Graco 236685, PRO 5500hc, 237300 Instructions And Parts List

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INSTRUCTIONS-PARTS LIST

308442

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

Rev. G

AUTOMATIC ELECTROSTATIC, HIGH CONDUCTIVITY

Model PRO 5500hcAir Spray Gun

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

The PRO 5500hc spray gun offers increased electrostatic performance when spraying metallic paints and highly conductive fluids. The gun is for use with Class I, Group D paint spray materials.

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 Foreign Patents Pending

Part No. 236685, Series A

Complete PRO 5500hc Spray Gun: includes spray gun, shroud, manifold, and mounting bracket

Part No. 237300

PRO 5500hc Conversion Kit: to convert the PRO 5500sc spray gun to the PRO 5500hc spray gun

03209

NOTE: 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

Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents

Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comparison of a PRO 5500sc to a PRO 5500hc

Spray Gun 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Characteristics and Gun Performance 6. . . . . . . .

Operating the Spray Function 6. . . . . . . . . . . . . . . . . . . .

Operating the Electrostatics 6. . . . . . . . . . . . . . . . . . . . . .

Switching to the Higher or Lower kV Setting 6. . . . . . . .

Gun Features and Options 6. . . . . . . . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Signs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth 9. . . . . . . . . . . . . . . . . . . . . . . .

Install the Air Line Accessories 10. . . . . . . . . . . . . . . . . .

Install the Fluid Line Accessories 10. . . . . . . . . . . . . . . .

Install the Gun and Mounting Bracket 10. . . . . . . . . . . .

Connect the Air and Fluid Lines 11. . . . . . . . . . . . . . . . .

Optional Fiber Optic Cable Connection 12. . . . . . . . . . .

Optional Fiber Optic Lens Kit Installation 12. . . . . . . . .

Ground the System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding 14. . . . . . . . . . . . . . . . . .

Install the Fabric Cover 15. . . . . . . . . . . . . . . . . . . . . . . . .

Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Included with the Gun 28. . . . . . . . . . . . . . . . . . . . .

Prepare the Gun for Service 28. . . . . . . . . . . . . . . . . . . .

Air Cap/Nozzle/Resistor Stud Replacement 29. . . . . . .

Electrode Needle Replacement 30. . . . . . . . . . . . . . . . . .

Fluid Packing Rod Removal and Repair 31. . . . . . . . . .

Piston Repair 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Barrel Removal 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Removal and Replacement 35. . . . . . . .

Power Supply Adjustment 35. . . . . . . . . . . . . . . . . . . . . .

Turbine Alternator Removal and Replacement 36. . . . .

Barrel Installation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the Gun onto the Manifold 37. . . . . . . . . . . . . . . .

Standard Spray Gun Parts 38. . . . . . . . . . . . . . . . . . . .

Manifold Parts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kit Parts and Installation 42. . . . . . . . . . . . . . . . . . . . .

Installing the PRO 5500hc Conversion Kit 42. . . . . . . .

Technical Data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Graco Warranty and Disclaimers 46. . . . . . . . . .

Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 16. . . . . . . . . . . . . . . . . . . . . .

Operating Checklist 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Fluid Nozzle and Air Cap 16. . . . . . . . . . . . .

Adjusting the Spray Pattern 17. . . . . . . . . . . . . . . . . . . . .

Activating and Adjusting the Electrostatics 18. . . . . . . .

Activating the kV Switch 18. . . . . . . . . . . . . . . . . . . . . . . .

Spraying 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Triggering the Fluid Alone 18. . . . . . . . . . . . . . . . . . . . . .

Shutdown 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Care and Cleaning 19. . . . . . . . . . . . . . . . . . . . . . . .

Clean the Air Cap and Fluid Nozzle 21. . . . . . . . . . . . . .

Check for Fluid Leakage 22. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Pattern Troubleshooting 23. . . . . . . . . . . . . . . . . .

Gun Operation Troubleshooting 24. . . . . . . . . . . . . . . . .

Electrical Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . .

Electrical Tests 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Gun Resistance 26. . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Power Supply Resistance 27. . . . . . . . . . . . . . . . . .

Test Resistor Stud Resistance 27. . . . . . . . . . . . . . . . . .

Graco Phone Number 46. . . . . . . . . . . . . . . . . . . . . . . .

Symbols

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 308442

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock.

 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 13.

 Check the spray gun resistance daily. See Test Gun Resistance, page 26.  If there is any static sparking while using the equipment, stop spraying immediately. Identify and

correct the problem.

 Provide fresh air ventilation to avoid the buildup of flammable or 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.

 When flushing or purging electrostatic equipment, use solvents with a flash point equal to or

greater than that of the fluid being sprayed.

 To clean the exterior of the electrostatic equipment, use solvents with a flash point higher than

100F (38C).

 Do not flush the system with the gun electrostatics turned on.  Do not turn on the gun electrostatics until all solvent is removed from the system.  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 16 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 operating the equipment.  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.

308442 3

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.

 This equipment is for professional use only.  Read all the instruction manuals, tags, and labels before operating the equipment.  Use the equipment only for its intended purpose. If you are uncertain about the usage, call your

Graco distributor.

 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.  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 equip-

ment has a 100 psi (7 bar, 0.7 MPa) 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.

4 308442

Introduction

03221 03904A

PRO 5500sc Spray Gun

8 in. (203.2 mm) fluid path

Comparison of a PRO 5500sc to a PRO 5500hc Spray Gun

The PRO 5500hc spray gun offers increased electrostatic performance when spraying highly conductive fluids and metallic paints.

In an electrostatic spray gun, the fluid in the fluid tube becomes a path to ground when the high voltage is turned on. The amount of current drawn through the fluid tube depends on the fluid resistivity and the length of the fluid path to ground.

PRO 5500hc Spray Gun

20 in. (711.2 mm) fluid path

The PRO 5500sc and PRO 5500hc guns will perform equally well when spraying fluids with high resistivity, as shown in the graph below. Even with the shorter fluid tube of the PRO 5500sc gun, very little current travels through the fluid, due to its high resistivity, and the spraying voltage is minimally affected. However, when the fluid resistivity decreases to low levels, more current is drawn through the fluid and the spraying voltage of the PRO 5500sc gun is reduced.

The PRO 5500hc gun can support high voltages when spraying conductive fluids because the longer fluid tube increases the total resistance of the fluid column and reduces the current draw through the fluid.

Full Spraying Voltage

Low Resistivity (high conductivity)

PRO 5500hc

PRO 5500sc

NOTE: Fluid resistance

value is approximate. Actual resistance will vary depending on the type of resistance meter and the fluid being used.

200

High Resistivity (low conductivity)

Fluid Resistivity MEG CM

308442 5

Introduction

Fluid Characteristics and Gun Performance

For some fluids (especially metallic paints), measuring the fluid resistivity is not always a reliable indicator of paint performance in a spray gun. The voltage applied by the resistivity meter is very low compared to the voltage applied by the spray gun. Some conductive components and additives in the fluid may exhibit reduced resistivity when high voltage is applied by the spray gun.

When testing a fluid to see if it will be suitable for electrostatic spraying, it is important to measure the spraying voltage when the fluid is flowing. The turbulence created when the fluid is flowing helps to retard the negative effects of the conductive components and additives in the fluid.

The PRO 5500hc guns offer the capability of monitoring the actual spraying voltage with the optional fiber optic spraying voltage readouts. Either the kV only readout or the kV and current readout can be very helpful in monitoring the voltage characteristics when spraying conductive fluids. Refer to Fig. 2, page 8.

To provide a smoother transition to the high voltage and prevent some very conductive fluids from shorting out, it may be necessary to operate the gun with the voltage first turned to the lower kV setting, then switch to the higher kV setting.

