Graco 312145D Operation manual

XTR™5 and XTR™7 Airless Spray Gun

Instructions/Parts

See page 9 for model numbers.

Maximum Working Pressure:

XTR 5: 5000 psi (35 MPa, 345 bar)

XTR 7: 7250 psi (50 MPa, 500 bar)

For use with protective coating materials

312145D

The following warnings are for the setup, use, grounding, maintenance, and repair of this equip-

ment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer

to procedure-specific risks. Refer back to these warnings. Additional product-specific warnings

may be found throughout the body of this manual where applicable.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This

may look like just a cut, but it is a serious injury that can result in amputation. Get

immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and

before cleaning, checking, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the

eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and

before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

ately.

IMPORTANT SAFETY INSTRUCTIONS.

Refer to your sprayer instruction manual for

pressure relief, priming, and spraying

instructions. Keep these instructions. ti5045b

II 2 G c T6

WARNING

2312145D

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or

explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric

lamps, and plastic drop cloths (potential static arc).

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

• Do not plug or unplug power cords or turn power or light switches on or off when

flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not

use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest

rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s

warnings. For complete information about your material, request MSDS forms from

distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with

genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

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

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

hot surfaces.

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause

a serious chemical reaction and equipment rupture. Failure to follow this warning may

result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocar-

bon solvents or fluids containing such solvents.

• Many other fluids may contain materials that are incompatible with aluminum. Con-

tact your material supplier for verification.

WARNING

312145D 3

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on

skin, inhaled, or swallowed.

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

• Store hazardous fluid in approved containers, and dispose of it according to appli-

cable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To

avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has

cooled completely.

RECOIL HAZARD

Gun may recoil when triggered. If you are not standing securely, you could fall and be

seriously injured.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in

the operating area of the equipment to help protect you from serious injury, including

eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes

but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

WARNING

Pressure Relief Procedure

4312145D

Pressure Relief Procedure

Follow this Pressure Relief Procedure

whenever you are instructed to relieve

pressure, stop spraying, check or service

equipment, or install or clean spray tip.

1. Engage trigger lock.

2. Shut off pump.

3. Disengage trigger lock.

4. Hold a metal part of the gun firmly to a

grounded metal pail. Trigger the gun to

relieve pressure.

5. Engage trigger lock.

6. Open fluid drain valve (see System

Requirements). Leave drain valve open.

If pressure is not fully relieved:

• Spray tip is clogged. For RAC tip, see

Cleaning Tips/Clearing Clogs, page 6.

For flat tip, slowly loosen tip guard retaining

nut to relieve pressure. Remove and clear

tip.

• Hose is clogged. Slowly loosen hose end

coupling to relieve pressure. Clean hose

obstruction.

System Requirements

• Install a bleed-type master air valve on a

pneumatic pump air supply line to relieve

air trapped between this valve and pump

after air regulator is shut off. Trapped air

can cause the pump to cycle unexpectedly.

• Install a fluid drain valve between the pump

and gun to relieve pressure in displacement

pump, hose, and gun. Triggering to relieve

pressure may not be sufficient. See Pres-

sure Relief Procedure.

Grounding

Check your local electrical code and

pump/sprayer manual for detailed grounding

instructions.

• Spray gun: ground through connection to a

grounded fluid hose and pump/sprayer.

• Fluid hose: use only grounded hoses.

• Fluid supply container: follow local code.

• Object being sprayed: follow local code.

• Solvent flushing pails: follow local code.

Use only conductive metal pails placed on

a grounded surface. Do not place pail on a

nonconductive surface, such as paper or

cardboard, which interrupts grounding

continuity.

• To maintain grounding continuity when

flushing or relieving pressure: hold metal

part of gun firmly to side of a grounded

metal pail, then trigger gun.

Gun Trigger Lock

To prevent injury when the gun is not in use,

always engage the gun’s trigger lock if unit is

being shut down or left unattended. A

wallet-sized warning card with important

injection treatment information is included

with the gun. Additional cards are available at

no charge. Provide a card to all operators.

The trigger lock must move freely, and easily

snap into a locked position. If the trigger lock

is damaged or movement is restricted,

replace with new trigger kit (16) immediately.

Trigger

Locked

(no spray)

Unlocked

(spray)

ti5048b

ti5049b

Tip Installation

312145D 5

Tip Installation

RAC Tip

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Snap gasket (20b) on

fluid seal (20a). Use

tool (A) to insert

gasket and seal into

housing, seal first.

Tip the tool to remove

it when seal is in

place.

3. Install tip cylinder

(20c) as shown. Turn

90 ° counterclockwise

to spray position, so

the arrow faces

forward. Install assembled RAC onto spray

gun.

Flat Tip

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Insert tip (32) and gasket (30) into back of

guard (31).

3. Install guard over end of gun.

Operation

1. Connect a grounded fluid hose.

2. Without spray tip, flush pump. Use lowest

pressure possible.

3. Prime. Refer to sprayer manual.

4. Follow Pressure Relief Procedure.

5. Install spray tip and tip guard.

6. RAC tips only: In spray

position, arrow on tip

cylinder (20c) faces

forward.

