Graco 2004230905 - Manual

List of Models/Selection Guide 309856P 5 Standard Flat Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for numbering code 247257, A MF1818 FTM317 247258,...

List of Models/Selection Guide 6 309856P Direct Impingement Round Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Round CeramTip ™ Part No., see page 50 for numbering code 247003, A XR2323 RT...

List of Models/Selection Guide 309856P 7 Direct Impingement Flat Pattern Guns Use only these mix module/tip combinations. Gun Part No., Series Slip-Fit ™ Polycarballoy ™ Mix Module Part No., see page 48 for numbering code Flat CeramTip ™ Part No., see page 50 for numbering code 247050, A XF1313 FTM3...

List of Models/Selection Guide 8 309856P Direct Impingement Flat Pattern Guns Four-Hose Gun Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold FLO W RA TE in gpm ( lpm)* PRESSURE in psi (MPa, bar) 2.0 (7.6) 1.6 (6.0) 1.2 (4.5) 0.4 (1.5) 0.8 (3.0) 0 XF292 9/FTM 424 XF5 757 /FT M6 38 XF4...

Overall View 309856P 11 Overall View Key: A A Side Fluid Valve (ISO) B B Side Fluid Valve (RESIN) C Air Cap D Air Line Quick Coupler E Muffler F Fluid Housing G Gun Fluid Manifold H Handle J Optional Air Inlet K Cleanoff Air Valve L Piston Safety Lock M CeramTip (behind air cap) N Optional Fluid Inl...

Isocyanate Hazard 12 309856P Isocyanate Hazard Keep A and B Components Separate Grounding Check your local electrical code and proportioner man-ual for detailed grounding instructions. Ground the spray gun through connection to a Graco-approved grounded fluid supply hose. Piston Safety Lock Engage p...

Setup 309856P 13 Setup 1. Close fluid valves A and B. 2. Connect A (ISO) and B (RESIN) fluid hoses to fluid manifold. 3. Engage piston safety lock, page 12. TI2411A A (ISO) B (RESIN) TI2417A TI3850a 4. Connect gun air whip hose (T) and air valve (U) to main air hose. Attach fluid manifold (G) to gun...

Adjust Purge Rod 309856P 15 Adjust Purge Rod 1. Engage piston safety lock, page 12. 2. Close fluid valves A and B. TI3850a TI3837a U A B 3. Connect air supply and open air valve (U). 4. Adjust purge rod with nut driver clockwise until it just touches CeramTip, then back off 1/8-1/4 turn. Be sure to ...

Adjust Flat CeramTip 16 309856P Adjust Flat CeramTip WARNING Read warnings, page 9. 1. Engage piston safety lock, page 12. 2. Close fluid valves A and B. TI3850a TI3837a U A B 3. Remove air cap (9). 4. Using nut driver, position CeramTip as desired. 5. Reassemble air cap (9) fingertight. 9 TI3854a T...

Shutdown 309856P 17 Shutdown Daily Shutdown Follow Pressure Relief Procedure, page 18. Shutdown for More than a Day 1. Flush Gun, page 22. 2. Follow Pressure Relief Procedure, page 18.

Pressure Relief Procedure 18 309856P Pressure Relief Procedure WARNING Read warnings, page 9. Relieve pressure before cleaning or repairing gun. 1. Engage piston safety lock, page 12. Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved. 2. Clos...

Optional Configurations 309856P 19 Optional Configurations Optional Fluid Manifold Position Fluid manifold is mounted to bottom of gun, with A side on left, viewed from operator’s position at back of gun. If desired, manifold may be moved to top of gun. Doing this will reposition A side parts (fluid...

Optional Configurations 20 309856P Optional Hose Position Fluid inlet swivels and air quick disconnect fitting point to rear. If desired, these positions can be changed so hoses travel downward. Fluid Hoses Air Hose CAUTION To prevent cross-contamination of gun’s wetted parts, do not interchange A c...

