Graco Inc. 309856 manual

309856P Instr uctions-P ar ts Plural Component, Imping ement Mix Mec hanical Pur ge Spra y Gun For use with non-flammab le f oam and poly urea. Not f or use in explosive atmospheres. 3500 psi (24.2 MP a, 242 bar) Maximum Fluid W orking Pressure 80-130 psi (0.55- 0.9 MP a, 5.5-9.1 ba r) Air Inlet Pressure Range 200 ° F (94 ° C) Maximum Fluid T emp[...]

2 309856P Contents Manual Con ventions . . . . . . . . . . . . . . . . . . . . . . . . 3 List of Models/Sele ction Guide . . . . . . . . . . . . . . . 4 Standard Rou nd P atter n Guns . . . . . . . . . . . . . . 4 Standard Flat Pattern Guns . . . . . . . . . . . . . . . . 5 Direct Impingem ent Round P attern Guns . . . . . . 6 Direct Impingem ent F[...]

Manual Conventions 309856P 3 Man ual Con ventions W arning Caution Note WA R N I N G A warning aler ts you to possib le serious injur y or death if you do not f ollow instr uctions. Symbols, such as flu id injection (shown), alert you to a specific hazard and d irect y ou to read the indicated hazard warnings on pages 9-10. CA UTION A caution aler [...]

List of Models/Selection Guide 4 309856P List of Models/Selection Guide Standar d Round P attern Guns Use only these mix module/tip comb inations. Gun P ar t No., Series Slip-Fit ™ P olycarballoy ™ Mix Module P ar t No., see page 48 for numbering code Round CeramTip ™ Part No., see page 50 for n umbering code 247211, A MR3535 RTM030 247212, A[...]

List of Models/Selection Guide 309856P 5 Standar d Flat P attern Guns Use only these mix module/tip combinations . Gun P ar t No., Series Slip-Fit ™ P olycarballoy ™ Mix Module P a rt No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for n umbering code 247257, A MF1818 FTM317 247258, A MF1818 FTM424 247265, A MF2929 F[...]

List of Models/Selection Guide 6 309856P Direct Impingement Round P attern Guns Use only these mix module/tip comb inations. Gun P ar t No., Series Slip-Fit ™ P olycarballoy ™ Mix Module P art No., see page 48 for numbering code Round CeramTip ™ Part No., see page 50 for n umbering code 247003, A XR2 323 R TM040 247006, A XR2 929 R TM030 2470[...]

List of Models/Selection Guide 309856P 7 Direct Impingement Flat P attern Guns Use only these mix module/tip combinations . Gun P ar t No., Series Slip-Fit ™ P olycarballoy ™ Mix Module P a rt No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for n umbering code 247050, A XF1313 FTM317 247051, A XF1313 FTM424 247057, A[...]

List of Models/Selection Guide 8 309856P Direct Impingement Flat P attern Guns Four -Hose Gun Wide Round P attern Gun with Four-Hose Recir culating Gun Manifold FLO W RA TE in gpm (lpm)* PRESSURE in psi (MP a, bar) 2.0 (7.6) 1.6 (6.0) 1.2 (4.5) 0.4 (1.5) 0.8 (3.0) 0 X F 2 9 2 9 / F T M 4 2 4 X F 5 7 5 7 / F T M 6 3 8 XF 4 7 4 7 /F T M 6 3 8 XF 3 5 [...]

Warning 309856P 9 W A RNING P ERSONAL PROTECTIVE EQUIPMENT Y ou m ust wear proper protectiv e equipment when oper ating, ser vicing, or when in the oper ating area of the equipment to help prot ect y ou from serious injury , including e ye inju r y , inhalation of toxic fu mes, burns, and hea ring loss. This equipment includes b ut is not limited t[...]

Warning 10 309856P FIRE AND EXPLOSION HAZARD Flammab le fumes, such as solv ent and paint fumes , in work area can ignite or e xplode. T o help pre ven t fire and e xplosion: • Use equ ipment only in well vent ilated area. • Elimin ate all ignition sources, such as pilot light s, cigarettes, por table electr ic lamps, and plastic drop cloths (p[...]

