For dispensing polyol and isocyanate materials only. For professional use only.
For indoor use only. Not approved for use in European explosive atmosphere
requirements.
3000 psi (21 MPa, 207 bar) Maximum Fluid Working Pressure
2500 psi (17 MPa, 172 bar) Maximum Hydraulic Working Pressure
180°F (82°C) Maximum Fluid Temperature
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
257492GX-16 Pour Gun, 24:1, Pour Handle, Right Side Chemical Tubes,
Star-Shaped Trigger Switch Connector
257493GX-16 Pour Gun, 24:1, Pour Handle, Left Side Chemical Tubes,
Star-Shaped Trigger Switch Connector
257494GX-16 Pour Gun, 24:1, Pour Handle, Right Side Chemical Tubes, Cir-
cular Trigger Switch Connector
257495GX-16 Pour Gun, 24:1, Pour Handle, Left Side Chemical Tubes, Circu-
lar Trigger Switch Connector
257496GX-16 Pour Gun, 24:1, Isolated Pistol Handle
257497GX-16 Pour Gun, 24:1, No Handle
257498GX-16 Pour Gun, No Handle, No Orifice
257499GX-16 Pour Gun, Reverse Block, No Handle, No Orifice
257502GX-16 Pour Gun, 1:1, No Handle
257503GX-16 Pour Gun, 1:1, No Handle, No Fittings
257504GX-16 Pour Gun, 1:1, No Handle, 3 ft Hoses
257505GX-16 Pour Gun, 1:1, Pistol Handle, No Orifice, Proximity Switch
257506GX-16 Pour Gun, 1:1, Isolated Pistol Handle, Proximity Switch
257507GX-16 Pour Gun, 1:1, Isolated Pistol Handle, No Orifice, Proximity
Switch
24E876◆
24E877◆GX-16 Pour Gun, HFR, NVH, Right, 24:1
24E878◆GX-16 Pour Gun, HFR, NVH, Right, Basic
24J187◆GX-16 Pour Gun, HFR, NVH, Straight, 24:1
24K233◆GX-16 Pour Gun, HFR, NVH, Left, 24:1
24K234◆GX-16 Pour Gun, HFR, NVH. Left, Basic
GX-16 Pour Gun, HFR
™
, NVH, Straight, Basic
Models
◆ Models used specifically for HFR machines.
313536H3
Page 4
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
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 MSDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
•Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
•Engage trigger lock when not dispensing.
•Do not point dispensing device at anyone or at any part of the body.
•Do not put your hand over the fluid outlet.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately
4313536H
Page 5
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
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).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•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 working fire extinguisher in the work area.
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.
313536H5
Page 6
Important Two-Component Material Information
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
•Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
•Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Keep Components A and B
Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
6313536H
Page 7
Important Two-Component Material Information
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
•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 lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid (TSL
The lubricant creates a barrier between the ISO and
the atmosphere.
•Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
•Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
•Never use solvent on one side if it has been contaminated from the other side.
•Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
™
), Part 206995.
Changing Materials
•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.
•Most materials use ISO on the A side, but some use
ISO on the B side.
•Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
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.
313536H7
Page 8
Grounding
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Pump: use ground wire and clamp (supplied). Connect
ground clamp to a true earth ground.
Gun: ground through connection to a properly grounded
fluid hose and pump.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts
grounding continuity.
Maintain grounding continuity: When flushing or
relieving pressure, hold metal part of the gun firmly to
the side of a grounded metal pail, then trigger the gun.
8313536H
Page 9
Trigger Lock
Trigger Lock
Verify that the trigger lock is engaged whenever you stop pouring to avoid accidental triggering. Check daily for chemical build-up on trigger, trigger lock, and trigger lock spring that can prevent proper trigger lock function.
Engage
To engage the trigger lock, release the trigger. The trigger lock is spring loaded and automatically engages
when the gun trigger is released.
Trigger Lock
ti14491a1
FIG. 1: Models 257509, 257510
Disengage
To engage the trigger lock, press the trigger lock down.
ti10442a
FIG. 2: Kit 24K223
To disengage the trigger lock, press trigger lock down.
To disengage the trigger lock, press the trigger lock up.
See the following figure.
ti12896a1
ti14491a1
FIG. 3: Models 257509, 257510
313536H9
FIG. 4: Kit 24K223
ti10441a
Page 10
Setup
Setup
Gun Connections
D
G
B
F
C
A
ti12897a
E
FIG. 5
RefDescriptionTape Color †Fitting SizeHFR Systems Only
A
B
C
D
E
F
G
† Only hoses are taped, fittings are not taped.
