Graco PRO 222700, PRO 308584, PRO 3500wb, 222700 Instructions Manual

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INSTRUCTIONS-PARTS LIST

308584

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

INSTRUCTIONS

Model PRO 3500wb Electrostatic Air Spray Gun

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

Part No. 222700, Series C

For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability:

1. The fluid has a flash point above 140F (60C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93.

Rev. H

2. The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

NOTE: The PRO 3500wb spray gun is Factory Mutual approved for use with Graco isolation systems. The spray gun is also approved for use with other Factory Mutual approved voltage isolations systems provided that the fluid hose is assembled as shown in Fig. 6, page 13. 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

05148B

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

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

Table of Contents

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

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

Introduction 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spraying Waterborne Fluids Electrostatically 6. . . .

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

Graco Waterborne Fluid Hose 8. . . . . . . . . . . . . . . .

Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Install the Air Line Accessories 11. . . . . . . . . . . . . .

Connect the Air Line 11. . . . . . . . . . . . . . . . . . . . . . .

Connect the Exhaust Tube 11. . . . . . . . . . . . . . . . . .

Install the Fluid LIne Accessories 11. . . . . . . . . . . .

Filter the Fluid 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Fluid Hose 12. . . . . . . . . . . . . . . . . . . . .

Ground the System 14. . . . . . . . . . . . . . . . . . . . . . . .

Check the Electrical Grounding 15. . . . . . . . . . . . . .

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

Fluid Voltage Discharge and

Grounding Procedure 16. . . . . . . . . . . . . . . . . . . . . .

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

Operating Checklist 17. . . . . . . . . . . . . . . . . . . . . . . .

Selecting a Fluid Nozzle and Air Cap 17. . . . . . . . .

Operating the Spray Gun 18. . . . . . . . . . . . . . . . . . .

Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Care and Cleaning 20. . . . . . . . . . . . . . . . . . . .

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

Flush the Spray Gun 21. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Loss Troubleshooting 22. . . . . . . . . . . . . . .

Electrical Troubleshooting 24. . . . . . . . . . . . . . . . . . .

Spray Pattern Troubleshooting 25. . . . . . . . . . . . . . .

Poor Electrostatic Wrap Troubleshooting 26. . . . . .

Gun Operation Troubleshooting 26. . . . . . . . . . . . . .

Service 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Included with the Gun 30. . . . . . . . . . . . . . . . .

Prepare the Gun for Service 30. . . . . . . . . . . . . . . . .

Air Cap/Nozzle/Resistor Stud Replacement 30. . .

Electrode Needle Replacement 32. . . . . . . . . . . . . .

Fluid Packing Rod Removal and Repair 33. . . . . . .

Fan Air Adjustment Valve Repair 35. . . . . . . . . . . . .

Fluid Adjustment Assembly Repair 35. . . . . . . . . . .

Air Trigger Valve Repair 36. . . . . . . . . . . . . . . . . . . .

Atomizing Air Valve Repair 37. . . . . . . . . . . . . . . . . .

ES ON-OFF Valve Repair 38. . . . . . . . . . . . . . . . . . .

Barrel Removal 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Replacement 40. . . . . . . . . . . . . . . . .

Turbine Alternator Replacement 41. . . . . . . . . . . . .

Barrel Installation 41. . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Waterborne Fluid Hose Repair 42. . . . . . . . .

PRO 3500sc Gun Conversion 43. . . . . . . . . . . . . . . . . . .

Spray Gun Parts 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Graco Warranty and Disclaimers 52. . . . . . . . . . . .

Graco Phone Number 52. . . . . . . . . . . . . . . . . . . . . . . . . .

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

Electrical Tests 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Gun Resistance 28. . . . . . . . . . . . . . . . . . . . . . .

Test Power Supply Resistance 29. . . . . . . . . . . . . . .

Test Resistor Stud Resistance 29. . . . . . . . . . . . . . .

2 308584

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding or an improper setup can cause a hazardous condition and result in an electric shock or other serious injury.

 Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all

other electrically conductive objects in the spray area. See Ground the System on page 14.

 The gun must be connected to a voltage isolation system that will discharge the system voltage

when the gun is not in use.

 Components of the isolation system which are charged with high voltage must be inaccessible to

personnel to avoid electric shock. These components must be contained in an enclosure or a safety fence that prohibits personnel from making contact with them before the system voltage is discharged.

 The areas of the waterborne fluid hose that are accessible to the personnel must be covered by

the conductive hose layer. The area on the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure. Refer to Fig. 6, page 13.

 Only use the red-colored Graco electrically conductive gun air hose with this gun. Do not use the

black or grey-colored Graco air hoses.

 Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the

spray gun. Do not splice hoses together.

 Follow the Fluid Voltage Discharge and Grounding Procedure on page 16 when instructed to

discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the safety fence or the enclosure for the isolated fluid supply.

 Do not enter a high voltage or hazardous area until all high voltage equipment has been

discharged.

 Do not come within 4 in. (101.6 mm) of the front of the gun until the Fluid Voltage Discharge and

Grounding Procedure on page 16 has been completed.

 Do not connect more than one gun to the same fluid isolation system. Regulations applying to this

type of equipment prohibit the use of multiple hand-held guns.

 If there is any static sparking while using the equipment, stop spraying immediately. Identify and

correct the problem.

 Follow the warnings and instructions in the voltage isolation system manual.

308584 3

WARNING

FIRE AND EXPLOSION HAZARD

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

 Electrostatic equipment must be used only by trained, qualified personnel who understand the

requirements stated in this instruction manual.

 Ground the equipment, personnel in or close to the spray area, the object being sprayed, and all

other electrically conductive objects in the spray area. See Ground the System on page 14.

 Test the gun electrical resistance daily as instructed on page 28.  Provide fresh air ventilation to avoid the buildup of toxic vapors. See Ventilate the Spray Booth

on page 9.

 Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front cover

of this manual.

 Only flush, purge, or clean the electrostatic, waterborne spray system with non-flammable fluids,

as defined on the front cover of this manual.

 Do not flush the system with the gun electrostatics turned on.  Use only non-sparking tools to clean residue from the booth and hangers.  Extinguish all open flames or pilot lights in the spray area.  Keep the spray area free of debris, including solvent, rags, and gasoline.  Do not store any flammable fluids in the spray area.  Do not turn on or off any light switch in the spray area while operating or if fumes are present.  Do not smoke in the spray area.  Do not operate a gasoline engine in the spray area.

PRESSURIZED EQUIPMENT HAZARD

Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause a serious injury.

 Do not point the spray gun at anyone or any part of the body.  Do not stop or deflect fluid leaks with your hand, body, glove, or rag.  Follow the Pressure Relief Procedure on page 16 whenever you: are instructed to relieve the

pressure; stop spraying; clean, check, or servicing the equipment; and install or clean the fluid nozzles.

 Tighten all the fluid connections before operating the equipment.  Check the hoses, tubes and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

4 308584

Warnings are continued on the next page.

WARNING

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

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

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

distributor.

 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.  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 (0.7 MPa, 7 bar) maximum working air and fluid pressure.

 Use fluids that are compatible with the equipment wetted parts. See the Technical Data section of

all the equipment manuals. Read the fluid manufacturer’s warnings.

 Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not

expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).

 Do not use the hoses to pull equipment.  Wear hearing protection when operating this equipment.  Comply with all applicable local, state, and national fire, electrical, and other safety regulations.

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.

 Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.  Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all

local, state, and national guidelines.

 Wear appropriate protective clothing, gloves, eyewear, and respirator.

308584 5

Introduction

Spraying Waterborne Fluids Electrostatically

The PRO 3500wb spray gun is a 60 kV electrostatic spray gun that is designed to spray conductive, waterborne, non-flammable fluids. When spraying waterborne fluids electrostatically, the gun must be connected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.

A safe, well designed isolation system should have the following features:

 All components of the isolation system that are

charged to high voltage must be contained within a fence or enclosure that prohibits personnel from making contact with the high voltage components.

 A means for automatically discharging the system

voltage if anyone opens the fence or enclosure.

 A bleed resistor to drain off the system voltage

when the spray gun is not in use.

 The system should not have any severe arcing

occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolated fluid supply are charged to high voltage, which means that the system has more electrical energy than a solventbased system. Therefore, only non-flammable fluids (defined on the front cover of this manual) can be sprayed with the system or be used to clean, flush. or purge the system.

Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards. When the spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or battery. The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. It is not safe to touch the front end of the gun until the stored energy is discharged. The amount of time it takes to discharge the energy depends on the system design. Follow the Fluid Voltage Discharge and Grounding Procedure, page 16, before approaching the front of the gun.

