Graco 307912G Model PRO 3500SC Owner's Manual

INSTRUCTIONS-PARTS LIST
307-912
GRACO
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
Rev. G
Supersedes
READ AND RETAIN FOR REFERENCE
Model PRO 3500%
Tu
MANUAL .ELECTROSTATIC
AIR SPRAY-GUN
100 psi (7 bar) MAXIMUM WORKING PRESSURE
U.S. PATENT NO. 4.290.091: 4.219.865: 4..497,447: 4,462,061: 4,660,774
Patented 1986, 1987 Canada
Brevete 1986.
~~~,1987
U.K. PATENT NO. 2.147.158: 2.142.5598: 2.140.327-8
Other U.S. and Foreign Patents Pending
Part No. 222-300 Air Spray Gun
With Two-Finger Trigger
Part No. 222-600 Air Spray Gun
With Four-Finger Trigger
Approved
@'
GRACO INC. P.O.
Part No. 222-300 shown
BOX 1441 MINNEAPOLIS, MN 55440-1441
0 COPYRIGHT 1989 GRACO INC.
E
2 307-912
,
Terms
sarer!
"
. . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . 3
Warnings . . . . . . . . , . . . . . . . . . . . . . . . . 4, 5
. . .
,.
Installation
Typical Installation ,
Warning Signs
.
Ventilate the Spray Booth
..
Connect the Air Line
Connect the Exhaust Tube .
..
Connect the Fluid Line
.
.
Check the Electrical Grounding
. . . . .. . . . . . . . . .. . . . .. .. 6
. . . . . . . . . . . . . . . . . . . .. . . . . . . 6
. .'.. . . . . . . . . . . . . . 7
.. .. . . . . . . . . . . .. . .. .. .. 7
. . . . .. . .. . . .. . . 7
. . . . . . . .. ...... ... . 7
. . .. . .. . . . . . .. 8
I
Operation
Filter the Fluid
Operating Checklist .
instail the Fluid Nozzle and Air Cap
Adjust the Spray Pattern
. . .. . . . . .. . . . . .. . . . . . .. . . .. . 9
. . . . . . . . .. . . . . . . . . . . . . . 9
. . . . . . . . . 11
. . . . . . . . . . . . . . . . . . 11
Maintenance
Daily Care and Cleaning
Clean the Air Cap and Fluid Nozzle
.
Flush the Spray Gun
. . . . . . . . .. . . . . . . . . . 12
. . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting
Spray Pattern Troubleshooting Chart..
Gun Operation Troubleshooting Chart
Electrical Troubleshooting Chart
. . . . . . . 14
. . . . . . . . 15
. .. . . . . . . . . . 16
Electrical Tests
Test Gun Resistance .
.
Test Power Supply Resistance
Test Resistor Stud Resistance
. . . . . . . . . . . . . . . . . . . . 17
. . . . . . . , . . . . . . 17
. . . . . . . , .'.. . . . 18
Service
Gun Disassembly .
. .
Air CaplNozzlelResistor Stud Replacement
Electrode Replacement
.
. ..
Barrel Removal
.
,
20,
Fluid PackingRemoval .
..
. .
Fluid Packing and Needle Repair
Power Cartridge Replacement ,
,
Turbine Alternator Replacement
. .
Fan Air Adjustment Valve Repair .
Air Trigger Valve Repair
. . .
ES On-Off Valve Repair
. . .
. . . . . . . . . . . . . . . . . . . . . 19
. . . 19
. . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . 21
. . . . .. . . . . . . . . . 22
. . . . :. . . . . . 22
. . . . . . . . . . . 23
. . . . . . . . . . 23
. . . . . . . . . . 24
. . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . .. 25
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . , . 26
Repair Kits ...............................
27
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parts List , . . . . . . . . . . , . . . . . . . . . . . . , . . . . . . . 29
Accessories . . . . . . . . . . . .... . . . . . . . . . . . . . 30, 31
Technical Data . . . . . . . . . . . . . . . . . . . . Back Cover
Warranty . . . . . . , . . . . . . . . . . . . . . . . . . . Back Cover
WARNING Alerts user to avoid or correct conditions
that could cause bodily harm.
CAUTION Alerts user to avoid or correct conditions
that could cause damage to or destruction
of equipment.
NOTE
Identifies essential procedures or helpful
information.
307-912
3
SERIOUS BODILY INJURY, EXPLOSION, FIRE,OR ELECTRIC SHOCKCAN OCCUR IF
THE PRECAUTIONS BELOW ARE NOT FOLLOWED.
READ AND UNDERSTAND ALL INSTRUCTION MANUALS, TAGS, AND WARNING
LABELS BEFORE OPERATING EQUIPMENT.
ELECTROSTATIC EQUIPMENT SHALL ONLY BE USED BY TRAINED, QUALIFIED
PERSONNEL WHO SHALL BE FULLY CONVERSANT WITH THE REQUIREMENTS
STATED WITHIN THIS INSTRUCTION MANUAL.
General Safety
Any misuse of the spray equipment or acoessories. such as
overpressurlzing. moditylngparts. using lncompatlblechemloais
and fluids, or uslng worn or damaged
parts, can cause themto
rupture and result In swrlous bodily Inlury.
flre. wxploslon or property damage.
Fluid Compatibility
NEVE~polntthespraygunatanyoneoratanypartofthebody.
NEVER put hand or fingers overthe spray nOZ2ie.
Pressure Relief Procedure
ALWAYS foilow thePressure Rellef Procedure, at rlght. before cieanlngor removing the fluid nozzle or servicing any system
equlpment.
NEVER try to stop or deflect leaks with your handor body.
NEVER alter or modify any part of thls equipment: doing
so could
cause It to malfunctton.
BE SURE ailfluids and solvents used are chemically compatible
with the 'Wetted parts" shown inthe TECHNICAL DATA on
the back ccVer' Always
read the fluid
and "Ivent
81'8
literature beforeusing the fluid or Solvent in this gun.
To reduce therlsk of serious bodily Injury. Including splashing In
the eyes or on the skin, Injury from moving parts or eiectrlc
shock. always followthis procedure When shutting off the SYStern. when checking Or 8ervbinB any Pa* of the Spray system.
when Instaiilng. cieanlng or changing
fluid nozzles, and whenever
YOU stop
. spraying.
. . .
1.
Turn the ES On-Off valve lever toOFF.
2.
Turn off the air and fiuld supplyto the gun.
container to
CHECK all spray equlpment regularly and repalr or replace worn 3.
or damaged parts hmedlately.
the gun Intoa grounded
relieve air and fluld pressure.
4.
S y s t e m Pressure
This gun hasa maxlmum working pressureof 100 psi (7 bar).
Never exceedthe maximum working pressure of the gun or any 5.
other component or accessory used Inthe system.
Open the pump drain valve. having a waste contalner ready
to catch thedralnage.
improper handilng of hazardous fiulds or Inhaling vapors can
Cause extremely serious bodliy Injury. even death, due to
splashing In the eyes. Ingestlon. tnhalatlon. or bodily oontamlnation. Know what fluid you are pumping andits specific hazards,
Store hazardous fluidsin approved contalners. Dispose ofany
Waste fluid according to all Local. State and Federal regulations
pertaining to the dlsposai of hazardous wastes.
observe all preCaUtiOnS whenhandilng knownor potentially hazardous flulds. Including. but not limited to, th# following.
TIGHTEN ail fluid connections securelybefore each use.
NEVERUseadamagedhose. Beforeeachuse. checktheentlre
hose for cuts, leak<. abrasion. bulging cover. or damage or
mOVEment of the hose couplings.If any of these conditlons exist. replace the hose immediately.
4 307-912
Leave the pump drain valve open until you are ready to
spray again.
1. Always wear appropriate, protectlve clothing and equlpment. such as eye protectlon, resplratory protection. and
pioves.
2. Provide for the safe plping and disposalOf all exhaust air.
3. P r o w proper ventilation In accordance withaccepted Industry standards and governmental regulations, Refer to
Ventilate the SprayBooth. on page 5.
HANDLE AND ROUTE HOSES CAREFULLY. DO not puli on
hoses to movw equipment. Do not use fluidsor solvents which
are not comoatlble withthe inner tube and cover of the hose.
.
