Graco Fusion Solvent Purge Gun Manual, 310648K

Graco Fusion Solvent Purge Gun Manual, 310648K
Instructions-Parts
310648K
EN
Solvent Purge Plural Component Gun
For use with non-flammable foam and polyurea. For professional use
only. Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
248597, Series A
Solvent Purge Manual Spray Gun
248647, Series B
Machine Mount Spray Valve with Manual Solvent Purge
248603, Series A
Standard Mechanical Purge Conversion Kit
3500 psi (24.2 MPa, 242 bar) Maximum Fluid Working Pressure
80-130 psi (0.55-0.9 MPa, 5.5-9.1 bar) Air Inlet Pressure Range
200°F (94°C) Maximum Fluid Temperature
3500 psi (24.2 MPa, 242 bar) Maximum Solvent Working Pressure
TI5006c
US Patent No. D479305, 7694893
Korean Patent No. 338185
Australian Patent No. 152610, 2003301667
ROC Patent No. I288661
Chinese Patent No ZL200380101833
Japanese Patent No. 4331721
TI4965b
II 2 G
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Keep A and B Components Separate . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loss of Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . 8
Conversion Kit 248603 . . . . . . . . . . . . . . . . . . . . . . 9
Mounting an Automatic Gun . . . . . . . . . . . . . . . . 11
Mounting to a rod . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting to a stationary support robotic arm . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecting Airline and Accessories . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hand Drilling of Mix Modules . . . . . . . . . . . . . . . . 14
To balance pressure and flow at the mix gun . . 14
Check Valve Filter Option . . . . . . . . . . . . . . . . . 14
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flushing with Solvent Purge Assembly . . . . . . . 16
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shutdown for More than a Day . . . . . . . . . . . . . 17
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 18
Optional Configurations . . . . . . . . . . . . . . . . . . . . 20
Optional Fluid Manifold Position . . . . . . . . . . . . 20
Optional Hose Position . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 22
Keep Gun Clean . . . . . . . . . . . . . . . . . . . . . . . . 22
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Weekly to Monthly . . . . . . . . . . . . . . . . . . . . . . . 22
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 23
Clean Air Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Fluid Manifold . . . . . . . . . . . . . . . . . . . . . 23
Clean Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Slip-Fit Polycarballoy Mix Module . . . . . . 24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 28
Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassemble Front End . . . . . . . . . . . . . . . . . . . 30
Reassemble Front End . . . . . . . . . . . . . . . . . . . 32
Slip-Fit Polycarballoy Mix Module . . . . . . . . . . . 34
Rear Rod Seal . . . . . . . . . . . . . . . . . . . . . . . . . 36
2
Adjust Rear Rod Seal . . . . . . . . . . . . . . . . . . . . 37
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Piston and Purge Rod . . . . . . . . . . . . . . . . . . . . 39
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . 41
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Solvent Purge Assembly . . . . . . . . . . . . . . . . . . 42
Static Mixer Assembly . . . . . . . . . . . . . . . . . . . . 43
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
248597 and 248647 Solvent Purge Plural
Component
Spray Guns, and 248603 Conversion Kit . . 45
248597 Solvent Purge Manual Spray Gun . . . . 46
248597 Solvent Purge Manual Spray Gun . . . . 47
248647 Machine Mount Spray Valve
with Manual Solvent Purge . . . . . . . . . . . . . 48
248647 Machine Mount Spray Valve
with Manual Solvent Purge . . . . . . . . . . . . . 49
Slip-Fit Polycarballoy Mix Module Kits . . . . . . . . 50
Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Gun Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Valve Filter Screen Kits (10 per kit) . . . . 53
Drill Bit Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Model 248647 Mounting Dimensions . . . . . . . . . . 54
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56
310648K
Manual Conventions
Manual Conventions
Warning
Caution
CAUTION
WARNING
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
A warning alerts you to possible serious injury or
death if you do not follow instructions.
Note
A note indicates additional helpful information.
Symbols, such as fluid injection (shown), alert you to a
specific hazard and direct you to read the indicated
hazard warnings on pages 4-5.
310648K
Component Labels
Depending on chemistry and material manufacturer,
individual fluid components have different labels. Sometimes (A) is the ISO or hardener. Sometimes (A) is the
RESIN or filled side. For the purpose of these valves
and this manual, (A) refers to the ISO, or hardener,
which will most often be the minor volume side. (B)
refers to the RESIN side, which normally contains the
fillers and is the major volume side.
3
Warning
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes,
burns, and hearing loss. This equipment includes but is not limited to:
•
Protective eyewear
•
Clothing and respirator as recommended by the fluid and solvent manufacturer
•
Gloves
•
Hearing protection.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•
Read Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using.
•
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•
Use equipment only in well ventilated area.
•
Eliminate all ignition sources, such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
•
Keep the work area free of debris, including solvent, rags, and gasoline.
•
Ground equipment and conductive objects. See Grounding, page 7.
•
Hold gun firmly to side of grounded pail when triggering into pail.
•
Use only grounded hoses.
•
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•
Keep a fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
4
•
Do not point the gun at anyone or at any part of the body.
•
Do not put your hand over the spray tip.
•
Do not stop or deflect leaks with your hand, body, glove, or rag.
•
Do not “blow back” fluid; this is not an air spray system.
•
Follow Pressure Relief Procedure, page 18, when you stop spraying and before cleaning, checking, or servicing equipment.
•
Use lowest possible pressure when flushing, priming, or troubleshooting.
•
Engage piston safety lock when not spraying.
•
Tighten all fluid connections before operating the equipment.
•
Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose.
310648K
Warning
WARNING
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
•
For professional use only.
•
Use equipment only for its intended purpose. Call your Graco distributor for information.
•
Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
•
Check equipment daily. Repair or replace worn or damaged parts immediately.
•
Do not alter or modify equipment. Use only Graco parts and accessories.
•
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
•
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•
Do not kink or overbend hoses or use hoses to pull equipment.
•
Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
310648K
5
Overall View
Overall View
K
F
L
P
C
D
T
M
W
R
N
H
V
X
G
Y
B
A
S
U
E
J
TI4966b
Key:
A
B
C
D
E
F
G
H
J
K
L
M
6
A Side Fluid Valve (ISO)
B Side Fluid Valve (RESIN)
Air Cap
Air Line Quick Coupler
Muffler
Fluid Housing
Gun Fluid Manifold
Handle
Optional Air Inlet
Cleanoff Air Valve
Piston Safety Lock
Solvent Purge Assembly
N
P
R
S
T
U
V
W
X
Y
Optional Fluid Inlets (A Side Shown)
Lock Ring
Fluid Inlet Swivels (A Side Shown)
Trigger
Gun Air Whip Hose
Air Valve
Solvent Purge Valve
Static Mixer
RAC tip
Solvent Fluid Inlet
310648K
Isocyanate Hazard
Isocyanate Hazard
Grounding
WARNING
Spraying materials containing isocyanates creates
potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Read warnings, page 4.
Check your local electrical code and proportioner manual for detailed grounding instructions.
Solvent line must be Graco approved grounded hose.
Primary ground is through the grounded solvent supply
hose.
Ensure that solvent supply pump is properly grounded.
Ensure continuity from the spray tip to grounded solvent
hose when using static mixers and tips other than supplied with gun.
