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Graco PRO Xs4 AA - page 1
Instructions - P ar ts List INSTRUCTIONS This manual contains important warnings and inf ormation. READ AND KEEP FOR REF ERENCE. Graco Inc . P.O. Box 1441M inneap olis, MN 554 40-1441 COPYRIGHT 2001, Grac o Inc. Graco I nc. is re g istered to I.S. EN ISO 90 01 309295 Rev . A ti1332b Standar d Model ti1509a Smart Model MANU AL ELECTR OST A TIC PR O ...
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Graco PRO Xs4 AA - page 2
2 309295 T ab le of Contents List of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wa r n i n g S y m b o l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . ...
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Graco PRO Xs4 AA - page 3
List of Models 309295 3 List of Models Symbols W arning Symbol This symbol a lerts you to the possibility of serious injury or death if you do not follow the ins tr uctions. Caution Symbol This symbol a lerts you to the possibility of da mage to or destruction of equipment if you do not follow the instructions . P art No . Mod el Des cri pti on Ope ...
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Graco PRO Xs4 AA - page 4
Warning 4 309295 WA R N I N G Fire, Explosion, and Electric Shoc k Hazar d Impr oper gr oundi ng, poor air ven tilation , open flame s, or sparks can caus e a hazar dou s condition and res ult in a fire, explo sion, or electric shock. • Electrostatic equipment must be used only by tra i ned, qualified personnel w ho understand the r equirements i ...
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Graco PRO Xs4 AA - page 5
Warning 309295 5 W ARNING Fluid Injection Hazar d Spr ay from th e gun, hose l eaks, or rupt ured comp onen ts can inject fluid into y our bod y and c ause an extr emely serious injury , including th e need for amputation. Splashing fluid in the eyes or on the skin c an a lso caus e ser ious inj ury . • Fluid injected into the skin might look li ...
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Graco PRO Xs4 AA - page 6
Warning 6 309295 W ARNING Equi pment Misus e Hazar d Equipment misuse can cause the equipment to ruptur e, malfunction, or start unexpectedly and r esu lt in a seri ous in jury . • This equipment is for pro fessional use only . • Read all manuals, tags, and labels befor e operating the equipment. • Use the equipment only for its intended purp ...
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Graco PRO Xs4 AA - page 7
Introduction 309295 7 Intr oduction Ho w the Electr ostatic AA Spra y Gun W orks The air-assisted sp ray gun combines a irless and air spraying concepts. The spray tip shapes the fluid into a fan pa tter n, as doe s a conv entio nal ai rless s pray t ip. Air from the air cap furthe r atomi zes the f luid a nd com- pletes the atomization of the flui ...
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Graco PRO Xs4 AA - page 8
Introduction 8 309295 Gun Overvie w The electrostatic gun includes the following controls (see Fig. 1). • Air cap/tip guard and spr ay tip. Never spray with- out the tip guard. See page 48 for spray tip sizes. • T rigger safety lock. Prevents the gun fr om spraying. • Atomizing AIR adjustmen t valve. Adj usts ato miz- ing ai r . • ES ON /OF ...
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Graco PRO Xs4 AA - page 9
Installation 309295 9 Installation Install the System Fig. 2 shows a typical electrostatic air-assisted spray system. It is n ot an actual system design. F or ass istance in des ign ing a syst em to s uit y our p arti cul ar nee ds, con- tac t you r G raco dist ri but or . W arning Sign Mount warning signs in the spray area where they can easily be ...
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Graco PRO Xs4 AA - page 10
Installation 10 309295 Fig. 2. Typical Installation Key ti1514b AB * C* D *E F G H J* K L M N O P Q* *R S T U* V W C Non-Hazar dous Area Hazardous Area D X The air supply to the gun must be electrically interlock ed with the v entilators to prev ent the po wer supply from operating without v entilating f ans on. A Mai n Air S upp ly Li ne B* V en t ...
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Graco PRO Xs4 AA - page 11
Installation 309295 11 Connect the Air Line 1. Connect the Graco Grounded Air S upply Hose (R) between the air supply line a n d the gun's ai r inlet (V) . Th e gun air i nle t fi ttin g has a le ft -hand thr e ad. Connect the air supply hose gr ound wire ( Q) to a true earth gr ound. 2. Instal l an air line filter/wa ter separat or (D) on the ...
