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Graco Inc. 222300 Paint Sprayer User Manual

1. 1 Relieve the pressure 2 Remove the air cap assembly 3 With the front of the gun pointed down clean the air cap fluid nozzle and front of the gun using a soft bristle brush and compatible solvent See Fig 6 4 Carefully re install the air cap assembly Avoid bending the electrode Tighten the retaining nut until it is snug allowing the air cap to turn with resistance 5 Test the gun resistance as instructed on page 19 Flush the Spray Gun A WARNING ELECTRIC SHOCK HAZARD To reduce the risk of fire explosion or electric shock turn the ES ON OFF lever OFF before flushing the gun A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve the pressure Relieve the pressure 2 Disconnect and plug the fluid line 3 Connect the solvent supply to the gun 4 Flush the gun with compatible solvent into a grounded container until it is clean 5 Relieve the pressure 6 Disconnect and plug the solvent line 7 Trigger the gun into a grounded container to drain out the solvent remaining in the gun 8 Place the gun in its hanging bracket with the nozzle pointing down until it is used again 9 When ready to spray again reconnect the fluid supply line 10 Turn on the fluid and air supplies 11 Make sure the ES ON OFF lever is OFF 12 T
2. Operator gets a shock when The workpiece is not properly grounded Clean workpiece hangers Check for proper touching the workpiece grounding on the conveyor or track ES indicator light is not on when the gun is triggered 18 307912 Electrical Tests The performance and safety of the spray gun are directly affected by the condition of the electrical components contained inside the gun The electrical tests below can be used to determine the condition of the power supply 18 and the resistor stud 22 as well as the continuity of the electrical path between the components Use megohmmeter P N 241079 A and an applied voltage of 500 volts to complete these electrical tests Connect the leads as shown A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Megohmmeter P N 241079 A see Fig 7 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 e The gun has been removed from the hazardous area Or all spraying devices in the hazardous area are turned off ventilation fans in the hazardous area are operating and there are no flammable vapors in the area such as open solvent 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 Test Gun Resistance Check the resistance with the gun triggered and with the trigger release
3. 10 All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded 307912 11 Operation 06443 Fig 4 Selecting a Fluid Nozzle and Air Cap A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 before removing or installing a fluid nozzle and or air cap The gun is supplied with a 0 059 in 1 5 mm fluid nozzle P N 185158 and air cap P N 193033 If your application requires a different nozzle and air cap combination use instruction manual 307803 or consult your authorized Graco distributor to select the ap propriate fluid nozzle and air cap Install the air cap and fluid nozzle into the gun barrel as instructed in Air Cap Nozzle Resistor Stud Replacement page 22 12 307912 DD 31 05151A Operating the Spray Gun A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve pressure A WARNING COMPONENT RUPTURE HAZARD To reduce the risk of component rupture CH ME which can cause serious injury do not exceed the maximum working pressure of the lowest rated system component This equip ment has a 100 psi 7 bar 0 7 MPa maximum working air and fluid pressure Follow the steps on pag
4. 4 Lightly lubricate the o ring 25 with petroleum jelly and install it on the resistor stud 22 5 Using the multi tool 62 install the resistor stud 22 in the fluid nozzle 21 Tighten to 10 in lb 1 12 Nem NOTE Make sure the electrode 20 is tightened properly as shown in Fig 13 Continued on the next page Service Air Cap Nozzle Resistor Stud 3 Unscrew and remove the fluid needle electrode Replacement continued 20 with the multi tool 62 See Fig 13 Hold the needle shaft end to prevent it from turning 6 Trigger the gun while installing the fluid nozzle 21 and resistor stud 22 assembly with the multi tool 62 Tighten until the fluid nozzle seats in the gun A CAUTION barrel Be careful not to damage the contact wire when 7 Install the air cap assembly 1 2 8 Test the gun removing the electrode from the gun resistance as instructed on page 19 4 Apply low strength purple Loctite or equivalent thread sealant to the electrode and needle shaft threads Install the new electrode finger tight Do not over tighten it A CAUTION To avoid damaging the plastic threads or contact wire be very careful when installing the electrode 5 Install the fluid nozzle resistor stud and air cap assembly as instructed at left 6 Test the gun resistance as instructed on page 19 ER Apply a very light coat of lubricant Tighten 1 8 to 1 4 turn past han
5. 0 eee eee eee ees 6 Connect the Air Line 0 0 e ee eee 7 Connect the Exhaust Tube 7 Connect the Fluid Line 005 7 Ground the System 0 cece eee eee 8 Check the Electrical Grounding 9 Operation nannaa 11 Pressure Relief Procedure 11 Filter the Fluid 0 00 0000 2 eee 11 Operating Checklist 000 000 11 Selecting a Fluid Nozzle and Air Cap 12 Operating the Spray Gun 12 SHULGOWN sae eee ee et aan ERREI 14 Maintenance 02 00 e eee eee 14 Daily Care and Cleaning 14 Clean the Air Cap and Fluid Nozzle 15 Flush the Spray Gun 00002e ee eee 15 Troubleshooting cee eee eee 16 Spray Pattern Troubleshooting 16 Gun Operation Troubleshooting 17 Electrical Troubleshooting 18 Electrical Tests 000000 eee eeaee 19 Test Gun Resistance 0 00 ee eee 19 Test Power Supply Resistance 20 Test Resistor Stud Resistance 20 2 307912 Service hug Rod Git prg u pana e ee aa 22 Prepare the Gun for Service 005 22 Air Cap Nozzle Resistor Stud Replacement 22 Electrode Replacement 0 05 23 Barrel Removal 00200e cece eee eee 24 Fluid Packing Removal ee eens 2
6. 47 to 0 50 100 30 5 75 to 80 5 2 to 5 5 0 52 to 0 55 7 8 Set the atomizing air valve 31 about 1 5 turns out for most applications The Atomizing Air Valve Adjustment chart shows the effect of the atomiz ing air valve adjustment on the air cap air flow Adjust the pattern width with the fan air valve 43 Atomizing Air Valve Adjustment 100 90 80 70 60 50 40 30 20 10 0 0 00 0 50 1 00 1 50 2 00 2 50 3 00 Air Cap Air Flow Fully Open Fully Closed Valve Turns Fine Adjustments of the Spray Gun To improve the atomization open the atomizing air valve further 31 If more atomizing air is needed beyond the fully open position of the valve increase the air hose inlet pressure Use the lowest air flow settings needed for accept able atomization The slower particle velocity will improve the electrostatic effect To reduce the atomization air and minimize any overspray turn the atomizing air valve in NOTE See the Spray Pattern Troubleshooting chart on page 16 to correct spray pattern problems 9 Turn the ES ON OFF lever to ON to begin spray ing with the electrostatics When spraying the ES indicator light DD should glow indicating the electrostatic charge CAUTION Hang the gun with its nozzle pointing down when it is not being used to avoid having fluid run into the gun air passages Fluid in the gun air pas
7. 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 5m 218101 25 ft 8 218102 36 ft 11 218103 50 ft 15 220119 75 ft 23 220120 100ft 3 m m m m 0 5 m Conductive Air Supply Hose gray 100 psi 7 bar 0 7 MPa Maximum Working Pressure FM Approved Color coded gray More flexible than black hose 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 223068 6ft 1 8 m 223069 15 ft 5 m 223070 25 ft 8 223071 36 ft 11 223072 50 ft 15 223073 75 ft 23 223074 100 ft 3 m m m m 0 5 m Conductive Air Supply Hose red 100 psi 7 bar 0 7 MPa Maximum Working Pressure Meets CENELEC EN 50 050 requirement for metallic ground path Color coded red Stainless steel braid ground path 0 315 in 8 mm ID 1 4 npsm f x 1 4 npsm f left hand thread 235068 _ sG ft 1 8 m 235069 15 ft 5 m 235070 25 ft 8 235071 36 ft 11 235072 50 ft 15 235073 75 ft 23 235074 100 ft 3 m m m m 0 5 m 36 307912 Air Swivel Fitting 236129 100 psi 7 bar 0 7 MPa Maximum Working Pressure Replaces standard fitting item 17 in Parts List 1 4 npsm m left hand thread Extended Air Fitting 189191 Replaces standard fitting item 17 in Parts List to provide an extended handle grip area Air Shutoff Valve 224754 150 psi 10 bar 1 0 MPa Maximum Working Pressure Air Adapte
