Graco 309297L Pro Auto Xs Users Manual Xs, Automatic Electrostatic Air Spray Gun, Instructions/Parts, English

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100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure

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

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

For use in Group II, Zone 1 areas using Group IIA spray materials.

For Professional Use ONLY.

U.S. Patent 7,226,004

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for Table of Contents and page 3 for

List of Models.

Instructions/Parts List

AUTOMATIC ELECTROSTATIC AIR SPRAY GUN

PRO

™

Auto Xs

TI1557A

#53

II 2 G EEx 0.24 mJ

309297L

EN

2309297L

Table of Contents

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

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3

Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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

Operating the Spray Function . . . . . . . . . . . . . . . 6

Operating the Electrostatics . . . . . . . . . . . . . . . . 6

Gun Features and Options . . . . . . . . . . . . . . . . . 6

Changing the kV Setting . . . . . . . . . . . . . . . . . . . 6

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

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

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Install the Air Line Accessories . . . . . . . . . . . . . 10

Install the Fluid Line Accessories . . . . . . . . . . . 10

Install the Gun and Mounting Bracket . . . . . . . . 10

Connect the Air and Fluid Lines . . . . . . . . . . . . 11

Manifold Connections . . . . . . . . . . . . . . . . . . . . 11

Optional Fiber Optic Cable Connection . . . . . . 12

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Check Electrical Grounding . . . . . . . . . . . . . . . 14

Check Fluid Resistivity . . . . . . . . . . . . . . . . . . . 15

Check Fluid Viscosity . . . . . . . . . . . . . . . . . . . . 15

Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 15

245324 HC Conversion Kit . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Relief Procedure . . . . . . . . . . . . . . . . 17

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 18

Select a Fluid Nozzle and Air Cap . . . . . . . . . . 18

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 19

Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 20

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 21

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 22

Clean the Air Cap and Fluid Nozzle . . . . . . . . . 24

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 25

Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 26

Test Power Supply Resistance . . . . . . . . . . . . . 27

Test Electrode Resistance . . . . . . . . . . . . . . . . . 28

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Spray Pattern Troubleshooting . . . . . . . . . . . . . 29

Gun Operation Troubleshooting . . . . . . . . . . . . 30

Electrical Troubleshooting . . . . . . . . . . . . . . . . . 31

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Prepare the Gun for Service . . . . . . . . . . . . . . . 32

Remove the Gun from the Manifold . . . . . . . . . . 33

Install the Gun on the Manifold . . . . . . . . . . . . . 33

Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 34

Electrode Replacement . . . . . . . . . . . . . . . . . . . 35

Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 36

Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 37

Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . . 39

Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 40

Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 41

Power Supply Removal and Replacement . . . . 42

Turbine Alternator Removal and Replacement . 43

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 52

Fluid Line Accessories . . . . . . . . . . . . . . . . . . . . 52

Miscellaneous Accessories . . . . . . . . . . . . . . . . 53

Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 54

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

List of Models

309297L 3

List of Models

Symbols

Warning Symbol

This symbol alerts you to the possibility of serious injury

or death if you do not follow the instructions.

Caution Symbol

This symbol alerts you to the possibility of damage to or

destruction of equipment if you do not follow the instruc-

tions.

Part No. Model Voltage

Type of Coatings

Standard High Conductivity

244589 PRO Auto Xs 40-85 kV X

244590 PRO Auto Xs 40-85 kV X

WARNING CAUTION

Warning

4309297L

WARNING

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

requirements of this manual.

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

Grounding instructions.

•Only use grounded Graco 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 comply 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 equip-

ment until you identify and correct the problem.

•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plas-

tic 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.

Toxic Fluid Hazard

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on

the skin, swallowed, or inhaled.

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

•Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all

local, state, and national guidelines.

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

Warning

309297L 5

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 distribu-

tor.

•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. Maxi-

mum 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 Techni-

cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warn-

ings.

•Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 180°F (82°C) or below -40°F (-40°C).

•Wear hearing protection when operating this equipment.

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

•Follow the steps under Prepare the Gun for Service, page 32, when you stop spraying and

before cleaning, checking, or repairing equipment.

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

•Tighten all fluid connections before each use.

Introduction

6309297L

Introduction

How the Electrostatic Air

Spray Gun Works

The automatic electrostatic air spray gun operates very

similar to a traditional air spray gun. The atomization

and fan air are emitted from the air cap. The atomization

air breaks up the fluid stream and controls the droplet

size. The fan air controls the shape and width of the

spray pattern. The fan and atomization air can be

adjusted independently.

Operating the Spray

Function

Applying a minimum of 50 psi (0.35 MPa, 3.5 bar) air

pressure to the gun manifold’s cylinder air fitting (CYL)

will retract the gun piston, which opens the air valves

and a short time later opens the fluid needle. This pro-

vides the proper air lead and lag when triggering the

gun. A spring returns the piston when the cylinder air is

shut off.

Operating the Electrostatics

To operate the electrostatics, apply air pressure to the

gun manifold’s turbine air fitting (TA) through a Graco

grounded air hose. The air enters the manifold and is

directed to the inlet of the power supply turbine. The air

spins the turbine, which then provides electrical power

to the internal high voltage power supply. The fluid is

charged by the spray gun electrode. The charged fluid is

attracted to the nearest grounded object, wrapping

around and evenly coating all surfaces.

The turbine air is exhausted into the shroud and out the

back of the manifold through the exhaust fitting (EXH).

The exhaust air helps keep contaminants out and helps

keep the gun clean.

Gun Features and Options

•The gun is designed for use with a reciprocator, and

can be mounted directly on a 1/2 in. (13 mm) rod.

With additional brackets, the gun can be mounted

for robotic applications.

•The gun’s quick-disconnect design enables its

removal without disconnecting the fluid and air lines

to the gun.

•Gun functions are activated from a separate control-

ler that sends the appropriate signal to the actuating

solenoids.

•The optional fiber optic readout system can be

installed to monitor the gun’s spraying voltage. A

fiber optic cable connected to the gun manifold car-

ries the signal from the gun to a remote display

module. Part No. 224117 Display Module displays

the gun’s spraying voltage and current. Bat-

tery-operated Display Module 189762 displays the

gun’s spraying voltage only.

Changing the kV Setting

The gun’s full voltage setting is 85 kV. Three lower volt-

age settings are possible by actuating the KV1 and KV2

switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure

to the KV1 and KV2 ports. Turn the air on or off as

shown in Table 1 to set the desired voltage.

The solenoid valves used to activate the KV1 and KV2

switches must bleed the air out of the lines for the

switches to draw back to the higher voltage setting.

Table 1: KV1 and KV2 Switch Settings

KV1 Air KV2 Air Output Voltage (kV)

OFF OFF 85

OFF ON 70

ON OFF 60

ON ON 45

Introduction

309297L 7

Fig. 1: Gun Overview

Key

TI1577A

TI1561A

TI1557A

Manifold Back View

A

B

CD

E

F

G

H

J

A1 A2

CYL

EXH

FO

KV2

P1 P2

TA

KV1

AAir Cap

B Fluid Nozzle

C Retaining Ring

D Shroud

E Mounting Bracket

FManifold

G Turbine

H Power Supply

J Electrode

Manifold Markings

A1 Atomization Air Inlet Fitting

A2 Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

EXH Shroud Exhaust Outlet Fitting

FO Fiber Optic Fitting (shipped unassembled)

KV1 kV Switch 1 Air Inlet

KV2 kV Switch 2 Air Inlet

P1 Fluid Supply Inlet Fitting

P2 Fluid Return Inlet Fitting (optional)

TA Turbine Air Inlet Fitting

Installation

8309297L

Installation

Install the System

F

IGURE

2 shows a typical electrostatic air spray system,

and F

IGURE

3 shows possible system options. It is not

an actual system design. For assistance in designing a

system to suit your particular needs, contact your Graco

distributor.

Warning Signs

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

Electrically interlock the gun turbine air supply (B) with

the ventilators to prevent gun operation without ventilat-

ing 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. The minimum allow-

able air exhaust velocity is 60 ft/minute (19 linear

meters/minute).

Key to F

IGURE

2 and F

IGURE

3

WARNING

Fire, Explosion, and Electric Shock Hazard

Installing and servicing this equipment

requires access to parts which may cause

electric shock or other serious injury if work

is not performed properly.

