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.
EN
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
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
32
2310648P
Manual Conventions
WarningCaution
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.
310648P3
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.
4310648P
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.
310648P5
Overall View
OverallView
K
P
L
F
C
M
D
T
W
R
N
X
Y
V
G
B
A
H
Key:
AA Side Fluid Valve (ISO)
BB Side Fluid Valve (RESIN)
CAir Cap
DAir Line Quick Coupler
EMuffler
FFluid Housing
GGun Fluid Manifold
HHandle
JOptional Air Inlet
KCleanoff Air Valve
LPiston Safety Lock
MSolventPurge Assembly
S
U
J
NOptional Fluid Inlets (A Side Shown)
PLock Ring
RFluid Inlet Swivels (A Side Shown)
STrigger
TGun Air Whip Hose
UAir Valve
VSolvent Purge Valve
W Static Mixer
XRAC tip
YSolvent Fluid Inlet
E
TI4966b
6310648P
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
•Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
•Use of isocyanates 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:
310648P7
____________
____________
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).
8310648P
NOTE:The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
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.
310648P9
Piston Safety Lock
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
10310648P
Conversion Kit 248603
A Standard Mechanical Purge Gun can be converted
into a Solvent Purge Gun with this kit.
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.
31
62
61
61
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).
310648P11
steps 1 through 6.
Mounting an Automatic Gun
Mounting an Automatic Gun
Mounting to a rodMounting 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
P
I - Activation
P - Purge/Clean-off
O - Deactivation
I
O
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.
12310648P
3. On the main air line, install a bleed-type air shutoff
valve.
Clean off air
Three 1/8 npt
ports (air
inlet)
I
P
O
I - Activation
P - Purge/Clean-off
O - Deactivation
Gun
actuation
Gun
deactuation
ti4751b
Setup
Setup
1. Read Hand Drilling of Mix Modules, page 15,
before performing setup procedure.
2. Assemble gaskets (40c), static mixer assembly
(40), o-ring (40d), adapter (41), and RAC tip and
guard (9, 63) assembly to fluid housing on front
end of gun.
40, 40d
41
9, 63
•Solvent purge knob (V) and inlet (Y) can be
rotated in any direction.
40c
VY
TI5033b
3. Close fluid valves A and B.
5. Engage piston safety lock (L), page 10.
L
TI3850a
6. Connect gun air whip hose (T) and air valve (U) to
main air hose. Attach fluid manifold (G) to gun.
T
G
To change position of fluid manifold or use
optional fluid inlets, see pages 21 and 22.
U
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.
K
4. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold (G).
B (RESIN)
G
U
D
J
A (ISO)
TI2417A
310648P13
To use optional air inlet (J), see page 22.
TI4969b
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.
Y
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.
V
TI5004b
12. Disengage piston safety lock (L), page 10.
L
TI3849a
13. Turn RAC tip (X) to spray position.
X
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.
B
A
14310648P
TI4970b
Hand Drilling of Mix Modules
Hand Drilling of Mix Modules
To balance pressure and
flow at the mix gun
Graco only makes 1:1 ratio mix modules. When applying a material that is different than 1:1 it is necessary to
modify the mix module to allow more material through
the larger part side.
The actual size of the orifice required is dependent on
many factors such as material viscosity, shear, ratio tip
size, etc. For example, a 2:1 material by volume does
not necessarily require the diameter on the larger part
side to be doubled.
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
310648P15
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.