Graco 308496F Automatic, 60 kV, Electtostatic, Model PRO 5500wb Air Spray Gun Owner's Manual

Parts
INSTRUCTIONS-PARTS LIST
308496
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Rev. F
INSTRUCTIONS
AUTOMATIC, 60 kV, ELECTROSTATIC,
Model PRO 5500wb
Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working
Pressure
For use when electrostatically spraying conductive,
waterborne fluids that meet at least one of the following conditions for non-flammability:
1. The fluid has a flash point above 140F (60C)
and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
04299
Part No. 237603
2. The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
Part No. 237603*, Series A
Includes the spray gun, shroud, manifold, and
mounting bracket.
Part No. 236824, Series A
Includes the spray gun and shroud only.
Part No. 238091, Series A
Includes the spray gun, shroud, manifold, regulator,
and mounting bracket.
NOTE: The fluid hose must be ordered separately.
05928
Part No. 238091
U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447;
4,462,061; 4,660,774; 5,063,350; 5,073,709; 5,080,289;
5,093,625; 5,289,977
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327–B
Other U.S. and Foreign Patents Pending
NOTE: The PRO 5500wb spray gun is Factory Mutual approved for use with Graco isolation systems. The spray gun is also
approved for use with other Factory Mutual approved voltage isolations systems provided that the fluid hose is assembled as
shown in Fig. 15, page 17. Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency
approvals.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994 GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation
Installing the System . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . . 9
Install the Air Line Accessories . . . . . . . . . . . . . . . . 11
Install the Gun and Mounting Bracket . . . . . . . . . . 11
Connect the Air Lines . . . . . . . . . . . . . . . . . . . . . . . . 12
Optional Fiber Optic Cable Connection . . . . . . . . . 13
Optional Fiber Optic Lens Kit Installation . . . . . . . 14
Install the Fluid Hose . . . . . . . . . . . . . . . . . . . . . . . . 15
Ground the System . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check the Electrical Grounding . . . . . . . . . . . . . . . 18
Install the Fabric Cover . . . . . . . . . . . . . . . . . . . . . . 18
Operation
Fluid Voltage Discharge & Grounding Procedure
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . .
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a Fluid Nozzle and Air Cap . . . . . . . . . . .
Operating the Spray Gun . . . . . . . . . . . . . . . . . . . . .
Service
Tools Included with the Gun . . . . . . . . . . . . . . . . . .
Prepare the Gun for Service . . . . . . . . . . . . . . . . . .
Air Cap/Nozzle/Resistor Stud Replacement . . . . .
Electrode Needle Replacement . . . . . . . . . . . . . . .
Fluid Packing Rod Removal and Repair . . . . . . . .
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Removal and Replacement . . . . . .
Turbine Alternator Removal and Replacement . . .
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Gun onto the Manifold . . . . . . . . . . . . . .
Part No. 238039 Fluid Regulator Repair . . . . . . . .
Part No. 238147 Fluid Regulator Conversion
Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Waterborne Fluid Hose Repair . . . . . . . . . .
35
35
36
37
38
39
41
42
43
44
44
46
47
48
Spray Gun Parts
Part No. 237603 and 236824 . . . . . . . . . . . . . . . . . 50
Part No. 237091 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Manifold Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
19
19
20
20
20
Maintenance
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . . 23
Clean the Air Cap and Fluid Nozzle . . . . . . . . . . . . 24
Check for Fluid Leakage . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . 60
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . 60
Symbols
Warning Symbol
Troubleshooting
Voltage Loss Troubleshooting . . . . . . . . . . . . . . . . .
Poor Electrostatic Wrap Troubleshooting . . . . . . .
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . .
Gun Operation Troubleshooting . . . . . . . . . . . . . . .
Spray Pattern Troubleshooting . . . . . . . . . . . . . . . .
26
28
29
30
32
Electrical Tests
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . . . . 33
Test Power Supply Resistance . . . . . . . . . . . . . . . . 34
Test Resistor Stud Resistance . . . . . . . . . . . . . . . . 34
2
308496
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the corresponding instructions.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding or an improper setup and usage of an isolated waterborne system can cause a
hazardous condition and result in an electric shock or other serious injury.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 17.
The gun must be connected to a voltage isolation system that will discharge the system voltage
when the gun is not in use.
All components of the isolation system that are charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from making contact with the high voltage components
before the system voltage is discharged.
The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air
supply anytime the isolation system enclosure or safety fence is opened.
The voltage isolation system must be interlocked with the spray area entrance to automatically
discharge the voltage and ground the fluid whenever someone enters the spray area.
The areas of the waterborne fluid hose that are accessible to the personnel must be covered by
the conductive hose layer. The area on the hose that is not covered by the conductive hose layer
must be inside the voltage isolation system enclosure. Refer to Fig. 15, page 17.
Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use the
black or grey-colored Graco air hoses.
Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the
spray gun. Do not splice hoses together.
Follow the Fluid Voltage Discharge and Grounding Procedure on page 19 when instructed to
discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the
front of the gun or the gun-mounted fluid regulator; and before opening the safety fence or the
enclosure for the isolated fluid supply.
Do not use the Graco ES Display Module readings to determine if your system is discharged. The
display modules will only display the system voltage while the gun power supply is operating.
Follow the Fluid Voltage Discharge and Grounding Procedure to ensure the system is discharged.
Do not enter a high voltage or hazardous area until all high voltage equipment has been
discharged.
Do not come within 2 ft. (610 mm) of the gun nozzle or gun-mounted fluid regulator during gun
operation or until after following the Fluid Voltage Discharge and Grounding Procedure.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Follow the warnings and instructions in the voltage isolation system manual.
308496
3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion.
Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements stated in this instruction manual.
Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all
other electrically conductive objects in the spray area. See Ground the System on page 17.
Test the gun electrical resistance daily as instructed on page 33.
Provide fresh air ventilation to avoid the buildup of toxic vapors. Interlock the gun turbine air supply
to prevent operation of the power supply unless the ventilating fans are on. See Ventilate the
Spray Booth on page 9.
Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front cover
of this manual.
Only flush, purge, or clean the electrostatic, waterborne spray system with non-flammable fluids,
as defined on the front cover of this manual.
Do not flush the system with the gun electrostatics turned on.
Use only non-sparking tools to clean residue from the booth and hangers.
Extinguish all open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not store any flammable fluids in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin
and cause a serious injury.
Do not point the spray gun at anyone or any part of the body.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 19 whenever you: are instructed to relieve the
pressure; stop spraying; clean, check, or servicing the equipment; and install or clean the fluid
nozzles.
Tighten all the fluid connections before each use.
Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Warnings are continued on the next page.
4
308496
WARNING
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
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 the instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Do not operate the gun power supply above 60 kV. Use only the Graco power supply, part no.
237250, with this spray gun.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working air and fluid pressure.
Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of
all the equipment manuals. Read the fluid manufacturer’s warnings.
Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull equipment.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all
local, state, and national guidelines.
Wear appropriate protective clothing, gloves, eyewear, and respirator.
308496
5
Introduction
The PRO 5500wb spray gun is a 60 kV electrostatic
spray gun that is designed to spray conductive, waterborne, non-flammable fluids. When spraying waterborne fluids electrostatically, the gun must be connected to a voltage isolation system, which isolates the
fluid supply from ground and allows voltage to be
maintained at the tip of the gun. For information on the
Graco H2O PRO Voltage Block System, contact your
Graco distributor.
Precautions must be taken when using electrostatic
waterborne equipment to avoid potential shock hazards. When the spray gun charges the isolated fluid to
high voltage, it is similar to charging a capacitor or
battery. The system will store some of the energy while
spraying and retain some of that energy after the spray
gun is shut off. It is not safe to touch the front end of
the gun until the stored energy is discharged. The
amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage
Discharge and Grounding Procedure, page 19,
before approaching the front of the gun.
A safe, well designed voltage isolation system should
have the following features:
Operating the Spray Function
Spraying Waterborne Fluids
Electrostatically
All components of the isolation system that are
charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from
making contact with the high voltage components
before the system voltage is discharged.
A means for automatically discharging the system
voltage if someone opens the fence or enclosure or
enters the spray area.
A bleed resistor to drain off the system voltage
when the spray gun is not in use.
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the
system components.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
When connected to a voltage isolation system, all of
the fluid in the spray gun, fluid hose, and isolated fluid
supply are charged to high voltage, which means that
the system has more electrical energy than a solventbased system. Therefore, only non-flammable fluids
(defined on the front cover of this manual) can be
sprayed with the system or be used to clean, flush, or
purge the system.
6
308496
Applying a minimum of 50 psi (345 kPa, 3.5 bar) air
pressure to the gun manifold’s cylinder air fitting (which
is marked “CYL”, see page 7) will retract the gun
piston, which opens the air valves and a short time
later opens the fluid needle. This provides the proper
air lead and lag when triggering the gun. A spring
returns the piston when the cylinder air is shut off.
Operating the Electrostatics
(Refer to page 7)
To operate the electrostatics, air pressure is applied to
the gun manifold’s turbine air fitting (which is marked
“TA”) through a Graco electrically conductive air hose.
The air enters the manifold and is directed to the inlet
of the power supply turbine (G). The air spins the
turbine, which then provides electrical power to the
internal high voltage power supply (H). The fluid is
charged by the spray gun electrode (J). The charged
fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.
The turbine air is exhausted into the shroud (D) and
out the back of the manifold through the fitting marked
“EXH”, unless you are using part no. 238091 spray
gun, then the air is exhausted out of the slot in the
bottom of the shroud. The exhaust air helps keep
contaminants out and helps keep the gun clean.
Introduction
F
F.O.
TA
CYL
A2
A1
EXH
(PA)
P1
Manifold Back View
A
C
D
E
04299
04302
H
B
J
G
04482
KEY
A
Air Cap
B
Fluid Nozzle
C
Retaining Nut
D
Shroud
E
Mounting 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 (PA) Shroud Exhaust Outlet or Pilot Air Inlet Fitting
F.O.
Fiber Optic Fitting
P1
Fluid Supply Inlet Fitting
TA
Turbine Air Inlet Fitting
KV
not used
P2
not used
308496
7
Introduction
Gun Features and Options
(Refer to page 7)
This fluid hose consists of three layers (see Fig. 1):
The gun is designed for use with a reciprocator,
and it can be directly mounted to a one-half inch
rod. With additional brackets, the gun can be
mounted for robotic applications.
Inner Hose Layer (EE): is a PTFE tube.
The gun is designed for quick-disconnect, which
enables the operator to quickly remove the spray
gun without disconnecting the fluid and air lines to
the gun.
Outer Hose Jacket (FF): is a protective polyethylene hose cover.
The gun functions are activated from a separate
controller that sends the appropriate signal to the
actuating solenoids. Refer to Fig. 2, page 10.
An optional fiber optic readout system can be
installed to monitor the gun’s spraying voltage. A
fiber optic cable connected to the gun manifold
carries the signal from the gun to a remote ES
(electrostatic) display module. An ES Display
Module, part no. 224117, is available and will
display the gun’s spraying voltage and current. A
battery operated ES Display Module, part no.
189762, is also available; it displays the gun’s
spraying voltage only. Refer to Fig. 3, page 10.
Part no. 238091 spray gun has a fluid regulator
located at the gun barrel inlet. The fluid regulator
provides precise fluid control.
WARNING
Conductive Hose Layer (DD): covers the PTFE
tube.
If a hose failure occurs, where the high voltage arcs
through the inner hose layer (EE), the voltage will be
discharged to ground through the conductive hose
layer (DD). When properly installed, the conductive
hose layer is grounded through its connection to the
grounded safety fence or enclosure (CC). All areas of
the fluid hose that are accessible to personnel must be
covered by the outer hose jacket (FF) to avoid electric
shock.
KEY-Fig. 1
DD
EE
FF
CC
Conductive Hose Layer
Inner Hose Layer
Outer Hose Jacket
Grounded Enclosure
The portion of the inner hose layer (EE-PTF tube) that is not
covered by the conductive hose layer (DD),
E must be inside the
safety fence or enclosure (CC).
The areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer
hose jacket (FF).
EE
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
do not use the Graco ES Display Module
readings to determine if your system is
discharged. The display modules will only display
the system voltage while the guns power supply
is operating. Follow the Fluid Voltage Discharge
and Grounding Procedure, page 19, to ensure
the system is discharged.
8
308496
FF CC
Graco Waterborne Fluid Hose (purchased
separately)
A Graco waterborne fluid hose must be used between
the voltage isolation system fluid outlet and the spray
gun fluid inlet.
DD
H2O PRO Voltage Block connection shown
Fig. 1
05179
Installation
Installing the System
WARNING
All components of the isolation system that are
charged to high voltage must be contained within a
fence or enclosure that prohibits personnel from
making contact with the high voltage components
before the system voltage is discharged.
