Graco 309295K - Electrostatic Air-Assisted PRO Xs4 AA Spray Gun, U.S. Instructions-Parts List Manual

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Graco 309295K - Electrostatic Air-Assisted PRO Xs4 AA Spray Gun, U.S. Instructions-Parts List Manual | Manualzz

Instructions/Parts List

Manual Electrostatic Air-Assisted

PRO

Xs4 AA

Spray Gun

For use with Class I, Div. I locations spraying Group D materials.

# 53

For use with Group II, Category 2 locations spraying Group IIA materials.

0.24 Mj

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

309295K

ti1509a ti1332b

2

Table of Contents

List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 4

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

How the Electrostatic AA Spray Gun Works . . . . 6

Gun Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Install the System . . . . . . . . . . . . . . . . . . . . . . . . 8

Warning Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 8

Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 10

Connect the Exhaust Tube . . . . . . . . . . . . . . . . 10

Connect the Fluid Line . . . . . . . . . . . . . . . . . . . 11

Filter the Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Select a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Check Electrical Grounding . . . . . . . . . . . . . . . . 13

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 14

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 14

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Low Voltage Adjustment (Smart Guns Only) . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flush the Spray Gun . . . . . . . . . . . . . . . . . . . . . 16

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 18

Test Power Supply Resistance . . . . . . . . . . . . . 19

Test Barrel Resistance . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Spray Pattern Troubleshooting . . . . . . . . . . . . . 21

Gun Operation Troubleshooting . . . . . . . . . . . . . 22

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pressure Relief Procedure . . . . . . . . . . . . . . . . 24

Prepare the Gun for Service . . . . . . . . . . . . . . . 25

Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Tip Guard, Air Cap, Spray Tip, or Seat Housing

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 26

Electrode Replacement . . . . . . . . . . . . . . . . . . . 28

Fluid Tube Replacement . . . . . . . . . . . . . . . . . . 29

Fluid Filter Removal . . . . . . . . . . . . . . . . . . . . . . 29

Fluid Needle Replacement . . . . . . . . . . . . . . . . 30

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 31

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Supply Removal and Replacement . . . . 32

Turbine Alternator Removal and Replacement . 33

Atomizing Air Adjustment Valve Repair . . . . . . . 34

Air Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . 35

ES ON/OFF Valve Repair . . . . . . . . . . . . . . . . . 36

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 44

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 44

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 44

Miscellaneous Accessories . . . . . . . . . . . . . . . . 45

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

309295K

List of Models

List of Models

Part No.

Model Description

244572, Series C PRO Xs4 AA Manual Air-Assisted Spray Gun

244573, Series C PRO Xs4 AA Manual Air-Assisted Spray Gun with smart display

Operation

Manual

309296/3W9296/

3Z9296

309296/3W9296/

3Z9296

309295K 3

4

Warnings

Warnings

Warning Symbol Caution Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

WARNING

Fire, Explosion, and Electric Shock Hazard

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.

• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this manual.

• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,

and all conductive objects in the spray area. See Grounding, page 12.

• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air supply to prevent operation unless

ventilating fans are on. See Ventilate the Spray Booth on page 8.

• Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all solvent is removed from the system.

• If there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.

• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.Check gun

resistance daily. See Test Gun Resistance on page 18.

• Use cleaning solvents with the highest possible flash point, preferably above ambient temperature.

• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the spray area.

• Use only non-sparking tools to clean residue from the booth and hangers.

309295K

309295K

Warning

WARNING

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.

• 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.

• Never spray without the tip guard in place.

• Lock the trigger safety when you stop spraying.

Follow the Pressure Relief Procedure, page 24, when you stop spraying and before cleaning,

checking, or repairing equipment.

• Check the hoses and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

• Tighten all fluid connections before each use.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

• Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local, state, and national guidelines.

• Wear appropriate protective clothing, gloves, eyewear, and respirator.

Equipment Misuse Hazard

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

• This equipment is for professional use only.

• Read all manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.

• Do not alter or modify equipment. Use only genuine Graco parts and accessories.

• Check the equipment daily. Repair or replace worn or damaged parts immediately.

• Do not exceed the maximum working pressure of the lowest rated system component.

Maximum working fluid pressure of this equipment is 3000 psi (21 MPa, 210 bar).

• Use fluids and solvents that are compatible with the equipment wetted parts. See the

Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180

°

F (82

°

C) or below -40

°

F (-40

°

C).

• Wear hearing protection when operating this equipment.

• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

5

6

Introduction

Introduction

How the Electrostatic AA

Spray Gun Works

WARNING

Skin Injection Hazard

Remember, this is not an air spray gun.

For your safety, read and follow all Warnings in this manual.

The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the fluid tails to produce a uniform pattern.

As the gun is triggered, part of the regulated air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge to supply high voltage current to the gun’s electrode.

The regulated air that is directed to the air cap can be further controlled using the gun’s atomizing air adjustment valve. This valve can be used to restrict air flow to the air cap while maintaining sufficient air flow to the turbine.The atomizing air adjustment valve does not control pattern width. To change pattern width, a new tip size must be used.

The high working fluid pressure of this gun provides the power needed to atomize higher solids materials.

The gun’s internal power supply provides high voltage current. The fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

NOTE: For airless atomization, if desired, turn the gun’s atomizing air adjustment valve completely off. Closing this valve does not affect turbine operation.

309295K

Introduction

Gun Overview

The electrostatic gun includes the following controls.

See F IG . 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 spraying.

Atomizing AIR adjustment valve. Adjusts atomizing air.

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 voltage to HI or LO (factory settings).

• LO voltage adjustment (smart models only).

Remove plug to adjust to four settings.