To reduce the risk of flre, explosion, or electric shock. which
may result from electrlcal dlscharge, It 1s essential that:
All parts of the electrostatic systemare properly grounded.
Ail personnel in or close to the spray area are properly
grounded.
Ail electrlcally conductlveobjects ordevlces lnthe spray area,
Including palnt containers. wash cans and tools,
are properly
grounded.
6.
All persons entering thespray area: shoes must have conductive soles. such as leather. or personal groundlng
straps must beworn. Rubber or plastlc solesare notconductive. The operator mustnot wear gloves whlch insulate
the hand from the spray gun. The gloves must be conductive or modified as shownon page 9.
7.
The lloor of the spray area must be electrlcally conductive
and grounded.Do not cover the floor wlth cardboard or
any
non-conductive material whlch would Interrupt groundlng
continuity.
When operating the electrostatic device, any ungrounded ob8.
jects inthe spray area (suchas people. Contalners, tools,eto.)
can become electrically charged. Arclng mayoccur If these objects then come In contact or close to ground. Arcing of sufficlent energy levelscan ignite the fluid belng sprayed. fumes
from
9,
solvents. dust particles. and other flammable substances. This
can cause aflre or exploslon and result In serious bodily Injury
and property damage.
Flammable llqulds In the spray area must be kept in approved. grounded containers. Do not store morethan the
quantity needed for one shift.
All solvent palls: use only grounded
metal palls. whlch are
conductive. Do not place the pall on any non-conductlve
surface. such ascardboard orpaper. whlch would Interrupt
grounding continuity.
Statlc electrlclty can also be generated by the flow of fluid
through the pump, hose. gun, and nozzle. butIt Is disslpated
through proper groundlng as descrlbed
In Grounding below.
lines and electric cables must be properly
10 All air and fluid
grounded.
If you experlence any arclng or feel even a slight shock,
STOP
Flushing and Cleaning Safety
SPRAYING IMMEDIATELY. Check for proper grounding of
the entire system. Be sure you have corrected the Droblem
before starting to spray again.
To reduce therlsk of static sparklng or splashlng, always follow
the Pressure Relief Procedureon page4 before flushing.
Grounding
Be sure theES valve lever is OFF before flushing or
cleaning any part of the spray system.
The followlng are minlmum requlrementsfor grounding a basic
electrostatic system.Your system may Include other equipment
or cblects whlch must alsobe grounded. Always check your local
electrlcal codefor detailed grounding instructions.Be sure your
system Is connected to a true earth ground.
1.
Pump: ground by using a ground wire and clamp as described In your separate pump Instruction manual.
2.
A i r compressors and hydraullc power supplies: ground ac-
3.
Electrostatic A l r SprayGun: obtain groundlng through connection to a properly grounded
air supply hose.use only the
Graco Electrically Conductive Air Supply Hose: seeACCESSORIES sectionto order.Connect the air hose ground
wire to a true earthground.
4.
cording to the manufacturer's recommendatlons.
Object beingsprayed: keep the work plece hangers clean
and grounded at all times. Contact polnts must be sharp
polnts or knife edges.
5. All electrlcally conductive objects or devlces In the spray
area. Including palnt contalners and wash cans, mustbe
properly grounded.
Use the lowest possible pressure
to flush. Trigger thegun into a
grounded metal waste container.
. . . ....
. . ..
To flush orpurge equipment. ALWAYS use solvents with
aflash
point equal to or greater than that of the fluld being sprayed.
~
,
To clean the exterior01 the equipment. ALWAYS use solvents
wlth a flash point of higher than 1000
F (380 C).
ALWAYS remove all solvent from the system before reactivating
the spray gun.
Use only non-sparking toolsto clean residuefrom the booth and
hangers.
Ventilate the Spray Booth
To prevent hazardous concentratlons toxic
of and/or flammable
vapors, spray only In a properly ventllated spray booth.
Check and follow ail National. State and Local codes regarding
alr exhaust velocity requlrements. Check and follow all local
safety and fire codes and OSHA standard 19iO-I07(b)(5)(l).
NEVER operate the spray gun unless the ventilating fans are
operating.
IMPORTANT
United States Government safety standards have been adopted under the Occupatlonai Safety and Health
Act. These standards--particularly the General Standards, Part1910.107 and any other appropriate regulatlons--should be consulted in ccnnectlon wlth the hstallatlon, operation. and maintenance of electrostatlc spray palntlng equipment.
HOW THE ELECTROSTATIC AIR SPRAY
The air hose supplies air to t h e spray gun. Part of the
air operates the turbine
and the rest of t h e air atomizes
the fluid being sprayed. The turbine generates power,
which is converted by the power cartridge, to supply
high voltage current to t h e 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.
307-912
5
i
.
Power Supply MustBe Interlocked
With Spray Booth Exhaust Fan.
KEY
A
B
C
0
E
F
G
H
Main Air Supply Line
Ventilation Fan Interlock Solenoid Vshre
Main Air SupplyShutoffValve (bleed-type)
Air 8 Water Separator
Pump Air SupplyShutoff Valve (bleed-type)
Air Line Lubricator
Air Pressurn Regulator
Pump
Pump GroundW~ra
Fluid Fiiter
Fluid Supply Line ShutoffValve
M
Fluid Pressure Regulator
N
Fluid SupplyLine
0
Air Fiiter (20 micron)
P Air Supply Line
Shutoff Valve (bleed-type)
J
K
L
Q
R
S
T
U
V
W
X
Air Hose Ground Wire
Grounded Air SupplyHose
Electrostatic Spray Gun
Air Line DrainVahw
fluid Drain Vaive
Gun Air Inlet
Gun Fluld Inlet
Gun Exhaust Tube
m e Typical Installation shown aboveIs only aguide for
selecting andinstalling electrostatic air spray
Systems. It
is not an actual system design.The particular typeand
size system for your operation mustbe custom designed
for your needs. For assistance in designing a System,
contact your Graco representative.
WARNING
Installing and servicing this equipment requires access to parts which may cause electric shock
or other
serious bodily injury If work is not performed properly.
Do noilnslali or serviceihls equipment unlessyou
are trained andquallfled.
Warning Signs
Be sure your installation complies with National,
State andLocal codes for theinstallationof electrical
apparatus in a Class1, Group D, Divisions 1 and 2
Hazardous Location.
Mount warning signs in the spray area where they can
easily be seen and read by all operators. See the
ACCESSORIES section l o order.
6 307-912
Ventilate the Spray Booth
4.
WARNING
To prevent hazardous concentrations of toxic
and/or flammable vapors, spray onlyin a properly
ventilated spray booth.Never operate the spray
gun unless ventilation fansare operating.
WARNING
The bleed-type air shutoffvalve is required in your
system to relieve air trapped between this valve
and the pump after the air regulator is closed.
Trapped aircan cause thepump to cycle unexpectedly, which could result in serious bodily injury, including splashing in the eyes or on the skin and injury frommoving parts.
Check and follow all of the National, Stateand
Local codes regarding air exhaust velocity
requirements.
Check and follow all local safety and fire codes
and OSHA standard 1910-107(b)(5)(i).
NOTE' High velocity ai, exhaust will decrease the operating efficiency of the electrostatic system.Air
exhaust velocity of 100 fl/min.(31 linear meters/
minute) should De sufficient.
Connect theAir Line (Refer to the Typical
Installation Drawing)
Install a bleed-type air shutoff Valve (C.E, P) on the
main air line, thepump line, and each gun air supply
an
line to shut offairto the pump and/or gun@). Install
additional bleed-typevalve on each pump air supply
line to relieve air trapped between this valve
and the
pump after the air regulator is shut off.
5. Install an air line lubricator(F) as close to the pump
(H) as possible.
Connect theExhaust 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 26.
WARNING
To reduce the risk
of electric shockor other serious
Connect the Fluid Line (Refer to the Typical
bodily injury, the air supplyhose must be electriInstallation Drawing)
cally connected to a true earth ground. Use
Only
1. Before connecting thefluid line (N), blow it out with air
Graco Electrically Conductive
Air Supply Hose.
andflush itwith solvent. Usesoiventwhich iscornpatThis hose, andthe gun, havespecial threadswhich
ible with.the fluid to besprayed.
prevent using any other type of
hose with thegun.
See the ACCESSORiES section to order the hose.
2. Install afluid regulator (M)on thefluid line to control
fluid pressure to the gun.
