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Instructions-Parts
310648P
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
TI4965b
II 2 G
2
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important Isocyanate (ISO) Information . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . 10
Loss of Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 10
Conversion Kit 248603 . . . . . . . . . . . . . . . . . . . . . 11
Mounting an Automatic Gun . . . . . . . . . . . . . . . . . 12
Mounting to a rod . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting to a stationary support robotic arm . . 12
Connecting Airline and Accessories . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hand Drilling of Mix Modules . . . . . . . . . . . . . . . . 15
To balance pressure and flow at the mix gun . . 15
Check Valve Filter Option . . . . . . . . . . . . . . . . . 15
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flushing with Solvent Purge Assembly . . . . . . . 17
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shutdown for More than a Day . . . . . . . . . . . . . 18
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 19
Optional Configurations . . . . . . . . . . . . . . . . . . . . 21
Optional Fluid Manifold Position . . . . . . . . . . . . 21
Optional Hose Position . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 23
Keep Gun Clean . . . . . . . . . . . . . . . . . . . . . . . . 23
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Weekly to Monthly . . . . . . . . . . . . . . . . . . . . . . . 23
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 24
Clean Air Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clean Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clean Fluid Manifold . . . . . . . . . . . . . . . . . . . . . 24
Clean Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clean Slip-Fit Polycarballoy Mix Module . . . . . . 25
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
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
Gun and Palm Grips . . . . . . . . . . . . . . . . . . . . . 50
Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Gun Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check Valve Filter Screen Kits (10 per kit) . . . . 52
Drill Bit Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Model 248647 Mounting Dimensions . . . . . . . . . . 53
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56
310648P
Manual Conventions
Manual Conventions
Warning
WARNING
A warning alerts you to possible serious injury or death if you do not follow instructions.
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.
Caution
CAUTION
A caution alerts you to possible equipment damage or destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
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.
310648P 3
Warning
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.
• Protective eyewear and 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 Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area well ventilated and always wear appropriate personal protective equipment. See Personal Protective Equip-
ment warnings in this manual.
• 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 9.
• 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.
4 310648P
310648P
Warning
WARNING
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.
• 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 19, when you stop spraying and before cleaning, check-
ing, 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.
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.
5
Overall View
Overall View
F
W
M
C
K P
D
L
T
Key:
A A Side Fluid Valve (ISO)
B B Side Fluid Valve (RESIN)
C Air Cap
D Air Line Quick Coupler
E Muffler
F Fluid Housing
G Gun Fluid Manifold
H Handle
J Optional Air Inlet
K Cleanoff Air Valve
L Piston Safety Lock
M Solvent Purge Assembly
6
N
R
H
X
Y
V
B
G
A
S
U
J E
N Optional Fluid Inlets (A Side Shown)
P Lock Ring
R Fluid Inlet Swivels (A Side Shown)
S Trigger
T Gun Air Whip Hose
U Air Valve
V Solvent Purge Valve
W Static Mixer
X RAC tip
Y Solvent Fluid Inlet
TI4966b
310648P
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: ____________
TIME: ____________
310648P 7
8
Important Isocyanate (ISO) Information
For all applications except spray foam Keep Components A and B
Separate
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.
Equipment must be carefully maintained and adjusted according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.
Material Self-ignition
Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:
• Never interchange component A and component B wetted parts.
• Never use solvent on one side if it has been contaminated from the other side.
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all wetted parts.
• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
• Always lubricate threaded parts with an appropriate lubricant when reassembling.
Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and
Safety Data Sheet (SDS).
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.
310648P
Grounding
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.
Changing Materials
NOTICE
Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.
• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical compatibility.
• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
Grounding
WARNING
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.
310648P 9
Piston Safety Lock
Piston Safety Lock
Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.
WARNING
Loss of Air Pressure
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:
• Push hard or hit end of safety lock, to engage piston safety lock.
Read warnings, page 5.
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.
• Close fluid valves A and B.
TI5003a
TI3850a
To disengage piston safety lock: push knob in and turn counterclockwise until it pops out.
TI4967b
TI3849a
10 310648P
61
Conversion Kit 248603
Conversion Kit 248603
A Standard Mechanical Purge Gun can be converted into a Solvent Purge Gun with this kit.
1.
Relieve pressure. See manual 309856.
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.
2.
3.
Disassemble front end of gun. Refer to manual
309856.
TI4988a
4.
Disassemble the piston and purge rod assembly from the gun, see Piston and Purge Rod in manual 309856.
Spacer (61) is optional. For more forward travel of piston, remove spacer.
5.
Remove purge rod (31) from assembly and place spacer (62) onto purge rod.
62
31
61
8.
Install piston safety lock assembly until bottomed out.
TI3847a
TI4989a
6.
Reassemble purge rod and piston assembly until positive stop on purge rod spacer (62).
9.
