INSTRUCTIONS-PARTS LIST
308584
Rev. H
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Model PRO 3500wb
t
Electrostatic Air Spray Gun
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
Part No. 222700, Series C
For use when electrostatically spraying con-
ductive, waterborne fluids that meet at least
one of the following conditions for non-flamma-
bility:
1. The fluid has a flash point above 140_ F
(60_ C) and a maximum organic solvent
concentration of 20%, by weight, per
ASTM Standard D93.
2. The fluid does not sustain burning when
tested per ASTM Standard D4206 Sus-
tained 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.
05148B
U.S. PATENT NO. 4,290,091; 4,219,865; 4,497,447; 4,462,061; 4,660,774 ; D313,064; 4,978,075
Patented 1986, 1987 Canada
Brevete 1986, 1987
U.K. PATENT NO. 2,147,158; 2,142,559B; 2,140,327B
French Patent No. 89 16305
Other U.S. and Foreign Patents Pending
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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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.
D 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.
D
T
h
e
g
u
n
m
u
s
t
b
e
c
o
n
n
e
c
t
e
d
t
o
a
v
o
l
t
a
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e
i
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o
l
a
t
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o
n
s
y
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e
m
t
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a
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w
i
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l
d
i
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c
h
a
r
g
e
t
h
e
s
y
s
t
e
m
v
o
l
t
a
g
e
when the gun is not in use.
D 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.
D 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.
D
O
n
l
y
u
s
e
t
h
e
r
e
d
-
c
o
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o
r
e
d
G
r
a
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i
c
a
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y
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o
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d
u
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g
u
n
a
i
r
h
o
s
e
w
i
t
h
t
h
i
s
g
u
n
.
D
o
n
o
t
u
s
e
t
h
e
black or grey-colored Graco air hoses.
D
I
n
s
t
a
l
l
o
n
l
y
o
n
e
c
o
n
t
i
n
u
o
u
s
G
r
a
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o
w
a
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o
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e
f
l
u
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o
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i
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o
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a
t
e
d
f
l
u
i
d
s
u
p
p
l
y
a
n
d
t
h
e
spray gun. Do not splice hoses together.
D 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.
D
D
o
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o
t
e
n
t
e
r
a
h
i
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a
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e
q
u
i
p
m
e
n
t
h
a
s
b
e
e
n
discharged.
D 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.
D
D
o
n
o
t
c
o
n
n
e
c
t
m
o
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e
t
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a
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m
.
R
e
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a
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i
o
n
s
a
p
p
l
y
i
n
g
t
o
t
h
i
s
type of equipment prohibit the use of multiple hand-held guns.
D
I
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e
r
e
i
s
a
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y
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t
a
t
i
c
s
p
a
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k
i
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w
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q
u
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,
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o
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a
y
i
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i
m
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e
d
i
a
t
e
l
y
.
I
d
e
n
t
i
f
y
a
n
d
correct the problem.
D
F
o
l
l
o
w
t
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e
w
a
r
n
i
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g
s
a
n
d
i
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m
a
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u
a
l
.
308584
3
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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.
D
E
l
e
c
t
r
o
s
t
a
t
i
c
e
q
u
i
p
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n
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d
o
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b
y
t
r
a
i
n
e
d
,
q
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f
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d
p
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o
n
n
e
l
w
h
o
u
n
d
e
r
s
t
a
n
d
t
h
e
requirements stated in this instruction manual.
D 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.
D
T
e
s
t
t
h
e
g
u
n
e
l
e
c
t
r
i
c
a
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a
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a
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d
o
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p
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2
8
.
D
P
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o
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f
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a
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v
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t
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b
u
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x
i
c
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a
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r
s
.
S
e
e
V
e
n
t
i
l
a
t
e
t
h
e
S
p
r
a
y
B
o
o
t
h
on page 9.
D
O
n
l
y
u
s
e
t
h
i
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e
q
u
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p
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n
t
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n
o
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-
f
l
a
m
m
a
b
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e
,
w
a
t
e
r
b
o
r
n
e
f
l
u
i
d
s
,
a
s
d
e
f
i
n
e
d
o
n
t
h
e
f
r
o
n
t
c
o
v
e
r
of this manual.
D
O
n
l
y
f
l
u
s
h
,
p
u
r
g
e
,
o
r
c
l
e
a
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e
e
l
e
c
t
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o
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t
a
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c
,
w
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p
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m
w
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o
n
-
f
l
a
m
m
a
b
l
e
f
l
u
i
d
s
,
as defined on the front cover of this manual.
D Do not flush the system with the gun electrostatics turned on.
D Use only non-sparking tools to clean residue from the booth and hangers.
D Extinguish all open flames or pilot lights in the spray area.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Do not store any flammable fluids in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do not smoke in the spray area.
D
D
o
n
o
t
o
p
e
r
a
t
e
a
g
a
s
o
l
i
n
e
e
n
g
i
n
e
i
n
t
h
e
s
p
r
a
y
a
r
e
a
.
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.
D
D
o
n
o
t
p
o
i
n
t
t
h
e
s
p
r
a
y
g
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o
r
a
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p
a
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t
o
f
t
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e
b
o
d
y
.
D
D
o
n
o
t
s
t
o
p
o
r
d
e
f
l
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c
t
f
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u
i
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l
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a
k
s
w
i
t
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y
o
u
r
h
a
n
d
,
b
o
d
y
,
g
l
o
v
e
,
o
r
r
a
g
.
D 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.
D
T
i
g
h
t
e
n
a
l
l
t
h
e
f
l
u
i
d
c
o
n
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c
t
i
o
n
s
b
e
f
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o
p
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a
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q
u
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p
m
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n
t
.
D
C
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c
k
t
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e
h
o
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e
s
,
t
u
b
e
s
a
n
d
c
o
u
p
l
i
n
g
s
d
a
i
l
y
.
R
e
p
l
a
c
e
w
o
r
n
,
d
a
m
a
g
e
d
,
o
r
l
o
o
s
e
p
a
r
t
s
i
m
m
e
d
i
a
t
e
l
y
.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Warnings are continued on the next page.
4
308584
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WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in a serious injury.
INSTRUCTIONS
D
T
h
i
s
e
q
u
i
p
m
e
n
t
i
s
f
o
r
p
r
o
f
e
s
s
i
o
n
a
l
u
s
e
o
n
l
y
.
D
R
e
a
d
a
l
l
t
h
e
i
n
s
t
r
u
c
t
i
o
n
m
a
n
u
a
l
s
,
t
a
g
s
,
a
n
d
l
a
b
e
l
s
b
e
f
o
r
e
o
p
e
r
a
t
i
n
g
t
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e
q
u
i
p
m
e
n
t
.
D
U
s
e
t
h
e
e
q
u
i
p
m
e
n
t
o
n
l
y
f
o
r
i
t
s
i
n
t
e
n
d
e
d
p
u
r
p
o
s
e
.
I
f
y
o
u
a
r
e
u
n
c
e
r
t
a
i
n
a
b
o
u
t
u
s
a
g
e
,
c
a
l
l
y
o
u
r
G
r
a
c
o
distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check the equipment daily. Repair or replace worn or damaged parts immediately.
D 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.
D
U
s
e
f
l
u
i
d
s
t
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a
t
a
r
e
c
o
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p
a
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w
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q
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p
a
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t
s
.
S
e
e
t
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e
T
e
c
h
n
i
c
a
l
D
a
t
a
s
e
c
t
i
o
n
o
f
all the equipment manuals. Read the fluid manufacturer’s warnings.
D 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).
D
D
o
n
o
t
u
s
e
t
h
e
h
o
s
e
s
t
o
p
u
l
l
e
q
u
i
p
m
e
n
t
.
D
W
e
a
r
h
e
a
r
i
n
g
p
r
o
t
e
c
t
i
o
n
w
h
e
n
o
p
e
r
a
t
i
n
g
t
h
i
s
e
q
u
i
p
m
e
n
t
.
