Page 3 - Warning Symbol; WARNING; Caution Symbol; CAUTION
308018 3 Table of Contents Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How the Electrostat...
Page 4 - FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
4 308018 WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition andresult in a fire, explosion, or electric shock. Electrostatic equipment must be used only by trained, qualified personnel who understand the...
Page 5 - PRESSURIZED EQUIPMENT HAZARD; EQUIPMENT MISUSE HAZARD
308018 5 WARNING PRESSURIZED EQUIPMENT HAZARD Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skinand cause a serious injury. Do not point the spray gun at anyone or any part of the body. Do not stop or deflect fluid leaks with your hand, body, glove, or...
Page 6 - Introduction; How the Electrostatic Air Spray Gun Works; Converting a PRO 3500sc Gun
6 308018 Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun. Part of theair operates the turbine and the rest of the air atomizesthe fluid being sprayed. The turbine generates power,which is converted by the power cartridge, to supplyhigh voltage curren...
Page 8 - Installation; Hazardous Area
8 308018 Installation KEY A Main Air Supply Line B* Ventilation Fan Interlock Solenoid ValveC* Main Air Supply Shutoff Valve (bleed-type) D Air & Water Separator E* Pump Air Supply Shutoff Valve (bleed-type) F Air Line Lubricator G Air Pressure Regulator H Pump J* Pump Ground Wire K Fluid Filter...
Page 9 - Installing the System; Warning Signs; Connect the Air Line
308018 9 Installation Installing the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause electric shock or other seriousinjury if work is not performed properly. Do not install or service this equip-ment unless you a...
Page 10 - Connect the Exhaust Tube; Ground the System
10 308018 Installation Connect the Exhaust Tube Press the exhaust tube (provided) onto the barbedadapter on the bottom of the gun handle. Secure thetube with the clamp provided. Refer to page 36. Connect the Fluid Line (Refer to Fig. 1) 1. Before connecting the fluid line (N), blow it out withair an...
Page 11 - Check the Electrical Grounding
308018 11 Installation Check the Electrical Grounding (See Fig. 2) WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDMegohmmeter P/N 241079 (AA-see Fig.2) is not approved for use in a hazard-ous area. To reduce the risk of sparking,do not use the megohmmeter to checkelectrical grounding unless: The ...
Page 12 - Notes
Page 13 - Operation; Pressure Relief Procedure; Filter the Fluid
308018 13 Operation Pressure Relief Procedure WARNING PRESSURIZED EQUIPMENT HAZARDThe system pressure must be manually relieved toprevent the system from starting or spraying acci-dentally. To reduce the risk of an injury from electricshock, accidental spray from the gun, splashingfluid, or moving p...
Page 14 - Selecting a Fluid Nozzle and Air Cap; Operating the Spray Gun
14 308018 Operation 05151A Fig. 4 06615 20 1 26 45 43 31 DD Selecting a Fluid Nozzle and Air Cap WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 13 before removing orinstalling a fluid nozzle and/or air cap. The gun is supplied with a ...
Page 16 - Shutdown; Maintenance; Daily Care and Cleaning
16 308018 Operation Shutdown WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 13 whenever you stopspraying and whenever you are instructed torelieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc...
Page 17 - Clean the Air Cap and Fluid Nozzle; Flush the Spray Gun
308018 17 Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spraytip holes as this could scratch them, and make surethe electrode wire is not damaged. Scratches in theair cap or spray tip or a damaged electrode wire candistort the spray pattern. Eq...
Page 18 - Troubleshooting; Spray Pattern Troubleshooting
18 308018 Troubleshooting WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts which maycause an electric shock or other serious injury if the work is not performed properly. Do notinstall or service this equipment unless you aretrained and qualified. WARNING ...
Page 19 - Gun Operation Troubleshooting
308018 19 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packingarea The needle packings or shaft are worn. Replace the packings or shaft; see page28. The packing nut is loose Tighten the packing nut; see page 28. Air leakage from the front of the g...
Page 20 - Electrical Troubleshooting
20 308018 Troubleshooting Electrical Troubleshooting Problem Cause Solution Poor wrap-around The ES ON-OFF lever is in the OFF (O)position.* Turn the lever to ON (1). The distance between the gun and work-piece is incorrect. Adjust the spraying distance to 8 to 12 inches(203 to 305 mm) The parts are...
Page 21 - Electrical Tests; Test Gun Resistance
308018 21 Electrical Tests The performance and safety of the spray gun aredirectly affected by the condition of the electricalcomponents contained inside the gun. The electricaltests below can be used to determine the condition ofthe power supply (18) and the resistor stud (22) as wellas the continu...
Page 22 - Test Power Supply Resistance
22 308018 Electrical Tests Test Power Supply Resistance Remove the power cartridge (18) from the gun handle.See Power Cartridge Replacement on page 29. Remove the turbine alternator from the power car-tridge. See Turbine Alternator Removal on page 30. Measure the resistance from the power supply’sgr...
Page 23 - Test Resistor Stud Resistance (continued)
308018 23 Electrical Tests Test Resistor Stud Resistance (continued) If the resistance is outside the specified range, removethe resistor stud (22). See Air Cap/Nozzle/ResistorStud Replacement on page 24. Check the resistancebetween the black resistor stud contact ring (D) andthe needle contact ring...
