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Instructions-Parts
Plural Component, Impingement Mix
Mechanical Purge Spray Gun
For use with non-flammable foam and polyurea.
Not for use in explosive atmospheres.
3500 psi (24.2 MPa, 242 bar) Maximum Fluid Working Pressure
80-130 psi (0.55-0.9 MPa, 5.5-9.1 bar) Air Inlet Pressure Range
200°F (94°C) Maximum Fluid Temperature
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
US Patent Number 7,036,171
D479,305
Korean Patent 338185
Australian Patent Number 152610
EP 1610904
2004230905
309856P
TI3840a
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Summary of Contents for Graco Fusion 2004230905
- Page 1 Instructions-Parts Plural Component, Impingement Mix Mechanical Purge Spray Gun For use with non-flammable foam and polyurea. Not for use in explosive atmospheres. 3500 psi (24.2 MPa, 242 bar) Maximum Fluid Working Pressure 80-130 psi (0.55-0.9 MPa, 5.5-9.1 bar) Air Inlet Pressure Range 200°F (94°C) Maximum Fluid Temperature Important Safety Instructions Read all warnings and instructions in this manual.
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Page 2: Table Of Contents
Contents Manual Conventions ......3 List of Models/Selection Guide ....4 Standard Round Pattern Guns . -
Page 3: Manual Conventions
Manual Conventions Warning WARNING A warning alerts you to possible serious injury or death if you do not follow instructions. Symbols, such as fluid injection (shown), alert you to a specific hazard and direct you to read the indicated hazard warnings on pages 9-10. 309856P Caution CAUTION... -
Page 4: List Of Models/Selection Guide
List of Models/Selection Guide List of Models/Selection Guide Standard 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 247211, A 247212, A 247213, A 247218, A 247219, A 247225, A... -
Page 5: Standard Flat Pattern Guns
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 247257, A 247258, A 247265, A 247266, A 247267, A 247273, A 247274, A 247275, A 247281, A 247282, A... -
Page 6: Direct Impingement Round Pattern Guns
List of Models/Selection Guide 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 247003, A 247006, A 247007, A 247011, A 247012, A 247013, A 247018, A 247019, A... -
Page 7: Direct Impingement Flat Pattern Guns
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 247050, A 247051, A 247057, A 247058, A 247061, A 247062, A 247063, A 247065, A 247066, A 247067, A... -
Page 8: Direct Impingement Flat Pattern Guns
List of Models/Selection Guide Direct Impingement Flat Pattern Guns (7.6) (6.0) (4.5) (3.0) (1.5) (5.6, 56) (8.7, 87) Four-Hose Gun Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold Gun Part No., Series Slip-Fit™ Polycarballoy™ Mix Module Part No., see page 48 for numbering code 249815, A 1250 1700... - Page 9 PERSONAL PROTECTIVE EQUIPMENT You must wear proper protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: •...
- Page 10 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).
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Page 11: Overall View
Overall View Key: A Side Fluid Valve (ISO) B Side Fluid Valve (RESIN) Air Cap Air Line Quick Coupler Muffler Fluid Housing Gun Fluid Manifold Handle Optional Air Inlet Cleanoff Air Valve Piston Safety Lock CeramTip (behind air cap) 309856P Optional Fluid Inlets (A Side Shown) Lock Ring Fluid Inlet Swivels (A Side Shown) -
Page 12: Isocyanate Hazard
Isocyanate Hazard Isocyanate Hazard Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized par- ticulates. 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 ventila- tion in the work area. -
Page 13: Setup
Setup Close fluid valves A and B. Connect A (ISO) and B (RESIN) fluid hoses to fluid manifold. B (RESIN) Engage piston safety lock, page 12. 309856P Connect gun air whip hose (T) and air valve (U) to main air hose. Attach fluid manifold (G) to gun. TI2411A To change position of fluid manifold or use optional fluid inlets, see pages 19 and 20. - Page 14 Setup Open B (RESIN) fluid valve (about three half turns). Then open A (ISO) fluid valve. Disengage piston safety lock, page 12. Test spray onto cardboard. Adjust pressure and temperature to get desired results. Apply layer of lubricant over front of gun and lock ring, or use gun cover to prevent overspray buildup and ease disassembly.
