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Graco 222625 - page 1
308018 Rev . W 06615 NOTE: Any modification of genuine Graco parts or replacement of parts with non-Graco parts will void agency approvals. INSTRUCTIONS-P ARTS LIST INSTRUCTIONS This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. Model PRO 3500hc Electrostatic Air Spray Gun 65 kV , HIGH CONDUCTIVITY , MANUAL GU ...
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Graco 222625 - page 2
2 308018 ...
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Graco 222625 - page 3
308018 3 T able of Contents W arnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How the Electrostatic Air Spray Gun W orks 6 . . . . Converting a P ...
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Graco 222625 - page 4
4 308018 W ARNING 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. Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements stated in this instruction man ...
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Graco 222625 - page 5
308018 5 W ARNING 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 ...
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Graco 222625 - page 6
6 308018 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 turbine generates power , which is converted by the power cartridge, to supply high voltage current to the gun ’ s ionizing electrode. The pu ...
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Graco 222625 - page 7
308018 7 Converting a PRO 3500sc Gun to a PRO 3500hc Gun 06616 Fig. A A B F G H J K L M C D E 06618 Fig. B 10 12 06619 Fig. C 06617 G H J 28 D E F 10 12 12a 12b Fig. D L M ...
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Graco 222625 - page 8
8 308018 Installation KEY A Main Air Supply Line B* V entilation Fan Interlock Solenoid V alve C* Main Air Supply Shutoff V alve (bleed-type) D Air & Water Separator E* Pump Air Supply Shutoff V alve (bleed-type) F Air Line Lubricator G Air Pressure Regulator H Pump J* Pump Ground Wire K Fluid Filter L Fluid Supply Line Shutoff V alve M Fluid P ...
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Graco 222625 - page 9
308018 9 Installation Installing the System W ARNING 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 . Do not install or service this equip- ment unless you are trained and qualified. Be sure y ...
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Graco 222625 - page 10
10 308018 Installation Connect the Exhaust T ube 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 36. 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 ...
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Graco 222625 - page 11
308018 1 1 Installation Check the Electrical Grounding (See Fig. 2) W ARNING FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD Megohmmeter P/N 241079 (AA-see Fig. 2) is not approved for use in a hazard- ous area. T o reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless: The gun has been removed from the hazardou ...
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Graco 222625 - page 12
12 308018 Notes ...
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Graco 222625 - page 13
308018 13 Operation Pressure Relief Procedure W ARNING PRESSURIZED EQUIPMENT HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying acci- dentally . T o reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure ...
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Graco 222625 - page 14
14 308018 Operation 05151A Fig. 4 06615 20 1 26 45 43 31 DD Selecting a Fluid Nozzle and Air Cap W ARNING PRESSURIZED EQUIPMENT HAZARD T o reduce the risk of an injury , follow the Pressure Relief Procedure on page 13 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, ...
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Graco 222625 - page 15
308018 15 Operation Operating the Spray Gun (continued) 1. Follow the Operating Checklist on page 13. 2. T o 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. T ighten the retaining nut until the air cap is hel ...
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Graco 222625 - page 16
16 308018 Operation Shutdown W ARNING PRESSURIZED EQUIPMENT HAZARD T o reduce the risk of an injury , follow the Pressure Relief Procedure on page 13 whenever you stop spraying and whenever you are instructed to relieve pressure. 1. Relieve the pressure. 2. Flush and clean the equipment. Follow the instruc- tion in Maintenance . Maintenance Daily C ...
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Graco 222625 - page 17
308018 17 Maintenance Clean the Air Cap and Fluid Nozzle CAUTION Do not use metal tools to clean the air cap or spray tip holes as this could scratch them, and make sure the electrode wire is not damaged. Scratches in the air cap or spray tip or a damaged electrode wire can distort the spray pattern. Equipment needed: Soft bristle brush Com ...
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Graco 222625 - page 18
18 308018 T roubleshooting W ARNING ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly . Do not install or service this equipment unless you are trained and qualified. W ARNING PRESSURIZED EQUIPMENT HAZARD T o reduce t ...
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Graco 222625 - page 19
308018 19 T roubleshooting Gun Operation T roubleshooting Problem Cause Solution Fluid leakage from the fluid packing area The needle packings or shaft are worn. Replace the packings or shaft; see page 28. The packing nut is loose Tighten the packing nut; see page 28. Air leakage from the front of the gun The air valve is not seating properly . Cle ...
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Graco 222625 - page 20
20 308018 T roubleshooting Electrical T roubleshooting 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 poorly grounded. Clean the workpiece hangers ...
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Graco 222625 - page 21
308018 21 Electrical T ests 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 compo ...
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Graco 222625 - page 22
22 308018 Electrical T ests T est 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 T urbine Alternator Removal on page 30. Measure the resistance from the power supply ’ s ground contact point (EE) to the contact s ...
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Graco 222625 - page 23
308018 23 Electrical T ests T est 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 24. Check the resistance between the black resistor stud contact ring (D) and the needle contact ring (E). Refer to Fig. 10. Y ou may have to pre ...
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Graco 222625 - page 24
24 308018 Service Prepare the Gun for Service W ARNING ELECTRIC SHOCK HAZARD Installing and servicing this equipment requires access to parts that may cause 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. W ARNING PRESSURIZED EQUIPMENT HAZA ...
