Graco 3A1602G User Manual

Instructions - Parts

E-8p

Portable Plural Component Sprayer

For spraying 1:1 mix ratio formulated no-heat polyurethane foams and dispensing 1:1 mix ratio polyurea joint-fill materials. For professional use only. Not approved for use in European explosive atmosphere locations.

2000 psi (14 MPa, 138 bar) Maximum Working Pressure

See page 3 for a list of models.

Important Safety Instructions

Read all warnings and instructions in all supplied manuals. Save all instructions.

3A1602G

TI17120a

Contents

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Proportioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

Important Two-Component Material Information . 7

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7

Foam Resins with 245 fa Blowing Agents . . . . . . 7

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . . . 9

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Requirements . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Lock/Unlock Handle . . . . . . . . . . . . . . . . . . . . . 12

Install 38 mm Spout Adapter . . . . . . . . . . . . . . . 12

Install Desiccant Dryers . . . . . . . . . . . . . . . . . . 12

Install Optional Recirculation Kit . . . . . . . . . . . . 13

Connect Fluid Hoses . . . . . . . . . . . . . . . . . . . . . 14

Connect Gun to Air Hose

(Air Operated Guns Only) . . . . . . . . . . . . . . 14

Connect Main Air Supply . . . . . . . . . . . . . . . . . 14

Flush Before Using Equipment . . . . . . . . . . . . . 14

Fill Wet-cups . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Install Pail Heaters . . . . . . . . . . . . . . . . . . . . . . 16

Recirculate Material . . . . . . . . . . . . . . . . . . . . . 16

Purge Air and Flush Fluid . . . . . . . . . . . . . . . . . 17

Connect Fluid Inlet Tubes . . . . . . . . . . . . . . . . . 18

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 27

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Before Beginning Repair . . . . . . . . . . . . . . . . . . 30

Recirculation/Spray Valves . . . . . . . . . . . . . . . . 30

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 31

Replace Function Knob/Potentiometer . . . . . . . 32

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure Transducers . . . . . . . . . . . . . . . . . . . . 35

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Cycle Counter Switch Replacement . . . . . . . . . 37

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Spout Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Suggested Spare Replacement Parts . . . . . . . . . 50

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 54

2 3A1602G

Systems

Maximum Working

Pressure,

Part

AP9082 2000 (14, 140) 259082 24M653 50 (15.2)

CS9082 2000 (14, 140) 259082 24M653 50 (15.2) P29082 2000 (14, 140) 259082 24M653 50 (15.2) Probler P2 GCP2R0 AP9083 2000 (14, 140) 259083 24M653 50 (15.2)

CS9083 2000 (14, 140) 259083 24M653 50 (15.2) P29083 2000 (14, 140) 259083 24M653 50 (15.2) Probler P2 GCP2R0

24R151 2000 (14, 140) 259082 24R823 35 (10.7) Manual 2K 24R021 24R154 2000 (14, 140) 259083 24R823 35 (10.7) Manual 2K 24R021

psi (MPa, var)

Proportioner

(see

Proportioners)

Hose Gun Model

Part Length Model Part

Fusion

™

Air Purge

™

Air Purge

™

246100

CS00RD

246100

CS00RD

Proportioners

The model no., series letter, and serial no. are located on the back of the Reactor E-8p™.

* Electrical

Connection

Part Volts

259082 120 V 15 A cord

★

(motor only) Application

259083 240 V 10 A cord

No-heat polyurethane foam. Polyurea joint-fill materials.

Maximum Working Pressure,

psi (MPa, bar)

2000 (14, 140)

* See page 11 for detailed electrical requirements.

Related Manuals

Manuals are available at www.graco.com.

Manual Description

313123 Displacement Pump Repair-Parts 309550

312666

™

Fusion tion-Parts

™

Fusion tion-Parts

Air Purge Spray Gun Instruc-

CS Spray Gun Instruc-

★ Approvals:

9902471

Conforms to ANSI/UL

Std. 73 Certified to

CAN/CSA Std.

C22.2 No. 68

Manual Description

313213

332198 Joint Fill Gun Instructions-Parts

NOTE: The pail heaters are shipped with the manual supplied by their manufacturer.

Probler tion-Parts

P2 Spray Gun Instruc-

3A1602G 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

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

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 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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the Pressure Relief Procedure when you stop spraying 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.

4 3A1602G

Warnings

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.

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.

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.

3A1602G 5

Warnings

WARNING

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.

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.

6 3A1602G

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

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: 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 felt washers in the pump wet cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere.

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 (isocyanate) and component B (resin) parts.

• 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.

• Always park pumps when you shutdown. See page 20.

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.

3A1602G 7

Overview

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• 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.

Overview

The Reactor E-8p is a portable, electric-powered, 1:1 mix ratio proportioner. It is for use with formulated no-heat polyurethane foams that may be applied with impingement mix spray guns and for use with polyurea joint fill materials that may be applied with static mix guns.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, the Reactor E-8p will circulate fluids back to the supply pails.

An electronic processor controls the motor, monitors fluid pressures, and alerts the operator if errors occur. See STATUS Indicator, page 10, for further information.

The Reactor E-8p has two recirculation speeds: slow and fast, and an adjustable pressure output.

Slow Recirculation

• Use for pump priming.

Fast Recirculation

• Use for flushing.

• Use for pump priming.

Pressure Adjust

Automatically maintains selected pressure output for spraying.

8 3A1602G

Component Identification

BACK VIEW

Component Identification

FRONT VIEW

TI17121a

FIG. 1: Component Identification

Key:

A Pump A B Pump B C Fluid Pressure Gauges D Recirc/Spray and Overpressure Relief Valves E Control Panel F Electric Motor and Drive Housings G Hose Bundle HSpray Gun J Recirculation Tubes K Air Line Inlet (quick-disconnect fitting) L Outlet Hose Connections MPower Cord N Lift Ring/Handle/Hose Rack P Fluid Inlet Tubes Q Desiccant Dryers

3A1602G 9

Controls and Indicators

Motor/Pump Control Function Knob

Status Codes

FIG. 2: Controls and Indicators

Power Switch

Powers the Reactor E-8p on and off.

Motor/Pump Control Function Knob

Use knob to select desired function.

Icon Setting Function

Stop/Park

Slow Recirc Slow recirculation speed.

Stops motor and automatically parks pumps.

Status Indicator

Power Switch

TI17123b

STATUS Indicator

Indicates system status, including power and error codes.

• Indicator steady on: power switch is turned on.

• Indicator blinking: If an error occurs, the status indicator light will blink one to seven times to indicate a specific status code, pause, and then repeat. The following table provides a brief description of each status code. For more detailed information and corrective action, see Status Codes on page 24.

Fast Recirc Fast recirculation speed.

Use fluid pressure settings

Static Mix

1-5 to dispense polyurea joint-fill materials through a static mixer.

Use fluid pressure settings

Spray

6-10 to spray polyurethane foam.

Table 1: Status Codes

(also located on front of Reactor)

Code Code Name

1 Pressure imbalance between A and B sides

2 Unable to maintain pressure setpoint

3 Pressure transducer A failure

4 Pressure transducer B failure

5 Excessive current draw

6 High motor temperature

7 No cycle counter switch input

NOTE: The default is to shut down if a status code indication occurs. Codes 1 and 2 may be set to disable automatic shutdown if desired; see page 25. You cannot set the other codes.

10 3A1602G

Setup

Location

• The Reactor E-8p should always be used on a level surface.

• Do not expose the Reactor E-8p to rain.

Electrical Requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

• Required power source: single dedicated circuit that is rated at a minimum of 15A.

NOTE: Cords must be 3-conductor grounded, rated for your environment.

• Power cord connector (120V):

One NEMA 5-15T

• Power cord connector (240 V):

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.

Reactor E-8p: grounded through power cord.

Generator (if used): follow your local code and manu-

facturer’s recommendations. Start and stop the generator with power cord(s) disconnected.