Reassemble the fluid housing onto the front end of
the gun. See Reassemble Front End, page 32,
310648P 11
Mounting an Automatic Gun
Mounting an Automatic Gun
Mounting to a rod
1.
To mount the gun on a 1/2 in. diameter rod, insert the bar (A) through the hole in the gun body as shown.
Mounting to a stationary support robotic arm
To mount gun to stationary support or robot arm, see
mounting hole dimensions, page 53.
2.
Secure the gun to the bar by tightening 1/4 in. - 20 mounting screws.
ti5007b
Two .128 in.
alignment pin holes
P I
O
Four M5 x 0.08 in. (6.3 mm) holes
I - Activation
P - Purge/Clean-off
O - Deactivation
Two 1/4 -
20 unc holes ti4751b
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
P I
Gun actuation
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
12 310648P
Setup
Setup
1.
Read Hand Drilling of Mix Modules, page 15,
before performing setup procedure.
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.
41
40, 40d
40c
5.
Engage piston safety lock (L), page 10.
L
TI3850a
6.
Connect gun air whip hose (T) and air valve (U) to main air hose. Attach fluid manifold (G) to gun.
9, 63 Y V
TI5033b
T
• Solvent purge knob (V) and inlet (Y) can be rotated in any direction.
3.
Close fluid valves A and B.
G U
TI4968b
TI2411A
4.
Connect A (ISO) and B (RESIN) fluid hoses to fluid manifold (G).
B (RESIN)
G
To change position of fluid manifold or use
optional fluid inlets, see pages 21 and 22.
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.
K
D U
J
To use optional air inlet (J), see page 22.
TI4969b
A (ISO)
TI2417A
310648P 13
Setup
8.
To adjust purge rod position, follow piston and
purge rod disassembly instruction on page 39.
12.
Disengage piston safety lock (L), page 10.
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.
13.
Turn RAC tip (X) to spray position.
TI3849a
TI5004b Y
V
To avoid getting mixed coating material in the solvent purge valve and line.
• 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.
10.
Turn on proportioner.
14.
X
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,
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
TI4970b
14 310648P
Hand Drilling of Mix Modules
Hand Drilling of Mix Modules
To balance pressure and flow at the mix gun
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.
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.
4.
Locate the larger part side (typically the B [RES] port at rear of Polycarballoy Mix Module).
Polycarballoy Mix Module cross section.
NOTE: View is not to scale.
A(ISO)
Check Valve Filter Option
See Check Valve Filter Screens, page 52. 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.
Tools required
• Assorted Drill Bit Kit 119386
• Pin Vise 117661
Two XF1313 Polycarbolloy mix modules are included with the gun. Additional mix modules are
TI3876a
B (RES)
Mix Module
XF1313
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 16.
B (RES)
117661
Pin Vise
Larger Modules XF3535, XF4747, XF5757 are available but not included with gun.
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
Remove Polycarballoy Mix Module, see page 34.
TI3862a
310648P 15
Hand Drilling of Mix Modules
6.
7.
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
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 pres-
sure gauges back into balance.
Module Port
A
B
Drill Bit Size
69
68
67
66
73
72
71
70
77
76
75
74
81
80
79
78
61
60
58
56
65
64
63
62
# size
Drill Bit Table
Drill Bit Sizes
Diameter (in.) Diameter (mm)
0.024
0.025
0.026
0.028
0.0292
0.031
0.032
0.033
0.013
0.0135
0.0145
0.016
0.018
0.02
0.021
0.0225
0.035
0.036
0.037
0.038
0.039
0.04
0.042
0.0465
0.61
0.64
0.66
0.71
0.74
0.79
0.81
0.84
0.33
0.34
0.37
0.41
0.46
0.51
0.53
0.57
0.89
0.92
0.94
0.97
0.99
1.02
1.07
1.18
A (ISO)
TI3863a
10.
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.
16 310648P
Operation
Operation
Spraying
1.
To spray, turn RAC tip (X) to spray position.
2.
Turn RAC tip (X) to clean position.
X
2.
Close solvent purge knob (V).
TI5096b
TI5097b
X
3.
Hold gun into a grounded metal pail, holding a metal part of fluid manifold firmly to side of pail.
4.
Open the solvent purge knob (V) to introduce solvent to the static mixer assembly.
V
3.
Trigger gun to spray.
WARNING
TI5004b
V
TI5110b
5.
When static mixer and tip are clean, close solvent purge knob (V).
Flushing with Solvent Purge
Assembly
1.
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.
310648P 17
Shutdown
Shutdown
Daily Shutdown
1.
Follow Pressure Relief Procedure, page 19.
2.
Shutdown for More than a
Day
1.
Follow Pressure Relief Procedure, page 19.
2.
18 310648P
Pressure Relief Procedure
Pressure Relief Procedure
4.
Turn RAC tip (X) to clean position.