•Do not install or service this equipment

unless you are trained and qualified.

•Be sure your installation complies with

National, State and Local codes for the

installation of electrical apparatus in a Class

I, Div. I, Group D or a Group II,

Category 2G Hazardous Location.

•Comply with all applicable local, state, and

national fire, electrical, and other safety regula-

tions.

WARNING

Flammable or Toxic Vapor Hazard

Provide fresh air ventilation to avoid the buildup of

flammable or toxic vapors when spraying, flushing, or

cleaning the gun. Do not operate the gun unless ven-

tilation fans are operating.

A Air Hose Ground Wire

B Graco Grounded Turbine Air Hose (TA)

C Atomizing Air Hose, 3/8 in. (10 mm) OD (A1)

D Fan Air Hose, 3/8 in. (10 mm) OD (A2)

E Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)

F Fluid Hose, 1/4-18 npsm gun fluid inlet (P1)

G To Fluid Supply

H Auto PRO Xs Air Spray Gun

J Mounting Bracket for 1/2 in. (13 mm) rod

K Solenoid Valve, requires quick exhaust port

L Bleed-Type Master Air Valve

M Air Pressure Regulator

N True Earth Ground

P 24 Volt Power Supply

Q 4-20 microampere Outputs

R Full Feature ES Display Module

S kV Only ES Display Module (battery operated)

T Fiber Optic Y Cable

U Bulkhead

V Fiber Optic Cable

W Main Air Line

XkV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV1

fitting if not used)

YkV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2

fitting if not used)

Installation

309297L 9

Fig. 2: Typical Installation

Fig. 3: Optional Fiber Optic Connection to Voltage Display Module

TI1712A

A

BCD

EF

J

K

M

N

G

NOTE:

* The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent

the power supply from operating without ventilating fans on.

Non-Hazardous Area Hazardous Area

Y

W

P1

CYL

A2A1

KV2

TA

K

K

See *

above

K

X

KV1

L

L

L

Manifold Back View

TI1583A

KV

μA

85.0 KV

Q

T

NOTE:

** A maximum of two splices with a total of 108 ft (33 m) of cable can be used. For the stron-

gest light signals, use a minimum number of bulkhead splices. See Accessories on page 53.

Non-Hazardous Area Hazardous Area

H

U**R

P

S

V**

Installation

10 309297L

Install the Air Line

Accessories

1. Install a bleed-type air valve (L) on the main air line

(W) to shut off all air to the gun (H).

2. Install an air line filter/water separator on the gun air

line to ensure a dry, clean air supply to the gun. Dirt

and moisture can ruin the appearance of your fin-

ished workpiece and can cause the gun to malfunc-

tion.

3. Install a bleed-type air regulator (M) on each of the

air supply lines (B, C, D, E, X, Y) to control air pres-

sure to the gun.

4. Install a solenoid valve (K) on the cylinder air line

(E) to actuate the gun. The solenoid valve must

have a quick exhaust port.

Install the Fluid Line

Accessories

1. Install a fluid filter and drain valve at the pump out-

let.

2. Install a fluid regulator on the fluid line to control

fluid pressure to the gun.

Install the Gun and Mounting

Bracket

1. Loosen the mounting bracket’s two set screws (103)

and slide the bracket (102) onto a 1/2 in. (13 mm)

mounting rod. See F

IGURE

4.

2. Position the gun and tighten the two set screws.

For added positioning reliability, insert a 1/8 in. (3 mm)

locating pin into the slot (NN) in the bracket and through

a hole in the rod. See the detail in F

IGURE

4.

Fig. 4: Mounting Bracket

WARNING

Pressurized Equipment Hazard

Trapped air can cause the gun to spray

unexpectedly, which can result in serious

injury, including splashing fluid in the eyes

or on the skin. The solenoid valves (K) must

have a quick exhaust port so trapped air will

be relieved between the valve and gun

when the solenoids are shut off.

WARNING

Pressurized Equipment Hazard

The fluid drain valve is required in your sys-

tem 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.

TI1570A

103

102

NN

03460

9.22 in

(234.2 mm)

2.88 in

(73.2 mm)

To nozzle tip

Installation

309297L 11

Connect the Air and Fluid

Lines

F

IGURE

3 shows a schematic of air and fluid line connec-

tions, and F

IGURE

5 shows the manifold connections.

Connect the air and fluid lines as instructed.

1. Connect the Graco Grounded Air Supply Hose (B)

to the gun's turbine air inlet (TA) and connect the

hose ground wire (A) to a true earth ground (N). The

gun turbine air inlet fitting has left-hand threads to

prevent connecting another type of air hose to the

turbine air inlet. See Accessories on page 52 for

further information about the hose.

2. Check the electrical grounding of the gun as

instructed on page 14.

3. Before connecting the fluid line (P1), blow it out with

air and flush it with solvent. Use solvent which is

compatible with the fluid to be sprayed.

Manifold Connections

Fig. 5: Manifold Connections

WARNING

Electric Shock Hazard

To reduce the risk of electric shock or other

serious injury, the turbine air supply hose

must be electrically connected to a true

earth ground. Use only Graco Grounded

Air Supply Hose.

A1 Atomization Air Inlet Fitting

Connect a 3/8 in. (10 mm) OD tube between this fitting and

the air supply.

A2 Fan Air Inlet Fitting

Connect a 3/8 in. (10 mm) OD tube between this fitting and

the air supply.

CYL Cylinder Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and

the solenoid. For quicker response, use the shortest hose

length possible.

EXH Shroud Exhaust Outlet Fitting

Connect a 1/4 in. (6 mm) OD x 4 ft (1.22 m) long tube to

this fitting.

FO Fiber Optic Fitting (Optional)

Connect the Graco Fiber Optic cable (see page 11).

KV1 kV Switch 1 Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and

the solenoid.

KV2 kV Switch 2 Air Inlet Fitting

Connect a 5/32 in. (4 mm) OD tube between this fitting and

the solenoid.

P1 Fluid Supply Inlet Fitting

Connect a 1/4 npsm swivel fitting between this fitting and

the fluid supply.

P2 Fluid Return Inlet Fitting (optional)

Order Part No. 233676 Fluid Recirculation Kit.

TA Turbine Air Inlet Fitting

Connect the Graco Electrically Conductive Air Hose

between this fitting (left-hand thread) and the solenoid.

Connect the air hose ground wire to a true earth ground.

TI1577A

A1 A2

CYL

EXH

FO

KV2

P1 P2

TA

KV1

Installation

12 309297L

Optional Fiber Optic Cable

Connection

An optional fiber optic fitting is shipped unassembled

with the gun. If an ES (kV) display module is used,

install the fitting in the FO port of the manifold. See F

IG

-

URE

3, page 9, for a schematic of the fiber optic connec-

tions.

1. Remove the plug (120) from the fiber optic port, and

install the fiber optic fitting (5, shipped loose with the

gun). See F

IGURE

6.

Fig. 6: Fiber Optic Fitting

2. Remove the nut (AA) from the fiber optic fitting (5)

and slide the nut over the end of the fiber optic cable

(BB). See F

IGURE

7.

3. Push the cable (BB) into the fitting (5) until it bot-

toms out. Tighten the nut (AA) to secure the cable.

Fig. 7: Fiber Optic Cable

Most of the fiber optic light transmission loss occurs at

the bulkhead splices. For the strongest light signals, use

a minimum number of bulkhead splices. A maximum of

two splices, with a total of 108 ft (33 m) of cable, is rec-

ommended.

4. See manual 308265 to install a Graco ES Display

Module.

TI1580A

120

5

TI1581A

AA

5

BB

Installation

309297L 13

Grounding

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 to the turbine

air inlet and connecting the air hose ground wire to a

true earth ground. See Check Electrical Ground-

ing, page 14.

•

Air compressors and hydraulic power supplies:

ground the equipment according to the manufac-

turer's recommendations.

•

All air and fluid lines

must be properly grounded.

•

All electrical cables

must be properly grounded.

•

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.

•

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.

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.

Installation

14 309297L

Check Electrical Grounding

1. Have a qualified electrician check the electrical

grounding continuity of the spray gun and turbine air

hose.

2. Make sure the turbine air hose (B) is connected and

the hose ground wire is connected to a true earth

ground.

3. Turn off the air and fluid supply to the gun. The fluid

hose must not have any fluid in it.

