112691 244927 198307 276695 276698 185105 107460 276741 185103 110231 116553 Description VALVE adjustment atomizing air includes items 20a 20d RING retaining O RING fluorocarbon HOUSING valve STEM valve VALVE air VALVE electrostatics ON OFF includes items 22a 22g O RING CV75 O RING fluoroelast
4. Dirty gun Clean See Operation Manual Operator gets mild shock Operator not grounded or is near ungrounded object See Grounding on page 12 Gun not grounded See Check Electrical Grounding on page 13 and Test Gun Resistance on page 18 Operator gets shock from workpiece Workpiece not grounded Resistance must be 1 megohm or less Clean workpiece hangers ES indicator light is off when the gun is triggered 309295L 23 Repair Repair Pressure Relief Procedure WARNING Skin Injection Hazard 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 A The system pressure must be manually e are instructed to relieve the pressure stop spraying checkor repair any of the system equipment e or install or clean the spray tip 1 Turn the ES ON OFF valve OFF maza 2 Lock the trigger 3 Turn off the air bleed valves to the fluid source and to the gun 24 ti1356a Unlock the trigger Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure Lock the trigger ti1as6a Open the pump drain valve and all other fluid drain valves in the system having a waste
5. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to m
6. 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 TRIGGER SAFETY LOCK DISPLAY l ON 0 OFF Smart Gun Installation Installation Install the System WARNING Fire Explosion and Electric Shock Hazard M 8 Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Do not install or service this equipment unless you are trained and qualified Be sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class I Div I Group D or a Group II Category 2G Hazardous Location Comply with all applicable local state and national fire electrical and other safety regulations 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 Flammable or Toxic Vapor Hazard Provide fresh air ventilation to avoid the M buildup of flammable or toxic vapors when a spraying flushing or cleaning the gun Do not operate the gun unless ventilation fans are operating Fi
7. 14 Check Fluid Viscosity 04 14 Operation a see ete ete ee LR TR 15 Low Voltage Adjustment Smart Guns Only 15 Maintenance lle 16 Flush the Spray Gun Ls 16 Electrical Tests lleseeese 18 Test Gun Resistance 0005 18 Test Power Supply Resistance 19 Test Barrel Resistance 20 2 Troubleshooting L atkasa 21 Spray Pattern Troubleshooting 21 Gun Operation Troubleshooting 22 Electrical Troubleshooting 23 Repair i kili kak bie 951 Ex mS 24 Pressure Relief Procedure 24 Prepare the Gun for Service 25 Tools Needed 2200 eee eee eee 25 Tip Guard Air Cap Spray Tip or Seat Housing Replacement 0220000 26 Electrode Replacement 28 Fluid Tube Replacement 29 Fluid Filter Removal llle 29 Fluid Needle Replacement 30 Barrel Removal 00 cece eee 31 Barrel Installation as 31 Power Supply Removal and Replacement 32 Turbine Alternator Removal and Replacement 33 Atomizing Air Adjustment Valve Repair 34 Air Valve Repair Ls 35 ES ON OFF Valve Repair 36 Parts 2222 eet Sant dae ees le eee eats 37 Accessories 0 02002 a eee eee 44 Air Line Accessories Lakis 44 Fluid Line Accessories
8. Install the fluid filter in the fluid fitting Tighten the bottom nut C onto the fitting and torque to 20 30 in Ib 2 3 3 4 Nem Make sure the top nut remains tight 4 Apply dielectric grease 40 to the entire length of the plastic extension on the end of the fluid tube 14 5b Apply low strength thread sealant to the fluid tube nut threads 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 fit ting Tighten the bottom nut C onto the fitting and torque to 20 30 in Ib 2 3 3 4 Nem Make sure the top nut remains tight SWAY A ID j jj IN SI bJ C a 1 E N Me A M J D M J A e JN ti1524a Fig 11 Fluid Tube Replacement 309295L N CAUTION Be sure the fluid tube 14 is not twisted after tighten ing the bottom nut C TI1521A Fig 12 Fluid Filter Removal 29 Repair Fluid Needle Replacement 1 Prepare the gun for service page 25 2 Remove the air cap assembly and seat housing page 26 3 Remove the barrel 16 page 31 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
9. 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