D
C
o
m
p
l
y
w
i
t
h
a
l
l
a
p
p
l
i
c
a
b
l
e
l
o
c
a
l
,
s
t
a
t
e
,
a
n
d
n
a
t
i
o
n
a
l
f
i
r
e
,
e
l
e
c
t
r
i
c
a
l
,
a
n
d
o
t
h
e
r
s
a
f
e
t
y
r
e
g
u
l
a
t
i
o
n
s
.
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.
D
K
n
o
w
t
h
e
s
p
e
c
i
f
i
c
h
a
z
a
r
d
s
o
f
t
h
e
f
l
u
i
d
y
o
u
a
r
e
u
s
i
n
g
.
R
e
a
d
t
h
e
f
l
u
i
d
m
a
n
u
f
a
c
t
u
r
e
r
’
s
w
a
r
n
i
n
g
s
.
D
S
t
o
r
e
h
a
z
a
r
d
o
u
s
f
l
u
i
d
i
n
a
n
a
p
p
r
o
v
e
d
c
o
n
t
a
i
n
e
r
.
D
i
s
p
o
s
e
o
f
t
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e
h
a
z
a
r
d
o
u
s
f
l
u
i
d
a
c
c
o
r
d
i
n
g
t
o
a
l
l
local, state, and national guidelines.
D
W
e
a
r
a
p
p
r
o
p
r
i
a
t
e
p
r
o
t
e
c
t
i
v
e
c
l
o
t
h
i
n
g
,
g
l
o
v
e
s
,
e
y
e
w
e
a
r
,
a
n
d
r
e
s
p
i
r
a
t
o
r
.
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Introduction
Precautions must be taken when using electrostatic
Spraying Waterborne Fluids
Electrostatically
waterborne equipment to avoid potential shock haz-
ards. 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 de-
pends on the system design. Follow the Fluid Voltage
Discharge and Grounding Procedure, page 16,
before approaching the front of the gun.
The PRO 3500wb spray gun is a 60 kV electrostatic
spray gun that is designed to spray conductive, water-
borne, non-flammable fluids. When spraying water-
borne fluids electrostatically, the gun must be con-
nected 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:
D 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.
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.
D
A
m
e
a
n
s
f
o
r
a
u
t
o
m
a
t
i
c
a
l
l
y
d
i
s
c
h
a
r
g
i
n
g
t
h
e
s
y
s
t
e
m
voltage if anyone opens the fence or enclosure.
D
A
b
l
e
e
d
r
e
s
i
s
t
o
r
t
o
d
r
a
i
n
o
f
f
t
h
e
s
y
s
t
e
m
v
o
l
t
a
g
e
when the spray gun is not in use.
D 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.
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/alter-
nator (T). The air spins the turbine, which then pro-
vides 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, wrap-
ping around and evenly coating all surfaces.
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 solvent-
based 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.
6
308584
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Introduction
KEY-Fig. 1
J
Fluid Adjustment Knob
K
L
Exhaust Tube
Hook
A
B
C
D
E
F
Air Cap
Electrode
Retaining Nut
Gun Barrel
Gun Handle
Air Inlet
M
N
P
R
S
T
ES Indicator Light
ES ON-OFF Lever
Fan Air Adjustment Valve
Atomizing Air Valve
Power Supply
G
H
Fluid Inlet
Trigger
Turbine/Alternator
M
L
D
E
*N
J
P
R
05151A
* 1 is ON 0 is OFF
F
B
A
C
K
05148B
H
G
S
T
05404
Fig. 1
308584
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Introduction
KEY-Fig. 2
Graco Waterborne Fluid Hose (purchased
separately)
DD Conductive Hose Layer
EE Inner Hose Layer
FF Outer Hose Jacket
CC Grounded Enclosure
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):
ꢀ 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).
D
I
n
n
e
r
H
o
s
e
L
a
y
e
r
(
E
E
)
:
i
s
a
P
T
F
E
t
u
b
e
.
ꢀ
EE
DD
FF
ꢁ
D
C
o
n
d
u
c
t
i
v
e
H
o
s
e
L
a
y
e
r
(
D
D
)
:
c
o
v
e
r
s
t
h
e
P
T
F
E
tube.
D
O
u
t
e
r
H
o
s
e
J
a
c
k
e
t
(
F
F
)
:
i
s
a
p
r
o
t
e
c
t
i
v
e
p
o
l
y
e
t
h
y
l
-
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.
CC
2
H O PRO Voltage Block connection shown
05179
Fig. 2
8
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Installation
Basic Guidelines
Installing the System
When spraying waterborne fluids electrostatically:
D 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.
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.
D 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.
D
D
o
n
o
t
i
n
s
t
a
l
l
o
r
s
e
r
v
i
c
e
t
h
i
s
e
q
u
i
p
m
e
n
t
u
n
l
e
s
s
D 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.
you are trained and qualified.
D Comply with all local, state, and national codes
for the installation of electrical apparatus in a
Class I, Group D, Hazardous Location.
Warning Signs
Mount the warning sign, part no. 186118, in the spray
area where it can easily be seen and read by all opera-
tors. Additional warning signs are available at no
charge.
D Comply with all applicable local, state, and
national fire, electrical, and other safety regula-
tions.
Fig. 3, page 10, shows a typical Model PRO 3500wb
waterborne system. The particular type and size sys-
tem for your operation must be custom designed for
your needs. For assistance in designing a system,
contact your Graco representative.
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.
Accessories are available from your Graco representa-
tive. Refer to the Product Data Sheet for the gun,
Form No. 305681.
Check and follow all local, state, and national codes
regarding air exhaust velocity requirements. High
velocity air exhaust will decrease the operating effi-
ciency of the electrostatic system. The minimum
allowable air exhaust velocity is 60 linear feet/minute
(18.3 linear meters/minute).
308584
9
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Installation
KEY-Fig. 3
A
B
C
D
E
F
Air Regulator
Spray Gun Air Shut-off Valve
Gun Fluid Regulator
Graco Waterborne Fluid Hose
Gun Fluid Inlet
PRO 3500wb Spray Gun
Gun Air Inlet
K
L
Air Supply Hose
Fluid Supply Hose
Gun Air Hose Ground Wire
True Earth Ground
Fluid Hose Port
M
N
P
R
S
T
2
H O PRO Batch System Voltage Block Enclosure
G
H
Main Ground Wire
Ground Lug
Graco Red Electrically Conductive Gun Air Hose
F
M
PRO 3500wb Gun shown with the
Graco H O PRO Batch System
G
2
N
H
Consult your isolation system
manual for other configurations.
B
R
A
T
S
E
D
N
K
L
P
C
05310
Fig. 3
10
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Installation
Connect the red-colored Graco Electrically Conductive
Install the Air Line Accessories
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.
1. Install an air line filter and an air and water separa-
tor 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.
NOTE: The hose and the gun have special left-hand
threads to prevent connecting another type of air hose
to the gun air inlet.
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.
Connect the Exhaust Tube
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).
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
WARNING
PRESSURIZED EQUIPMENT HAZARD
1. Before connecting the fluid line, blow it out with air
and flush it with water.
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 re-
quired on the main air supply line so trapped air will
be relieved between this valve and the pump after
the air regulator is closed.
2. A fluid regulator (C) is needed in the fluid line to
control fluid pressure to the gun. Refer to Fig. 3,
page 10.
2
NOTE: The H O PRO voltage block comes with a fluid
regulator already installed.
3. Install a fluid filter and drain valve at the pump
outlet.
Connect the Air Line
WARNING
WARNING
ELECTRIC SHOCK HAZARD
To reduce the risk of an electric shock or
other serious injury, you must use the
red-colored Graco Electrically Conduc-
tive 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.
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
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Installation
Filter the Fluid
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.
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.
2. Inspect the condition of the o-rings (G) on the hose
barbed-fitting. Replace the o-rings if they are worn
or damaged.
Connect the Fluid Hose
NOTE:
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.
D 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.
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
D 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.