4. Measure the resistance between the turbine air inlet

fitting (TA) and a true earth ground (N).

a.

If using a black or grey turbine air hose,

use a

megohmmeter to measure the resistance. Use

an applied voltage of 500 minimum to 1000

volts maximum. The resistance should not

exceed 1 megohm.

b.

If using a red turbine air hose,

use an ohmmeter

to measure the resistance. The resistance

should not exceed 100 ohms.

3. If the resistance is greater than the maximum read-

ing specified above for your hose, check the tight-

ness of the ground connections and be sure the

turbine air hose ground wire is connected to a true

earth ground. If the resistance is still too high,

replace the turbine air hose.

Fig. 8. Check Gun Grounding

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F

IGURE

8) is not approved for use in a haz-

ardous area. To reduce the risk of sparking,

do not use the megohmmeter to check

electrical grounding unless:

•The gun has been removed from the

hazardous area;

•Or all spraying devices in the hazardous

area are turned off, ventilation fans in the

hazardous area are operating, and there

are no flammable vapors in the area

(such as open solvent containers or

fumes from spraying).

Failure to follow this warning could cause

fire, explosion, and electric shock and result

in serious injury and property damage.

TI1584

A

B

AA

TA

N

Installation

309297L 15

Check Fluid Resistivity

Graco Part No. 722886 Resistance Meter and 722860

Probe are available as accessories to check that the

resistivity of the fluid being sprayed meets the require-

ments of an electrostatic air spray system.

Follow the instructions included with the meter and

probe. Readings of 25 megohms-cm and above provide

the best electrostatic results.

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.

Install the Fabric Cover

1. Install a fabric cover (XX) over the front of the gun

and slide it back to cover the exposed tubing and

hoses at the back of the manifold. See F

IGURE

9.

2. Route the exhaust tube (YY) outside the cover. This

enables you to monitor the exhaust tube for the

presence of any paint or solvent. See Check for

Fluid Leakage on page 25. Strap down the exhaust

tube to prevent it from moving around.

Fig. 9. Fabric Cover

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.

Failure to follow this warning could cause

fire, explosion, or electric shock and result

in serious injury and property damage.

ti1571a

TI1579A

YY

YY

XX

Installation

16 309297L

245324 HC Conversion Kit

Part No. 245324 Conversion Kit is available to convert

PRO Auto Xs standard coating guns (Part No. 244589)

to high conductivity guns (244590).

The kit is for use with fluids with low resistivity values.

1. Turn the turbine air (TA) off.

2. Flush the gun.

3. Relieve the pressure.

4. Remove the retaining ring (1), air cap (3), and

shroud (2).

5. Refer to the parts drawing for Model 244589 on

page 45. Loosen the two nuts (20) and remove the

fluid tube (19) and ferrules (21, 22). Remove the

other parts (14, 15, 16, 17, 18) at the gun barrel

inlet.

6. Slide the loops of the hc tube (19) onto the gun bar-

rel (9).

7. Make sure the barrel threads are clean and dry.

Apply Graco Part No. 116553 dielectric grease to

the fluid fitting (19d) threads and o-rings. Thread

the fitting into the barrel inlet. See F

IGURE

10.

8. Slide the nut (20) and ferrules (21, 22) onto the

coiled tube (19). Insert the end of the tube into the

fitting (23). Make sure the ferrules seat in the fitting.

Tighten the nut (20).

Fig. 10. HC Conversion Kit

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before installing this kit.

TI1731A

23

19

9

19d

20

21

22

Operation

309297L 17

Operation

Pressure Relief Procedure

1. Turn off all the air to the spray gun except the cylin-

der air, which triggers the gun. If an air pilot fluid

regulator is used in the system, the air pressure is

needed at the regulator air inlet.

2. Turn off the fluid supply to the gun.

3. Trigger the gun into a grounded metal waste con-

tainer to relieve the fluid pressure.

4. If an air pilot fluid regulator is used, turn off the air

pressure at the regulator air inlet.

5. Relieve fluid pressure in the fluid supply equipment

as instructed in its instruction manual.

6. Turn off the main air supply by closing the

bleed-type master air valve on the main air supply

line. Leave the valve closed until you are ready to

spray again.

WARNING

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 moving parts, follow the

Pressure Relief Procedure whenever you:

•are instructed to relieve the pressure

•stop spraying

•check or service any of the system equipment

•or install or clean the fluid nozzle.

Operation

18 309297L

Operating Checklist

Check the following list daily, before starting to operate

the system, to help ensure you of safe, efficient opera-

tion.

Select a Fluid Nozzle and Air

Cap

The gun is supplied with Part No. 197266 Nozzle and

24A438 Air Cap. If you require a different size, refer to

Table 2 and Table 3 , and instruction manual 309419, or

consult with your Graco distributor. See Air Cap/Nozzle

Replacement on page 34.

*Also available in the following colors: 24A276 - blue,

24A277 - red, 24A278 - green

All operators are properly trained to safely

operate an automatic electrostatic air spray

system as instructed in this manual.

All operators are trained in the Pressure

Relief Procedure on page 17.

The warning sign provided with the gun is

mounted in the spray area where it can be

easily seen and read by all operators.

The system is thoroughly grounded and the

operator and all persons entering the spray

area are properly grounded. See Grounding

on page 13.

The condition of the gun’s electrical compo-

nents has been checked as instructed in Elec-

trical Tests on page 26.

Ventilation fans are operating properly.

Workpiece hangers are clean and grounded.

All debris, including flammable fluids and rags,

is removed from the spray area.

All flammable fluids in the spray booth are in

approved, grounded containers.

All conductive objects in the spray area are

electrically grounded and the floor of the spray

area is electrically conductive and grounded.

The manifold exhaust tubes have been

checked for the presence of any fluid as

instructed in Check for Fluid Leakage on

page 25.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before removing or installing a fluid nozzle

and/or air cap.

Table 2: Fluid Nozzles

Part No. Size,

mm (in.) Part No. Size,

mm (in.)

197263 0.75 (.030) 197266 1.5 (.055)

197264 1.0 (.042) 197267 1.8 (.070)

197265 1.2 (.047) 197268 2.0 (.080)

Table 3: 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)

24A376* 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.

Operation

309297L 19

Adjust the Spray Pattern

Follow the steps below to establish the correct fluid flow

and air flow. Do not turn on the turbine air (TA) yet.

1. Relieve the pressure.

2. Loosen the air cap retaining ring, and rotate the air

cap for a vertical or horizontal spray pattern. See

F

IGURE

11. Tighten the retaining ring until the air cap

is held firmly in place; you should not be able to

rotate the air cap horns by hand.

Fig. 11. Air Cap Positions

3. Adjust the fluid flow with the fluid pressure regulator.

Refer to instruction manual 309419 to set the fluid

pressure for various fluid flows, according to the

size of the fluid nozzle being used.

4. Use the air pressure regulator on the atomization air

supply line (A1) to adjust the degree of atomization.

See F

IGURE

12. For example, for a fluid flow rate of

10 ounces per minute (0.3 liters per minute), a typi-

cal atomization pressure would be 20-30 psi

(1.4-2.1 bar, 0.14-0.21 MPa) at the gun manifold.

5. Use the air pressure regulator on the fan air supply

line (A2) to adjust the pattern size.

•For the most efficiency, always use the lowest air

pressure possible.

•When increasing to a wide, flat pattern, it may be

necessary to increase the supply of fluid to the gun

to maintain the same amount of coverage over a

large area.

•See Spray Pattern Troubleshooting on page 29 to

correct spray pattern problems.

Fig. 12. Manifold Air Connections

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

whenever you are instructed to relieve the

pressure.

Vertical Pattern

Horizontal Pattern

TI1577A

A1 A2

CYL

KV2

TA

KV1

Operation

20 309297L

Adjust the Electrostatics

1. Shut off the fluid supply.

2. Trigger the gun, then turn on the turbine air (TA).

See F

IGURE

12.

3. Refer to Table 4 to set the proper pressure at the

turbine air hose inlet

when air is flowing

. Do not

exceed these pressures as there is no added bene-

fit and turbine life could be reduced.

4. Check the voltage output of the gun using a high

voltage probe and meter or by reading the ES (kV)

Display Module.

