Graco Inc 222600, 307912, 222300 User Manual

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INSTRUCTIONS-PARTS LIST

307912

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

INSTRUCTIONS

Model PRO 3500sc Electrostatic Air Spray Gun

65 kV, MANUAL GUN

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

Part No. 222300, Series B

With Two-Finger Trigger

Part No. 222600, Series B

With Four-Finger Trigger

Rev. AC

Part No. 222300 shown

NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals. U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774 ; D313,064; 4,978,075

Patented 1986, 1987 Canada Brevete 1986, 1987 U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327B French Patent No. 89 16305 Other U.S. and Foreign Patents Pending

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

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

06443

Table of Contents

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

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

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

How the Electrostatic Air Spray Gun Works 5. . . .

Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the System 5. . . . . . . . . . . . . . . . . . . . . . . .

Warning Signs 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilate the Spray Booth 5. . . . . . . . . . . . . . . . . . . .

Non-hazardous Area 6. . . . . . . . . . . . . . . . . . . . . . . .

Hazardous Area 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Air Line 7. . . . . . . . . . . . . . . . . . . . . . . .

Connect the Exhaust Tube 7. . . . . . . . . . . . . . . . . . .

Connect the Fluid Line 7. . . . . . . . . . . . . . . . . . . . . . .

Ground the System 8. . . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding 9. . . . . . . . . . . . . . .

Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 11. . . . . . . . . . . . . . . . . .

Filter the Fluid 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Checklist 11. . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Fluid Nozzle and Air Cap 12. . . . . . . . .

Operating the Spray Gun 12. . . . . . . . . . . . . . . . . . .

Shutdown 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Gun for Service 22. . . . . . . . . . . . . . . . . . . .

Air Cap/Nozzle/Resistor Stud Replacement 22. . . . . .

Electrode Replacement 23. . . . . . . . . . . . . . . . . . . . . . . .

Barrel Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing Removal 25. . . . . . . . . . . . . . . . . . . . . . . .

Fluid Packing and Needle Repair 26. . . . . . . . . . . . . . . .

Power Cartridge Replacement 27. . . . . . . . . . . . . . . . . .

Turbine Alternator Replacement 28. . . . . . . . . . . . . . . .

Barrel Installation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Air Adjustment Valve Repair 29. . . . . . . . . . . . . . . .

Fluid Adjustment Assembly Repair 30. . . . . . . . . . . . . . .

Air Trigger Valve Repair 31. . . . . . . . . . . . . . . . . . . . . . . .

Atomizing Air Valve Removal and Replacement 31. . .

ES ON-OFF Valve Repair 32. . . . . . . . . . . . . . . . . . . . . .

Parts 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Graco Warranty and Disclaimers 40. . . . . . . . . .

Graco Phone Number 40. . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Care and Cleaning 14. . . . . . . . . . . . . . . . . . . .

Clean the Air Cap and Fluid Nozzle 15. . . . . . . . . .

Flush the Spray Gun 15. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Pattern Troubleshooting 16. . . . . . . . . . . . . . .

Gun Operation Troubleshooting 17. . . . . . . . . . . . . .

Electrical Troubleshooting 18. . . . . . . . . . . . . . . . . . .

Electrical Tests 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Gun Resistance 19. . . . . . . . . . . . . . . . . . . . . . .

Test Power Supply Resistance 20. . . . . . . . . . . . . . .

Test Resistor Stud Resistance 20. . . . . . . . . . . . . . .

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 307912

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 8.

 Check the spray gun resistance daily. See Test Gun Resistance, page 19.  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 5.

 When cleaning, flushing, or purging electrostatic equipment, use solvents that comply with your

local regulations. For countries following the U.S. National Fire Protection Association (NFPA) 33 requirements, use solvents with a flash point higher than 100 F (38 C) or a solvent normally used in spray operations. For European Countries complying with EN 50053, use solvents with a flash point as high as possible and higher than the ambient temperatures.

 Use only non-sparking tools to clean residue from the booth and hangers.  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.  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.

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.

Warnings are continued on the next page.

307912 3

WARNING

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 11 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.

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

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

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

distributor.

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

4 307912

Introduction

How the Electrostatic Air Spray Gun Works

The air hose supplies air to the spray gun. Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed. The turbine generates power, which is converted by the power cartridge, to supply high voltage current to the gun’s ionizing electrode.

Installation

Installing the System

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.

The pump supplies fluid to the hose and gun, where the fluid is electrostatically charged as it passes the electrode. The charged fluid is attracted to the grounded workpiece, wrapping around and evenly coating all surfaces.

Warning Signs

Mount 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 English, French, German, and Spanish signs are available at no charge. See Accessories to order them.

Ventilate the Spray Booth

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.

 Comply with all applicable local, state, and

national fire, electrical, and other safety regulations.

Fig. 1 shows a typical electrostatic air spray system. It is not an actual system design. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, contact your Graco distributor.

Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.

NOTE: High velocity air exhaust will decrease the operating efficiency of the electrostatic system. Air exhaust velocity of 100 ft/min (31 linear meters/minute) should be sufficient.

307912 5

KEY A Main Air Supply Line

B* Ventilation Fan Interlock Solenoid Valve C* Main Air Supply Shutoff Valve (bleed-type) D Air & Water Separator E* Pump Air Supply Shutoff V alve (bleed-type) F Air Line Lubricator G Air Pressure Regulator H Pump J* Pump Ground Wire K Fluid Filter L Fluid Supply Line Shutoff Valve M Fluid Pressure Regulator N Fluid Supply Line O Air Filter (20 micron)

Installation

P Air Supply Line Shutoff Valve Q* Air Hose Ground Wire R* Graco Electrically Conductive Air Hose S Electrostatic Spray Gun T Air Line Drain Valve U* Fluid Drain Valve V Gun Air Inlet W Gun Fluid Inlet X Gun Exhaust Tube

* Required for safe operation. Must purchase separately. See

Accessories. NOTE: Solenoid Valve (B) is not offered as a Graco accessory.

ES ON-OFF Lever

1 is ON 0 is OFF

Fig. 1

B* C* D

K L

Non-hazardous Area Hazardous Area

The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on.

WARNING

SIGN

0389

6 307912

Installation

Connect the Air Line (Refer to Fig. 1)

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an 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.

1. Connect the Graco Electrically Conductive Air Supply Hose (R) between the air supply line and the gun’s air inlet (V). The gun air inlet fitting has a left hand thread. Connect the air supply hose ground wire to a true earth ground.