1. Connect the air supply hose (R) between theair sup3. Install afluid filler (K)
and drain valve
(U) at the pump
ply line and thegun's air inlet
The gun aif inletfitoutlet.
ting has a left handthread. Connect the air supply
hose ground wireto a true earth ground.
WARNING
2. Install an airline filter (0)and an air
and water separaThe fluid drain valve (U) is required in your system
tor (D) on the air lineto ensure a dry, clean air supply
to assistin relievingfluid pressure in the displaceto thegun. Dirtand moisture can ruin the appearance
ment pump, hose and gun; triggering thegun to reto
of yourfinished workpiece and can cause the gun
lieve pressure may
not be sufficient. Install drain
a
malfunction. A combinationairfilterlmoistureseparavalve close to the pump's fluid outlet. The drain
tor is shown in the ACCESSORIES section.
valve reduces the risk
of property damageor serious bodily injury, including splashing in the eyes
3. Installa bleed-type air regulator(G) on the pump
and
or on the skinand contamination from hazardous
gun air supply lines to control air pressure to the
fluids.
pump andgun.
4.
Connect the fluid line to the 3/8-18.6(m) gun fluid
inlet 0 .
307-912
7
Check the Electrical Grounding (See Fig 1)
WARNING
Proper electrical grounding of every partof your
system is essential. For your safety, read the
warning section, FIRE
OR EXPLOSION HAZARD,
on page 5.Ground the system
as explained there.
Then check your system as explained
below.
1. Turn the ES ON-OFF Lever lo OFF (0). See the
Typical lnstallatlon drawing for thelocation of theES
ON-OFF lever.
2. Tum off the airand fluid supply to the gun.
3. Have a qualified electrician check the electrical
grounding continuityof the spraygun and air hose.
a. With the electrically conductive air hose connected (see Connect theAlr Llne, page 7)and
properly grounded,use a megohmmeter (shown
in ACCESSORIES section)to measuretheresislance between thegun handle and a true earth
ground. Use an applied voltage of 500 minimum
to 1000 volts maximum. See Fig 1.
b; If the resistance is greater than 2 megohms,
check the tightnessof the round connections,
and be sure the airsupply ose ground wire is
connected to a true earth ground.Ifthe resistance
is still greater than2 megohms, replace the air
supply hose.
9,
6 307-912
Flg 1
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including
splashing in the eyesor on the skin, injury from moving parts or electric shock,alwaysfoilowthisprocedure when shuttingoff the system,when chedcing
inor servicing any part of the spray system, when
stalling, cleaning or changing fluid nozzles, and
whenever you stop spraying.
1. Turn the ES ON-OFF Lever to OFF (0).
2. Turn off the air andfluid supply to the gun.
3. Trigger the gun into a grounded metal waste
Operating Checklist
Check thefollowing listdaily, before starting to operate
thesystem, to help ensure you of safe, efficient operation.
-1.
-2.
Be sure the system is thoroughly grounded.
See FIRE OR EXPLOSION HAZARD on page
5. and Check the Electrlcal Groundlng on
page 8.
-4.
Be sure the operator andall persons entering
the spray area are
properly grounded by wearing shoes with conductive soles or personal
grounding straps.
4. Open the pump drain valve, havinga waste
5. Leave the pump drain valve open until you are
ready to spray again.
Filter the Fluid
-5.
Filter thefluid lo remove coarse particles and sediment must
which could clog the spray nozzle.
-6.
3 In. (76 mm)
Square Cutout
Be sure ail operators are trained howto properly and completely relieve system pressure.
-3.
container to relieve fluid pressure.
container readyto catch the drainage.
Be sure all operators are properly trained to
safely operate an electrostatic air spray
system.
-7.
Operator mustnot wear gloves which insulate
the hand from the spray gun.If wom, gloves
be conductive or modified as shown in
Fig 2.
Be sureventilation fansare operating properly.
Be sure the workpiece hangersare clean and
grounded. Contact points must
be sharp points
or knife edges.
-8.
Be sure all refuse is removed from the spray
booth.
-9.
Be sure all flammable liquids in spray booth
are in approved, grounded containers.
-10. Be sureall conductive objectswithin20 fl(6 m)
of the gun are electrically grounded andthe
floorofthe spray areais electricallyconductive
and grounded.
Fig 2
307-912
9
.
:
... . .
.
ES Indicator
LiQht
Fluld Adjustment Screw
10 307-912
Install the Fluid Nozzle and
Air Cap
2. First, complete all the checks under the Operating
Checkllst on page 9. mentum the ES ON-OFF lever
to ON (1). When spraying, the ES indicator light
should glow,indicating the electrostatic charge.
I
1
I
To reduce the risk of serious bodily injury, including
solashina in the eves or on the skin or electric
s'hock, ;ways
foll6w the Pressure Relief Procedure on page9 before installing, or removing the
fluid nozzlelair cap assembly.
I
1. Choose the correctfluid nozzle and air cap combinaiion for your application. See Manual 307-803 to
select a fluid nozzle and air cap.
2. Be sure the ES ON-OFF Lever Is OFF (0).
3. Use an airpressure regulatorto adjust the degree of
.
4.
the inlet pressure below 40 psi, the optional air cap
COntfOl valve (See Fig 3) is supplied with the gun and
can be installed and used to limit the airthe
to air cap.
as described In Air Cap/Noule/Reslstor, Stud
Replacement on page 19.
Follow these stepsto establishthe Correct fluid flow and
airflow. DO NOTtum the ES ON-OFF leverto ON (1) yet:
1. Adjust the fluid flow bv usinQ the fluid Dressure
regulator installed in theiluid liiie.
A minimum of 2.8 bar (40 psi) air supply is requiredl o
ensure full voltage from thepower supply. The gun
may be operated at a lower air pressure/voitage
if required, but maylose some electrostaticwrap.
5. Iftheflowtotheaircapisstillexcessiveafterlowering .
3. Install the aircap and fluid nozzle into the gun barrel
Adjust the Spray Pattern
atomization. Always use the
lowest air pressurepossible for the most efficiency.
6.
Use the fanair control valve i o change the shape of
the sorav oattern. When increasino
- to~a wide.
- fiat
~ oattem,'it may be necessary to~increasethe supply of
fluid to the gun to maintain the same amount of
coverage over a large area.
~~
.
NOTE See the Spray Pattern Troubleshootlng Chart
on page 14 to correct spray pattern problems.
307-912
11
Daily Care and Cleaning
WARNING
To reduce the risk
of serious bodily injury, including
splashing in the eyes or on lhe skin or electic
shock, always follow the Pressure Rellef Procedure Warnlng on page 9 when shuttingoff the system, whenyou slop spraying and before checking,
servicing, installing,cleaning or changing any part
in lhe system.
CAUTION
Clean all parts with a non-conductive solvent,
compatible with the fluid being sprayed. Conduclive solvents cancause the gun to malfunction.
Methylene chloride is not recommended as a
flushing or cleaning solvent with this gun or any
other device with nylon components.
Immersing the gun
in solvent is not recommended
as a routinecleaning~method.Solvent lefl in the
gun passages could result in a poor quality paint
finish and may draw current
and reduce theelectrostatic effect.
1. Clean thefluid and airline filters daily.
2.
Clean theoutside of the gun daily with a soft cloth
dampened in a compatible solvent.
3. Clean the aircap and fluid nozzle daily, minimum.
Some applications require more frequent cleaning.
Replace thefluid nozzle and air
cap if they are damaged. See Clean theAir Cap and FluidNozzle.
4. Check the electrode wire. Straighten
if bent, and replace if broken or damaged. See Electrode Needle
Replacement.
5. Check all ofthework hangersforbuild-up of material:
clean them, If necessary.
Clean theAir Cap and Fluid Nozzle
CAUTION
Do not use metal tools toclean the aircap holes as
this may scratchthem, and make sure the electrode wireis not damaged. Scratches
in the aircap
holes or a damaged electrode wire
can distort the
spray pattern.
DO not use any Cleaning method whichmay al-
low solvent intothe gunair passages. Clogged
air passages cause poor atomization and excessive current demands. Point the gun down while
cleaning to prevent dirty solvent from running
back
into the air passages.
12 307-912
Equipment needed:
Sofl bristle brush (supplied).