Keep A and B
Components
Separate
CAUTION
To prevent cross-contamination of the gun’s wetted
parts, do not interchange A component (isocyanate)
and B component (resin) parts. The gun is shipped
with the A side on the left. The fluid manifold, fluid
housing, and check valve cartridge are marked on the
A side. The fluid housing is marked with RES on the
opposite side.
310648K
7
Piston Safety Lock
Piston Safety Lock
Loss of Air Pressure
Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.
In event of loss of air pressure while gun is triggered,
gun will continue to spray. To shut off gun, do one of the
following:
•
WARNING
Push hard or hit end of safety lock, to engage piston
safety lock.
Read warnings, page 4.
To engage piston safety lock: push knob in and turn
clockwise. When engaged, piston safety lock allows
some purge rod movement but shuts off fluid flow and
gun cannot spray.
TI5003a
•
Close fluid valves A and B.
TI3850a
To disengage piston safety lock: push knob in and
turn counterclockwise until it pops out.
TI4967b
TI3849a
8
310648K
Conversion Kit 248603
Conversion Kit 248603
A Standard Mechanical Purge Gun can be converted
into a Solvent Purge Gun with this kit.
7.
Liberally lubricate piston o-rings. Install spacer (61)
onto piston assembly. Reinstall piston. Shaft is
keyed for proper assembly. Push firmly to seat piston. Rotate piston/purge rod assembly clockwise
with nut driver until piston is fully seated.
1.
Relieve pressure. See manual 309856.
2.
Flush Gun, page 23.
3.
Disassemble front end of gun. Refer to manual
61
309856.
TI4988a
4.
Disassemble the piston and purge rod assembly
from the gun, see Piston and Purge Rod in manual 309856.
5.
Spacer (61) is optional. For more forward travel of
piston, remove spacer.
Remove purge rod (31) from assembly and place
8.
spacer (62) onto purge rod.
Install piston safety lock assembly until bottomed
out.
62
31
61
TI3847a
TI4989a
9.
6.
Reassemble purge rod and piston assembly until
Reassemble the fluid housing onto the front end of
the gun. See Reassemble Front End, page 32,
steps 1 through 6.
positive stop on purge rod spacer (62).
310648K
9
Conversion Kit 248603
10
310648K
Mounting an Automatic Gun
Mounting an Automatic Gun
Mounting to a rod
Mounting to a stationary
support robotic arm
1.
To mount gun to stationary support or robot arm, see
mounting hole dimensions, page 54.
To mount the gun on a 1/2 in. diameter rod, insert
the bar (A) through the hole in the gun body as
shown.
Two .128 in.
alignment
pin holes
P
I
Two 1/4 20 unc
holes
O
ti5007b
ti4751b
Four M5 x .08 in. (6.3 mm) holes
2.
I - Activation
P - Purge/Clean-off
O - Deactivation
Secure the gun to the bar by tightening 1/4 in. - 20
mounting screws.
Connecting Airline and Accessories
1.
On the gun air supply line, install an air pressure
regulator.
•
•
A minimum of 80 psi (0.55 MPA, 5.5 bar) air
pressure must be supplied to the gun for proper
operation.
A four-way air valve, which exhausts cylinder air
in both directions, is required.
3.
On the main air line, install a bleed-type air shutoff
valve.
Clean off air
Gun
actuation
I
P
2.
On the gun air supply line, install a bleed-type air
shutoff valve downstream of the gun air regulator.
Three 1/8 npt
ports (air
inlet)
O
Gun
deactuation
ti4751b
I - Activation
P - Purge/Clean-off
O - Deactivation
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11
Setup
Setup
1.
Read Hand Drilling of Mix Modules, page 14,
5.
Engage piston safety lock (L), page 8.
before performing setup procedure.
L
2.
Assemble gaskets (40c), static mixer assembly
(40), o-ring (40d), adapter (41), and RAC tip and
guard (9, 63) assembly to fluid housing on front
end of gun.
40, 40d
41
6.
40c
Connect gun air whip hose (T) and air valve (U) to
main air hose. Attach fluid manifold (G) to gun.
9, 63
•
TI3850a
Y
V
TI5033b
T
Solvent purge knob (V) and inlet (Y) can be
rotated in any direction.
G
U
TI4968b
3.
Close fluid valves A and B.
To change position of fluid manifold or use
optional fluid inlets, see pages 20 and 21.
7.
Connect air line to quick coupler (D). Turn on air.
Open air valve (U). Air valve (K) should be screwed
tight. There is no clean off air to adjust on the solvent purge gun.
TI2411A
K
4.
Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold (G).
B (RESIN)
G
D U
TI4969b
J
TI2417A
A (ISO)
12
To use optional air inlet (J), see page 21.
310648K
Setup
8.
To adjust purge rod position, follow piston and
12.
Disengage piston safety lock (L), page 8.
purge rod disassembly instruction on page 39.
L
9.
Attach Graco approved grounded fluid supply hose
to solvent inlet (Y).
Make sure solvent purge valve (V) is closed before
pressurizing the solvent hose.
TI3849a
13.
Y
Turn RAC tip (X) to spray position.
TI5004b
V
X
To avoid getting mixed coating material in the solvent purge valve and line.
•
•
•
•
•
10.
14.
Pressurize the solvent line before triggering the gun.
Have an adequate solvent supply before
spraying.
Keep air purged out of solvent hose.
Install an accessory check valve at purge
valve inlet.
Never trigger gun with solvent valve open.
TI5096b
Test spray onto cardboard. Adjust pressure,
temperature, or orifice size to get desired
results. If applying materials that are greater
than 1:1 ratio, follow the instructions for increasing orifice size, see Drilling of Mix Modules,
page 14.
Turn on proportioner.
TI3861a
11.
Open B (RESIN) fluid valve. Then open A (ISO)
fluid valve.
15.
Apply layer of lubricant over front of gun and
lock ring, or use gun cover to prevent overspray
buildup and ease disassembly.
16.
Gun is ready to spray.
B
A
310648K
TI4970b
13
Hand Drilling of Mix Modules
Hand Drilling of Mix Modules
To balance pressure and
flow at the mix gun
4.
Graco only makes 1:1 ratio mix modules. When applying
a material that is different than 1:1 it is necessary to
modify the mix module to allow more material through
the larger part side.
Polycarballoy Mix Module cross section.
Locate the larger part side (typically the B [RES]
port at rear of Polycarballoy Mix Module).
NOTE: View is not to scale.
The actual size of the orifice required is dependent on
many factors such as material viscosity, shear, ratio tip
size, etc. For example, a 2:1 material by volume does
not necessarily require the diameter on the larger part
side to be doubled.
A(ISO)
Check Valve Filter Option
See Check Valve Filter Screens, page 53. Gun is
shipped with 80 mesh filters on both the A and B check
valves. 40 mesh (quantity 2) and 60 mesh (quantity 2)
filters are included with the gun. For wider ratio materials it is advisable to decrease the filter size on the larger
part side to decrease pressure drop.
TI3876a
B (RES)
Mix Module
XF1313
Tools required
•
Assorted Drill Bit Kit 119386
•
Pin Vise 117661
Two XF1313 Polycarbolloy mix modules are
included with the gun. Additional mix modules are
available, see page 50.
5.
