Instructions
Manual Electrostatic
™
™
PRO Xs3 and PRO Xs4
Air Spray Guns
309292L
For use with Class I Group D spray materials.
For use with Class II 2 G spray materials.
0.24 Mj
Important Safety Instructions:
Read all warnings and instructions in this manual.
Save these instructions.
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
U.S. Patent 7,226,004
ti1600a
Smart Model
ti1248a
Standard Model
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001
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List of Models
Type of Coatings
Standard
X
Smart
Display
Part No.
Model
Operation Manual
High Conductivity
244400,
Series C
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs3
PRO Xs4
PRO Xs4
309294/3W9294/3Z9294
309294/3W9294/3Z9294
309294/3W9294/3Z9294
309294/3W9294/3Z9294
309294/3W9294/3Z9294
309294/3W9294/3Z9294
244579,
Series C
X
X
X
X
244575,
Series C
X
X
244576,
Series C
244401,
Series C
X
X
244580,
Series C
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Symbols
Symbols
Warning Symbol
Caution Symbol
CAUTION
WARNING
This symbol alerts you to the possibility of serious injury
or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to or
destruction of equipment if you do not follow the instruc-
tions.
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,
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 venti-
Do not flush with the gun electrostatics on. Do not turn on the gun electrostatics until all sol-
vent is removed from the system.
•
•
•
If there is any static sparking while using the equipment, stop spraying immediately. Iden-
tify 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.
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.
Keep a fire extinguisher in the work area.
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 warn-
ings.
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.
4
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Symbols
WARNING
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 dis-
tributor.
•
•
•
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. Max-
imum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).
Use fluids and solvents that are compatible with the equipment wetted parts. See the Tech-
nical 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).
Do not kink or overbend hoses or use hoses to pull equipment.
Wear hearing protection when operating this equipment.
•
•
•
•
•
Comply with all applicable local, state, and national fire, electrical, and other safety regula-
tions.
Pressurized Equipment Hazard
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and
cause serious injury.
•
•
•
Do not point the spray gun at anyone or at any part of the body.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
ing, checking, or repairing equipment.
•
•
Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
Tighten all fluid connections before each use.
309292L
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Introduction
Introduction
•
•
Fan AIR adjustment valve. Adjusts fan size and
shape.
How the Electrostatic Air Spray
Gun Works
The air hose supplies air to the spray gun. Part of the air
operates the turbine and the rest of the air atomizes the
fluid being sprayed. The turbine generates power, which
is converted by the power cartridge to supply high volt-
age current to the gun’s electrode.
Atomizing air RESTRICTOR valve. Restricts
atomizing air flow. Replace with plug (included) if
desired.
•
•
•
ES ON/OFF valve. Turns electrostatics ON (I) or
OFF (0).
The pump supplies fluid to the hose and gun, where the
fluid is electrostatically charged as it passes the elec-
trode. The charged fluid is attracted to the grounded
workpiece, wrapping around and evenly coating all sur-
faces.
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,
Gun Overview
The electrostatic gun includes the following controls
•
•
ES HI/LO switch (smart models only). Sets volt-
age to HI or LO (factory settings).
LO VOLTAGE adjustment (smart models only).
Remove plug to adjust to four settings.
•
FLUID adjustment valve. Adjusts fluid rod travel.
Use only in low flow conditions, to reduce wear.
DISPLAY
ES INDICATOR
LO VOLTAGE
100%
0
ES HI/LO
KV
μα
ES ON/OFF
HI
LO
ES
ES
I
O
ES ON/OFF
ES
I
O
RESTRICTOR
AIR
AIR
RESTRICTOR
FLUID
FLUID
ti1266a
ti1253a
Standard Model
Smart Model
Fig. 1. Gun Overview
6
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Installation
Installation
Install the System
Warning Sign
Mount warning signs in the spray area where they can
easily be seen and read by all operators. An English
Warning Sign is provided with the gun.
WARNING
Fire, Explosion, and Electric Shock Hazard
Ventilate the Spray Booth
Installing and servicing this equipment
requires access to parts which may cause
electric shock or other serious injury if work
is not performed properly.
WARNING
• 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, Group D or a Class II 2G Haz-
ardous Location.
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.
• Comply with all applicable local, state,
and national fire, electrical, and other
safety regulations.
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.
is not an actual system design. For assistance in
designing a system to suit your particular needs, contact
your Graco distributor.
High velocity air exhaust will decrease the operating effi-
ciency of the electrostatic system. Air exhaust velocity of
100 ft/min (31 linear meters/minute) should be sufficient.
309292L
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Installation
ES ON/OFF valve: I is ON, 0 is OFF
A
ES
I
O
M
D C*
H
C
O
B*
S
*E
G
J*
F
L
V
G
*R
W
N
P
K
U*
The air supply to the
gun must be electri-
cally interlocked with
the ventilators to pre-
vent the power supply
from operating without
ventilating fans on.
Q*
T
Non-Hazardous Area
Hazardous Area
ti1498a
Fig. 2. Typical Installation
Key
N
Fluid Supply Line
A
Main Air Supply Line
O
P
Gun Air Line Filter/Water Separator
Gun Air Supply Line Shutoff Valve
B* Ventilation Fan Interlock Solenoid Valve
C* Main Air Supply Shutoff Valve (bleed-type)
Q* Air Hose Ground Wire
D
Pump Air Line Filter/Water Separator
R* Graco Grounded Air Hose
E* Pump Air Supply Shutoff Valve (bleed-type)
S
T
Electrostatic Air Spray Gun
Air Line Drain Valve
F
Air Line Lubricator
Air Pressure Regulator
Pump
G
H
U* Fluid Drain Valve
V
W
*
Gun Air Inlet
J* Pump Ground Wire
Gun Fluid Inlet
K
L
Fluid Filter
Required for safe operation. Must be purchased
separately. NOTE: Solenoid valve (B) is not
offered as a Graco accessory.
Fluid Supply Line Shutoff Valve
Fluid Pressure Regulator
M
8
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Installation
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.
Connect the Air Line
WARNING
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other
Pressurized Equipment Hazard
serious injury, the air supply hose must be
electrically connected to a true earth
ground. Use only Graco Grounded Air
Supply Hose.
The bleed-type air valve (E) is required in
your system to relieve air trapped between
the valve and the pump after the air regula-
tor is shut off. Trapped air can cause the
pump to cycle unexpectedly, which can
result in serious injury, including 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.
