Graco Inc. 309292S Paint Sprayer User Manual
Contents
1. Glass reinforced acetal construction j T Air cap 24A439 must be used with a 2 0 mm 0 080 in nozzle 10 Also available in the following colors 24A276 blue 24A277 red 24A278 green 244919 HC Conversion Kit Part No 244919 Conversion Kit converts PRO Xs3 stan dard coating guns Part Nos 244400 and 244579 to high conductivity guns 244575 and 244576 For further instruction and parts see manual 309453 The kit is for use with fluids with low resistivity values Ah WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the tan Pressure Relief Procedure in your gun manual before installing this kit 1 Turn the ES ON OFF valve OFF 2 Flush and relieve the pressure 3 Disconnect the fluid and air lines to the gun 3092925 10 11 Remove the fluid tube and fittings Remove the fluid inlet bracket Install the new bracket 3 from the kit loosely See FIG 3 Place the spacer 5 in the barrel inlet Apply Graco dielectric grease 4 to the o rings 2a 2b and to both threads of the fluid fitting 2 Thread the fitting into the barrel inlet Thread the nut 1d onto the fitting 2 Make sure the ferrules 1c and 1b are on the tube 1a and are seated on the fitting 2 before tightening the nut 1d Slide the tube case 1e onto the barrel inlet over the o ring 2b The coiled tube 1a will compress slightly Insert the end of the2. 1 Connect the Graco Grounded Air Supply Hose R between the air supply line and the gun s air inlet V The gun air inlet fitting has a left hand thread Connect the air supply hose ground wire Q to a true earth ground 2 Install an air line filter water separator O on the gun air line to ensure a dry clean air supply to the gun Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction 3 Install a bleed type air regulator G on the pump and gun air supply lines to control air pressure to the pump and gun 4 Install a bleed type air valve E on the pump air line to shut off air to the pump Install an additional bleed type air valve C on the main air line A to isolate the accessories for servicing Ah WARNING Pressurized Equipment Hazard The bleed type air valve E is required in your system to relieve air trapped between aia 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 splashing fluid in the eyes or on the skin Installation 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 Connect the Fluid Line 1 Before connecting the fluid
3. VALVE electrostatics ON OFF includes 22a 22g O RING CV75 O RING fluoroelastomer SHAFT valve PLATE retaining WASHER PIN KNOB Qty 3092925 Ref No 23 23a 23b 23c 23d 24 24a 25 26 26a 26b 26c 26d 26e 26f 26g 26h 27 27a 28 29 30 gis 32 35 Part No 244559 197594 197591 111504 101021 249323 112085 244593 244597 244521 111316 116905 178409 178763 197641 185495 186069 244695 244696 244927 198307 276695 276697 277007 276698 110077 110079 244834 3092928 Description VALVE air atomizing includes 23a 23d HOUSING valve SHAFT O RING fluoroelastomer RING retaining VALVE exhaust includes 24a O RING fluorocarbon VALVE adjustment fluid ROD packing used on 244400 and 244575 includes 26a 26h ROD packing used on 244401 includes 26a 26h O RING fluoroelastomer SEAL SPREADER packing UHMWPE PACKING rod acetal NUT packing HOUSING packing SPACER packing acetal ROD packing used on 244400 and 244575 ROD packing used on 244401 RING retaining includes 27a PACKING u cup HOOK NEEDLE electrode NEEDLE electrode used on HC guns models 244575 and 244576 TRIGGER FERRULE tube fluid used on 244400 and 244401 NUT tube fluid used on 244400 and 244401 SWIVEL air 1 4 npsm m left hand threads Qty 1 Ref
4. T 8 E 7 R Non Hazardous Area The air supply to the gun must be electri de gta cally interlocked with N the ventilators to pre ii Q vent the power supply Xx from operating without T ventilating fans on Hazardous Area Fig 2 Typical Installation Key A B T OZ 2 TF Xx Main Air Supply Line Ventilation Fan Interlock Solenoid Valve Main Air Supply Shutoff Valve bleed type Pump 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 Fluid Supply Line Gun Air Line Filter Water Separator Gun Air Supply Line Shutoff Valve ti1498a Air Hose Ground Wire Graco Grounded Air Hose Electrostatic Air Spray Gun Air Line Drain Valve Fluid Drain Valve Gun Air Inlet Gun Fluid Inlet Required for safe operation Must be purchased separately NOTE Solenoid valve B is not offered as a Graco accessory 3092925 Connect the Air Line Ah WARNING Electric Shock Hazard gt To reduce the risk of electric shock or other ly serious injury the air supply hose must be electrically connected to a true earth ground Use only Graco Grounded Air Supply Hose
5. 27a is in place with the lips facing forward 7 Test gun resistance page 18 ti1501a Fig 11 Air Cap Nozzle Replacement 26 3092925 Electrode Replacement 1 Prepare the gun for service page 25 2 Remove the air cap and nozzle page 26 3 Unscrew the electrode 29 with the multi tool 37 Hold the packing rod end 26h to prevent it from turning FIG 12 CAUTION To avoid damaging the plastic threads be very careful when installing the electrode 4 Apply low strength purple Loctite or equivalent thread sealant to the electrode and packing rod threads Install the electrode finger tight Do not overtighten 5 Install the fluid nozzle and air cap page 26 6 Test gun resistance page 18 3092925 Repair ia ti1502a Fig 12 Electrode Replacement 27 Repair Fluid Packing Removal 1 Prepare the gun for service page 25 2 Remove the air cap and fluid nozzle page 26 3 Remove the electrode page 27 4 Loosen the trigger screws 8 and trigger 30 See FIG 13 5 Remove the packing rod 26 using the multi tool 37 CAUTION Clean all parts in non conductive solvent compati ble with the fluid being used such as xylol or min eral spirits Use of conductive solvents can cause the gun to malfunction 6 Check all parts for wear or damage and replace if necessary 28 Fig 13 Fluid Packing Removal TI1549A 3092
6. Fig 7 Test Power Supply Resistance 3092925 19 Electrical Tests Test Electrode Resistance 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 Measure the resistance between the conductive rod B and the electrode 29 The resistance should be 20 30 megohms See FIG 8 If in range refer to Electrical Troubleshooting on page 23 for other possible causes of poor perfor mance or contact your Graco distributor Remove the electrode 29 page 27 Measure the resistance between the contact E and the elec trode wire F The resistance should be 20 30 meg ohms If out of range replace the electrode See FIG 9 Make sure the metal contact C in the barrel the nozzle contact ring 7a FIG 10 and the electrode contact E are clean and undamaged 1 APE ti1499a Fig 8 Test Electrode Resistance 20 DALI F 29 E dd ho Fig 9 Electrode Fig 10 Nozzle Conductive O Ring ti1548a 3092925 Troubleshooting Troubleshooting PINAG NINE Ah WARNING Electric Shock Hazard Pressurized Equipment Hazard Installing and servicing this equipment To reduce the risk of an injury follow the na are trained and qualified install or repair this equipment unless you requires