G
H
J
O-Rings
Outer Hose Jacket
Conductive Hose Layer
Inner Hose Layer
K
ꢀ
Apply a light coat of dielectric grease to the o-rings (G) and the
entire length of the inner hose layer (K)
WARNING
ꢁ
ꢂ
4.075 + 0.10 in. (103.5 + 2.5 mm)
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.
Minimum of 4.375 + 0.10 in. (111.1 + 2.5 mm)
G
ꢂ
ꢁ
1. For the fluid hose to seal properly and be held
securely, the hose must be stripped and as-
sembled 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.
Spray Gun
Hose End
ꢀ
H
J
K
05342
Fig. 4
Continued on the next page
12
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Installation
Connect the Fluid Hose (continued)
WARNING
5. Insert the hose (Y) into the hose ferrule housing
(79). See Fig. 5.
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.
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 NSm). 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
The Graco warranty is void if the spray gun is con-
nected to a non-Graco voltage isolation system or if
the gun is operated above 60 kV.
CAUTION
KEY- Fig. 6
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.
H
K
R
Outer Hose Jacket
Inner Hose Layer
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).
8. Connect the other end of the hose to the isolated
fluid supply as instructed in the voltage isolation
system manual. See Fig. 6.
ꢁ
ꢂ
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).
KEY- Fig. 5
The conductive hose layer (J) must be grounded through its
connection to the isolation system’s grounded safety fence or
enclosure (R).
Y
Graco Waterborne Fluid Hose
75 Fluid Inlet Tube
77 Hose Ferrule
79 Hose Ferrule Housing
ꢁ
ꢀ
K
H
ꢀ
Torque to 50 in-lb (5.6 NS m)
R
ꢂ
DETAIL
K
J
H
75
79
R
2
77
Y
H O PRO Voltage Block
connection shown
ꢀ
05149B
Fig. 6
05405B
Fig. 5
308584
13
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Installation
2. PRO 3500wb Electrostatic Air Spray Gun:
Ground the System
Install the red-colored Graco electrically conduc-
tive 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.
WARNING
FIRE, EXPLOSION, AND
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.
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, explo-
sion, or electric shock. Follow the
grounding instructions below.
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.
The following grounding instructions are minimum re-
quirements 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.
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 continu-
ity.
1. Fluid Supply: Ground the fluid supply by connect-
ing a ground wire and clamp between the fluid
supply and a true earth ground. See your fluid
supply instruction manual for grounding instruc-
tions.
8. All electrically conductive objects or devices
in the spray area: They must be properly
grounded.
14
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Installation
KEY- Fig. 7
Check the Electrical Grounding
AA Gun Handle
BB True Earth Ground
CC Ohmmeter
DD ES ON-OFF Lever
1. Have a qualified electrician check the electrical
grounding continuity of the spray gun and air hose.
EE Graco Electrically Conductive Air Hose
EE
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.
DD
AA
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 ohmme-
ter (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.
BB
05150B
CC
Fig. 7
308584
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Operation
Fluid Voltage Discharge and Grounding
Pressure Relief Procedure
Procedure
WARNING
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Proce-
dure whenever you:
ELECTRIC SHOCK HAZARD
The high voltage fluid supply is charged
with high voltage until the voltage is dis-
charged. Contact with the charged com-
ponents of the isolation system or spray gun elec-
trode will cause an electric shock. To avoid an elec-
tric shock, follow the Fluid Voltage Discharge
and Grounding Procedure:
D are instructed to relieve the pressure,
D stop spraying,
D
w
h
e
n
i
n
s
t
r
u
c
t
e
d
t
o
d
i
s
c
h
a
r
g
e
t
h
e
v
o
l
t
a
g
e
,
D check or service any of the system equipment,
D or install or clean the fluid nozzle.
D
b
e
f
o
r
e
c
l
e
a
n
i
n
g
,
f
l
u
s
h
i
n
g
,
o
r
s
e
r
v
i
c
i
n
g
t
h
e
s
y
s
-
tem equipment,
D
b
e
f
o
r
e
a
p
p
r
o
a
c
h
i
n
g
t
h
e
f
r
o
n
t
o
f
t
h
e
g
u
n
,
D
a
n
d
b
e
f
o
r
e
o
p
e
n
i
n
g
t
h
e
s
a
f
e
t
y
f
e
n
c
e
o
r
t
h
e
enclosure for the isolated fluid supply.
1. Follow the Fluid Voltage Discharge and
Grounding Procedure, at left.
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.
2. Relieve fluid pressure in the fluid supply and
voltage isolation system as instructed in their
instruction manuals.
1. Turn off the gun electrostatics by turning the gun
ES ON-OFF lever to the OFF position.
2. Discharge the voltage at the voltage isolation
system by following the procedure specified in the
voltage isolation system instruction manual.
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 sys-
tem.
3. Touch the electrode of the gun with a grounded rod
to make sure that the voltage has been dis-
charged. If an arc is seen, verify that the electros-
tatics are turned off or see Troubleshooting,
page 24, or the voltage isolation system manual
for other possible problems. Resolve the problem
before proceeding.
5. Trigger the gun into a grounded metal waste
container to relieve fluid pressure.
16
308584
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Operation
3 in. (76 mm) square cut out and
finger of glove cut off
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.
NOTE: If gloves are worn, they must be conductive or
modified as shown so they do not interfere with operator
grounding through the gun.
____ 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.
Fig. 8
____ 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.
Selecting a Fluid Nozzle and Air Cap
____ 6. The condition of the electrical components of
the spray gun has been checked as instructed
in Electrical Tests, page 28.
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.
____ 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.
308584
17
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Operation
1. Follow the Operating Checklist on page 17.
Operating the Spray Gun
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.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire and explosion,
only use this equipment to spray non-
flammable, 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
Vertical Pattern
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.
Horizontal Pattern
02020
Fig. 9
Follow the Fluid Voltage Discharge and Ground-
ing Procedure on page 16 when you stop spray-
ing and whenever you are instructed to discharge
the voltage.
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.
WARNING
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.
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 pres-
sure required to get full voltage from the power
supply. To avoid shortening the turbine life, do not
exceed the recommended air pressures.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of component rupture,
which can cause serious injury, do not
Air Hose
Length
ft. (m)
Dynamic pressure at air hose inlet
required for full voltage
psi (kPa, bar)
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.
15 (4.6)
25 (7.6)
45 to 50 (314 to 345, 3.1 to 3.4)
50 to 55 (345 to 379, 3.4 to 3.7)
60 to 65 (410 to 444, 4.1 to 4.4)
68 to 73 (465 to 501, 4.5 to 5.0)
75 to 80 (514 to 550, 5.1 to 5.5)
50 (15.3)
75 (22.9)
100 (30.5)
Follow the steps below to establish the correct fluid
flow and air flow. Do not turn the ES ON-OFF lever to
ON yet:
18
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Operation
7. Set the atomizing air valve (R) about 1.5 turns out
11. Use the same spraying technique you would use
with a conventional air spray system to coat the
workpiece.
for most applications. The Atomizing Air Valve
Adjustment chart shows the effect of the atomiz-
ing air valve adjustment on the air cap air flow.
12. Relieve the pressure and discharge the voltage
when you stop spraying.
8. Adjust the pattern width with the fan air valve (P).
Atomizing Air Valve Adjustment
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 pas-
sages can cause poor atomization and excessive
current demands and damage the gun.
100
90
80
70
60
50
40
30
20
10
KEY-Fig. 10
M
J
Fluid Adjustment Knob
ES Indicator Light
ES ON-OFF Lever
Fan Air Adjustment Valve
Atomizing Air Valve
M
N
P
R
0
0.00 0.50 1.00 1.50 2.00 2.50 3.00
Fully Open
Fully Closed
Valve Turns
Fine Adjustments of the Spray Gun
D 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 accept-
able atomization. The slower particle velocity will
improve the electrostatic effect.
*N
J
P
R
05151A
Fig. 10
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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.