TRIGGER SAFETY LOCK

TIP GUARD

AIR CAP

ES INDICATOR

SPRAY TIP

ES ON/OFF

(I = ON,

0 = OFF)

ES HI/LO ti1509a

0

KV

μα

100 %

LO

ES

HI

AIR

ES ON/OFF

(I = ON,

0 = OFF)

Standard Gun ti1366a

Fig. 1. Gun Overview

Smart Gun ti1333a

DISPLAY

LO

AIR

309295K 7

8

Installation

Installation

Install the System Warning Sign

WARNING

Fire, Explosion, and Electric Shock

Hazard

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

• Do not install or service this equipment unless you are trained and qualified.

• Be sure your installation complies with

National, State and Local codes for the installation of electrical apparatus in a

Class I, 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.

F IG . 2. shows a typical electrostatic air-assisted spray

system. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.

Mount warning signs in the spray area where they can easily be seen and read by all operators. An English

Warning Sign is provided with the gun.

Ventilate the Spray Booth

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.

Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and

Local codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

309295K

Installation

D C*

H

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.

B* D

J*

P

O

V

Q*

L

M

T

*R

G *E

F X

K

U*

Non-Hazardous Area

W

N

C

Hazardous Area ti1514b

S

Fig. 2. Typical Installation

Key

A Main Air Supply Line

B* Ventilation Fan Interlock Solenoid Valve

C* Main Air Supply Shutoff Valve (bleed-type)

D Air Line Filter/Water Separator

E* Pump Air Supply Shutoff Valve (bleed-type)

F Air Line Lubricator

G Air Pressure Regulator

H Pump

J* Pump Ground Wire

K Fluid Filter

L Fluid Supply Line Shutoff Valve

M Fluid Pressure Regulator

N Grounded Fluid Supply Line, with spring guards

O Gun Air Regulator

P Gun Air Supply Line Shutoff Valve

Q* Air Hose Ground Wire

R* Graco Grounded Air Hose

S Electrostatic Air-Assisted Spray Gun

T Fluid Pressure Gauge

U* Fluid Drain Valve

V Gun Air Inlet

W Gun Fluid Inlet

X Pump Runaway Valve

* Required for safe operation. Must be purchased separately. NOTE: Solenoid valve (B) is not offered as a Graco accessory.

309295K 9

Installation

Connect the Air Line

3.

Install a bleed-type air regulator (G, O) on the pump and gun air supply lines to control air pressure to the pump and gun.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true earth ground. Use only Graco Grounded Air

Supply Hose.

WARNING

Skin Injection Hazard

The bleed-type air valve (E) is required in your system to relieve air trapped between the valve and the pump after the air regulator is shut off. Trapped air can cause the pump to cycle unexpectedly, which can result in serious injury, including fluid injection and splashing fluid in the eyes or on the skin.

1.

Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet

(V). The gun air inlet fitting has a left-hand thread.

Connect the air supply hose ground wire (Q) to a true earth ground.

2.

Install an air line filter/water separator (D) on the air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

4.

Install a bleed-type air valve (E) on the pump air line to shut off air to the pump. Install an additional bleed-type air valve (C) on the main air line (A) to isolate the accessories for servicing.

5.

Install an air shutoff valve ( P) on each gun air supply line to shut off air to the gun(s).

Connect the Exhaust Tube

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 producing a fluid pressure greater than the 3000 psi (21

MPa, 210 bar) Maximum Working Fluid Pressure of the gun. For example, the air supply pressure to a

30:1 ratio pump must not exceed 100 psi (0.7 MPa, 7 bar).

Press the exhaust tube (38) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (39).

10 309295K

Installation

Connect the Fluid Line

1.

Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

2.

Install a fluid regulator (M) on the fluid line to control fluid pressure to the gun.

Filter the Fluid

Install a fluid filter (K) at the pump outlet to remove particles and sediment which could clog the spray tip.

The gun includes an inline fluid filter (1) for additional filtration.

Select a Spray Tip

WARNING

Skin Injection Hazard

The fluid drain valve (U) is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun. Triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump's fluid outlet. The drain valve reduces the risk of serious injury, including fluid injection and splashing in the eyes or on the skin.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure, page 24, before removing or installing

the spray tip, air cap, or tip guard.

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.

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.

309295K 11

Installation

Grounding

WARNING

Fire, Explosion, and Electric Shock

Hazard

When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock.

Follow the grounding instructions below.

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 glove, to ensure your hand contacts the grounded gun handle.

Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded.

Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

Electrostatic Air-Assisted Spray Gun: ground the gun by connecting the Graco Grounded Air Hose and connecting the air hose ground wire to a true

earth ground. See Check Electrical Grounding, page 13.

Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift. ti1259a

Air compressors: ground the equipment according to the manufacturer's recommendations.

All air and fluid lines must be properly grounded.

Use only grounded hoses with a maximum of 100 feet (30.5 m) combined hose length to ensure grounding continuity.

• All electrically conductive objects or devices in the

spray area: including fluid containers and wash cans, must be properly grounded.

12 309295K

Installation

Check Electrical Grounding

WARNING

Fire, Explosion, and Electric Shock

Hazard

Megohmmeter Part No. 241079 (AA-see

F IG . 3.) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area

(such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

1.

Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose.

2.

Turn the ES ON/OFF valve OFF.

3.

Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4.

Make sure the grounded air hose (R) is connected and the hose ground wire is connected to a true earth ground.

ti1259a

5.

Measure the resistance between the gun handle

(BB) and a true earth ground (CC). Use an applied voltage of 500 minimum to 1000 volts maximum.

The resistance should not exceed 1 megohm. See

F IG . 3.

