Graco PRO Auto Xs Series Instructions-Parts List Manual Download Page 32

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Repair

309297K

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.

Flush and clean the gun, page 22.

Relieve the pressure, page 17.

Remove the gun from the manifold, page 33.

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.

Summary of Contents for PRO Auto Xs Series

Page 1: ...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 309297K ENG ...

Page 2: ...ap 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 Troubl...

Page 3: ...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 ...

Page 4: ...t 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 p...

Page 5: ...rts 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 o...

Page 6: ...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...

Page 7: ...ounting Bracket F Manifold 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 ...

Page 8: ...e 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 ve...

Page 9: ...tion fans to prevent the power supply from operating without ventilating fans on Non Hazardous Area Hazardous Area Y W P1 CYL A2 A1 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 Haza...

Page 10: ...103 and slide the bracket 102 onto a 1 2 in 13 mm mounting rod See FIGURE 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 FIGURE 4 Fig 4 Mounting Bracket WARNING Pressurized Equipment Hazard Trapped air can cause the gun to spray unexpectedly which...

Page 11: ...o 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 Exh...

Page 12: ...ee FIGURE 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 FIGURE 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 ...

Page 13: ...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 ...

Page 14: ... 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...

Page 15: ...pwatch 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 FIGURE 9 2 Route the exhaust tube YY outside the cover This enables...

Page 16: ...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 FIGURE 10 8 Slide the nut 20 and ferrules 21 22 onto the coiled tube 19 Insert the end of...

Page 17: ...luid 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 th...

Page 18: ...an 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...

Page 19: ...upply line A1 to adjust the degree of atomization See FIGURE 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 W...

Page 20: ...oltage 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 Ai...

Page 21: ...f 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 fl...

Page 22: ... 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 ...

Page 23: ...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...

Page 24: ...n 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 Fi...

Page 25: ...reas 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 inju...

Page 26: ...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 FIGURE 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 re...

Page 27: ...ing 12b See FIGURE 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...

Page 28: ...oubleshooting 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 FIGURE 18 5 Make sure the metal contact C in the barrel the nozzle contact ring 4a FIGURE 19 and the elec tr...

Page 29: ...t 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 bui...

Page 30: ...e 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 ...

Page 31: ...ng 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 r...

Page 32: ...x 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 ...

Page 33: ... on the manifold See FIGURE 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...

Page 34: ...he 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...

Page 35: ...ply 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 threa...

Page 36: ...ut 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 Pack...

Page 37: ...own 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 th...

Page 38: ...icone 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 ...

Page 39: ... between the actuator arm 29 and the fluid packing rod nut E which allows the atomizing air to actuate before the fluid See FIGURE 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 gu...

Page 40: ... the jam nut 28 and actuator arm 29 See page 38 5 Loosen the three screws 10 33 See FIGURE 28 6 Hold the gun body 32 with one hand and pull the barrel 9 straight off the body See FIGURE 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...

Page 41: ...positely 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 CA...

Page 42: ... 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 g...

Page 43: ...embly 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 ass...

Page 44: ...Repair 44 309297K Notes ...

Page 45: ...s 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 ...

Page 46: ...18 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 press...

Page 47: ...355 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 a...

Page 48: ...ngs 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 ...

Page 49: ... 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...

Page 50: ...9752 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 CO...

Page 51: ...n 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 ...

Page 52: ...si 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 flui...

Page 53: ... 308265 Fiber Optic Y Cables See item T in FIGURE 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 FIGURE 3 on page 9 Connect gun mani fold and remote voltage display bulkhead connector and remote display or bulkhe...

Page 54: ...me 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 ...

Page 55: ...O 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 volta...

Page 56: ...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 WARRA...

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