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which could
cause an electric shock or other serious
injury if the work is not performed properly.
The gun turbine air supply must be interlocked with
the isolation system to shut off the turbine air
supply anytime the isolation system enclosure or
safety fence is opened.
Do not install or service this equipment unless
you are trained and qualified.
The voltage isolation system must be interlocked
with the spray area entrance to automatically
discharge the voltage and ground the fluid whenever someone enters the spray area.
Comply with all local, state, and national codes
for the installation of electrical apparatus in a
Class I, Group D, Hazardous Location.
Comply with all applicable local, state, and
national fire, electrical, and other safety regulations.
Fig. 2, page 10, shows a typical Model PRO 5500wb
waterborne system. Fig. 3 shows the optional ES
Display Modules. The particular type and size system
for your operation must be custom designed for your
needs. For assistance in designing a system, contact
your Graco representative.
Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun,
Form No. 305678.
Basic Guidelines
When spraying waterborne fluids electrostatically:
The gun must be connected to a voltage isolation
system, which isolates the fluid supply from ground
and allows voltage to be maintained at the tip of the
gun.
The gun must be connected to a voltage isolation
system that will discharge the system voltage when
the gun is not in use.
The system should not have any severe arcing
occurring when the isolation mechanism opens and
closes. Severe arcing will shorten the life of the
system components.
Warning Signs
Mount the warning signs, part no. 186118 and 290171,
at the entrance to the spray booth, where it can easily
be seen and read by all operators. Additional warning
signs are available at no charge.
Ventilate the Spray Booth
WARNING
TOXIC FLUID HAZARD
Provide fresh air ventilation to avoid the
buildup of toxic vapors. Do not operate
the gun unless the ventilating fans are
on.
Electrically interlock the gun turbine air supply with the
ventilators to prevent operation of the electrostatic
power supply unless the ventilating fans are on.
Check and follow all local, state, and national codes
regarding air exhaust velocity requirements. High
velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum
allowable air exhaust velocity is 60 linear feet/minute
(18.3 linear meters/minute).
308496
9
Installation
BASIC SYSTEM
P
Non-Hazardous Area
Q
Hazardous Area
H
B
A
K
*
C
D
L
E
K
*
*
*
*
A1
*
P1
TA
A2
CYL
EXH (PA)
F
J
S
M
M
N
G
R
05929
Fig. 2
Non-Hazardous Area
Hazardous Area
SYSTEM OPTION
ES Display Module
W
Z
T
U
Y
kV
*
F.O.
mA
X
V
kV
AA
04300
Fig. 3
KEY
A
B
Ground Wire on Graco Electrically Conductive Air Hose
Graco Electrically Conductive Air Hose (Turbine Air Hose),
P/N 235068 to 235074, color coded red
C Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.
D Fan Air Hose, 3/8 inch (9.5 mm) O.D.
E Cylinder Air Hose, 1/4 inch (6.4 mm) O.D.
F Graco Waterborne Fluid Hose, see page 56 for parts
G Graco H2O PRO Voltage Block Isolation System
H PRO 5500wb Spray Gun
J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189581
K Solenoid Valve-requires quick-exhaust port
L Bleed-type Air Shut-off Valve
M Air Pressure Regulator for fluid regulator pilot
N True Earth Ground
P Main Air Line
Q Bleed-type Master Air Valve
R Shroud Exhaust Port for Gun P/N 237603 or Pilot Air Line for Gun
P/N 238091; 1/4 inch (6.4 mm) O.D.
10
308496
S
T
U
V
W
X
Y
Z
AA
*
Check Valve
Fiber Optic Cable, P/N 224680 to 224686
Bulkhead, P/N 189870
Fiber Optic Cable, P/N 224670 to 224676
24 Volt Power Supply, P/N 235301
4–20 mA Outputs
PRO 5500wb Spray Gun
Full Feature ES Display Module, P/N 224117
kV Only ES Display Module (battery operated), P/N 189762
The turbine air supply must be interlocked with the spray booth
ventilation fans and the voltage isolation system.
A maximum of two splices with a total of 108 feet (32.94 m) of
cable can be used. For the strongest light signals, use a minimum
number of bulkhead splices.
See page 12 for a description of the manifold connections.
Installation
Install the Air Line Accessories
1. Install an air line filter and an air and water separator on the main air supply line to ensure a dry,
clean air supply to the gun. Dirt and moisture can
ruin the appearance of your finished workpiece
and can cause the gun to malfunction.
B
A = 2 in. (51 mm)
A
B = 4 in. (102 mm)
2. Install a bleed-type air shutoff valve (Q) on the
main air supply line to shut off all the air to the gun.
3. Install a bleed-type air regulator (M) on each of the
gun air supply lines to control the air pressure to
the gun. See Fig. 2, page 10.
A
A
05937
Fig. 4
1. Loosen the two square head bolts (103), and slide
the mounting bracket onto a 0.50 inch (12.7 mm)
mounting rod. See Fig. 5.
2. Position the gun, and tighten the two bolts (103)
securely.
4. Install a bleed-type air shutoff valve (L) on the fan
(C) and atomization (D) air lines to shut off the fan
and atomization air to the gun.
2.775 in.
(70.5 mm)
WARNING
PRESSURIZED EQUIPMENT HAZARD
Trapped air can cause the gun to spray
unexpectedly, which could result in a
serious injury, including splashing in the
eyes or on the skin. The bleed-type air shutoff
valve is required on the fan and atomization air
lines so trapped air will be relieved between the
valve and the gun after the valves are closed.
5. Install a check valve (S) in the pilot air line (R) to
prevent fluid from backing up into the air controls.
103
0.50 in.
(12.7 mm)
rod
9.32 in.
(236.7 mm)
103
04301
Fig. 5
NOTE: For added positioning reliability, the mounting
bracket (DD) has an 1/8 inch (3.2 mm) slot where a
locating pin (BB–not included) can be inserted through
the mounting rod (CC). See Fig. 6.
BB
DD
Install the Gun and Mounting Bracket
CAUTION
To avoid electrical breakdown damage to the fluid
regulator and other gun components, do not have
any grounded objects within the minimum clearance
zone shown in Fig. 4 during gun operation.
CC
03460
Fig. 6
308496
11
Installation
Connect the Air Lines
See Fig. 2, page 10, for a schematic of air line connections. Connect the air lines to the gun manifold as
instructed at right.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of a fire, explosion, or
electric shock, the gun turbine air supply
must be interlocked with:
Manifold Connections (See Fig. 7)
A1
Atomization Air Inlet Fitting
Connect a 3/8 inch (9.5 mm) O.D. tube between the
fitting and the air supply.
A2
Fan Air Inlet Fitting
Connect a 3/8 inch (9.5 mm) O.D. tube between the
fitting and the air supply.
CYL
Cylinder Air Inlet Fitting
Connect a 1/4 inch (6.4 mm) O.D. tube between this
fitting and the solenoid. For quicker trigger response, use the shortest hose length possible.
EXH
(PA)
Shroud Exhaust Outlet or Pilot Air Inlet Fitting
If using part no. 238091 spray gun, which includes a
fluid regulator, connect a 1/4 inch (6.4 mm) O.D.
pilot line to the fitting to control the fluid outlet pressure. If using part no. 237603 or 236824 spray gun,
connect a 1/4 inch O.D. (6.4 mm) x 4 foot (1.22 m)
long exhaust tube to the fitting.
F.O.
Fiber Optic Fitting (Optional)
Connect the Graco Fiber Optic Cable as instructed
on page 13.
P1
Fluid Supply Inlet Fitting
Connect a Graco waterborne fluid supply hose as
instructed on page 15.
TA
Turbine Air Inlet Fitting
Connect the red Graco Electrically Conductive Air
Hose between this fitting (left-hand thread) and the
solenoid. Connect the air hose ground wire to a true
earth ground.
The isolation system to shut off the
turbine air supply anytime the enclosure or safety fence is opened.
The ventilators to prevent operation
of the power supply unless the ventilating fans are on.
Graco Electrically Conductive Air Hose
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock or
other serious injury, you must use the
red-colored Graco Electrically Conductive Air Hose for the turbine air hose, and you must
connect the hose ground wire to a true earth
ground. Do not use the black or grey-colored Graco
air hoses.
Connect the red-colored Graco Electrically Conductive
Air Hose (B) to the gun turbine air inlet and connect
the hose ground wire (A) to a true earth ground (N).
Refer to Fig. 2, page 10. Check the electrical grounding of the gun as instructed on page 18. See page 57
to order the air hose.
NOTE: The hose and the gun have special left-hand
threads to prevent connecting another type of air hose
to the gun turbine air inlet.
12
308496
F.O.
TA
CYL
A2
A1
EXH
(PA)
P1
Manifold Back View
Fig. 7
04302
Installation
2. Remove the nut (EE) from the fiber optic fitting
(124), and slide the nut over the end of the fiber
optic cable (FF). See Fig. 9.
Optional Fiber Optic Cable Connection
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
do not use the Graco ES Display Module
readings to determine if your system is
discharged. The display modules will only display
the system voltage while the guns power supply
is operating. Follow the Fluid Voltage Discharge
and Grounding Procedure, page 19, to ensure
the system is discharged.
3. Insert the cable (FF) into the fitting (124), and push
the cable in until it bottoms out. Tighten the nut
(EE) to secure the cable.
EE
An optional fiber optic fitting (124) is shipped unassembled with the gun. If an ES (kV) display module is
used, install the fitting in the manifold. See Fig. 3, page
10, for a schematic of the fiber optic connections.
1. Remove the 1/8 npt plug (115) from the manifold’s
fiber optic port, and install the black fiber optic
fitting (124). See Fig. 8.
124
FF
04306
Fig. 9
4. If you have two bulkhead splices in your system, it
is recommended that you install the fiber optic lens
kit, as described on page 14.
124
115
NOTE: Most of the fiber optic light transmission loss
occurs at the bulkhead splices. For the strongest light
signals, use a minimum number of bulkhead splices. A
maximum of two splices, with a total of 108 feet (32.94
m) of cable, is recommended.
04305
Fig. 8
5. See manual 308265 to install a Graco ES Display
Module.
308496
13
Installation
Optional Fiber Optic Lens Kit Installation
HH
NOTE: The fiber optic lens kit is not included with the
gun. Order it separately; the part number is 236852.
JJ
1. Remove the gun from the manifold as instructed
on page 35.
2. Make sure the lens (HH) is clean. Push the lens
into the counterbore (KK) in the manifold fiber optic
port (GG). See Fig. 10 and 11.
3. Press the lens retainer (JJ) into the manifold fiber
optic port (GG) until it is flush with the manifold
surface.
4. Assemble the gun to the manifold as instructed on
page 44.
GG
HH
JJ
04484
Fig. 10
14
308496
GG
Fig. 11
KK
04485
Installation
Install the Fluid Hose
NOTE:
A Graco waterborne fluid hose must be used
between the voltage isolation system fluid outlet
and the spray gun fluid inlet. See page 56 to order
the Graco waterborne fluid hoses and the hose
replacement parts.
Before connecting the fluid supply line to the gun,
blow it out with air, and flush it with water to remove
contaminants.
3. Unscrew the strain relief nut (L) from the fluid inlet
fitting (P1), and slide the nut onto the hose (H).
See Fig. 13.
4. Apply a light coat of dielectric grease (supplied
with the gun) to the entire length of the exposed
inner hose layer (K). See Fig. 12.
Apply a light coat of dielectric grease to the o-rings (G) and the
entire length of the inner hose layer (K)
5.1 + 0.10 in.
(130 + 2.5 mm)
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
install only one continuous Graco waterborne fluid hose between the isolated
fluid supply and the spray gun. Do not splice hoses
together.
G
Minimum:
6.85 in.
(174 mm)
H
J
Spray Gun
Hose End
K
04303
Fig. 12
1. For the fluid hose to seal properly, the hose must
be stripped and assembled to the dimensions
shown in Fig. 12. A new Graco waterborne fluid
hose comes fully assembled to the proper dimensions.
CAUTION
L
H
Be careful not to cut into the inner hose layer (K)
when stripping the hose. Nicks or cuts in the tube will
cause premature hose failure.
2. Inspect the condition of the o-rings (G) on the hose
barbed-fitting. Replace the o-rings if they are worn
or damaged.
P1
04304
Fig. 13
308496
15
Installation
Install the Fluid Hose (continued)
5. Insert the hose into the fluid inlet fitting (P1). See
Fig. 14.
6. Push the hose into the fitting until the o-rings (G)
on the hose barbed-fitting are seated and the hose
bottoms out.
