Graco 236685 Instructions And Parts List
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Graco 236685 Instructions And Parts List

Graco 236685 Instructions And Parts List

Air spray gun
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INSTRUCTIONS-PARTS LIST
Parts
INSTRUCTIONS
AUTOMATIC ELECTROSTATIC, HIGH CONDUCTIVITY
Model PRO 5500hctAir 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
5500sct spray gun to the PRO 5500hc spray gun
NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals.
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
308442
Rev. G
03209

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Summary of Contents for Graco 236685

  • Page 1 5500sct 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 ECOPYRIGHT 1994, GRACO INC.

  • Page 2: Table Of Contents

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

  • Page 3: Warnings

    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. D Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction manual.
  • Page 4 D Use the equipment only for its intended purpose. If you are uncertain about the usage, call your Graco distributor. D Do not alter or modify this equipment. Use only genuine Graco parts and accessories. D Check the equipment daily. Repair or replace worn or damaged parts immediately.

  • Page 5: Introduction

    Introduction 03221 03904A PRO 5500sc Spray Gun PRO 5500hc Spray Gun 8 in. (203.2 mm) fluid path 20 in. (711.2 mm) fluid path Comparison of a PRO 5500sc to a PRO The PRO 5500sc and PRO 5500hc guns will perform equally well when spraying fluids with high resistivity, 5500hc Spray Gun as shown in the graph below.

  • Page 6: Fluid Characteristics And Gun Performance

    (which is marked fiber optic cable (V) connected to the gun manifold “TA”, see page 7) through a Graco electrically con- carries the signal from the gun to a remote ES ductive air hose. The air enters the manifold and is (electrostatic) display module.
  • Page 7 Introduction F.O. Manifold Back View 03209 03213 04803 Manifold Markings A1 Atomization Air Inlet Fitting Air Cap A2 Fan Air Inlet Fitting Fluid Nozzle CYL Cylinder Air Inlet Fitting Retaining Nut EXH Shroud Exhaust Outlet Fitting Shroud F.O. Fiber Optic Fitting Mounting Bracket KV kV Switch Air Inlet Manifold...

  • Page 8: Installation

    Installation BASIC SYSTEM Non-Hazardous Area Hazardous Area Fig. 1 Non-Hazardous Area Hazardous Area SYSTEM OPTIONS D Spraying Voltage Display Module F.O. 04801 Fig. 2 308442...

  • Page 9: Installing The System

    Fig. 1, page 8, shows a typical Model PRO 5500hc system. Fig. 2 shows some possible system options. Ground Wire on Graco Electrically Conductive Air Hose Graco Electrically Conductive Air Hose (Turbine Air Hose), See page 11 for part numbers Atomizing Air Hose, 3/8 inch (9.5 mm) O.D.

  • Page 10: Install The Air Line Accessories

    Installation Install the Air Line Accessories 2. Install a fluid regulator on the fluid line to control fluid pressure to the gun. 1. Install a bleed-type master air valve (X) on the main air supply line (W) to shut off all the air to the Install the Gun and Mounting Bracket gun.

  • Page 11: Connect The Air And Fluid Lines

    Use Only Graco Electrically Con- F.O. Fiber Optic Fitting (Optional) ductive Air Supply Hose. Connect the Graco Fiber Optic Cable as instructed on page 12. Connect the Graco electrically conductive air hose (B) kV Switch Air Inlet Fitting to the gun turbine air inlet and connect the hose Connect a 1/4 inch O.D.

  • Page 12: Optional Fiber Optic Cable Connection

    See Fig. 2, page 8, for a schematic of the fiber optic connections. 5. See manual 308265 to install a Graco ES Display Module. 1. Remove the 1/8 npt plug (115) from the manifold’s...

  • Page 13: Ground The System

    Installation Ground the System 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 WARNING hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on FIRE, EXPLOSION, AND page 14.

  • Page 14: Check The Electrical Grounding

    Installation Check the Electrical Grounding (See Fig. 10) a. If using a black or grey turbine air hose, use a megohmmeter (WW) to measure the resistance. Use an applied voltage of 500 WARNING minimum to 1000 volts maximum. Resistance should not exceed 2 megohms. FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD b.

  • Page 15: Install The Fabric Cover

    Installation Install the Fabric Cover (See Fig. 11) 2. Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for 1. Install the fabric cover (XX) over the front of the the presence of any paint or solvent. See Check gun and slide it back to cover the exposed tubing for Fluid Leakage on page 22.