8. are done operating the gun See page 15 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 e Immersing the gun in fluid is not recom mended Do not use any cleaning method which may allow solvent into the gun air passages Point the gun down while cleaning to prevent fluid from running into the air passages See Fig 6 Hang the gun with its nozzle pointing down when it is not being used Clean all parts with a non conductive compatible solvent Conductive solvents can cause the gun to malfunction Methylene chloride is not recommended as a flush ing or cleaning solvent with this gun as it will damage nylon components 14 307912 Maintenance Clean the Air Cap and Fluid Nozzle A CAUTION Do not use metal tools to clean the air cap or spray nozzle holes as this could scratch them and make sure the electrode wire is not damaged Scratches in the air cap or spray nozzle or a damaged electrode wire can distort the spray pattern Equipment needed e Soft bristle brush e Compatible solvent Procedure A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying before installing or cleaning the fluid nozzle and whenever you are instructed to relieve the pressure
9. extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accor dance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may includ
10. holes or full air pressure from the clean horn hole forces the fan pattern toward the clogged end Tighten Clean the air cap with a soft implement or submerge it in water and wipe it clean see page 15 The electrode is bent Straighten the electrode The fluid nozzle or air cap holes are dam aged There is fluid buildup on the perimeter of the fluid nozzle orifice or a partially clogged fluid nozzle orifice Replace the damaged part see page 22 Remove the obstruction never use wire or hard instruments see page 15 The electrode is bent The fan air pressure is too high Straighten the electrode wire Reduce the fan air pressure The fluid is too thin Increase the fluid viscosity There is not enough fluid pressure The fan air pressure is too low Increase the fluid pressure Increase the fan air pressure The fluid is too thick Reduce the fluid viscosity lt gt There is too much fluid The last coat of fluid is applied too wet Reduce the fluid flow Reduce fluid pres sure on pressure feed guns and or adjust the fluid adjusting screw until proper pat tern is obtained Apply a drier finish using multiple strokes There is too much air pressure Decrease the air pressure The air pressure is insufficient Increase the air pressure SSS aS 16 307912 The spray pattern is non uniform Clean or replace the air cap see page 1
11. operating or if fumes are present Do not smoke in the spray area Do not operate a gasoline engine in the spray area TOXIC FLUID HAZARD Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin swallowed or inhaled e Know the specific hazards of the fluid you are using Read the fluid manufacturer s warnings e Store hazardous fluid in an approved container Dispose of the hazardous fluid according to all local state and national guidelines e Wear appropriate protective clothing gloves eyewear and respirator Warnings are continued on the next page 307912 3 A WARNING PRESSURIZED EQUIPMENT HAZARD Spray from the gun hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause a serious injury Do not point the spray gun at anyone or any part of the body Do not stop or deflect fluid leaks with your hand body glove or rag Follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve the pressure stop spraying clean check or servicing the equipment and install or clean the fluid nozzles Tighten all the fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn damaged or loose parts immediately Permanently coupled hoses cannot be repaired replace the entire hose EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture
12. 18f 62 191744 TOOL multi 1 18at 185134 e GASKET power supply 634 107460 WRENCH barrel 1 18bt 106555 e O RING Viton 66 185103 TUBE exhaust polyurethane 1 18c 110098 e SPRING compression 67 110231 CLAMP exhaust tube 1 18d 185141 e CUSHION power supply 69 110086 TOOL hex key allen wrench 2mm 1 71 4 180060 SIGN warning English See Accessories for additional signs 1 72 180209 COVER gun Order Part No 218374 18e 185099 e PAD 18f 185145 e PAD 19f 106555 O RING Viton aN i a 20 190933 NEEDLE electrode for package of 10 l 1 21 185158 NOZZLE fluid See Manual 307803 76 235300 BRACKET gun hanging 1 for available nozzles 77 185079 PLUG optional to install in place of 22 223977 STUD resistor item 31 1 23 109450 O RING PTFE 24 110083 SET SCREW lever M4 x 0 7 25 111507 O RING fluoroelastomer 26 186839 LEVER ES valve These parts are included in Fluid Seal Repair Kit 223020 which may be purchased separately t These parts are included in Air Seal Repair Kit 223021 which may be purchased separately E ooo 28 223444 FLUID PACKING amp NEEDLE ASSY Parts not show Includes items 28a 28h 1 A Replacement Danger and Warning labels signs tags and 28a 223024 e NEEDLE fluid 1 cards are available at no cost 28b 185495 e HOUSING packing 1 307912 35 Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose black 100 psi 7 bar 0 7 MPa Maximum
13. 35 1 Flush the gun as instructed in Flush the Spray Gun page 15 2 Relieve the pressure 3 Disconnect the air and fluid lines from the gun 4 Remove the spray gun from the worksite for service or repair Service or repair area must be clean 22 307912 Air Cap Nozzle Resistor Stud Replacement A CAUTION Hold the front end of the gun up and trigger the gun while removing the nozzle and resistor stud to help drain the gun and prevent any fluid left in the gun from entering the air passages 1 Prepare the gun for service as instructed at left 2 Remove the air cap assembly Point the front end of the gun up and squeeze the trigger while remov ing the fluid nozzle resistor stud 21 22 assembly with the multi tool 62 See Fig 11 page 23 NOTE If the resistor stud remains in the gun when the fluid nozzle is removed start the nozzle thread onto the stud and pull the stud out 3 Unscrew and remove the resistor stud 22 with the multi tool 62 See Fig 12 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD The resistor stud contact ring D is a conductive contact ring not a sealing o ring See Fig 11 To reduce the risk of sparking or electric shock do not remove the resistor stud contact ring D except to replace it and never operate the gun without the contact ring in place Do not replace the contact ring with anything but a genuine Graco part To install the resistor stud
14. 5 Fluid Packing and Needle Repair 26 Power Cartridge Replacement 27 Turbine Alternator Replacement 28 Barrel Installation 00 c cee eee eee 28 Fan Air Adjustment Valve Repair 29 Fluid Adjustment Assembly Repair 30 Air Trigger Valve Repair 00 eee eee 31 Atomizing Air Valve Removal and Replacement 31 ES ON OFF Valve Repair 000005 32 PartS eure law ent biates tie a TENE ENE EANES 34 Accessories cece eee eee eee 36 Technical Data 0 0 e eee eee 39 The Graco Warranty and Disclaimers 40 Graco Phone Number 40 Symbols Warning Symbol A WARNING This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions Caution Symbol A CAUTION This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the corresponding instructions A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Improper grounding poor air ventilation open flames or sparks can cause a hazardous condition and result in a fire explosion or electric shock e Electrostatic equipment must be used only by trained qualified personnel who understand the requirements stated in this instruction manual Ground the equipment personnel in or close to the spray area the object being sp
