Graco 308496D AUTOMATIC, 60 kV, ELECTROSTATIC,Model PRO 5500wb Air Spray Gun Owner's Manual

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Graco 308496D AUTOMATIC, 60 kV, ELECTROSTATIC,Model PRO 5500wb Air Spray Gun Owner's Manual | Manualzz

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

308–496

Rev. D

Supersedes C

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 140 F (60 C) and a maximum organic solvent concentration of

20%, by weight, per ASTM Standard D93.

2. The fluid does not sustain burning when tested per

ASTM Standard D4206 Sustained Burn Test.

Part No. 237–603*, Series A

Includes the spray gun, shroud, manifold, and mounting bracket.

Part No. 236–824, Series A

Includes the spray gun and shroud only.

Part No. 238–091, Series A

Includes the spray gun, shroud, manifold, regulator, and mounting bracket.

NOTE: The fluid hose must be ordered separately.

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

Part No. 237–603

Part No. 238–091

04299

05928

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 . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . . . .

Install the Air Line Accessories . . . . . . . . . . . . . . . .

Install the Gun and Mounting Bracket . . . . . . . . . .

11

11

9

9

9

Connect the Air Lines . . . . . . . . . . . . . . . . . . . . . . . .

Optional Fiber Optic Cable Connection . . . . . . . . .

Optional Fiber Optic Lens Kit Installation . . . . . . .

Install the Fluid Hose

Ground the System

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding

Install the Fabric Cover

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

12

13

14

15

17

18

18

Operation

Fluid Voltage Discharge & Grounding Procedure 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 19

Operating Checklist . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Fluid Nozzle and Air Cap . . . . . . . . . .

Operating the Spray Gun . . . . . . . . . . . . . . . . . . . . .

20

20

20

Maintenance

Daily Care and Cleaning . . . . . . . . . . . . . . . . . . . . .

Clean the Air Cap and Fluid Nozzle . . . . . . . . . . . .

Check for Fluid Leakage . . . . . . . . . . . . . . . . . . . . .

23

24

25

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. 238–039 Fluid Regulator Repair . . . . . . .

Part No. 238–147 Fluid Regulator Conversion

Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Waterborne Fluid Hose Repair . . . . . . . . . .

38

39

41

42

43

35

35

36

37

44

44

46

47

48

Spray Gun Parts

Part No. 237–603 and 236–824

Part No. 237–091

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

50

52

Manifold Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Numbers . . . . . . . . . . . . . . .

Back Cover

Back Cover

Symbols

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 . . . . . . . . . . . . . . . . . . . . . . . .

Test Power Supply Resistance . . . . . . . . . . . . . . . .

Test Resistor Stud Resistance . . . . . . . . . . . . . . . .

33

34

34

Warning Symbol

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.

2 308–496

ELECTRIC SHOCK HAZARD

WARNING

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.

308–496 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.

4 308–496

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.

237–250, 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 180 F (82 C) or below –40 F (–40 C).

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.

308–496 5

Introduction

Spraying Waterborne Fluids

Electrostatically

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 H 2 O 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

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.

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. 238–091 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.

6 308–496

F

Introduction

TA

CYL

A1

P1

F.O.

A2

EXH

(PA)

Manifold Back View

04302

A C D E

04299

H

J

B

G

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

A2

Atomization Air Inlet Fitting

Fan Air Inlet Fitting

CYL Cylinder Air Inlet Fitting

EXH (PA) Shroud Exhaust Outlet or Pilot Air Inlet Fitting

F.O.

P1

TA

KV

P2

Fiber Optic Fitting

Fluid Supply Inlet Fitting

Turbine Air Inlet Fitting not used not used

04482

308–496 7

Introduction

Gun Features and Options

(Refer to page 7)

D 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.

This fluid hose consists of three layers (see Fig. 1):

D Inner Hose Layer (EE): is a PTFE r tube.

D Conductive Hose Layer (DD): covers the tube.

PTFE

D 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.

D The gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids. Refer to Fig. 2, page 10.

D 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. 224–117, is available and will display the gun’s spraying voltage and current. A battery operated ES Display Module, part no.

189–762, is also available; it displays the gun’s spraying voltage only. Refer to Fig. 3, page 10.

D Part no. 238–091 spray gun has a fluid regulator located at the gun barrel inlet. The fluid regulator provides precise fluid control.

D Outer Hose Jacket (FF): is a protective polyethylene hose cover.

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 Conductive Hose Layer

EE Inner Hose Layer

FF Outer Hose Jacket

CC Grounded Enclosure

The portion of the inner hose layer (EE– PTFE tube) that is not covered by the conductive hose layer (DD), 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).

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.

EE DD

CC

FF

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.

Fig. 1

H 2 O PRO Voltage Block connection shown

05179

8 308–496

Installing the System

Installation

WARNING

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.

Do not install or service this equipment unless you are trained and qualified.

Comply with all local, state, and national codes for the installation of electrical apparatus in a

Class , 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.

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 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. 186–118 and

290–171, 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

Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun,

Form No. 305–678.

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.

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.

Electrically interlock the gun turbine air supply with the ventilators to prevent operation of the electrostatic power supply unless the ventilating fans are on.

The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.

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).

308–496 9

Installation

P Q

M

Non-Hazardous Area

K

K

L

N

Hazardous Area

A

E

D

C

M R

B

S

* TA

*

*

A1

A2

CYL

EXH (PA)

* P1

F

G

Fig. 2

Non-Hazardous Area Hazardous Area

W

Z T U kV m A

X

V kV

AA

Fig. 3

KEY

A Ground Wire on Graco Electrically Conductive Air Hose

B Graco Electrically Conductive Air Hose (Turbine Air Hose),

P/N 235–068 to 235–074, 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 H 2 O PRO Voltage Block Isolation System

H PRO 5500wb Spray Gun

J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189–581

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 237–603 or Pilot Air Line for

Gun P/N 238–091; 1/4 inch (6.4 mm) O.D.

