Page 1
Instructions - Parts
EP
™
Gun
313872B
Plural Component, Impingement Mix, Mechanical Purge Pour Gun
™
with Throat Seal Liquid
For use with non-flammable foam. Not for use in explosive atmospheres.
Model 257999, 24C932, 24C933, 24C934
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
80-100 psi (0.55-0.69 MPa, 5.5-6.9 bar) Air Inlet Pressure Range
180°F (82°C) Maximum Fluid Temperature
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Technology
ENG
US Patent Pending
TI14450a
Page 2
Contents
RelatedManuals ...........................3
Models ...................................4
Orifice Flow Area Ratio Chart ............... 4
Fixed Orifice Flowrate Data .................5
Variable Orifice Flowrate Data .............. 6
Warnings .................................9
Important Two-Component Material Information 11
Isocyanate Conditions .................... 11
Material Self-ignition ..................... 11
Keep Components A and B Separate ........11
Moisture Sensitivity of Isocyanates ..........11
Foam Resins with 245 fa Blowing Agents .....11
Changing Materials ...................... 12
A (Red) and B (Blue) Components ..........12
Throat Seal Liquid .........................13
Grounding ...............................13
PistonSafetyLock ........................13
TriggerLock..............................13
Loss of Air Pressure .......................14
Hook Support .............................14
Component Identification ...................16
CutawayView ..........................17
Theory of Operation .......................18
Gun Triggered (Fluid Pouring) .............18
Gun Detriggered ........................ 18
Setup....................................19
AdjustOrifices..........................20
Optional Hose Position ...................21
Pressure Relief Procedure ..................22
Shutdown ................................23
Short Term Shutdown ....................23
Long Term Shutdown .................... 23
Maintenance ..............................24
Supplied Tool Kit ........................ 24
Lubrication ............................24
Bleed Throat Seal Liquid Cartridge .......... 24
FlushGun .............................25
CleanOutsideofGun ....................25
CleanBreatherPlug ..................... 26
Clean Fluid Manifold ..................... 26
Clean Check Valves ..................... 27
Clean Fluid Housing Passages .............28
Clean Orifice ...........................29
Replace Mix Chamber and Front Seal .......30
Repair ...................................31
Tools Required .........................31
Lubrication .............................31
Replace Throat Seal Liquid Cartridge .......31
Remove Front End ......................33
Disassemble Front End ...................34
Assemble Front End .....................34
AttachFrontEnd ........................35
Pistons and Bulkhead ....................35
PurgeRod .............................37
Solenoid Valve ..........................38
Troubleshooting ...........................39
ElectricalDiagram .......................41
Parts ....................................42
Kits .....................................45
Orifice Kits .............................50
DrillBitKits ............................51
Complete O-ring Placement Guide ..........52
Accessories ..............................53
Lubricant for Gun Rebuild .................53
Throat Seal Liquid Cartridges
FluidInletCover ........................53
Gun Cleaning Kit ........................53
Flushing Manifold .......................53
15B817 Manifold Block ...................53
Circulation Manifold ......................53
Reactor IP Harness ......................53
Solvent Flush Canister Kit .................54
SolventFlushPailKit.....................54
TechnicalData ............................55
Dimensions ............................56
Graco Standard Warranty ...................58
GracoInformation .........................58
..............53
2 313872B
Page 3
Related Manuals
Manuals are available at www.graco.com.
Component manuals in U.S. English:
Power-LockTMHeated Hose
Part Description
309572 Instructions - Parts
Solvent Flush Kits
Part Description
309963 Instructions - Parts
Circulation Manifold Kit
Part Description
309818 Instructions - Parts
Heated Hoses and Applicator Kits
Related Manuals
Part Description
3A0237 Instructions - Parts
313872B 3
Page 4
Models
Models
Purge Rod
Diameter
Part
257999 0.250 (6.35) 0.031 (0.79) Handheld
24C932 0.250 (6.35) 0.031 (0.79) Auto
24C933 0.375 (9.53) 0.047 (1.2) Handheld
24C934 0.375 (9.53) 0.047 (1.2) Auto
in. (mm)
Orifice Flow Area Ratio Chart
In general, flow area ratio should be equal to material ratio but will be influenced by material viscosity. The ideal flow
area ratio is dependent on flow rates, material viscosity, and material ratio. Choose the correct size orifices to equalize fluid pressures at the proportioner.
Orifice Size
in. (mm) Handle Type
Available Orifice Flow Area Ratios
Dia-
meter 0.016 0.020 0.024 0.028 0.031 0.035 0.039 0.042 0.047 0.052 0.055 0.060 0.063 0.067 0.073 0.086
0.016 1.0 1.6 2.3 3.1 3.8 4.8 5.9 6.9 8.6 10.6 11.8 14.1 15.5 17.5 20.8 28.9
0.020 1.6 1.0 1.4 2.0 2.4 3.1 3.8 4.4 5.5 6.8 7.6 9.0 9.9 11.2 13.3 18.5
0.024 2.3 1.4 1.0 1.4 1.7 2.1 2.6 3.1 3.8 4.7 5.3 6.3 6.9 7.8 9.3 12.8
0.028 3.1 2.0 1.4 1.0 1.2 1.6 1.9 2.3 2.8 3.4 3.9 4.6 5.1 5.7 6.8 9.4
0.031 3.8 2.4 1.7 1.2 1.0 1.3 1.6 1.8 2.3 2.8 3.1 3.7 4.1 4.7 5.5 7.7
0.035 4.8 3.1 2.1 1.6 1.3 1.0 1.2 1.4 1.8 2.2 2.5 2.9 3.2 3.7 4.4 6.0
0.039 5.9 3.8 2.6 1.9 1.6 1.2 1.0 1.2 1.5 1.8 2.0 2.4 2.6 3.0 3.5 4.9
0.042 6.9 4.4 3.1 2.3 1.8 1.4 1.2 1.0 1.3 1.5 1.7 2.0 2.3 2.5 3.0 4.2
0.047 8.6 5.5 3.8 2.8 2.3 1.8 1.5 1.3 1.0 1.2 1.4 1.6 1.8 2.0 2.4 3.3
0.052 10.6 6.8 4.7 3.4 2.8 2.2 1.8 1.5 1.2 1.0 1.1 1.3 1.5 1.7 2.0 2.7
0.055 11.8 7.6 5.3 3.9 3.1 2.5 2.0 1.7 1.4 1.1 1.0 1.2 1.3 1.5 1.8 2.4
0.060 14.1 9.0 6.3 4.6 3.7 2.9 2.4 2.0 1.6 1.3 1.2 1.0 1.1 1.2 1.5 2.1
0.063 15.5 9.9 6.9 5.1 4.1 3.2 2.6 2.3 1.8 1.5 1.3 1.1 1.0 1.1 1.3 1.9
0.067 17.5 11.2 7.8 5.7 4.7 3.7 3.0 2.5 2.0 1.7 1.5 1.2 1.1 1.0 1.2 1.6
0.073 20.8 13.3 9.3 6.8 5.5 4.4 3.5 3.0 2.4 2.0 1.8 1.5 1.3 1.2 1.0 1.4
0.086 28.9 18.5 12.8 9.4 7.7 6.0 4.9 4.2 3.3 2.7 2.4 2.1 1.9 1.6 1.4 1.0
Flowrate Increases as Diameter Increases =>
Flowrate Increases as Diameter Increases=>
4 313872B
Page 5
Fixed Orifice Flowrate Data
Models
5.00
4.75
4.50
4.25
4.00
3.75
3.50
3.25
3.00
2.75
2.50
2.25
Flow (gpm)
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
500 750 1000 1250 1500 1750 2000
EP Fixed Orifice Flow Data
0.086 in. Diameter Orifice
0.067 in. Diameter Orifice
0.060 in. Diameter Orifice
0.047 in. Diameter Orifice
0.031 in. Diameter Orifice
0.020 in. Diameter Orifice
Pressure (psi)
313872B 5
Page 6
Models
Variable Orifice Flowrate Data
VARIABLE ORIFICE FLOWRATE DATA (1000 PSI)
0.086
0.073
0.067
0.063
0.060
0.055
0.052
0.047
0.041
0.039
0.033
0.031
ORIFICE DIAMETER (in.)