10. can be further controlled using the gun s atomizing air adjust ment valve This valve can be used to restrict air flow to the air cap while maintaining sufficient air flow to the tur bine 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 For airless atomization if desired turn the gun s atomizing air adjustment valve completely off Closing this valve does not affect turbine operation 309295L Gun Overview The electrostatic gun includes the following controls See FiG 1 Air cap tip guard and spray tip Never spray with out the tip guard See page 46 for spray tip sizes Trigger safety lock Prevents the gun from spray ing Atomizing AIR adjustment valve Adjusts atomiz ing air TIP GUARD AIR CAP SPRAY TIP ES INDICATOR ES ON OFF l ON 0 OFF B Standard Gun Fig 1 Gun Overview 309295L ES ON OFF Introduction 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
11. component Maximum working fluid pressure of this equipment is 3000 psi 21 MPa 210 bar e 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 warnings e 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 e Comply with all applicable local state and national fire electrical and other safety regulations 309295L Introduction Introduction How the Electrostatic AA Spray Gun Works A WARNING Skin Injection Hazard For your safety read and follow all Warn Remember this is not an air spray gun D ings 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 oper ates 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
12. 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 10 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 A WARNING Skin Injection Hazard The bleed type air valve E is reguired 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 seri ous 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 sup ply 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 309295L 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 A WARNING Skin Injection Ha
13. handle 17 See FIG 18 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 Checkthe power supply resistance page 19 Replace if necessary NOTE Before installing the power supply make sure the o rings 18a 19a spring 18b and pads 196 are in place 6 On Smart Models only connect the 6 pin flexible cir cuit 59 to the power supply 32 N Connect the 3 wire connector B Slide the alterna tor 19 down onto the power supply 18 Lubricate the alternator o ring 19a with non sili cone grease Part No 111265 Do not over lubri cate Lubricate the power supply o ring 18a with dielec tric grease 40 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 Install the barrel 16 page 31 Test gun resistance page 18 Fig 18 Power Supply and Turbine Alternator 309295L Turbine Alternator Removal and Replacement NOTE Replace turbine bearings after 2000 hours of operation Order Part No 223688 Bearing Kit 1 Prepare gun f
14. includes items 18a 18b O RING fluoroelastomer SPRING compression TURBINE alternator includes items 19a 19e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure VALVE adjustment atomizing air includes items 20a 20d RING retaining O RING fluorocarbon HOUSING valve STEM valve VALVE air VALVE electrostatics ON OFF includes items 22a 22g O RING CV75 O RING fluoroelastomer SHAFT valve PLATE retaining WASHER PIN KNOB VALVE exhaust includes item 24a O RING fluorocarbon CAP air valve NEEDLE fluid includes item 26a SPRING compression RING retaining air cap includes item 27a Qty Ref No 27a 28 30 35 36 37 38 39 40 41 42 43 44 45 47 48 49 50 51 52 53 54 55 59 Part No 198307 276695 276698 185105 107460 276741 185103 110231 116553 244915 179791 180060 112080 198516 197967 198058 222385 188774 244627 111450 276734 197910 197624 245265 Description PACKING u cup HOOK TRIGGER FITTING air left hand threads WRENCH ball end 4 mm MULTI TOOL TUBE exhaust CLAMP GREASE dielectric tube not shown COVER gun box of 10 not shown TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost TOOL needle 2 mm CAP
15. kit must be purchased separately Kit parts are marked with an asterisk for example 6 A WARNING Some PRO Xs4 AA Gun replacement parts look sim ilar to other PRO Gun parts but are not interchange able 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 malfunc tion and result in serious injury fire explosion or property damage 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 Tools Needed 2mm driver supplied 4mm driver supplied Multi Tool supplied e adjustable wrench e medium screwdriver snap ring pliers 25 Repair Tip Guard Air Cap Spray Tip or Seat Housing N CAUTION Replacement The barrel resistor cartridge B is part of the barrel and is not replaceable To avoid destroying the gun 1 Prepare gun for service page 25 barrel do not attempt to remove the barrel resistor 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 A WARNING 3 Replace the tip gasket 3a if damaged Fire Explosion a