Operating the Spray Function

Applying a minimum of 50 psi (3.5 bar, 0.35 MPa) 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

To operate the electrostatics, air pressure is applied to the gun manifold’s turbine air fitting (which is marked “TA”, see page 7) 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”. The exhaust air helps keep contaminants out and helps keep the gun clean.

Switching to the Higher or Lower kV Setting

The gun’s full high voltage setting is 85 kilovolts. The gun’s spraying voltage can be reduced by switching to the low voltage setting for spraying in areas where too much electrostatic wrap is not desirable. Applying a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the kV switch air inlet (which is marked “KV”, see page

7) will activate it and switch to the lower voltage setting. The lower voltage is factory set to 60 kilovolts at zero microamperes. This setting can be adjusted from 45 to 80 kilovolts, as instructed on page 35. The solenoid valve used to activate the kV switch must bleed the air out of the line for the switch to draw back to the higher voltage setting.

Gun Features and Options

 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.

 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.

 The gun functions are activated from a separate

controller that sends the appropriate signal to the actuating solenoids (K). See Fig. 1, page 8.

 An optional fiber optic readout system can be

installed to monitor the gun’s spraying voltage. A fiber optic cable (V) connected to the gun manifold carries the signal from the gun to a remote ES (electrostatic) display module. See Fig. 2, page 8. An ES Display Module (R), P/N 224117, is available and will display the gun’s spraying voltage and current. A battery operated ES Display Module (S), P/N 189762, is also available; it displays the gun’s spraying voltage only.

6 308442

Introduction

AB C D E

CYL

F.O.

EXH

Manifold Back View

0321303209

KEY

A Air Cap B Fluid Nozzle C Retaining Nut D Shroud E Mounting Bracket F Manifold G Turbine H Power Supply J Electrode

04803

Manifold Markings

A1 Atomization Air Inlet Fitting A2 Fan Air Inlet Fitting CYL Cylinder Air Inlet Fitting EXH Shroud Exhaust Outlet Fitting F.O. Fiber Optic Fitting KV kV Switch Air Inlet P1 Fluid Supply Inlet Fitting P2 Fluid Return Inlet Fitting TA Turbine Air Inlet Fitting

308442 7

Fig. 1

Installation

BASIC SYSTEM

Non-Hazardous Area Hazardous Area



CYL

K K K K

Fig. 2

Non-Hazardous Area Hazardous Area



SYSTEM OPTIONS

 Spraying Voltage

Display Module

F.O.

04801

8 308442

Installation

KEY-Fig. 1 and 2

A Ground Wire on Graco Electrically Conductive Air Hose B Graco Electrically Conductive Air Hose (Turbine Air Hose),

See page 11 for part numbers 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 Fluid Hose, 1/4–18.6 npsm gun fluid inlet G To Fluid Supply H PRO 5500hc Spray Gun, P/N 236685 J Mounting Bracket for 1/2 inch (127 mm) rod, P/N 189581 K Solenoid Valve, requires quick-exhaust port M Air Pressure Regulator N True Earth Ground P 24 Volt Power Supply, P/N 235301 Q4–20 mA Outputs R Full Feature ES Display Module, P/N 224117 S kV Only ES Display Module (battery operated), P/N 189762 T Fiber Optic Cable, P/N 224680 to 224686 U Bulkhead, P/N 189870 V Fiber Optic Cable, P/N 224670 to 224676 W Main Air Line X Bleed-type Master Air Valve Y kV Switch Air Hose, 1/4 inch (6.4 mm) O.D., plug the gun fitting if

it is not used Z Air Pilot Fluid Regulator, P/N 236854

 The turbine air supply must be interlocked with the spray booth

ventilation fans.

 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 11 for a description of the manifold connections.

Installing the System

Fig. 1, page 8, shows a typical Model PRO 5500hc system. Fig. 2 shows some possible system options.

Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun, Form No. 305660.

For assistance in designing a system that is customized for your application, contact your Graco distributor.

Warning Signs

Mount the warning signs in the spray area where they can easily be seen and read by all operators. An English Warning Sign is provided with the gun. Additional signs are available at no charge. See below.

Part No. Description 180060 Warning Sign (English)

Ventilate the Spray Booth

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.

 Do not install or service this equip-

ment unless you are trained and qualified.

 Be sure your installation complies with National,

State and Local codes for the installation of electrical apparatus in a Class I, Group D Hazardous Location.

 Comply with all applicable local, state, and

national fire, electrical, and other safety regulations.

WARNING

FLAMMABLE OR TOXIC VAPOR HAZARD

Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors. Do not operate the gun unless ventilation fans are operating.

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

Check and follow all local, state, and national codes regarding air exhaust velocity requirements. High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 feet/minute (19 linear meters/minute).

308442 9

Installation

Install the Air Line Accessories

1. Install a bleed-type master air valve (X) on the main air supply line (W) to shut off all the air to the gun. See Fig. 1, page 8.

2. To ensure a dry, clean air supply to the gun, install an air line filter and an air and water separator on the air lines. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install an air regulator (M) on each of the air supply lines (B, C, D, E, Y) to control the air pressure to the gun.

4. Install a solenoid valve (K) on the fan and atomization air lines (C, D) to actuate the gun and shut off the fan and atomization air to the gun. The solenoid valves must have a quick exhaust port.

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 solenoid valves (K) must have a quick-exhaust port so trapped air will be relieved between the valve and the gun when the solenoids are shut off.

Install the Fluid Line Accessories

1. Install a fluid filter and drain valve at the pump outlet. See Fig. 1, page 8.

WARNING

2. Install a fluid regulator on the fluid line to control fluid pressure to the gun.

Install the Gun and Mounting Bracket

1. Loosen the mounting bracket’s two square head bolts (103) and slide the mounting bracket onto a

0.50 in. (12.7 mm) mounting rod. See Fig. 3.

2. Position the gun and tighten the two bolts (103) securely.

2.775 in . (70.5 mm)

PRO 5500 Gun

103

0.50 in.

(12.7 mm)

rod

103

Fig. 3

NOTE: For added positioning reliability, the mounting

bracket (MM) has an 1/8 in. (3.2 mm) slot where a locating pin (NN-not included) can be inserted through the mounting rod (PP). See Fig. 4.

9.32 in. (236.7 mm)

03444

PRESSURIZED EQUIPMENT HAZARD

The fluid drain valve is required in your system to assist in relieving fluid pressure in the displacement pump, hose and gun; triggering the gun to relieve pressure may not be sufficient. Install a drain valve close to the pump’s fluid outlet. The drain valve reduces the risk of serious injury, including splashing in the eyes or on the skin.

10 308442

Fig. 4

03460

Installation

Connect the Air and Fluid Lines

See Fig. 1 and 2, page 8, for a schematic of air and fluid connections. Connect the air and fluid lines to the gun manifold as instructed at right.

Graco Electrically Conductive Air Hose

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of electric shock or other serious injury, the air supply hose must be electrically connected to a true

earth ground. Use Only Graco Electrically Con-

ductive Air Supply Hose.

Connect the Graco electrically conductive air hose (B) to the gun turbine air inlet and connect the hose ground wire (A) to a true earth ground. See Fig. 1, page 8. Check the electrical grounding of the gun as instructed on page 14.

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.

Graco Electrically Conductive Air Hose

Required for gun operation.

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

0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand

Manifold Connections (See Fig. 5)

A1 Atomization Air Inlet Fitting

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

A2 Fan Air Inlet Fitting

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

CYL Cylinder Air Inlet Fitting

Connect a 1/4 inch O.D. tube between this fitting and the solenoid. For quicker trigger response, use the shortest hose length possible.