0.028
0.024
0.020
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
FLOWRATE (gpm)
6 313872B
Page 7
VARIABLE ORIFICE FLOWRATE DATA (1500 PSI)
0.086
0.073
0.067
0.063
0.060
0.055
0.052
0.047
0.041
0.039
0.033
0.031
ORIFICE DIAMETER (in.)
0.028
0.024
0.020
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75
Models
FLOWRATE (gpm)
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
313872B 7
Page 8
Models
ORIFICE DIAMETER (in.)
VARIABLE ORIFICE FLOWRATE DATA (2000 PSI)
0.086
0.073
0.067
0.063
0.060
0.055
0.052
0.047
0.041
0.039
0.033
0.031
0.028
0.024
0.020
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75
FLOWRATE (gpm)
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
8 313872B
Page 9
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-
turer.
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
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.
313872B 9
Page 10
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.
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.
10 313872B
Page 11
Important Two-Component Material Information
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
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Keep Components A and B
Moisture Sensitivity of Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid™(TSL™), Part
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Separate
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
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.
313872B 11
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Page 12
Important Two-Component Material Information
Changing Materials
• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISOontheBside.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
A (Red) and B (Blue) Components
IMPORTANT!
Material suppliers can vary in how they refer to plural
component materials.
Be aware that when standing in front of the manifold on
proportioner:
• Component A (Red) is on the left side. The A (Red)
side is intended for ISO, hardeners, and catalysts.
• Component B (Blue) is on the right side.The B
(Blue) side is intended for polyols, resins, and
bases.
For ratios higher than 1:1, the higher volume is typically
the B (Blue) side.
• Most polyurethanes use ISO on the A (Red) side
and polyol on the B (blue side, but some use ISO on
the B (Blue) side.
• Epoxies often have amines on the B (hardener) side
• Polyureas often have amines on the B (resin) side.
• Silicones often have the catalyst on the B side.
12 313872B
Page 13
Throat Seal Liquid
Throat Seal Liquid
Read material MSDS to know specific hazards and
precautions related to Throat Seal Liquid.
Grounding
Check your local electrical code and proportioner manual for detailed grounding instructions.
Ground the pour gun through connection to a
Graco-approved grounded fluid supply hose. Always
ground the gun when flushing.
Disengage
To disengage piston safety lock, push knob in and turn
counterclockwise until it pops out. There will be a gap
between knob and gun body.
TI14473b TI14474a
FIG. 2: Piston Safety Lock Disengaged
Trigger Lock
Engage trigger lock whenever you stop pouring to avoid
accidental triggering. Must be used with piston safety
lock.
Piston Safety Lock
Engage piston safety lock whenever you stop pouring to
avoid accidental triggering and serious injury.
Engage
To engage piston safety lock, push knob in and turn
clockwise. If engaged, gun will not dispense.
TI14454b TI14475a
FIG. 1: Piston Safety Lock Engaged
Engage
TI10442a
Disengage
TI10441a
313872B 13
Page 14
Loss of Air Pressure
Loss of Air Pressure
Purge rod actuation is controlled by air pressure. In
event of loss of air pressure, the purge rod will remain
retracted, the impingement ports will remain open, and
the gun will continue to pour. To stop pouring, do one of
the following:
• Engage piston safety lock, see Piston Safety Lock
section
• Close fluid valves A and B, see FIG.3
Hook Support
If necessary, use the hook support located on the top of
the gun to support the weight of the gun. Connect a
strong rope or chain able to support the weight of the
gun to the hook, then connect the other end to a support. This will enable the user to use the gun without
having to support the weight of the gun.
TI14450a1
FIG.3
TI14457a
14 313872B
Page 15
Hook Support
313872B 15
Page 16
Component Identification
Component Identification
See Parts on page 42 for part numbers and further
component identification.
K
H
E
B
A
M
H
C
J
N
D
P
R
FIG.4
Key:
A Hook Support
B Fluid Housing
C Orifice
D Fluid Manifold
E Air Cylinder, Gun Body
F Mounting Plate
G Electric Trigger Handle (optional)
L
F
G
TI14451a
H Dual Pistons
J Bulkhead
K Piston Safety Lock
L Throat Seal Liquid Cartridge
M Airline Fitting
N Solenoid Valve Gasket
P Solenoid Valve Mounting Plate
R Solenoid Valve
16 313872B
Page 17
Cutaway View
B
E
Component Identification
H
J
H
A
K
D
R
C
G
TI14462a
313872B 17
Page 18
Theory of Operation
Theory of Operation
Gun Triggered (Fluid Pouring)
Purge rod retracts, opening the impingement ports and
allowing fluid to mix and flow through the nozzle. Throat
Seal Liquid lubricates the purge rod.
Purge Rod
Throat Seal Liquid
Side View
TI14476a
Gun Detriggered
Purge rod extends, closing the impingement ports and
stopping fluid flow. Throat Seal Liquid lubricates the
purge rod.
Purge Rod
Side View
Throat Seal Liquid
TI14477a
Top View
18 313872B
TI14485a
Top View
TI14486a
Page 19
Setup
Setup
Perform this setup procedure to get the pour gun ready
for operation.
1. Close fluid valves A and B.
B
A
TI2411a
FIG.5
2. Connect A and B fluid hoses to fluid manifold.
6. Connect gun air whip hose (AA) to air quick
coupler (AC). Turn on air. Open air valve (AB).
IG.6.
See F
AA
AB
AC
AD
TI14452a
FIG.6
7. Connect signal cable to solenoid valve.
8. Models with a handle, connect signal cable to handle.
9. Disengage piston safety lock. See page 13.
TI2417a
3. Engage piston safety lock. See page 13.
4. Connect gun air whip hose (AA) and air valve (AB)
to main air hose. See F
IG. 6. Verify air valve is
closed.
5. Assemble fluid manifold (AD) to gun by hand then
use 5/16 in. nut driver to torque bolt to 20-30 in-lb
(2.26-3.39 N•m). See FIG.6.
In the following step, do not point gun at yourself. If
necessary, use a mirror to verify purge rod travel.
Pointing gun at yourself or someone else can lead to
accidentally spraying yourself or someone else with
fluid. If the purge rod was not correctly installed,
purge rod can shoot out of the barrel when gun is
actuated and can cause severe injury.
10. Verify fluid valves are closed, see F
IG. 5, then trigger
gun to check for full purge rod travel.
Purge Rod
TI14452a1
FIG.7
313872B 19
Page 20
Setup
11. Engage piston safety lock. See page 13.
12. Perform Bleed Throat Seal Liquid Cartridge procedure. See page 24.
13. Turn on proportioner. See proportioner manual.
14. Open fluid valves A and B.
TI14458a1
F
IG.8
15. Disengage piston safety lock. See page 13.
Adjust Orifices
In order to balance pressures between the A component
and B component the needle in each orifice may need to
be adjusted. Be sure that all necessary adjustments to
the proportioner are made prior to adjusting the orifices,
see proportioner manual.