Open up resin porting to raise ISO pressure. Starting with the smallest drill bit size, drill into port. For
drill bit sizes, see Drill Bit Table, page 15.
B (RES)
117661
Pin Vise
Larger Modules XF3535, XF4747, XF5757 are
available but not included with gun.
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
3.
Remove Polycarballoy Mix Module, see page 34.
14
TI3862a
310648K
Hand Drilling of Mix Modules
Module Port
When drilling, be careful not to allow bit to come
in contact with ID of mix module.
The largest drill size that can be used on the
XF1313 mix module is #56. To get more flow,
order a larger mix module: XF3535, XF4747,
XF5757
A
B
Drill Bit Table
Drill Bit Sizes
# size
6.
Reassemble gun, page 34.
7.
Check pressure gauges. A (ISO) and B (RES)
gauges should balance at the required pressure,
flow, and temperature operation points.
8.
If ISO gauge still reads lower than the RESIN,
repeat steps 1 through 7. Use the next drill bit size
for drilling the B (RES) port on the mix module.
9.
If you get the system pressure balanced but do not
have enough flow at the gun, drilling port A (ISO)
may be necessary. Drill port A (ISO) out to next
size. Repeat steps 1 through 8 to bring the pressure gauges back into balance.
A (ISO)
10.
Drill Bit Size
81
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
58
56
Diameter (in.)
0.013
0.0135
0.0145
0.016
0.018
0.02
0.021
0.0225
0.024
0.025
0.026
0.028
0.0292
0.031
0.032
0.033
0.035
0.036
0.037
0.038
0.039
0.04
0.042
0.0465
Diameter (mm)
0.33
0.34
0.37
0.41
0.46
0.51
0.53
0.57
0.61
0.64
0.66
0.71
0.74
0.79
0.81
0.84
0.89
0.92
0.94
0.97
0.99
1.02
1.07
1.18
TI3863a
Repeat drilling until system pressures are balanced.
11.
After system pressures are balanced, record the
final drill bit sizes for each port in the chart
below. Use this information when it is time to
replace the Polycarballoy Mix Module.
310648K
15
Operation
Operation
Spraying
1.
2.
Turn RAC tip (X) to clean position.
To spray, turn RAC tip (X) to spray position.
TI5097b
X
X
TI5096b
3.
2.
Hold gun into a grounded metal pail, holding a
metal part of fluid manifold firmly to side of pail.
Close solvent purge knob (V).
4.
Open the solvent purge knob (V) to introduce solvent to the static mixer assembly.
V
3.
TI5004b
Trigger gun to spray.
WARNING
V
5.
TI5110b
When static mixer and tip are clean, close solvent
purge knob (V).
Read warnings page, 4.
Flushing with Solvent Purge
Assembly
1.
16
Detrigger the gun and engage safety lock.
V
TI5004b
•
For more thorough static mixer cleaning,
remove the spray tip.
•
Minimize the amount of flushing time. Do not
atomize solvent.
310648K
Shutdown
Shutdown
Daily Shutdown
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
Shutdown for More than a
Day
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
310648K
17
Pressure Relief Procedure
Pressure Relief Procedure
4.
WARNING
Turn RAC tip (X) to clean position.
Read warnings, page 4. Relieve pressure before
cleaning or repairing gun.
1.
X
Engage piston safety lock (L), page 8.
L
5.
TI5097b
Trigger gun onto cardboard or into waste container
to relieve pressure.
TI3850a
Air supply is required for gun actuation. Do not
disconnect gun air supply until fluid pressure is
relieved.
2.
TI5009a
Close fluid valves A and B. Leave air valve (U)
open.
B
U
A
3.
TI5005b
Disengage piston safety lock (L), page 8.
L
TI3849a
18
310648K
Pressure Relief Procedure
6.
Engage piston safety lock (L), page 8.
L
TI3850a
WARNING
If fluid in the hose and proportioner is still under pressure, follow the Pressure Relief Procedure in the proportioner manual.
To relieve pressure in the hose after the gun is
removed, place the fluid manifold over containers, facing away from you. Very carefully open the fluid valves.
Under high pressure, fluid will spray sideways from the
fluid ports.
TI2484A
7.
Flush static mixer and tip, see Flushing with Solvent Purge Assembly, page 16.
8.
Shut off air to solvent supply. Open solvent purge
knob (V) and relieve pressure in the solvent line.
V
310648K
TI5110b
19
Optional Configurations
Optional Configurations
Optional Fluid Manifold
Position
3.
Unscrew lock ring (P) until front end of gun is
loose.
Fluid manifold is mounted to bottom of gun, with A side
on left, viewed from operator’s position at back of gun. If
desired, manifold may be moved to top of gun. Doing
this will reposition A side parts (fluid inlet, check valve,
and fluid housing A side) to right.
CAUTION
To prevent cross-contamination of gun’s wetted parts,
do not interchange A component (isocyanate) and B
component (resin) parts.
1.
Follow Pressure Relief Procedure, page 18.
2.
Disconnect air (D) and remove fluid manifold (G).
4.
Rotate fluid housing (F) 180° and retighten lock
ring very securely.
5.
Attach fluid manifold. Connect air. Return gun to
service.
P
F
G
D
TI4968b
20
310648K
Optional Configurations
Optional Hose Position
4.
Apply thread sealant to plugs (Z), elbows (AA), and
male threads of swivels (R). Install elbows (V) in
optional inlets (N), facing down. Install swivels (A,
B) in elbows. Be sure to install A swivel (smaller) in
A side. Install plugs (Z) where swivels had been.
Torque all parts to 235-245 in-lb (26.6-27.7 N•m).
Fluid inlet swivels and air quick disconnect fitting point to
rear. If desired, these positions can be changed so
hoses travel downward.
Fluid Hoses
Z
CAUTION
To prevent cross-contamination of gun’s wetted parts,
do not interchange A component (ISO) and B component (RESIN) parts.
AA
R
N
1.
R
TI2646A
Follow Pressure Relief Procedure, page 18. Also
relieve system pressure and flush both fluid hoses,
see proportioner manual.
5.
Connect appropriate hoses to A and B swivels.
Air Hose
2.
Disconnect air (D) and remove fluid manifold (G).
1.
Remove fitting (D) and plug (J). Reverse positions.
Apply thread sealant and torque to 125-135 in-lb
(14-15 N•m).
D
G
D
G
TI4968b
TI4965b
3.
J
Disconnect fluid hoses from inlet swivels (A, B).
Remove swivels. Remove plugs from optional
inlets (N).
2.
Attach fluid manifold (G). Connect air. Return gun
to service.
B
A
N
310648K
TI2417A
21
Maintenance
Maintenance
Supplied Tool Kit
•
Hex Nut Driver; 5/16
•
Screwdriver; 1/8 blade
•
#81, 60, 58, and 56 drill bits.
•
117661 Pin Vise; dual reversible chucks
3.
Clean Muffler, page 23.
4.
Clean Fluid Manifold, page 23.
5.
Clean Slip-Fit Polycarballoy Mix Module, page
24.
Reversible
Reversible
•
TI3864a
Drill Bit Kit 119386.
Daily
Follow Shutdown, page 17.
Keep Gun Clean
Weekly to Monthly
Keep gun clean with accessory gun cover 244915.
1.