The gun’s normal high voltage reading is 60-70 kV. If a

ball end high voltage measurement probe is used, the

gun voltage will rise to about 85 kV. This will happen

with all resistive electrostatic guns.

See Electrical Troubleshooting on page 31 to correct

voltage problems.

Table 4: Dynamic Turbine Air Pressures

Turbine Air

Hose Length

ft (m)

Air pressure at turbine air hose

inlet for full voltage

psi (bar, MPa)

15 (4.6) 54 (3.8, 0.38)

25 (7.6) 55 (3.85, 0.38)

36 (11) 56 (3.9, 0.39)

50 (15.3) 57 (4.0, 0.40)

75 (22.9) 59 (4.1, 0.41)

100 (30.5) 61 (4.3, 0.43)

Operation

309297L 21

Spraying

1. Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air

pressure to the cylinder air fitting (CYL) to activate

the on/off sequence of atomization air (A1), fan air

(A2), and fluid (P1). See F

IGURE

12.

2. Turn the gun functions on and off by using the air

solenoid valves on the cylinder (CYL) and turbine

(TA) air supply lines.

3. To change to a lower voltage setting, activate the

solenoids controlling the KV1 and KV2 ports. See

Changing the kV Setting on page 6.

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomiza-

tion (A1) and fan (A2) air lines, using the bleed-type

air shutoff valves.

2. Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the

cylinder air fitting (CYL) to trigger the fluid.

Shutdown

1. Relieve the pressure.

2. Flush and clean the equipment. See Maintenance

on page 22.

WARNING

Electric Shock Hazard

To reduce the risk of electric shock, do not

touch the gun electrode or come within 4 in.

(10 cm) of the nozzle during gun operation.

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is

detected, stop spraying immediately. Fluid

leakage into the gun shroud could cause

fire or explosion and result in serious injury

and property damage. See Check for Fluid

Leakage on page 25.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you

are instructed to relieve the pressure.

Maintenance

22 309297L

Maintenance

Daily Care and Cleaning

CAUTION

•Clean all parts with a non-conductive, compatible

solvent. Conductive solvents can cause the gun to

malfunction.

•Do not use methylene chloride as a flushing or

cleaning solvent with this gun as it will damage

nylon components.

•Fluid in the air passages could cause the gun to

malfunction and could draw current and reduce the

electrostatic effect. Fluid in the power supply cavity

can reduce the alternator life. Whenever possible,

point the gun down when cleaning it. Do not use

any cleaning method which could allow fluid into

the gun air passages.

Do not immerse the gun in fluid.

Do not point the gun up while cleaning it. Do not wipe the gun with a cloth that is heavily

saturated; wring out the excess fluid.

TI1573A

TI1574A

02027A

Maintenance

309297L 23

Daily Care and Cleaning,

continued

•Clean the fluid and air line filters daily.

•Clean the outside of the gun daily with a soft cloth

dampened in a compatible solvent.

•Clean the air cap and fluid nozzle daily, minimum.

Some applications require more frequent cleaning.

Replace the fluid nozzle and air cap if they are dam-

aged. See Clean the Air Cap and Fluid Nozzle,

page 24.

•Check the electrode and replace if broken or dam-

aged. See Electrode Replacement on page 35.

•Check for fluid leakage from the gun and fluid

hoses. See Check for Fluid Leakage on page 25.

Tighten fittings or replace equipment as needed.

•Flush the gun before changing colors and whenever

you are done operating the gun.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

before doing any maintenance on the gun

or system.

WARNING

Fire, Explosion, and Electric Shock Hazard

To reduce the risk of fire, explosion, or elec-

tric shock, turn off the turbine air (TA)

before flushing the gun or any part of the

system.

Maintenance

24 309297L

Clean the Air Cap and Fluid

Nozzle

Equipment Needed

•soft bristle brush

•compatible solvent

Procedure

1. Relieve the pressure.

2. Remove the air cap assembly (1, 3) and shroud (2).

See F

IGURE

13.

3. Wipe the fluid nozzle (4), shroud (2), and exterior of

the gun clean with a cloth dampened in solvent.

Avoid getting any solvent into the air passages.

Whenever possible, point the gun down when

cleaning it.

4. If it appears that there is paint inside the fluid nozzle

(4) air passages, remove the gun from the line for

servicing.

5. Clean the air cap (3) with the soft bristle brush and

solvent or submerge the air cap in suitable solvent

and wipe it clean.

6. Slide the shroud (2) onto the gun.

7. Carefully install the air cap (3). Be sure to insert the

electrode (7) through the center hole of the air cap.

Rotate the air cap to the desired position.

8. Make sure the u-cup (1a) is in place on the retaining

ring (1). The lips must face forward. Tighten the

retaining ring until the air cap is held firmly in place;

you should not be able to rotate the air cap horns by

hand.

9. Test gun resistance, page 26.

Fig. 13. Clean Air Cap and Fluid Nozzle

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you

are instructed to relieve the pressure.

CAUTION

Do not use metal tools to clean the

air cap or fluid nozzle holes as this

could scratch them, and make sure

the electrode is not damaged.

Scratches in the air cap or nozzle or

a damaged electrode can distort the

spray pattern.

TI1560A

2

47

13

1a

Maintenance

309297L 25

Check for Fluid Leakage

During operation, periodically check the manifold

exhaust tube (YY) and both ends of the gun shroud (ZZ)

for the presence of fluid. See F

IGURE

14. Fluid in these

areas indicates leakage into the shroud, which could be

caused by leaks at the fluid tube connections or fluid

packing leakage.

If fluid is seen in these areas, stop spraying immedi-

ately. Relieve the pressure, then remove the gun for

repair.

Fig. 14. Check for Fluid Leakage

WARNING

Fire and Explosion Hazard

If any fluid leakage from the gun is

detected, stop spraying immediately. Fluid

leakage into the gun shroud could cause

fire or explosion and result in serious injury

and property damage.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

when you stop spraying and whenever you

are instructed to relieve the pressure.

ti1571a

TI1579A

YY

YY

ZZ

ZZ

Electrical Tests

26 309297L

Electrical Tests

Electrical components inside the gun affect performance

and safety. The following procedures test the condition

of the power supply (12) and electrode (7), 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

1. Flush and dry the fluid passage.

2. Measure resistance between the electrode needle

tip (7) and the gun body (32) or the turbine air inlet

fitting (TA); it should be 156-180 megohms. If out-

side this range, remove the gun for service (page

32) and go to the next test. If in range, refer to Elec-

trical Troubleshooting on page 31 for other possi-

ble causes of poor performance.

Fig. 15. Test Gun Resistance

WARNING

Fire, Explosion, and Electric Shock Hazard

Megohmmeter Part No. 241079 (AA-see

F

IGURE

15) is not approved for use in a haz-

ardous area. To reduce the risk of sparking,

do not use the megohmmeter to check

electrical grounding unless:

•The gun has been removed from the haz-

ardous area;

•Or all spraying devices in the hazardous

area are turned off, ventilation fans in the

hazardous area are operating, and there

are no flammable vapors in the area

(such as open solvent containers or

fumes from spraying).

Failure to follow this warning could cause

fire, explosion, and electric shock and result

in serious injury and property damage.

TI1585B

TI1577A

AA

7

TA

TA

Electrical Tests

309297L 27

Test Power Supply

Resistance

1. Remove the power supply (12), page 42.

2. Remove the turbine alternator (13) from the power

supply, page 43.

3. Measure resistance from the power supply's ground

strips (EE) to the spring (12b). See F

IGURE

16.

4. The resistance should be 135-150 megohms. If out-

side this range, replace the power supply. If in

range, proceed to the next test.

5. If you still have problems, refer to Electrical Trou-

bleshooting on page 31 for other possible causes

of poor performance, or contact your Graco distribu-

tor.

6. Be sure the spring (12b) is in place before reinstall-

ing the power supply.

Fig. 16. Test Power Supply Resistance

ti1599a

EE

12b

Electrical Tests

28 309297L

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 (7). The resistance should be

20-30 megohms. See F

IGURE

17.

3. If in range, refer to Electrical Troubleshooting on

page 31 for other possible causes of poor perfor-

mance, or contact your Graco distributor.

4. Remove the electrode (7), page 35. Measure the

resistance between the contact (E) and the elec-

trode wire (F). The resistance should be 20-30 meg-

ohms. If out of range, replace the electrode. See

F

IGURE

18.