WARNING
ELECTRIC SHOCK HAZARD
To maintain grounding continuity, the
conductive hose layer (J) must be
engaged in the fitting (P1) when the nut
(L) is tightened. See Fig.14. Failure to properly
install the hose into the fitting could result in an
electric shock.
7. Tighten the nut (L) firmly with a wrench to about 55
in-lb (6.2 N m). Pull back on the hose to make
sure it is secure.
CAUTION
If the hose comes loose from the fitting, fluid leakage
will occur. Make sure the nut (L) is tight and that
nothing will pull or catch on the hose during operation.
8. Check the gun’s electrical grounding as instructed
on page 18.
9. Connect the other end of the hose as instructed in
the voltage isolation system manual. See Fig. 15.
P1
L
WARNING
G
ÇÇÇÇÇÇ
ÇÇÇÇÇÇ
P1
Fig. 14
16
308496
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock,
the areas of the waterborne fluid hose
that are accessible to personnel during
normal operation must be covered by the outer
hose jacket (H). See Fig. 15.
J
L
CAUTION
05927
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
Installation
Install the Fluid Hose (continued)
K
H
DETAIL
K
J
H
R
R
H2O PRO Voltage Block
connection shown
The areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (H).
The portion of the inner hose layer (K) that is not covered by the outer hose jacket (H) must be inside the voltage isolation system enclosure (R).
The conductive hose layer (J) must be grounded through
its connection to the isolation system’s grounded safety
fence or enclosure (R).
04574
Fig. 15
Ground the System
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
When operating the electrostatic device,
any ungrounded objects in the spray
area (such as people, containers, tools,
etc.) can become electrically charged.
Improper grounding can result in static
sparking, which can cause a fire, explosion, or electric shock. Follow the
grounding instructions below.
The following grounding instructions are minimum
requirements for a basic electrostatic, waterborne
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 earth ground.
1. Fluid Supply: Ground the fluid supply by connecting a ground wire and clamp between the fluid
supply and a true earth ground. See your fluid
supply instruction manual for grounding instructions.
2. PRO 5500wb Electrostatic Air Spray Gun:
Install the red-colored Graco electrically conductive air hose between the gun and air supply line
and connect the air hose ground wire to a true
earth ground. Check the electrical grounding of the
gun as instructed on page 18.
3. Graco Waterborne Fluid Hose: The conductive
layer of the hose must be properly grounded by
correct installation as instructed on pages 15 to 17.
4. Voltage Isolation System: Ground the system
according to the manufacturer’s instructions.
5. All persons entering the spray area: Their
shoes must have conductive soles, such as
leather, or personal grounding straps must be
worn. Rubber or plastic soles are not conductive.
6. Object being sprayed: Keep the workpiece
hangers clean and grounded at all times. Contact
points must be sharp points or knife edges.
7. The floor of the spray area: The floor must be
electrically conductive and grounded. Do not cover
the floor with cardboard or any non-conductive
material which would interrupt grounding continuity.
8. All electrically conductive objects or devices
in the spray area: They must be properly
grounded.
308496
17
Installation
Check the Electrical Grounding
Install the Fabric Cover
1. Have a qualified electrician check the electrical
grounding continuity of the gun and turbine air
hose (M). See Fig. 16.
2. Make sure the turbine air hose (M) [the red Graco
electrically conductive air hose] is connected and
the hose ground wire is connected to a true earth
ground.
3. The air and fluid supplies to the gun must be
turned off and the fluid hose must not have any
fluid in it when checking the continuity.
4. Measure the resistance between the turbine air
inlet fitting (N) and a true earth ground (P) with an
ohmmeter (Q). Resistance should not exceed 100
ohms.
(Part No. 237603 and 236824 Guns Only)
1. Install a fabric cover (AA) over the front of the gun,
and slide it back to cover the exposed tubing and
hoses at the back of the manifold. See Fig. 17.
2. Route the exhaust tube (BB) outside the cover.
This enables you to monitor the exhaust tube for
the presence of any paint or solvent. See Check
for Fluid Leakage on page 25. Strap down the
exhaust tube to prevent it from moving around.
5. If the resistance is greater than 100 ohms, check
the tightness 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.
N
M
AA
BB
04308
Q
BB
Manifold Back View
P
Fig. 17
04307B
Fig. 16
18
308496
04309
Operation
Fluid Voltage Discharge and Grounding
Procedure
WARNING
ELECTRIC SHOCK HAZARD
The high voltage fluid supply is charged
with high voltage until the voltage is discharged. Contact with the charged components of the isolation system or spray gun electrode will cause an electric shock. To avoid an electric shock, follow the Fluid Voltage Discharge
and Grounding Procedure:
when instructed to discharge the voltage,
before cleaning, flushing, or servicing the system equipment,
before approaching the front of the gun or the
gun-mounted fluid regulator,
and before opening the safety fence or the
enclosure for the isolated fluid supply.
NOTE: An accessory grounding rod, part no. 210084,
is available to discharge any voltage remaining on a
system component. Contact your Graco representative
to order it.
1. Turn off the turbine air to all of the spray guns
connected to the isolated fluid supply.
2. Discharge the voltage at the voltage isolation
system by following the procedure specified in the
voltage isolation system instruction manual.
3. Touch the electrode of the gun with a grounded rod
to make sure that the voltage has been discharged. If an arc is seen, verify that the electrostatics are turned off or see Electrical Troubleshooting, page 29, or the voltage isolation system
manual for other possible problems. Resolve the
problem before proceeding.
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. To
reduce the risk of an injury from accidental spray
from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the fluid nozzle.
1. Follow the Fluid Voltage Discharge and
Grounding Procedure, at left.
2. Relieve fluid pressure in the fluid supply and
voltage isolation system as instructed in their
instruction manuals.
3. Turn off the fluid supply to the gun.
4. Turn off all the air to the spray gun except the
cylinder air, which triggers the gun. If an air pilot
regulator is used in the system, the air pressure is
also needed at the regulator air inlet.
NOTE: The shut-off device must bleed the air out of
the system.
5. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.
6. Turn off all the remaining air supplies to the gun.
7. Turn off the main air supply by closing the bleedtype master air valve on the main air supply line.
Leave the valve closed until you are ready to spray
again.
308496
19
Operation
Operating Checklist
Check the following list daily, before starting to operate
the system, to help ensure you of safe, efficient operation.
____ 1. All the operators are properly trained to safely
operate an automatic, electrostatic, waterborne, air spray system as instructed in this
manual and the voltage isolation system
manual.
____ 2. All the operators are trained how to properly
relieve system pressure as instructed on page
19.
____ 3. All the operators are trained how to properly
discharge the voltage as instructed on page
19.
____ 4. The system is thoroughly grounded and the
operator and all persons entering the spray
area are properly grounded. See Ground the
System, page 17, and Check the Electrical
Grounding, page 18.
____ 5. The condition of the electrical components of
the spray gun has been checked as instructed
in Electrical Tests, page 33.
____ 6. All fluid hose connections are tight.
____ 7. The ventilation fans are operating properly.
____ 8. All the debris, including flammable liquids and
rags, is removed from the spray area.
____ 9. The manifold exhaust tubes have been
checked for the presence of fluid as instructed
in Check for Fluid Leakage, page 25.
Selecting a Fluid Nozzle and Air Cap
Part no. 237603 and 236824 spray guns are supplied
with a 0.07 inch (1.8 mm) fluid nozzle, part no. 191834.
Part no. 238091 spray gun is supplied with a 0.047
inch (1.2 mm) fluid nozzle, part no. 191832. The air
cap for all the guns is part no. 193033. If your application requires a different nozzle and air cap combination, see instruction manual 307803 or consult your
authorized Graco distributor to select the appropriate
fluid nozzle and air cap. Install the air cap and fluid
nozzle into the gun barrel as instructed on page 36.
20
308496
Operating the Spray Gun
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire and explosion,
only use this equipment to spray nonflammable, waterborne fluids as defined
on the front cover of this manual.
WARNING
ELECTRIC SHOCK HAZARD
Contact with the charged components of
the spray gun will cause an electric
shock.
Follow the Fluid Voltage Discharge and
Grounding Procedure on page 19 when you
stop spraying and whenever you are instructed
to discharge the voltage.
Do not come within 2 ft. (610 mm) of the gun
nozzle or gun-mounted fluid regulator during
gun operation or until after following the Fluid
Voltage Discharge and Grounding Procedure.
Do not use the Graco ES Display Module
readings to determine if your system is
discharged. Follow the Fluid Voltage Discharge and Grounding Procedure to ensure
the system is discharged.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
when you stop spraying, before installing
or cleaning the fluid nozzle, and whenever you are
instructed to relieve the pressure.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of component rupture,
which can cause serious injury, do not
exceed the maximum working pressure
of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum
working air and fluid pressure.
Operation
Operating the Spray Gun (continued)
Follow the steps below to establish the correct fluid
flow and air flow. Do not turn on the turbine air/electrostatics (TA) yet.
5. Part No. 237603 and 236824 Spray Guns: Pressurize the fluid supply, and adjust the fluid flow
with the fluid pressure regulator installed in the
fluid line.
Part No. 238091 Spray Gun: Set the fluid supply
pressure to the gun at 70 to 80 psi (480 to 550
kPa, 4.9 to 5.6 bar). Control the fluid flow out of
the gun by adjusting the air pilot pressure to the
gun-mounted fluid regulator. Increase or decrease
the pilot air pressure until you have the desired
flow rate.
CAUTION
If any fluid leakage from the gun is detected, stop
spraying immediately. See Check for Fluid Leakage, page 25.
NOTE: The fluid regulator has a air bleed hole in
the cover, which will emit some air leakage.
1. Complete all the checks under the Operating
Checklist on page 20.
2. Make sure the system voltage is discharged.
Loosen the air cap retaining nut, and rotate the air
cap for a vertical or horizontal spray pattern. See
Fig. 18. Then tighten the retaining nut until the air
cap is held firmly in place; you should not be able
to rotate the air cap horns by hand.
6. Use the air pressure regulator on the atomization
air supply line (A1) to adjust the degree of atomization. For example, for a fluid flow rate of
10 ounces per minute (0.3 liters/min.), a typical
atomization pressure would be about 20 to 30 psi
(140 to 210, 1.4 to 2.1 bar) at the gun manifold.
7. Use the air pressure regulator on the fan air supply
line (A2) to adjust the pattern size.
NOTES:
For the most efficiency, always use the lowest
atomizing air pressure possible.
When increasing to a wide, flat pattern, it may be
necessary to increase the supply of fluid to the gun
to maintain the same amount of coverage over a
large area.
Vertical Pattern
See Spray Pattern Troubleshooting on page 32
to correct spray pattern problems.
Horizontal Pattern
02020
Fig. 18
F.O.
TA
CYL
3. Apply a minimum of 50 psi (345 kPa, 3.5 bar) air
pressure to the cylinder air fitting (CYL) to activate
the on/off sequence of atomization air (A1), fan air
(A2), and fluid (P1). Refer to Fig. 19.
4. Turn the gun functions off and on by using the air
solenoid valves on the cylinder (CYL) and turbine
(TA) air supply lines. Refer to Fig. 2, page 10.
NOTE: To trigger the fluid alone, shut off and relieve
the air pressure to the atomization (A1) and fan (A2)
air lines, using the bleed-type air shut-off valves. Apply
50 psi (345 kPA, 3.5 bar) air pressure to the cylinder
air fitting (CYL) to trigger the fluid.
A2
A1
EXH
(PA)
P1
Manifold Back View
Fig. 19
04302
Continued on the next page.
308496
21
Operation
Operating the Spray Gun (continued)
Activating and Adjusting the Electrostatics
8. Make sure the fan (A2) and atomizing (A1) air are
on, then turn on the turbine air (TA).
9. The turbine air pressure should be adjusted to 30
psi (210 kPa, 2.1 bar) at the gun manifold inlet
when air is flowing. Do not exceed 40 psi (280
kPa, 2.8 bar) air pressure at the gun manifold inlet
as there is no added benefit and turbine life could
be reduced.
Use the chart below to set the proper pressure at
the turbine hose inlet. Do not exceed these recommended pressures or turbine life will be reduced.
10. Check the voltage output of the gun using a high
voltage probe and meter or by reading the ES (kV)
Display Module.
NOTES:
The gun’s normal high voltage reading is 45 to 55
kV due to spraying current demands and isolation
system losses.
See Voltage Loss Troubleshooting on page 26 to
correct voltage problems.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
11. Operate the voltage isolation system as instructed
in the system manual.