6.

If the resistance is greater than 1 megohm, check the tightness of the ground connections and be sure the air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

BB

AA

CC ti1340a ti1337a

Fig. 3. Check Gun Grounding

309295K 13

Installation

Check Fluid Resistivity

WARNING

Fire, Explosion, and Electric Shock

Hazard

Check the fluid resistivity in a non-hazardous area only. Resistance Meter 722886 and Probe 722860 are not approved for use in a hazardous area.

Failure to follow this warning could cause fire, explosion, electric shock and result in serious injury and property damage.

Graco Part No. 722886 Resistance Meter and 722860

Probe are available as accessories to check that the resistivity of the fluid being sprayed meets the requirements of an electrostatic air-assisted spray system.

Follow the instructions included with the meter and probe. Readings of 25 megohms-cm and above provide the best electrostatic results.

Check Fluid Viscosity

To check fluid viscosity you will need:

• a viscosity cup

• a stopwatch.

1.

Completely submerge the viscosity cup in the fluid.

Lift the cup out quickly, starting the stopwatch as soon as the cup is completely removed.

2.

Watch the stream of fluid coming from the bottom of the cup. As soon as there is a break in the stream, shut off the stopwatch.

3.

Record the fluid type, elapsed time, and size of the viscosity cup.

4.

If the viscosity is too high or too low, contact the material supplier and adjust as necessary.

14 309295K

Operation

Operation

INSTRUCTIONS

Refer to the gun operation manual (supplied) for Setup, Shutdown, and Daily Care procedures.

Low Voltage Adjustment

(Smart Guns Only)

The ES HI/LO switch enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set, but can be adjusted.

1.

Set the ES HI/LO switch to LO.

2.

Remove the LOW VOLTAGE adjustment plug (53).

Set the desired voltage, using a small screwdriver to slide switches 1 and 2 ON or OFF, according to

Table 1 . Also see F

IG . 4.

Table 1: Low Voltage Adjustment

1

ON

ON

OFF

OFF

2

ON

OFF

ON

OFF kV

70

60

50

40

OFF

2 1

ON

0

KV

μα

100 %

53 ti1529a

Fig. 4. Low Voltage Adjustment Switches

309295K 15

Maintenance

Maintenance

Refer to the gun operation manual (supplied) for Daily Care and Cleaning procedures.

INSTRUCTIONS

Flush the Spray Gun

Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun.

1.

Turn the ES ON/OFF valve OFF.

ti1337a

WARNING

Fire, Explosion, and Electric Shock

Hazard

To reduce the risk of fire, explosion, or electric shock, turn the ES ON/OFF valve OFF before flushing the gun.

WARNING

Skin Injection Hazard

To reduce the risk of a fluid injection injury,

always follow the Pressure Relief Proce-

dure, page 24, whenever you are instructed

to relieve the pressure.

2.

Relieve the pressure.

ti1341a

CAUTION

Flush the gun with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.

Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.

3.

Remove and clean the air cap and the spray tip.

Continued on page 17.

ti1334b

16 309295K

Maintenance

4.

Change the fluid source to solvent, or disconnect the fluid line and connect a solvent supply line to the gun.

6.

Relieve the pressure. Lock the trigger.

ti1465a ti1287a

5.

Point the gun into a grounded metal pail. Flush until clean solvent flows from the gun.

7.

Shut off or disconnect the solvent line.

8.

Hang the gun from its hook, with the nozzle pointing down.

ti1349a ti1465a

9.

When ready to spray again, reconnect the fluid supply line. Follow the Setup procedure in the Gun

Operation Manual.

309295K 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.

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.

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 F IG . 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.

AA

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

F IG . 5.) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:

• The gun has been removed from the hazardous area;

• Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area

(such as open solvent containers or fumes from spraying).

Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.

9b

Fig. 5. Test Gun Resistance

35

TI1469A

18 309295K

Electrical Tests

Test Power Supply

Resistance

1.

Remove the power supply (18), page 32.

2.

Remove the turbine alternator (19) from the power

supply, page 33.

3.

Measure resistance from the power supply's ground strips (EE) to the spring (18b). See F IG . 6.

4.

The resistance should be 135-150 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.

5.

If you still have problems, refer to Electrical Trou-

bleshooting on page 23 for other possible causes

of poor performance, or contact your Graco distributor.

6.

Be sure the spring (18b) is in place before reinstalling the power supply.

18b

EE ti1599a

Fig. 6. Test Power Supply Resistance

309295K 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 test) and against the metal contact (C) in the front of the barrel.

2.

Measure the resistance between the conductive rod

(B) and the barrel contact ring (16a). See F IG . 7.

The resistance should be 19-29 megohms. If the resistance is incorrect, make sure the metal contact

(C) in the barrel and the barrel contact ring (16a) are clean and undamaged.

3.

If the resistance is still outside the range, remove the barrel contact ring (16a) and measure the resistance between the conductive rod (B) and the wire lead at the bottom of the contact ring groove.

4.

If the resistance is in range, replace the contact ring

(16a) with a new one. Press the contact ring firmly into the groove on the front of the barrel.

16a

C

Fig. 7. Test Barrel Resistance

B ti1515b

WARNING

Fire, Explosion, and Electric Shock

Hazard

The barrel contact ring (16a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring (16a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine

Graco part.

20 309295K

Troubleshooting

Troubleshooting

WARNING

Electric Shock Hazard

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

WARNING

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.

Spray Pattern Troubleshooting

NOTE: Check all possible remedies in the Troubleshooting Chart before disassembling the gun.

NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.

Problem

Fluttering or spitting spray.

Cause

No fluid.

Air in fluid supply.