Do not intentionally ground out the system by arcing the electrode to ground when you are done spraying. Sudden arcs or shocks to the gun and system puts extra stress on the components and will shorten the life of the gun and fluid hose. When hanging up the gun, avoid arcing the gun to a grounded gun hanger. An optional plastic gun holster is available, which can be used to hang up the gun without causing arcs.

Operating the Electrostatics

Refer to Fig. 1, page 7

To operate the electrostatics, air pressure is supplied through a Graco electrically conductive air hose to the gun air inlet (F). When the gun is triggered, air enters the gun and is directed to the inlet of the turbine/alternator (T). The air spins the turbine, which then provides electrical power to the power supply. The fluid is charged by the spray gun electrode (B). The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.

6 308584

Introduction

KEY-Fig. 1

A Air Cap B Electrode C Retaining Nut D Gun Barrel E Gun Handle F Air Inlet G Fluid Inlet H Trigger

J Fluid Adjustment Knob K Exhaust Tube L Hook M ES Indicator Light N ES ON-OFF Lever P Fan Air Adjustment Valve R Atomizing Air Valve S Power Supply T Turbine/Alternator

BAC

* 1 is ON 0 is OFF

P*N R

05151A

05148B

Fig. 1

05404

308584 7

Introduction

Graco Waterborne Fluid Hose (purchased separately)

A Graco waterborne fluid hose must be used between the voltage isolation system fluid outlet and the spray gun fluid inlet. This fluid hose consists of three layers (see Fig. 2):

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

 Conductive Hose Layer (DD): covers the PTFE

tube.

 Outer Hose Jacket (FF): is a protective polyethyl-

ene hose cover.

If a hose failure occurs, where the high voltage arcs through the inner hose layer (EE), the voltage will be discharged to ground through the conductive hose layer (DD). When properly installed, the conductive hose layer is grounded through its connection to the grounded safety fence or enclosure (CC). All areas of the fluid hose that are accessible to personnel must be covered by the outer hose jacket (FF) to avoid electric shock.

KEY-Fig. 2

DD Conductive Hose Layer EE Inner Hose Layer FF Outer Hose Jacket CC Grounded Enclosure

 The portion of the inner hose layer (EE–PTFE tube) that is not

covered by the conductive hose layer (DD), must be inside the safety fence or enclosure (CC).

 The areas of the waterbase fluid hose that are accessible to

personnel during normal operation must be covered by the outer hose jacket (FF).



DDEE

FF 

H2O PRO Voltage Block connection shown

Fig. 2

05179

8 308584

Installation

Installing the System

WARNING

ELECTRIC SHOCK HAZARD

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

injury if the work is not performed properly.  Do not install or service this equipment unless

you are trained and qualified.

 Comply with all local, state, and national codes

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

 Comply with all applicable local, state, and

national fire, electrical, and other safety regulations.

Fig. 3, page 10, shows a typical Model PRO 3500wb waterborne system. The particular type and size system for your operation must be custom designed for your needs. For assistance in designing a system, contact your Graco representative.

Accessories are available from your Graco representative. Refer to the Product Data Sheet for the gun, Form No. 305681.

Basic Guidelines

When spraying waterborne fluids electrostatically:  The gun must be connected to a voltage isolation

system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.

 All components of the isolation system that are

charged to high voltage must be contained within a fence or enclosure that prohibits personnel from making contact with the high voltage components.

 The system should not have any severe arcing

occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.

Warning Signs

Mount the warning sign, part no. 186118, in the spray area where it can easily be seen and read by all operators. Additional warning signs are available at no charge.

Ventilate the Spray Booth

WARNING

TOXIC FLUID HAZARD

Provide fresh air ventilation to avoid the buildup of toxic vapors. Do not operate the gun unless the ventilating fans are on.

Check and follow all local, state, and national codes regarding air exhaust velocity requirements. High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 linear feet/minute (18.3 linear meters/minute).

308584 9

KEY-Fig. 3

A Air Regulator B Spray Gun Air Shut-off Valve C Gun Fluid Regulator D Graco Waterborne Fluid Hose E Gun Fluid Inlet F PRO 3500wb Spray Gun G Gun Air Inlet H Graco Red Electrically Conductive Gun Air Hose

Installation

K Air Supply Hose L Fluid Supply Hose M Gun Air Hose Ground Wire N True Earth Ground P Fluid Hose Port R H2O PRO Batch System Voltage Block Enclosure S Main Ground Wire T Ground Lug

PRO 3500wb Gun shown with the Graco H2O PRO Batch System

Consult your isolation system manual for other configurations.

E D

Fig. 3

10 308584

05310

Installation

Install the Air Line Accessories

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

2. Install a bleed-type air regulator (A) on the pump and gun air supply lines to control air pressure to the pump and gun. Refer to Fig. 3, page 10.

3. Install a bleed-type air shutoff valve on the main air line, the pump air line (to shut off air to the pump), and the gun air line (B) (to shut off air to the gun).

WARNING

PRESSURIZED EQUIPMENT HAZARD

Trapped air can cause the pump to cycle or the gun to spray unexpectedly, which could result in a serious injury, including splashing in the eyes or on the skin. The bleed-type air shutoff valve is required on the main air supply line so trapped air will be relieved between this valve and the pump after the air regulator is closed.

Connect the red-colored Graco Electrically Conductive Air Hose (H) to the gun air inlet and connect the hose ground wire (M) to a true earth ground (N). Refer to Fig. 3, page 10. Check the electrical grounding of the gun as instructed on page 15. See page 48 to order the air hose.

NOTE: The hose and the gun have special left-hand threads to prevent connecting another type of air hose to the gun air inlet.

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 46.

Install the Fluid LIne Accessories

1. Before connecting the fluid line, blow it out with air and flush it with water.

2. A fluid regulator (C) is needed in the fluid line to control fluid pressure to the gun. Refer to Fig. 3, page 10.

NOTE: The H2O PRO voltage block comes with a fluid regulator already installed.

Connect the Air Line

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock or other serious injury, you must use the

red-colored Graco Electrically Conductive Air Hose for the gun air supply hose, and you must connect the hose ground wire to a true earth ground. Do not use the black or grey-colored Graco air hoses.

3. Install a fluid filter and drain valve at the pump outlet.

WARNING

PRESSURIZED EQUIPMENT HAZARD

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

308584 11

Installation

Filter the Fluid

Filter the fluid to remove coarse particles and sediment which could clog the fluid nozzle. The filter must be installed at the grounded fluid inlet to the voltage isolation system.

Connect the Fluid Hose

CAUTION

Be careful not to cut into the inner hose layer (K) when stripping the hose. Nicks or cuts in the tube will cause premature hose failure.

2. Inspect the condition of the o-rings (G) on the hose barbed-fitting. Replace the o-rings if they are worn or damaged.

NOTE:

 A Graco waterborne fluid hose must be used

between the voltage isolation system fluid outlet and the spray gun fluid inlet. See page 48 to order the Graco waterborne fluid hoses and the hose replacement parts.

 Before connecting the fluid supply line to the gun,

blow it out with air, and flush it with water to remove contaminants. Flush the gun before using it.

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, install only one continuous Graco water-

borne fluid hose between the isolated fluid supply and the spray gun. Do not splice hoses together.

1. For the fluid hose to seal properly and be held securely, the hose must be stripped and assembled to the dimensions shown in Fig. 4. Refer also to Fig. 29, page 42. A new Graco waterborne fluid hose comes fully assembled to the proper dimensions.

3. Unscrew the hose ferrule housing (79) from the gun fluid inlet fitting, and slide the nut onto the barbed-end of the hose. Refer to Fig. 5.

4. Apply a light coat of dielectric grease (supplied with the gun) to the o-rings (G) and to the entire length of the inner hose layer (K). See Fig. 4.

KEY- Fig. 4

G O-Rings H Outer Hose Jacket J Conductive Hose Layer K Inner Hose Layer

 Apply a light coat of dielectric grease to the o-rings (G) and the

entire length of the inner hose layer (K)

 4.075 + 0.10 in. (103.5 + 2.5 mm)  Minimum of 4.375 + 0.10 in. (111.1 + 2.5 mm)





Spray Gun

HJK

Fig. 4



Hose End

05342

12 308584

Continued on the next page

Installation

Connect the Fluid Hose (continued)

5. Insert the hose (Y) into the hose ferrule housing (79). See Fig. 5.

6. Push the hose firmly through the fluid inlet tube (75) until the o-rings on the hose barbed fitting are seated and the hose bottoms out.

7. Tighten the hose ferrule (77) firmly with a wrench to about 50 in-lb (5.6 Nm). Pull back on the hose to make sure it is secure. If not, disconnect the hose and inspect it for damage. Check the hose connection periodically for signs that the hose is loosening.