Spray gun: ground through connection to a properly grounded fluid hose and grounded Reactor E-8p. Do not operate without at least one grounded fluid hose.

Fluid supply container: follow local code.

Object being sprayed: 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 nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

One IEC 320, with two local adapters

Euro CEE74 Adapter

Australia/China Adapter

• Extension cord requirements:

Required Wire Size

Up to 50 ft (15 m) Up to 100 ft (30 m)

AWG 14 AWG 12

3A1602G 11

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray gun

firmly to the side of a grounded metal pail, then trigger the gun.

Setup

Lock/Unlock Handle

Lock the handle when the sprayer is moved, laid on its side, or turned upside down.

Unlock

To unlock the handle, remove lanyard and locking pin from cart handle. Pull on handle to extend cart handle and move sprayer.

Install 38 mm Spout Adapter

The sprayer is supplied with a 40 mm spout adapter. Install 38 mm spout adapters if necessary.

1. Loosen containment knob.

2. Remove suction tube caps and place in containment tray.

3. For installation instructions, see Spout Adapter, page 40.

40 mm

Black

38 mm

Silver

ti17513a

FIG. 3

Lock

To lock the handle, press down handle pins and slide cart handle through tubes. Insert pin through cart handle and lock with lanyard.

ti18063a

FIG. 5: Spout Adapters

Install Desiccant Dryers

1. Use needle nose pliers to remove two plugs (P) from the dryer (73).

2. Remove plug from adapter housing (57).

3. Screw the dryer into the adapter housing (57) handtight only. Do not overtighten.

ti17475a

FIG. 6: Desiccant Dryer Installation

ti17514a

FIG. 4

12 3A1602G

Setup

Install Optional Recirculation Kit

Use Hose Recirculation Kit 24M654 to help evenly distribute heat when using supplemental heaters and circulate material through the fluid manifold, out to the gun, and back to the material supply container. See Acces- sories, page 50.

Apply thread sealant to all non-swiveling pipe threads.

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

1. Relieve pressure. See Pressure Relief Procedure, page 20.

2. Flush. See page Flushing, page 22.

3. Remove fluid tubes (36).

507

511

515

508

515

507

508

552

B Side A Side

551

218

509

510

507

508

510

501

509

ti18824a

FIG. 7

4. Place a wrench on the pressure transducer manifold (33) and remove the adapters (34). Set A and B side adapters aside.

5. Remove fittings (509) and (510). Remove two swivel fittings (515) and elbow fittings (511) from tee fitting (508). Remove tee fittings and gauges (507) from manifold (501). Set A and B side parts aside. Elbow fittings (511) are not used with recirculation setup.

6. Install 1/4 npt x -6 JIC adapter fitting (510) in the B side fluid manifold outlet port. Install 1/4 npt x -5 JIC fitting (509) in the A side fluid manifold outlet port.

WLD

FIG. 8

7. Install plugs (552).

8. Loosen pump lock nut (218) by hitting firmly with right-to-left with a non-sparking hammer. Rotate pump until there is enough space to install pressure gauges. If the transducer cable is tight, remove bottom cover and cut cable ties. See F

IG. 56, page 32.

9. Install A and B side tee fittings (508) in the pressure transducer manifolds (33). Install adapter fitting (551) and adapter fitting (34) in tee fittings (508).

10. Install gauges (507) in tee fittings (508).

NOTE: Ensure that there is enough space to dispense Graco ISO pump oil in the wet cup through the pump cover.

11. Tighten locknut (218) by hitting firmly with a non-sparking hammer.

12. Install fluid tubes (36).

3A1602G 13

Setup

Connect Fluid Hoses

Connect fluid supply hoses to outlet hose connections (F

IG. 9 and FIG. 10). Red hoses for component A (ISO),

blue for component B (RES). Fittings are sized to prevent connection errors. Connect other end of hoses to A and B inputs of gun.

NOTE: If using the Recirculation Hose Kit 24M654, connect hoses to Recirculation Gun Manifold Kit 249523. See F

IG. 10.

Connect Gun to Air Hose (Air Operated Guns Only)

Connect gun air hose to the gun air input and to the air filter outlet. If you are using more than one hose bundle, join the air hoses with the nipple provided with the hose bundle.

Connect Main Air Supply

NOTE: The Reactor E-8p requires 4 scfm

(0.112 m spray guns to work correctly.

Connect the main air supply to the quick disconnect fitting on the unit. The air supply hose must be at least 5/16 in. (8 mm) ID up to 50 ft (15 m) or 3/8 in. (10 mm) ID up to 100 ft (30 m).

/min) compressed air for the air operated

Flush Before Using Equipment

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 Flushing, page 22.

B (RES)

FIG. 9: Hose and Air Connections

Compressed Air Line

B (RES)

A (ISO)

Air

ti17122a

14 3A1602G

A Recirculation

A (ISO)

Setup

B Recirculation

A (ISO)

B (RES)

Compressed Air Line

B (RES)

Recirculation Gun Manifold Kit 249523

(only compatible with Fusion Air Purge Gun)

601

607

604

602

603

FIG. 10: Hose and Air Connections - Recirculation Hose Kit 24M654

Air

604

605

607

605

TI7134A

3A1602G 15

Setup

Fill Wet-cups

Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere.

The pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from the wet-cup during operation. Shut off power before filling the wet-cup.

Fill wet-cups through the slots in the plate, or remove a screw and swing the plate to the side.

Slots

Recirculate Material

The standard system circulates material from the fluid manifold back to the supply container. To circulate material from the gun back to the material supply container, purchase and install Hose Recirculation Kit 24M654. See Install Optional Recirculation Kit on page 13.

1. Insert inlet tubes into pails. See Connect Fluid Inlet Tubes, page 18.

2. Set function knob to Stop/Park.

TI17127b

FIG. 12

TI17124a

FIG. 11: Fill Wet Cup

Install Pail Heaters

Follow all warnings and instructions from both the fluid manufacturer technical data sheet and the pail heater installation manual.

If the material viscosity at room temperature is greater than 2000 centipoise the pump may not siphon feed on-ratio. Purchase and install the optional flexible pail heaters so the material can be warmed, resulting in a lower viscosity and enabling the pump to properly siphon feed. See Accessories on page 50.

Install and operate according to the included pail heater manufacturer’s installation manual.

3. Plug in power cord.

4. Turn on power.

TI17134a

FIG. 13

5. Set the Recirc/Spray valves to Recirc.

FIG. 14

TI17133a

16 3A1602G

Setup

6. Set function knob to Slow Recirc or Fast Recirc

TI17128b

FIG. 15

7. When material exits both recirculation tubes, set the

function knob to Stop/Park

8. Set the Recirc/Spray valves to Spray.

TI17132a

Purge Air and Flush Fluid

1. Insert inlet tubes into pails of solvent.

TI17126a

FIG. 17

2. Insert recirculation tubes into waste containers.

3. Set function knob to Stop/Park

FIG. 16

TI17127b

FIG. 18

4. Plug in power cord.

5. Turn on power.

TI17134a

FIG. 19

6. Set the Recirc/Spray valves to Recirc.

TI17133a

FIG. 20

3A1602G 17

Setup

7. Set function knob to Slow Recirc or Fast Recirc

TI17128b

FIG. 21

8. When clean solvent exits both recirculation tubes,

set the function knob to Stop/Park

9. Insert inlet tubes into pails. See Connect Fluid Inlet Tubes, page 18.

10. Set the Recirc/Spray valves to Spray.

Connect Fluid Inlet Tubes

1. Loosen containment knob.

2. Remove suction tube caps and place in containment tray.

3. Insert each fluid inlet tube through the pour spout on the appropriate five-gallon pail. Tighten the ring to the pour spout.

Ring

FIG. 22

11. Run until material exits gun manifold.

TI17132a

TI17125a

FIG. 23

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

Label one pail “A” and the other “B”, using the red and blue labels provided. Always double check which material you have before placing fluid inlet tube into the pail.