16. supplied with the gun If non Graco gloves are worn cut off fingers or palm area of glove to ensure your hand contacts the grounded gun han dle Object being sprayed keep the workpiece hangers clean and grounded at all times Resistance must not exceed 1 megohm 0 31 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 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 309295L Installation Check Electrical Grounding 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 A WARNING and Fire Explosion and Electric Shock Hazard A Megohmmeter Part No 241079 AA see ik FIG 3 is not approved for use in a hazard 5 Measure the resistance between the gun handle ous area To reduce the risk of sparking do BB and a true earth ground CC Use an applied not use the megohmmeter to check electri voltage of 500 minimum to 1000 volts maximum cal grounding unless T
17. 0 200 250 0 023 0 584 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 0 025 0 635 GG3525 10 12 250 300 GG3625 12 14 300 350 GG3725 14 16 350 400 GG3825 16 18 400 450 309295L Technical Data Technical Data 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 Sound Pressure measured 1 m from gun at 100 psi 0 7 MPa 7 bar 99 7 dB A 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 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 Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Fluoroelastomer PEEK Tungsten Wire Polyethylene Loctite is a registered trademark of the Loctite Corporation 309295L 47 Graco Standard
18. 44 Gun Accessories uuaa Lakis 44 Miscellaneous Accessories 45 Spray Tip Selection Chart 46 Technical Data ss 47 Graco Standard Warranty 48 Graco Information 48 309295L List of Models List of Models T Operation Part No Model Description Manual 244572 Series C PRO Xs4 AA Manual Air Assisted Spray Gun 309296 3W9296 329296 244573 Series C PRO Xs4 AA Manual Air Assisted Spray Gun with smart display 309296 3W9296 329296 309295L 3 Warnings Warnings Warning Symbol Caution Symbol A WARNING A CAUTION This symbol alerts you to the possibility of serious injury This symbol alerts you to the possibility of damage to or or death if you do not follow the instructions destruction of eguipment if you do not follow the instruc tions AM WARNING Fire Explosion and Electric Shock Hazard 4 Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Electrostatic equipment must be used only by trained qualified personnel who understand the ik reguirements of this manual e Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Only use grounded Graco conductive air supply hoses Check gun and hose resistance and electrical grounding daily Inter
19. G 2 shows a typical electrostatic air assisted spray system lt is not an actual system design For assistance in designing a system to suit your particular needs con tact your Graco distributor Electrically interlock the gun air supply with the ventila tors to prevent gun operation without ventilating fans operating Check and follow all National State and Local codes regarding air exhaust velocity reguire ments NOTE High velocity air exhaust will decrease the oper ating efficiency of the electrostatic system Air exhaust velocity of 100 ft min 31 linear meters minute should be sufficient 309295L C A The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on Installation E Tt P eoo Allee ae Non Hazardous Area Fig 2 Typical Installation Key A B C Zz A Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve bleed type Air Line Filter Water Separator Pump Air Supply Shutoff Valve bleed type Air Line Lubricator Air Pressure Regulator Pump Pump Ground Wire Fluid Filter Fluid Supply Line Shutoff Valve Fluid Pressure Regulator Grounded Fluid Supply Line with spring guards 309295L Q R S T U V W X
20. Instructions Parts List G Manual Electrostatic Air Assisted GRACO PRO Xs4 AA Spray Gun 309295L ENG For use in Class I Div I hazardous locations using Group D spray materials M APPROVED For use in Group II Zone 1 areas using Group IIA spray materials C x i 2 G EEx 0 24MJ For Professional Use ONLY Smart Model 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 3000 psi 21 MPa 210 bar Maximum Working Fluid Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See for page 2 Table of Contents and page 3 for List of Models U S Patent 7 226 004 Standard Model ti1332b HOO3 PROVEN QUALITY LEADING TECHNOLOGY Table of Contents List of Models eee 3 Warnings ele ana da a a a a vs 4 Warning Symbol LLP 4 Caution Symbol LL 4 Warning ainiai 3 io ete La ee Sa 4 Introduction e sateen a eee ees 6 How the Electrostatic AA Spray Gun Works 6 Gun Overview 0 0 0 cee eee 7 Installation Lakis 8 Install the System La 8 Warning Sign LLP 8 Ventilate the Spray Booth 8 Connect the Air Line 10 Connect the Exhaust Tube 10 Connect the Fluid Line 11 Filter the Fluid Ls 11 Select a Spray Tip lt 11 Grounding aka 12 Check Electrical Grounding 13 Check Fluid Resistivity
21. ake changes at any time without notice This manual contains English MM 309295 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2001 Graco Inc is registered to ISO 9001 WWW graco com Revised 10 2009