2. Install an air line filter (O) and an air and water separator (D) on the air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.

3. Install a bleed-type air regulator (G) on the pump and gun air supply lines to control air pressure to the pump and gun.

4. Install a bleed-type air shutoff valve on the main air line (C) and the pump air line (E) to shut off air to the pump. Install an additional bleed-type valve on each pump air supply line to relieve air trapped between this valve and the pump after the air regulator is shut off.

5. Install an air line lubricator (F) as close to the pump (H) as possible.

6. Install an air shutoff valve (P) on each gun air supply line to shut off air to the gun(s).

Connect the Exhaust Tube

Press the exhaust tube (provided) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp provided. Refer to page 34.

Connect the Fluid Line (Refer to Fig. 1)

1. Before connecting the fluid line (N), blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

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

3. Install a fluid filter (K) and drain valve (U) at the pump outlet.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The fluid drain valve (U) 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.

WARNING

PRESSURIZED EQUIPMENT HAZARD

The bleed-type air shutoff valve is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury, including splashing in the eyes or on the skin.

4. Connect the fluid line to the 3/8–18.6(m) gun fluid inlet (W).

5. Before running any paint through the spray gun, flush it out with a compatible solvent.

307912 7

Installation

Ground the System

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

When operating the electrostatic device, any ungrounded objects in the spray area (such as people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock. Follow the grounding instructions below.

The following are minimum grounding requirements for a basic electrostatic system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.

1. Pump: ground the pump by connecting a ground wire and clamp as described in your separate pump instruction manual.

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

3. Electrostatic Air Spray Gun: ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 9.

4. All air and fluid lines must be properly grounded. Use only grounded hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity.

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. The operator must not wear gloves that insulate the hand from the spray gun. The gloves must be conductive or modified as shown in Fig. 3, page 11.

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

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

8 307912

Installation

Check the Electrical Grounding (See Fig. 2)

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 241079 (AA-see Fig.

2) 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.

b. If using a red turbine air hose, use an ohmme-

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

6. 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 air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the air hose.

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

2. Turn the ES ON-OFF Lever to OFF. See Fig. 4, page 12, for the location of the lever.

3. Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.

4. Make sure the air hose (R) is connected and the hose ground wire is connected to a true earth ground.

5. Measure the resistance between the gun handle (BB) and a true earth ground (CC).

a. If using a black or grey air hose, use a me-

gohmmeter (AA) to measure the resistance. Use an applied voltage of 500 minimum to 1000 volts maximum. The resistance should not exceed 2 megohms.

0644B

Fig. 2

307912 9

Notes

10 307912

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 electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

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

1. Turn the ES ON–OFF Lever to OFF.

2. Turn off the air and fluid supply to the gun.

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

4. Open the pump drain valve, having a waste container ready to catch the drainage.

5. Leave the pump drain valve open until you are ready to spray again.

Filter the Fluid

Operating Checklist

Check the following list daily, before starting to operate the system, to help ensure safe, efficient operation.

____ 1. All the operators are properly trained to

safely operate an electrostatic air spray system as instructed in this manual.

____ 2. All the operators are trained how to properly

relieve pressure as instructed at left.

____ 3. The system is thoroughly grounded and the

operator and all persons entering the spray area are properly grounded. See Ground the System, page 8.

____ 4. The operator is not wearing gloves which

insulate the hand from the spray gun. If worn, gloves must be conductive or modified as shown in Fig. 3 so as not to interfere with the operator grounding through the gun.

____ 5. The condition of the electrical components of

the spray gun has been checked as

instructed in Electrical Tests, page 19. ____ 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.

Filter the fluid to remove coarse particles and sediment which could clog the spray nozzle.



 3 in. (76 mm) square cut out and finger of glove cut off

NOTE: If gloves are worn, they must be conductive or modified as shown so they do not interfere with operator grounding through the gun.

Fig. 3

06445

____ 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.

307912 11

Operation

06443

Fig. 4

Selecting a Fluid Nozzle and Air Cap

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 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, P/N 185158, and air cap, P/N 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 22.

26 43

05151A

Operating the Spray Gun

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop

spraying and whenever you are instructed to relieve pressure.

WARNING

COMPONENT RUPTURE HAZARD

To reduce the risk of component rupture, which can cause serious injury, do not

exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (7 bar, 0.7 MPa) maximum working air and fluid pressure.

12 307912

Follow the steps on page 13 to establish the correct fluid flow and air flow. Do not turn the ES ON-OFF lever to ON yet.

Operation

Operating the Spray Gun (continued)

1. Follow the Operating Checklist on page 11.

2. To adjust the air cap for a vertical or horizontal spray pattern, first make sure the pressure is relieved. Then loosen the air cap retaining nut, and rotate the air cap as directed in Fig. 5. Tighten the retaining nut until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

Vertical Pattern

Horizontal Pattern

Fig. 5

3. Adjust the fluid flow by using 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.

4. If necessary, further adjust the fluid flow rate with the fluid adjustment knob (45). See Fig. 4.

5. Fully open the fan air valve (43).

02020

7. Set the atomizing air valve (31) about 1.5 turns out for most applications. The Atomizing Air Valve Adjustment chart shows the effect of the atomizing air valve adjustment on the air cap air flow.

8. Adjust the pattern width with the fan air valve (43).

Atomizing Air Valve Adjustment

100

90 80 70 60 50 40 30 20

Air Cap Air Flow (%)

0.00 0.50 1.00 1.50 2.00 2.50 3.00

Fully Open Fully Closed

Valve Turns

Fine Adjustments of the Spray Gun

 To improve the atomization, open the atomizing air

valve further (31). If more atomizing air is needed beyond the fully open position of the valve, increase the air hose inlet pressure.

Use the lowest air flow settings needed for acceptable atomization. The slower particle velocity will improve the electrostatic effect.

 To reduce the atomization air and minimize any

overspray, turn the atomizing air valve in.

6. Set the air pressure with the air pressure regulator. The following chart shows the air hose inlet pressure required to get full voltage from the power supply. To avoid shortening the turbine life, do not exceed the recommended air pressures.

Air Hose

Length

ft. (m) 15 (4.6) 45 to 50 (3.1 to 3.5, 0.31 to 0.35) 25 (7.6) 50 to 55 (3.5 to 3.8, 0.35 to 0.38)

50 (15.3) 60 to 65 (4.2 to 4.5, 0.42 to 0.45) 75 (22.9) 68 to 73 (4.7 to 5.0, 0.47 to 0.50)

100 (30.5) 75 to 80 (5.2 to 5.5, 0.52 to 0.55)

Dynamic pressure at air hose inlet

required for full voltage

psi (bar, MPa)

NOTE: See the Spray Pattern Troubleshooting chart on page 16 to correct spray pattern problems.