10. Operate the voltage isolation system as instructed
in the system manual. Normal spraying voltage for
the system will be 45 to 55 kV.
05424
Fig. 11
308584
19
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Operation
1. Relieve the pressure.
Shutdown
2. Flush and clean the equipment. Follow the instruc-
WARNING
tion in Maintenance.
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
Daily Care and Cleaning
WARNING
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.
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire and explosion:
D Only flush, purge, or clean the PRO
3500wb spray gun with non-flam-
mable fluids, as defined on the front
cover of this manual.
D
Immersing the gun in fluid is not recom-
mended.
D
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d
on.
D
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.
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.
D
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.
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.
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.
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 whenev-
er you are done operating the gun. See page 21.
20
308584
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Maintenance
Clean the Air Cap and Fluid Nozzle
Flush the Spray Gun
1. Relieve the pressure and discharge the system
voltage as instructed on page 16.
Equipment needed:
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2. Make sure the gun ES ON-OFF lever is turned to
OFF.
CAUTION
3. Turn off the air to the spray gun.
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.
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.
Procedure:
6. Shut off the fluid supply and relieve the pressure
as instructed on page 16.
1. Relieve the pressure and discharge the system
voltage 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.
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.
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 damp-
ened 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.
05152A
Fig. 12
8. Test the gun resistance as instructed on page 28.
308584
21
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Troubleshooting
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WARNING
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s
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.
Waterborne Fluid Hose
D Dielectric failure of hose (pin-hole leak through
PTFE layer)
D Air gap in the fluid column between the gun and
isolated fluid supply, causing a low voltage reading
on the isolation system voltage meter.
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.
Voltage Block
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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 troubleshoot-
ing tests that follow.
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.
1. Check that all of the air and fluid tubes and hoses
are properly connected.
Voltage Loss Troubleshooting
2. Check that the voltage isolation system valves and
controls are properly set for operation. Refer to the
voltage isolation system manual.
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.
3. Check that the spray gun and voltage isolation
system have sufficient air pressure.
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 con-
nected through the conductive, waterborne fluid.
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.
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:
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.
Spray Gun
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6. Make sure the voltage isolation system is in the
“isolate” mode, where it is isolating the fluid volt-
age from ground.
fluid packings
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22
308584
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Troubleshooting
4. Position the end of the hose as far as possible
Voltage Loss Troubleshooting (continued)
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.
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.
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.
8. Check the spray gun cover and barrel for accumu-
lated 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.
6. Discharge the system voltage by waiting 30 se-
conds 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.
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:
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outer jacket, which may indicate an internal leak
If the reading is below 45 kV, the problem is in the
gun or fluid hose.
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s
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.
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.
1. Flush the system with water and leave the lines
filled with water.
2. Relieve the pressure and discharge the system
voltage as instructed on page 16.
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.
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.
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
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Troubleshooting
D
Fluid packings
Voltage Loss Troubleshooting (continued)
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.
11. A dielectric breakdown is most likely in one of the
following three areas. Repair or replace the com-
ponent that is failing.
D
Fluid hose
D
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.
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.
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.
Inspect the end of the hose connected to the
voltage block. Look for cuts or nicks.
13. Reconnect the fluid hose as instructed on page 12.
Make sure the hose is properly stripped; see
Fig. 4, page 12, for hose stripping dimensions.
Restrip or replace the hose.
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 Pro-
cedure
Gun electrostatics (gun ES lever) are Turn off the gun electrostatics.
not turned off.
Did not wait long enough for the volt- Wait a longer period of time before
age to discharge through the voltage touching the electrode with a
bleed resistor.
grounded rod. Check for possible
bleed resistor failure.
There is an air pocket in the fluid line Determine the cause of the air pocket
that leaves the fluid near the gun
isolated.
and fix the problem. Purge the air out
of the fluid line.
Voltage isolation system failed.
See the isolation system manual for
service information.
The operator gets a shock
The operator is not properly grounded Be sure the floor and the operator are
or is near an ungrounded object.
properly grounded; see Ground the
System, page 14.
The gun is not properly grounded.
See Check the Electrical Ground-
ing, page 15.
The operator gets a shock when
touching the workpiece
The workpiece is not properly
grounded.
Clean the workpiece hangers; check
for proper grounding on the conveyor
or track
24
308584
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Troubleshooting
Spray Pattern Troubleshooting
NOTE: Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Cause
Solution
The fluid supply is insufficient.
Adjust the fluid regulator, or fill the
fluid supply.
Fluttering or spitting spray
The fluid nozzle is loose, or the fluid
nozzle taper seat is damaged.
Tighten or replace the fluid nozzle;
see page 30.
There is dirt between the fluid nozzle, Clean the parts; see page 21.
taper seat, and gun body.
The coupler at the fluid inlet is loose
or cracked.
Tighten or repair the coupler.
There is fluid build-up on the air cap; Clean the air cap with a soft imple-
partially clogged horn holes; or full air ment or submerge it in water and
Improper spray pattern
pressure from the clean horn hole
forces the fan pattern toward the
clogged end.
wipe it clean; see page 21.
The electrode is bent.
Straighten the electrode.
The fluid nozzle or air cap holes are
damaged.
Replace the damaged part; see page
30.
There is fluid buildup on the perimeter Remove the obstruction; never use
of the fluid nozzle orifice, or a partially wire or hard instruments; see page
clogged fluid nozzle orifice.
21.
The electrode is bent.
Straighten the electrode wire.
Reduce the fan air pressure.
The fan air pressure is too high.
The fluid is too thin.
Reduce the fluid viscosity.
Increase the fluid pressure.
Increase the fan air pressure.
Reduce the fluid viscosity.
Reduce the fluid flow.
There is not enough fluid pressure.
The fan air pressure is too low.
The fluid is too thick.
There is too much fluid.
The last coat of fluid is applied too
wet.
Apply a drier finish using multiple
strokes.
Streaks
There is too much air pressure.
The air pressure is insufficient.
The spray pattern is non-uniform.
Decrease the air pressure.
Increase the air pressure.
Clean or replace the air cap; see
page 21.
308584
25
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Troubleshooting
Poor Electrostatic Wrap Troubleshooting
Problem
Cause
Solution
The distance between the gun and
workpiece is incorrect.
Adjust the spraying distance to 8 to
12 inches (203 to 305 mm).
The system is holding voltage but
there is poor electrostatic wrap on
the part being sprayed
The parts are poorly grounded.
Clean the workpiece hangers; check
for proper grounding on the conveyor
or track.
Booth exhaust velocity is too high.
Reduce the exhaust velocity within
the code limits.
The atomizing air pressure is too
high.
Reduce the atomizing air pressure.
The fluid pressure is too high.
Reduce the fluid pressure.
The fluid viscosity is not right for
electrostatic spray.
Check with the supplier for proper
fluid viscosity for electrostatic spray.
Gun Operation Troubleshooting
Problem
Cause
Solution
The fluid rod packings or fluid rod are Replace the packings or rod; see
Fluid leakage from the fluid pack-
ing area
worn.
page 33.
The packing nut is loose
The air valve is not seating properly.
Tighten the packing nut; see page 33.
Clean and service the air valve; see
page 36.
Air leakage from the front of the
gun
The air valve o-ring is sticking.
The fluid rod is worn or damaged.
The fluid seat is worn.
Lubricate the o-ring; see page 36.
Replace the fluid rod; see page 33.
Fluid leakage from the front of the
gun
Replace the fluid nozzle and/or elec-
trode needle; see pages 30 to 32.
The fluid packing is too tight.
The resistor stud is loose.
Lubricate and adjust the packing nut;
see page 33.
Tighten the resistor stud; see page
30.
The fluid nozzle is loose.
Tighten the fluid nozzle; see page 30.
Replace the o-ring; see page 30.
The resistor stud o-ring is damaged.
The air pressure is insufficient for
good atomization.
Increase the air cap air pressure by
opening the atomizing air valve more
or increasing the gun air inlet pres-
sure; use the least air pressure need-
ed for good results.