5. Install an air shutoff valve ( P) on each gun air sup-
ply line to shut off air to the gun(s).
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.
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).
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.
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Installation
Connect the Fluid Line
WARNING
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.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
before removing or installing a fluid nozzle
and/or air cap.
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.
Table 1: Fluid Nozzles
Part No.
197263
197264
197265
197266
197267
197268
249920*
249921*
249922*
249923*
249924*
249925*
Orifice Size
WARNING
0.75 mm (.030 in.)
1.0 mm (.042 in.)
1.2 mm (.047 in.)
1.5 mm (.055 in.)
1.8 mm (.070 in.)
2.0 mm (.080 in.)
0.75 mm (.030 in.)
1.0 mm (.042 in.)
1.2 mm (.047 in.)
1.5 mm (.055 in.)
1.8 mm (.070 in.)
2.0 mm (.080 in.)
Pressurized Equipment Hazard
The fluid drain valve (U) is required in your
system to assist in relieving fluid pressure in
the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may
not be sufficient. Install a drain valve close
to the pump's fluid outlet. The drain valve
reduces the risk of serious injury, including
splashing in the eyes or on the skin.
4. Connect the fluid line to the 3/8 npsm gun fluid inlet
(W).
5. Before running any paint through the spray gun,
flush it out with a compatible solvent.
* Glass-reinforced acetal construction.
Table 2: Air Caps
Filter the Fluid
Install a fluid filter (K) to remove particles and sediment
which could clog the spray nozzle.
Pattern Shape
Part No. and Length
in. (mm)
Recommended Fluids and
Production Rates
Round end;
197477
Light to medium viscosity.
Medium to high production.
15-17 (381-432)
Select a Fluid Nozzle and Air
Cap
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
consult with your Graco distributor. See Air Cap/Nozzle
Round end;
197478
Light to medium viscosity.
Low to medium production.
15-17 (381-432)
Tapered end;
197479
Light to medium viscosity.
Medium to high production.
13-15 (330-381)
Medium to high viscosity
and high solids.
Low to medium production.
Round end;
197480
16-18 (406-457)
Medium to high viscosity
and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
Tapered end;
197481
17-19 (432-483)
10
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Installation
9. Slide the tube case (1e) onto the barrel inlet, over
244919 HC Conversion Kit
the o-ring (2b). The coiled tube (1a) will compress
slightly.
Part No. 244919 Conversion Kit converts PRO Xs3
standard coating guns (Part Nos. 244400 and 244579)
to high conductivity guns (244575 and 244576). For fur-
ther instruction and parts, see manual 309453.
10. Insert the end of the coiled tube (1a) into the bracket
(3). Make sure the ferrules (1c, 1b) seat on the
bracket.
The kit is for use with fluids with low resistivity values.
11. Secure the bracket by tightening the swivel (A).
Tighten the nut (1d). Reinstall the exhaust tube (B)
and clamp (C).
WARNING
12. Reconnect the fluid and air lines to the gun.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure in your gun
manual before installing this kit.
1. Turn the ES ON/OFF valve OFF.
2. Flush and relieve the pressure.
3. Disconnect the fluid and air lines to the gun.
4. Remove the fluid tube and fittings.
5. Remove the fluid inlet bracket.
2
5
2a
2b
1b
1c
1d
3
A
6. Install the new bracket (3) from the kit loosely. See
1e
7. Place the spacer (5) in the barrel inlet. Apply Graco
dielectric grease (4) to the o-rings (2a, 2b) and to
both threads of the fluid fitting (2). Thread the fitting
into the barrel inlet.
B
1a
C
1e
8. Thread the nut (1d) onto the fitting (2). Make sure
the ferrules (1c and 1b) are on the tube (1a) and are
seated on the fitting (2) before tightening the nut
(1d).
1e
1e
1e
ti10674a
FIG. 3: 244919 Conversion Kit
309292L
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Installation
•
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.
Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any
ungrounded objects in the spray area (peo-
ple, containers, tools, etc.) can become
electrically charged. Improper grounding
can result in static sparking, which can
cause a fire, explosion, or electric shock.
Follow the grounding instructions below.
•
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 con-
ductive and grounded. Do not cover the floor with
cardboard or any non-conductive material which
would interrupt grounding continuity.
•
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.
•
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
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Installation
4. Make sure the grounded air hose (R) is connected
and the hose ground wire is connected to a true
earth ground.
Check Electrical Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
ti1259a
Megohmmeter Part No. 241079 (AA-see
FIG. 4.) is not approved for use in a hazard-
ous area. To reduce the risk of sparking, do
not use the megohmmeter to check electri-
cal grounding unless:
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
FIG. 4.
• The gun has been removed from the
hazardous area;
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.
• 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).
BB
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.
AA
2. Turn the ES ON/OFF valve OFF.
CC
ES
I
O
ti1274a
ti1273a
3. Turn off the air and fluid supply to the gun. The fluid
hose must not have any fluid in it.
Fig. 4. Check Gun Grounding
309292L
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Installation
Check Fluid Resistivity
Check Fluid Viscosity
To check fluid viscosity you will need:
•
•
a viscosity cup
a stopwatch.
WARNING
Fire, Explosion, and Electric Shock Hazard
Check the fluid resistivity in a non-hazard-
ous area only. Resistance Meter 722886
and Probe 722860 are not approved for use
in a hazardous area.
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.
Failure to follow this warning could cause
fire, explosion, or electric shock and result
in serious injury and property damage.
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.
Graco Part No. 722886 Resistance Meter and 722860
Probe are available as accessories to check that the
resistivity of the fluid being sprayed meets the require-
ments of an electrostatic air spray system.
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.
Follow the instructions included with the meter and
probe. Readings of 25 megohms-cm and above provide
the best electrostatic results.
14
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Operation
Operation
Refer to the gun operation manual (supplied)
for Setup, Shutdown, and Daily Care proce-
dures.
INSTRUCTIONS
Low Voltage Adjustment (Smart
Guns Only)
The ES HI/LO switch enables you to switch between full
voltage and a lower voltage output. The lower voltage is
factory set, but can be adjusted.