NOTE: Use a drill and mixing blade to mix filled or separated materials in the pail before placing fluid inlet tube into the pail.

18 3A1602G

Spraying

NOTE: For air operated guns, air is supplied to spray

gun with gun piston safety lock engaged and gun fluid manifold valves A and B closed (if present).

NOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual.

FIG. 24

1. Set function knob to Stop/Park.

Spraying

6. Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code 1) is inactive for 10 seconds after entering spray pressure mode, to allow time to balance pressures.

In this example, the B side pressure is higher, so use the B side valve to balance pressures.

TI17137a

FIG. 28

TI17127b

FIG. 25

2. Engage piston safety lock.

3. Open gun manifold.

4. Set Recirc/Spray valves to Spray.

TI17132a

FIG. 26

5. Turn the pressure control knob to the right until fluid pressure gauges show desired pressure.

NOTE: Watch gauges for 10 seconds to ensure pressure holds on both sides and pumps are not moving.

7. Open gun fluid manifold valves A and B (impingement mix guns only).

FIG. 29

NOTE: On impingement guns, never open fluid mani-

fold valves or trigger gun if pressures are imbalanced.

8. Disengage piston safety lock.

FIG. 30

NOTE: It is desirable to use lower pressure for joint fill-

ing applications.

9. Test spray onto cardboard or plastic sheet. Verify that material fully cures in the required length of time, and is the correct color. Adjust pressure and

TI17129b

temperature to get desired results. Equipment is ready to spray.

FIG. 27

3A1602G 19

Pressure Relief Procedure

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

NOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual.

1. Engage piston safety lock.

FIG. 31

2. Set function knob to Stop/Park

Shutdown

NOTE: For longer breaks (more than 10 minutes), use

the following procedure. If you will be shut down for more than three days, perform the Flushing procedure, page 22, first.

NOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual.

1. Follow Pressure Relief Procedure.

2. Close gun fluid valves A and B. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

FIG. 34

3. Shut off power.

TI17127b

FIG. 32

3. Turn Recirc/Spray valves to Recirc. Fluid will be returned to material pails. Pumps will move to the bottom of their stroke. Ensure gauges drop to 0.

TI17133a

FIG. 33

TI17135a

FIG. 35

4. Loosen rings from pour spouts and remove fluid inlet tubes from pails. Allow residual fluid to drain into the appropriate pail.

Ring

TI17125a

FIG. 36

20 3A1602G

Maintenance

5. Use solvent to wipe down fluid inlet tubes.

6. Install suction tube caps on each fluid inlet tube and rest in the containment tray. Tighten the containment knob to press the bracket against the fluid inlet tubes.

Containment Knob

TI17458a

FIG. 37

7. Refer to your separate spray gun manual to perform the gun shutdown procedure.

Caps

Maintenance

• Check pump wet-cups fluid level daily. Refer to Fill Wet-cups, page 16.

• Do not overtighten packing nut/wet-cup. Throat u-cup is not adjustable.

• Keep component A from exposure to moisture in atmosphere, to prevent crystallization.

• Check desiccant filters weekly. Filter is blue when fresh, and turns pink when saturated.

• Generally, flush if you will shutdown for more than three days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

• Close gun fluid valves A and B when not spraying. Doing this will keep the internal parts of the gun cleaner and prevent crossover. Clean gun mix chamber ports and check valve screens regularly. See spray gun manual.

8. Wrap hoses around sprayer.

9. Disconnect power cord before moving.

TI17459a

FIG. 38

FIG. 39

• Always grease the gun after use until purge air carries grease mist out the front of the gun. Use Part No. 117773 Grease. See spray gun manual.

• Always grease the inlet tube spout adapters after use. Use Part No. 117773 Grease and grease gun supplied with spray gun.

• Remove any material from containment tray with solvent.

3A1602G 21

Flushing

Flush equipment only in a well-ventilated area. Do not spray flammable fluids.

• Generally, flush if you will be shut down for more than 3 days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

3. Remove both recirculation tubes from material pails and secure each one to a dedicated waste container.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.

• Use the lowest possible pressure when flushing.

• Always leave some type of fluid in system. Do not use water.

• For long term storage, flush out the solvent with a storage fluid such as Bayer Mesamoll plasticizer or, at minimum, clean motor oil.

1. Engage piston safety lock or trigger safety lock. Close fluid valves A and B. Leave air on.

FIG. 40

2. Set function knob to Stop/Park.

TI17126a

FIG. 42

4. Turn Recirc/Spray valves to Recirc.

TI17133a

FIG. 43

5. Set function knob to Fast Recirc . Pump mate-

rial from fluid inlet tubes until no more comes out.

TI17130b

FIG. 44

6. Set function knob to Stop/Park .

7. Set function knob to Fast Recirc . Pump solvent

through system into waste containers.

8. When nearly clear solvent exits the fluid inlet tubes,

TI17127b

FIG. 41

set function knob to Stop/Park

NOTE: To flush the spray gun, refer to your separate spray gun instruction manual.

22 3A1602G

9. Purge gun hoses.

a. Disconnect hoses from gun and secure to a pail

of solvent.

b. Turn Recirc/Spray valve A to Spray.

TI17136a

FIG. 45

c. Open gun into waste container A.

d. Set function knob to Slow Recirc until hose

is flushed.

Flushing

e. Set function knob to Stop/Park

f. Repeat for B side.

10. Set function knob to Stop/Park

11. Solvent flushing is a two step process. Go back to step 3, drain solvent, and flush again with fresh solvent.

12. Place fluid inlet tubes in a pail of plasticizer or clean motor oil and circulate fluid through the system. Leave fluid in the unit.

NOTE: Never leave the unit dry unless it has been disassembled and cleaned. If fluid residue dries in the pumps, the ball checks may stick the next time you use the unit.

3A1602G 23

Troubleshooting

Status Codes

Determine the status code by counting the number of times the status indicator blinks.

STATUS Indicator

FIG. 46

Status Code 1: Pressure Imbalance

TI17123b1

2. Reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures.

In this example, B side pressure is higher, so use the B side valve to balance pressures.

TI17137a

FIG. 47

NOTE: Turn Recirc/Spray valve only enough to balance

pressure. If turned completely, all pressure will bleed off.

3. Check fluid inlet strainers and fluid filters at gun.

Status Code 2: Pressure Deviation from Setpoint

NOTE: The unit does not check for pressure imbalance

at setpoints less than 250 psi (1.75 MPa, 17.5 bar). The unit does not check for pressure imbalance for 10 seconds after entering pressure mode.

Unit senses pressure imbalance between components A and B, and warns or shuts down, depending on settings of DIP switches 1 and 2. To turn off automatic shutdown and/or tighten pressure tolerances for status code 1, see Status Code 1 and 2 Settings.

1. Check fluid supply of lower pressure component and refill if necessary.

NOTE: The unit does not check for pressure deviation at setpoint less than 400 psi (2.8 MPa, 28 bar).

Unit senses pressure deviation from setpoint, and warns or shuts down, depending on settings of DIP switches 3 and 4. If equipment cannot maintain enough pressure for a good mix at the gun, try using a smaller mix chamber or nozzle.

To turn off automatic shutdown and/or tighten pressure tolerances for status code 2, see Status Code 1 and 2 Settings.

24 3A1602G

Troubleshooting

Status Code 1 and 2 Settings

1. Locate switch SW2 on the control board.

2. Set the four DIP switches to the desired positions. See F

IG. 48 and Table 2.