5. Make sure the metal contact (C) in the barrel, the

nozzle contact ring (4a, F

IGURE

19), and the elec-

trode contacts (E) are clean and undamaged.

Fig. 17. Test Electrode Resistance

Fig. 18. Electrode

Fig. 19. Nozzle Conductive O-Ring

ti1499a

B

7

C

ti1548a

F7E

ti1513a

4a

Troubleshooting

309297L 29

Troubleshooting

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.

WARNING

Electric Shock Hazard

Installing and servicing this equipment

requires access to parts which may cause

an electric shock or other serious injury if

the work is not performed properly. Do not install or

repair this equipment unless you are trained and

qualified.

WARNING

Pressurized Equipment Hazard

To reduce the risk of an injury, follow the

Pressure Relief Procedure on page 17

whenever you are instructed to relieve the

pressure.

Problem Cause Solution

Fluttering or spitting spray. No fluid. Refill supply.

Loose, dirty, damaged nozzle/seat. Clean or replace nozzle, page 34.

Air in fluid supply. Check fluid source. Refill.

Improper spray pattern. Damaged nozzle or air cap. Replace, page 34.

Fluid buildup on air cap or nozzle. Clean. See page 24.

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 34.

Troubleshooting

30 309297L

Gun Operation Troubleshooting

Problem Cause Solution

Excessive spray fog. Atomizing air pressure too high. Decrease air pressure as low as pos-

sible.

Fluid too thin. Increase viscosity.

“Orange Peel” finish. Atomizing air pressure too low. Increase air 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 pages

36 or 37.

Air leaks from the air cap Worn piston stem o-rings (34e, 34f). Replace; see page 38.

Fluid leakage from the front of the

gun

Worn or damaged packing rod (8). Replace; see page 36

Worn fluid seat. Replace fluid nozzle (4) and/or elec-

trode needle (7); see pages 34 to 35.

Loose fluid nozzle (4). Tighten; see page 34.

Damaged nozzle o-ring (4b). Replace; see page 34.

Gun does not spray Low fluid supply. Add fluid if necessary.

Damaged air cap (3). Replace; see page 34.

Dirty or clogged fluid nozzle (4). Clean; see page 34.

Damaged fluid nozzle (4). Replace; see page 34.

Piston (34) not actuating. Check cylinder air. Check piston

u-cup (34d); see page 38.

Actuator arm (29) is out of position. Check actuator arm and nuts. See

page 39.

Dirty air cap Misaligned air cap (3) and fluid noz-

zle (4).

Clean fluid buildup off air cap and

fluid nozzle seat; see page 24.

Damaged nozzle orifice. Replace nozzle (4); see page 34.

Fluid is coming on before the air. Check actuator arm and nuts. See

page 39.

Air leaks from manifold Manifold is not tight. Tighten manifold screws (106).

Fluid leaks at the quick-disconnect. Manifold is not tight. Tighten manifold screws (106).

Fluid hose o-rings are worn or miss-

ing.

Inspect or replace o-rings.

Troubleshooting

309297L 31

Electrical Troubleshooting

Problem Cause Solution

Poor wrap. Turbine air is not turned on. Turn on.

Booth exhaust velocity is too high. Reduce velocity to within code limits.

Atomizing air pressure too high. Decrease.

Fluid pressure too high. Decrease.

Incorrect distance from gun to part. Should be 8-12 in. (200-300 mm).

Poorly grounded parts. Resistance must be 1 megohm or

less. Clean workpiece hangers.

Faulty gun resistance. See Test Gun Resistance on page

26.

Low fluid resistivity. Check fluid resistivity, page 15.

Fluid leaks from the packing (8d) and

causes a short.

Clean the packing rod cavity.

Replace the packing rod. See page

37.

Faulty turbine alternator. Be sure the plug is in place on the

back of the turbine alternator hous-

ing. Remove and test the turbine

alternator. See page 43.

The KV switch is stuck on low. Check the switch actuation; replace if

needed.

No power. Replace power supply. See page 42.

No voltage or low voltage reading on

the gun ES display module

Damaged fiber optic cable or connec-

tion.

Check; replace damaged parts.

Turbine air is not turned on. Turn on.

Poor wrap. See causes and solutions under Poor

Wrap, above.

Operator gets mild shock. Operator not grounded or is near

ungrounded object.

See Grounding on page 13.

Gun not grounded. See Check Electrical Grounding on

page 14 and Test Gun Resistance

on page 26.

Operator gets shock from workpiece. Workpiece not grounded. Resistance must be 1 megohm or

less. Clean workpiece hangers.

Repair

32 309297L

Repair

Prepare the Gun for Service

•Check all possible remedies in Troubleshooting

before disassembling the gun.

•Use a vise with padded jaws to prevent damage to

plastic parts.

•Lubricate the power supply o-ring (12a), some pack-

ing rod parts (8), and certain fluid fittings with Part

No. 116553 Dielectric Grease, 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.

1. Flush and clean the gun, page 22.

2. Relieve the pressure, page 17.

3. Remove the gun from the manifold, page 33.

4. Remove the gun from the worksite. Repair area

must be clean.

WARNING

Electric Shock Hazard

Installing and repairing this equipment

requires access to parts that may cause

electric shock or other serious injury if the

work is not performed properly. Do not install or ser-

vice this equipment unless you are trained and quali-

fied.

WARNING

Pressurized Equipment Hazard

To reduce the risk of injury, follow the Pres-

sure Relief Procedure on page 17 before

checking or servicing any part of the system

and whenever you are instructed to relieve the pres-

sure.

Repair

309297L 33

Remove the Gun from the

Manifold

1. Loosen the bottom gun screw (31) until the gun sits

loosely in the mounting bracket slot (A). See F

IGURE

20.

2. Holding the gun firmly in hand, loosen the three

screws (106) from the back of the manifold.

3. Remove the gun from the manifold and take it to the

service area.

Fig. 20. Remove Gun from Manifold

Install the Gun on the

Manifold

1. Make sure the gasket (112) and spring (105) are in

place on the manifold. See F

IGURE

20. Inspect the

parts for damage and replace them as needed.

2. Secure the gun to the manifold by tightening the

three screws (106).

3. Secure the gun to the mounting bracket (102) by

tightening the bottom screw (31).

CAUTION

The piston return spring (105) is compressed

between the manifold and the gun body when they

are assembled. To avoid sudden movement of the

gun, loosen the bottom gun screw (31) before loos-

ening the three manifold screws (106). This allows

the gun to move forward gradually as the manifold

screws are loosened. Hold the gun firmly in hand

while loosening the manifold screws.

TI1559A

106

105

112

102

A

Repair

34 309297L

Air Cap/Nozzle Replacement

1. Prepare gun for service, page 32.

2. Remove the retaining ring (1) and air cap (3). See

F

IGURE

21.

3. Point gun up while removing the fluid nozzle (4)

assembly with the multi-tool (40).

Fig. 21. Air Cap/Nozzle Replacement

Use non-silicone grease, Part No. 111265, on the small

o-ring (4b). Do not over-lubricate. Do not lubricate the

contact ring (4a).

4. Lightly lubricate the o-ring (4b). Install it and the

contact ring (4a) on the nozzle (4).

Make sure the electrode needle (7) is finger- tight (page

35).

5. Install the fluid nozzle (4) with the multi-tool (40).

Tighten until the fluid nozzle seats in the gun barrel

(1/8 to 1/4 turn past hand-tight).

6. Carefully install the air cap (3). Be sure to insert the

electrode (7) through the center hole of the air cap.

Rotate the air cap to the desired position.

7. Make sure the u-cup (1a) is in place on the retaining

ring (1). The lips must face forward. Tighten the

retaining ring until the air cap is held firmly in place;

you should not be able to rotate the air cap horns by

hand.

8. Test gun resistance, page 26.

9. Install the gun onto the manifold and bracket. See

page 33.

CAUTION

Hold the front end of the gun up and trigger the gun

while removing the nozzle to help drain the gun and

prevent any paint or solvent left in the gun from enter-

ing the air passages.

TI1572A

1, 3

3

4

4a

4b

1

40

4

7

1a

WARNING

Fire, Explosion, and Electric Shock Hazard

The nozzle contact ring (4a) 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 (4a) except

to replace it and never operate the gun

without the contact ring in place. Do not

replace the contact ring with anything but a

genuine Graco part.