Turbine Air
Hose Length
Dynamic pressure at the turbine
hose inlet required for full
voltage
15 ft. (4.6 m)
36 psi (251 kPa, 2.5 bar)
25 ft. (7.6 m)
38 psi (265 kPa, 2.6 bar)
50 ft. (15.3 m)
40 psi (280 kPa, 2.8 bar)
75 ft. (22.9 m)
42 psi (294 kPa, 2.9 bar)
100 ft. (30.5 m)
45 psi (314 kPa, 3.1 bar)
22
308496
12. Use the same spraying technique you would use
with a conventional air spray system to coat the
workpiece.
13. Relieve the pressure and discharge the voltage
when you stop spraying.
NOTE: Flush and clean the equipment by following the
instructions in the Maintenance section, pages 23 to
25.
Maintenance
Daily Care and Cleaning
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire and explosion:
Only flush, purge, or clean the spray
gun with non-flammable fluids, as
defined on the front cover of this
manual.
CAUTION
Fluid 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 while cleaning it. Do
not use any cleaning method which could allow
fluid into the gun air passages.
Do not point the gun up while cleaning it.
Do not flush with the turbine air (TA) to the gun
turned on.
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 19
before cleaning or flushing the gun to
ensure the voltage is discharged and avoid serious
injury from an electric shock.
04311
Do not immerse the gun in fluid.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
when you stop spraying, before installing
or cleaning the fluid nozzle, and whenever you are
instructed to relieve the pressure.
04310
Do not wipe the gun with a cloth that is heavily
saturated; wring out the excess fluid.
1. Clean the fluid and air line filters daily.
2. Clean the outside of the gun daily with a soft cloth
dampened in a non-flammable cleaning fluid.
02027
3. Clean the air cap and fluid nozzle daily, minimum,
as instructed on page 24. Some applications
require more frequent cleaning. Replace the fluid
nozzle and air cap if they are damaged. See page
36.
5. Check for any fluid leakage from the gun and fluid
hoses. See page 25. Tighten the fittings or replace
the equipment as needed.
6. Check all of the work hangers for a buildup of fluid;
clean them if necessary.
4. Check the electrode wire. Straighten it if it is bent
and replace it if it is broken or damaged. See
page 37.
7. Flush the gun before changing colors and whenever you are done operating the gun.
308496
23
Maintenance
Clean the Air Cap and Fluid Nozzle
Equipment needed:
Soft bristle brush
Non-flammable cleaning fluid
CAUTION
03511
Do not use metal tools to
clean the air cap or fluid
nozzle holes as this could
scratch them, and make sure
the electrode wire is not damaged. Scratches in the air
cap or nozzle or a damaged
electrode wire can distort the
spray pattern.
6. Slide the shroud (2) onto the gun (P).
7. Carefully install the air cap (12). Be sure to insert
the electrode (13) wire through the center air cap
hole and do not bend the wire. Rotate the air cap
horns to the desired position.
8. Make sure the o-ring (8) is in place on the retaining
nut (1). Tighten the retaining nut (1) until the air
cap is held firmly in place; you should not be able
to rotate the air cap horns by hand.
9. Test the gun resistance as instructed on page 33.
P
Procedure:
1. Relieve the pressure and discharge the system
voltage as instructed on page 19.
2. Remove the air cap assembly (1, 12) and gun
shroud (2). See Fig. 20.
2
8
3. Clean the fluid nozzle (14), shroud (2), and exterior
of the gun (P) with a cloth dampened in a nonflammable cleaning fluid. Avoid getting any fluid
into the air passages. Whenever possible, point
the gun down while cleaning it.
4. If it appears that there is fluid inside the fluid
nozzle (14) air passages, remove the gun from the
line for servicing.
5. Clean the air cap (12) with the soft bristle brush
and a compatible solvent or submerge the air cap
in the solvent and wipe it clean.
24
308496
14
13
1
12
Fig. 20
04312
Maintenance
Check for Fluid Leakage (See Fig. 21)
During operation, periodically check the manifold
exhaust tube (N) and both ends of the gun shroud (Q)
for the presence of fluid. Fluid in these areas would
indicate fluid leakage into the shroud, which could be
caused by leaks at the fluid tube connections or fluid
packing leakage. If an air pilot line is used, check it for
the presence of fluid also.
CAUTION
If any fluid leakage from the gun is detected, stop
spraying immediately.
WARNING
If fluid is seen in any of these areas, stop spraying
immediately. Relieve the pressure and discharge the
voltage, then remove the gun for repair.
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 19
whenever you are instructed to discharge the voltage to avoid serious injury from an
electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
whenever you are instructed to relieve
the pressure.
N
Q
Q
N
Fig. 21
Check for the signs of fluid leakage where
indicated by the arrows and in the air pilot
line (not shown) if used.
Manifold Back View
04309
04308
308496
25
Troubleshooting
WARNING
ELECTRIC SHOCK HAZARD
Installing and servicing this equipment
requires access to parts which may
cause an electric shock or other serious
injury if the work is not performed properly. Do not
install or service this equipment unless you are
trained and qualified.
Follow the Fluid Voltage Discharge and Grounding Procedure on page 19 before checking or
servicing the system and whenever you are
instructed to discharge the voltage to ensure the
voltage is discharged and avoid serious injury from
an electric shock.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
before checking or servicing the system
and whenever you are instructed to relieve the
pressure.
Voltage Loss Troubleshooting
Normal spraying voltage for a system using the PRO
5500wb gun is 45 to 55 kV. The system voltage is
lower due to spraying current demands and voltage
isolation system losses.
A loss of spraying voltage can be caused by a problem
with the spray gun, fluid hose, or voltage block, since
all of the system components are electrically connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage block
itself, you need to determine which component in the
system is most likely causing a problem. Possible
causes include the following:
26
308496
Spray Gun
Fluid leakage
Dielectric breakdown at the fluid hose connection or
fluid packings
Not enough air pressure for the turbine
Faulty power supply
Excessive overspray on gun surfaces
Fluid in the air passages
Waterborne Fluid Hose
Dielectric failure of hose (pin-hole leak through
PTFE layer)
Air gap in the fluid column between the gun and
isolated fluid supply, causing a low voltage reading
on the isolation system voltage meter.
Voltage Block
Fluid leakage
Dielectric breakdown of hoses, seals, or connections
Isolators not functioning properly
Visual Check
First, check the system for any visible faults or errors
to help isolate whether the spray gun, fluid hose or
voltage block has failed. A voltage probe and meter,
part no. 236003, is helpful for diagnosing voltage
problems and is required for some of the troubleshooting tests that follow.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
2. Check that the voltage isolation system valves and
controls are properly set for operation. Refer to the
voltage isolation system manual.
3. Check that the spray gun and voltage isolation
system have sufficient air pressure.
4. Check that the gun turbine air is on and the pressure is set correctly.
5. Check that the voltage isolation system’s enclosure door or safety fence gate is closed and that
any safety interlocks are engaged and working
properly.
6. Make sure the voltage isolation system is in the
“isolate” mode, where it is isolating the fluid voltage from ground.
Troubleshooting
Voltage Loss Troubleshooting (continued)
7. To eliminate air gaps in the fluid column, spray
enough fluid to purge the air out between the
voltage isolation system and the spray gun. An air
gap in the fluid hose can break the electrical
continuity between the spray gun and the isolated
fluid supply and cause a low voltage reading on a
voltage meter connected to the isolated fluid
supply.
8. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a
conductive path back to the grounded gun handle.
Install a new gun cover and clean the exterior of
the gun.
9. Inspect the entire system for any visible fluid
leakage and repair any fluid leaks that are found.
Pay special attention to the following areas:
Packing area of the spray gun
Fluid hose: check for leakage or any bulges in the
outer jacket, which may indicate an internal leak
Internal voltage isolation system components
4. Position the end of the hose as far as possible
away from any grounded surface. The end of the
hose must be at least 1 ft. (305 mm) from any
ground. Make sure that no one is within 3 ft.
(914 mm) of the end of the hose.
5. Turn the turbine air to the gun on. Measure the
voltage at the gun electrode with a voltage probe
and meter.
6. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a
grounded rod.
7. If the meter reading is 45 to 55 kV, the gun and
fluid hose are okay, and the problem is in the
voltage isolation system. See the voltage isolation
system manual for further troubleshooting
information.
If the reading is below 45 kV, the problem is in the
gun or fluid hose.
Tests
If you still have no voltage, separate the spray gun and
hose from the voltage isolation system and check
whether the gun and hose alone will hold voltage with
the following test.
8. Flush the fluid hose and gun with enough air to dry
out the fluid passages.
1. Flush the system with water and leave the lines
filled with water.
9. Turn the turbine air to the gun on. Measure the
voltage at the gun electrode with a voltage probe
and meter.
2. Relieve the pressure and discharge the system
voltage as instructed on page 19.
3. Disconnect the fluid hose from the voltage isolation
system.
NOTE: Avoid allowing any water to leak out of the fluid
hose as that could cause a significant air gap in the
fluid column up to the gun electrode, which can break
the conductivity path and conceal a potential failure
area.
10. If the meter reading is 55 to 60 kV, the gun power
supply is okay, and there is probably a dielectric
breakdown somewhere in the fluid hose or gun.
Continue with step 11.
If the reading is below 55 kV, do the electrical tests
on page 33 to check the gun and power supply
resistance. If those tests show the gun and power
supply are okay, continue with step 11, page 28.
308496
27
Troubleshooting
Voltage Loss Troubleshooting (continued)
Remove the packing assembly from the gun
as instructed on page 38, and look for signs of
fluid leakage or any blackened areas, which
would indicate arcing is occurring along the
packing rod.
11. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the component that is failing.
Fluid hose
Check for leakage or any bulges in the outer
jacket, which may indicate a pin-hole leak
through the PTFE layer. Disconnect the fluid
hose from the gun, and look for signs of fluid
contamination on the outside of the PTFE
portion of the fluid tube.
Inspect the end of the hose connected to the
voltage block. Look for cuts or nicks.
Fluid packings
Fluid hose connection joint to the spray gun
A breakdown at the fluid hose connection joint
would be caused by fluid leaking past the
o-ring seals on the end of the hose. Remove
the hose at the gun connection and look for
signs of fluid leakage along the PTFE tube.
12. Before reassembling the gun, clean and dry the
gun fluid inlet tube (item 17 on page 50). Repack
the inner spacer of the fluid packing rod with
dielectric grease and reassemble the gun.
13. Reconnect the fluid hose as instructed on page 15.
Make sure the hose is properly stripped; see
Fig. 12, page 15, for hose stripping dimensions. Restrip or replace the hose.
14. Check the gun voltage with the voltage probe and
meter before filling the gun with fluid.
Poor Electrostatic Wrap Troubleshooting
Problem
Cause
Solution
The system is holding voltage but The distance between the gun and
there is poor electrostatic wrap on workpiece is incorrect.
the part being sprayed
The parts are poorly grounded.
Adjust the spraying distance to 8 to
12 inches (203 to 305 mm).
Booth exhaust velocity is too high.
Reduce the exhaust velocity within
the code limits.
The atomizing air pressure is too
high.
Reduce the atomizing air pressure.
The fluid pressure is too high.
Reduce the fluid pressure.
The fluid viscosity is not right for
electrostatic spray.
Check with the supplier for proper
fluid viscosity for electrostatic spray.
28
308496
Clean the workpiece hangers; check
for proper grounding on the conveyor
or track.
Troubleshooting
Electrical Troubleshooting
Problem
Cause
Solution
Voltage is still present at the gun
after following the Fluid Voltage
Discharge and Grounding Procedure
Gun electrostatics (turbine air) are
not turned off.
Turn off the gun electrostatics.
Did not wait long enough for the voltage to discharge through the voltage
bleed resistor.
Wait a longer period of time before
touching the electrode with a
grounded rod. Check for possible
bleed resistor failure.
There is an air pocket in the fluid line
that leaves the fluid near the gun
isolated.
Determine the cause of the air pocket
and fix the problem. Purge the air out
of the fluid line.
Voltage isolation system failed.
See the isolation system manual for
service information.
The operator gets a shock
The operator is not properly grounded Be sure the floor and the operator are
or is near an ungrounded object.
properly grounded; see Ground the
System, page 17.
The gun is not properly grounded.
See Check the Electrical Grounding, page 18.
The operator gets a shock when
touching the workpiece
The workpiece is not properly
grounded.
Clean the workpiece hangers; check
for proper grounding on the conveyor
or track
No or low voltage output reading
on the gun ES (kV) display
module
The fiber optic cable or connection is
damaged.
Check the cables and connections;
replace the parts if they are damaged.
The turbine air is not on.
Turn on the turbine air.
308496
29
Troubleshooting
Gun Operation Troubleshooting
Problem
Cause
Solution
Fluid leakage from the fluid packing area
The fluid rod packings or fluid rod are
worn.
Replace the packings or rod; see
page 38.