OFF

1 2 3 4

TI7023a

FIG. 48. DIP Switch (SW2) Settings

1 2 3 4

(Default)

TI7024a

Table 2: Status Code 1 and 2 Settings

DIP Switch and Function Left Right (default setting)

DIP Switch 1

If selected, causes shutdown or displays a warning if the pressure imbalance exceeds selection made in DIP Switch 2

DIP Switch 2

If selected, causes shutdown if A and B pressure imbalance is greater than

If selected, causes warning if A and B pressure imbalance is greater than

DIP Switch 3

If selected, causes shutdown or displays a warning due to deviation of pressure from setpoint exceeds selection made in DIP Switch 4

DIP Switch 4

Causes warning if deviation of pressure from setpoint is greater than

WARNING SHUTDOWN

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

300 psi (2.1 MPa, 21 bar) (50% if < 800 psi [5.6 MPa, 56 bar] running)

WARNING SHUTDOWN

300 psi (2.1 MPa, 21 bar) (25% if < 800 psi [5.6 MPa, 56 bar])

800 psi (5.6 MPa, 56 bar) (70% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (40% if < 800 psi [5.6 MPa, 56 bar])

Status Code 3: Transducer A Failure

1. Check transducer A electrical connections (J3) at board, page 34.

2. Reverse A and B transducer electrical connections at board, page 34. If error moves to transducer B (Status Code 4), replace transducer A, page 33.

Status Code 4: Transducer B Failure

1. Check transducer B electrical connections (J8) at board, page 34.

2. Reverse A and B transducer electrical connections at board, page 34. If error moves to transducer A (Status Code 4), replace transducer B, page 33.

Status Code 5: Excessive Current Draw

Shut off unit and contact distributor before resuming operation.

1. Locked rotor: motor unable to turn. Replace motor, page 38.

2. Short on control board. Replace board, page 33.

3. Worn or hung up motor brush causing arching of brush at commutator. Replace brushes, page 39.

3A1602G 25

Troubleshooting

Status Code 6: High Motor Temperature

Motor is running too hot.

1. Motor temperature too high. Reduce pressure duty cycle, gun tip size, or move Reactor E-8p to a cooler location. Allow 1 hour for cooling.

2. Check fan operation. Clean fan and motor housing.

Status Code 7: No Cycle Counter Switch Input

Have not received input from cycle counter switch for 10 seconds after selecting Recirculation Mode.

1. Check cycle counter switch connection to board (J10, pins 5, 6), page 34 (figure control module wiring connections).

2. Check that magnet (224) and cycle counter switch (223) are in place under B side motor end cover (227). Replace if necessary.

26 3A1602G

Troubleshooting Chart

Problem Cause Solution

Reactor E-8p does not operate. No power. Plug in power cord.

Cycle Motor Power off ,

Troubleshooting

Motor does not operate. Power turned on with function knob

then on to reset breaker.

Set function knob to Stop/Park

set to a run position.

, then select desired function.

Loose connection on control board. Check connection at J11 (120V

models) or J4 (240V models). See page 33.

Worn brushes. Check both sides. Replace brushes

worn to less than 1/2 in. (13 mm), see page 39.

Broken or misaligned brush springs. Realign or replace, page 39.

Brushes or springs binding in brush holder.

Clean brush holder and align brush leads for free movement.

Shorted armature. Replace motor, page 38.

Check motor commutator for burn spots, black pitting, or other damage.

Remove motor. Have motor shop resurface commutator, or replace motor, page 38.

Failed control board. Replace board. See page 33.

Fan not working. Loose fan cable. Check that cable is connected at fan

and at J9 on control board. See pages 39 and 33.

Defective fan. Test and replace if necessary,

page 39.

Pump output low. Plugged fluid inlet strainer. Clear, see page 21.

Plugged disposable mixer. Clean or replace.

Leaking or plugged piston valve or

Check valves. See pump manual.

intake valve in displacement pump.

One side doesn’t come up to pressure in spray mode.

Dirty or damaged Recirc/Spray valve.

Clean or repair, page 30.

Plugged fluid inlet strainer. Clear, see page 21.

Pump intake valve plugged or stuck open.

Material is too viscous to siphon feed.

Clean pump intake valve. See page 31.

Warm the material feed pails with flexible band heaters. See Acces- sories on page 50.

3A1602G 27

Troubleshooting

Problem Cause Solution

Pressure is higher on one side when setting pressure with function knob.

Pressures are not balanced when running, but pressure is generated and holds on both strokes.

Pump intake valve partially plugged. Clean pump intake valve. See page

31.

Air in hose. Fluid is compressible. Purge air from hose.

Unequal size hoses or unequal hose construction.

Use matching hoses, or balance pressures before spraying.

Unequal viscosities. Check that A and B chemicals are

within the chemical manufacturer’s specified application temperature range.

Change restrictor at mix point to balance back pressure.

Restriction on one side. Clean mix module or restrictor at

mix manifold.

Clean gun check valve screens.

Fluid leak in pump packing nut area. Worn throat seals. Replace. See pump manual.

Pressure doesn’t hold when stalled against gun in spray mode.

Leaking Recirc/Spray valve. Repair, page 30.

Leaking piston valve or intake valve

Repair. See pump manual.

in displacement pump.

Leaking gun shutoff. Repair. See gun manual.

Pressure is higher on B side during startup of recirculation, especially in High Recirc mode.

This is normal. Component B is typically higher viscosity than component A until the material is heated during recirculation.

One gauge shows half as many

Loss of pressure on downstoke. Intake valve is leaking or not clospulses as the other when pumps are cycling.

Loss of pressure on upstoke. Piston valve is leaking or not clos-

Status indicator (red LED) not lit. Motor Power switch off.

Loose indicator cable. Check that cable is connected at

Failed control board. Replace board. See page 33.

No action required.

ing. Clean or replace valve; see page 31.

ing. Clean or replace valve or packings; see page 31.

Cycle Motor Power off ,

then on to reset breaker.

J10 pins 1 (red) and 2 (black) on control board. See page 33.

28 3A1602G

Troubleshooting

Problem Cause Solution

A side rich; lack of B side. A side gauge is low. B side restriction downstream of

gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

B side gauge is low. B side material supply problem.

Check B side inlet strainer and pump intake valve.

B side rich; lack of A side. A side gauge is low. A side material supply problem.

Check A side inlet strainer and pump intake valve.

B side gauge is low. A side restriction downstream of

gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

3A1602G 29

Repair

Before Beginning Repair

Repairing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see page 11. Be sure to shut off all power to the equipment before repairing.

1. Flush if possible, see page 22. If not possible, clean all parts with solvent immediately after removal, to prevent isocyanate from crystallizing due to moisture in the atmosphere.

2. Set function knob to Stop/Park

FIG. 49

3. Shut off power.

TI17127b

Recirculation/Spray Valves

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

2. Clean and inspect all parts for damage. Ensure that the seat (503a) and gasket (503b) are positioned inside each valve cartridge (503).

3. Apply PTFE pipe sealant to all tapered pipe threads before reassembling.

4. Reassemble in reverse order, following all notes in F

IG. 51.

505

504

503

503a

503b

1 2

501

507

506

502

TI17135a

510

508

FIG. 50

4. Relieve pressure, page 20. 511

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

Apply lubricant to mating surfaces.

Part of item 503.

515

509

TI17460a

FIG. 51: Recirculation/Spray Valves

30 3A1602G

Repair

Displacement Pump

Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

NOTE: Use drop cloth or rags to protect Reactor E-8p and surrounding area from spills.

See Before Beginning Repair, page 30. Relieve pressure, page 20.

To remove intake valve only

NOTE: If pump is not generating any pressure, the

intake ball check may be stuck closed with dried material.

If the pump is not generating pressure on the downstroke, intake ball check may be stuck open.

Either of these conditions can be serviced with the pump in place.

1. Loosen nut and press the inlet tube down away from the pump intake valve. Inspect the two o-rings (52) for damage and replace if necessary. Move the inlet tube (53) aside.

2. Remove intake valve by hitting ears (E) firmly right-to-left with a non-sparking hammer. Unscrew from pump. See manual 313123 for repair and parts.