22. ake 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 WARNING 5 Install the air cap assembly page 26 Electric Shock Hazard 6 Test gun resistance page 18 To reduce the risk of fire explosion or elec 9b tric shock do not operate the spray gun S without the electrode installed in the air cap PU 1 Prepare the gun for service page 25 2 Remove the air cap assembly page 26 3 Pullthe electrode 9b out of the back of the air cap CC BB H using a needle nose pliers 02013 Fig 10 Electrode Replacement 28 309295L Fluid Tube Replacement 1 Prepare the gun for service page 25 2 Disconnect the bottom fluid tube nut C See FIG 11 3 Carefully unscrew the top fluid tube nut D N 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 Repair Fluid Filter Removal 1 Prepare the gun for service page 25 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 Replacement filters are available in 100 mesh standard or 60 mesh sizes See page 45 4
23. arge from Graco Instruction Signs 198310 English Setup Instructions 198320 English Daily Care Instructions Electrostatic Conductive Gloves box of 12 117823 Small 117824 Medium 117825 Large 45 Spray Tip Selection Chart Spray Tip Selection Chart 46 ran Width at Orifice Size Part No 10 in 250 mm in mm in mm GG3107 2 4 50 100 0 007 0 178 GG3207 4 6 100 150 GG3307 6 8 150 200 GG3209 4 6 100 150 0 009 0 229 GG3309 6 8 150 200 GG3409 8 10 200 250 GG3211 4 6 100 150 0 011 0 279 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 0 013 0 330 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 0 015 0 381 GG3315 6 8 150 200 GG3415 8 10 200 250 GG3515 10 12 250 300 GG3615 12 14 300 350 Fan widest Orifice Size Part No 10 in 250 mm in mm in mm GG3217 4 6 100 150 0 017 0 432 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 0 019 0 483 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 0 021 0 533 GG3521 10 12 250 300 GG3621 12 14 300 350 GG3721 14 16 350 400 GG3821 16 18 400 450 GG3423 8 1
24. c Shock Hazard ti M Wy cause a fire explosion or electric shock When operating the electrostatic gun any ungrounded objects in the spray area peo ple containers tools etc can become electrically charged Improper grounding can result in static sparking which can 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 12 Pump ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual 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 13 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 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
25. container ready to catch the drainage Leave the drain valve s open until you are ready to spray again If the nozzle or hose is completely clogged or pres sure is not fully relieved slowly loosen the hose end coupling Now clear the nozzle or hose 309295L Prepare the Gun for Service A WARNING Electric Shock Hazard reguires access to parts that may cause electric shock or other serious injury if the work is not performed properly Do not install or ser vice this eguipment unless you are trained and guali fied W Installing and repairing this equipment A WARNING Skin Injection Hazard sure Relief Procedure on page 24 before checking or repairing any part of the system and whenever you are instructed to relieve the pressure R To reduce the risk of injury follow the Pres NOTE e Check all possible remedies in Troubleshooting before disassembling the gun Use a vise with padded jaws to prevent damage to plastic parts e 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 309295L Repair e 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 e Air Seal Repair Kit 244781 is available The
26. damage 18 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 shootingon page 23 for other possible causes of poor performance 35 TI1469A Fig 5 Test Gun Resistance 309295L Electrical Tests Test Power Supply 6 Be sure the spring 18b is in place before reinstall ing the power supply Resistance 1 Remove the power supply 18 page 32 2 Remove the turbine alternator 19 from the power supply page 33 I 3 Measure resistance from the power supply s ground i strips EE to the spring 18b See FiG 6 4 The resistance should be 135 150 megohms If out side this range replace the power supply If in range proceed to the next test 18b EE 5 If you still have problems refer to Electrical Trou bleshooting on page 23 for other possible causes o G of poor performance or contact your Graco distribu L W1899a tor Fig 6 Test Power Supply Resistance 309295L 19 Electrical Tests Test Barrel Resistance 5 If the resistance is still outside the range replace the barrel 1 Insert a conductive rod B into the gun barrel removed for the power supply tes