Fluid leakage from the front of the
gun
The fluid rod is worn or damaged.
Replace the fluid rod; see page 38.
The fluid seat is worn.
Replace the fluid nozzle and/or electrode needle; see pages 36 to 37.
The resistor stud is loose.
Tighten the resistor stud; see page
36.
The fluid nozzle is loose.
Tighten the fluid nozzle; see page 36.
The resistor stud o-ring is damaged.
Replace the o-ring; see page 36.
The air pressure is insufficient for
good atomization.
Increase the air cap air pressure by
increasing the gun air inlet pressure;
use the least air pressure needed for
good results.
The fluid is poorly mixed or filtered.
Remix or refilter the fluid.
An improper thinner is being used.
Use the proper thinner.
The air pressure is too high.
Reduce the air cap air pressure by
decreasing the gun air inlet pressure;
use the least air pressure needed for
good results.
The fluid is thinned too much.
Properly thin the fluid.
The fluid supply is low.
Check the fluid supply; add fluid if
necessary.
The fluid nozzle is dirty or clogged.
Clean the fluid nozzle; see page 24.
The fluid nozzle is damaged.
Replace the fluid nozzle; see page
36.
The piston is not actuating.
Check the cylinder air; check the
piston u-cup; see page 39.
The actuator arm is out of position.
Check the actuator arm and nuts; see
page 39.
The exhaust air flow is insufficient or
not directed properly.
Check for the proper CFM; check the
baffles and direction of the air flow.
The distance between the gun and
workpiece is incorrect.
Adjust the spraying distance to 8 to
12 inches (203 to 305 mm).
The electrode is bent.
Straighten the electrode.
The nozzle orifice is damaged.
Replace the fluid nozzle; see page
36.
The fluid is coming on before the air.
Check the position of the actuator
arm.
“Orange Peel” finish
Excessive spray fog
No fluid sprays from the gun
The equipment is covered with
fluid
Dirty air cap
30
308496
Troubleshooting
Gun Operation Troubleshooting (continued)
Problem
Cause
Solution
Dirty air cap
The air cap and fluid nozzle are misaligned.
Check the air cap and fluid nozzle
seat for fluid buildup. Clean or
replace parts as needed; see page 24
or 36.
Air Cap
Fluid Nozzle
ALIGNED
MISALIGNED
Air leakage from the air cap
The o-rings on the piston stem are
worn.
Inspect the o-rings; replace them as
needed; see page 39.
Air leakage from the manifold
The manifold gasket is damaged, or
the manifold is not tight.
Replace the gasket or tighten the
manifold screws; see page 44.
Fluid leakage at the quickdisconnect
The manifold is not tight.
Tighten the manifold screws.
The fluid hose is not seated properly.
Make sure the hose was stripped and
installed correctly; see page 15.
The o-rings on the fluid hose are
worn or missing.
Inspect or replace the o-rings.
308496
31
Troubleshooting
Spray Pattern Troubleshooting
NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
Fluttering or spitting spray
The fluid supply is insufficient.
Adjust the fluid regulator, or fill the
fluid supply.
The fluid nozzle is loose, or the fluid
nozzle taper seat is damaged.
Tighten or replace the fluid nozzle;
see page 36.
There is dirt between the fluid nozzle,
taper seat, and gun body.
Clean the parts; see page 24.
The coupler at the fluid inlet is loose
or cracked.
Tighten or repair the coupler.
There is fluid build-up on the air cap;
partially clogged horn holes; or full air
pressure from the clean horn hole
forces the fan pattern toward the
clogged end.
Clean the air cap with a soft implement or submerge it in water and
wipe it clean; see page 24.
The electrode is bent.
Straighten the electrode.
The fluid nozzle or air cap holes are
damaged.
Replace the damaged part; see page
36.
There is fluid buildup on the perimeter Remove the obstruction; never use
of the fluid nozzle orifice, or a partially wire or hard instruments; see page
clogged fluid nozzle orifice.
24.
Streaks
32
308496
The electrode is bent.
Straighten the electrode wire.
The fan air pressure is too high.
Reduce the fan air pressure.
The fluid is too thin.
Reduce the fluid viscosity.
There is not enough fluid pressure.
Increase the fluid pressure.
The fan air pressure is too low.
Increase the fan air pressure.
The fluid is too thick.
Reduce the fluid viscosity.
There is too much fluid.
Reduce the fluid flow.
The last coat of fluid is applied too
wet.
Apply a drier finish using multiple
strokes.
There is too much air pressure.
Decrease the air pressure.
The air pressure is insufficient.
Increase the air pressure.
The spray pattern is non-uniform.
Clean or replace the air cap; see
page 24.
Electrical Tests
WARNING
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
and Grounding Procedure on page 19
before checking or servicing the system
and whenever you are instructed to discharge the
voltage to ensure the voltage is discharged and
avoid serious injury from an electric shock.
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of sparking, which
could cause fire, explosion, or electric
shock and result in serious injury, do not
use the megohmmeter in the hazardous
area. Remove the gun from the hazardous area before testing it.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
before checking or servicing the system
and whenever you are instructed to relieve the
pressure.
Test Gun Resistance
1. Prepare the gun for service as instructed on
page 35.
2. Measure the resistance between the end of the
electrode (13) and the gun body (29). See Fig. 22.
WARNING
FIRE, EXPLOSION, AND
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 241079 (L–see Fig.
22) is not approved for use in a hazardous area. To reduce the risk of sparking,
do not use the megohmmeter to do
electrical tests unless:
The gun has been removed from the
hazardous area;
3. The resistance should be between 329 to 401
megohms. If the resistance is outside the specified
range, measure the power supply and resistor stud
resistance as instructed on page 34.
4. If you still have problems, refer to Voltage Loss
Troubleshooting , page 26, for other possible
causes of poor performance, or contact the nearest authorized service agency.
Or all spraying devices in the hazardous area
are turned off, ventilation fans in the hazardous
area are operating, and there are no flammable
vapors in the area (such as open solvent containers or fumes from spraying).
L
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
The performance of the spray gun is directly affected
by the condition of the electrical components contained
inside the gun. The electrical tests can be used to
determine the condition of the power supply and the
resistor stud as well as the continuity of the electrical
path between the components.
29
Use megohmmeter (L), part no. 241079, and an applied voltage of 500 volts to complete these electrical
tests. Connect the leads as shown.
Remove the gun from the manifold and bracket, as
instructed on page 35, before performing the electrical
tests.
13
04313B
Fig. 22
308496
33
Electrical Tests
Test Power Supply Resistance
Test Resistor Stud Resistance
1. Prepare the gun for service as instructed on
page 35.
1. Prepare the gun for service as instructed on
page 35.
2. Remove the power supply (27) from the gun body
(29) as instructed on page 42.
3. Remove the turbine alternator (25) from the power
supply as instructed on page 43.
4. Measure the resistance from the power supply’s
ground contact point (R) to the contact inside of
the power supply seal (D) [the conductive rubber
contact may be slightly recessed into the seal].
See Fig. 23.
5. The resistance should be 297 to 363 megohms. If
the resistance is outside the specified range, the
power supply is defective and must be replaced. If
the resistance of the power supply is correct,
proceed to the next test.
2. Remove the resistor stud (15) as instructed on
page 36.
3. Check the resistance between the black resistor
stud ring contact (S) and the needle contact ring
(T). See Fig. 24. You may have to press down on
the contact ring (S) in several places to get a good
reading.
4. The resistance should be 21 to 29 megohms. If the
resistance is correct, make sure the metal contact
in the gun barrel and the needle contact ring (T)
are clean. If the resistance is outside the specified
range, the resistor is defective and the resistor
stud (15) must be replaced. See page 36 to replace the resistor stud.
WARNING
L
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
The resistor stud contact ring (S) is a
conductive contact ring, not a sealing
o-ring. See Fig. 24. To reduce the risk of
sparking, which could cause a sparking
or electric shock, do not remove the
resistor stud contact ring (S) or operate
the gun without the contact ring in place.
Do not replace the resistor stud (15) with
anything but a genuine Graco part.
15
R
D
27
S
T
TI0378
Fig. 23
34
Fig. 24
308496
0442
Service
Tools Included with the Gun
1. Discharge the voltage as instructed on page 19.
Ball End Wrench
Multi-tool
2. Flush the gun with a non-flammable cleaning fluid.
Prepare the Gun for Service
3. Relieve the system pressure as instructed on page
19.
NOTE:
Check all the possible remedies in Troubleshooting, pages 26 to 32, before disassembling the gun.
If the plastic parts of the gun must be held in a vise,
use padded vise jaws to avoid damaging parts.
NOTE: The service area must be clean. Remove the
gun from the worksite as instructed in the following
steps.
4. Loosen the bottom gun screw (21). See Fig. 25.
Lightly lubricate o-rings and seals with petroleum
jelly. Do not over-lubricate.
Only use genuine Graco parts. Do not mix or use
parts from other PRO Gun models.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of a fire, explosion, or
electric shock:
Follow the Fluid Voltage Discharge
and Grounding Procedure on page
19 before flushing, checking, or servicing the system and whenever you
are instructed to discharge the voltage.
Clean all the parts with a non-flammable fluid as
defined on the front cover of this manual.
Do not service this equipment unless you are
trained and qualified.
Do not come within 2 ft. (610 mm) of the gun
nozzle or gun-mounted fluid regulator during
gun operation or until after following the Fluid
Voltage Discharge and Grounding Procedure.
CAUTION
The piston return spring (105) is compressed
between the manifold (101) and gun body when they
are assembled. To avoid sudden movement of the
gun, loosen the bottom gun screw (21) before loosening the three manifold bolts (106). This allows the
gun to move forward gradually as the manifold bolts
are loosened. Hold the gun firmly in hand while
loosening the manifold bolts.
5. Holding the gun (B) firmly in hand, loosen the three
bolts (106) from the back of the manifold (101)
with the ball end wrench (77–not shown).
6. Remove the gun (B) from the manifold (101), and
take it to the service area.
106
105
A
101
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
before checking or servicing the system
and whenever you are instructed to relieve the
pressure.
21
B
04314
Fig. 25
308496
35
Service
Air Cap/Nozzle/Resistor Stud
Replacement
Apply a very light coat of lubricant to the o-ring (16).
Tighten the nozzle (14) hand-tight, then 1/8 to 1/4 turn more.
Removal
1
1. Prepare the gun for service as instructed on
page 35.
1, 3, 9, 12
9
83
2. Point the front end of the gun up while removing
the air cap assembly (1, 3, 9, 12). See Fig. 26.
3
12
CAUTION
14
Hold the front end of the gun up while removing the
nozzle and resistor stud to help drain the gun and
prevent any fluid left in the gun from entering the air
passages.
14 S
15
13
15
16 3. Remove the fluid nozzle (14) with the multi-tool
(83).
The resistor stud (15) should come out with the
fluid nozzle. If the resistor stud remains in the gun,
start the nozzle threads onto the resistor stud and
pull it out.
4. Unscrew the resistor stud (15) from the fluid
nozzle (14) with the multi-tool (83). See Fig. 27.
03455A
Fig. 26
Tighten the resistor stud (15) into the nozzle (14) to 10 in-lbs (1.13
N m).
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
The resistor stud contact ring (S) is a
conductive contact ring, not a sealing
o-ring. See Fig. 26. To reduce the risk of
sparking, which could cause a sparking
or electric shock, do not remove the
resistor stud contact ring (S) or operate
the gun without the contact ring in place.
Do not replace the resistor stud (15) with
anything but a genuine Graco part.
36
308496
83
14
15 Fig. 27
0444A
Service
Air Cap/Nozzle/Resistor Stud
Replacement (continued)
Installation
1. Lightly lubricate the o-ring (16) with petroleum jelly
and install it on the resistor stud (15). See Fig. 26.
CAUTION
To avoid damaging the plastic threads or contact
wire, be very careful when installing the electrode
needle.
2. Make sure the electrode needle (13) is tightened
properly. Refer to Fig. 28.
5. Install the fluid nozzle, resistor stud, and air cap as
described on page 36.
3. Install the resistor stud (15) in the fluid nozzle (14)
with the multi-tool (83). Tighten the resistor stud to
10 in-lb (1.13 N m). See Fig. 27.
6. Test the gun resistance as instructed on page 33.
4. Install the fluid nozzle (14) and resistor stud (15)
assembly with the multi-tool (83). Tighten it until
the fluid nozzle seats in the gun barrel (1/8 to 1/4
turn past hand-tight). See Fig. 26.
Apply low-strength (purple) Loctite or equivalent to the fluid rod
threads, then install the electrode needle (13).
5. Carefully install the air cap (12) and gasket (3). Do
not bend the electrode wire (13), and be sure to
insert the electrode wire through the center air cap
hole. Rotate the air cap horns to the desired
position.