CAUTION

If the hose comes loose from the fitting, fluid leakage will occur. Make sure the hose ferrule (77) is tight and that nothing will pull or catch on the hose during operation.

8. Connect the other end of the hose to the isolated fluid supply as instructed in the voltage isolation system manual. See Fig. 6.

KEY- Fig. 5

Y Graco W aterborne Fluid Hose 75 Fluid Inlet Tube 77 Hose Ferrule 79 Hose Ferrule Housing

 Torque to 50 in-lb (5.6 Nm)

WARNING

ELECTRIC SHOCK HAZARD

To reduce the risk of an electric shock, the areas of the waterborne fluid hose

that are accessible to personnel during normal operation must be covered by the outer hose jacket (H). See Fig. 6.

CAUTION

The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.

KEY- Fig. 6

H Outer Hose Jacket K Inner Hose Layer R Voltage Isolation System Enclosure

 The areas of the waterborne fluid hose that are accessible to

personnel during normal operation must be covered by the outer hose jacket (H).

 The portion of the inner hose layer (K) that is not covered by

the outer hose jacket (H) must be inside the voltage isolation system enclosure (R).

 The conductive hose layer (J) must be grounded through its

connection to the isolation system’s grounded safety fence or enclosure (R).





Fig. 5

75 79 77



05405B

Fig. 6



DETAIL

H2O PRO Voltage Block connection shown

05149B

308584 13

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

1. Fluid Supply: Ground the fluid supply by connecting a ground wire and clamp between the fluid supply and a true earth ground. See your fluid supply instruction manual for grounding instructions.

2. PRO 3500wb Electrostatic Air Spray Gun: Install the red-colored Graco electrically conductive air hose between the gun and air supply line and connect the air hose ground wire to a true earth ground. Check the electrical grounding of the gun as instructed on page 15.

3. Graco Waterborne Fluid Hose: The conductive layer of the hose must be properly grounded by correct installation as instructed on pages 12 to 13.

4. Voltage Isolation System: Ground the system according to the manufacturer’s instructions.

5. All persons entering the spray area: Their shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Rubber or plastic soles are not conductive. The operator must not wear gloves which insulate the hand from the spray gun. The gloves must be conductive or modified as shown on page 17.

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

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

8. All electrically conductive objects or devices in the spray area: They must be properly grounded.

14 308584

Installation

Check the Electrical Grounding

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

2. Make sure the red Graco electrically conductive air hose (EE) is connected to the gun and the hose ground wire is connected to a true earth ground. See Fig. 7.

3. The air and fluid supplies to the fluid hose must be turned off and the fluid hose must not have any fluid in it when checking the continuity.

4. Turn the gun ES ON-OFF lever (DD) to OFF.

5. Measure the resistance between the gun handle (AA) and a true earth ground (BB) with an ohmmeter (CC). Resistance should not exceed 100 ohms.

6. If the resistance is greater than 100 ohms, 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.

KEY- Fig. 7

AA Gun Handle BB True Earth Ground CC Ohmmeter DD ES ON-OFF Lever EE Graco Electrically Conductive Air Hose

Fig. 7

05150B

308584 15

Operation

Fluid Voltage Discharge and Grounding Procedure

WARNING

ELECTRIC SHOCK HAZARD

The high voltage fluid supply is charged with high voltage until the voltage is dis-

charged. Contact with the charged components of the isolation system or spray gun electrode will cause an electric shock. To avoid an electric shock, follow the Fluid Voltage Discharge and Grounding Procedure:

 when instructed to discharge the voltage,  before cleaning, flushing, or servicing the sys-

tem equipment,

 before approaching the front of the gun,  and before opening the safety fence or the

enclosure for the isolated fluid supply.

NOTE: An accessory grounding rod, part no. 210084, is available to discharge any voltage remaining on a system component. Contact your Graco representative to order it.

1. Turn off the gun electrostatics by turning the gun ES ON-OFF lever to the OFF position.

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Proce- dure whenever you:

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

1. Follow the Fluid Voltage Discharge and Grounding Procedure, at left.

2. Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals.

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

3. Touch the electrode of the gun with a grounded rod to make sure that the voltage has been discharged. If an arc is seen, verify that the electrostatics are turned off or see Troubleshooting, page 24, or the voltage isolation system manual for other possible problems. Resolve the problem before proceeding.

3. Turn off the fluid supply to the gun.

4. Shut off the air supply to the spray gun. The shut-off device must bleed the air out of the system.

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

16 308584

Operation

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, waterborne, air spray system as instructed in this manual and the voltage isolation system manual.

____ 2. All the operators are trained how to properly

relieve system pressure as instructed on page

16.

____ 3. All the operators are trained how to properly

discharge the voltage as instructed on page

16.

____ 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. 8 so as not to interfere with the operator grounding through the gun.

____ 5. The system is thoroughly grounded and the

operator and all persons entering the spray area are properly grounded. See Ground the

System, page 14, and Check the Electrical Grounding, page 15.

____ 6. The condition of the electrical components of

the spray gun has been checked as instructed

in Electrical Tests, page 28. ____ 7. All fluid hose connections are tight. ____ 8. The ventilation fans are operating properly. ____ 9. All the debris, including flammable liquids and

rags, is removed from the spray area.

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. 8

Selecting a Fluid Nozzle and Air Cap

The gun is supplied with a 0.06 inch (1.5 mm) fluid nozzle, part no. 191833, and an air cap, part no.

193033. If your application requires a different nozzle and air cap combination, see instruction manual 307803 or consult your authorized Graco distributor to select the appropriate fluid nozzle and air cap. Install the air cap and fluid nozzle as instructed on page 30.

308584 17

Operation

Operating the Spray Gun

WARNING

FIRE AND EXPLOSION HAZARD

To reduce the risk of fire and explosion, only use this equipment to spray nonflammable, waterborne fluids as defined on the front cover of this manual.

WARNING

ELECTRIC SHOCK HAZARD

Contact with the charged components of the spray gun will cause an electric

shock. Do not touch the gun nozzle or electrode or come within 4 inches (101.6 mm) of the front of the gun during gun operation or until after following the Fluid Voltage Discharge and Grounding Procedure on page 16.

Follow the Fluid Voltage Discharge and Ground- ing Procedure on page 16 when you stop spraying and whenever you are instructed to discharge the voltage.

WARNING

1. Follow the Operating Checklist on page 17.

2. Make sure the system voltage is discharged. Loosen the air cap retaining nut, and rotate the air cap for a vertical or horizontal spray pattern. See Fig. 9. Then tighten the retaining nut until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

Vertical Pattern

Horizontal Pattern

Fig. 9

3. Pressurize the fluid supply, and adjust the fluid flow by using the fluid pressure regulator installed in the fluid line. Refer to instruction manual 307803 to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.

02020

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 when you stop

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

WARNING

COMPONENT RUPTURE HAZARD

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

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

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

4. If necessary, further adjust the fluid flow rate with the fluid adjustment knob (J). See Fig. 10.

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

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 (314 to 345, 3.1 to 3.4) 25 (7.6) 50 to 55 (345 to 379, 3.4 to 3.7)

50 (15.3) 60 to 65 (410 to 444, 4.1 to 4.4) 75 (22.9) 68 to 73 (465 to 501, 4.5 to 5.0)

100 (30.5) 75 to 80 (514 to 550, 5.1 to 5.5)

Dynamic pressure at air hose inlet

required for full voltage

psi (kPa, bar)

18 308584

Operation

7. Set the atomizing air valve (R) 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 (P).

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

11. Use the same spraying technique you would use with a conventional air spray system to coat the workpiece.

12. Relieve the pressure and discharge the voltage when you stop spraying.

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. See Fig. 11. Fluid in the gun air passages can cause poor atomization and excessive current demands and damage the gun.

KEY-Fig. 10

J Fluid Adjustment Knob M ES Indicator Light N ES ON-OFF Lever P Fan Air Adjustment Valve R Atomizing Air Valve

Fine Adjustments of the Spray Gun

 To improve the atomization, open the atomizing air

valve further (R). 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.

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

NOTE: See Spray Pattern Troubleshooting on page 25 to correct spray pattern problems. See Voltage Loss Troubleshooting on page 22 to correct voltage problems.

Fig. 10

P*N R

05151A

10. Operate the voltage isolation system as instructed in the system manual. Normal spraying voltage for the system will be 45 to 55 kV.

Fig. 11

05424

308584 19

Operation

Shutdown

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 whenever you stop

spraying and whenever you are instructed to relieve pressure.

Maintenance

WARNING

FIRE AND EXPLOSION HAZARD

To reduce the risk of fire and explosion:  Only flush, purge, or clean the PRO

3500wb spray gun with non-flammable fluids, as defined on the front cover of this manual.