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Graco PRO Xs4 AA - page 12
Installation 12 309295 Connect th e Fl uid Li ne 1. Bef o re connecting the fluid line (N), blow it o ut with air and flush it with solvent. Use solvent which is compa tible with the fluid to be sprayed. 2. In stall a fluid regulator (M) on the fluid line to co n- trol fluid pr essure to the gun. 3. Install a dr ain valve (U) nea r the pump out let ...
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Graco PRO Xs4 AA - page 13
Installation 309295 13 Gr ounding The follow ing ar e minimum grounding requirements for a basic electrostatic syste m. Y our system may include other equipment or objects which must be grounded. Check your local electrical code for deta iled grounding instruction s. Y our system must be conn ected to a true earth ground. • Pump: gr ound the pump ...
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Graco PRO Xs4 AA - page 14
Installation 14 309295 Chec k Electrical Grounding 1. Have a qualified electrician check the electrical gr ound ing c on tinui ty of the spra y gu n an d air h ose. 2. T urn the E S ON/O FF va lve OFF . 3. T urn off th e air and fluid su pply to t he gun. Th e fluid hose must not ha ve an y flui d in i t. 4. Make sur e the gr ounded ai r hose (R ) ...
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Graco PRO Xs4 AA - page 15
Installation 309295 15 Chec k Fluid Resistivity Graco P art No. 72 2886 Re sistance Meter and 7 22860 Pr obe ar e avai lable as accessories t o check th at the r esis- tivity of the fluid being sprayed meets the r equirements of an electr ostatic air- assisted spray system. Follow the in str uctions included with the meter and pr obe. Readi ngs of ...
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Graco PRO Xs4 AA - page 16
Operation 16 309295 Operation Low V oltag e Adjus tment (Smar t Guns Onl y) The ES HI/LO switch enables you to switch be tween full volt age and a lo wer volt age output . The lower vo lt- age is factory set, but can be adju sted. 1. Set the ES HI/LO switch to LO. 2. Remove the LOW VOL T AGE adjustment plug (53). Set the desired voltage, using a sm ...
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Graco PRO Xs4 AA - page 17
Maintenance 309295 17 Maintenance Flush th e Spra y Gun Flush the gun befor e changing colors, at the end of the day , before storing, and before r epairing the gun. 1. T ur n the ES ON/OFF valve OFF . 2. Reli eve th e pressure. 3. Remove and clea n the ai r cap and the spray tip. Continue d on page 18. INSTRUCTIONS Refer to the gu n operation manu ...
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Graco PRO Xs4 AA - page 18
Maintenance 18 309295 4. Change th e fluid source to solvent, or disconnect the fluid line and connect a solvent supply line to the gun. 5. P oint the gun into a grounded metal pa il. Flush until clean solvent flow s fr om the gun. 6. Relieve the pressur e. Lock the trigger . 7. Shut off or dis connect the solvent line. 8. Han g the gun fr om its h ...
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Graco PRO Xs4 AA - page 19
Electrical Tests 309295 19 Electrical T ests Electrical components inside the g un af fect performance and safety . Th e following procedur es test the condition of the pow er supply ( 18) and barr el ( 16), and el ectrical continuity betw een components. Use megoh mmeter Part No . 241079 (A A) with a n applied voltage of 500 V . Conn ect the le ad ...
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Graco PRO Xs4 AA - page 20
Electrical Tests 20 309295 T est P ower Suppl y Resistance 1. Remove the power supply (18), page 33. 2. Remo ve the turbine alternator (19) fr om the power supply , page 34. 3. Measur e r esistance fr om t he power supply's gr ound strips (EE) to th e spring (1 8b). See Fig. 6. 4. The resist ance sho uld be 135-1 50 megoh ms. If out- side this ...
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Graco PRO Xs4 AA - page 21
Electrical Tests 309295 21 T est Barre l Resistance 1. Insert a cond uctive r od (B) into the gun barrel (r emoved for the po wer supply test) and again st the metal contact (C) in the front of the barrel. 2. Measure the resis tance between the conductive ro d (B) and the barr el conta ct ring (16a). See Fig. 7. The resistance shou ld be 19-29 mego ...
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Graco PRO Xs4 AA - page 22
Troubleshooting 22 309295 T r oubleshooting NO TE: Check all possible r emedies in the T roubleshoot- ing Chart before disassembli ng the gun. Spra y P attern T roub leshooti ng NO TE: Some spray pattern problem s are caus ed by the improper balance between air and fluid. W ARNING Electric Shoc k Hazar d Installi ng and servicing this equipment req ...