EXH Shroud Exhaust Outlet Fitting

Connect a 1/4 inch O.D. x 4 foot (1.22 m) long tube to the fitting.

F.O. Fiber Optic Fitting (Optional)

Connect the Graco Fiber Optic Cable as instructed on page 12.

KV kV Switch Air Inlet Fitting

Connect a 1/4 inch O.D. tube between the fitting and the air solenoid.

P1 Fluid Supply Inlet Fitting

Connect a 1/4 inch npsm swivel fitting between the fitting and the fluid supply.

P2 Fluid Return Inlet Fitting (Optional)

Connect 1/4 inch O.D. tube between the fitting and the dump valve for recirculation.

TA Turbine Air Inlet Fitting

Connect the 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.

Part No.

Length Black Hose Grey Hose Red Hose

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)

Black Hose: standard hose, semi-conductive nylon core, urethane outer Grey Hose: more flexible (less durable) than black hose, modified semi-conductive polyamide core, urethane cover Red Hose: conductive SST wire braid for grounding, polyurethane tube and cover

220444 218100 218101 218102 218103 220119 220120

223068 223069 223070 223071 223072 223073 223074

235068 235069 235070 235071 235072 235073 235074

Fluid Line

Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent that is compatible with the fluid being sprayed.

CYL

Fig. 5

F.O.

EXH

Manifold Back View

03213

308442 11

Installation

Optional Fiber Optic Cable Connection

An optional fiber optic fitting (37) is shipped unassembled with the gun. If an ES (kV) display module is used, install the fitting in the manifold. See Fig. 2, page 8, 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 (37). See Fig. 6.

115

Fig. 6

03508

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 308265 to install a Graco ES Display Module.

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 236852.

1. Remove the gun from the manifold as instructed on page 28.

2. Make sure the lens (TT) is clean. Push the lens into the counterbore (VV) in the manifold fiber optic port (SS). See Fig. 8 and 9.

3. Press the lens retainer (UU) into the manifold fiber optic port (SS) until it is flush with the manifold surface.

4. Assemble the gun to the manifold as instructed on page 37.

2. Remove the nut (QQ) from the fiber optic fitting (37), and slide the nut over the end of the fiber optic cable (RR). See Fig. 7.

3. Insert the cable (RR) into the fitting (37), and push the cable in until it bottoms out. Tighten the nut (QQ) to secure the cable.

Fig. 7

4. If you have two bulkhead splices in your system, it is recommended that you install the fiber optic lens kit, as described at right.

03509A

Fig. 8

Fig. 9

VVSS

04798

04485

12 308442

Installation

Ground the System

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

When operating the electrostatic gun, 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 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. Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

3. Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose to the turbine air inlet and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 14.

4. All air and fluid lines must be properly grounded.

5. All electric cables must be properly grounded.

6. 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.

7. Object being sprayed: keep the workpiece hangers clean and grounded at all times. Contact points must be sharp points or knife edges.

8. The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.

9. Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not store more than the quantity needed for one shift.

2. Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer’s recommendations.

10. All electrically conductive objects or devices in the spray area: including fluid containers and wash cans, must be properly grounded.

308442 13

Installation

Check the Electrical Grounding (See Fig. 10)

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 241079 (WW) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding 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.

a. If using a black or grey turbine air hose, use a

megohmmeter (WW) to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. Resistance should not exceed 2 megohms.

b. If you are using a red turbine air hose, use an

ohmmeter to measure the resistance. Resistance should not exceed 100 ohms.

5. If the resistance is greater than the maximum reading specified above for your hose, 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.

1. Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose.

2. Make sure the turbine air hose (B) 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 (TA) and a true earth ground (N).

TI0376

Fig. 10

14 308442

Installation

Install the Fabric Cover (See Fig. 11)

1. Install the fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and hoses at the back of the manifold.

Fig. 11

2. Route the exhaust tube (YY) 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 22. Strap down the exhaust tube to prevent it from moving around.

Manifold Back View

03446

03445

308442 15

Operation

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

 are instructed to relieve the pressure,  stop spraying,  check or service any of the system equipment,  and install or clean the fluid nozzle.

1. Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid regulator is used in the system, the air pressure is needed at the regulator air inlet.

2. Turn off the fluid supply to the gun.

3. Trigger the gun into a grounded metal waste container to relieve fluid pressure.

4. If the air pilot fluid regulator is used, turn off the air pressure at the regulator air inlet.

5. Relieve fluid pressure in the fluid supply equipment as instructed in its instruction manual.

6. 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.

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 air spray system as instructed in this manual.

____ 2. All the operators are trained how to properly

relieve pressure, using the Pressure Relief Procedure at left.

____ 3. The warning sign provided with the gun is

mounted in the spray area where it can be easily seen and read by all operators.

____ 4. The system is thoroughly grounded and the

operator and all persons entering the spray area are properly grounded. See Ground the System, page 13.

____ 5. The condition of the electrical components of

the spray gun has been checked as

instructed in Electrical Tests, page 26. ____ 6. The ventilation fans are operating properly. ____ 7. The workpiece hangers are clean and

grounded. Contact points must be sharp

points or like knife edges. ____ 8. All the debris, including flammable liquids

and rags, is removed from the spray area. ____ 9. All flammable liquids in the spray booth are

in approved, grounded containers. ____ 10. All conductive objects in the spray area are

electrically grounded and the floor of the

spray area is electrically conductive and

grounded. ____ 11. The manifold exhaust tubes have been

checked for the presence of any fluid as

instructed in Check for Fluid Leakage, page

22.

Selecting a Fluid Nozzle and Air Cap

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure, above, before removing or

installing a fluid nozzle and/or air cap.

The gun is supplied with a 0.059 in. (1.5 mm)) fluid nozzle, part no. 191833, and air cap, part no. 193033. If your application requires a different nozzle and air cap combination, use instruction manual 307803 or consult your authorized Graco distributor to select the appropriate fluid nozzle and air cap. Install the air cap and fluid nozzle into the gun barrel as instructed in Air

Cap/Nozzle/Resistor Stud Replacement, page 29.

16 308442

Operation

Adjusting the Spray Pattern

Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet.

WARNING

PRESSURIZED EQUIPMENT HAZARD

To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 16 whenever you are instructed

to relieve the pressure.

1. Make sure the system pressure is relieved.

2. Loosen the air cap retaining ring, and rotate the air cap for a vertical or horizontal spray pattern. See Fig. 12. Then tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

4. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization. Refer to Fig. 13. For example, for a fluid flow rate of 10 ounces per minute (0.3 liters/min.), a typical atomization pressure would be 20 to 30 psi (1.4–2.1 bar, 0.14–0.21 MPa) at the gun manifold.

5. Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size.

NOTES:

 For the most efficiency, always use the lowest 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 23

to correct spray pattern problems.

Vertical Pattern

Horizontal Pattern

Fig. 12

3. Adjust the fluid flow with the fluid line pressure regulator. Refer to instruction manual 307803 to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.

02020

CYL

Fig. 13

Manifold Back View

03213

308442 17

Operation

Activating and Adjusting the Electrostatics

1. Make sure the fan (A2) and atomizing (A1) air are on, then turn on the turbine air (TA). Refer to Fig. 13, page 17.

2. The turbine air pressure should be adjusted to 30 psi (2.1 bar, 0.21 MPa) at the gun manifold inlet when air is flowing. Do not exceed 40 psi (2.8 bar,

0.28 MPa) air pressure as there is no added benefit and turbine life could be reduced.

Use the chart below to set the proper pressure at the turbine hose inlet. Do not exceed these recommended pressures or turbine life will be reduced.

