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Graco TI3840a manual

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Table of contents for the manual

  • Page 1

    309856U Instructions-Parts Plural Component, Impingement Mix Mechanical Purge Spray Gun For use with non-flammable foam and polyurea. Not for use in explosive atmospheres. For professional use only. 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( 9 4 ° C) Maximum[...]

  • Page 2

    2 309856U Contents M a n u a lC o n v e n t i o n s ........................ 3 List of Models/Selection Guide ............... 4 Standard Round Pattern Guns .............. 4 Standard Flat Pattern Guns ................ 5 Direct Impingement Round Pattern Guns ...... 6 Direct Impingement Flat Pattern Guns ........ 7 Direct Impingement Flat Pattern Guns[...]

  • Page 3

    Manual Conventions 309856U 3 Manual Conventions Warning Caution Note 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 9-10. CAUTION A caution alerts you to possible[...]

  • Page 4

    List of Models/Selection Guide 4 309856U List of Models/Selection Guide Standard Round Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Round CeramTip ™ Part No., see page 50 for numbering code 247211, A MR3535 RTM030 247212, A MR3535 R[...]

  • Page 5

    List of Models/Selection Guide 309856U 5 Standard Flat Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for numbering code 247257, A MF1818 FTM317 247258, A MF1818 FTM424 247265, A MF2929 FTM424 247[...]

  • Page 6

    List of Models/Selection Guide 6 309856U Direct Impingement Round Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Round CeramTip ™ Part No., see page 50 for numbering code 247003, A XR2323 RTM040 247006, A XR2929 RTM030 247007, A XR292[...]

  • Page 7

    List of Models/Selection Guide 309856U 7 Direct Impingement Flat Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for numbering code 247050, A XF1313 FTM317 247051, A XF1313 FTM424 247057, A XF1818 [...]

  • Page 8

    List of Models/Selection Guide 8 309856U Direct Impingement Flat Pattern Guns Four-Hose Gun Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold FLOW RATE in gpm (lpm)* PRESSURE in psi (MPa, bar) 2.0 (7.6) 1.6 (6.0) 1.2 (4.5) 0.4 (1.5) 0.8 (3.0) 0 XF2929/FTM 424 XF5757/FTM638 XF4747/FTM 638 XF3535/FTM 638 * To calculate flow in lb/min, [...]

  • Page 9

    Warning 309856U 9 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 e[...]

  • Page 10

    Warning 10 309856U 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 stati[...]

  • Page 11

    Overall View 309856U 11 Overall View 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 CeramTip (behind air cap) N Optional Fluid Inlets (A Side Shown) P Lock Ring R Fluid Inlet Swive[...]

  • Page 12

    Isocyanate Hazard 12 309856U Isocyanate Hazard Keep A and B Components Separate Grounding Check your local electrical code and proportioner man- ual for detailed grounding instructions. Ground the spray gun through connection to a Graco-approved grounded fluid supply hose. Piston Safety Lock Engage piston safety lock whenever you stop spray- ing, t[...]

  • Page 13

    Setup 309856U 13 Setup 1. Close fluid valves A and B. 2. Connect A (ISO) and B (RESIN) fluid hoses to fluid manifold. 3. Engage piston safety lock, page 12. TI2411A A (ISO) B (RESIN) TI2417A TI3850a 4. Connect gun air whip hose (T) and air valve (U) to main air hose. Attach fluid manifold (G) to gun. To change position of fluid manifold or use opti[...]

  • Page 14

    Setup 14 309856U 8. Open B (RESIN) fluid valve (about three half turns). Then open A (ISO) fluid valve. 9. Disengage piston safety lock, page 12. 10. Test spray onto cardboard. Adjust pressure and temperature to get desired results. 11. Apply layer of lubricant over front of gun and lock ring, or use gun cover to prevent overspray buildup and ease [...]

  • Page 15

    Adjust Purge Rod 309856U 15 Adjust Purge Rod 1. Engage piston safety lock, page 12. 2. Close fluid valves A and B. TI3850a TI3837a U A B 3. Connect air supply and open air valve (U). 4. Adjust purge rod with nut driver clockwise until it just touches CeramTip, then back off 1/8-1/4 turn. Be sure to back out purge rod 1-2 turns before changing Ceram[...]