Applying a light coat of lubricant will make cleaning easier. Lubricate threads and outside of lock ring (11) to
ease disassembly. Use Fusion Gun Lubricant 118665.
screens.
2.
As Needed
1.
Clean Outside of Gun, page 23.
2.
Clean Air Cap, page 23.
22
Clean Check Valves, page 38. Check o-rings and
Check that piston safety lock threaded connection
is tight, page 41.
310648K
Maintenance
Flush Gun
Clean Air Cap
If it is necessary to flush the mix module, use following
procedure.
Soak air cap in compatible solvent. If necessary, clean
gently with stiff brush.
WARNING
Read warnings, page 4.
Clean Spray Tip
Clean spray tip with a solvent soaked brush. Clean front
of tip frequently to reduce fluid build up. Clean tip and tip
guard at the end of each work day.
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush with a compatible solvent.
A partially plugged muffler will slow gun actuation.
Remove and clean muffler with compatible solvent.
3.
Flush into a grounded metal pail, holding a metal
Clean Fluid Manifold
part of fluid manifold firmly to side of pail. Use the
lowest possible fluid pressure when flushing.
Solvent Flush Kits 248139 and 248229 are available as accessories.
Clean Muffler
Clean fluid manifold sealing faces with compatible solvent and a brush whenever removed from gun. Be sure
to clean the two fluid ports (AB) in the top mating surface. Do not damage the flat sealing surfaces. Cover
with Fusion Lubricant 118665 if left exposed, to seal out
moisture.
Clean Outside of Gun
AB
Wipe off outside of gun with compatible solvent.
CAUTION
Use N Methyl Pyrrolidone (NMP), Dynasolve CU-6,
Dzolv, or equivalent to soften cured material when
cleaning the outside of gun. Do not use as flushing
solvents.
TI2411-1
Clean Mixer
The center mix element can be pressed out, front to
back, even if fully cured. The mix element can then be
cleaned with a wire brush.
310648K
23
Maintenance
Clean Slip-Fit Polycarballoy
Mix Module
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
TI3863a
3.
Remove mix module, page 34.
FIG. 1. Cleaning Component A (ISO) Ports
CAUTION
To avoid damaging mix module, do not force drill bits
when cleaning impingement ports. Some ports are
offset or angled.
4.
See FIG. 1 and FIG. 2. Clean mix module impingement ports (IP) with appropriate size drill (supplied). See identification chart under Drill Bit Kits,
page 51. See the recorded drill bit size from step
11 page 15.
TI3862a
FIG. 2. Cleaning Component B (Resin) Ports
5.
24
•
Component B (RES) impingement ports, at
rear of mix module, are angled toward front of
gun. See FIG. 2.
•
When cleaning do not scratch the sealing
edges and ports.
Reassemble, page 34.
310648K
Maintenance
310648K
25
Troubleshooting
Troubleshooting
1.
Follow Pressure Relief Procedure, page 18,
before checking or repairing gun.
2.
Check all possible problems and causes before
disassembling gun.
CAUTION
To prevent cross-contamination of the gun’s wetted
parts, do not interchange A component (isocyanate)
and B component (resin) parts.
PROBLEM
CAUSE
Gun does not fully actuate when trig- Piston safety lock engaged.
gered.
Purge rod will not actuate.
Pressure imbalance.
Disengage piston safety lock, page 8.
Plugged muffler (22).
Clean, page 23.
Damaged air valve o-rings (24).
Replace, page 41.
Fluid does not spray when gun is fully Closed fluid valves (12b).
actuated.
Gun actuates slowly or with delayed
action.
SOLUTION
Open.
Plugged impingement ports.
Clean, page 24.
Plugged check valves (36).
Clean, page 38.
Plugged muffler (22).
Clean, page 23.
Damaged piston o-rings (16, 19).
Replace, page 39.
Dirty air valve, or damaged o-rings
(24).
Clean air valve or replace o-rings,
page 41.
Mix module nut (25) too tight.
Loosen nut, then retighten, page 33.
Loose lock ring (11).
Tighten, use tool if necessaryConversion Kit 248603, page 9.
No air pressure.
Connect air supply.
Low air pressure.
Set air pressure above 80 psi (0.56
MPa, 5.6 bar).
Buildup on purge rod (31).
Clean purge rod.
Plugged impingement ports.
Clean, page 24. Reinstall mix module, page 34.
Plugged check valves (36).
Clean, page 38.
Viscosities not equal.
Adjust temperature to compensate.
See Drilling of Mix Modules, page 14.
Ratio not equal.
26
See Drilling of Mix Modules, page 14.
310648K
Troubleshooting
PROBLEM
CAUSE
SOLUTION
Fluid does not shut off when fluid
valves are closed.
Damaged fluid valves (12b).
Replace.
Air leakage around fluid housing.
Damaged or missing o-ring (20).
Replace.
Air leakage from piston safety lock.
Damaged or missing o-rings (18).
Replace, page 39.
Burst of air from muffler when gun is
triggered.
Normal.
No action required.
Steady air leakage from muffler.
Damaged air valve o-rings (24).
Replace, page 41.
Damaged piston o-rings (16, 19).
Replace, page 39.
Air leakage from front air valve.
Damaged air valve o-rings (24).
Replace, page 41.
Component B (resin) leak from fluid
housing.
Worn rear rod seal.
Adjust Rear Rod Seal, page 37.
Cross Contamination of A and B
components.
Worn out mix module.
Replace.
Sealing surface OD not clean.
Clean sealing surface on fluid housing.
Air leakage from holes on solvent
purge assembly.
Cleanoff air valve open.
Close cleanoff air valve tightly. Cleanoff air valve should never be open
when using solvent purge gun.
Fluid leakage from holes on solvent
purge assembly.
Mix module nut is only handtight.
Tighten mix module nut 1/12 with
wrench.
310648K
27
Troubleshooting
Theory of Operation
Gun Triggered (Fluid Spraying)
Purge rod (31) moves back, opening impingement ports
(IP). Components A and B combine in mix module (39).
Fluid mixes in static mixer chamber (40) and sprays
from RAC tip (9).
KEY
Fluid
31
IP
40
39
9
ti5099
Gun Detriggered (Mechanical and Solvent Purging)
Purge rod (31) moves forward, closing impingement
ports (IP) and shutting off fluid flow. Rod pushes through
mix module (39), forcing out excess fluid and restoring
proper orifice diameter. Solvent purge knob (28f) is
opened, allowing solvent to flush out static mixer (40)
and tip (9).
KEY
Fluid
IP
31
28f
40
39
28
9
ti5098
310648K
Troubleshooting
Cutaway View
61
31
21
48
62
3
18
44
28
40
63
36
19
39
14
25
16
20
9
24
22
12b
310648K
TI4992b
29
Repair
Repair
Tools Required
3.
purge assembly (28).
Tools needed for complete gun repair:
•
•
•
•
•
•
•
adjustable wrench
flat head screwdriver (included)
channel-lock pliers (2 pair)
5/16 hex nut driver (included)
o-ring pick
medium-strength Loctite®
solvent or alcohol
Lubrication
Remove RAC tip (9), static mixer (40) and solvent
40
28
9
TI5002b
4.
Remove mix module nut (25), using a wrench.
Remove front seal (46).
Liberally lubricate all o-rings, seals, and threads with
Fusion Gun Lubricant, 118665. Lubricate threads and
outside of lock ring (11).
