Graco 3A0232R User Manual

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Operation - Repair

™

Gun and

Cutter

For use with polyester resin and gel-coat.

For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model information, including maximum working pressure.

3A0232R

External Mix Chop Gun with Cutter shown

II 2 G c T6

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Two-Component Information . . . . . . . . 6

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 6

Keep Components A and B Separate . . . . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6

Important Methyl Ethyl Ketone Peroxide (MEKP)

Safety Information . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . . . . . 10

External Mix Gel Gun, 258840 . . . . . . . . . . . . . 10

Internal Mix Gel Gun, 258853 . . . . . . . . . . . . . . 11

Internal Mix Chop Gun, 258854 . . . . . . . . . . . . 12

Internal Mix Chop Gun, 24P436, High Flow, Carbide

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

External Mix Chop Gun, 258852 . . . . . . . . . . . 14

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 15

External Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Internal Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Chop Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Impingement versus Airless Spray Tips . . . . . . 15

Air Assist Containment

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Adjust AAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Internal Mix Flush . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 20

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 21

Long-Term Shutdown . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Flush System . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fluid Leaking from Front of Gun . . . . . . . . . . . . 29

Adjust Trigger Clamp . . . . . . . . . . . . . . . . . . . . 29

Fluid Leaking from Under Trigger Clamp Assembly

Adjust Needle Packing Tension . . . . . . . . . . . . 30

Adjust Actuator Pin Adjustment Screws . . . . . . 31

™

(AAC™) . . . . . . . . . . . 15

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Remove Hardened Material from Internal Mix Front

Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Replace Internal Mix Element . . . . . . . . . . . . . 34

Replace External Mix Check Valve and O-Rings 35

Replace Material Needle Assembly . . . . . . . . . . 36

Replace Center Needle Assembly . . . . . . . . . . 36

Replace Needle Packing . . . . . . . . . . . . . . . . . . 37

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

External Mix Gel Gun, 258840 . . . . . . . . . . . . . 38

Internal Mix Gel Gun, 258853 . . . . . . . . . . . . . . 40

External Mix Chop Gun with Cutter, 258970 . . . 42 Internal Mix Chop Gun with Cutter, 258971 . . . 42 Internal Mix, High Flow, Chop Gun with Cutter,

24P435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chop Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Front Head Assemblies . . . . . . . . . . . . . . . . . . . 49

Needle Assembly, 24E417 . . . . . . . . . . . . . . . . 52

O-ring Identification . . . . . . . . . . . . . . . . . . . . . . 53

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fusion

INDy or Formula Adapter Kit, 125797 . . . . . . . . 54

LPA2 Adapter Kit, 125843 . . . . . . . . . . . . . . . . . 54

Universal Adapter Kit, 257754 . . . . . . . . . . . . . . 54

Resin Transfer Molding (RTM) Nozzle Adapter Kit,

Casting Nozzle Adapter Kit, 16T707 . . . . . . . . . 54

External Mix High-Flow Kit, 24H336 . . . . . . . . . 54

Internal Mix High-Flow Kit, 24H337 . . . . . . . . . . 54

AAC Regulators . . . . . . . . . . . . . . . . . . . . . . . . . 55

External Mix Gel Gun to Chop Gun Conversion 55 Internal Mix Gel Gun to Chop Gun Conversion . 55

Pressure Fed Roller Adapter Kit, 16T708 . . . . . 56

Extension Gelcoat Spraying Kit, 16T709 . . . . . . 56

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Carbide Resin Seat, 24M833 . . . . . . . . . . . . . . 56

External Mix Chopper Extension Kit, 24V096 . . 56

Impingement (Chop) Spray Tips . . . . . . . . . . . . 58

Airless (Gel) Spray Tips . . . . . . . . . . . . . . . . . . . 60

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 66

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 66

Grease . . . . . . . . . . . . . . . . . . . . . . . . . 54

16T680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2 3A0232R

Models

See Technical Data on page 62 for more specifications.

Models

Model Description

258853

258854

258971

24P435

258840

258852

258970

Internal Mix

Gel Gun

Internal Mix

Chop Gun,

No Cutter

Internal Mix

Chop Gun,

Cutter

Internal Mix

Chop Gun,

High Flow,

Cutter

External Mix

Gel Gun

External Mix

Chop Gun,

No Cutter

External Mix

Chop Gun,

Cutter

Maximum Fluid

Working Pressure

psi (MPa, bar)

2000 (14, 138) 2000 (14, 138)

2000 (14, 138) 200 (1.4, 14)

Maximum Catalyst

Working Pressure

psi (MPa, bar)

Air Inlet Working

Pressure Range

psi (MPa, bar)

0-125

(0-0.86, 0-8.6)

0-125

(0-0.86, 0-8.6)

80-125

(0.55-0.86, 5.5-8.6)

80-125

(0.55-0.86, 5.5-8.6)

0-125

(0-0.86, 0-8.6)

0-125

(0-0.86, 0-8.6)

80-125

(0.55-0.86, 5.5-8.6)

Maximum Fluid

Tem peratu re

°F (°C)

100 (38)

Related Manuals

The following is a list of component manuals written in English. These manuals and any translated versions available can be found at www.graco.com.

Part Description

3A1226 Universal Adapter Kit 257754 Instructions

3A2054 Indy or Formula Adapter Kit 125797 Instructions

3A2079 LPA2 Adapter Kit 125843 Instructions

332574 RS Gun Cutter Assemblies Operation-Repair

334010 RS Gun External Mix Chopper Extension Kit 24V096 Instructions

3A0232R 3

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• 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.

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.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

4 3A0232R

Warnings

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.

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.

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.

3A0232R 5

Important Two-Component Information

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

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 (catalyst) and component B (resin) parts.

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.

6 3A0232R

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

MEKP is among the more hazardous materials found in commercial channels. Proper handling of the “unstable (reactive)” chemicals presents a definite challenge to the plastics industry. The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins and gel-coats also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal.

Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP, especially in regards to contamination and heat. They must be thoroughly instructed regarding the proper action to be taken in the storage, use and disposal of MEKP and other hazardous materials used in the laminating operation.

MEKP is flammable and potentially explosive, as well as potentially damaging to the eyes and skin. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to MEKP.

Contaminated MEKP can become explosive. Prevent contamination of MEKP with other materials, which includes, but is not limited to polyester overspray, polymerization accelerators and promoters, and non-stainless metals. Even small amounts of contaminates can make MEKP explosive. This reaction may start slowly, and gradually build-up heat, which can accelerate until fire or an explosion result. This process can take from seconds to days.

Heat applied to MEKP, or heat build-up from contamination reactions can cause it to reach what is called its Self-Accelerating Decomposition Temperature (SADT), which can cause fire or explosion. Spills should be promptly removed, so no residues remain. Spillage can heat up to the point of self-ignition. Dispose in accordance with manufacture’s recommendation.

Store MEKP in a cool, dry and well-ventilated area in the original containers away from direct sunlight and away from other chemicals. It is strongly recommended that the storage temperature remain below 86° F (30° C). Heat will increase the potential for explosive decomposition. Refer to NFPA 432. Keep MEKP away from heat, sparks and open flames.

Current catalysts are premixed and do not require any diluents. Graco strongly recommends that diluents not be used. Diluents add to the possibility of contaminates entering the catalyst system. Never dilute MEKP with acetone or any solvent since this can produce an extremely shock-sensitive compound which can explode.

Use only original equipment or equivalent parts from Graco in the catalyst system (i.e.: hoses, fittings, etc.) because a hazardous chemical reaction may result between substituted parts and MEKP.

To prevent contact with MEKP, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area.

3A0232R 7

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

Polyester Resins and Gel-Coats

Spraying materials containing polyester resin and gel-coats creates potentially harmful mist, vapors and atomized particulates. Prevent inhalation by providing sufficient ventilation and the use of respirators in the work area.

Read the material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to polyester resins and gel-coats.

To prevent contact with polyester resins and gel-coats, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area.

Spraying and Lamination Operations

Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur. If this waste is allowed to build up, spillage of catalyst is more likely to start a fire.

If cleaning solvents are required, read material manufacture’s warnings and material MSDS to know specific hazards and precautions. (Graco recommends that clean-up solvents be nonflammable.)

NOTE: Graco recommends that you consult OSHA Sections 1910.94, 1910.106, 1910.107 and NFPA No. 33, Chapter 16,17, and NFPA No. 91 for further guidance.

8 3A0232R

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

3A0232R 9

Component Identification

External Mix Gel Gun, 258840

Key:

A Trigger Clamp Assembly B Gun Mount C Front Head Locking Ring D Air Cap Retaining Ring E External Mix Aircap F External Mix Front Head

258840_3A0232_1g

GSpray Tip H Trigger guard J Trigger K Trigger lock L Handle M Actuator Pin

FIG. 1

10 3A0232R

Internal Mix Gel Gun, 258853

NOTE: On internal mix guns, the tip rotates to allow a

vertical or horizontal spray pattern.

Component Identification

Key:

A Trigger Clamp Assembly BGun Mount C Front Head Locking Ring D Air Cap Retaining Ring E Internal Mix Aircap F Internal Mix Front Head

ti21003a

GSpray Tip H Trigger guard J Trigger K Trigger lock L Handle M Actuator Pin

IG. 2

3A0232R 11

Component Identification

Internal Mix Chop Gun, 258854

NOTE: On internal mix guns, the tip rotates to allow ver-

tical or horizontal spray pattern.

Key:

A Trigger Clamp Assembly B Cutter Mount C Front Head Locking Ring D Air Cap Retaining Ring E Internal Mix Aircap F Internal Mix Front Head

ti21004b

GSpray Tip H Trigger guard J Trigger K Trigger lock L Handle MActuator Pin

IG. 3

12 3A0232R

Component Identification

Internal Mix Chop Gun, 24P436, High Flow, Carbide Seat

NOTE: On internal mix guns, the tip rotates to allow ver-

tical or horizontal spray pattern.

Key:

A Trigger Clamp Assembly B Cutter Mount C Front Head Locking Ring D Air Cap Retaining Ring E Internal Mix Aircap F Internal Mix Front Head,

High Flow

ti21005b

GSpray Tip H Trigger guard J Trigger K Trigger lock L Handle MActuator Pin

IG. 4

3A0232R 13

Component Identification

External Mix Chop Gun, 258852

ti21006b

Key:

A Trigger Clamp Assembly B Cutter Mount C Front Head Locking Ring D Air Cap Retaining Ring E External Mix Aircap F External Mix Front Head

GSpray Tip H Trigger guard J Trigger K Trigger lock L Handle M Actuator Pin

FIG. 5

14 3A0232R

Theory of Operation

External Mix

The resin or gelcoat stream and the catalyst stream impinge when they exit the spray tip. The catalyst is atomized with air pressure by the AAC air to achieve high mix quality. External mixing reduces internal clogs from cured material.