“Orange Peel” finish
The fluid is poorly mixed or filtered.
An improper thinner is being used.
Remix or refilter the fluid.
Use the proper thinner.
26
308584
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Troubleshooting
Gun Operation Troubleshooting (continued)
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 pres-
sure; use the least air pressure
Excessive spray fog
needed for good results. Do not re-
duce below minimum pressure need-
ed for full voltage. See page 18.
The fluid is thinned too much.
The fluid supply is low.
Properly thin the fluid.
Check the fluid supply; add fluid if
necessary.
No fluid sprays from the gun
The fluid nozzle is dirty or clogged.
The fluid nozzle is damaged.
Clean the fluid nozzle; see page 21.
Replace the fluid nozzle; see page
30.
The exhaust air flow is insufficient or Check for the proper CFM; check the
The equipment is covered with
fluid
not directed properly.
baffles and direction of the air flow.
The distance between the gun and
workpiece is incorrect.
Adjust the spraying distance to 8 to
12 inches (203 to 305 mm).
The electrode is bent.
Straighten the electrode.
Dirty air cap
The nozzle orifice is damaged.
Replace the fluid nozzle; see page
30.
The air cap and fluid nozzle are mis- Check the air cap and fluid nozzle
aligned.
seat for fluid buildup. Clean or
replace parts as needed; see page 21
or 30.
Air
Cap
Fluid
Nozzle
ALIGNED
MISALIGNED
308584
27
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Electrical Tests
Use the megohmmeter (A), part no. 218979, and an
WARNING
ELECTRIC SHOCK HAZARD
Follow the Fluid Voltage Discharge
applied voltage of 500 volts to complete these
electrical tests. Connect the leads as shown.
Test Gun Resistance
and Grounding Procedure on page 16
before checking or servicing and when-
ever you are instructed to discharge the voltage to
ensure the voltage is discharged and avoid serious
injury from an electric shock.
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.
2. Measure the resistance between the end of the
gun electrode (20) and the air inlet fitting (17). See
Fig. 13.
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.
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 near-
est authorized service agency.
WARNING
FIRE, EXPLOSION, AND
KEY-Fig. 13
ELECTRIC SHOCK HAZARD
Megohmmeter P/N 218979 (A-see Fig.
13) is not approved for use in a hazard-
ous area. To reduce the risk of sparking,
do not use the megohmmeter to do
electrical tests unless:
A
A
Megohmmeter
17 Air Inlet Fitting
20 Electrode
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hazardous area;
D 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 con-
tainers or fumes from spraying).
Failure to follow this warning could cause fire,
explosion, electric shock and result in serious injury
and property damage.
20
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 com-
ponents.
17
5153B
Fig. 13
Continued on the next page.
28
308584
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Electrical Tests
Test Power Supply Resistance
Test Resistor Stud Resistance
1. Prepare the gun for service as instructed on
page 30.
1. Prepare the gun for service as instructed on
page 30.
2. Remove the resistor stud (22) as instructed on
page 30.
2. Remove the power supply (18) from the gun
handle as instructed on page 40.
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.
3. Remove the turbine alternator (37) from the power
supply as instructed on page 41.
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 re-
place the resistor stud.
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.
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.
KEY-Fig. 14
A
B
Megohmmeter
Ground Contact Point
A
18 Power Supply
18c Contact Spring
KEY-Fig. 15
C
D
Needle Contact Ring
Resistor Stud Contact Ring
22 Resistor Stud
22
B
18c
18
D
03566
C
Fig. 14
0442
Fig. 15
308584
29
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Service
Tools Included with the Gun
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.
D
M
u
l
t
i
-
t
o
o
l
D Ball-end Wrench
D 2 mm Hex Key Allen Wrench
Prepare the Gun for Service
1. Discharge the voltage as instructed on page 16.
NOTE:
D Check all the possible remedies in Troubleshoot-
ing before disassembling the gun.
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
D
I
f
t
h
e
p
l
a
s
t
i
c
p
a
r
t
s
o
f
t
h
e
g
u
n
m
u
s
t
b
e
h
e
l
d
i
n
a
v
i
s
e
,
use padded vise jaws to avoid damaging parts.
4. Relieve the system pressure as instructed on page
16.
D
L
i
g
h
t
l
y
l
u
b
r
i
c
a
t
e
o
-
r
i
n
g
s
a
n
d
s
e
a
l
s
w
i
t
h
p
e
t
r
o
l
e
u
m
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.
jelly. Do not over-lubricate.
D
O
n
l
y
u
s
e
g
e
n
u
i
n
e
G
r
a
c
o
p
a
r
t
s
.
D
o
n
o
t
m
i
x
o
r
u
s
e
parts from other PRO Gun models.
Air Cap/Nozzle/Resistor Stud
Replacement
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
Removal
1. Prepare the gun for service as instructed at left.
To reduce the risk of a fire, explosion, or
electric shock:
2. Remove the air cap assembly (1, 2, 8). See Fig.
16, page 31.
D 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 dis-
charge the voltage.
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.
D
C
l
e
a
n
a
l
l
t
h
e
p
a
r
t
s
w
i
t
h
a
n
o
n
-
f
l
a
m
m
a
b
l
e
f
l
u
i
d
a
s
defined on the front cover of this manual.
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).
D
D
o
n
o
t
s
e
r
v
i
c
e
t
h
i
s
e
q
u
i
p
m
e
n
t
u
n
l
e
s
s
y
o
u
a
r
e
trained and qualified.
D Do not touch the gun nozzle or come within 4
inches (101.6 mm) of the nozzle during gun op-
eration or until after following the Fluid Voltage
Discharge and Grounding Procedure.
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.
Continued on the next page.
30
308584
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Service
8. Tighten the retaining nut (8) until the air cap is held
Air Cap/Nozzle/Resistor Stud
Replacement (continued)
firmly in place; you should not be able to rotate the
air cap horns by hand.
4. Unscrew the resistor stud (22) from the fluid
nozzle (21) with the multi-tool (62). See Fig. 17.
ꢀ
ꢁ
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.
WARNING
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
1
8
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.
2
62
ꢁ
ꢀ
21
22
D
5. Remove the retaining ring (2) to free the air cap (1)
from the retaining nut (8).
25
20
Installation
1. Lightly lubricate the o-ring (25) with petroleum jelly,
and install it on the resistor stud (22). See Fig. 16.
05154A
2. Make sure the electrode (20) is tightened properly,
as shown in Fig. 18, page 32.
Fig. 16
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 NSm). See Fig. 17.
ꢀ
Tighten the resistor stud (22) into the nozzle (21) to 10 in-lbs
(1.13 NS m).
21
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 hand-
tight). See Fig. 16.
ꢀ
22
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).
62
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.
0444A
Fig. 17
308584
31
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Service
ꢀ
Apply low-strength (purple) Loctite or equivalent to the fluid rod
Electrode Needle Replacement
threads, then install the electrode needle (20).
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.
62
ꢀ
20
E
4. Apply low-strength (purple) Loctiter 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
To avoid damaging the plastic threads or contact
wire, be very careful when installing the electrode
needle.
05155A
Fig. 18
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.
32
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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, preventa-
tive maintenance of the fluid packing assembly must
be performed at regular intervals.
28
62
13
Use the following formula to calculate the best packing
service interval for your application:
Service Interval in Days = 25,000
T x H
4
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,
05159A
Fig. 19
25,000 = 25,000 = 312.5
10 x 8
80
4. Remove the fluid packing rod assembly (28) with
the multi-tool (62).
The service interval would be 312 work days.
Procedure
5. Check all the parts for wear or damage and re-
place if necessary.
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.
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.
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.
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.
3. Loosen the trigger screws (4) far enough to
remove the trigger (13). See Fig. 19.
If installing the complete fluid rod assembly, go to
step 11, page 34.
308584
33
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Service
11. Lubricate the o-ring (28g).
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.
12. Make sure the spring (30) is installed against the
nut (U) as shown in Fig. 20.