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Graco PRO Xs4 AA - page 23
Troubleshooting 309295 23 Gun Ope ration T r oubleshooting Pro blem Cause Solution Excess iv e spra y f og. Atomizi ng air press ure too high . Close atomizing a ir v alv e so me , or decrease a ir pressure as low as p os- sible; minimum 40 psi (0.28 MP a, 2.8 bar) neede d at gun for full voltage . Fluid too th in. Increase v iscosity . “Orange P ...
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Graco PRO Xs4 AA - page 24
Troubleshooting 24 309295 Electrical T r oub leshooting * ES i ndicator ligh t is off when th e gun is tr iggered. Problem C ause Solution P oo r wrap . ES ON/OFF val ve OFF (0 ).* T urn O N (I). Gun ai r pressure too lo w . Check air p r essur e to gun; minimum 40 psi ( 0.28 MP a , 2.8 bar) needed at gun for full voltage. Atom izing air pres sure ...
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Graco PRO Xs4 AA - page 25
Repair 309295 25 Repair Pressure Relief Procedure 1. T urn the ES ON/OFF valve OFF . 2. L o ck the trigger . 3. T urn of f the air bleed valves to the fluid so urce and to the gun. 4. Unlo ck the trigger . 5. T rigger the g un into a gr ounded metal was te con- tainer to relieve the fluid pr essure. 6. Lock th e trigger . 7. Open the pump drain val ...
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Graco PRO Xs4 AA - page 26
Repair 26 309295 Prepare the Gun f or Se rvice NO TE: • Check all pos sible r emedies in “ T roubleshooti ng ” befo re di sass emb ling t he gun. • Use a vise with padded jaws to prevent damage to plastic parts. • Lubricate the power supply o-ring (18a) an d the plastic end of the fluid tube (14) with dielectric gr ea se (4 0). • Lightl ...
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Graco PRO Xs4 AA - page 27
Repair 309295 27 Tip G uar d, Air C ap, Spra y Tip, or Seat Hous ing Replacement 1. Prepar e gun fo r service, page 26. 2. Remove the retaining ring (2 7 ), tip guard (4), air cap (9a), an d spray ti p (3). Y ou may have t o turn the ai r cap with the tip guard to r emove it. See Fig. 8. 3. Replace the tip gasket (3a) if dam aged. Fig. 8. Tip Guard ...
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Graco PRO Xs4 AA - page 28
Repair 28 309295 5. T rig ger the gun and instal l the gray-colored seat housing (2). T ighten until snug, then 1/4 turn m o re. 6. Assemble t he spray tip (3), ai r cap (9a) , and tip guard (4) . Make sur e the electr ode (9b) is not da m- aged or m issing. I nstall the air cap as sembly wi th the retaining ring (27). The u-cup (2 7a) lips must fa ...
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Graco PRO Xs4 AA - page 29
Repair 309295 29 Electr ode Replaceme nt 1. Prepar e the gun for service, page 26. 2. Remove the air cap assem bly , pag e 27. 3. Pull th e electr ode (9b) out of the back of the air ca p, using a needle-nos e pliers. 4. Push the new electrode thro ugh the air cap hole. Make sure the short end (BB) o f the electro de engages the hole (CC) in the ba ...
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Graco PRO Xs4 AA - page 30
Repair 30 309295 Flui d T ube Re placement 1. Prepar e the gun fo r service, page 26. 2. Disco nnect the bottom fluid tube nut (C). See Fig. 11 . 3. Carefully unscrew the top fluid tube nut (D). 4. Apply dielectric grease (40) to the entire length of the plastic extension on the end of the fluid tube (14). 5. Apply low str ength thread sealant to t ...
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Graco PRO Xs4 AA - page 31
Repair 309295 31 Fluid Needle Replacement 1. Prepar e the gun for service, page 26. 2. Remov e the air ca p assembly and seat h ousing, page 27. 3. Remove the barr el (16), page 32 . 4. Remove the trigger screws (8) and trigger (30). 5. Remove the spri ng cap (4 5) and the spri ng (26a) fr om the barr el. See Fig. 13. 6. Place the 2 mm driver (44) ...
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Graco PRO Xs4 AA - page 32
Repair 32 309295 Barrel Remov al 1. Prepar e the gun for service, page 26. 2. Carefully loosen the nut (C ) from the bracket fluid fitting (1 3). See Fig . 15. 3. Loosen the thr ee scr ews (1 1). 4. Hold the gun handle (17) with one hand and pull the barr el (16) stra ight off the handle. Fig . 1 . Fig. 15. Bar rel Removal Barrel Installation 1. B ...