Turbine Air Hose Length

15 ft. (4.6 m) 36 psi (2.5 bar, 0.25 MPa) 25 ft. (7.6 m) 38 psi (2.7 bar, 0.27 MPa) 50 ft. (15.3 m) 40 psi (2.8 bar, 0.28 MPa) 75 ft. (22.9 m) 42 psi (2.9 bar, 0.29 MPa)

Dynamic pressure at the turbine hose inlet required for full voltage

Activating the kV Switch

Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the kV switch air fitting (KV) to activate it and switch to the lower voltage setting. The lower voltage setting is factory set to 60 kilovolts at zero microamperes. To change this setting, see page 35.

The solenoid valve used to activate the kV switch must bleed the air out of the line for the switch to draw back to the higher voltage setting.

Spraying

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, do not touch the gun electrode or come within 4 inches (101.6 mm) of the nozzle during gun operation.

1. Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) 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. 13.

2. Turn the gun functions off and on by using the air solenoid valves on the cylinder (CYL) and turbine (TA) air supply lines.

100 ft. (30.5 m) 45 psi (3.1 bar, 0.31 MPa)

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

NOTE: The gun’s normal high voltage reading is 60 to 70 kV. If a ball end high voltage measurement probe is used, the gun voltage will rise to about 85 kV. This will happen with all resistive electrostatic guns.

See Electrical Troubleshooting on page 25 to correct voltage problems.

WARNING

FIRE AND EXPLOSION HAZARD If any fluid leakage from the gun is detected, stop spraying immediately!

Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage. See

Check for Fluid Leakage, page 22.

Triggering the Fluid Alone

1. Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleedtype air shut-off valves.

2. Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.

18 308442

Operation

Shutdown

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure

on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

Maintenance

Daily Care and Cleaning

 Clean all parts with a non-conductive solvent,

compatible with the fluid being sprayed. Conductive solvents can cause the gun to malfunction.

 Methylene chloride is not recommended as a

flushing or cleaning solvent with this gun as it will damage nylon components.

1. Relieve the system pressure.

2. Flush and clean the equipment. Follow the instructions in the Maintenance section, below.

CAUTION

Do not immerse the gun in fluid.

 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.

03906A

03907A

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

02027

308442 19

Maintenance

Daily Care and Cleaning (continued)

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 16 before doing any mainte-

nance on the gun or system.

 Clean the fluid and air line filters daily.

 Clean the outside of the gun daily with a soft cloth

dampened in a compatible solvent.

 Clean the air cap and fluid nozzle daily, minimum.

Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See Clean the Air Cap and Fluid Nozzle, page 21.

 Check the electrode wire: straighten it if it is bent

and replace it if it is broken or damaged. See Electrode Needle Replacement, page 30.

 Check for fluid leakage from the gun and fluid

hoses. See Check for Fluid Leakage, page 22. Tighten fittings or replace equipment as needed.

 Check all of the work hangers for fluid buildup;

clean them if necessary.

 Flush the gun before changing colors and when-

ever you are done operating the gun.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of a fire, explosion, or electric shock, be sure the turbine air (TA) is off before flushing the gun or any part of the system.

20 308442

Maintenance

Clean the Air Cap and Fluid Nozzle

Equipment needed:

 Soft bristle brush  Solvent compatible with fluid being sprayed

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

Procedure:

1. Relieve the system pressure.

2. Remove the air cap assembly (1, 12) and gun shroud (2). See Fig. 14.

3. Wipe the fluid nozzle (14), shroud (2), and exterior of the gun (P) clean with a cloth dampened in solvent. Avoid getting any solvent into the air passages. Whenever possible, point the gun down while cleaning it.

6. Slide the shroud (2) onto the gun (P). Make sure the shroud o-ring (121) is in place.

7. Carefully install the air cap (12). 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.

8. Make sure the o-ring (8) is in place on the retaining ring (1). Tighten the air cap retaining ring (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 26.

121

4. If it appears that there is paint 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 solvent or submerge the air cap in suitable solvent and wipe it clean.

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.

03511

03897A

Fig. 14

308442 21

Maintenance

Check for Fluid Leakage (See Fig. 15)

WARNING

FIRE AND EXPLOSION HAZARD If any fluid leakage from the gun is detected, stop spraying immediately!

Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 16 when you stop spraying and whenever you are instructed to relieve the pressure.

During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ) 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 fluid is seen in any of these areas, stop spraying immediately! Relieve the system pressure, then remove the gun for repair.

Fig. 15

Check for signs of fluid leakage where indicated by arrows.

Manifold Back View

03446

03445

22 308442

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 prop-

nance or service on the gun or system.

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure on page 16 before doing any mainte-

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

NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the gun.

Spray Pattern Troubleshooting

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

PROBLEM CAUSE SOLUTION

Fluttering or spitting spray The fluid supply is insufficient.

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.

Gun is spitting when triggered or detriggered.

The air cap is damaged or dirty. The actuator arm is out of position (it is too

close to the fluid needle). The fluid seat is worn.

Adjust the fluid regulator, or fill the fluid tank.

Tighten or replace the fluid nozzle; see page 29.

Clean the parts; see page 21.

Tighten or repair the coupler .

Clean or replace the air cap; see page 21. Reposition the actuator arm; see page 32.

Replace the fluid nozzle and/or electrode needle; see page 29 and 30.

There is fluid buildup 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 dam-

aged. 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. The fluid is too thin. There is not enough fluid pressure. The fan air pressure is too low. The fluid is too thick. There is too much fluid.

Streaks The last coat of fluid is applied too wet.

There is too much air pressure. The air pressure is insufficient.

Clean the air cap with a soft implement or submerge it in water and wipe it clean; see page 21.

Straighten the electrode. Replace the damaged part; see page 29.

Remove the obstruction; never use wire or hard instruments; see page 21.

Straighten the electrode. Reduce the fan air pressure. Increase the fluid viscosity. Increase the fluid pressure. Increase the fan air pressure. Reduce the fluid viscosity. Reduce the fluid flow. Apply a drier finish using multiple strokes. Decrease the air pressure. Increase the air pressure.

The spray pattern is non-uniform.

Clean or replace the air cap; see page 21.

308442 23

Troubleshooting

Gun Operation Troubleshooting

PROBLEM CAUSE SOLUTION

Fluid leakage from the fluid packing area

Fluid leakage from the front of the gun

“Orange Peel” finish The air pressure is insufficient.

Excessive spray fog The air pressure is too high.

No fluid sprays from the gun The fluid supply is low.

The fluid rod packings or fluid rod are worn.

The fluid rod is worn or damaged. The fluid seat is worn.

The resistor stud is loose. The fluid nozzle is loose. The resistor stud o-ring is damaged.

The fluid is poorly mixed or filtered. An improper thinner is being used.

The fluid is thinned too much.

The fluid nozzle is dirty or clogged. The fluid nozzle is damaged. The piston is not actuating.

The actuator arm is out of position.

Replace the packings or rod; see page

31. Replace the fluid rod; see page 31.

Replace the fluid nozzle and/or electrode needle; see page 29 and 30.

Tighten the resistor stud; see page 29. Tighten the fluid nozzle; see page 29. Replace the o-ring; see page 29.

Increase the air pressure; use the least air pressure needed for good results.

Remix or refilter the fluid. Use the proper thinner.

Reduce the air pressure; use the least air pressure needed for good results.

Properly thin the fluid. Check the fluid supply; add fluid if

necessary. Clean the fluid nozzle; see page 21. Replace the fluid nozzle; see page 29. Check the cylinder air; check the piston

u-cup; see page 32. Check the actuator arm and nuts; see

page 33.

The equipment is covered with fluid The exhaust air flow is insufficient or not

directed properly. The distance between the gun and work-

piece is incorrect.