7. Installing and repairing this equipment ul requires access to parts that may cause ba 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 Ah WARNING Pressurized Equipment Hazard To reduce the risk of injury follow the Pres s sure Relief Procedure on page 24 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure 3092925 Repair Check all possible remedies in Troubleshooting before disassembling the gun Use a vise with padded jaws to prevent damage to plastic parts Lubricate the power supply o ring 18a some pack ing rod parts 26 and certain fluid fittings with dielectric grease 40 as specified in the text Lightly lubricate o rings and seals with non silicone grease Order Part No 111265 Lubricant Do not over lubricate Only use genuine Graco parts Do not mix or use parts from other PRO Gun models Air Seal Repair Kit 244781 is available The kit must be purchased separately Kit parts are marked with an asterisk for example 6 Fluid Seal Repair Kit 244911 is available The kit must be purchased separately Kit parts are marked with a double asterisk for example 5 Flush the gun page 16 Relieve the pressure page 24 Disconnect the gun air and fluid lines Remove the gun from the worksite Repair area mu
8. No 36 37 38 39 40 41 424 434 47 48 49 49a 49b 50 50a 50b 50c 50d 50e 50f 55 56 Part No 107460 276741 185103 110231 116553 244915 179791 180060 197967 198058 245211 116768 157277 244918 198302 111286 111285 112644 198270 198271 197624 24A431 Description 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 replace ment available at no cost SIGN warning not shown replace ment available at no cost PLUG SCREW cap socket hd FITTING fluid used on 244575 includes 49a 49b O RING O RING TUBE fluid used on 244575 includes 50a 50f TUBE fluid coiled FERRULE front FERRULE back NUT CASE tube CAP end SPRING grounding KIT wide pattern not shown Included in Air Seal Repair Kit 244781 Included in Fluid Seal Repair Kit 244911 Rubber seal is not removable Parts Qty Optional replacement Electrode Needle 277007 is available for abrasive materials A Replacement Warning labels signs tags and cards are available at no cost 39 Parts Part Nos 244579 and 24A511 60 kV Electrostatic Gun Series C items 1 48 51 59 Part No 244576 60 kV Electrostatic Gun Series C items 1 30 35 59 Part No 244580 85 kV Electrostatic Gun Series C items 1 48 51 59 See page 41 for detai
9. air valve UHMWPE NOZZLE 1 5 mm orifice includes 7a and 7b O RING conductive O RING fluoroelastomer SCREW trigger AIR CAP GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm BRACKET inlet fluid used on 244400 and 244401 BRACKET inlet fluid used on 244575 TUBE fluid used on 244400 TUBE fluid used on 244401 SPRING compression BARREL gun used on 244400 and 244575 BARREL gun used on 244401 HANDLE gun includes item 28 used on 244400 HANDLE gun includes item 28 used on 244575 HANDLE gun includes item 28 used on 244401 Qty 4 Ref No 18 18a 18b 19 19a 19b 19c 19d 19e 20 20a 20b 20c 20d 94 22 22a 22b 22c 22d 22e 22f 229 Part No 244540 244541 103337 197624 244555 110073 223688 244577 111745 198821 244556 101021 106560 197566 197567 244557 244558 111516 113137 198403 198404 198453 198464 276753 Description POWER SUPPLY 60 kV used on 244400 and 244575 includes 18a 18d POWER SUPPLY 85 kV used on 244401 includes 18a 18b O RING fluoroelastomer SPRING compression TURBINE alternator includes 19a 19e O RING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure VALVE adjustment fan includes 20a 20d RING retaining O RING fluorocarbon HOUSING fan valve STEM fan valve VALVE air
10. into the gun handle using a wrench on the flats of the housing Torque to 15 25 in Ib 1 7 2 8 Nem NGO ne 33 Repair Fluid Adjustment Valve Repair 4 Remove the air valve 21 with a pliers Inspect the rubber sealing surface and replace the air valve if damaged 1 Prepare the gun for service page 25 2 Remove the fluid adjustment valve 25 It can only AN CAUTION be replaced as a complete assembly See FIG 20 When removing the air valve 21 be careful not to 3 Screw the valve 25 into the gun handle Torque to damage the seat area The rubber seal is not 15 25 in lb 1 7 2 8 Nem removable A 5 Inspect the u cup 6 Do not remove the u cup a NN unless damaged If removed install the new one 1 gt pa AW with its lips facing into the gun handle 17 Install the air valve 21 and spring 15 into the gun handle 17 7 Install the fluid adjustment valve 25 Torque to 15 25 in Ib 1 7 2 8 Nem SA 8 Install the barrel page 30 VAY ti1507a Fig 20 Fluid Adjustment Valve Air Valve Repair 1 Prepare the gun for service page 25 2 Remove the barrel page 30 3 Remove the fluid adjustment valve 25 from the handle 17 Remove the spring 15 See Fia 21 CAUTION te Fig 21 Air Valve Clean all parts in non conductive solvent compati ble with the fluid being used such as xylol or min eral spirits Use of conductive solv
11. 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 3092925 23 Repair Repair Pressure Relief Procedure 2 Turn off the air bleed valves to the fluid source and to the gun WARNING Pressurized Equipment Hazard The system pressure must be manually ta relieved to prevent the system from starting or spraying accidentally To reduce the risk 3 of an injury from electric shock accidental spray from the gun splashing fluid or mov ing parts follow the Pressure Relief Pro cedure whenever you Trigger the gun into a grounded metal waste con tainer to relieve the fluid pressure eare instructed to relieve the pressure estop spraying echeck or service any of the system equip 4 Open the pump drain valve having a waste con ment tainer ready to catch the drainage Leave the pump eor install or clean the fluid nozzle drain valve open until you are ready to spray again 1 Turn the ES ON OFF valve OFF 5 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 24 309292S Prepare the Gun for Service Ah WARNING Electric Shock Hazard