Internal Mix

The material and catalyst pass through an internal static mixer where they mix. The mixed solution is dispensed.

Chop Guns

Fiberglass is pulled through cutter and cut into small strands. The cut strands are then dispensed into the mixed material stream.

Grounding

This equipment must be grounded.

Grounding reduces the risk of static shock by providing an escape wire for electrical current due to static build up or in the event of short circuit.

NOTE: Grounding wire and clamp assembly 17440-00 is included with Graco FRP proportioner. If using a different proportioner that does not come with a grounding wire and clamp assembly, order 17440-00 or provide your own.

Ground the dispense gun through connection to a Graco approved grounded fluid supply hose.

Check your local electrical code and related manuals for detailed grounding instructions of all equipment in the work area.

Impingement versus Airless Spray Tips

Impingement spray tips are typically for chop guns. This utilizes multiple impinging streams to create the fan pattern.

Airless spray tips are typically for gel guns. This utilizes a single cat-eye shaped orifice to create the fan pattern.

Air Assist Containment™

™

(AAC

When material exits the spray tip, air is sprayed against the material stream to shape it into a more consistent pattern.

)

Introduction

To have the optimal RS gun experience, the most important procedures to understand and perform as specified are:

• Startup on page 18

• Adjust Trigger Clamp on page 29

• Adjust Anvil to Blade Cartridge Tension. Refer to RS Gun Cutter Assemblies Operation-Repair manual for details.

• Daily Shutdown on page 21

NOTICE

Failure to perform these procedures correctly and according to the prescribed schedule can result in poor mixing, fluid leaking, cured material in the gun, and premature component wear.

3A0232R 15

Setup

NOTICE

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flush System, page 24.

1. Before first use, flush the gun. See Flush System, page 24.

NOTE: The recommended solvent pressure during flushing is 80-100 psi (550-700 kPa, 5.5-7.0 bar).

2. Engage trigger lock.

3. For guns with cutters, install cutter:

a. If necessary, use a crescent wrench to adjust

pivot (541) so that it is parallel to gun front end and the open end points to the front of the gun. See F

IG. 6.

e. Adjust cutter dispensing angle and chute angle

as desired.

4. For internal mix guns, verify solvent knob (BD) is adjusted to the fully closed position. See F

IG. 7 on

page 17.

5. Attach gun connections as described in F

IG. 7 on

page 17. See Techn ical Data on page 62 for fitting sizes.

6. For internal mix guns, prime the solvent line. Turn solvent adjustment knob (BD) until solvent discharges from the front of the gun. See F

IG. 7 on

page 17.

NOTICE

Internal mix guns: To prevent material curing inside the gun, do not trigger gun if solvent is not primed.

NOTE: The recommended solvent line pressure is 80-100 psi (550-700 kPa, 5.5-7.0 bar).

541

IG. 6

b. Back out screws (630). See F

542

630

ti21008a

IG. 6.

c. Install cutter onto pivot so glass feed holes are

on top.

NOTE: Ensure proper engagement of o-ring (542) into the cutter assembly. Verify there is no excess air leakage because it will greatly reduce the performance of the air motor. See F

IG. 6.

d. Tighten screws (630) to lock cutter in place.

7. For guns with cutters, insert glass strands into feed.

8. For guns with cutters, adjust anvil to blade tension. Refer to RS Gun Cutter Assemblies Operation-Repair for part identification:

a. Release lockdown.

b. Adjust tension knob as desired.

c. Tighten lockdown.

d. Release idler lock down.

e. Adjust idler lock down until it touches anvil.

f. Tighten idler lock down.

g. Perform test spray to verify proper cutting of

glass strands.

h. Adjust tension as necessary.

9. For external mix guns, adjust AAC knob (BD) to middle of possible range of movement. See F

IG. 7

on page 17.

16 3A0232R

10. Adjust AAC pressure on proportioner.

11. Perform test spray. Adjust system and gun settings as necessary to get desired results.

Setup

IG. 7: Fitting Details

258840_3A0232_2g

BABE

Ref External Mix Internal Mix Chop Internal Mix Gel Fitting Size

Atomized Air

(Catalyst)

Air Assist Contain-

ment (AAC)

Plugged 1/4 tube

BB Resin Inlet 1/4 NPSM

Air Assist Con-

tainment (AAC)

Solvent 1/8 NPSM

BD Adjustment Knob --

BE Chop Air Inlet

Air Assist Contain-

ment (AAC)

3/8 tube

BF Catalyst Inlet #4 JIC

3A0232R 17

Startup

1. Inspect o-rings on housings. Replace as needed. See F

IG. 8.

Housing O-rings

258840_3A0232_3g

IG. 8

2. Prime the system as required.

NOTICE

Gun damage can occur when the system is primed with the front head installed. To avoid damage, only prime the system with the front head removed.

3. Align front head with housings and install front head. Tighten front head locking ring (C).

4. Verify air cap retaining ring (D) is tight.

Ensure locking ring (C) and retaining ring (D) are tight before spraying. Spraying while either item is loose may result in skin injection.

5. Verify fluid and air lines are at the desired pressures then begin using the gun.

18 3A0232R

Operation

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the dispense outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

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

Tri gg er Lock

Operation

Adjust AAC

If the spray pattern is not even, the AAC air pressure may need to be adjusted. For all guns, the AAC air pressure is set at the system. The external mix gun includes an AAC air pressure adjustment on the gun also, see AAC reference in F pressure on the external mix gun, turn knob counter-clockwise. To decrease air pressure, turn knob clockwise. For large changes in AAC air pressure, adjust the pressure at the system.

IG. 7 on page 17. To increase AAC air

Bad

Good

Engage trigger lock whenever you stop spraying to avoid accidental triggering.

Engage

TI10442a

Disengage

TI10441a

FIG. 9

Internal Mix Flush

NOTE: The recommended solvent line pressure is

80-100 psi (550-700 kPa, 5.5-7.0 bar).

After spraying, open the solvent knob (BC) to allow solvent to flow through the gun. See F While flushing, hold a metal part of the gun firmly to a grounded metal pail.

IG. 7 on page 17.

3A0232R 19

Pressure Relief Procedure

1. Shutdown proportioner.

2. Relieve proportioner pressure. See proportioner manual.

3. Engage gun trigger lock.

4. Close the bleed-type master air valve.

5. Disengage the trigger lock.

6. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

7. Engage the trigger lock.

8. With a waste container in place, open all fluid drain valves in the system. Leave drain valve(s) open until you are ready to spray again.

9. If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen retaining ring (D) or loosen hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction. See F part references.

IG. 1 on page 10 for

20 3A0232R

Shutdown

Daily Shutdown

NOTICE

Failure to perform this procedure correctly and according to the prescribed schedule can result in poor mixing, fluid leaking, and cured material in or on the gun.

1. Perform Pressure Relief Procedure.

2. Solvent flush at 80-100 psi (550-700 kPa,

5.5-7.0 bar) for five seconds.

4. For internal mix guns, remove mixing element.

ti17896b

5. Remove front head.

ti17897b

3. Loosen then remove air cap retaining ring.

3A0232R 21

Shutdown

6. Immerse front head, front cap, and the mixing element (internal mix guns only) in solvent. Use a sealed container to prevent solvent evaporation.

NOTICE

Immersing the cutter assembly in solvent will damage it and void the warranty.

ti17898a

NOTICE

In the following step, do not rinse catalyzed solvent over the resin port. This may result in cured material.

8. Rinse excess resin from the resin port.

ti17900b

9. Lubricate the gun front face and check valve ports with grease (Part No. 118665) as shown in the following illustration.

NOTICE

To prevent catalyst fumes from mixing with resin resulting in cured material, make sure to put grease in the resin port.

7. Rinse front face of gun with clean solvent. Use a squirt bottle or paint brush dipped in clean solvent.

ti17899b

ti17901b

22 3A0232R

Shutdown

NOTICE

Failure to clean the surface between the trigger clamp and the gun body can lead to material buildup preventing the clamp from seating properly resulting in material leakage from the front of the gun.

10. Wipe the trigger clamp assembly, actuator pins, and surface between the trigger clamp and the gun body with a rag to remove material. Use a compatible solvent.

Long-Term Shutdown

If gun will be unused for at least one week, perform this long-term shutdown procedure.

1. Perform Daily Shutdown procedure, beginning on page 21.

2. Flush System, see page 24.

ti17902a

3A0232R 23

Maintenance

Flush System

NOTE:

• Flush before changing colors, before fluid can dry in the equipment, before storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

NOTICE

Immersing the cutter assembly in solvent will damage it and void the warranty.

1. Follow Pressure Relief Procedure, page 20.

2. Remove front head from gun and soak in solvent.

3. Place siphon tube in grounded metal pail containing solvent.

4. Set pump to lowest possible fluid pressure then start pump.

NOTE: The recommended solvent pressure during flushing is 80-100 psi (550-700 kPa, 5.5-7.0 bar).

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until clean solvent dispenses.

6. Perform Pressure Relief Procedure, page 20.

7. Remove gun from hose.

ti21012a

24 3A0232R

Troubleshooting

See the troubleshooting procedures beginning on page 29 for additional troubleshooting help.

Problem Cause Solution

Catalyst leaking Trigger clamp assembly slipped See Fluid Leaking from Front of Gun on

page 29.

Catalyst hose loose Inspect and tighten

Catalyst fitting loose Inspect and tighten

Locking ring loose Clean and tighten

Air cap catalyst post o-ring damaged or missing

Catalyst check valve housing o-rings missing or damaged

Needle assembly o-ring damaged or missing

Needle packing loose See Fluid Leaking from Under Trigger

Valve seat worn or damaged Inspect and replace if necessary

Valve seat seal damaged Inspect and replace if necessary

Resin leaking Trigger clamp assembly slipped or mis-

aligned

Resin hose loose Inspect and tighten

Resin fitting loose Inspect and tighten

Locking ring loose Clean and tighten

Air cap catalyst post o-ring damaged or missing

Resin check valve housing o-rings missing or damaged

Needle assembly o-ring damaged or missing

Needle packing loose See Fluid Leaking from Under Trigger

Valve seat worn or damaged Inspect and replace if necessary

Valve seat seal damaged Inspect and replace if necessary

Inspect and replace if necessary

Clamp Assembly on page 30

See Fluid Leaking from Front of Gun on page 29.