25
46
Disassemble Front End
TI4986a
WARNING
Read warnings, page 4. Proper attachment of front
end is critical. Do not operate gun if front end is loose
or lock ring is not snug against handle.
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
30
310648K
Repair
5.
Remove mix module (39).
39
Ti3846a
CAUTION
If lock ring (11) is stuck due to material buildup, do not
force it by turning entire front end. Locating tabs (Z)
may break off. Soak front of gun in solvent to soften
cured material and free lock ring.
CAUTION
To prevent damage to purge rod (31), always pull front
end straight off handle (1).
6.
Unscrew lock ring (11) to remove front end and mix
module. Pull front end straight off handle.
Z
11
31
TI3865b
310648K
31
Repair
Reassemble Front End
1.
Check that o-rings (20, 21) are in position. Liberally
lubricate o-rings, threads of lock ring (11) and handle (1), and outside of lock ring.
CAUTION
To prevent damage to purge rod (31), always slide
front end straight onto purge rod.
3.
Carefully slide front end straight onto purge rod
(31). Screw lock ring (11) onto handle (1) as far as
possible by hand. Push on front end to ensure it is
properly seated. Continue screwing lock ring onto
handle until tightened very securely. When properly assembled, lock ring is snug against handle.
11
21
1
2.
11
7
TI3871a
Orient front end as required for desired fluid manifold mounting (bottom mounting shown). Align
slots (Y) to engage tabs (Z).
31
Y
TI3866a
20
4.
Push mix module (39) onto rod (31) as far as possible.
TI3871a
31
39
7
Z
TI3845a
TI3873a
32
310648K
Repair
CAUTION
Do not overtighten mix module nut (25). Overtightening can deform impingement holes and cause slow
gun actuation.
6.
Reinstall solvent purge assembly (28). Lubricate
all threads. Install static mixer (40) and RAC tip (9).
Tighten with wrench.
40
5.
28
9
Lubricate all threads and reassemble mix module
nut (25) fingertight. Tighten additional 1/12 turn
with wrench. Install front seal (46) on rod (31).
TI5002b
1/12 Turn
25
46
31
310648K
TI4986a
33
Repair
Slip-Fit Polycarballoy Mix
Module
6.
Disengage piston safety lock (L), page 8. Trigger
and detrigger gun once to release mix module (39)
from fluid housing (7). Remove mix module.
Engage piston safety lock.
See page 50 for available Slip-Fit Polycarballoy Mix
Module sizes.
11
L
39
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
3.
Remove fluid manifold (G). Leave air connected.
7
TI3845a
If mix module (39) does not protrude from fluid
housing (7), slightly loosen then retighten lock
ring (11), to allow gripping of edge for removal.
7.
sible.
G
TI4972b
4.
Push mix module (39) onto rod (31) as far as pos-
31
39
Remove RAC tip and guard (9, 63), static mixer
(40), and solvent purge assembly (28).
7
9, 63
40
28
TI3845a
TI5032b
5.
Remove mix module nut (25), using a wrench.
Remove front seal (46).
25
46
TI3843a
34
310648K
Repair
CAUTION
Do not overtighten mix module nut (25). Overtightening can deform impingement holes and cause slow
gun actuation.
9.
Reinstall solvent purge assembly (28). Lubricate
all threads. Install static mixer (40) and RAC tip
and guard (9, 63). Tighten with wrench.
9, 63
8.
40
28
Lubricate all threads and reassemble mix module
nut (25) fingertight. Tighten additional 1/12 turn
with wrench. Install front seal (46) on rod (31).
1/12 Turn
25
TI5032b
10.
Attach fluid manifold. Return gun to service.
46
TI4986a
310648K
35
Repair
Rear Rod Seal
7.
Reassemble new rear seal (46) in rear rod seal nut
(23). Lubricate threads and install in fluid housing
(7) with nut driver.
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
8.
Reassemble Front End, page 32.
3.
Remove fluid manifold (G). Leave air connected.
9.
Attach fluid manifold. Connect air. Return gun to
service.
G
TI4972b
4.
Disassemble Front End, page 30.
5.
Remove rear rod seal nut (23) with nut driver (53).
23
53
TI3869a
6.
Push out rear seal (46) with screwdriver (54).
54
46
TI3872a
36
310648K
Repair
Adjust Rear Rod Seal
1.
Follow Pressure Relief Procedure, page 18.
6.
Remove fluid housing (7) from rod (31).
2.
Flush Gun, page 23.
7.
Reassemble Front End, page 32.
3.
Remove fluid manifold (G). Leave air connected.
8.
Attach fluid manifold. Return gun to service.
G
TI4972b
4.
Disassemble Front End, page 30.
5.
Assemble fluid housing (7) backwards onto lubricated purge rod (31). Adjust rear rod seal nut (23)
with nut driver until drag is felt when sliding on rod.
7
31
23
TI3831a
310648K
37
Repair
Check Valves
WARNING
Before disassembling, press on ball (36c) to test
check valve for proper movement and spring
action.
1.
Read warnings, page 4. Damaged check valve o-rings
(36f, 36g) may result in external leakage. Replace
o-rings if any damage is seen.
Follow Pressure Relief Procedure, page 18.
5.
2.
Slide filter (36d) off. Clean and inspect parts. Thoroughly inspect o-rings (36f, 36g). If necessary,
remove screw (36b) and disassemble check valve.
Flush Gun, page 23.
B
3.
Disconnect air (D) and remove fluid manifold (G).
A
Clean and inspect check valve mating surfaces
and fluid ports.
36
G
36e
36c
36d
36g
36a
36f
TI4987a
D
TI4968b
CAUTION
To prevent cross-contamination of the check valves,
do not interchange A component and B component
parts. The A component check valve is marked with
an A.
4.
36b
Pry out check valves (36) at notch.
Check valve filters are available, see Check Valve
Filter Option page 14.
6.
Reassemble check valves. Screw (36b) should be
flush (within 1/16 in. or 1.5 mm) of housing (36a)
surface. Liberally lubricate o-rings (36f, 36g) and
carefully reinstall in fluid housing.
7.
Attach fluid manifold. Connect air. Return gun to
service.
38
310648K
Repair
Piston and Purge Rod
6.
ton o-ring (16) and shaft o-ring (19).
Spacer (61) is optional. For more forward travel of
piston, remove spacer. Using spacer (61) eliminates “spitting” when gun is closed. Removing
spacer (61) allows purge rod to travel further for
more efficient purging.
1.
Pull purge rod to remove piston (32). Inspect pis-
32
Follow Pressure Relief Procedure, page 18.
16
19
2.
Flush Gun, page 23.
3.
Disconnect air (D) and remove fluid manifold (G).
TI4988a
7.
Inspect purge rod (31) for scratches or damage.
Unscrew rod from piston with nut driver. Inspect
o-ring (18). Liberally lubricate with Fusion Gun
Lubricant. To reassemble, thread purge rod (31)
into piston (32) until rod stops. Spacer (62) acts as
a positive stop.
32
G
61
D
31
62
18
19
TI4968b
16
4.
Disassemble Front End, page 30.
5.
Unscrew purge rod stop (15) to remove piston
8.
safety lock assembly. Inspect o-rings (14, 18) in
place.