27. e as low as pos sible 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 46 Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing area Worn fluid needle packings or shaft Replace fluid needle assembly 26 see page 30 Air leaks from the front of the gun Air valve 21 is not seating properly Clean and service air valve see page 35 Fluid leakage from the front of the gun Worn or damaged fluid needle ball Replace fluid needle 26 see page 30 Worn fluid seat housing 2 Replace seat housing see page 26 Loose spray tip 3 Tighten retaining ring 27 see page 26 Damaged tip seal 3a Replace see page 26 Gun does not spray Low fluid supply Add fluid if necessary Damaged spray tip 3 Replace see page 26 Dirty or clogged spray tip 3 Clean see gun operation manual Damaged fluid needle 26 Replace see page 30 Dirty air cap Damaged or plugged air cap 9 Clean air cap see gun operation manual 22 309295L Electrical Troubleshoo
28. e the pressure Lock the trigger Shut off or disconnect the solvent line Hang the gun from its hook with the nozzle pointing down When ready to spray again reconnect the fluid sup ply line Follow the Setup procedure in the Gun Operation Manual 17 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 barrel 16 and electrical continuity between components N 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 Megohmmeter Part No 241079 AA see FiG 5 is not approved for use in a hazard ous area To reduce the risk of sparking do not use the megohmmeter to check electri cal grounding unless CE E The gun has been removed from the hazardous area Orall 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
29. emble the retaining ring 20a Unscrew the valve stem from the housing until it is stopped by the retaining ring Screw the valve assembly 20 into the gun handle using a wrench on the flats of the housing Torque to 15 25 in Ib 1 7 2 8 Nem KO eS gt TI1487A 309295L Repair Air Valve Repair 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 1 Prepare the gun for service page 25 6 Install the air valve 21 and spring 15 into the gun 2 Remove the barrel page 31 handle 17 3 Remove the air valve cap 25 from the handle 17 7 Install the air valve cap 25 Torque to 15 25 in Ib Remove the spring 15 See FIG 20 1 7 2 8 Nem 8 Install the barrel page 31 N 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 the rubber sealing surface and replace the air valve if damaged ti1527a N CAUTION When removing the air valve 21 be careful not to damage the seat area The rubber seal is not remov able Fig 20 Air Valve 309295L 35 Repair 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 rin
30. epair 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 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 Alternator Bearing Kit 223688 To repair the turbine alternator 309295L Accessories Cleaning Brush 105749 For cleaning air cap and fluid nozzle Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding pump and other components and equipment in the spray area 12 gauge 25 ft 7 6 m Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in hazardous areas Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure resistance of paint Not for use in hazardous areas Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint Not for use in hazardous areas Safety Warning Sign 180060 English Warning Sign FM Approved Avail able at no ch
31. fluid being sprayed meets the require ments of an electrostatic air assisted spray system Follow the instructions included with the meter and probe Readings of 25 megohms cm and above provide the best electrostatic results 14 Check Fluid Viscosity To check fluid viscosity you will need aviscosity cup e astopwatch 1 Completely submerge the viscosity cup in the fluid Lift the cup out guickly 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 309295L Operation Operation Refer to the gun operation manual supplied e for Setup Shutdown and Daily Care procedures INSTRUCTIONS Low Voltage Adjustment Table 1 Low Voltage Adjustment Smart Guns Only 1 2 KV ON ON 70 The ES HI LO switch enables you to switch between full ON OFE 50 voltage and a lower voltage output The lower voltage is factory set but can be adjusted OFF ON 50 OFF OFF 40 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 fff Table 1 Also see F