OFF
ON
2
1
100%
0
KV
1. Set the ES HI/LO switch to LO.
μα
53
2. Remove the LO VOLTAGE adjustment plug (53). Set
the desired voltage, using a small screwdriver to
slide switches 1 and 2 ON or OFF, according to
ti1529a
Fig. 5. Low Voltage Adjustment Switches
Table 3: Low Voltage Adjustment
60 kV Guns
85 kV Guns
1
2
kV
1
2
kV
70
60
50
40
ON
ON
OFF
OFF
ON
OFF
ON
OFF
50
40
35
30
ON
ON
OFF
OFF
ON
OFF
ON
OFF
Factory
Setting
309292L
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Maintenance
Maintenance
Refer to the gun operation manual (supplied)
for Daily Care and Cleaning procedures.
INSTRUCTIONS
1. Turn the ES ON/OFF valve OFF.
Flush the Spray Gun
ES
I
O
Flush the gun before changing colors, at the end of the
day, before storing, and before repairing the gun.
ti1273a
WARNING
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or elec-
tric shock, turn the ES ON/OFF valve OFF
before flushing the gun.
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
whenever you are instructed to relieve the
pressure.
2. Relieve the pressure.
CAUTION
ti1276a
Flush the gun with a non-conductive, compatible
solvent. Conductive solvents can cause the gun to
malfunction.
3. Change the fluid source to solvent, or disconnect
the fluid line and connect a solvent supply line to the
gun.
Do not use methylene chloride as a flushing or
cleaning solvent with this gun as it will damage
nylon components.
4. Point the gun into a grounded metal pail. Flush until
clean solvent flows from the gun.
ti1276a
5. Relieve the pressure.
ti1276a
6. Shut off or disconnect the solvent line.
16
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Maintenance
7. Hang the gun from its hook, with the nozzle pointing
down.
8. When ready to spray again, reconnect the fluid sup-
ply line. Follow the Setup procedure in the Opera-
tion Manual.
ti1288a
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Electrical Tests
Electrical Tests
Electrical components inside the gun affect performance
and safety. The following procedures test the condition
of the power supply (18) and electrode (29), and electri-
cal continuity between components.
Test Gun Resistance
1. Flush and dry the fluid passage.
2. Measure resistance between the electrode needle
tip (29) and the air swivel (35); it should be 117-137
megohms for the PRO Xs3, and 156-180 megohms
for the PRO Xs4. If outside this range, go to the next
test. If in range, refer to Electrical Troubleshooting
mance.
Use megohmmeter Part No. 241079 (AA) and an
applied voltage of 500 V. Connect the leads as shown.
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
ous area. To reduce the risk of sparking, do
not use the megohmmeter to check electri-
cal grounding unless:
AA
• 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).
29
Failure to follow this warning could cause
fire, explosion, and electric shock and result
in serious injury and property damage.
35
TI1468A
Fig. 6. Test Gun Resistance
18
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Electrical Tests
6. Be sure the spring (18b) is in place before reinstall-
ing the power supply.
Test Power Supply Resistance
2. Remove the turbine alternator (19) from the power
supply, page 31.
3. Measure resistance from the power supply's ground
4. The resistance should be 95-105 megohms for the
PRO Xs3, and 135-150 megohms for the PRO Xs4.
If outside this range, replace the power supply. If in
range, proceed to the next test.
EE
18b
of poor performance, or contact your Graco distribu-
tor.
ti1599a
Fig. 7. Test Power Supply Resistance
309292L
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Electrical Tests
Test Electrode Resistance
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 electrode (29). The resistance should be
F
29
E
mance, or contact your Graco distributor.
ti1548a
resistance between the contact (E) and the elec-
trode wire (F). The resistance should be 20-30
megohms. If out of range, replace the electrode.
Fig. 9. Electrode
5. Make sure the metal contact (C) in the barrel, the
contact (E) are clean and undamaged.
7a
ti1513a
Fig. 10. Nozzle Conductive O-Ring
C
B
29
ti1499a
Fig. 8. Test Electrode Resistance
20
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Troubleshooting
Troubleshooting
WARNING
WARNING
Electric Shock Hazard
Installing and servicing this equipment
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
whenever you are instructed to relieve the
pressure.
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 repair this equipment unless you
are trained and qualified.
Check all possible remedies in the Troubleshooting
Chart before disassembling the gun.
Spray Pattern Troubleshooting
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray.
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Air in fluid supply.
Check fluid source. Refill.
Improper spray pattern.
Damaged nozzle or air cap.
Fluid buildup on air cap or nozzle.
Fan air pressure too high.
Clean. See Operation Manual.
Decrease.
Fluid too thin.
Increase viscosity.
Increase.
Fluid pressure too low.
Fan air pressure too low.
Increase.
Fluid too thick.
Reduce viscosity.
Too much fluid.
Decrease flow.
Streaks.
Did not apply 50% overlap.
Dirty or damaged air cap.
Overlap strokes 50%.
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Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Solution
Excessive spray fog.
Atomizing air pressure too high.
Close restrictor valve some, or
decrease air pressure as low as pos-
sible; minimum 40 psi (0.28 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.
Fluid too thick.
Remix or refilter fluid.
Reduce viscosity.
Fluid leaks from the fluid packing
area
Worn packings or rod.
Replace packings or rod; see page
29.
Air leaks from the front of the gun
Air valve (21) is not seating properly. Clean and service air valve; see
Fluid leakage from the front of the
gun
Worn fluid seat.
Replace fluid nozzle and/or electrode
Loose fluid nozzle (7).
Replace; see page 26.
Add fluid if necessary.
Replace; see page 26.
Clean; see page 26.
Replace; see page 26.
Damaged nozzle o-ring (7b).
Low fluid supply.
Gun does not spray
Damaged air cap (9).
Dirty or clogged fluid nozzle (7).
Damaged fluid nozzle (7).
Dirty air cap
Misaligned air cap (9) and fluid noz- Clean fluid buildup off air cap and
zle (7).
22
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Troubleshooting
Electrical Troubleshooting
Problem
Cause
Solution
Poor wrap.
ES ON/OFF valve OFF (0).*
Gun air pressure too low.
Turn ON (I).
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.
Fluid pressure too high.
Decrease.
Decrease.
Incorrect distance from gun to part.
Poorly grounded parts.
Should be 8-12 in. (200-300 mm).
Resistance must be 1 megohm or
less. Clean workpiece hangers.
Faulty gun resistance.
Low fluid resistivity.
18.
Fluid leaks from the packing (26d)
and causes a short.
Clean the packing rod cavity.