To remove entire pump assembly

1. Loosen nut and press the inlet tube down away from the pump intake valve.

2. Disconnect swivel (32) from pump outlet and loosen swivel at the fluid manifold. Turn the fluid outlet line out of the way of the sprayer.

FIG. 53: Fluid Outlet Line

3. Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hitting firmly right-to-left with a non-sparking hammer. Unscrew pump. See manual 311076 for pump repair and parts.

Flat side faces up. Tighten by hitting firmly with non-sparking hammer.

Lubricate threads with ISO oil or grease.

217

ti17462a

218

222

ti17463a

FIG. 54

4. Install pump in reverse order of disassembly, following all notes in F

IG. 54. Reconnect fluid inlet (C) and

outlet (D) lines.

5. Tighten fluid outlet fitting (D), then tighten locknut

ti17461a

FIG. 52: Fluid Inlet Tube

3A1602G 31

(218) by hitting firmly with a non-sparking hammer.

6. Set function knob to Slow Recirc . Purge air and prime. See page 17.

Repair

Replace Function Knob/Potentiometer

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

2. Insert pin through cart handle and lock with lanyard.

ti17464a

FIG. 55

4. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle.

NOTE: Always use two people when lifting the sprayer up on to a workbench.

5. Remove four screws (10) and control board cover (61) to expose the control board (12).

6. Disconnect potentiometer wires from J2 on control board (12). See Fig 12.

7. See Fig 11. Remove two setscrews (16a) and pull function knob (23) off potentiometer (16) shaft.

8. Remove nut (N, part of 16) and detent plate (22). Remove potentiometer (16) and washer (87).

9. Install new potentiometer (16) in reverse order. Position potentiometer so slot (S) is horizontal. Position knob (16) so pointer (P) faces toward the top. Install knob on shaft so slot (S) engages alignment pin in knob. Push knob onto shaft against detent spring before tightening setscrews (16a).

3. Carefully lay sprayer on its side on a level surface.

16a

10. Reconnect potentiometer wires to J2 as shown in Fig 12.

ti17465a

FIG. 56. Function Knob/Potentiometer

32 3A1602G

Repair

Control Board

Power Bootup Check

NOTE: There is one red LED (D11) on the board. Power

must be on to check. See F is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Status code (motor not running): LED blinks status code

Control Board Replacement

NOTE: Check motor before replacing board. See Electric Motor, page 38.

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

2. Insert pin through cart handle and lock with lanyard.

3. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle.

IG. 58 for location. Function

Table 3: Control Board Connectors

(see FIG. 58)

Board

Jack

J1 n/a J2 n/a J3 n/a J4 n/a J7 1, 2 J8 n/a J9 n/a

J10 1, 2

J11 n/a

Pin Description

Main power from breaker Function knob Transducer A Motor power (230 V units) Motor thermal overload signal Transducer B Fan Status Indicator

3, 4 5, 6 7, 8

9, 10

Not used Cycle switch signal Jumpered Jumpered Motor power (120 V)

10 (x4)

NOTE: Always use two people when lifting the sprayer up on to a workbench.

4. Remove four screws (10) and control board cover (61) to expose the control board (12).

5. Disconnect all cables and connectors from board.

6. Remove seven screws (13) and remove board.

7. Install new board in reverse order.

NOTE: Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate. Order Part No. 110009 Thermal Compound.

13 (x7)

ti17466a

FIG. 57: Control Board Removal

3A1602G 33

Repair

LINE

Motor Power

On/Off

(20 A

Breaker)

Motor

Cycle

Counter

Black Twin Flat Cable

Fan

Status

Indicator

Black Sheath

Red

Black

Yellow

Ye l l o w

Red

Black

Jumper

Black

White

Function

J11 (120 V

J11

Board)

Knob

CONTROL

BOARD

not used

1 2

3 4 5 6

J10

7 8 9

249434 (120 V)

ONOFF

1 2 3 4

SW2 (see page 25 to adjust settings)

not used

Black

Red

White

Black Sheath

J3J8

Pressure Transducer A

Black Phone Cable and Plug

Pressure Transducer B

FIG. 58: Control Module Wiring Connections

34 3A1602G

Repair

Pressure Transducers

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

2. Insert pin through cart handle and lock with lanyard.

3. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle.

NOTE: Always use two people when lifting the sprayer up on to a workbench.

4. Remove four screws (10) and control board cover (61) to expose the control board (12).

5. Disconnect transducer cables from J3 and J8 at board; see F nections and check if status code follows the bad transducer, page 25.

6. Reconnect good transducer to proper connector. Disconnect failed transducer from board, and unscrew from base of transducer manifold.

7. Install new transducer (35) in manifold (33). Mark board end of cable with tape (red=transducer A, blue =transducer B).

8. Route cable under the electric motor and through grommet to control board (12).

9. Connect transducer cable at board; see F page 34.

IG. 58. page 34. Reverse A and B con-

IG. 58.

Drive Housing

Removal

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

1. Loosen nut and press the fluid inlet tube down away from the pump intake valve.

2. Disconnect swivel (32) from pump outlet and loosen swivel at the fluid manifold. Turn the fluid outlet line toward the center of the sprayer.

3. Disconnect pressure transducer (35) from manifold.

4. Disconnect swivel (32) from pump outlet and loosen fluid outlet line swivel (36) at the fluid manifold. Turn the fluid outlet lines toward the center of the sprayer.

5. Remove screws (207) and end covers (221, 227), F

IG. 61, page 37.

NOTE: Examine connecting rod (216). If rod needs replacing, first remove the pump (219), page 31.

NOTICE

Do not drop gear reducer (214) and crank shaft (210) when removing drive housing (215). These parts may stay engaged in motor end bell (MB) or may pull away with drive housing.

ti17467a

FIG. 59: Pressure Transducer Connection

3A1602G 35

Repair

6. Disconnect cart handles.

a. Remove screws (42) from handle (37).

b. Hold pin (40) and remove screw (10).

c. Gently tap the top-center of the handle with a

rubber mallet until the handle is disengaged from the drive housing.

d. If removing both drive housings, complete steps

6a-6c on the other handle to remove the entire cart handle assembly.

NOTE: B side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crankshaft with magnet on B side.

If replacing crankshaft, remove magnet (224). Reinstall magnet in center of offset shaft on new crankshaft. Position shaft in Park position.

2. Install bronze bearings (211, 213) in drive housing (215), as shown.

3. Install bronze bearings (209, 211) and steel washer (208) on crankshaft (210). Install bronze bearing (213) and steel washer (212) on gear reducer (214).

4. Install gear reducer (214) and crankshaft (210) into motor end bell (MB).

NOTE: Crankshaft (210) must be inline with crankshaft at other end of motor. Pumps will move up and down together.

If connecting rod (216) or pump (219) were removed, reassemble rod in housing and install pump, page 31.

5. Push drive housing (215) onto motor (201). Install screws (220).

6. Install cart handle assembly.

ti17468a

FIG. 60: Cart Handle Removal

7. Remove screws (220) and pull drive housing (215) off motor (201) Connecting rod (216) will disengage from crankshaft (210).

8. Examine crankshaft (210), gear reducer (214), thrust washers (208, 212), and bearings (209, 211,

213). See F

IG. 61, page 37.

Installation

1. Apply grease liberally to washers (208, 212), bearings (209, 211, 213), gear reducer (214), crankshaft (210), and inside drive housing (215). Grease is supplied with replacement parts kits. See F page 37.

IG. 61,

a. Engage handle through back of drive housing.

Install screws in driver housing. Repeat for other drive housing if entire cart handle assembly was removed. See F

IG. 60.

b. Gently tap the handle (39) and align holes of

handle (37) and tube (38).

c. Apply medium strength anaerobic thread seal-

ant on screw threads (42) and install in handle (37).

NOTICE

To prevent stripping threads inside handle tube (38), do not overtighten screws (42).

7. Install drive housing covers (221 on A side, 227 on B side) and screws (207). Pumps must be in phase (both at same position in stroke).