Solvent compatible with fluid being sprayed.
Procedure:
1. Follow thePressure Rellef Procedure Warning on
page 9.
2. Remwe the aircap assembly.
3. With the front of the gunpointed down, clean the air
cap, fluid nozzle, and front of the gun,
using the soft
bristle brush and solvent. See Fig 4.
4.
Carefully reinstall air cap assembly. Avoid bending
the electrode. Tighten the retaininguntil
nutit is snug,
allowing the aircap to tum with resistance.
Flush the Spray Gun
I
WARNING
To reduce the riskof fire or explosion and serious
bodily Injury, theES ON-OFF lever mustbe OFF,(OJ
before flushing.
CAUTION
.
Metby/ene cblorlde Is not recommended as a
flushing or cleaning solvent with this gun or any
other device with nylon components.
-
1. Follow the Pressure Relief Procedure
Warnlna on
page 9.
2. Disconnect andplug the fluid line.
3. Connect the solventsupply to the gun.
4.
Flush the gun wlth solvent
until it is clean,
5. Follow the Pressure Relief Procedure Warnlng,
then disconnect the solvent supply.
6. Reconnect thefluid supply line.
7. Tum on the fluid and air supplies.
8. Trigger the gununtil it is clear of solvent.
307-912 13
-
..... ......
Installing and servicingthis equipment requires accessto parts which may cause
electric shock or other serious
bodily injury if the work
is not performed properly. Do not
instail or servicethis equipment unless you trained
are
and
qualified.
To reduce therisk of seriousbodily injury, including splashingfluid or solventin the eyesor on the skin,alwaysfoilow
Warning on page9 beforechecking. adjusting, cleaning orrepairing
thegun orany
the Pressure Relief Procedure
part of the system. Disconnect thefluid hose from the gun.
NOTE: Check all possible remedies in the Troubleshooting Charts before disassembling the
gun.
I
PROBLEM:
IMPROPER SPRAY
PATTERN
SOLUTION
CAUSE
Fluttering orspitting spray
Insufficientfluid supply.
.,
Loose fluid nozzle or damaoed
fluid nozzle taper seat.
Dirt betweenfluid nozzle, taper
seat and body.
I
I
0
,,!y'%"
&@:<:
..~,'W
&
&
Streaks
I
I
Adjust fluid regulator orfill fluid tank.
Tighten or replace fluid nozzle.
See page 11.
Clean. See page 12.
Loose or cracked coupler at
fluid inlet.
Tighten or repair,
Loose fluid tube in tank.
Tighten.
Fluid build-up on air cap;partially
clogged horn holes.Full air pressure from clean horn hole forces
fan pattern toward clogged end.
Clean withsoft implement or
submerge in suitable solvent and
wipe clean. See page 12.
Damaged fluid nozzle or air
cao holes.
Repiace damaged part.See
page 11.
Fluid build-up on the perimeter
of fluid nozzle orifice, orpartially
clogged fluid nozzle orifice
Remove obstruction. Neveruse
wire or hard instruments.
See
page 12.
Too high fan air pressure.
Reduce air pressure or adjust
fan
air adjusting valve.
Fluid too thin.
Regulate fluid viscosity.
Not enoughfluid pressure
Increase fluid pressure.
Low atomization air pressure
Increase air pressure.
Fluid too thick
Regulate fluid viscosity.
Too much fluid,
Reduce fluid flow. Reducefluid
pressure on pressure feed guns
and/or adjustfluid adjusting screw
until proper pattern
is obtained.
~
~~
Last coat offluid applied too wet.
Apply drier finish withmultiple
strokes.
Too much air pressure.
Use least air pressure necessary.
Insufficient air pressure
Increase air pressure.
Non-uniform spray pattern
Clean or replace air cap. See
page 12.
1
~~
PROBLEM
~~
Leakage from fluid
packing area.
~~
~~
SOLUTION
~
Loose packing nut.
Tighten. See page 22.
Wom needle packings or shaft.
Replace needle packings or shaft.
See Daae22.
~~~
Air leakage from front
of gun.
Excessive sprayfog.
No fluid sprays from gun.
Equipment covered
with fluid.
Dirty air cap.
Air valve not seating properly.
Clean, service.See page 24.
Air valve O-ring sticking.
Lubricate O-ring. See page 24.
Needle wornor damaged.
Replace needle.See page 22.
Worn fluid seat.
Replace fluid nozzle and/or
electrode. See page 20 and 22
Fluid packing too tight.
Lubricate and adjustpacking nut.
See page 22.
Loose resistor stud.
Tighten resistor stud.
See page 19.
Loose fluid nozzle.
Tighten fluid nozzle. See page 11.
Damaged resistorstud O-ring.
Replace O-ring. See page 19.
Insufficient air pressure.
Increase, use least air pressure
needed for good results.
Fluid poorly mixed or filtered.
Remix orrefilter fluid.
IrnoroDer thinnerbeina used.
Use DroDer thinner.
Too much air pressure.
Reduce,use leastair pressure
needed for good resulls.
Fluid thinnedtoo much.
Properly thin fluid.
Fluid low.
Check, add If necessary.
Damaged air cap.
Replace air cap. See page 11.
Dirty or clogged fluid nozzle.
Clean fluid nozzle. See page 12.
Damaged fluid nozzle.
Check, replacefluid nozzle.'
See page 11.
Exhaust air flow insufficient
ornot directed properly.
Check for properCFM, check
baffles and direction ofair flow.
Improper distance betweengun
and work piece.
Adjust distance to 8-12 in.
(203-305 mm).
Misalignment between aircap
and fluid nozzle.
Remove andclean air cap and fluid
nozzle asdescribed in Maintenance
Section under Clean the Air Cap
and Fluid Nozzle, then reinstall
them.
Or replace fluid nozzle andair cap.
Aligned
Mialigned
,307-91 2
15
PROBLEM
Poor wrap-around,
CAUSE
'ES ON-OFF lever in OFF (0) positior
Improper distance between gun
and workpiece.
Parts poorly grounded.
.
Clean hangers, check for proper
ground on conveyer or track.
Atomizing air pressure too high.
Reduce air pressure.
Fluid pressure too high.
Reduce fluid pressure.
Fluid viscosity.
Check supplier for proper fluid for
electrostatic spray.
Fluid resistivity too low.
Check fluid resistivity with paint
meter and probe.
Check if ES ON-OFF lever is ON (7),
Check air supplyto gun. Check for
dirt or moisture In turbine. See
page 23.
Faulty gun resistance.
Check gun resistance. See page 17.
Faulty resistor stud resistance.
Check resistor stud resistance.
See page 18.
Faulty power supply resistance.
Check power supply resistance.
See page 17.
Faulty needle electrode assembly,
Replace needle electrode assembly.
See page 20.
Fluid leaks from needle packing
and causes short.
Clean needle cavity, tighten or
replace packing. See page 22.
Operator not properly grounded
or is in contact with ungrounded
object.
Gun not properly grounded.
Workpiece not properly
grounded.
*ES indicator light not on
when gun is triggered.
16 307-912
Adjust spraying distance to
8-1 2 in. (203-305 mm)
Reduce within code limits.
'Faulty turbine alternator.
Operator getsmild
shock when touching
workpiece.
Turn lever to ON (7).
High booth exhaust velocity.
*Turbine alternatornot operating.
Operator getsmiid shock.
SOLUTION
Be sure plug is in place on back of
turbine alternator housing.Remove
and test turbine alternatcir.See
page 23.
Be sure floor is properly grounded.
Wear shoeswith conductive soles
and wear personal grounding straps.
Be sure operator is not in contact
with or carrying any metallic items
which could build UP electrical
charge. If worn, agiove must be
conductive or modified as shownon
page 9.
See Check theElectrical Grounding.
Clean workpiece hangers. Check
for proper groundon conveyor or
track.
..
m e performance ofthe spray gun is directly affectedby
the condition of the electrical components contained inside the gun. The electricaltests below can be usedto determine thecondition of the power supply
(18) and the resistor stud (22)as well as the continuity of the electrical
path between the components.
KEY
A
17
20
Megohmmeter
Airmting
Electrode
Use megohmmeter 218-979 (see ACCESSORIES) and
an applied voltage of 500voits tocomplete these electrical tests. Connect theleads as shown.