Inspect and replace if necessary

Clamp Assembly on page 30

3A0232R 25

Troubleshooting

Problem Cause Solution

Gun does not fully actuate when triggered

Trigger clamp not opening properly Perform Adjust Trigger Clamp procedure on

page 29

Safety lock engaged Disengage safety lock

Trigger clamp pins bent Inspect and replace if necessary

Cutter air valve stuck Inspect and replace if necessary

Overspray on trigger clamp pins Clean and lubricate

Needle assembly stuck Check and adjust needle packing tension,

see Adjust Needle Packing Tension on page 30

Hardened material in the needle/seat area Remove needle assembly, clean and replace if

necessary

Fluid does not spray when trigger is fully actuated

Proportioner off or in bypass mode Turn on proportioner and make ready to spray

Worn trigger clamp pins Inspect and replace if necessary

Worn trigger Inspect and replace if necessary

Loose trigger clamp assembly Inspect and torque as specified, see Adjust

Trigger Cl a m p on page 29

Misadjusted or missing actuator pin adjustment screws

If missing, replace screws. If misadjusted, see Adjust Actuator Pin Adjustment Screws, page 31.

Hardened material in front head (passageway and spray tip)

Check for blockage, perform Remove Hard- ened Material from Internal Mix Front Head on page 32 as necessary.

Hardened material in the needle/seat area Remove needle assembly, clean and replace if

necessary

Resin is present but NO catalyst

No catalyst Check catalyst fluid level

Catalyst pump in bypass Turn on and make ready to spray

Trigger clamp out of phase 1) Adjust Trigger Clamp, page 29

2) Adjust Actuator Pin Adjustment Screws, page 31

Actuator pin adjustment screw missing Replace then perform Adjust Actuator Pin

Adjustment Screws, page 31

Trigger worn Inspect and replace if necessary

Actuator pin worn Inspect and replace if necessary

Trigger clamp assembly loose Inspect and torque as specified, see Adjust

Trigger Cl a m p on page 29

Catalyst check valve stuck closed Inspect and replace if necessary

Hardened material in the needle/seat area Remove needle assembly, clean and replace if

necessary

26 3A0232R

Problem Cause Solution

Catalyst is present but no resin

No resin Check material fluid level

Trigger clamp out of phase 1) Adjust Trigger Clamp, page 29

2) Adjust Actuator Pin Adjustment Screws, page 31

Catalyst pump in bypass Turn on and make ready to spray

Actuator adjustment screw missing Replace then perform Adjust Actuator Pin

Adjustment Screws, page 31

Trigger worn Inspect and replace if necessary

Actuator pin worn Inspect and replace if necessary

Trigger clamp assembly loose Inspect and torque as specified, see Adjust

Trigger Cl a m p on page 29

Hardened material in the needle/seat area Remove needle assembly, clean and replace if

necessary

Catalyst pressure drops on initial trigger

Material continues to spray after trigger is released

Trigger clamp not opening evenly 1) Adjust Trigger Clamp, page 29

2) Adjust Actuator Pin Adjustment Screws, page 31

Foreign object under trigger clamp Clean and replace if necessary

Overspray on trigger clamp pins Clean and lubricate

Actuator pins sticking Clean and replace if necessary

Needle packing too tight Check and adjust needle packing tension,

see Adjust Needle Packing Tension on page 30

Material spraying out AAC ports

Retaining ring not tight Tighten retaining ring

Cut or missing internal mix diffuser o-ring Inspect and replace if necessary

Cut or missing external mix check valve

Inspect and replace if necessary

o-ring

Internal mix check valve seat missing or

Inspect and replace if necessary

damaged or not tight

External mix check valve seat missing or

Inspect and replace if necessary

damaged or not tight

Material not mixed External mix catalyst tips plugged Clean and replace

Atomizing air pressure too low Adjust

Static mixer missing Replace, see Replace Internal Mix Element

on page 34.

Static mixer worn Inspect and replace if necessary, see Replace

Internal Mix Element on page 34.

Incorrect static mixer Replace if necessary, see Replace Internal

Mix Element on page 34.

AAC does not function

Air supply to gun is shut off Open air supply

Air regulator set incorrectly Adjust

Ports plugged Clean air capped or replace

AAC needle valve closed (external mix) Open AAC needle valve

Trigger clamp assembly loose Adjust Trigger Clamp, page 29

Troubleshooting

3A0232R 27

Troubleshooting

Problem Cause Solution

No solvent Not enough solvent pressure Increase solvent pressure to the recommended

range of 80-100 psi (550-700 kPa, 5.5-7.0 bar).

No fluid in pressure pot Refill pressure pot

Output valve closed Open output valve

Check valve stuck closed Increase pressure in pressure pot

Material check valve plugged Clean and replace as needed

Solvent needle valve closed Open solvent needle valve

Solvent check valve stuck closed Ensure the solvent check valve opens freely

Solvent in catalyst/resin mix

Solvent needle valve open Close solvent needle valve

Solvent check valve o-ring damaged or

Inspect and replace if necessary

missing

Solvent valve damaged Inspect and replace if necessary

Resin in solvent line Solvent needle valve open Close solvent needle valve

Solvent check valve o-ring damaged or

Inspect and replace if necessary

missing

Solvent valve damaged Inspect and replace if necessary

AAC does not shut

AAC needle o-ring damaged (internal mix) Inspect and replace if necessary

off

Atomized catalyst air does not shut off

Air leakage Air lines not fully seated in push lock tube

Atomized catalyst air needle o-ring damaged (external mix)

Inspect and replace if necessary

Ensure air lines are fully seated in fitting

fittings

Cutter assembly pivot tube o-ring damaged

Inspect and replace if necessary

or missing

AAC/Atomized catalyst external needle

Inspect and replace if necessary

o-ring damaged

Cutter air valve seat damaged Inspect and replace if necessary

G hook o-ring missing Inspect and replace if necessary

Cutter mount o-ring missing Inspect and replace if necessary

28 3A0232R

Troubleshooting

Fluid Leaking from Front of Gun

To prevent skin injection, never use a gun that has a resin and/or catalyst leakage.

Perform this procedure to find the source of the leakage and to stop the leak.

1. Perform Adjust Trigger Clamp to attempt to fix the leak.

2. If the leakage still exists:

a. Follow Pressure Relief Procedure, page 20.

b. Remove the leaking needle valve.

Adjust Trigger Clamp

To prevent skin injection, never use a gun that has a resin and/or catalyst leakage.

NOTICE

Failure to perform this procedure correctly and when required can result in poor mixing and fluid leaking.

Perform this procedure if there is fluid leakage from the front of the gun or if the gun is out of phase. This procedure. See F

IG. 10.

113

111

216

115, 215

ti17903a

c. Verify no obstruction between the ball and seat.

Clean as necessary.

d. If the resin side is leaking, use a 9/64 in.

allen-wrench to remove the seat.

e. If the catalyst side is leaking, use a 0.093 in.

allen wrench to remove the seat.

f. Verify the seat surface is free of wear and

scratches.

g. If wear or scratches are found on the seat, dis-

card defective seat and replace with new seat.

h. Install seat.

i. Install valve.

j. See Adjust Trigger Clamp on page 29 to install

and adjust the trigger clamp.

IG. 10: External Mix shown

1. Perform Pressure Relief Procedure, page 20.

2. Engage trigger lock.

3. Loosen four screws (113).

4. While pressing the trigger clamp assembly (111) firmly against the gun body, tighten the four screws (113) in the following sequence:

a. Tighten the two inside screws to 25 in-lb

(2.8 N•m).

NOTE: Do not overtighten the two outside screws as this may cause leakage.

b. Tighten the two outside screws to 10 in-lb

(1.1 N•m).

5. Loosen front head locking ring (C) then remove front head assembly (F).

6. Pressurize the resin and catalyst fluid lines to operating pressures and verify there is no leakage.

k. Install front head assembly (F).

3A0232R 29

Troubleshooting

Fluid Leaking from Under Trigger Clamp Assembly

1. Follow Pressure Relief Procedure, page 20.

2. Remove trigger clamp assembly (A).

3. Tighten packing nut (906).

c. Discard the o-ring (909) if wear or damage is

found.

d. Reassemble the needle assembly.

e. Install the needle assembly into the gun.

f. See Adjust Trigger Clamp on page 29 to install

and adjust the trigger clamp.

Adjust Needle Packing Tension

If there is a fluid leak at the rear of the needle assembly, the packings can be tightened to stop the leak.

1. Follow Pressure Relief Procedure, page 20.

2. Loosen four screws (113) then remove trigger clamp assembly (111). See page 38.

ti17903a

4. If the leakage stopped, see Adjust Trigger Clamp on page 29 to install and adjust the trigger clamp.

5. If the leakage still exists:

a. Disassemble the needle assembly.

b. Discard the packing disk (904).

906

901

907

905

904

903

902

909

908

ti16592a

3. Use 7/16 in. wrench to tighten packing nut (906) 1/8th of a turn.

4. Re-pressurize and re-check for leaks in rear of needle. If leak remains, packings may need to be replaced. If necessary, see Replace Needle Pack- ing on page 37.

5. Ensure needle flats are aligned with one another.

6. Install trigger clamp assembly on gun then perform Adjust Trigger Clamp procedure on page 29.

7. Trigger gun to check for smooth operation of material needles. If material needles do not operate smoothly, packings may need to be replaced.

NOTICE

Be careful not to overtighten trigger clamp assembly as this will cause the material needles to bind and cause material needles to operate incorrectly.

Beveled edge must face rear of needle

30 3A0232R

Troubleshooting

Adjust Actuator Pin Adjustment Screws

Perform this procedure if the trigger clamp pulls away from the gun body unevenly when the trigger is pulled, see F

IG. 12. This procedure adjusts the actuator

pins (111) in the trigger clamp, see F

When the trigger is pulled, it moves the trigger clamp assembly resulting in fluid flow from each component.

NOTE: The actuator pins are factory set. If the trigger, trigger clamp assembly, or pins are removed the trigger may need to be adjusted.

NOTE: When installing the four finger trigger (16F627), ensure trigger lock functions and clamp assembly opens correctly, see F perform this Adjust Actuator Pin Adjustment Screws procedure.