10 308–496

* F.O.

BASIC SYSTEM

J

H

SYSTEM OPTION

ES Display Module

Y

04300

S Check Valve

T Fiber Optic Cable, P/N 224–680 to 224–686

U Bulkhead, P/N 189–870

V Fiber Optic Cable, P/N 224–670 to 224–676

W 24 Volt Power Supply, P/N 235–301

X 4–20 mA Outputs

Y PRO 5500wb Spray Gun

Z Full Feature ES Display Module, P/N 224–117

AA kV Only ES Display Module (battery operated), P/N 189–762

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.

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.

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.

B

A = 2 in. (51 mm)

B = 4 in. (102 mm)

Fig. 4

A A A

05937

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.

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.

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.

103

0.50 in.

(12.7 mm) rod

Fig. 5

103

9.32 in.

(236.7 mm)

04301

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

Fig. 6

CC

03460

308–496 11

Connect the Air Lines

Installation

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:

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.

Manifold Connections (See Fig. 7)

A1

A2

CYL

Atomization Air Inlet Fitting

Connect a 3/8 inch (9.5 mm) O.D. tube between the fitting and the air supply.

Fan Air Inlet Fitting

Connect a 3/8 inch (9.5 mm) O.D. tube between the fitting and the air supply.

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)

F.O.

P1

TA

Shroud Exhaust Outlet or Pilot Air Inlet Fitting

If using part no. 238–091 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. 237–603 or 236–824 spray gun, connect a 1/4 inch O.D. (6.4 mm) x 4 foot (1.22

m) long exhaust tube to the fitting.

Fiber Optic Fitting (Optional)

Connect the Graco Fiber Optic Cable as instructed on page 13.

Fluid Supply Inlet Fitting

Connect a Graco waterborne fluid supply hose as instructed on page 15.

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.

F.O.

TA

CYL

A1

A2

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.

P1

EXH

(PA)

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.

Fig. 7

Manifold Back View

04302

12 308–496

Installation

Optional Fiber Optic Cable Connection

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.

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 124

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.

Fig. 9

FF

04306

Fig. 8

124

115

04305

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.

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.

5. See manual 308–265 to install a Graco ES Display

Module.

308–496 13

Installation

Optional Fiber Optic Lens Kit Installation

NOTE: The fiber optic lens kit is not included with the gun. Order it separately; the part number is 236–852.

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.

JJ

HH

GG

Fig. 11

JJ

GG

HH

KK

04485

04484

Fig. 10

14 308–496

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.

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.

Before connecting the fluid supply line to the gun, blow it out with air, and flush it with water to remove contaminants.

Apply a light coat of dielectric grease to the o-rings (G) and the entire length of the inner hose layer (K)

G

Minimum:

6.85 in.

(174 mm)

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.

H

Fig. 12

J K

Spray Gun

Hose End

04303

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

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.

Fig. 13

P1

L

H

04304

308–496 15

Installation

Install the Fluid Hose (continued)

5. Insert the hose into the fluid inlet fitting (P1). See

Fig. 14.

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.

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.

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

G

WARNING

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.

ÇÇÇÇÇÇ

ÇÇÇÇÇÇ

Fig. 14

P1 J L

05927

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.

16 308–496

Install the Fluid Hose (continued)

K H

Installation

Fig. 15

R

Ground the System

R

K

WARNING

DETAIL

J

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

H 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.

H 2 O 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

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.

308–496 17

Installation

Check the Electrical Grounding

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.

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.

Install the Fabric Cover

(Part No. 237–603 and 236–824 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.

P

Q

AA

BB

04308

M

04307

Fig. 17

BB

Manifold Back View

04309

Fig. 16

N

18 308–496

Operation

Fluid Voltage Discharge and Grounding

Procedure

Pressure Relief 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.

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.

NOTE: An accessory grounding rod, part no. 210–084, is available to discharge any voltage remaining on a system component. Contact your Graco representative to order it.

3. Turn off the fluid supply to the gun.

1. Turn off the turbine air to all of the spray guns connected to the isolated fluid supply.

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.

2. Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual.

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.

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 Trouble-

shooting, page 29, or the voltage isolation system manual for other possible problems. Resolve the problem before proceeding.

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.

308–496 19

Operation

Operating the Spray Gun 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.

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.

____ 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. 237–603 and 236–824 spray guns are supplied with a 0.07 inch (1.8 mm) fluid nozzle, part no. 191–834. Part no. 238–091 spray gun is supplied with a 0.047 inch (1.2 mm) fluid nozzle, part no.

191–832. The air cap for all the guns is part no.

177–033. If your application requires a different nozzle and air cap combination, see instruction manual

307–803 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.

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 Proce-

dure.

Do not use the Graco ES Display Module readings to determine if your system is discharged. Follow the Fluid Voltage Dis-

charge 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.

20 308–496

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. 237–603 and 236–824 Spray Guns:

Pressurize the fluid supply, and adjust the fluid flow with the fluid pressure regulator installed in the fluid line.

CAUTION

If any fluid leakage from the gun is detected, stop spraying immediately. See Check for Fluid Leak-

age, page 25.

Part No. 238–091 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.

1. Complete all the checks under the Operating

Checklist on page 20.

NOTE: The fluid regulator has a air bleed hole in the cover, which will emit some air leakage.

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.

Vertical Pattern

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.

See Spray Pattern Troubleshooting on page 32 to correct spray pattern problems.

Horizontal Pattern

F.O.

02020

TA

Fig. 18

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.

A1

A2

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.

P1

EXH

(PA)

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.

Fig. 19

Manifold Back View

04302

Continued on the next page.

308–496 21

Operation

Operating the Spray Gun (continued)

10. Check the voltage output of the gun using a high voltage probe and meter or by reading the ES (kV)

Display Module.

