Page 2 - Warning Symbol; WARNING; Caution Symbol; CAUTION
2 307912 Table of Contents Symbols 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How the Electrostat...
Page 3 - FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
307912 3 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 4 - PRESSURIZED EQUIPMENT HAZARD; EQUIPMENT MISUSE HAZARD
4 307912 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 5 - Introduction; How the Electrostatic Air Spray Gun Works; Installation; Installing the System; Warning Signs
307912 5 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 6 - Hazardous Area
6 307912 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 WireK Fluid Filter L ...
Page 7 - Connect the Air Line; Connect the Exhaust Tube
307912 7 Installation Connect the Air Line (Refer to Fig. 1) WARNING ELECTRIC SHOCK HAZARDTo reduce the risk of an electric shock orother serious injury, the air supply hosemust be electrically connected to a true earth ground. Use Only Graco Electrically Con-ductive Air Supply Hose. 1. Connect the ...
Page 8 - Ground the System
8 307912 Installation Ground the System WARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARDWhen operating the electrostatic device,any ungrounded objects in the sprayarea (such as people, containers, tools,etc.) can become electrically charged.Improper grounding can result in staticsparking, which ca...
Page 10 - Notes
Page 11 - Operation; Pressure Relief Procedure; Filter the Fluid
307912 11 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 12 - Selecting a Fluid Nozzle and Air Cap; Operating the Spray Gun
12 307912 Operation Fig. 4 06443 05151A DD 31 26 43 1 20 45 Selecting a Fluid Nozzle and Air Cap WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 11 before removing orinstalling a fluid nozzle and/or air cap. The gun is supplied with a ...
Page 14 - Shutdown; Maintenance; Daily Care and Cleaning
14 307912 Operation Shutdown WARNING PRESSURIZED EQUIPMENT HAZARDTo reduce the risk of an injury, follow the PressureRelief Procedure on page 11 whenever you stopspraying and whenever you are instructed torelieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc...
Page 15 - Clean the Air Cap and Fluid Nozzle; Flush the Spray Gun
307912 15 Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spraynozzle holes as this could scratch them, and makesure the electrode wire is not damaged. Scratches inthe air cap or spray nozzle or a damaged electrodewire can distort the spray patte...
Page 16 - Troubleshooting; Spray Pattern Troubleshooting
16 307912 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 17 - Gun Operation Troubleshooting
307912 17 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 page26. The packing nut is loose Tighten the packing nut; see page 26. Air leakage from the front of the g...
Page 18 - Electrical Troubleshooting
18 307912 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 19 - Electrical Tests; Test Gun Resistance
307912 19 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 20 - Test Power Supply Resistance
20 307912 Electrical Tests Test Power Supply Resistance Remove the power cartridge (18) from the gun handle.See Power Cartridge Replacement on page 27. Remove the turbine alternator from the power car-tridge. See Turbine Alternator Removal on page 28. Measure the resistance from the power supply’sgr...
Page 21 - Test Resistor Stud Resistance (continued)
307912 21 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 22. Check the resistancebetween the black resistor stud contact ring (D) andthe needle contact ring...
Page 22 - Service; Prepare the Gun for Service
22 307912 Service Prepare the Gun for Service 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...
Page 23 - Electrode Replacement
307912 23 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 24 - Barrel Removal
24 307912 Service Barrel Removal 1. Prepare the gun for service as instructed on page22. 2. Carefully loosen the nut from the fluid fitting (10).Pull the tube (12) out of the fitting. Make sure bothferrules and the nut stay with the tube. See Fig.14. 3. Using the wrench (63) supplied, loosen the thr...
Page 25 - Fluid Packing Removal
307912 25 Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page22. 2. Remove the air cap assembly, fluid nozzle andresistor stud and electrode as instructed on page23. 3. Loosen the trigger screws (4) far enough toremove the trigger (13). 4. Remove the packing cartridge ...
Page 26 - Fluid Packing and Needle Repair
26 307912 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 27 - Power Cartridge Replacement
307912 27 Service Fig. 18 7 35 37a 37b 18b 18c 18a 18 18d 37 F 05160 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 28 - Turbine Alternator Replacement
28 307912 Service Turbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours ofoperation. See your authorized Graco representative. 1. Prepare the gun for service as instructed on page22. 2. Remove the power cartridge from the gun handleas instructed on page 27. 3. Squeeze the t...
Page 29 - Fan Air Adjustment Valve Repair
307912 29 Service Fan Air Adjustment Valve Repair 1. Prepare the gun for service as instructed on page22. 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 30 - Fluid Adjustment Assembly Repair
30 307912 Service Fluid Adjustment Assembly Repair 1. Prepare the gun for service as instructed on page22. 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 31 - Air Trigger Valve Repair
307912 31 Service Air Trigger Valve Repair 1. Prepare the gun for service as instructed on page22. 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 32 - ES ON-OFF Valve Repair
32 307912 Service ES ON-OFF Valve Repair 1. Prepare the gun for service as instructed on page22. 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 34 - Parts
34 307912 Parts Item 18 includes items 18a to 18fItem 28 includes items 28a to 28hItem 37 includes items 37a and 37bItem 43 includes items 43b to 43eItem 45 includes items 45a to 45e 6 7 4 13 3 1 8 2 22 20 21 25* 28 35 34 44 45d 23 39 40 42 66 17 15 19 33 12 14 10 *29 24 26 36 46 38 47 32 31 9* 16 4...
Page 35 - Part No. 222600 Electrostatic Air Spray Gun
307912 35 Parts WARNING Some PRO 3500sc Gun replacement parts look similar toother PRO Gun parts but are not interchangeable! Whenservicing, do not mix or use other PRO Gun parts!Use of parts other than those specified in the parts listbelow could alter the grounding continuity of the gun,cause part...
Page 36 - Accessories; Use Only Genuine Graco Parts and Accessories
36 307912 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 39 - Technical Data; Manual Change Summary
307912 39 Technical Data Category Data Gun Weight 1.87 lb (0.85 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...