  • Page 16

    Adjust Flat CeramTip 16 309856U Adjust Flat CeramTip WARNING Read warnings, page 9. 1. Engage piston safety lock, page 12. 2. Close fluid valves A and B. TI3850a TI3837a U A B 3. Remove air cap (9). 4. Using nut driver, position CeramTip as desired. 5. Reassemble air cap (9) fingertight. 9 TI3854a TI3867a[...]

  • Page 17

    Shutdown 309856U 17 Shutdown Daily Shutdown Follow Pressure Relief Procedure , page 18. Shutdown for More than a Day 1. Flush Gun , page 22. 2. Follow Pressure Relief Procedure , page 18.[...]

  • Page 18

    Pressure Relief Procedure 18 309856U Pressure Relief Procedure WARNING Read warnings, page 9. Relieve pressure before cleaning or repairing gun. 1. Engage piston safety lock, page 12. 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. [...]

  • Page 19

    Optional Configurations 309856U 19 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) t[...]

  • Page 20

    Optional Configurations 20 309856U 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 Air Hose CAUTION To prevent cross-contamination of gun’s wetted parts, do not interchange A component (ISO) and B compo- nent (RESIN) parts. [...]

  • Page 21

    Maintenance 309856U 21 Maintenance Supplied Tool Kit • Hex Nut Driver; 5/16 • Screwdriver; 1/8 blade • CeramTip Drill Bit; various sizes depending on CeramTip size. See T ABLE 2, page 26. • Mix Module Drill Bit; various sizes depending on port size. See T ABLE 1, page 24. • 117661 Pin Vise; dual reversible chucks • 15B817 Flush Manifold[...]

  • Page 22

    Maintenance 22 309856U Flush Gun If it is necessary to flush gun, use following procedure. Clean Outside of Gun Wipe off outside of gun with compatible solvent. Clean Air Cap Soak air cap in compatible solvent. If necessary, clean gently with stiff brush. Clean Muffler A partially plugged muffler will slow gun actuation. Remove and clean muffler wi[...]

  • Page 23

    Maintenance 309856U 23 Clean Slip-Fit Polycarballoy Mix Module 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Remove mix module, page 38. 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- m[...]

  • Page 24

    Maintenance 24 309856U Table 1: Impingement Port Cleanout Drill Sizes Standard Round Slip-Fit Polycarballoy Mix Modules Mix Module Part No. No. of Impingement Ports Impingement Port Drill Counterbore Drill A B Drill Size (nominal) Drill Diameter in. (mm) Drill Size (nominal) Drill Diameter in. (mm) MR3535 2 2 #73 .0240 (0.61) N/A N/A MR4747 2 2 #67[...]

  • Page 25

    Maintenance 309856U 25 Direct Impingement Flat Slip-Fit Polycarballoy Mix Modules Mix Module Part No. No. of Impingement Ports Impingement Port Drill Counterbore Drill A B Drill Size (nominal) Drill Diameter in. (mm) Drill Size (nominal) Drill Diameter in. (mm) XF1313 1 1 #81 .0130 (0.33) #67 .0320 (0.81) XF1818 1 1 #77 .0180 (0.46) #67 .0320 (0.81[...]

  • Page 26

    Maintenance 26 309856U Clean CeramTip Round CeramTip Flat CeramTip External Quick Cleaning Method 1. Follow Pressure Relief Procedure , page 18. 2. Remove CeramTip, page 34. 3. Clean CeramTip hole with appropriate size drill (supplied). See T ABLE 2. Also see identification chart under Drill Bit Kits , page 51. Table 2: Cleanout Drill Sizes for Rou[...]

  • Page 27

    Maintenance 309856U 27 Stuck Purge Rod If purge rod (31) is stuck and cannot actuate, use this procedure to free it. Clean Purge Rod Clean purge rod (31) weekly or monthly. 3. Clean CeramTip hole (E) with appropriate size drill (supplied). See T ABLE 2. Also see identification chart under Drill Bit Kits , page 51. Clean flat tip slit (H) with tip c[...]

  • Page 28

    Maintenance 28 309856U Adjust Front Rod Seal If fluid misting occurs from tip when gun is not triggered, use following procedure to temporarily stop leakage until parts are replaced. 3. Disconnect air (D) and remove fluid manifold (G). 4. Disassemble Front End , page 35. 5. Clean exposed portion of purge rod (31). Apply Fusion Gun Lubricant, page 5[...]