Overall View 309856P 11 Overall Vie w Key: A A Side Fluid V a lve (ISO) B B Side Fluid V a lv e (RESIN) CA i r C a p D Air Line Quick Coupler EM u f f l e r F Fluid Housing G Gun Fluid Manifold H Handle J Optional Air Inlet K Cleanoff Air V a lv e L Piston Saf ety Lock M CeramTip (behind air cap) N Optional Fluid Inlets (A Side Shown) P Lock Ring R[...]

Isocyanate Hazard 12 309856P Isocy anate Hazar d K eep A and B Components Separate Gr ounding Chec k yo ur local electrical code and propor tioner man- ual f or detailed grounding instructions. Ground the spray gun through connection t o a Graco-appro ved g rounded fluid supply hose . Piston Safe ty Loc k Engage piston saf ety lock wh enever y ou s[...]

Setup 309856P 13 Setup 1. Close fluid v alves A and B . 2. Connect A (ISO) and B (RESIN) fluid hose s to fluid manif old. 3. Engage piston saf ety lock, page 12 . TI2411A A (ISO) B (RESIN) TI2417A TI3850a 4. Connect gun air whip hose (T) and air valv e (U) to main air hose . Attach flui d manif old (G) to gun. T o change position of fluid manif old[...]

Setup 14 309856P 8. Open B (RESIN) fluid v alv e (about three half tur ns). Then open A (ISO) fluid valv e. 9. Disengage piston saf ety lock, pag e 12. 10. T est spra y onto cardboard . Adjust pressure and temperature to get de sired results. 11. Apply la yer of lubricant over front of gun and loc k ring, or use gun cov er to pre vent o verspra y b[...]

Adjust Purge Rod 309856P 15 Adjust Pur g e Rod 1. Engage piston saf ety lock, page 12 . 2. Close fluid v alves A and B . TI3850a TI3837a U A B 3. Connect air supply and open air v alve (U). 4. Adjust purge rod with nut driver clockwise until it just touches CeramTip, then back off 1/8-1/ 4 tur n. Be sure to back out purge rod 1-2 tur ns before chan[...]

Adjust Flat CeramTip 16 309856P Adjust Flat CeramTip WA R N I N G Read wa rnings, page 9. 1. Engage piston saf ety lock, page 12 . 2. Close fluid v alves A and B . TI3850a TI3837a U A B 3. Remov e air cap (9). 4. Using nut driver , position CeramTip as desired. 5. Reassemble air cap (9) fingertight. 9 TI3854a TI3867a[...]

Shutdown 309856P 17 Shutdo wn Dail y Shutdo wn F ollow Pressure Relief Pro cedure , page 18. Shutdo wn f or More than a Da y 1. Flush Gun , page 22. 2. F ollow Pressure Relief Pro cedure , page 18.[...]

Pressure Relief Procedure 18 309856P Pressure Relief Pr ocedure WA R N I N G Read wa rn ings , page 9. Relie ve pressure bef ore cleaning or repairing gun. 1. Engage piston saf ety lock, page 12 . Air supply is requir ed f or gun actuation. Do not disconnect gun air supply until fluid pr essure is relie ved. 2. Close fluid v alves A and B. Lea ve a[...]

Optional C onfigurations 309856P 19 Optional Configurations Optional Fluid Manif old Po s i t i o n Fluid manif old is mounted to bottom of gun, with A side on left, vie wed from oper ator’ s position at bac k of gun. If desired, manif old ma y be moved to top of gun. Doing this will reposition A side par ts (fluid inlet, check v alve , and fluid[...]

Optional Co nfigurations 20 309856P Optional Hose P osition Fluid inlet s wivels and air quick disconnect fitting point to rear . If desired, these positions can be changed so hoses tra vel downw ard. Fluid Hoses Air Hose CA UTION T o pre vent cross-contam ination of gun’ s wetted parts, do not interchang e A component (ISO) and B compo- nent (RE[...]

Maintenance 309856P 21 Maintenance Supplied T ool Kit • He x Nut Driver; 5/16 • Scre wd river ; 1/8 blade • Cer amTip Drill Bit; various sizes depending on CeramTip size . See T ABLE 2, page 26. • Mix Module Drill Bit; various sizes depending on por t size. See T ABLE 1, page 2 4. • 1 17661 Pin Vise; dual re versib le chucks • 1 5B817 F[...]