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.
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.
9. Place the fluid packing (28e), needle packing
(28d), and housing (28b) on the fluid rod (28a), as
shown in Fig. 20.
15. Install the electrode needle, fluid nozzle and resis-
tor stud assembly and the air cap assembly as
instructed on page 32.
10. Lightly tighten the packing nut (28c) with the multi-
tool (62). The packing nut is properly tightened
when there is 2 lbs. (9 N) of drag force when slid-
ing the packing housing (28b) assembly along the
shaft. Tighten or loosen the packing nut as need-
ed.
16. Test the gun resistance as instructed on page 28.
ꢀ
ꢁ
ꢂ
ꢃ
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)
ꢂ
ꢀ
ꢁ
28a
28d 28e 28g
28h
28 28b 28c
f
U
30
ꢃ
28
03558
Fig. 20
34
308584
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Service
ꢀ
A
p
p
l
y
a
v
e
r
y
l
i
g
h
t
c
o
a
t
o
f
l
u
b
r
i
c
a
n
t
t
o
t
h
e
o
-
r
i
n
g
s
(
4
3
e
)
a
n
d
Fan Air Adjustment Valve Repair
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 NS m).
NOTE: The fan air valve (43) can be replaced as an
assembly or as individual parts.
DETAIL
ꢁ
43d
1. Prepare the gun for service as instructed on
page 30.
43b
ꢀ
43c
43e
ꢀ
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.
43
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.
5. Clean all the parts and inspect them for wear or
damage.
05161B
Fig. 21
6. Install the o-rings (43e) on the adjusting screw
(43c). Lubricate the o-rings and the adjusting
screw threads with petroleum jelly.
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.
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.
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).
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 NSm).
Continued on the next page.
308584
35
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Service
Fluid Adjustment Assembly Repair
(continued)
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-ring (41) and air valve shaft (39) can be pushed
into the gun air passage and blemish the finish on
the workpiece.
5. 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).
5. Unscrew the packing nut (40) to check the u-cup
(42). Do not remove the u-cup unless it is dam-
aged.
7. Repair or replace any damaged parts. Lubricate
the o-ring (45b).
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.
8. Carefully apply low strength (purple) Loctiter 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.
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 bot-
toms.
CAUTION
Do not allow Loctite to get onto the stem (45a) during
assembly or the stem will not turn.
ꢀ
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.
9. Place the fluid adjustment assembly on the work-
bench with its threaded end facing down and allow
the Loctite to cure over night.
ꢂ
D
o
n
o
t
r
e
m
o
v
e
u
-
c
u
p
(
4
2
)
u
n
l
e
s
s
d
a
m
a
g
e
d
.
I
n
s
t
a
l
l
w
i
t
h
l
i
p
s
facing into handle. Tighten packing nut (40) until it bottoms.
10. After the Loctite has cured, assemble the fluid
adjustment assembly into the gun.
45
45c
45a
Air Trigger Valve Repair
ꢀ
4
5
b
ꢁ
45d
1. Prepare the gun for service as instructed on
page 30.
44
39
ꢀ
2. Using a 14 mm socket wrench, remove the fluid
adjustment assembly (45), o-ring (23), and spring
(44). See Fig. 22.
41
23
45e
3. Loosen the air valve packing nut (40) one full turn.
Remove the air valve shaft (39) with a pliers.
CAUTION
40, 42
ꢂ
When removing the air valve shaft (39), be careful
not to damage the seat area.
05162B
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.
Fig. 22
36
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Service
ꢀ
Apply PTFE paste to the fan air valve housing threads; Torque
Atomizing Air Valve Repair
to 10–12 in-lb (1.1–1.4 NS m)
1. Prepare the gun for service as instructed on
page 30.
31
19
2. Remove the fan air adjustment valve (43) as
instructed on page 35.
ꢀ
CAUTION
43
To avoid damaging the atomizing air valve, the fan
air adjustment valve must be removed before remov-
ing the atomizing air valve.
3. Remove the atomizing air valve (31) and o-ring
(19). See Fig. 23.
05162B
4. Install a new atomizing air valve and o-ring.
Fig. 23
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 NSm).
308584
37
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Service
7. Install the valve (38) with the regulator disc (46)
ES ON-OFF Valve Repair
and o-ring (36) into the gun handle. Install the
spacer (32) on the valve.
1. Prepare the gun for service as instructed on
page 30.
8. Install the retaining ring (47) into the groove in the
handle.
2. Loosen the set screw (24) with the 2 mm hex key
(69). Remove the lever (26) from the valve. See
Fig. 24.
WARNING
WARNING
MOVING PARTS HAZARD
To reduce the risk of an eye injury, wear
safety glasses when removing or install-
ing the retaining ring (47) as the retain-
ing ring could slip off the tool when com-
pressed.
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.
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.
9. Install the lever (26) and tighten the set screw (24).
ꢀ
ꢁ
Apply a very light coat of lubricant to the o-ring (36).
4. Remove the valve body (38) from the handle; be
careful not to drop the regulator disk (46) and
spacer (32).
Bevelled side of the regulator disk (46) toward the valve (38).
26
47
ꢀ
36
5. Clean and inspect the parts for damage. Replace
parts if necessary. Lightly lubricate the o-ring (36)
with petroleum jelly.
24
CAUTION
Do not over-lubricate parts. Excessive lubricant on
the o-ring (36) can be pushed into the gun air pas-
sage and blemish the finish on the workpiece.
32
38
ꢁ
4
6
6. Install the regulator disk (46) in the valve (38) with
its bevelled side facing toward the valve.
CAUTION
05363B
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.
Fig. 24
38
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Service
78
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 ball-
end wrench (63).
3
7
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
18
To avoid damaging the power cartridge (18), always
pull the gun barrel straight away from the gun han-
dle. If necessary, gently move the barrel from side to
side to free the power supply from the gun handle.
05157
Fig. 26
79
76 78 75
63
5
05156
Fig. 25
308584
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Service
5. Inspect the power supply cavity in the handle for
Power Supply Replacement
dirt or moisture. Clean out the cavity with a clean,
dry rag to avoid a loss in electrostatic perfor-
mance.
1. Prepare the gun for service as instructed on
page 30.
2. Remove the barrel as instructed on page 39.
6. Lightly lubricate the o-rings (18b, 37a) on the
power supply with petroleum jelly.
CAUTION
Be careful when handling the power supply to avoid
damaging it.
CAUTION
All the o-rings (18b, 37a) and the compression spring
(18c) must be in place or the gun will malfunction.
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.
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.
4. Inspect the power supply for any physical damage.
Check the electrical resistance as instructed in
Test Power Supply Resistance, page 29. If nec-
essary, replace the power supply.
9. Test the gun resistance as instructed on page 28.
ꢀ Apply a very light coat of lubricant to the o-rings 37a.
ꢁ Do not expose the gasket (18a) to solvents.
35
18d
18
18c
ꢁ
18a
18b
7
V
ꢀ
37a
37
37b
05160
Fig. 27
40
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Service
3. Place the barrel (3) over the power supply (18) and
Turbine Alternator Replacement
onto the gun handle (7). Make sure the fluid nee-
dle 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.
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.
4. Tighten the three screws (5) oppositely and evenly
with the ball-end wrench (63). Tighten the cap
screws to 18 in-lbs (2 NSm) maximum (about a half
turn past snug). Do not over-tighten the screws.
2. Remove the barrel as instructed on page 39.
3. Remove the power supply as instructed on
page 40.
CAUTION
To avoid damaging the gun, do not over-tighten the
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.
screws (5).
5. Install the ferrule housing (79) through the gun
bracket (76), and secure it with the nut (78).
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
6. Test the gun resistance as instructed on page 28.
resistance should be 3 to 5 ohms. If the resis-
tance varies from this value, replace the alternator.