12. the nut 32 5 Test gun resistance page 18 ti1506a Fig 16 Barrel Installation 309292S Power Supply Removal and Replacement 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 30 ZA CAUTION Be careful when hanaling 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 handle 17 See Fla 17 4 Disconnect the 3 wire connector GG from the power supply Slide the alternator up and off the power supply Inspect the power supply and alterna tor for damage On Smart Models only disconnect the 6 pin flexible circuit 59 from the power supply 5 Check the power supply resistance page 19 Replace if necessary Before installing the power supply make sure the o rings 18a 19a spring 18b and pads 19e are in place 6 On Smart Models only connect the 6 pin flexible cir cuit 59 to the power supply 7 Connect the 3 wire connector GG Slide the alter nator 19 down onto the power supply 18 3092925 Repair 8 Lubricate the alternator o r
13. 925 Packing Rod Repair You may replace the packing rod as individual parts or as an assembly The assembly is pre adjusted at the factory Before installing the fluid packing rod into the gun barrel make sure the internal surfaces of the barrel are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arc ing If marks are present replace the barrel To assemble the individual parts 1 Place the packing nut 26e and seal 26b on the fluid rod 26h Flats on the packing nut must face the back of the fluid rod The seal o ring must face away from the packing nut See FIG 14 2 Fill the inner cavity of the spacer 26g with dielec tric grease 40 Place the spacer on the fluid rod 26h in the direction shown Generously apply dielectric grease to the outside of the spacer 3 Place the rod packing 26d packing spreader 26c and housing 26f on the packing rod 26h Fig 14 Packing Rod 3092925 11 Repair Lightly tighten the packing nut 26e The packing nut is properly tightened when there is 3 Ib 13 3 N of drag force when sliding the packing housing 26f assembly along the rod Tighten or loosen the pack ing nut as needed Install the o ring 26a on the outside of housing 26f Lubricate the o ring with non silicone grease Part No 111265 Do not over lubricate Install the spring 4 against the nut E as shown In
14. AG Been ees eb 12 Check Electrical Grounding 13 Check Fluid Resistivity 14 Check Fluid Viscosity 14 Operation ito aa Sain oe ee 15 Low Voltage Adjustment Smart Guns Only 15 Maintenance eee ee eee eee 16 Flush the Spray Gun 00000 16 Electrical Tests ooooooommmmmmmmo o 18 Test Gun Resistance 18 Test Power Supply Resistance 19 Test Electrode Resistance 20 Troubleshooting 002 eee eee e eee eee 21 Spray Pattern Troubleshooting 21 Gun Operation Troubleshooting 22 Electrical Troubleshooting 23 2 Repaint ARENE Bana eee a ane lod ka 24 Pressure Relief Procedure 24 Prepare the Gun for Service 25 Air Cap Nozzle Replacement 26 Electrode Replacement 27 Fluid Packing Removal 28 Packing Rod Repair aa 29 Barrel Removal o 30 Barrel Installation AA 30 Power Supply Removal and Replacement 31 Turbine Alternator Removal and Replacement 32 Fluid Tube Removal and Replacement PRO Xs4 Guns Only paan k aha ora Pha te 32 Fan Air Adjustment Valve Repair 33 Fluid Adjustment Valve Repair 34 Air Valve Repair a 34 Atomizing Air Restrictor Valve Removal and Replacement a 35 ES ON OFF Va
15. ING fluoroelastomer BEARING KIT includes front and rear bearings and fan COIL RING retaining PAD pressure VALVE adjustment fan includes 20a 20d RING retaining O RING fluorocarbon HOUSING fan valve STEM fan valve VALVE air VALVE electrostatics ON OFF includes 22a 22g O RING CV75 O RING fluoroelastomer SHAFT valve PLATE retaining WASHER PIN KNOB VALVE air atomizing includes 23a 23d HOUSING valve SHAFT O RING fluoroelastomer RING retaining VALVE exhaust includes 24a O RING fluorocarbon VALVE adjustment fluid ROD packing used on 244579 and 244576 includes 26a 26h ROD packing used on 244580 includes 26a 26h O RING fluoroelastomer SEAL SPREADER packing UHMWPE Qty DO ee LA ee de aY h A e ee a a gt mb mh mb N gt a 3092925 Ref No 26d 26e 26f 269 26h 27 27a 28 29 30 aie 32 35 36 37 38 39 40 41 424 43a 47 48 Part No 178763 197641 185495 186069 244695 244696 244927 198307 276695 276697 277007 276698 110077 110079 244834 107460 276741 185103 110231 116553 244915 179791 180060 197967 198058 3092928 Description PACKING rod acetal NUT packing HOUSING packing SPACER packing acetal ROD packing used on 244579 and 244576 ROD packing used on 244580 RING retaining ai
16. Instructions GQ GRACO Manual Electrostatic PRO Xs3 and PRO Xs4 Air Spray Guns 309292S ENG For use in Class I Div hazardous locations using Group D spray materials M APPROVED For use in Group Il Zone 1 areas using Group IIA spray materials CE buzaerxo2m For Professional Use ONLY Important Safety Instructions Mi Read all warnings and instructions in this manual Save these instructions See page 2 for Table of Contents and page 3 for List of Models 100 psi 0 7 MPa 7 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Maximum Working Fluid Pressure U S Patent 7 226 004 Smart Model N ti1600a Standard Model ti1248a HO03 PROVEN QUALITY LEADING TECHNOLOGY Table of Contents List of Models ooo oooooooooomoo o 3 WarningS eco ae ae ed 4 Warning Symbol 00 eee e eee 4 Caution Symbol eee eee eee 4 Introduction 00 cece eee eee eee eee 6 How the Electrostatic Air Spray Gun Works 6 Gun Overview 0 0 0 cece eee 6 Installation a ve ak eae eee ke ees 7 Install the System 0A 7 Warning Sign 7 Ventilate the Spray Booth 7 Connect the Air Line oooo 9 Connect the Exhaust Tube 9 Connect the Fluid Line 9 Filter the Fluid 00 9 Selecta Fluid Nozzle and Air Cap 10 244919 HC Conversion Kit 10 Grounding puna a N
17. MPa 2 8 bar needed at gun for full voltage Fluid too thin Increase viscosity Orange Peel finish Atomizing air pressure too low Open atomizing air valve more or increase gun air inlet pressure use lowest air pressure necessary Poorly mixed or filtered fluid Remix or refilter fluid Fluid too thick Reduce viscosity Fluid leaks from the fluid packing area Worn packings or rod Replace packings or rod see page 29 Air leaks from the front of the gun Air valve 21 is not seating properly Clean and service air valve see page 34 Fluid leakage from the front of the gun Worn or damaged packing rod 26 Replace see page 29 Worn fluid seat Replace fluid nozzle and or electrode needle see pages 26 to 27 Loose fluid nozzle 7 Tighten see page 26 Damaged nozzle o ring 7b Replace see page 26 Gun does not spray Low fluid supply Add fluid if necessary Damaged air cap 9 Replace see page 26 Dirty or clogged fluid nozzle 7 Clean see page 26 Damaged fluid nozzle 7 Replace see page 26 Damaged fluid adjustment valve 25 Replace see page 34 Dirty air cap Misaligned air cap 9 and fluid noz zle 7 Clean fluid buildup off air cap and fluid nozzle seat see page 26 22 3092925 Electrical Troubleshooting Troubleshooting Problem Cause S