If after adjusting pressures neither orifice can achieve
the desired pressure both orifices should be replaced
with a larger or smaller size. Note that a smaller orifice
will provide higher pressure and a larger orifice will provide lower pressure.
If after attempting to balance pressures the pressure difference is over 500 psi one orifice should be replaced
with a different size. If that is the case, adjust the needle
in each orifice all the way open (counter-clockwise) and
observe the pressures. The orifice whose pressure is
farthest from the desired pressure should be replaced.
Note that a smaller orifice will provide higher pressure
and a larger orifice will provide lower pressure.
1. Insert a 5/64 in. hex key (supplied) into the opening
in the hex on the orifice.
16. Perform a test pour into a waste container. Adjust
pressure and temperature to get desired results,
see proportioner manual. Also, see Adjust Ori-
fices.
TI14455a
FIG.9
2. In order to increase the pressure, turn the needle
clockwise.
TI15102a
In order to decrease the pressure, turn the needle
counter-clockwise.
TI15104a
20 313872B
Page 21
Setup
Optional Hose Position
As shipped, fluid inlet swivel fittings point to rear of the
gun. If desired, use the following procedure to make the
fluid inlet swivel fittings point downward.
NOTICE
To prevent cross-contamination of gun’s wetted parts,
do not interchange A component (isocyanate) and B
component (resin) parts.
1. Follow Pressure Relief Procedure, page 22.
2. Disconnect air quick coupler (AC). Use hex nut
driver to remove fluid manifold (AD).
5. Apply thread sealant to plugs (AH), elbows (AJ),
and male threads of swivels (AE). Install
elbows (AJ) in optional inlets, facing down. See FIG.
11. Install swivels in elbows. Be sure to install the A
swivel in the A side. Install plugs (AH) where swivels
had been. Torque all parts to 235-245 in-lb
(26.6-27.7 N•m).
AH
AJ
AE
TI2646
FIG.11
6. Connect the A hose to the A swivel and the B hose
to the B swivel.
AD
AC
TI14463a
3. Disconnect signal cable.
4. Place a cap over the end of each hose. Disconnect
fluid hoses from inlet swivels (AE). Remove plugs
from optional inlets (AG).
AE
7. Attach fluid manifold (AD) to gun. Torque fluid manifold bolt to 20-30 in-lb (2.26-3.39 N•m).
8. Connect air quick coupler (AC).
TI2417a
AE
AG
FIG.10
313872B 21
Page 22
Pressure Relief Procedure
Pressure Relief Procedure
1. Engage piston safety lock. See page 13.
NOTE: Air supply is required for purge rod actuation. Do
not disconnect gun air supply until fluid pressure is
relieved.
2. Close fluid valves A and B. Leave air valve (AB)
open.
7. Relieve system pressure. See Pressure Relief Procedure in proportioner manual.
8. Ensure fluid valves are closed then remove fluid
manifold.
9. Place the fluid manifold over waste containers, facing away from you.
10. Very slowly open the fluid valves. Under high pressure, fluid will spray sideways from the fluid ports.
AB
AC
TI14457a
FIG.12
3. Disengage piston safety lock. See page 13.
4. Trigger gun onto cardboard or into waste container
to relieve pressure.
TI2484a
TI14456a
FIG.13
5. Disconnect air quick coupler (AC). See FIG.12.
6. Engage piston safety lock. See page 13.
22 313872B
Page 23
Shutdown
Shutdown
Short Term Shutdown
Perform Short Term Shutdown procedure if gun will not
be used for more than one hour.
1. Perform Pressure Relief Procedure on page 22.
2. Trigger gun 3-4 times with piston safety lock
engaged in order to ensure material does not build
up on the purge rod. When purge rod is retracted,
spray some Throat Seal Lubricant into the front
nose.
3. Leave air turned on and gun detriggered.
4. Remove any material build-up on front of gun.
Long Term Shutdown
Perform Long Term Shutdown procedure if gun will not
be used for more than 48 hours.
1. Perform Short Term Shutdown.
2. Flush Gun, see page 25.
313872B 23
Page 24
Maintenance
Maintenance
Procedure Schedule
Bleed Throat Seal Liquid Cartridge, page 24
Replace Mix Chamber and Front
Seal, see page 30
Clean Clean Check Valves, page 27 Monthly
Clean Outside of Gun, page 25 As Needed
Replace Throat Seal Liquid Cartridge, page 31
Clean Breather Plug, page 26 As Needed
Clean Fluid Manifold, page 26 As Needed
Clean Fluid Housing Passages,
page 28
Clean Orifice, page 29 As Needed
Weekly
Every 2-4
Weeks
As Needed
As Needed
Supplied Tool Kit
See Parts on page 42 for tool illustrations.
• Hex Nut Driver; 5/16
• Screwdriver; 1/8 blade
Lubrication
See Accessories on page 53 to order lubricant. Liberally lubricate all o-rings, seals, and threads.
NOTICE
Use only Throat Seal Liquid on the o-rings, seals,
and threads of the Throat Seal Liquid cartridge.
Fusion grease or other petroleum-based or vegetable-based lubricants will cause cartridge o-rings
and seals to swell and stick.
Bleed Throat Seal Liquid Cartridge
To effectively coat the purge rod, air must be bled out of
the TSL cartridge weekly. Perform this procedure after
replacing the mix module or front end to bleed TSL from
cartridge. Before replacing the mix module or front end,
bleed all TSL to prevent spilling TSL.
• Impingement Port Drill Bit; various sizes depending
on port size
• 117661 Pin Vise; dual reversible chucks,
see FIG.14
• 118665 Fusion grease
Reversible
Reversible
TI3684a
FIG. 14: Pin Vise
1. With bleed port facing away from you and with air
supply connected, use a 5/16 in. nut driver (supplied) to slowly open the bleed valve 1/4 to 1/2 turn
until air/fluid begins to slowly exit the valve. See FIG.
15.
ti14478a
FIG. 15: Open the Bleed Port
2. When no more air comes out of the bleed valve,
close the bleed valve.
24 313872B
Page 25
Maintenance
Flush Gun
1. Follow Pressure Relief Procedure, page 22.
2. Remove fluid manifold (AD).
AD
TI14457a
FIG.16
NOTE: For a more thorough flush, solvent flush kits are
available as an accessory. See Accessories on
page 53.
TI14470a
FIG. 18: 256510, 1 qt (0.95 liter) Solvent Cup
7. Remove flush hoses from flush manifold. Remove
flush manifold from gun.
8. Remove Recirculation Block 15C850 from fluid
manifold.
3. Disconnect signal cable.
4. Install flush hoses to flush manifold 15B817. See
FIG. 17. Install flush manifold onto gun. Torque flush
manifold bolt to 20-30 in-lb (2.26-3.39 N•m).
TI2647a
FIG. 17: Flush Manifold
5. Holding a metal part of flush manifold firmly to side
of grounded pail and flush with compatible solvent
into a grounded metal pail. See wetted parts info in
Technical Data, page 55. Use lowest possible fluid
pressure when flushing.
6. Follow Pressure Relief Procedure, page 22.
9. Connect fluid manifold to gun. Torque fluid manifold
bolt to 20-30 in-lb (2.26-3.39 N•m).
10. Connect signal cable.
Clean Outside of Gun
The solvents listed in this section may ignite if used in
flushing. Use them only for external cleaning.
Wipe the outside of the gun with a compatible solvent.