Replace the packing rod. See page
29.
Faulty turbine alternator.
Be sure the plug is in place on the
back of the power supply housing.
Remove and test the turbine alterna-
The KV HI-LO lever is on LO.
ES ON/OFF valve OFF (0).*
Check the lever actuation; replace if
needed.
ES indicator or voltage/current dis-
play is not lit.
Turn ON (I).
No power.
Should be 8-12 in. (200-300 mm).
Voltage/current display stays red
(smart guns only).
Gun too close to part.
Check fluid resistivity.
Dirty gun.
Clean. See Operation Manual.
Operator gets mild shock.
Operator not grounded or is near
ungrounded object.
Gun not grounded.
on page 18.
Operator gets shock from workpiece. Workpiece not grounded.
* ES indicator light is off when the gun is triggered.
Resistance must be 1 megohm or
less. Clean workpiece hangers.
309292L
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Repair
Repair
2. Turn off the air bleed valves to the fluid source and
to the gun.
Pressure Relief Procedure
WARNING
ti1289a
Pressurized Equipment Hazard
The system pressure must be manually
relieved to prevent the system from starting
or spraying accidentally. 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 Pro-
cedure whenever you:
3. Trigger the gun into a grounded metal waste con-
tainer to relieve the fluid pressure.
ti1276a
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system
equipment
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.
• or install or clean the fluid nozzle.
1. Turn the ES ON/OFF valve OFF.
ES
I
O
ti1290a
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.
ti1273a
t
24
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Repair
Prepare the Gun for Service
•
•
•
Check all possible remedies in Troubleshooting
before disassembling the gun.
WARNING
Use a vise with padded jaws to prevent damage to
plastic parts.
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.
Lubricate the power supply o-ring (18a), some pack-
ing rod parts (26), and certain fluid fittings with
dielectric grease (40), as specified in the text.
•
Lightly lubricate o-rings and seals with non-silicone
grease. Order Part No. 111265 Lubricant. Do not
over-lubricate.
•
•
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
WARNING
Air Seal Repair Kit 244781 is available. The kit must
be purchased separately. Kit parts are marked with
an asterisk, for example (6*).
Pressurized Equipment Hazard
checking or servicing any part of the system
and whenever you are instructed to relieve
the pressure.
•
Fluid Seal Repair Kit 244911 is available. The kit
must be purchased separately. Kit parts are marked
with a double asterisk, for example (5**).
3. Disconnect the gun air and fluid lines.
4. Remove the gun from the worksite. Repair area
must be clean.
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Repair
Air Cap/Nozzle Replacement
WARNING
CAUTION
Fire, Explosion, and Electric Shock Hazard
The nozzle contact ring (7a) is a conductive
contact ring, not a sealing o-ring. To reduce
the risk of sparking or electric shock, do not
remove the nozzle contact ring (7a) except
to replace it and never operate the gun with-
out the contact ring in place. Do not replace
the contact ring with anything but a genuine
Graco part.
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.
2. Remove the retaining ring (27) and air cap (9). See
Use non-silicone grease, Part No. 111265, on the small
o-ring (7b). Do not over-lubricate. Do not lubricate the
contact ring (7a).
3. Point gun up and squeeze trigger while removing
the fluid nozzle (7) assembly with the multi-tool (37).
4. Lightly lubricate the o-ring (7b). Install it and the
contact ring (7a) on the nozzle (7).
27
Make sure the electrode needle (29) is finger- tight
27a*
9
5. Trigger gun while installing the fluid nozzle (7) with
the multi-tool (37). Tighten until the fluid nozzle
seats in the gun barrel (1/8 to 1/4 turn past
hand-tight).
6. Install the air cap (9) and retaining ring (27). Make
sure the u-cup (27a*) is in place with the lips facing
forward.
37
7
7a
7b
ti1501a
Fig. 11. Air Cap/Nozzle Replacement
26
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Repair
Electrode Replacement
3. Unscrew the electrode (29) with the multi-tool (37).
Hold the packing rod end (26h) to prevent it from
37
CAUTION
To avoid damaging the plastic threads, be very
careful when installing the electrode.
®
4. Apply low-strength (purple) Loctite or equivalent
thread sealant to the electrode and packing rod
threads. Install the electrode finger-tight. Do not
overtighten.
ti1502a
Fig. 12. Electrode Replacement
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Repair
Fluid Packing Removal
4. Loosen the trigger screws (8) and trigger (30). See
37
5. Remove the packing rod (26), using the multi-tool
(37).
30
CAUTION
8
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.
TI1549A
Fig. 13. Fluid Packing Removal
28
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Repair
4. Lightly tighten the packing nut (26e). The packing
Packing Rod Repair
You may replace the packing rod as individual parts or
as an assembly. The assembly is pre-adjusted at the
factory.
nut is properly tightened when there is 3 lb (13.3 N)
of drag force when sliding the packing housing (26f)
assembly along the rod. Tighten or loosen the pack-
ing nut as needed.
Before installing the fluid packing rod into the gun barrel,
make sure the internal surfaces of the barrel are clean.
Remove any residue with a soft brush or cloth. Check
the inside of the barrel for marks from high voltage arc-
ing. If marks are present, replace the barrel.
5. Install the o-ring (26a**) on the outside of housing
(26f). Lubricate the o-ring with non-silicone grease,
Part No. 111265. Do not over-lubricate.
6. Install the spring (4) against the nut (E) as shown.
To assemble the individual parts:
7. Install the packing rod assembly (26) into the gun
barrel. Using the multi-tool (37), tighten the assem-
bly until just snug.
1. Place the packing nut (26e) and seal (26b**) on the
fluid rod (26h). Flats on the packing nut must face
the back of the fluid rod. The seal o-ring must face
8. Install the trigger (30) and screws (8).
2. Fill the inner cavity of the spacer (26g**) with dielec-
tric grease (40). Place the spacer on the fluid rod
(26h) in the direction shown. Generously apply
dielectric grease to the outside of the spacer.
3. Place the rod packing (26d**), packing spreader
(26c**), and housing (26f) on the packing rod (26h) .
4
E
TI1489A
26h
26e
**26b
**26g
**26d
**26c
26f
**26a
Fig. 14. Packing Rod
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Repair
Barrel Removal
Barrel Installation
1. Be sure the gasket (10*) and grounding spring (55)
are in place. Make sure the air holes are aligned
2. Carefully loosen the nut (32 or 50d) from the bracket
fluid fitting (13). Pull the tube (14 or 50a) out of the
fitting. Make sure both ferrules and the nut stay with
the tube.