 Do not flush with the gun electrostatics turned

on.

WARNING

ELECTRIC SHOCK HAZARD Follow the Fluid Voltage Discharge and Grounding Procedure on page 16

before cleaning or flushing the gun to ensure the voltage is discharged and avoid serious injury from an electric shock.

1. Relieve the pressure.

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

Daily Care and Cleaning

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. 12.

 Hang the gun with its nozzle pointing down

when it is not being used.

1. Clean the fluid and air line filters daily.

2. Clean the outside of the gun daily with a soft cloth dampened in a non-flammable cleaning fluid.

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 when you stop

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

20 308584

3. Clean the air cap and fluid nozzle daily, minimum, as instructed on page 21. Some applications require more frequent cleaning. Replace the fluid nozzle and air cap if they are damaged. See page

30.

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

32.

5. Check for any 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.

7. Flush the gun before changing colors and whenever you are done operating the gun. See page 21.

Maintenance

Clean the Air Cap and Fluid Nozzle

Equipment needed:

 Soft bristle brush  Non-flammable cleaning fluid

CAUTION

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

Procedure:

1. Relieve the pressure and discharge the system voltage as instructed on page 16.

2. Remove the air cap retaining nut and air cap.

3. Clean the air cap with the soft bristle brush and a non-flammable cleaning fluid or submerge the air cap in the cleaning fluid and wipe it clean.

Flush the Spray Gun

1. Relieve the pressure and discharge the system voltage as instructed on page 16.

2. Make sure the gun ES ON-OFF lever is turned to OFF.

3. Turn off the air to the spray gun.

4. Change the fluid supply over to the cleaning fluid. Read the voltage isolation system manual for specific flushing procedures.

5. Spray the cleaning fluid until the fluid that comes out of the gun is clear.

6. Shut off the fluid supply and relieve the pressure as instructed on page 16.

7. Before spraying paint again, reconnect the paint supply, turn on the fluid and air supplies, and trigger the gun until it is clear of cleaning fluid.

4. With the front of the gun pointed down, clean the fluid nozzle and the front of the gun with the soft bristle brush and cleaning fluid. See Fig. 12.

NOTE: If it appears that there is fluid inside the fluid nozzle air passages, remove the gun from the line for servicing.

5. Clean the exterior of the gun with a cloth dampened in a non-flammable cleaning fluid.

6. Carefully install the air cap. Be sure to insert the electrode wire through the center air cap hole and do not bend the wire. Rotate the air cap horns to the desired position.

7. 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.

8. Test the gun resistance as instructed on page 28.

05152A

Fig. 12

308584 21

Troubleshooting

WARNING

ELECTRIC SHOCK HAZARD

Installing and servicing this equipment requires access to parts which may

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

Follow the Fluid Voltage Discharge and Ground- ing Procedure on page 16 before checking or servicing the system and whenever you are instructed to discharge the voltage to ensure the voltage is discharged and avoid serious injury from an electric shock.

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 before checking or

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

Voltage Loss Troubleshooting

Normal spraying voltage for a system using the PRO 3500wb gun is 45 to 55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.

A loss of spraying voltage can be caused by a problem with the spray gun, fluid hose, or voltage block, since all of the system components are electrically connected through the conductive, waterborne fluid.

Before troubleshooting or servicing the voltage block itself, you need to determine which component in the system is most likely causing a problem. Possible causes include:

Spray Gun

 Fluid leakage  Dielectric breakdown at the fluid hose connection or

fluid packings

 Not enough air pressure for the turbine

 Faulty power supply  Excessive overspray on gun surfaces  Fluid in the air passages

Waterborne Fluid Hose

 Dielectric failure of hose (pin-hole leak through

PTFE layer)

 Air gap in the fluid column between the gun and

isolated fluid supply, causing a low voltage reading on the isolation system voltage meter.

Voltage Block

 Fluid leakage  Dielectric breakdown of hoses, seals, or connec-

tions

 Isolators not functioning properly

Visual Check

First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage block has failed. A voltage probe and meter, part no. 236003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow.

1. Check that all of the air and fluid tubes and hoses are properly connected.

2. Check that the voltage isolation system valves and controls are properly set for operation. Refer to the voltage isolation system manual.

3. Check that the spray gun and voltage isolation system have sufficient air pressure.

4. Check that the gun ES ON-OFF lever is in the ON position and that the gun ES indicator light comes on. If the ES indicator light does not come on, remove the spray gun for service, and complete the electrical tests on page 28.

5. Check that the voltage isolation system’s enclo- sure door or safety fence gate is closed and that any safety interlocks are engaged and working properly.

6. Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage from ground.

22 308584

Troubleshooting

Voltage Loss Troubleshooting (continued)

7. To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply.

8. Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a conductive path back to the grounded gun handle. Install a new gun cover and clean the exterior of the gun.

9. Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas:

 Packing area of the spray gun  Fluid hose: check for leakage or any bulges in the

outer jacket, which may indicate an internal leak

 Internal voltage isolation system components

Tests

If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test.

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

4. Position the end of the hose as far as possible away from any grounded surface. The end of the hose must be at least 1 ft. (305 mm) from any ground. Make sure that no one is within 3 ft. (914 mm) of the end of the hose.

5. Turn the ES ON-OFF valve to ON, and trigger the gun just enough to turn on the air to the gun but not the fluid. Measure the voltage at the gun electrode with a voltage probe and meter.

6. Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod.

7. If the meter reading is 45 to 55 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system. See the voltage isolation system manual for further troubleshooting information.

If the reading is below 45 kV, the problem is in the gun or fluid hose.

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

9. Turn the ES ON-OFF valve to ON, and trigger the gun. Measure the voltage at the gun electrode with a voltage probe and meter.

2. Relieve the pressure and discharge the system voltage as instructed on page 16.

3. Disconnect the fluid hose from the voltage isolation system.

NOTE: Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode, which can break the conductivity path and conceal a potential failure area.

10. If the meter reading is 55 to 60 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue with step 11.

If the reading is below 55 kV range, do the electrical tests on page 28 to check the gun and power supply resistance. If those tests show the gun and power supply are okay, continue with step 11, page 24.

308584 23

Troubleshooting

Voltage Loss Troubleshooting (continued)

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

 Fluid hose

Check for leakage or any bulges in the outer jacket, which may indicate a pin-hole leak through the PTFE layer. Disconnect the fluid hose from the gun, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.

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

Make sure the hose is properly stripped; see Fig. 4, page 12, for hose stripping dimensions. Restrip or replace the hose.

 Fluid packings

Remove the packing assembly from the gun as instructed on page 33, and look for signs of fluid leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.

 Fluid hose connection joint to the spray gun

A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o-ring seals on the end of the hose. Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube.

12. Before reassembling the gun, clean and dry the gun fluid inlet tube (item 75 on page 46). Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun as instructed on page 34.

13. Reconnect the fluid hose as instructed on page 12.

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

Electrical Troubleshooting

Problem Cause Solution

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

Discharge and Grounding Procedure

The operator gets a shock The operator is not properly grounded

The operator gets a shock when touching the workpiece

Gun electrostatics (gun ES lever) are not turned off.

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

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

Voltage isolation system failed. See the isolation system manual for

or is near an ungrounded object.

The gun is not properly grounded. See Check the Electrical Ground-

The workpiece is not properly grounded.

Turn off the gun electrostatics.

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

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

service information. Be sure the floor and the operator are

properly grounded; see Ground the

System, page 14.

ing, page 15.

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

24 308584

Troubleshooting

Spray Pattern Troubleshooting

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

Problem Cause Solution

Fluttering or spitting spray

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.

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

damaged. 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 30.

Clean the parts; see page 21.

Tighten or repair the coupler.

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

Replace the damaged part; see page

30. Remove the obstruction; never use

wire or hard instruments; see page

21.

Streaks

The fluid is too thin. Reduce the fluid viscosity. There is not enough fluid pressure. Increase the fluid pressure. The fan air pressure is too low. Increase the fan air pressure. The fluid is too thick. Reduce the fluid viscosity. There is too much fluid. Reduce the fluid flow. The last coat of fluid is applied too

wet. 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

Apply a drier finish using multiple strokes.

page 21.

308584 25

Troubleshooting

Poor Electrostatic Wrap Troubleshooting

Problem Cause Solution

The system is holding voltage but there is poor electrostatic wrap on the part being sprayed

The distance between the gun and workpiece is incorrect.

The parts are poorly grounded. Clean the workpiece hangers; check

Booth exhaust velocity is too high. Reduce the exhaust velocity within

The atomizing air pressure is too high.

The fluid pressure is too high. Reduce the fluid pressure. The fluid viscosity is not right for

electrostatic spray.

