Graco Fusion, 248597248647, 248603 Instructions-parts List Manual

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Page 1

Instructions-Parts

310648P

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 thismanual. 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 ConversionKit

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 FluidTemperature 3500 psi (24.2 MPa, 242 bar) Maximum Solvent Working Pressure

TI5006c

TI4965b

II 2 G

Page 2

Contents

Manual Conventions ........................3

OverallView ...............................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

CheckValve 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 SprayTip .........................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 ...................

Slip-Fit Polycarballoy Mix Module ...........34

Rear Rod Seal ..........................36

Adjust Rear Rod Seal ....................37

CheckValves ...........................38

Piston and Purge Rod ....................39

Piston Safety Lock .......................41

AirValve...............................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 SprayValve

with Manual Solvent Purge .............48

248647 Machine Mount SprayValve

with Manual Solvent Purge .............49

Slip-Fit Polycarballoy Mix Module Kits ........50

GunandPalmGrips .....................50

Drill Bit Kits ............................51

Gun Repair Kits ...........................52

CheckValve Filter Screen Kits (10 per kit) ....52

DrillBitKit .............................52

Model 248647 Mounting Dimensions ..........53

Technical Data ............................54

Graco Standard Warranty ...................56

Graco Information .........................56

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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 4-5.

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 havedifferent 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.

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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 PersonalProtective 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.

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Page 5

Warning

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks,or ruptured components will pierce skin. This maylook 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 spraysystem.

• Follow Pressure Relief Procedure, page 19, when you stop spraying and before cleaning, checking, or servicing equipment.

• Use lowest possible pressure when flushing, priming, or troubleshooting.

• Engage piston safety lock when not spraying.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose.

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. SeeTechnical 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.

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Overall View

OverallView

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 SolventPurge Assembly

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

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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 involvespotentially hazardous procedures. Do not spraywith 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 mustwear appropriaterespiratory protection.Alwayswear aproperly fittingrespirator,which mayinclude a supplied-air respirator.Ventilatethe workarea accordingto instructions inthe fluid manufacturer’sSDS.

• 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 exposureto isocyanates continues after spraying.Anyonewithout 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

____________ ____________

Page 8

Important Isocyanate (ISO) Information

For all applications except spray foam

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. Alwayswear 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 regardinghandling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

Material Self-ignition

Keep Components A and B Separate

Cross-contamination can result incured material influid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component B wetted parts.

• Neveruse solventon oneside if ithas 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 becomesuspended 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).

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NOTE:The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Page 9

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.

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Piston Safety Lock

Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.

WARNING

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.

TI3850a

To disengage piston safety lock: push knob in and

turn counterclockwise until it pops out.

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.

TI5003a

• Close fluid valves A and B.

TI4967b

TI3849a

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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.

2. Flush Gun, page 24.

Conversion Kit 248603

7. Liberallylubricate 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.

3. Disassemble front end of gun. Refer to manual

309856.

4. Disassemble the piston and purge rod assembly

from the gun, see Piston and Purge Rod in manual 309856.

5. Remove purge rod (31) from assembly and place

spacer (62) onto purge rod.

TI4988a

Spacer (61) is optional. For more forward travelof piston, remove spacer.

8. Install piston safety lock assembly until bottomed

out.

TI3847a

TI4989a

9. Reassemble the fluid housing onto the front end of

the gun. See Reassemble Front End, page 32,

6. Reassemble purge rod and piston assembly until

positive stop on purge rod spacer (62).

310648P 11

steps 1 through 6.

Page 12

Mounting an Automatic Gun

Mounting to a rod Mounting to a stationary

support robotic arm

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.

ti5007b

To mount gun to stationary support or robot arm, see

mounting hole dimensions, page 53.

Two .128 in. alignment pin holes

Four M5 x 0.08 in. (6.3 mm) holes

2. Secure the gun to the bar by tightening 1/4 in. - 20

mounting screws.

Connecting Airline and Accessories

I - Activation P - Purge/Clean-off O - Deactivation

Two 1/4 20 unc holes

ti4751b

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-wayair valve, which exhausts cylinder air in both directions, is required.

2. On the gun air supply line, install a bleed-type air

shutoff valve downstream of the gun air regulator.

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3. On the main air line, install a bleed-type air shutoff

valve.

Clean off air

Three 1/8 npt

ports (air inlet)

I - Activation P - Purge/Clean-off O - Deactivation

Gun actuation

Gun deactuation

ti4751b

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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.

40, 40d

9, 63

• Solvent purge knob (V) and inlet (Y) can be rotated in any direction.

40c

TI5033b

3. Close fluid valves A and B.

5. Engage piston safety lock (L), page 10.

TI3850a

6. 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 optional fluid inlets, see pages 21 and 22.

TI4968b

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

TI2411A

the solvent purge gun.

4. Connect A (ISO) and B (RESIN) fluid hoses to fluid

manifold (G).

B (RESIN)

A (ISO)

TI2417A

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To use optional air inlet (J), see page 22.

TI4969b

Page 14

Setup

8. To adjust purge rod position, follow piston and

purge rod disassembly instruction on page 39.

9. Attach Gracoapproved groundedfluid supply hose

to solvent inlet (Y). Make sure solvent purge valve (V) is closed before pressurizing the solvent hose.