Maintenance 22 309856P Flush Gun If it is necessary to flush gun, use f ollowing procedure. Clean Outside of Gun Wipe off outside of gun wit h compatib le solvent. Clean Air Cap Soak air cap in compatib le solvent. If necessary , clean gently with stiff brush. Clean Muffler A par tially plugged muffle r will slow gun actuation. Remov e and clean mu[...]

Maintenance 309856P 23 Clean Slip-Fit P olycarballo y Mix Module 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Remov e mix module , page 38. CA UTION T o av oid damaging mix module, do not f orce dr ill bits when cleaning impingemen t por ts. Some ports are offset or angled . 4. See F IG . 1 and F IG . 2. Clean mix mod[...]

Maintenance 24 309856P T able 1: Impingement P or t Cleanout Dril l Sizes Standard Round Slip-Fit Pol ycarballoy Mix Modules Mix Module Par t No . No. of Impinge- ment P orts Impingement Port Drill Counterbore Drill Drill Size (nominal) Drill Diameter in. (mm) Drill Size (nominal) Drill Diameter in. (mm) MR3535 2 #73 .0240 (0.61) N/A N/A MR4747 2 #[...]

Maintenance 309856P 25 Direct Impingement F lat Slip-Fit P olycarballoy Mix Modules Mix Module Par t No . No. of Impinge- ment P orts Impingement Port Drill Counterbore Drill Drill Size (nominal) Drill Diameter in. (mm) Drill Size (nominal) Drill Diameter in. (mm) XF1313 1 #81 .0130 (0.33) #67 .0320 (0.81) XF1818 1 #77 .0180 (0.46) #67 .0320 (0.81)[...]

Maintenance 26 309856P Clean CeramTip Round CeramTip Flat CeramTip External Quic k Cleaning Method 1. F ollow Pressure Relief Pro cedure , page 18. 2. Remov e CeramTip, page 34. 3. Clean CeramTip hole with appropr iate size drill (supplied). See T AB LE 2. Als o see identificatio n char t under Drill Bit Kits , page 51 . T able 2: Clea nout Drill S[...]

Maintenance 309856P 27 Stuc k Purge Rod If purge rod (3 1) is stuc k and cannot actuate , use this procedure to fr ee it. Clean Pur g e Rod Clean purg e rod (31) wee kly or mont hly . 3. Clean CeramTip hole (E) with appropriate size drill (supplied). See T AB LE 2. Also see identification char t under Drill Bit Kits , page 51 . Clean flat tip slit [...]

Maintenance 28 309856P Adjust Fr ont Rod Seal If fluid misting occurs from t ip when gun is not tr iggered, use f ollowing procedure to tempor ar ily stop leakage until par ts are replaced. 3. Disconnect air (D) and re mov e fluid manif old (G). 4. Disassemb le Front End , page 35. 5. Clean e xposed por tion of purge rod (31). Apply Fusion Gun Lubr[...]

Maintenance 309856P 29 Adjust Rear Rod Seal 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Remov e fluid manif old (G). Lea v e air connected. 4. Disassemb le Front End , page 35. 5. Assemb le fluid housing (7) backw ards onto lubri- cated purge rod (31) . Adjust rear rod seal nut (23) with nut driv er until drag is f e[...]

Troubleshooting 30 309856P T r oubleshooting 1. F ollow Pressure Relief Pro cedure , page 18, bef ore checking or re pair ing gun. 2. Check all possible prob lem s and causes before disassemb ling gun. CA UTION T o pre v ent cross-contamination of the gun’ s wetted par ts, do not interchange A component (isocy anate) and B component (resin) par t[...]

Troubleshooting 309856P 31 Loss of round pat tern. Dir ty CeramTip (40) . Clean, page 26 . T oo little cleanoff air . Readjust, page 13. Loss of flat pattern. Plugged CeramTip (40). Clean in compatib le solvent. W or n CeramTip (40). Replace, page 34. Pressure imbalance . Plugged impingement ports. Clean, page 23. Reinstall mix mod- ule , page 38. [...]

