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Instructions 


Manual Electrostatic 

PRO™ Xs Waterborne 
Air Spray Gun 



GRACO 


312900G 

EN 


For use with conductive spray materials (waterborne and other materials 
less than 1 megohm-cm). For professional use ONLY. 

For use in Class I, Div. I hazardous locations using Group D spray materials. 

<F^ 

c^^us 

APPROVED 



PROVEN QUALITY. LEADING TECHNOLOGY. 








Table of Contents 

Warnings .3 

Overview.5 

How the Electrostatic Air Spray Gun Works .... 5 

Installation.9 

Install the System .9 

Warning Sign.9 

Ventilate the Spray Booth .9 

Connect the Air Line.11 

Connect the Charging Probe .11 

Connect the Exhaust Tube .12 

Connect the Fluid Line .12 

Filter the Fluid.12 

Select a Fluid Nozzle and Air Cap .13 

Grounding.14 

Check Electrical Grounding.15 

Check Fluid Resistivity .15 

Check Fluid Viscosity .16 

Prepare to Paint .16 

Flush.18 

Pressure Relief .19 

Shutdown.19 

Maintenance.20 

Electrical Troubleshooting.22 

Electrical Tests .23 

Test Total Gun Resistance .23 

Test Gun Resistance.23 

Test Charging Probe Resistance.23 

Test Power Supply Resistance .24 

Test Barrel Resistance .24 


Spray Pattern Troubleshooting.25 

Gun Operation Troubleshooting.26 

Gun Repair.27 

Prepare the Gun for Repair.27 

Replace Air Cap/Nozzle .28 

Replace Fluid Needle .28 

Remove Fluid Packing.29 

Repair Packing Rod.30 

Remove Barrel.31 

Install Barrel.31 

Remove and Replace Power Supply.32 

Remove and Replace Turbine Alternator.33 

Repair Fan Air Adjustment Valve.33 

Repair Fluid Adjustment Valve .34 

Repair Air Valve.34 

Remove and Replace Atomizing Air 

Restrictor Valve.35 

Repair ES ON/OFF Valve .35 

Parts .36 

Accessories .41 

Air Line Accessories .41 

Fluid Line Accessories .41 

Gun Accessories.42 

Miscellaneous Accessories.42 

Technical Data .43 

Graco Warranty .44 

Graco Information .44 


2 


312900G 

























































Warnings 


Warnings 

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama¬ 
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When 
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and 
warnings not covered in this section may appear throughout the body of this manual where applicable. 


AWARNING 

[• 

[7T 

k 

1 

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD 

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire 

and explosion: 

• Electrostatic equipment must be used only by trained, qualified personnel who understand the require¬ 
ments of this manual. 

• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See 
Grounding instructions. 

• Only use grounded Grace conductive air supply hoses. 

• Check gun and hose resistance and electrical grounding daily. 

• Use and clean equipment only in well ventilated area. 

• Interlock the gun air supply to prevent operation unless ventilating fans are on. 

• Use cleaning solvents with highest possible flash point when flushing or cleaning equipment. To com¬ 
ply with EN50050 requirements, cleaning solvents must have a flash point at least 5°C above ambient 
temperature. 

• Always turn the electrostatics off when flushing, cleaning or servicing equipment. 

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until 
you identify and correct the problem. 

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop 
cloths (potential static arc). 

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present. 

• Keep work area free of debris, including solvent, rags and gasoline. 

• Keep a working fire extinguisher in the work area. 

A 

ELECTRIC SHOCK HAZARD 

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric 
shock. 

• Turn off air supply before servicing equipment. 

• All electrical wiring must be done by a qualified electrician and comply with all local codes and 
regulations. 

• Do not touch gun electrode when electrostatics are on. 

• Do not expose to rain. Store indoors. 

A 

PRESSURIZED EQUIPMENT HAZARD 

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and 
cause serious injury. 

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, 
checking, or servicing equipment. 

• Tighten all fluid connections before operating the equipment. 

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


312900G 


3 












Warnings 


AWARNING 


EQUIPMENT MISUSE HAZARD 

Misuse can cause death or serious injury. 

• Do not operate the unit when fatigued or under the influence of drugs or alcohol. 

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com¬ 
ponent. See Technical Data in all equipment manuals. 

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and 
follow the Pressure Relief Procedure in this manual when equipment is not in use. 

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac¬ 
turer’s replacement parts only. 

• Do not alter or modify equipment. 

• Use equipment only for its intended purpose. Call your distributor for information. 

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. 

• Do not kink or over bend hoses or use hoses to pull equipment. 

• Keep children and animals away from work area. 

• Comply with all applicable safety regulations. 


TOXIC FLUID OR FUMES HAZARD 

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal¬ 
lowed. 

• Read MSDS’s to know the specific hazards of the fluids you are using. 

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. 

• Always wear impervious gloves when spraying or cleaning equipment. 

• If this equipment is used with isocyanate material, see additional information on isocyanates in Isocya¬ 
nate Conditions Section of this manual. 


4 


312900G 






Overview 


Overview 


How the Electrostatic Air Spray Gun Works 

The air hose supplies air to the spray gun. Part of the air The pump supplies fluid to the hose and gun, where the 

operates the turbine and the rest of the air atomizes the fluid is atomized by the air cap and the atomized parti- 

fluid being sprayed. The turbine generates power, which cles are electrostatically charged as they pass the 

is converted by the power cartridge to supply high volt- external charging probe. The charged fluid is attracted 

age current to the gun’s external charging probe. to the grounded workpiece, wrapping around and 

evenly coating all surfaces. The external charging 
allows the fluid supply to remain grounded at all times 
and therefore eliminate the need for an isolation sys¬ 
tem. 


KEY 

A Air swivel inlet page 6 
B Fluid inlet page 6 
C Turbine air exhaust page 6 
D Air cap and nozzle page 6 
E Fluid needle page 6 
F Fluid adjustment page 7 
G Fan air adjustment valve page 7 
H Atomizing air restrictor valve page 7 
I ES ON/OFF switch page 7 
J ES indicator (247936 only) page 8 
K Voltage/current display (247937 only) page 8 
L ES HI/LO switch (247937 only) page 8 
M LO voltage adjustment (247937 only) page 8 





312900G 


5 




























































Overview 


A. Air swivel inlet Left-hand thread. 



B. Fluid inlet. 




Turbine air exhaust 


D. 


Air cap and nozzle. See page 13 for sizes. 




E. Fluid needle. Shuts off fluid flow and provides a 
ground point. 



6 


312900G 









Overview 


F. Fluid adjustment valve. Adjusts fluid needle travel. 
Use only in low flow conditions, to reduce needle 
wear. 



G. 