Repair

309297L 35

Electrode Replacement

1. Prepare the gun for service, page 32.

2. Remove the air cap and nozzle, page 34. Remove

the gun shroud (2).

3. Unscrew the electrode (7) with the multi-tool (40).

Hold the packing rod end (8h) to prevent it from

turning, F

IGURE

22.

4. Apply low-strength (purple) Loctite

®

or equivalent

thread sealant to the electrode and packing rod

threads. Install the electrode finger-tight. Do not

overtighten.

5. Install the fluid nozzle, page 34.

6. Test gun resistance, page 26.

7. Install the gun shroud (2) and air cap, page 34.

8. Install the gun onto the manifold and bracket. See

page 33.

Fig. 22. Electrode Replacement

CAUTION

To avoid damaging the plastic threads, be very care-

ful when installing the electrode.

TI1565A

40

8h

Repair

36 309297L

Fluid Packing Removal

You may replace the packing rod as an assembly, as

described below, or as individual parts (see page 37).

The assembly is pre-adjusted at the factory.

1. Prepare the gun for service, page 32.

2. Remove the air cap, page 34. Remove the gun

shroud (2).

3. Remove the jam nut (28) and actuator arm (29).

See page 38.

The fluid nozzle (4) must be in place when removing or

installing the jam nut and actuator arm.

4. Remove the fluid nozzle (4) and electrode (7). See

pages 34 and 35.

5. Remove the packing rod (8), using the multi-tool

(40).

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

necessary.

Before installing the packing rod, clean the internal sur-

face of the barrel (9) with a soft cloth or brush. Check for

marks from high voltage arcing. If marks are present,

replace the barrel.

Fig. 23. Fluid Packing Removal

CAUTION

Clean all parts in non-conductive solvent compatible

with the fluid being used, such as xylol or mineral

spirits. Use of conductive solvents can cause the gun

to malfunction.

TI1566A

40

28

9

Repair

309297L 37

Packing Rod Repair

You may replace the packing rod as individual parts, as

described below, or as an assembly (see page 36). The

assembly is pre-adjusted at the factory.

Before installing the fluid packing rod into the gun barrel,

make sure the internal surfaces of the barrel are clean.

Remove any residue with a soft brush or cloth. Check

the inside of the barrel for marks from high voltage arc-

ing. If marks are present, replace the barrel.

To

assemble the individual parts:

1. Place the packing nut (8e) and seal (8b) on the fluid

rod (8h). 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 F

IGURE

24.

2. Fill the inner cavity of the spacer (8g) with dielectric

grease. Place the spacer on the fluid rod (8h) in the

direction shown. Generously apply dielectric grease

to the outside of the spacer.

3. Place the rod packing (8d), packing spreader (8c),

and housing (8f) on the packing rod (8h).

4. Lightly tighten the packing nut (8e). The packing nut

is properly tightened when there is 3 lb (13.3 N) of

drag force when sliding the packing housing (8f)

assembly along the rod. Tighten or loosen the pack-

ing nut as needed.

5. Install the o-ring (8a) on the outside of housing (8f).

Lubricate the o-ring with non-silicone grease, Part

No. 111265. Do not over-lubricate.

6. Install the spring (25) against the nut (E) as shown.

7. Install the packing rod assembly (8) into the gun

barrel. Using the multi-tool (40), tighten the assem-

bly until just snug.

8. Install the electrode, page 35 and nozzle, page 34.

9. Install and adjust the actuator arm (29) and jam nut

(28). See page 39.

10. Test gun resistance, page 26.

11. Install the gun shroud (2) and air cap, page 34.

12. Install the gun onto the manifold and bracket. See

page 33.

Fig. 24. Packing Rod

TI1489A

8a

8b

8c

8d

8e

8f

8g

8h

E

25

Repair

38 309297L

Piston Repair

1. Prepare the gun for service, page 32.

2. Remove the air cap, page 34. Remove the gun

shroud (2).

3. Remove the jam nut (28), actuator arm (29), and

adjustment nut (30). See F

IGURE

25.

The fluid nozzle (4) must be in place when removing or

installing the jam nut and actuator arm.

Fig. 25. Actuator Arm

4. Push on the piston rod (34b) to push the piston out

the back of the gun.

5. Inspect the o-rings (34e, 34f, 34g) and u-cup pack-

ing (34d) for damage. See Table 5 and F

IGURE

26.

6. Lubricate the o-rings (34e, 34f, 34g) and u-cup

packing (34d) with non-silicone grease, Part No.

111265. Do not over-lubricate.

7. Align the two stems (34c) with the holes in the gun

body and press the piston assembly into the back of

the gun until it bottoms.

8. Install and adjust the actuator arm, page 39.

Fig. 26. Piston O-Rings

TI1709A

28 29 30 34b

Table 5: Piston O-Rings

Description Function

Shaft O-Ring

(34g)

Seals cylinder air along the piston rod

(34b). Replace if air leaks along rod.

Front O-Ring

(34e)

Air shutoff seal. Replace if air leaks from

air cap when gun is de-triggered.

Back O-Ring

(34f)

Separates cylinder air from fan and

atomizing air.

U-Cup (34d) Replace if air leaks from small vent hole

at back of manifold when gun is trig-

gered.

TI1575A

TI1576A

34a

34d

34c

34f

34e

34g

34b

34e

34g

34f

34d

Atomizing Air Side

Fan Air Side

Repair

309297L 39

Adjust the Actuator Arm

The fluid nozzle (4) must be in place when removing or

installing the jam nut and actuator arm.

1. Install the adjustment nut (30), actuator arm (29),

and jam nut (28) onto the piston rod (34b). Note that

the jam nut (28) has a slightly larger hex and a thin-

ner profile than the adjustment nut (30). See F

IGURE

25 on page 38.

2. Position the parts so there is a 0.125 in. (3 mm) gap

between the actuator arm (29) and the fluid packing

rod nut (E), which allows the atomizing air to actuate

before the fluid. See F

IGURE

27.

3. Tighten the adjustment nut (30) against the actuator

arm (29). Check that the 0.125 in. (3 mm) gap has

been maintained. In addition, there should be 3-4

mm of electrode needle travel when the gun is trig-

gered. Adjust the jam nut position to obtain these

dimensions.

4. Test gun resistance, page 26.

5. Install the gun shroud (2) and air cap (3), page 34.

6. Install the gun onto the manifold and bracket. See

page 33.

Fig. 27. Actuator Arm Adjustment

TI1567A

28

29

30 34b E

0.125 in. (3 mm) gap

Repair

40 309297L

Barrel Removal

1. Prepare the gun for service, page 32.

2. Remove the air cap, page 34. Remove the gun

shroud (2).

3. Carefully loosen the fluid fitting nut (20). Pull the

tube (19) out of the fitting (23). Make sure both fer-

rules (21, 22) and the nut stay with the tube.

4. Remove the jam nut (28) and actuator arm (29).

See page 38.

5. Loosen the three screws (10, 33). See F

IGURE

28.

6. Hold the gun body (32) with one hand and pull the

barrel (9) straight off the body. See F

IGURE

28.

Fig. 28. Barrel Removal

Fig. 29. Disconnect Fluid Tube

CAUTION

To avoid damaging the power supply (12), pull the

gun barrel (9) straight away from the gun body (32). If

necessary, gently move the gun barrel from side to

side to free it from the gun body.

TI1563A

10

32

9

33

TI1709A

28

29

30

19

32

9

20 23

Repair

309297L 41

Barrel Installation

1. Be sure the gasket (11) and grounding spring (51)

are in place. Make sure the air holes are aligned

properly. Replace if damaged. See F

IGURE

30.

2. Place the barrel (9) over the power supply (12) and

onto the gun body (32).

3. Tighten the three screws (10, 33) oppositely and

evenly (about a half turn past snug).

4. Assemble the fluid tube (19) into the fluid fitting (23).

Ensure that the ferrules (21, 22) are in place.

Tighten the nut (20).

5. Install and adjust the actuator arm (29) and jam nut

(28). See page 39.

6. Test gun resistance, page 26.

7. Install the gun shroud (2) and air cap, page 34.

8. Install the gun onto the manifold and bracket. See

page 33.

Fig. 30. Barrel Installation

CAUTION

Do not over-tighten the screws (10, 33).