36 3A1602G

Cycle Counter Switch Replacement

NOTE: B side drive housing cover (227) includes the cycle

counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on B side.

Feed the cable under the electric motor and through the grommet and connect to the control board.

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

Repair

221

201

212

(steel)

213

(bronze)

214

213 (bronze)

Crankshaft must be in line with crankshaft at other end of motor, so pumps move up and down in unison.

208 (steel)

209 (bronze)

224

216

210

211 (bronze)

215

220

227

207

219

TI17469a

FIG. 61: Drive Housing

3A1602G 37

Repair

Electric Motor

Test Motor

If motor is not locked up by pumps, it can be tested using a 9 V battery.

1. Open recirculating valves, disconnect J4 or J11 from control board, see F

2. Touch jumpers from battery to motor connections. Motor should turn slowly and smoothly.

Removal

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

IG. 58, page 34.

10 (x4)

13 (x7)

10 (x4)

2. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle assembly.

NOTE: Always use two people when lifting the sprayer up on to a workbench.

3. Remove screws (10) and control board cover (61) to expose the control board (12).

4. Disconnect all cables and connectors from board (12).

5. Unplug cable (94) from fan (202). See F

39.

6. Remove screws (13) and board (12).

7. Remove screws (10).

8. Feed proportioner cables out of grommet in the cart (1) and lift the cart off of the motor.

9. Remove drive housing/pump assemblies and cart handle assembly, page 35.

IG. 63, page

TI17470a

FIG. 62: Electric Motor Removal

38 3A1602G

Repair

Installation

See FIG. 62, page 38.

1. If replacing motor, install fan assembly and fan mount threaded bushing on new motor.

2. Place cart (1), with motor plate (8) installed, on bottom of the motor and fan. Feed motor cables through grommet.

3. Fasten motor to cart with four screws (10).

4. Fasten board to cart with seven screws (13). Connect all cables. See F

5. Install cover (61) with screws (10).

NOTE: Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate. Order Part No. 110009 Thermal Compound.

6. Carefully rotate cart to the upright position.

7. Install bracket (28) and screws (29).

8. Install drive housing/pump assemblies, page 35. Reconnect inlet assemblies to pumps.

9. Connect fluid inlet and outlet lines.

IG. 58, page 34.

Motor Brushes

NOTE: Replace brushes worn to less than 1/2 in. (13

mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 287735 is available; kit includes instruction sheet 406582.

Motor commutator should be smooth. If not, resurface commutator or replace motor.

1. See Before Beginning Repair, page 30. Relieve pressure, page 20.

2. See instruction sheet 406582, included with Brush Repair Kit 287735. Remove old brushes and install new ones supplied in kit.

Fan

1. Disconnect fan cable (37) from fan (202). With Motor Power on, test cable connector for line voltage (120 V or 240 V).

2. If voltage is correct, fan is defective. Remove screws holding fan to shield (206). Install new fan in reverse order.

10. Return to service.

3. If voltage is not correct, check fan cable connection at J9 on control board; see F

FIG. 63: Fan

IG. 58, page 34.

202

TI7030a

3A1602G 39

Repair

Spout Adapter

The sprayer is supplied with a 40 mm spout adapter. Follow these instructions to install 38 mm spout adapters or repair the A and B side spout adapters.

See Pour Spout Adapter, page 49 for parts.

1. Loosen containment knob.

2. Remove adapter.

a. Use a small flat head screwdriver to remove

retaining ring (405) from adapter.

b. Loosen housing (403) from nut cap (402).

c. Slide spout adapter (404), housing (403), plate

(401), and nut cap (402), off fluid tube (P).

d. Remove spout adapter (404) from housing.

Remove nut cap (402).

NOTICE

3. Connect 38 mm or 40 mm spout adapter.

a. Place spout adapter (404) on a flat level sur-

face. Place retaining ring (405) above housing base (403) and insert the bottom of the housing in the spout adapter (404).

b. Use two flat head screwdrivers to insert the bot-

tom of the retaining ring (405) in the groove. After the bottom has gotten started in the groove, continue to press down on the retaining ring with one screwdriver and rotate the spout adapter (404) with your other hand until the retaining ring snaps in the groove.

c. Install nut cap (402) and plate (AP) on fluid tube

(P).

d. Apply grease on o-rings (406, 407) and slide

over fluid tube threads and recirculation tube.

e. Slide housing (403) on fluid tube (P) and align

orings (4067, 407) in grooves of housing (403).

To prevent damage to spout adapter o-ring, gently remove adapter housing from fluid tube.

402

401

405

407

406

403

508

404

FIG. 64

f. Tighten nut cap (402) on housing (403).

40 3A1602G

Parts

120 V and 240 V Fusion Air Purge System Packages 120 V and 240 V Fusion CS System Packages 120 V and 240 V P2 System Packages 120 V and 230 V Manual 2K System Packages

Parts

102

101

System

Package

AP9082 120V AP9083 240V CS9082 120V CS9083 240V P29082 120V P29083 240V 24R151 120V 24R154 240V

Volts Description

System with Air Operated Gun shown

Fusion Air Purge Proportioner Package Fusion Air Purge Proportioner Package Fusion CS Proportioner Package Fusion CS Proportioner Package P2 Proportioner Package P2 Proportioner Package Manual 2K Proportioner Package Manual 2K Proportioner Package

Bare Proportioner

(101)

see page 42

259082 24M653 259083 24M653 259082 24M653 259083 24M653 259082 24M653 259083 24M653 259082 24R823 259083 24R823

ti17122a

Hose (102)

see page 47

103

Gun

(103)

see gun manual

246100

246100 CS00RD CS00RD GCP2R0 GCP2R0

24R021

3A1602G 41

Parts

259082 (120V) and 259083 (240V), Bare Proportioner

36 (2x)

34 (2x)

33 (2x)

31 (2x)

32 (2x)

29 (4x)

48 (2x)

30 (2x)

53 (2x)

35 (2x)

47 (2x)

49 (2x)

51 (2x)

52 (4x)

Apply sealant to threads.

Apply sealant to all non-swiveling pipe threads.

Apply lubricant to all o-rings and bolt-wheel connection (3, 91).

Cover entire surface of sensor probe with lubricant before assembling onto motor plate (8).

Torque to 5-6 ft-lbs (6.7-8 N•m).

TI17471b

42 3A1602G

259082 (120V) and 259083 (240V), Bare Proportioner (continued)

Parts

92▲

10 (4x)

13 (7x)

10 (4x)

11 (4x)

16a

3A1602G 43

TI17472a

Parts

259082 (120V) and 259083 (240V), Bare Proportioner (continued)

37 (2x)

40 (2x)

88 (2x)

41 (4x)

43 (2x)

10 (2x)

42 (2x)

1 3 5

91 (2x)

7 (4x)

5 (2x)

84 (2x)

29 (2x)

54 (2x)

55 (2x)

56 (2x)

3 (2x)

44 3A1602G

259082 (120V) and 259083 (240V), Bare Proportioner (continued)

Parts

Ref. Part Description Qty.