Fan air adjustment valve. Adjusts fan size and 
shape. 



H. Atomizing air restrictor valve. Restricts atomizing 
air flow. Replace with plug (included) if desired. 



I. ES ON/OFF switch. Turns electrostatics ON (I) or 
OFF (0). 



312900G 


7 

















































Overview 


J. ES indicator (247936 oniy). Green when ES is ON 

(I). 



K. Voitage (247937 oniy). Shows voltage and 
current. 

Green/yellow=spray, 

red=see Electrical Troubleshooting, page 22. 

NOTE: Normal current draw for this model is higher 
and the yellow current bar will be lit. 



L. ES Hi/LO switch (247937 oniy). Sets voltage to HI 
or LO (factory settings). 



M. LO voitage adjustment (247937 oniy). Remove 
plug to adjust to 4 settings. 



ti12582 


M 


8 


312900G 







Installation 


Installation 

Install the System Warning Sign 



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 elec¬ 
trical 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 regula¬ 
tions. 


Fig. 1. shows a typical electrostatic air 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 








Provide fresh air ventilation to avoid t 
flammable or toxic vapors when spra^ 
or cleaning the gun. Do not operate tt 
ventilation fans are operating. 

he buildup of 
ring, flushing, 
ie gun unless 


Electrically interlock the gun air supply with the ventila¬ 
tors to prevent gun operation without ventilating fans 
operating. Check and follow all National, State, and 
Local codes regarding air exhaust velocity require¬ 
ments. 


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


312900G 


9 





















Installation 



Fig. 1. Typical Installation 


Key 

a Main Air Supply Line 

bt Ventilation Fan Interlock Solenoid Valve 
ci: Main Air Supply Shutoff Valve (bleed-type) 
d Pump Air Line FilterA/Vater Separator 
et Pump Air Supply Shutoff Valve (bleed-type) 

f Air Line Lubricator 

g Air Pressure Regulator 

h Pump 

Pump Ground Wire 
k Fluid Filter 

I Fluid Supply Line Shutoff Valve 

m Fluid Pressure Regulator 

n Fluid Supply Line 

0 Gun Air Line FilterA/Vater Separator 

p Gun Air Supply Line Shutoff Valve (bleed-type) 
qt Air Hose Ground Wire 


r^ Grace Grounded Air Hose 
s Electrostatic Air Spray Gun 
t Air Line Drain Valve 
ut Fluid Drain Valve 
V Gun Air Inlet 

w Gun Fluid Inlet 

t These items are required for proper operation 
and must be purchased separately. 

NOTE: Solenoid valve (b) is not offered as a 
Grace accessory. 


10 


312900G 










































































Installation 


Connect the Air Line 


A 


A 






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


1. Connect the Graco Grounded Air Supply Hose (R) 
between the air supply line and the gun's air inlet (V) 
(Fig. 2). The gun air inlet fitting has a left-hand 
thread. Connect the air supply hose ground wire (Q) 
to a true earth ground. 



Fig. 2 


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

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

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




The bleed-type air valve (E) is required in your sys¬ 
tem 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 splashing fluid 
in the eyes or on the skin. 


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

Connect the Charging Probe 

1. Apply dielectric grease to probe socket. 



2. Press electrode on in Connect/Disconnect position 
shown in Fig. 4. 

3. Rotate electrode to spray position. 



NOTICE 


The external charging probe rotates easily. Do not 
press too hard when rotating it or it could be dam¬ 
aged. 


NOTICE 


For proper performance, do not operate electro¬ 
statics if the charging probe is not in spray position. 


312900G 


11 


















































Installation 


Connect the Exhaust Tube 

Press the exhaust tube (38) onto the barbed adapter on 
the bottom of the gun handle. Secure the tube with the 
clamp (39) (Fig. 5). 



Connect the Fluid Line 



Fig. 6 


5. Before running any paint through the spray gun, 
flush it with a compatible solvent. 

Filter the Fluid 

Install a fluid filter (K) to remove particles and sediment 
that could clog the spray nozzle. 


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


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


3. Install a fluid filter (K) and drain valve (U) at the 
pump outlet. 


A 

A 






Thef 
assis 
pump 
press 
close 
reduc 
in the 

uid drain valve (U) is required in your system to 
t in relieving fluid pressure in the displacement 

1 , hose, and gun. Triggering the gun to relieve 
ure may not be sufficient. Install a drain valve 
to the pump's fluid outlet. The drain valve 
;es the risk of serious injury, including splashing 
i eyes or on the skin. 


4. Connect the fluid line to the 3/8 npsm gun fluid inlet 
(W) (Fig. 6). 


12 


312900G 














Installation 


Select a Fluid Nozzle and Air 
Cap 

The gun is supplied with Part No. 197266 Nozzle and 
24A276 Air Cap. If you require a different size, refer to 
Table 1 and Table 2 , and instruction manual 309419, or 
consult with your Graco distributor. See Replace Air 
Cap/Nozzle on page 28. 

A wide pattern kit (P/N 24A431) is included with the gun 
and if installed, will provide more fan air for wider spray 
patterns. (If pattern becomes split, use the fan air valve 
to reduce the amount of fan air.) 



To reduce the risk of an injury, follow the Pressure 
Relief procedure on page 19 before removing or 
installing a fluid nozzle and/or air cap. 


NOTE: Due to the larger needle diameter, use a nozzle 
one size larger than you would use with a standard Pro 
Xs gun (i.e., 1.5 mm = 1.2 mm flow area). 

Table 1: Fluid Nozzles 


Part No. 

Orifice Size 

197265 

1.2 mm (.047 in.) 

197266 

1.5 mm (.055 in.) 

197267 

1.8 mm (.070 in.) 

249922* 

1.2 mm (.047 in.) 

249923* 

1.5 mm (.055 in.) 

249924* 

1.8 mm (.070 in.) 


* Glass-reinforced acetal construction. 


Table 2: Air Caps 


Part No. 

Pattern Shape 
and Length in. 
(mm) 

Recommended Fluids and 

Production Rates 

24A438 

Round end; 

15-17 (381-432) 

Light to medium viscosity. 

Up to 15 oz/min (450 cc/min) 

24A279 

Round end; 
14-16(356-406) 

Medium to high viscosity and 
high solids. 

Up to 15 oz/min (450 cc/min) 

24A276* 

Tapered end; 
17-19(432-483) 

Light to medium viscosity. 

Up to 15 oz/min (450 cc/min) 

24A274 

Tapered end; 
12-14(305-356) 

Light to medium viscosity. 

Up to 15 oz/min (450 cc/min) 

24A439 

Round end; 
11-13(279-330) 

Medium to high viscosity and 
high solids. 

Up to 15 oz/min (450 cc/min) 
For use with 2.0 mm nozzle. 