18. a non hazard ous area only Resistance Meter 722886 and Probe 722860 are not approved for use W in a hazardous area W Failure to follow this warning could cause fire explosion or electric shock and result in serious injury and property damage Graco Part No 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the require ments of an electrostatic air spray system Follow the instructions included with the meter and probe Readings of 25 megohms cm and above provide the best electrostatic results 14 Check Fluid Viscosity To check fluid viscosity you will need e aviscosity cup e astopwatch 1 Completely submerge the viscosity cup in the fluid Lift the cup out quickly starting the stopwatch as soon as the cup is completely removed 2 Watch the stream of fluid coming from the bottom of the cup As soon as there is a break in the stream shut off the stopwatch 3 Record the fluid type elapsed time and size of the viscosity cup 4 If the viscosity is too high or too low contact the material supplier Adjust as necessary 309292S Operation BA Refer to the gun operation manual supplied for Setup Shutdown and Daily Care proce dures INSTRUCTIONS 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 vo
19. access to parts which may cause it Pressure Relief Procedure on page 24 an electric shock or other serious injury if the work is not performed properly Do not whenever you are instructed to relieve the pressure Spray Pattern Troubleshooting Some spray pattern problems are caused by the improper balance between air and fluid Check all possible remedies in the Troubleshooting Chart before disassembling the gun Problem Cause Solution Fluttering or spitting spray No fluid Refill supply Loose dirty damaged nozzle seat Clean or replace nozzle page 26 Air in fluid supply Check fluid source Refill Improper spray pattern Damaged nozzle or air cap Replace page 26 Fluid buildup on air cap or nozzle Clean See Operation Manual A 2 Fan air pressure too high Decrease Fluid too thin Increase viscosity Fluid pressure too low Increase Fan air pressure too low Increase o Fluid too thick Reduce viscosity Too much fluid Decrease flow Streaks Did not apply 50 overlap Overlap strokes 50 Dirty or damaged air cap Clean or replace page 26 3092925 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog Atomizing air pressure too high Close restrictor valve some or decrease air pressure as low as pos sible minimum 40 psi 0 28
20. aterials A 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 15ft 4 6m 244965 25ft 7 6m 244966 36ft 11 m 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 6tft 1 8m 223069 15 ft 4 6 m 223070 25 ft 7 6 m 223071 36ft 11 m 223072 50ft 15 m 223073 75 ft 23 m 223074 100 ft 30 5 m Bleed Type Master Air Valve 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between this valve and the pump air motor when closed 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 swive
21. coiled tube 1a into the bracket 3 Make sure the ferrules 1c 1b seat on the bracket Secure the bracket by tightening the swivel A Tighten the nut 1d Reinstall the exhaust tube B and clamp C 3092925 Installation 12 Reconnect the fluid and air lines to the gun ti10674a FIG 3 244919 Conversion Kit 11 Installation Grounding WARNING Fire Explosion and Electric Shock Hazard When operating the electrostatic gun any y ungrounded objects in the spray area peo ple containers tools etc can become W electrically charged Improper grounding can result in static sparking which can W 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 e Pump ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual e Electrostatic Air Spray Gun ground the gun by con necting the Graco Grounded Air Hose and connect ing the air hose ground wire to a true earth ground See Check Electrical Grounding page 13 e Air compressors ground the equipment according to the manufacturer s recommendations e All air and fluid lines mu
22. ction when operating this equipment e Comply with all applicable local state and national fire electrical and other safety regulations a Pressurized Equipment Hazard E49 Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury e Do not point the spray gun at anyone or at any part of the body e Donot stop or deflect fluid leaks with your hand body glove or rag e Follow the Pressure Relief Procedure page 24 when you stop spraying and before cleaning checking or repairing equipment e Check hoses and couplings daily Replace worn damaged or loose parts immediately e Tighten all fluid connections before each use 3092925 5 Introduction Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed The turbine generates power which is converted by the power cartridge to supply high volt age current to the gun s electrode The pump supplies fluid to the hose and gun where the fluid is electrostatically charged as it passes the elec trode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all sur faces Gun Overview The electrostatic gun includes the following controls see FIG 1 e FLUID adjustment valve Adjusts fluid rod travel Use only in lo
23. ctri cal grounding unless eThe gun has been removed from the haz ardous area eOr 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 SER Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose Turn the ES ON OFF valve OFF Turn off the air and fluid supply to the gun The fluid hose must not have any fluid in it 30929258 Installation Make sure the grounded air hose R is connected and the hose ground wire is connected to a true earth ground 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 4 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 LE Bs a a N F pud I po gt Fig 4 Check Gun Grounding 13 Installation Check Fluid Resistivity WARNING Fire Explosion and Electric Shock Hazard Check the fluid resistivity in
24. d Operating Temperature Paint Resistivity Range Short Circuit Current Output Voltage Output Sound Power measured per ISO Standard 9216 Sound Pressure measured 1 m from gun Air inlet fitting left hand thread Fluid inlet fitting Gun Weight Gun Length Wetted Parts Data 100 psi 0 7 MPa 7 bar 100 psi 0 7 MPa 7 bar 40 psi 0 28 MPa 2 8 bar 120 F 48 C 3 megohm cm to infinity 125 microamperes PRO Xs3 244400 244575 60 kV PRO Xs3 244579 244576 30 60 kV PRO Xs4 244401 85 kV PRO Xs4 244580 40 85 kV at 40 psi 0 28 MPa 2 8 bar 90 4 dB A at 100 psi 0 7 MPa 7 bar 105 4 dB A at 40 psi 0 28 MPa 2 8 bar 87 dB A at 100 psi 0 7 MPa 7 bar 99 dB A 1 4 npsm m 3 8 npsm m PRO Xs3 25 1 oz 712 g PRO Xs4 27 8 oz 788 g PRO Xs3 9 7 in 24 6 cm PRO Xs4 11 1 in 28 2 cm Stainless Steel Nylon Acetal Ultra High Molecular Weight Polyethylene Fluoroelastomer PEEK Tungsten Wire Polyethylene Loctite is a registered trademark of the Loctite Corporation 46 309292S Technical Data 3092925 47 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Grac
25. d to ISO 9001 www graco com Revised 06 2010