1 24J139 CART 1 2 16H888 GROMMET, 7/8 in. ID 1 3 16F820 WHEEL, caster 2 4 16H352 SPACER, axle 1 5 121573 BUMPER, urethane, 3/8-16,

80-90 dur

6 24J766 ADAPTER, spout, pour, 40 mm

assembly, B; see page 49 7 120454 WASHER, flat 4 8 16G939 PLATE, motor mount 1 9 ◆24L885 PROPORTIONER, 120V;

see page 46

✖24L979 PROPORTIONER, 240V;

see page 46 10 117493 SCREW, mach, hex washer hd 10 11 102040 NUT, lock, hex 6 12 ◆249434 BOARD, circuit (115V) 1

✖249432 BOARD, circuit (230V) 1 13 107156 SCREW, mach, pan hd 7 14 24K983 SWITCH, rocker, w/breaker, 240V,

20A 15 119930 DIODE ,light-emitting 1 16 24L002 POTENTIOMETER, adjustment,

pressure 17 119897 FITTING, bulkhead, cablE, 0.250 1 18 ◆24K995 CORD SET, power, 125V 1

✖15G220 CORD SET, power, 240V 1 19 15G230 CABLE, harness, power 1 20 15C866 WIRE, jumper 2 21 116773 CONNECTOR, plug, 3.81 mm (10

position) 22 15G053 PLATE, detent, display 1 23 24L001 KNOB, control 1 27 24J147 MANIFOLD, recirculation 1 28 24J140 BRACKET, recirculation manifold 1 29 115492 SCREW ,mach, slot hex wash hd 12 30 108296 SCREW, mach, hex wash hd 2 31 156971 NIPPLE, short 2 32 155541 SWIVEL, 90° 2 33 15G292 MANIFOLD, pressure transducer 2 34 116704 ADAPTER, #6 JIC x 1/4 npt 2 35 24K999 TRANSDUCER, pressure, control 2 36 16H530 TUBE, fluid 2 37 16G943 BRACKET, lift handle 2 38 16G945 TUBE, lift handle, fixed 1 39 24J244 HANDLE, lift, sliding 1 40 16H546 PIN, mounting, lift handle 2 41 16H547 PIN, alignment, lift handle 4 42 110037 SCREW, mach, pnh 2 43 109032 SCREW, mach, pnh 3 44 24J154 PIN, W/LANYARD 1 45 249629 HOSE, component A; 1/4 in.

(6 mm) ID; thermoplastic hose with

moisture guard; 1/4 npsm(f) x 48 in.

(1219 mm)

Ref. Part Description Qty.

46 249630 HOSE, component B (resin), 1/4 in.

(6 mm) ID; thermoplastic hose; 1/4

npsm(f) x 48 in. (1219 mm) 47 100030 BUSHING 2 48 125212 FITTING, -3 JIC x 1/8 npt(m) 2

49 16H615 TUBE, recirculation 2 51 115099 WASHER, garden hose 2

52 117559 O-RING 4 53 246010 HOSE, suction 2 54 113575 O-RING 2 55 15W249 CAP, tube, suction 2

56 112144 SCREW, mach, pan hd 2 57 24J155 ADAPTER, spout, pour, 40 mm

58 103473 STRAP, TIE, WIRE 4 61 24J141 COVER, electronics 1 62 24J151 COVER, shroud, front 1 63 24J152 COVER, shroud, back 1 64 16J414 LABEL, control 1 65 16H202 LABEL, branding 1

66 16J415 LABEL, quick start 1 67▲ 16H569 LABEL, warning 1 73 24K984 DRYER, desiccant, mini in-line 2

80 16H809 TRAY, containment 1 81 16H810 BRACKET, containment 1 82 16H811 KNOB, containment 1 84 125321 CABLE, sst lanyard, 10 in. 2 85 16H543 HANDLE, pull 1 86 121114 NUT, hex, self locking 2 87 261841 WASHER, flat 1

88 104859 SCREW, tapping pan hd 2 89 111743 WASHER, flat 1 90 112154 PIN, straight, slotted 2 91 15M314 SCREW, cap 2 92▲ 189930 LABEL, caution 1 93

◆16H902 TAG, informational (120V); not

✖16M900 TAG, informational (240V); not

94 15G458 CABLE, fan 1 95 16H984 CAP, adapting cap, 38 mm 1 96 242001 CORD SET, adapter, Europe

97 242005 CORD SET, adapter, Australia

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

◆ Only used with proportioner 259082.

✖ Only used with proportioner 259083.

assembly, A; see page 49

shown

(240V); not shown

3A1602G 45

Parts

24L885, 120 V Bare Proportioner 24L979, 240 V Bare Proportioner

‡221

201

207

210*209*208*

223

204

†212

†213

†214

202

203

205

Ref. Part Description Qty

201 24E355 MOTOR, electric; 120 V 1

24E356 MOTOR, electric; 240 V 1

202 24K985 FAN, cooling; 120 V 1

24K986 FAN, cooling; 240 V 1 203 115836 GUARD, finger 1 204 RIVET, blind; 5/32 x 3/8 grip 1 205 SCREW, machine, slotted hd; 8-32

x 2 in. (51 mm)

207‡ 115492 SCREW, machine, hex washer hd;

8-32 x 3/8 in. (10 mm) 208* 116074 WASHER, thrust; steel 2 209* 107434 BEARING, thrust; bronze 2 210* 248231 CRANKSHAFT KIT 2 211* 180131 BEARING, thrust; bronze 2 212† 116073 WASHER, thrust; steel 2 213† 116079 BEARING, thrust; bronze 4 214† 287057 GEAR REDUCER KIT 2 215‡ 24L979 DRIVE HOUSING KIT 2 216◆ 287053 CONNECTING ROD KIT 2

224

215‡

211*

220‡

227

†213

◆216

218

220‡

219

217◆

207‡

Ref. Part Description Qty

217◆ 196762 PIN, straight 2 218 195150 NUT, jam, pump 2 219 256767 PUMP, displacement; see 313123 2 220‡ 117493 SCREW, machine, hex washer hd;

1/4-20 x 1-1/2 in. (38 mm) 221‡ 15B254 COVER, drive housing, A side 1 222‡ 15B589 COVER, pump rod 2

223 117770 SWITCH, reed, w/cable 1 224 24K982 MAGNET 1

227 249854 COVER, drive housing, B side;

includes item 223 and 228 228 115711 TAPE, mounting, reed switch; not

shown

* Included in 248231 Crankshaft Kit.

† Included in 287057 Gear Reducer Kit.

‡ Included in 287055 Drive Housing Kit.

◆ Included in 287053 Connecting Rod Kit.

207‡

222‡

TI17473a

46 3A1602G

Parts

3/8 in. ID x 50 ft Insulated Hose Bundle without Recirculation Lines with Air Hose, 24M653

301

302 (Ref)

302 305

303

306

TI6992a

Ref. Part Description Qty

301 16V331 HOSE, fluid (component A), mois-

ture guard; grounded, 3/8 in. (9.5 mm) ID; no. 5 JIC fittings (mxf); 50 ft (15 m)

302 24M671 HOSE, fluid (component B); 3/8 in.

(9.5 mm) ID; no. 6 JIC fittings (mxf); 50 ft (15 m)

303 261535 HOSE, air; 3/8 in. (9.5 mm) ID; 3/4

npsm (fbe); 50 ft (15 m)

305 156971 NIPPLE; 3/8 npt; for joining air line

to another hose bundle

306 --- INSULATION 1

1/4 in. ID x 35 ft Non-Insulated Hose Bundle without Recirculation Lines and No Air Hose, 24R823

Ref. Part Description Qty

351 249508 HOSE, coupled, 35 ft x 1/4 in., 1/2-20 UNF,

moisture guard, static dissipative

352 249509 HOSE, coupled, 35 ft, x 1/4 in., 9/16-18 UNF,

static dissipative

3A1602G 47

Parts

Recirculation Manifold, 24J147

506

507

505

504

503

503a

503b

1 2

501

502

Ref. Part Description Qty

501 24K993 MANIFOLD, recirculation 1 502 111763 ELBOW; 1/4 npt (mbe) 4 503 239914 VALVE, recirc/spray; includes

items 503a, 503b 503a 15E022 . SEAT 1 503b 111699 . GASKET 1 504 224807 BASE, valve 2

505 187625 HANDLE, valve, drain 2 506 111600 PIN, grooved 2 507 113641 GAUGE, pressure, fluid 2 508 116504 TEE; 1/4 npt(m) x 1/4 npt(f) run;

1/4 npt(f) branch 509 119998 ADAPTER; 5/16 JIC x 1/4

npt(m) 510 116704 ADAPTER; 3/8 JIC x 1/4 npt(m) 1 511 556765 ELBOW, tube; 1/4 npt(m) x 3/8

in. (10 mm) OD tube 515 156823 UNION, swivel; 1/4-18 npt 2

510

511

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

Apply lubricant to mating surfaces.