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.

TI5004b

12. Disengage piston safety lock (L), page 10.

TI3849a

13. Turn RAC tip (X) to spray position.

TI5096b

14. Test spray onto cardboard. Adjust pressure,

temperature, or orifice size to get desired results. If applying materials that are greater than 1:1 ratio, follow the instructions for increasing orifice size, see Drilling of Mix Modules, page 15.

10. Turn on proportioner.

TI3861a

11. Open B (RESIN) fluid valve. Then open A (ISO)

fluid valve.

15. Apply layer of lubricant over front of gun and

lock ring, or use gun cover to prevent overspray buildup and ease disassembly.

16. Gun is ready to spray.

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TI4970b

Page 15

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.

CheckValve 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.

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)

TI3876a

B (RES)

Mix Module XF1313

Tools required

• Assorted Drill Bit Kit 119386

• Pin Vise 117661 Two XF1313 Polycarbolloy mix modules are

included with the gun. Additional mix modules are available, see page 50.

Larger Modules XF3535, XF4747, XF5757 are available but not included with gun.

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Remove Polycarballoy Mix Module, see page 34.

5. Open up resin porting to raise ISO pressure. Start-

ing with the smallest drill bit size,drill into port. For drill bit sizes, see Drill BitTable, page 16.

B (RES)

117661 Pin Vise

TI3862a

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Page 16

Hand Drilling of Mix Modules

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

6. Reassemble gun, page 34.

7. Check pressure gauges. A (ISO) and B (RES)

gauges should balance at the required pressure, flow, and temperature operation points.

8. If ISO gauge still reads lower than the RESIN,

repeat steps 1 through 7. Use the next drill bit size for drilling the B (RES) port on the mix module.

9. If you get the system pressure balanced but do not

have enough flow at the gun, drilling port A (ISO) may be necessary. Drill port A (ISO) out to next size. Repeat steps 1 through 8 to bring the pressure gauges back into balance.

Module Port Drill Bit Size

A B

Drill BitTable

Drill Bit Sizes

# size Diameter (in.) Diameter (mm)

81 0.013 0.33 80 0.0135 0.34 79 0.0145 0.37 78 0.016 0.41 77 0.018 0.46 76 0.02 0.51 75 0.021 0.53 74 0.0225 0.57 73 0.024 0.61 72 0.025 0.64 71 0.026 0.66 70 0.028 0.71 69 0.0292 0.74 68 0.031 0.79 67 0.032 0.81 66 0.033 0.84 65 0.035 0.89 64 0.036 0.92 63 0.037 0.94 62 0.038 0.97 61 0.039 0.99 60 0.04 1.02 58 0.042 1.07 56 0.0465 1.18

A (ISO)

TI3863a

10. Repeat drilling until system pressures are bal-

anced.

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.

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Page 17

Operation

Spraying

1. To spray, turn RAC tip (X) to spray position.

2. Close solvent purge knob (V).

TI5004b

2. Turn RAC tip (X) to clean position.

TI5097b

TI5096b

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 sol-

vent to the static mixer assembly.

3. Trigger gun to spray.

WARNING

Read warnings page, 4.

Flushing with Solvent Purge Assembly

1. Detrigger the gun and engage safety lock.

TI5110b

5. When static mixer and tip are clean, close solvent

purge knob (V).

• For more thorough static mixer cleaning, remove the spray tip.

• Minimize the amount of flushing time. Do not atomize solvent.

TI5004b

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Page 18

Shutdown

Daily Shutdown

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

Shutdown for More than a Day

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

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Page 19

Pressure Relief Procedure

WARNING

Read warnings, page 5. Relieve pressure before cleaning or repairing gun.

1. Engage piston safety lock (L), page 10.

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.

4. Turn RAC tip (X) to clean position.

TI5097b

5. Trigger gun onto cardboard or into waste container

to relieve pressure.

TI5009a

TI5005b

3. Disengage piston safety lock (L), page 10.

TI3849a

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Page 20

Pressure Relief Procedure

6. Engage piston safety lock (L), page 10.

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-

vent Purge Assembly, page 17.

8. Shut off air to solvent supply. Open solvent purge

knob (V) and relieve pressure in the solvent line.

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TI5110b

Page 21

Optional Configurations

Optional Fluid Manifold Position

Fluid manifold is mounted to bottom of gun, with A side on left, viewed from operator’sposition at back of gun. If desired, manifold may be moved to top of gun. Doing this will reposition A side parts (fluid inlet, check valve, and fluid housing A side) to right.

CAUTION

To prevent cross-contamination of gun’s wetted parts,

do not interchange A component (isocyanate) and B component (resin) parts.

1. Follow Pressure Relief Procedure, page 19.

2. Disconnect air (D) and remove fluid manifold (G).

3. Unscrew lock ring (P) until front end of gun is

loose.

4. Rotate fluid housing (F) 180° and retighten lock

ring very securely.

5. Attach fluid manifold. Connect air. Return gun to

service.

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Page 22

Optional Configurations

Optional Hose Position

Fluid inlet swivels andair quick disconnect fitting point to rear. If desired, these positions can be changed so hoses travel downward.