24A275 

Tapered end; 
14-16(356-406) 

Light to medium viscosity and 
high solids. 

Aerospace coatings. 

Up to 25 oz/min (750 cc/min). 


‘Also available in the following colors: 
24A376 - gray 
24A277 - red 
24A278 - green 


312900G 


13 




























Installation 


Grounding 


A 


0f 



A 


A 

m 

Fire, Explosion, and 

When operating the ek 
objects in the spray an 
etc.) can become eleci 
grounding can result ir 
cause a fire, explosion 
grounding instructions 

Electric Shock Hazard 

jctrostatic gun, any ungrounded 
3a (people, containers, tools, 
trically charged. Improper 

1 static sparking, which can 
, or electric shock. Follow the 
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 gloves to 
ensure your hand contacts the grounded gun han¬ 
dle. 



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. 


• Electrostatic Air Spray Gun: ground the gun by con¬ 
necting the Graco Grounded Air Hose and connect¬ 
ing the air hose ground wire to a true earth ground. 
See Check Electrical Grounding, page 15. 



• 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. 


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



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



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




• All electrically conductive objects or devices in the 
spray area: including fluid containers and wash 
cans, must be properly grounded. 



14 


312900G 























Installation 


Check Electrical Grounding 


A 


A 


A 

m 

1 

Fire, Explosion, and E 

Electric Shock Hazard 


Megohmmeter Part No. 241079 (AA-see Fig. 7.) 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, explo¬ 
sion, and electric shock and result in serious injury 
and property damage. 


BB 



Fig. 7. Check Gun Grounding 

Check Fluid Resistivity 


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 fiuid suppiy to the gun. The fiuid 
hose must not have any fiuid in it. 


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


i m 

\% 1 ■ 


5. Measure the resistance between the gun handie 
(BB) and a true earth ground (CC). Use an appiied 
voitage of 500 minimum to 1000 voits maximum. 
The resistance shouid not exceed 1 megohm. See 
Fig. 7. 



Fire, Expiosion, and Eiectric Shock Hazard 

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

Failure to follow this warning couid cause fire, explo¬ 
sion, or electric shock and result in serious injury and 
property damage. 


Grace Part No. 722886 Resistance Meter and 722860 
Probe are avaiiable as accessories to check that the 
resistivity of the fiuid being sprayed meets the require¬ 
ments of an eiectrostatic air spray system. 

Foiiow the instructions inciuded with the meter and 
probe. If the material is above 1 megohm-cm, then a Pro 
Xs3 HC gun may be a better option. The Pro Xs WB gun 
is intended to spray very conductive waterborne materi¬ 
als and other materials less than 1 megohm-cm. 


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. 


312900G 


15 





































Installation 


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. Adjust as necessary. 

Prepare to Paint 

1. Position air cap. 



2. Fully open fan air adjustment valve. 



4. Fully open atomizing air restrictor valve. 




NOTE: This illustration 
shows the switch in the 
ON (I) position to view 
I and O indicators. 


ti 12723 

6. Start pump. Adjust fluid regulator until stream from 
gun travels 8-12 in. (200-300 mm) before falling off. 
Typically, if fluid pressure is below 5 psi (.04 MPa, 
0.4 bar) or above 20 psi (0.14 MPa, 1.4 bar), a 
change of nozzle size is recommended. 




3. 


Fully open fluid adjustment valve. 



16 


312900G 


























































Installation 


7. 


Set gun air regulator to deliver minimum 40 psi (0.28 
MPa, 2.8 bar) at gun when triggered, for maximum 
transfer efficiency. See table at right. 




Air Hose* Length 
ft(m) 

Regulator Setting** 
psi (MPa, bar) 

15 (4.6) 

50 (0.35, 3.5) 

25 (7.6) 

60 (0.42, 4.2) 

50(15.3) 

75 (0.52, 5.2) 


* 5/16 in. (8 mm) diameter/8 mm (5/16 in.) 

“Gun triggered 

8. Spray test pattern. Check atomization. If over-atomi- 
zation occurs at minimum pressure, adjust restrictor 
valve. If atomization is inadequate, increase air 
pressure. 


ti1282b 

9. Adjust fan air adjustment valve: clockwise for a 
shorter pattern, counterclockwise for wider pattern. 




11. Check that ES indicator or display is lit. If not, 

see Electrical Troubleshooting, page 22. 



12. Spray test piece. Examine edges for coverage. If 
wrap is poor, see Spray Pattern Troubleshooting, 
page 25. 




312900G 


17 



































































Installation 


Flush 


A 


0f 



A 



Fire, Explosion, and 
Read Fire and Explos 
Hazards, page 3. Folic 
gun when using gun fir 
fluid dries, at end of dc 

Electric Shock Hazard 
iion, and Electric Shock 

)w steps 1 -6 below to flush the 
St time, changing colors, before 
ly, and before storing gun. 


NOTICE 


This gun has nylon components which will be dam¬ 
aged if you use methylene chloride as a flushing or 
cleaning solvent. 


1 . 


Turn ES ON/OFF switch OFF (O). 



2. Relieve pressure, page 19. 



ti1934 


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



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



ti1934 


5. Relieve pressure, page 19. 



ti1934 


6 . 


Hang gun from hook. Nozzle must point down. 



til 2718 


18 


312900G 







































Pressure Relief 


Pressure Relief 



Pressurized Equipment Hazard 

The system pressure must be manually relieved to 
prevent the system from starting or spraying acciden¬ 
tally. To reduce the risk of an injury from electric shock, 
accidental spray from the gun, splashing fluid, or mov¬ 
ing parts, follow the Pressure Relief Procedure 
whenever you: 

• are instructed to relieve the pressure 

• stop spraying 

• check or service any of the system equipment 


5. If the nozzle or hose is completely clogged or pres¬ 
sure is not fully relieved, slowly loosen the hose end 
coupling. Now clear the nozzle or hose. 



Shutdown 

Follow these steps at end of workshift and before clean¬ 
ing, checking, or repairing equipment 


1. Turn the ES ON/OFF valve OFF. 


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


ti1289 




3. 


Trigger the gun into a grounded metal waste con¬ 
tainer to relieve the fluid pressure. 



1 . 


Flush, page 18. 



2 . 


Hang gun from hook. Nozzle must point down. 



ti12718 


4. 


Open the pump drain valve, having a waste con¬ 
tainer ready to catch the drainage. Leave the pump 
drain valve open until you are ready to spray again. 



312900G 


19 





























Maintenance 


Maintenance 


Clean Gun Daily 


1. Flush, page 18. 



a. Clean outside of gun with non-conductive, 
compatible solvent. Point gun down. 

b. Use soft, damp cloth. 

c. Do not immerse gun. 