WARNING
Read warnings, page 5. Relieve pressure before cleaning or repairing gun.
1.
Engage piston safety lock (L), page 10.
L
TI3850a
Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved.
2.
Close fluid valves A and B. Leave air valve (U) open.
X
TI5097b
5.
Trigger gun onto cardboard or into waste container to relieve pressure.
TI5009a
B
U
A
3.
Disengage piston safety lock (L), page 10.
L
TI5005b
TI3849a
310648P 19
Pressure Relief Procedure
6.
Engage piston safety lock (L), page 10.
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 Sol-
8.
Shut off air to solvent supply. Open solvent purge knob (V) and relieve pressure in the solvent line.
V
TI5110b
20 310648P
Optional Configurations
Optional Configurations
Optional Fluid Manifold
Position
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.
3.
Unscrew lock ring (P) until front end of gun is loose.
4.
Rotate fluid housing (F) 180° and retighten lock ring very securely.
CAUTION
To prevent cross-contamination of gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) parts.
5.
Attach fluid manifold. Connect air. Return gun to service.
1.
Follow Pressure Relief Procedure, page 19.
2.
Disconnect air (D) and remove fluid manifold (G).
P
F
G
D
TI4968b
310648P 21
Optional Configurations
Optional Hose Position
Fluid inlet swivels and air quick disconnect fitting point to rear. If desired, these positions can be changed so hoses travel downward.
Fluid Hoses
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).
Z
AA
R
CAUTION
To prevent cross-contamination of gun’s wetted parts, do not interchange A component (ISO) and B component (RESIN) parts.
N
R
TI2646A
1.
Follow Pressure Relief Procedure, page 19. Also
relieve system pressure and flush both fluid hoses, see proportioner manual.
5.
Connect appropriate hoses to A and B swivels.
2.
Disconnect air (D) and remove fluid manifold (G).
Air Hose
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
TI4968b
G
TI4965b
3.
Disconnect fluid hoses from inlet swivels (A, B).
Remove swivels. Remove plugs from optional inlets (N).
B
J
2.
Attach fluid manifold (G). Connect air. Return gun to service.
N
A
TI2417A
22 310648P
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
Reversible
3.
4.
5.
Clean Fluid Manifold, page 24.
Clean Slip-Fit Polycarballoy Mix Module, page
Reversible
TI3864a
Daily
• Drill Bit Kit 119386.
Keep Gun Clean
Keep gun clean with accessory gun cover 244915.
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.
Weekly to Monthly
1.
Clean Check Valves, page 38. Check o-rings and
screens.
As Needed
2.
Check that piston safety lock threaded connection
1.
Clean Outside of Gun, page 24.
2.
310648P 23
Maintenance
Flush Gun
If it is necessary to flush the mix module, use following procedure.
WARNING
Clean Air Cap
Soak air cap in compatible solvent. If necessary, clean gently with stiff brush.
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.
Read warnings, page 4.
1.
Follow Pressure Relief Procedure, page 19.
2.
Flush with a compatible solvent.
Clean Muffler
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 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 Outside of Gun
Wipe off outside of gun with compatible solvent.
Clean Fluid Manifold
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.
AB
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.
24 310648P
Maintenance
Clean Slip-Fit Polycarballoy
Mix Module
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
F IG . 1. Cleaning Component A (ISO) Ports
TI3863a
CAUTION
To avoid damaging mix module, do not force drill bits when cleaning impingement ports. Some ports are offset or angled.
4.
See F IG . 1 and F IG . 2. Clean mix module impinge-
ment ports (IP) with appropriate size drill (sup-
F IG . 2. Cleaning Component B (Resin) Ports
TI3862a
• Component B (RES) impingement ports, at rear of mix module, are angled toward front of
• When cleaning do not scratch the sealing edges and ports.
5.
310648P 25
Troubleshooting
Troubleshooting
1.
Follow Pressure Relief Procedure, page 19,
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
Gun does not fully actuate when triggered.
CAUSE
Piston safety lock engaged.
Fluid does not spray when gun is fully actuated.
Plugged muffler (22).
Damaged air valve o-rings (24).
Closed fluid valves (12b).
Gun actuates slowly or with delayed action.
Plugged impingement ports.
Plugged check valves (36).
Plugged muffler (22).
Damaged piston o-rings (16, 19).
Dirty air valve, or damaged o-rings
(24).
Mix module nut (25) too tight.
Loose lock ring (11).
Purge rod will not actuate.
Pressure imbalance.
No air pressure.
Low air pressure.
Buildup on purge rod (31).
Plugged impingement ports.
Plugged check valves (36).
Viscosities not equal.
Ratio not equal.
SOLUTION
Disengage piston safety lock, page
Open.
Clean air valve or replace o-rings,
Loosen nut, then retighten, page 33.
Tighten, use tool if necessaryCon-
Connect air supply.