Dirty air cap The electrode is bent.

The nozzle orifice is damaged. The fluid is coming on before the air.

The air cap and fluid nozzle are misaligned.

Air Cap

Fluid Nozzle

ALIGNED MISALIGNED

Air leakage from the air cap The o-rings on the piston stem are worn. Inspect the o-rings; replace them as

Air leakage from the manifold The manifold gasket is damaged, or the

manifold is not tight.

Fluid leakage at the quick-disconnect The manifold is not tight.

The o-rings on the fluid hose are worn or missing.

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. Replace the fluid nozzle; see page 29. Check the actuator arm and nuts; see

page 33. Check the air cap and fluid nozzle seat for

fluid buildup. Clean or replace parts as needed; see page 21 or 29.

needed; see page 32. Replace the gasket or tighten the manifold

screws; see page 37. Tighten the manifold screws; see page

37. Inspect or replace the o-rings.

24 308442

Troubleshooting

Electrical Troubleshooting

PROBLEM CAUSE SOLUTION

Poor wrap-around The turbine air is not on.

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 electros-

tatic spray. The voltage output is too low. The turbine alternator is not operating. The gun resistance is faulty. Fluid leaks from the fluid rod packing and

causes a short. The turbine alternator is faulty.

The KV switch is stuck on low.

The operator gets a shock The operator is not properly grounded or

is near an ungrounded object.

The gun is not properly grounded.

The operator gets a shock when touching the workpiece

The workpiece is not properly grounded. Clean the workpiece hangers; check for

Turn on the turbine air. 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. Check the possible causes listed below. Check the air supply to the gun. Check the gun resistance; see page 26. Clean the fluid rod cavity, replace the

packing; see page 31. Be sure the plug is in place on the back of

the turbine alternator housing; remove and test the turbine alternator; see page 36.

Check the switch actuation; replace the KV switch if necessary.

Be sure the floor and the operator are properly grounded; see Ground the Sys- tem, page 13.

See Check the Electrical Grounding, page 14.

proper grounding on the conveyor or track.

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

The fiber optic cable or connection is damaged.

The turbine air is not on.

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

Turn on the turbine air. See other causes under Problem - Poor

wrap-around, above. Refer also to the Graco ES display mod-

ule manual 308265.

308442 25

Electrical Tests

The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun. The following electrical tests can be used to determine the condition of the power supply (27) and the resistor stud (15), as well as the continuity of the electrical path between the components.

Flush the gun fluid passages with solvent and air. To get an accurate reading, the fluid hose must not have any fluid in it.

Use part no. 241079 megohmmeter (L) and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 241079 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:

Test Gun Resistance (See Fig. 16)

Measure the resistance between the end of the electrode (13) and the gun body (29). The resistance should be between 329 to 401 megohms. If the resistance is outside the specified range, go to the next test. If the resistance is correct, refer to Electrical Troubleshooting on page 25 for other possible causes of poor performance.

 The gun has been removed from the

hazardous area (see page 28 to remove gun);

 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.

03898B

Fig. 16

26 308442

Electrical Tests

T est Power Supply Resistance (See Fig. 17)

Remove the power supply (27) from the gun body (29) as instructed on page 35.

Measure the resistance from the power supply’s ground contact point (R) to the contact inside of the power supply seal (D) [the conductive rubber contact may be slightly recessed into the seal].

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.

NOTE: Be sure the seal (D) is in place on the end of the power supply before installing the power supply back into the gun.

Test Resistor Stud Resistance (See Fig. 18)

Remove the resistor stud (15) as instructed on page

29. Check the resistance between the black resistor

stud ring contact (S) and the needle contact ring (T). You may have to press down on the contact ring (S) in several places to get a good reading.

Fig. 17

0441

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 29 to replace the resistor stud.

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. 18. To reduce the risk of sparking, which could cause a fire, explosion, or electric shock, do not remove the resistor stud contact ring (S) or operate the gun without the contact ring in place. If the resistor stud (15) is being replaced, only use a genuine Graco part.

Fig. 18

0442

308442 27

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 23 to 25, before disassembling the gun.

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure

on page 16 when you stop spraying, before servicing the gun, and whenever you are instructed to relieve the pressure.

1. Flush the gun with a compatible solvent.

 If the plastic parts of the gun must be held in a vise,

use padded vise jaws to avoid damaging parts.

WARNING

EQUIPMENT MISUSE HAZARD

Do not mix or install parts from different PRO gun models. Some PRO 5500hc Gun parts look similar to other PRO Gun parts but they have different part numbers and they are not interchangeable. Use of parts other than those specified in the PRO 5500hc Gun parts list on page 39 could alter the grounding conti-

nuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction, which could result in a fire, explosion, or electric shock.

WARNING

FIRE, EXPLOSION, AND

ELECTRIC SHOCK HAZARD

To reduce the risk of a fire, explosion, or

electric shock:

 Be sure the turbine air (TA) is off

before flushing the gun or any part of the system.

 Clean all the parts with a compatible

solvent that is suitable for electrostatic equipment.

 Do not service this equipment unless you are

trained and qualified.

 Do not touch the gun nozzle or come within 4

inches (101.6 mm) of the nozzle during gun operation.

2. Relieve the system pressure.

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

4. Loosen the bottom gun screw (21) until the gun (B) sits loosely in the mounting bracket slot (A). Refer to Fig. 19.

CAUTION

The piston return spring (105) is compressed between the manifold (101) and gun body when they are assembled. To avoid sudden movement of the gun, loosen the bottom gun screw (21) before loosening the three manifold bolts (106). This allows the gun to move forward gradually as the manifold bolts are loosened. Hold the gun firmly in hand while loosening the manifold bolts.

5. Holding the gun (B) firmly in hand, loosen the three bolts (106) from the back of the manifold (101) with the ball end wrench (77–not shown).

6. Remove the gun (B) from the manifold (101), and take it to the service area.

105

106

101

CAUTION

Methylene chloride is not recommended as a flushing or cleaning solvent with this gun as it will damage nylon components.

28 308442

Fig. 19

102

03218

Air Cap/Nozzle/Resistor Stud Replacement

Service



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. Prepare the gun for service as instructed on page 28.

2. Point the front end of the gun up while removing the air cap assembly (1, 3, 9, 12). See Fig. 20.

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.

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. 21.

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. 20. To reduce the risk of sparking or electric shock, do not remove the contact ring (S) from the resistor stud or operate the gun without the contact ring in place. If the resistor stud (15) is being replaced, only use a genuine Graco part.

5. Lightly lubricate the o-ring (16) with petroleum jelly and install it on the resistor stud (15). See Fig. 20.

1, 3, 9,12

Fig. 20

 Tighten the resistor stud (15) into the nozzle (14) to 10 in-lbs (1.15

Nm).



Fig. 21

9 3





03455A

0444A

Continued on the next page.

308442 29

Air Cap/Nozzle/Resistor Stud Replacement (continued)

Service

CAUTION

6. Make sure the electrode needle (13) is tightened properly. Refer to Fig. 22.

7. Install the resistor stud (15) in the fluid nozzle (14). Tighten to 10 in-lb (1.12 Nm). See Fig. 21, page

29.

8. Install the fluid nozzle (14) and resistor stud (15) assembly with the multi-tool (83). See Fig. 20, page 29. Tighten until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past hand-tight).

9. Carefully install the air cap (12). Avoid bending 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.

10. Make sure the o-ring (9) is in place on the retaining ring (1). Tighten the air cap retaining ring (1) until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

11. Test the gun resistance as instructed on page 26.

12. Install the gun onto the manifold and bracket as instructed on page 37.

To avoid damaging the plastic threads or contact wire, be very careful when installing the electrode needle.