9. Turn the ES ON-OFF lever to ON to begin spraying with the electrostatics. When spraying, the ES indicator light (DD) should glow, indicating the electrostatic charge.

CAUTION

Hang the gun with its nozzle pointing down when it is not being used to avoid having fluid run into the gun air passages. Fluid in the gun air passages can cause poor atomization and excessive current demands and damage the gun.

307912 13

Operation

Shutdown

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop

spraying and whenever you are instructed to relieve pressure.

Maintenance

Daily Care and Cleaning

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 when you stop

spraying, before cleaning or flushing the spray gun, and whenever you are instructed to relieve the pressure.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, or electric shock, turn the ES ON-OFF lever OFF before flushing the gun.

1. Relieve the pressure.

2. Flush and clean the equipment. Follow the instruction in Maintenance.

1. Clean the fluid and air line filters daily.

2. Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent.

3. Clean the air cap and fluid nozzle daily, minimum. See page 15. Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See page 22.

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

23.

5. Check for fluid leakage from the gun and fluid hoses. Tighten fittings or replace equipment as needed.

6. Check all of the work hangers for build-up of material; clean them if necessary.

CAUTION

Fluid left in gun air passages could result in a poor quality paint finish and may draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the alternator life.

 Immersing the gun in fluid is not recom-

mended.

 Do not use any cleaning method which may

allow solvent into the gun air passages. Point the gun down while cleaning to prevent fluid from running into the air passages. See Fig. 6.

 Hang the gun with its nozzle pointing down

when it is not being used.

Clean all parts with a non-conductive, compatible solvent. 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.

7. Flush the gun before changing colors and whenever you are done operating the gun. See page 15.

14 307912

Maintenance

Clean the Air Cap and Fluid Nozzle

WARNING

CAUTION

Do not use metal tools to clean the air cap or spray nozzle holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or spray nozzle or a damaged electrode wire can distort the spray pattern.

Equipment needed:

 Soft bristle brush  Compatible solvent

Procedure:

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop

spraying, before installing or cleaning the fluid nozzle, and whenever you are instructed to relieve the pressure.

1. Relieve the pressure.

2. Remove the air cap assembly.

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 whenever you stop

spraying and whenever you are instructed to relieve the pressure.

1. Relieve the pressure.

2. Disconnect and plug the fluid line.

3. Connect the solvent supply to the gun.

4. Flush the gun with compatible solvent into a grounded container until it is clean.

5. Relieve the pressure.

6. Disconnect and plug the solvent line.

7. Trigger the gun into a grounded container to drain out the solvent remaining in the gun.

8. Place the gun in its hanging bracket, with the nozzle pointing down, until it is used again.

9. When ready to spray again, reconnect the fluid supply line.

3. With the front of the gun pointed down, clean the air cap, fluid nozzle, and front of the gun, using a soft bristle brush and compatible solvent. See Fig.

4. Carefully re-install the air cap assembly. Avoid bending the electrode. Tighten the retaining nut until it is snug, allowing the air cap to turn with resistance.

5. Test the gun resistance as instructed on page 19.

Flush the Spray Gun

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of fire, explosion, or electric shock, turn the ES ON-OFF lever OFF before flushing the gun.

10. Turn on the fluid and air supplies.

11. Make sure the ES ON-OFF lever is OFF.

12. Trigger the gun until it is clear of solvent.

06446

Fig. 6

307912 15

Troubleshooting

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious

injury if the work is not performed properly. Do not

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 11 before checking or

servicing any part of the system and whenever you are instructed to relieve the pressure.

WARNING

install or service this equipment unless you are trained and qualified.

NOTE: Check all possible remedies in the Troubleshooting Chart 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

Improper spray pattern

The fluid supply is insufficient. Adjust the fluid regulator, or fill the fluid

supply.

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

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

The coupler at the fluid inlet is loose or cracked.

Loose fluid tube in tank. Tighten. There is fluid build-up on the air cap;

partially clogged horn holes; or full air pressure from the clean horn hole forces the fan pattern toward the clogged end.

The electrode is bent. Straighten the electrode. 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. Straighten the electrode wire. The fan air pressure is too high. Reduce the fan air pressure.

Tighten or replace the fluid nozzle; see page 22.

Clean the parts; see page 15.

Tighten or repair the coupler .

Clean the air cap with a soft implement or submerge it in water and wipe it clean; see page 15.

Replace the damaged part; see page 22.

Remove the obstruction; never use wire or hard instruments; see page 15.

Streaks

16 307912

The fluid is too thin. Increase the fluid viscosity. There is not enough fluid pressure. Increase the fluid pressure. The fan air pressure is too low. Increase the fan air pressure.

The fluid is too thick. Reduce the fluid viscosity. There is too much fluid. Reduce the fluid flow. Reduce fluid pres-

sure on pressure feed guns and/or adjust the fluid adjusting screw until proper pattern is obtained.

The last coat of fluid is applied too wet. Apply a drier finish using multiple strokes. There is too much air pressure. Decrease the air pressure. The air pressure is insufficient. Increase the air pressure. The spray pattern is non-uniform. Clean or replace the air cap; see page 15

or 22.

Troubleshooting

Gun Operation Troubleshooting

Problem Cause Solution

Fluid leakage from the fluid packing area

Air leakage from the front of the gun

Fluid leakage from the front of the gun

“Orange Peel” finish

Excessive spray fog

No fluid sprays from the gun The fluid supply is low. Check the fluid supply; add fluid if

The equipment is covered with fluid

The air cap is dirty

The needle packings or shaft are worn. Replace the packings or shaft; see page

26. The packing nut is loose Tighten the packing nut; see page 26. The air valve is not seating properly. Clean and service the air valve; see page

31. The air valve o-ring is sticking. Lubricate the o-ring; see page 31. The needle is worn or damaged. Replace the needle; see page 26. The fluid seat is worn. Replace the fluid nozzle and/or electrode

needle; see pages 26 to 23.

The fluid packing is too tight. Lubricate and adjust the packing nut; see

page 26. The resistor stud is loose. Tighten the resistor stud; see page 22. The fluid nozzle is loose. Tighten the fluid nozzle; see page 22. The resistor stud o-ring is damaged. Replace the o-ring; see page 22. The air pressure is insufficient for good

atomization.