1. Perform Pressure Relief Procedure, page 20.

IG. 11.

IG. 12. If any adjustments are needed

7. Adjust each screw until the actuator pin just begins to touch the trigger. This can be verified by the trigger just beginning to lift off of the trigger lock.

8. Back each screw out 1/2 turn.

9. Disengage trigger lock.

10. While watching the trigger clamp assembly, trigger the gun to verify both sides of the trigger clamp assembly pull away from the gun body at the same time.

Bad

Uneven

IG. 12

Good

Even

2. Engage trigger lock.

3. Use 5/64 in. allen key to remove adjustment screws (114).

114

111

FIG. 11

4. Apply medium strength thread sealant to threads of screws.

5. Install adjustment screws (114) into trigger clamp assembly (111).

6. Squeeze trigger so that it touches the trigger lock. If trigger cannot touch trigger lock, back out adjustment screws until trigger touches the trigger lock.

11. Hold the trigger fully engaged and measure the space between the trigger clamp and the gun body on both sides. The gaps should be at least 0.065 in. (1.65 mm) in the open position. Adjust screws as necessary. See F

IG. 12.

3A0232R 31

Repair

Remove Hardened Material from Internal Mix Front Head

802

801

804

803

805

816*

806*

810

808

* Parts shown are not available on internal mix, high flow front heads

IG. 13

Perform this procedure when the internal mix diffuser assembly is filled with cured material. When this happens, the diffuser assembly must be drilled out.

1. Perform Pressure Relief Procedure, page 20.

2. Loosen then remove retaining ring (810) and air cap assembly (808) from head (801).

3. Remove diffuser assembly (803).

4. Use two wrenches on flats of diffuser and cap (806) to remove cap.

5. Use punch to break the check valve (812) and valve seat (816) loose from the hardened material. Discard the valve seat and spring (813).

812*

813*

6. Use punch to break hardened material loose from the diffuser cap (806).

32 3A0232R

Repair

7. For standard 1/4 in. mixers, use a 0.152 in. drill in the diffuser assembly outlet to remove hardened material.

For high flow 3/8 in. mixers, use a 0.161 in. drill.

Outlet

ti17687a

IG. 14

8. For 1/4 in. mixers, use a 0.246 in. drill in the diffuser assembly inlet to remove hardened material.

For 3/8 in. mixers, use a 0.359 in. drill.

Inlet

12. Install check valve (812) and new spring (813) into the seat then install cap (806). See F

IG. 18 for orien-

tation of parts.

NOTE: Parts shown are not available on internal mix, high flow front heads

FIG. 16

13. Remove and inspect o-ring (804). Replace if worn or damaged.

14. Lubricate o-ring and install onto diffuser. Install diffuser into head.

15. Torque cap to 23-27 in-lb (2.6-3.1 N•m).

16. Install diffuser into head (801).

ti17688a

IG. 15

9. Use a pick to remove any cured material from the front air cap (808).

10. Install new mix element into diffuser (803).

11. Install new check valve seat (816) into diffuser. See F

IG. 16 for seat orientation.

17. Install air cap assembly and tighten retaining ring.

3A0232R 33

Repair

Replace Internal Mix Element

802

801

804

* Parts shown are not available on internal mix, high flow front heads

803

805

816*

806*

810

808

812*

813*

FIG. 17

See internal mix front head parts list on page 50 for available kits.

NOTICE

There is a half-moon pin pressed into the front head (801) behind the diffuser assembly (803). Do not attempt to remove this pin. Removal will result in poor mixing.

1. Perform Pressure Relief Procedure, page 20.

2. Remove retaining ring (810) and air cap assembly (808) from head (801).

3. Remove diffuser assembly (803).

4. Use two wrenches on flats of diffuser and cap (806) to remove cap. Spring (813) and check valve (812) will fall out when cap is removed.

5. Use a small hex key in the small hole in the back of the diffuser to push the mix element (805) and check valve seat (816) out.

6. Install new mix element into diffuser (803).

7. Install check valve seat (816) into diffuser. See F 17 for seat orientation.

IG.

8. Install check valve (812) and spring (813) into the seat then install cap (806). See F tion of parts.

NOTE: Parts shown are not available on internal mix, high flow front heads

FIG. 18

9. Remove and inspect o-ring (804). Replace if worn or damaged.

10. Lubricate o-ring and install onto diffuser. Install diffuser into head.

11. Torque cap to 23-27 in-lb (2.6-3.1 N•m).

12. Install diffuser into head (801).

13. Install air cap assembly and tighten retaining ring.

IG. 18 for orienta-

34 3A0232R

Replace External Mix Check Valve and O-Rings

702

701

717

703

704

718

705

706

710

Repair

709

FIG. 19

See Front Head Assemblies beginning on page 49 for available kits.

1. Perform Pressure Relief Procedure, page 20.

2. Remove retaining ring (710) and air cap assembly (709) from head (701).

3. Remove check valve assembly (703).

4. Use two wrenches on flats of seal (703) and check valve cap (706) to remove cap. Spring (705) and ball (704) will fall out when cap is removed.

5. Remove and inspect o-ring (717) and washer (718). Replace if worn or damaged.

6. Lubricate o-ring and install onto check valve assembly (703).

7. Install washer (718), ball (704), and spring (705) into check valve seal (703) then install check valve cap (706) onto check valve seal finger-tight.

10. Install air cap onto head and tighten retaining ring (710).

NOTICE

To prevent distorting the end of the cap (706), do not over-tighten the check valve assembly.

8. Use two wrenches on flats of seal (703) and check valve cap (706) to torque check valve cap onto check valve seal to 23-27 in-lb (2.6-3.1 N•m).

9. Install check valve assembly into head. See F for assembly orientation.

3A0232R 35

IG. 19

Repair

Replace Material Needle Assembly

NOTE: The material needle assemblies are the two side

needles (105) in the rear of the gun. See page 38.

1. Follow Pressure Relief Procedure, page 20.

2. Loosen four screws (113) then remove trigger clamp assembly (111). See page 38.

3. Use 1/2 in. deep well socket to break loose and remove material needle assemblies.

4. Install new material needle assemblies.

5. Ensure needle flats are aligned with one another.

6. Install trigger clamp assembly on gun then perform

Adjust Trigger Clamp procedure on page 29.

Replace Center Needle Assembly

1. Follow Pressure Relief Procedure, page 20.

2. Loosen four screws (113) then remove trigger clamp assembly (111). See page 38.

3. Use 7/32 in. deep well socket to remove retainer (108) then remove the needle (106), spring (107), and o-ring (110).

4. Install new o-ring. Verify needle is clean before reinstalling. Use a liberal amount of lubrication.

5. Install rear packing retainer with a liberal amount of lubrication.

NOTICE

Be careful not to overtighten trigger clamp assembly as this will cause the material needles to bind and cause material needles to operate incorrectly.

36 3A0232R

Replace Needle Packing

NOTE: The needle packing is the seal (904) inside the

needle assembly (105). See pages 38 and 52.

NOTICE

Needles bend easily. To prevent bending and damaging the needles, be careful when using wrenches to remove the needle packings.

1. Follow Pressure Relief Procedure, page 20.

2. Use 9/64 in. hex key to loosen the four screws (114) on trigger clamp (111). Remove clamp. See page 38.

Repair

3. Use 7/16 in. wrench to break loose then remove the packing nuts (906). See page 52.

4. Remove needle (908).

5. Remove old packing from needle.

6. Liberally lubricate the new packing with grease (Part No. 118665).

7. Install new packing onto needle. Install packing with beveled edge facing rear of needle.

8. Install needle.

9. Install packing nuts and torque to 30 in-lb (3.4 N•m).

10. Ensure needle flats are aligned with one another.

11. Slide trigger clamp onto gun then, with the trigger clamp loose, perform Adjust Trigger Clamp proce- dure on page 29.

NOTICE

Be careful not to overtighten trigger clamp assembly as this will cause the material needles to bind and cause material needles to operate incorrectly.

3A0232R 37

Parts

External Mix Gel Gun, 258840

129

130

133

160

131

134

114

106

138

153

127

132

128

113

111

112

109

108

107

105

110

139

141

104

134 143

116

116a

115b

115

115a

136

135

103

102

159

126

122

123

124

119

101

118

125

152

120

117

155

ti21015a

121

38 3A0232R

Ref Part Description Qty

100 199360 DOCUMENT, declaration 1 101 24N711 HANDLE, gun 1 102†‡ 24E428 SEAL, needle, seat (pack of 6) 2 103‡ 16C104 RETAINER, seat, needle valve,

resin

24M833 OPTIONAL - RETAINER, seat,

needle valve, resin, carbide 104† 24D201 RETAINER, seat, catalyst 1 105** 24E417 NEEDLE, assembly 2 106❄ 16C101 NEEDLE, aac 1 107❄ 123633 SPRING, needle assembly 1 108❄ 16C100 RETAINER, aac 1 109❄ 24E429 O-RING (pack of 6) 1 110❄ 24E430 O-RING (pack of 6) 1 111◆ 16C098 CLAMP, trigger, top 1 112◆ 16C099 CLAMP, trigger, bottom 1 113◆ 124057 SCREW, cap, sh 4 114◆ GC2082 SCREW, set, flpt 2 115❖ 24E423 HOUSING, check valve asm,

catalyst 115a 123934 O-RING, FKM (smaller o-ring in

housing) 115b 112319 O-RING (larger o-rings on

outside of housing) 116❖ 24E424 HOUSING 3 116a 112319 O-RING 6 117 24E427 HEAD, asm, ext mix, vert 1 118 16C705 PLUG, trigger 1 119 111316 PACKING, o-ring 1 120✿ 179737 PIN, actuator 2 121✿ 16C085 TRIGGER, gun, 2-finger 1 121a 16F627 TRIGGER, 4-finger (not shown) 1 122✿ 123733 BOLT, shoulder, self locking 2 123 276745 STOP, trigger 1 124 112033 PIN, dowel 1 125 16C130 GUARD, trigger 1 126 111945 SCREW, cap, fl hd 2 127 16C107 FITTING, resin hose 1

128* 16C118 FITTING, solvent 1 129* 16C117 VALVE, solvent 1 130* 24E437 PACKING, o-ring (pack of 6) 1

131* 24E431 O-RING (pack of 6) 1 132* 24E432 RING, retaining, e-ring

(pack of 6) 133* 16C119 FITTING, insert, solvent 1 134* 111450 PACKING, o-ring 2 135 123737 FITTING, tube, push connector 1 136 123736 FITTING, tube, push connector 1 138★ 16C108 FITTING, catalyst hose 1

Ref Part Description Qty

139 16C279 BODY, gel gun mount 1 141 123909 SCREW, cap, sh 2 143 124282 SCREW, set 1 148 24F007 KIT, tool, hex keys, gun 1 152 126395 SCREW, set, flat point 1

153★ 16D039 RESTRICTOR, catalyst 1 154▲ 222385 TAG, skin injection warning and

note to physician 155 CST521 TIP, spray, 521 1 158▲ 16P319 LABEL, quick start, RS gun 1 159 295662 PLUG, pipe 1 160 189018 SWIVEL 1

* Parts included in Solvent/AAC assembly kit 24E415.