See materials of construction info in Technical Data,
page 55. Use N-Methylpyrrolidone (NMP), Dynasolve
CU-6, Dzolv, or an equivalent solvent to soften cured
material. Applying a light coat of lubricant will make
future cleaning easier.
313872B 25
Page 26
Maintenance
Clean Breather Plug
The solvents listed in this section may ignite if used in
flushing. Use them only for external cleaning.
Remove and clean breather plug with compatible solvent. See materials of construction info in Technical
Data, page 55. The breather plug is part of the solenoid
manifold assembly (30). See FIG. 19. Use N-Methylpyrrolidone (NMP), Dynasolve CU-6, Dzolv, or an equivalent to soften cured material. Applying a light coat of
lubricant will make future cleaning easier. Torque
breather plug to 30-40 in-lb (3.89-4.82 N•m).
Breather
Plug
30
2. Use 5/16 in. hex nut driver to remove fluid
manifold (AD).
AD
TI14463a1
3. Disconnect signal cable.
4. Clean fluid manifold fluid ports with compatible solvent and brush whenever removed from gun. See
materials of construction info in Technical Data,
page 55. To prevent damaging the internal sealing
surfaces, do not use brush to clean inside diameter
of fluid ports. Fill fluid ports with grease if left
exposed, to seal out moisture. See FIG.20.
FIG. 19: Breather Plug
Clean Fluid Manifold
Fluid Manifold Fluid Ports
TI2411a
FIG.20
1. Follow Pressure Relief Procedure.
ti14469a1
5. Install fluid manifold. Torque fluid manifold bolt to
20-30 in-lb (2.26-3.39 N•m).
6. Connect signal cable.
26 313872B
Page 27
Maintenance
Clean Check Valves
1. Follow Pressure Relief Procedure, page 22.
2. Flush Gun, page 25.
3. Disconnect air quick coupler (AC). Use hex nut
driver to remove fluid manifold (AD).
AD
AC
6. Use flat tip screwdriver to pry out check valves at
notch.
TI14464a
Damaged check valve o-rings may result in external
leakage. Replace o-rings if worn or damaged.
7. Press on ball (BC) to test check valve for proper
movement and spring action. Replace check valve
assembly if necessary.
TI14463a
4. Disconnect signal cable.
5. Clean and inspect check valve mating surfaces and
fluid ports. See Clean Fluid Manifold on page 26.
NOTICE
To prevent cross-contamination of the check valves,
do not interchange A component and B component
parts. The A component check valve is marked with
an A.
8. Slide filter (BD) off. Clean and inspect parts. Thoroughly inspect o-rings (BE, BG). If necessary,
remove screw (BA) and disassemble check valve.
B
A
BA
AK
FIG.21
9. Liberally lubricate o-rings (BE, BG). Reassemble
check valves. Screw (BA) should be flush with
check valve housing surface (within 1/16 in. or
1.5 mm).
BB
BC
BD
BE
BF
BG
TI14464a
10. Install check valves into fluid housing (AK).
313872B 27
Page 28
Maintenance
11. Use hex nut driver to install fluid manifold (AD).
Torque fluid manifold bolt to 20-30 in-lb
(2.26-3.39 N•m). Connect air quick coupler (AC).
AK
AD
TI14484a
AC
12. Connect signal cable.
Clean Fluid Housing Passages
4. Use 5/16 in. nut driver (supplied) to remove
orifices (C). See FIG. 4 on page 16.
NOTICE
To prevent cross-contamination of the orifices do
not interchange A component and B component
parts. The A component orifice is marked with an
A.
5. Remove Front End, see page 33.
6. Remove all items from front end to enable cleaning
of passages. See Disassemble Front End on
page 34.
7. Use appropriate drill bits to clean fluid housing passages. See FIG. 23. See Drill Bit Kits, page 51.
CF
CA
CE
If necessary, use drill bits to clean the passages in the
fluid housing and gun body. See Drill Bit Kits, page 51.
1. Follow Pressure Relief Procedure on page 22.
2. Remove Throat Seal Liquid cartridge.
3. Remove Throat Seal Liquid bleed port screw.
ti14478a
FIG.22
CB
CC
CC
Key:
CA Orifice Passage
CB Throat Seal Liquid Inlet
CC Fluid Inlets (on bottom of fluid housing)
CD Throat Seal Liquid Pop-Off
CE Nozzle
CF Throat Seal Liquid Bleed Port
FIG. 23: Fluid Housing Passages
8. See Assemble Front End on page 34.
9. Attach Front End, see page 35.
10. Install orifices. Torque to 20-30 in-lb
(2.26-3.39 N•m).
CD
CA
TI14480a
28 313872B
Page 29
Clean Orifice
1. Follow Pressure Relief Procedure on page 22.
2. Use 5/16 in. nut driver (supplied) to remove
orifices (C). See FIG. 4 on page 16.
NOTICE
To prevent cross-contamination of the orifices do
not interchange A component and B component
parts. The A component orifice is marked with an
A.
NOTE: The cap is held in place with reverse threads.
3. Remove cap (26) from orifice (25). See Parts on
page 42.
Maintenance
4. Remove needle (60) from orifice. Thoroughly
inspect all o-rings and replace if necessary.
5. If necessary, use drill bit that is the same size as the
orifice to drill out the orifice. Orifice size is marked
on the orifice.
6. Use Fusion grease to liberally lubricate all o-rings.
7. Reassemble in reverse order. Torque orifice body
into orifice cap to 60-70 in-lb (6.78-7.91 N•m).
Torque orifices into fluid housing to 20-30 in-lb
(2.26-3.39 N•m).
313872B 29
Page 30
Maintenance
Replace Mix Chamber and Front Seal
19
18
17
ti14469a1
1. Use nut driver to open the Throat Seal Liquid bleed
port and drain all Throat Seal Liquid or replace with
empty cartridge.
10. Replace front pour tip and torque to 60-70 in-lb
(6.78-7.91 N•m).
NOTICE
To prevent cross-contamination of the orifices do
not interchange A component and B component
parts. The A component orifice is marked with an
A.
11. Replace orifices. Torque to 20-30 in-lb
(2.26-3.39 N•m).
12. Perform Replace Throat Seal Liquid Cartridge,
page 31.
ti14478a
FIG. 24: Open the Bleed Port
2. Follow Pressure Relief Procedure on page 22.
3. Close Throat Seal Liquid bleed port.
4. Use 5/16 in. nut driver (supplied) to remove
orifices (25, 26, 27).
5. Use a 3/4 in. wrench to remove front pour tip (19).
6. Connect air quick coupler (AC).
7. Press and release trigger to push out the mix
chamber (17) and front seal (18) and discard.
8. Disconnect air quick coupler (AC).
9. Install new mix chamber and front seal.
30 313872B
Page 31
Repair
Repair
Tools Required
Tools required to complete some gun repair procedures:
• 15/16 in. wrench
• flat head screwdriver (supplied)
• 5/16 hex nut driver (supplied)
• 1/2 in. socket
• 3/4 in. socket
• 5/64 in. allen wrench (supplied)
• 9/64 in. allen wrench
• 5/32 in. allen wrench
• Phillips screwdriver
Lubrication
See Accessories on page 53 to order lubricant. Liberally lubricate all o-rings, seals, and threads.
NOTICE
Use only Throat Seal Liquid on the o-rings, seals,
and threads of the Throat Seal Liquid cartridge.
Fusion grease or other petroleum-based or vegetable-based lubricants will cause cartridge o-rings
and seals to swell and stick.