Troubleshooting 32 309856P Theory of Operation Gun T rig g ered (Fluid Spra ying) Purge rod (31) mov es back, opening im pingement por ts (IP). Compon ents A and B comb ine in mix module (39). Fluid spra ys from CeramTip (40). Cleanoff air flo ws whether gun is triggered or detrig- gered. See page 13 to adjust. Gun Detriggered (M echanical Purging)[...]

Troubleshooting 309856P 33 Cutawa y Vie w 44 19 31 16 24 9 21 3 36 12b 22 28 25 40 48 39 18 14 20[...]

Repair 34 309856P Repair T ools Required T ools needed f or complete gun repair: • a djustabl e wrench • f lat head screwdriv er (included) • c hannel-loc k pliers (2 pair) • 5 /16 hex nut driv er (included) • o -ring pick • medium-strength Loct ite ® • s olv ent or alcoh ol Lubrication Liberally lubricate all o-rings, seals , and th[...]

Repair 309856P 35 Disassemble Fr ont End WA R N I N G Read wa r nings, page 9. Pro per attachmen t of front end is critical. Do not operat e gun if front end is loose or loc k ring is not snug against handle . 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Bac k out purge ro d 1-2 tur ns with nut driv er . 4. Remov e ai[...]

Repair 36 309856P Reassemble Fr ont End 1. Check that o-ring s (20, 21) are in pos ition. Liberally lubricate o-rings, threads of loc k ring (11) and han- dle (1), and outside of loc k ring. 2. Orient front end as required f or desired fluid mani- f old mounting (bottom mo unting shown). Align slots (Y) to engage tabs (Z) . TI3871a 11 21 TI3873a TI[...]

Repair 309856P 37 CA UTION Do not ov er tighten mix module nut (25). Ov er tighten- ing can def or m impingement holes and cause slo w gun actuation. 5. Lubr icate all threads and re assemble mix module nut (25) fingertight . Tighte n additional 1/12 tur n with air cap (9 ) or wrench . Install front seal (46) on rod (31). TI3843a 9 46 31 25 1/12 Tu[...]

Repair 38 309856P Slip-Fit P olycarballo y Mix Module See page 48 f or av ailable Slip-Fit P olycarballoy Mix Module siz es. 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Remov e fluid manif old (G). Lea v e air connected. 4. Remov e air cap (9), retainer (28 ), and CeramTip (40). 5. Remov e mix module nut (25), using [...]

Repair 309856P 39 CA UTION Do not ov er tighten mix module nut (25). Ov er tighten- ing can def or m impingement holes and cause slo w gun actuation. 8. Lubr icate all threads and re assemble mix module nut (25) fingertight . Tighte n additional 1/12 tur n with air cap (9 ) or wrench . Install front seal (46) on rod (31). TI3843a 9 46 31 25 1/12 Tu[...]

Repair 40 309856P Rear Rod Seal 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Remov e fluid manif old (G). Lea v e air connected. 4. Disassemb le Front End , page 35. 5. Remov e rear rod seal nut (23) with nut driv er (53). 6. Push out re ar seal (46) w ith screwdriver (54). TI3852a G 23 TI3869a 53 54 46 TI3872a 7. Rea[...]

Repair 309856P 41 Chec k V alves Bef ore disassemblin g, press on ball (36c) to test chec k v alve f or proper mov ement and spring action. 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and re mov e fluid manif old (G). Clean and inspect chec k valv e mating surf aces and fluid ports. CA UTION T o pr[...]

Repair 42 309856P Piston and Pur g e Rod 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and re mov e fluid manif old (G). 4. Disassemb le Front End , page 35. 5. Unscrew purge rod stop (15) to remo ve pist on saf ety lock assemb ly . Inspect o-rings (14, 18) in place. TI3837a G D 15 14 TI3847a 18 6. P[...]

Repair 309856P 43 9. Install piston saf ety lock assemb ly until bottomed out. 10. Reassemble Front End , page 36. 11. Adjust Purge Rod , pag e 15. 12. Attach fluid manif old. Connect air . Return gun to ser vice. TI3847a[...]