Part of item 503.

515

508

509

TI17460a

48 3A1602G

Pour Spout Adapter

Parts

Part Description

24J155

24J766 24M052 24M053

40 mm A Side Pour Spout Adapter 40 mm B Side Pour Spout Adapter 38 mm B Side Pour Spout Adapter 38 mm A Side Pour Spout Adapter

402

401

407

403a 403b

404a 404b

405

406

508

Ref. Part Description Qty

401 16H539 PLATE, crush, inlet 1 402 16H540 CAP, spout, pour 1 403 HOUSING, inlet tube, 403a or

403b 403a 15H541 HOUSING, inlet tube, A side 1 403b 16H882 HOUSING, inlet tube, B side 1 404 CAP, adapting, 40 mm; 404a or

404b 16H542 CAP, adapting, 40 mm; black 1 16H984 CAP, adapting, 38mm; silver 1

405 125179 RING, retaining 1 406 112319 PACKING, o-ring 1

407 117559 O-RING 1 408 100846 FITTING, lubrication 1

Lubricate o-rings and retaining ring with grease.

Apply sealant to threads.

3A1602G 49

Suggested Spare Replacement Parts

Part Description

24K984 DRYER, desiccant 246385 STRAINER, pump inlet 24K983 SWITCH, motor power, with circuit breaker 113641 GAUGE, pressure, fluid; sst 239914 VALVE, recirc/spray; includes seat and gasket 24L002 POTENTIOMETER, control knob 24G886 BOARD, control; 120 V units only 24G887 BOARD, control; 240 V units only 24K999 TRANSDUCER, pressure 24L006 PUMP, displacement; fits either side 249855 REPAIR KIT, displacement pump; includes

seals, balls, bearings, intake valve seat) 246010 SUCTION HOSE, pump to 5 gallon pail 24M115 ADAPTER, spout, pour, assembly A; 40 mm 24M114 ADAPTER, spout, pour, assembly B; 40 mm 24M052 ADAPTER, spout, pour, assembly A; 38 mm 24M053 ADAPTER, spout, pour, assembly B; 38 mm 16H615 TUBE, recirculation

Unheated Hoses with Scuff Guard, 2000 psi (138 bar, 13.8 MPa)

24R823 HOSE BUNDLE, 1/4 in. (6.4 mm), 35 ft

(10 m), no air hose, uninsulated 249633 HOSE BUNDLE, 1/4 in. (6.4 mm), 35 ft

(10 m), air, uninsulated 24R137 HOSE BUNDLE, 3/8 in. (9.5 mm), 50 ft

(15 m), no air hose, uninsulated 24M653 HOSE BUNDLE, 3/8 in. (9.5 mm), 50 ft

(15 m), air, insulated

Accessories

Fusion Air Purge Gun

Air purge gun, available in round or flat patterns. See manual 309550.

Manual 2K Gun

Manually opened and closed, two-component gun. See manual 332198.

Pail Heater, 16U623

Flexible band heaters for 5 gallon pails.

Recirculation Hose Kit, 24M654

3/8 in. (9.5 mm), 50 ft. (15 m)

Ref. Part Description Qty

550 24M939 HOSE, non-heated, insulated, recir-

culation, quad, 2000 psi (14 MPa, 138 bar), 3/8 in. (9.5 mm), 50 ft.

(15 m) 551 111697 ADAPTER, #5 JIC x 1/4 NPT 1 552 119998 PLUG, pipe 2 553 249523 MANIFOLD, gun, assembly, 4-hose 1

Recirculation Gun Manifold Kit, 249523

Only compatible with Fusion Air Purge Gun.

Ref. Part Description Qty

601 --- MANIFOLD 1 602 246356 VALVE, fluid 2 603 15B221 BOLT; 5/16-24 1 604 117634 SWIVEL, B side; 1/8 npt(m) x # 6

JIC(f) 605 117635 SWIVEL, A side, 1/8 npt(m) x #5

JIC(f) 606 15B993 SPRING, ring, lock 1 607 112307 ELBOW, street; 1/8 npt (m x f);

round and flat pattern guns only

601

607

604

607

605

604

Fusion ClearShot

Air purge gun with ClearShot Liquid Technology, available in round or flat patterns. See manual 312666.

™

Probler® P2

Air purge gun, available in round or flat patterns. See manual 313213.

50 3A1602G

603

Torque to 235-245 in.-lb (26.6-27.7 N•m).

Torque to 32-40 ft-lb (43-54 N•m).

602

TI7134A

Dimensions

34.58 in. (87.8 cm)

24.12 in. (61.3 cm)

15.06 in. (38.3 cm)

TI17120a

3A1602G 51

Dimensions

52 3A1602G

Technical Data

Reactor E-8p

US Metric

Maximum fluid working pressure 2000 psi 14 MPa, 138 bar Electrical requirements Model 259082: 120 Vac, 1 phase, 50/60 Hz, 1800 W;

requires a single dedicated 15 A circuit Generator Size 2500 W minimum Maximum Ambient Temperature 110°F 43°C Maximum Output at 340 cycles/min 12 lb/min 5.4 kg/min Output per Cycle (A and B) .00352 gal. (.0133 liter) Overpressure Relief Recirc/Spray valves automatically relieve excessive fluid

pressure back to supply tanks

Sound Pressure

In fast circulation mode

At 2000 psi (14 MPa, 138 bar), 0.72 gpm (2.7 lpm)

Sound Pressure per ISO 9614-2

In fast circulation mode

At 2000 psi (14 MPa, 138 bar), 0.72 gpm (2.7 lpm)

Inlet/Outlet Sizes

Fluid Outlet - Component A (ISO)

Fluid Outlet - Component B(RES)

Fluid Circulation Return - Component A (ISO)

Fluid Circulation Return - Component B(RES)

Air Inlet 1/4 in. quick-disconnect industrial type pin fitting Air Outlet 1/4 npsm(m)

Hose Markings

A Side Red B Side

Weight (empty), without gun and hose

Wetted Parts

Maximum Hose Length

Aluminum, stainless steel, carbon steel, brass, carbide,

chrome, chemically resistant o-rings, PTFE, ultra-high

95 lbs. 43.1 kg

molecular weight polyethylene

105 ft 32 m

78.7 dB(A)

84.5 dB(A)

88.6 dB(A)

94.4 dB(A)

-5 JIC male

-6 JIC male

-5 JIC male

-6 JIC male

Blue

3A1602G 53

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 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

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 3A1602

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised October 2014

Graco 3A1602G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Systems

Proportioners

Related Manuals

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Keep Components A and B Separate

Foam Resins with 245 fa Blowing Agents

Overview

Changing Materials

Component Identification

Controls and Indicators

Setup

Location

Electrical Requirements

Grounding

Lock/Unlock Handle

Install 38 mm Spout Adapter

Install Desiccant Dryers

Install Optional Recirculation Kit

Connect Fluid Hoses

Connect Gun to Air Hose (Air Operated Guns Only)

Connect Main Air Supply

Flush Before Using Equipment

Fill Wet-cups

Recirculate Material

Install Pail Heaters

Purge Air and Flush Fluid

Connect Fluid Inlet Tubes

Spraying

Pressure Relief Procedure

Shutdown

Maintenance

Flushing

Troubleshooting

Status Codes

Troubleshooting Chart

Repair

Before Beginning Repair

Recirculation/Spray Valves

Displacement Pump

Replace Function Knob/Potentiometer

Control Board

Pressure Transducers

Drive Housing

Cycle Counter Switch Replacement

Electric Motor

Motor Brushes

Spout Adapter

Parts

Suggested Spare Replacement Parts

Accessories

Dimensions

Technical Data

Graco Standard Warranty