26. e barrel 16 3 Apply dielectric grease 40 to the threads of the fit ting 1 the o ring 5 and the sleeve S of the fluid tube 14 4 Slide the fitting 1 onto the fluid tube 14 and thread the fitting into the barrel 16 5 With the ferrules 31 seated to the bracket 13 screw the nut 32 onto the bracket ili Das 31 Fig 18 PRO Xs4 Fluid Tube 3092925 Fan Air Adjustment Valve Repair 1 Prepare the gun for service page 25 2 Place a wrench on the flats of the valve assembly 20 and unscrew it from the handle 17 You may replace the valve as an assembly go to step 9 or as individual parts steps 3 9 3 Remove the retaining ring 20a See FiG 19 4 Turn the valve stem 20d counterclockwise until it comes free from the valve housing 20c 5 Remove the o ring 20b 20b 20c 0 20a o D Fig 19 Fan Air Adjustment Valve 3092925 20d Repair Clean all parts and inspect for wear or damage Use non silicone grease Part No 111265 Do not over lubricate When reassembling the fan air valve 20 lightly lubricate the valve threads and screw the stem 20d fully into the housing 20c until bottomed Install the o ring 20b lubricate and unscrew the valve stem until the o ring enters the housing Reassemble the retaining ring 20a Unscrew the valve stem from the housing until it is stopped by the retaining ring Screw the valve assembly 20
27. ents can cause the gun to malfunction 34 3092925 Atomizing Air Restrictor Valve Removal and Replacement 1 Prepare the gun for service page 25 2 Remove the atomizing air restrictor valve 23 Inspect the o ring 23c Replace if necessary See FIG 22 3 Install a new atomizing air restrictor valve 23 or disassemble and replace parts individually The valve protrusion must be oriented to clear the air valve 21 shaft If the atomizing air restrictor valve is not desired install the supplied plug 47 D Torque the valve housing 23a to 15 20 in Ib 1 7 2 3 Nem 23b ti1508a Fig 22 Atomizing Air Restrictor Valve 3092925 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 rings 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 4 Clean and inspect parts for damage Replace if nec essary 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 22d 2 _ 229 22e N Y 22b N KI Fig 23 ES ON OFF Valve 35 Parts Parts Part No 244400 60 kV Electrostatic Gun Series C items 1 48 55 Par
28. ers or fumes from spraying Failure to follow this warning could cause fire explosion and electric shock and result in serious injury and property damage 18 Test Gun Resistance 1 Flush and dry the fluid passage 2 Measure resistance between the electrode needle tip 29 and the air swivel 35 it should be 117 137 megohms for the PRO Xs3 and 156 180 megohms for the PRO Xs4 If outside this range go to the next test If in range refer to Electrical Troubleshooting on page 23 for other possible causes of poor perfor mance TI1468A Fig 6 Test Gun Resistance 3092925 Electrical Tests Test Power Supply Resistance 6 Be sure the spring 18b is in place before reinstall ing the power supply 1 Remove the power supply 18 page 30 2 Remove the turbine alternator 19 from the power supply page 31 DANE 3 Measure resistance from the power supply s ground strips EE to the spring 18b See FIG 7 4 The resistance should be 95 105 megohms for the PRO Xs3 and 135 150 megohms for the PRO Xs4 If outside this range replace the power supply If in 18b EE range proceed to the next test Pd 5 If you still have problems refer to Electrical Trou Cad bleshooting on page 23 for other possible causes i __ 1599a of poor performance or contact your Graco distribu tor
29. ic hazards of the fluid you are using Read the fluid manufacturer s warnings e 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 A 3092925 Warnings IWS 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 air and fluid pressure of this equipment is 100 psi 0 7 MPa 7 0 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 e Do not kink or overbend hoses or use hoses to pull equipment e Wear hearing prote
30. ing 19a with non sili cone grease Part No 111265 Do not over lubri cate 9 Lubricate the power supply o ring 18a with dielec tric grease 40 10 Insert the power supply alternator assembly in the gun handle 17 Make sure the ground strips make contact with the handle On Smart Models only con nect the flexible circuit 59 to the socket at the top of the handle Push the 6 pin connector into the socket to ensure it is properly connected 11 Install the barrel 16 page 30 12 Test gun resistance page 18 ti1505c 18a 18b Fig 17 Power Supply 31 Repair Turbine Alternator Removal and Replacement Replace turbine alternator bearings after 2000 hours of operation Order Part No 223688 Bearing Kit 1 Prepare gun for service page 25 2 Remove the power supply alternator assembly page 31 3 Disconnect the alternator from the power supply page 31 4 Measure resistance between the two outer termi nals of the 3 wire connector GG it should be 2 5 3 5 ohms If outside this range replace the alter nator coil 5 Follow the bearing replacement procedure in the bearing kit manual 308034 6 Install the alternator on the power supply page 31 7 Install the power supply alternator assembly page 31 32 Fluid Tube Removal and Replacement PRO Xs4 Guns Only 1 Remove the nut 32 from the bracket 13 2 Loosen the fitting 1 to remove the fluid tube 14 from th
31. l to provide extended handle grip area Left hand thread Fluid Line Accessories Fluid Hose 225 psi 14 bar 1 4 MPa Maximum Working Pressure FM Approved nylon 3 8 npsm fbe 215637 1 4in 6 mm ID x 25 ft 7 6 m 215638 1 4 in 6 mm ID x 50 ft 15 2 m Fluid Shutoff Drain Valve 500 psi 35 bar 3 5 MPa Maximum Working Pressure For turning fluid on or off to the gun and for relieving fluid line pressure at the pump 208630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids Fluid Swivel 5800 psi 405 bar 40 MPa Maximum Working Pressure 115898 1 4 npsm m x 1 4 npsm f 309292S Gun Accessories Gun Repair Kits 244781 Air Seal Repair Kit 244911 Fluid Seal Repair Kit Round Pattern Kits Consists of fluid tip diffuser and air cap 245217 4 6 in 102 152 mm diameter 245219 8 10 in 203 254 mm diameter Adjustable Round Pattern Kit 277851 Slow velocity bell shaped spray pattern for excellent transfer efficiency Pattern is adjustable from 6 12 in Push Pull Fan Air Valve 244912 For quick change of fan size ES Always On Kit 244913 Replaces inlet fitting with ball valve to shut off air during flushing Converts ES ON OFF valve to always ON condition Handle Grips 245263 Medium Grip 245264 Large Grip Gun Washer Kit 245270 Use to convert Graco gun washers so they can clean PRO Xs3 and PRO Xs4 air spray guns Pressure Cups Includes air regulators for gun atomi