Page 24 - Service; Prepare the Gun for Service
24 308018 Service Prepare the Gun for Service WARNING ELECTRIC SHOCK HAZARDInstalling and servicing this equipmentrequires access to parts that may causeelectric shock or other serious injury if the work is not performed properly. Do not install orservice this equipment unless you are trained andqua...
Page 25 - Electrode Replacement
308018 25 Service Air Cap/Nozzle/Resistor StudReplacement (continued) 6. Trigger the gun while installing the fluid nozzle (21)and resistor stud (22) assembly with the multi-tool(62). Tighten until the fluid nozzle seats in the gunbarrel. 7. Install the air cap assembly (1, 2, 8). Test the gunresist...
Page 26 - Barrel Removal
26 308018 Service Barrel Removal 1. Prepare the gun for service as instructed on page24. 2. Carefully loosen the nut (14) from the bracket/fluidfitting (16). Pull the tube (12) out of the fitting.Make sure both ferrules and the nut stay with thetube. See Fig. 14. 3. Using the wrench (63) supplied, l...
Page 27 - Fluid Packing Removal
308018 27 Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page24. 2. Remove the air cap assembly, fluid nozzle andresistor stud, and electrode as instructed on page25. 3. Loosen the trigger screws (4) far enough to re-move the trigger (13). 4. Remove the packing cartrid...
Page 28 - Fluid Packing and Needle Repair
28 308018 Service Fluid Packing and Needle Repair The fluid packings and needle can be replaced asindividual parts or as assemblies. The overall assem-bly is pre-adjusted at the factory. NOTE: Before installing the packing and needle as-sembly into the gun barrel, make sure the internalsurfaces of t...
Page 29 - Power Cartridge Replacement
308018 29 Service 06629 Fig. 18 7 35 37a 37b 18b 18c 18a 18 18d 37 F Apply a very light coat of lubricant Do not expose to solvents Power Cartridge Replacement NOTE: The power cartridge consists of the alternator(37), power supply (18) and retaining ring (35). SeeFig. 18. 1. Prepare the gun for serv...
Page 30 - Turbine Alternator Replacement
30 308018 Service Turbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours ofoperation. See your authorized Graco distributor. 1. Prepare the gun for service as instructed on page24. 2. Remove the power cartridge from the gun handleas instructed on page 29. 3. Squeeze the two ...
Page 31 - Fan Air Adjustment Valve Repair
308018 31 Service Fan Air Adjustment Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Place a wrench on the flats of the valve housingand remove it from the handle. See Fig. 20. NOTE: The fan air valve (43) can be replaced as anassembly or as individual parts. To disassemble t...
Page 32 - Fluid Adjustment Assembly Repair
32 308018 Service Fluid Adjustment Assembly Repair 1. Prepare the gun for service as instructed on page24. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45). See Fig. 21. 3. Turn the stem (45a) fully clockwise and removethe sleeve stop (45e). 4. To completely disassemble the f...
Page 33 - Air Trigger Valve Repair
308018 33 Service Air Trigger Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Using a 14 mm socket wrench, remove the fluidadjustment assembly (45), o-ring (23) and spring(44). See Fig. 21. CAUTION Clean all parts in non-conductive solvent compatiblewith the fluid being used,...
Page 34 - ES ON-OFF Valve Repair
34 308018 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page24. 2. Loosen the set screw (24) with the 2 mm hex key(69) provided. Remove the lever (26) from thevalve. See Fig. 23. WARNING MOVING PARTS HAZARDTo reduce the risk of eye injury, be sureto wear safety glass...
Page 35 - Tube and Shroud Removal/Replacement
308018 35 Service Tube and Shroud Removal/Replacement 1. Prepare the gun for service as instructed on page24. 2. Remove the air cap, nozzle and resistor stud, andelectrode as instructed on page 29. 3. Loosen the nut (14) and disconnect the fluid tube(12) from the bracket/fluid fitting (16). See theP...
Page 36 - Parts
36 308018 Parts 06614 6 7 4 13 3 1 8 2 22 20 21 25 35 34* 44 45d 23* 39 40 42* 66 17 15 19 33 12 10 24 26 36 47 32 31 12d 16 37a* 37b 18a* 18c 18b* 30 5 18d 19* See Detail A 67 28a 43b 43d 43e* 43c 18f 18e 12c REF. 16 12a 12b 12e DETAIL A 28g 28b 28d 28e 28f 28c 28h 46 38 41* 28 Item 12 includes ite...
Page 39 - Accessories; Use Only Genuine Graco Parts and Accessories
308018 39 Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black100 psi (7 bar, 0.7 MPa) Maximum Working Pressure FM Approved; Color coded black; 0.315 in. (8 mm) ID;1/4 npsm(f) x 1/4 npsm(f) left-hand thread 220444 6 ft (1.8 m) 218100 15 ft (...
Page 41 - Technical Data; Manual Change Summary
308018 41 Technical Data Category Data Gun Weight 1.89 lb (0.86 kg) Gun Length 9.5 in. (240 mm) Maximum WorkingPressure 100 psi (7 bar, 0.7 MPa) Air PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Fluid PressureOperating Range 0–100 psi (0–7 bar, 0–0.7 MPa) Voltage Output 0–65 kV Paint Resist...