Set air pressure above 80 psi (0.56
MPa, 5.6 bar).
Clean purge rod.
Clean, page 25. Reinstall mix mod-
Adjust temperature to compensate.
See Drilling of Mix Modules, page 15.
See Drilling of Mix Modules, page 15.
26 310648P
Troubleshooting
PROBLEM CAUSE
Fluid does not shut off when fluid valves are closed.
Air leakage around fluid housing.
Damaged fluid valves (12b).
Steady air leakage from muffler.
Damaged or missing o-ring (20).
Air leakage from piston safety lock.
Damaged or missing o-rings (18).
Burst of air from muffler when gun is triggered.
Normal.
Damaged air valve o-rings (24).
Damaged piston o-rings (16, 19).
Air leakage from front air valve.
Component B (resin) leak from fluid housing.
Cross Contamination of A and B components.
Damaged air valve o-rings (24).
Worn rear rod seal.
Worn out mix module.
Sealing surface OD not clean.
Air leakage from holes on solvent purge assembly.
Cleanoff air valve open.
Fluid leakage from holes on solvent purge assembly.
Mix module nut is only handtight.
SOLUTION
Replace.
Replace.
No action required.
Adjust Rear Rod Seal, page 37.
Replace.
Clean sealing surface on fluid housing.
Close cleanoff air valve tightly. Cleanoff air valve should never be open when using solvent purge gun.
Tighten mix module nut 1/12 with wrench.
310648P 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
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).
9
KEY
Fluid
31 IP
28f
40 ti5099
28
39
9 ti5098
310648P
Troubleshooting
Cutaway View
40
28
48
44
21
31
62
61
18
63
36
39
19
25
20
9
16
14
24
3
310648P
12b
22
TI4992b
29
Repair
Repair
Tools Required
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 p
• solvent or alcohol
Lubrication
Liberally lubricate all o-rings, seals, and threads with
Fusion Gun Lubricant, 118665. Lubricate threads and outside of lock ring (11).
Disassemble Front End
WARNING
3.
Remove RAC tip (9), static mixer (40) and solvent purge assembly (28).
28
40
9
TI5002b
4.
Remove mix module nut (25), using a wrench.
Remove front seal (46).
46
25
TI4986a
Read warnings, page 5. 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 19.
2.
30 310648P
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
310648P 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.
11
21
TI3871a
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.
1
7 11
2.
Orient front end as required for desired fluid manifold mounting (bottom mounting shown). Align slots (Y) to engage tabs (Z).
Y
20
31
TI3866a
TI3871a
4.
Push mix module (39) onto rod (31) as far as possible.
39
31
7
Z
TI3845a
TI3873a
32 310648P
Repair
CAUTION
Do not overtighten mix module nut (25). Overtightening can deform impingement holes and cause slow gun actuation.
5.
Lubricate all threads and reassemble mix module nut (25) fingertight. Tighten additional 1/12 turn with wrench. Install front seal (46) on rod (31).
6.
Reinstall solvent purge assembly (28). Lubricate all threads. Install static mixer (40) and RAC tip (9).
Tighten with wrench.
28
40
9
TI5002b
1/12 Turn
25
46
31
TI4986a
310648P 33
Repair
Slip-Fit Polycarballoy Mix
Module
See page 50 for available Slip-Fit Polycarballoy Mix
Module sizes.
1.
Follow Pressure Relief Procedure, page 19.
6.
Disengage piston safety lock (L), page 10. Trigger
and detrigger gun once to release mix module (39) from fluid housing (7). Remove mix module.
Engage piston safety lock.
11
39
L
2.
3.
Remove fluid manifold (G). Leave air connected.
G
TI4972b
4.
Remove RAC tip and guard (9, 63), static mixer
(40), and solvent purge assembly (28).
28
9, 63
40
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.
Push mix module (39) onto rod (31) as far as possible.
39
31
7
TI3845a
TI5032b
5.
Remove mix module nut (25), using a wrench.
Remove front seal (46).
46
25
TI3843a
34 310648P
Repair
CAUTION
Do not overtighten mix module nut (25). Overtightening can deform impingement holes and cause slow gun actuation.
8.
Lubricate all threads and reassemble mix module nut (25) fingertight. Tighten additional 1/12 turn with wrench. Install front seal (46) on rod (31).
9.
Reinstall solvent purge assembly (28). Lubricate all threads. Install static mixer (40) and RAC tip and guard (9, 63). Tighten with wrench.
28
9, 63
40
TI5032b
1/12 Turn 10.
Attach fluid manifold. Return gun to service.
46
25
TI4986a
310648P 35
Repair
Rear Rod Seal
1.
Follow Pressure Relief Procedure, page 19.
7.
Reassemble new rear seal (46) in rear rod seal nut
(23). Lubricate threads and install in fluid housing
(7) with nut driver.
8.