32. l views of the fluid tube assemblies alterna tor 19 fan adjustment valve 20 ES ON OFF valve 22 and packing rod 26 28 15 PI 21 kkk FH IN OY dd we 40 309292S Ref No 19 Alternator Parts Ref No 20 Fan Adjustment Valve 19d 19c Ref No 22 ES ON OFF Valve 22f 22e O 22 22b Ng 29 22 a a O N a ae pa A a Y A par 48 26a Fluid Tube Model 244579 Fluid Tube Model 244576 pr Nd 1 of a DAS O a 14 N na 31 30929258 xx NG Ng Ref No 26 Packing Rod 26h 26e 26b 269 26d Fluid Tube Model 244580 50a 50f 50d 50b 50c 41 Parts Part No 244579 and 24A511 60 kV Electrostatic Gun Series C items 1 48 51 59 Part No 244576 60 kV Electrostatic Gun Series C items 1 30 35 59 Part No 244580 85 kV Electrostatic Gun Series C items 1 48 51 59 Ref No 1 5 6 7a 7b 10 11 13 14 15 16 17 18 18a 18b 42 Part No 110078 198587 185111 185120 102982 188749 197266 197265 111261 111507 197369 24A376 197517 197518 15M678 15M679 197588 244574 185116 244395 244394 245291 289278 245287 244540 244541 103337 197624 Description FITTING tube fluid used on 244579 FITTING tube fluid used on 244580 SPRING compression SPACER fluid nylon used on 244579 and 244576 O RING
33. line N blow it out with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed 2 Install a fluid regulator M on the fluid line to control fluid pressure to the gun 3 Install a fluid filter K and drain valve U at the pump outlet Ah WARNING Pressurized Equipment Hazard The fluid drain valve U is required in your system to assist in relieving fluid pressure in the displacement pump hose and gun Triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including splashing in the eyes or on the skin CE 3092925 4 Connect the fluid line to the 3 8 npsm gun fluid inlet W 5 Before running any paint through the spray gun flush it out with a compatible solvent Filter the Fluid Install a fluid filter K to remove particles and sediment which could clog the spray nozzle Installation Select a Fluid Nozzle and Air Cap The gun is supplied with Part No 197266 Nozzle and 24A376 Air Cap If you require a different size refer to Table 1 and Table 2 and instruction manual 309419 or consult with your Graco distributor See Air Cap Nozzle Replacement on page 26 A wide pattern kit P N 24A431 is included with the gun and if installed will provide more fan air for wider spray patterns If pattern becomes split use the fan air valve t
34. losion e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements of this manual e Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions e Only use grounded Graco conductive air supply hoses e Check gun and hose resistance and electrical grounding daily e Use and clean equipment only in well ventilated area e Interlock the gun air supply to prevent operation unless ventilating fans are on e Use cleaning solvents with highest possible flash point when flushing or cleaning equipment e To comply with EN50050 cleaning solvents must have a flash point at least 5 C above ambient temperature e Always turn the electrostatics off when flushing cleaning or servicing equipment e If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e Do not plug or unplug power cords or turn lights on or off when flammable fumes are present e Keep work area free of debris including solvent rags and gasoline e Keep a working fire extinguisher in the work area D4 Toxic Fluid Hazard AR Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin swallowed or inhaled e Know the specif
35. ltage is factory set but can be adjusted 1 Set the ES HI LO switch to LO 2 Remove the LO VOLTAGE adjustment plug 53 Set the desired voltage using a small screwdriver to slide switches 1 and 2 ON or OFF according to Table 3 Also see FIG 5 ti1529a Operation Fig 5 Low Voltage Adjustment Switches Table 3 Low Voltage Adjustment 60 kV Guns 85 kV Guns 1 2 kV 1 2 kV ON ON 50 ON ON 70 ON OFF 40 ON OFF 60 Patak OFF TON 35 OFF ON 50 OFF OFF 30 OFF OFF 40 3092925 15 Maintenance Maintenance Refer to the gun operation manual supplied o for Daily Care and Cleaning procedures INSTRUCTIONS Flush the Spray Gun 1 Turn the ES ON OFF valve OFF Flush the gun before changing colors at the end of the y aka day before storing and before repairing the gun L WARNING WARNING Fire Explosion and Electric Shock Hazard To reduce the risk of fire explosion or elec 5 J si tric shock turn the ES ON OFF valve OFF Pressurized Equipment Hazard before flushing the gun To reduce the risk of an injury follow the W s Pressure Relief Procedure on page 24 whenever you are instructed to relieve the pressure y 2 Relieve the pressure A CAUTION Flush the gun with a non conductive compatible solvent Conductive solvents can cause the gun to malfunction 3 Change the fluid source
36. lve Repair 35 PAS aan 36 Accessories 0 0000 e ee eee eee eee 44 Air Line Accessories 44 Fluid Line Accessories 44 Gun Accessories aaa 45 Miscellaneous Accessories 45 Technical Data eee eee eens 46 Graco Standard Warranty oo oo ooo 48 Graco Information oooooooooooooo 48 3092925 List of Models List of Models Type of Coatings Part No Model pla Operation Manual pay Standard High Conductivity 244400 PRO Xs3 X 309294 3W9294 3Z9294 Series D 244579 PRO Xs3 Series D 1 5 mm nozzle X X 309294 3W9294 3Z9294 24A511 PRO Xs3 Series B 1 2 mm nozzle 244575 PRO Xs3 X 309294 3W9294 3Z9294 Series D 244576 PRO Xs3 X X 309294 3W9294 3Z9294 Series D 244401 PRO Xs4 X 309294 3W9294 3Z9294 Series D 244580 PRO Xs4 X X 309294 3W9294 3Z9294 Series D 309292S 3 Warnings Warnings Warning Symbol Caution Symbol WARNING 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 equipment if you do not follow the instruc tions Ah WARNING W Fire Explosion and Electric Shock Hazard Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent all fire and exp
37. ned 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 Grac
38. o reduce the amount of fan air WARNING Pressurized Equipment Hazard To reduce the risk of an injury follow the Table 2 Air Caps Pattern Shape Part No and Length in Recommended Fluids and Production Rates mm 24A438 Round end Light to medium viscosity 15 17 381 432 Up to 15 oz min 450 cc min Round end Medium to high viscosity and 248278 14 16 356 406 19 solids Up to 15 oz min 450 cc min 74A376 apered end Light to medium viscosity 17 19 432 483 Up to 15 oz min 450 cc min Tapered end 12 14 305 356 Light to medium viscosity 24A274 Up to 15 oz min 450 cc min Medium to high viscosity and high solids Up to 15 oz min 450 cc min For use with 2 0 mm nozzle Round end 24A439 11 13 279 330 Light to medium viscosity and high solids Aerospace coatings Tapered end 24A275 14 16 356 406 Up to 25 oz min 750 cc min s Pressure Relief Procedure on page 24 before removing or installing a fluid nozzle and or air cap Table 1 Fluid Nozzles Part No Orifice Size 197263 0 75 mm 030 in 197264 1 0 mm 042 in 197265 1 2 mm 047 in 197266 1 5 mm 055 in 197267 1 8 mm 070 in 1972681 2 0 mm 080 in 249920 0 75 mm 030 in 249921 1 0 mm 042 in 249922 1 2 mm 047 in 249923 1 5 mm 055 in 249924 1 8 mm 070 in 249925 t 2 0 mm 080 in