6. Make sure the o-ring (9) is in place on the air cap
retaining nut (1). Tighten the retaining nut (1) until
the air cap is held firmly in place; you should not
be able to rotate the air cap horns by hand.
83
13
7. Test the gun resistance as instructed on page 33.
Electrode Needle Replacement
1. Prepare the gun for service as instructed on
page 35.
2. Remove the air cap, nozzle and resistor stud as
instructed on page 36.
3. Unscrew and remove the electrode needle (13)
with the multi-tool (83). See Fig. 28. Be careful not
to damage the contact wire. If the fluid rod turns,
hold the back end of the fluid rod (C).
C
4. Apply low-strength (purple) Loctite or equivalent
thread sealant to the fluid rod threads.
Hold the back end of the fluid rod (C) to prevent it
from turning while installing the new electrode
needle (13) finger-tight. Do not over-tighten the
electrode needle.
04315A
Fig. 28
308496
37
Service
Fluid Packing Rod Removal and Repair
Preventative Maintenance
CAUTION
If the conductive fluid is allowed to leak through the
packings, it will eventually cause an electrical short
through the packings and along the gun barrel,
resulting in a loss of voltage at the tip of the gun.
Severe arcing can cause barrel damage. To avoid
voltage loss and possible barrel damage, preventative maintenance of the fluid packing assembly must
be performed at regular intervals.
83
28
Use the following formula to calculate the best packing
service interval for your application:
Service Interval in Days =
25,000
TxH
Where T = trigger cycles per minute
and
H = hours of operation per day
For example: If the trigger cycles per minute equals
10 and the hours of operation per day equals 8, the
equation would be,
25,000 = 25,000 = 312.5
10 x 8
80
The service interval would be 312 work days.
Procedure
NOTE: The fluid packing rod can be replaced as
individual parts or as an assembly. If the assembly is
purchased, it is pre-adjusted at the factory.
1. Prepare the gun for service as instructed on
page 35.
2. Remove the jam nut (46) and actuator arm (19).
See Fig. 31, page 39.
3. Remove the air cap assembly, fluid nozzle and
resistor stud and electrode needle as instructed on
pages 36 and 37.
4. Remove the fluid packing rod assembly (28) with
the multi-tool (83). See Fig. 29.
38
308496
04319A
Fig. 29
5. Check all the parts for wear or damage and
replace if necessary.
Before installing the fluid packing rod assembly
(28), clean the internal surfaces of the barrel with a
soft brush or cloth. Check the inside of the barrel
for marks from high voltage arcing. If the marks
are present, replace the barrel.
6. If the parts are purchased separately, assemble
them as instructed in steps 7 to 10 and as shown
in Fig. 30, on page 39.
If installing the complete fluid rod assembly, go to
step 11, page 39.
Service
Fluid Packing Rod Removal and Repair
(continued)
11. Lubricate the o-ring (28h) on the outside of the
packing housing (28a).
7. Place the packing nut (28c) and o-ring (28g) on the
fluid rod (28b). Flats on the packing nut must be
facing toward the back of the fluid rod.
12. Make sure the spring (11) is installed against the
nut (U) as shown in Fig. 30.
8. Fill the entire inner cavity of the spacer (28d) with
the dielectric grease included with the gun. Place
the spacer on the fluid rod (28b), in the direction
shown in Fig. 30. Generously apply the grease to
the outside of the spacer.
13. Install the fluid packing rod assembly (28) into the
gun barrel. Using the multi-tool (83), tighten the
assembly until just snug.
9. Place the fluid packing (28f), needle packing (28e),
and housing (28a) on the fluid rod (28b), as shown
in Fig. 30.
14. Install the electrode needle, nozzle and resistor
stud assembly and the air cap assembly as
instructed on page 37.
10. Lightly tighten the packing nut (28c) with the
multi-tool (83). The packing nut is properly tightened when there is 2 lbs. (9 N) of drag force when
sliding the packing housing (28a) assembly along
the shaft. Tighten or loosen the packing nut as
needed.
Apply a very light coat of lubricant to the o-ring (28h).
Fill the inner spacer (28d) cavity with the dielectric grease and
generously lubricate the outside of the spacer.
28e
28b
15. Install and adjust the actuator arm (19) and jam
nut (46) as instructed on page 40.
16. Test the gun resistance as instructed on page 33.
Tighten the packing nut (28c) to 2 lbs (9 N) of drag force.
The spring (11) is not included with the fluid packing rod assembly
(28).
28f 28h 28a 28d
U
11
28g 28c
28
03224
Fig. 30
Piston Repair
1. Prepare the gun for service as instructed on
page 35.
2. Remove the air cap assembly and the gun shroud.
3. Remove the jam nut (46), actuator arm (19), and
adjustment nut (36). See Fig. 31.
46 19 36 23g
NOTE: The fluid nozzle must be in place when removing or installing the jam nut and actuator arm.
04317
Fig. 31
308496
39
Service
Piston Repair (continued)
4. Push on the piston rod (23g) to push the piston
assembly out the back of the gun.
Apply a very light coat of lubricant to the o-rings (23a, 23b, 23c)
and u-cup (23f).
Align the two stems (23d) with the holes in the gun body and
press the piston assembly until it bottoms.
5. Inspect the o-rings (23a, 23b, 23c) and u-cup
packing (23f) for damage. See Fig. 33. Refer to
Fig. 34 to isolate air leakage problems.
6. Lubricate the o-rings (23a, 23b, 23c) and u-cup
packing (23f) with petroleum jelly.
23d
23c
23b
23e
7. Align the two stems (23d) with the holes in the gun
body and press the piston assembly into the back
of the gun until it bottoms.
23f 23g
23a 8. Installing the Actuator Arm and Nuts:
a. Install the adjustment nut (36), actuator arm
(19), and jam nut (46) onto the piston rod
(23g). See Fig. 32.
03530
Fig. 33
NOTE: The jam nut (46) has a slightly larger hex and a
thinner profile than the adjustment nut (36).
b. Thread the jam nut (46) flush with the end of
the piston rod (23g).Tighten the adjustment nut
(36) against the actuator arm (19). When
properly assembled, there should be about a
0.125 in. (3 mm) gap between the actuator
arm (19) and the fluid packing rod nut (U),
which allows the atomizing air to actuate
before the fluid actuates. See Fig. 32. In
addition, there should be 3 to 4 mm of electrode needle travel when the gun is triggered.
If necessary, adjust the jam nut (46) position to
obtain these dimensions.
Description Function
O-Ring (23a)
Shaft Air Seal
It seals the cylinder air along the piston
rod. If the air leaks along the piston rod
(23g), replace this o-ring (23a).
O-Ring (23b)
Front Air Seal
It is the air shut-off seal. If the air leaks
from the air cap when the gun is detriggered, replace these o-rings.
O-Ring (23c)
Back Air Seal
It separates the cylinder air pressure from
the fan and atomizing air pressure.
U-cup (23f)
Cylinder Air
Seal
If the air leaks from the small vent hole in
the back of the manifold when the gun is
triggered, replace the u-cup.
There should be a 0.125 in. (3 mm) gap between the actuator
arm (19) and the fluid packing rod nut (U).
23c
U
23b
Fan Air Side
23a
23f
Atomization Air Side
Fig. 34
46 19 36 23g
04823
Fig. 32
40
308496
03531
Service
4. Part No. 238091 Spray Gun: Disconnect the air
pilot line from the fluid regulator fitting.
Barrel Removal
1. Prepare the gun for service as instructed on
page 35.
5. Loosen the three screws (24) with the ball end
wrench (77–not shown). See Fig. 37.
2. Remove the air cap assembly (A) and the
shroud (2). See Fig. 35.
6. Hold the gun body (29) with one hand and pull the
barrel (26) straight away from the body to remove
it.
2
CAUTION
A
To avoid damaging the power supply (27), pull the
gun barrel straight away from the gun body. If necessary, gently move the barrel from side to side to free
the power supply from the gun body.
Fig. 35
3. Remove the jam nut (46) and actuator arm (19).
See Fig. 36.
26
NOTE: The fluid nozzle (14) must be in place when
removing or installing the jam nut and actuator arm.
24
29
27
14
46
Fig. 36
19
04317
04316
Fig. 37
308496
41
Service
4. Inspect the power supply for any physical damage.
Check the electrical resistance as instructed in
Test Power Supply Resistance, page 34. If
necessary, replace the power supply.
Power Supply Removal and Replacement
NOTES:
To avoid a loss in electrostatic performance, inspect
the gun body power supply cavity for dirt or moisture. Clean the cavity with a clean, dry rag.
5. Before installing the power supply, inspect the seal
(D) for any damage or swelling. Replace the seal if
necessary. Make sure the gaskets and pads
(27a–27f) are in place.
Do not expose the seal (D) or gasket (27a) to
solvents as it will damage the parts.
1. Prepare the gun for service as instructed on
page 35.
2. Remove the barrel as instructed on page 41.
6. Lubricate the o-ring (25a), and install the power
supply (27) in the gun body (29).
3. Grasp the power supply (27) with your hand. With
a gentle side-to-side motion, being careful not to
damage the power supply, pull the power supply
free from the gun body (29), then pull it straight
out. See Fig. 38.
7. Install the barrel on the gun body as instructed on
page 44.
Apply a very light coat of lubricant to the o-ring (25a).
Do not expose the seal (D) or gasket (27a) to solvents.
30
27
27e
27b
29
27a 27c
26
D
V
25a
25b
25
04320B
Fig. 38
42
308496
Service
Turbine Alternator Removal and
Replacement
NOTE: Replace turbine bearings after 2,000 hours of
operation. See your authorized Graco representative.
1. Prepare the gun for service as instructed on
page 35.
2. Remove the barrel as instructed on page 41.
3. Remove the power supply as instructed on
page 42.
4. Squeeze the two ends of the retaining ring (30)
together, and carefully pull the alternator (25) away
from the power supply (27) until the wire connector
(V) disengages. See Fig. 38, page 42.
5. Use an ohmmeter to test the turbine alternator coil.
Measure the resistance between the two outer
terminals of the 3-wire connector (V). Resistance
should be 3 to 5 ohms. If the reading varies from
this value, replace the alternator.
6. Measure the resistance between each outer
terminal of the 3-wire connector (V) and the alternator (25) housing. The resistance should be
infinite. If the resistance is not infinite, replace the
alternator.
7. Connect the 3-wire connector to the 3 prongs in
the power supply. Push the alternator (25) onto the
power supply (27) until the retaining ring (30)
engages with the alternator.
8. Install the power supply in the gun body as
instructed on page 42.
9. Install the barrel on the gun body as instructed on
page 44.
308496
43
Service
Barrel Installation
Install the Gun onto the Manifold
1. Be sure the gaskets (20, 27a) and spring (11) are
in place. See Fig. 39. Replace the parts if they are
damaged.
2. Place the barrel (26) over the power supply (27)
and onto the gun body (29). Make sure the fluid
needle spring (11) is seated properly.
3. Install the fluid tube (17) into the gun body (29).
4. Using the ball end wrench (77–not shown), tighten
the three screws (24) oppositely and evenly to 18
in-lbs (2 N m) maximum (about a half turn past
snug); do not over-tighten the screw.
CAUTION
To avoid damaging the gun, do not over-tighten the
screws (24).
5. Install and adjust the actuator arm (19) and jam
nut (46) as instructed on page 40.
6. Test the gun resistance as instructed on page 33.
1. Make sure the gaskets (121, 108) and the spring
(105) are on the manifold (101). See Fig. 41, page
45. Inspect the parts for damage and replace as
needed.
2. Make sure the fluid hose PTFE tube (A), which
inserts into the gun, and the gun fluid tube (17)
opening are clean.
If the parts are dirty, clean them and apply a light
coat of the dielectric grease to the entire length of
the PTFE tube (A). Keep the fluid tubes free of
contaminants during assembly.
CAUTION
If the PTFE tube (A) or the gun fluid tube (17)
become contaminated, a conductive path may be
created, which may short out the gun. Keep these
parts free of contaminants.
7. Part No. 238091 Spray Gun: Connect the air pilot
line to the fluid regulator fitting.
Tighten the screws (24) to 18 in-lbs (2 N m) maximum (about half
turn past snug), using the wrench (77) provided.
Install the nut (46) flush to the end of the piston rod (23g).
3. Inspect the condition of the o-rings (C) on the fluid
hose barbed-fitting. See Fig. 40, page 45. Replace
the o-rings if they are worn or damaged.
29
27a
4. Align the gun (B) and slide it onto the PTFE tube
(17) until the gun meets the manifold (101). See
Fig. 41.