ꢀ
T
i
g
h
t
e
n
t
h
e
s
c
r
e
w
s
(
5
)
t
o
1
8
i
n
-
l
b
s
(
2
N
S
m
)
m
a
x
i
m
u
m
(
a
b
o
u
t
h
a
l
f
turn past snug), using the wrench (63) provided..
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.
18a
18
34
ꢀ
5
3
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.
30
7
8. Install the power supply in the gun handle as
instructed on page 40.
9. Install the barrel on the handle as instructed below.
91
76
Barrel Installation
75
78
1. Clean and dry the inside of the fluid inlet tube (75).
See Fig. 28.
79
05158B
Fig. 28
2. Be sure the gaskets (34, 18a) and spring (30) are
in place. Replace the parts if they are damaged.
308584
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Service
5. Carefully cut through the outer hose jacket (H) and
Graco Waterborne Fluid Hose Repair
peel it back about 12 inches (105 mm). Do not cut
into the conductive layer (J) of the hose.
WARNING
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.
FIRE, EXPLOSION, AND ELECTRIC
SHOCK HAZARD
To reduce the risk of a fire, explosion, or
electric shock:
D 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 dis-
charge the voltage.
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.
D
C
l
e
a
n
a
l
l
t
h
e
p
a
r
t
s
w
i
t
h
a
n
o
n
-
f
l
a
m
m
a
b
l
e
f
l
u
i
d
a
s
defined on the front cover of this manual.
D
D
o
n
o
t
s
e
r
v
i
c
e
t
h
i
s
e
q
u
i
p
m
e
n
t
u
n
l
e
s
s
y
o
u
a
r
e
trained and qualified.
D Do not touch the gun nozzle or come within 4
inches (101.6 mm) of the nozzle during gun op-
eration or until after following the Fluid Voltage
Discharge and Grounding Procedure..
9. Install a new barbed fitting by applying red dielec-
tric grease to the outside of the barbs, and press-
ing the fitting into the gun end of the hose. Refer to
the drawing of the Waterborne Fluid Hose Assem-
bly on page 48.
WARNING
PRESSURIZED EQUIPMENT HAZARD
10. Install the three o-rings on the barbed fitting.
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.
11. Connect the fluid hose to the gun as instructed on
page 12.
Measurements, inches (mm)
Damaged hoses or hoses that have a “pin-hole” dielec-
tric failure, close to the end of the hose, can be re-
paired by cutting away the failed portion and restrip-
ping the hoses to the dimensions shown in Fig. 29.
A*
B*
C
D
7.75 + 0.1
(196.85 +
2.5)
9.375 + 0.1
(238.13 +
2.5)
4.075 + 0.1
(103.5 + 2.5) (111.1 + 2.5)
4.375 + 0.1
1. Discharge the voltage as instructed on page 16.
* The measurements specified are for use with the Graco
2
H O PRO Voltage Block isolation system.
2. Relieve the system pressure as instructed on page
16.
Isolation System End
Spray Gun End
3. Disconnect the fluid hose from the gun and voltage
isolation system.
D
C
B
A
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.
K
J
J
K
H
05180
Fig. 29
42
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PRO 3500sc Gun Conversion
NOTE: See page 48 to order the conversion kit, part
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.
no. 223114. The fluid hose and air hose are not in-
cluded 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.
7. Loosen the trigger screws (L) far enough to re-
move the trigger (M).
PRO 3500SC Gun Disassembly
1. Remove the air fitting (D), exhaust tube clamp (F),
and the exhaust tube (E). Keep these parts for
reassembly.
8. Remove the fluid packing rod assembly (K) with
the 9 mm hex nut driver.
H
Z
P
2. Remove the fluid tube fitting (B) and fluid seal (A)
from the gun. See Fig. 30.
G
3. Remove the gun fitting bracket (C) with the hose
assembly.
4. Remove the air cap assembly (G, P, Z) and dis-
card the retaining nut (G).
C
L
D
Q
NOTE: Keep all the following parts for reassembly.
A
M
B
K
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.
J
R
E
F
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.
05423A
Fig. 30
Continued on the next page.
308584
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PRO 3500sc Gun Conversion
H
Z
P
8*
L
D
ꢂ
M
ꢁ
*
8
0
ꢁ
*
8
1
28*
ꢀ
E
F
20*
91
ꢁ
*
7
5
*78
*76
ꢀ
A
p
p
l
y
a
v
e
r
y
l
i
g
h
t
c
o
a
t
o
f
l
u
b
r
i
c
a
n
t
t
o
t
h
e
o
-
r
i
n
g
o
n
t
h
e
outside of the fluid packing rod (28).
ꢁ
A
p
p
l
y
d
i
e
l
e
c
t
r
i
c
g
r
e
a
s
e
t
o
t
h
e
o
-
r
i
n
g
s
(
8
0
,
8
1
)
a
n
d
t
u
b
e
(
7
5
)
threads.
*79
*77
ꢂ
A
p
p
l
y
h
i
g
h
s
t
r
e
n
g
t
h
L
o
c
t
i
t
e
r
to the air fitting (D) threads.
Torque the fitting to 35 to 45 in-lbs (4 to 5.1 NS m).
N
05164B
Fig. 31
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.
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 assem-
bly (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.
4. Install the trigger (L) and tighten the trigger
screws (K).
2. Lubricate the o-ring on the outside of the fluid
packing rod assembly. Make sure the spring is in-
stalled on the fluid packing rod nut.
5. Install the electrode needle (20*), fluid nozzle and
resistor stud assembly (H) and the air cap assem-
bly (P, 8*, Z) as instructed on page 32.
NOTE: See Fig. 20, page 34, for information on indi-
vidual fluid packing rod parts.
44
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PRO 3500sc Gun Conversion
6. Assemble the two o-rings (80*, 81*) onto the fluid
11. Press the exhaust tube (E) onto the barbed
adapter on the bottom of the gun handle. Secure
the tube with the clamp (F).
inlet tube (75*). Apply dielectric grease to the
o-rings and tube threads.
12. Test the gun resistance as instructed on page 28.
7. Screw the fluid inlet tube (75*) into the barrel inlet
until it bottoms out.
13. Mount the warning sign (71*) in the spray area
where it can easily be seen and read by all opera-
tors.
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.
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.
8. Loosely assemble the ferrule housing parts (77*,
78*, 79*) to the gun bracket (76*).
9. Apply high strength Loctite
r
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
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.
NSm).
10. Tighten the nut (78*) onto the ferrule housing (79*).
308584
45
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Spray Gun Parts
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
28a
See Detail A
20
25*
28
22
37
21
2
18d
18e
18
1
8
**37a
18c
37b
45c
18b**
18a**
35
**34
18f
43c
23**
43e**
5
43d
43b
45b
3
45e
44
4
31
39
19**
45a
24
41**
45d
13
26
6
30
47
7
*80
*81
32
36
15
19
33
38
46
42**
40
75
17
66
67
91
DETAIL
28d*
28b
28g*
78
76
28c
28f*
79
28h*
28e*
77
05165B
46
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Spray Gun Parts
Ref.
No.
Part No.
Description
Qty.
WARNING
EQUIPMENT MISUSE HAZARD
Use only genuine Graco replacement parts. Using
non-Graco parts could alter the gun’s grounding
continuity or cause parts to rupture or fail, which
could result in a serious injury and property
damage.
33
185112
185113
185114
113746
222319
ADAPTER, exhaust hose
GASKET, manifold; polyethylene
RING, retainer, alternator
O–RING, CV75
ALTERNATOR, turbine
Includes items 37a & 37b
S O–RING, Viton
1
1
1
1
34
35
36
37
{
1
1
1
1
1
1
37a
37b
38
39
40
{
110073
185124
185118
224194
185115
111508
S
C
U
S
H
I
O
N
VALVE, electrostatic
SHAFT ASSY., air valve
NUT, packing
O–RING, trigger valve;
fluoroelastomer
Part No. 222700, Series C
Model PRO 3500wb Spray Gun
41
{
{
1
1
Ref.
No.
42
43
105452
222321
U–CUP, PTFE
Part No.
Description
Qty.