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

The fluid rod packings or fluid rod are worn.

The packing nut is loose Tighten the packing nut; see page 33. The air valve is not seating properly. Clean and service the air valve; see

The air valve o-ring is sticking. Lubricate the o-ring; see page 36. The fluid rod is worn or damaged. Replace the fluid rod; see page 33. The fluid seat is worn. Replace the fluid nozzle and/or elec-

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

The resistor stud is loose. Tighten the resistor stud; see page

The fluid nozzle is loose. Tighten the fluid nozzle; see page 30. The resistor stud o-ring is damaged. Replace the o-ring; see page 30. 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.

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

for proper grounding on the conveyor or track.

the code limits. Reduce the atomizing air pressure.

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

Replace the packings or rod; see page 33.

page 36.

trode needle; see pages 30 to 32.

see page 33.

30.

Increase the air cap air pressure by opening the atomizing air valve more or increasing the gun air inlet pressure; use the least air pressure needed for good results.

26 308584

Troubleshooting

Gun Operation Troubleshooting (continued)

Excessive spray fog

No fluid sprays from the gun

The equipment is covered with fluid

Dirty air cap

The air pressure is too high. Reduce the air cap air pressure by

closing the atomizing air valve more or decreasing the gun air inlet pressure; use the least air pressure needed for good results. Do not reduce below minimum pressure need-

ed for full voltage. See page 18. The fluid is thinned too much. Properly thin the fluid. The fluid supply is low. Check the fluid supply; add fluid if

necessary. The fluid nozzle is dirty or clogged. Clean the fluid nozzle; see page 21. The fluid nozzle is damaged. Replace the fluid nozzle; see page

30.

The exhaust air flow is insufficient or not directed properly.

The distance between the gun and workpiece is incorrect.

The electrode is bent. Straighten the electrode. The nozzle orifice is damaged. Replace the fluid nozzle; see page

The air cap and fluid nozzle are misaligned.

Air Cap

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).

30.

Check the air cap and fluid nozzle

seat for fluid buildup. Clean or

replace parts as needed; see page 21

or 30.

ALIGNED

Fluid Nozzle

MISALIGNED

308584 27

Electrical Tests

WARNING

ELECTRIC SHOCK HAZARD Follow the Fluid Voltage Discharge and Grounding Procedure on page 16

before checking or servicing and whenever you are instructed to discharge the voltage to ensure the voltage is discharged and avoid serious injury from an electric shock.

Use the megohmmeter (A), part no. 218979, and an applied voltage of 500 volts to complete these electrical tests. Connect the leads as shown.

Test Gun Resistance

NOTE: The fluid passage must be flushed and dried

to get an accurate reading. Check the resistance with the gun triggered and untriggered.

1. Prepare the gun for service as instructed on page 30.

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 before checking or

servicing the gun and whenever you are instructed to relieve the pressure.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

Megohmmeter P/N 218979 (A-see Fig.

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

 The gun has been removed from the

hazardous area;

 Or all spraying devices in the hazardous area

are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area (such as open solvent containers or fumes from spraying).

2. Measure the resistance between the end of the gun electrode (20) and the air inlet fitting (17). See Fig. 13.

3. The resistance should be between 180 to 220 megohms. If the resistance is outside the specified range, go to the next test.

4. If you still have problems, refer to Voltage Loss Troubleshooting, page 22, for other possible causes of poor performance, or contact the nearest authorized service agency.

KEY-Fig. 13

A Megohmmeter 17 Air Inlet Fitting 20 Electrode

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

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 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.

28 308584

Fig. 13

5153B

Continued on the next page.

Electrical Tests

Test Power Supply Resistance

1. Prepare the gun for service as instructed on page 30.

2. Remove the power supply (18) from the gun handle as instructed on page 40.

3. Remove the turbine alternator (37) from the power supply as instructed on page 41.

4. Measure the resistance from the power supply’s ground contact point (B) to the contact spring (18c) on the other end of the power supply. See Fig. 14.

5. 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.

KEY-Fig. 14

A Megohmmeter B Ground Contact Point 18 Power Supply 18c Contact Spring

Test Resistor Stud Resistance

1. Prepare the gun for service as instructed on page 30.

2. Remove the resistor stud (22) as instructed on page 30.

3. Check the resistance between the black resistor stud contact ring (D) and the needle contact ring (C). See Fig. 15. You may have to press down on the contact ring (D) in several places to get a good reading.

4. The resistance should be 21 to 29 megohms. If the resistance is correct, make sure the metal contact in the gun barrel and the needle contact ring (C) are clean. If the resistance is outside the specified range, the resistor is defective and the resistor stud (22) must be replaced. See page 30 to replace the resistor stud.

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. 15. To reduce the risk of sparking, which could cause a 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.

18c 18

Fig. 14

KEY-Fig. 15

C Needle Contact Ring D Resistor Stud Contact Ring 22 Resistor Stud

03566

Fig. 15

0442

308584 29

Tools Included with the Gun

 Multi-tool  Ball-end Wrench  2 mm Hex Key Allen Wrench

Prepare the Gun for Service

Service

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 before checking or

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

NOTE:  Check all the possible remedies in Troubleshoot-

ing before disassembling the gun.

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

use padded vise jaws to avoid damaging parts.

 Lightly lubricate o-rings and seals with petroleum

jelly. Do not over-lubricate.

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

parts from other PRO Gun models.

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of a fire, explosion, or electric shock:

 Follow the Fluid Voltage Discharge

and Grounding Procedure on page

16 and be sure the ES ON-OFF lever is turned to OFF before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.

 Clean all the parts with a non-flammable fluid as

defined on the front cover of this manual.

 Do not service this equipment unless you are

trained and qualified.

 Do not touch the gun nozzle or come within 4

inches (101.6 mm) of the nozzle during gun operation or until after following the Fluid Voltage Discharge and Grounding Procedure.

1. Discharge the voltage as instructed on page 16.

2. Flush the gun with a non-flammable cleaning fluid as instructed on page 21.

3. Purge the fluid out of the lines with air

4. Relieve the system pressure as instructed on page

16.

5. Disconnect the air and fluid hoses from the gun, and remove the gun from the worksite for service. The service area must be clean.

Air Cap/Nozzle/Resistor Stud Replacement

Removal

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

2. Remove the air cap assembly (1, 2, 8). See Fig. 16, page 31.

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.

3. Point the front end of the gun up and squeeze the trigger while removing the fluid nozzle/resistor stud (21, 22) assembly with the nozzle wrench (70).

NOTE: If the resistor stud (22) remains in the gun when the fluid nozzle is removed, start the nozzle thread onto the stud and pull the stud out.

30 308584

Continued on the next page.

Service

Air Cap/Nozzle/Resistor Stud Replacement (continued)

4. Unscrew the resistor stud (22) from the fluid nozzle (21) with the multi-tool (62). See Fig. 17.

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. 16. To reduce the risk of sparking, which could cause a 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.

5. Remove the retaining ring (2) to free the air cap (1) from the retaining nut (8).

Installation

1. Lightly lubricate the o-ring (25) with petroleum jelly, and install it on the resistor stud (22). See Fig. 16.

8. Tighten the retaining nut (8) until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.

 Apply a very light coat of lubricant to the o-ring (25).  Tighten the nozzle (21) hand-tight, then 1/8 to 1/4 turn more.

1 8

2 62



21 22



25 20

2. Make sure the electrode (20) is tightened properly, as shown in Fig. 18, page 32.

3. Install the resistor stud (22) in the fluid nozzle (21) with the multi-tool (62). Tighten the resistor stud to 10 in-lb (1.13 Nm). See Fig. 17.

4. Trigger the gun while installing the fluid nozzle (21) and resistor stud (22) assembly with the multi-tool (62). Tighten the assembly until the fluid nozzle seats in the gun barrel (1/8 to 1/4 turn past handtight). See Fig. 16.

5. Test the gun resistance as instructed on page 28.

6. Install the air cap (1) into the retaining nut (8), and secure it with the retaining ring (2).

7. Carefully install the air cap assembly (1, 2, 8) onto the gun barrel. Do not bend the electrode (20) wire, and be sure to insert the electrode wire through the center air cap hole. Rotate the air cap horns to the desired position.

Fig. 16

 Tighten the resistor stud (22) into the nozzle (21) to 10 in-lbs

(1.13 Nm).



Fig. 17

0444A

05154A

308584 31

Service

Electrode Needle Replacement

1. Prepare the gun for service as instructed on page 30.

2. Remove the air cap, nozzle and resistor stud as instructed on page 30.

3. Unscrew and remove the electrode needle (20) with the multi-tool (62). See Fig. 18. Be careful not to damage the contact wire. If the fluid rod turns, hold the back end of the fluid rod (E) by placing a screw driver blade into the slot on the shaft, near the trigger.