  • Page 29

    Maintenance 309856U 29 Adjust Rear Rod Seal 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Remove fluid manifold (G). Leave air connected. 4. Disassemble Front End , page 35. 5. Assemble fluid housing (7) backwards onto lubri- cated purge rod (31). Adjust rear rod seal nut (23) with nut driver until drag is felt when slid[...]

  • Page 30

    Troubleshooting 30 309856U 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 S[...]

  • Page 31

    Troubleshooting 309856U 31 Loss of round pattern. Dirty CeramTip (40). Clean, page 26. Too little cleanoff air. Readjust, page 13. Loss of flat pattern. Plugged CeramTip (40). Clean in compatible solvent. Worn CeramTip (40). Replace, page 34. Pressure imbalance. Plugged impingement ports. Clean, page 23. Reinstall mix mod- ule, page 38. Plugged che[...]

  • Page 32

    Troubleshooting 32 309856U 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 sprays from CeramTip (40). Cleanoff air flows whether gun is triggered or detrig- gered. See page 13 to adjust. Gun Detriggered (Mechanical Purging) Purge rod ([...]

  • Page 33

    Troubleshooting 309856U 33 Cutaway View 44 19 31 16 24 9 21 3 36 12b 22 28 25 40 48 39 18 14 20[...]

  • Page 34

    Repair 34 309856U 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 [...]

  • Page 35

    Repair 309856U 35 Disassemble Front End WARNING Read warnings, page 9. 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 22. 3. Back out purge rod 1-2 turns with nut driver. 4. Remove air cap (9), retainer ([...]

  • Page 36

    Repair 36 309856U Reassemble Front End 1. Check that o-rings (20, 21) are in position. Liberally lubricate o-rings, threads of lock ring (11) and han- dle (1), and outside of lock ring. 2. Orient front end as required for desired fluid mani- fold mounting (bottom mounting shown). Align slots (Y) to engage tabs (Z). TI3871a 11 21 TI3873a TI3871a Z Y[...]

  • Page 37

    Repair 309856U 37 CAUTION Do not overtighten mix module nut (25). Overtighten- ing 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 air cap (9) or wrench. Install front seal (46) on rod (31). TI3843a 9 46 31 25 1/12 Turn 6. Reinstal[...]

  • Page 38

    Repair 38 309856U Slip-Fit Polycarballoy Mix Module See page 48 for available Slip-Fit Polycarballoy Mix Module sizes. 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Remove fluid manifold (G). Leave air connected. 4. Remove air cap (9), retainer (28), and CeramTip (40). 5. Remove mix module nut (25), using air cap (9) bac[...]

  • Page 39

    Repair 309856U 39 CAUTION Do not overtighten mix module nut (25). Overtighten- ing 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 air cap (9) or wrench. Install front seal (46) on rod (31). TI3843a 9 46 31 25 1/12 Turn 9. Reinstal[...]

  • Page 40

    Repair 40 309856U Rear Rod Seal 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Remove fluid manifold (G). Leave air connected. 4. Disassemble Front End , page 35. 5. Remove rear rod seal nut (23) with nut driver (53). 6. Push out rear seal (46) with screwdriver (54). TI3852a G 23 TI3869a 53 54 46 TI3872a 7. Reassemble new[...]

  • Page 41

    Repair 309856U 41 Check Valves Before disassembling, press on ball (36c) to test check valve for proper movement and spring action. 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and remove fluid manifold (G). Clean and inspect check valve mating surfaces and fluid ports. CAUTION To prevent cross-contam[...]

  • Page 42

    Repair 42 309856U Piston and Purge Rod 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and remove fluid manifold (G). 4. Disassemble Front End , page 35. 5. Unscrew purge rod stop (15) to remove piston safety lock assembly. Inspect o-rings (14, 18) in place. TI3837a G D 15 14 TI3847a 18 6. Pull purge rod[...]

  • Page 43

    Repair 309856U 43 9. Install piston safety lock assembly until bottomed out. 10. Reassemble Front End , page 36. 11. Adjust Purge Rod , page 15. 12. Attach fluid manifold. Connect air. Return gun to service. TI3847a[...]

  • Page 44

    Repair 44 309856U Piston Safety Lock Air Valve 1. Follow Pressure Relief Procedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and remove fluid manifold (G). 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). 5. Lubricate o-rings (14, 1[...]