TI3848a
Liberally lubricate piston o-rings. Install spacer (61)
onto piston assembly. Reinstall piston. Shaft is
keyed for proper assembly. Push firmly to seat piston. Rotate piston/purge rod assembly clockwise
with nut driver until piston is fully seated.
15
18
14
TI4988a
TI3847a
310648K
39
Repair
9.
Install piston safety lock assembly until bottomed
out.
TI3847a
10.
Reassemble Front End, page 32.
11.
Attach fluid manifold. Connect air. Return gun to
service.
40
310648K
Repair
Piston Safety Lock
Air Valve
1.
Follow Pressure Relief Procedure, page 18.
1.
Follow Pressure Relief Procedure, page 18.
2.
Flush Gun, page 23.
2.
Flush Gun, page 23.
3.
Disconnect air (D) and remove fluid manifold (G).
3.
Disconnect air (D) and remove fluid manifold (G).
G
G
D
D
TI4968b
4.
Unscrew cap (10) from stop (15), using two pair of
TI4968b
4.
channel-lock pliers. Inspect spring (17), safety
actuator (3), bushing (4), and o-rings (14, 18).
Unscrew air valve plug (2) and remove spring (26).
Using small screwdriver (54), push spool (27) out
from front. Inspect o-rings (24).
15
14
18
17
10
3, 4
TI3835b
26
2
27
5.
Lubricate o-rings (14, 18) and piston safety lock
actuator (3), and reassemble. Use Fusion Gun
Lubricant 118665. Clean threads with solvent or
alcohol. Apply medium-strength Loctite® or equivalent to threads on stop (15) and cap (10), and
reassemble.
6.
24
TI4990a
5.
Liberally lubricate o-rings and reassemble. Use
Fusion Gun Lubricant 118665. Torque plug (2) to
125-135 in-lb (14-15 N•m).
Attach fluid manifold. Connect air. Return gun to
service.
6.
Attach fluid manifold. Connect air. Return gun to
service.
310648K
41
Repair
Solvent Purge Assembly
1.
6.
Reassemble air cap (28b) to housing (28a), then
install (28c) and (28d) into housing (28a).
Follow Pressure Relief Procedure, page 18.
7.
2.
Flush Gun, page 23.
3.
Disconnect air (D) and remove fluid manifold (G).
Assemble (28e). Lubricate packings. Slide (28h)
over assembled (28e) into groove and lubricate.
8.
Assemble knob (28f) onto (28e). Assemble screws
(28g) and tighten with a 3/32 in. allen wrench.
40
9.
To position correctly, turn knob (28f) fully counter
clockwise to the open position. Screw assembly
(28e) into housing (28a). Tighten using the wrench
flats on (28e).
9, 63
G
D
TI4968b
4.
10.
Reassemble RAC tip and guard (9, 63) and
static mixer (40) to solvent purge assembly (28).
Tighten with wrench.
Disassemble RAC tip and guard (9, 63), static
28
mixer (40), and solvent purge assembly (28) from
front end of gun.
9, 63
9, 63
40
28
40
TI5033b
TI5002b
5.
11.
Disassemble Solvent Purge Assembly (28a-m).
Attach fluid manifold. Connect air. Return gun to
service.
Inspect parts for damage, replace if necessary.
28m
28a
28c
28h 28e
28g
28d
28b
42
28k
28j
28f
TI5035a
310648K
Repair
Static Mixer Assembly
1.
2.
6.
Reassemble static mixer assembly (40a-e).
7.
Reassemble RAC tip, guard (9, 63) and static
Follow Pressure Relief Procedure, page 18.
mixer (40) from solvent purge assembly (28).
Flush Gun, page 23.
28
9, 63
3.
40
Disconnect air (D) and remove fluid manifold (G).
40
TI5033b
9, 63
G
8.
D
Attach fluid manifold. Connect air. Return gun to
service.
TI4968b
4.
Disassemble RAC tip, guard (9, 63) and static
mixer (40) from solvent purge assembly (28).
9, 63
40
28
TI5002b
5.
Disassemble static mixer housing (40a), mixer
(40b), gasket (40c), packing (40d), and adapter
(41). Inspect parts for damage, replace if necessary.
40b
40c
40a
40d
41
310648K
43
Repair
44
310648K
Parts
Parts
248597 and 248647 Solvent Purge Plural Component
Spray Guns, and 248603 Conversion Kit
41
40d
40a
40b
40c
28m
28a
28c
28h
28e
28g
TI5034a
28d
Static Mixer Assembly
28b
28k
28j
TI5035a
Solvent Purge Assembly
28f
Ref.
28
28a
28b
28c
28d
28e
28f
28g
28h
28j
28k
28m
40
40a
40b
40c
40d
Part No. Description
Qty.
248643 SOLVENT PURGE ASSY.; includes
1
items 28a-28m
15E111 . HOUSING
1
15E130 . CAP, air
1
113618 . GASKET, FFR
1
15E137 . SEAT
1
248641 . KIT, retainer
1
15E114 . KNOB
1
101366 . SCREW, set
2
248648 . PACKING KIT, includes 6 o-rings
1
191892 . ELBOW, 90°
1
191872 . ADAPTER
1
119796 . GASKET
1
248642 STATIC MIXER; includes items
1
40a-40d
15E125 . HOUSING
1
15E126 . MIXER, static 3 in.
1
166969 . GASKET
1
104892 . PACKING, o-ring
1
310648K
45
Parts
248597 Solvent Purge Manual Spray Gun
46*†‡
28
63
25
39
15
40
10 17 6059
4 3
14*
18 31
16*
32
9
61 19
18
62
8
Supplied Tools
53
23‡
21*‡ 46*†‡
‡44
11‡ 35‡
1
20
‡*24
†‡7
34
56
2
†‡36b
22
‡36e
‡36d
36c‡
6
†‡36a
12e
30
2
1
1
48
29
1
12f
‡36
4
13
‡*36g
†‡*36f
TI3870a
54
5
1
†12a
3
12b
12c
1
2
1
24†‡
12d
12g
46
27 26
50
49
1
Torque to 125-135 in-lb (14-15 N•m).
2
Torque to 20-30 in-lb (2.3-3.4 N•m).
3
Torque to 32-40 ft-lb (43-54 N•m).
4
Torque to 35-45 in-lb (4-5 N•m).
51
TI4991b
310648K
Parts
248597 Solvent Purge Manual Spray Gun
Ref.
No.
1
2
3
4
5
6
7†‡
8
9
10
Part No.