7. Hold gun perpendicular and approximately

12 inches (304 mm) from surface. Wear

gloves if fluid temperature exceeds 110°F

(43°C).

8. Move gun first, then pull gun trigger to

spray onto test paper.

a. Adjust fluid pressure until spray is com-

pletely atomized.

b. If adjusting pressure does not give a

good spray pattern, follow Pressure

Relief Procedure, then try another tip

size.

9. Trigger gun full-open or full-close.

Adjusting Spray Pattern

The spray tip orifice and spray angle determine

pattern coverage and size. When you need

more coverage, use a larger spray tip rather

than increasing fluid pressure.

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Loosen tip guard retaining nut.

3. Align guard horizontally to spray a

horizontal pattern. Align guard vertically to

spray a vertical pattern.

4. Tighten nut.

20c

20a

20b

ti10635c

ti10051a

20c

ti11482a

ti10636b

Maintenance

6312145D

Cleaning Tips/Clearing Clogs

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Clean spray tip as follows:

a. RAC tips: Rotate tip 180°

so arrow on tip cylinder

(20c) faces backward.

Disengage trigger lock.

Trigger gun into pail or

onto ground to remove

clog. Engage trigger lock. Rotate tip

180° back to spray position.

b. Flat tips: Remove tip and clean with a

solvent-soaked brush.

3. RAC tips: If tip is still clogged:

a. Shut off sprayer and disconnect power

source.

b. Open fluid drain valve (see System

Requirements on page 4) to relieve

pressure.

c. Remove and clean spray tip.

Maintenance

Flushing

Flush pump and gun before fluid can dry in it. If

available, use flushing procedure provided in

your pump or sprayer manual instead of this

procedure.

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Remove spray tip and guard from gun.

Clean with solvent.

3. Put the pump intake in a grounded pail of

compatible solvent.

4. Start pump at its lowest pressure.

5. Disengage trigger lock, then trigger gun

into the paint pail. When solvent appears,

release trigger.

6. Trigger gun into solvent pail. Circulate fluid

until system is thoroughly flushed.

7. Follow Pressure Relief Procedure.

Engage trigger lock.

Cleaning/Replacing Filter

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Disconnect trigger

guard from gun body

by pushing up on

guard hook and

pulling it out of notch.

3. The trigger guard

beneath the gun

handle can then be

used as a wrench to

loosen the nut.

4. When alignment

notches are no longer engaged, use your

hand to twist handle and remove it from

gun head.

5. Remove filter.

6. Clean filter using a soft brush.

7. Replace filter.

8. Apply light coating of grease to threads and

then attach.

9. Use trigger guard to tighten the nut.

10.Reattach the trigger guard to the gun.

Cleanup

Flush gun after each work shift and store in a

dry location. Do not leave the gun or any parts

in water or cleaning solvents.

Clean tip and tip guard at end of each work

day.

Failure to clean or replace the filter or

damaged handle bore can result in serious

injury.

Before performing any maintenance on the

gun, read all warnings in this manual and

relieve pressure.

20c

ti11483a

ti5052a

ti5054a

Repair

312145D 7

Repair

Disassembly

1. Follow Pressure Relief Procedure.

Engage trigger lock.

2. Disconnect fluid hose. Remove RAC tip

guard and tip (19 and 20a-20c) or flat tip

guard and tip (30, 31 and 32).

3. RAC tip only: use tool to push gasket and

seal out back of housing.

4. Using a wrench, remove the cap (4) with

spring (5) (releases spring tension on

needle).

5. Remove the valve seat (10) and

gasket (9).

6. Holding the needle with

tool (36) remove the

needle retainer (6).

7. Pull the needle (8) out.

8. Using a socket wrench,

remove the seal retainer

(2) from the back of the

gun. Use a pick to remove

the gasket (3).

9. Clean and replace parts as needed.

If you need to remove the trigger

XTR 7 Guns

1. Using a wrench,

remove screw

(11b) from the pivot

pin (11a).

2. Slide the pivot pin

(11a) out of the

gun body, and

remove the trigger

(16).

3. Before installing trigger, grease the

actuator pins (7) and the pivot pin (11a).

XTR 5 Guns

1. Using a socket wrench, remove screw (12)

from each side of the gun body and remove

trigger.

2. Before installing trigger, grease the

actuator pins (7).

Assembly

1. Press a new gasket (3*) into the gun body.

Lightly grease the seal retainer (2*) and

install. Torque to 48-72 in-lb (5-8 N•m).

2. Lightly grease and replace the needle (8*).

Press the needle through the seal retainer.

3. Apply light-strength Loctite™to needle

threads. Holding the needle with tool (36*),

install needle retainer (6). Tighten until it

bottoms out. Do not overtighten.

4. Lightly grease valve seat (10*) threads.

Squeeze the trigger to retract the needle

and install gasket (9*) and valve seat (10*).

Torque valve seat to 26-32 ft-lb

(34-43 N•m).

5. Grease and install the spring (5) and cap

(4). Tighten the cap to 10-13 ft-lb

(8-10 N•m).