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Page 15: Adjust Purge Rod
Adjust Purge Rod Engage piston safety lock, page 12. Close fluid valves A and B. 309856P Connect air supply and open air valve (U). Adjust purge rod with nut driver clockwise until it just touches CeramTip, then back off 1/8-1/4 turn. TI3850a Be sure to back out purge rod 1-2 turns before changing CeramTips or mix modules. -
Page 16: Adjust Flat Ceramtip
Adjust Flat CeramTip Adjust Flat CeramTip WARNING Read warnings, page 9. Engage piston safety lock, page 12. Close fluid valves A and B. Remove air cap (9). TI3850a Using nut driver, position CeramTip as desired. Reassemble air cap (9) fingertight. TI3837a TI3854a TI3867a... -
Page 17: Shutdown
Shutdown Daily Shutdown Follow Pressure Relief Procedure, page 18. Shutdown for More than a Flush Gun, page 22. Follow Pressure Relief Procedure, page 18. 309856P Shutdown... -
Page 18: Pressure Relief Procedure
Pressure Relief Procedure Pressure Relief Procedure WARNING Read warnings, page 9. Relieve pressure before cleaning or repairing gun. Engage piston safety lock, page 12. Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved. -
Page 19: Optional Configurations
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 inlet, check valve, and fluid housing A side) to right. -
Page 20: Optional Hose Position
Optional Configurations 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 CAUTION To prevent cross-contamination of gun’s wetted parts, do not interchange A component (ISO) and B compo- nent (RESIN) parts. -
Page 21: Maintenance
Maintenance Supplied Tool Kit • Hex Nut Driver; 5/16 • Screwdriver; 1/8 blade • CeramTip Drill Bit; various sizes depending on CeramTip size. See T 2, page 26. ABLE • Mix Module Drill Bit; various sizes depending on port size. See T 1, page 24. -
Page 22: Flush Gun
Maintenance Flush Gun If it is necessary to flush gun, use following procedure. WARNING Read warnings, page 10. Follow Pressure Relief Procedure, page 18. Flush with a compatible solvent. Flush into a grounded metal pail, holding a metal part of fluid manifold firmly to side of pail. Use the lowest possible fluid pressure when flushing. -
Page 23: Clean Slip-Fit Polycarballoy Mix Module
Clean Slip-Fit Polycarballoy Mix Module Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Remove mix module, page 38. CAUTION To avoid damaging mix module, do not force drill bits when cleaning impingement ports. Some ports are offset or angled. See F . - Page 24 Maintenance Table 1: Impingement Port Cleanout Drill Sizes Mix Module Part No. MR3535 MR4747 MR5757 MR6666 MR8282 MR9494 Mix Module Part No. MF1818 MF2929 MF3535 MF4747 MF5757 Direct Impingement Round Slip-Fit Polycarballoy Mix Modules Mix Module Part No. XR2323 XR2929 XR3535 XR4747 XR5757...
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Page 25: Xf2323
Direct Impingement Flat Slip-Fit Polycarballoy Mix Modules Mix Module Part No. XF1313 XF1818 XF2323 XF2929 XF3535 XF4747 XF5757 XF1318 XF1824 XF2332 309856P No. of Impingement Port Drill Impinge- Drill Size Drill Diameter ment Ports (nominal) in. (mm) .0130 (0.33) .0180 (0.46) .0230 (0.57) .0292 (0.74) .0240 (0.61) -
Page 26: Clean Ceramtip
Maintenance Clean CeramTip Round CeramTip Follow Pressure Relief Procedure, page 18. Remove CeramTip, page 34. Clean CeramTip hole with appropriate size drill (supplied). See T 2. Also see identification ABLE chart under Drill Bit Kits, page 51. Table 2: Cleanout Drill Sizes for Round CeramTips Round CeramTip Kit Drill Size Part No. -
Page 27: Stuck Purge Rod
Clean CeramTip hole (E) with appropriate size drill (supplied). See T 2. Also see identification ABLE chart under Drill Bit Kits, page 51. Clean flat tip slit (H) with tip cleanout tool 15D234 (page 53). 15D234 Open B (RESIN) fluid valve (about three half turns). -
Page 28: Adjust Front Rod Seal
Maintenance Disconnect air (D) and remove fluid manifold (G). Disassemble Front End, page 35. Clean exposed portion of purge rod (31). Apply Fusion Gun Lubricant, page 53. Reassemble Front End, page 36. Adjust Purge Rod, page 15. Attach fluid manifold. Connect air. Return gun to service. -
Page 29: Adjust Rear Rod Seal
Adjust Rear Rod Seal Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Remove fluid manifold (G). Leave air connected. Disassemble Front End, page 35. Assemble fluid housing (7) backwards onto lubri- cated purge rod (31). Adjust rear rod seal nut (23) with nut driver until drag is felt when sliding on rod. -
Page 30: Troubleshooting
Troubleshooting Troubleshooting Follow Pressure Relief Procedure, page 18, before checking or repairing gun. 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) and B component (resin) parts. PROBLEM Gun does not fully actuate when trig- gered. - Page 31 PROBLEM Loss of round pattern. Loss of flat pattern. Pressure imbalance. Fluid mist from CeramTip. Excessive overspray. Rapid buildup of material on air cap. Fluid does not shut off when fluid valves are closed. Reduced cleanoff air. Air leakage around fluid housing. Air leakage from piston safety lock.
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Page 32: Theory Of Operation
Troubleshooting Theory of Operation Gun Triggered (Fluid Spraying) Purge rod (31) moves back, opening impingement ports (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. -
Page 33: Cutaway View
Troubleshooting Cutaway View 28 25 309856P... -
Page 34: Repair
Repair 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-rings, seals, and threads with Fusion Gun Lubricant, page 53. -
Page 35: Disassemble Front End
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. Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Back out purge rod 1-2 turns with nut driver. -
Page 36: Reassemble Front End
Repair Reassemble Front End 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. Orient front end as required for desired fluid mani- fold mounting (bottom mounting shown). Align slots (Y) to engage tabs (Z). - Page 37 CAUTION Do not overtighten mix module nut (25). Overtighten- ing can deform impingement holes and cause slow gun actuation. Lubricate all threads and reassemble mix module nut (25) fingertight. Tighten additional 1/12 turn with air cap (9) or wrench. Install front seal (46) on rod (31).
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Page 38: Slip-Fit Polycarballoy Mix Module
Repair Slip-Fit Polycarballoy Mix Module See page 48 for available Slip-Fit Polycarballoy Mix Module sizes. Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Remove fluid manifold (G). Leave air connected. Remove air cap (9), retainer (28), and CeramTip (40). - Page 39 CAUTION Do not overtighten mix module nut (25). Overtighten- ing can deform impingement holes and cause slow gun actuation. Lubricate all threads and reassemble mix module nut (25) fingertight. Tighten additional 1/12 turn with air cap (9) or wrench. Install front seal (46) on rod (31).
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Page 40: Rear Rod Seal
Repair Rear Rod Seal Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Remove fluid manifold (G). Leave air connected. Disassemble Front End, page 35. Remove rear rod seal nut (23) with nut driver (53). Push out rear seal (46) with screwdriver (54). Reassemble new rear seal (46) in rear rod seal nut (23). -
Page 41: Check Valves
Check Valves Before disassembling, press on ball (36c) to test check valve for proper movement and spring action. Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Disconnect air (D) and remove fluid manifold (G). Clean and inspect check valve mating surfaces and fluid ports. -
Page 42: Piston And Purge Rod
Repair Piston and Purge Rod Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Disconnect air (D) and remove fluid manifold (G). Disassemble Front End, page 35. Unscrew purge rod stop (15) to remove piston safety lock assembly. Inspect o-rings (14, 18) in place. - Page 43 Install piston safety lock assembly until bottomed out. Reassemble Front End, page 36. Adjust Purge Rod, page 15. Attach fluid manifold. Connect air. Return gun to service. 309856P TI3847a Repair...
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Page 44: Piston Safety Lock
Repair Piston Safety Lock Follow Pressure Relief Procedure, page 18. Flush Gun, page 22. Disconnect air (D) and remove fluid manifold (G). Unscrew cap (10) from stop (15), using two pair of channel-lock pliers. Inspect spring (17), safety actuator (3), bushing (4), and o-rings (14, 18). Lubricate o-rings (14, 18) and piston safety lock actuator (3), and reassemble. -
Page 45: Notes
Notes Notes 309856P... -
Page 46: Parts
Parts Parts 25 39 †‡ ‡ ‡◆ †‡ ‡ ◆†‡ †‡ ‡ ‡ ‡ *36g ‡ †‡ *36f †‡ ‡ † Torque to 125-135 in-lb (14-15 N•m). Torque to 20-30 in-lb (2.3-3.4 N•m). Torque to 32-40 ft-lb (43-54 N•m). Torque to 35-45 in-lb (4-5 N•m). ★... - Page 47 Ref. Part No. Description 248002 HANDLE 15B208 PLUG, air valve ★ 15C374 ACTUATOR; safety ★ 15C390 BUSHING, safety 203953 SCREW; 10-24 x 3/8 in. (10 mm) 1 192272 PIN HOUSING, fluid †‡◆ 118145 SPRING, purge rod 15C375 AIR CAP ★ 15C373 CAP, rear 11‡◆...
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Page 48: Slip-Fit Polycarballoy Mix Module Kits
Parts Slip-Fit Polycarballoy Mix Module Kits Slip-Fit Polycarballoy Mix Module Part Numbering Code Example First Two Digits Part No. MR3535 MR=Mechanical purge standard, round pattern MF3535 MF=Mechanical purge standard, flat pattern XR3535 XR=Mechanical purge direct impingement, round pattern XF3535 XF=Mechanical purge direct impingement, flat pattern *** Some modules have multiple impingement ports (see below). - Page 49 Direct Impingement Round Pattern Guns Slip-Fit Polycarballoy No. of Mix Module Kit Impingement (includes drill bits) Ports XR2323 XR2929 XR3535 XR4747 XR5757 Direct Impingement Flat Pattern Guns Slip-Fit Polycarballoy No. of Mix Module Kit Impingement (includes drill bits) Ports XF1313 XF1818 XF2323 XF2929...
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Page 50: Ceramtip Kits
Parts CeramTip Kits Round CeramTip Part Numbering Code Example First Three Digits Part No. RTM055 RTM=Round CeramTip mechanical purge Round CeramTips (include drill bit) CeramTip Part No. Drill Bit Size, nominal** RTM024 RTM030 RTM040 RTM055 RTM070 RTM080 2.0 mm RTM090 RTM100 RTM110 7/64... -
Page 51: Drill Bit Kits
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 nominal 246623 246810 7/64 246813 246624 3/32 246812 246625 246811 2 mm 246626 248893 1/16... -
Page 52: Gun Repair Kits
Parts Gun Repair Kits Read the chart left to right and top to bottom to find the quantity of each part in the kits. Ref. Bulk O-ring 246351 Kits, (qty) Check Valve O-ring Kit 248136 (6) 248135 (6) 248095 (6) 248096 (6) 248138 (6) 248132 (6) -
Page 53: Accessories
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 Cleanout Tool 15D234 Designed to fit CeramTip internal dome and flat tip slits. -
Page 54: Solvent Flush Pail Kit
Accessories 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 D-gun hose set. -
Page 55: Technical Data
Technical Data Category Maximum Fluid Working Pressure Minimum Air Inlet Pressure Maximum Air Inlet Pressure Maximum Fluid Temperature Air Inlet Size A Component (ISO) Inlet Size B Component (Resin) Inlet Size Typical Flow Rate Sound Pressure Sound Power, measured per ISO 9416-2 Length Height... -
Page 56: Graco Standard Warranty
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.