15. 5 or 22 Troubleshooting Gun Operation Troubleshooting Problem Cause Solution Fluid leakage from the fluid packing The needle packings or shaft are worn Replace the packings or shaft see page area 26 The packing nut is loose Tighten the packing nut see page 26 Air leakage from the front of the gun The air valve is not seating properly Clean and service the air valve see page 31 The air valve o ring is sticking Lubricate the o ring see page 31 Fluid leakage from the front of the gun The needle is worn or damaged Replace the needle see page 26 The fluid seat is worn Replace the fluid nozzle and or electrode needle see pages 26 to 23 The fluid packing is too tight Lubricate and adjust the packing nut see page 26 The resistor stud is loose Tighten the resistor stud see page 22 The fluid nozzle is loose Tighten the fluid nozzle see page 22 The resistor stud o ring is damaged Replace the o ring see page 22 Orange Peel finish The air pressure is insufficient for good Increase the air cap air pressure by open atomization ing the atomizing air valve more or in creasing the gun air inlet pressure use the least air pressure needed for good results The fluid is poorly mixed or filtered Remix or refilter the fluid An improper thinner is being used Use the proper thinner Excessive spray fog The air pressure is too high Reduce the air cap air pres
16. CAP See Manual 307803 for 37 222319 ALTERNATOR turbine Includes items 37a amp 37b 37at 110073 O RING Viton 37b 185124 CUSHION 38 185118 VALVE electrostatic 224194 SHAFT ASSY air valve 40 185115 NUT packing 41t 111508 O RING trigger valve fluoroelastomer 42t 105452 U CUP PTFE 43 222321 VALVE ASSY fan air available air caps 2 176930 RING retaining 3 222314 BARREL gun 4 185095 SCREW trigger 5 185096 SCREW cap relieved M5 x 0 8 6 185097 HOOK 7 222666 HANDLE gun 8 187423 NUT air cap 9 110077 FERRULES fluid tube E ee ee Ce ees Ce ee eC e o 10 110078 FITTING fluid tube Includes items 43b 43e 1 11At 179791 TAG warning 43b 105681 e RING retaining 1 12 185100 TUBE fluid 43c 191805 KNOB fan air adjustment 1 13 191904 TRIGGER 2 finger 43d 185090 e HOUSING valve 1 Mode 222300 only 1 43et 103557 e O RING Viton 2 191905 TRIGGER 4 finger 44 185116 SPRING compression air valve 1 Mode 222600 only 1 45 238895 VALVE ASSY fluid adjustment 14 110079 NUT fluid tube 1 Includes items 45a 45e 1 15 185122 MUFFLER flame arrestor 1 45a 186826 e STEM fluid adjustment 1 16 185104 BRACKET 2 finger 45b 111516 e O RING CV75 1 Model 222300 only 1 45c 186822 KNOB 1 236120 BRACKET 4 finger 45d 191794 e SLEEVE guide 1 Mode 222600 only 1 45e 191795 e STOP sleeve 1 17 185105 FITTING air 1 46 107107 REGULATOR disc 1 18 222333 POWER CARTRIDGE 65 kV 47 110082 RING retaining 1 Includes items 18a
17. INSTRUCTIONS PARTS LIST gt 307912 Rev AC This manual contains important GRACO Le a warnings and information READ AND KEEP FOR REFERENCE INSTRUCTIONS Model PRO 3500sc Electrostatic Air Spray Gun 65 kV MANUAL GUN 100 psi 7 bar 0 7 MPa Maximum Working Pressure Part No 222300 Series B S So ae With Two Finger Trigger H IN N Part No 222600 Series B With Four Finger Trigger o Ta Approved SR CE ays Part No 222300 shown 06443 NOTE Any modification of genuine Graco parts or replacement of parts with non Graco parts will void agency approvals U S PATENT NO 4 290 091 4 219 865 4 497 447 4 462 061 4 660 774 D313 064 4 978 075 Patented 1986 1987 Canada Brevete 1986 1987 U K PATENT NO 2 147 158 2 142 559B 2 140 327B French Patent No 89 16305 Other U S and Foreign Patents Pending GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1989 GRACO INC gy Graco Inc is registered to I S EN ISO 9001 Hoes Table of Contents SYMDOINS oe Enr epn a Scien R E Sod 2 Warnings eseria nts cow cet REENER AA ed 3 Introduction ananuna aana 5 How the Electrostatic Air Spray Gun Works 5 Installation naana 5 Installing the System 0002 eee 5 Warning SignS 0 eee eee eee 5 Ventilate the Spray Booth 5 Non hazardous Area 2 0202200es 6 Hazardous Area 6
18. Polyethylene Ceramic Maximum Working 100 psi 7 bar 0 7 MPa Pressure Fluoroelastomer Music Wire Air Pressure 0 100 psi 0 7 bar Operating Range 0 0 7 MPa j ee levels irate as a 40 eS 2 8 bar air supply at 3 the gun air inlet and typical gun air flow settings Fluid Pressure 0 100 psi 0 7 bar Operating Range 0 0 7 fest Noise levels measured with a 100 psi 7 bar air supply at the gun air inlet and maximum gun air flow settings Voltage Output 0 65 kV t Sound pressure was measured per Cagi Pneurop 1969 Bell Resistivity 7 megohm cm to infinity Sound power was measured per ISO 3744 1981 ange Kalrez and Viton are registered trademarks of the Air Inlet 1 4 npsm m left hand DuPont Co 9 MIGGEN JE NPSMH Loctite is a registered trademark of the Loctite Corporation Typical Noise Level Sound Pressure tT 87 Db A i at 40 psi 2 8 bar Sound Power 90 4 Db A Chemraz is a registered trademark of the Green Tweed 0 28 MPa and Company Maximum Noise Sound Pressure t 99 Db A Level at 100 psi Sound Power 105 4 Db A 7 bar 0 7 MPa Manual Change Summary This manual has been changed per ECO s V6099 V5645 and V5457 307912 39 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use With the exception of any special
19. amp as described in your separate pump instruction manual Air compressors and hydraulic power supplies ground the equipment according to the manufac turer s recommendations Electrostatic Air Spray Gun ground the gun by connecting the Graco Electrically Conductive Air Hose and connecting the air hose ground wire to a true earth ground Check the electrical grounding of the gun as instructed on page 9 307912 4 10 All air and fluid lines must be properly grounded Use only grounded hoses with a maximum of 500 feet 150 m combined hose length to ensure grounding continuity All electric cables must be properly grounded All persons entering the spray area their shoes must have conductive soles such as leather or personal grounding straps must be worn Rubber or plastic soles are not conductive The operator must not wear gloves that insulate the hand from the spray gun The gloves must be conductive or modified as shown in Fig 3 page 11 Object being sprayed keep the workpiece hangers clean and grounded at all times Contact points must be sharp points or like knife edges The floor of the spray area must be electrically conductive and grounded Do not cover the floor with cardboard or any non conductive material which would interrupt grounding continuity Flammable liquids in the spray area must be kept in approved grounded containers Do not store more than the quantity needed for one shift All elec
20. d The fluid passage must be flushed and dried to get an accurate reading Measure the resistance between the end of the elec trode 20 and the gun air fitting 17 See Fig 7 The resistance should be between 180 to 220 megohms If the resistance is outside the specified range go to the next test If the resistance is correct resume spraying or refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor perform ance 17 06447B Fig 7 Continued on the next page 307912 19 Electrical Tests Test Power Supply Resistance Remove the power cartridge 18 from the gun handle See Power Cartridge Replacement on page 27 Remove the turbine alternator from the power car tridge See Turbine Alternator Removal on page 28 Measure the resistance from the power supply s ground contact point EE to the contact spring 18c on the other end of the power supply See Fig 8 The resistance should be 157 5 to 192 5 megohms If the resistance is outside the specified range the power supply is defective and must be replaced If the resistance of the power supply is correct proceed to the next test If you still have problems refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor performance or contact the nearest authorized service agency Test Resistor Stud Resistance Insert a conductive rod B into t