TI1569A

9

11

10

12

32

51 28

29

19

20

23

33

Repair

42 309297L

Power Supply Removal and

Replacement

•Inspect the gun body power supply cavity for dirt or

moisture. Clean with a clean, dry rag.

•Do not expose gasket (11) to solvents.

1. Prepare gun for service, page 32.

2. Remove the barrel (9), page 40.

3. Grasp the power supply (12) with your hand. With a

gentle side to side motion, free the power sup-

ply/alternator assembly from the gun body (32),

then carefully pull it straight out. Disconnect the flex-

ible circuit (39) from the socket at the top of the

body (32). See F

IGURE

31.

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. Disconnect the 6-pin flexible circuit

(39) from the power supply.

5. Check the power supply resistance, page 27.

Replace if necessary.

Before installing the power supply, make sure the

o-rings (12a, 13a), spring (12b), and pads (13e) are in

place.

6. Connect the 6-pin flexible circuit (39) to the power

supply.

7. Connect the 3-wire connector (GG). Slide the alter-

nator (13) down onto the power supply (12).

8. Lubricate the alternator o-ring (13a) with non-sili-

cone grease, Part No. 111265. Do not over-lubri-

cate.

9. Lubricate the power supply o-ring (12a) with dielec-

tric grease.

10. Insert the power supply/alternator assembly in the

gun body (32). Make sure the ground strips make

contact with the body. Connect the flexible circuit

(39) to the socket at the top of the body. Push the

6-pin connector into the socket to ensure it is prop-

erly connected.

11. Install the barrel (9), page 41.

12. Test gun resistance, page 26.

CAUTION

Be careful when handling the power supply (12) to

avoid damaging it.

Repair

309297L 43

Fig. 31. Power Supply

Turbine Alternator Removal

and Replacement

Replace turbine alternator bearings after 2000 hours of

operation. Order Part No. 223688 Bearing Kit.

1. Prepare gun for service, page 32.

2. Remove the power supply/alternator assembly,

page 42.

3. Disconnect the alternator from the power supply,

page 42.

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 42.

7. Install the power supply/alternator assembly, page

42.

TI1568A

13

12a

12b

11

13a

GG

12

13e

32

39

Repair

44 309297L

Notes

Parts

309297L 45

Parts

Part No. 244589 PRO Auto Xs Electrostatic Gun, Series B, for standard coatings

ti1601a

TI1481a

TI1558A

7

18

16

12

19

15

34a

35

9

4a 4b

10

12a

12b

32

2

34d

1

3

4

8

11

13

13e

13a

20

22

21

17

14 34c

34f

34e

34g

34b

30

27

26

29

28

24

31

23

25

19 (Ref) 20 21

22

13a

13b

13b

13c

Ref. No. 13: Alternator Detail

13d

13e

8a

8b

8c

8d

8e

8f

8g

8h

Ref. No. 8: Packing Rod Detail

39

1a

40

41

33

51

Parts

46 309297L

Part No. 244589 PRO Auto Xs Electrostatic Gun, Series B, for standard coatings

Ref.

No. Part No. Description Qty

1 244950 RING, retaining, air cap; includes

1a

1

1a*† 198307 . U-CUP 1

2 245312 SHROUD 1

3 24A438 AIR CAP 1

4 197266 NOZZLE; 1.5 mm orifice; includes

4a and 4b

1

4a 111261 . O-RING, conductive 1

4b 111507 . O-RING; fluoroelastomer 1

5 198486 CONNECTOR, tube, fiber optic;

pictured on page 51 (unassem-

bled)

1

7 276697 NEEDLE, electrode 1

8 244521 ROD, packing; includes 8a-8h 1

8a* 111316 . O-RING; fluoroelastomer 1

8b* 116905 . SEAL 1

8c* 178409 . SPREADER, packing; uhmwpe 1

8d* 178763 . PACKING, rod; acetal 1

8e 197641 . NUT, packing 1

8f 185495 . HOUSING, packing 1

8g* 186069 . SPACER, packing; acetal 1

8h 244696 . ROD, packing 1

9 244394 BARREL, gun 1

10 197518 SCREW; socket-hd; 10-24 x 3/4

in. (19 mm)

1

11*† 197517 GASKET, barrel 1

12 244541 POWER SUPPLY, 85 kV; includes

12a-12b

1

12a*† 103337 . O-RING; fluoroelastomer 1

12b 197624 . SPRING, compression 1

13 244555 TURBINE, alternator; includes

13a-13e

1

13a*† 110073 . O-RING; fluoroelastomer 1

13b 223688 . BEARING KIT; includes front

and rear bearings and fan

1

13c 244577 . COIL 1

13d 111745 . RING, retaining 1

13e 198821 . PAD, pressure 2

14* 111316 O-RING 1

15* 102982 O-RING 1

16 189757 FITTING, fluid 1

17 112642 SPACER 1

18 111370 CONNECTOR, elbow; includes

items 20, 21, 22

1

19 198043 TUBE, fluid 1

20 112644 NUT 1

21* 111285 FERRULE, back 1

22* 111286 FERRULE, front 1

23 189549 FITTING, fluid, quick-disconnect 1

24* 111450 O-RING 1

25 185111 SPRING, compression 1

26 189367 CAP, exhaust 1

27 185122 MUFFLER 1

28 101324 NUT, jam, hex 1

29 197919 ARM, actuator 1

30 102025 NUT, hex 1

31 112689 SCREW, button-hd; 1/4-20 x 3/4

in. (19 mm)

1

32 245662 BODY, gun 1

Ref.

No. Part No. Description Qty

Parts

309297L 47

* Recommended spare parts. Keep on hand to reduce

downtime.

† Included in repair kit 15D592.

Replacement Warning labels, signs, tags, and cards are

available at no cost.

33 116575 SCREW, cap, socket-hd; 10-24; 3

in. (76 mm)

2

34 244702 PISTON; includes 34a-34g 1

34a 197920 . PISTON 1

34b 189754 . ROD, piston 1

34c 189355 . STEM, piston 2

34d*† 189752 . PACKING, u-cup 1

34e*† 111504 . O-RING 2

34f*† 112319 . O-RING 2

34g*† 111508 . O-RING 1

35 244586 MANIFOLD; see separate parts

list on page 51

1

39 245265 CIRCUIT, flexible 1

40 276741 MULTI-TOOL 1

Ref.

No. Part No. Description Qty

41 107460 WRENCH, ball end; 4 mm 1

42 179791 TAG, warning (not shown);

replacement available at no cost

1

43 180060 SIGN, warning (not shown);

replacement available at no cost

1

44 239945 COVER, gun; box of 10 (not

shown)

1

51 197624 SPRING, grounding 1

Ref.

No. Part No. Description Qty

Parts

48 309297L

Part No. 244590 PRO Auto Xs Electrostatic Gun, Series B, for high conductivity coatings

ti1601a

TI1586A

7

19 (Ref)

12

19

34a

35

9

4a 4b

10

12a 12b

32

2

34d

1

3

4

8

11

13

13e

13a

19c

19d

19b

34c

34f

34e

34g

34b

30

27

26

29

28

24

31

23

25

19 (Ref) 20 21

22

8a

8b

8c

8d

8e

8f

8g

8h

Ref. No. 8: Packing Rod Detail

19a

39

1a

40

41

33

TI1481a

13a

13b

13b

13c

Ref. No. 13: Alternator Detail

13d

13e

51

Parts

309297L 49

Part No. 244590 PRO Auto Xs Electrostatic Gun, Series B, for high conductivity coatings

Ref.