† Parts included in catalyst seat kit 24E420.

‡ Parts included in resin seat kit 24E421.

◆ Parts included in needle clamp kit 24E416.

❄ Parts included in AAC needle kit 24E419.

★ Parts included in catalyst fitting kit 24H269.

✿ Parts included in gun trigger kit 24H268.

** Kit 24E436 includes 6 needle assemblies.

❖ O-rings on housings are available in kit 257425.

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Parts

3A0232R 39

Parts

Internal Mix Gel Gun, 258853

233

234

260

237

229

214

227

235

238

230

231

203

228

202

232

236

213

211

212

206

205

204

When converting an Internal Gel gun to an Internal Chop gun, replace top housing with 24M045.

215b

217

217a

239

240

222

201

216

216a

234

244

215

215a

217b

259

222

226

241

224

223

225

219

220

218

254

ti21016a

221

40 3A0232R

Ref Part Description Qty

200 199360 DOCUMENT, declaration 1 201 24N711 HANDLE, gun 1 202†‡ 24E428 SEAL, needle, seat (pack of 6) 2 203‡ 16C104 RETAINER, seat, needle valve,

resin

24M833 OPTIONAL - RETAINER, seat,

needle valve, resin, carbide 204† 24D201 RETAINER, seat, catalyst 1 205** 24E417 NEEDLE, assembly 2 206 GC2241 SCREW, set 1 211◆ 16C098 CLAMP, trigger, top 1 212◆ 16C099 CLAMP, trigger, bottom 1 213◆ 124057 SCREW, cap, sh 4 214◆ GC2082 SCREW, set, flpt 2 215❖ 24G764 HOUSING, check valve asm,

catalyst 215a 123934 O-RING, FKM (smaller o-ring in

housing) 215b 112319 O-RING (larger o-rings on outside

of housing) 216❖ 24E424 HOUSING 2 216a 112319 O-RING 6 217❖ 24H270 HOUSING, check valve asm,

solvent 217a 123934 O-RING, FKM (smaller o-ring in

housing) 217b 112319 O-RING (larger o-rings on outside

of housing) 218 24G615 HEAD, asm, internal mix, gel 1 219 16C705 PLUG, trigger 1 220✿ 179737 PIN, actuator 2 221✿ 16C085 TRIGGER, gun, 2-finger 1 221a 16F627 TRIGGER, 4-finger (not shown) 1 222✿ 123733 BOLT, shoulder, self locking 2 223 276745 STOP, trigger 1 224 112033 PIN, dowel 1 225 16C130 GUARD, trigger 1 226 111945 SCREW, cap, fl hd 2 227 16C107 FITTING, resin hose 1 228* 16C118 FITTING, solvent 1 229* 16C117 VALVE, solvent 1 230* 24E437 PACKING, o-ring (pack of 6) 1 231* 24E431 O-RING (pack of 6) 1 232* 24E432 RING, retaining, e-ring (pack of 6) 1 233* 16C119 FITTING, insert, solvent 1 234* 111450 PACKING, o-ring 2 235 123737 FITTING, tube, push connector 1 236 116134 PLUG, pipe, headless 1

Ref Part Description Qty

237★ 16D039 RESTRICTOR, catalyst 1 238★ 16C108 FITTING, catalyst hose 1 239 16C279 BODY, gel gun mount 1 240 123909 SCREW, cap, sh 2 241 111316 PACKING, o-ring 1

244 124282 SCREW, set 1 249 24F007 KIT, tool, hex keys, gun 1 254 CST521 TIP, spray, 521 1 257▲ 222385 TAG, skin injection warning and

note to physician 258▲ 16P319 LABEL, quick start, RS Gun 1 259 295662 PLUG, pipe 1 260 189018 SWIVEL 1

* Parts included in Solvent/AAC assembly kit 24E415.

† Parts included in catalyst seat kit 24E420.

‡ Parts included in resin seat kit 24E421.

◆ Parts included in needle clamp kit 24E416.

★ Parts included in catalyst fitting kit 24H269.

✿ Parts included in gun trigger kit 24H268.

❖ O-rings on housings are available in kit 257425.

** Kit 24E436 includes 6 needle assemblies.

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Parts

3A0232R 41

Parts

External Mix Chop Gun with Cutter, 258970

Ref Part Description Qty

301 258852 GUN, external mix, chop 1 302 24E512 CUTTER ASSEMBLY, external mix 1 303 16P320 LABEL, quick start, RS gun 1

Internal Mix Chop Gun with Cutter, 258971

Ref Part Description Qty

401 258854 GUN, internal mix, chop 1 402 24P681 CUTTER ASSEMBLY, internal mix 1 303 16P320 LABEL, quick start, RS gun 1

Internal Mix, High Flow, Chop Gun with Cutter, 24P435

Ref Part Description Qty

501 24P436 GUN, internal mix, chop, high flow 1 402 24P681 CUTTER ASSEMBLY, internal mix 1 303 16P320 LABEL, quick start, RS gun 1

301, 401, 501

302, 402

ti21017b

External Mix Chop Gun shown

42 3A0232R

Chop Guns

External Mix Chop Gun, 258852

Parts

567

529

533

534

538

514

527

530

506

563

531

505

536

532

535

528

503

502

513

511

508

512

509

559

546

507

558

534

504

502

543

539

545

549

516a1

501

541

520

560

542

540

516a

515b

515

515a

564

563

526

510

522

524

548

523

517

561

518

521

525

ti17943b

3A0232R 43

Parts

Internal Mix Chop Gun, 258854

563

533

529

534

567

514

537

530

538

531

505

527

532

536

528

506

535

513

503

510

511

502

512

509

508

543

546

507

559

504

540

545

502

549

558

539

534

501

560

541

542

516a

516a1

516b2

515b

515

516b1

515a

516b

564

563

522

526

524

523

548

525

518

520

517

561

521

ti21018a

44 3A0232R

High Flow Internal Mix Chop Gun, 24P436

563

Parts

533

529

534

567

537

514

530

538

505

527

531

532

528

536

535

506

503

513

510

511

502

512

509

508

543

546

507

559

504

540

545

502

549

558

539

534

501

560

541

516a

542

516b

516a1

516b2

515b

515

515a

516b1

564

522

517

524

548

561

563

523

518

526

525

3A0232R 45

520

521

ti21019a

Parts

External Mix, Internal Mix, and Internal Mix High Flow Chop Gun Parts

Quantity

Ref Part Description

500 199360 DOCUMENT, declaration 1 1 1

501 24N711 HANDLE, gun 1 1 1

502†‡ 24E428 SEAL, needle, seat (pack of 6) 2 2 2

503 16C104‡ RETAINER, seat, needle valve, resin 1 1

24M833 RETAINER, seat, needle valve, resin, carbide

505** 24E417 NEEDLE, assembly 2 2 2

506 ❄ 16C101 NEEDLE, aac 1 1 1

507❄ 123633 SPRING, needle assembly 1 1 1

508❄ 16C100 RETAINER, aac 1 1 1

509❄ 24E429 O-RING (pack of 6) 1 1 1

510❄ 24E430 O-RING (pack of 6) 1 1 1

511✿ 16C098 CLAMP, trigger, top 1 1 1

512✿ 16C099 CLAMP, trigger, bottom 1 1 1

513✿ 124057 SCREW, cap, sh 4 4 4

514✿ GC2082 SCREW, set, flpt 2 2 2

515✠ 24G764 HOUSING, check valve, catalyst 1 1

24E423 HOUSING, check valve, catalyst 1

515a 123934 O-RING, FKM (smaller o-ring in housing) 1 1 1

515b 112319 O-RING (larger o-rings on outside of housing) 2 2 2

516a✠ 24E424 HOUSING 3 2 2

516a1 112319 O-RING 1 1 1

516b✠ 24H270 HOUSING, check valve asm, solvent 1 1

516b1 123934 O-RING, FKM (smaller o-ring in housing) 1 1 1

516b2 112319 O-RING (larger o-rings on outside of housing) 2 2 2

517 24E426 HEAD, external mix, horizontal 1

24E442 HEAD, internal mix, chop 1

24P562 HEAD, internal mix, chop, high flow 1

517a 123934 O-RING, FKM (smaller o-ring in housing) 1 1 1

517b 112319 O-RING (larger o-rings on outside of housing) 2 2 2

518 24E425 VALVE, air, assy, trigger 1 1 1

520❖ 179737 PIN, actuator 2 2 2

521❖ 16C085 TRIGGER, gun, 2-finger 1 1 1

521a 16F627 TRIGGER, 4-finger (not shown) 1 1 1

522❖ 123733 BOLT, shoulder, self locking 2 2 2

523 276745 STOP, trigger 1 1 1

524 112033 PIN, dowel 1 1 1

525 16C130 GUARD, trigger 1 1 1

526 111945 SCREW, cap, fl hd 2 2 2

527 16C107 FITTING, resin hose 1 1 1

528* 16C118 FITTING, solvent 1 1 1

529* 16C117 VALVE 1 1 1

530* 24E437 PACKING, o-ring (pack of 6) 1 1 1

531* 24E431 O-RING (pack of 6) 1 1 1

532* 24E432 RING, retaining, e-ring (pack of 6) 1 1 1

533* 16C119 FITTING, insert, solvent 1 1 1

534*◆ 111450 PACKING, o-ring 2 2 2

535 123737 FITTING, tube, push connector 1 1 1

536 123736 FITTING, tube, push connector 1 1 1

537★ 16D039 RESTRICTOR, catalyst 1 1

538★ 16C108 FITTING, catalyst hose 1 1 1

258852 258854 24P436

46 3A0232R

Quantity

Ref Part Description

539◆ 16C103 BODY, chopper mount 1 1 1

540◆ 16C120 ADAPTER, chopper rotation 1 1 1

541◆ 16F501 TUBE, air pivot 1

24F997 TUBE, air pivot 1 1

542◆ 24E433 PACKING, o-ring (pack of 6) 1 1 1

543◆ 123909 SCREW, cap, socket head 2 2 2

544 239663 SWIVEL, straight 1 1 1

545◆ 124397 SPRING, belleville 1 1 1

546◆ C19080 SCREW, cap, hex head 1 1 1

548 124058 SPRING, compression 1 1 1

549 124282 SCREW, set, cppt 1 1 1

554 24F008 KIT, tool, hex keys, chop 1 1 1

558◆ 16F500 EXTENSION, cutter 1 1 1

559◆ 295662 PLUG, pipe 1 1 1

560 126395 SCREW, set, flat point 1 1 1

561 CST443 TIP, spray, 443 1 1 1

562▲ 222385 TAG, skin injection warning and note to

physician

563 125412 FITTING, elbow, male, swivel 2 2 2

564 125473 TUBE, pneumatic, polyurethane 1 1 1

567 189018 SWIVEL 1 1 1

258852 258854 24P436

1 1 1

* Parts included in solvent/AAC assembly kit 24E415.