WARNING
of sparking,which could cause
fire or explosion and result in serious bodily in]ury,
DO NOT use the megohmmeter in the hazardous
area. Remove the gun from the hazardous area
before testing it.
Test Gun Resistance
NOTE: Check the resistancewilh the gun triggered and
with the trigger released.
Measure the resistance between the end of the electrode
(20) and the gun air
fitting (17). See Fig 5. The resistance
should be between 180 to 220 megohms. If the resistance
is outside thespecified range, go tothe next test.If the
resistance Is correct, refer to the Electrlcal
Troubleshootlng Chart on page 16 for other possible
causes of poor performance.
Test Power Supply Resistance
Remove thepower cartridge from the
gun handle (7).See
Power Cartrldge Replacement.
Remove the turbine alternator(37) from the power cartrldge. See Tkirblne Alternator Removal.
J
17
Fig 5
KEY
18 Power Supply
18c Contact Spring
EE Ground Contact Polnt
/
A
Measure the resistance from the power supply's ground
(1 8c) on the other
contact point (EE) io the contact spring
end of the power supply.See Fig 6.
The resistance shouldbe 157.5 to 192.5 megohms. Ifthe
resistance is outside the specified range, the power supply Is defective and must be replaced. If the resistance
of
the powersupply is correct, proceed to the nexl test.
If you still have problems, refer to the Electrlcal
Troubleshooting Chart forother possiblecauses of poor
peltomIanCe. or contact the nearest authorized service
agency.
EE
18C
I
18
Fig 6
307-912
17
Test Resistor Stud Resistance
insert a conductive rod
(B)intothe gun barrel (removedfor
the power supplytest) and againstthe metal contact
(C) in
the frontof the barrel. See Fig 7.
KEY
A
B
C
Megohmmeter
Conductive Rod
MetalConW
Electrode
20
Measure the resistance between the conductive
rod (B)
and the gun electrode
(20). The resistance shouldbe 22.5
to 27.5 megohms.If the resistanceis correct, referto the
Electrical Troubleshootlng Chart for other possible
causes of poor performance or contact the nearest
authorized setvice agency.
I
If the resistance is outside the specified range, remove
the resistor stud. See Air Cap/Noule/Resistor Stud
Replacement. Checkthe resistance between the resistor
(E). Refer to
stud spring(D) and the needle contact ring
Fig 8.
The resistance should be 22.5 to 27.5 megohms. If the
resistance is correct. make sure the metal contact (C)
in
the barrel and the needle contact wire
(E) are clean. If the
resistance is outside the specified range, the resistor
is
See
defective and the resistor stud (22) must be replaced.
Air Cap/Nozzle/Reslstor Stud Replacement.
\
B
c
Fig 7
KEY
D
E
'
Resistor Stud Spring
Needle Contact Ring
I
E
Fig 8
18 307-912
.D
Flush the gun as
described under Flush the Spray Gun in
the Operation Section. Follow the
Pressure Relief Procedure Warning on page 9. Disconnect the air and
fluid
line from the gun
with the wrench(70) suppIiedSee Fig 9.
Air CaplNoulelResistor Stud Replacement
I
Fig 9
21
Torque to
KEY
21
22
25
62
Fluid Nozzle
Resistor Stud
0-Ring
0 mm Hex Key
any paint or solventleft in the gun from entering the
of the
Remove the aircap assembly. Point the front end
gun up and squeeze the trigger
while removing the fluid
nozzlelresistor stud (21, 22) assembly with the nozzle
wrench (70). See Fig 9.
NOTE If the resistor stud remainsin the gun when the
fluid nozzle is removed, start the nozzle thread
onto thestud and pull the studout.
Using the 8 mm hex key (62) supplied, unscrew and
remove the resistor stud
(22). See Fig 10.
I
-DE+AIL
25
I
To install the resistor stud:
Lubricate theO-ring (25) with petroleumjelly and install it
(22).
on the resistor stud
Using the 8 mm hex key (62), install the resistor stud(22)
in the fluid nozzle (21). Tighten to 10 in-lb (1.12 Nom).
NOTE Make sure the electrode(20) is tightened properly, as shownin Fig 11, page 20.
Trigger the gunwhile installing the fluid nozzle (21) and
resistor stud(22) assembly with the nozzle wrench(70).
Tighten until the fluid nozzle seatsin the gun barrel.
Fig 10
L
Install theair cap assembly (1, 2, 8). Test the gun resistance as instructed onpage 17.
307-912
19
Electrode Replacement
Remove the air cap, nozzle and resistor stud as described in Air Cap/Nozzle/Reslstor Stud ReplaCenWnt.
Unscrew and remove the
fluid needlelelectrode (20) with
the electrodetool (64)provided. See Fig 11. If the needle
shafl turns,hold the needle shaft assembly
by placing a
screw driver blade into the slot on the shafl, near the
trigger.
CAUTION
Be careful notto damage the contact wire when
removing the electrode from the gun.
Hold the gun handle
(7)with one hand and
pull the barrel
(3)straight awayfrom the handle
to remove it. See Fig 13.
"_.._..
CAIlTlnN
To avoid damaging the power cartridge (la),
always pull the gunbarrel straight away. If necessary,gentlymovethegunbarrelfromsidetosideto
free it from the gun handle.
KEY
5
10
12
63
CapScrews
Fluid Fitting
Tube
Wrench
Apply low-strength (purple) Loctitem or equivalent thread
sealanttotheelectrodeandneedleshaftthreads.Referto
SERVICE NOTES, page 26. Install the new electrode
finger tight. DO NOT over tighten.
CAUTION
To avoid damaging theplastic threads or contact
wire, be very careful wheninstallingthe electrode.
Trigger the gunwhile installing the fluid nozzle and resistor stud assembly.Install the air cap assembly. Test the
gun resistance asinstructed on page17.
KEY
20
64
Electrode
Electrode Tool
Apply low-strength
(purple) Loctlte
KEY
3
7
18
Gun Banel
Gun Handle
Power CarMdge
Fig 11
Barrel Removal
Carefully loosen thenul from thefluid fitting (10).Puli the
tube (12)out ofthe fitting. Make sure both ferrules and the
nut stay with the tube. See
Fig 12.
Using the wrench(63) supplied, loosen the three socket
head cap screws (5).
20 307-912
Flg 13
KEY
3
5
7
10
Gun B m l
Cap Screws
Gun Handle
FiuidTube Fitting
18 Power Catttidge
188 Gasket
30 Spring
34 Gasket
Fig 14
307-912
21
Fluid Packing Removal
Remove the air cap assembly,
fluid nozzle and resistor
stud, and electrode as described under Electrode
Replacement.
Loosen the trigger screws(4) far enoughto remove the
trigger (13).
KEY
4
13
28
61
Trigger Screws
Trigger
Fluid PackinglNeedle Assembly
Driver
Use the 9 mm hex nut driver(61) to remove the packing
See Fig 15.
cartridge and needle assembly (28).
CAUTION
compatible with the
fluid beingused, suchasxylol
or mineral spirits. Use of conductive solvents can
cause the gunto malfunction.
Check all the parts for wear or damage and replace if
necessary.
Fluid Packing and NeedleRepair
The fluid packings and needie can
be replaced asindividual partsor as assemblies. The overall assemblyis preadjusted at the factory.
Iffhe parts are purchased separate/K assemble them as
instructed below and as shown
in Fig 16.
Place the packing nut (28c) and O-ring (289 onfluid
the
needle (26a). Fiats on the packing nut must
be facing toward thebackofthe fluid needle. Generousiyappiypetroleum jelly on thefluid needle, stoppingthe application a
minimum of 1 in. (25.4 mm) from theO-ring (28f).
Piacethe spacer(28h) on the fluid needle and generously
apply petroleumjelly on the.outside ofthe spacer.
Fig 15
Lubricate the O-ring (289) on
the outside of the packing
housing (28b).
Install the packing and needle assemblyinto the gun
barrel. Using the9 mm hex nut driver (61), tighten the
assembly until just snug, then check the drag on the
needle.
(30) is installed on the nut as shown
Make sure the spring
in Fig 16.
Place thefluid packing (28e), needle packing (286), and
housing (28b)on the fluid needle (28a) as shownin Fig 16.
Install the trigger(13) and tighten the trigger screws(4).