Solution

Refill supply.

Check fluid source. Refill.

Irregular pattern.

Fluid buildup; partially plugged tip.

Clean. See gun operation manual.

Worn/damaged tip or air cap holes.

Clean or replace.

Pattern pushed to one side; air cap gets dirty.

Tails in pattern.

Air cap holes plugged.

Air pressure too low.

Fluid pressure too low.

Clean. See gun operation manual.

Open atomizing air adjustment valve.

Increase.

Fluid buildup on air cap/tip guard.

Air pressure too high.

Fluid pressure too low.

Decrease.

Increase.

309295K 21

Troubleshooting

Gun Operation Troubleshooting

Problem

Excessive spray fog.

“Orange Peel” finish.

Fluid leaks from the fluid packing area

Air leaks from the front of the gun

Fluid leakage from the front of the gun

Gun does not spray

Dirty air cap

Cause Solution

Atomizing air pressure too high.

Close atomizing air valve some, or decrease air pressure as low as possible; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.

Increase viscosity.

Fluid too thin.

Atomizing air pressure too low.

Spray tip is too large.

Poorly mixed or filtered fluid.

Open atomizing air valve more or increase gun air inlet pressure; use lowest air pressure necessary.

Use smaller tip. See page 46.

Remix or refilter fluid.

Fluid too thick.

Reduce viscosity.

Worn fluid needle packings or shaft.

Replace fluid needle assembly (26);

see page 30.

Air valve (21) is not seating properly.

Clean and service air valve; see

page 35.

Worn or damaged fluid needle ball.

Replace fluid needle (26); see page

30.

Worn fluid seat housing (2).

Loose spray tip (3).

Replace seat housing; see page 26.

Tighten retaining ring (27); see page

26.

Damaged tip seal (3a).

Low fluid supply.

Damaged spray tip (3).

Dirty or clogged spray tip (3).

Damaged fluid needle (26).

Damaged or plugged air cap (9).

Replace; see page 26.

Add fluid if necessary.

Replace; see page 26.

Clean; see gun operation manual.

Replace; see page 30.

Clean air cap; see gun operation manual.

22 309295K

Troubleshooting

Electrical Troubleshooting

Poor wrap.

Problem

ES indicator or voltage/current display is not lit.

Cause Solution

ES ON/OFF valve OFF (0).*

Gun air pressure too low.

Atomizing air pressure too high.

Fluid velocity too high.

Turn ON (I).

Check air pressure to gun; minimum

40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage.

Decrease.

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.

Check fluid resistivity. See page 14.

Low fluid resistivity.

Fluid leaks from the fluid needle (26) packings and causes a short.

Faulty turbine alternator (19).

Clean the needle cavity. Replace the

fluid needle. See page 30.

Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine

alternator. See page 33.

The KV HI-LO lever is on LO.

ES ON/OFF valve OFF (0).*

Check the lever position; replace if needed.

Turn ON (I).

Voltage/current display stays red

(smart guns only).

Operator gets mild shock.

No power.

Gun too close to part.

Check fluid resistivity.

Dirty gun.

Operator not grounded or is near ungrounded object.

Gun not grounded.

Operator gets shock from workpiece. Workpiece not grounded.

Repair/replace alternator turbine;

replace power supply. See page 32.

Should be 8-12 in. (200-300 mm).

See “Check Fluid Resistivity” on page 14.

Clean. See Operation Manual.

See “Grounding” on page 12.

See “Check Electrical Grounding” on

page 13 and “Test Gun Resistance” on page 18.

Resistance must be 1 megohm or less. Clean workpiece hangers.

* ES indicator light is off when the gun is triggered.

309295K 23

Repair

Repair

Pressure Relief Procedure

4.

Unlock the trigger.

WARNING

Skin Injection Hazard

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or electric shock, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure

• stop spraying

• check or repair any of the system equipment

• or install or clean the spray tip.

1.

Turn the ES ON/OFF valve OFF.

5.

Trigger the gun into a grounded metal waste container to relieve the fluid pressure.

ti1406a

6.

Lock the trigger.

ti1341a ti1356a

7.

Open the pump drain valve and all other fluid drain valves in the system, having a waste container ready to catch the drainage. Leave the drain valve(s) open until you are ready to spray again.

ti1337a ti1290a

8.

If the nozzle or hose is completely clogged or pressure is not fully relieved, slowly loosen the hose end coupling. Now clear the nozzle or hose.

2.

Lock the trigger.

t ti1356a

3.

Turn off the air bleed valves to the fluid source and to the gun.

ti1289a

24 309295K

Repair

Prepare the Gun for Service

• 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.

• Air Seal Repair Kit 244781 is available. The kit must be purchased separately. Kit parts are marked with an asterisk, for example (6*).

WARNING

Electric Shock Hazard

Installing and repairing this equipment requires access to parts that may cause electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

WARNING

Skin Injection Hazard

To reduce the risk of injury, follow the Pres-

sure Relief Procedure on page 24 before

checking or repairing any part of the system and whenever you are instructed to relieve the pressure.

NOTE:

Check all possible remedies in Troubleshooting

before disassembling the gun.

• Use a vise with padded jaws to prevent damage to plastic parts.

• Lubricate the power supply o-ring (18a) and the plastic end of the fluid tube (14) with dielectric grease (40).

• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.

WARNING

Some PRO Xs4 AA Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When repairing, do not mix or use other

PRO Gun parts that may look similar, but have

different part numbers! Use of parts other than those specified in the PRO Xs4 AA Gun parts lists could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion, or property damage.