Activating and Adjusting the Electrostatics

8. Make sure the fan (A2) and atomizing (A1) air are on, then turn on the turbine air (TA).

NOTES:

The gun’s normal high voltage reading is 45 to 55 kV due to spraying current demands and isolation system losses.

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.

See Voltage Loss Troubleshooting on page 26 to correct voltage problems.

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.

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

15 ft. (4.6 m)

25 ft. (7.6 m)

50 ft. (15.3 m)

75 ft. (22.9 m)

100 ft. (30.5 m)

Dynamic pressure at the turbine hose inlet required for full voltage

36 psi (251 kPa, 2.5 bar)

38 psi (265 kPa, 2.6 bar)

40 psi (280 kPa, 2.8 bar)

42 psi (294 kPa, 2.9 bar)

45 psi (314 kPa, 3.1 bar)

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.

22 308–496

Daily Care and Cleaning

Maintenance

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.

Do not flush with the turbine air (TA) to the gun turned on.

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.

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.

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.

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.

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.

4. Check the electrode wire. Straighten it if it is bent and replace it if it is broken or damaged. See page 37.

Do not immerse the gun in fluid.

04311

Do not wipe the gun with a cloth that is heavily saturated; wring out the excess fluid.

04310

02027

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.

7. Flush the gun before changing colors and whenever you are done operating the gun.

308–496 23

Maintenance

Clean the Air Cap and Fluid Nozzle

Equipment needed:

Soft bristle brush

Non-flammable cleaning fluid

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.

03511

CAUTION

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.

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

2. Remove the air cap assembly (1, 12) and gun shroud (2). See Fig. 20.

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.

Fig. 20

12

1

13

14

04312

24 308–496

Maintenance

Check for Fluid Leakage (See Fig. 21)

CAUTION

If any fluid leakage from the gun is detected, stop spraying immediately.

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.

WARNING

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.

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.

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.

Fig. 21

N

Q

Q

Check for the signs of fluid leakage where indicated by the arrows and in the air pilot line (not shown) if used.

04308

N

Manifold Back View

04309

308–496 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 Ground-

ing 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.

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. 236–003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow.

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.

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.

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:

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.

26 308–496

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.

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.

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

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.

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.

8. Flush the fluid hose and gun with enough air to dry out the fluid passages.

9. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.

1. Flush the system with water and leave the lines filled with water.

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.

308–496 27

Troubleshooting

Voltage Loss Troubleshooting (continued)

Fluid packings

11. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing.

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 occuring along the packing rod.

Fluid hose

Fluid hose connection joint to the spray gun

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 ouside of the PTFE portion of the fluid tube.

Inspect the end of the hose connected to the voltage block. Look for cuts or nicks.

Make sure the hose is properly stripped; see

Fig. 12, page 15, for hose stripping dimensions. Restrip or replace the hose.

Poor Electrostatic Wrap Troubleshooting

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.

14. Check the gun voltage with the voltage probe and meter before filling the gun with fluid.

Problem

The system is holding voltage but the part being sprayed

Cause

The distance between the gun and workpiece is incorrect.

The parts are poorly grounded.

Booth exhaust velocity is too high.

The atomizing air pressure is too high.

The fluid pressure is too high.

The fluid viscosity is not right for electrostatic spray.

Solution

Adjust the spraying distance to 8 to

12 inches (203 to 305 mm).

Clean the workpiece hangers; check for proper grounding on the conveyor or track.

Reduce the exhaust velocity within the code limits.

Reduce the atomizing air pressure.

Reduce the fluid pressure.

Check with the supplier for proper fluid viscosity for electrostatic spray.

28 308–496

Troubleshooting

Electrical Troubleshooting

Problem

Voltage is still present at the gun after following the Fluid Voltage

Discharge and Grounding Procedure

Cause

Gun electrostatics (turbine air) are not turned off.

The operator gets a shock

The operator gets a shock when touching the workpiece

No or low voltage output reading on the gun ES (kV) display module

Solution

Turn off the gun electrostatics.

Did not wait long enough for the voltage to discharge through the voltage bleed resistor.

There is an air pocket in the fluid line that leaves the fluid near the gun isolated.

Voltage isolation system failed.

The operator is not properly grounded or is near an ungrounded object.

The gun is not properly grounded.

The workpiece is not properly grounded.

The fiber optic cable or connection is damage.

The turbine air is not on.

Wait a longer period of time before touching the electrode with a grounded rod. Check for possible bleed resistor failure.

Determine the cause of the air pocket and fix the problem. Purge the air out of the fluid line.

See the isolation system manual for service information.

Be sure the floor and the operator are properly grounded; see Ground the

System, page 17.

See Check the Electrical Ground-

ing, page 18.

Clean the workpiece hangers; check for proper grounding on the conveyor or track

Check the cables and connections; replace the parts if they are damaged.

Turn on the turbine air.

308–496 29

Troubleshooting

Gun Operation Troubleshooting

Problem

Fluid leakage from the fluid packing area gun

“Orange Peel” finish

Excessive spray fog

No fluid sprays from the gun

The equipment is covered with

Cause

The fluid rod packings or fluid rod are worn.

The fluid seat is worn.

Solution

Replace the packings or rod; see page 38.

Replace the fluid rod; see page 38.

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.

The fluid is poorly mixed or filtered.

An improper thinner is being used.

The air pressure is too high.

Increase the air cap air pressure by increasing the gun air inlet pressure; use the least air pressure needed for good results.

Remix or refilter the fluid.

Use the proper thinner.

Reduce the air cap air pressure by decreasing the gun air inlet pressure; use the least air pressure needed for good results.

Properly thin the fluid.

The fluid is thinned too much.

The fluid supply is low.

The fluid nozzle is dirty or clogged.

The fluid nozzle is damaged.

The piston is not actuating.

The actuator arm is out of position.

The exhaust air flow is insufficient or not directed properly.

The distance between the gun and workpiece is incorrect.

The electrode is bent.

Check the fluid supply; add fluid if necessary.