Tighten the packing nut
to 2 Ibs. (9 N) of drag force when
sliding the needle through the packing cartridge.
lnstaii the electrode, nozzle and resistor stud assembly
and the air cap assembly as described under
Electrode
Replacement.
Before installing the packing and needle assembly into
the gun barrel, make sure the internal surfaces of the
barrel are clean. Remove any residue with
sofla brush or
cloth.
KEY
28
Fluid PackinglNeedle Assembly
28a Fluid Needle28b Packing Housing
28c Packing Nut
28d Needle Packing
Fluid Packing
0-Ring
0-Ring
Spacer
Spring
28C
28e
281
28g
28h
30
Fig 16
22 307-912
28
26a
(Item 30 not included with
PackinglNeedleAssp)
30
KEY
F
3-wire Connector
7
Gun Handle
18 Power Supply
188 Gasket
18b 0-Ring
180 Compresslon Spring
35
37
37e
Retainer Ring
Anemator
0-Ring
37b Cushion
NOTE The power cartridge
consists of items 18,
Fig 17
, .
..'... ,~
,. .. . ..
Power Cartridge Replacement
Turbine Alternator Replacement
Remove thebarrel as described underBarrel Removal.
Squeeze thetwo ends of the retaining ring (35) together
and carefullypull the alternator(37) away from the power
supply until the connector(F) disengages. See Fig 17.
The power cartridgeconsists of the alternator (37), power
supply (18) and retaining ring (35). See Fig 17.
CAUTION
Be careful when handling the power cartridge to
Remove the power cartridge from the gun handle as
described.in Power Cartrldge Replacement.
r
Using an ohmmeter, test the
coil in the turbine alternator.
Measure the resistance between the two outer terminals
of the 3-wire connector(F). The resistance shouldbe 3 to
Grasp the power'cartridge with your hand. With a gentle5 ohms. If the reading varies from this value, replace the
alternator.
side to side motion,pull it free from the gun handle(7).
Then pull the power cartridge straight out of the handle.
Measure the resistance between each outer terminal
of the 3-wire connector and the turbine alternator
CAUTION
housing. The resistance should beinfinite. If the resisInspect the power cartridge cavity
in the handle for
is not infinite, replace thealternator.
tance
out the cavity with aclean,
dirt or moisture. Clean
dry ragif necessary.
Connect the 3-wire Connector
to the 3 prongs
in the power
supply.
Push
thealternator
onto
the
powersuppiy
until the
Lightly lubricate the O-rings (18b, 37a) on
the new
ring
engages
with
the
alternator.
retaining
All theo-rings
power cartridgewithpetroleurn jelly.
and the compression spring
(18c) mustbe in place
Installthe powercartridge in the gun handle as described
or the gunwill malfunction.
under Power Cartridge Replacement.
avoid damaging it.
Insert the new power
cartridge in the gun handle.Be sure
the gasket(18a) is in place.
Barrel
Installthe barrel on the handle as described under
Removal.
307-912
23
Air Trigger Valve Repair
Fan Air Adjustment Valve Repair
Place a wrench onthe fiats of the valve housing and
remove it from the handle.See Fig 18.
Using a screwdriver, remove cap
the (45), O-ring (23) and
spring (44). See Fig 19.
NOTE: The fan air valve (43) can be replaced as an
assembly or asindividual parts.
To disassemble the fanva/ve,
Remove the retaining ring (ab). Rotate the air adjusting
screw (43c)counterclockwise until it is disengagedfrom
the valve housing threads (436).
Pull the adjusting screw
out of the valve housing.
Clean all the parts and Inspectthem for
wear or damage. If
replacing the seal (43a), unscrew it clockwise and
remove it from the adjusting screw (43c).
Loosen theair valve packing nut(40) one full turn. R e
move theair valve shaft (39) with a
pliers.
CAUTION
When removing the air valve shaft
(39) be careful
not to damage theseat area.
(41, 23) for damage and replaceif
Check the
Apply medium grade thread sealant
to the small threads
on the end of the adjusting screw
(43c) andinstall a new petroleum
jelly lo
the
seal (43a) (lefthand thread).
Unscrew thepacking nut (40)to check the u-cup (42).Do
it is damaged.
When reassembling the fanair valve (43), lubricate the
not removethe u-cup
O-rings (43e) and theadjusting screw threads (43c) with
Installthe air valveshaft, with theO-ring (41), and spring
petroleum jelly.
(7). M the u-cup (42)
(44) into the back of the gun handle
the retaining ring (43b) is installed on the adjusting wasremoved,
installthe airvaive shaft (39) before installout of the valve
ing the u-cup. Installthe u-cup withits lips facing into the
(43c), back the adjusting
housing (436) until it bottoms out against the retaining gun
handle.
ring.
Install thecap (45), with the O-ring (23). Tighten the cap
ApplyPTFE paste to the threads of the valve housing with a Screw driver. Tighten the air valve packingnut (40)
it bottoms.
(436) and instail it in the handle. Torque the housingto
10-12in-lb (1.1-1.4 Nm).
43 Fan Air Valve Assy
43a Valve Seal
43b Retaining Ring
40
45
Packing Nut
430 0-Ring
41
10-12 in-lb
40,42
U-CUP (42) lips
lace into handle
Fig 1a
24 307-912
Fig 19
.. , .. . .
:
.
.
~
~
':.w
~
?
~
~ "::Fs<;.Lp..
~
~
~~
.............................
"
~
:~
..., :,~>;;*:.-*,=?>n
~
~,
SERVICE
.
~ ~ ~
~
ES ON-OFF Valve Repair
Loosen the set screw(24)with the 2 mm hex key (69)
provided. Remove the lever(26)from the valve. See
Fig 20.
WARNING
To reduce the riskof eye injury, BE SURE to wear
safely glasses when removing or installing the
retaining ring (47)as the retaining
ring could slip off
~
~~~~~~~~~~~~~~~~~~~~~~~~~~~
~ ~
~
~
~
j
."......i.<!:*,x,*x<.,.h.: ...
/._.v,.%h
.,..,..
,,.
24
26
32
36
38
46
47
SeiScrew
Lever
Spacer
0-Ring
vaiveBody
Regulator Disk
Retaining Ring
Use internal snapring pliers (see ACCESSORIES) to
remove the retaining ring (47)from the handle. Align the
(32)to
holes in the retainingring with the flat on the spacer
ease assemblyand disassembly,
Remove the valve body (38) from the handle; be careful
not to drop the regulatordisk (46)and spacer (32).
46
Bevelled
Clean and inspect.the parts for damage. Replace if-.
necessary. Lubricate the O-ring(36)with petroleum jelly.
side in
toward
valve (38)
Install the regulator disk (46)in the valve (38)with Its
bevelled side facing in toward the valve.
CAUTION
BESURE the regulatordisk (46)is installedcorrectly.
A missing or incorrectly installed regulator disc can
cause severe damage to the powersupply.
Install thevalve (38)with the regulator
disc (46)and O-ring
(36)into the gun handle. Install the spacer(32)on the
valve.
"
Fig 20
Install the retaining
ring (47)into the groovein the handle.
InStall the lever(26)and tighten theset screw (24).
307-912
25
26 307-912
REPAIR KITS
- . : . :.~~
~
. ~ ;~
~ :~~
~ ~ :~
: ~~.~.:. ,,~.~~:~~~~~~ :~: ~
:, :_: : ': ~
, ~~
: ~
, ~ ~.~~ ~ ~ ~
,.,.,.~~x..~Ax~.::*.;?:::.:.~::~..~,*?
_j
~
.,_#;**<E#$
Air Seal Repair Kit 223-021
?
~
Must be ordered separately. Includes:
Assembly Status
Changed
REF
222-300&
NO.
PART NO. DESCRIPTION
1 Ea
18b
19
23
34
185-134
106-555
106-555
110-099
185-113
37a 110-073
41 110-081
'
42 105-452
103-557
43e
QTY
GASKET, power supply
O-RING, Vitone
O-RING: Viton
O-RING,PTFE
GASKET, manifold; polyethylene
O-RING, Viton
O-RING, trigger valve;
Kalrez or Chernraz
U- PTFE
O-RING, Viton
1
2
1
1
1
1
1
2
PART NO.