Reassemble Front End, page 32.
2.
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
6.
Push out rear seal (46) with screwdriver (54).
54
46
TI3869a
TI3872a
36 310648P
Repair
Adjust Rear Rod Seal
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
Remove fluid manifold (G). Leave air connected.
6.
7.
Remove fluid housing (7) from rod (31).
Reassemble Front End, page 32.
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
310648P 37
Repair
Check Valves
Before disassembling, press on ball (36c) to test check valve for proper movement and spring action.
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
Disconnect air (D) and remove fluid manifold (G).
Clean and inspect check valve mating surfaces and fluid ports.
G
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.
Pry out check valves (36) at notch.
Read warnings, page 4. Damaged check valve o-rings
(36f, 36g) may result in external leakage. Replace o-rings if any damage is seen.
5.
Slide filter (36d) off. Clean and inspect parts. Thoroughly inspect o-rings (36f, 36g). If necessary, remove screw (36b) and disassemble check valve.
B
36
A
36b
36e
36c
36d
36g
36a
36f
TI4987a
Check valve filters are available, see Check Valve
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.
WARNING
Attach fluid manifold. Connect air. Return gun to service.
38 310648P
Repair
Piston and Purge Rod
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.
Follow Pressure Relief Procedure, page 19.
6.
Pull purge rod to remove piston (32). Inspect piston o-ring (16) and shaft o-ring (19).
32
19 16
2.
3.
Disconnect air (D) and remove fluid manifold (G).
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.
31 18
32
62
61
19
D
TI4968b
16
4.
Disassemble Front End, page 30.
TI3848a
5.
Unscrew purge rod stop (15) to remove piston safety lock assembly. Inspect o-rings (14, 18) in place.
18
15
8.
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.
14
TI3847a
TI4988a
310648P 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 310648P
Repair
Piston Safety Lock
1.
Follow Pressure Relief Procedure, page 19.
2.
Air Valve
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
Disconnect air (D) and remove fluid manifold (G).
3.
Disconnect air (D) and remove fluid manifold (G).
G G
D D
TI4968b TI4968b
4.
Unscrew cap (10) from stop (15), using two pair of channel-lock pliers. Inspect spring (17), safety actuator (3), bushing (4), and o-rings (14, 18).
14
18
15
4.
Unscrew air valve plug (2) and remove spring (26).
Using small screwdriver (54), push spool (27) out from front. Inspect o-rings (24).
17
10
3, 4
TI3835b 2
26
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 p or equivalent to threads on stop (15) and cap (10), and reassemble.
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).
6.
Attach fluid manifold. Connect air. Return gun to service.
6.
Attach fluid manifold. Connect air. Return gun to service.
310648P 41
Repair
Solvent Purge Assembly
1.
Follow Pressure Relief Procedure, page 19.
6.
Reassemble air cap (28b) to housing (28a), then install (28c) and (28d) into housing (28a).
2.
7.
Assemble (28e). Lubricate packings. Slide (28h) over assembled (28e) into groove and lubricate.
3.
Disconnect air (D) and remove fluid manifold (G).
40
8.
Assemble knob (28f) onto (28e). Assemble screws
(28g) and tighten with a 3/32 in. allen wrench.
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).
G
D
9, 63
TI4968b
4.
Disassemble RAC tip and guard (9, 63), static mixer (40), and solvent purge assembly (28) from front end of gun.
10.
Reassemble RAC tip and guard (9, 63) and static mixer (40) to solvent purge assembly (28).
Tighten with wrench.
28
40
9, 63
9, 63
40
28
TI5002b
5.
Disassemble Solvent Purge Assembly (28a-m).
Inspect parts for damage, replace if necessary.
28m
28a
28c
28h
28e
28g
28d
28b 28k
28j
28f
TI5035a
TI5033b
11.
Attach fluid manifold. Connect air. Return gun to service.
42 310648P
Static Mixer Assembly
1.
Follow Pressure Relief Procedure, page 19.
2.
3.
Disconnect air (D) and remove fluid manifold (G).
40
6.
Reassemble static mixer assembly (40a-e).
7.
Reassemble RAC tip, guard (9, 63) and static mixer (40) from solvent purge assembly (28).
28
40
9, 63
Repair
G
D
9, 63
TI4968b
4.
Disassemble RAC tip, guard (9, 63) and static mixer (40) from solvent purge assembly (28).
9, 63
40
28
TI5033b
8.
Attach fluid manifold. Connect air. Return gun to service.
TI5002b
5.
Disassemble static mixer housing (40a), mixer
(40b), gasket (40c), packing (40d), and adapter
(41). Inspect parts for damage, replace if necessary.