Clean the fluid nozzle; see page 24.

Replace the fluid nozzle; see page

36.

Check the cylinder air; check the piston u-cup; see page 39.

Check the actuator arm and nuts; see page 39.

Check for the proper CFM; check the baffles and direction of the air flow.

Adjust the spraying distance to 8 to

12 inches (203 to 305 mm).

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.

30 308–496

Troubleshooting

Gun Operation Troubleshooting (continued)

Problem

Dirty air cap

Air leakage from the air cap

Air leakage from the manifold

Fluid leakage at the quickdisconnect

Cause

The air cap and fluid nozzle are misaligned.

Air Cap

Solution

Check the air cap and fluid nozzle seat for fluid buildup. Clean or replace parts as needed; see page 24 or 36.

ALIGNED

Fluid Nozzle

MISALIGNED

The o-rings on the piston stem are worn.

The manifold gasket is damaged, or the manifold is not tight.

The manifold is not tight.

Inspect the o-rings; replace them as needed; see page 39.

Replace the gasket or tighten the manifold screws; see page 44.

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.

308–496 31

Troubleshooting

Spray Pattern Troubleshooting

NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.

Problem

Fluttering or spitting spray

Streaks

Cause

The fluid supply is insufficient.

The fluid nozzle is loose, or the fluid nozzle taper seat is damaged.

There is dirt between the fluid nozzle, taper seat, and gun body.

The coupler at the fluid inlet is loose or cracked.

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.

The electrode is bent.

The fluid nozzle or air cap holes are damaged.

There is fluid buildup on the perimeter of the fluid nozzle orifice, or a partially clogged fluid nozzle orifice.

The electrode is bent.

The fan air pressure is too high.

Solution

Adjust the fluid regulator, or fill the fluid supply.

Tighten or replace the fluid nozzle; see page 36.

Clean the parts; see page 24.

Tighten or repair the coupler.

Clean the air cap with a soft implement or submerge it in water and wipe it clean; see page 24.

Straighten the electrode.

Replace the damaged part; see page

36.

Remove the obstruction; never use wire or hard instruments; see page

24.

Straighten the electrode wire.

Reduce the fan air pressure.

The fluid is too thin.

There is not enough fluid pressure.

Reduce the fluid viscosity.

Increase the fluid pressure.

The fan air pressure is too low.

The fluid is too thick.

Increase the fan air pressure.

Reduce the fluid viscosity.

There is too much fluid.

The last coat of fluid is applied too wet.

There is too much air pressure.

The air pressure is insufficient.

The spray pattern is non-uniform.

Reduce the fluid flow.

Apply a drier finish using multiple strokes.

Decrease the air pressure.

Increase the air pressure.

Clean or replace the air cap; see page 24.

32 308–496

Electrical Tests

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.

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.

Remove the gun from the manifold and bracket, as instructed on page 35, before performing the electrical tests.

WARNING

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.

Test Gun Resistance

1. Prepare the gun for service as instructed on page 35.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

Megohmmeter P/N 218–979 (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;

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).

Failure to follow this warning could cause fire, explosion, electric shock and result in serious injury and property damage.

2. Measure the resistance between the end of the electrode (13) and the gun body (29). See Fig. 22.

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.

L

29

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.

Use megohmmeter (L), part no. 218–979, and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown.

13

Fig. 22

04313

308–496 33

Electrical Tests

Test Power Supply Resistance

1. Prepare the gun for service as instructed on page 35.

Test Resistor Stud Resistance

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.

2. Remove the resistor stud (15) as instructed on page 36.

3. Remove the turbine alternator (25) from the power supply as instructed on page 43.

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. Measure the resistance from the power supply’s ground contact point (R) to the contact inside of the power supply seal (27d) [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.

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.

L

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. 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

Fig. 23

27d 27

R

0441

Fig. 24

T

S

0442

34 308–496

Service

Tools Included with the Gun

Ball End Wrench

Multi-tool

Prepare the Gun for Service

NOTE:

Check all the possible remedies in Troubleshoot-

ing, pages 26 to 32, before disassembling the gun.

1. Discharge the voltage as instructed on page 19.

2. Flush the gun with a non-flammable cleaning fluid.

3. Relieve the system pressure as instructed on page

19.

NOTE: The service area must be clean. Remove the gun from the worksite as instructed in the following steps.

If the plastic parts of the gun must be held in a vise, use padded vise jaws to avoid damaging parts.

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.

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.

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 Proce-

dure.

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.

A

105

106

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.

Fig. 25

B

21

04314

308–496 35

Service

Air Cap/Nozzle/Resistor Stud

Replacement

Removal

1. Prepare the gun for service as instructed on page 35.

2. Point the front end of the gun up while removing the air cap assembly (1, 3, 9, 12). See Fig. 26.

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.

1, 3, 9, 12

83

1

9

3

12

CAUTION

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

15

13

S

14

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.

Fig. 26

03455A

Tighten the resistor stud (15) into the nozzle (14) to 10 in-lbs (1.13

N m).

83 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.

Fig. 27

14

15

0444A

36 308–496

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.

5. Install the fluid nozzle, resistor stud, and air cap as described on page 36.

2. Make sure the electrode needle (13) is tightened properly. Refer to Fig. 28.

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.

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.

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.

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).

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.

6. Test the gun resistance as instructed on page 33.

C

Apply low-strength (purple) Loctite or equivalent to the fluid rod threads, then install the electrode needle (13).

Fig. 28

13

83

04315A

308–496 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.

Use the following formula to calculate the best packing service interval for your application:

Service Interval in Days = 25,000

T x H

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.

28

83

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.

38 308–496

Service

Fluid Packing Rod Removal and Repair

(continued)

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.

11. Lubricate the o-ring (28h) on the outside of the packing housing (28a).

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.

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.

14. Install the electrode needle, nozzle and resistor stud assembly and the air cap assembly as instructed on page 37.

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.

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.