2. Close air valve (AB).
AB
TI14452a
FIG.25
3. Push in and rotate cartridge 1/4 turn counterclockwise. See FIG. 26. Pull cartridge out of gun body.
Replace Throat Seal Liquid Cartridge
NOTE: If Throat Seal Liquid cartridge removal or instal-
lation is difficult, lubricate cartridge o-rings and cartridge
bore with a few drops of Throat Seal Liquid.
Water-based lubricants can be used as well.
NOTICE
Use only Throat Seal Liquid on the o-rings, seals,
and threads of the Throat Seal Liquid cartridge.
Fusion grease or other petroleum-based or vegetable-based lubricants will cause cartridge o-rings
and seals to swell and stick.
1. Follow Pressure Relief Procedure, page 22.
TI14461a
FIG.26
313872B 31
Page 32
Repair
4. Use 5/16 in. nut driver to verify Throat Seal Liquid
bleed port is closed.
TI14452a1
5. Remove plastic cap from new Throat Seal Liquid
cartridge.
7. Push in and rotate cartridge 1/4 turn clockwise to
lock it into gun body.
TI14460a
FIG.29
8. Open air valve (AB). See FIG.30.
TI11340a
FIG.27
6. Insert cartridge into gun body. Ensure cartridge tabs
are aligned correctly with cartridge tab recesses in
gun body.
TI14459a
FIG.28
AB
TI14452a
FIG.30
9. Perform Bleed Throat Seal Liquid Cartridge procedure, see page 24.
32 313872B
Page 33
Repair
Remove Front End
NOTICE
Proper attachment of front end is critical. Do not
operate gun if front end is loose or not snug against
body. Improper attachment can cause slow leaks.
1. Perform Pressure Relief Procedure, page 22.
2. Flush Gun, see page 25.
3. Perform Bleed Throat Seal Liquid Cartridge procedure on page 24 to bleed all fluid from cartridge or
replace with empty cartridge. TSL will spill if any
fluid remains in cartridge after this step.
4. Disconnect air quick coupler (AC). Use hex nut
driver to remove fluid manifold (AD).
7. Pull fluid housing away from gun body to remove. If
fluid housing cannot be removed perform the following steps.
a. Attach air quick coupler.
b. Pull and release the trigger or press and release
the red button on the solenoid valve.
c. Remove fluid housing.
d. Disconnect air quick coupler.
8. Disengage purge rod from ball socket in piston shaft
then remove purge rod.
AD
AC
TI14463a
5. Disconnect signal cable.
6. Rotate fluid housing (AK) 45 degrees counterclockwise to disengage fluid housing slots.
AK
ti14481a
9. Inspect fluid housing o-rings for wear or damage.
Replace if necessary.
ti14479a
313872B 33
Page 34
Repair
Disassemble Front End
NOTICE
To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate)
and component B (resin) parts. The gun is shipped with
the A side on the left. The fluid manifold, fluid housing,
side seal assembly, check valve cartridge, and mix
chamber are marked on the A side.
3
23
21
26
20
7
16b
1
7
17
22
3
18
19
6
1
3
Assemble Front End
NOTICE
To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate)
and component B (resin) parts. The gun is shipped with
the A side on the left. The fluid manifold, fluid housing,
side seal assembly, check valve cartridge, and mix
chamber are marked on the A side.
26a
23
3
21
26
20
7
16b
1
7
17
22
3
18
19
6
1
25a
3
25
16a
1
ti14469a1
1. Remove Front End, see page 33.
2. Remove Throat Seal Liquid bleed port screw (16b).
3. Remove check valve assembly (16a).
4. Remove orifice (25). Repeat for opposite side.
5. Remove pour tip (19).
6. Remove front packing (18) then mix module (17).
7. Remove rear packing nut (23), seal (22), rear packing housing (21), and o-ring (20).
25
16a
31
29
3
28
3
ti14469a1
30
1
Part is only included with 375 orifices.
32
3
6
7
5
Torque to 20-30 in-lb (2.26-3.39 N•m)
Torque to 60-70 in-lb (6.78-7.91 N•m)
34
Part is only included with 250 applicator.
35
3
1. Install o-ring (20), rear packing housing (21),
seal (22), and rear packing nut (23). Torque rear
packing nut to 20-30 in-lb (2.26-3.39 N•m).
2. Install mix module (17) then front packing (18).
3. Install pour tip (19) hand-tight.
34 313872B
Page 35
Repair
4. Install purge rod into rear of fluid housing. Leave
3/4 in. of ball socket end of purge rod extended out
of housing as shown in FIG.31.
5. Install check valve assembly. See Clean Check
Valves on page 27 for detailed assembly instructions.
6. Install Throat Seal Liquid bleed port screw (16b).
7. Install orifice components (25). Install orifice
cap (25a) and torque to 20-30 in-lb (2.26-3.39 N•m).
Repeat for opposite side.
8. See Attach Front End procedure.
Attach Front End
NOTICE
Proper attachment of front end is critical. Do not
operate gun if front end is loose or not snug against
body. Improper attachment can cause slow leaks.
1. Engage piston safety lock.
6. Push fluid housing flush to the gun body. Rotate
fluid housing 45 degrees clockwise to engage fluid
housing slots.
AK
ti14483a
7. Torque pour tip (19) to 60-70 in-lb (6.7-9.1 N•m).
8. Use hex nut driver to install fluid manifold (AD).
Torque fluid manifold bolt to 20-30 in-lb
(2.26-3.39 N•m). Connect air quick coupler (AC).
2. Liberally lubricate o-rings and install on fluid
housing (AK).
3. Apply thin coat of TSL to purge rod.
4. Install fluid housing onto purge rod.
5. Insert end of purge rod into ball socket in piston
shaft.
ti14482a
FIG.31
AD
TI14484a
AC
9. Connect signal cable.
Pistons and Bulkhead
User should have piston seals kit 24D312 available
before performing this procedure.
1. Follow Pressure Relief Procedure, page 22.
313872B 35
Page 36
Repair
2. Use hex nut driver to remove fluid manifold (AD).
AD
TI14463a1
3. Disconnect signal cable.
4. Remove Front End, see page 33.
5. Disconnect air quick coupler (AC).
AC
7. Place 1/2 in. socket on the piston shaft through the
front of the gun body. Entering through the rear of
the gun body, place a 3/4 in. socket with extension
on the rear piston. Hold piston shaft in place and
remove the rear piston. Inspect rear piston o-ring
and replace if necessary.
Access the
Pistons and
Bulkhead
Piston
Shaft
TI14465a
8. Entering through the rear of the gun body, place a
3/4 in. socket with extension on the bulkhead.
Remove the bulkhead. Inspect bulkhead o-rings and
replace as necessary.
9. Push piston shaft towards rear of gun to remove
front piston and piston shaft from the gun body.
10. Use a 1/2 in. socket on the piston shaft and
15/16 in. wrench on the front piston to remove front
piston from piston shaft.
TI14463a1
6. Unscrew piston safety lock assembly and remove.
Inspect o-ring and replace if necessary.
TI14465a
11. Inspect o-rings. Replace if worn or damaged. Liberally lubricate o-rings then reinstall.
12. Apply medium strength threadlocker to threads then
install front piston onto piston shaft. Torque to
100-110 in-lb (11.3-12.4 N•m). See Component
Identification on page 16.
13. Install piston shaft and piston assembly into gun
body. See Component Identification on page 16.
14. Install bulkhead onto piston shaft. Torque to
100-110 in-lb (11.3-12.4 N•m). See Component
Identification on page 16.