Test Gun Before Using

1. Engage trigger lock. Connect fluid hose to

gun.

2. Start and prime the pump.

3. Disengage the trigger lock and trigger the

gun into a metal waste container.

4. Release the trigger. The gun should

immediately stop spraying and there should

be no leaks. If there is a problem, follow

Pressure Relief Procedure. Check

through Assembly procedure and correct

problem.

5. Install tip and tip guard before regular use.

To avoid losing parts, be ready for two

actuator pins (7) to fall out of the gun body

when the trigger (16) is removed.

ti10637b

ti5187a

11b

11a

16 ti5190a

Caution

Use only tool (36) and fingers to tighten nee-

dle. Do not overtighten or breakage may

occur.

Parts

8312145D

Parts

11b

†

10* 11a

†

21*

16c

†

16a

†

16b

†

14b

14a

XTR 5 trigger attachment

†

15 (XTR 5 only

‡

)

ti5192c

Parts

312145D 9

Parts

▲Replacement Danger and Warning labels,

tags, and cards are available at no cost.

* Parts included in Repair Kit 248837, pur-

chased separately.

† Parts included in Trigger Kits 287449 (16a),

287450 (16b), and 287451 (16c), purchased

separately.

‡NOTE: Handle is not pressure rated for use

with the XTR 7. For an XTR 7, order handle

13 and sleeve 14a or 14b depending on

your model (see Table 1).

Ref Part Description Qty

1 15J771 BODY, gun, aluminum,

(XTR 5 only) 1

15E178 BODY, gun, sst (XTR 7 only) 1

2* 245881 SEAL, retainer assembly 1

3* n/a GASKET (kit 248837 only, not

sold separately) 1

4 15K000 CAP, end (XTR 5 only) 1

15A864 CAP, end (XTR 7 only) 1

5 117350 SPRING, 1

6 15E088 RETAINER, needle 1

7 15E085 PIN, actuator 2

8* 248591 NEEDLE 1

9* 156766 GASKET 1

10* 245858 SEAT, valve 1

11a† 192272 PIN, pivot (XTR 7 only) 1

11b† 203953 SCREW, cap, hex-hd;

10-24 x 3/8 in. (10 mm)

[XTR7 only]

12† 117602 SCREW, shoulder, pan hd;

8-32 x 5/16 in. (8 mm)

[XTR 5 only]

13 248952 HANDLE, includes trigger

guard, swivel, tube, and o-ring;

see Tables 1 and 2

14a 276997 HANDLE SLEEVE, insulated,

(see Tables 1 and 2) 1

14b 15E083 HANDLE SLEEVE, 1 in. (25

mm), (see Tables 1 and 2) 1

15‡ 255275 HANDLE, includes trigger

guard, swivel, and tube, 1 in.

(25 mm) OD, (XTR 5 only, see

Table 2)

16a† 287449 TRIGGER KIT, also includes

11a, 11b, and 12, see Tables 1

and 2,

16b† 287450 TRIGGER KIT, also includes

11a, 11b, and 12, see Tables 1

and 2

16c† 287451 TRIGGER KIT, also includes

11a, 11b, and 12, see Tables 1

and 2

21* 179733 SEAL, sleeve 1

24 n/a O-RING (kit 248952 only, not

sold separately) 1

26 287032 FILTER, 60 mesh, included

with gun 1

287034 FILTER, 60 and 100 mesh

combo

29▲222385 TAG, warning (not shown) 1

36* 194744 TOOL, repair, packing 1

Table 1: XTR 7 Models

XTR 7

Gun

Part No.

Reference Numbers

13 14a 14b 16a 16b 16c 19 20

XTR700 ✔✔✔ ✔

XTR701 ✔✔✔

XTR702 ✔✔ ✔ ✔✔

XTR703 ✔✔ ✔ ✔✔

XTR704 ✔✔✔ ✔✔

XTR705 ✔✔ ✔ ✔✔

Table 2: XTR 5 Models

XTR 5

Gun

Part No.

Reference Numbers

13 14a 14b 15 16a 16b 16c 19 20

XTR500 ✔✔ ✔

XTR501 ✔✔

XTR502 ✔✔ ✔✔✔

XTR503 ✔✔ ✔ ✔✔

XTR504 ✔✔ ✔✔

XTR505 ✔✔✔✔

Tip and Guard

10 312145D

Tip and Guard

✓Included in OneSeal™Repair Kit XHD010

(5 each per package, purchase separately).

RAC Tip Flat Tip

Ref Part Description Qty

19 XHD001 GUARD, RAC tip (see Tables 1

and 2)

20 XHDxxx SWITCH, RAC tip, 519 size

included (includes 20a - 20c,

see Tables 1 and 2)

20a✓SEAL, fluid 1

20b✓GASKET 1

20c TIP, spray, XHD RAC 1

30 166969 GASKET, (XTR501 and

XTR701 only)

31 220251 GUARD, flat tip (XTR501 and

XTR701 only)

32 163519 TIP, flat (XTR501 and XTR701

only)

20a

20b

19 20c

ti10050a

ti10051a

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