Maintenance 309856P 21 Maintenance Supplied Tool Kit • Hex Nut Driver; 5/16 • Screwdriver; 1/8 blade • CeramTip Drill Bit; various sizes depending on CeramTip size. See T ABLE 2, page 26. • Mix Module Drill Bit; various sizes depending on port size. See T ABLE 1, page 24. • 117661 Pin Vise; dual rev...

Maintenance 22 309856P Flush Gun If it is necessary to flush gun, use following procedure. Clean Outside of Gun Wipe off outside of gun with compatible solvent. Clean Air Cap Soak air cap in compatible solvent. If necessary, clean gently with stiff brush. Clean Muffler A partially plugged muffler wi...

Maintenance 26 309856P Clean CeramTip Round CeramTip Flat CeramTip External Quick Cleaning Method 1. Follow Pressure Relief Procedure, page 18. 2. Remove CeramTip, page 34. 3. Clean CeramTip hole with appropriate size drill (supplied). See T ABLE 2. Also see identification chart under Drill Bit Kits...

Maintenance 309856P 27 Stuck Purge Rod If purge rod (31) is stuck and cannot actuate, use this procedure to free it. Clean Purge Rod Clean purge rod (31) weekly or monthly. 3. Clean CeramTip hole (E) with appropriate size drill (supplied). See T ABLE 2. Also see identification chart under Drill Bit ...

Maintenance 28 309856P Adjust Front Rod Seal If fluid misting occurs from tip when gun is not triggered, use following procedure to temporarily stop leakage until parts are replaced. 3. Disconnect air (D) and remove fluid manifold (G). 4. Disassemble Front End, page 35. 5. Clean exposed por tion of ...

Maintenance 309856P 29 Adjust Rear Rod Seal 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Remove fluid manifold (G). Leave air connected. 4. Disassemble Front End, page 35. 5. Assemble fluid housing (7) backwards onto lubri- cated purge rod (31). Adjust rear rod seal nut (2...

Troubleshooting 30 309856P Troubleshooting 1. Follow Pressure Relief Procedure, page 18, before checking or repairing gun. 2. Check all possible problems and causes before disassembling gun. CAUTION To prevent cross-contamination of the gun’s wetted parts, do not interchange A component (isocyanate)...

Troubleshooting 32 309856P Theory of Operation Gun Triggered (Fluid Spraying) Purge rod (31) moves back, opening impingement por ts (IP). Components A and B combine in mix module (39). Fluid sprays from CeramTip (40). Cleanoff air flows whether gun is triggered or detrig-gered. See page 13 to adjust...

Troubleshooting 309856P 33 Cutaway View 44 19 31 16 24 9 21 3 36 12b 22 28 25 40 48 39 18 14 20

Repair 34 309856P Repair Tools Required Tools needed for complete gun repair: • adjustable wrench • flat head screwdriver (included) • channel-lock pliers (2 pair) • 5/16 hex nut driver (included) • o-ring pick • medium-strength Loctite ® • solvent or alcohol Lubrication Liberally lubricate all o-ri...

Repair 309856P 35 Disassemble Front End WARNING Read warnings, page 9. Proper attachment of front end is critical. Do not operate gun if front end is loose or lock ring is not snug against handle. 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Back out purge rod 1-2 turns wi...

Repair 36 309856P Reassemble Front End 1. Check that o-rings (20, 21) are in position. Liberally lubricate o-rings, threads of lock ring (11) and han-dle (1), and outside of lock ring. 2. Orient front end as required for desired fluid mani- fold mounting (bottom mounting shown). Align slots (Y) to e...

Repair 40 309856P Rear Rod Seal 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Remove fluid manifold (G). Leave air connected. 4. Disassemble Front End, page 35. 5. Remove rear rod seal nut (23) with nut driver (53). 6. Push out rear seal (46) with screwdriver (54). TI3852a ...

Repair 309856P 41 Check Valves Before disassembling, press on ball (36c) to test check valve for proper movement and spring action. 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Disconnect air (D) and remove fluid manifold (G). Clean and inspect check valve mating surfaces ...

