Graco PRO Xs4 AA - Manual

Warning 309295 5 WARNING Fluid Injection Hazard Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause serious injury. • Fluid injected ...

Warning 6 309295 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 equip...

Introduction 309295 7 Introduction How the Electrostatic AA Spray Gun Works The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and com-plet...

Introduction 8 309295 Gun Overview The electrostatic gun includes the following controls (see Fig. 1). • Air cap/tip guard and spray tip. Never spray with- out the tip guard. See page 48 for spray tip sizes. • Trigger safety lock. Prevents the gun from spraying. • Atomizing AIR adjustment valve. Adj...

Installation 309295 9 Installation Install the System Fig. 2 shows a typical electrostatic air-assisted spray system. It is not an actual system design. For assistance in designing a system to suit your particular needs, con-tact your Graco distributor. Warning Sign Mount warning signs in the spray ...

Installation 309295 11 Connect the Air Line 1. Connect the Graco Grounded Air Supply Hose (R) between the air supply line and the gun's air inlet (V). The gun air inlet fitting has a left-hand thread. Connect the air supply hose ground wire (Q) to a true earth ground. 2. Install an air line filter/w...

Installation 12 309295 Connect the Fluid Line 1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed. 2. Install a fluid regulator (M) on the fluid line to con-trol fluid pressure to the gun. 3. Install a ...

Installation 309295 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...

Installation 14 309295 Check Electrical Grounding 1. Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose. 2. Turn the ES ON/OFF valve OFF. 3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it. 4. Make sure the ...

Installation 309295 15 Check Fluid Resistivity Graco Part No. 722886 Resistance Meter and 722860 Probe are available as accessories to check that the resis-tivity of the fluid being sprayed meets the requirements of an electrostatic air-assisted spray system. Follow the instructions included with th...

Operation 16 309295 Operation Low Voltage Adjustment (Smart Guns Only) The ES HI/LO switch enables you to switch between full voltage and a lower voltage output. The lower volt-age is factory set, but can be adjusted. 1. Set the ES HI/LO switch to LO. 2. Remove the LOW VOLTAGE adjustment plug (53). ...

Maintenance 309295 17 Maintenance Flush the Spray Gun Flush the gun before changing colors, at the end of the day, before storing, and before repairing the gun. 1. Turn the ES ON/OFF valve OFF. 2. Relieve the pressure. 3. Remove and clean the air cap and the spray tip. Continued on page 18. INSTRUCT...

Electrical Tests 309295 19 Electrical Tests Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (18) and barrel (16), and electrical continuity between components. Use megohmmeter Part No. 241079 (AA) with an applied vol...

Electrical Tests 309295 21 Test Barrel 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 barrel contact ring (16a). See Fig. ...

Troubleshooting 22 309295 Troubleshooting NOTE: Check all possible remedies in the Troubleshoot- ing Chart before disassembling the gun. Spray Pattern Troubleshooting NOTE: Some spray pattern problems are caused by the improper balance between air and fluid. WARNING Electric Shock Hazard Installing ...

Troubleshooting 309295 23 Gun Operation Troubleshooting Problem Cause Solution Excessive spray fog. Atomizing air pressure too high. Close atomizing air valve some, or decrease air pressure as low as pos-sible; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage. Fluid too thin. Increa...

Troubleshooting 24 309295 Electrical Troubleshooting * ES indicator light is off when the gun is triggered. Problem Cause Solution Poor wrap. ES ON/OFF valve OFF (0).* Turn ON (I). Gun air pressure too low. Check air pressure to gun; minimum 40 psi (0.28 MPa, 2.8 bar) needed at gun for full voltage....

Repair 309295 25 Repair Pressure Relief Procedure 1. Turn the ES ON/OFF valve OFF. 2. Lock the trigger. 3. Turn off the air bleed valves to the fluid source and to the gun. 4. Unlock the trigger. 5. Trigger the gun into a grounded metal waste con-tainer to relieve the fluid pressure. 6. Lock the tri...

Repair 26 309295 Prepare the Gun for Service NOTE: • 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 (18a) and the plastic end of the fluid tube (14) with dielectric g...

Repair 309295 29 Electrode Replacement 1. Prepare the gun for service, page 26. 2. Remove the air cap assembly, page 27. 3. Pull the electrode (9b) out of the back of the air cap, using a needle-nose pliers. 4. Push the new electrode through the air cap hole. Make sure the short end (BB) of the elec...

Repair 30 309295 Fluid Tube Replacement 1. Prepare the gun for service, page 26. 2. Disconnect 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)....

Repair 309295 31 Fluid Needle Replacement 1. Prepare the gun for service, page 26. 2. Remove the air cap assembly and seat housing, page 27. 3. Remove the barrel (16), page 32. 4. Remove the trigger screws (8) and trigger (30). 5. Remove the spring cap (45) and the spring (26a) from the barrel. See ...

Repair 32 309295 Barrel Removal 1. Prepare the gun for service, page 26. 2. Carefully loosen the nut (C) from the bracket fluid fitting (13). See Fig. 15. 3. Loosen the three screws (11). 4. Hold the gun handle (17) with one hand and pull the barrel (16) straight off the handle. Fig. 1. Fig. 15. Bar...

Repair 36 309295 Air Valve Repair 1. Prepare the gun for service, page 26. 2. Remove the barrel, page 32. 3. Remove the air valve cap (25) from the handle (17). Remove the spring (15). See Fig. 19. 4. Remove the air valve (21) with a pliers. Inspect the seal (21a) and replace if damaged. Be sure the...

Repair 309295 37 ES ON/OFF Valve Repair 1. Prepare the gun for service, page 26. 2. Loosen the screw (48). Remove the valve. 3. Lubricate the o-rings (22a* and 22b*) with non-sili-cone grease, Part No. 111265. Do not over-lubricate. 4. Clean and inspect parts for damage. Replace if nec-essary. NOTE:...

Parts 38 309295 Parts Part No. 244572 85 kV Electrostatic Gun, 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 alternator (19), atomizing air adjustment valve (20)...

Accessories 46 309295 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 ...

Accessories 309295 47 Gun Accessories Gun Repair Kit 244781 Air Seal Repair Kit Electrode Replacement Kit 244917 Includes five electrodes. Inline Fluid Filters 238561 100 mesh filter. Set of three. 238563 60 mesh filter. Set of three. Round Pattern Kit Provides higher level of performance to electro...

Spray Tip Selection Chart 48 309295 Spray Tip Selection Chart Part No. Fan Width at 10 in. (250 mm) in. (mm) Orifice Size in. (mm) 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 (200-250) GG3211 4-6 (100...

Technical Data 309295 49 Technical Data and Viton® Loctite® is a registered trademark of the Loctite Corporation. Category Data Maximum Working Fluid Pressure 3000 psi (21 MPa, 210 bar) Maximum Working Air Pressure 100 psi (0.7 MPa, 7 bar) Minimum Air Pressure to Gun Inlet 40 psi (0.28 MPa, 2.8 bar)...

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 by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warran...