Fluid Hoses

CAUTION

To prevent cross-contamination of gun’s wetted parts, do not interchange A component (ISO) and B component (RESIN) parts.

1. Follow Pressure Relief Procedure, page 19. Also

relievesystem pressure and flush both fluid hoses, see proportioner manual.

2. Disconnect air (D) and remove fluid manifold (G).

4. Apply threadsealant 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).

TI2646A

5. Connect appropriate hoses to A and B swivels.

Air Hose

1. Remove fitting (D) and plug (J). Reversepositions.

Apply thread sealant and torque to 125-135 in-lb (14-15 N•m).

TI4968b

3. Disconnect fluid hoses from inlet swivels (A, B).

Remove swivels. Remove plugs from optional inlets (N).

TI2417A

TI4965b

2. Attach fluid manifold (G). Connect air. Return gun

to service.

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Page 23

Maintenance

SuppliedTool Kit

• Hex Nut Driver; 5/16

• Screwdriver; 1/8 blade

• #81, 60, 58, and 56 drill bits.

• 117661 Pin Vise; dual reversible chucks Reversible

Reversible

• Drill Bit Kit 119386.

TI3864a

Keep Gun Clean

Keep gun clean with accessory gun cover 244915. Applying a light coat of lubricant will make cleaning eas-

ier. Lubricate threads and outside of lock ring (11) to ease disassembly. Use Fusion Gun Lubricant 118665.

3. Clean Muffler, page 24.

4. Clean Fluid Manifold, page 24.

5. Clean Slip-Fit Polycarballoy Mix Module, page

25.

Daily

Follow Shutdown, page 18.

Weekly to Monthly

1. Clean Check Valves, page 38. Check o-rings and

screens.

As Needed

1. Clean Outside of Gun, page 24.

2. Clean Air Cap, page 24.

2. Check that piston safety lock threaded connection

is tight, page 41.

310648P 23

Page 24

Maintenance

Flush Gun

If it is necessary to flush the mix module, use following procedure.

WARNING

Read warnings, page 4.

1. Follow Pressure Relief Procedure, page 19.

2. Flush with a 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 Air Cap

Soak air cap in compatible solvent. If necessary, clean gently with stiff brush.

Clean SprayTip

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.

Clean Muffler

A partially plugged muffler will slow gun actuation. Remove and clean muffler 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.

Clean Outside of Gun

Wipe off outside of gun with compatible solvent.

CAUTION

Use N Methyl Pyrrolidone (NMP), Dynasolve CU-6, Dzolv, or equivalent to soften cured material when cleaning the outside of gun. Do not use as flushing

solvents.

TI2411-1

Clean Mixer

The center mix element can be pressed out, front to

back, even if fully cured. The mix element can then be cleaned with a wire brush.

24 310648P

Page 25

Clean Slip-Fit Polycarballoy Mix Module

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

Maintenance

TI3863a

3. Remove mix module, page 34.

CAUTION

To avoid damaging mix module, do not force drill bits

when cleaning impingement ports. Some ports are offset or angled.

4. See FIG. 1 and FIG. 2. Clean mix module impinge-

ment ports (IP) with appropriate size drill (supplied). See identification chart under Drill Bit Kits, page 51. See the recorded drill bit size from step 11 page 16.

• Component B (RES) impingement ports, at rear of mix module, are angled toward front of gun. See FIG.2.

• When cleaning do not scratch the sealing edges and ports.

FIG. 1. Cleaning Component A (ISO) Ports

TI3862a

FIG. 2. Cleaning Component B (Resin) Ports

5. Reassemble, page 34.

310648P 25

Page 26

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 CAUSE SOLUTION

Gun does not fully actuate when triggered.

Fluid doesnot spraywhen gun is fully actuated.

Gun actuates slowly or with delayed action.

Purge rod will not actuate. No air pressure. Connect air supply.

Pressure imbalance. Plugged impingement ports. Clean, page 25. Reinstall mix mod-

Piston safety lock engaged. Disengage piston safety lock, page

10. Plugged muffler (22). Clean, page 24. Damaged air valve o-rings (24). Replace, page 41. Closed fluid valves (12b). Open.

Plugged impingement ports. Clean, page 25. Plugged check valves (36). Clean, page 38. Plugged muffler (22). Clean, page 24.

Damaged piston o-rings (16, 19). Replace, page 39. Dirty air valve, or damaged o-rings

(24). Mix module nut (25) too tight. Loosen nut, then retighten, page 33. Loose lock ring (11). Tighten, use tool if necessaryCon-

Low air pressure. Set air pressure above 80 psi (0.56

Buildup on purge rod (31). Clean purge rod.

Plugged check valves (36). Clean, page 38. Viscosities not equal. Adjust temperature to compensate.

Clean air valve or replace o-rings, page 41.

version Kit 248603, page 11.

MPa, 5.6 bar).

ule, page 34.

See Drilling of Mix Modules, page 15.

Ratio not equal. See Drilling of Mix Modules, page 15.

26 310648P

Page 27

PROBLEM CAUSE SOLUTION

Fluid does not shut off when fluid

Damaged fluid valves (12b). Replace.

valves are closed. Air leakage around fluid housing. Damaged or missing o-ring (20). Replace. Air leakage from piston safety lock. Damaged or missing o-rings (18). Replace, page 39. Burst of air from muffler when gun is

Normal. No action required.

triggered. Steady air leakage from muffler. Damaged air valve o-rings (24). Replace, page 41.