39. o 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 redaction du pr sente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intentes 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 make changes at any time without notice Original instructions This manual contains English MM 309292 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2001 Graco Inc is registere
40. o 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 retur
41. olution Poor wrap ES ON OFF valve OFF 0 Turn ON 1 Gun air pressure too low Check air pressure to gun minimum 40 psi 0 28 MPa 2 8 bar needed at gun for full voltage Atomizing air pressure too high Decrease Fluid pressure too high Decrease Incorrect distance from gun to part Should be 8 12 in 200 300 mm Poorly grounded parts Resistance must be 1 megohm or less Clean workpiece hangers Faulty gun resistance See Test Gun Resistance on page 18 Low fluid resistivity Check fluid resistivity page 14 Fluid leaks from the packing 26d and causes a short Clean the packing rod cavity Replace the packing rod See page 29 Faulty turbine alternator Be sure the plug is in place on the back of the power supply housing Remove and test the turbine alterna tor See page 32 The KV HI LO lever is on LO Check the lever actuation replace if needed ES indicator or voltage current dis play is not lit ES ON OFF valve OFF 0 Turn ON 1 No power Replace power supply See page 31 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 Dirty gun Clean See Operation Manual Operator gets mild shock Operator not grounded or is near ungrounded object See Grounding
42. r cap includes item 27a PACKING u cup HOOK NEEDLE electrode NEEDLE electrode used on HC guns models 244575 and 244576 TRIGGER FERRULE tube fluid used on 244579 and 244580 NUT tube fluid used on 244579 and 244580 SWIVEL air 1 4 npsm m 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 replace ment available at no cost SIGN warning not shown replace ment available at no cost PLUG SCREW cap socket hd Qty X 2 mm 3 gt o na gt 2 o 4 o a Ref No 49 245211 FITTING fluid used on 244575 includes 49a 49b 49a 116768 O RING 49b 157277 O RING 50 244918 TUBE fluid used on 244576 includes 50a 50f 50a 198302 TUBE fluid coiled 50b 111286 FERRULE front 50c 111285 FERRULE back 50d 112644 NUT 50e 198270 CASE tube 50f 198271 CAP end 51 244627 SWITCH ES HI LO 52 111450 O RING 53 276734 PLUG LO voltage adjustment 54 197910 SCREW pivot 55 197624 SPRING grounding 59 245265 CIRCUIT flexible 60 24A431 KIT wide pattern not shown Part No Description Included in Air Seal Repair Kit 244781 Included in Fluid Seal Repair Kit 244911 Rubber seal is not removable Parts Qty mb hh 24 mb 2 4 4 NN N Optional replacement Electrode Needle 277007 is available for abrasive m
43. st be clean 25 Repair Air Cap Nozzle Replacement Ah WARNING CAUTION Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages Fire Explosion and Electric Shock Hazard The nozzle contact ring 7a is a conductive contact ring not a sealing o ring To reduce the risk of sparking or electric shock do not remove the nozzle contact ring 7a except to replace it and never operate the gun with out the contact ring in place Do not replace the contact ring with anything but a genuine Graco part xke 1 Prepare gun for service page 25 2 Remove the retaining ring 27 and air cap 9 See FIG 11 Use non silicone grease Part No 111265 on the small o ring 7b Do not over lubricate Do not lubricate the 3 Point gun up and squeeze trigger while removing contact ring 7a the fluid nozzle 7 assembly with the multi tool 37 Lightly lubricate the o ring 7b Install it and the contact ring 7a on the nozzle 7 az 27 E I ja fi x Make sure the electrode needle 29 is finger tight w L ly 27a page 27 5 Trigger gun while installing the fluid nozzle 7 with the multi tool 37 Tighten until the fluid nozzle seats in the gun barrel 1 8 to 1 4 turn past hand tight o Install the air cap 9 and retaining ring 27 Make sure the u cup
44. st be properly grounded Use only grounded hoses with a maximum of 100 feet 30 5 m combined hose length to ensure grounding continuity 12 All persons entering the spray area shoes must have conductive soles such as leather or personal grounding straps must be worn Do not wear shoes with non conductive soles such as rubber or plastic If gloves are necessary wear the conductive gloves that are supplied with the gun If non Graco gloves are worn cut off fingers or palm area of gloves to ensure your hand contacts the grounded gun han dle Object being sprayed keep the workpiece hangers clean and grounded at all times Resistance must not exceed 1 megohm vn 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 3092925 Check Electrical Grounding WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 4 is not approved for use in a hazard ous area To reduce the risk of sparking do not use the megohmmeter to check ele
45. stall the packing rod assembly 26 into the gun barrel Using the multi tool 37 tighten the assem bly until just snug Install the trigger 30 and screws 8 Install the electrode page 27 Install the nozzle and air cap page 26 Test gun resistance page 18 TIt489a 29 Repair Barrel Removal 1 2 Prepare the gun for service page 25 Carefully loosen the nut 32 or 50d from the bracket fluid fitting 13 Pull the tube 14 or 50a out of the fitting Make sure both ferrules and the nut stay with the tube Loosen the three screws 11 N 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 hanale 17 with one hand and pull the barrel 16 straight off the handle See Fic 15 Fig 15 Barrel Removal 30 Barrel Installation 1 Be sure the gasket 107 and grounding spring 55 are in place Make sure the air holes are aligned properly Replace if damaged See FIG 16 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 N CAUTION Do not over tighten the screws 11 4 Assemble the fluid tube 14 into the bracket fitting 13 Ensure that the ferrules are in place Tighten