28b

28e

28f 28h 28a 28d

28g

28c

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).

U 11

28

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.

NOTE: The fluid nozzle must be in place when removing or installing the jam nut and actuator arm.

Fig. 31

03224

46 19 36 23g

04317

308–496 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.

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.

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.

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.

Fig. 33

23b

23c

23d

23a

23g

23f

23e

03530

Description Function

O-Ring (23a)

Shaft Air Seal

O-Ring (23b)

Front Air Seal

O-Ring (23c)

Back Air Seal

U-cup (23f)

Cylinder 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).

It is the air shut-off seal. If the air leaks from the air cap when the gun is detriggered, replace these o-rings.

It separates the cylinder air pressure from the fan and atomizing air pressure.

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).

U

23b

23c

Fig. 34

Fan Air Side

Atomization Air Side

23a

23f

03531

Fig. 32

46 19 36 23g

04823

40 308–496

Barrel Removal

1. Prepare the gun for service as instructed on page 35.

Service

4.

Part No. 238–091 Spray Gun: Disconnect the air pilot line from the fluid regulator fitting.

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

A

CAUTION

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.

NOTE: The fluid nozzle (14) must be in place when removing or installing the jam nut and actuator arm.

26

24

29

27

14

Fig. 36

46 19

04317

Fig. 37

04316

308–496 41

Service

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.

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.

Do not expose the seal (27d) or gasket (27a) to solvents as it will damage the parts.

5. Before installing the power supply, inspect the seal

(27d) for any damage or swelling. Replace the seal if necessary. Make sure the gaskets and pads

(27a–27e) are in place.

1. Prepare the gun for service as instructed on page 35.

2. Remove the barrel as instructed on page 41.

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.

6. Lubricate the o-ring (25a), and install the power supply (27) in the gun body (29).

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 (27d) or gasket (27a) to solvents.

27a

27

27b

W

27e

30

29

27c

26

27d

V

25b

25a

25

04320

Fig. 38

42 308–496

Turbine Alternator Removal and

Replacement

Service

NOTE: Replace turbine bearings after 2,000 hours of operation. See your authorized Graco representative.

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.

1. Prepare the gun for service as instructed on page 35.

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.

2. Remove the barrel as instructed on page 41.

3. Remove the power supply as instructed on page 42.

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.

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.

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.

308–496 43

Service

Install the Gun onto the Manifold Barrel Installation

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.

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.

3. Install the fluid tube (17) into the gun body (29).

2. Make sure the fluid hose PTFE r tube (A), which inserts into the gun, and the gun fluid tube (17) opening are clean. 4. Using the ball end wrench (77– not shown), tighten the three screws (24) oppositely and evenly to 18 in-lbs (2 N S m) maximum (about a half turn past snug); do not over-tighten the screw.

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

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.

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. 238–091 Spray Gun: Connect the air pilot line to the fluid regulator fitting.

Tighten the screws (24) to 18 in-lbs (2 N S 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

20

27

27a

4. Align the gun (B) and slide it onto the PTFE tube

(17) until the gun meets the manifold (101). See

Fig. 41.

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).

46

19

23g

36

17

6. Secure the gun (B) to the mounting bracket (102) by tightening the screw (21) with the ball end wrench (77).

13

Fig. 39

11

04318

44 308–496

Service

Install the Gun onto the Manifold

(continued)

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.

P1 D

WARNING

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.

C

P1

ÇÇÇÇÇ

ÇÇÇÇÇ

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.

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.

B

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.

121

108

105

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

E

2

101

D

1

9 102

A

12

17

21

13

Fig. 41

04321

308–496 45

Service

Part No. 238–039 Fluid Regulator Repair

NOTE: The fluid regulator is item 17 in the parts list for the part no. 238–091 spray gun. It is not included with part no. 237–603 and 236–824 spray guns. A Conversion Kit is available to add the fluid regulator to those spray guns. See page 47.

5. Replace the o-rings, seat, ball bearing, and diaphragm with the parts included in the Regulator

Repair Kit, part no. 238–148.

6. Be sure all the parts are clean and dry, then re-assemble the regulator.

1. Prepare the gun for service as instructed on page 35.

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.

4. Disassemble the regulator parts as shown in

Fig. 42.

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.

8. Install the barrel on the gun body as instructed on page 44.

9. Install the gun onto the manifold as instructed on page 44.

Make sure the seat (408) is aligned with the regulator body (401) threads to avoid cross-threading.

PTFE side of diaphragm (413) faces up, toward body (401).

Tighten the cover (402) firmly

406 411*

403

*404 *418 405

Fig. 42

413*

407*

402

420

421

410

409*

415*

408*

401

412

05931

Fluid Regulator Parts List

Includes items 401 to 418

Ref.

No.

401

Part No.

Description

238–037 BODY ASSY.

402

403

404*

405

190–868 COVER

109–193 ELBOW, tube fitting

111–316 O-RING, fluoroelastomer

190–872 OUTLET FITTING

406 190–871 OUTLET STEM

407* 110–497 O-RING, Viton r

408* 188–944 SEAT

409* 102–922 BALL BEARING

410 112–204 SPRING, compression

411* 111–450

412

420

421

238–215

191–406

113–522

O-RING, CV–75

ACTUATOR

413* 187–168 DIAPHRAGM

415* 107–505 O-RING,

418* 102–982 O-RING,

COVER

PTFE

PTFE r

SCREW, 1/4–20

* These parts are included in Repair Kit 238–148, which may be purchased separately .

Qty.

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

46 308–496

Service

Part No. 238–147 Fluid Regulator

Conversion Kit Installation

To add a fluid regulator to part no. 237–603 and

236–824 PRO 5500wb spray guns, follow this procedure:

8. Install the barrel on the gun body as instructed on page 44.

9. Install the air tubing (90) between the regulator elbow fitting (E) and the tube fitting (89). Cut the tubing to the length needed.