3. Remove air cap. 



ti1296 



4. 


Clean air cap, retaining ring, and nozzle with soft 
brush and non-conductive, compatible solvent. 



5. Clean probe with soft brush and compatible solvent. 



ti12716 


6. Use toothpick or other soft tool to clean air cap 
holes. Do not use metal tools. 



7. Reinstall air cap. Tighten securely. 



20 


312900G 













Maintenance 


Daily System Care 


1. Relieve pressure, page 19. 



2. Clean fluid and air filters. 



5. Check movement of trigger (T) and valves (V). 
Lubricate if necessary. 



3. Check for fluid leaks. Tighten all fittings. 



4. Clean workpiece hangers. Use non-sparking tools. 



312900G 


21 




































Electrical Troubleshooting 


Electrical Troubleshooting 


A 

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 prop¬ 
erly. Do not install or repair this equipment unless you 
are trained and qualified. 



NOTE: Check all possible remedies in the Troubleshoot¬ 
ing Chart before disassembling the gun. 


Problem 

Cause 

Solution 

Poor wrap. 

(In general, a Pro Xs Waterborne gun 
will have less wrap than a Pro Xs 
solventborne gun.) 

ES ON/OFF valve OFF (0).* 

Turn ON (I). 

Gun air pressure too low. 

Check air pressure to gun; minimum 
40 psi (0.28 MPa, 2.8 bar) needed at 
gun for full voltage. 

Atomizing air pressure too high. 

Decrease. 

Fluid pressure too high. 

Decrease. 

Incorrect distance from gun to part. 

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

Poorly grounded parts. 

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

Faulty gun resistance. 

See Test Total Gun Resistance on 

page 23. 

Faulty turbine alternator. 

Be sure the plug is in place on the 
back of the power supply housing. 
Remove and test the turbine alterna¬ 
tor. See page 33. 

The KV HI-LO lever is on LO. 

Check the lever actuation; replace if 
needed. 

ES indicator or voltage/current dis¬ 
play is not lit. 

ES ON/OFF valve OFF (0).* 

Turn ON (1). 

No power. 

Replace power supply. See page 32. 

Voltage/current display stays red 
(smart guns only). 

Gun too close to part. 

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

Dirty gun. 

Clean. See Maintenance on page 

20. 

Operator gets mild shock. 

Operator not grounded or is near 
ungrounded object. 

See Grounding on page 14. 

Gun not grounded. 

See Check Electrical Grounding on 
page 15 and Test Total Gun Resis¬ 
tance on page 23. 

Operator gets shock from workpiece. 

Workpiece not grounded. 

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


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


22 


312900G 






































Electrical Tests 


Electrical Tests 


Electrical components inside the gun affect performance 
and safety. The following procedures test the condition 
of the power supply (18), barrel (16) and charging probe 
(31), and electrical continuity between components. 

Use megohmmeter Part No. 241079 (AA) and an 
applied voltage of 500 V. Connect the leads as shown. 


Test Gun Resistance 

Measure resistance between the air swivel (35) and the 
charging probe socket (CC) (see Fig. 9); it should be 
70-95 megohms. If outside this range, check the power 
supply and barrel resistance. If in range, test the charg¬ 
ing probe resistance. 


A 







Fire, Expiosion, and Eiectric Shock Hazard 


Megohmmeter Part No. 241079 (AA-see Fig. 8. 
through Fig. 12.) is not approved for use in a hazard¬ 
ous areas. 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, explo¬ 
sion, and electric shock and result in serious injury 
and property damage. 


Test Total Gun Resistance 

Measure resistance between the charging probe tip 
(BB) and the air swivel (35) (see Fig. 8.); it should be 
90-130 megohms. If outside this range, go to the next 
test. If in range, refer to Gun Repair on page 27 for 
other possible causes of poor performance. 


AA 





BB 



Fig. 8. Test Totai Gun Resistance 


ti1468ax 



ti13731 


Test Charging Probe Resistance 

Measure resistance between the metal spring in the 
charging probe (DD) and the charging probe tip (BB) 
(see Fig. 9); it should be 15-30 megohms. If outside this 
range, replace the charging probe. If in range, inspect 
the spring and barrel socket for possible causes of poor 
continuity. Reassemble the charging probe and retest 
the gun resistance. 



Fig. 10. Test Charging Probe Resistance 


312900G 


23 



















































































Electrical Tests 


Test Power Supply Resistance 

1. Remove the power supply (18), page 31. 

2. Remove the turbine alternator (19) from the power 
supply, page 32. 

3. Measure resistance from the power supply's ground 
strips (EE) to the conductive contact in the center of 
the power supply seal (FF). See Fig. 11. 

4. The resistance should be 55-70 megohms. If out¬ 
side this range, replace the power supply. If in 
range, proceed to the next test. 



Fig. 11. Test Power Supply Resistance 


Test Barrel Resistance 

1. Insert a conductive rod (GG) into the gun barrel 
(removed for the power supply test) and against the 
metal contact (HH) in the front of the barrel. 

2. Measure the resistance between the conductive rod 
(GG) and the charging probe socket (CC). See Fig. 
12. The resistance should be 15-30 megohms. 

3. If the resistance is outside the range, replace barrel. 

4. If resistance is in range, reassemble the gun and 
test the gun resistance. 

5. If you still have problems, refer to Gun Repair on 
page 27 for other possible causes of poor perfor¬ 
mance, or contact your Graco distributor. 



ti12821 


Fig. 12. Test Barrel Resistance 


24 


312900G 























































































Spray Pattern Troubleshooting 


Spray Pattern Troubleshooting 


NOTE: Check all possible remedies In the Troubleshoot¬ 
ing Chart before disassembling the gun. 

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


A 





Pressurized Equipment Hazard 

To reduce the risk of an injury, follow the Pressure 
Relief procedure on page 19 whenever you are 
instructed to relieve the pressure. 


A 



A 





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 prop¬ 
erly. Do not install or repair this equipment unless you 
are trained and qualified. 


Problem 

Cause 

Solution 

Fluttering or spitting spray. 

> l| 

No fluid. 

Refill supply. 

Loose, dirty, damaged nozzle/seat. 

Clean or replace nozzle, page 28. 

Air in fluid supply. 

Check fluid source. Refill. 

Improper spray pattern. 

Damaged nozzle or air cap. 

Replace, page 28. 


Fluid buildup on air cap or nozzle. 

See Maintenance on page 20. 


Fan air pressure too high. 

Decrease. 

Fluid too thin. 

Increase viscosity. 

Fluid pressure too low. 

Increase. 


Fan air pressure too low. 

Increase. 

Fluid too thick. 

Reduce viscosity. 