27
20
24
26
5. Secure the gun (B) to the manifold (101) by tightening the three screws (106) with the ball end
wrench (77–not shown).
17
36
6. Secure the gun (B) to the mounting bracket (102)
by tightening the screw (21) with the ball end
wrench (77).
23g
19
46 13
11
04318
Fig. 39
44
308496
Service
Install the Gun onto the Manifold
(continued)
P1
D
7. To ensure the o-rings (C) on the barbed-fitting are
seated in the gun, loosen the nut (D) and push the
fluid hose into the gun until the barbed-fitting
bottoms out. See Fig. 40.
WARNING
C
ELECTRIC SHOCK HAZARD
To maintain grounding continuity, the
conductive hose layer (E) must be
engaged in the fitting (P1) when the nut
(D) is tightened. See Fig. 40. Failure to properly
install the hose into the fitting could result in an
electric shock.
ÇÇÇÇÇ
ÇÇÇÇÇ
P1
E
D
05927
Fig. 40
8. Tighten the nut (D) firmly with a wrench to about
55 in-lb (6.2 N m). Pull back on the hose to make
sure it is secure.
9. Slide the shroud (2) onto the gun (B). See Fig. 41.
10. Carefully install the air cap (12) and gasket (3–not
shown). Do not bend the electrode (13), and be
sure to insert the electrode wire through the center
air cap hole. Rotate the air cap horns to the desired position.
CAUTION
If the hose comes loose from the fitting (P1), fluid
leakage will occur. Make sure the nut (D) is tight and
that nothing will pull or catch on the hose during
operation.
11. Make sure the o-ring (9) is in place on the air cap
retaining nut (1). Tighten the retaining nut until the
air cap (12) is held firmly in place; you should not
be able to rotate the air cap horns by hand.
106
121
108
105
B
E
D
101
2
1
9
102
A
12
17
21
13
04321
Fig. 41
308496
45
Service
Part No. 238039 Fluid Regulator Repair
NOTE: The fluid regulator is item 17 in the parts list for
the part no. 238091 spray gun. It is not included with
part no. 237603 and 236824 spray guns. A Conversion
Kit is available to add the fluid regulator to those spray
guns. See page 47.
1. Prepare the gun for service as instructed on
page 35.
5. Replace the o-rings, seat, ball bearing, and diaphragm with the parts included in the Regulator
Repair Kit, part no. 238148.
6. Be sure all the parts are clean and dry, then re-assemble the regulator.
7. Screw the regulator outlet fitting (B) into the gun
barrel (C), and tighten the fitting securely. Connect
the air tubing (90) to the elbow fitting (E). Refer to
Fig. 43.
2. Remove the barrel as instructed on page 41.
3. Remove the regulator assembly from the gun
barrel by loosening the outlet fitting (B) from the
gun barrel (C) and disconnecting the air tubing (90)
from the elbow fitting (E). Refer to Fig. 43.
8. Install the barrel on the gun body as instructed on
page 44.
4. Disassemble the regulator parts as shown in
Fig. 42.
9. Install the gun onto the manifold as instructed on
page 44.
Fluid Regulator Parts List
Make sure the seat (408) is aligned with the regulator body (401)
threads to avoid cross-threading.
PTF side of diaphragm (413) faces up, toward body (401).
E
Tighten
the cover (402) firmly
406 411*
*404 *418 405
401
410
409*
415*
408* 412
407*
402
420
421
05931
Fig. 42
46
308496
Ref.
No.
Part No.
Description
401
402
403
404*
405
406
407*
408*
409*
410
411*
412
413*
415*
418*
420
421
238037
190868
109193
111316
190872
190871
110497
188944
102922
112204
111450
238215
187168
107505
102982
191406
113522
BODY ASSY.
COVER
ELBOW, tube fitting
O-RING, fluoroelastomer
OUTLET FITTING
OUTLET STEM
O-RING, Viton
SEAT
BALL BEARING
SPRING, compression
O-RING, CV–75
ACTUATOR
DIAPHRAGM
O-RING, PTF O-RING, PTF
E
COVER E
SCREW, 1/4–20
*
413* 403
Includes items 401 to 418
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
These parts are included in Repair Kit 238148, which may
be purchased separately.
Service
9. Install the air tubing (90) between the regulator
elbow fitting (E) and the tube fitting (89). Cut the
tubing to the length needed.
Part No. 238147 Fluid Regulator
Conversion Kit Installation
To add a fluid regulator to part no. 237603 and 236824
PRO 5500wb spray guns, follow this procedure:
10. Install the gun onto the manifold as instructed on
page 44.
1. Prepare the gun for service as instructed on
page 35.
NOTE: Use the parts drawing and list on pages 52 and
53 to order replacement parts for your gun after adding
the fluid regulator.
2. Remove the barrel as instructed on page 41.
3. Remove the fluid fitting (17) and o-rings (18, 22)
from the gun barrel. Refer to page 50.
Conversion Kit Parts List
4. Make sure the o-ring (A) is in place on the regulator outlet fitting (B). See Fig. 43.
Includes items 2, 17, 88, 89, and 90
5. Screw the regulator outlet fitting (B) into the gun
barrel (C), and tighten the fitting securely.
6. Apply high strength (green) Loctite or equivalent.
to the adapter (88) threads, and install the adapter
into the gun body (D).
Ref.
No.
Part No.
Description
2**
17
88
89
90
190905
238039
190899
111328
054730
SHROUD
FLUID REGULATOR
ADAPTER
TUBE FITTING
AIR TUBING; 5/32 O.D.
Qty.
1
1
1
1
** Order the warning label 290069, at no cost, when ordering the shroud. Affix the label to the shroud.
7. Install the tube fitting (89) into the adapter (88).
8. Install the barrel on the gun body as instructed on
page 44.
1 ft. (305 mm) of tubing included with kit. To replace tubing, order the length needed.
D
2
88
89
C
B
A
90
17
E
05494
Fig. 43
308496
47
Service
Graco Waterborne Fluid Hose Repair
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of a fire, explosion, or
electric shock:
Follow the Fluid Voltage Discharge
and Grounding Procedure on page
19 before flushing, checking, or servicing the system and whenever you
are instructed to discharge the voltage.
Clean all the parts with a non-flammable fluid as
defined on the front cover of this manual.
Do not service this equipment unless you are
trained and qualified.
Do not come within 2 ft. (610 mm) of the gun
nozzle or gun-mounted fluid regulator during
gun operation or until after following the Fluid
Voltage Discharge and Grounding Procedure.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 19
before checking or servicing the system
and whenever you are instructed to relieve the
pressure.
Damaged hoses or hoses that have a “pin-hole” dielectric failure, close to the end of the hose, can be repaired by cutting away the failed portion and restripping the hoses to the dimensions shown in Fig. 44.
1. Discharge the voltage as instructed on page 19.
5. Carefully cut through the outer hose jacket (H) and
peel it back about 12 inches (105 mm). Do not cut
into the conductive layer (J) of the hose.
6. Cut through the first 1/2 inch (12.7 mm) of the
conductive hose layer (J) to create an edge to hold
onto. Peel back the conductive hose layer by
unwrapping it in a spiral pattern. Cut it off at the
dimension shown in Fig. 44.
7. Cut off the inner hose layer (K) to the dimension
shown in Fig. 44.
8. Inspect the hose for any nicks or cuts. Any nicks
or cuts into the inner hose layer (K) will weaken
the dielectric strength of the hose and shorten the
service life. Repeat the above procedure if any
damage is found.
9. Install a new barbed fitting by applying red dielectric grease to the outside of the barbs, and pressing the fitting into the gun end of the hose. Refer to
the drawing of the Waterborne Fluid Hose Assembly on page 56.
10. Install the three o-rings on the barbed fitting.
11. Connect the fluid hose to the gun as instructed on
page 15.
Measurements, inches (mm)
A*
B*
C
D
7.75 + 0.1
(197 + 2.5)
9.375 + 0.1
(238 + 2.5)
5.1 + 0.1
(130 + 2.5)
6.85 + 0.1
(174 + 2.5)
* The measurements specified are for use with the Graco
H2O PRO Voltage Block isolation system.
2. Relieve the system pressure as instructed on page
19.
Isolation System End
Spray Gun End
B
D
3. Disconnect the fluid hose from the gun and voltage
isolation system.
4. Cut off the damaged end of the hose. If the hose
has a pin-hole failure, strip back the outer hose
jacket (H) and the conductive layer (J) about 12
inches (105 mm) on each hose end. Look for the
failure point, which will be a very small pin-hole,
discolored due to arcing. Continue stripping back
the hose until the failure point is found.
48
308496
A
K
Fig. 44
J
H
J
C
K
05495
Notes
308496
49
Spray Gun Parts
Part No. 237603 and 236824
Spray Gun
See below
28b
13
16
15
28
14
Item 23
Item 25
Item 27
Item 28
87
12
3
9
includes 23a–23g
includes 25a and 25b
includes 27a–27f
includes 28a–28h
1
27f
27b
2
25a
25
20
25b
30
24
27c
26
27
27a
See page 55 to
order the parts
75
22
23e
18
17
23f
23d
29
23c
23b
11
7
6
23g
23a
04326B
REF NO. 28,
Packing Rod Assembly
Includes items 28a–28h
28g
28c
28d
28f
28e
36
21
28a
28h
19
46
0601
50
308496
Spray Gun Parts
WARNING
EQUIPMENT MISUSE HAZARD
Use only genuine Graco replacement parts. Using
non-Graco parts could alter the gun’s grounding
continuity or cause parts to rupture or fail, which
could result in a serious injury and property
damage.
Part No. 237603 Spray Gun
Includes items 1 to 87
Part No. 236824 Spray Gun
Includes items 1 to 46, 76–87
Ref.
No.
Part No.
Description
1
2**
3
6
7
9
11
12
189768
189770
189786
189367
185122
110492
185111
193033
13
14
186615
191834
15
16*
17
18*
19
20
21
22*
23
223977
111507
237506
102982
186766
185113
112689
111316
236826
23a
23b
23c
23d
23e
23f
111508
111504
112319
189355
189747
189752
23g
24
25
189754
185096
222319
25a
25b
110073
185124
RETAINING RING, air cap
1
SHROUD
1
GASKET, air cap nut
1
CAP, exhaust
1
MUFFLER/FLAME ARRESTOR
1
O-RING, PTF 1
SPRING, compression
1
E
AIR CAP; See Manual 307803 for
other air caps
1
NEEDLE, electrode
1
NOZZLE, fluid
1
See Manual 307803 for other nozzles
STUD, resistor
1
O-RING, fluoroelastomer
1
FITTING, fluid
1
O-RING; PTF
1
ARM, actuator
1
E
GASKET, manifold; polyethylene
1
SCREW, socket; 1/4 x 0.75”
1
O-RING, fluoroelastomer
1
PISTON ASSY.;
Includes items 23a–23g
1
O-RING; fluoroelastomer
1
O-RING; fluoroelastomer
2
O-RING; fluoroelastomer
2
STEM, piston
2
PISTON
1
PACKING, u-cup; ultra high molecular
weight polyethylene
1
ROD, piston
1
SCREW, cap, relieved; M5 x 0.8
3
ALTERNATOR, turbine
Includes items 25a and 25b
1
O-RING, Viton
1
CUSHION
1
Qty.
Ref.
No.
Part No.
Description
26
27
223940
237250
27a
27b
27c
27f
28
186840
185099
185145
192361
224747
28a
28b
28c
28d*
28e
28f*
28g*
28h*
29
30
31
185495
223981
185488
186069
178763
178409
111504
111316
190055
185114
112638
36
46
75
102025
101324
237553
77
78
80
83
84
85
86
87
107460
186118
217115
191744
179791
189888
290171
290069
BARREL, gun
POWER SUPPLY ASSY.; 60 kV
Includes items 27a–27f
GASKET
PAD
PAD
PAD
PACKING ROD ASSY.
Includes items 28a–28h
HOUSING, packing
ROD, fluid
NUT, packing
SPACER, packing
PACKING, rod
PACKING, fluid
O-RING, fluoroelastomer
O-RING, fluoroelastomer
BODY, gun
RETAINER RING, alternator
FITTING, fiber optic (shown on
page 54)
NUT, hex; 1/4”–20
NUT, hex jam; 1/4”–20
MANIFOLD ASSY.; 237603 only;
See separate parts list on page 55
WRENCH, ball end
SIGN, warning, spray area, English
GREASE, dielectric, tube
MULTI-TOOL
TAG, warning
COVER, gun
SIGN, warning English
LABEL, warning
Qty.
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* These parts are included in Fluid Seal Repair Kit 237765,
which may be purchased separately. This kit also includes the fluid hose o-rings; refer to page 56.