  • Page 45

    Notes 309856U 45 Notes[...]

  • Page 46

    Parts 46 309856U Parts TI3851c TI2647a 92 8 46* †‡ 25 39 19 32 16* 8 31 14* ★ 15 ★ 10 ★ 17 ★ 59 ★ 3 ★ 18 ★ 18 1 35 ‡ ◆ 11 ‡ ◆ 23 ‡ 46* †‡ 21* ‡ ◆ 20 ‡ 44 ‡ *24 ◆ †‡ 7 ‡ 36e 36c ‡ ‡ 36d †‡ *36f †‡ 36a ‡ *36g ‡ 36 † 12a 12b 12d 12g 50 12c 12e 12f 5 13 6 29 22 24 †‡ 27 26 2 30 48 49[...]

  • Page 47

    Parts 309856U 47 * 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). ▲ R[...]

  • Page 48

    Parts 48 309856U Slip-Fit Polycarballoy Mix Module Kits Slip-Fit Polycarballoy Mix Module Part Numbering Code *** Some modules have multiple impingement ports (see below). Size is given as the equivalence of a single port. Standard Round Pattern Guns Standard Flat Pattern Guns **For further information, see identification chart under Drill Bit Kits[...]

  • Page 49

    Parts 309856U 49 Direct Impingement Round Pattern Guns Direct Impingement Flat Pattern Guns **For further information, see identification chart under Drill Bit Kits , page 51. Slip-Fit Polycarballoy Mix Module Kit (includes drill bits) No. of Impingement Ports Impingement Port Drill Bit Size, nominal** AB XR2323 1 1 #74 XR2929 1 1 #69 XR3535 2 2 #7[...]

  • Page 50

    Parts 50 309856U CeramTip Kits Round CeramTip Part Numbering Code Round CeramTips (include drill bit) **For further information, see identification chart under Drill Bit Kits , page 51. Flat CeramTip Part Numbering Code Flat CeramTips Example Part No. First Three Digits Last Three Digits RTM055 RTM =Round CeramTip mechanical purge Equivalent orific[...]

  • Page 51

    Parts 309856U 51 Drill Bit Kits For cleaning gun ports and orifices. Illustrations are for diameter comparison. Actual length may vary. Not all sizes are used with your gun. Kit Part No. Qty in Kit Drill Bit Size Illustration nominal in. mm 246623 3 #32 0.116 2.90 246810 3 7/64 0.109 2.77 246813 3 #39 .099 2.51 246624 3 3/32 .094 2.39 246812 3 #43 [...]

  • Page 52

    Parts 52 309856U Gun Repair Kits Read the chart left to right and top to bottom to find the quantity of each part in the kits. 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) Ref. No. Bulk O-ring [...]

  • Page 53

    Accessories 309856U 53 Accessories Gun Cover 244915 Keeps gun clean while spraying. Pack of 10. Fusion Gun Lubricant Kit 248279 Pack of 10 Tubes, 4 oz (113 gram) High adhesion, water resistant, lithium-based lubricant for rebuilding Fusion Gun. MSDS sheet MSD025 avail- able at www.graco.com. Tip Cleanout Tool 15D234 Designed to fit CeramTip interna[...]

  • Page 54

    Accessories 54 309856U Solvent Flush Pail Kit 248229 5.0 gal. (19 liter) Pail Includes flush manifold with individual A and B shutoff valves, and air regulator. See manual 309963. Hose Adapter Kits 246944 To connect non-Graco gun to Graco heated hose. 248029 To connect Graco Fusion gun to non-Graco D-gun hose set. 246945 To connect Graco Fusion gun[...]

  • Page 55

    Technical Data 309856U 55 Technical Data $OORWKHUEUDQGQDPHVRUPDUNVDUHXVHGIRULGHQWLILFDWLRQSXUSRVHVDQGDUHWUDGHPDUNVRIWKHLUUHVSHFWLYHRZQHUV Category Data Maximum Fluid Working Pressure 3500 psi (24.2 MPa, 242 bar) Minimum Air Inlet Pressure 80 psi (0.55 MPa, 5.5 bar) Maximum Air Inlet Pressure 130[...]

  • Page 56

    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. )RUSDWHQWLQIRUPDWLRQ VHH ZZZJUDFRFRPSDWHQWV Original instructions. This manual contains English. MM 309856 Graco Headquarters: [...]