4. Apply low-strength (purple) Loctite or equivalent thread sealant to the fluid rod threads.

Hold the back end of the fluid rod (E) to prevent it from turning while installing the new electrode needle (20) finger-tight. Do not over-tighten the electrode needle.

CAUTION

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

threads, then install the electrode needle (20).



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

5. Install the fluid nozzle and resistor stud assembly and the air cap assembly as instructed on page

31.

6. Test the gun resistance as instructed on page 28.

Fig. 18

05155A

32 308584

Service

Fluid Packing Rod Removal and Repair

Preventative Maintenance

CAUTION

If the conductive fluid is allowed to leak through the packings, it will eventually cause an electrical short through the packings and along the gun barrel, resulting in a loss of voltage at the tip of the gun. Severe arcing can cause barrel damage. To avoid voltage loss and possible barrel damage, preventative maintenance of the fluid packing assembly must be performed at regular intervals.

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

Service Interval in Days = 25,000 T x H

Where T = trigger cycles per minute and H = hours of operation per day

For example: If the trigger cycles per minute equals 10 and the hours of operation per day equals 8, the equation would be,

25,000 = 25,000 = 312.5 10 x 8 80

The service interval would be 312 work days.

Fig. 19

4. Remove the fluid packing rod assembly (28) with the multi-tool (62).

05159A

Procedure NOTE: The fluid packing rod can be replaced as

individual parts or as an assembly. If the assembly is purchased, it is pre-adjusted at the factory.

1. Prepare the gun for service as instructed on page 30.

2. Remove the air cap assembly, fluid nozzle, and resistor stud, and electrode as instructed on pages 30 to 32.

3. Loosen the trigger screws (4) far enough to remove the trigger (13). See Fig. 19.

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

Before installing the fluid packing rod assembly (28), clean the internal surfaces of the barrel with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If the marks are present, replace the barrel.

6. If the parts are purchased separately, assemble them as instructed in steps 7 to 16 and as shown in Fig. 20, on page 34.

If installing the complete fluid rod assembly, go to step 11, page 34.

308584 33

Service

Fluid Packing Rod Removal and Repair (continued)

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

8. Fill the entire inner cavity of the spacer (28h) with the dielectric grease included with the gun. Place the spacer on the fluid rod (28a), in the direction shown in Fig. 20. Generously apply the grease to the outside of the spacer.

9. Place the fluid packing (28e), needle packing (28d), and housing (28b) on the fluid rod (28a), as shown in Fig. 20.

10. Lightly tighten the packing nut (28c) with the multitool (62). The packing nut is properly tightened when there is 2 lbs. (9 N) of drag force when sliding the packing housing (28b) assembly along the shaft. Tighten or loosen the packing nut as needed.

11. Lubricate the o-ring (28g).

12. Make sure the spring (30) is installed against the nut (U) as shown in Fig. 20.

13. Install the fluid packing rod assembly (28) into the gun barrel. Using the multi-tool (62), tighten the assembly until just snug.

14. Install the trigger (13) and tighten the trigger screws (4). See Fig. 19.

15. Install the electrode needle, fluid nozzle and resistor stud assembly and the air cap assembly as instructed on page 32.

16. Test the gun resistance as instructed on page 28.

 Apply a very light coat of lubricant to the o-ring (28g).  Fill the inner spacer (28h) cavity with the dielectric grease and generously lubricate the outside of the spacer.  Tighten the packing nut (28c) to 2 lbs (9 N) of drag force.  The spring (30) is not included with the fluid packing rod assembly (28)



Fig. 20



28a 28h U

28g 30

28e



28b 28c28d 28



03558

34 308584

Service

Fan Air Adjustment Valve Repair

NOTE: The fan air valve (43) can be replaced as an

assembly or as individual parts.

1. Prepare the gun for service as instructed on page 30.

2. Place a wrench on the flats of the valve housing and remove it from the handle. See Fig. 21.

3. If the parts are purchased separately, install them as instructed in steps 4 to 8.

If installing the complete valve, go to step 8.

4. Remove the retaining ring (43b). Rotate the air adjusting screw (43c) counterclockwise until it is disengaged from the valve housing threads (43d). Pull the adjusting screw out of the valve housing.

 Apply a very light coat of lubricant to the o-rings (43e) and

adjusting screw (43c) threads.

 Apply PTFE paste to the valve housing (43d) threads and

tighten the housing into the handle to 10–12 in-lb (1.1–1.4 Nm).

DETAIL



43d

43b



43c

43e



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

6. Install the o-rings (43e) on the adjusting screw (43c). Lubricate the o-rings and the adjusting screw threads with petroleum jelly.

7. Install the adjusting screw (43c) into the valve housing (43d), and install the retaining ring (43b) on the adjusting screw (43c). Back the adjusting screw out of the valve housing until it bottoms out against the retaining ring.

8. 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).

05161B

Fig. 21

Fluid Adjustment Assembly Repair

1. Prepare the gun for service as instructed on page 30.

2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45). See Fig. 22, page 36.

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).

Continued on the next page.

308584 35

Fluid Adjustment Assembly Repair (continued)

Service

CAUTION

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

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

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

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 is bottomed 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.

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.

Air Trigger Valve Repair

1. Prepare the gun for service as instructed on page 30.

2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45), o-ring (23), and spring (44). See Fig. 22.

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

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 knob (45), with the o-ring (23). Tighten the cap with a screw driver. Tighten the air valve packing nut (40) until it bottoms.

 Apply a very light coat of lubricant to the o-rings (41, 23).  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.





45d



45b

45a

45e

45c

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 them if necessary. Apply a very light coat of petroleum jelly to the o-rings.

36 308584

Fig. 22

40, 42



05162B

Atomizing Air Valve Repair

1. Prepare the gun for service as instructed on page 30.

Service



Apply PTFE paste to the fan air valve housing threads; Torque to 10–12 in-lb (1.1–1.4 Nm)

2. Remove the fan air adjustment valve (43) as instructed on page 35.

CAUTION

To avoid damaging the atomizing air valve, the fan air adjustment valve must be removed before removing the atomizing air valve.

3. Remove the atomizing air valve (31) and o-ring (19). See Fig. 23.

4. Install a new atomizing air valve and o-ring.

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).

Fig. 23

05162B



308584 37

Service

ES ON-OFF Valve Repair

1. Prepare the gun for service as instructed on page 30.

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

WARNING

MOVING PARTS HAZARD

To reduce the risk of an eye injury, 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 (Graco part no.

110090) 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 parts if necessary. Lightly 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.

WARNING

MOVING PARTS HAZARD

Always 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.

9. Install the lever (26) and tighten the set screw (24).

 Apply a very light coat of lubricant to the o-ring (36).  Bevelled side of the regulator disk (46) toward the valve (38).



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 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 turbine.

38 308584

Fig. 24



05363B

Service

Barrel Removal

1. Prepare the gun for service as instructed on page 30.

2. Loosen the nut (78) from the ferrule housing (79). Pull the ferrule housing through the gun bracket (76). See Fig. 25.

3. Loosen the three barrel screws (5) with the ballend wrench (63).

4. Hold the gun handle (7) with one hand and pull the barrel (3) straight away from the handle to remove it. Be prepared to catch the nut (78). See Fig. 26.

CAUTION

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

Fig. 26

3 7

05157

Fig. 25

78797576

05156

308584 39

Service

Power Supply Replacement

1. Prepare the gun for service as instructed on page 30.

2. Remove the barrel as instructed on page 39.

CAUTION

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

3. Grasp the power supply with your hand. With a gentle side to side motion, loosen the power supply from the gun handle (7), then pull it straight out. See Fig. 27.

4. Inspect the power supply for any physical damage. Check the electrical resistance as instructed in Test Power Supply Resistance, page 29. If necessary, replace the power supply.

 Apply a very light coat of lubricant to the o-rings 37a.  Do not expose the gasket (18a) to solvents.

5. Inspect the power supply cavity in the handle for dirt or moisture. Clean out the cavity with a clean, dry rag to avoid a loss in electrostatic performance.

6. Lightly lubricate the o-rings (18b, 37a) on the power supply with petroleum jelly.

CAUTION

All the o-rings (18b, 37a) and the compression spring (18c) must be in place or the gun will malfunction.

7. Be sure the gasket (18a) is in place. Insert the power supply in the gun handle.

8. Install the barrel on the handle as instructed on page 41.

9. Test the gun resistance as instructed on page 28.

18d

Fig. 27

18c



18a

18b



37a

37b

05160

40 308584

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 30.