2. Place the barrel (16) over the power supply (18) and
onto the gun handle (17).
3. Loosen the three screws (11).
3. Tighten the three screws (11) oppositely and evenly
(about a half turn past snug).
CAUTION
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.
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 (32).
4. Hold the gun handle (17) with one hand and pull the
14
32
*10
18
13
11
16
11
16
55
ti1503a
ti1506a
Fig. 16. Barrel Installation
17
ti1504a
Fig. 15. Barrel Removal
30
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Repair
8. Lubricate the alternator o-ring (19a*) with non-sili-
Power Supply Removal and
Replacement
cone grease, Part No. 111265. Do not over-lubri-
cate.
•
Inspect the gun handle power supply cavity for dirt
or moisture. Clean with a clean, dry rag.
9. Lubricate the power supply o-ring (18a*) with dielec-
tric grease (40).
•
Do not expose gasket (10) to solvents.
10. Insert the power supply/alternator assembly in the
gun handle (17). Make sure the ground strips make
contact with the handle. On Smart Models only, con-
nect the flexible circuit (59) to the socket at the top
of the handle. Push the 6-pin connector into the
socket to ensure it is properly connected.
CAUTION
Be careful when handling the power supply (18) to
avoid damaging it.
3. Grasp the power supply (18) with your hand. With a
gentle side to side motion, free the power sup-
ply/alternator assembly from the gun handle (17),
then carefully pull it straight out. On Smart Models
only, disconnect the flexible circuit (59) from the
17
10*
19a*
19
4. Disconnect the 3-wire connector (GG) from the
power supply. Slide the alternator up and off the
power supply. Inspect the power supply and alterna-
tor for damage. On Smart Models only, disconnect
the 6-pin flexible circuit (59) from the power supply.
19e
Replace if necessary.
59
ti1505c
GG
Before installing the power supply, make sure the
o-rings (18a*, 19a*), spring (18b), and pads (19e)
are in place.
6. On Smart Models only, connect the 6-pin flexible cir-
cuit (59) to the power supply.
7. Connect the 3-wire connector (GG). Slide the alter-
nator (19) down onto the power supply (18).
18
*18a
18b
Fig. 17. Power Supply
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Repair
Turbine Alternator Removal and Fluid Tube Removal and
Replacement
Replace turbine alternator bearings after 2000 hours of
operation. Order Part No. 223688 Bearing Kit.
Replacement (PRO Xs4 Guns
Only)
1. Remove the nut (32) from the bracket (13).
2. Loosen the fitting (1) to remove the fluid tube (14)
from the barrel (16).
2. Remove the power supply/alternator assembly,
3. Apply dielectric grease (40) to the threads of the fit-
ting (1), the o-ring (5), and the sleeve (S) of the fluid
tube (14).
3. Disconnect the alternator from the power supply,
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.
4. Slide the fitting (1) onto the fluid tube (14) and
thread the fitting into the barrel (16).
5. With the ferrules (31) seated to the bracket (13),
screw the nut (32) onto the bracket.
5. Follow the bearing replacement procedure in the
bearing kit manual 308034.
5
S
1
14
6. Install the alternator on the power supply, page 31.
7. Install the power supply/alternator assembly, page
31.
32
31
TI1490A
Fig. 18. PRO Xs4 Fluid Tube
32
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Repair
6. Clean all parts and inspect for wear or damage.
Fan Air Adjustment Valve Repair
Use non-silicone grease, Part No. 111265. Do not
over-lubricate.
2. Place a wrench on the flats of the valve assembly
(20) and unscrew it from the handle (17).
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.
You may replace the valve as an assembly (go to
8. Reassemble the retaining ring (20a). Unscrew the
valve stem from the housing until it is stopped by the
retaining ring.
4. Turn the valve stem (20d) counterclockwise until it
comes free from the valve housing (20c).
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).
5. Remove the o-ring (20b).
20d
TI1487A
20b*
20c
20a
Fig. 19. Fan Air Adjustment Valve
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Repair
4. Remove the air valve (21) with a pliers. Inspect the
rubber sealing surface and replace the air valve if
damaged.
Fluid Adjustment Valve Repair
2. Remove the fluid adjustment valve (25). It can only
CAUTION
When removing the air valve (21) be careful not to
damage the seat area.The rubber seal is not
removable.
3. Screw the valve (25) into the gun handle. Torque to
15-25 in-lb (1.7-2.8 N•m).
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).
25
ti1507a
Fig. 20. Fluid Adjustment Valve
Air Valve Repair
25
15
21
17
3. Remove the fluid adjustment valve (25) from the
*6
ti1512a
CAUTION
Fig. 21. Air Valve
Clean all parts in non-conductive solvent compati-
ble with the fluid being used, such as xylol or min-
eral spirits. Use of conductive solvents can cause
the gun to malfunction.
34
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Repair
Atomizing Air Restrictor Valve
Removal and Replacement
ES ON/OFF Valve Repair
2. Loosen the screw (48). Remove the valve.
2. Remove the atomizing air restrictor valve (23) .
Inspect the o-ring (23c*). Replace if necessary. See
3. Lubricate the o-rings (22a* and 22b*) with non-sili-
cone grease, Part No. 111265. Do not over-lubri-
cate.
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.
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.
If the atomizing air restrictor valve is not desired,
install the supplied plug (47).
4. Clean and inspect parts for damage. Replace if nec-
essary.
4. Torque the valve housing (23a) to 15-20 in-lb
(1.7-2.3 N•m).
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).
23c*
23a
47
22g
22d
22f
22e
22b*
23d
23b
22c
22a*
ti1508a
Fig. 22. Atomizing Air Restrictor Valve
48
TI1488A
Fig. 23. ES ON/OFF Valve
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Parts
Parts
Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55)
Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55)
Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55)
See page 37 for detail views of the fluid tube assemblies, alternator
(19), fan adjustment valve (20), ES ON/OFF valve (22), and packing
rod (26).