1. Prepare the gun for service as instructed on page 35.

10. Install the gun onto the manifold as instructed on page 44.

2. Remove the barrel as instructed on page 41.

NOTE: Use the parts drawing and list on pages 52 and

53 to order replacement parts for your gun after adding the fluid regulator.

3. Remove the fluid fitting (17) and o-rings (18, 22) from the gun barrel. Refer to page 50.

4. Make sure the o-ring (A) is in place on the regulator outlet fitting (B). See Fig. 43.

5. Screw the regulator outlet fitting (B) into the gun barrel (C), and tighten the fitting securely.

2**

17

88

89

90

Conversion Kit Parts List

Includes items 2, 17, 88, 89, and 90

Ref.

No.

Part No.

Description

190–905 SHROUD

238–039 FLUID REGULATOR

190–899 ADAPTER

111–328 TUBE FITTING

054–730 AIR TUBING; 5/32 O.D.

6. Apply high strength (green) Loctite or equivalent.

to the adapter (88) threads, and install the adapter into the gun body (D).

7. Install the tube fitting (89) into the adapter (88).

Qty.

1

1

1

1

** Order the warning label 290–069, at no cost, when ordering the shroud. Affix the label to the shroud.

1 ft. (305 mm) of tubing included with kit. To replace tub ing, order the length needed.

Fig. 43

2 88

89

D

C

B

A

17

E

90

05494

308–496 47

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 Proce-

dure.

Service

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.

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.

10. Install the three o-rings on the barbed fitting.

11. Connect the fluid hose to the gun as instructed on page 15.

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.

2. Relieve the system pressure as instructed on page

19.

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.

Measurements, inches (mm)

A*

7.75 + 0.1

(197 + 2.5)

B*

9.375 + 0.1

(238 + 2.5)

C

5.1 + 0.1

(130 + 2.5)

D

6.85 + 0.1

(174 + 2.5)

* The measurements specified are for use with the Graco

H 2 O PRO Voltage Block isolation system.

Isolation System End

A

B

K

Fig. 44

J H

Spray Gun End

D

C

J K

05495

48 308–496

Notes

308–496 49

Spray Gun Parts

Part No. 237–603 and 236–824

Spray Gun

See below

28b

13

16

15

14

12

87

3

9

1

27e

27b

2

20

28

Item 23 includes 23a–23g

Item 25 includes 25a and 25b

Item 27 includes 27a–27e

Item 28 includes 28a–28h

30

25b

25

25a

24

26

27a

27d

27

27c

See page 55 to order the parts

75

6

22

18 17

29

7

11

23b

23c

23d

23f

23e

21

23a

23g

REF NO. 28,

Packing Rod Assembly

Includes items 28a–28h

28e

28f

28a

28h

28d

28g

28c

04326

46

19

36

0601

50 308–496

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. 237–603 Spray Gun

Includes items 1 to 87

Part No. 236–824 Spray Gun

Includes items 1 to 46, 76–87

Ref.

No.

Part No.

Description Qty.

7

9 {

11

12

1

2**

3 {

6

13

14

189–768 RETAINING RING, air cap

189–770 SHROUD

189–786 GASKET, air cap nut

189–367 CAP, exhaust

185–122 MUFFLER/FLAME ARRESTOR

110–492

185–111

O-RING, PTFE r

SPRING, compression

177–033 AIR CAP; See Manual 307–803 for other air caps

186–615 NEEDLE, electrode

191–834 NOZZLE, fluid

See Manual 307–803 for other nozzles

1

1

1

1

1

1

1

1

1

1

15

16*

17

18*

19

20 {

21

223–977 STUD, resistor

111–507 O-RING, fluoroelastomer

237–506 FITTING, fluid

102–982 O-RING; PTFE

186–766 ARM, actuator

185–113 GASKET, manifold; polyethylene

112–689 SCREW, socket; 1/4 x 0.75”

22*

23

23b

23d

{

111–316 O-RING, fluoroelastomer

236–826 PISTON ASSY.;

23a { 111–508

111–504

S

S

Includes items 23a–23g

O-RING; fluoroelastomer

O-RING; fluoroelastomer

23c { 112–319 S O-RING; fluoroelastomer

23e

189–355 S STEM, piston

189–747 S PISTON

23f { 189–752 S PACKING, u-cup; ultra high molecular

23g

24

25

189–754

185–096

222–319

S weight polyethylene

ROD, piston

SCREW, cap, relieved; M5 x 0.8

ALTERNATOR, turbine

Includes items 25a and 25b

25a { 110–073 S O-RING, Viton r

25b 185–124 S CUSHION

1

1

1

1

1

1

1

1

1

1

3

1

1

1

2

2

1

1

2

1

Spray Gun Parts

Ref.

No.

Part No.

Description Qty.

26

27

27a

27b

27c

27d

27e

28

223–940 BARREL, gun

237–250 POWER SUPPLY ASSY.; 60 kV

Includes items 27a–27e

186–840 S GASKET

185–099 S PAD

185–145 S PAD

186–637 S SEAL

185–141 S CUSHION

224–747 PACKING ROD ASSY.

Includes items 28a–28h

1

28a

28b

185–495 S HOUSING, packing

223–981 S ROD, fluid

28c 185–488 S NUT, packing

28d* 186–069 S SPACER, packing

28e

28f*

28g*

28h*

29

30

31

36

178–763 S PACKING, rod

178–409 S PACKING, fluid

111–504

111–316

190–055 BODY, gun

185–114

112–638

S

S

O-RING, fluoroelastomer

O-RING, fluoroelastomer

RETAINER RING, alternator

FITTING, fiber optic page 54)

102–025 NUT, hex; 1/4”–20

(shown on

46

75

77 .

101–324 NUT, hex jam; 1/4”–20

237–553 MANIFOLD ASSY.; 237–603 only;

107–460

See separate parts list on page 55

WRENCH, ball end

1

78 .Y

186–118 SIGN, warning, spray area, English 1

80 .