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

• 2 mm driver (supplied)

• 4 mm driver (supplied)

• Multi-Tool (supplied)

• adjustable wrench

• medium screwdriver

• snap ring pliers

309295K 25

Repair

Tip Guard, Air Cap, Spray

Tip, or Seat Housing

Replacement

1.

Prepare gun for service, page 25.

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 F IG . 8.

3.

Replace the tip gasket (3a) if damaged.

27

27a

4

9a

3a

3

CAUTION

The barrel resistor cartridge (B) is part of the barrel and is not replaceable. To avoid destroying the gun barrel, do not attempt to remove the barrel resistor.

WARNING

Fire, Explosion, and Electric Shock

Hazard

The barrel contact ring (16a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the barrel contact ring (16a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine

Graco part.

B

2

Fig. 8. Tip Guard, Air Cap, and Spray Tip Replacement

4.

Trigger the gun and remove the seat housing (2) with the tool (37) provided. See F IG . 9.

37

Fig. 9. Seat Housing Replacement

Continued on page 27.

26 309295K

Repair

CAUTION

To avoid damaging the seat housing and gun barrel, never over-tighten the seat housing. Over-tightening may result in improper fluid shut-off.

5.

Trigger the gun and install the gray-colored seat housing (2). Tighten until snug, then 1/4 turn more.

CAUTION

To avoid damaging the tip guard (4), orientate the air cap (9a) before tightening the retaining ring (27). Do not turn the cap when the retaining ring is tight.

6.

Assemble the spray tip (3), air cap (9a), and tip guard (4). Make sure the electrode (9b) is not damaged or missing. Install the air cap assembly with the retaining ring (27). The u-cup (27a) lips must face forward.

7.

Test gun resistance, page 18.

309295K 27

Repair

Electrode Replacement

WARNING

Electric Shock Hazard

To reduce the risk of fire, explosion, or electric shock, do not operate the spray gun without the electrode installed in the air cap.

4.

Push the new electrode through the air cap hole.

Make sure the short end (BB) of the electrode engages the hole (CC) in the back of the air cap.

Press the electrode in place firmly with your fingers.

See F IG . 10.

5.

Install the air cap assembly, page 26.

6.

Test gun resistance, page 18.

9b

1.

Prepare the gun for service, page 25.

2.

Remove the air cap assembly, page 26.

3.

Pull the electrode (9b) out of the back of the air cap, using a needle-nose pliers.

CC

BB

Fig. 10. Electrode Replacement

02013

28 309295K

Repair

Fluid Tube Replacement

1.

Prepare the gun for service, page 25.

2.

Disconnect the bottom fluid tube nut (C). See F IG .

11.

3.

Carefully unscrew the top fluid tube nut (D).

CAUTION

Be careful not to damage the fluid tube assembly (14) when cleaning or installing it, especially the sealing surface (E). If the sealing surface is damaged, the entire fluid tube assembly must be replaced.

4.

Apply dielectric grease (40) to the entire length of the plastic extension on the end of the fluid tube

(14).

5.

Apply low strength thread sealant to the fluid tube nut threads.

6.

Install the fluid tube into the gun barrel and tighten the top nut (D) hand-tight, then 1/4 to 1/2 turn with a wrench. There will be a gap between the nut and barrel. Do not overtighten the nut.

7.

Make sure the fluid filter (1) is in place in the fluid fitting. Tighten the bottom nut (C) onto the fitting and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

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 F IG . 12.

NOTE: Replacement filters are available in 100 mesh

(standard) or 60 mesh sizes. See page 45.

4.

Install the fluid filter in the fluid fitting. Tighten the bottom nut (C) onto the fitting and torque to 20-30 in-lb (2.3-3.4 N•m). Make sure the top nut remains tight.

CAUTION

Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).

TI1521A

C

1

14

C

1

E

D ti1524a

Fig. 12. Fluid Filter Removal

Fig. 11. Fluid Tube Replacement

309295K 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 F IG . 13.

6.

Place the 2 mm driver (44) in the back of the fluid needle assembly. Push the tool in and turn it counterclockwise about 12 full turns to unthread the needle.

7.

Using the u-shaped tool (37), pull back on the packing nut (N) to remove the fluid needle assembly. See

F IG . 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 F IG . 15.

9.

Install the spring (26a).

10. Install the spring cap (45), making sure the grounding spring (55) is in place.

11. Install the trigger (30) and screws (8).

12. Install the barrel (16), page 31.

TI1618A

Fig. 13. Spring Cap and Springs

Fig. 14. Fluid Needle Removal

N

30

26a

45

55

8

37

TI1526B

CAUTION

To avoid damaging the seat housing and gun barrel, never overtighten the seat housing. Overtightening may result in improper fluid shutoff.

8

30

13. Install the seat housing and air cap, page 26.

14. Test gun resistance, page 18.

Fig. 15. Fluid Needle Replacement

30 309295K

Repair

Barrel Removal

1.

Prepare the gun for service, page 25.

2.

Carefully loosen the nut (C) from the bracket fluid fitting (13). See F IG . 16.

3.

Loosen the three screws (11).

2.

Place the barrel (16) over the power supply (18) and onto the gun handle (17).

3.

Tighten the three screws (11) oppositely and evenly

(about a half turn past snug).

CAUTION

Do not over-tighten the screws (11).

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.

Make sure the fluid filter (1) is in place in the fluid fitting. Tighten the bottom fluid tube nut (C) onto the bracket (13) fluid fitting and torque to 20-30 in-lb

(2.3-3.4 N•m). Make sure the top nut remains tight.

4.

Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle.

13 C

CAUTION

Be sure the fluid tube (14) is not twisted after tightening the bottom nut (C).

5.

Test gun resistance, page 18.