Repair 42 309856P Piston and Purge Rod 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Disconnect air (D) and remove fluid manifold (G). 4. Disassemble Front End, page 35. 5. Unscrew purge rod stop (15) to remove piston safety lock assembly. Inspect o-rings (14, 18) in place....

Repair 44 309856P Piston Safety Lock Air Valve 1. Follow Pressure Relief Procedure, page 18. 2. Flush Gun, page 22. 3. Disconnect air (D) and remove fluid manifold (G). 4. Unscrew cap (10) from stop (15), using two pair of channel-lock pliers. Inspect spring (17), safety actuator (3), bushing (4), a...

Parts 46 309856P Parts TI3851c TI2647a 9 28 46* †‡ 25 39 19 32 16* 8 31 14* ★ 15 ★ 10 ★ 17 ★ 59 ★ 3 ★ 18 ★ 18 1 35 ‡ ◆ 11 ‡ ◆ 23 ‡ 46* †‡ 21* ‡ ◆ 20 ‡ 44 ‡ *24 ◆ †‡ 7 ‡ 36e 36c ‡ ‡ 36d †‡ *36f †‡ 36a ‡ *36g ‡ 36 † 12a 12b 12d 12g 50 12c 12e 12f 5 13 6 29 22 24 †‡ 27 26 2 30 48 49 51 34 29 (Ref) 52 1...

Parts 48 309856P Slip-Fit Polycarballoy Mix Module Kits Slip-Fit Polycarballoy Mix Module Part Numbering Code *** Some modules have multiple impingement ports (see below). Size is given as the equivalence of a single port. Standard Round Pattern Guns Standard Flat Pattern Guns **For fur ther informa...

Parts 50 309856P CeramTip Kits Round CeramTip Part Numbering Code Round CeramTips (include drill bit) **For fur ther information, see identification chart under Drill Bit Kits, page 51. Flat CeramTip Part Numbering Code Flat CeramTips ExamplePart No. First Three Digits Last Three Digits RTM055 RTM=R...

Parts 309856P 51 Drill Bit Kits For cleaning gun ports and orifices. Illustrations are actual size, for comparison. Not all sizes are used with your gun. Kit Part No. Qty in Kit Drill Bit Size Illustration nominal in. mm 246623 3 #32 0.116 2.90 246810 3 7/64 0.109 2.77 246813 3 #39 .099 2.51 246624 ...

Parts 52 309856P Gun Repair Kits Read the chart left to right and top to bottom to find the quantity of each part in the kits. Check Valve Filter Screen Kits (10 per kit) 80 mesh filter screen is standard with gun. 246357 40 mesh (.015 in., 375 micron) 246358 60 mesh (.010 in., 238 micron) 246359 80...

Accessories 309856P 53 Accessories Gun Cover 244915 Keeps gun clean while spraying. Pack of 10. Fusion Gun Lubricant Kit 248279 Pack of 10 Tubes, 4 oz (113 gram) High adhesion, water resistant, lithium-based lubricant for rebuilding Fusion Gun. MSDS sheet MSD025 avail-able at www.graco.com. Tip Clea...

Accessories 54 309856P Solvent Flush Pail Kit 248229 5.0 gal. (19 liter) Pail Includes flush manifold with individual A and B shutoff valves, and air regulator. See manual 309963. Hose Adapter Kits 246944 To connect non-Graco gun to Graco heated hose. 248029 To connect Graco Fusion gun to non-Graco ...

Technical Data 309856P 55 Technical Data All other brand names or marks are used for identification purposes and are trademarks of their respective owners. Category Data Maximum Fluid Working Pressure 3500 psi (24.2 MPa, 242 bar) Minimum Air Inlet Pressure 80 psi (0.55 MPa, 5.5 bar) Maximum Air Inle...

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 309856 Graco Headquarters: Minneapolis International Offices: Bel...