The fluid is poorly mixed or filtered. Remix or refilter the fluid. An improper thinner is being used. Use the proper thinner. The air pressure is too high. Reduce the air cap air pressure by closing

The fluid is thinned too much. Properly thin the fluid.

The air cap is damaged. Replace the air cap; see page 22. The fluid nozzle is dirty or clogged. Clean the fluid nozzle; see page 15. The fluid nozzle is damaged. Replace the fluid nozzle; see page 22. The fluid adjustment valve is damaged. Replace the o-ring; see page 31. The exhaust air flow is insufficient or not

directed properly. The distance between the gun and work-

piece is incorrect. The air cap and fluid nozzle are mis-

aligned.

Increase the air cap air pressure by open-

ing the atomizing air valve more or in-

creasing the gun air inlet pressure; use

the least air pressure needed for good

results.

the atomizing air valve more or decreas-

ing the gun air inlet pressure; use the

least air pressure needed for good results.

Do not reduce below minimum pressure

needed for full voltage. See page 13.

necessary.

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).

Check the air cap and fluid nozzle seat for

fluid buildup.

Air Cap

Fluid Nozzle

ALIGNED MISALIGNED

Clean or replace parts as needed; see

page 15 or 22.

307912 17

Troubleshooting

Electrical Troubleshooting

Problem Cause Solution

Poor wrap-around The ES ON-OFF lever is in the OFF (O)

position.* The distance between the gun and work-

piece is incorrect. The parts are poorly grounded. Clean the workpiece hangers. Check for

The booth exhaust velocity is too high. Reduce exhaust velocity within code limits. The atomizing air pressure is too high. Reduce the atomizing air pressure. The fluid pressure is too high. Reduce the fluid pressure. The fluid viscosity is not right for electros-

tatic spray. The fluid resistivity is too low. Check the fluid resistivity with a paint meter

The turbine alternator is not operating.* Check if the ES ON-OFF lever is ON (1).

The gun resistance is faulty. Check the gun resistance. See page 19. Fluid leaks from the needle packing and

causes a short. The turbine alternator is faulty. Be sure the plug is in place on the back of the

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

is near an ungrounded object. The gun is not properly grounded. See Check the Electrical Grounding,

Operator gets a shock when touching the workpiece

The workpiece is not properly grounded. Clean workpiece hangers. Check for proper

Turn the lever to ON (1).

Adjust the spraying distance to 8 to 12 inches (203 to 305 mm)

proper grounding on the conveyer or track.

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

and probe.

Check the air supply to the gun. Check for dirt or moisture in the turbine. See page 28.

Clean the needle cavity. Replace the fluid needle. See page 26.

turbine alternator housing. Remove and test the turbine alternator. See page 28.

Be sure the floor and the operator are properly grounded. See Ground the System, page 8.

page 9.

grounding on the conveyor or track.

* ES indicator light is not on when the gun is triggered.

18 307912

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 electrical tests below can be used to determine the condition of the power supply (18) and the resistor stud (22) as well as the continuity of the electrical path between the components.

Use megohmmeter P/N 241079 (A) 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 (A-see Fig.

7) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to do electrical tests unless:

 The gun has been removed from the

hazardous area;

Measure the resistance between the end of the electrode (20) and the gun air fitting (17). See Fig. 7. The resistance should be between 180 to 220 megohms. If the resistance is outside the specified range, go to the next test. If the resistance is correct, resume spraying or refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor performance.

 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.

Test Gun Resistance

Check the resistance with the gun triggered and with the trigger released. The fluid passage must be flushed and dried to get an accurate reading.

Fig. 7

06447B

Continued on the next page.

307912 19

Electrical Tests

Test Power Supply Resistance

Remove the power cartridge (18) from the gun handle. See Power Cartridge Replacement on page 27.

Remove the turbine alternator from the power cartridge. See Turbine Alternator Removal on page 28.

Measure the resistance from the power supply’s ground contact point (EE) to the contact spring (18c) on the other end of the power supply. See Fig. 8.

The resistance should be 157.5 to 192.5 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.

If you still have problems, refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor performance, or contact the nearest authorized service agency.

Test Resistor Stud Resistance

Insert a conductive rod (B) into the gun barrel (removed for the power supply test) and against the metal contact (C) in the front of the barrel. See Fig. 9.

Fig. 8

18c

03566B

Measure the resistance between the conductive rod (B) and the gun electrode (20). The resistance should be 21 to 29 megohms. If the resistance is correct, resume spraying or refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor performance. Contact the nearest authorized service agency if problems continue.

Fig. 9

Continued on the next page.

06448B

20 307912

Electrical Tests

Test Resistor Stud Resistance (continued)

If the resistance is outside the specified range, remove the resistor stud (22). See Air Cap/Nozzle/Resistor Stud Replacement on page 22. Check the resistance between the black resistor stud contact ring (D) and the needle contact ring (E). Refer to Fig. 10. You may have to press down on the contact ring (D) in several places to get a good reading.

The resistance should be 21 to 29 megohms. If the resistance is correct, make sure the metal contact (C) in the barrel and the needle contact wire (E) are clean. If the resistance is outside the specified range, the resistor is defective and the resistor stud (22) must be replaced. See Air Cap/Nozzle/Resistor Stud Re-

placement on page 22.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

The resistor stud contact ring (D) is a conductive contact ring, not a sealing o-ring. See Fig. 10. To reduce the risk of sparking or electric shock, do not remove the resistor stud contact ring (D) or operate the gun without the contact ring in place. Do not replace the resistor stud (22) with anything but a genuine Graco part.

Fig. 10

0442

307912 21

Service

Prepare the Gun for Service

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may

cause an electric shock or other serious injury if the work is not performed properly. Do not install or service this equipment unless you are trained and qualified.

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of injury, follow the Pressure Relief Procedure on page 11 before checking or

servicing any part of the system and whenever you are instructed to relieve the pressure.

NOTE:

 Check all possible remedies in Troubleshooting

before disassembling the gun.

Air Cap/Nozzle/Resistor Stud Replacement

CAUTION

Hold the front end of the gun up, and trigger the gun 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.

1. Prepare the gun for service as instructed at left.

2. Remove the air cap assembly. Point the front end of the gun up and squeeze the trigger while removing the fluid nozzle/resistor stud (21, 22) assembly with the multi-tool (62). See Fig. 11, page 23.

NOTE: If the resistor stud remains in the gun when the fluid nozzle is removed, start the nozzle thread onto the stud and pull the stud out.