No. Part No. Description Qty

1 244950 RING, retaining, air cap; includes

1a

1

1a*† 198307 . U-CUP 1

2 245312 SHROUD 1

3 24A438 AIR CAP 1

4 197266 NOZZLE; 1.5 mm orifice; includes

4a and 4b

1

4a 111261 . O-RING, conductive 1

4b 111507 . O-RING; fluoroelastomer 1

5 198486 CONNECTOR, tube, fiber optic;

pictured on page 51 (unassem-

bled)

1

7 276697 NEEDLE, electrode 1

8 244521 ROD, packing; includes 8a-8h 1

8a* 111316 . O-RING; fluoroelastomer 1

8b* 116905 . SEAL 1

8c* 178763 . SPREADER, packing; uhmwpe 1

8d* 178409 . PACKING, rod; acetal 1

8e 197641 . NUT, packing 1

8f 185495 . HOUSING, packing 1

8g* 186069 . SPACER, packing; acetal 1

8h 244696 . ROD, packing 1

9 244394 BARREL, gun 1

10 197518 SCREW; socket-hd; 10-24 x 3/4

in. (19 mm)

1

11*† 197517 GASKET, barrel 1

12 244541 POWER SUPPLY, 85 kV; includes

12a-12b

1

12a*† 103337 . O-RING; fluoroelastomer 1

12b 197624 . SPRING, compression 1

13 244555 TURBINE, alternator; includes

13a-13e

1

13a*† 110073 . O-RING; fluoroelastomer 1

13b 223688 . BEARING KIT; includes front

and rear bearings and fan

1

13c 244577 . COIL 1

13d 111745 . RING, retaining 1

13e 198821 . PAD, pressure 2

19 237297 TUBE, fluid; coiled; includes

19a-19d

1

19a* 102982 . O-RING 1

19b* 111450 . O-RING 1

19c* 103337 . O-RING 2

19d 186818 . FITTING 1

20 112644 NUT 1

21* 111285 FERRULE, back 1

22* 111286 FERRULE, front 1

23 189549 FITTING, fluid, quick-disconnect 1

24* 111450 O-RING 1

25 185111 SPRING, compression 1

26 189367 CAP, exhaust 1

27 185122 MUFFLER 1

28 101324 NUT, jam, hex 1

29 197919 ARM, actuator 1

30 102025 NUT, hex 1

31 112689 SCREW, button-hd; 1/4-20 x 3/4

in. (19 mm)

1

32 245662 BODY, gun 1

33 116575 SCREW, cap, socket-hd; 10-24; 3

in. (76 mm)

2

Continued on page 50.

Ref.

No. Part No. Description Qty

Parts

50 309297L

* Recommended spare parts. Keep on hand to reduce

downtime.

† Included in repair kit 15D592.

Replacement Warning labels, signs, tags, and cards are

available at no cost.

34 244702 PISTON; includes 34a-34g 1

34a 197920 . PISTON 1

34b 189754 . ROD, piston 1

34c 189355 . STEM, piston 2

34d*† 189752 . PACKING, u-cup 1

34e*† 111504 . O-RING 2

34f*† 112319 . O-RING 2

34g*† 111508 . O-RING 1

35 244586 MANIFOLD; see separate parts

list on page 51

1

39 245265 CIRCUIT, flexible 1

40 276741 MULTI-TOOL 1

Ref.

No. Part No. Description Qty

41 107460 WRENCH, ball end; 4 mm 1

42 179791 TAG, warning (not shown);

replacement available at no cost

1

43 180060 SIGN, warning (not shown);

replacement available at no cost

1

44 239945 COVER, gun; box of 10 (not

shown)

1

51 197624 SPRING, grounding 1

Ref.

No. Part No. Description Qty

Parts

309297L 51

Part No. 244586 Manifold, Series A

† Included in repair kit 15D592.

TI1582A

TI1578A

101

101 (Ref)

102

103

104

105

106 (Ref)

107

106

111

110

118

119 114

112

117

109

113

116

116a

120

108

115

5 (see pages 46 or 49)

Ref.

No. Part No. Description Qty

101 198216 MANIFOLD 1

102 189581 BRACKET, reciprocator 1

103 110465 SCREW, set 2

104 112689 SCREW, button-hd 2

105 112640 SPRING, compression 1

106 197518 SCREW; socket-hd; 10-24 x 3/4

in. (19 mm)

3

107 111157 FITTING, tube, exhaust 1

108 186845 FITTING, turbine, air 1

109 110078 FITTING, tube, air 2

110 112646 PLUG 1

111 189551 FITTING, quick-disconnect, fluid 1

112† 197925 GASKET, manifold 1

113 108290 SCREW, machine 2

114 189365 CAP, kV, HI/LO 2

115 198764 RESTRICTOR 1

116 244772 PISTON; includes 116a 2

116a† 112085 . O-RING (1 per piston) 2

117 114263 FITTING, tube, air 3

118 111450 O-RING 1

119 116621 SPRING, compression 2

120 112645 PLUG 1

Ref.

No. Part No. Description Qty

Accessories

52 309297L

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 (Grey)

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)

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.

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 (15.2 m)

Fluid Shutoff/Drain Valve

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

For turning fluid on or off to the gun and for relieving

fluid line pressure at the pump.

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

PTFE; for non-corrosive fluids

Drain Valve

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

236853 Mounts directly to gun manifold for faster

flushing and color changes. Must be used

with 233676 Fluid Recirculation Kit.

Fluid Recirculation Kit

233676 Converts standard gun to a recirculating

gun. Requires 236853 Drain Valve.

Gun Mounted Fluid Regulator

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

236854 Air-piloted fluid regulator mounts directly to

gun manifold for precise fluid control.

Accessories

309297L 53

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.

ES Display Module

224117 Receives fiber optic transmission from the

PRO Auto Xs gun and displays the gun’s

output voltage and current. Mounts in a

standard 19 in. DIN rack. See 308265.

Fiber Optic Y Cables

See item T in F

IGURE

3 on page 9. For use with 224117

Display Module only. Connect gun manifold and display

module, or bulkhead connector and display module. See

308265.

224682 25 ft (7.6 m)

224684 50 ft (15 m)

224686 100 ft (30.5 m)

Fiber Optic Cables

See item V in F

IGURE

3 on page 9. Connect gun mani-

fold and remote voltage display, bulkhead connector

and remote display, or bulkhead connector and gun

manifold. See 308265.

224672 25 ft (7.6 m)

224674 50 ft (15 m)

224676 100 ft (30.5 m)

Power Supply

235301 Supplies low voltage DC power to 224117

Display Module. See 308265.

Remote Voltage Display

189762 Battery-operated meter displays actual

spraying voltage. remote mount outside

hazardous area. Connects to gun via fiber

optic cable. See 308265.

Remote Voltage Display Kits

Include 189762 Remote Voltage Display and fiber optic

cable.

236917 25 ft (7.6 m)

236919 50 ft (15 m)

236921 100 ft (30.5 m)

Bulkhead Connector

189870 For connecting two fiber optic cables.

Accessories

54 309297L

Gun Accessories

Round Pattern Kits

Consists of fluid tip, diffuser and air cap.

245217 4-6 in. (102-152 mm) diameter

245219 8-10 in. (203-254 mm) diameter

Dielectric Grease

116553 1 oz (28 g) tube of dielectric grease for the

power supply o-ring (12a), some packing

rod parts (8), and certain fluid fittings.

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.

HC Conversion Kit

245324 Converts PRO Auto Xs standard coating

gun (Part No. 244589) to high conductivity

gun (244590). The kit is for use with fluids

with low resistivity values. See page 16.

Technical Data

309297L 55

Technical Data

Loctite® is a registered trademark of the Loctite Corporation.

Category Data

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

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

Minimum Air Pressure at Gun Inlet 40 psi (0.28 MPa, 2.8 bar)

Maximum Fluid Operating Temperature 120°F (48°C)

Paint Resistivity Range 3 megohm/cm to infinity

Short Circuit Current Output 125 microamperes

Voltage Output 40-85 kV

Sound Power (measured per ISO Standard 9216) 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)

Sound Pressure (measured 1 m from gun) at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A)

at 100 psi (0.7 MPa, 7 bar): 99 dB(A)

Turbine air inlet fitting, left-hand thread 1/4 npsm(m)

Atomizing air inlet fitting 3/8 in. OD nylon tube

Fan air inlet fitting 3/8 in. OD nylon tube

Cylinder air inlet fitting 5/32 in. OD nylon tube

Hi/Lo voltage selector air inlet fittings 5/32 in. OD nylon tube

Fluid inlet fitting 1/4-18 npsm(m)

Gun Weight 3.52 lb (1.6 kg)

Gun Length 12.25 in. (31.1 cm)

Wetted Parts Stainless Steel; Nylon, Acetal, Ultra-High Molecular

Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten

Wire, Polyethylene

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 309297

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2002, Graco Inc. is registered to ISO 9001

www.graco.com

Rev L, 12/2014

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 gun barrel, gun body, manifold, mounting bracket, 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

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