Damaged piston o-rings (16, 19). Replace, page 39. Air leakage from front air valve. Damaged air valve o-rings (24). Replace, page 41. Component B (resin) leak from fluid

Worn rear rod seal. Adjust Rear Rod Seal, page 37.

housing. Cross Contamination of A and B

components.

Worn out mix module. Replace.

Sealing surface OD not clean. Clean sealing surface on fluid hous-

ing.

Air leakage from holes on solvent purge assembly.

Cleanoff air valve open. Close cleanoff air valve tightly. Clea-

noff air valve should never be open when using solvent purge gun.

Fluid leakage from holes on solvent purge assembly.

Mix module nut is only handtight. Tighten mix module nut 1/12 with

wrench.

Troubleshooting

310648P 27

Page 28

Troubleshooting

Theory of Operation

GunTriggered (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

Gun Detriggered (Mechanical and Solvent Purging)

Purge rod (31) moves forward, closing impingement ports (IP) and shutting off fluid flow.Rod pushes through mix module (39), forcing out excess fluid and restoring proper orifice diameter. Solvent purge knob (28f) is opened, allowing solvent to flush out static mixer (40) and tip (9).

KEY

Fluid

28f

ti5099

28 310648P

ti5098

Page 29

CutawayView

Troubleshooting

12b

TI4992b

310648P 29

Page 30

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 Loctitep

• 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).

TI5002b

4. Remove mix module nut (25), using a wrench.

Remove front seal (46).

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. Flush Gun, page 24.

30 310648P

Page 31

5. Remove mix module (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).

Repair

6. Unscrew lock ring (11) to remove front end and

mix module. Pull front end straight off handle.

TI3865b

310648P 31

Page 32

Repair

Reassemble Front End

1. Checkthat o-rings (20, 21)are in position. Liberally

lubricate o-rings, threads of lock ring (11) and handle (1), and outside of lock ring.

TI3871a

2. Orient front end as required for desired fluid mani-

fold mounting (bottom mounting shown). Align slots (Y) to engage tabs (Z).

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.

TI3866a

TI3871a

4. Push mix module (39) onto rod (31) as far as pos-

sible.

TI3873a

TI3845a

32 310648P

Page 33

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).

1/12 Turn

TI4986a

6. Reinstall solvent purge assembly (28). Lubricate

all threads.Install static mixer (40) and RAC tip (9).

Tighten with wrench.

TI5002b

310648P 33

Page 34

Repair

Slip-Fit Polycarballoy Mix Module

See page 50 for available Slip-Fit Polycarballoy Mix Module sizes.

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Remove fluid manifold (G). Leave air connected.

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.

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.

TI3845a

7. Push mix module (39) onto rod (31) as far as pos-

sible.

TI4972b

4. Remove RAC tip and guard (9, 63), static mixer

(40), and solvent purge assembly (28).

9, 63

TI5032b

5. Remove mix module nut (25), using a wrench.

Remove front seal (46).

TI3845a

TI3843a

34 310648P

Page 35

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).

1/12 Turn

TI4986a

9. Reinstall solvent purge assembly (28). Lubricate

all threads. Install static mixer (40) and RAC tip and guard (9, 63).Tighten with wrench.

9, 63

TI5032b

10. Attach fluid manifold. Return gun to service.

310648P 35

Page 36

Repair

Rear Rod Seal

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Remove fluid manifold (G). Leave air connected.

TI4972b

7. Reassemble newrear 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.

9. Attach fluid manifold. Connect air. Return gun to

service.

4. Disassemble Front End, page 30.

5. Remove rear rod seal nut (23) with nut driver (53).

TI3869a

6. Push out rear seal (46) with screwdriver (54).

TI3872a

36 310648P

Page 37

Adjust Rear Rod Seal

Repair

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Remove fluid manifold (G). Leave air connected.

TI4972b

4. Disassemble Front End, page 30.

6. Remove fluid housing (7) from rod (31).

7. Reassemble Front End, page 32.

8. Attach fluid manifold. Return gun to service.

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 sliding on rod.

7 31

TI3831a

310648P 37

Page 38

Repair

CheckValves

Before disassembling, press on ball (36c) to test check valve for proper movement and spring action.

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

Clean and inspect check valvemating surfaces and fluid ports.

TI4968b

WARNING

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. Thor-

oughly inspect o-rings (36f, 36g). If necessary, remove screw (36b) and disassemble check valve.

36b 36e

36c

Check valvefilters are available, see Check Valve Filter Option page 15.

36d 36g

36a 36f

TI4987a

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.

6. Reassemble check valves. Screw (36b) should be

flush (within 1/16 in. or 1.5 mm) of housing (36a) surface. Liberally lubricate o-rings (36f, 36g) and carefully reinstall in fluid housing.

7. Attach fluid manifold. Connect air. Return gun to

service.

38 310648P

Page 39

Repair

Piston and Purge Rod

Spacer (61) is optional. For more forward travelof 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.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

6. Pull purge rod to remove piston (32). Inspect pis-

ton o-ring (16) and shaft o-ring (19).