3. Unscrew and remove the resistor stud (22) with the multi-tool (62). See Fig. 12.

 If the plastic parts of the gun must be held securely,

always clamp them in padded vice jaws to prevent damage to the parts.

 Lightly lubricate o-rings and seals with petroleum

jelly. Do not over-lubricate.

 Only use genuine Graco parts. Do not mix or use

parts from other PRO Gun models. See page 35.

1. Flush the gun as instructed in Flush the Spray Gun, page 15.

2. Relieve the pressure.

3. Disconnect the air and fluid lines from the gun.

4. Remove the spray gun from the worksite for service or repair. Service or repair area must be clean.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

The resistor stud contact ring (D) is a conductive contact ring, not a sealing o-ring. See Fig. 11. To reduce the risk of sparking or electric shock, do not remove the resistor stud contact ring (D) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine Graco part.

To install the resistor stud:

4. Lightly lubricate the o-ring (25) with petroleum jelly and install it on the resistor stud (22).

5. Using the multi-tool (62), install the resistor stud (22) in the fluid nozzle (21). Tighten to 10 in-lb (1.12 Nm).

NOTE: Make sure the electrode (20) is tightened properly, as shown in Fig. 13.

22 307912

Continued on the next page.

Service

Air Cap/Nozzle/Resistor Stud Replacement (continued)

6. Trigger the gun while installing the fluid nozzle (21) and resistor stud (22) assembly with the multi-tool (62). Tighten until the fluid nozzle seats in the gun barrel.

7. Install the air cap assembly (1, 2, 8). Test the gun resistance as instructed on page 19.

1, 8



21 22

D 25



3. Unscrew and remove the fluid needle/electrode (20) with the multi-tool (62). See Fig. 13. Hold the needle shaft end to prevent it from turning.

CAUTION

Be careful not to damage the contact wire when removing the electrode from the gun.

4. Apply low-strength (purple) Loctite or equivalent thread sealant to the electrode and needle shaft threads. Install the new electrode finger-tight. Do not over-tighten it.

CAUTION

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

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

6. Test the gun resistance as instructed on page 19.

 Apply a very light coat of lubricant  Tighten 1/8 to 1/4 turn past hand tight

Fig. 11



 Torque to 10 in-lbs (1.12 Nm)

Fig. 12

06449

0444A

Electrode Replacement

1. Prepare the gun for service as instructed on page

22.

2. Remove the air cap, nozzle and resistor stud as instructed on page 22.



 Apply low-strength (purple) Loctite or equivalent to needle shaft

threads

Fig. 13

06450

307912 23

Service

Barrel Removal

1. Prepare the gun for service as instructed on page

22.

2. Carefully loosen the nut from the fluid fitting (10). Pull the tube (12) out of the fitting. Make sure both ferrules and the nut stay with the tube. See Fig.

14.

3. Using the wrench (63) supplied, loosen the three socket head cap screws (5).

4. Hold the gun handle (7) with one hand and pull the barrel (3) straight away from the handle to remove it. See Fig. 15.

CAUTION

To avoid damaging the power cartridge (18), pull the gun barrel straight away from the gun handle. If necessary, gently move the barrel from side to side to free it from the gun handle.

06452

Fig. 15

Fig. 14

06451

24 307912

Service

Fluid Packing Removal

1. Prepare the gun for service as instructed on page

22.

2. Remove the air cap assembly, fluid nozzle and resistor stud and electrode as instructed on page

23.

3. Loosen the trigger screws (4) far enough to remove the trigger (13).

4. Remove the packing cartridge and needle assembly (28), using the multi-tool (62). See Fig. 16.

CAUTION

Clean all 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.

5. Check all the parts for wear or damage and replace if necessary.

Fig. 16

06454

307912 25

Service

Fluid Packing and Needle Repair

The fluid packings and needle can be replaced as individual parts or as assemblies. The overall assembly is pre-adjusted at the factory.

NOTE: Before installing the packing and needle assembly into the gun barrel, make sure the internal surfaces of the barrel are clean. Remove any residue 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.

If the parts are purchased separately, assemble them as instructed below and as shown in Fig. 17.

1. Place the packing nut (28c) and o-ring (28f) on the fluid needle (28a). Flats on the packing nut must be facing toward the back of the fluid needle.

2. Fill the entire inner cavity of the spacer (28h) with petroleum jelly. Place the spacer on the fluid needle (28a) in the direction shown in Fig. 17. Generously apply petroleum jelly to the outside of the spacer.

3. Place the fluid packing (28e), needle packing (28d), and housing (28b) on the fluid needle (28a) as shown in Fig. 17.

4. Lubricate the o-ring (28g) on the outside of the packing housing (28b).

5. Make sure the spring (30) is installed against the nut as shown in Fig. 17.

6. Install the packing and needle assembly into the gun barrel. Using the multi-tool (62), tighten the assembly until just snug, then check the drag on the needle.

7. Tighten the packing nut to 2 lbs. (9 N) of drag force when sliding the needle through the packing cartridge.

8. Install the trigger (13) and tighten the trigger screws (4).

9. Install the electrode, nozzle and resistor stud assembly and the air cap assembly as instructed on page 23.

28g

28b

28d

28e

 Item 30 is not included with the Packing/Needle Assy. (28)

Fig. 17

28h

28f

10. Test the gun resistance as instructed on page 19.

28c

28a



03559

26 307912

18a



18c

Service

18b

18d



 Apply a very light coat of lubricant  Do not expose to solvents

Fig. 18

37b

Power Cartridge Replacement

NOTE: The power cartridge consists of the alternator

(37), power supply (18) and retaining ring (35). See Fig. 18.

1. Prepare the gun for service as instructed on page

22.

2. Remove the barrel as instructed on page 24.

CAUTION

Be careful when handling the power cartridge to avoid damaging it.

3. Grasp the power cartridge with your hand. With a gentle side to side motion, pull it free from the gun handle (7). Then pull the power cartridge straight out of the handle.



37a

05160

CAUTION

To avoid a loss in electrostatic performance, inspect the power cartridge cavity in the handle for dirt or moisture. Clean out the cavity with a clean, dry rag if necessary.

Lightly lubricate the o-rings (18b, 37a) on the new power cartridge with petroleum jelly. All the o-rings and the compression spring (18c) must be in place or the gun will malfunction.

4. Insert the new power cartridge in the gun handle. Be sure the gasket (18a) is in place.

5. Install the barrel on the handle as instructed on page 28.

6. Test the gun resistance as instructed on page 19.

307912 27

Service

Turbine Alternator Replacement

NOTE: Replace turbine bearings after 2,000 hours of

operation. See your authorized Graco representative.

1. Prepare the gun for service as instructed on page

22.

2. Remove the power cartridge from the gun handle as instructed on page 27.

3. Squeeze the two ends of the retaining ring (35) together and carefully pull the alternator (37) away from the power supply until the 3-wire connector (F) disengages. See Fig. 18, page 27.

4. Use an ohmmeter to test the turbine alternator coil. Measure the resistance between the two outer terminals of the 3-wire connector (F). The resistance should be 3 to 5 ohms. If the reading varies from this value, replace the alternator.

5. Measure the resistance between each outer terminal of the 3-wire connector and the turbine alternator housing. The resistance should be infinite. If the resistance is not infinite, replace the alternator.

Barrel Installation

1. Be sure the gaskets (34 and 18a) and spring (30) are in place. See Fig. 19. Replace if damaged.

2. Place the barrel (3) over the power cartridge (18) and onto the gun handle (7). Make sure the fluid needle spring (30) is seated properly.

3. Tighten the three socket head cap screws (5) oppositely and evenly to 18 in-lbs (2 Nm) maximum (about a half turn past snug) with the wrench (63) supplied.

4. Tighten the three socket head cap screws (5) oppositely and evenly with the wrench (63) supplied. Tighten the cap screws to 18 in-lbs (2 Nm) maximum (about a half turn past snug).

CAUTION

To avoid damaging the gun, do not over-tighten the cap screws (5).

5. Assemble the fluid tube (12) back into the fluid fitting (10).

6. Connect the 3-wire connector to the 3 prongs in the power supply. Push the alternator onto the power supply until the retaining ring engages with the alternator.

7. Install the power cartridge in the gun handle as instructed on page 27.

6. Test the gun resistance as instructed on page 19.

18a



 Tighten to 18 in-lbs (2 Nm) maximum (about half turn past

Fig. 19

snug), using wrench provided.

06453

28 307912

Service

Fan Air Adjustment Valve Repair

1. Prepare the gun for service as instructed on page

22.

2. Place a wrench on the flats of the valve housing and remove it from the handle. See Fig. 20.

NOTE: The fan air valve (43) can be replaced as an assembly or as individual parts.

To disassemble the fan valve:

3. Remove the retaining ring (43b). Rotate the fan air adjustment knob (43c) counterclockwise until it is disengaged from the valve housing threads (43d). Pull the adjustment knob out of the valve housing.

4. Clean all the parts and inspect them for wear or damage.

5. When reassembling the fan air valve (43), lubricate the o-rings (43e) and the adjustment knob threads (43c) with petroleum jelly.

6. After the retaining ring (43b) is installed on the adjustment knob (43c), back the adjustment knob out of the valve housing (43d) until it bottoms out against the retaining ring.

DETAIL



43d

43b



43c



43e

 Lubricate o-rings (43e) and top knob threads (43c) with petro-

leum jelly

 Apply PTFE paste to the valve housing threads (43d); Torque to

10–12 in-lb (1.1–1.4 Nm)

7. Apply PTFE paste to the threads of the valve housing (43d) and install it in the handle. Torque the housing to 10 to 12 in-lb (1.1 to 1.4 Nm).

Fig. 20

06455

307912 29

Service

Fluid Adjustment Assembly Repair

1. Prepare the gun for service as instructed on page

22.

2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45). See Fig. 21.

3. Turn the stem (45a) fully clockwise and remove the sleeve stop (45e).

4. To completely disassemble the fluid adjustment assembly, the sleeve stop (45e) must be assembled back on to the stem (45a). Turn the stem until the sleeve is protruding about 0.4 inches (10 mm).

5. To remove the sleeve (45d), hold the cap (45c) and turn the sleeve stop (45e) counterclockwise with a wrench.

6. Remove the stem (45a) and o-ring (45b).

7. Repair or replace any damaged parts. Lubricate the o-ring (45b) with petroleum jelly.

DETAIL



0636A

40, 42





45d



45b

45e

45c

45a

8. Carefully apply low strength (purple) Loctite or equivalent thread sealant to the sleeve (45d) external threads. Turn the sleeve in with the sleeve stop (45e) until it bottoms out, then back it out 1/8 turn.

CAUTION

Do not allow Loctite to get onto the stem (45a) during assembly or the stem will not turn after assembly.

9. Place the fluid adjustment assembly on the workbench with its threaded end facing down and allow the Loctite to cure over night.

10. After the Loctite has cured, assemble the fluid adjustment assembly into the gun.

 Lubricate o-rings with petroleum jelly  Carefully apply low strength (purple) Loctite or equivalent to

sleeve (45d) external thread. Turn sleeve in with sleeve stop (45e) until it bottoms out, then back out 1/8 turn. Allow Loctite to cure overnight.

 Do not remove u-cup (42) unless damaged. Install with lips

facing into handle. Tighten packing nut (40) until it bottoms.

Fig. 21

06456

30 307912

Service

Air Trigger Valve Repair

1. Prepare the gun for service as instructed on page

22.

2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45), o-ring (23) and spring (44). See Fig. 21.

CAUTION

Clean all 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.

3. Loosen the air valve packing nut (40) one full turn. Remove the air valve shaft (39) with a pliers.

CAUTION

When removing the air valve shaft (39) be careful not to damage the seat area.

4. Check the o-rings (41, 23) for damage and replace if necessary. Apply petroleum jelly to the o-rings.

Atomizing Air Valve Removal and Replacement

1. Prepare the gun for service as instructed on page

22.

2. Remove the fan air valve (43). See Fig. 22.

CAUTION

To avoid damaging the atomizing air valve (31), the fan air valve (43) must be removed before removing the atomizing air valve.

3. Remove the atomizing air valve (31) from the gun handle. Inspect the o-ring (19) and replace if necessary.

4. Install a new atomizing air valve (31).

5. Apply PTFE paste to the fan air valve (43) housing threads and install the valve in the handle. Torque the housing to 10 to 12 in-lb (1.1 to 1.4 Nm).

CAUTION

Do not over-lubricate parts. Excessive lubricant on the o-ring (41) and air valve shaft (39) can be pushed into the gun air passage and blemish the finish on the workpiece.

5. Unscrew the packing nut (40) to check the u-cup (42). Do not remove the u-cup unless it is damaged.

6. Install the air valve shaft (39), with the o-ring (41), and spring (44), into the back of the gun handle (7). If the u-cup (42) was removed, install the air valve shaft (39) before installing the u-cup. Install the u-cup with its lips facing into the gun handle.