11

16

11

*10

18

17

16

TI1516A

17

Fig. 16. Barrel Removal ti1517a

Barrel Installation

1.

Be sure the gasket (10*, F IG . 17.) and grounding spring (55, F IG . 13.) are in place and the gasket air holes are aligned properly. Replace if damaged.

1

14

Fig. 17. Barrel Installation

13

C

TI1520B

309295K 31

Repair

Power Supply Removal and

Replacement

NOTE:

• Inspect the gun handle power supply cavity for dirt or moisture. Clean with a clean, dry rag.

• Do not expose gasket (10) to solvents.

1.

Prepare gun for service, page 25.

2.

Remove the barrel (16), page 31.

CAUTION

Be careful when handling the power supply (18) to avoid damaging it.

7.

Connect the 3-wire connector (B). Slide the alternator (19) down onto the power supply (18).

8.

Lubricate the alternator o-ring (19a*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

9.

Lubricate the power supply o-ring (18a*) with dielectric grease (40).

10. Insert the power supply/alternator assembly in the gun handle (17). Make sure the ground strips make contact with the handle. On Smart Models only, connect the flexible circuit (59) to the socket at the top of the handle. Push the 6-pin connector into the socket to ensure it is properly connected.

11. Install the barrel (16), page 31.

12. Test gun resistance, page 18.

3.

Grasp the power supply (18) with your hand. With a gentle side to side motion, free the power supply/alternator assembly from the gun handle (17), then carefully pull it straight out. On Smart Models

only, disconnect the flexible circuit (59) from the socket at the top of the handle (17). See F IG . 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.

Check the 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 (19e) are in place.

6.

On Smart Models only, connect the 6-pin flexible circuit (59) to the power supply.

19e

B

*18a

18b

19

18

*19a

59

*10

17 ti1505c

Fig. 18. Power Supply and Turbine Alternator

32 309295K

Repair

Turbine Alternator Removal and Replacement

NOTE: Replace turbine 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 32.

3.

Disconnect the alternator from the power supply, page 32.

4.

Measure resistance between the two outer terminals of the 3-wire connector (B); it should be 2.5-3.5 ohms. If outside this range, replace the alternator coil.

5.

Follow the bearing replacement procedure in the bearing kit manual 308034.

6.

Install the alternator on the power supply, page 32.

7.

Install the power supply/alternator assembly, page

32.

309295K 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 F IG . 19.

4.

Turn the valve stem (20d) counterclockwise until it comes free from the valve housing (20c).

5.

Remove the o-ring (20b).

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 bottomed. Install the o-ring (20b*), lubricate, and unscrew the valve stem until the o-ring enters the housing.

8.

Reassemble the retaining ring (20a). Unscrew the valve stem from the housing until it is stopped by the retaining ring.

9.

Screw the valve assembly (20) into the gun handle, using a wrench on the flats of the housing. Torque to

15-25 in-lb (1.7-2.8 N•m).

20d

TI1487A

20b*

20a

20c

Fig. 19. Atomizing Air Adjustment Valve

34 309295K

Repair

Air Valve Repair

1.

Prepare the gun for service, page 25.

2.

Remove the barrel, page 31.

3.

Remove the air valve cap (25) from the handle (17).

Remove the spring (15). See F IG . 20.

5.

Inspect the u-cup (6*). Do not remove the u-cup unless damaged. If removed, install the new one with its lips facing into the gun handle (17).

6.

Install the air valve (21) and spring (15) into the gun handle (17).

7.

Install the air valve cap (25). Torque to 15-25 in-lb

(1.7-2.8 N•m).

8.

Install the barrel, page 31.

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.

21

15

25

4.

Remove the air valve (21) with a pliers. Inspect the the rubber sealing surface and replace the air valve if damaged.

*6

CAUTION

When removing the air valve (21) be careful not to damage the seat area. The rubber seal is not removable.

Fig. 20. Air Valve ti1527a

309295K 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-rings (22a* and 22b*) with non-silicone grease, Part No. 111265. Do not over-lubricate.

4.

Clean and inspect parts for damage. Replace if necessary.

NOTE: The protrusion on the retainer plate (22d) must point upward.

5.

Reinstall the valve. Torque the screw (48) to 15-25 in-lb (1.7-2.8 N•m).

22g

22f

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.

22a*

22c

22b*

22e

22d

48

TI1488A

Fig. 21. ES ON/OFF Valve

36 309295K

Parts

Parts

Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50)

16a

16 ti1366a

*18a

18b

22

20

18

See page 38 for detail views of the alternator (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22).

19e

19

19a*

28

17

21***

15

25

*10

11

26a

45

11

26

55 *6

47

24a*

24

13

14

8

30

35

3a

2

14 (Ref)

1

38

39

36

37

44

27

27a*

4

9a

3

9b ti1511C

309295K 37

Parts

Ref. No. 19: Alternator

19a*

19b

19b

TI1481a

19e

19d 19c

Ref. No. 22: ES ON/OFF Valve

22e

22d

22f

22b*

22c

22a*

TI1488A

48

22g

20a

Ref. No. 20: Atomizing Air Adjustment Valve

20d

TI1487A

20b*

20c

38 309295K

Parts

2

3

Part No. 244572 85 kV Electrostatic Gun, Series C (items 1-50)

Ref.

No.

Part No. Description Qty

Ref.

No.