Parts

† Parts included in catalyst seat kit 24E420.

‡ Parts included in resin seat kit 24E421.

✿ Parts included in needle clamp kit 24E416.

❄ Parts included in AAC needle kit 24E419.

** Kit 24E436 includes 6 needle assemblies.

★ Parts included in catalyst fitting kit 24H269.

❖ Parts included in gun trigger kit 24H268.

✠ O-rings on housings are available in kit 257425.

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

◆ Parts included in Cutter Adapter Kits, page 48.

3A0232R 47

Parts

Cutter Adapter Kits

External Mix Cutter Adapter Kit, 24E422 ★ Internal Mix Cutter Adapter Kit, 24G832

Internal Mix Adapter External Mix Adapter

ti21020a

These kits provide replacement parts for the cutter adapter.

To convert an external mix gel gun to an external mix chop gun, see External Mix Gel Gun to Chop Gun Conversion on page 55. The internal mix gel gun cannot be converted to a chop gun.

★ For single strand, external mix chop, low pressure applications, an external mix cutter extension adapter kit may be purchased in addition to the external mix cutter adapter kit. See External Mix Chopper Extension Kit, 24V096, page 56.

48 3A0232R

Front Head Assemblies

External Mix Horizontal Spray Pattern Front Head, 24E426 External Mix Vertical Spray Pattern Front Head, 24E427

702

701

708

708a

705

706

713

Parts

708a

709

712

711

717

703

704

718

Ref Part Description Qty

701 702 16C220 RING, locking 1 703* 704*† 705*† 706* 708

708a 111504 O-RING 3 709★ 262699 AIR CAP, vertical

710✿❄★ 711 GC2081 SCREW, set, flat point 1 712✿❄★ 713✿❄★ 107313 PACKING, o-ring 1 717*† 113137 PACKING, o-ring 1 718*†

* Parts available in external mix front head check valve

262696

16C489 M72843 123743 16C490 262697

❄ 262700 AIR CAP, horizontal

16E378

15G998

168588

kit 24E446.

HEAD, spray, external mix 1

SEAL, tip, external mix 1 BALL, sst 1 SPRING, compression 1 CAP, check valve, external mix 1 INSERT, valve assist, asm, ext mix

(Model 24E427 only)

(Model 24E426 only) RING, retaining 1

WASHER 1

WASHER, non-metallic 1

710

† Parts available in external mix front head check valve

repair kit 24E447.

✿ Parts included in retaining ring kit 24H274.

❄ Parts included in horizontal air cap kit 24H275.

★ Parts included in vertical air cap kit 24H283.

3A0232R 49

Parts

Internal Mix Gel Front Head, 24G615 Internal Mix Chop Front Head, 24E442

NOTICE

There is a half-moon pin pressed into the front head (801) behind the diffuser assembly (803). Do not attempt to remove this pin. Removal will result in poor mixing.

802

801

804

805

803

816

813

811

808

809

810

812

Part orientation detail

Ref Part Description Qty

801 262703 HEAD, spray, internal 1 802 16C220 RING, locking 1 803 16C327 DIFFUSER, internal mix 1 804 113746 PACKING, o-ring 1 805* 16C300 ELEMENT, mixing, internal mix 1 806* 16C397 CAP, check valve, internal mix 1 808❄ 262701 AIR CAP, asm, internal mix,

chop (Model 24E442 only)

★ 262702 AIR CAP, asm, internal mix, gel

coat (Model 24G615 only) 809✿❄★ 15G998 WASHER 1 810✿❄★ 16E376 RING, retaining 1 811✿❄★ 107313 PACKING, o-ring 1 812*† 16C408 VALVE, check, internal mix 1 813*† 123734 SPRING, compression 1 816*† 16F323 SEAT, check valve, int mix 1

806

* Parts available in internal mix front head check valve

kit 24E443.

† Parts available in internal mix check valve spring kit

24E444.

✿ Parts included in retaining ring kit 24H274.

❄ Parts included in internal mix chop air cap kit

24H277.

★ Parts included in internal mix gel air cap kit 24H278.

50 3A0232R

Internal Mix, High Flow Chop Front Head, 24P562

NOTICE

There is a half-moon pin pressed into the front head (801) behind the diffuser assembly (803). Do not attempt to remove this pin. Removal will result in poor mixing.

802

801

803

804

805

Parts

811

808

809

810

✿ Parts included in retaining ring kit 24H274.

Ref Part Description Qty

801 262703 HEAD, spray, internal 1 802 16C220 RING, locking 1 803 16G806 DIFFUSER, internal mix, 3/8 1 804 113746 PACKING, o-ring 1 805 20310-90 ELEMENT, mixing, spiral 1 808❄ 262701 AIR CAP, asm, internal mix,

chop (Model 24E442 only)

★ 262702 AIR CAP, asm, internal mix, gel

coat (Model 24G615 only) 809✿❄★ 15G998 WASHER 1 810✿❄★ 16E376 RING, retaining 1 811✿❄★ 107313 PACKING, o-ring 1

3A0232R 51

❄ Parts included in internal mix chop air cap kit

24H277.

★ Parts included in internal mix gel air cap kit 24H278.

Parts

Needle Assembly, 24E417

902

909

908

906

901

907

905

904

903

ti16592a

Beveled edge must face rear of needle

Ref Part Description Qty

901 123634 SPRING, needle assembly 1 902 16C080 HOUSING, needle packing 1 903* 16C081 RETAINER, packing 1 904* 24H279 PACKING, disk (pack of 6) 1 905* 16C083 RETAINER, packing 1 906 16C086 NUT, packing material 1 907* 16C087 CLIP, retainer 1 908 24C780 NEEDLE, assembly 1 909* 24H281 O-RING (pack of 6) 1

* Parts included in needle repair kit 24E418.

52 3A0232R

O-ring Identification

The following illustration shows all available o-rings at actual size. See the respective illustration in the Parts section beginning on page 38 for part references and locations.

White (PTFE) O-rings

Parts

131, 231, 531

110, 510

109, 509

130, 230, 530

708a

Part of:

215, 216, 217,

115, 116

713, 811

637

Black (FKM) O-rings

717

119, 241

804

909

638

542

603

134, 234, 534

3A0232R 53

Accessories

Fusion® Grease

118665, 4 oz. (113 gram)

High adhesion, water resistant, lithium-based lubricant. Use this to lubricate the gun. MSDS sheets available at www.graco.com.

INDy or Formula Adapter Kit, 125797

Ideal for mounting an RS gun in place of an INDy or Formula gun. Kit includes the necessary items to connect the RS gun to the connections used by INDy and Formula guns.

LPA2 Adapter Kit, 125843

Ideal for mounting an RS gun in place of an LPA2 gun. Kit includes the necessary items to connect the RS gun to the connections used by the LPA2 gun.

NOTE: An air assist tube and a catalyst hose are required to mount the RS gun in place of the LPA2 gun but they are not included in this kit. The existing air assist tube or catalyst hose may be able to be re-used. See the following table if additional parts are needed.

Part Description

9704-83 Air Assist Tube (order by the foot) 24C540 25 ft Catalyst Hose 24G429 35 ft Catalyst Hose 24C541 50 ft Catalyst Hose

Universal Adapter Kit, 257754

Allows the flexibility to mount an RS gun in place of a variety of guns, including competitor guns.

Resin Transfer Molding (RTM) Nozzle Adapter Kit, 16T680

Ideal for resin transfer molding applications.

Casting Nozzle Adapter Kit, 16T707

Ideal for casting nozzle applications.

External Mix High-Flow Kit, 24H336

Use this kit to replace the external mix front head check valve assembly with a non-check valve spacer in order to increase the output. See check valve assembly kit 24E446 parts shown in the Front Head Assemblies section on page 49.

NOTE: This kit replaces the check valve.

Part Description Qty

113137 O-RING 1 16G800 SPACER, tip, external mix 1

Internal Mix High-Flow Kit, 24H337

Use this kit to replace the standard 1/4 in. mixer in the internal mix front head assembly with a 3/8 in. mixer in order to increase the output. The kit includes a new diffuser assembly which does not use or require a check valve.

NOTE: This kit replaces the entire diffuser assembly, including a check valve, and the new diffuser does not use or require a check valve.

Part Description Qty

16G806 DIFFUSER, internal mix, 3/8 in. 1 113746 O-RING 1 20310-90 ELEMENT, mixing, 3/8 in. 1

54 3A0232R

Accessories

AAC Regulators

24G571 - for use with internal mix gel guns 22632-00 - for use with internal mix chop guns

1001

1005

1003

1002

1004

24G571_3A0232_1a

Ref Part Description Qty

1001 115841 FITTING, elbow

(Assembly 24G571 only)

20735-02 FITTING, elbow

(Assembly 22632-00 only)

1002 7597-04 FITTING, swivel, 3/8 nptm x

3/8 npsm

1003 8115-06 FITTING, pipe, nipple, hex, 3/8 x

1/4 1004 ISD-141-3 REGULATOR, mini 1 1005 ISD-142 GAUGE, pot, solvent 1

External Mix Gel Gun to Chop Gun Conversion

To convert your external mix gel gun to a chop gun, purchase and install the following kits:

• External Mix Cutter Adapter Kit, 24E422

• Trigger Air Valve Kit, 24E425

• Cutter Assembly, 24E512

To complete the conversion from an external mix gel gun to a chop gun, remove catalyst restrictor (153) from gun. See External Mix Gel Gun, 258840 on page 38.