32. gs 22a and 22b with non sili cone grease Part No 111265 Do not over lubri cate N 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 36 4 Clean and inspect parts for damage Replace if nec essary NOTE The protrusion on the retainer plate 22d must point upward 5 Reinstall the valve Torque the screw 48 to 15 25 in Ib 1 7 2 8 Nem 22f 22g voc N 22a wl TT gt THAB8A Fig 21 ES ON OFF Valve 309295L Parts Parts Part No 244572 85 kV Electrostatic Gun Series C items 1 50 See page 38 for detail views of the alternator 19 atomizing air adjustment valve 20 and ES ON OFF valve 22 p NUM T f N 192 28 t J 19619 7 m v Ne a 17 15 21 5 a A ti1511C 309295L 37 Parts Ref No 19 Alternator Ref No 20 Atomizing Air Adjustment Valve Ref No 22 ES ON OFF Valve 221 22d N 38 309295L Part No 244572 85 kV Electrostatic Gun Series C items 1 50 Ref No 1 2 3 3a 6 9a 9b 10 11 13 14 15 16 16a 17 18 18a 18b 19 19a 19b 19c 19d 19e Part No 205264 245280 GG3XXX 183459 276767 188749 197369 245276 198679 244917 197517 197518 15M680 244713 185116 244531 197486 245286 244541 103337 197624 244555 110073 223688
33. he resistance should not exceed 1 megohm See Wy FIG 3 r The gun has been removed from the FIRERIQOURIHI S 6 Ifthe 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 Orall 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 1 Have a qualified electrician check the electrical IN grounding continuity of the spray gun and air hose 2 Turn the ES ON OFF valve OFF lt gt e fe NEP ti1340a Fig 3 Check Gun Grounding 309295L 13 Installation Check Fluid Resistivity A WARNING Fire Explosion and Electric Shock Hazard Check the fluid resistivity in a non hazard ous 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 CE E Graco Part No 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the
34. iG 4 0 100 i S p ti1529a Fig 4 Low Voltage Adjustment Switches 309295L 15 Maintenance Maintenance 5 INSTRUCTIONS 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 A WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec p tric shock turn the ES ON OFF valve OFF before flushing the gun E N CAUTION Flush the gun with a non conductive compatible sol vent Conductive solvents can cause the gun to mal function Do not use methylene chloride as a flushing or clean ing solvent with this gun as it will damage nylon com ponents 16 1 Turn the ES ON OFF valve OFF mara A WARNING Skin Injection Hazard always follow the Pressure Relief Proce dure page 24 whenever you are instructed to relieve the pressure To reduce the risk of a fluid injection injury 2 Relieve the pressure Continued on page 17 309295L 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 309295L Maintenance Reliev
35. 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
36. lock the gun air supply to prevent operation unless ventilating fans are on Use and clean equipment only in well ventilated area Use cleaning solvents with highest possible flash point when flushing or cleaning equipment Always turn the electrostatics off when flushing cleaning or servicing equipment If there is static sparking or you feel a shock stop operation immediately Do not use equip ment until you identify and correct the problem Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plas tic drop cloths potential static arc e Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Keep work area free of debris including solvent rags and gasoline Keep a working fire extinguisher in the work area d Skin 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 e Fluid injected into the skin might look like just a cut but is a serious injury Get immediate surgical treatment 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 e Never spray without the tip guard in place Lock the trigger safety when you s
37. nd 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 with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part SER Fig 8 Tip Guard Air Cap and Spray Tip Replace ment 4 Trigger the gun and remove the seat housing 2 with the tool 37 provided See FiG 9 Fig 9 Seat Housing Replacement Continued on page 27 26 309295L N CAUTION Repair To avoid damaging the seat housing and gun barrel never over tighten the seat housing Over tightening may result in improper fluid shut off N CAUTION 5 Trigger the gun and install the gray colored seat housing 2 Tighten until snug then 1 4 turn more 309295L 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 7 Assemble the spray tip 3 air cap 9a and tip guard 4 Make sure the electrode 9b is not dam aged or missing Install the air cap assembly with the retaining ring 27 The u cup 27a lips must face forward Test gun resistance page 18 27 Repair Electrode Replacement 4 Push the new electrode through the air cap hole M