Part No. Description

1

3a

205264 FILTER, fluid, inline

245280 HOUSING, seat

GG3XXX SPRAY TIP (customer’s choice); includes item 3a

183459 . SEAL, spray tip

1

1

1

1

20 244556

20a 101021

20b* 106560

20c 197566

VALVE, adjustment, atomizing air; includes items 20a-20d

. RING, retaining

. O-RING; fluorocarbon

. HOUSING, valve

4

6*

8

276767

188749

197369

TIP GUARD

PACKING, u-cup, air valve;

UHMWPE

SCREW, trigger

1

1

2

20d 197567

21*** 244557

22 244558

. STEM, valve

VALVE, air;

VALVE, electrostatics, ON/OFF; includes items 22a-22g

9 245276 AIR CAP ASSEMBLY; includes items 9a and 9b

1

22a* 111516

22b* 113137

. O-RING; CV75

. O-RING; fluoroelastomer

9a

9b

198679

244917

. AIR CAP

. ELECTRODE (kit of 5)

1

1

22c 198403

22d 198404

. SHAFT, valve

. PLATE, retaining

10*

11

13

197517

197518

GASKET, barrel

SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)

15M680 BRACKET, inlet, fluid

1

3

1

22e 198453

22f 198464

22g 276753

24 249323

. WASHER

. PIN

14

15

244713

185116

TUBE, fluid

SPRING, compression

1

1

24a* 112085

. KNOB

VALVE, exhaust; includes item

24a

. O-RING; fluorocarbon

16 244531

16a 197486

BARREL, gun; includes item 16a

. O-RING; conductive

1

1

25

26

197966

244714

CAP, air valve

NEEDLE, fluid; includes item 26a

17

18

245286

244541

18a* 103337

HANDLE, gun (includes item 28)

POWER SUPPLY, 85 kV; includes items 18a-18b

. O-RING; fluoroelastomer

1

1

1

26a 112691

27 244927

27a* 198307

. SPRING, compression

RING, retaining, air cap; includes item 27a

. PACKING, u-cup

18b 197624

19 244555

19a* 110073

. SPRING, compression

TURBINE, alternator; includes items 19a-19e

. O-RING; fluoroelastomer

1

1

1

28

30

35

36

276695

276698

HOOK

TRIGGER

19b 223688 . BEARING KIT; includes front and rear bearings and fan

1

185105

107460

FITTING, air; left-hand threads

WRENCH, ball end; 4 mm

19c 244577

19d 111745

. COIL

. RING, retaining

1

1

37

38

276741

185103

MULTI-TOOL

TUBE, exhaust

19e 198821 . PAD, pressure 2

39

40

110231

116553

CLAMP

GREASE, dielectric, tube (not shown)

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

309295K 39

Parts

42

43

44

45

47

Ref.

No.

Part No. Description

41 244915

179791

180060

112080

198516

197967

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

1

1

1

1

1

Ref.

No.

Part No. Description

48

49

50

198058

222385

188774

SCREW, cap, socket hd

CARD, warning (not shown); replacement available at no cost

TAG, warning (not shown); replacement available at no cost

Qty

1

1

1

* Included in Air Seal Repair Kit 244781.

*** Rubber seal is not removable.

Replacement Warning labels, signs, tags, and cards are available at no cost.

40 309295K

Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59)

0

KV

μα

100 %

LO

ES

HI

16

53 (Ref)

51 (Ref)

22

20

See page 42 for detail views of the alternator (19), atomizing air adjustment valve (20), and ES ON/OFF valve (22).

59

19

19e

19a*

17

28

53

52

51

54

15

21***

25

18 ti1253a

*18a

18b

*10

11

26a

45

26

11

14

55 *6

8

30

47

24a*

24

13

35

16a

3a

14 (Ref)

1

2

38

36

39

37

44

27

27a*

4

9a

3

9b ti1510d

Parts

309295K 41

Parts

Ref. No. 19: Alternator

19b

19b

19a*

TI1481a

20a

Ref. No. 20: Atomizing Air Adjustment Valve

20d

TI1487A

20b*

20c

19e

19d 19c

Ref. No. 22: ES ON/OFF Valve

22c

22a*

22b*

22e

22d

22f

22g

48

TI1488A

Part No. 244573 85 kV Electrostatic Gun, Series C (items 1-59)

3a

4

6*

8

9

9a

1

2

3

Ref.

No.

Part No. Description

205264

276767

188749

FILTER, fluid, inline

245280 HOUSING, seat

GG3XXX SPRAY TIP (customer’s choice); includes item 3a

183459 . SEAL, spray tip

TIP GUARD

PACKING, u-cup, air valve;

UHMWPE

SCREW, trigger 197369

245276

198679

AIR CAP ASSEMBLY

. AIR CAP

Qty

1

1

1

2

1

1

1

1

1

Ref.

No.

Part No. Description

9b 244917 . ELECTRODE (kit of 5)

10*

11

13

197517

197518

GASKET, barrel

SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)

15M680 BRACKET, inlet, fluid

14

15

244713

185116

16 244531

16a 197486

17 245288

TUBE, fluid

SPRING, compression

BARREL, gun; includes item 16a

. O-RING; conductive

HANDLE, gun (includes item 28)

Qty

1

1

3

1

1

1

1

1

1

42 309295K

Parts

Ref.

No.

Part No. Description

18 244541

18a* 103337

18b 197624

19 244555

19a* 110073

19b 223688

19c 244577

19d 111745

19e 198821

20 244556

20a 101021

20b* 106560

20c 197566

20d 197567

21*** 244557

22 244558

22a* 111516

22b* 113137

22c 198403

22d 198404

22e 198453

22f 198464

22g 276753

24 249323

24a* 112085

25

26

197966

244714

26a 112691

27 244927

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

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

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No. Description

35

36

37

38

27a* 198307

28

30

276695

276698

39

40

185105

107460

276741

185103

110231

116553

41

42

43

50

54

55

59

51

52

53

44

45

47

48

49

244915

179791

180060

112080

198516

197967

198058

222385

188774

244627

111450

276734

197910

197624

245265

. 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, 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

Qty

1

1

1

1

1

* Included in Air Seal Repair Kit 244781.