21. d on page necessary 22 Lightly lubricate the o rings 18b 37a on the new 2 Remove the barrel as instructed on page 24 power cartridge with petroleum jelly All the o rings and the compression spring 18c must be in place or the gun will malfunction 4 Insert the new power cartridge in the gun handle Be sure the gasket 18a is in place l 5 Install the barrel on the handle as instructed on 3 Grasp the power cartridge with your hand With a page 28 gentle side to side motion pull it free from the gun handle 7 Then pull the power cartridge straight 6 Test the gun resistance as instructed on page 19 out of the handle 307912 27 Service Barrel Installation Turbine Alternator Replacement NOTE Replace turbine bearings after 2 000 hours of operation See your authorized Graco representative 1 28 Prepare the gun for service as instructed on page 22 Remove the power cartridge from the gun handle as instructed on page 27 Squeeze the two ends of the retaining ring 35 together and carefully pull the alternator 37 away from the power supply until the 3 wire connector F disengages See Fig 18 page 27 Use an ohmmeter to test the turbine alternator coil Measure the resistance between the two outer terminals of the 3 wire connector F The resistance should be 3 to 5 ohms If the reading varies from this value replace the alternator Measure the resistance between each outer ter
22. d remove 45a ai the sleeve stop 45e 1 45b 2 45d k 4 To completely disassemble the fluid adjustment 44 N assembly the sleeve stop 45e must be 39 assembled back on to the stem 45a Turn the stem until the sleeve is protruding about 0 4 inches X 10 mm 5 To remove the sleeve 45d hold the cap 45c and turn the sleeve stop 45e counterclockwise with a wrench 40 42 3 6 Remove the stem 45a and o ring 45b 7 Repair or replace any damaged parts Lubricate the o ring 45b with petroleum jelly 8 Carefully apply low strength purple Loctite or T Lubricate o rings with petroleum jelly equivalent thread sealant to the sleeve 45d external threads Turn the sleeve in with the sleeve stop 45e until it bottoms out then back it out 1 8 turn Carefully apply low strength purple Loctite or equivalent to sleeve 45d external thread Turn sleeve in with sleeve stop 45e until it bottoms out then back out 1 8 turn Allow Loctite to cure overnight Do not remove u cup 42 unless damaged Install with lips facing into handle Tighten packing nut 40 until it bottoms A CAUTION Fig 21 06456 Do not allow Loctite to get onto the stem 45a during assembly or the stem will not turn after assembly 9 Place the fluid adjustment assembly on the work bench with its threaded end facing down and allow the Loctite to cure over night 10 After the Loctite has cu
23. d tight NJI 06449 Fig 11 1 Torque to 10 in lbs 1 12 Nem Fig 12 0444A Electrode Replacement 1 Apply low strength purple Loctite or equivalent to needle shaft 1 Prepare the gun for service as instructed on page threads 22 Fig 13 06450 2 Remove the air cap nozzle and resistor stud as instructed on page 22 307912 23 Service Barrel Removal 1 Prepare the gun for service as instructed on page 2 Carefully loosen the nut from the fluid fitting 10 Pull the tube 12 out of the fitting Make sure both ferrules and the nut stay with the tube See Fig 14 3 Using the wrench 63 supplied loosen the three socket head cap screws 5 4 Hold the gun handle 7 with one hand and pull the barrel 3 straight away from the handle to remove it See Fig 15 To avoid damaging the power cartridge 18 pull the gun barrel straight away from the gun handle If necessary gently move the barrel from side to side RTA to free it from the gun handle Fig 15 06451 Fig 14 24 307912 Service Fluid Packing Removal 1 Prepare the gun for service as instructed on page 2 Remove the air cap assembly fluid nozzle and resistor stud and electrode as instructed on page 23 3 Loosen the trigger screws 4 far enough to remove the trigger 13 4 Remove the packing cartridge and needle assem bly 28 using the multi
24. e 13 to establish the correct fluid flow and air flow Do not turn the ES ON OFF lever to ON yet Operation Operating the Spray Gun continued 1 2 Follow the Operating Checklist on page 11 To adjust the air cap for a vertical or horizontal spray pattern first make sure the pressure is relieved Then loosen the air cap retaining nut and rotate the air cap as directed in Fig 5 Tighten the retaining nut until the air cap is held firmly in place you should not be able to rotate the air cap horns by hand Horizontal Pattern 02020 Fig 5 3 4 5 6 Adjust the fluid flow by using the fluid line pressure regulator Refer to instruction manual 307803 to set the fluid pressure for various fluid flows ac cording to the size of the fluid nozzle being used If necessary further adjust the fluid flow rate with the fluid adjustment knob 45 See Fig 4 Fully open the fan air valve 43 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 Air Hose Length ft m Dynamic pressure at air hose inlet required for full voltage psi bar MPa 15 4 6 45 to 50 3 1 to 3 5 0 31 to 0 35 25 7 6 50 to 55 3 5 to 3 8 0 35 to 0 38 50 15 3 60 to 65 4 2 to 4 5 0 42 to 0 45 75 22 9 68 to 73 4 7 to 5 0 0
25. e 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 to wear safety glasses when removing or installing the retaining ring 47 as the retaining ring could slip off the tool when com pressed 3 Use internal snap ring pliers to remove the retain ing ring 47 from the handle Align the holes in the retaining ring with the flat on the spacer 32 to ease assembly and disassembly 4 Remove the valve body 38 from the handle be careful not to drop the regulator disk 46 and spacer 32 5 Clean and inspect the parts for damage Replace if necessary Lubricate the o ring 86 with petroleum jelly A CAUTION Do not over lubricate parts Excessive lubricant on the o ring 86 can be pushed into the gun air pas sage and blemish the finish on the workpiece 1 Bevelled side of disk 46 faces toward valve 38 2 Lubricate o rings with petroleum jelly 6 Install the regulator disk 46 in the valve 38 with its bevelled side facing in toward the valve Fig 23 06457 A CAUTION Be sure the regulator disk 46 is installed correctly A missing or incorrectly installed regulator disc can cause severe damage to the power supply 32 307912 Notes 307912 33 Parts DETAIL A Item 18 inc
26. e the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or othe
27. he flats of the valve housing and remove it from the handle See Fig 20 NOTE The fan air valve 43 can be replaced as an assembly or as individual parts To disassemble the fan valve 3 Remove the retaining ring 43b Rotate the fan air adjustment knob 48c counterclockwise until it is disengaged from the valve housing threads 43d Pull the adjustment knob out of the valve housing Clean all the parts and inspect them for wear or damage When reassembling the fan air valve 43 lubricate the o rings 43e and the adjustment knob threads 43c with petroleum jelly After the retaining ring 43b is installed on the adjustment knob 43c back the adjustment knob out of the valve housing 43d until it bottoms out against the retaining ring 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 Ib 1 1 to 1 4 Nem DETAIL Lubricate o rings 43e and top knob threads 43c with petro leum jelly Apply PTFE paste to the valve housing threads 43d Torque to 10 12 in lb 1 1 1 4 Nem 06455 Fig 20 307912 29 Service Fluid Adjustment Assembly Repair DETAIL 1 Prepare the gun for service as instructed on page 2 Using a 14 mm socket wrench remove the fluid adjustment assembly 45 See Fig 21 45 3 Turn the stem 45a fully clockwise an