  • Page 16: Operation

    307803 or spray system as instructed in this manual. consult your authorized Graco distributor to select the ____ 2. All the operators are trained how to properly appropriate fluid nozzle and air cap. Install the air cap...

  • Page 17: Adjusting The Spray Pattern

    Operation Adjusting the Spray Pattern 4. Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atom- Follow the steps below to establish the correct fluid ization. Refer to Fig. 13. For example, for a fluid flow and air flow.

  • Page 18: Activating And Adjusting The Electrostatics

    Operation Activating and Adjusting the Activating the kV Switch Electrostatics 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 1.

  • Page 19: Shutdown

    Operation Shutdown 1. Relieve the system pressure. 2. Flush and clean the equipment. Follow the instruc- WARNING tions in the Maintenance section, below. 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 pres- sure.
  • Page 20 Maintenance D Check the electrode wire: straighten it if it is bent Daily Care and Cleaning (continued) and replace it if it is broken or damaged. See Electrode Needle Replacement, page 30. WARNING D Check for fluid leakage from the gun and fluid hoses.

  • Page 21: Clean The Air Cap And Fluid Nozzle

    Maintenance Clean the Air Cap and Fluid Nozzle 6. Slide the shroud (2) onto the gun (P). Make sure the shroud o-ring (121) is in place. Equipment needed: D Soft bristle brush 7. Carefully install the air cap (12). Do not bend the D Solvent compatible with fluid being sprayed electrode (13) and be sure to insert the electrode wire through the center air cap hole.

  • Page 22: Check For Fluid Leakage

    Maintenance Check for Fluid Leakage (See Fig. 15) During operation, periodically check the manifold WARNING exhaust tube (YY) and both ends of the gun shroud (ZZ) for the presence of fluid. Fluid in these areas FIRE AND EXPLOSION HAZARD would indicate fluid leakage into the shroud, which If any fluid leakage from the gun is de- could be caused by leaks at the fluid tube connections tected, stop spraying immediately!

  • Page 23: Troubleshooting

    Troubleshooting WARNING WARNING ELECTRIC SHOCK HAZARD PRESSURIZED EQUIPMENT Installing and servicing this equipment To reduce the risk of a serious injury, requires access to parts which may follow the Pressure Relief Procedure cause an electric shock or other serious on page 16 before doing any mainte- injury if the work is not performed prop- nance or service on the gun or system.

  • Page 24: Gun Operation Troubleshooting

    Troubleshooting Gun Operation Troubleshooting PROBLEM CAUSE SOLUTION Fluid leakage from the fluid packing The fluid rod packings or fluid rod are Replace the packings or rod; see page area worn. Fluid leakage from the front of the The fluid rod is worn or damaged. Replace the fluid rod;...

  • Page 25: Electrical Troubleshooting

    The turbine air is not on. 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...

  • Page 26: Electrical Tests

    Electrical Tests The performance and safety of the spray gun are Test Gun Resistance (See Fig. 16) directly affected by the condition of the electrical components contained inside the gun. The following Measure the resistance between the end of the elec- electrical tests can be used to determine the condition trode (13) and the gun body (29).

  • Page 27: Test Power Supply Resistance

    (S) or operate the gun without the contact ring in place. If the resistor stud (15) is 0442 Fig. 18 being replaced, only use a genuine Graco part. 308442...

  • Page 28: Service

    Service Tools Included with the Gun WARNING D Ball End Wrench PRESSURIZED EQUIPMENT D Multi-tool To reduce the risk of a serious injury, follow the Pressure Relief Procedure Prepare the Gun for Service on page 16 when you stop spraying, before servicing the gun, and whenever you are NOTE: instructed to relieve the pressure.

  • Page 29: Air Cap/Nozzle/Resistor Stud Replacement

    (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. 0444A 5. Lightly lubricate the o-ring (16) with petroleum jelly Fig. 21 and install it on the resistor stud (15).

  • Page 30: Electrode Needle Replacement

    Service Air Cap/Nozzle/Resistor Stud CAUTION Replacement (continued) To avoid damaging the plastic threads or contact 6. Make sure the electrode needle (13) is tightened wire, be very careful when installing the electrode properly. Refer to Fig. 22. needle. 7. Install the resistor stud (15) in the fluid nozzle (14). Tighten to 10 in-lb (1.12 NSm).

  • Page 31: Fluid Packing Rod Removal And Repair

    Service Fluid Packing Rod Removal and Repair 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. NOTE: The fluid packing rod can be replaced as individual parts or as an assembly.