Too much fluid. 

Decrease flow. 

Streaks. 

Did not apply 50% overlap. 

Overlap strokes 50%. 

Dirty or damaged air cap. 

Clean or replace, page 28. 


312900G 


25 





































Gun Operation Troubleshooting 


Gun Operation Troubleshooting 


NOTE: Check all possible remedies in the Troubleshoot¬ 
ing Chart before disassembling the gun 



Pressurized Equipment Hazard 

To reduce the risk of an injury, follow the Pressure 
Relief procedure on page 19 whenever you are 
instructed to relieve the pressure. 


A 



A 





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 prop¬ 
erly. Do not install or repair this equipment unless you 
are trained and qualified. 


Problem 

Cause 

Solution 

Excessive spray fog. 

Atomizing air pressure too high. 

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

Fluid too thin. 

Increase viscosity. 

“Orange Peel” finish. 

Atomizing air pressure too low. 

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

Poorly mixed or filtered fluid. 

Remix or refilter fluid. 

Fluid too thick. 

Reduce viscosity. 

Fluid leaks from the fluid packing 
area 

Worn packings or rod. 

Replace packings or rod; see page 

30. 

Air leaks from the front of the gun 

Air valve (21) Is not seating properly. 

Clean and service air valve; see 
page 34. 

Fluid leakage from the front of the 
gun 

Worn or damaged packing rod (26). 

Replace; see page 30 

Worn fluid seat. 

Replace fluid nozzle and/or needle; 
see page 28. 

Loose fluid nozzle (7). 

Tighten; see page 28. 

Damaged nozzle o-ring (7b). 

Replace; see page 28. 

Gun does not spray 

Low fluid supply. 

Add fluid if necessary. 

Damaged air cap (9). 

Replace; see page 28. 

Dirty or clogged fluid nozzle (7). 

Clean; see page 28. 

Damaged fluid nozzle (7). 

Replace; see page 28. 

Damaged fluid adjustment valve (25). 

Replace; see page 34. 

Dirty air cap 

Misaligned air cap (9) and fluid 
nozzle (7). 

Clean fluid buildup off air cap and 
fluid nozzle seat; see page 28. 


26 


312900G 









































Gun Repair 


Gun Repair 


Prepare the Gun for Repair 



A 





A 


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. 


Pressurized Equipment Hazard 

• To reduce the risk of injury, follow the Pressure 
Relief procedure on page 19 before checking or 
servicing any part of the system and whenever you 
are instructed to relieve the pressure. 



Check all possible remedies in Gun Operation 
Troubleshooting before disassembling the gun. 

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

Lubricate the power supply seal (18a), some pack¬ 
ing rod parts (26), and certain fluid fittings with 
dielectric grease (40), as specified in the text. 

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

Only use genuine Grace parts. Do not mix or use 
parts from other PRO Gun models. 

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

Fluid Seal Repair Kit 244911 is available. The kit 
must be purchased separately. Kit parts are marked 
with a double asterisk, for example (5t). 


1. Flush the gun, page 18. 


2. Relieve the pressure, page 19. 


3. Disconnect the gun air and fluid lines. 


4. Remove the gun from the worksite. Repair area 
must be clean. 


312900G 


27 





















Gun Repair 


Replace Air Cap/Nozzle 


NOTICE 


Hold the front end of the gun up and trigger the 
gun while removing the nozzle to help drain the 
gun and prevent any paint or solvent left in the gun 
from entering the air passages. 


Use non-silicone grease, Part No. 111265, on the 
smaii o-ring (7b). Do not over-iubricate. Do not iubri- 
cate the contact ring (7a). 

5. Lightly lubricate the o-ring (7b). Install it and the 
contact ring (7a) on the nozzle (7). 

Make sure the fluid needle (29) is finger- tight (page 
28). 


1. Prepare gun for repair page 27. 

2. Remove probe. 

3. Remove the retaining ring (27) and air cap (9). See 
Fig. 13. 


4. Point gun up and squeeze trigger while removing 
the fluid nozzle (7) assembly with the multi-tool (37). 



Fig. 13. Repiace Air Cap/Nozzie 


6. Trigger gun while installing the fluid nozzle (7) with 
the multi-tool (37). Tighten until the fluid nozzle 
seats in the gun barrel (1/8 to 1/4 turn past 
hand-tight). 

7. Install the air cap (9) and retaining ring (27). Make 
sure the u-cup (27a*) is in place with the lips facing 
forward. 

Replace Fluid Needle 

1. Prepare the gun for repair page 27. 

2. Remove the air cap and nozzle, page 28. 

3. Unscrew the fluid needle (29). Hold the packing rod 
end (26) to prevent it from turning, Fig. 13. 

4. Apply low-strength (purple) Loctite® or equivalent 
thread sealant to the fluid needle and packing rod 
threads. Install the fluid needle finger-tight. Do not 
overtighten. 

5. Install the fluid nozzle and air cap, page 28. 


A 



A 




Fire, Explosion, and 

The nozzle contact rin( 
ring, not a sealing o-rir 
ing or electric shock, d( 
ring (7a) except to repi 
gun without the contac 
the contact ring with ai 
part. 

Electric Shock Hazard 

g (7a) is a conductive contact 
ig. To reduce the risk of spark- 
0 not remove the nozzle contact 
ace it and never operate the 
;t ring in place. Do not replace 
lything but a genuine Graco 


28 


312900G 
















Gun Repair 


Remove Fluid Packing 

1. Prepare the gun for repair, page 27. 

2. Remove the air cap and fiuid nozzie, page 28. 

3. Remove the fiuid needie, page 28. 

4. Loosen the trigger screws (8) and trigger (30). See 
Fig. 14. 

5. Remove the packing rod (26), using the muiti-tooi 
(37). 


NOTICE 


Clean all parts in non-conductive solvent compati¬ 
ble with the fluid being used, such as xylol or min¬ 
eral spirits. Use of conductive solvents can cause 
the gun to malfunction. 


6. Check all parts for wear or damage and replace if 
necessary. 



Fig. 14. Remove Fluid Packing 


312900G 


29 














Gun Repair 


Repair Packing Rod 

You may replace the packing rod as individual parts or 
as an assembly. The assembly is pre-adjusted at the 
factory for proper air lead and lag. The gun begins emit¬ 
ting air before the fluid is discharged and the fluid stops 
before the air flow stops. 

To adjust the lead/lag air flow: 

1. Remove the spring (4) from the nut (E). 

2. Use a hex wrench to hold the end of the packing 
rod. Turn the nut (E) out to increase the lead/lag 
time for the air flow. The recommended adjustment 
is one half turn and not more than one full turn. 