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.

TI4968b

4. Disassemble Front End, page 30.

5. Unscrew purge rod stop (15) to remove piston

safety lock assembly. Inspect o-rings (14, 18) in place.

TI3847a

TI3848a

8. Liberallylubricate 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.

TI4988a

310648P 39

Page 40

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

Page 41

Piston Safety Lock AirValve

Repair

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

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).

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

TI4968b

4. Unscrew air valve plug (2) and remove spring (26).

Using small screwdriver (54), push spool (27) out from front. Inspect o-rings (24).

3, 4

TI3835b

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 Loctitep or equivalent to threads on stop (15) and cap (10), and reassemble.

6. Attach fluid manifold. Connect air. Return gun to

service.

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.

310648P 41

Page 42

Repair

Solvent Purge Assembly

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

9, 63

TI4968b

4. Disassemble RAC tip and guard (9, 63), static

mixer (40), and solvent purge assembly (28) from front end of gun.

6. Reassemble air cap (28b) to housing (28a), then

install (28c) and (28d) into housing (28a).

7. Assemble (28e). Lubricate packings. Slide (28h)

over assembled (28e) into groove and lubricate.

8. Assemble knob (28f) onto (28e). Assemble screws

(28g) and tighten with a 3/32 in. allen wrench.

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).

10. Reassemble RAC tip and guard (9, 63) and

static mixer (40) to solvent purge assembly (28). Tighten with wrench.

9, 63

TI5002b

9, 63

5. Disassemble Solvent Purge Assembly (28a-m).

Inspect parts for damage, replace if necessary.

28b

28m

28k

28j

28d

28a

28c

28h

28e

28f

28g

TI5035a

TI5033b

11. Attach fluid manifold. Connect air. Return gun to

service.

42 310648P

Page 43

Repair

Static Mixer Assembly

1. Follow Pressure Relief Procedure, page 19.

2. Flush Gun, page 24.

3. Disconnect air (D) and remove fluid manifold (G).

9, 63

TI4968b

6. Reassemble static mixer assembly (40a-e).

7. Reassemble RAC tip, guard (9, 63) and static

mixer (40) from solvent purge assembly (28).

9, 63

TI5033b

8. Attach fluid manifold. Connect air. Return gun to

service.

4. Disassemble RAC tip, guard (9, 63) and static

mixer (40) from solvent purge assembly (28).

TI5002b

9, 63

5. Disassemble static mixer housing (40a), mixer

(40b), gasket (40c), packing (40d), and adapter (41). Inspect parts for damage, replace if necessary.

40b

40a

40d

40c

310648P 43

Page 44

Repair

44 310648P

Page 45

Parts

248597 and 248647 Solvent Purge Plural Component Spray Guns, and 248603 Conversion Kit

Parts

Ref. Part No. Description Qty.

28❖ 248643 SOLVENTPURGE ASSY.; 28a 15E111 . HOUSING 1

28b 15E130 . CAP, air 1 28c 113618 . GASKET, FFR 1 28d 15E137 . SEAT 1 28e 248641 . KIT, retainer 1 28f 15E114 . KNOB 1 28g 101366 . SCREW, set 2 28h 248648 . PACKING KIT, includes 6 o-rings 1 28j 191892 . ELBOW, 90° 1 28k 191872 . ADAPTER 1 28m 119796 . GASKET 1 40 248642 STATIC MIXER; includes items

40a 15E125 . HOUSING 1 40b 15E126 . MIXER, static 3 in. 1 40c 166969 . GASKET 1 40d 104892 . PACKING, o-ring 1

40d

Static Mixer Assembly

includes items 28a-28m

40a-40d

40a

40b

TI5034a

40c

28b

Solvent Purge Assembly

28m

28a

28c

28h

28d

28k

28j

28e

28g

TI5035a

28f

310648P 45

Page 46

Parts

248597 Solvent Purge Manual Spray Gun

‡44

‡*24

◆†‡7

†‡36b

‡36e ‡36d

‡*36g

†‡36a †‡*36f

28❖

46*†‡ 25

14*★

15★

10★ 17★ 59★

60★

4★

3★

16*

61❖

18★

62❖

Supplied Tools

23‡

21*‡◆

46*†‡

35‡◆

11‡◆

TI3870a

36c‡

12e

12f

12c

24†‡

Torque to 125-135 in-lb (14-15 N•m).

Torque to 20-30 in-lb (2.3-3.4 N•m).

Torque to 32-40 ft-lb (43-54 N•m).

Torque to 35-45 in-lb (4-5 N•m).

TI4991b

‡36

†12a

12b

12d

12g

46 310648P

Page 47

248597 Solvent Purge Manual Spray Gun

Ref.