A Pressure LineRed
A Return LineRed and White
B Pressure LineBlue
B Return LineBlue and White
Hydraulic Open LineGreen and White
Hydraulic Close LineGreen
Proximity Switch or Plug
(depending on model)
7/16 ORG x
#6 JIC Female
7/16 ORG x
#6 JIC Male
7/16 ORG x
#5 JIC Female
7/16 ORG x
#5 JIC Male
7/16 ORG x
#4 JIC Male Extension
7/16 ORG x
#4 JIC Male Elbow
NANANA
7/16 ORG x
#5 JIC Female
7/16 ORG x
#5 JIC Male
7/16 ORG x
#6 JIC Female
7/16 ORG x
#6 JIC Male
7/16 ORG x
#4 JIC Male Extension
7/16 ORG x
#4 JIC Male Elbow
10313536H
Page 11
Setup
Fluid Line
Fluid Filter: Use a 25 micron stainless steel element to
filter particles from the fluid as it leaves the pump.
Fluid Drain Valve: Required in your system, to relieve
fluid pressure in the hose and gun.
Gun Setup
Trapped air can cause the pump to cycle unexpectedly,
which could result in serious injury from splashing or
moving parts.
1. Verify hydraulic power pack is off.
2. Install hydraulic hoses to power pack.
NOTE: Pressure should not increase while air is purged
from hoses.
5. Turn off power pack. Verify no pressure exists in
hoses.
6. Remove the 7/16 in. JIC male-male adapter connecting the hydraulic hoses.
7. Attach hydraulic hoses to the gun.
ti14496a
FIG. 7
Customer supplied hydraulic hoses must be at least
1/4 in. inner diameter and rated to at least 2500 maximum working pressure.
3. Use a 7/16 in. JIC male-male adapter at the gun end
to connect hoses together. This creates a hydraulic
fluid circulation loop.
ti14495a
F
IG. 6
8. Set power pack to manual mode.
9. Attach trigger switch cable and proximity switch
cable (if applicable) to gun and power pack.
ti14497a
F
IG. 8
10. Verify power pack pressure is 1800 - 2500 psi.
Adjust pressure as required.
4. Turn on the power pack. Circulate oil for 10 minutes
to purge air from hydraulic hoses.
313536H11
Page 12
Setup
11. Install chemical hoses to gun. See FIG. 5 on page
F
IG. 9
10 and F
IG. 9.
ti18184a
Shutoff Valve Setup
The shutoff valves are used to control chemical flow.
Mounting
Use the following mounting dimensions to mount the
GX-16 gun body.
D
B
A
C
A Width: 1.125 in.(28.58 mm)
B Diameter:0.159 in. (4.04 mm),
10/32 UNF Thread on one side
C From edge: 0.188 in. (4.78 mm)
D From edge: 0.218 in.(5.54 mm)
FIG. 11: Mounting Hole Dimensions
ti14493a
ti18185a
FIG. 10: Shutoff Valve Setup
1. Perform pressure relief procedure. See Pressure
Relief Procedure on page 15.
2. Use four chemical hoses to connect shutoff valves
to gun. See F
IG. 10.
3. Perform gun setup procedure to connect remaining
hoses. See Gun Setup on page 11.
4. Perform Startup procedure on page 13.
B
A
A Width: 0.578 in. (14.7 mm)
B Height: 0.440 in. (11.2 mm)
F
IG. 12: Mounting Block Dimensions
ti14492a
12313536H
Page 13
Startup
Startup
1. If your setup uses the optional shutoff valves,
rotate the handles to the “open” position.
Open Position
F
IG. 13: Shutoff Valves Positions
2. Verify cables and hoses are correctly setup. See
Gun Connections section on page 10.
3. Check for excessive wear on cables and hoses.
Replace as necessary.
Closed Position
ti18186a
4. Close dump valve on hydraulic power pack.
Hydraulic pressure must not exceed the maximum
working pressure of 2500 psi (17 MPa, 172 bar).
5. Start power pack and verify hydraulic pressure is
1800 - 2500 psi.
6. Start chemical pumps.
Chemical pressure must not exceed the maximum
working pressure of 3000 psi (21 MPa, 207 bar).
7. Verify chemical pressure is in desired range.
8. Dispense a test shot into a waste container.
9. Clean any residual material from the tip of the gun.
313536H13
Page 14
Operation
Operation
Theory of Operation
Circulation
FDCBAE
H
Key:
AA Pressure Line
BA Return Line
CB Pressure Line
DB Return Line
EHydraulic Open Line
FHydraulic Close Line
GPiston Rod
HHydraulic Piston
Dispense
FDCBAE
H
G
Key:
AA Pressure Line
BA Return Line
CB Pressure Line
DB Return Line
EHydraulic Open Line
FHydraulic Close Line
GPiston Rod
HHydraulic Piston
G
F
IG. 14: Circulation
Hydraulic pressure extends the piston rod to the circulation position. Material enters the material pressure line
and is sent to the material return line.