Repair 44 309856P Piston Safety Loc k Air V alve 1. F ollow Pressure Relief Pro cedure , page 18. 2. Flush Gun , page 22. 3. Disconnect air (D) and re mov e fluid manif old (G). 4. Unscrew cap (10) from st op (15), using tw o pair of channel-lock pliers . Insp ect s pring (17), safety actuator (3 ), bushing (4), and o-rin gs (14, 18) . 5. Lubricate[...]

Notes 309856P 45 Notes[...]

Parts 46 309856P Pa r t s 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[...]

Parts 309856P 47 * These par ts are only av a ilable in repair kits. T o select a kit, ref er to Gun Repair Kits on page 52. † These par ts are not av ailable singly . ‡ These par ts are included in F ront End Replacement Kit 246875 (i ncludes 1 of items 24 and 4 6). ★ These par ts are included in Safety Stop Assembly 248028 (include s 1 of i[...]

Parts 48 309856P Slip-Fit P olycarballo y Mix Module Kits Slip-Fit P olycarballo y Mix Module Part Numbering Code *** Some module s hav e multiple impin gement por ts (see belo w). Size is giv en as the equiv alence of a single port . Standard Round P attern Guns Standard Flat P attern Guns **F or fur ther inf or mation, see iden tification chart u[...]

Parts 309856P 49 Direct Impingement Round P attern Guns Direct Impingement Flat P attern Guns **F or fur ther inf or mation, see iden tification char t under Drill Bit Kits , page 51. Slip-Fit P olycarballo y Mix Module Kit (inc ludes drill bits) No. of Impinge ment Po r t s Impinge ment P or t Drill Bit Size , nominal** XR2323 1 #74 XR2929 1 #69 X[...]

Parts 50 309856P CeramTip Kits Round CeramTip P a r t Numbering Code Round CeramTips (include dr ill bit) **F or fur ther inf or mation, see iden tification chart under Drill Bit Kits , page 51. Flat CeramTip P ar t Numbering Code Flat CeramTips Example Pa r t N o . First T hree Digits Last Three Digits RTM 0 55 RT M =Round CeramTip mechanical purg[...]

Parts 309856P 51 Drill Bit Kits F or cleaning gun por ts and orifices. Illustr ations are actual size , for comparison. Not all sizes are used with your gun. Kit P ar t No. Qty in K it Drill Bit Siz e Illustration nomina l in. mm 246623 3 #32 0. 116 2.90 246810 3 7/64 0.1 09 2.77 246813 3 #39 .099 2.51 246624 3 3/32 .094 2.39 246812 3 #43 .089 2.26[...]

Parts 52 309856P Gun Repair Kits Read the char t left to right and top t o bottom to find the quantity of each pa r t in the kits. Chec k V alve 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. Bul[...]

Accessories 309856P 53 Accessories Gun Co ver 244915 K eeps gun clean while spra ying. P ack of 10. Fusion Gun Lubricant Kit 248279 P ack of 10 T ubes, 4 oz (113 gram) High adhesio n, water resistant, lit hium-based lu bricant f or rebuilding Fusion Gun. MSDS sheet MSD025 a vail- able at www .graco .com. Tip Cleanout T ool 15D234 Designed to fit Ce[...]

Accessories 54 309856P Solvent Flush P a il Kit 248229 5.0 gal. (19 liter) P ail Includes flush manif old with individual A and B shutoff v a lv es, and air regula tor . See manual 309963. Hose Adapter Kits 246944 T o conn ect non-Graco g un to Graco he ated hose. 248029 T o connec t Graco Fusion gun to non- Graco D-gun hose set. 246945 T o connect[...]

Technical Data 309856P 55 T echnical Data All other brand names or marks are used for ide ntification purposes and are trademarks of their respective owners. Category Data Maximum Fluid W orking Pressure 3500 psi (24.2 MP a, 242 bar) Minimum Air Inle t Pressure 80 psi (0.55 MP a, 5.5 bar) Maximum Air Inlet Pre s sure 130 psi (0.9 MP a, 9 bar) Maxim[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. This manual contains English. MM 309856 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. P.O. BOX 14[...]