5. Install the gun shroud.

6. Install the fluid nozzle, resistor stud, and air cap assembly as instructed at left.

7. Test the gun resistance as instructed on page 26.

8. Install the gun onto the manifold and bracket as instructed on page 37.

 Apply low-strength (purple) Loctite or equivalent to the fluid rod

threads, then install the electrode needle (13) finger-tight; do not over-tighten.

Electrode Needle Replacement

1. Prepare the gun for service as instructed on page 28.

2. Remove the air cap, nozzle and resistor stud as instructed on page 29. Remove the gun shroud.

3. Unscrew and remove the electrode needle (13) with the multi-tool (83). See Fig. 22. 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.

Fig. 22



03899A

30 308442

Service

Fluid Packing Rod Removal and Repair

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 28.

2. Remove the air cap assembly and the gun shroud.

3. Remove the jam nut (46) and actuator arm (19). See Fig. 25, page 32.

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

4. Remove the fluid nozzle, resistor stud, and electrode needle as instructed on page 29.

5. Remove the fluid packing rod assembly (28) with the multi-tool (83). See Fig. 23.

7. If the parts are purchased separately, assemble them as instructed in steps 8 to 11 and as shown in Fig. 24, on page 32.

If installing the complete fluid rod assembly, go to step 12, page 32.

6. Clean all the parts, and check them for wear or damage. Replace the parts 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.

CAUTION

Clean all the parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.

Fig. 23

03902A

Continued on the next page.

308442 31

Service

Fluid Packing Rod Removal and Repair (continued)

8. Place the packing nut (28c) and o-ring (28g) on the fluid rod (28b). The flats on the packing nut must be facing toward the back of the fluid rod.

9. Fill the entire inner cavity of the spacer (28d) with petroleum jelly. Place the spacer on the fluid rod (28b), in the direction shown in Fig. 24. Generously apply petroleum jelly to the outside of the spacer.

10. Place the fluid packing (28f), needle packing (28e), and housing (28a) on the fluid rod (28b) as shown in Fig. 24.

11. 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.

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

13. Make sure the spring (11) is installed against the nut (U) as shown in Fig. 24.

14. Install the fluid packing rod assembly (28) into the gun barrel. Using the multi-tool (83), tighten the assembly until it is just snug, then check the drag on the fluid rod. See Fig. 23, page 31.

15. Install the electrode needle, fluid nozzle and resistor stud as instructed on page 30.

16. Install and adjust the actuator arm (19) and jam nut (46) as instructed on page 33.

17. Test the gun resistance as instructed on page 26.

18. Install the gun shroud and air cap assembly.

19. Install the gun onto the manifold and bracket as instructed on page 37.

 Apply a very light coat of lubricant to the o-ring (28h).  Fill the inner spacer (28d) cavity with petroleum jelly and gener-

ously lubricate the outside of the spacer.



28h

28f

28e

28b

Fig. 24

28a

28d

28g



28c

Piston Repair

1. Prepare the gun for service as instructed on page 28.

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. 25.

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

 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).

11U

46 19 36 23g

Fig. 25



03224

03904A

32 308442

Service

Piston Repair (continued)

4. Push on the piston rod (23g) to push the piston assembly out the back of the gun.

5. Inspect the o-rings (23a, 23b, 23c) and u-cup packing (23f) for damage. See Fig. 27. Refer to Fig. 28 to isolate any 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. 25.

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. 26. 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.

9. Test the gun resistance as instructed on page 26.

10. Install the gun shroud and air cap assembly.

11. Install the gun onto the manifold and bracket as instructed on page 37.

 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.



23d



23c



23b

23e



23f

23g



23a

Fig. 27

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.

23c

23b

03530

 There should be a 0.125 in. (3 mm) gap between the actuator arm

(19) and the fluid packing rod nut (U).

19 U



Fig. 26

04823

Fig. 28

Fan Air Side

23f

23a

Atomization Air Side

03531

308442 33

Service

Barrel Removal

1. Prepare the gun for service as instructed on page 28.

2. Remove the air cap assembly and the shroud from the gun.

3. Carefully loosen the fluid fitting nut (43). See Fig. 30. Pull the tube (33) out of the fitting. Make sure that both ferrules and the nut stay with the tube.

26 24

4. Remove the jam nut (46) and actuator arm (19).

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

5. Loosen the three screws (24) with the ball end wrench (77–not shown). See Fig. 29.

6. Hold the gun body (29) with one hand and pull the barrel (26) straight away from the body to remove it.

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. 29

03900A

Fig. 30

34 308442

46 19 36

03904A

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.

 Do not expose the seal (D) or gasket (27a) to

solvents as this will damage them.

1. Prepare the gun for service as instructed on page 28.

2. Remove the barrel as instructed on page 34.

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. 31.

4. Inspect the power supply for any physical damage. Check the electrical resistance as instructed in Test Power Supply Resistance, page 27. If necessary, replace the power supply.

5. Before installing the power supply, inspect the seal (D) for any damage or swelling. Make sure the gaskets and pads (27a–27f) are in place.

6. Lubricate the o-ring (25a) and insert the power supply in the gun body.

7. Assemble the gun as instructed in Barrel

Installation, page 36.

Power Supply Adjustment

The kV switch, in the manifold, enables you to switch between full voltage and a lower voltage output. The lower voltage is factory set at 60 kV, but can be adjusted between 45 and 80 kV.

To adjust the low voltage setting, use a small blade end screw driver to turn the potentiometer (W). Turn it clockwise to decrease the voltage or counterclockwise to increase the voltage; fully clockwise is 45 kV, fully counterclockwise is 80 kV.

 Apply a very light coat of lubricant to the o-ring (25a).  Do not expose the seal (D) or gasket (27a) to solvents.

Fig. 31

27a



27b



27f

27c

25b



25a

03903B

308442 35

Service

Turbine Alternator Removal and Replacement

NOTE: Replace the turbine bearings after 2000 hours

of operation. See your authorized Graco representative.

1. Prepare the gun for service as instructed on page 28.

2. Remove the power supply from the gun body as instructed on page 35.

3. 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. 31, page 35.

4. 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.

Barrel Installation

1. Be sure the gaskets (20, 27a) and spring (11) are in place. See Fig. 32. Replace the parts if they are damaged.

2. Place the barrel (26) over the power supply (27) and onto the gun body (29). Make sure the fluid needle spring (11) is seated properly.

3. Using the ball end wrench (77–not shown), tighten the three screws (24) oppositely and evenly to 18 in-lbs (2 Nm) maximum (about a half turn past snug); do not over-tighten.

CAUTION

To avoid damaging the gun, do not over-tighten the screws (24).

4. Install the fluid tube back into the fluid fitting (4) and tighten the nut (43).

5. Install and adjust the actuator arm (19) and jam nut (46) as instructed on page 33.

5. 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.

6. Install the power supply in the gun body as instructed on page 35.

7. Assemble the gun as instructed at right.

NOTE: Make sure the entire fluid tube (33) is clear of the actuator arm to avoid having the tube rub against it during operation.

6. Test the gun resistance as instructed on page 26.

7. Install the gun shroud and air cap assembly.

8. Install the gun onto the manifold and bracket as instructed on page 37.

36 308442

Service

 Tighten the screws (24) to 18 in-lbs (2 Nm) maximum (about half

turn past snug), using the wrench (77) provided.

 Install the nut (46) flush to the end of the piston rod (23g).





Fig. 32

 Adjust the nut (36) to create 0.125 in. (3 mm) gap between the

actuator arm (19) and the nut.

 Make sure the entire fluid tube (33) is clear of the actuator

arm (19).