46. t No 244575 60 kV Electrostatic Gun Series C items 4 30 35 55 Part No 244401 85 kV Electrostatic Gun Series C items 1 48 55 See page 37 for detail views of the fluid tube assemblies alternator 19 fan adjustment valve 20 ES ON OFF valve 22 and packing rod 26 ti1480b 27a 36 3092925 Ref No 19 Alternator Parts Ref No 20 Fan Adjustment Valve 19d 19c Ref No 22 ES ON OFF Valve 22f 22e ea 2 a 22b h N Pa g 22c J PN 22a Go W A a 26a Fluid Tube Model 244400 Fluid Tube Model 244575 30929258 Ref No 26 Packing Rod 26d 26c A 26f Ng e 48 Na 26e 26h NM 26g DA Fluid Tube Model 244401 50a 50f 50d 50b 50c 37 Parts Part No 244400 60 kV Electrostatic Gun Series C items 1 48 55 Part No 244575 60 kV Electrostatic Gun Series C items 4 30 35 55 Part No 244401 85 kV Electrostatic Gun Series C items 1 48 55 Ref No pr 6 7a 7b 10 11 13 14 15 16 17 38 Part No 110078 198587 185111 185120 102982 188749 197266 111261 111507 197369 24A376 197517 197518 15M678 15M679 197588 244574 185116 244395 244394 245290 289277 245285 Description FITTING tube fluid used on 244400 FITTING tube fluid used on 244401 SPRING compression SPACER fluid nylon used on 244400 and 244575 O RING used on 244401 PACKING u cup
47. tallation complies with Provide fresh air ventilation to avoid the National State and Local codes for the u buildup of flammable or toxic vapors when installation of electrical apparatus in a Class a spraying flushing or cleaning the gun Do 5 Q Div I Group D or a Group Il Ay not operate the gun unless ventilation fans Category 2G Hazardous Location are operating eComply with all applicable local state and national fire electrical and other safety reg Electrically interlock the gun air supply with the ventila ulations tors to prevent gun operation without ventilating fans operating Check and follow all National State and FIG 2 shows a typical electrostatic air spray system lt Local codes regarding air exhaust velocity require is not an actual system design For assistance in ments designing a system to suit your particular needs contact your Graco distributor High velocity air exhaust will decrease the operating effi ciency of the electrostatic system Air exhaust velocity of 100 ft min 31 linear meters minute should be sufficient 3092925 7 Installation ES ON OFF valve is ON O is OFF 6f TO it Sid Bia NA J la WO Nerd
48. to solvent or disconnect the fluid line and connect a solvent supply line to the Do not use methylene chloride as a flushing or gun cleaning solvent with this gun as it will damage nylon components 4 Point the gun into a grounded metal pail Flush until clean solvent flows from the gun 5 Relieve the pressure 6 Shut off or disconnect the solvent line 16 3092925 7 Hang the gun from its hook with the nozzle pointing down 3092925 Maintenance 8 When ready to spray again reconnect the fluid sup ply line Follow the Setup procedure in the Opera tion 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 electrode 29 and electri cal continuity between components Use megohmmeter Part No 241079 AA and an applied voltage of 500 V Connect the leads as shown WARNING Fire Explosion and Electric Shock Hazard Megohmmeter Part No 241079 AA see FIG 6 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 xke eThe gun has been removed from the haz ardous 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 contain
49. used on 244580 PACKING u cup air valve UHMWPE NOZZLE 1 5 mm orifice used on 244579 includes 7a and 7b NOZZLE 1 2 mm orifice used on 24A511 includes 7a and 7b O RING conductive O RING fluoroelastomer SCREW trigger AIR CAP GASKET barrel SCREW socket hd 10 24 x 3 4 in 19 mm BRACKET inlet fluid used on 244579 and 244580 BRACKET inlet fluid used on 244576 TUBE fluid used on 244579 TUBE fluid used on 244580 SPRING compression BARREL gun used on 244579 and 244576 BARREL gun used on 244580 HANDLE gun includes item 28 used on 244579 HANDLE gun includes item 28 used on 244576 HANDLE gun includes item 28 used on 244580 POWER SUPPLY 60 kV used on 244579 and 244576 includes 18a 18d POWER SUPPLY 85 kV used on 244580 includes 18a 18b O RING fluoroelastomer SPRING compression Qty o mo wo N ss xm fn ee eee A Ref No 19 19a 19b 19c 19d 19e 20 20a 20b 20c 20d pq 22 22a 22b 22c 22d 22e 22f 229 23 23a 23b 23c 23d 24 24a 25 26 26a 26b 26c Part No 244555 110073 223688 244577 111745 198821 244556 101021 106560 197566 197567 244557 244558 111516 113137 198403 198404 198453 198464 276753 244559 197594 197591 111504 101021 249323 112085 244593 244597 244521 111316 116905 178409 Description TURBINE alternator includes 19a 19e O R
50. w flow conditions to reduce wear ES INDICATOR AIR FLUID tit266a Standard Model Fig 1 Gun Overview ES HI LO ES ON OFF Fan AIR adjustment valve Adjusts fan size and shape Atomizing air RESTRICTOR valve Restricts atomizing air flow Replace with plug included if desired ES ON OFF valve Turns electrostatics ON I or OFF 0 ES INDICATOR standard gun only Green when ES is ON I Voltage current DISPLAY smart models only Shows voltage V and current A Green spray yellow red see Troubleshooting page 23 ES HI LO switch smart models only Sets volt age to HI or LO factory settings LO VOLTAGE adjustment smart models only Remove plug to adjust to four settings DISPLAY 7 zo LO VOLTAGE AIR RESTRICTOR a EP FLUID ti1253a Smart Model 3092925 Installation Installation Install the System Warning Sign Mount warning signs in the spray area where they can A WARN ING easily be seen and read by all operators An English Warning Sign is provided with the gun 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 Ventilate the Spray Booth Ah WARNING eDo not install or service this equipment SER unless you are trained and qualified Flammable or Toxic Vapor Hazard eBe sure your ins
51. zation air and sup ply air to pressure cup 244731 1 Quart 0 95 Liter 244732 2 Quart 1 90 Liter Gun Valve Lubricant 111265 4 oz 113 g tube of sanitary non silicone lubricant for fluid seals and wear areas Alternator Bearing Kit 223688 To repair the turbine alternator Cleaning Brush 105749 For cleaning air cap and fluid nozzle 3092928 Accessories Abrasive Material Electrode Needle 277007 Optional replacement Electrode Needle is available for abrasive materials Miscellaneous Accessories Ground Wire and Clamp 222011 For grounding pump and other components and equipment in the spray area 12 gauge 25 ft 7 6 m Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in hazardous areas Paint Resistance Meter 722886 Use with 722860 Paint Probe to measure resistance of paint Not for use in hazardous areas Paint Probe 722860 Use with 722886 Paint Resistance Meter to measure resistance of paint Not for use in hazardous areas Safety Warning Signs 180060 English Warning Sign FM Approved Avail able at no charge from Graco Instruction Signs 198309 198319 English Setup Instructions English Daily Care Instructions Electrostatic Conductive Gloves box of 12 117823 Small 117824 Medium 117825 Large 45 Technical Data Technical Data Category Maximum Working Fluid Pressure Maximum Working Air Pressure Minimum Air Pressure at Gun Inlet Maximum Flui
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