3. Apply thread-locking adhesive to fix the nut in the 
new position. 

Before installing the fluid packing rod into the gun 
barrel, make sure the internal surfaces of the barrel 
are clean. Remove any residue with a soft brush or 
cloth. Check the inside of the barrel for marks from 
high voltage arcing. If marks are present, replace 
the barrel. 

To assemble the individual parts: 

1. Place the packing nut (26g) and seal (26ft) on the 
fluid rod (26a). Flats on the packing nut must face 
the back of the fluid rod. The seal o-ring must face 
away from the packing nut. See Fig. 15. 


2. Fill the inner cavity of the spacer (26et) with dielec¬ 
tric grease (40). Place the spacer on the fluid rod 
(26a) in the direction shown. Generously apply 
dielectric grease to the outside of the spacer. 

3. Place the rod packing (26dt), packing spreader 
(26ct), and housing (26b) on the packing rod (26h). 

4. Lightly tighten the packing nut (26g). The packing 
nut is properly tightened when there is 3 lb (13.3 N) 
of drag force when sliding the packing housing (26b) 
assembly along the rod. Tighten or loosen the pack¬ 
ing nut as needed. 

5. Install the o-ring (26ht) on the outside of housing 
(26f). Lubricate the o-ring with non-silicone grease, 
Part No. 111265. Do not over-lubricate. 

6. Install the spring (4) against the nut (E) as shown. 

7. Install the packing rod assembly (26) into the gun 
barrel. Using the multi-tool (37), tighten the assem¬ 
bly until just snug. 

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

9. Install the fluid needle page 28. 

10. Install the nozzle and air cap, page 28. 

11. Install the probe. 


26g 




ti12719 


30 


312900G 


Gun Repair 


Remove Barrel 


Install Barrel 


1. Prepare the gun for repair, page 27. 

2. Carefully loosen the nut (54) from the bracket fluid 
fitting (13). Pull the tube (14 or 50a) out of the fitting. 
Make sure both ferrules and the nut stay with the 
tube. 


1. Be sure the gasket (10*) and grounding spring (53) 
are in place. Make sure the air holes are aligned 
properly. Replace if damaged. See Fig. 17. 

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


3. Loosen the three screws (11). 


NOTICE 


To avoid damaging the power supply (18), pull the 
gun barrel straight away from the gun handle. If 
necessary, gently move the gun barrel from side to 
side to free it from the gun handle. 


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



3. Tighten the three screws (11) oppositely and evenly 
(about a half turn past snug). 


NOTICE 


Do not over-tighten the screws (11). 


4. Assemble the fluid tube (14) into the bracket fitting 
(13). Ensure that the ferrules are in place. Tighten 
the nut (54). 


5. Test gun resistance, page 23. 



312900G 


31 














Gun Repair 


Remove and Replace Power 
Supply 

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


11. Install the barrel (16), page 31. Ensure the ground 
spring (53) is in place. 

12. Test gun resistance, page 23. 


• Do not expose gasket (10) to solvents. 

1. Prepare gun for service, page 27. 

2. Remove the barrel (16), page 31. 


3. Grasp the power supply (18) with your hand. With a 
gentle side to side motion, free the power sup¬ 
ply/alternator assembly from the gun handle (17), 
then carefully pull it straight out. On Smart Model 
only, disconnect the flexible circuit (59) from the 
socket at the top of the handle (17). See Fig. 18. 

4. Disconnect the 3-wire connector (GG) from the 
power supply. Slide the alternator up and off the 
power supply. Inspect the power supply and alterna 
tor for damage. On Smart Model only, disconnect 
the 6-pin flexible circuit (59) from the power supply. 

5. Check the power supply resistance, page 24. 

Replace if necessary. Piq_ pQy^0|- Supply 


6. On Smart Model only, connect the 6-pin flexible cir¬ 
cuit (59) to the power supply. 

7. Connect the 3-wire connector (GG). Slide the alter¬ 
nator (19) down onto the power supply (18). 

8. Lubricate the alternator o-ring (19a*) with non-sili- 
cone grease. Part No. 111265. Do not over-lubri- 
cate. Ensure the alternator pads (19e) are in place. 

9. Lubricate the power supply seal (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 Model only, con¬ 
nect the flexible circuit (59) to the socket at the top 
of the handle. Push the 6-pin connector into the 
socket to ensure it is properly connected. 


NOTICE 


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




32 


312900G 










Gun Repair 


Remove and Replace Turbine 
Alternator 

Replace turbine alternator bearings after 2000 hours 
of operation. Order Part No. 223688 Bearing Kit. 

1. Prepare gun for repair, page 27. 

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 termi¬ 
nals of the 3-wire connector (GG); it should be 

2.5-3.5 ohms. If outside this range, replace the alter¬ 
nator coil. 

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

6. Install the alternator on the power supply, page 32. 

7. Install the power supply/alternator assembly, page 
32. 


Repair Fan Air Adjustment Valve 

1. Prepare the gun for service, page 27. 

2. Place a wrench on the flats of the valve assembly 
(20) and unscrew it from the handle (17). 

You may replace the valve as an assembly (go to 
step 9) or as individual parts (steps 3-9). 

3. Remove the retaining ring (20a). See Fig. 19. 

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

5. Remove the o-ring (20b). 

6. Clean all parts and inspect for wear or damage. 

Use non-silicone grease. Part No. 111265. Do not 
over-lubricate. 

7. When reassembling the fan air valve (20), lightly 
lubricate the valve threads and screw the stem (20d) 
fully into the housing (20c) until bottomed. Install the 
o-ring (20b*), lubricate, and unscrew the valve stem 
until the o-ring enters the housing. 

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). 



20b* 



Fig. 19. Fan Air Adjustment Valve 


312900G 


33 


Gun Repair 


Repair Fluid Adjustment Valve 

1. Prepare the gun for repair, page 27. 

2. Remove the fluid adjustment valve (25). It can only 
be replaced as a complete assembly. See Fig. 20.. 

3. Screw the valve (25) into the gun handle. Torque to 
15-25 in-lb (1.7-2.8 N»m). 



Repair Air Valve 


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 fluid adjustment valve (25). Torque to 
15-25 in-lb (1.7-2.8 N»m). 

8. Install the barrel, page 31. 



Fig. 21. Air Vaive 


1. Prepare the gun for service, page 27. 

2. Remove the barrel, page 31. 

3. Remove the fluid adjustment valve (25) from the 
handle (17). Remove the spring (15). See Fig. 21. 


NOTICE 


Clean all parts in non-conductive solvent compati¬ 
ble with the fluid being used, such as xylol or min¬ 
eral spirits. Use of conductive solvents can cause 
the gun to malfunction. 