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Graco PRO Xs4 AA - page 33
Repair 309295 33 P o wer Suppl y Remo v al and Replacement NO T E: • Insp ec t th e gu n han dle powe r su ppl y ca vity for dir t or moisture. Clean with a clean, dry rag. • Do not expose gasket (10) to solvents. 1. Prepar e gun fo r service, page 26. 2. Remove the barr el (16), page 32 . 3. Grasp the power supply (18) with your hand. W it h a ...
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Graco PRO Xs4 AA - page 34
Repair 34 309295 T urbine Alternator Rem o v al and Replacement NO TE: Repl ace turbine beari ngs after 2000 hours of operatio n. Or der Part No. 223688 Bearin g Kit. 1. Prepar e gun for service, pa ge 26. 2. Remove the power supply /alternator assembly , page 33. 3. Disconnect t he altern ator fr om th e power su pply , page 33. 4. Me asur e r esi ...
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Graco PRO Xs4 AA - page 35
Repair 309295 35 Atomizing Air Adjustment V alve Repair 1. Prepar e the gun for service, page 26. 2. Place a wrench on the flats of the valve assembly (20) and unscr ew it fr om t he handle (1 7). NO T E: Y ou may replace the valve as an assembly (go to step 9) or as indivi dual parts (st eps 3-9). 3. Remove th e r etaining ring (20a). See Fig . 18 ...
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Graco PRO Xs4 AA - page 36
Repair 36 309295 Air V alve Re pair 1. Prepar e the gun fo r service, page 26. 2. Remove the barrel, page 32. 3. Remove the air va lve cap (25) fr om the ha ndle (17). Remove the spring (15). See Fig. 19. 4. Remo ve the air valve (21) with a pliers. Inspect the seal (21a ) and r epla ce if dama ged. Be su r e the seal is pressed secur ely onto the ...
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Graco PRO Xs4 AA - page 37
Repair 309295 37 ES ON/OFF V alve Repai r 1. Prepar e the gun for service, page 26. 2. Loosen the scr ew (48). Rem ove the valve. 3. L ubricate the o-rin gs (22a* and 22b*) with non - sili- cone gr ease, Part No. 1 1 126 5. Do not over -lubricate. 4. Clean and inspe c t par ts for da mage. Repl ace if nec- ess ary . NO TE: The protrus ion on the re ...
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Graco PRO Xs4 AA - page 38
Parts 38 309295 Pa r t s P art No. 2445 72 85 kV Electr os tatic G un, Series A (items 1 -50) ti1511b I O ES ti1366a 27 4 9a 26 16 11 18 19 *10 17 28 20 22 25 15 21 35 13 24 38 8 *6 9b 11 *18a 18b 21a* 24a* 27a* 30 39 47 See page 39 for detail views of the al ternator (19), at omizing air adjustmen t v alve (20), an d ES ON/OFF v alve (22). 26a 14 ...
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Graco PRO Xs4 AA - page 39
Parts 309295 39 TI1487A 20a 20b* 20c 20d Ref. No. 22: ES ON/OFF V alve Ref. No. 20: Atomizing Air Adjustme n t V alve Ref. No. 19: Al ternator TI1481a 19a* 19b 19b 19c 19d 19e TI1488A 22a* 22b* 22c 22d 22e 22f 22g 48 ...
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Graco PRO Xs4 AA - page 40
Parts 40 309295 P art No. 2445 72 85 kV Electr os tatic G un, Series A (items 1 -50) Ref. No. P art No. Des cription Qty 1 205264 FIL TER, fluid , inline 1 2 245280 HOUSIN G, seat 1 3 GG3XXX SPRA Y TIP (customer ’ s choice); includ es item 3a 1 3a 183459 . SEAL, spr a y tip 1 4 276767 TIP GU ARD 1 6* 188749 P A CKING , u-cu p , air v a lv e; UHMW ...
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Graco PRO Xs4 AA - page 41
Parts 309295 41 * Include d in Air Seal Repair Kit 244 781. Replaceme nt W ar nin g labels, signs, tags, and car ds are av ailable at no cost. 36 107460 WRENCH, ball end; 4 mm 1 37 110 087 DRIV ER, hex nut; 9 mm 1 38 1851 03 TUBE, ex haust 1 39 1102 31 CLAMP 1 40 1165 53 GR E ASE, dielect ric, tube (not shown) 1 41 2449 15 CO VER, g un; bo x of 10 ...