15. Apply medium strength threadlocker to threads then
install rear piston onto piston shaft. Torque to
100-110 in-lb (11.3-12.4 N•m). See Component
Identification on page 16.
16. Install piston safety lock. See Component Identifi-
cation on page 16.
17. Attach Front End, see page 35.
36 313872B
Page 37
Repair
18. Use hex nut driver to install fluid manifold (AD).
Torque fluid manifold bolt to 20-30 in-lb
(2.26-3.39 N•m). Connect air quick coupler (AC).
AD
TI14484a
AC
19. Connect signal cable.
Purge Rod
1. Flush Gun, page 25.
2. Follow Pressure Relief Procedure, page 22.
3. Disconnect air quick coupler (AC). Use hex nut
driver to remove fluid manifold (AD).
AD
AC
TI14463a
4. Disconnect signal cable.
5. Remove Front End, see page 33. Inspect purge
rod for wear or damage. Replace if necessary.
6. Use 3/4 in. wrench to loosen front tip. Coat purge
rod with TSL then replace purge rod.
7. Attach Front End, see page 35.
8. Attach air quick coupler to fully extend purge rod.
Tighten front tip to 60-70 in-lb (6.78-7.91 N•m)
9. Install fluid manifold. Torque fluid manifold bolt to
20-30 in-lb (2.26-3.39 N•m).
10. Connect signal cable.
313872B 37
Page 38
Repair
Solenoid Valve
1. Follow Pressure Relief Procedure on page 22.
2. Disconnect air quick coupler (AC). Use hex nut
driver to remove fluid manifold (AD).
AD
3. Disconnect electronic cables from solenoid valve
and handle (if installed).
4. Use 5/32 in. allen wrench to remove handle mounting plate screws. Remove handle mounting plate
and handle. See Component Identification on
page 16.
5. Use Phillips screwdriver to remove solenoid valve.
Inspect and replace if necessary. Inspect gasket on
bottom of solenoid valve and replace if necessary.
See Component Identification on page 16.
6. Use a 9/64 in. allen wrench to remove the solenoid
valve mounting plate and gasket. Inspect gasket
and replace if necessary. See Component Identifi-
cation on page 16.
AC
TI14463a
7. Assemble in reverse order. Torque fluid manifold
bolt to 20-30 in-lb (2.26-3.39 N•m). Torque screws
connecting handle to body to 20-30 in-lb
(2.26-3.39 N•m). See Component Identification
on page 16.
38 313872B
Page 39
Troubleshooting
Follow Pressure Relief Procedure, page 22, before
checking or repairing gun.
NOTICE
To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate)
and component B (resin) parts. The gun is shipped with
the A side on the left. The fluid manifold, fluid housing,
side seal assembly, check valve cartridge, and mix
chamber are marked on the A side.
Use the following table to check all possible problems
and causes before disassembling gun. See Mainte-
nance on page 24 and Repair on page 31 for referenced procedures.
Troubleshooting
Problem Cause Solution
Gun does not fully actuate when triggered
Fluid does not pour when gun is fully
actuated
Gun actuates slowly Plugged breather plug Clean breather plug
Gun delays, then actuates abruptly Cured material around the purge rod Inspect purge rod, mix module, and
Gun does not actuate when triggered Air supply to gun is shut off Open air supply
Pressure imbalance Plugged orifice ports Clean orifice ports
Safety lock engaged Disengage piston safety lock
Plugged breather plug Clean breather plug
Damaged air valve Replace if necessary
Closed fluid valves Open valves.
Plugged orifice ports Clean orifice ports
Plugged check valves Clean check valves
Safety lock engaged Disengage piston safety lock
Damaged piston o-rings Replace air piston o-rings
Damaged air gasket Replace
Dirty or damaged air valve Clean or replace valve
orifices. Replace if necessary
Empty TSL cartridge Replace cartridge
Foam build-up around front tip 1) Clean off front tip.
2) Use 3/4 in. wrench to loosen front
tip 1/8 turn and re-tighten.
Signal cable is disconnected Connect signal cable
Plugged check valves Clean check valves
Viscosities not equal Adjust temperature or orifice needle
to compensate
Plugged fluid screens Clean screens
313872B 39
Page 40
Troubleshooting
Problem Cause Solution
Fluid does not shut off when fluid
Damaged fluid valves Replace
valves are closed
Burst of air from muffler when gun is
Normal No action required
triggered
Steady air leakage from muffler Damaged air valve Replace
Damaged air gasket Replace
Damaged piston o-rings Replace
Leak between air cylinder and fluid
Damaged o-ring Replace
housing
Throat Seal Liquid cartridge installa-
tion or removal is difficult
Friction between cartridge o-rings
and cartridge bore
Lubricate cartridge o-rings and/or
cartridge bore with a few drops of
Throat Seal Liquid
Airison Turnairoff
Throat Seal Liquid cartridge is pressure locked in cartridge bore
Cannot bleed Throat Seal Liquid car-
Cartridge is empty. Temporary cartridge pressure lock
Bleed Throat Seal Liquid cartridge
pressure
Foam build-up in fluid housing Inspect and clean fluid housing
tridge
Material leaking out weep ports in
fluid housing near air cylinder
Mix module and rear seal worn Inspect and replace mix module and
rear seal, clean fluid housing
40 313872B
Page 41
Electrical Diagram
Troubleshooting
24
315
AIR
1 2
2
YE
1
4
BROWN
BLUE
5
3
2
1
2
3
4
5
1
2
3
4
5
4
5
3
2
1 1
MALE FEMALE
BLACK #2
BLACK #1
1 1
MALE FEMALE
SWITCH SIGNAL
1
2
24VDC COMMON
3
SOLENOID ACTIVATION
4
5
4
1
MALE
5
3
2
313872B 41
Page 42
Parts
Parts
12
ti14469a
Model 257999 Shown
7
9
11
5
8
4
10
4
54
3
26
3
3
20
7
7
23
21
22
3
2
13
24
5
2
16
1
5
17
16
18
1
25
19
6
3
4
1
29
31
3
14
15
6
4
3
32
5
34
30
33
35
37
36
1
Part is only included with 375
orifices.
2
Torque to 125-135 in-lb
(14.1-15.3 N•m)
3
3
3
Torque to 20-30 in-lb
(2.26-3.39 N•m)
4
Torque to 100-110 in-lb
(11.3-12.4 N•m)
5
Torque to 10-12 in-lb
(1.13-1.36 N•m)
6
Torque to 60-70 in-lb
(6.78-7.91 N•m)
7
Part is only included with 250
applicator.