28. he gun barrel re moved for the power supply test and against the metal contact C in the front of the barrel See Fig 9 Measure the resistance between the conductive rod B and the gun electrode 20 The resistance should be 21 to 29 megohms If the resistance is correct resume spraying or refer to the Electrical Troubleshooting chart on page 18 for other possible causes of poor performance Contact the nearest authorized service agency if problems continue 20 307912 _ _ SJL os c a om H 18c EE 18 03566B Fig 8 06448B Continued on the next page Electrical Tests Test Resistor Stud Resistance continued If the resistance is outside the specified range remove the resistor stud 22 See Air Cap Nozzle Resistor Stud Replacement on page 22 Check the resistance between the black resistor stud contact ring D and the needle contact ring E Refer to Fig 10 You may have to press down on the contact ring D in several places to get a good reading The resistance should be 21 to 29 megohms If the resistance is correct make sure the metal contact C in the barrel and the needle contact wire E are clean Fig 10 If the resistance is outside the specified range the resistor is defective and the resistor s
29. hich could clog the spray nozzle 7 1 3in 76 mm square cut out and finger of glove cut off NOTE If gloves are worn they must be conductive or modified as shown so they do not interfere with operator grounding through the gun 06445 Fig 3 Operating Checklist Check the following list daily before starting to operate the system to help ensure safe efficient operation 1 All the operators are properly trained to safely operate an electrostatic air spray system as instructed in this manual 2 All the operators are trained how to properly relieve pressure as instructed at left 3 The system is thoroughly grounded and the operator and all persons entering the spray area are properly grounded See Ground the System page 8 4 The operator is not wearing gloves which insulate the hand from the spray gun If worn gloves must be conductive or modified as shown in Fig 3 so as not to interfere with the operator grounding through the gun 5 The condition of the electrical components of the spray gun has been checked as instructed in Electrical Tests page 19 6 The ventilation fans are operating properly 7 The workpiece hangers are clean and grounded Contact points must be sharp points or like knife edges 8 All the debris including flammable liquids and rags is removed from the spray area 9 All flammable liquids in the spray booth are in approved grounded containers
30. ludes items 18a to 18f 28d D Item 28 includes items 28a to 28h Item 37 includes items 37a and 37b 28g 28b Item 43 includes items 43b to 43e 28 See DetailA 28a Item 45 includes items 45a to 45e pare 28 Y 28h D 28e 35 D ye i SS i S Je ssa is wT gt Lb 06458 34 307912 A WA R N N G A Part No Description Qty 185488 e NUT packing 1 Some PRO 3500sc Gun replacement parts look similar to 178763 e PACKING needle 1 other PRO Gun parts but are not interchangeable When 178409 e PACKING fluid 1 servicing do not mix or use other PRO Gun parts 111504 O RING fluoroelastomer 1 Use of parts other than those specified in the parts list 111316 O RING fluoroelastomer 1 below could alter the grounding continuity of the gun 186069 e SPACER 1 cause parts to leak or rupture or cause the gun to 185120 SEAL fluid 1 malfunction and result in serious injury fire explosion or 185111 SPRING compression 1 property damage 238927 VALVE atomizing air 1 185119 SPACER lever 1 Part No 222300 Series B 33 185112 ADAPTER exhaust hose Electrostatic Air Spray Gun with two finger trigger 188878 E only 1 7 3 exhaust hose Part No 222600 Electrostatic Air Spray Gun Model 222600 only 1 Electrostatic Air Spray Gun with four finger trigger 34 185113 GASKET manifold polyethylene 1 Ref 35 185114 RING retainer alternator 1 No Part No Description Qty 36 113746 O RING CV75 1 1 193033 AIR
31. malfunction or start unexpectedly and result INSTRUCTIONS in a serious injury E Mkaa e Ra This equipment is for professional use only Read all the instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are uncertain about usage call your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check the equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component This equip ment has a 100 psi 7 bar 0 7 MPa maximum working air and fluid pressure Use fluids that are compatible with the equipment wetted parts See the Technical Data section of all the equipment manuals Read the fluid manufacturer s warnings Route the hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 40 F 40 C Do not use the hoses to pull equipment Wear hearing protection when operating this equipment Comply with all applicable local state and national fire electrical and other safety regulations 4 307912 Introduction How the Electrostatic Air Spray Gun Works The air hose supplies air to the spray gun Part of the air operates the turbine and the rest of the air atomizes the fluid being sprayed The turbi
32. minal of the 3 wire connector and the turbine alternator housing The resistance should be infinite If the resistance is not infinite replace the alternator Connect the 3 wire connector to the 3 prongs in the power supply Push the alternator onto the power supply until the retaining ring engages with the alternator Install the power cartridge in the gun handle as instructed on page 27 307912 1 Be sure the gaskets 34 and 18a and spring 30 are in place See Fig 19 Replace if damaged Place the barrel 3 over the power cartridge 18 and onto the gun handle 7 Make sure the fluid needle spring 30 is seated properly Tighten the three socket head cap screws 5 oppositely and evenly to 18 in lbs 2 Nem maxi mum about a half turn past snug with the wrench 63 supplied Tighten the three socket head cap screws 5 oppositely and evenly with the wrench 63 sup plied Tighten the cap screws to 18 in lbs 2 Nem maximum about a half turn past snug CAUTION To avoid damaging the gun do not over tighten the cap screws 5 Assemble the fluid tube 12 back into the fluid fitting 10 Test the gun resistance as instructed on page 19 10 Tighten to 18 in lbs 2 Nem maximum about half turn past snug using wrench provided 06453 Fig 19 Service Fan Air Adjustment Valve Repair 1 Prepare the gun for service as instructed on page Place a wrench on t
33. mp 208630 1 2 npt m x 3 8 npt f carbon steel and PTFE for non corrosive fluids Ly SPRAY SYSTEM ACCESSORIES Electrostatic System 223106 Includes 222300 Electrostatic Air Spray Gun 223070 Grounded Air Hose 25 ft 8 m 216076 Fluid Hose 25 ft 8 m 106148 Air Filter Electrostatic System 223027 Includes 222300 Electrostatic Air Spray Gun 223070 Grounded Air Hose 25 ft 8 m 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter Electrostatic System 223028 Includes 222300 Electrostatic Air Spray Gun 223071 Grounded Air Hose 36 ft 11 m 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter Electrostatic System 223029 Includes 222300 Electrostatic Air Spray Gun 223072 Grounded Air Hose 50 ft 15 m 206199 Air Regulator with Gauge 106149 Air Filter 158491 Nipple 158212 Bushing 164672 Adapter Continued on page 38 307912 37 Accessories Use Only Genuine Graco Parts and Accessories MISCELLANEOUS ACCESSORIES Snap Ring Pliers 110090 For removing the ES ON OFF Valve Retaining Ring item 47 in Parts List Paint Resistance Meter 722886 Used with 722860 Paint Probe to measure resistance of paint Not for use in Hazardous areas Paint Probe 722860 Used with 722886 Paint Resistance Meter to measure resistance of paint Not for use in Hazardous areas Grounding Clamp And Wire 222011 12 ga 25 ft 7 6 m