VALVE ASSY, fan air
Includes items 43b–43e
S RING, retaining
S VALVE, fan air adjustment
S HOUSING, valve
S O–RING, Viton
SPRING, compression, air valve
VALVE, fluid adjustment
Includes items 45a–45e
S STEM, fluid adjustment
S O-RING, CV 75
S CAP
S SLEEVE, guide
S STOP, sleeve
REGULATOR, disc
RING, retaining
1
1
1
1
2
1
1
193033
AIR CAP; See Manual 307803 for
available air caps
RING, retaining
BARREL, gun
SCREW, trigger
SCREW, cap, relieved; M5 x 0.8
HOOK
HANDLE, manifold
RETAINING NUT
TAG, warning
TRIGGER, 2 finger
MUFFLER
FITTING, air
43b
43c
43d
43e
44
105681
191805
185090
103557
185116
238895
1
1
1
2
3
1
1
1
1
1
1
1
2
3
4
5
6
7
8
176930
222314
185095
185096
185097
222315
223653
179791
191904
185122
185105
222333
{
{
45
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
45a
45b
45c
45d
45e
46
186826
111516
186822
191794
191795
107107
110082
191744
107460
185103
110231
110086
Y 186118
180209
196161
190759
190863
185548
190862
110736
103338
217115
196158
11
13
15
17
18
.
POWER SUPPLY
Includes items 18a–18f
S GASKET, power supply
47
1
1
1
1
1
1
1
2
1
62
63
66
67
69
71
72
75
76
77
78
79
.
.
MULTI-TOOL
WRENCH, barrel
18a
18b
18c
18d
18e
18f
{
{
185134
106555
178504
185141
185099
185145
106555
186615
185158
S
O
–
R
I
N
G
,
V
i
t
o
n
r
TUBE, exhaust; polyurethane
CLAMP, exhaust tube
WRENCH, allen, hex key; 2 mm
SIGN, warning, English
COVER, gun
HOUSING TUBE
BRACKET
HOSE FERRULE
NUT
FERRULE HOUSING
O-RING
S SPRING, compression
S CUSHION, power supply
S PAD
S PAD
O–RING; Viton
NEEDLE, electrode
NOZZLE, fluid
See Manual 307803 for
available nozzles
STUD, resistor
O–RING, PTFE
SET SCREW, lever; sch; M4 x 0.7
O–RING; fluoroelastomer
LEVER, ES valve
FLUID PACKING & NEEDLE ASSY
Includes items 28a–28h
S NEEDLE, fluid
S HOUSING, packing
S NUT, packing
S PACKING, needle
S PACKING, fluid
S O–RING, fluoroelastomer
S O–RING, fluoroelastomer
S SPACER
SPRING, compression
VALVE, atomizing air
SPACER, lever
.
.
.
19**
20
21
1
1
22
23**
24
25*
26
28
223977
110099
110083
111507
186839
223444
80*
81*
1
O-RING
DIELECTRIC GREASE
SLEEVE
1
1
1
82
91
.
*
These parts are included in Fluid Seal Repair Kit 238146,
which may be purchased separately.
1
1
1
1
1
1
1
1
1
1
1
1
28a
28b
28c
28d*
28e*
28f*
28g*
28h*
30
223024
185495
185488
178763
178409
111504
111316
186069
185111
238927
185119
{
These parts are included in Air Seal Repair Kit 223021,
which may be purchased separately.
l An Optional Plug 185079 is provided with the gun.
. These parts are not shown in the parts drawing.
31
32
l
Y Replacement Warning signs are available at no cost.
308584
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Accessories
Use Only Genuine Graco Parts and Accessories
Waterborne Fluid Hose Assembly
PRO 3500sc Gun Conversion Kit 223114
Ref.
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
2
No.
Part No.
Description
Qty.
To connect between the Graco H O PRO Voltage
Block and the gun; 0.25 in. (6.35 mm) ID; PTFE
8
223653
186615
223444
186118
196161
190759
190863
185548
190862
110736
103338
217115
196158
RETAINING NUT
ELECTRODE NEEDLE
PACKING ROD ASSEMBLY
WARNING SIGN (not shown)
HOUSING TUBE
BRACKET
HOSE FERRULE
NUT
FERRULE HOUSING
O-RING
1
1
1
1
1
1
1
1
1
1
1
1
1
20
28
71
75
76
77
78
79
80
81
Fluid Hose
Assy. Part No.
Hose Length
25 ft. (7.6 m)
36 ft. (11 m)
50 ft. (15.3 m)
237924
237925
237926
O-RING
DIELECTRIC GREASE
SLEEVE
Waterborne Fluid Hose Replacement Parts
Ref.
82
91
.
No.
Part No.
Description
Qty.
The Kit Ref Nos. correspond with the Gun Ref Nos. on page 37.
301
302
111450
190143
O-RING
BARBED FITTING
3
1
Waterborne Fluid Hose
301
28
20
302
05342
80
8
Graco Electrically Conductive Air Hose
81
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
75
Hose Part No.
235068
Hose Length
6 ft. (1.8 m)
91
235069
15 ft. (4.6 m)
25 ft. (7.6 m)
36 ft. (11.0 m)
50 ft. (15.2 m)
75 ft. (23.0 m)
100 ft. (30. 5 m)
78
235070
76
235071
79
235072
05166
77
235073
235074
48
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Accessories
Use Only Genuine Graco Parts and Accessories
Snap Ring Pliers 110090
Gun Cover 180209
For removing the ES ON-OFF Valve Retaining Ring
(item 47 in Parts List).
Order Part No. 218374 for package of 10.
Gun High Voltage Probe & Meter 217452
For direct measurement of the gun output voltage.
Gun Holster 236090
Mount the gun holster to the side of the spray booth.
Hang gun in holster while the voltage discharges.
Megohmmeter 218979
500 Volt output; 0.01–2000 megohms.
Not for use in Hazardous areas.
Grounding Rod 210084
For use in the Fluid Voltage Discharge and Ground-
ing 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
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N
50
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Technical Data
Category
Weight
Data
Category
Data
1.87 lb (0.85 Kg)
Wetted Parts
Stainless Steel, Brass,
Nylon, Acetal, PTFE,
Fluoroelastomer, PTFE
High Molecular Weight
Polyethylene, Ceramic
Gun Length
9.5 in. (240 mm)
Maximum Working
Pressure
100 psi (0.7 MPa, 7 bar)
Air Pressure Operating
Range
0–100 psi (0–0.7 MPa,
0–7 bar)
Typical Noise Level with
atomization air at 40 psi
(280 kPa, 2.8 bar) and
typical air flow
Fluid Pressure Operating 0–100 psi (0–0.7 MPa,
Range
0–7 bar)
Voltage Output
Air Inlet
0–65 kV*
Sound Pressure
Sound Power
{
87 Db(A)
90.4 Db(A)
}
1/4 npsm(m) L.H.
Maximum Noise Level
with atomization air at
100 psi (0.7 MPa, 7 bar)
and maximum air flow
Fluid Inlet
custom inlet for Graco
waterborne fluid hose
Fluid Specification
For use with fluids that
meet at least one of the
following conditions:
D The fluid has a flash
point above 140_ F
(60_ C) and a maxi-
mum organic solvent
concentration of 20%,
by weight, per ASTM
Standard D93.
Sound Pressure
Sound Power
{
99 Db(A)
105.4 Db(A)
}
{
}
*
Sound pressure was measured per Cagi Pneurop, 1969.
Sound power was measured per ISO–3744, 1981.
2
Voltage output when used with Graco H O PRO is 0–59
kV due to bleed resistor current draw.
D The fluid does not
sustain burning when
tested per ASTM
Vitonr is a registered trademark of the
DuPont Co.
Standard D4206 Sus-
tained Burn Test.
Loctiter is a registered trademark of the Loctite Corporation.
308584
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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 defec-
tive. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written rec-
ommendations.
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, instal-
lation, 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 consequen-
tial damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
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
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