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


NOTICE 


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


34 


312900G 












Gun Repair 


Remove and Replace Atomizing 
Air Restrictor Valve 

1. Prepare the gun for repair, page 27. 

2. Remove the atomizing air restrictor valve (23). 
Inspect the o-ring (23c*). Replace if necessary. See 
Fig. 22. 

3. Install a new atomizing air restrictor valve (23), or 
disassemble and replace parts individually. The 
valve protrusion must be oriented to clear the air 
valve (21) shaft. 

If the atomizing air restrictor valve is not desired, 
install the supplied plug (2). 

4. Torque the valve housing (23a) to 15-20 in-ib 
(1.7-2.3 N»m). 



Repair ES ON/OFF Valve 

1. Prepare the gun for repair, page 27. 

2. Loosen the screw (48). Remove the vaive. 

3. Lubricate the o-rings (22a* and 22b*) with non-siii- 
cone grease. Part No. 111265. Do not over-lubri- 
cate. 


NOTICE 


Do not over-iubricate parts. Excessive iubricant on 
the o-rings can be pushed into the gun air passage 
and biemish the finish on the workpiece. 


4. Clean and Inspect parts for damage. Replace if nec¬ 
essary. 

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

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



Fig. 23. ES ON/OFF Valve 


312900G 


35 







Parts 


Parts 

Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model) 

See page 38 for detail views of the alternator (19), fan adjustment 
valve (20), ES ON/OFF valve (22), and packing rod (26). 



36 


312900G 




Parts 


Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model) 


See page 38 for detail views of the alternator (19), fan adjustment 
valve (20), ES ON/OFF valve (22), and packing rod (26). 


A Maximum torque 10 in-lb (1.1 N»m) 



Ref. No. 37: Multi-tool 



14 24a* 

/ 24 " 

54 


ti 12659 


25 


312900G 


37 







Parts 


Ref. No. 19: Alternator Ref. No. 20: Fan Adjustment Valve 




38 


312900G 














































Part No. 247936 60 kV Electrostatic Gun, Series A (Standard model) 
Part No. 247937 60 kV Electrostatic Gun, Series A (Smart model) 


Ref. 

No. 

Part No. 

Description 

Qty 

Ref. 

No. 

Part No. 

Description 

1 

111157 

FITTING, tube, fluid 

1 

20 

244556 

VALVE, adjustment, fan; includes 
20a-20d 

2 

197967 

PLUG, handle 

1 

20a 

101021 

. RING, retaining 

3 

198058 

SCREW, cap, socket head 

1 

20b* 

106560 

. O-RING; fluorocarbon 

4 

185111 

SPRING, compression 

1 

20c 

197566 

. HOUSING, fan valve 

5 

111450 

PACKING, o-ring (247937 only) 

1 

20d 

197567 

. STEM, fan valve 

6* 

188749 

PACKING, u-cup, air valve; 
UHMWPE 

1 

21 ❖ 

244557 

VALVE, air; 

7 

197266 

NOZZLE; 1.5 mm orifice; includes 

1 

22 

244558 

VALVE, electrostatics, ON/OFF; 



7a and 7b 




includes 22a-22g 

7a 

111261 

. O-RING, conductive 

1 

22a* 

111516 

. O-RING; CV75 

7b 

111507 

. O-RING; fluoroelastomer 

1 

22b* 

113137 

. O-RING; fluoroelastomer 

8 

24A445 

SCREW, trigger 

2 

22c 

198403 

. SHAFT, valve 

9 

24A276 

AIR CAP 

1 

22d 

198404 

. PLATE, retaining 

10* 

197517 

GASKET, barrel 

1 

22e 

198453 

. WASHER 

11 

197518 

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

3 

22f 

198464 

. PIN 




22g 

249185 

. KNOB 

13 

24A336 

BRACKET, inlet, fluid 

1 

23 

244559 

VALVE, air restrictor; includes 

14 

24A334 

TUBE, fluid 

1 



23a-23d 

15 

185116 

SPRING, compression 

1 

23a 

197594 

. HOUSING, valve 

16 

24A329 

BODY, gun; ES; includes 16a-16e 

1 

23b 

197591 

. SHAFT 

17 

24A596 

HANDLE, smart (247937) 

1 

23c* 

111504 

. O-RING; fluoroelastomer 


24A595 

HANDLE, standard (247936) 

1 

23d 

101021 

. RING, retaining 

18 

24A332 

POWER SUPPLY, 60 kV 

1 

24 

249323 

VALVE, exhaust; includes 24a 

18a 

256267 

. SEAL 

1 

24a* 

112085 

. O-RING; fluorocarbon 

19 

244555 

TURBINE, alternator; includes 
19a-19e 

1 

25 

244593 

VALVE, adjustment, fluid 

19a* 

110073 

. O-RING; fluoroelastomer 

1 




19b 

223688 

. BEARING KIT; includes front and 
rear bearings and fan 

1 




19c 

244577 

. COIL 

1 




19d 

111745 

. RING, retaining 

1 




19e 

198821 

. PAD, pressure 

2 





312900G 



Parts 


Ref. 

No. 

Part No. 

Description 

Qty 

26 

24A331 

NEEDLE; includes 26a-26h 

1 

26a 

24A330 

. NEEDLE, assembly 

1 

26b 

185495 

. HOUSING, packing 

1 

26ct 

178763 

. PACKING, needle 

1 

26dt 

178409 

. PACKING, fluid 

1 

26et 

186069 

. SPACER, packing 

1 

26ft 

116905 

. SEAL 

1 

26g 

197641 

. NUT, packing 

1 

26ht 

111316 

. PACKING, o-ring 

1 

27 

244927 

RING, retaining; includes 27a 

1 

27a* 

198307 

. PACKING, u-cup 

1 

29 

24A338 

NEEDLE, electrode 

1 

30 

24A335 

TRIGGER 

1 

31 

24A328 

PROBE, external charging 

2 

32 

111285 

FERRULE, back 

1 

35 

24N626 

SWIVEL, air; 1/4 npsm(m); 
left-hand threads 

1 

36 

107460 

WRENCH, ball end; 4 mm 

1 

37 

276741 

MULTI-TOOL 

1 

38 

185103 

TUBE, exhaust (not shown) 

1 

39 

110231 

CLAMP (not shown) 

1 

40 

116553 

GREASE, dielectric, tube (not 
shown) 

1 

41 

244915 

COVER, gun; box of 10 (not shown) 

1 


Ref. 

No. 

Part No. 