40c
40b
40a
40d
41
310648P 43
Repair
44 310648P
Parts
Parts
248597 and 248647 Solvent Purge Plural Component
Spray Guns, and 248603 Conversion Kit
41
40b
40c
40d
40a
28m
Static Mixer Assembly
TI5034a
28b
28k
28j
Solvent Purge Assembly
28d
28a
28c
28h
28e
28g
28f
TI5035a
Ref.
Part No. Description
28 ❖ 248643 SOLVENT PURGE ASSY.; includes items 28a-28m
28a
28b
28c
28d
15E111 . HOUSING
15E130 . CAP, air
113618 . GASKET, FFR
15E137 . SEAT
Qty.
1
28e 248641 . KIT, retainer
28f 15E114 . KNOB
28g 101366 . SCREW, set 2
28h 248648 . PACKING KIT, includes 6 o-rings 1
1
1
1
1
1
1
28j
28k
28m
40
191892 . ELBOW, 90°
191872 . ADAPTER
119796 . GASKET
248642 STATIC MIXER; includes items
40a-40d
40a 15E125 . HOUSING
40b 15E126 . MIXER, static 3 in.
40c 166969 . GASKET
40d 104892 . PACKING, o-ring
1
1
1
1
1
1
1
1
310648P 45
Parts
248597 Solvent Purge Manual Spray Gun
28 ❖ 46* †‡ 25 39
63 40
14* ★
15 ★ 10 ★ 17 ★ 60 ★ 59 ★
4 ★
3 ★
‡ 44
‡ *24
◆ †‡ 7
†‡ 36b
‡ 36e
‡ 36d
‡ *36g
†‡ 36a
†‡ *36f
‡ 36
† 12a
3
12b
12d
9
18 31
16*
61
❖ 19
32
8
21* ‡ ◆
46* †‡
20
23 ‡
11 ‡
◆ 35 ‡ ◆
62
❖
36c ‡
12e
1
2
12f
12g 50
5
1
13
12c
1
24 †‡
56
6
1
2
29
27 26
22
4
18
30
★
1
1
48
Supplied Tools
34
53
54
2
1
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
TI3870a
TI4991b
46 310648P
Parts
248597 Solvent Purge Manual Spray Gun
Ref.
No.
Part No. Description Qty
1
2
3 ★
4 ★
5
248002 HANDLE
15B208 PLUG, air valve
15C374 ACTUATOR; safety
15C390 BUSHING, safety
6
7 †‡ ◆
8
203953 SCREW; 10-24 x 3/8 in. (10 mm)
192272 PIN
HOUSING, fluid
118145 SPRING, purge rod
9 XHD521 TIP, spray, RAC
10 ★ 15C373 CAP, rear
11‡ ◆
12
15B215 RING, lock
246012 MANIFOLD, fluid;
12a † includes 12a-12g
. MANIFOLD
12b 246356 . VALVE, fluid
12c 100139 . PLUG, pipe; 1/8-27 npt
12d 15B221 . BOLT; 5/16-24
12e 117634 . SWIVEL, B side; 1/8 npt(m) x no. 6 JIC(f)
12f 117635 . SWIVEL, A side; 1/8 npt(m) x no. 5 JIC(f)
12g 15B993 . SPRING, ring, lock
13 15B209 TRIGGER
14* ★ 248136 O-RING, rod stop; package of 6
15 ★ 15C372 STOP, purge rod
16* 248135 O-RING, piston; package of 6
17 ★ 118144 SPRING, piston safety lock
18 ★ 248095 O-RING, purge rod; package of 6
19 248096 O-RING, piston shaft;
20 package of 6
248138 O-RING, housing, small; package of 6
21 ‡
◆ * 248132 O-RING, housing, large; package of 6
1
1
1
22 119626 MUFFLER
23 ‡ 15C378 NUT, rod seal, rear
24 ‡ * 246354 O-RING; package of 6
25 15C377 NUT, mix module
26
27
28 ❖
117485 SPRING, air valve
15B202 SPOOL, air valve
SOLVENT PURGE ASSY.;
includes items 28a-j; see page 45
29
30 for parts
100721 PLUG, pipe; 1/4-18 npt
117509 QUICK-DISCONNECT, male, air;
1/4 npt(m)
31
32
248001 ROD, purge; includes 1 of item 18
15C371 PISTON
34 117661 VISE, pin; dual reversible chucks
35 ‡ ◆ 116550 RING, retaining
36 ‡ 246731 VALVE, check, A side; includes
1
1
1
1
1
1
1
1
1
1
1
1
1
1
36a-36g
246352 VALVE, check, B side; includes
36a ‡†
36a-36g
. HOUSING
36b ‡† 15B214 . SCREW; 5/16-18 x
1/2 in. (13 mm)
36c ‡ 104396 . BALL; carbide
36d ‡
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No. Description
36e ‡ 117490 . SPRING
36f ‡ * 248133 . O-RING, check valve face; package of 6
36g ‡* 248129 . O-RING, check valve housing; package of 6
37
▲
222385 TAG, warning; not shown
39 MODULE, mix, flat, direct impinge-
40
41
STATIC MIXER; includes items
40a-40d; see page 45 for parts
15E244 ADAPTER, static mixer;
44‡
15C382 VALVE, cleanoff air
46 †‡ * 248003 SEAL KIT, purge rod; includes 4 seals
48
49
117510 COUPLER, air line
15B772 HOSE, air; 1/4 npsm (fbe); 18 in.