38. omer SHAFT valve PLATE retaining WASHER PIN KNOB VALVE exhaust includes item 24a O RING fluorocarbon CAP air valve NEEDLE fluid includes item 26a SPRING compression RING retaining air cap includes item 27a PACKING u cup HOOK TRIGGER FITTING air left hand threads WRENCH ball end 4 mm MULTI TOOL TUBE exhaust CLAMP GREASE dielectric tube not shown Parts Qty 39 Parts Ref No 41 42 43 44 45 47 40 Part No 244915 179791 180060 112080 198516 197967 Description COVER gun box of 10 not shown TAG warning not shown replacement available at no cost SIGN warning not shown replacement available at no cost TOOL needle 2 mm CAP spring PLUG Qty Ref No 48 49 50 Part No 198058 222385 188774 Description SCREW cap socket hd CARD warning not shown replacement available at no cost TAG warning not shown replacement available at no cost Included in Air Seal Repair Kit 244781 Rubber seal is not removable Qty Replacement Warning labels signs tags and cards are available at no cost 309295L Parts Part No 244573 85 kV Electrostatic Gun Series C items 1 59 See page 42 for detail views of the alternator 19 atomizing air 53 Ref adjustment valve 20 and ES ON OFF valve 22 51 Ref 22 3 ti1510d 9a 4 27a 309295L 41 Parts
39. or service page 25 2 Remove the power supply alternator assembly page 32 3 Disconnect the alternator from the power supply page 32 309295L Repair Measure resistance between the two outer termi nals of the 3 wire connector B it should be 2 5 3 5 ohms If outside this range replace the alternator Coil Follow the bearing replacement procedure in the bearing kit manual 308034 Install the alternator on the power supply page 32 Install the power supply alternator assembly page 32 33 Repair Atomizing 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 NOTE 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 FiG 19 4 Turn the valve stem 20d counterclockwise until it comes free from the valve housing 20c 5 Remove the o ring 20b 20c QN 20a Fig 19 Atomizing Air Adjustment Valve 34 6 Clean all parts and inspect for wear or damage NOTE Use non silicone grease Part No 111265 Do not over lubricate 7 When reassembling the atomizing air valve 20 lightly lubricate the valve threads and screw the stem 20d fully into the housing 20c until bot tomed Install the o ring 20b lubricate and unscrew the valve stem until the o ring enters the housing Reass
40. sed 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 44 1 4 npsm m x 1 4 npsm f left hand thread 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 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 5000 psi 850 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 Fluoroelastomer seals 210658 3 8 npt m Fluoroelastomer seals 210659 3 8 npt x 1 4 npt m Fluoroelastomer seals 214037 1 4 npt m PTFE seals Fluid Swivel 5800 psi 405 bar 40 MPa Maximum Working Pressure 115898 1 4 npsm m x 1 4 npsm f 309295L Gun Accessories Gun Repair Kit 244781 Air Seal R
41. spring PLUG SCREW cap socket hd CARD warning not shown replacement available at no cost TAG warning not shown replacement available at no cost SWITCH ES HI LO O RING PLUG LO voltage adjustment SCREW pivot SPRING grounding CIRCUIT flexible Included in Air Seal Repair Kit 244781 Rubber seal is not removable Parts Qty Replacement Warning labels signs tags and cards are available at no cost 43 Accessories Accessories Air Line Accessories AirFlex Flexible Grounded Air Hose 100 psi 7 bar 0 7 MPa Maximum Working Pressure 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 244963 6ft 1 8m 244964 15 ft 4 6 m 244965 25 ft 7 6 m 244966 36ft 11m 244967 50ft 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 6ft 1 8m 223069 15 ft 4 6 m 223070 25 ft 7 6 m 223071 36ft 11 m 223072 50 ft 15 m 223073 75 ft 23 m 223074 100 ft 30 5 m 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 left hand threads 236130 236131 3 ft 0 9 m 6 ft 1 8 m Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the pump air motor when clo
42. t 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 C 3 If the resistance is still outside the range remove 16a B the barrel contact ring 16a and measure the resis 4d uc tance between the conductive rod B and the wire lead at the bottom of the contact ring groove ti1515b 4 Ifthe 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 Fig 7 Test Barrel Resistance A 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 with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part C E 20 309295L Troubleshooting AWARNING Electric Shock Hazard v qualified Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is no
43. t performed properly Do not install or service this equipment unless you are trained and 8 Skin Injection Hazard To reduce the risk of a fluid injection injury always follow the Pressure Relief Proce dure on page 24 whenever you are instructed to relieve the pressure Troubleshooting A WARNING NOTE Check all possible remedies in the Troubleshoot ing Chart before disassembling the gun 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 Air cap holes plugged Clean See gun operation manual Tails in pattern Air pressure too low Open atomizing air adjustment valve Fluid pressure too low Increase Fluid buildup on air cap tip guard 309295L Air pressure too high Decrease Fluid pressure too low Increase 21 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog Atomizing air pressure too high Close atomizing air valve some or decrease air pressur