27a



23g



03901A

Install the Gun onto the Manifold

1. Make sure the gaskets (108, 121), and spring (105) are in place on the manifold (101). See Fig.

33. Inspect the parts for damage and replace them as needed.

2. Secure the gun (B) to the manifold (101) by tightening the three screws (106) with the ball end wrench (77–not shown).

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

Fig. 33

121 108

105

102

308442 37

106

101

03218

Standard Spray Gun Parts

Part No. 236685 Standard PRO 5500hc Spray Gun

Item 23 includes 23a–23g Item 25 includes 25a & 25b Item 27 includes 27a–27f Item 28 includes 28a–28h

28a, 28c–28h

See page 39

27f

27b

27c

28b

25a

25b

27a

REF 33

23d

23c

23b

23a

10 5 4

23e

23f

23g

REF 33

38 308442

35 34

03905B

Standard Spray Gun Parts

Ref.

WARNING

No. Part No. Description Qty.

Some PRO 5500hc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When

servicing, do not mix or use other PRO Gun parts!

Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to malfunction and result in serious injury, fire, explosion or property damage.

Part No. 236685 Standard PRO 5500hc Spray Gun;

Includes items 1–85

Ref. No. Part No. Description Qty.

1 189768 RET AINING RING, air cap 1 2 189770 SHROUD 1 3 189786 GASKET, air cap nut 1 4 189549 FITTING, fluid, quick-disconnect 1 5* 111450 O-RING; fluoroelastomer 2 6 189367 CAP, exhaust 1 7 185122 MUFFLER/FLAME ARRESTOR 1 9 110492 O-RING, PTFE 10 108290 SCREW 1 1 1 185111 SPRING, compression 1 12 193033 AIR CAP; See Manual 307803 for

available air caps 1 13 190933 NEEDLE, electrode 1 14 191833 NOZZLE, fluid; See Manual 307803

for available nozzles 1 15 223977 STUD, resistor 1 16* 1 11507 O-RING; fluoroelastomer 1 17 186818 FITTING, fluid 1 18* 102982 O-RING; PTFE 1 19 186766 ARM, actuator 1 20 185113 GASKET, manifold; polyethylene 1 21 112689 SCREW, socket; 1/4 x 0.75” 1 23 236826 PISTON ASSY;

Includes items 23a–23g 1 23a 111508 23b 111504  O-RING; fluoroelastomer 2 23c 112319 23d 189355  STEM, piston 2 23e 189747 23f 189752  PACKING, u-cup; UHMW

23g 189754 24 185096 SCREW, cap, relieved; M5 x 0.8 3 25 222319 ALTERNATOR, turbine

25a 110073 25b 185124 26 223940 BARREL, gun 1 27 224093 POWER SUPPLY ASSY; 85 kV

 O-RING; fluoroelastomer 1

 O-RING; fluoroelastomer 2

 PISTON 1

polyethylene 1

 ROD, piston 1

Includes items 25a & 25b 1

 O-RING, Viton 1

 CUSHION 1

Includes items 27a–27f 1

 1

27a 186840 27b 185099 27c 185145 27f 192361 28 224747 PACKING ROD ASSY

28a 185495 28b 223981 28c 185488 28d* 186069 28e 178763 28f* 178409 28g* 111504 28h* 111316 29 190055 BODY, gun 1 30 185114 RETAINER RING, alternator 1 32* 103337 O-RING, Viton 2 33 TUBE; PTFE 1 34* 111286 FERRULE 1 35* 111285 FERRULE 1 36 102025 NUT, hex; 1/4”-20 1 37 112638 FITTING, fiber optic (shown on

43 112644 NUT ; for 1/4” O.D. tube fitting 1 46 101324 NUT, hex jam; 1/4”–20 1 75 236830 MANIFOLD ASSY.

77 107460 WRENCH, ball end 1 78 180060 SIGN, warning, English

83 191744 MULTI-TOOL 1 84 179791 TAG, warning 1 85 189888 COVER, gun 1

* These parts are included in Fluid Seal Repair Kit 237543,

which may be purchased separately.

 These parts are included in Air Seal Repair Kit 236827,

which may be purchased separately.

 These parts are not shown in the parts drawing.  Replacement Danger and Warning labels, tags and cards

are available at no cost.

 The coiled fluid tube parts (5, 17, 18, 32, 33) are available

as an assembly. Order part no. 237298.

REF NO. 28, Packing Rod Assembly

Includes items 28a–28h

 GASKET, power supply 1  PAD 1  PAD 2  PAD 1

Includes items 28a–28h 1

 HOUSING, packing 1  ROD, fluid 1  NUT, packing 1  SPACER, packing 1  PACKING, rod 1  PACKING, fluid 1  O-RING, fluoroelastomer 1  O-RING, fluoroelastomer 1

page 40) 1

See separate parts list on page 41 1

See Accessories for additional signs 1

28c

28g

28d

28f

28e

28a

28h

0601

308442 39

Manifold Parts

Front View

Back View



113

108



109

105

107

121



101



115

114



Ref. 101

106

110

110a



122



111

102



104

103

 Apply low strength (purple) Loctite or an

equivalent sealant to the threads.

 Press fit the spring (105)  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.

 Concave side of the disk (114) faces toward

the manifold.

 Replace the spring (122) every 300,000

cycles.

 An optional fiber optic fitting (37) is included

with the gun assembly; see page 39. Remove the plug (115) and install the fitting (37) if a KV display is being used.

03462

106



117



116

40 308442

118

112

03226

Manifold Parts

WARNING

Some PRO 5500hc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When

servicing, do not mix or use other PRO Gun parts!

Part No. 236830 Gun Manifold

For Standard PRO 5500HC Spray Gun; Includes items 101–122

Ref. No. Part No. Description Qty.

101 190056 MANIFOLD 1 102 189581 MOUNTING BRACKET 1 103 110465 BOLT, square head 2 104 112689 SCREW; 1/4–20 x 0.75” 2 105 112640 SPRING, compression 1 106 186846 BOLT, manifold; M5 x 0.8 3 107 111157 FITTING, tube; for 1/4” OD tube 3 108 189363 GASKET, manifold 1 109 108290 SCREW; 8–32 x 1/4” 2 110 236696 KV SWITCH; Includes item 110a 1 110a 111316  O-RING, fluoroelastomer 1 1 11 189365 KV CAP 1 112 110078 FITTING, tube; for 3/8” OD tube 2 113 186845 FITTING, turbine; 1/4–18 npsm

left hand thread 1 114 107107 DISK, regulator 1 1 15 112645 PLUG; 1/8–27 npt 1 1 16 112646 PLUG; 5/8–18 x 5/8” 1 1 17 189551 FLUID FITTING, quick-disconnect 1 118* 111450 O-RING; CV–75 1 121 190301 GASKET, foam 1 122 112641 SPRING 1

Part No. 236852 Optional Fiber Optic Kit

The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224117 to improve light transmission when two bulkhead splices are used. The kit includes items 201–203.

Ref. No. Part No. Description Qty.

201 112638 FITTING, fiber optic; see item 37 on

page 40 1 202 111224 LENS 1 203 189875 SLEEVE 1

202

203

04798

* These parts are included in Fluid Seal Repair Kit 237543,

which may be purchased separately.

 These parts are included in Air Seal Repair Kit 236827,

which may be purchased separately.

 Optional gaskets are available:

Part No. 111180: Viton

308442 41

Kit Parts and Installation

Part No. 237300 PRO 5500hc Conversion Kit; To convert the PRO

5500sc spray gun to the PRO 5500hc spray gun; Includes items 201–204

Ref. No. Part No. Description Qty.