Internal Mix Gel Gun to Chop Gun Conversion

To convert your internal mix gel gun to a chop gun, purchase and install the following kits:

• Internal Mix Cutter Adapter Kit, 24G832

• Trigger Air Valve Kit, 24E425

• Cutter Assembly, 24E512

• Blank Housing Assembly, 24M045

To complete the conversion from an internal mix gel gun

to a chop gun, replace housing (216) from gun. See Internal Mix Gel Gun, 258853 on page 40.

3A0232R 55

Accessories

Pressure Fed Roller Adapter Kit, 16T708

Ideal for pressure feed rolling with the RS gun.

Application Specific:

Part Description Qty

232122 EXTENSION, roller, fixed (0.5 meter) 244163 EXTENSION, pole gun, 3 feet 244164 EXTENSION, pole gun, 6 feet

Extension Gelcoat Spraying Kit, 16T709

For spraying into deep channels.

Application Specific:

Part Description Qty

XHD117 TIP, spray, cylinder (117) 1 XHD119 TIP, spray, cylinder (119) 1 XHD121 TIP, spray, cylinder (121) 1 XHD217 TIP, spray, cylinder (217) 1 XHD219 TIP, spray, cylinder (219) 1 XHD221 TIP, spray, cylinder (221) 1 XHD225 TIP, spray, cylinder (225) 1 XHD227 TIP, spray, cylinder (227) 1 XHD229 TIP, spray, cylinder (229) 1 XHD231 TIP, spray, cylinder (231) 1 XHD235 TIP, spray, cylinder (235) 1 XHD239 TIP, spray, cylinder (239) 1

Tools

Hex Keys for Guns, 24F007

Includes:

• One 3/32 in. hex key

• One 9/64 in. hex key

• ne 3/16 in. hex key

1 1

Carbide Resin Seat, 24M833

Ideal for use with heavily filled materials. It is to replace standard resin seat 16C104.

External Mix Chopper Extension Kit, 24V096

For extending the chopper assembly on external mix chopper guns.

1107

1104

1102

1103

1101

1105

Ref Part Description Qty

1101 1102 1103 1104 1105 1107

56 3A0232R

16X784 FITTING, extension 1 16F501 TUBE, air pivot 1 111516 PACKING, o-ring 1 295662 PLUG, pipe 1 127367 FITTING, nipple, 1/8 NPT 1 125412 FITTING, elbow 1

Accessories

3A0232R 57

Accessories

Impingement (Chop) Spray Tips

Pattern Width◆ Increases

6 in.

(15 cm)

CSTS31 CSTS41 CSTS51 CSTS61 CSTS71 CSTS81 CSTS91

Flow Increases

CSTS32 CSTS42 CSTS52 CSTS62 CSTS72 CSTS82 CSTS92

CSTS33 CSTS43 CSTS53 CSTS63 CSTS73 CSTS83

CSTS34 CSTS44 CSTS54 CSTS64 CSTS74 CSTS84

CSTS35 CSTS45 CSTS55 CSTS65 CSTS75 CSTS85

CSTS36 CSTS46 CSTS56 CSTS66 CSTS76 CSTS86

CSTS37 CSTS47 CSTS57 CSTS67

RS Gun

Impingement Spray

Tip Part No. †

CSTS31 0.018 in. (0.46 mm) 0.012 in. (0.30 mm) 6 in. (150 mm) 23005-C1

CSTS32 0.021 (0.53) 0.014 (0.36) 6 (150) 23005-C2

CSTS33 0.036 (0.91) 0.025 (0.64) 6 (150) 23005-C3

CSTS34 0.042 (1.07) 0.029 (0.74) 6 (150) 23005-C4

CSTS35 0.052 (1.32) 0.036 (0.91) 6 (150) 23005-C5

CSTS36 0.062 (1.57) 0.043 (1.09) 6 (150) 23005-C6

CSTS37 0.070 (1.78) 0.052 (1.32) 6 (150) 23005-C7

CSTS41 0.018 (0.46) 0.012 (0.30) 8 (200) 23005-E1

CSTS42 0.021 (0.53) 0.014 (0.36) 8 (200) 23005-E2

CSTS43 0.036 (0.91) 0.025 (0.64) 8 (200) 23005-E3

CSTS44 0.042 (1.07) 0.029 (0.74) 8 (200) 23005-E4

CSTS45 0.052 (1.32) 0.036 (0.91) 8 (200) 23005-E5

CSTS46 0.062 (1.57) 0.043 (1.09) 8 (200) 23005-E6

CSTS47 0.070 (1.78) 0.052 (1.32) 8 (200) 23005-E7

CSTS51 0.018 (0.46) 0.012 (0.30) 10 (250) 23005-G1

CSTS52 0.021 (0.53) 0.014 (0.36) 10 (250) 23005-G2

CSTS53 0.036 (0.91) 0.025 (0.64) 10 (250) 23005-G3

CSTS54 0.042 (1.07) 0.029 (0.74) 10 (250) 23005-G4

CSTS55 0.052 (1.32) 0.036 (0.91) 10 (250) 23005-G5

CSTS56 0.062 (1.57) 0.043 (1.09) 10 (250) 23005-G6

CSTS57 0.070 (1.78) 0.052 (1.32) 10 (250) 23005-G7

CSTS61 0.018 (0.46) 0.012 (0.30) 12 (300) 23005-J1

CSTS62 0.021 (0.53) 0.014 (0.36) 12 (300) 23005-J2

8 in.

(20 cm)

Angled Hole

10 in.

(25 cm)

Diameter

12 in.

(30 cm)

Straight Hole

14 in.

(36 cm)

Diameter Pattern Width ◆

16 in.

(41 cm)

18 in.

(46 cm)

GlasCraft

Part No. Ref

Tip

58 3A0232R

Accessories

RS Gun

Impingement Spray

Tip Part No. †

Angled Hole

Diameter

Straight Hole

Diameter Pattern Width ◆

CSTS63 0.036 (0.91) 0.025 (0.64) 12 (300) 23005-J3

CSTS64 0.042 (1.07) 0.029 (0.74) 12 (300) 23005-J4

CSTS65 0.052 (1.32) 0.036 (0.91) 12 (300) 23005-J5

CSTS66 0.062 (1.57) 0.043 (1.09) 12 (300) 23005-J6

CSTS67 0.070 (1.78) 0.052 (1.32) 12 (300) 23005-J7

CSTS71 0.018 (0.46) 0.012 (0.30) 14 (350) 23005-K1

CSTS72 0.021 (0.53) 0.014 (0.36) 14 (350) 23005-K2

CSTS73 0.036 (0.91) 0.025 (0.64) 14 (350) 23005-K3

CSTS74 0.042 (1.07) 0.029 (0.74) 14 (350) 23005-K4

CSTS75 0.052 (1.32) 0.036 (0.91) 14 (350) 23005-K5

CSTS76 0.062 (1.57) 0.043 (1.09) 14 (350) 23005-K6

CSTS81 0.018 (0.46) 0.012 (0.30) 16 (400) 23005-M1

CSTS82 0.021 (0.53) 0.014 (0.36) 16 (400) 23005-M2

CSTS83 0.036 (0.91) 0.025 (0.64) 16 (400) 23005-M3

CSTS84 0.042 (1.07) 0.029 (0.74) 16 (400) 23005-M4

CSTS85 0.052 (1.32) 0.036 (0.91) 16 (400) 23005-M5

CSTS86 0.062 (1.57) 0.043 (1.09) 16 (400) 23005-M6

CSTS91 0.018 (0.46) 0.012 (0.30) 18 (450) 23005-P1

CSTS92 0.021 (0.53) 0.014 (0.36) 18 (450) 23005-P2

CSTT36 0.062 (1.57) 0.043 (1.09) 6 (150) 23005-TC6

CSTT37 0.070 (1.78) 0.052 (1.32) 6 (150) 23005-TC7

CSTT46 0.062 (1.57) 0.043 (1.09) 8 (200) 23005-TE6

CSTT47 0.070 (1.78) 0.052 (1.32) 8 (200) 23005-TE7

CSTT56 0.062 (1.57) 0.043 (1.09) 10 (250) 23005-TG6

CSTT57 0.070 (1.78) 0.052 (1.32) 10 (250) 23005-TG7

CSTT66 0.062 (1.57) 0.043 (1.09) 12 (300) 23005-TJ6

CSTT67 0.070 (1.78) 0.052 (1.32) 12 (300) 23005-TJ7

CSTT76 0.062 (1.57) 0.043 (1.09) 14 (350) 23005-TK6

CSTT86 0.062 (1.57) 0.043 (1.09) 16 (400) 23005-TM6

GlasCraft

Part No. Ref

Tip

† Tip Code Reference:

CST = Composite Spray Tip 4th digit = S for stainless steel, T for tool steel 5th digit = pattern width code. Double number to get pattern size at 18 in. (450 mm). Example: 5 = 10 in. (250 mm) pattern at 18 in. (450 mm) distance to target. 6th digit = orifice size code. Number roughly matches a 0.010 in. (0.254 mm) increment of the angled hole dia. Exp: 5 = 0.052 in. (1.32 mm) dia. angled holes.

◆ Approximate pattern width at 18 in. (45 cm) to target. Actual pattern width varies depending on various conditions.

3A0232R 59

Accessories

Airless (Gel) Spray Tips

Pattern Width◆ Increases

4 in.