DESCRIPTION
9
25
110-on
1 1 0-080
178-763
178-409
110-072
1 1 0-071
186-069
1 85-1 20
FERRULES, fluid tube
O-RING; KalreZQor Chernraz
PACKING, needle
PACKING, fluid
O-RING, Kalrez or Chernraz
O-RING, Kalrez or Chemraz
SPACER
SEAL,fluid
28d
28e
28f
289
28h
29
NEW
222-600
Part No.
Name
180-739
Air C ~ D
177-033
Air Cap
185-157
Nozzle
185-158
Nozzle
OLD
Gun NEW
~
Tube
12
ADDED
16
ADDED
ADDED
1
Tube
186-650
Bracket
74
111-006
Screw
75
186-649
Adapter
MISCELLANEOUS CHANGES:
Must be ordered separately. Includes:
NO.
-
OLD
1
Fluid Seal Repair Kit 223-020
REF
~
QTY
.Added thread sealant to the electrode and needle shaft
threads.
*Addedthe ES AlwaysOn Conversion Kit to the Accessories.
1
1
1
1
1
.
1
1
1
307-912 27
...
.
28 307-912
Part No. 222-300 Electrostatic Air SprayGun
With Two-Finger Trigger
Part No. 222-600 Electrostatic Air SprayGun
With Four-Finger Trigger
Includes items 1-75
REF
NO.
PART NO.
DESCRIPTION
REF
NO. PART NO.
1
1n-033
AIR CAP; See Manual 307-803for
available air caps
RING, retaining
BARREL. gun
SCREW,trimer
SCREW,
relieved; M5 x 0.8
HOOK
HANDLE, gun
NUT. air
FERRULES.
fluid tube
~.
FITTING, fluid tuba
TAG, warning (not shown)
TUBE, fluid
TRIGGER, 2 finger;
Model 222-300 only
TRIGGER, 4 finger
Model 222-600only
NUT, fluid tube
MUFFLER (flame arrestor)
BRACKET, 2 finger;
Model 222-300 only
BRACKET, 4 finger;
Model 222-300 only
FITTING, air
POWER CARTRIDGE
Includes items18a-1%
.GASKET, power supply
.O-RING. Vitone
SPRING, compression
.CUSHION, power supply
PAD
PAD
O-RING; Viton
NEEDLE, electrode
NOZZLE. fluid, See Manual307-803
for available nozzles
STUD, resistor
O-RING, PTFE
SET SCREW, lever; sch; M4 x 0.7
O-RING, Kalrezs or Chemraz
LEVER, ES valve
PLATE. identification
FLUID PACKING& NEEDLEASSY
Includes items 28a-28h
.NEEDLE. fluid
.HOUSING, packing
-NUT, packing
.PACKING. needle
.PACKING. fluid
.O-RING. Kalrez or Chemraz
.O-RING. Kalrez or Chemraz
.SPACER
SEAL, fluid
SPRING, compression
PLUG
SPACER, lever
Includes
items 1-73
2
176-930
3
222-314
4
185-095
5
185-096
6
185-097
7
222-666
8
185-098
'
9
110-077
10 110-078
11
179-791
12 185-100
222-670
€
222-671
l3
14 110-079
15 185-122
185-104
I
186-650
l6
17 185-105
18
222-333
18a" 185-134
18b**106-555
18c 110-098
1 8 6 185-141
188 185-099
18f
185-145
19*' 106-555
20
185-107
21
185-158
22 222-316
23** 110-099
24 110-083
25'
110-080
26 185-121
27
28 223-444
28a 223-024
28b 185-495
28C 185-488
286' 178-763
28e' 178-409
28f* 110-072
2 8 ~ * 110-071
28h' 186-069
29'
30
31t
32
185-120
185-111
185-079
185-119
cap:
cap
~
QN
1
33
185-112
35
36
37
185-114
110-084
222-319
34** 185-113
1
1
2
3
1
1
1
1
1
1
1
1
37a** 110-073
37b 185-124
38 185-118
39 222-320
40 185-115
41** 110-081
42.'
43
105-452
22-321
1
1
1
43a 181-383
43b 105-681
43c 185-089
434 185-090
43e** 103-557
44
185-116
45 185-117
46 107-107
47 110-082
49 223-334
50
185-935
51 110-625
61 110-087
1
62
1
1
1
1
1
1
1
1
1
2
110-088
1
63
64
65
66
67
68
69
1
1
70 185-965
71 180-060
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1 1
1
72
73
74
75
107-460
185-123
105-749
185-103
110-231
110-089
110-086
185-536
223-440
111-006
186-649
DESCRIPTION
QTY
ADAPTER, exhaust hose
GASKET, manifold; polyethylene
RING, retainer, alternator
O-RING, Kalrez or Chemraz
ALTERNATOR, turbine
Includes items37a & 37b
-O-RING, Viton
.CUSHION
VALVE, electrostatic
SHAFT ASSY.. air valve
NUT, packing
O-RING, trigger valve;
Kalrez or Chemraz
U-CUP, PTFE
VALVE ASSY, fan air
Includes items 43a-43~
.SEAL, valve
.RING, retaining
.SCREW, adjustine
.HOUSING. valve
.O-RING. Viton
SPRING, compression, air valve
CAF: air valve
REGULATOR, disc
RING, retaining
SCREW, fluid adjustment
NUT, fluid adjustment
SPRING
TOOL, driver, hexnut; 9 mm
(not shown)
TOOL, allen wrench; 8 mm
(not shown)
WRENCH, barrel (not shown)
WRENCH, electrode (not shown)
BRUSH, cleaning (not shown)
TUBE, exhaust; polyurethane
CLAMF: exhaust tube
WRAP. sniral
TOOL, hex key,allen wrench: 2 mm
(not shown)
WRENCH, nozzle (not shown)
SIGN, warning, English (not shown)
See Accessories for additional signs,
available at no charge
COVER. gun (mtshown)
SEAL, fluid inlet
SCREW, cap; 10-32x 0.25"
ADAPTER, fluid
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
1
1
1
1
1
*Included in FluldSeal Repair Kit
223-020.
"included In Air Seal RepairKit 223-021
toptional AirRestrictor Valve 222-322 is includedwith the gun.
1
WARNING
When servicing use only genuine Graco replacement parts. Use of other parts or any modification
of the guncould alter the grounding continuity of
the gunor cause partsto rupture and result in serious injury, fire, explosion or property damage.
307-912 29
Accessories must be purchased separately.
Use only GENUINE GRACO PARTS AND ACCESSORIES.
~
~~~~
..-.......-
~~~
NEVER operate your equipment
at aworking pressure rating that
is higher than the lowest rated component
in your
to withstand the pressure developed
by the pump andmay
system. Lower rated components may not be able
ruoture. causina serious bodilv iniurv or DroDertv damaae.
I
The accessories in the box, below, are approved by Factory Mutual.
~~
SAFETY WARNING SIGNS
bailable at no charge from
Must be ordered separately.
180-060 Warning Sign
180-061 Warning Sign
180-062 Warning Sign
180-063 Warning Sign
~~~
Graco.
(English)
(French)
(German)
(Spanish)
FOUR-FINGER TRIGGER CONVERSION
KIT 223-054
For converting from two-finger triggerto fourfinger trigger.
GROUNDED AIR SUPPLY HOSE
100 psi (7 bar) MAXIMUM WORKING PRESSURE
0.315 in. (8 mm) ID; 1/4npsm(fbe);
Color coded black
220-444
218-100
218-101
216-102
218-103
220-119
220-120
4 ft (1.2rn)
15 ft (5 rn)
25 ft (8 m)
36 ft ( 1 1 rn)
50 ft (15 rn)
75 ft (23 rn)
100 ft (30.5rn)
AIR LINE ACCESSORIES
GROUNDED AIR SUPPLY HOSE
100 psi (7 bar) MAXIMUM WORKING PRESSURE
0.315in. (8 rnm) ID;1/4npsm(fbe);
Color coded gray; More ilexlble than black hose
223-068 4 ft (1.2 m)
223-069
223-070
223-071
223-072
223-073
223-074
15 ft (5 rn)
25 ft (8 rn)
36 ft (11 rn)
50 ft (15 rn)
75 ft (23 rn)
100 ft (30.5rn)
QUICK DISCONNECT COUPLING ASSY. 110-805
Includes a quick disconnect coupling insert, which
replaces air inlet fitting 185-105. and a shut-off coupling body (left hand thread), which connects to the
grounded air hose.