2. Remove the barrel as instructed on page 39.

3. Remove the power supply as instructed on page 40.

4. Squeeze the two ends of the retaining ring (35) together, and carefully pull the alternator (37) away from the power supply (18) until the connector (V) disengages. See Fig. 27, page 40.

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

6. Measure the resistance between each outer terminal of the 3-wire connector (V) and the turbine alternator (37) housing. The resistance should be infinite. If the resistance is not infinite, replace the alternator.

7. Connect the 3-wire connector (V) to the 3 prongs in the power supply (18). Push the alternator (37) onto the power supply until the retaining ring (35) engages with the alternator.

8. Install the power supply in the gun handle as instructed on page 40.

3. Place the barrel (3) over the power supply (18) and onto the gun handle (7). Make sure the fluid needle spring (30) is seated properly, and align the fluid inlet tube (75) with the bracket port. Slide the nut (78) onto the end of the fluid inlet tube.

4. Tighten the three screws (5) oppositely and evenly with the ball-end wrench (63). Tighten the cap screws to 18 in-lbs (2 Nm) maximum (about a half turn past snug). Do not over-tighten the screws.

CAUTION

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

5. Install the ferrule housing (79) through the gun bracket (76), and secure it with the nut (78).

6. Test the gun resistance as instructed on page 28.

 Tighten the screws (5) to 18 in-lbs (2 Nm) maximum (about half

turn past snug), using the wrench (63) provided..

18a



9. Install the barrel on the handle as instructed below.

Barrel Installation

1. Clean and dry the inside of the fluid inlet tube (75). See Fig. 28.

2. Be sure the gaskets (34, 18a) and spring (30) are in place. Replace the parts if they are damaged.

Fig. 28

05158B

308584 41

Service

Graco Waterborne Fluid Hose Repair

WARNING

FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD

To reduce the risk of a fire, explosion, or electric shock:

 Follow the Fluid Voltage Discharge

and Grounding Procedure on page

16 and be sure the ES ON-OFF lever is turned to OFF before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.

 Clean all the parts with a non-flammable fluid as

defined on the front cover of this manual.

 Do not service this equipment unless you are

trained and qualified.

 Do not touch the gun nozzle or come within 4

inches (101.6 mm) of the nozzle during gun operation or until after following the Fluid Voltage

Discharge and Grounding Procedure..

WARNING

PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury, follow the Pressure Relief Procedure on page 16 before checking or

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

5. Carefully cut through the outer hose jacket (H) and peel it back about 12 inches (105 mm). Do not cut into the conductive layer (J) of the hose.

6. Cut through the first 1/2 inch (12.7 mm) of the conductive hose layer (J) to create an edge to hold onto. Peel back the conductive hose layer by unwrapping it in a spiral pattern. Cut it off at the dimension shown in Fig. 29.

7. Cut off the inner hose layer (K) to the dimension shown in Fig. 29.

8. Inspect the hose for any nicks or cuts. Any nicks or cuts into the inner hose layer (K) will weaken the dielectric strength of the hose and shorten the service life. Repeat the above procedure if any damage is found.

9. Install a new barbed fitting by applying red dielectric grease to the outside of the barbs, and pressing the fitting into the gun end of the hose. Refer to the drawing of the Waterborne Fluid Hose Assembly on page 48.

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

11. Connect the fluid hose to the gun as instructed on page 12.

Damaged hoses or hoses that have a “pin-hole” dielectric failure, close to the end of the hose, can be repaired by cutting away the failed portion and restripping the hoses to the dimensions shown in Fig. 29.

1. Discharge the voltage as instructed on page 16.

2. Relieve the system pressure as instructed on page

16.

3. Disconnect the fluid hose from the gun and voltage isolation system.

4. Cut off the damaged end of the hose. If the hose has a pin-hole failure, strip back the outer hose jacket (H) and the conductive layer (J) about 12 inches (105 mm) on each hose end. Look for the failure point, which will be a very small pin-hole, discolored due to arcing. Continue stripping back the hose until the failure point is found.

42 308584

Measurements, inches (mm) A* B* C D

7.75 + 0.1 (196.85 +

2.5)

* The measurements specified are for use with the Graco

H2O PRO Voltage Block isolation system.

Isolation System End Spray Gun End

Fig. 29

9.375 + 0.1 (238.13 +

2.5)

4.075 + 0.1 (103.5 + 2.5)

4.375 + 0.1 (111.1 + 2.5)

J K

05180

PRO 3500sc Gun Conversion

NOTE: See page 48 to order the conversion kit, part no. 223114. The fluid hose and air hose are not included with this kit. See page 48 to order hoses. Use only the electrically conductive air supply hoses and waterborne fluid hoses specified in this manual.

PRO 3500SC Gun Disassembly

1. Remove the air fitting (D), exhaust tube clamp (F), and the exhaust tube (E). Keep these parts for

reassembly.

2. Remove the fluid tube fitting (B) and fluid seal (A) from the gun. See Fig. 30.

3. Remove the gun fitting bracket (C) with the hose assembly.

4. Remove the air cap assembly (G, P, Z) and discard the retaining nut (G).

NOTE: Keep all the following parts for reassembly.

5. Point the front end of the gun up and squeeze the trigger while removing the fluid nozzle/resistor stud assembly (H) with the nozzle wrench.

6. Unscrew and remove the electrode needle (J) with the electrode tool. Be careful not to damage the contact wire. If the fluid rod turns, hold the back end of the fluid rod by placing a screw driver blade into the slot on the shaft, near the trigger.

7. Loosen the trigger screws (L) far enough to remove the trigger (M).

8. Remove the fluid packing rod assembly (K) with the 9 mm hex nut driver.

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.

Fig. 30

05423

Continued on the next page.

308584 43

PRO 3500sc Gun Conversion

 *80

28* 

20*

 Apply a very light coat of lubricant to the o-ring on the

outside of the fluid packing rod (28).

 Apply dielectric grease to the o-rings (80, 81) and tube (75)

threads.

 Apply high strength Loctite to the air fitting (D) threads.

Torque the fitting to 35 to 45 in-lbs (4 to 5.1 Nm).

Fig. 31

 *81

Installing the Fluid Needle Assembly

NOTE: The parts marked with an asterisk (*) are

included with the conversion kit, part no. 223114.

1. Before installing the new fluid packing rod assembly (28*), clean the internal surfaces of the barrel with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If the marks are present, replace the barrel.

2. Lubricate the o-ring on the outside of the fluid packing rod assembly. Make sure the spring is installed on the fluid packing rod nut.

NOTE: See Fig. 20, page 34, for information on individual fluid packing rod parts.

D 

 *75

*78

*76

*79

*77

3. Install the fluid packing rod assembly (28*) into the gun barrel. See Fig. 31. Using the 9 mm hex nut driver, tighten the assembly until just snug, then check the drag on the fluid rod. The fluid rod packing nut is properly tightened when there is 2 lbs. (9 N) of drag force. Tighten or loosen the packing nut as needed.

4. Install the trigger (L) and tighten the trigger screws (K).

5. Install the electrode needle (20*), fluid nozzle and resistor stud assembly (H) and the air cap assembly (P, 8*, Z) as instructed on page 32.

05164B

44 308584

PRO 3500sc Gun Conversion

6. Assemble the two o-rings (80*, 81*) onto the fluid inlet tube (75*). Apply dielectric grease to the o-rings and tube threads.

7. Screw the fluid inlet tube (75*) into the barrel inlet until it bottoms out.

a. Apply dielectric grease (82) to the O.D.

threads of the fluid inlet tube (75*). Thread the sleeve (91) onto the fluid inlet tube until it bottoms out.

8. Loosely assemble the ferrule housing parts (77*, 78*, 79*) to the gun bracket (76*).

9. Apply high strength Loctite to the air fitting (D) threads. Align the nut (78*) with the fluid inlet tube (75*), and install the air fitting to hold the bracket in place; torque the fitting to 35 to 45 in-lbs (4 to 5.1 Nm).

10. Tighten the nut (78*) onto the ferrule housing (79*).

11. Press the exhaust tube (E) onto the barbed adapter on the bottom of the gun handle. Secure the tube with the clamp (F).

12. Test the gun resistance as instructed on page 28.

13. Mount the warning sign (71*) in the spray area where it can easily be seen and read by all operators.

14. Follow the additional warnings, installation, operation, service, and other instructions given in this manual for a water-base system. Order replacement parts for the gun from the parts list on page 47.

WARNING

ELECTRIC SHOCK HAZARD

To help avoid electric shock, which could cause serious injury, only use the air and fluid hoses listed on page 48.