7. Install the fluid adjustment assembly (45), with the o-ring (23). Tighten the adjustment knob (45c) with the 14 mm socket wrench. Tighten the air valve packing nut (40) until it bottoms.

Apply PTFE paste to the fan air valve housing threads; Torque



to 10–12 in-lb (1.1–1.4 Nm)

Fig. 22



06455

307912 31

Service

ES ON-OFF Valve Repair

1. Prepare the gun for service as instructed on page

22.

2. Loosen the set screw (24) with the 2 mm hex key (69) provided. Remove the lever (26) from the valve. See Fig. 23.

WARNING

MOVING PARTS HAZARD

To reduce the risk of eye injury, be sure to wear safety glasses when removing or

installing the retaining ring (47) as the retaining ring could slip off the tool when compressed.

3. Use internal snap ring pliers to remove the retaining ring (47) from the handle. Align the holes in the retaining ring with the flat on the spacer (32) to ease assembly and disassembly.

4. Remove the valve body (38) from the handle; be careful not to drop the regulator disk (46) and spacer (32).

5. Clean and inspect the parts for damage. Replace if necessary. Lubricate the o-ring (36) with petroleum jelly.

7. Install the valve (38), with the regulator disc (46) and o-ring (36), into the gun handle. Install the spacer (32) on the valve.

8. Install the retaining ring (47) into the groove in the handle. Install the lever (26) and tighten the set screw (24).

WARNING

MOVING PARTS HAZARD

Make sure that the retaining ring (47) is engaged in the groove in the gun handle

when installing the ES ON-OFF Valve. If the retaining ring is missing or improperly installed, the valve assembly can be propelled out of the gun when air pressure is applied and cause serious injury.





CAUTION

Do not over-lubricate parts. Excessive lubricant on the o-ring (36) can be pushed into the gun air passage and blemish the finish on the workpiece.

6. Install the regulator disk (46) in the valve (38) with its bevelled side facing in toward the valve.

CAUTION

Be sure the regulator disk (46) is installed correctly. A missing or incorrectly installed regulator disc can cause severe damage to the power supply.

 Bevelled side of disk (46) faces toward valve (38)  Lubricate o-rings with petroleum jelly

Fig. 23

06457

32 307912

Notes

307912 33

Parts

28g*

28b

DETAIL A

28d*

28f*

28c

See Detail A

28a

Item 18 includes items 18a to 18f Item 28 includes items 28a to 28h Item 37 includes items 37a and 37b Item 43 includes items 43b to 43e Item 45 includes items 45a to 45e

28h*

28e*

25*

18d

18e

37a

37b

18c

18a

34

18b

18f

43c

43e

19

43b

43d

45d

45e

45c

23

45a

45b

41

*29

REF. 12

30 40

42

MODEL 222600

66 67

06458

34 307912

Parts

WARNING

Some PRO 3500sc 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. 222300, Series B

Electrostatic Air Spray Gun, with two-finger trigger

Part No. 222600 Electrostatic Air Spray Gun

Electrostatic Air Spray Gun, with four-finger trigger

Ref No. Part No. Description Qty

1 193033 AIR CAP; See Manual 307803 for

available air caps 1 2 176930 RING, retaining 1 3 222314 BARREL, gun 1 4 185095 SCREW, trigger 2 5 185096 SCREW, cap, relieved; M5 x 0.8 3 6 185097 HOOK 1 7 222666 HANDLE, gun 1 8 187423 NUT, air cap 1 9* 110077 FERRULES, fluid tube 1 10 110078 FITTING, fluid tube 1 11 179791 TAG, warning 1 12 185100 TUBE, fluid 1 13 191904 TRIGGER, 2 finger;

Model 222300 only 1

191905 TRIGGER, 4 finger

Model 222600 only 1 14 110079 NUT, fluid tube 1 15 185122 MUFFLER (flame arrestor) 1 16 185104 BRACKET, 2 finger;

Model 222300 only 1

236120 BRACKET, 4 finger;

Model 222600 only 1 17 185105 FITTING, air 1 18 222333 POWER CARTRIDGE, 65 kV

Includes items 18a–18f 1 18a 185134  GASKET, power supply 1 18b 106555  O-RING, Viton 18c 110098  SPRING, compression 1 18d 185141  CUSHION, power supply 1 18e 185099  PAD 1 18f 185145  PAD 1 19 106555 O-RING; Viton 2 20 190933 NEEDLE, electrode 1 21 185158 NOZZLE, fluid, See Manual 307803

for available nozzles 1 22 223977 STUD, resistor 1 23 109450 O-RING, PTFE 24 110083 SET SCREW, lever; M4 x 0.7 1 25* 111507 O-RING; fluoroelastomer 1 26 186839 LEVER, ES valve 1 28 223444 FLUID PACKING & NEEDLE ASSY.

Includes items 28a–28h 1 28a 223024 28b 185495

 NEEDLE, fluid 1

 HOUSING, packing 1

 1

Ref No. Part No. Description Qty

28c 185488  NUT, packing 1 28d* 178763 28e* 178409 28f* 111504 28g* 111316 28h* 186069 29* 185120 SEAL, fluid 1 30 185111 SPRING, compression 1 31 238927 VALVE, atomizing air 1 32 185119 SPACER, lever 1 33 185112 ADAPTER, exhaust hose;

188878 ADAPTER, exhaust hose;

34 185113 GASKET, manifold; polyethylene 1 35 1851 14 RING, retainer, alternator 1 36 113746 O-RING, CV75 1 37 222319 ALTERNATOR, turbine

37a 110073 37b 185124 38 185118 VALVE, electrostatic 1 39 224194 SHAFT ASSY., air valve 1 40 185115 NUT, packing 1 41 111508 O-RING, trigger valve; fluoroelastomer 1 42 105452 U-CUP, PTFE 1 43 222321 VALVE ASSY., fan air

43b 105681 43c 191805 43d 185090 43e 103557 44 185116 SPRING, compression, air valve 1 45 238895 VALVE ASSY., fluid adjustment

45a 186826 45b 111516 45c 186822 45d 191794 45e 191795 46 107107 REGULATOR, disc 1 47 110082 RING, retaining 1 62 191744 TOOL, multi 1 63 107460 WRENCH, barrel 1 66 185103 TUBE, exhaust; polyurethane 1 67 110231 CLAMP, exhaust tube 1 69 110086 TOOL, hex key, allen wrench; 2 mm 1 71 180060 SIGN, warning, English

72 180209 COVER, gun; Order Part No. 218374 76 235300 BRACKET, gun hanging 1

77 185079 PLUG, optional, to install in place of

* These parts are included in Fluid Seal Repair Kit 223020,

which may be purchased separately.