30 307-912
FLUID HOSE ASSEMBLIES (Nylon)
14 bar (225 psi) MAXIMUM WORKING PRESSURE
0.25 in. (6.35mm) ID, 3/8npsm(fbe)
215-637
215-6.38
215-639
215-640
215-641
25 ft (8 rn)
50 ft (15 rn)
75 ft (23 rn)
100 ft (30.5rn)
150 ft (46 m)
FLUID HOSE ASSEMBLIES (Nylon)
35 bar (500 psi) MAXIMUM WORKiNGPRESSURE
0.25 in. (6.35mm) ID, 3/8npsm(fbe)
216-076 25 ft (8 rn)
216-077 50 ft (15 m)
216-078 75 ft (23 rn)
216-079 100 ft (30 rn)
216-080 150 ft (46 rn)
CONVERTING TO A WATER-BASE SYSTEM
Contact your Graco representative for informationor
converting Model PRO 3500SC spray gun to Model
PRO 3500WB water-base spraygun, for use in a waterbase system. Referto Instruction Manual307-978.
HIGH VOLUME AIR REGULATOR 206-199
0-125 psi (0-9 bar) Regulated Pressure
200 psi (14 bar) Steel Pressure Gauge
t/2 npt(f) inlet and outlet
AIR FILTER & MOISTURE
SEPARATOR 106-148
250 psi (17.5 bar) MAXIMUM WORKING PRESSURE
For cleaning and dryingair in air spray
system. 20 micron element, 5 oz. bowl
capacity, 318 npt(f) inlet and outlet
AIR ADAPTER NIPPLE 185-493
For connecting two or more grounded gun air supply
hoses. 114 npt x 114 npsm (left hand)
FILTER (AIR OR PAINT) 202-271
750 psi (52 bar) MAXIMUM WORKING PRESSURE
With 60 mesh (250 micron) element,
318 npt(f) inlet,' 3/8 npt(mj outlet
SPRAY SYSTEM ACCESSORIES
ELECTROSTATIC SYSTEM223-1 06
Includes:
Electrostatic Air Spray Gun
222-300
223-070
Grounded Air Hose: 25 ft (8 m)
216-076
Fluid Hose: 25 ft (8 m)
106-148
Air Filter
ELECTROSTATIC SYSTEM223-027
Includes:
222-300
Electrostatic Air Spray Gun
223-070
Grounded Air Hose; 25 f t (8 m)
206-1 99 Air Regulator withGauge
106-149
Air Filter
158-491
Nipple
158-21 2 Bushing
164-672
Adapter
ELECTROSTATIC SYSTEM223-028
includes:
222-300
Electrostatic Air Spray Gun
223-071
Grounded Air Hose: 36 ft ( 1 1 m)
206-199
Air Regulator with Gauge
106-149
Air Filter
158-491
Nipple
158-212
Bushing
164-672
Adapter
ELECTROSTATIC SYSTEM223-029
Includes:
222-300
Electrostatic Air Spray Gun
223-072
Grounded Air Hose: 50 ft (15 m)
206-199
Air Regulator with Gauge
106-1 49 Air Filter
158-491
Nipple
158-212 .Bushing
164-672
Adapter
MISCELLANEOUS
ACCESSORIES
.~
PAINT RESISTANCE METER 722-886
Used with 722-880 Paint Probe to measure resistance
of paint. Not for use in'Hazardous areas.
PAINT PROBE 722-860
Used with 722-886 Paint Resistance Meter to
measure resistance of paint. Not for use in
Hazardous areas.
MEGOHMMETER 218-979
500 Volt output: 0.01-2000 megohms.
Not for use In Hazardous areas.
HIGH CONDUCTIVIN GUN CONVERSION
KIT 223-451
For converting the PRO 3500SC gun to the PRO
3500HC gun.
REFERENCE ONLY
AIR RESTRICTOR VALVE 222-322
Allows air cap air to be restricted without losing
alternator power.
GUN COVER 185-536
Order Part No.223-161 for package of 10.
SNAP RING PLIERS 110-090
For removing the ES ON-OFF Valve Retaining Ring
(item 47 in Parts List).
ES ALWAYS ON CONVERSION KIT 223-976
Converts the gun'sES ON/OFFvalve to a constantON
setting, ensuring that an electrostatic charge will be
present whenever the gun is triggered.
307-912
31
High Molecular Weight PolyethylWeight .........................
1.87 Ib (0.85 Kg)
ene. Ceramic. Chemrazm
9.5 in. (240 mm)
Gun
Lenoth .....................
.
MaximuiWorking Pressure . . . . . . . . . . 100 psi (7 barj
Air Pressure Operating Range
0-100 psi (0-7 bar) Tefionm,
and Kalrezm areregistered trademarksof
the
Co.
Fluid Pressure Operating Range. . 0-100 psi (0-7 bar)
0-65 Kv
Loctitem is a registered trademark of the LOctite
bitage output..........................
Paint Resistivity Range. . . . . . 1 megohm cm to infinity
Corporation,
Air Inlet ........................
1/4 npsm(m)
. . L.H.
Chemrazmis a registered trademarkofthe Green, Tween
Fluid inlet ..........................
3/8 npsrn(m)
and COmpany.
Wetted Parts . . . . . . Stainless Steel, Polyethylene, NyIon, Acetal, PTFE Kairezm, Ultra
~~~
~~~
~~
~
WARRANTY
Graco warrantsall equipment manufactured by
it and bearingits name to be free from defectsin material
use.
and workmanship on the date of by
sale
an authorized Graco distributor
to the original purchaser for
As purchaser's sole remedy for breach
of this warranty, Gracowill, for a period of twelve monthstwo
or
thousand hours of operation from time
of sale, repair or replace any part of the equipment proven defective. However,anydeficiencyinthe internal powersupply and aiternator (excluding turbine
bearings)will
be repaired or reDlaCed for thirty six months or six thousand hours of operation time
from of sale.This
warranty applies'only whenthe equipment is installed, operated and maintainedin accordance with
Graco's written recommendations.
Thiswarrantydoes notcover, and Graco shall
notbe liablefor, any malfunction, damage orwear caused
by faulty instaliation. misapplication, abrasion, corrosion, inadequate or improper maintenance,
negligence, accident. tampering,or substitution of non-Graco component parts. Nor shall Graco
be liablefor
malfunction, damageor wearcaused by the
incompatibilitywlth Graco equipment of 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 claimedto be defective to an
is verified, Gracowill reDair
authorized Gracodistributorforverificationof the claim.Ifthe claimed defect
or replace free of charge any defective parts.
The equipment will be returned to theoriginal purchaser
transportation prepaid. If inspection
of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs
of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
THETERMSOFTHISWARRANNCONSTITUTEPURCHASER'SSOLEANDEXCLUSIVEREMEDYANDAREIN
LIEUOFANYOTHERWARRANTIES(EXPRESSORIMPLIED).INCLUDINGWARRANTYOFMERCHANTABlLlTY
ORWARRANTYOFFlTNESSFORAPARTlCUIARPURPOSE,ANDOFANY NON-CONTRACTUALLIABILITIES.
lNCLUDlNGPRODUCTLIABILITIES,~BASEDON
NEGLIGENCEORSTRICTLIABILITY EVERY FORM OFLIABILI T Y FOR DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND
DENIED. IN NO CASE SHALL GRACO'S LIABILITYEXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY
ACTION FOR BREACH OF WARRANTY MUST BE BROUGHTWITHIN TWO (2) YEARS OF THE DATEOF SALE.
EQUIPMENT NOT COVEREDBY GRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIESOF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECTTO ACCESSORIES, EQUIPMENT, MATERIALS,
OR
COMPONENTS SOLDBUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured
by
Graco (such as
electric motor, switches, hose,etc.) are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance
in making any claim for breach
of these
warranties.
Factory Branches: Atlanta, Chicago, Dallas, Detroit,LOS Angeles, West Caidwell (N.J.)
SubSldiary and Affiliate Companies: Canada; England; Switzerland; France; Germany;
Hang Kong; J~~~~
GRACO INC. PO.BOX 1441 MINNEAPOLIS, MN 55440-1441
PRINTED IN U S A .
307-912 1/89
Revised 9/90