(10 cm)

Flow Increases

CST215 CST315 CST415 CST515 CST615

CST217 CST317 CST417 CST517 CST617

CST219 CST319 CST419 CST519 CST619

CST221 CST321 CST421 CST521 CST621

CST223 CST323 CST423 CST523 CST623

CST227 CST327 CST427 CST527 CST627

CST231 CST331 CST431 CST531 CST631

CST235 CST335 CST435 CST535 CST635

RS Gun

Airless Spray Tip

Part No. † Orifice Diameter Pattern Width ◆

CST215 0.015 in. (0.38 mm) 4-6 in. (100-150 mm) LPA2-147-1525 CST217 0.017 (0.43) 4-6 (100-150) LPA2-147-1825 CST219 0.019 (0.48) 4-6 (100-150) --CST221 0.021 (0.53) 4-6 (100-150) LPA2-147-2125 CST223 0.023 (0.58) 4-6 (100-150) LPA2-147-2325 CST227 0.027 (0.69) 4-6 (100-150) --CST231 0.031 (0.79) 4-6 (100-150) LPA2-147-3125 CST235 0.035 (0.89) 4-6 (100-150) LPA2-147-3625 CST315 0.015 (0.38) 6-8 (150-200) --CST317 0.017 (0.43) 6-8 (150-200) --CST319 0.019 (0.48) 6-8 (150-200) --CST321 0.021 (0.53) 6-8 (150-200) --CST323 0.023 (0.58) 6-8 (150-200) --CST327 0.027 (0.69) 6-8 (150-200) --CST331 0.031 (0.79) 6-8 (150-200) --CST335 0.035 (0.89) 6-8 (150-200) --CST343 0.043 (1.09) 6-8 (150-200) LPA2-147-4325 CST351 0.051 (1.30) 6-8 (150-200) LPA2-147-5225 CST415 0.015 (0.38) 8-10 (200-250) LPA2-147-1540 CST417 0.017 (0.43) 8-10 (200-250) LPA2-147-1840 CST419 0.019 (0.48) 8-10 (200-250) ---

6 in.

(15 cm)

CST343 CST443 CST543 CST643

CST351 CST451 CST551 CST651

8 in.

(20 cm)

CST461 CST561 CST661

CST471 CST571 CST671

10 in.

(25 cm)

12 in.

(30 cm)

GlasCraft Tip

Part No. Ref

60 3A0232R

RS Gun

Airless Spray Tip

Part No. † Orifice Diameter Pattern Width ◆

GlasCraft Tip

Part No. Ref

CST421 0.021 (0.53) 8-10 (200-250) LPA2-147-2140 CST423 0.023 (0.58) 8-10 (200-250) LPA2-147-2340 CST427 0.027 (0.69) 8-10 (200-250) LPA2-147-2640 CST431 0.031 (0.79) 8-10 (200-250) LPA2-147-3140 CST435 0.035 (0.89) 8-10 (200-250) LPA2-147-3640 CST443 0.043 (1.09) 8-10 (200-250) LPA2-147-4340 CST451 0.051 (1.30) 8-10 (200-250) LPA2-147-5240 CST461 0.061 (1.55) 8-10 (200-250) LPA2-147-6240 CST471 0.071 (1.80) 8-10 (200-250) LPA2-147-7240 CST515 0.015 (0.38) 10-12 (250-300) --CST517 0.017 (0.43) 10-12 (250-300) LPA2-147-1850 CST519 0.019 (0.48) 10-12 (250-300) --CST521 0.021 (0.53) 10-12 (250-300) LPA2-147-2150 CST523 0.023 (0.58) 10-12 (250-300) LPA2-147-2350 CST527 0.027 (0.69) 10-12 (250-300) LPA2-147-2650 CST531 0.031 (0.79) 10-12 (250-300) LPA2-147-3150 CST535 0.035 (0.89) 10-12 (250-300) LPA2-147-3650 CST543 0.043 (1.09) 10-12 (250-300) LPA2-147-4350 CST551 0.051 (1.30) 10-12 (250-300) LPA2-147-5250 CST561 0.061 (1.55) 10-12 (250-300) LPA2-147-6250 CST571 0.071 (1.80) 10-12 (250-300) --CST615 0.015 (0.38) 12-14 (300-350) --CST617 0.017 (0.43) 12-14 (300-350) --CST619 0.019 (0.48) 12-14 (300-350) --CST621 0.021 (0.53) 12-14 (300-350) --CST623 0.023 (0.58) 12-14 (300-350) --CST627 0.027 (0.69) 12-14 (300-350) --CST631 0.031 (0.79) 12-14 (300-350) --CST635 0.035 (0.89) 12-14 (300-350) --CST643 0.043 (1.09) 12-14 (300-350) --CST651 0.051 (1.30) 12-14 (300-350) LPA2-147-5265 CST661 0.061 (1.55) 12-14 (300-350) LPA2-147-6265 CST671 0.071 (1.80) 12-14 (300-350) ---

Accessories

† Tip Code Reference:

CST = Composite Spray Tip 4th digit = pattern width code. Double number to get pattern size at 12 in. (305 mm). Example: 5 = 10 in. (250 mm) pattern at 12 in. (305 mm) distance to target. 5th & 6th digit = equivalent orifice size as a round diameter orifice.

◆ Approximate pattern width at 12 in. (30 cm) to target. Actual pattern width varies depending on various conditions.

3A0232R 61

Technical Data

See Models on page 3 for more information.

RS Gun and Cutter

US Metric

Maximum Fluid Working Pressure Internal Mix 258853 2000 psi 138 bar, 14 MPa 258854 2000 psi 138 bar, 14 MPa 258971 2000 psi 138 bar, 14 MPa 24P435 2000 psi 138 bar, 14 MPa External Mix 258840 2000 psi 138 bar, 14 MPa 258852 2000 psi 138 bar, 14 MPa 258970 2000 psi 138 bar, 14 MPa Maximum Catalyst Working Pressure 258853 2000 psi 138 bar, 14 MPa 258854 2000 psi 138 bar, 14 MPa 258971 2000 psi 138 bar, 14 MPa 24P435 2000 psi 138 bar, 14 MPa 258840 200 psi 14 bar, 1.4 MPa 258852 200 psi 14 bar, 1.4 MPa 258970 200 psi 14 bar, 1.4 MPa Air Inlet Working Pressure 258853 0-125 psi 0-8.6 bar, 0-0.86 MPa 258854 0-125 psi 0-8.6 bar, 0-0.86 MPa 258971 80-125 psi 5.5-8.6 bar, 0.55-0.86 MPa 24P435 80-125 psi 5.5-8.6 bar, 0.55-0.86 MPa 258840 0-125 psi 0-8.6 bar, 0-0.86 MPa 258852 0-125 psi 0-8.6 bar, 0-0.86 MPa 258970 80-125 psi 5.5-8.6 bar, 0.55-0.86 MPa Maximum Fluid Temperature 258853 100°F 38°C 258854 100°F 38°C 258971 100°F 38°C 24P435 100°F 38°C 258840 100°F 38°C 258852 100°F 38°C 258970 100°F 38°C Minimum Air Flow (at 100 psi, 7 bar, 0.7 Mpa) 258853 12.5 scfm

258854 2.25 scfm

258840 2.0 scfm

24E512 16.5 scfm

0.375 m3 per min.

0.064 m3 per min.

0.06 m3 per min.

0.47 m3 per min.

62 3A0232R

Technical Data

RS Gun and Cutter

US Metric

Weight 258853 2.32 lb 1.05 kg 258854 2.46 lb 1.12 kg 258840 2.08 lb 0.94 kg 258852 2.33 lb 1.04 kg Sound Power

Measured per ISO-3746 258853 98.1 dB (A) at 60 psig 258854 90.6 dB(A) at 50 psig 258840 90.8 dB(A) at 50 psig Sound Pressure

Measured at 3 ft (1 m) from equipment. 258853 80.3 dB (A) at 60 psig 258854 72.8 dB(A) at 50 psig 258840 73.0 dB(A) at 50 psig Wetted Parts Aluminum, stainless steel, carbon steel, carbide, chemically

resistant o-rings

Materials of Construction Aluminum, stainless steel, carbon steel, carbide, chemically

resistant o-rings Maximum Air Pressure 125 psi 9 bar, 0.9 MPa Maximum Fluid Temperature 100°F 38°C

3A0232R 63

Technical Data

Dimensions

258840_3A0232_1g

Dimensions; in. (mm)

External, Gel Internal, Gel Internal, Chop External, Chop

A, Height 7.37 (187) 7.37 (187) 10.29 (261.4) 10.29 (261.4)

B, Length 7.60 (193) 9.2 (234) 9.2 (234) 7.60 (193)

C, Width 2.36 (59.9) 2.36 (59.9) 5.07 (129) 5.07 (129)

64 3A0232R

Technical Data

3A0232R 65

Graco Standard Warranty

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 par ts. 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

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 3A0232

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised August 2014

Graco 3A0232R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Related Manuals

Warnings

Important Two-Component Information

Material Self-ignition

Keep Components A and B Separate

Changing Materials

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

Component Identification

External Mix Gel Gun, 258840

Internal Mix Gel Gun, 258853

Internal Mix Chop Gun, 258854

Internal Mix Chop Gun, 24P436, High Flow, Carbide Seat

External Mix Chop Gun, 258852

Theory of Operation

External Mix

Internal Mix

Chop Guns

Grounding

Impingement versus Airless Spray Tips

Introduction

Setup

Startup

Operation

Tri gg er Lock

Adjust AAC

Internal Mix Flush

Pressure Relief Procedure

Shutdown

Daily Shutdown

Long-Term Shutdown

Maintenance

Flush System

Troubleshooting

Fluid Leaking from Front of Gun

Adjust Trigger Clamp

Fluid Leaking from Under Trigger Clamp Assembly

Adjust Needle Packing Tension

Adjust Actuator Pin Adjustment Screws

Repair

Remove Hardened Material from Internal Mix Front Head

Replace Internal Mix Element

Replace External Mix Check Valve and O-Rings

Replace Material Needle Assembly

Replace Center Needle Assembly

Replace Needle Packing

Parts

External Mix Gel Gun, 258840

Internal Mix Gel Gun, 258853

External Mix Chop Gun with Cutter, 258970

Internal Mix Chop Gun with Cutter, 258971

Internal Mix, High Flow, Chop Gun with Cutter, 24P435

Chop Guns

Front Head Assemblies

Needle Assembly, 24E417

O-ring Identification

Accessories

Fusion® Grease

INDy or Formula Adapter Kit, 125797

LPA2 Adapter Kit, 125843

Universal Adapter Kit, 257754

Resin Transfer Molding (RTM) Nozzle Adapter Kit, 16T680

Casting Nozzle Adapter Kit, 16T707

External Mix High-Flow Kit, 24H336

Internal Mix High-Flow Kit, 24H337

AAC Regulators

External Mix Gel Gun to Chop Gun Conversion

Internal Mix Gel Gun to Chop Gun Conversion

Pressure Fed Roller Adapter Kit, 16T708

Extension Gelcoat Spraying Kit, 16T709

Tools

Carbide Resin Seat, 24M833

External Mix Chopper Extension Kit, 24V096

Impingement (Chop) Spray Tips

Airless (Gel) Spray Tips

Technical Data