22
28
20
18
ES
I
O
19a*
25
19
19e
15
17
21***
ti1266a
18b
11
*18a
25 (Ref)
11
23c*
23a
47
16
23d
55
*10 *6
4
24a*
24
23b
8
26
29
30
35
13
38
39
7b
36
7a
ti1480b
37
7
9
27a*
27
36
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Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
20d
19a*
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d
19c
Ref. No. 26: Packing Rod
Ref. No. 22: ES ON/OFF Valve
22f
ti1601a
26h
26e
26b**
22d
26g**
26d**
22e
22g
22b*
26c**
26f
22c
22a*
26a**
48
TI1488A
Fluid Tube: Model 244400
Fluid Tube: Model 244575
Fluid Tube: Model 244401
5**
5**
1
49a
49b
5
1
14
50e
31
32
32 **31
14
32
50a
50f
49
50c
31**
50b
TI1490A
50d 50b 50c
50d
ti1492a
TI491A
309292L
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Parts
Part No. 244400 60 kV Electrostatic Gun, Series C (items 1-48, 55)
Part No. 244575 60 kV Electrostatic Gun, Series C (items 4-30, 35-55)
Part No. 244401 85 kV Electrostatic Gun, Series C (items 1-48, 55)
Ref.
No.
Part No. Description
Qty
Ref.
No.
Part No. Description
Qty
18
244540 POWER SUPPLY, 60 kV; used on
244400 and 244575; includes
18a-18d
1
1
110078 FITTING, tube, fluid; used on 244400
198587 FITTING, tube, fluid; used on 244401
185111 SPRING, compression
1
1
1
1
244541 POWER SUPPLY, 85 kV; used on
244401; includes 18a-18b
1
4
18a* 103337 . O-RING; fluoroelastomer
18b 197624 . SPRING, compression
1
1
1
5**
185120 SPACER, fluid; nylon; used on
244400 and 244575
102982 O-RING; used on 244401
1
1
19
244555 TURBINE, alternator; includes
19a-19e
6*
7
188749 PACKING, u-cup, air valve;
UHMWPE
19a* 110073 . O-RING; fluoroelastomer
1
1
197266 NOZZLE; 1.5 mm orifice; includes 7a
and 7b
1
19b 223688 . BEARING KIT; includes front and
rear bearings and fan
7a
7b
8
111261 . O-RING, conductive
111507 . O-RING; fluoroelastomer
197369 SCREW, trigger
197477 AIR CAP
1
1
2
1
1
3
19c 244577 . COIL
1
1
2
1
19d 111745 . RING, retaining
19e 198821 . PAD, pressure
9
20
244556 VALVE, adjustment, fan; includes
20a-20d
10*
11
197517 GASKET, barrel
20a 101021 . RING, retaining
20b* 106560 . O-RING; fluorocarbon
20c 197566 . HOUSING, fan valve
20d 197567 . STEM, fan valve
21*** 244557 VALVE, air;
1
1
1
1
1
1
197518 SCREW; socket-hd; 10-24 x 3/4 in.
(19 mm)
13
15M678 BRACKET, inlet, fluid; used on
244400 and 244401
1
1
15M679 BRACKET, inlet, fluid; used on
244575
14
197588 TUBE, fluid; used on 244400
244574 TUBE, fluid; used on 244401
185116 SPRING, compression
1
1
1
1
22
244558 VALVE, electrostatics, ON/OFF;
includes 22a-22g
22a* 111516 . O-RING; CV75
22b* 113137 . O-RING; fluoroelastomer
22c 198403 . SHAFT, valve
22d 198404 . PLATE, retaining
22e 198453 . WASHER
1
1
1
1
1
1
1
15
16
244395 BARREL, gun; used on 244400 and
244575
244394 BARREL, gun; used on 244401
1
1
17
245290 HANDLE, gun; (includes item 28)
used on 244400
22f
198464 . PIN
289277 HANDLE, gun; (includes item 28)
used on 244575
22g 276753 . KNOB
245285 HANDLE, gun; (includes item 28)
used on 244401
1
38
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Parts
Ref.
No.
Ref.
No.
Part No. Description
Qty
Part No. Description
Qty
23
244559 VALVE, air, atomizing; includes
23a-23d
1
35
244834 SWIVEL, air; 1/4 npsm(m) ; left-hand
threads
1
23a 197594 . HOUSING, valve
23b 197591 . SHAFT
1
1
2
1
1
1
1
1
36
37
38
39
40
107460 WRENCH, ball end; 4 mm
276741 MULTI-TOOL
185103 TUBE, exhaust
110231 CLAMP
1
1
1
1
1
23c* 168518 . O-RING; fluoroelastomer
23d 101021 . RING, retaining
24
249323 VALVE, exhaust; includes 24a
116553 GREASE, dielectric, tube (not
shown)
24a* 112085 . O-RING; fluorocarbon
41
244915 COVER, gun; box of 10 (not shown)
1
1
25
26
244593 VALVE, adjustment, fluid
42▲ 179791 TAG, warning (not shown); replace-
244597 ROD, packing; used on 244400 and
244575; includes 26a-26h
ment available at no cost
43▲ 180060 SIGN, warning (not shown); replace-
1
244521 ROD, packing; used on 244401;
includes 26a-26h
1
1
1
1
1
ment available at no cost
47
48
49
197967 PLUG
1
1
1
26a* 111316 . O-RING; fluoroelastomer
*
198058 SCREW, cap, socket hd
26b* 116905 . SEAL
*
245211 FITTING, fluid; used on 244575;
includes 49a-49b
26c* 178409 . SPREADER, packing; UHMWPE
*
49a 116768 . O-RING
49b 110749 . O-RING
1
1
1
26d* 178763 . PACKING, rod; acetal
*
50
244918 TUBE, fluid; used on 244575;
includes 50a-50f
26e 197641 . NUT, packing
1
1
1
50a 198302 . TUBE, fluid, coiled
50b 111286 . FERRULE, front
50c 111285 . FERRULE, back
50d 112644 . NUT
1
2
2
2
1
1
1
26f
185495 . HOUSING, packing
26g* 186069 . SPACER, packing; acetal
*
26h 244695 . ROD, packing; used on 244400
and 244575
1
50e 198270 . CASE, tube
244696 . ROD, packing; used on 244401
1
1
1
1
1
50f
55
198271 . CAP, end
27
27a* 198307 . PACKING, u-cup
28 276695 HOOK
244927 RING, retaining; includes 27a
197624 SPRING, grounding
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Rubber seal is not removable.