44. ting 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 18 Low fluid resistivity Check fluid resistivity See page 14 Fluid leaks from the fluid needle 26 packings and causes a short Clean the needle cavity Replace the fluid needle See page 30 Faulty turbine alternator 19 Be sure the plug is in place on the back of the turbine alternator hous ing Remove and test the turbine alternator See page 33 The KV HI LO lever is on LO Check the lever position replace if needed ES indicator or voltage current dis play is not lit ES ON OFF valve OFF 0 Turn ON I No power Repair replace alternator turbine replace power supply See page 32 Voltage current display stays red smart guns only Gun too close to part Should be 8 12 in 200 300 mm Check fluid resistivity See Check Fluid Resistivity on page 14
45. tool in and turn it coun terclockwise about 12 full turns to unthread the nee dle 7 Using the u shaped tool 37 pull back on the pack ing nut N to remove the fluid needle assembly See FiG 14 8 Install the fluid needle assembly in the gun barrel Push in on the needle with the 2 mm driver 44 and tighten See FiG 15 9 Install the spring 26a 10 Install the spring cap 45 making sure the ground ing spring 55 is in place 11 Install the trigger 30 and screws 8 12 Install the barrel 16 page 31 N 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 26 14 Test gun resistance page 18 30 TI1618A Fig 13 Spring Cap and Springs Fig 15 Fluid Needle Replacement 309295L Repair Barrel Removal 2 Place the barrel 16 over the power supply 18 and onto the gun handle 17 1 Prepare the gun for service page 25 3 Tighten the three screws 11 oppositely and evenly about a half turn past snug 2 Carefully loosen the nut C from the bracket fluid fit ting 13 See Fia 16 3 Loosen the three screws 11 N CAUTION Do not over tighten the screws 11 N CAUTION To avoid damaging the power supply 18 pull the gun barrel straight away from the gun handle If nec essary gently mo
46. top spraying Follow the Pressure Relief Procedure page 24 when you stop spraying and before cleaning checking or repairing equipment e 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 4 309295L Warning AM WARNING 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 e Wear appropriate protective clothing gloves eyewear and respirator 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 e 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 e Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system
47. ve the gun barrel from side to side to free it from the gun handle 4 Make sure the fluid filter 1 is in place in the fluid fit ting Tighten the bottom fluid tube nut C onto the bracket 13 fluid fitting and torque to 20 30 in Ib 2 3 3 4 Nem Make sure the top nut remains tight 4 Hold the gun handle 17 with one hand and pull the N CAUTION barrel 16 straight off the handle J Be sure the fluid tube 14 is not twisted after tighten 4 ing the bottom nut C 5b Test gun resistance page 18 Fig 16 Barrel Removal Fig 17 Barrel Installation Barrel Installation 1 Besure the gasket 10 FiG 17 and grounding spring 55 FiG 13 are in place and the gasket air holes are aligned properly Replace if damaged 309295L 31 Repair Power Supply Removal and Replacement NOTE e 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 31 N 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 sup ply 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
48. zard system to assist in relieving fluid pressure in the displacement pump hose and gun Trig gering 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 seri ous injury including fluid injection and splashing in the eyes or on the skin R The fluid drain valve U is reguired in your 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 309295L Installation Filter the Fluid Install a fluid filter K at the pump outlet to remove parti cles and sediment which could clog the spray tip The gun includes an inline fluid filter 1 for additional fil tration Select a Spray Tip A WARNING Skin Injection Hazard always follow the Pressure Relief Proce dure page 24 before removing or installing the spray tip air cap or tip guard To reduce the risk of a fluid injection injury 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 46 as a guide for selecting the appropriate spray tip for your application Refer to the gun operation manual to install the spray tip 11 Installation Grounding A WARNING Fire Explosion and Electri
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