Ref. No. Part No. Description Qty

1 248002 HANDLE 1 2 15B208 PLUG, air valve 1 3★ 15C374 ACTUATOR; safety 1

★ 15C390 BUSHING, safety 1

4 5 203953 SCREW; 10-24 x 3/8 in. (10 mm) 1 6 192272 PIN 1 7†‡◆ HOUSING, fluid 1 8 118145 SPRING, purge rod 1 9 XHD521 TIP, spray, RAC 1 10★ 15C373 CAP, rear 1

11‡◆

15B215 RING, lock 1

12 246012 MANIFOLD, fluid;

includes 12a-12g 12a† . MANIFOLD 1 12b 246356 . VALVE, fluid 2 12c 100139 . PLUG, pipe; 1/8-27 npt 2 12d 15B221 . BOLT; 5/16-24 1 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 1 13 15B209 TRIGGER 1 14*★ 248136 O-RING, rod stop; package of 6 1 15★ 15C372 STOP, purge rod 1 16* 248135 O-RING, piston; package of 6 1 17★ 118144 SPRING, piston safety lock 1 18★ 248095 O-RING, purge rod; package of 6 1 19 248096 O-RING, piston shaft;

package of 6

20 248138 O-RING, housing, small;

package of 6

21‡◆* 248132 O-RING, housing, large;

package of 6 22 119626 MUFFLER 1 23‡ 15C378 NUT, rod seal, rear 1 24‡* 246354 O-RING; package of 6 1 25 15C377 NUT, mix module 1 26 117485 SPRING, air valve 1 27 15B202 SPOOL, air valve 1 28❖ SOLVENT PURGE ASSY.;

includes items 28a-j; see page 45

for parts 29 100721 PLUG, pipe; 1/4-18 npt 1 30 117509 QUICK-DISCONNECT, male, air;

1/4 npt(m) 31 248001 ROD, purge; includes 1 of item 18 1 32 15C371 PISTON 1 34 117661 VISE, pin; dual reversible chucks 1 35‡◆ 116550 RING, retaining 1 36‡ 246731 VALVE, check, A side; includes

36a-36g

246352 VALVE, check, B side; includes

36a-36g 36a‡† . HOUSING 1 36b‡† 15B214 . SCREW; 5/16-18 x

1/2 in. (13 mm) 36c‡ 104396 . BALL; carbide 1 36d‡ . SCREEN; see page 52 1

No. Part No. Description Qty

‡ 117490 . SPRING 1

36e 36f

‡* 248133 . O-RING, check valve face;

‡* 248129 . O-RING, check valve housing;

36g 37▲ 222385 TAG, warning; not shown 1

39 MODULE, mix, flat, direct impinge-

ment; see page 50

40 STATIC MIXER; includes items

40a-40d; see page 45 for parts

41 15E244 ADAPTER, static mixer;

see page 45

44‡

15C382 VALVE, cleanoff air 1

†‡* 248003 SEAL KIT, purge rod; includes 4

seals 48 117510 COUPLER, air line 1 49 15B772 HOSE, air; 1/4 npsm (fbe); 18 in.

(0.46 m) 50 112307 ELBOW, street;1/8 npt (m x f) 2

51 15B565 VALVE, ball; 1/4 npt (m x f) 1 53 117642 NUT DRIVER, hex; 5/16 1

54 118575 SCREWDRIVER; 1/8 blade 1 56 15C480 WASHER, wave 1 57■ 118665 LUBRICANT, Fusion Gun; 4 oz

(113 gram) 59★ 15D329 STOP, rod 1 60★ 115452 RING, retaining 1 61❖ 15E132 SPACER, piston 1 62❖ 15E133 SPACER, purge rod 1 63 XHD001 GUARD, tip 1

64 119386 DRILL BIT KIT, not shown 1

* These parts are only available in repair kits.To

select a kit, refer to Gun Repair Kits on page 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.

1 1

Parts

package of 6

1 1 1

310648P 47

Page 48

Parts

248647 Machine Mount Spray Valve with Manual Solvent Purge

46*†‡

14*★

62❖

16*

15★

10★

17★

3★

4★

59★

60★

‡44

‡*24

†‡7

‡36;

see detail

at right

†12a

61❖

35‡

11‡

18★

Check Valve (36) Detail

†‡36b

23‡

21*‡

46*†‡

‡36e

‡36c

‡36d

*‡36g †‡36a

*‡36f

12e

Supplied Tools

12f

12b

12d

12c

ti8661a

12g

Torque to 125-135 in-lb (14-15 N•m).

Torque to 32-40 ft-lb (43-54 N•m).

48 310648P

Page 49

248647 Machine Mount Spray Valve with Manual Solvent Purge

Ref.

Ref. No. Part No. Description Qty

1 16H942 BODY, mechanical purge 1

★ 15C374 ACTUATOR; safety 1

3 4

★ 15C390 BUSHING, safety 1

7†‡◆ HOUSING, fluid 1 8 118145 SPRING, purge rod 1 9 XHD521 TIP, spray, RAC 1 10★ 15C373 CAP, rear 1

11‡◆

12 246012 MANIFOLD, fluid; 12a

12b 246356 . VALVE, fluid 2 12c 100139 . PLUG, pipe; 1/8-27 npt 2 12d 15B221 . BOLT; 5/16-24 1 12e 117634 . SWIVEL, B side; 1/8 npt(m) x

12f 117635 . SWIVEL, A side; 1/8 npt(m) x 12g 15B993 . SPRING, ring, lock 1

14*★ 248136 O-RING, rod stop; package of 6 1 15★ 15C372 STOP, purge rod 1 16* 248135 O-RING, piston; package of 6 1 17★ 118144 SPRING, piston safety lock 1 18★ 248095 O-RING, purge rod; package of 6 1 19 248096 O-RING, piston shaft;