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Graco PRO Xs4 AA - page 42
Parts 42 309295 P art No. 2445 73 85 kV Electr os tatic G un, Series A (items 1 -59) ti1510c ti1253a 100 % KV µα 0 HI LO ES I O I O ES 20 See page 43 f or det ail view s of t he alter nator (19), a t omizing air adjustment valve (20), and ES O N/OFF valve (22). 22 53 (R ef) 51 (Ref) 27 4 9a 26 16 11 18 19 *10 17 28 25 15 21 35 13 24 38 8 *6 9b 11 ...
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Graco PRO Xs4 AA - page 43
Parts 309295 43 TI1488A TI1487A TI1481a 20a 20b* 20c 20d Ref. No. 20: Atomizing Air Adjustme n t V alve Ref. No. 19: Al ternator Ref. No. 22: ES ON/ OFF V alve 19a* 19b 19b 19c 19d 19e 22a* 22b* 22c 22d 22e 22f 22g 48 ...
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Graco PRO Xs4 AA - page 44
Parts 44 309295 P art No. 2445 73 85 kV Electr os tatic G un, Series A (items 1 -59) Ref. No. P art No. Des cription Qty 1 205264 FIL TER, fluid , inline 1 2 245280 HOUSIN G, seat 1 3 GG3XXX SPRA Y TIP (customer ’ s choice); includ es item 3a 1 3a 183459 . SEAL, spr a y tip 1 4 276767 TIP GU ARD 1 6* 188749 P A CKING , u-cu p , air v a lv e; UHMW ...
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Graco PRO Xs4 AA - page 45
Parts 309295 45 * Include d in Air Seal Repair Kit 244 781. Replaceme nt W ar nin g labels, signs, tags, and car ds are av ailable at no cost. 35 1851 05 FITTING, air; left-hand th reads 1 36 107460 WRENCH, ball end; 4 mm 1 37 110 087 DRIV ER, hex nut; 9 mm 1 38 1851 03 TUBE, ex haust 1 39 1102 31 CLAMP 1 40 1165 53 GR E ASE, dielect ric, tube (not ...
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Graco PRO Xs4 AA - page 46
Accessories 46 309295 Accessories Air Line Accessories AirFlex ™ Flex ible Gr ounded Air Hose 100 psi (7 bar , 0.7 MPa) Maximum W orking Pr essur e 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f ) left-hand thread 244963 6 f t (1.8 m) 244964 15 ft (4.6 m ) 244965 25 ft (7.6 m ) 244966 36 ft (1 1 m) 244967 50 ft (15 m ) 244968 75 ft (23 m ) 244969 ...
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Graco PRO Xs4 AA - page 47
Accessories 309295 47 Gun Accessories Gun Repair Kit 244781 Air Seal Re pair Kit Elec tr ode Re placemen t Ki t 244917 In cludes five electrodes. Inline Fluid Filter s 238561 1 00 mesh filter . Set of three. 238563 6 0 mesh filter . Set of three. Round P attern Kit Pro vides higher level of performance to electr ostatic spraying. 245282 In cludes t ...
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Graco PRO Xs4 AA - page 48
Spray Tip Selection Chart 48 309295 Spra y Tip Selection Char t Pa r t N o. Fan Width at 10 in. (250 mm) in. (mm) Orifice S ize in. (m m) GG3107 2-4 ( 50-100 ) 0.007 ( 0.178 ) GG3207 4-6 ( 100-150 ) GG3307 6-8 ( 150-200 ) GG3209 4-6 ( 100-150 ) 0.009 ( 0.229 ) GG3309 6-8 ( 150-200 ) GG3409 8-10 ( 200-25 0 ) GG321 1 4-6 ( 100-150 ) 0.01 1 ( 0.279 ) ...
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Graco PRO Xs4 AA - page 49
Technical Data 309295 49 T ec hnical Data and Viton ® Loctite ® is a registered trademark of the L octite Corpo r atio n. Category Data Maximum Worki ng Fluid Pressur e 3000 ps i (21 MP a, 210 bar) Maximum Worki ng Air Pressu r e 100 p si (0.7 MP a, 7 bar) Minimum Air Pressure to Gun Inlet 40 psi ( 0.28 MP a, 2 .8 bar) Maximum Fl uid Operating T ...
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Graco PRO Xs4 AA - page 50
Graco Standar d W arranty Graco war rants all equi pmen t manuf actured b y Gr aco and bearing its nam e to be free from def ects in mat erial and w orkmanship on the dat e of sa le b y an a uthoriz ed Gr aco di stributo r to the original pu rchaser f or use. With the e xception o f any special , e xtend ed, or lim ited w arr anty pub lish ed b y G ...
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