Description 

Qty 

42A 

179791 

TAG, warning (not shown); replace¬ 
ment available at no cost 

1 

43A 

180060 

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

1 

53 

197624 

SPRING, compression 

1 

54 

112644 

NUT, swagelock 

1 

55 

111286 

FERRULE, front 

1 

56 

197910 

SCREW, pivot, ES HI/LO (247937 
only) 

1 

57 

276734 

PLUG, KV adjust (247937 only) 

1 

58 

244627 

SWITCH, ES HI/LO (247937 only) 

1 

59 

245265 

CIRCUIT, flexible (247937 only) 

1 

60 

248130 

O-RING (pack of 6) 

1 

61 

24A431 

KIT, wide pattern (not shown) 

1 


* Included in Air Seal Repair Kit 244781. 

t Included in Fluid Seal Repair Kit 244911. 

❖ Rubber seal is not removable. 

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


40 


312900G 



Accessories 


Accessories 


Air Line Accessories 

AirFlex™ Flexible Grounded Air Hose 

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand 
thread 

244963 6 ft (1.8 m) 

244964 15 ft (4.6 m) 

244965 25 ft (7.6 m) 

244966 36 ft (11 m) 

244967 50 ft (15 m) 

244968 75 ft (23 m) 

244969 100 ft (30.5 m) 

Standard Grounded Air Hose 

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand 
thread 

223068 6 ft (1.8 m) 

223069 15 ft (4.6 m) 

223070 25 ft (7.6 m) 

223071 36 ft (11 m) 

223072 50 ft (15 m) 

223073 75 ft (23 m) 

223074 100 ft (30.5 m) 

High Flow Grounded Air Hose 

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

0.375 in. (10 mm) ID; 3/8 npsm(f) x 1/4 npsm(f) left-hand 
thread 

24A225 50 ft (15.2 m) 

24A226 75 ft (22.9 m) 

Bleed-Type Master Air Valve 

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure 

Relieves air trapped in the air line between this valve 
and the pump air motor when closed. 

107141 3/4 npt 

Air Line Shutoff Valve 

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure 
For turning air to gun on or off. 

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


Air Line Quick Disconnect 

112534 Swiveling quick disconnect replaces stan¬ 
dard air inlet swivel. 

Air Hose Adapter Nipple 

185493 Use to connect multiple air hoses. 1/4 npt x 
1/4 npsm left-hand thread. 

Non-Swivel Air Inlet Fitting 

185105 Replaces standard swivel. Left-hand thread. 

Extended Air Inlet Fitting 

189191 Replaces standard swivel to provide 
extended handle grip area. Left-hand 
thread. 

Fluid Line Accessories 

Fluid Hose 

225 psi (14 bar, 1.4 MPa) Maximum Working Pressure 

FM Approved; nylon; 3/8 npsm(fbe) 

215637 1/4 in. (6 mm) ID X 25 ft (7.6 m) 

215638 1/4 in. (6 mm) ID X 50 ft 05.2 m) 

Fluid Shutoff/Drain Valve 

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure 

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

208630 1/2 npt(m) x 3/8 npt(f); carbon steel and 

PTFE; for non-corrosive fluids 

Fluid Swivel 

5800 psi (405 bar, 40 MPa) Maximum Working Pressure 
115898 1/4 npsm(m) X 1/4 npsm(f) 


312900G 


41 



Accessories 


Gun Accessories 

Gun Repair Kits 

244781 Air Seal Repair Kit 

244911 Fluid Seal Repair Kit 

Push/Pull Fan Air Vaive 

244912 For quick change of fan size. 

ES Aiways On Kit 

244913 Replaces inlet fitting with ball valve to shut 
off air during flushing. Converts ES ON/OFF 
valve to always ON condition. 

Handle Grips 

245263 Medium Grip 

245264 Large Grip 

Gun Washer Kit 

245270 Use to convert Grace gun washers so they 
can clean PRO Xs3 and PRO Xs4 air spray 
guns. 

Pressure Cups 

Includes air regulators for gun atomization air and sup¬ 
ply air to pressure cup. 

244731 1 Ouart (0.95 Liter) 

244732 2 Ouart (1.90 Liter) 

Gun Valve Lubricant 

111265 4 oz (113 g) tube of sanitary (non-silicone) 

lubricant for fluid seals and wear areas. 

Alternator Bearing Kit 

223688 To repair the turbine alternator. 

Cleaning Brush 

105749 For cleaning air cap and fluid nozzle. 


Miscellaneous Accessories 

Ground Wire and Clamp 

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

12 gauge, 25 ft (7.6 m). 

Megohmmeter 

241079 500 Volt output; 0.01 -2000 megohms. 

Not for use in hazardous areas. 

Paint Resistance Meter 

722886 Use with 722860 Paint Probe to measure 
resistance of paint. 

Not for use in hazardous areas. 

Paint Probe 

722860 Use with 722886 Paint Resistance Meter to 
measure resistance of paint. 

Not for use in hazardous areas. 

Safety Warning Signs 

180060 English Warning Sign. FM Approved. Avail¬ 
able at no charge from Graco. 

Electrostatic Conductive Gloves (box of 12) 

117823 Small 
117824 Medium 
117825 Large 


42 


312900G 



Technical Data 


Technical Data 


Category 

Maximum Working Fluid Pressure. 

Maximum Working Air Pressure. 

Maximum Fluid Operating Temperature. 

Maximum voltage output. 

Sound Pressure (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 (with probe). 

Paint Resistivity. 

Wetted Parts. 


Data 

100 psi (0.7 MPa, 7 bar) 

100 psi (0.7 MPa, 7 bar) 

120°F(49°C) 

60kV 

at 40 psi (0.28 MPa, 2.8 bar); 90.4 dB(A) 
at 100 psi (0.7 MPa 7 bar): 105.4 dB(A) 
at 40 psi (0.28 MPa, 2.8 bar); 87 dB(A) 
at 100 psi (0.7 MPa 7 bar): 199 dB(A) 

1/4 npsm 

3/8-18 npsm (R 3/8-19) compound thread 
247936: 22.4 oz (634 g) 

247937: 25.1 oz (712 g) 

10.6 in. (24.6 cm) 

<1 megohm-cm 

Polyethylene, Stainless Steel; Nylon, Acetal, PTFE, 
UHMWPE, Fluoroelastomer, PEEK, Nickel Plate 


312900G 


43 















Graco 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 Grace'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 redaction du presente document sera en Anglais, ainsi que tous documents, avis et 
procedures judiciaires executes, donnes ou intentes a la suite de ou en rapport, directement ou indirectement, avec les 
procedures concernees. 

Graco Information 

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. 

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. 

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 


All written and visual data contained in this document reflects the latest product information available at the time of publication. 
Graco reserves the right to make changes at any time without notice. 

Original instructions. This manual contains English. MM 312900 

Graco Headquarters: Minneapolis 
International Offices: Belgium, China, Japan, Korea 

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA 
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. 

www.graco.com 
Revised December 2013