20 248138 O-RING, housing, small; 21‡◆* 248132 O-RING, housing, large; 23‡ 15C378 NUT, rod seal, rear 1

24‡* 246354 O-RING; package of 6 1 25 15C377 NUT, mix module 1 28❖ SOLVENT PURGE ASSY.;

31 248001 ROD, purge; includes 1 of item 18 1 32 15C371 PISTON 1 34 117661 VISE, pin; dual reversible chucks 1 35‡◆ 116550 RING, retaining 1 36‡ 246731 VALVE, check, A side; includes

36a‡† . HOUSING 1 36b‡† 15B214 . SCREW; 5/16-18 x

36c‡ 104396 . BALL; carbide 1 36d‡ . SCREEN; see below 1 36e‡ 117490 . SPRING 1 36f‡* 248133 . O-RING, check valve face;

36g‡* 248129 . O-RING, check valve housing; 37▲ 222385 TAG, warning; not shown 1

15B215 RING, lock 1

includes 12a-12g

† . MANIFOLD 1

no. 6 JIC(f) no. 5 JIC(f)

package of 6 package of 6 package of 6

includes items 28a-j; see page 45 for parts

36a-36g

246352 VALVE, check, B side; includes

36a-36g

1/2 in. (13 mm)

package of 6 package of 6

No. Part No. Description Qty

39 MODULE, mix, flat, direct impinge40 STATIC MIXER; includes items 41 15E244 ADAPTER, static mixer;

44‡

46†‡* 248003 SEAL KIT, purge rod; includes 4

50 112307 ELBOW, street;1/8 npt (m x f) 2 53 117642 NUT DRIVER, hex; 5/16 1 54 118575 SCREWDRIVER; 1/8 blade 1 57■ 118665 LUBRICANT, Fusion Gun; 4 oz

59★ 15D329 STOP, rod 1

60★ 115452 RING, retaining 1 61❖ 15E132 SPACER, piston 1

62❖ 15E133 SPACER, purge rod 1 63 XHD001 GUARD, tip 1 64 119386 DRILL BIT KIT, not shown 1 65 100139 PLUG, 1/8 NPT 3

* These parts are only available in repair kits.To

select a kit, refer to Gun Repair Kits, page 52.

† These parts are not available singly.

‡ These parts are included in Fluid Housing Assembly

1 1

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.

Parts

ment, see page 50

40a-40d; see page 45 for parts

see page 45

15C382 VALVE, cleanoff air 1

seals

(113 gram)

310648P 49

Page 50

Parts

Slip-Fit Polycarballoy Mix Module Kits

Slip-Fit Polycarballoy Mix Module Part Numbering Code

Example Part No.

XR3535 XR=Mechanical purge direct impingement, round pattern 35=Component A XF3535 XF=Mechanical purge direct impingement, flat pattern

*** Some modules have multiple impingement ports (see below). Size is given as the equivalence of a single port.

FirstTwo Digits SecondTwo Dig-

its

impingement port size (.035 in.).***

LastTwo Digits

35=Component B

impingement port size (.035 in.).***

Direct Impingement Flat Pattern Guns

Slip-Fit Polycarballoy Mix Module Kit (includes drill bits)

XF1313 1 #81 #67 XF1818 1 #77 #67 XF2323 1 #74 N/A XF2929 1 #69 N/A XF3535 2 #73 N/A XF4747 2 #67 N/A XF5757 3 #67 N/A

No. of Impingement Ports

Impingement Port Drill Bit Size, nominal**

Counterbore Drill Bit Size, nominal**

**For further information, see identification chart under Drill Bit Kits, page 51.

**For further information, see identification chart under

Drill Bit Kits, page 51.

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-fatigueproperties and minimize the applicator's grip strength.

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 10 Pack 17G543 50 Pack 17G544 100 Pack

Palm Grip Kit

Palm Grips are designed to adhere to any disposable/removable glove.

Kit Part No. Qty in Kit

17G545 10 Pack 17G546 50 Pack 17G547 100 Pack

50 310648P

Page 51

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.

Parts

Kit Part No. Qty in Kit

Drill Bit Size

nominal in. mm

246623 3 #32 0.116 2.90

246810 3 7/64 0.109 2.77

246813 3 #39 .099 2.51

246812 3 #43 .089 2.26

246624 3 3/32 .094 2.39

246625 3 #44 .086 2.18

246811 3 2 mm .079 2.00

246626 6 #50 .070 1.78

246627 6 #53 .060 1.52

246809 6 #54 .055 1.40

246628 6 #55 .052 1.32

Illustration

246814* 6 #56 .046 1.18

246629* 6 #58 .042 1.07

246808* 6 #60 .040 1.02

246807† 6 #67 .032 0.81

246630† 6 #69 .029 0.74

246815† 6 #73 .024 0.61

276984† 6 #74 .023 0.57

246631† 6 #76 .020 0.51

246816† 6 #77 .018 0.46

246817* 6 #81 .013 0.33

* Included with gun, one each. † Included with gun in Drill Bit Kit 119386. Includes one of each.

310648P 51

Page 52

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.