201 237297 COILED TUBE ASSY. 1 202 112644 NUT ; nylon; for 1/4 ” O.D. tube 1 203 111285 FERRULE; nylon 1 204 111286 FERRULE; nylon 1

201

202 203

204

Fig. 34

03933A

7. Position the coiled tube assembly so its threaded inlet fitting (C) is aligned with the barrel fluid inlet (A), then tighten the fitting into the inlet as shown in Fig. 37.

8. Slide the nylon nut (202) and ferrules (203 & 204) onto the coiled tube assembly (201). See Fig. 34.

9. Install the coiled tube assembly (201) into the fluid fitting and tighten the nut (202). See Fig. 37. Make sure the entire tube is clear of the actuator arm (D) to avoid having the tube rub against it during operation.

10. Install the gun onto the manifold as instructed on page 37.

Fig. 35

A B

03934

Installing the PRO 5500hc Conversion Kit

WARNING

PRESSURIZED EQUIPMENT

To reduce the risk of a serious injury, follow the Pressure Relief Procedure

on page 16 when you stop spraying, before servicing the gun, and whenever you are instructed to relieve the pressure.

1. Flush the gun with a compatible solvent.

2. Relieve the system pressure.

3. Prepare the gun for service as instructed on page

28.

4. Remove the PRO 5500sc gun’s fluid tube, fittings, o-rings, and spacer (B). See Fig. 35.

5. Clean the barrel fluid inlet (A) with compatible solvent. Inspect the barrel fluid inlet for damage and replace if needed.

6. Slide the coils of the tube assembly (201) over the front of the gun barrel, until it is past the barrel fluid inlet (A). See Fig. 36 and 37.

42 308442

201

Fig. 36

Fig. 37

03935A

202D 201

03904A

Technical Data

Category Data

Gun Weight (gun

3.57 lb (1620 g)

and manifold)

Maximum Working

100 psi (7 bar, 0.7 MPa)

Pressure Air Pressure

Operating Range Fluid Pressure

Operating Range

0–100 psi (0–7 bar, 0–0.7 MPa)

0–100 psi (0–7 bar,

0–0.7 MPa) Voltage Output 0–85 kV Short Circuit Current

120 mA Output

Paint Resistivity

3 megohm-cm to infinity Range

Maximum Fluid

120F (49C) Temperature

Turbine Air Inlet 1/4 npsm(m) left-hand Typical Noise Level

at 40 psi (2.8 bar,

Sound Pressure  91 Db(A)

Sound Power  90.7 Db(A)

0.28 MPa)

Maximum Noise Level at 100 psi (7 bar, 0.7 MPa)

Sound Pressure  101.5 Db(A) Sound Power  107 Db(A)

Wetted Parts Stainless Steel, Nylon, Acetal,

PTFE,Kalrez, Ultra High Molecular Weight Polyethylene, Ceramic, Chemraz, Fluoro-polymer, Music Wire

 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.

Viton and Kalrez are registered trademarks of the

DuPont Co. Loctite

 is a registered trademark of the Loctite Corporation.

Chemraz Co.

 This is the allowable paint resistivity range for this gun.

 is a registered trademark of the Green, Tweed, &

Note that electrostatic effect may drop off below about 25 megohm cm.

308442 43

Accessories

Use Only Genuine Graco Parts and Accessories

CABLE ACCESSORIES

Fiber Optic Cable Assembly

For connection between gun manifold and display module or between bulkhead connector and display module.

PART NO. LENGTH

224682 25 ft (8 m) 224684 50 ft (15 m) 224686 100 ft (30.5 m)

Fiber Optic Cable Extender

For connection between gun manifold and bulkhead connector.

PART NO. LENGTH

224672 25 ft (8 m) 224674 50 ft (15 m) 224676 100 ft (30.5 m)

Bulkhead Connector 189870

For connection between two fiber optic cables.

AIR LINE ACCESSORIES

Conductive Air Supply Hose; black

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

FM Approved; Color coded black; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

220444 6 ft (1.8 m) 218100 15 ft (5 m) 218101 25 ft (8 m) 218102 36 ft (11 m) 218103 50 ft (15 m) 220119 75 ft (23 m) 220120 100 ft (30.5 m)

Conductive Air Supply Hose; gray

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

FM Approved; Color coded gray; More flexible than black hose; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

223068 6 ft (1.8 m) 223069 15 ft (5 m) 223070 25 ft (8 m) 223071 36 ft (11 m) 223072 50 ft (15 m) 223073 75 ft (23 m) 223074 100 ft (30.5 m)

Conductive Air Supply Hose; red

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

Meets CENELEC EN 50 050 requirement for metallic ground path; Color coded red; Stainless steel braid ground path; 0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread

235068 6 ft (1.8 m) 235069 15 ft (5 m) 235070 25 ft (8 m) 235071 36 ft (11 m) 235072 50 ft (15 m) 235073 75 ft (23 m) 235074 100 ft (30.5 m)

Air Shutoff Valve 224754

150 psi (10 bar, 1.0 MPa) Maximum Working Pressure

For turning air to gun off or on. 1/4 npsm(m) x 1/4 npsm(f) left-hand thread

Bleed-type Master Air Valve 107141

300 psi (21 bar, 2.1 MPa) Maximum Working Pressure

Relieves air trapped in the air line between the paint pump air motor and this valve when closed. 3/4 npt

FLUID LINE ACCESSORIES

Fluid Hose Assemblies (Nylon)

225 psi (14 bar, 1.4 MPa) Maximum Working Pressure

FM Approved; 1/4 in. (6.35 mm) ID, 3/8 npsm(fbe)

215637 25 ft (8 m) 215638 50 ft (15 m)

Fluid Hose Assemblies (Nylon)

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

FM Approved; 1/4 in. (6.35 mm) ID, 3/8 npsm(fbe)

216076 25 ft (8 m) 216077 50 ft (15 m) 216079 100 ft (30 m)

Fluid Shutoff/Drain Valve

500 psi (35 bar, 3.5 MPa) Maximum Working Pressure

For turning fluid off or on to the gun and for relieving fluid line pressure at the pump

208630 1/2 npt(m) x 3/8 npt(f); carbon steel and

PTFE; for non-corrosive fluids

44 308442

Accessories

Use Only Genuine Graco Parts and Accessories

MISCELLANEOUS ACCESSORIES

Grounding Clamp and Wire 222011

12 ga, 25 ft (7.6 m) wire

Megohmmeter 241079

500 Volt output; 0.01–2000 megohms.

Not for use in Hazardous areas.

TI0377

Paint Resistance Meter 722886

Used with 722860 Paint Probe to measure resistance of paint. Not for use in Hazardous areas.

Paint Probe 722860

Used with 722886 Paint Resistance Meter to measure resistance of paint. Not for use in Hazardous areas.

Safety Warning Signs

FM Approved; Available at no charge from Graco. Must be ordered separately.

180060 Warning Sign (English)

KV Display Module 189762

Receives fiber optic transmission from the gun and displays the gun’s output voltage. Battery operated.

ES Display Module 224117

Receives fiber optic transmission from the gun and displays the gun’s output voltage and current. Mounts in a standard 19” DIN Rack.

24 Volt Power Supply 235301

Provides 24 volt power for up to 23 ES Display Modules.

308442 45

Graco Standard Warranty

Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property , o r a ny other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

Graco makes no warranty , and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1–800–367–4023 Toll Free

Manual Change Summary

This manual has been changed per ECO V6565.

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.

International Offices: Belgium, Korea, Hong Kong, Japan

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

PRINTED IN U. S . A . 308442 September 1994, Revised September 2000

46 308442

Sales Offices: Minneapolis, Detroit

www.graco.com

Graco 236685, PRO 5500hc, 237300 Instructions And Parts List

Specifications and Main Features

Frequently Asked Questions

User Manual