Graco XTR 5 Parts list manual

XTR
™
5 and XTR
™
7 Airless Spray Gun
Instructions/Parts
See Parts, beginning on page 8, 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
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.
II 2 G c T6
ti5045b
312145G
EN

WARNING
2312145G
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

WARNING
312145G 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
4312145G
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 displace-
ment pump, hose, and gun. Triggering to
relieve pressure may not be sufficient. See
Pressure 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 Trigger
Locked
(no spray)
Unlocked
(spray)
ti5048b
ti5049b

Tip Installation
312145G 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
A
20a
20b
ti10635c
ti10051a
30
32
31
20c
ti11482a
ti10636b

Maintenance
6312145G
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
(Not applicable for XTR510)
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
312145G 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
(16b) from the
pivot pin (16a).
2. Slide the pivot pin
(16a) out of the
gun body, and
remove the trigger
(16).
3. Before installing trigger, grease the
actuator pins (7) and the pivot pin (16a).
XTR 5 Guns
1. Using a socket wrench, remove screw
(16c) 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
36
6
ti5187a
16b
7
16a
16
ti5190a
Caution
Use only tool (36) and fingers to tighten nee-
dle. Do not overtighten or breakage may
occur.

Parts
8312145G
Parts
4
5
6
2*
3*
1
16c†
7
8*
9*
10* 16c†
21*
26
16
15
14
13‡
ti21834a
24
RAC Tip Flat Tip
20a
20b
19 20c
ti10050a
30
32
31
ti10051a
XTR5

Parts
312145G 9
--- Not for sale.
▲ Replacement Danger and Warning labels, tags, and
cards are available at no cost.
* Parts included in Repair Kit 248837, purchased sep-
arately.
† Trigger kit (16) includes mounting hardware for either
XTR5 or XTR7 gun. See table and illustration for
which parts to use.
‡ Handle is not pressure rated for use with the XTR 7.
For an XTR 7, order handle 248952 and sleeve
276977 or 15E083 depending on your model.
✓ Included in OneSeal
™
Repair Kit XHD010
(5 each per package, purchase separately).
Ref. Part Description Quantity
XTR500 XTR501 XTR502 XTR503 XTR504 XTR505 XTR510
115J771 BODY, gun 1 1 1 1 1 1 1
2* 245881 SEAL, retainer assembly 1 1 1 1 1 1 1
3* --- GASKET 1 1 1 1 1 1 1
415K000 CAP, end 1 1 1 1 1 1 1
5117350 SPRING 1 1 1 1 1 1 1
615E088 RETAINER, needle 1 1 1 1 1 1 1
715E085 PIN, actuator 2 2 2 2 2 2 2
8* 248591 NEEDLE 1 1 1 1 1 1 1
9* 156766 GASKET 1 1 1 1 1 1 1
10* 245858 SEAT, valve 1 1 1 1 1 1 1
13‡ 255275 HANDLE; includes trigger guard and
swivel 1 1 1 1 1
14 248952 HANDLE KIT 1 1
15 276997 HANDLE SLEEVE, insulated 1 1
16†
287449 TRIGGER KIT, 4-finger, straight;
includes 16c 1 1 1 1
287451 TRIGGER KIT, 4-finger, curved;
includes 16c 1
287450 TRIGGER KIT, 2-finger; includes 16c 1 1
16c† 117602 SCREW, shoulder, #8-32 2 2 2 2 2 2 2
19 XHD001 GUARD, RAC tip 1 1 1 1 1 1
20 XHDxxx SWITCH, RAC tip; 519 size included 1 1 1 1
XHDxxx SWITCH, RAC tip; 519 size 1
20a✓--- SEAL, fluid 1 1 1 1 1
20b✓--- GASKET 1 1 1 1 1
20c --- TIP, spray, XHD RAC 1 1 1 1 1
21* 179733 SEAL, sleeve 1 1 1 1 1 1 1
24 119740 O-RING 1 1
26
287032 FILTER, 60 mesh included with gun 1 1 1 1 1 1
287034 FILTER, 60 mesh and 100 mesh
combo 1 1 1 1 1 1
29▲222385 TAG, warning (not shown) 1 1 1 1 1 1 1
30 166969 GASKET 1
31 220251 GUARD, flat tip 1
32 163519 TIP, flat 1
36* 194744 TOOL, repair, packing 1 1 1 1 1 1 1

Parts
10 312145G
4
5
6
2*
3*
1
16b†
7
8*
9*
10* 16a†
21*
26
16
15
15
14
ti21835a
24
24
RAC Tip Flat Tip
20a
20b
19 20c
ti10050a
30
32
31
ti10051a
XTR7