*** Rubber seal is not removable.

Replacement Warning labels, signs, tags, and cards are available at no cost.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

309295K 43

Accessories

Accessories

Air Line Accessories Air Line Quick Disconnect

112534 Swiveling quick disconnect replaces standard air inlet swivel.

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

244964

244965

244966

244967

244968

244969

6 ft (1.8 m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

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.

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

223069

223070

223071

223072

223073

223074

6 ft (1.8 m)

15 ft (4.6 m)

25 ft (7.6 m)

36 ft (11 m)

50 ft (15 m)

75 ft (23 m)

100 ft (30.5 m)

Fluid Line Accessories

Nylon Fluid Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

223540 1/4 in. (6 mm) ID x 25 ft (7.6 m), 1/4 npsm

223541 1/4 in. (6 mm) ID x 50 ft (15.2 m), 1/4 npsm

Grounded Air Whip Hose

100 psi (7 bar, 0.7 MPa) Maximum Working Pressure

0.188 in. (5 mm) ID; 1/4 npsm(m) x 1/4 npsm(f) left-hand threads

236130

236131

3 ft (0.9 m)

6 ft (1.8 m)

Fluid Whip Hose

3000 psi (210 bar, 21 MPa) Maximum Working Pressure

0.125 in. (3 mm) ID; 1/4 npsm(f) x 1/4 npt(m)

236134

236135

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 closed.

107141 3/4 npt

Fluid Shutoff/Drain Valve

5000 psi (350 bar, 35 MPa) Maximum Working Pressure

For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.

210657 1/2 npt(m), Fluoroelastomer seals

210658

210659

214037

3/8 npt(m), Fluoroelastomer seals

3/8 npt x 1/4 npt(m), Fluoroelastomer seals

1/4 npt(m), PTFE seals

Air Line Shutoff Valve

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun on or off.

224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.

Fluid Swivel

5800 psi (405 bar, 40 MPa) Maximum Working Pressure

115898 1/4 npsm(m) x 1/4 npsm(f)

44 309295K

Accessories

Gun Accessories Cleaning Brush

105749 For cleaning air cap and fluid nozzle.

Gun Repair Kit

244781 Air Seal Repair Kit

Miscellaneous Accessories

Electrode Replacement Kit

244917 Includes five electrodes.

Ground Wire and Clamp

222011 For grounding pump and other components and equipment in the spray area.

12 gauge, 25 ft (7.6 m).

Inline Fluid Filters

238561

238563

100 mesh filter. Set of three.

60 mesh filter. Set of three.

Megohmmeter

241079 500 Volt output; 0.01-2000 megohms.

Not for use in hazardous areas.

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

245264

Medium Grip

Large Grip

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. Available at no charge from Graco.

Gun Washer Kit

245271 Use to convert Graco gun washers so they can clean PRO Xs4 air-assisted spray guns.

Instruction Signs

198310

198320

English Setup Instructions.

English Daily Care Instructions.

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.

Electrostatic Conductive Gloves (box of 12)

117823

117824

117825

Small

Medium

Large

309295K 45

Spray Tip Selection Chart

Spray Tip Selection Chart

Part No.

GG3411

GG3511

GG3611

GG3213

GG3313

GG3413

GG3513

GG3613

GG3107

GG3207

GG3307

GG3209

GG3309

GG3409

GG3211

GG3311

GG3215

GG3315

GG3415

GG3515

GG3615

Fan Width at

10 in. (250 mm) in. (mm)

2-4 (50-100)

4-6 (100-150)

6-8 (150-200)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

Orifice Size in. (mm)

0.007 (0.178)

0.009 (0.229)

0.011 (0.279)

0.013 (0.330)

0.015 (0.381)

Part No.

GG3619

GG3719

GG3421

GG3521

GG3621

GG3721

GG3821

GG3423

GG3217

GG3317

GG3417

GG3517

GG3617

GG3319

GG3419

GG3519

GG3523

GG3623

GG3723

GG3823

GG3425

GG3525

GG3625

GG3725

GG3825

Fan Width at

10 in. (250 mm) in. (mm)

4-6 (100-150)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

6-8 (150-200)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

8-10 (200-250)

10-12 (250-300)

12-14 (300-350)

14-16 (350-400)

16-18 (400-450)

Orifice Size in. (mm)

0.017 (0.432)

0.019 (0.483)

0.021 (0.533)

0.023 (0.584)

0.025 (0.635)

46 309295K

Technical Data

Technical Data

Category

Maximum Working Fluid Pressure

Maximum Working Air Pressure

Minimum Air Pressure to Gun Inlet

Maximum Fluid 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

3000 psi (21 MPa, 210 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 Xs4 AA (244572): 85 kV

PRO Xs4 AA (244573): 40-85 kV at 40 psi (0.28 MPa, 2.8 bar): 88.9 dB(A) at 100 psi (0.7 MPa, 7 bar): 99.7 dB(A) 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)

1/4 npsm(m)

1/4-18 npsm(m)

29.1 oz (825 g)

11.4 in. (29 cm)

Stainless Steel; Nylon, Acetal, Ultra-High Molecular

Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten

Wire, Polyethylene

Loctite® is a registered trademark of the Loctite Corporation.

309295K 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, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the barrel, handle, trigger, hook, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by

Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.

The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT

NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.

Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

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.

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 I.S. EN ISO 9001 www.graco.com

Revised 1/2009

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