Graco 309295K - Electrostatic Air-Assisted PRO Xs4 AA Spray Gun, U.S. Instructions-Parts List Manual
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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.
• 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
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
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.
Remix or refilter fluid.
Fluid too thick.
Reduce viscosity.
Worn fluid needle packings or shaft.
Replace fluid needle assembly (26);
Air valve (21) is not seating properly.
Clean and service air valve; see
Worn or damaged fluid needle ball.
Replace fluid needle (26); see page
Worn fluid seat housing (2).
Loose spray tip (3).
Replace seat housing; see page 26.
Tighten retaining ring (27); see page
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).
Add fluid if necessary.
Clean; see gun operation manual.
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
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
Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine
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 “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.
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.
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.
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,
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.
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,
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
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.
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.
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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Table of contents
- 3 List of Models
- 4 Warnings
- 4 Warning Symbol
- 4 Caution Symbol
- 4 Warning
- 6 Introduction
- 6 How the Electrostatic AA Spray Gun Works
- 7 Gun Overview
- 8 Installation
- 8 Install the System
- 8 Warning Sign
- 8 Ventilate the Spray Booth
- 10 Connect the Air Line
- 10 Connect the Exhaust Tube
- 11 Connect the Fluid Line
- 11 Filter the Fluid
- 11 Select a Spray Tip
- 12 Grounding
- 13 Check Electrical Grounding
- 14 Check Fluid Resistivity
- 14 Check Fluid Viscosity
- 15 Operation
- 15 Low Voltage Adjustment (Smart Guns Only)
- 16 Maintenance
- 16 Flush the Spray Gun
- 18 Electrical Tests
- 18 Test Gun Resistance
- 19 Test Power Supply Resistance
- 20 Test Barrel Resistance
- 21 Troubleshooting
- 21 Spray Pattern Troubleshooting
- 22 Gun Operation Troubleshooting
- 23 Electrical Troubleshooting
- 24 Repair
- 24 Pressure Relief Procedure
- 25 Prepare the Gun for Service
- 25 Tools Needed
- 26 Tip Guard, Air Cap, Spray Tip, or Seat Housing Replacement
- 28 Electrode Replacement
- 29 Fluid Tube Replacement
- 29 Fluid Filter Removal
- 30 Fluid Needle Replacement
- 31 Barrel Removal
- 31 Barrel Installation
- 32 Power Supply Removal and Replacement
- 33 Turbine Alternator Removal and Replacement
- 34 Atomizing Air Adjustment Valve Repair
- 35 Air Valve Repair
- 36 ES ON/OFF Valve Repair
- 37 Parts
- 44 Accessories
- 44 Air Line Accessories
- 44 Fluid Line Accessories
- 45 Gun Accessories
- 45 Miscellaneous Accessories
- 46 Spray Tip Selection Chart
- 47 Technical Data
- 48 Graco Standard Warranty
- 48 Graco Information