34. ne generates power which is converted by the power cartridge to supply high voltage current to the gun s ionizing electrode The pump supplies fluid to the hose and gun where the fluid is electrostatically charged as it passes the electrode The charged fluid is attracted to the grounded workpiece wrapping around and evenly coating all surfaces Installation Installing the System A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly e Do not install or service this equip ment unless you are trained and qualified e Be sure your installation complies with National State and Local codes for the installation of electrical apparatus in a Class Group D Hazardous Location Comply with all applicable local state and national fire electrical and other safety regula tions Fig 1 shows a typical electrostatic air spray system It is not an actual system design The particular type and size system for your operation must be custom designed for your needs For assistance in designing a system contact your Graco distributor Warning Signs Mount warning signs in the spray area where they can easily be seen and read by all operators An English Warning Sign is provided with the gun Additional English French German and Spanish signs are available at no cha
35. ng 41 and air valve shaft 39 can be pushed into the gun air passage and blemish the finish on the workpiece 5 Unscrew the packing nut 40 to check the u cup 42 Do not remove the u cup unless it is dam aged Apply PTFE paste to the fan air valve housing threads Torque 6 Install the air valve shaft 39 with the o ring 41 to 10 12 in lb 1 1 1 4 Nem and spring 44 into the back of the gun handle f 06455 7 If the u cup 42 was removed install the air Fig 22 seee valve shaft 39 before installing the u cup Install the u cup with its lips facing into the gun handle 7 Install the fluid adjustment assembly 45 with the o ring 23 Tighten the adjustment knob 45c with the 14 mm socket wrench Tighten the air valve packing nut 40 until it bottoms 307912 31 Service ES ON OFF Valve Repair 7 Install the valve 38 with the regulator disc 46 and o ring 36 into the gun handle Install the 1 Prepare the gun for service as instructed on page spacer 32 on the valve 8 Install the retaining ring 47 into the groove in the 2 Loosen the set screw 24 with the 2 mm hex key handle Install the lever 26 and tighten the set 69 provided Remove the lever 26 from the screw 24 valve See Fig 23 A WARNING MOVING PARTS HAZARD To reduce the risk of eye injury be sure A WARNING MOVING PARTS HAZARD Make sure that the retaining ring 47 is engaged in the groov
36. ng distance to 8 to 12 inches 203 to 305 mm The parts are poorly grounded Clean the workpiece hangers Check for proper grounding on the conveyer or track The booth exhaust velocity is too high Reduce exhaust velocity within code limits The atomizing air pressure is too high Reduce the atomizing air pressure The fluid pressure is too high Reduce the fluid pressure The fluid viscosity is not right for electros tatic spray Check with the supplier for proper fluid viscos ity for electrostatic spray The fluid resistivity is too low Check the fluid resistivity with a paint meter and probe The turbine alternator is not operating Check if the ES ON OFF lever is ON 1 Check the air supply to the gun Check for dirt or moisture in the turbine See page 28 The gun resistance is faulty Check the gun resistance See page 19 Fluid leaks from the needle packing and causes a short Clean the needle cavity Replace the fluid needle See page 26 The turbine alternator is faulty The operator is not properly grounded or is near an ungrounded object Be sure the plug is in place on the back of the turbine alternator housing Remove and test the turbine alternator See page 28 Be sure the floor and the operator are properly grounded See Ground the System page 8 The gun is not properly grounded See Check the Electrical Grounding page 9
37. o the gun The fluid hose must not have any fluid in it lt gt O A 4 Make sure the air hose R is connected and the n akhi CC hose ground wire is connected to a true earth Weve ground 0644B 5 Measure the resistance between the gun handle Fig 2 BB and a true earth ground CC a If using a black or grey air hose use a me gohmmeter AA to measure the resistance Use an applied voltage of 500 minimum to 1000 volts maximum The resistance should not exceed 2 megohms 307912 9 Notes 10 307912 Operation Pressure Relief Procedure A 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 electric shock accidental spray from the gun splashing fluid or moving parts follow the Pressure Relief Procedure whenever you e are instructed to relieve the pressure e stop spraying e check or service any of the system equipment e or install or clean the fluid nozzle 1 Turn the ES ON OFF Lever to OFF 2 Turn off the air and fluid supply to the gun 3 Trigger the gun into a grounded metal waste container to relieve fluid pressure 4 Open the pump drain valve having a waste con tainer ready to catch the drainage 5 Leave the pump drain valve open until you are ready to spray again Filter the Fluid Filter the fluid to remove coarse particles and sediment w
38. r Nipple 185493 For connecting two or more grounded gun air supply hoses 1 4 npt x 1 4 npsm left hand thread For turning air to gun off or on 1 4 npsm m 1 4 npsm f left hand thread Quick Disconnect Swivel Coupling Assy 112534 Includes a quick disconnect coupling insert which replaces air inlet fitting 185105 and a swivel shut off coupling body left hand thread which connects to the grounded air hose Bleed type Master Air Valve 107141 300 psi 21 bar 2 1 MPa Maximum Working Pressure Relieves air trapped in the air line between the paint pump air motor and this valve when closed 3 4 npt Ey Accessories Use Only Genuine Graco Parts and Accessories FLUID LINE ACCESSORIES Fluid Hose Assemblies Nylon 225 psi 14 bar 1 4 MPa Maximum Working Pressure FM Approved 1 4 in 6 35 mm ID 3 8 npsm fbe 215637 215638 25 ft 8 m 50 ft 15 m Fluid Hose Assemblies Nylon 500 psi 35 bar 3 5 MPa Maximum Working Pressure FM Approved 1 4 in 6 35 mm ID 3 8 npsm fbe 216076 25 ft 8m 216077 50 ft 15m 216079 100 ft 30 m Fluid Tube PTFE 185806 100 psi 7 bar 0 7 MPa Maximum Working Pressure For reducing flushing time Replaces item 12 in parts list 0 078 in 1 98 mm ID 0 375 in 9 53 mm OD 5 50 in 139 mm long Fluid Shutoff Drain Valve 500 psi 35 bar 3 5 MPa Maximum Working Pressure For turning fluid off or on to the gun and for relieving fluid line pressure at the pu
39. rayed and all other electrically conductive objects in the spray area See Ground the System on page 8 Check the spray gun resistance daily See Test Gun Resistance page 19 If there is any static sparking while using the equipment stop spraying immediately Identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors Interlock the gun turbine air supply to prevent operation of the power supply unless the ventilating fans are on See Ventilate the Spray Booth on page 5 When cleaning flushing or purging electrostatic equipment use solvents that comply with your local regulations For countries following the U S National Fire Protection Association NFPA 33 requirements use solvents with a flash point higher than 100 F 38 C or a solvent normally used in spray operations For European Countries complying with EN 50053 use solvents with a flash point as high as possible and higher than the ambient temperatures Use only non sparking tools to clean residue from the booth and hangers Do not flush the system with the gun electrostatics turned on Do not turn on the gun electrostatics until all solvent is removed from the system Extinguish all open flames or pilot lights in the spray area Keep the spray area free of debris including solvent rags and gasoline Do not store any flammable fluids in the spray area Do not turn on or off any light switch in the spray area while