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Graco 222625 - page 25
308018 25 Service Air Cap/Nozzle/Resistor Stud Replacement (continued) 6. T rigger 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 barrel. 7. Install the air cap assembly (1, 2, 8). T est the gun resistance as instructed on page 21. 06449 Fig. 1 ...
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Graco 222625 - page 26
26 308018 Service Barrel Removal 1. Prepare the gun for service as instructed on page 24. 2. Carefully loosen the nut (14) from the bracket/fluid fitting (16). 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. ...
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Graco 222625 - page 27
308018 27 Service Fluid Packing Removal 1. Prepare the gun for service as instructed on page 24. 2. Remove the air cap assembly , fluid nozzle and resistor stud, and electrode as instructed on page 25. 3. Loosen the trigger screws (4) far enough to re- move the trigger (13). 4. Remove the packing cartridge and needle assem- bly (28), using the mult ...
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Graco 222625 - page 28
28 308018 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 ...
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Graco 222625 - page 29
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). See Fig. 18. 1. Prepare the gun for service as instructed on page 24. 2. ...
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Graco 222625 - page 30
30 308018 Service T urbine Alternator Replacement NOTE: Replace turbine bearings after 2,000 hours of operation. See your authorized Graco distributor . 1. Prepare the gun for service as instructed on page 24. 2. Remove the power cartridge from the gun handle as instructed on page 29. 3. Squeeze the two ends of the retaining ring (35) together and ...
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Graco 222625 - page 31
308018 31 Service Fan Air Adjustment V alve Repair 1. Prepare the gun for service as instructed on page 24. 2. Place a wrench on the 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. T o disassemble the fan valve: 3. Remove the retaining ring (4 ...
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Graco 222625 - page 32
32 308018 Service Fluid Adjustment Assembly Repair 1. Prepare the gun for service as instructed on page 24. 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45). See Fig. 21. 3. T urn the stem (45a) fully clockwise and remove the sleeve stop (45e). 4. T o completely disassemble the fluid adjustment assembly , the sleeve stop (4 ...
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Graco 222625 - page 33
308018 33 Service Air T rigger V alve Repair 1. Prepare the gun for service as instructed on page 24. 2. Using a 14 mm socket wrench, remove the fluid adjustment assembly (45), o-ring (23) and spring (44). See Fig. 21. CAUTION Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of co ...
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Graco 222625 - page 34
34 308018 Service ES ON-OFF V alve Repair 1. Prepare the gun for service as instructed on page 24. 2. Loosen the set screw (24) with the 2 mm hex key (69) provided. Remove the lever (26) from the valve. See Fig. 23. W ARNING MOVING P ARTS HAZARD T o reduce the risk of eye injury , be sure to wear safety glasses when removing or installing the retai ...
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Graco 222625 - page 35
308018 35 Service T ube and Shroud Removal/Replacement 1. Prepare the gun for service as instructed on page 24. 2. Remove the air cap, nozzle and resistor stud, and electrode as instructed on page 29. 3. Loosen the nut (14) and disconnect the fluid tube (12) from the bracket/fluid fitting (16). See the Parts Drawing on page 36. 4. Remove the trigge ...
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Graco 222625 - page 36
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 DET AIL A 28g 28b 28d 28e 28f 28c 28h 46 38 41* 28 Item 12 includes items 12a to 12e Item 18 includes items 18a to 18f ...
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Graco 222625 - page 37
308018 37 Parts W ARNING Some PRO 3500hc Gun replacement parts look similar to other PRO Gun parts but are not interchangeable! When servicing, do not mix or use other PRO Gun parts! Use of parts other than those specified in the parts list below could alter the grounding continuity of the gun, cause parts to leak or rupture, or cause the gun to ma ...
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Graco 222625 - page 38
38 308018 Parts Part No. 223451 Conversion Kit Kit must be purchased separately . Ref No. Part No. Description Qty Ref No. Part No. Description Qty 10 186102 SHROUD 1 12 223450 TUBE, fluid Includes items 12a – 12e 1 12a 1 1 1450 O-RING; fluoroelastomer 1 12b 1 10749 O-RING; fluoroelastomer 1 12c 1 10079 NUT , fluid tube 1 12d 1 10077 ...
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Graco 222625 - page 39
308018 39 Accessories Use Only Genuine Graco Parts and Accessories AIR LINE ACCESSORIES Conductive Air Supply Hose; black 100 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 (5 m) 218101 25 ft (8 m) 218102 36 ft (1 1 m) 21 ...
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Graco 222625 - page 40
40 308018 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 25 ft (8 m) 215638 50 ft (15 m) Fluid Hose Assemblies (Nylon) 500 psi (35 bar , 3.5 MPa) Maximum Working Pressure FM Appro ...
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Graco 222625 - page 41
308018 41 T echnical Data Category Data Gun Weight 1.89 lb (0.86 kg) Gun Length 9.5 in. (240 mm) Maximum Working Pressure 100 psi (7 bar , 0.7 MPa) Air Pressure Operating Range 0 – 100 psi (0 – 7 bar , 0 – 0.7 MPa) Fluid Pressure Operating Range 0 – 100 psi (0 – 7 bar , 0 – 0.7 MPa) V oltage Output 0 – 65 kV Paint Resistivity Range 3 ...
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Graco 222625 - page 42
42 308018 Notes ...
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Graco 222625 - page 43
308018 43 Notes ...
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Graco 222625 - page 44
44 308018 Graco Standard W arranty 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, extended , or limited warranty published by Graco, Graco will, for ...
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