14 248136 (6) 1 16 248135 (6) 1 18 248095 (6) 2 19 248096 (6) 1 20 248138 (6) 1 21 248132 (6) 1 24 246354 (6) 4* 28c 1 28h 248648 (6) 1 36f 248133 (6) 2 2 36g 248129 (6) 2 2 40c 1 40d 1 46 248003 (4) 2

Bulk O-ring Kits, (qty)

246351 CheckValve O-ring Kit

248887 Solvent Purge Gun Complete O-ring Kit

*248647 only requires one #24. There will be three spares when ordering the 248887 solvent purge gun complete o-ring kit.

CheckValve 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

Page 53

Model 248647 Mounting Dimensions

Measurement Definition

in. (mm)

0.73 (18.54)

1.30 (33.0)

0.625 (15.88)

1.06 (26.92)

2 x 1/4-20

1 (25.4)

4xM5

3 x 1/8 npt

2x໅ 0.127 (3.23)

ti4751b

0.625 (15.88)

310648P 53

Page 54

Technical Data

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 psi (0.9 MPa, 9 bar) Maximum Fluid Temperature 200° F (94° C) Air Inlet Size 1/4 npt Quick Disconnect Nipple Solvent Inlet Size 1/4-18 NPSM A Component (ISO) Inlet Size -5 JIC; 1/2-20 UNF female swivel in 1/8 npt (f) port B Component (Resin) Inlet Size -6 JIC; 9/16-18 UNF female swivel in 1/8 npt (f) port Sound Pressure 70 dB(A), at 100 psi (0.7 MPa, 7 bar) Sound Power, measured per ISO

9416-2 Length 9 in. (228 mm) Height 8.1 in. (206 mm) Width 3.5 in. (89 mm) Weight 3.7 lb (1.68 kg)

Wetted Parts

79.9 dB(A), at 100 psi (0.7 MPa, 7 bar)

Aluminum, stainless steel, carbon steel, chemically resistant o-rings, ultra-high molecular weight polyethylene (UHMWPE), Polycarballoy, Nylon

Static Mixer 248642 Data

Inlet Thread 11/16-16 female straight thread Outlet thread 11/16-16 male straight thread Length 2.84 in. (72.2 mm) Maximum Working Pressure 3500 psi (24.2 MPa, 242 bar) Wetted Parts 303 stainless steel, Acetal plastic gaskets.

Disposable Static Mixer Adapter 15E244

Inlet Thread 11/16-16 female straight thread Outlet thread 7/8-14 male straight thread with tapered bell Usage Allows the use of disposable mixers, jackets, and RAC assemblies.

$OORWKHUEUDQGQDPHVRUPDUNVDUHXVHGIRULGHQWLILFDWLRQSXUSRVHVDQGDUHWUDGHPDUNVRIWKHLUUHVSHFWLYHRZQHUV

Data

54 310648P

Page 55

Technical Data

310648P 55

Page 56

Graco StandardWarranty

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.

THISWARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITEDTO 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 acknowledgethat they haverequired 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 convenuque 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

www.graco.com

Revision P, February 2016

Graco Fusion, 248597248647, 248603 Instructions-parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Manual Conventions

Overall View

Important Isocyanate (ISO) Information

Material Self-ignition

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Grounding

Foam Resins with 245 fa Blowing Agents

Changing Materials

Piston Safety Lock

Loss of Air Pressure

Conversion Kit 248603

Mounting an Automatic Gun

Mounting to a rod Mounting to a stationary

Connecting Airline and Accessories

Setup

Hand Drilling of Mix Modules

CheckValve Filter Option

Tools required

Operation

Spraying

Flushing with Solvent Purge Assembly

Shutdown

Daily Shutdown

Shutdown for More than a Day

Pressure Relief Procedure

Optional Configurations

Optional Fluid Manifold Position

Optional Hose Position

Maintenance

SuppliedTool Kit

Keep Gun Clean

Daily

Weekly to Monthly

As Needed

Flush Gun

Clean Air Cap

Clean SprayTip

Clean Muffler

Clean Fluid Manifold

Clean Outside of Gun

Clean Mixer

Clean Slip-Fit Polycarballoy Mix Module

Troubleshooting

Theory of Operation

CutawayView

Repair

Tools Required

Lubrication

Disassemble Front End

Reassemble Front End

Slip-Fit Polycarballoy Mix Module

Rear Rod Seal

Adjust Rear Rod Seal

CheckValves

Piston and Purge Rod

Piston Safety Lock AirValve

Solvent Purge Assembly

Static Mixer Assembly

Parts

248597 and 248647 Solvent Purge Plural Component Spray Guns, and 248603 Conversion Kit

248597 Solvent Purge Manual Spray Gun

248597 Solvent Purge Manual Spray Gun

248647 Machine Mount Spray Valve with Manual Solvent Purge

248647 Machine Mount Spray Valve with Manual Solvent Purge

Slip-Fit Polycarballoy Mix Module Kits

Gun and Palm Grips

Drill Bit Kits

Gun Repair Kits

CheckValve Filter Screen Kits (10 per kit)

Drill Bit Kit

Model 248647 Mounting Dimensions

Technical Data

Graco StandardWarranty

Graco Information