40. red assemble the fluid adjustment assembly into the gun 30 307912 Service Air Trigger Valve Repair Atomizing Air Valve Removal and 1 Prepare the gun for service as instructed on page Replacement 1 Prepare the gun for service as instructed on page 2 Using a 14 mm socket wrench remove the fluid adjustment assembly 45 o ring 23 and spring 2 Remove the fan air valve 43 See Fig 22 44 See Fig 21 A CAUTION A CAUTION Clean all parts in non conductive solvent compatible To avoid damaging the atomizing air valve 31 the fan air valve 43 must be removed before removing with the fluid being used such as xylol or mineral the atomizing air valve spirits Use of conductive solvents can cause the gun to malfunction 3 Remove the atomizing air valve 31 from the gun handle Inspect the o ring 19 and replace if 3 Loosen the air valve packing nut 40 one full turn necessary Remove the air valve shaft 39 with a pliers 4 Install a new atomizing air valve 31 A CAUTION 5 Apply PTFE paste to the fan air valve 43 housing threads and install the valve in the handle Torque When removing the air valve shaft 89 be careful not the housing to 10 to 12 in Ib 1 1 to 1 4 Nem to damage the seat area 4 Check the o rings 41 23 for damage and replace if necessary Apply petroleum jelly to the o rings A CAUTION Do not over lubricate parts Excessive lubricant on the o ri
41. rge See Accessories to order them Ventilate the Spray Booth A WARNING FLAMMABLE OR TOXIC VAPOR HAZARD Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors Do g not operate the gun unless ventilation IKA fans are operating Electrically interlock the gun air supply with the ventila tors to prevent gun operation without ventilating fans operating Check and follow all National State and Local codes regarding air exhaust velocity requirements k NOTE High velocity air exhaust will decrease the operating efficiency of the electrostatic system Air exhaust velocity of 100 ft min 31 linear meters minute should be sufficient 307912 5 Installation KEY A Main Air Supply Line P Air Supply Line Shutoff Valve B Ventilation Fan Interlock Solenoid Valve Q Air Hose Ground Wire C Main Air Supply Shutoff Valve bleed type R Graco Electrically Conductive Air Hose D Air amp Water Separator S Electrostatic Spray Gun E Pump Air Supply Shutoff Valve bleed type T Air Line Drain Valve F Air Line Lubricator U Fluid Drain Valve G Air Pressure Regulator V Gun Air Inlet H Pump W Gun Fluid Inlet J Pump Ground Wire X Gun Exhaust Tube K Fluid Filter L Fluid Supply Line Shutoff Valve Required for safe operation Must purchase separately See M Fluid Pressure Regulator Accessories NOTE Solenoid Valve B is not offered as a Graco N Fluid Supply Line accessory O Air Filter 20 mic
42. rigger the gun until it is clear of solvent 06446 Fig 6 307912 15 Wi 4 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 Troubleshooting A WARNING install or service this equipment unless you are trained and qualified A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure NOTE Check all possible remedies in the Troubleshooting Chart before disassembling the gun Spray Pattern Troubleshooting NOTE Some spray pattern problems are caused by the improper balance between air and fluid Problem Fluttering or spitting spray The fluid supply is insufficient Solution Adjust the fluid regulator or fill the fluid supply The fluid nozzle is loose or the fluid noz zle taper seat is damaged Tighten or replace the fluid nozzle see page 22 li There is dirt between the fluid nozzle taper seat and gun body Clean the parts see page 15 The coupler at the fluid inlet is loose or cracked Tighten or repair the coupler Improper spray pattern P 2 C Loose fluid tube in tank There is fluid build up on the air cap partially clogged horn
43. ron M ES ON OFF Lever 1is ON 0 is OFF A a HN 4y ete co am E ons N OH S B C D f G F uf J Q 2 S e CH D e OW f 5 D WARNING U 4 SIGN pau pee L Non hazardous Area Hazardous Area The air supply to the gun must be electrically interlocked with the ventilators to prevent the power supply from operating without ventilating fans on 0389 Fig 1 6 307912 Installation Connect the Air Line Refer to Fig 1 A WARNING ELECTRIC SHOCK HAZARD To reduce the risk of an electric shock or E other serious injury the air supply hose must be electrically connected to a true earth ground Use Only Graco Electrically Con ductive Air Supply Hose 1 Connect the Graco Electrically Conductive Air Supply Hose R between the air supply line and the gun s air inlet V The gun air inlet fitting has a left hand thread Connect the air supply hose ground wire to a true earth ground 2 Install an air line filter O and an air and water separator D on the air line to ensure a d
44. rwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Phone Number TO PLACE AN ORDER contact your Graco distributor or call Graco 1 800 367 4023 Toll Free All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice 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 307912 January 1989 Revised September 2000 40 307912
45. ry clean air supply to the gun Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction 3 Install a bleed type air regulator G on the pump and gun air supply lines to control air pressure to the pump and gun 4 Install a bleed type air shutoff valve on the main air line C and the pump air line E to shut off air to the pump Install an additional bleed type valve on each pump air supply line to relieve air trapped between this valve and the pump after the air regulator is shut off A WARNING PRESSURIZED EQUIPMENT HAZARD The bleed type air shutoff valve is required in your system to relieve air trapped between this valve and the pump after the air regulator is closed Trapped air can cause the pump to cycle unexpect edly which could result in serious injury including splashing in the eyes or on the skin 5 Install an air line lubricator F as close to the pump H as possible Install an air shutoff valve P on each gun air supply line to shut off air to the gun s Connect the Exhaust Tube Press the exhaust tube provided onto the barbed adapter on the bottom of the gun handle Secure the tube with the clamp provided Refer to page 34 Connect the Fluid Line Refer to Fig 1 1 Before connecting the fluid line N blow it out with air and flush it with solvent Use solvent which is compatible with the fluid to be sprayed Install a fluid regula
46. sages can cause poor atomization and excessive current de mands and damage the gun 307912 13 Operation Shutdown 1 Relieve the pressure 2 Flush and clean the equipment Follow the instruc A WARNING tion in Maintenance PRESSURIZED EQUIPMENT HAZARD To reduce the risk of an injury follow the Pressure Relief Procedure on page 11 whenever you stop spraying and whenever you are instructed to relieve pressure Maintenance Daily Care and Cleaning 1 Clean the fluid and air line filters daily 2 Clean the outside of the gun daily with a soft cloth A WARNING dampened in a compatible solvent PRESSURIZED EQUIPMENT HAZARD 3 Clean the air cap and fluid nozzle daily minimum Relief Procedure on page 11 when you stop frequent cleaning Replace the fluid nozzle and air spraying before cleaning or flushing the spray gun cap if they are damaged See page 22 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 A WARNING z 5 Check for fluid leakage from the gun and fluid FIRE EXPLOSION AND ELECTRIC hoses Tighten fittings or replace equipment as To reduce the risk of fire explosion or electric shock turn the ES ON OFF 6 Check all of the work hangers for build up of lever OFF before flushing the gun material clean them if necessary 7 Flush the gun before changing colors and whenev A CAUTION er you
47. sure by closing the atomizing air valve more or decreas ing the gun air inlet pressure use the least air pressure needed for good results Do not reduce below minimum pressure needed for full voltage See page 13 The fluid is thinned too much Properly thin the fluid No fluid sprays from the gun The fluid supply is low Check the fluid supply add fluid if necessary The air cap is damaged Replace the air cap see page 22 The fluid nozzle is dirty or clogged Clean the fluid nozzle see page 15 The fluid nozzle is damaged Replace the fluid nozzle see page 22 The fluid adjustment valve is damaged Replace the o ring see page 31 The equipment is covered with fluid The exhaust air flow is insufficient or not Check for the proper CFM check the directed properly baffles and direction of the air flow The distance between the gun and work Adjust the spraying distance to 8 to 12 piece is incorrect inches 203 to 305 mm The air cap is dirty The air cap and fluid nozzle are mis Check the air cap and fluid nozzle seat for aligned fluid buildup Clean or replace parts as needed see page 15 or 22 Fluid Nozzle ALIGNED MISALIGNED 307912 17 Troubleshooting Electrical Troubleshooting Poor wrap around Operator gets a mild shock 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 sprayi