50
51
53
54
(0.46 m)
112307 ELBOW, street;1/8 npt (m x f)
15B565 VALVE, ball; 1/4 npt (m x f)
117642 NUT DRIVER, hex; 5/16
118575 SCREWDRIVER; 1/8 blade
56 15C480 WASHER, wave
57
■
118665 LUBRICANT, Fusion Gun; 4 oz
(113 gram)
59 ★ 15D329 STOP, rod
60 ★ 115452 RING, retaining
61
❖
15E132 SPACER, piston
62
❖
15E133 SPACER, purge rod
63 XHD001 GUARD, tip
64 119386 DRILL BIT KIT, not shown
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
* These parts are only available in repair kits. To
select a kit, refer to Gun Repair Kits on page 52.
† 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.
310648P 47
Parts
248647 Machine Mount Spray Valve with Manual Solvent Purge
‡
‡
‡
†‡
44
*24
7
36; see detail at right
† 12a
3
12b
12d
25
39
46* †‡
28
40
63
9
16*
62 ❖
31
61
❖
32
19
21* ‡
46* †‡
20
23 ‡
8
11 ‡
35 ‡
14* ★
18 ★
1
65
15 ★
10 ★
17 ★
Check Valve
(36) Detail
†‡36b
65
‡ 36e
‡ 36c
‡ 36d
*‡36g
†‡36a
12e
12g
1
12f
12c
1
50
1
*‡36f
Supplied Tools ti8661a
53
34
54
1 Torque to 125-135 in-lb (14-15 N•m).
3 Torque to 32-40 ft-lb (43-54 N•m).
3 ★
4 ★
59 ★
60 ★
48 310648P
Parts
248647 Machine Mount Spray Valve with Manual Solvent Purge
Ref.
No.
Part No. Description
1
3 ★
4 ★
7 †‡ ◆
8
16H942 BODY, mechanical purge
15C374 ACTUATOR; safety
15C390 BUSHING, safety
HOUSING, fluid
118145 SPRING, purge rod
9 XHD521 TIP, spray, RAC
10 ★ 15C373 CAP, rear
11‡ ◆
12
15B215 RING, lock
246012 MANIFOLD, fluid;
12a † includes 12a-12g
. MANIFOLD
12b 246356 . VALVE, fluid
12c 100139 . PLUG, pipe; 1/8-27 npt
12d 15B221 . BOLT; 5/16-24
12e 117634 . SWIVEL, B side; 1/8 npt(m) x no. 6 JIC(f)
12f 117635 . SWIVEL, A side; 1/8 npt(m) x no. 5 JIC(f)
12g 15B993 . SPRING, ring, lock
14* ★ 248136 O-RING, rod stop; package of 6
15 ★ 15C372 STOP, purge rod
16* 248135 O-RING, piston; package of 6
17 ★ 118144 SPRING, piston safety lock
18 ★ 248095 O-RING, purge rod; package of 6
19 248096 O-RING, piston shaft;
20 package of 6
248138 O-RING, housing, small; package of 6
21 ‡
◆
* 248132 O-RING, housing, large; package of 6
23 ‡ 15C378 NUT, rod seal, rear
24 ‡ * 246354 O-RING; package of 6
25
28
❖
15C377 NUT, mix module
SOLVENT PURGE ASSY.;
includes items 28a-j; see page 45
for parts
31
32
248001 ROD, purge; includes 1 of item 18 1
15C371 PISTON
34 117661 VISE, pin; dual reversible chucks
35 ‡ ◆ 116550 RING, retaining
36 ‡ 246731 VALVE, check, A side; includes
36a-36g
246352 VALVE, check, B side; includes
36a ‡†
36a-36g
. HOUSING
36b ‡† 15B214 . SCREW; 5/16-18 x
1/2 in. (13 mm)
36c ‡ 104396 . BALL; carbide
36d ‡ . SCREEN; see below
36e ‡ 117490 . SPRING
36f ‡ * 248133 . O-RING, check valve face; package of 6
36g ‡* 248129 . O-RING, check valve housing; package of 6
37
▲
222385 TAG, warning; not shown
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No. Description
39
40
MODULE, mix, flat, direct impinge-
STATIC MIXER; includes items
40a-40d; see page 45 for parts
41 15E244 ADAPTER, static mixer;
44‡ 15C382 VALVE, cleanoff air
46 †‡ * 248003 SEAL KIT, purge rod; includes 4
50
53 seals
112307 ELBOW, street;1/8 npt (m x f)
117642 NUT DRIVER, hex; 5/16
54 118575 SCREWDRIVER; 1/8 blade
57
■
118665 LUBRICANT, Fusion Gun; 4 oz
(113 gram)
59 ★ 15D329 STOP, rod
60 ★ 115452 RING, retaining
61
❖
15E132 SPACER, piston
62
❖
15E133 SPACER, purge rod
63 XHD001 GUARD, tip
64
65
119386 DRILL BIT KIT, not shown
100139 PLUG, 1/8 NPT
Qty
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
* These parts are only available in repair kits. To
select a kit, refer to Gun Repair Kits, page 52.