29*** 276697 NEEDLE, electrode
*
30
276698 TRIGGER
1
1
**** Optional replacement Electrode Needle 277060 is
available for abrasive materials.
31** 110077 FERRULE, tube, fluid; used on
244400 and 244401
▲ Replacement Warning labels, signs, tags, and cards
are available at no cost.
32
110079 NUT, tube, fluid; used on 244400 and
244401
1
309292L
39
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Parts
Part No. 244579 60 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59)
Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59)
tor (19), fan adjustment valve (20), ES ON/OFF valve (22), and
packing rod (26).
53 (Ref)
51 (Ref)
100%
0
KV
μα
28
HI
59
19a*
LO
ES
17
25
22
51 54
53 52
19
19e
ES
20
I
O
15
21***
18
11
18b
ti1253a
*18a
11
23c*
23a
25 (Ref)
16
47
23b
23d
55 *10 *6
8
4
24a*
24
26
29
30
35
13
38
7b
36
39
7a
37
7
9
27a*
27
40
309292L
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Parts
Ref. No. 19: Alternator
Ref. No. 20: Fan Adjustment Valve
19a*
20d
19b
TI1487A
20b*
20c
19b
TI1481a
20a
19e
19d
19c
Ref. No. 22: ES ON/OFF Valve
Ref. No. 26: Packing Rod
ti1601a
22f
26h
22d
26e
22e
22g
26b**
26g**
26d**
26c**
22b*
22c
22a*
26f
48
26a**
TI1488A
Fluid Tube: Model 244579
Fluid Tube: Model 244576
Fluid Tube: Model 244580
5**
5**
1
49a
49b
5
1
14
50e
31
32
32 **31
14
32
50a
50f
49
50c
31**
50b
TI1490A
50d 50b 50c
50d
ti1492a
TI491A
309292L
41
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Parts
Part No. 244579 60 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Part No. 244576 60 kV Electrostatic Gun, Series C (items 1-30, 35-59)
Part No. 244580 85 kV Electrostatic Gun, Series C (items 1-48, 51-59)
Ref.
No.
Part No. Description
Qty
Ref.
No.
Part No. Description
Qty
19a* 110073 . O-RING; fluoroelastomer
1
1
1
110078 FITTING, tube, fluid; used on 244579
198587 FITTING, tube, fluid; used on 244580
185111 SPRING, compression
1
1
1
1
19b
223688 . BEARING KIT; includes front and
rear bearings and fan
4
19c
19d
19e
20
244577 . COIL
1
1
2
1
5**
185120 SPACER, fluid; nylon; used on
244579 and 244576
111745 . RING, retaining
198821 . PAD, pressure
102982 O-RING; used on 244580
1
1
1
244556 VALVE, adjustment, fan; includes
20a-20d
6*
7
188749 PACKING, u-cup, air valve; UHMWPE
197266 NOZZLE; 1.5 mm orifice; includes 7a
and 7b
20a
101021 . RING, retaining
1
1
1
1
1
1
20b* 106560 . O-RING; fluorocarbon
7a
7b
8
111261 . O-RING, conductive
111507 . O-RING; fluoroelastomer
197369 SCREW, trigger
197477 AIR CAP
1
1
2
1
1
3
20c
20d
197566 . HOUSING, fan valve
197567 . STEM, fan valve
21*** 244557 VALVE, air;
22 244558 VALVE, electrostatics, ON/OFF;
includes 22a-22g
9
10*
11
197517 GASKET, barrel
197518 SCREW; socket-hd; 10-24 x 3/4 in.
(19 mm)
22a* 111516 . O-RING; CV75
1
1
1
1
1
1
1
1
22b* 113137 . O-RING; fluoroelastomer
13
15M678 BRACKET, inlet, fluid; used on
244579 and 244580
1
1
22c
22d
22e
22f
22g
23
198403 . SHAFT, valve
198404 . PLATE, retaining
198453 . WASHER
198464 . PIN
15M679 BRACKET, inlet, fluid; used on
244576
14
197588 TUBE, fluid; used on 244579
244574 TUBE, fluid; used on 244580
185116 SPRING, compression
1
1
1
1
276753 . KNOB
15
16
244559 VALVE, air, atomizing; includes
23a-23d
244395 BARREL, gun; used on 244579 and
244576
23a
23b
197594 . HOUSING, valve
197591 . SHAFT
1
1
2
1
1
1
1
1
244394 BARREL, gun; used on 244580
1
1
17
245291 HANDLE, gun; (includes item 28)
used on 244579
23c* 168518 . O-RING; fluoroelastomer
23d
24
101021 . RING, retaining
289278 HANDLE, gun; (includes item 28)
used on 244576
249323 VALVE, exhaust; includes 24a
24a* 112085 . O-RING; fluorocarbon
245287 HANDLE, gun; (includes item 28)
used on 244580
1
1
25
26
244593 VALVE, adjustment, fluid
244597 ROD, packing; used on 244579 and
244576; includes 26a-26h
18
244540 POWER SUPPLY, 60 kV; used on
244579 and 244576; includes
18a-18d
244521 ROD, packing; used on 244580;
includes 26a-26h
1
244541 POWER SUPPLY, 85 kV; used on
244580; includes 18a-18b
1
26a** 111316 . O-RING; fluoroelastomer
26b** 116905 . SEAL
1
1
1
1
1
18a* 103337 . O-RING; fluoroelastomer
1
1
1
18b
19
197624 . SPRING, compression
26c** 178409 . SPREADER, packing; UHMWPE
26d** 178763 . PACKING, rod; acetal
244555 TURBINE, alternator; includes
19a-19e
26e
197641 . NUT, packing
42
309292L
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Parts
Ref.
No.
Ref.
No.