These parts are included in Air Seal Repair Kit 236827,
which may be purchased separately.
** Order the warning label 290069 (item 87), at no cost,
when ordering the shroud. Affix the label to the shroud.
These parts are not shown in the parts drawing.
Replacement Warning labels, tags, and signs are available at no cost.
308496
51
Spray Gun Parts
Part No. 238091 Spray Gun
See below
28b
13
16
28
15
14
87
12
Item 23 includes 23a–23g
Item 25 includes 25a and 25b
Item 27 includes 27a–27f
Item 28 includes 28a–28h
3
9
1
27f
27b
2
25a
25
20
25b
30
24
27c
26
27
27a
See page 55 to
order the parts
75
90
17
See page 46 to
order the parts
23e
23f
23d
23c
23b
11
7
6
23g
05431B
23a
29
REF NO. 28,
Packing Rod Assembly
Includes items 28a–28h
28g
28c
28d
28f
28e
21
28a
46
19
36
89
88
28h
0601
52
308496
Spray Gun Parts
WARNING
EQUIPMENT MISUSE HAZARD
Use only genuine Graco replacement parts. Using
non-Graco parts could alter the gun’s grounding
continuity or cause parts to rupture or fail, which
could result in a serious injury and property
damage.
Part No. 238091 Spray Gun
Includes items 1 to 90
Ref.
No.
Part No.
Description
1
2**
3
6
7
9
11
12
189768
190905
189786
189367
185122
110492
185111
193033
13
14
186615
191832
15
17
223977
238039
18*
19
20
21
23
102982
186766
185113
112689
236826
23a
23b
23c
23d
23e
23f
111508
111504
112319
189355
189747
189752
23g
24
25
189754
185096
222319
25a
25b
26
110073
185124
223940
RETAINING RING, air cap
1
SHROUD
1
GASKET, air cap nut
1
CAP, exhaust
1
MUFFLER/FLAME ARRESTOR
1
O-RING, PTF 1
SPRING, compression
1
E
AIR CAP; See Manual 307803 for
other air caps
1
NEEDLE, electrode
1
NOZZLE, fluid; See Manual 307803
for other nozzles
1
STUD, resistor
1
REGULATOR, fluid; See separate parts
list on page 46
1
O-RING; PTF
1
ARM, actuator
1
E
GASKET, manifold; polyethylene
1
SCREW, socket; 1/4 x 0.75”
1
PISTON ASSY.;
Includes items 23a–23g
1
O-RING;
1
O-RING; fluoroelastomer
1
O-RING; fluoroelastomer
1
STEM, piston
2
PISTON
1
PACKING, u-cup; ultra high molecular
weight polyethylene
1
ROD, piston
1
SCREW, cap, relieved; M5 x 0.8
3
ALTERNATOR, turbine
Includes items 25a and 25b
1
O-RING, Viton
1
CUSHION
1
BARREL, gun
1
Qty.
Ref.
No.
Part No.
Description
27
237250
27a
27b
27c
27f
28
186840
185099
185145
192361
224747
28a
28b
28c
28d*
28e
28f*
28g*
28h*
29
30
31
185495
223981
185488
186069
178763
178409
111504
111316
238097
185114
112638
36
46
75
102025
101324
237553
77
78
80
83
84
85
86
87
88
89
90
107460
186118
217115
191744
179791
189888
290171
290069
190899
111328
054730
POWER SUPPLY ASSY.; 60 kV
Includes items 27a–27f
1
GASKET
1
PAD
1
PAD
2
PAD
1
PACKING ROD ASSY.
Includes items 28a–28h
1
HOUSING, packing
1
ROD, fluid
1
NUT, packing
1
SPACER, packing
1
PACKING, rod
1
PACKING, fluid
1
O-RING, fluoroelastomer
1
O-RING, fluoroelastomer
1
BODY, gun
1
RETAINER RING, alternator
1
FITTING, fiber optic (shown on
page 54)
1
NUT, hex; 1/4”–20
1
NUT, hex jam; 1/4”–20
1
MANIFOLD ASSY.; See separate parts
list on page 55
1
WRENCH, ball end
1
SIGN, warning, spray area, English
1
GREASE, dielectric, tube
1
MULTI-TOOL
1
TAG, warning
1
COVER, gun
1
SIGN, warning English
1
LABEL, warning
1
ADAPTER
1
FITTING, tube
1
TUBING, air; 5/32 O.D.
Qty.
* These parts are included in Fluid Seal Repair Kit 237765,
which may be purchased separately. This kit also includes the fluid hose o-rings; refer to page 56.
These parts are included in Air Seal Repair Kit 236827,
which may be purchased separately.
** Order the warning label 290069 (item 87), at no cost,
when ordering the shroud. Affix the label to the shroud.
These parts are not shown in the parts drawing.
Order the length of tubing needed.
Replacement Warning labels, tags, and signs are available at no cost.
308496
53
Manifold Parts
101
106
121
108
111 109
102
104 105
103
Front View
119
106
115 04323
31 REF. 101
112
114
113 120
107
116 118
117
Back View
54
308496
04322
Apply low strength (purple) Loctite or an equivalent sealant to the threads.
Apply high strength (green) Loctite or an
equivalent sealant to the threads.
Tighten the fitting until the hex bottoms against
the manifold.
This fitting (113) has left-hand threads.
Install the kV cap (111) flush to the outside
surface.
An optional fiber optic fitting (31) is included with
the gun assembly; see page 51. Remove the
plug (115) and install the fitting (31) if a kV
display is being used.
Press fit the spring (105).
Manifold Parts
Part No. 236852 Optional Fiber Optic Kit
The kit is not included with the gun. The kit is only for
use with the ES Display Part No. 224117 to improve
light transmission when two bulkhead splices are used.
The kit includes items 201203.
WARNING
EQUIPMENT MISUSE HAZARD
Use only genuine Graco replacement parts. Using
non-Graco parts could alter the gun’s grounding
continuity or cause parts to rupture or fail, which
could result in a serious injury and property
damage.
Part No. 237553 Gun Manifold
Includes items 101–121.
Ref.
No.
Part No.
Description
101
102
103
104
105
106
107
108
109
111
112
113
192095
189581
110465
112689
112640
186846
111157
189363
108290
189365
110078
186845
114
115
116
117
118
119
120
121 107107
112645
112646
190220
190219
290068
290069
190301
MANIFOLD
MOUNTING BRACKET
BOLT, square head
SCREW; 1/4–20 x 0.75”
SPRING, compression
BOLT, manifold; M5 x 0.8
FITTING, tube; for 1/4” O.D. tube
GASKET, manifold
SCREW; 8–32 x 1/4”
kV CAP
FITTING, tube; for 3/8” O.D. tube
FITTING, turbine; 1/4”–18 npsm
left-hand thread
REGULATOR, disk
PLUG; 1/8”–27 npt
PLUG; 5/8–18 x 5/8”
NUT, strain relief
FITTING, strain relief
LABEL, caution
LABEL, warning
GASKET, foam
Ref.
No.
Part No.
Description
201
112638
202
203
111224
189875
FITTING, fiber optic; see item 31 on
page 54
LENS
SLEEVE
Qty.
1
1
1
Qty.
1
1
2
2
1
3
2
1
2
1
1
202
203
1
1
2
1
1
1
1
1
1
04485
These parts are included in Air Seal Repair Kit 236827,
which may be purchased separately.
Optional gaskets are available:
Part No. 111180:
Viton
Part No. 111333: Ethylene Propylene
Replacement Warning labels are available at no cost.
308496
55
Accessories
Use Only Genuine Graco Parts and Accessories
Hoses for use with non-Graco voltage
isolation systems**:
Waterborne Fluid Hoses
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
For connection between the voltage isolation system
and the spray gun; 0.25 in. (6.35 mm) I.D.; PTFE Fluid Hose
Assy. Part No.
Hose Length
237545
25 ft. (7.6 m)
237546
50 ft. (15.2 m)
Shielded Hoses for use with the Graco H2O PRO
Voltage Block:
Fluid Hose
Assy. Part No.
Hose Length
237920
25 ft. (7.6 m)
237921
36 ft. (11 m)
237922
50 ft. (15.2 m)
Fluid Hose Replacement Parts
For fluid hoses 237920/921/922
Ref.
No.
Part No.
Description
301*
302
111450
190143
Fluid Hose Replacement Parts
For fluid hoses 237545/546
Ref.
No.
Part No.
Description
301*
302
303
111450
190143
112480
O-RING
BARBED FITTING
SWIVEL FITTING
3
1
1
303
Qty.
O-RING
BARBED FITTING
Qty.
3
1
*301
302
*301
Waterborne Fluid Hose
04324
302
*
05342
*
The three o-rings are included in Fluid Seal Repair Kit
237765.
Unshielded Hoses for use with the Graco H2O PRO
Voltage Block:
Bare PTFE fluid hoses, without the ground shield. See
Manual 308688 for information on the hoses.
Fluid Hose
Assy. Part No.
Hose Length
238877
25 ft. (7.6 m)
238878
50 ft. (15.2 m)
Hoses for use with Graco Fenced Isolation
System:
56
Fluid Hose
Assy. Part No.
Hose Length
237548
25 ft. (7.6 m)
237549
36 ft. (11 m)
237550
50 ft. (15.2 m)
308496
The three o-rings are included in Fluid Seal Repair Kit
237765.
** The Graco warranty is void if the spray gun is connected
to a non-Graco voltage isolation system.
Accessories
Use Only Genuine Graco Parts and Accessories
Electrically Conductive Air Hoses
Fluid Regulator Conversion Kit 238147
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
To add a fluid regulator to the part no. 237603 and
236824 PRO 5500wb spray guns. See page 47 for kit
installation instructions.
For connection between the air supply and the spray
gun; conductive, stainless steel, wire braid for grounding; polyurethane tube and cover; 0.315 in. I.D.; 1/4
npsm(f) x 1/4 npsm(f) left-hand thread; the hose is
color-coded red
Gun High Voltage Probe & Meter 217452
For direct measurement of the gun output voltage.
Megohmmeter 241079
Hose Part No.
Hose Length
235068
6 ft. (1.8 m)
235069
15 ft. (4.6 m)
235070
25 ft. (7.6 m)
235071
36 ft. (11.0 m)
235072
50 ft. (15.2 m)
235073
75 ft. (23.0 m)
235074
100 ft. (30. 5 m)
500 Volt output; 0.01–2000 megohms.
Not for use in Hazardous areas.
TI0377
Grounding Rod 210084
For use in the Fluid Voltage Discharge and Grounding Procedure.
308496
57
Technical Data
Category
Data
Category
Data
Maximum Working
Pressure
100 psi (0.7 MPa, 7 bar)
Maximum Fluid
Temperature
120F (49C)
Air Pressure Operating
Range
0–100 psi (0–0.7 MPa,
0–7 bar)
Wetted Parts
Fluid Pressure Operating
Range
0–100 psi (0–0.7 MPa,
0–7 bar)
Stainless Steel, Nylon,
Acetal, PTFE , Kalrez,
Ceramic, Chemraz,
Fluoro-polymer
Voltage Output
0–60 kV*
Short Circuit Current
Output
120 mA
Turbine Air Inlet
1/4 npsm(m), left-hand
Fluid Inlet
custom inlet for Graco
waterborne fluid hose
Maximum Noise Level
with atomization air at
100 psi (0.7 MPa, 7 bar)
and maximum air flow
Sound Pressure
Sound Power Sound pressure was measured per Cagi Pneurop, 1969.
The measurement was taken 3.28 feet (1 meter) from the
air cap.
Weight (gun and
manifold)
Part No. 237603
Part No. 238091
Fluid Specification
101.5 Db(A)
107.0 Db(A)
3.6 lb (1620 g)
4.0 lb (1818 g)
For use with fluids that
meet at least one of the
following conditions for
non-flammability:
The fluid has a flash
point above 140F
(60C) and a maximum organic solvent
concentration of 20%,
by weight, per ASTM
Standard D93.
The fluid does not
sustain burning when
tested per ASTM
Standard D4206 Sustained Burn Test.
Sound power was measured per ISO–3744, 1981.
*
Do not exceed 60 kV. Operating the gun above 60 kV will
void the Graco warranty. The gun’s normal high voltage
reading is 45 to 55 kV due to spraying current demands
and isolation system losses.
PTFE , Viton, and Kalrez are registered trademarks
Loctite is a registered trademark of the Loctite Corporation.
Chemraz is a registered trademark of the Green, Tweed, &
Company.
Manual Change Summary
This manual has been changed per ECO’s V5645, V481, and V389203.
58
308496
Notes
308496
59
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
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned 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 WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
www.graco.com
PRINTED IN U.S.A. 308496 January 1995, Revised November 2000
60
308496

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