217–115 GREASE, dielectric, tube 1

1

1

1

83 .

191–744 MULTI-TOOL

84 .Y

179–791 TAG, warning

85 .

189–888 COVER, gun

86 .Y

290–171 SIGN, warning English

87 Y 290–069 LABEL, warning

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 237–765, which may be purchased separately. This kit also in cludes the fluid hose o-rings; refer to page 56.

{ These parts are included in Air Seal Repair Kit 236–827, which may be purchased separately .

** Order the warning label 290–069 (item 87), at no cost, when ordering the shroud. Affix the label to the shroud.

.

These parts are not shown in the parts drawing.

Y Replacement Warning labels, tags, and signs are avail able at no cost.

308–496 51

Part No. 238–091 Spray Gun

Spray Gun Parts

See below

28b

13

16

15

14

12

87

3

9

1

27e

27b

2

20

28

Item 23 includes 23a–23g

Item 25 includes 25a and 25b

Item 27 includes 27a–27e

Item 28 includes 28a–28h

30

25b

25

25a

24

26

27a

27d

27

27c

See page 55 to order the parts

75

See page 46 to order the parts

6

7

17

11

46 19 36 89 88

90

23b

23c

23d

23f

23e

21

23a

29

23g

REF NO. 28,

Packing Rod Assembly

Includes items 28a–28h

28e

28f

28a

28h

28d

28g

28c

05431

0601

52 308–496

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. 238–091 Spray Gun

Includes items 1 to 90

Ref.

No.

Part No.

Description Qty.

1

2**

3 {

6

7

9 {

11

12

189–768 RETAINING RING, air cap

190–905 SHROUD

189–786 GASKET, air cap nut

189–367 CAP, exhaust

185–122 MUFFLER/FLAME ARRESTOR

110–492 O-RING,

185–111

PTFE r

SPRING, compression

13

14

177–033 AIR CAP; See Manual 307–803 for other air caps

186–615 NEEDLE, electrode

191–832 NOZZLE, fluid; See Manual 307–803 for other nozzles

223–977 STUD, resistor

1

1

15

17

18*

19

20 {

21

23

238–039 REGULATOR, fluid; See separate parts list on page 46

102–982

186–766

185–113

112–689

O-RING; PTFE

ARM, actuator

GASKET, manifold; polyethylene

SCREW, socket; 1/4 x 0.75”

236–826 PISTON ASSY.;

23a { 111–508

23b { 111–504

S

S

Includes items 23a–23g

O-RING; 1

O-RING; fluoroelastomer

23c { 112–319 S O-RING; fluoroelastomer

23d

23e

189–355 S STEM, piston

189–747 S PISTON

23f { 189–752 S PACKING, u-cup; ultra high molecular weight polyethylene

23g

24

25

189–754

185–096

222–319

S ROD, piston

SCREW, cap, relieved; M5 x 0.8

ALTERNATOR, turbine

Includes items 25a and 25b

25a { 110–073 S O-RING, Viton r

25b

26

185–124 S CUSHION

223–940 BARREL, gun

2

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description Qty.

27

27a

27b

27c

27d

27e

28

237–250 POWER SUPPLY ASSY.; 60 kV

Includes items 27a–27e

186–840 S GASKET

185–099 S PAD

185–145 S PAD

186–637 S SEAL

185–141 S CUSHION

224–747 PACKING ROD ASSY.

28a

28b

28c

Includes items 28a–28h

185–495 S HOUSING, packing

223–981

185–488

S

S

ROD, fluid

NUT, packing

28d* 186–069 S SPACER, packing

28e

28f*

28g*

28h*

29

30

31

36

46

178–763 S PACKING, rod

178–409

111–504

111–316

S

S

S

PACKING, fluid

O-RING, fluoroelastomer

O-RING, fluoroelastomer

238–097 BODY, gun

185–114 RETAINER RING, alternator

112–638 FITTING, fiber optic (shown on page 54)

102–025 NUT, hex; 1/4”–20

101–324 NUT, hex jam; 1/4”–20

75 237–553 MANIFOLD ASSY.; See separate parts list on page 55

77 .

107–460 WRENCH, ball end

78 .Y

186–118 SIGN, warning, spray area, English 1

80 .

217–115 GREASE, dielectric, tube

83 .

191–744 MULTI-TOOL

1

1

1

1

1 84 .Y

179–791 TAG, warning

85 .

189–888 COVER, gun

86 .Y

290–171 SIGN, warning English

87 Y 290–069 LABEL, warning

88

89

90

190–899

111–328

ADAPTER

FITTING, tube

054–730 TUBING, air; 5/32 O.D.

1

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 237–765, which may be purchased separately. This kit also in cludes the fluid hose o-rings; refer to page 56.

{ These parts are included in Air Seal Repair Kit 236–827, which may be purchased separately .

** Order the warning label 290–069 (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.

Y Replacement Warning labels, tags, and signs are avail able at no cost.

308–496 53

108

121

101

Manifold Parts

111

106

109

REF. 101

119

120

105

106 115

Front View

31

112

102

104

103

04323

Apply low strength (purple) Loctite r or an equivalent sealant to the threads.

Apply high strength (green) Loctite r 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).

113

116

107

114

118

117

Back View

04322

54 308–496

Manifold 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. 237–553 Gun Manifold

Includes items 101–121.

Ref.

No.

Part No.

Description

101

102

103

104

192–095 MANIFOLD

189–581 MOUNTING BRACKET

110–465 BOLT, square head

112–689 SCREW; 1/4–20 x 0.75”

105

106

112–640 SPRING, compression

186–846 BOLT, manifold; M5 x 0.8

107 111–157 FITTING, tube; for 1/4” O.D. tube

108 { 189–363 GASKET, manifold

109

111

112

113

114

108–290

189–365

110–078

186–845

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

107–107 REGULATOR, disk

115

116

117

118

112–645 PLUG; 1/8”–27 npt

112–646 PLUG; 5/8–18 x 5/8”

190–220 NUT, strain relief

190–219 FITTING, strain relief

119 290–068 LABEL, caution

120 Y 290–069 LABEL, warning

121 {} 190–301 GASKET, foam

Qty.