248002
15B208
15C374
15C390
203953
192272
12
118145
XHD521
15C373
15B215
246012
12a†
12b
12c
12d
12e
246356
100139
15B221
117634
12f
117635
12g
13
14*
15
16*
17
18
19
15B993
15B209
248136
15C372
248135
118144
248095
248096
20
248138
11‡
21‡* 248132
22
23‡
24‡*
25
26
27
28
119626
15C378
246354
15C377
117485
15B202
29
30
100721
117509
31
32
34
35‡
36‡
248001
15C371
117661
116550
246731
246352
36a‡†
36b‡† 15B214
36c‡
36d‡
104396
310648K
Description
Qty
HANDLE
1
PLUG, air valve
1
ACTUATOR; safety
1
BUSHING, safety
1
SCREW; 10-24 x 3/8 in. (10 mm)
1
PIN
1
HOUSING, fluid
1
SPRING, purge rod
1
TIP, spray, RAC
1
CAP, rear
1
RING, lock
1
MANIFOLD, fluid;
1
includes 12a-12g
. MANIFOLD
1
. VALVE, fluid
2
. PLUG, pipe; 1/8-27 npt
2
. BOLT; 5/16-24
1
. SWIVEL, B side; 1/8 npt(m) x
1
no. 6 JIC(f)
. SWIVEL, A side; 1/8 npt(m) x
1
no. 5 JIC(f)
. SPRING, ring, lock
1
TRIGGER
1
O-RING, rod stop; package of 6
1
STOP, purge rod
1
O-RING, piston; package of 6
1
SPRING, piston safety lock
1
O-RING, purge rod; package of 6
1
O-RING, piston shaft;
1
package of 6
O-RING, housing, small;
1
package of 6
O-RING, housing, large;
1
package of 6
MUFFLER
1
NUT, rod seal, rear
1
O-RING; package of 6
1
NUT, mix module
1
SPRING, air valve
1
SPOOL, air valve
1
SOLVENT PURGE ASSY.;
1
includes items 28a-j; see page 45
for parts
PLUG, pipe; 1/4-18 npt
1
QUICK-DISCONNECT, male, air;
1
1/4 npt(m)
ROD, purge; includes 1 of item 18
1
PISTON
1
VISE, pin; dual reversible chucks
1
RING, retaining
1
VALVE, check, A side; includes
1
36a-36g
VALVE, check, B side; includes
1
36a-36g
. HOUSING
1
. SCREW; 5/16-18 x
1
1/2 in. (13 mm)
. BALL; carbide
1
. SCREEN; see page 53
1
Ref.
No.
36e‡
36f‡*
Part No. Description
Qty
117490 . SPRING
1
248133 . O-RING, check valve face;
1
package of 6
1
36g‡* 248129 . O-RING, check valve housing;
package of 6
37 222385 TAG, warning; not shown
1
39
MODULE, mix, flat, direct impinge- 1
ment; see page 50
40
STATIC MIXER; includes items
1
40a-40d; see page 45 for parts
41
15E244 ADAPTER, static mixer;
1
see page 45
44‡
15C382 VALVE, cleanoff air
1
46†‡* 248003 SEAL KIT, purge rod; includes 4
1
seals
48
117510 COUPLER, air line
1
49
15B772 HOSE, air; 1/4 npsm (fbe); 18 in.
1
(0.46 m)
50
112307 ELBOW, street;1/8 npt (m x f)
2
51
15B565 VALVE, ball; 1/4 npt (m x f)
1
53
117642 NUT DRIVER, hex; 5/16
1
54
118575 SCREWDRIVER; 1/8 blade
1
56
15C480 WASHER, wave
1
57 118665 LUBRICANT, Fusion Gun; 4 oz
1
(113 gram)
59 15D329 STOP, rod
1
60 115452 RING, retaining
1
61 15E132 SPACER, piston
1
62 15E133 SPACER, purge rod
1
63
XHD001 GUARD, tip
1
64
119386 DRILL BIT KIT, not shown
1
*
These parts are only available in repair kits. To select
a kit, refer to Gun Repair Kits on page 53.
†
These parts are not available singly.
‡
These parts are included in Front End Replacement
Kit 246875 (includes 1 of items 24 and 46).
 These parts are included in Safety Stop Assembly
248028 (includes 1 of item 18).
 Replacement Danger and Warning labels, tags, and
cards are available at no cost.
 Available in 248279 Kit, package of 10.
 Available in Fluid Housing Assembly Kit 248004.
 Available in Solvent Purge Conversion Kit 248603.
47
Parts
248647 Machine Mount Spray Valve
with Manual Solvent Purge
25
4
39
46*†‡
10 17 60 59
28
3
15
40
14*
63
31
16* 62
32
9
Check Valve (36)
Detail
61 19
18
8
†‡36b
11‡ 35‡
23‡
‡44
‡*24
‡36e
1
21*‡ 46*†‡
20
‡36c
‡36d
*‡36g
†‡36a
†‡7
*‡36f
TI3927A
Supplied Tools
53
‡36;
see
detail
at right
12e
1
12f
1
†12a
3
34
12b
12c
1
12d
50
12g
48
TI3870a
54
TI5036c
1
Torque to 125-135 in-lb (14-15 N•m).
3
Torque to 32-40 ft-lb (43-54 N•m).
310648K
Parts
248647 Machine Mount Spray Valve
with Manual Solvent Purge
Ref.
No.
1
3
4
7†‡
8
9
10
Part No.
16H942
15C374
15C390
12
118145
XHD521
15C373
15B215
246012
12a†
12b
12c
12d
12e
246356
100139
15B221
117634
12f
117635
12g
14*
15
16*
17
18
19
15B993
248136
15C372
248135
118144
248095
248096
20
248138
11‡
21‡* 248132
23‡
24‡*
25
28
31
32
34
35‡
36‡
15C378
246354
15C377
248001
15C371
117661
116550
246731
246352
36a‡†
36b‡† 15B214
36c‡
36d‡
36e‡
36f‡*
104396
117490
248133
36g‡* 248129
37
222385
310648K
Description
Qty
BODY, mechanical purge
1
ACTUATOR; safety
1
BUSHING, safety
1
HOUSING, fluid
1
SPRING, purge rod
1
TIP, spray, RAC
1
CAP, rear
1
RING, lock
1
MANIFOLD, fluid;
1
includes 12a-12g
. MANIFOLD
1
. VALVE, fluid
2
. PLUG, pipe; 1/8-27 npt
2
. BOLT; 5/16-24
1
. SWIVEL, B side; 1/8 npt(m) x
1
no. 6 JIC(f)
. SWIVEL, A side; 1/8 npt(m) x
1
no. 5 JIC(f)
. SPRING, ring, lock
1
O-RING, rod stop; package of 6
1
STOP, purge rod
1
O-RING, piston; package of 6
1
SPRING, piston safety lock
1
O-RING, purge rod; package of 6
1
O-RING, piston shaft;
1
package of 6
O-RING, housing, small;
1
package of 6
O-RING, housing, large;
1
package of 6
NUT, rod seal, rear
1
O-RING; package of 6
1
NUT, mix module
1
SOLVENT PURGE ASSY.;
1
includes items 28a-j; see page 45
for parts
ROD, purge; includes 1 of item 18 1
PISTON
1
VISE, pin; dual reversible chucks
1
RING, retaining
1
VALVE, check, A side; includes
1
36a-36g
VALVE, check, B side; includes
1
36a-36g
. HOUSING
1
. SCREW; 5/16-18 x
1
1/2 in. (13 mm)
. BALL; carbide
1
. SCREEN; see below
1
. SPRING
1
. O-RING, check valve face;
1
package of 6
. O-RING, check valve housing;
1
package of 6
TAG, warning; not shown
1
Ref.
No.