When the piston rod is extended to this position, it
removes gelled material from the nose assembly.
14313536H
FIG. 15: Dispense
Hydraulic pressure retracts the piston rod to the dispense position. Material enters the A and B material
pressure lines and mixes in the mixing chamber.
When the piston rod is in this position, it blocks material
flow from entering the material return line.
Page 15
Pressure Relief Procedure
Pressure Relief
Procedure
1. If your setup uses the optional shutoff valves,
rotate the handles to the “open” position.
2. Shut down chemical pumps.
3. Drain air pressure from the A and B side chemical
tanks.
4. After tank air pressure is at zero, close the A and B
tank outlet valves.
5. Verify pressures read zero on chemical pressure
gauges.
6. Turn off hydraulic power pack.
7. Bleed hydraulic pressure via dump valve on power
pack.
Shutdown
1. Perform Pressure Relief Procedure.
2. Perform any required maintenance. See Mainte-nance on page 16.
3. If system will not be in use for longer than two weeks, the A and B chemical tanks must have
10 psi of dry air pressure.
NOTICE
Air must be dry. Moist air will react with isocyanate
and cause crystallization resulting in significant
component damage.
4. If the gun will not be used for longer than four weeks, flush the gun.
8. Verify pressures read zero on hydraulic pressure
gauges.
313536H15
Page 16
Maintenance
Maintenance
ProcedureFrequency
Inspect the gun, fluid lines, trigger switch cable
and, if installed, the proximity switch cable for wear
or damage
Grease the gunWeekly or Every
Clean and service the orifices and filtersAs Needed
Recommended Tools
•7/16 in. open end wrench
•3/8 in. open end wrench
•1/8 in. allen key
•1/4 in. allen key
•Pin vise 117661
•Drill bit (see etching on orifice for size, drill bit
should be same size as orifice)
•O-Ring Pick
•Small brass brush
•1/4 in. brass barrel brush
•Small flashlight
•Small solvent pump can
•Cleaning rags
•Chemically impermeable gloves
•Safety glasses
•Small chemical and solvent waste container
•Grease gun
•Grease, part 117773 or 0553-6
Daily
15,000 Shots
3. Use a grease gun with the required synthetic
grease, part 117773 or 0553-6, to purge the gun
body until grease exits the weep hole without evidence of hydraulic oil or hardened material.
FIG. 16: Grease Fitting
NOTE: The presence of hydraulic oil at the grease fitting
may indicate the need to replace or rebuild the gun.
4. Use a 1/8 in. allen key to install the weep plug.
ti14494a1
Grease the Gun
1. Perform pressure relief procedure. See Pressure
Relief Procedure on page 15.
2. Use a 1/8 in. allen key to remove the weep plug.
ti12899a1
16313536H
Page 17
Maintenance
Clean and Service the Orifices
and Filters
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
H
J
G
F
E
H
L
2. If your setup uses the optional shutoff valves,
rotate the handles to the “close” position
3. Use a 7/16 in. wrench to remove the orifice.
4. Use a 1/8 in. allen key to remove the cleanout plug
next to the orifice.
5. Use a 1/4 in. allen key to remove the filter plug (A).
6. Remove the filter (D).
7. Use a pick to remove any hardened material from filter.
8. Use solvent to flush residue from this side of the gun
block.
9. Use a pin vise and drill bit to carefully clean the orifice.
10. Remove the orifice o-rings.
11. Use a pick to remove any hardened material from
the orifice body.
K
12. Flush the orifice body with solvent then dry the orifice.
257700Orifice Plug
2577010.011 in.
2577020.013 in.
2577030.016 in.
2577040.018 in.
2577050.020 in.
2577060.022 in.
2577070.023 in.
2577080.024 in.
2577090.025 in.
2577100.026 in.
2577110.028 in.
2577120.029 in.
2577130.032 in.
2577140.035 in.
2577150.036 in.
2577160.038 in.
2577170.039 in.
2577180.040 in.
2577190.042 in.
2577200.043 in.
2577210.044 in.
2577220.049 in.
2577230.052 in.
2577240.061 in.
24K6820.085 in.
NOTE: O-rings and cleanout drill bits are included in all
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.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO 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 acknowledge that they have required 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 convenu que 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.
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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 313536
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised July 2012
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