1

3

2

2

2

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

{ These parts are included in Air Seal Repair Kit 236–827, which may be purchased separately .

} Optional gaskets are available:

Part No. 111–180: Viton r

Part No. 111–333: Ethylene Propylene

Y Replacement Warning labels are available at no cost.

Part No. 236–852 Optional Fiber Optic Kit

The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224–117 to improve light transmission when two bulkhead splices are used.

The kit includes items 201–203.

Ref.

No.

Part No.

Description Qty.

201

202

203

112–638 FITTING, fiber optic; see item 31 on page 54

111–224 LENS

189–875 SLEEVE

1

1

1

203

202

04485

308–496 55

Accessories

Use Only Genuine Graco Parts and Accessories

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

Shielded Hoses for use with the Graco H 2 O PRO

Voltage Block:

Fluid Hose

Assy. Part No.

237–920

237–921

237–922

Hose Length

25 ft. (7.6 m)

36 ft. (11 m)

50 ft. (15.2 m)

Fluid Hose Replacement Parts

For fluid hoses 237–920/921/922

Ref.

No.

Part No.

Description

301*

302

111–450 O-RING

190–143 BARBED FITTING

Qty.

3

1

Hoses for use with non-Graco voltage isolation systems**:

Fluid Hose

Assy. Part No.

237–545

237–546

Hose Length

25 ft. (7.6 m)

50 ft. (15.2 m)

Fluid Hose Replacement Parts

For fluid hoses 237–545/546

Ref.

No.

Part No.

Description

301* 111–450

302

303

190–143

O-RING

BARBED FITTING

112–480 SWIVEL FITTING

303

Qty.

3

1

1

*301

302

*301

Waterborne Fluid Hose 302

05342

* The three o-rings are included in Fluid Seal Repair Kit

237–765.

Unshielded Hoses for use with the Graco H 2

Voltage Block:

O PRO

Bare PTFE fluid hoses, without the ground shield. See

Manual 308–688 for information on the hoses.

Fluid Hose

Assy. Part No.

238–877

237–878

Hose Length

25 ft. (7.6 m)

50 ft. (15.2 m)

Hoses for use with Graco Fenced Isolation

System:

Fluid Hose

Assy. Part No.

237–548

237–549

237–550

Hose Length

25 ft. (7.6 m)

36 ft. (11 m)

50 ft. (15.2 m)

04324

* The three o-rings are included in Fluid Seal Repair Kit

237–765.

** The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system.

56 308–496

Hose Part No.

235–068

235–069

235–070

235–071

235–072

235–073

235–074

Accessories

Use Only Genuine Graco Parts and Accessories

Electrically Conductive Air Hoses

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

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

Hose Length

6 ft. (1.8 m)

15 ft. (4.6 m)

25 ft. (7.6 m)

36 ft. (11.0 m)

50 ft. (15.2 m)

75 ft. (23.0 m)

100 ft. (30. 5 m)

Fluid Regulator Conversion Kit 238–147

To add a fluid regulator to the part no. 237–603 and

236–824 PRO 5500wb spray guns. See page 47 for kit installation instructions.

Gun High Voltage Probe & Meter 217–452

For direct measurement of the gun output voltage.

Megohmmeter 218–979

500 Volt output; 0.01–2000 megohms.

Not for use in Hazardous areas.

Grounding Rod 210–084

For use in the Fluid Voltage Discharge and Ground-

ing Procedure.

308–496 57

Technical Data

Category

Maximum Working

Pressure

Air Pressure Operating

Range

Fluid Pressure Operating

Range

Voltage Output

Short Circuit Current

Output

Turbine Air Inlet

Fluid Inlet

Data

100 psi (0.7 MPa, 7 bar)

0–100 psi (0–0.7 MPa,

0–7 bar)

0–100 psi (0–0.7 MPa,

0–7 bar)

0–60 kV*

120 m A

1/4 npsm(m), left-hand custom inlet for Graco waterborne fluid hose

Weight (gun and manifold)

Part No. 237–603

Part No. 238–091

Fluid Specification

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:

D The fluid has a flash point above 140 _ F

(60 _ C) and a maximum organic solvent concentration of 20%, by weight, per ASTM

Standard D93.

D The fluid does not sustain burning when tested per ASTM

Standard D4206 Sustained Burn Test.

Category

Maximum Fluid

Temperature

Wetted Parts

Data

120 _ F (49 _ C)

Stainless Steel, Nylon,

Acetal, PTFE r , Kalrez r ,

Ceramic, Chemraz r ,

Fluoro-polymer

Maximum Noise Level with atomization air at

100 psi (0.7 MPa, 7 bar) and maximum air flow

Sound Pressure {

Sound Power }

101.5 Db(A)

107.0 Db(A)

{ Sound pressure was measured per Cagi Pneurop, 1969.

The measurement was taken 3.28 feet (1 meter) from the air cap.

} 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 r , Viton r , and Kalrez r

Loctite r is a registered trademark of the Loctite Corporation.

Chemraz r is a registered trademark of the Green, Tweed, &

Company.

Manual Change Summary

The manual was revised to add information about mounting and operating distance from the gun mounted fluid regulator, and to add cover 191–406 and screw 113–522 to the fluid regulator parts list.

58 308–496

Notes

308–496 59

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it 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. As purchaser’s sole remedy for breach of this warranty,

Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven defective. However, any deficiency in the gun barrel, gun body, manifold, mounting bracket, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty six months or six thousand hours of operation from time of sale. 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, 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 with Graco equipment of 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 claim. 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. in no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, 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.

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: Atlanta, Chicago, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–496 January 1995, Revised November 1996

60 308–496

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