  • Page 32: Piston Repair

    Service Fluid Packing Rod Removal and Repair 12. Lubricate the o-ring (28h) on the outside of the packing housing (28a). (continued) 13. Make sure the spring (11) is installed against the 8. Place the packing nut (28c) and o-ring (28g) on the nut (U) as shown in Fig.
  • Page 33 Service Piston Repair (continued) Apply a very light coat of lubricant to the o-rings (23a, 23b, 23c) and u-cup (23f). 4. Push on the piston rod (23g) to push the piston Align the two stems (23d) with the holes in the gun body and assembly out the back of the gun.

  • Page 34: Barrel Removal

    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.

  • Page 35: Power Supply Removal And Replacement

    Service Power Supply Removal and Replacement 5. Before installing the power supply, inspect the seal (D) for any damage or swelling. Make sure the NOTES: gaskets and pads (27a–27f) are in place. D To avoid a loss in electrostatic performance, inspect the gun body power supply cavity for dirt or mois- 6.

  • Page 36: Turbine Alternator Removal And Replacement

    See Fig. 32. Replace the parts if they are NOTE: Replace the turbine bearings after 2000 hours damaged. of operation. See your authorized Graco representa- tive. 2. Place the barrel (26) over the power supply (27) and onto the gun body (29). Make sure the fluid 1.

  • Page 37: Install The Gun Onto The Manifold

    Service Tighten the screws (24) to 18 in-lbs (2 NSm) maximum (about half Adjust the nut (36) to create 0.125 in. (3 mm) gap between the turn past snug), using the wrench (77) provided. actuator arm (19) and the nut. Install the nut (46) flush to the end of the piston rod (23g).

  • Page 38: Standard Spray Gun Parts

    Standard Spray Gun Parts 28a, 28c–28h Part No. 236685 See page 39 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 REF 33 03905B REF 33...
  • Page 39 223981 ROD, fluid property damage. 185488 NUT, packing 28d* 186069 SPACER, packing 178763 PACKING, rod Part No. 236685 28f* 178409 PACKING, fluid Standard PRO 5500hc Spray Gun; 28g* 111504 O-RING, fluoroelastomer 28h* 111316 O-RING, fluoroelastomer Includes items 1–85...

  • Page 40: Manifold Parts

    Manifold Parts Front View 110a 03462  Apply low strength (purple) Loctite or an Back View equivalent sealant to the threads. Press fit the spring (105) Tighten the fitting until the hex bottoms against Ref. 101 the manifold. This fitting (113) has left-hand threads. Install the KV cap (111) flush to the outside surface.
  • Page 41 Manifold Parts Part No. 236852 Optional Fiber Optic Kit WARNING The kit is not included with the gun. The kit is only for use with the ES Display Part No. 224117 to improve Some PRO 5500hc Gun replacement parts look similar to light transmission when two bulkhead splices are used.

  • Page 42: Kit Parts And Installation

    Kit Parts and Installation Part No. 237300 7. Position the coiled tube assembly so its threaded PRO 5500hc Conversion Kit; To convert the PRO inlet fitting (C) is aligned with the barrel fluid inlet 5500sct spray gun to the PRO 5500hc spray gun; (A), then tighten the fitting into the inlet as shown Includes items 201–204 in Fig.

  • Page 43: Technical Data

    Technical Data Sound Pressure { 101.5 Category Data Maximum Noise Level at 100 psi Db(A) Gun Weight (gun 3.57 lb (1620 g) Sound Power } 107 Db(A) (7 bar, 0.7 MPa) and manifold) Wetted Parts Stainless Steel, Nylon, Acetal, Maximum Working 100 psi (7 bar, 0.7 MPa) PTFE,rKalrezr, Ultra High Pressure...

  • Page 44: Accessories

    Accessories Use Only Genuine Graco Parts and Accessories CABLE ACCESSORIES Conductive Air Supply Hose; red 100 psi (7 bar, 0.7 MPa) Maximum Working Pressure Fiber Optic Cable Assembly Meets CENELEC EN 50 050 requirement for metallic For connection between gun manifold and display ground path;...
  • Page 45 Not for use in Hazardous areas. Grounding Clamp and Wire 222011 Safety Warning Signs 12 ga, 25 ft (7.6 m) wire FM Approved; Available at no charge from Graco. Must be ordered separately. 180060 Warning Sign (English)

  • Page 46: The Graco Warranty And Disclaimers

    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.

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