Part No. Description
Qty
Part No. Description
Qty
26f
185495 . HOUSING, packing
1
1
1
49
245211 FITTING, fluid; used on 244575;
includes 49a-49b
1
26g** 186069 . SPACER, packing; acetal
49a
49b
50
116768 . O-RING
110749 . O-RING
1
1
1
26h
244695 . ROD, packing; used on 244579 and
244576
244696 . ROD, packing; used on 244580
1
1
244918 TUBE, fluid; used on 244576;
includes 50a-50f
27
244927 RING, retaining, air cap; includes item
27a
50a
50b
50c
50d
50e
50f
51
198302 . TUBE, fluid, coiled
111286 . FERRULE, front
111285 . FERRULE, back
112644 . NUT
1
2
2
2
1
1
1
1
1
1
1
1
27a* 198307 . PACKING, u-cup
28 276695 HOOK
29**** 276697 NEEDLE, electrode
1
1
1
1
1
30
276698 TRIGGER
198270 . CASE, tube
31**
110077 FERRULE, tube, fluid; used on
244579 and 244580
198271 . CAP, end
244627 SWITCH, ES HI/LO
111450 O-RING
32
35
110079 NUT, tube, fluid; used on 244579 and
244580
1
1
52
53
276734 PLUG, LO voltage adjustment
197910 SCREW, pivot
197624 SPRING, grounding
245265 CIRCUIT, flexible
244834 SWIVEL, air; 1/4 npsm(m) ; left-hand
threads
54
55
36
37
38
39
40
41
107460 WRENCH, ball end; 4 mm
276741 MULTI-TOOL
1
1
1
1
1
1
1
59
185103 TUBE, exhaust
* Included in Air Seal Repair Kit 244781.
** Included in Fluid Seal Repair Kit 244911.
*** Rubber seal is not removable.
110231 CLAMP
116553 GREASE, dielectric, tube (not shown)
244915 COVER, gun; box of 10 (not shown)
42▲ 179791 TAG, warning (not shown); replace-
ment available at no cost
**** Optional replacement Electrode Needle 277060 is
available for abrasive materials.
43▲ 180060 SIGN, warning (not shown); replace-
1
ment available at no cost
47
48
197967 PLUG
1
1
▲ Replacement Warning labels, signs, tags, and cards
are available at no cost.
198058 SCREW, cap, socket hd
309292L
43
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Accessories
Accessories
Air Line Quick Disconnect
112534 Swiveling quick disconnect replaces stan-
dard air inlet swivel.
Air Line Accessories
™
AirFlex Flexible Grounded Air Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
Air Hose Adapter Nipple
185493 Use to connect multiple air hoses. 1/4 npt x
1/4 npsm left-hand thread.
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)
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
Fluid Line Accessories
Fluid Hose
223068
223069
223070
223071
223072
223073
223074
6 ft (1.8 m)
225 psi (14 bar, 1.4 MPa) Maximum Working Pressure
FM Approved; nylon; 3/8 npsm(fbe)
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)
215637
215638
1/4 in. (6 mm) ID x 25 ft (7.6 m)
1/4 in. (6 mm) ID x 50 ft (15.2 m)
Fluid Shutoff/Drain Valve
Bleed-Type Master Air Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving fluid
line pressure at the pump.
Relieves air trapped in the air line between this valve
and the pump air motor when closed.
208630
1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
107141
3/4 npt
Fluid Swivel
Air Line Shutoff Valve
5800 psi (405 bar, 40 MPa) Maximum Working Pressure
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
115898
1/4 npsm(m) x 1/4 npsm(f)
224754
1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
44
309292L
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Accessories
Cleaning Brush
Gun Accessories
Gun Repair Kits
105749
For cleaning air cap and fluid nozzle.
Abrasive Material Electrode Needle
244781
244911
Air Seal Repair Kit
Fluid Seal Repair Kit
277060
Optional replacement Electrode Needle is
available for abrasive materials.
Round Pattern Kits
Consists of fluid tip, diffuser and air cap.
Miscellaneous Accessories
245217
245219
4-6 in. (102-152 mm) diameter
8-10 in. (203-254 mm) diameter
Ground Wire and Clamp
Push/Pull Fan Air Valve
222011
For grounding pump and other components
and equipment in the spray area.
12 gauge, 25 ft (7.6 m).
244912
For quick change of fan size.
ES Always On Kit
Megohmmeter
241079 500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
244913
Replaces inlet fitting with ball valve to shut
off air during flushing. Converts ES ON/OFF
valve to always ON condition.
Paint Resistance Meter
Handle Grips
722886
Use with 722860 Paint Probe to measure
resistance of paint.
Not for use in hazardous areas.
245263
245264
Medium Grip
Large Grip
Gun Washer Kit
245270 Use to convert Graco gun washers so they
Paint Probe
722860
Use with 722886 Paint Resistance Meter to
measure resistance of paint.
can clean PRO Xs3 and PRO Xs4 air spray
guns.
Not for use in hazardous areas.
Pressure Cups
Safety Warning Signs
180060 English Warning Sign. FM Approved. Avail-
able at no charge from Graco.
Includes air regulators for gun atomization air and sup-
ply air to pressure cup.
244731
244732
1 Quart (0.95 Liter)
2 Quart (1.90 Liter)
Instruction Signs
198309
198319
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.
Electrostatic Conductive Gloves (box of 12)
117823
117824
117825
Small
Medium
Large
Alternator Bearing Kit
223688
To repair the turbine alternator.
309292L
45
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Technical Data
Technical Data
Category
Data
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Maximum Fluid Operating Temperature
Paint Resistivity Range
100 psi (0.7 MPa, 7 bar)
100 psi (0.7 MPa, 7 bar)
40 psi (0.28 MPa, 2.8 bar)
120°F (48°C)
3 megohm/cm to infinity
125 microamperes
PRO Xs3 (244400, 244575): 60 kV
PRO Xs3 (244579, 244576): 30-60 kV
PRO Xs4 (244401): 85 kV
Short Circuit Current Output
Voltage Output
PRO Xs4 (244580): 40-85 kV
Sound Power (measured per ISO Standard 9216)
Sound Pressure (measured 1 m from gun)
at 40 psi (0.28 MPa, 2.8 bar): 90.4 dB(A)
at 100 psi (0.7 MPa, 7 bar): 105.4 dB(A)
at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A)
at 100 psi (0.7 MPa, 7 bar): 99 dB(A)
Air inlet fitting, left-hand thread
Fluid inlet fitting
1/4 npsm(m)
3/8 npsm(m)
Gun Weight
PRO Xs3: 25.1 oz (712 g)
PRO Xs4: 27.8 oz (788 g)
Gun Length
Wetted Parts
PRO Xs3: 9.7 in. (24.6 cm)
PRO Xs4: 11.1 in. (28.2 cm)
Stainless Steel; Nylon, Acetal, Ultra-High Molecular
Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten
Wire, Polyethylene
®
Loctite is a registered trademark of the Loctite Corporation.
46
309292L
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Technical Data
309292L
47
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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 309292
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
10/2001, Revised 8/2007
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