28
3
4-Hose Fluid Manifold
28
249523
52
43
48
47
49
42 313872B
ti14472a
28
43
ti7134a
Page 43
Quantity
Ref Part Description
257999,
EP Gun, 250,
0.031 in.
orifice,
Handheld
24C932,
EP Gun, 250,
0.031 in.
orifice, Auto
24C933,
EP Gun, 375,
0.047 in.
orifice,
Hand-Held
24C934,
EP Gun, 375,
0.047 in.
orifice, Auto
1 24D682 CYLINDER, machined 1 1 1 1
2 24C413 HOOK, vertical mount assem-
1 1 1 1
bly
3 113003 SCREW, socket head cap 2 2 2 2
4 16A425 SHAFT, piston, dual 1 1 1 1
5 * PACKING, o-ring 3 3 3 3
6 15Y977 PISTON, front 1 1 1 1
7 * PACKING, o-ring 1 1 1 1
8 15Y976 BULKHEAD, applicator 1 1 1 1
9 * PACKING, o-ring 1 1 1 1
10 15Y978 PISTON, rear 1 1 1 1
11 * O-RING 1 1 1 1
12 24D295 STOP, assy, safety 1 1 1 1
13 15T897 PLUG, air valve 1 1 1 1
14 188554 PACKING, o-ring 1 1 1 1
15 121552 PIN, roll, 1/16 in. x 3/8 in. 1 1 1 1
16 257979 HOUSING, fluid, assy 1 1 1 1
17 *‡ MODULE, mix, 250 rod 1 1
**‡ MODULE, mix, 375 rod 1 1
18 *‡ PACKING, front, 250 rod 1 1
**‡ PACKING, front, 375 rod 1 1
19 24D316 TIP, pour, 250 rod 1 1
24D324 TIP, pour, 375 rod 1 1
20 *** PACKING, o-ring 6 6
21 *** HOUSING, packing, rear, 250
1 1
rod
22 ***‡ SEAL 6 6
24D325‡ SEAL 6 6
23 24D326 NUT, packing, rear, 250 1 1
24D325 NUT, packing, rear, 375 1 1
24 24D317 ROD, purge, 250 1 1
24D323 ROD, purge, 375 1 1
25 † RESTRICTOR, adjustable,
2 2
250, 031
† RESTRICTOR, adjustable,
2 2
375, 047
26 † RESTRICTOR, adjustable,
2 2
iso, 250, 031
† RESTRICTOR, adjustable,
2 2
iso, 375, 047
28 246012 MANIFOLD, fluid 1 1 1 1
Parts
313872B 43
Page 44
Parts
Quantity
Ref Part Description
257999,
EP Gun, 250,
0.031 in.
orifice,
Handheld
24C932,
EP Gun, 250,
0.031 in.
orifice, Auto
24C933,
EP Gun, 375,
0.047 in.
orifice,
Hand-Held
24C934,
EP Gun, 375,
0.047 in.
orifice, Auto
29 24D315 GASKET, solenoid, manifold 1 1 1 1
30 257977 MANIFOLD, solenoid, assy 1 1 1 1
31 106245 SCREW, socket head cap 3 3 3 3
32 24D318 VALVE, solenoid, 4 way 1 1 1 1
33 24D319 CORD SET, euro/male,
1 1 1 1
din/female
34 15Y968 PLATE, adapter, handle 1 1 1 1
35 15D256 SCREW, socket head cap 4 4 4 4
36 24D073 HANDLE, 2k dispense 1 1
37 C19980 SCREW, cap, socket hd 4 4
41 172479 ▲ TAG, warning 1 1 1 1
43 112307 ELBOW, street 2 2 2 2
44 117510 COUPLER, line, air, 1/4 npt 1 1 1 1
45 15B772 HOSE, air, 18 inch 1 1 1 1
46 15B565 VALVE, ball 1 1 1 1
47 117661 PIN, vise 1 1 1 1
48 117642 TOOL, nut driver 1 1 1 1
49 118575 TOOL, screw driver, 1/8 blade 1 1 1 1
51 222385 ▲ TAG, warning 1 1 1 1
52 295598 TOOL, wrench, hex 1 1 1 1
54 24D320 CONNECTOR, splitter 1 1
▲ Replacement Danger and Warning labels, tags and
cards are available at no cost.
* Parts included in Kit 24D314.
** Parts included in Kit 24D322.
*** Parts included in Kit 24D326.
† See Orifice Kits section starting on page 50.
‡ Suggested spares. These parts should be kept
on-hand to prevent down time. Kits 24D321, 246731,
246352 should also be kept on-hand. See Kits start-
ing on page 45 for contents of each kit.
44 313872B
Page 45
Kits
See Maintenance on page 24 and Repair on page 31
for appropriate kit installation procedures. See Com-
plete O-ring Placement Guide on page 52 for o-ring
identification help.
Kits
Kit
Description Kit Number
250 Mix
Chamber
375 Mix
Chamber
Throat Seal
Liquid Bleed
Port O-Ring
Kit
250 Iso Orifice
375 Iso Orifice
24D314 Mix Chamber 1
24D322 Mix Chamber 1
246354 O-Ring 6
24D223 24D238;
see Orifice
Kits on
page 50
24D239 24D254;
see Orifice
Kits on
page 50
Parts included in Kit
Description
Front Bearing 1
Front Bearing 1
O-Ring Installation
Tool
Orifice Housing 1
O-Ring 1
O-Ring 1
O-Ring 1
Needle 1
Backup Ring 1
O-Ring 1
Iso Orifice Cap 1
Cleanout Drill 1
Orifice Housing 1
O-Ring 1
O-Ring 1
O-Ring 1
Needle 1
Backup Ring 1
O-Ring 1
Iso Orifice Cap 1
Orifice Spacer 1
Cleanout Drill 1
Qty
1
Illustration
313872B 45
Page 46
Kits
Kit
Description Kit Number
250 Orifice 24C751 -
24C756,
24C805 24C815;
see Orifice
Kits on
page 50
375 Orifice 24C761 -
24C766,
24C794 24C804;
see Orifice
Kits on
page 50
Orifice
24D321 O-Ring 1
O-Ring Kit
Parts included in Kit
Description
Orifice Housing 1
O-Ring 1
O-Ring 1
O-Ring 1
Needle 1
Backup Ring 1
O-Ring 1
Orifice Cap 1
Cleanout Drill 1
Orifice Housing 1
O-Ring 1
O-Ring 1
O-Ring 1
Needle 1
Backup Ring 1
O-Ring 1
Orifice Cap 1
Orifice Spacer 1
Cleanout Drill 1
O-Ring 1
O-Ring 1
O-Ring 1
Backup Ring
Qty
Illustration
Orifice
248130 O-Ring 6
O-Ring Kit
Orifice
248128 O-Ring 6
O-Ring Kit
46 313872B
Page 47
Kits
Kit
Description Kit Number
Iso Check
246731 Check Valve Hous-
Valve
Parts included in Kit
Description
ing
Spring Retaining
Screw
Carbide Ball 1
Filter 1
Check Valve Spring 1
O-Ring 1
O-Ring 1
Check Valve 246352 Check Valve Hous-
ing
Spring Retaining
Screw
Carbide Ball 1
Filter 1
Check Valve Spring 1
O-Ring 1
O-Ring 1
40 Mesh Fil-
246357 40 Mesh Screen 10
ter Kit (40
mesh,
0.015 in.,
375 micron)
60 Mesh Fil-
246358 60 Mesh Screen 10
ter Kit (60
mesh,
0.010 in.,
238 micron)
80 Mesh Fil-
246359 80 Mesh Screen 10
ter Kit (80
mesh,
0.007 in.,
175 micron)
Check Valve
248129 O-Ring 6
O-Ring Kit
Qty
1
1
1
1
Illustration
313872B 47
Page 48
Kits
Kit
Description Kit Number
Check Valve
248133 O-Ring 6
Face O-Ring
Kit
250 Fluid
24D313 Housing Outer
Housing
Seals
Outer Fluid
24E611 O-Ring 6
Housing
O-Ring Kit
Parts included in Kit
Description
O-Ring
Housing Inner
O-Ring
Qty
1
1
Illustration
Inner Fluid
256773 O-Ring 6
Housing
O-Ring Kit
250 Lip Seal 24E252 250 Lip Seal 6
O-Ring 6
375 Lip Seal 24D325 375 Lip Seal 6
Piston Seals 24D312 Rod O-Ring 3
Front Piston O-Ring 1
Bulkhead O-Ring 1
Rear Piston O-Ring 1
48 313872B
Page 49
Kits
Kit
Description Kit Number
Piston Safety
24D295 Back Cap 1
Stop
Parts included in Kit
Description
O-Ring 1
Piston Stop 1
Safety Stop Shaft 1
O-Ring 1
Spring 1
Stop Shaft
257425 O-Ring 6
O-Ring Kit
Handle 24D073 2K Electric Handle 1
Handle Mounting
Screw
Qty
4
Illustration
Located inside back cap
Trigger
Switch Harness
Fluid Housing Kit
24D049 Trigger Switch 1
Switch Spacer 1
Air Valve Plug 1
Strain Relief 1
Signal Cable 1
24D680 250 Fluid Housing 1
24D681 375 Fluid Housing 1
313872B 49
Page 50
Kits
Kit
Description Kit Number
TSL Check
Valve Kit
24B843 Check Valve Seat 1
Parts included in Kit
Description
Ball 1
Spring 1
O-Ring 1
Qty
Illustration
Orifice Kits
In the following table, shaded rows indicate “Super Standard” items that are typically stocked and provide the
best delivery dates.