48. tool 62 See Fig 16 A CAUTION Clean all parts in non conductive solvent compatible with the fluid being used such as xylol or mineral spirits Use of conductive solvents can cause the gun to malfunction 5 Check all the parts for wear or damage and re place if necessary Fig 16 06454 307912 25 Service Fluid Packing and Needle Repair The fluid packings and needle can be replaced as individual parts or as assemblies The overall assem bly is pre adjusted at the factory NOTE Before installing the packing and needle as sembly into the gun barrel make sure the internal surfaces of the barrel are clean Remove any residue with a soft brush or cloth Check the inside of the barrel for marks from high voltage arcing If the marks are present replace the barrel If the parts are purchased separately assemble them as instructed below and as shown in Fig 17 1 7 Place the packing nut 28c and o ring 28f on the fluid needle 28a Flats on the packing nut must be facing toward the back of the fluid needle Fill the entire inner cavity of the spacer 28h with petroleum jelly Place the spacer on the fluid needle 28a in the direction shown in Fig 17 Generously apply petroleum jelly to the outside of the spacer 28g 28h 3 Place the fluid packing 28e needle packing 28d and housing 28b on the fluid needle 28a as shown in Fig 17 Lubricate the o ring 28g on the o
49. tor M on the fluid line to control fluid pressure to the gun Install a fluid filter K and drain valve U at the pump outlet A WARNING PRESSURIZED EQUIPMENT HAZARD The fluid drain valve U is required in your system to assist in relieving fluid pressure in the displace ment pump hose and gun triggering the gun to relieve pressure may not be sufficient Install a drain valve close to the pump s fluid outlet The drain valve reduces the risk of serious injury including splashing in the eyes or on the skin Connect the fluid line to the 3 8 18 6 m gun fluid inlet W Before running any paint through the spray gun flush it out with a compatible solvent 307912 7 Installation Ground the System A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD When operating the electrostatic device any ungrounded objects in the spray area such as people containers tools etc can become electrically charged Improper grounding can result in static sparking which can cause a fire explo sion or electric shock Follow the grounding instructions below The following are minimum grounding requirements for a basic electrostatic system Your system may include other equipment or objects which must be grounded Check your local electrical code for detailed grounding instructions Your system must be connected to a true earth ground 1 8 Pump ground the pump by connecting a ground wire and cl
50. trically conductive objects or devices in the spray area including fluid containers and wash cans must be properly grounded Installation Check the Electrical Grounding See Fig 2 b If using a red turbine air hose use an ohmme ter to measure the resistance Resistance A WARNING should not exceed 100 ohms 6 If the resistance is greater than the maximum FIRE EXPLOSION AND reading specified above for your hose check the ELECTRIC SHOCK HAZARD tightness of the ground connections and be sure Megohmmeter P N 241079 AA see Fig the air hose ground wire is connected to a true 2 is not approved for use in a hazard earth ground If the resistance is still too high ous area To reduce the risk of sparking replace the air hose do not use the megohmmeter to check electrical grounding unless R e The gun has been removed from the hazardous area e 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 1 Have a qualified electrician check the electrical grounding continuity of the spray gun and air hose 2 Turn the ES ON OFF Lever to OFF See Fig 4 page 12 for the location of the lever 3 Turn off the air and fluid supply t
51. tud 22 must be replaced See Air Cap Nozzle Resistor Stud Re placement on page 22 A WARNING FIRE EXPLOSION AND ELECTRIC SHOCK HAZARD The resistor stud contact ring D is a conductive contact ring not a sealing 0442 o ring See Fig 10 To reduce the risk of sparking or electric shock do not remove the resistor stud contact ring D or operate the gun without the contact ring in place Do not replace the resistor stud 22 with anything but a genuine Graco part 307912 21 Service Prepare the Gun for Service A WARNING ELECTRIC SHOCK HAZARD iy 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 A WARNING PRESSURIZED EQUIPMENT HAZARD To reduce the risk of injury follow the Pressure Relief Procedure on page 11 before checking or servicing any part of the system and whenever you are instructed to relieve the pressure NOTE e Check all possible remedies in Troubleshooting before disassembling the gun e lf the plastic parts of the gun must be held securely always clamp them in padded vice jaws to prevent damage to the parts e Lightly lubricate o rings and seals with petroleum jelly Do not over lubricate e Only use genuine Graco parts Do not mix or use parts from other PRO Gun models See page
52. utside of the packing housing 28b Make sure the spring 30 is installed against the nut as shown in Fig 17 Install the packing and needle assembly into the gun barrel Using the multi tool 62 tighten the assembly until just snug then check the drag on the needle Tighten the packing nut to 2 Ibs 9 N of drag force when sliding the needle through the packing cartridge Install the trigger 13 and tighten the trigger screws 4 Install the electrode nozzle and resistor stud assembly and the air cap assembly as instructed on page 23 10 Test the gun resistance as instructed on page 19 28c 28a 30 U 28b e 3 C 2 Pe R 28e 28f Item 30 is not included with the Packing Needle Assy 28 Fig 17 26 307912 28 03559 Service o i Apply a very light coat of lubricant Do not expose to solvents NI 05160 Fig 18 Power Cartridge Replacement NOTE The power cartridge consists of the alternator 37 power supply 18 and retaining ring 35 See To avoid a loss in electrostatic performance inspect Fig 18 the power cartridge cavity in the handle for dirt or moisture Clean out the cavity with a clean dry rag if 1 Prepare the gun for service as instructe
53. wire CBs Safety Warning Signs FM Approved Available at no charge from Graco Must be ordered separately 180060 Warning Sign English Megohmmeter 241079 500 Volt output 0 01 2000 megohms Not for use in Hazardous areas T10377 38 307912 ES ON OFF Valve Conversion Kit 223976 Converts the ES ON OFF Valve to a constant on setting A ball valve is included for complete air shut off at the gun Push Pull Pattern Adjustment Valve 224883 Pattern adjustment valve that allows quick adjustment of the pattern width between two adjustable settings Four finger Trigger Conversion Kit 223054 FM Approved For converting from two finger trigger to four finger trigger Converting To A Waterborne System FM Approved Contact your Graco representative for information on converting Model PRO 3500sc spray gun to Model PRO 3500WB waterborne spray gun for use in a waterborne system Refer to Instruction Manual 308584 High Conductivity Gun Conversion Kit 223451 For converting PRO 3500sc gun to PRO 3500hc gun REFERENCE ONLY Not Included ae Ss INA ES Doo High Conductivity Hose Kit 223780 Installation of this kit enables the PRO 3500sc gun to apply fluids with a resistivity range of 2 0 megohm cm to infinity Technical Data Category oa Gun Weight 1 87 Ib 0 85 Kg Gun Length 9 5 in 240 mm Category Data Wetted Parts Stainless Steel Polyethylene Nylon Acetal PTFE Ultra High Molecular Weight

Graco Inc. 222300 Paint Sprayer User Manual

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