308584 45

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

Spray Gun Parts

28a

See Detail A

25*

18d

43c

45e

18f

45b

45d

23**

37b

45a

45c

**37a

18c

18b**

**34

*80

*81

18a**

19**

42**

18e

43e**

43d

43b

41**

28d*

28b

28g*

46 308584

DETAIL

28e*

28h*

28c

28f*

05165B

Spray Gun Parts

WARNING

Ref. No. Part No. Description Qty.

EQUIPMENT MISUSE HAZARD

Use only genuine Graco replacement parts. Using non-Graco parts could alter the gun’s grounding continuity or cause parts to rupture or fail, which could result in a serious injury and property damage.

Part No. 222700, Series C Model PRO 3500wb Spray Gun

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 222315 HANDLE, manifold 1 8 223653 RETAINING NUT 1 11 179791 T AG, warning 1 13 191904 TRIGGER, 2 finger 1 15 185122 MUFFLER 1 17 185105 FITTING, air 1 18 222333 POWER SUPPLY

Includes items 18a–18f 1 18a 185134 18b 106555 O–RING, Viton 1 18c 178504 18d 185141 CUSHION, power supply 1 18e 185099 PAD 1 18f 185145 PAD 1 19** 106555 O–RING; Viton 2 20 186615 NEEDLE, electrode 1 21 185158 NOZZLE, fluid

22 223977 STUD, resistor 1 23** 110099 O–RING, PTFE 1 24 110083 SET SCREW, lever; sch; M4 x 0.7 1 25* 111507 O–RING; fluoroelastomer 1 26 186839 LEVER, ES valve 1 28 223444 FLUID PACKING & NEEDLE ASSY

28a 223024 28b 185495 HOUSING, packing 1 28c 185488 28d* 178763 PACKING, needle 1 28e* 178409 P ACKING, fluid 1 28f* 111504 O–RING, fluoroelastomer 1 28g* 111316 O–RING, fluoroelastomer 1 28h* 186069 30 185111 SPRING, compression 1 31 238927 V ALVE, atomizing air 1 32 185119 SPACER, lever 1

GASKET, power supply 1

SPRING, compression 1

See Manual 307803 for

available nozzles 1

Includes items 28a–28h 1

NEEDLE, fluid 1

NUT, packing 1

SPACER 1

33 185112 ADAPTER, exhaust hose 1 34 185113 GASKET, manifold; polyethylene 1 35 185114 RING, retainer, alternator 1 36 113746 O–RING, CV75 1 37 222319 ALTERNATOR, turbine

Includes items 37a & 37b 1 37a 110073 37b 185124 CUSHION 1 38 185118 VALVE, electrostatic 1 39 224194 SHAFT ASSY., air valve 1 40 185115 NUT, packing 1 41 111508 O–RING, trigger valve;

42 105452 U–CUP, PTFE 1 43 222321 VALVE ASSY, fan air

43b 105681 43c 191805 43d 185090 HOUSING, valve 1 43e 103557 O–RING, Viton 2 44 185116 SPRING, compression, air valve 1 45 238895 VALVE, fluid adjustment

45a 186826 45b 111516  O-RING, CV 75 1 45c 186822  CAP 1 45d 191794  SLEEVE, guide 1 45e 191795  STOP, sleeve 1 46 107107 REGULATOR, disc 1 47 110082 RING, retaining 1 62 191744 MULTI-TOOL 1 63 107460 WRENCH, barrel 1 66 185103 TUBE, exhaust; polyurethane 1 67 110231 CLAMP, exhaust tube 1 69 110086 WRENCH, allen, hex key; 2 mm 1 71 186118 SIGN, warning, English 1 72 180209 COVER, gun 1 75 196161 HOUSING TUBE 1 76 190759 BRACKET 1 77 190863 HOSE FERRULE 1 78 185548 NUT 1 79 190862 FERRULE HOUSING 1 80* 110736 O-RING 1 81* 103338 O-RING 1 82 217115 DIELECTRIC GREASE 1 91 196158 SLEEVE 1

* These parts are included in Fluid Seal Repair Kit 238146,

which may be purchased separately.

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

which may be purchased separately.

 An Optional Plug 185079 is provided with the gun.

 These parts are not shown in the parts drawing.

 Replacement Warning signs are available at no cost.

O–RING, Viton 1

fluoroelastomer 1

Includes items 43b–43e 1

RING, retaining 1

VALVE, fan air adjustment 1

Includes items 45a–45e 1

 STEM, fluid adjustment 1

308584 47

Accessories

Use Only Genuine Graco Parts and Accessories

Waterborne Fluid Hose Assembly

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

To connect between the Graco H2O PRO Voltage Block and the gun; 0.25 in. (6.35 mm) ID; PTFE

Fluid Hose

Assy. Part No. Hose Length

237924 25 ft. (7.6 m) 237925 36 ft. (11 m) 237926 50 ft. (15.3 m)

Waterborne Fluid Hose Replacement Parts Ref.

No. Part No. Description Qty.

301 111450 O-RING 3 302 190143 BARBED FITTING 1

Waterborne Fluid Hose

301

PRO 3500sc Gun Conversion Kit 223114

Ref. No. Part No. Description Qty.

8 223653 RETAINING NUT 1 20 186615 ELECTRODE NEEDLE 1 28 223444 PACKING ROD ASSEMBLY 1 71 186118 WARNING SIGN (not shown) 1 75 196161 HOUSING TUBE 1 76 190759 BRACKET 1 77 190863 HOSE FERRULE 1 78 185548 NUT 1 79 190862 FERRULE HOUSING 1 80 110736 O-RING 1 81 103338 O-RING 1 82 217115 DIELECTRIC GREASE 1 91 196158 SLEEVE 1

The Kit Ref Nos. correspond with the Gun Ref Nos. on page 37.

302

05342

Graco Electrically Conductive Air Hose

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

Conductive SST wire braid for grounding; polyurethane tube and cover; 0.315 inch I.D.; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread; the hose is color-coded red

Hose Part No. Hose Length

235068 6 ft. (1.8 m) 235069 15 ft. (4.6 m) 235070 25 ft. (7.6 m) 235071 36 ft. (11.0 m) 235072 50 ft. (15.2 m) 235073 75 ft. (23.0 m) 235074 100 ft. (30. 5 m)

05166

48 308584

Accessories

Use Only Genuine Graco Parts and Accessories

Snap Ring Pliers 110090

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

Gun High Voltage Probe & Meter 217452

For direct measurement of the gun output voltage.

Megohmmeter 218979

500 Volt output; 0.01–2000 megohms.

Not for use in Hazardous areas.

Gun Cover 180209

Order Part No. 218374 for package of 10.

Gun Holster 236090

Mount the gun holster to the side of the spray booth. Hang gun in holster while the voltage discharges.

Grounding Rod 210084 For use in the Fluid Voltage Discharge and Grounding Procedure.

Manual Change Summary

Rev. D – The manual was updated to change air cap part no. 173033 to 193033. Rev. H – The manual was updated to add part 196158, Dielectric Fluid Tube Sleeve per ECO Z001153.

308584 49

50 308584

Technical Data

Category Data

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* Air Inlet 1/4 npsm(m) L.H. Fluid Inlet custom inlet for Graco

Fluid Specification For use with fluids that

100 psi (0.7 MPa, 7 bar)

0–100 psi (0–0.7 MPa, 0–7 bar)

waterborne fluid hose

meet at least one of the following conditions:  The fluid has a flash

point above 140F (60C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93.

 The fluid does not

sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.

Category Data

Wetted Parts Stainless Steel, Brass,

Nylon, Acetal, PTFE, Fluoroelastomer, PTFE High Molecular Weight Polyethylene, Ceramic

Typical Noise Level with atomization air at 40 psi (280 kPa, 2.8 bar) and typical air flow

Sound Pressure  Sound Power 

Maximum Noise Level with atomization air at 100 psi (0.7 MPa, 7 bar) and maximum air flow

Sound Pressure  Sound Power 

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

* Voltage output when used with Graco H

kV due to bleed resistor current draw.

Viton is a registered trademark of the

DuPont Co. Loctite is a registered trademark of the Loctite Corporation.

87 Db(A)

90.4 Db(A)

99 Db(A)

105.4 Db(A)

O PRO is 0–59

308584 51

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven 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, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

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

DISCLAIMERS AND LIMITATIONS

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

EQUIPMENT NOT COVERED BY GRACO WARRANTY

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

Graco Phone Number

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

1–800–367–4023 Toll Free

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

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

International Offices: Belgium, Korea, Hong Kong, Japan

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

PRINTED IN U.S.A. 308584 August 1995 Revised September 2000

52 308584

Sales Offices: Minneapolis, Detroit

www.graco.com

Graco PRO 222700, PRO 308584, PRO 3500wb, 222700 Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual