Graco 2004230905, TI3840a, 309856, 309856P User Manual
Instructions-Parts
Plural Component, Impingement Mix
Mechanical Purge Spray Gun
For use with non-flammable foam and polyurea.
Not for use in explosive atmospheres.
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
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
309856P
US Patent Number 7,036,171
D479,305
Korean Patent 338185
Australian Patent Number 152610
2004230905
EP 1610904
TI3840a
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . 8
Four-Hose Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 12
Keep A and B Components Separate . . . . . . . . . 12
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . 12
Loss of Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjust Purge Rod . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjust Flat CeramTip . . . . . . . . . . . . . . . . . . . . . . 16
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shutdown for More than a Day . . . . . . . . . . . . . 17
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 18
Optional Configurations . . . . . . . . . . . . . . . . . . . . 19
Optional Fluid Manifold Position . . . . . . . . . . . . 19
Optional Hose Position . . . . . . . . . . . . . . . . . . . 20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 21
Keep Gun Clean . . . . . . . . . . . . . . . . . . . . . . . . 21
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Weekly to Monthly . . . . . . . . . . . . . . . . . . . . . . . 21
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 22
Clean Air Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clean Fluid Manifold . . . . . . . . . . . . . . . . . . . . . 22
Clean Slip-Fit Polycarballoy Mix Module . . . . . . 23
Clean CeramTip . . . . . . . . . . . . . . . . . . . . . . . . 26
Stuck Purge Rod . . . . . . . . . . . . . . . . . . . . . . . . 27
Clean Purge Rod . . . . . . . . . . . . . . . . . . . . . . . 27
Adjust Front Rod Seal . . . . . . . . . . . . . . . . . . . . 28
Adjust Rear Rod Seal . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 32
Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replace CeramTip . . . . . . . . . . . . . . . . . . . . . . 34
Disassemble Front End . . . . . . . . . . . . . . . . . . . 35
Reassemble Front End . . . . . . . . . . . . . . . . . . . 36
Slip-Fit Polycarballoy Mix Module . . . . . . . . . . . 38
Rear Rod Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Piston and Purge Rod . . . . . . . . . . . . . . . . . . . . 42
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . 44
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Slip-Fit Polycarballoy Mix Module Kits . . . . . . . . 48
CeramTip Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Gun Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check Valve Filter Screen Kits (10 per kit) . . . . 52
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Gun Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fusion Gun Lubricant Kit . . . . . . . . . . . . . . . . . . 53
Tip Cleanout Tool . . . . . . . . . . . . . . . . . . . . . . . . 53
Gun Cleaning Kit . . . . . . . . . . . . . . . . . . . . . . . . 53
Circulation Manifold . . . . . . . . . . . . . . . . . . . . . . 53
Flushing Manifold . . . . . . . . . . . . . . . . . . . . . . . 53
Solvent Flush Kits . . . . . . . . . . . . . . . . . . . . . . . 53
Solvent Flush Pail Kit . . . . . . . . . . . . . . . . . . . . . 54
Hose Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . 54
Pour Nozzle Kit . . . . . . . . . . . . . . . . . . . . . . . . . 54
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 309856P
Manual Conventions
Warning Caution
Manual Conventions
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 equipment damage or
destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
309856P 3
List of Models/Selection Guide
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 RTM040
247213, A MR3535 RTM055
247218, A MR4747 RTM040
247219, A MR4747 RTM055
247225, A MR5757 RTM055
247226, A MR5757 RTM070
247231, A MR6666 RTM070
247232, A MR6666 RTM080
247233, A MR6666 RTM090
247239, A MR8282 RTM090
247240, A MR8282 RTM100
247245, A MR9494 RTM100
247246, A MR9494 RTM110
5.0
(18.9)
4.0
(15.1)
3.0
(11.4)
2.0
(7.6)
1.0
(3.8)
9
R
M
0
1
1
M
T
R
/
4
9
4
2
8
R
M
0
09
M
T
R
/
2
8
6
6
6
R
M
0
8
0
TM
R
/
6
7
5
7
5
R
M
4
R
M
R
M
0
7
0
M
T
R
/
5
5
0
M
T
R
/
7
4
7
0
4
0
TM
R
/
5
3
5
3
FLOW RATE in gpm (lpm)*
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
0
800
(5.6, 56)
1250
(8.7, 87)
1700
(11.9, 119)
2150
(15.0, 150)
2600
(18.2, 182)
3050
(21.3, 213)
3500
(24.5, 245)
PRESSURE in psi (MPa, bar)
4 309856P
Standard Flat Pattern Guns
Use only these mix module/tip combinations.
List of Models/Selection Guide
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
247266, A MF2929 FTM438
247267, A MF2929 FTM624
247273, A MF3535 FTM438
247274, A MF3535 FTM624
247275, A MF3535 FTM638
247281, A MF4747 FTM624
247282, A MF4747 FTM638
247283, A MF4747 FTM838
247289, A MF5757 FTM638
247290, A MF5757 FTM838
247291, A MF5757 FTM848
FLOW RATE in gpm (lpm)*
2.0
(7.6)
1.6
(6.0)
1.2
(4.5)
0.8
(3.0)
0.4
(1.5)
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
0
800
(5.6, 56)
1250
(8.7, 87)
5
7
5
F
M
4
F
M
M
1700
(11.9, 119)
2150
(15.0, 150)
2600
(18.2, 182)
PRESSURE in psi (MPa, bar)
F
/
7
4
7
3
F
M
3
6
M
T
M
T
F
/
7
F
/
5
3
5
2
9
2
F
8
1
F
M
(21.3, 213)
8
6
T
9
1
8
3
6
M
T
F
/
F
/
8
3050
3
M
T
8
4
M
4
2
4
2
4
(24.5, 245)
3500
309856P 5
List of Models/Selection Guide
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 XR2929 RTM040
247011, A XR3535 RTM030
247012, A XR3535 RTM040
247013, A XR3535 RTM055
247018, A XR4747 RTM040
247019, A XR4747 RTM055
247025, A XR5757 RTM055
247026, A XR5757 RTM070
5.0
(18.9)
0
7
0
M
4.0
(15.1)
R
X
T
R
/
/
7
5
7
5
FLOW RATE in gpm (lpm)*
* To calculate flow in lb/min, multiply gpm rate by 10.
3.0
(11.4)
2.0
(7.6)
1.0
(3.8)
Example: 2 gpm x 10 = 20 lb/min.
0
800
(5.6, 56)
(8.7, 87)
1250
1700
(11.9, 119)
2150
(15.0, 150)
2600
(18.2, 182)
PRESSURE in psi (MPa, bar)
7
4
R
X
R
X
9
2
R
X
3
2
R
X
(21.3, 213)
4
5
3
9
2
3
2
3050
5
5
0
M
T
R
/
7
0
4
0
TM
R
/
5
3
0
4
0
TM
R
/
0
4
0
M
T
R
/
3500
(24.5, 245)
6 309856P
Direct Impingement Flat Pattern Guns
Use only these mix module/tip combinations.
List of Models/Selection Guide
Gun Part No., Series Slip-Fit™ Polycarballoy™ Mix Module Part No.,
see page 48 for numbering code
247050, A XF1313 FTM317
247051, A XF1313 FTM424
247057, A XF1818 FTM317
247058, A XF1818 FTM424
247061, A XF2323 FTM424
247062, A XF2323 FTM438
247063, A XF2323 FTM624
247065, A XF2929 FTM424
247066, A XF2929 FTM438
247067, A XF2929 FTM624
247073, A XF3535 FTM438
247074, A XF3535 FTM624
247075, A XF3535 FTM638
247081, A XF4747 FTM624
247082, A XF4747 FTM638
Flat CeramTip™ Part No.,
see page 50 for numbering code
247083, A XF4747 FTM838
247089, A XF5757 FTM638
247090, A XF5757 FTM838
247091, A XF5757 FTM848
247163, A XF2332 FTM438
309856P 7
List of Models/Selection Guide
Direct Impingement Flat Pattern Guns
2.0
(7.6)
1.6
(6.0)
1.2
(4.5)
7
5
F
X
XF
XF
8
3
6
M
T
F
/
7
5
4
7
4
5
3
8
3
6
M
T
/F
7
8
3
6
M
T
/F
5
3
0.8
(3.0)
0.4
(1.5)
9
2
9
2
F
X
2
3
2
F
X
8
1
8
1
F
X
3
1
3
1
F
X
4
2
4
M
T
F
/
4
2
4
M
T
F
/
3
4
2
4
M
T
F
/
4
2
4
M
T
F
/
FLOW RATE in gpm (lpm)*
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
0
800
(5.6, 56)
1250
(8.7, 87)
1700
(11.9, 119)
2150
(15.0, 150)
2600
(18.2, 182)
3050
(21.3, 213)
PRESSURE in psi (MPa, bar)
Four-Hose Gun
Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold
Gun Part No., Series Slip-Fit™ Polycarballoy™ Mix Module Part No.,
see page 48 for numbering code
249815, A XF2323 FTM438
Flat CeramTip™ Part No.,
see page 50 for numbering code
3500
(24.5, 245)
8 309856P
Warning
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes,
burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
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 18, 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.
309856P 9
Warning
WARNING
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 12.
• 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.
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 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.
10 309856P
Overall View
F
C
M
Overall View
P
K
L
D
T
G
Key:
A A Side Fluid Valve (ISO)
B B Side Fluid Valve (RESIN)
CAir Cap
D Air Line Quick Coupler
EMuffler
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)
R
N
H
AB
S
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
UAir Valve
U
TI3840a-1
309856P 11
Isocyanate Hazard
Isocyanate Hazard
Spraying materials containing isocyanates creates
potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Piston Safety Lock
Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.
WARNING
Read warnings, page 9.
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. To disengage piston safety lock:
TI3850a
push knob in and turn counterclockwise until it pops out.
Keep A and B Components Separate
CAUTION
To prevent cross-contamination of the gun’s wetted
parts, do not interchange A component (isocyanate)
and B component (resin) parts. The gun is shipped
with the A side on the left. The fluid manifold, fluid
housing, check valve cartridge, and mix module are
marked on the A side.
Grounding
WARNING
Read warnings, page 10.
TI3849a
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.
TI4022a
• Close fluid valves A and B.
Check your local electrical code and proportioner manual for detailed grounding instructions.
Ground the spray gun through connection to a
Graco-approved grounded fluid supply hose.
12 309856P
TI3837a
Setup
Setup
1. Close fluid valves A and B.
TI2411A
2. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold.
B (RESIN)
TI2417A
A (ISO)
4. Connect gun air whip hose (T) and air valve (U) to
main air hose. Attach fluid manifold (G) to gun.
T
G
U
TI3830a
To change position of fluid manifold or use
optional fluid inlets, see pages 19 and 20.
5. Connect air line to quick coupler (D). Turn on air.
Open air valve (U). Air should flow from air cap
around CeramTip (M). Open cleanoff air valve (K)
about 1/4 to 1/2 turn, then adjust air flow as
required.
3. Engage piston safety lock, page 12.
TI3850a
K
M
D
To use optional air inlet, see page 20.
6. Adjust purge rod, page 15.
7. Turn on proportioner.
U
TI3839a
309856P 13
Setup
8. Open B (RESIN) fluid valve (about three half
turns). Then open A (ISO) fluid valve.
B
A
TI3838a
9. Disengage piston safety lock, page 12.
TI3849a
10. Test spray onto cardboard. Adjust pressure and
temperature to get desired results.
TI3861a
11. Apply layer of lubricant over front of gun and
lock ring, or use gun cover to prevent overspray
buildup and ease disassembly. See page 53 to
order Fusion Gun Lubricant and gun cover.
12. Gun is ready to spray.
14 309856P
Adjust Purge Rod
Adjust Purge Rod
1. Engage piston safety lock, page 12.
2. Close fluid valves A and B.
B
A
U
TI3850a
TI3837a
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.
1/8-1/4 Turn
TI3829a TI3828a
Be sure to back out purge rod 1-2 turns before
changing CeramTips or mix modules. Readjust
purge rod after replacing CeramTips or mix
modules.
309856P 15
Adjust Flat CeramTip
Adjust Flat CeramTip
WARNING
Read warnings, page 9.
1. Engage piston safety lock, page 12.
2. Close fluid valves A and B.
3. Remove air cap (9).
9
TI3854a
TI3850a
4. Using nut driver, position CeramTip as desired.
TI3867a
B
A
U
TI3837a
5. Reassemble air cap (9) fingertight.
16 309856P
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.
Shutdown
309856P 17
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