† These parts are not available singly.
‡ These parts are included in Fluid Housing Assembly
Kit 246875 (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 Repair Kit
248004.
▲
Replacement Danger and Warning labels, tags, and cards are available at no cost.
■
Available in 248279 Kit, package of 10.
310648P 49
Parts
Slip-Fit Polycarballoy Mix Module Kits
Slip-Fit Polycarballoy Mix Module Part Numbering Code
Example
Part No.
First Two Digits
XR3535 XR=Mechanical purge direct impingement, round pattern 35=Component A
XF3535 XF=Mechanical purge direct impingement, flat pattern
Second Two Digits impingement port size (.035 in.).***
Last Two Digits
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)
XF1313
XF1818
XF2323
XF2929
XF3535
XF4747
XF5757
2
2
1
1
3
1
1
No. of Impingement
Ports
#74
#69
#73
#67
#67
Impingement Port Drill
Bit Size, nominal**
#81
#77
N/A
N/A
N/A
N/A
N/A
Counterbore Drill
Bit Size, nominal**
#67
#67
**For further information, see identification chart under
**For further information, see identification chart under
Gun Grip Kit
Graco Gun Grips are designed to be used on Fusion
®
A, CS, or Probler
®
P2 Guns.
Kit Part No.
Qty in Kit
17G542
17G543
17G544
10 Pack
50 Pack
100 Pack
Gun and Palm Grips
Applicator's comfort level with a spray gun is an essential part of the spray foam and polyurea installation process. The applicator's fatigue level can dramatically affect the pattern and productivity of a project. 3M™
Gripping Material Technology is designed to:
• Reduce fatigue
• Provide comfort
• Give thermal protection
Gun Grips can be used alone to provide a strong secure grip, or in combination with the Palm Grips to maximize the comfort and anti-fatigue properties and minimize the applicator's grip strength.
Palm Grip Kit
Palm Grips are designed to adhere to any disposable/removable glove.
Kit Part No.
Qty in Kit
17G545
17G546
17G547
10 Pack
50 Pack
100 Pack
50 310648P
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.
246626
246627
246809
246628
246814*
246629*
246808*
246807†
Kit Part No.
Qty in Kit
246623 3
Drill Bit Size nominal
#32 in.
mm
0.116
2.90
Illustration
246810
246813
3
3
7/64
#39
0.109
.099
2.77
2.51
246812
246624
246625
246811
3
3
3
3
#43
3/32
#44
2 mm
.089
.094
.086
.079
2.26
2.39
2.18
2.00
6
6
6
6
6
6
6
6
#50
#53
#54
#55
#56
#58
#60
#67
.070
.060
.055
.052
.046
.042
.040
.032
1.78
1.52
1.40
1.32
1.18
1.07
1.02
0.81
246630†
246815†
276984†
246631†
6
6
6
6
246816†
246817*
6
6
* Included with gun, one each.
#77
#81
#69
#73
#74
#76
.029
0.74
.024
0.61
.023
0.57
.020
0.51
.018
0.46
.013
0.33
† Included with gun in Drill Bit Kit 119386. Includes one of each.
310648P 51
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
248887
Solvent Purge Gun
Complete O-ring Kit
1 14
16
18
19
20
21
24
36f
36g
40c
40d
248136 (6)
248135 (6)
248095 (6)
248096 (6)
248138 (6)
248132 (6)
246354 (6)
28c
28h 248648 (6)
248133 (6)
248129 (6)
2
2
1
2
1
1
1
4*
1
1
2
2
1
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.
52 310648P
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)
1.06 (26.92)
0.625 (15.88)
1 (25.4)
4 x M5
0.625
(15.88)
3 x 1/8 npt
2 x
0.127 (3.23) ti4751b
310648P 53
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.
$OORWKHUEUDQGQDPHVRUPDUNVDUHXVHGIRULGHQWLILFDWLRQSXUSRVHVDQGDUHWUDGHPDUNVRIWKHLUUHVSHFWLYHRZQHUV
54 310648P
Technical Data
310648P 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
.
For patent information, see
www.graco.com/patents .
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
Revision P, February 2016
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