Impingement
Port Size
0.016 0.41 24C805 24D229 24C794 24D245
0.020 0.51 24C751 24D223 24C761 24D239
0.024 0.61 24C806 24D230 24C795 24D246
0.028 0.71 24C807 24D231 24C796 24D247
0.031 0.79 24C752 24D224 24C762 24D240
0.035 0.89 24C808 24D232 24C797 24D248
0.039 0.99 24C809 24D233 24C798 24D249
0.042 1.07 24C810 24D234 24C799 24D250
0.047 1.19 24C753 24D225 24C763 24D241
0.052 1.32 24C811 24D235 35C800 24D251
0.055 1.40 24C812 24D236 24C801 24D252
0.060 1.52 24C754 24D226 24C764 24D242
0.063 1.60 24C813 24D237 24C802 24D253
0.067 1.70 24C755 24D227 24C765 24D243
0.073 1.85 24C815 24D238 24C804 24D254
0.086 2.18 24C756 24D228 24C766 24D244
All 250 Super
Standard Orifices
All 375 Super
Standard Orifices
250 Model Polyol
Orifice Kit
24E250 NA NA
NA NA 24E251
Kit Type and Kit Number
250 Model Iso
Orifice Kit
375 Model Polyol
Orifice Kit
375 Model Iso
Orifice Kitin. mm
50 313872B
Page 51
Kits
Drill Bit Kits
For cleaning fluid housing passages and orifices. Drill bit illustrations are actual size for comparison. See Clean Fluid
Housing Passages on page 28. Not all sizes are used with every gun model.
Kit
Number
24D289
246631
246815
248892
24D293
24D294
248640
246629
249764
246628
246809
Drill Bit
Size
#78
#76
#73
#70
#68
#65
#61
#58
#56
#55
#54
Qty in
Kit
6 0.016
6 0.020
6 0.024
6 0.028
6 0.031
6 0.035
6 0.039
6 0.042
6 0.047
6 0.052
6 0.055
Orifice Size
Illustrationin. mm
0.41
0.51
0.61
0.71
0.79
0.89
0.99
1.07
1.20
1.32
1.40
246627
249113
24D290
24D291
246625
246624 3/32 in. 3 0.094 2.39
249115
24D327 #15 1 0.180 4.57
#53
1/16 in.
#51
#49
#44
1/8 in.
6 0.060
6 0.063
6 0.067
6 0.073
3
6
0.086
0.125
1.52
1.60
1.70
1.85
2.18
3.18
313872B 51
Page 52
Kits
Complete O-ring Placement Guide
The following illustration shows all gun o-rings at actual size. See Kits on page 45 for o-ring kit details including
quantities of each o-ring in each kit.
Ref Part
EA 119421
EB 111450
EC 123449
ED 117724
EE 103338
EF C20138
EG 102867
EH 123150
EJ 112319
EK C20272
EL 124171
EM 121370
EN 168518
EH
EF
ED
EM
EP
EN
EK
EL
EG
EA
EJ
EB
EE
EC
52 313872B
Page 53
Accessories
Accessories
Lubricant for Gun Rebuild
NOTICE
Use only Throat Seal Liquid on the o-rings, seals,
and threads of the Throat Seal Liquid cartridge.
Fusion grease or other petroleum-based or vegetable-based lubricants will cause cartridge o-rings
and seals to swell and stick.
248279, 4 oz (113 gram) [10]
High adhesion, water resistant, lithium-based lubricant.
MSDS sheet available at www.graco.com.
Throat Seal Liquid Cartridges
NOTICE
Use only Throat Seal Liquid on the o-rings, seals,
and threads of the Throat Seal Liquid cartridge.
Fusion grease or other petroleum-based or vegetable-based lubricants will cause cartridge o-rings
and seals to swell and stick.
Flushing Manifold
15B817 Manifold Block
Attaches to gun fluid manifold to enable flushing.
ti2647a
Circulation Manifold
246362
Attaches to gun fluid manifold to enable preheating of
hose. See manual 309818.
See Throat Seal Liquid MSDS, part 307765.
Kit Description
24C822 Single Cartridge
24C823 Package of 6 cartridges
Fluid Inlet Cover
15C850 Recirculation Block
T3877a1
Gun Cleaning Kit
15D546
Kit includes gun pick, tip cleaning tool, o-ring tool, utility
knife and blades, and seven different brushes.
T3877a
Reactor IP Harness
24D679
Attaches to gun signal cable to enable connection to
Reactor IP proportioners.
TI15103a
313872B 53
Page 54
Accessories
Solvent Flush Canister Kit
256510, 1 qt (0.95 liter) Solvent Cup
Includes flushing manifold to flush gun with solvent. Portable for remote flushing. See manual 309963.
TI14470a
Solvent Flush Pail Kit
248299 5.0 gal. (19 liter) Pail
Includes flush manifold with individual A and B shutoff
valves, and air regulator. See manual 309963.
TI14471a
54 313872B
Page 55
Technical Data
Technical Data
Maximum Fluid Working Pressure ................ 3000 psi (20.7 MPa, 207 bar)
Minimum Air Inlet Pressure...................... 80psi(0.55MPa,5.5bar)
Maximum Air Inlet Pressure ..................... 100psi(0.69MPa,6.9bar)
Maximum Fluid Temperature .................... 180°F (82°C)
AirInletSize................................. 1/4nptQuickDisconnect Nipple
A Component Inlet Size ........................ -5JIC,1/2-20UNF
B Component Inlet Size ........................ -6JIC,9/16-18UNF
Weight...................................... Models with Handle: 7.4 lb (3.4 kg)
Models without Handle: 6.4 lb (2.9 kg)
Materials of Construction ....................... Aluminum,stainlesssteel,acetal, chemically resistant
o-rings, carbon steel, fluoroelastomer o-rings
WettedParts................................. Aluminum,stainlesssteel,acetal, chemically resistant
o-rings
313872B 55
Page 56
Technical Data
Dimensions
A
C
B
Side View
TI14487a
E
D
TI14488a
Bottom View
F
Ref Dimension, in. (mm)
A 10.8 (274)
B 11.7 (297)
C 6.1 (155)
D 3.1 (79)
E 0.73 (19)
F 1.06 (27); Mounting: 4x 10-24
56 313872B
Page 57
Technical Data
313872B 57
Page 58
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 reserves the right to make changes at any time without notice.
This manual contains English. MM 313872
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
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