39
Part No. Description
Qty
MODULE, mix, flat, direct impinge- 1
ment, see page 50
40
STATIC MIXER; includes items
1
40a-40d; see page 45 for parts
41
15E244 ADAPTER, static mixer;
1
see page 45
44‡
15C382 VALVE, cleanoff air
1
46†‡* 248003 SEAL KIT, purge rod; includes 4
1
seals
50
112307 ELBOW, street;1/8 npt (m x f)
2
53
117642 NUT DRIVER, hex; 5/16
1
54
118575 SCREWDRIVER; 1/8 blade
1
57 118665 LUBRICANT, Fusion Gun; 4 oz
1
(113 gram)
59 15D329 STOP, rod
1
60 115452 RING, retaining
1
61 15E132 SPACER, piston
1
62 15E133 SPACER, purge rod
1
63
XHD001 GUARD, tip
1
64
119386 DRILL BIT KIT, not shown
1
65
100139 PLUG, 1/8 NPT
3
*
These parts are only available in repair kits. To select
a kit, refer to Gun Repair Kits, page 53.
†
These parts are not available singly.
‡
These parts are included in Fluid Housing Assembly
Kit 248004 (includes 1 of items 24 and 46).
 These parts are included in Safety Stop Assembly
248028 (includes 1 of item 18).
 Available in Fluid Housing Assembly Kit 248004.
 Replacement Danger and Warning labels, tags, and
cards are available at no cost.
 Available in 248279 Kit, package of 10.
49
Parts
Slip-Fit Polycarballoy Mix Module Kits
Slip-Fit Polycarballoy Mix Module Part Numbering Code
Example
Part No.
First Two Digits
Second Two Digits
Last Two Digits
XR3535
XR=Mechanical purge direct impingement, round pattern
XF3535
XF=Mechanical purge direct impingement, flat pattern
35=Component A
impingement port
size (.035 in.).***
35=Component B
impingement port
size (.035 in.).***
*** Some modules have multiple impingement ports (see below). Size is given as the equivalence of a single port.
Direct Impingement Flat Pattern Guns
Slip-Fit Polycarballoy
Mix Module Kit
(includes drill bits)
No. of
Impingement
Ports
Impingement
Port Drill Bit
Size, nominal**
Counterbore
Drill Bit Size,
nominal**
XF1313
1
#81
#67
XF1818
1
#77
#67
XF2323
1
#74
N/A
XF2929
1
#69
N/A
XF3535
2
#73
N/A
XF4747
2
#67
N/A
XF5757
3
#67
N/A
**For further information, see identification chart under Drill Bit Kits, page 51.
**For further information, see identification chart under Drill Bit Kits, page 51.
50
310648K
Parts
Drill Bit Kits
For cleaning gun ports and orifices and sizing mix module orifices. Illustrations are actual size, for comparison.
Not all sizes are used with your gun.
Drill Bit Size
Kit Part No.
Qty in Kit
246623
3
#32
0.116
2.90
246810
3
7/64
0.109
2.77
246813
3
#39
.099
2.51
246812
3
#43
.089
2.26
246624
3
3/32
.094
2.39
246625
3
#44
.086
2.18
246811
3
2 mm
.079
2.00
246626
6
#50
.070
1.78
246627
6
#53
.060
1.52
246809
6
#54
.055
1.40
246628
6
#55
.052
1.32
246814*
6
#56
.046
1.18
246629*
6
#58
.042
1.07
246808*
6
#60
.040
1.02
246807†
6
#67
.032
0.81
246630†
6
#69
.029
0.74
246815†
6
#73
.024
0.61
276984†
6
#74
.023
0.57
246631†
6
#76
.020
0.51
246816†
6
#77
.018
0.46
246817*
6
#81
.013
0.33
nominal
* Included with gun, one each.
310648K
in.
mm
Illustration
† Included with gun in Drill Bit Kit 119386. Includes one of each.
51
Parts
52
310648K
Gun Repair Kits
Gun Repair Kits
Read the chart left to right and top to bottom to find the quantity of each part in the kits.
Ref.
No.
Bulk O-ring
Kits, (qty)
246351
Check Valve
O-ring Kit
14
248136 (6)
1
16
248135 (6)
1
18
248095 (6)
2
19
248096 (6)
1
20
248138 (6)
1
21
248132 (6)
1
24
246354 (6)
4*
28c
248887
Solvent Purge Gun
Complete O-ring Kit
1
28h
248648 (6)
1
36f
248133 (6)
2
2
36g
248129 (6)
2
2
40c
1
40d
1
46
248003 (4)
2
*248647 only requires one #24. There will be three spares
when ordering the 248887 solvent purge gun complete o-ring
kit.
Check Valve Filter Screen Kits (10 per kit)
80 mesh filter screen is standard with gun.
246357 40 mesh (.015 in., 375 micron)
246358 60 mesh (.010 in., 238 micron)
246359 80 mesh (.007 in., 175 micron)
Drill Bit Kit
Drill Bit Kit 119386
20 piece drill bit set #61 - #80.
310648K
53
Model 248647 Mounting Dimensions
Model 248647 Mounting Dimensions
Measurement Definition
in. (mm)
0.73
(18.54)
2 x 1/4-20
1.30 (33.0)
1 (25.4)
0.625 (15.88)
1.06 (26.92)
3 x 1/8 npt
4 x M5
2 x ⌀ 0.127 (3.23)
ti4751b
0.625
(15.88)
54
310648K
Technical Data
Technical Data
Category
Maximum Fluid Working Pressure
Minimum Air Inlet Pressure
Maximum Air Inlet Pressure
Maximum Fluid Temperature
Air Inlet Size
Solvent Inlet Size
A Component (ISO) Inlet Size
B Component (Resin) Inlet Size
Sound Pressure
Sound Power, measured per ISO
9416-2
Length
Height
Width
Weight
Wetted Parts
Data
3500 psi (24.2 MPa, 242 bar)
80 psi (0.55 MPa, 5.5 bar)
130 psi (0.9 MPa, 9 bar)
200° F (94° C)
1/4 npt Quick Disconnect Nipple
1/4-18 NPSM
-5 JIC; 1/2-20 UNF female swivel in 1/8 npt (f) port
-6 JIC; 9/16-18 UNF female swivel in 1/8 npt (f) port
70 dB(A), at 100 psi (0.7 MPa, 7 bar)
79.9 dB(A), at 100 psi (0.7 MPa, 7 bar)
9 in. (228 mm)
8.1 in. (206 mm)
3.5 in. (89 mm)
3.7 lb (1.68 kg)
Aluminum, stainless steel, carbon steel, chemically resistant o-rings,
ultra-high molecular weight polyethylene (UHMWPE), Polycarballoy™,
Nylon
Static Mixer 248642
Inlet Thread
Outlet thread
Length
Maximum Working Pressure
Wetted Parts
Data
11/16-16 female straight thread
11/16-16 male straight thread
2.84 in. (72.2 mm)
3500 psi (24.2 MPa, 242 bar)
303 stainless steel, Acetal plastic gaskets.
Disposable Static Mixer Adapter
15E244
Inlet Thread
Outlet thread
Usage
Data
11/16-16 female straight thread
7/8-14 male straight thread with tapered bell
Allows the use of disposable mixers, jackets, and RAC assemblies.
All other brand names or marks are used for identification purposes and are trademarks of their respective owners.
310648K
55
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material
and workmanship on the date of sale to the original purchaser for use. With the exception of any special, 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 accordance 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 substitution 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 include 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 otherwise.
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 reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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.
Original instructions. This manual contains English. MM 310648
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2004, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised 09/2011
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