 These parts are included in Air Seal Repair Kit 223021,

which may be purchased separately.

 Parts not shown.  Replacement Danger and Warning labels, signs, tags and

cards are available at no cost.

 PACKING, needle 1  PACKING, fluid 1  O-RING, fluoroelastomer 1  O-RING, fluoroelastomer 1  SPACER 1

Model 222300 only 1 Model 222600 only 1

Includes items 37a & 37b 1

O-RING, Viton 1 CUSHION 1

Includes items 43b–43e 1

 RING, retaining 1  KNOB, fan air adjustment 1  HOUSING, valve 1  O-RING, Viton 2

Includes items 45a–45e 1

 STEM, fluid adjustment 1  O-RING, CV75 1  KNOB 1  SLEEVE, guide 1  STOP, sleeve 1

See Accessories for additional signs 1 for package of 10 1

item 31 1

307912 35

Accessories

Use Only Genuine Graco Parts and Accessories

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 Swivel Fitting 236129

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

Replaces standard fitting (item 17 in Parts List); 1/4 npsm(m) left-hand thread

Extended Air Fitting 189191

Replaces standard fitting (item 17 in Parts List) to provide an extended handle grip area.

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

Air Adapter Nipple 185493

For connecting two or more grounded gun air supply hoses. 1/4 npt x 1/4 npsm left-hand thread

Quick Disconnect Swivel Coupling Assy. 112534

Includes a quick disconnect coupling insert, which replaces air inlet fitting 185105, and a swivel shut-off coupling body (left-hand thread), which connects to the grounded air hose.

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

36 307912

Accessories

Use Only Genuine Graco Parts and Accessories

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 Tube (PTFE) 185806

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

For reducing flushing time. Replaces item 12 in parts list. 0.078 in. (1.98 mm) ID, 0.375 in. (9.53 mm) OD,

5.50 in. (139 mm) long

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

SPRAY SYSTEM ACCESSORIES

Electrostatic System 223106

Includes:

222300 Electrostatic Air Spray Gun 223070 Grounded Air Hose; 25 ft (8 m) 216076 Fluid Hose; 25 ft (8 m) 106148 Air Filter

Electrostatic System 223027

Includes:

222300 Electrostatic Air Spray Gun 223070 Grounded Air Hose; 25 ft (8 m) 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter

Electrostatic System 223028

Includes:

222300 Electrostatic Air Spray Gun 223071 Grounded Air Hose; 36 ft (11 m) 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter

Electrostatic System 223029

Includes:

222300 Electrostatic Air Spray Gun 223072 Grounded Air Hose; 50 ft (15 m) 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter

Continued on page 38.

307912 37

Accessories

Use Only Genuine Graco Parts and Accessories

MISCELLANEOUS ACCESSORIES

Snap Ring Pliers 110090

For removing the ES ON-OFF Valve Retaining Ring (item 47 in Parts List).

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.

Grounding Clamp And Wire 222011

12 ga, 25 ft (7.6 m) wire

ES ON/OFF Valve Conversion Kit 223976

Converts the ES ON/OFF Valve to a constant on setting. A ball valve is included for complete air shutoff at the gun.

Push-Pull Pattern Adjustment Valve 224883

Pattern adjustment valve that allows quick adjustment of the pattern width between two adjustable settings.

Four-finger Trigger Conversion Kit 223054

FM Approved; For converting from two-finger trigger to four-finger trigger.

Converting To A Waterborne System

FM Approved; Contact your Graco representative for information on converting Model PRO 3500sc spray gun to Model PRO 3500WB waterborne spray gun, for use in a waterborne system. Refer to Instruction Manual 308584.

High Conductivity Gun Conversion Kit 223451

For converting PRO 3500sc gun to PRO 3500hc gun.

REFERENCE ONLY

Not Included

Safety Warning Signs

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

180060 Warning Sign (English)

Megohmmeter 241079

500 Volt output; 0.01–2000 megohms.

Not for use in Hazardous areas.

TI0377

High Conductivity Hose Kit 223780

Installation of this kit enables the PRO 3500sc gun to apply fluids with a resistivity range of 2.0 megohm cm to infinity.

38 307912

Technical Data

Category Data

Gun Weight 1.87 lb (0.85 Kg) Gun Length 9.5 in. (240 mm) Maximum Working

Pressure Air Pressure

Operating Range Fluid Pressure

Operating Range Voltage Output 0–65 kV Paint Resistivity

Range Air Inlet 1/4 npsm(m) left-hand Fluid Inlet 3/8 npsm(m) Typical Noise Level

at 40 psi (2.8 bar,

0.28 MPa)* Maximum Noise

Level at 100 psi (7 bar, 0.7 MPa)**

100 psi (7 bar, 0.7 MPa)

0–100 psi (0–7 bar, 0–0.7 MPa)

7 megohm-cm to infinity

Sound Pressure  87 Db(A) Sound Power  90.4 Db(A)

Sound Pressure  99 Db(A) Sound Power  105.4 Db(A)

Category Data

Wetted Parts Stainless Steel, Polyethylene,

Nylon, Acetal, PTFE, Ultra  High Molecular Weight Polyethylene, Ceramic, Fluoroelastomer, Music Wire

* Noise levels measured with a 40 psi (2.8 bar) air supply at

the gun air inlet and typical gun air flow settings.

** Noise levels measured with a 100 psi (7 bar) air supply at

the gun air inlet and maximum gun air flow settings.

 Sound pressure was measured per Cagi Pneurop, 1969.  Sound power was measured per ISO–3744, 1981.

Kalrez

 and Vitonare registered trademarks of the

DuPont Co.

 is a registered trademark of the Loctite Corporation.

Loctite Chemraz is a registered trademark of the Green, Tweed

and Company.

Manual Change Summary

This manual has been changed per ECO’s V6099, V5645, and V5457.

307912 39

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 an y 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 Graco: 1–800–367–4023 Toll Free

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

International Offices: Belgium, Korea, Hong Kong, Japan

Sales Offices: Minneapolis, Detroit

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

PRINTED IN U.S.A. 307912 January 1989, Revised September 2000

40 307912

Graco Inc 222600, 307912, 222300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual