Graco 312666R User's Manual
Contents
1. 052 1 30 7 Push mix chamber back into position 8 Tighten A and B side seals 9 Attach Front End page 37 10 Attach fluid manifold M Connect air D Return gun to service 312666R Troubleshooting Troubleshooting 1 Follow Pressure Relief Procedure page CAUTION 17 before checking or repairing gun To prevent cross contamination of gun s wet 2 Check all possible problems and causes ted parts do not interchange A component before disassembling gun isocyanate and B component resin parts PROBLEM CAUSE SOLUTION Gun does not fully actuate when Safety lock engaged Disengage piston safety lock See triggered Piston Safety Lock page 12 Plugged breather plug 9 Clean Breather Plug page 26 Damaged air valve o rings 15 Replace See Air Valve page 43 Fluid does not spray when gun is Closed fluid valves 1b Open fully actuated Plugged impingement ports Clean Impingement Ports page 29 Plugged check valves 44 45 Clean See Check Valves page 41 Gun actuates slowly Plugged breather plug 9 Clean Breather Plug page 26 Damaged piston o rings 4a 4c Replace See Piston page 42 Dirty air valve or damaged Clean air valve or replace o rings o rings 15 See Air Valve page 43 Gun delays then actuates Cured material around side seals Inspect side seals 42c and mix abruptly 42 43 chamber 14 for ditas na Replace see Mix Chamber and Side Seal Assemblies2. 3av 3C 4av 4cv 4d 4e 4f Part 256466 256462 256462 15B221 100139 117634 117635 256460 256459 15U395 256457 100846 248648 256773 248132 256456 256774 25 426 25 425 256454 256772 256775 25 424 25 426 121642 312666R Description MANIFOLD hose assy MANIFOLD KIT valve check a side includes 1c and 256469 O ring KIT valve check b side includes 1b and 256469 O ring BOLT 5 16 24 PLUG pipe SWIVEL union 6 JIC SWIVEL union VALVE ball resin VALVE ball iso ADAPTER male x female 1 8 npt HOUSING fluid assy includes 2a 2f and 42 45 FITTING lubrication O RING pack of 6 O RING pack of 6 O RING pack of 6 HOUSING ADJUSTER variable flow O RING pack of 6 O RING pack of 6 O RING pack of 6 PISTON assy O RING pack of 6 PISTON O RING pack of 6 O RING PISTON dosing assy includes 4d and 4f O RING pack of 6 RING retaining internal spiral Qty i L N e a QM N S ll ll lll Ref NOO Part 15B209 192272 203953 150480 121540 256458 151897 117485 256455 256414 Description TRIGGER PIN pivot SCREW 10 24 x 3 8 in 10 mm WASHER wave PLUG breather HANDLE kit includes ref 12 PLUG air valve CHAMBER mix O RING SPRING compression VALVE spool includes 15 RETAINER cover pack of 5 256415 COVER front round tip pack of 5 425
3. Maximum Air Inlet Pressure 130 psi 0 9 MPa 9 bar C A Component ISO Inlet Size 75 27 dB A using RD0202 at 100 psi 73 45 dB A using RDO202 at 100 psi Sound Power measured per ISO 9416 2 0 7 MPa 7 bar 7 5 x 8 1 x 8 3 in 191 x 206 x 84 mm Weight 2 6 lbs 1 18 kg Aluminum stainless steel carbon steel car Wetted Parts i bide chemically resistant o rings All other brand names or marks are used for identification purposes and are trademarks of their respective owners Air Flow Data Air Pressure detriggered Air Flow in scfm m min psi MPa bar for all mix chambers 2 1 80 0 56 5 6 0 059 3 100 0 7 7 0 088 5 2 130 0 9 9 0 147 312666R 57 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 inst
4. may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 7 BURN HAZARD fi Am Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely 312666R 7 Warnings 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 unt
5. sure is relieved page 17 15 Shutdown Shutdown Overnight Shutdown 3 Unscrew and remove front cover retainer C Remove front cover U 1 Follow Pressure Relief Procedure page 17 4 Using grease gun dispense a half shot of grease into fitting G Do not over grease 2 Leave air turned on and gun detriggered use a half shot maximum Ag Grease gun daily to prevent two compo nent curing and keep fluid passages clean Purge air carries grease mist through air chamber AC impingement ports IP and out mix chamber nozzle N coating all surfaces Use Graco 117773 grease TI11335a FiG 16 5 Replace front cover U and front cover retainer C Always leave a ClearShot Liquid cartridge in gun handle to prevent cartridge bore contamination Fluid nin Grease TI12124a Fic 15 16 312666R Pressure Relief Procedure Pressure Relief Procedure We e 1 Engage piston safety lock page 12 1112240a FIG 19 4 Trigger gun onto cardboard or into waste container to relieve pressure TI11326a Fic 17 CAUTION Air supply is required for gun actuation Do not disconnect gun air supply until fluid pres sure is relieved T111336a 2 Close fluid valves A and B Leave air valve W open FIG 20 5 Engage piston safety lock page 12 we amp Fluid in the hose and proportioner is still under pressure Follow the Pressure Relief
6. 12666R Clean Passages If necessary clean out passages in fluid hous ing and handle with drill bits All drill bits are available in an accessory kit Order kit 256526 for ClearShot Handle Drill Kit see Accesso ries page 55 312666R Maintenance Clean Impingement Ports 1 Follow Pressure Relief Procedure page 17 2 Disconnect air D and remove fluid mani fold M ism Gat Sa aner TI11330a Fic 41 3 Flush Gun page 26 If gun will not flush see Mix Chamber and Side Seal Assem blies page 38 4 Remove Front End page 36 29 Maintenance 5 Loosen A and B side seals two turns 6 Pull out mix chamber from back of fluid housing See Table 2 for appropriate size drill to clean ports Also see identification chart under Drill Bit Kits page 53 Some mix chambers have counter bored holes and require two drill sizes to clean impingement ports completely Impingement Port T1112097a IP CB IP e T3533a Mix Chambers RD and Mix Chambers RD and FL FL 2020 and 2929 4242 or larger FiG 42 30 Table 2 Impingement Port Drill Bit Sizes Counter bore CB Drill Bit Size in mm Mix Impingement Chamber Port IP Drill Bit Size in mm RD2020 76 020 0 50 453 060 1 50 RDOOOO 69 029 0 70 53 060 1 50 8 042 100 RDO101 RD0202 55 052 1 30 RD0303 53 060 1 50 N A FL2020 FLOOOO FLO101 58 042 1 00 FLO202 55
7. 4 RD0101 CSO2WD B WDO0202 0 046 1 17 18 457 2 RD0202 CS03WD B WD0303 0 057 1 45 03 18 457 2 RD0303 6 312666R Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equip ment 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 ZN 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 inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 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 e Head MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to appli cable guidelines e Always wear impervious gloves when spraying or cleaning equipment SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This
8. 45e 45f 256468 Side Seal Housing 256640 Fluid Head Check Valves 256471 1 1 1 Fluid Head 256470 2 1 Air Piston 256472 256469 Hose Manifold Check Valves Bulk O ring Kits The following table indicates the specific o ring s reference number and corresponding kit num ber Each kit includes a quantity of six o rings Reference Number 1b 2b 2C 42d 42e 44e 44f 43d 43e 45e 45f Kit 256469 248648 256773 248132 256774 256772 256775 256467 256468 246354 256771 Includes installation tools and side seal springs 312666R 51 Parts Complete O ring Kit Placement Guide Each o ring in kit 256490 is labeled by the reference number See the table entry for 256490 in O ring Repair Kits on page 51 for the quantity of each 42d 44e 43d 45e eee 3a Check Valve Filter Screen Kits Kits include 10 filter screens The 80 mesh filter screen is standard with gun Part Description 246357 40 mesh 0 015 in 375 micron 246358 60 mesh 0 010 in 238 micron 246359 80 mesh 0 007 in 175 micron 52 312666R Parts Drill Bit Kits For cleaning gun ports and orifices Illustrations are actual size for comparison AL Not all sizes are used with every gun model Qty in Drill Bit Tum nominal in qe ale ill ela i ld aa all o7 Ber p p e p p pe ee p pe ee m p p e ee jaa A ia a B ii ee a mu a p p e o ee p o per pope qe
9. 6416 COVER front flat tip 296385 117661 117773 117792 118665 117510 15B565 15B772 112307 117642 118575 172479 222385 pack of 5 TIP spray KIT clearshot cartridge pack of 25 TOOL cleanout TOOL cleanout TOOL cleanout 69 PIN vise LUBRICANT GUN grease GREASE Fusion 4 oz COUPLER line air 1 4 npt VALVE ball HOSE air 18 in ELBOW street NUT DRIVER SCREW DRIVER 1 8 blade TAG instruction TAG warning Parts Qty i i ee Oe a i i M st o NO SS es ss lll 45 Parts Ref Part 40 256641 41 256642 42 256463 42a 42b 256923 42c 256464 42dv 256467 42ev 256468 43T 256463 43a 43b 256923 43c 256464 43dv 256467 43ev 256468 449 257422 44a 257427 44b 257420 44c 257419 44d 257421 44ev 246354 A4iY 256771 45 257423 45a 25 428 45b 257420 45c 257419 45d 257421 45bev 246354 4bfv 256771 46 256567 478 246360 49 100721 50 117509 46 Description MANIFOLD flush includes 1d 49 and 50 KIT inlet cap includes 1d KIT seal a side assy includes 42a 42e and 43 HOUSING seal side SPRING compression pack of 10 SEAL side includes 42d O RING pack of 6 O RING pack of 6 KIT seal b side assy includes 42 and 43a 43e HOUSING seal side SPRING compression SEAL side includes 43d O RING pack of 6 O RING pack of 6 KIT valve check a side includes 44a 44f HOUSING check valve a side pack of 10 BAL
10. Instructions Parts GG g GRACO TM Fusion CS 312666R EN Plural Component Impingement Mix Air Purge Spray Gun with ClearShot Liquid Technology For professional use only For use with non flammable foam and polyurea Not for use in explosive atmospheres 3500 psi 24 5 MPa 245 bar Maximum Fluid Working Pressure 80 130 psi 0 56 0 9 MPa 5 6 9 0 bar Air Inlet Pressure Range 200 F 94 C Maximum Fluid Temperature Important Safety Instructions e Read all warnings and instructions in this manual Save these instructions See page 4 for model information TI11323a CE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 2 Models Mix Chamber Selection Guide 3 Round Pattern Guns llus 3 Flat Pattern Guns less 4 Wide Round Pattern Gun 5 Warnings Dc 6 Overall View 2 xax Pr REUS d Eat 8 ClearShot Liquid 9 Isocyanate Hazard 9 Moisture Sensitivity of Isocyanates 9 Keep Components A and B Separate 10 Foam Resins with 245 fa Blowing Agents 10 Changing Materials 10 GYOURGING uk IEEE onn Y 11 Piston Safety Lock 11 Remove Front Cover 12 Loss of Air Pressure 12 SEUD nanc 13 ShutdoWln v 23er ERR SEP EL NE NA MUI ERES 15 Pressure Relie
11. L carbide pack of 10 SPRING compression pack of 10 RETAINER ball pack of 10 O RING pack of 6 O RING pack of 6 KIT valve check b side includes 45a 45f HOUSING check valve b side pack of 10 BALL carbide pack of 10 SPRING compression pack of 10 RETAINER ball pack of 10 O RING pack of 6 O RING pack of 6 RETAINER tip O RING PTFE pack of 3 PLUG pipe FITTING air line 1 4 npt Qty ee l ee ee ee ee ee ee ee d A Replacement Danger and Warning labels tags and cards are available at no cost Not shown Wide and round pattern models only 4 Flat pattern models only See tables on page 47 for kit number S Also included in o ring repair kit s see page 51 ClearShot Liquid cartridges also available in packages of 50 and 100 See Accessories page 55 Side seals also available in packages of 2 and 20 See Accessories page 55 ge Also included in Kits FLOOOO0 FLO101 FLO202 and FL2020 Parts included in kit 256461 See Flat Tip Kits page 50 for part number Replacement handles are available in Kit 24W 375 312666R Parts Wide and Round Pattern Models Varying Convert Round Pattern to Flat Pattern Parts Table To convert a round pattern gun to a flat pattern Reference Number gun order the following parts CS00WD Order Kit WD0000 pee bea VACCEDDMON Qty CS01WD Order Kit WD0101 14 FLxxxx CHA
12. MBER mix see Flat 1 CS01WD bond Pattern Mix Chamber Kits CS02WD Order Kit WD0202 page 50 CSO03WD Order KitWD0303 20 256416 COVER front flat tip 1 CS22WD Order Kit WD2222 pack of 5 l CSO1RD Order Kit RD0101 ie 21 FIxxxx TIP spray see Flat Tip Part 1 Reference Guide page 50 EM Order Kit RD0202 46 256567 RETAINER tip CSO3RD Order Kit RDOS03 CS20RD Order Kit RD2020 CSOORD Order Kit RDOOOO Flat Pattern Models Varying Parts Table Convert Flat Pattern to Round Pattern To convert a flat pattern gun to a round pattern Reference Number gun order the following parts Ref Part Description Qty re 14 RDxxxx CHAMBER mix see Round 1 Pattern Mix Chamber Kits pago 49 Miren Caan ine ied MN cm age 49 20 256415 COVER front round tip 1 Order Kit FLO101 pack of 5 csore oero CSOIF3 OmerKtRiUi Order Kit FLO101 DI CSOIFS Orderki Foo Order Kit FLO101 Order Kit FLO202 Order Kit FL0202 Order Kit FLO202 EE CSOpF4 Orderki F022 Order Kit FLO202 RR Order Kit FLO202 CS20F1 Order Kit FL2020 CS20F2 Order Kit FL2020 312666R 47 Parts Detail Views Flat Pattern Detail Supplied Tools a A oe TI3870a 36 Fluid Inlet Cover Detail A T112197a 48 2 Hose Fluid Manifold 1 Detail T112107a Flush Manifold Detail 50 T112108a AN Apply lubricant to seals A Apply sealant to threads 312666
13. Parts Manual English Solvent Flush Kits 309963 Instructions Parts Manual English 256566 Circulation Manifold Kit 313058 Instructions Parts Manual English 256569 TP100 Kit and 256570 Stud Wall Foam Kit 313121 Instructions Parts Manual English 256526 Cleanout Tool Kit 313129 Instructions Parts Manual English 312666R Related Manuals Models Mix Chamber Selection Guide Models Mix Chamber Selection Guide Round Pattern Guns Mix Chamber Impingement Gun Part Port Size Equivalent Seal Series in mm Material SST CS20RD B RD2020 0 020 0 50 008 io 20 Ib min Rp2020 000 WD2222 FLOW RATE in gpm Ipm To calculate flow in Ib min multiply gom rate by 10 Example 2 gpm x 10 500 1000 1500 2000 2500 3000 3500 8 5 35 6 9 69 10 3 103 13 8 138 17 4 172 4 20 7 207 24 1 241 PRESSURE in psi MPa bar Accessory WD wide pattern mix chambers are available See page 49 4 312666R Models Mix Chamber Selection Guide Flat Pattern Guns Gun Part Impingement Equivalent Pattern Size Orifice Size Port Size in mm Size in mm Series in mm CS20F1 B FL2020 0 020 0 50 FT0424 8 10 203 254 0 024 0 61 CS20F2 B FL2020 0 020 0 50 FT0438 8 10 203 254 0 038 0 97 CSOO0F1 B FLOOO0 0 029 0 70 00 FT0424 8 10 203 254 0 024 0 61 CSOO0F2 B FLO000 0 029 0 70 FT0438 8 10 203 254 0 038 0 97 CSOOF3 B FLOOOO C
14. Procedure in the proportioner manual To relieve pressure in the hose manifold after the Jj TI11327a gun is removed place the fluid manifold over Fic 18 containers facing away from you Ensure fluid valves are closed Very slowly open fluid mani fold check valves 2 to 2 1 2 turn Under high 3 Disengage piston safety lock page 12 pressure fluid will spray sideways from the fluid ports 312666R 17 Optional Hose Position Optional Hose Position Fluid inlet swivel fittings point to rear If 4 Apply thread sealant to plugs 16 elbows desired these positions can be changed so 35 and male threads of fluid valve hoses point downward assemblies Install elbows 35 in optional inlets facing down Install fluid valve assemblies in elbows Be sure to install A ae l fluid assembly in A side Install plugs where To prevent cross contamination of gun s wet swivels had been Torque all parts to ted parts do not interchange A component 235 245 in lb 26 6 27 7 Nem isocyanate and B component resin parts 1 Follow Pressure Relief Procedure page 17 Also relieve system pressure see pro portioner manual 2 Disconnect air D and remove fluid mani fold M T112085a FiG 23 5 Connect A and B hoses to A and B swivels 6 Attach fluid manifold Connect air Return gun to service TI11330a Fic 21 3 Disconnect fluid hoses from inlet swivels A B Remove f
15. R Parts Mix Chamber Kits Round Pattern Mix Chamber Kits Mix Pattern Nozzle Impinge Chamber Diameter at 24 Drill Bit ment Port Counter Kit in 609 6 mm Nozzle Size Impinge Drill Bit Counter bore Drill Bit includes to target in Orifice in mm ment Port Size in bore Size Size drill bits mm Size Size mm in mm RD2020 127 0 042 58 0 020 76 0 50 0 060 53 1 50 1 00 5 00 RD0000 8 203 0 052 55 0 029 69 0 70 0 060 53 1 50 1 30 RDO101 11 279 0 060 53 0 042 58 1 00 N A N A 1 50 RD0202 12 305 0 070 50 0 052 55 1 30 N A N A 1 75 RD0303 14 356 0 086 0 060 53 1 50 N A N A 2 15 Wide Pattern Mix Chamber Kits Kits include mix chamber and cleanout drills To spray larger diameter patterns than standard mix chambers Pattern Diameter at 24 in 609 6 mm Equivalent flow to Nozzle Drill Bit Size Impingement Drill Bit Size to target in mm mix chamber size in mm WD2222 8 203 2 0 047 1 20 74 0 022 0 56 203 2 WDO0000 15 381 0 Ref RD0000 1 16 0 062 1 59 70 0 028 0 71 6 406 4 WD0101 16 406 4 Ref RDO101 50 0 070 1 78 61 0 039 0 99 WD0202 18 457 2 Ref RDO202 0 085 2 15 56 0 046 1 17 WD0303 18 457 2 Ref RD0303 42 0 089 2 26 1 45 mm 0 057 1 45 312666R 49 Parts Flat Pattern Mix Chamber Kits Mix Impinge Chamber Kit Nozzle ment Port Counter
16. Relief Procedure page 17 For a more thorough flush a solvent flush kit 256510 248229 is available as an accessory 26 Clean Outside of Gun Wipe off outside of gun with compatible sol vent Use N Methylpyrrolidone NMP Dyna solve CU 6 Dzolv or an equivalent to soften cured material CAUTION These solvents are not recommended for flushing use only for cleaning Clean or Replace Front Cover and Retainer Soak front cover retainer C and front cover U in compatible solvent Brush or wipe clean Replace as needed Clean Breather Plug Remove and clean breather plug with compati ble solvent 312666R Clean Fluid Manifold Clean fluid manifold fluid ports with compatible solvent and brush whenever removed from gun Do not damage the internal sealing sur faces Fill fluid ports with grease if left exposed to seal out moisture Fluid Ports TI12089a FiG 36 Clean or Replace Fluid Screens 1 Follow Pressure Relief Procedure page 17 2 Relieve pressure in hose manifold after gun is removed a Place the fluid manifold over containers facing away from you b Ensure fluid valves are closed c Very slowly open fluid manifold check valves 2 to 2 1 2 turn Under high pres sure fluid will spray sideways from the fluid ports T111337a FIG 37 312666R Maintenance 3 Remove fluid screens by unthreading them from fluid manifold CAUTION To prevent cross cont
17. SOOFA B FLOOOO 0 029 0 70 CSOOF5 B FLOOOO CSOOF6 B FLOOOO 0 029 0 70 0 029 0 70 0 029 0 70 FT0624 12 14 305 356 0 024 0 61 FT0638 12 14 305 356 000 FT0838 16 18 406 457 FT0848 16 18 406 457 0 038 0 038 0 048 0 97 0 97 1 22 0 042 1 00 0 042 1 00 0 042 1 00 0 042 1 00 E AN E oe NL NEL NN EE ON 0024 6 0096 37 0024 65 0096 097 16 18 406 457 0 048 1 22 0 024 0 61 0 038 0 97 0 038 0 97 0 048 1 22 CS02F3 B FLO202 0 052 1 30 FT0624 12 14 305 356 CS02F4 B FLO202 0 052 1 30 FTO638 12 14 305 356 CSO2F5 B FLO202 0 052 1 30 FTO838 16 18 406 457 CS02F6 B FLO202 0 052 1 30 FTO848 16 18 406 457 312666R 5 Models Mix Chamber Selection Guide o a D S t Q nm c D E EE D c2 EQ 2 I E ce t x cC Pt 51 2020 with ETXX24 tip S 265 oO 3 Q o5 e x x LL 500 1000 1500 2000 2500 3000 3500 3 5 35 6 9 69 10 3 103 13 8 138 17 4 172 4 20 7 207 24 1 241 PRESSURE in psi MPa bar Wide Round Pattern Gun Mix Chamber Impingement Pattern Diameter at 24 in 610 mm to Equivalent Flow to Gun Part Pm Port Size Equivalent i et ur Chamber Size Series in mm Reference Part No 8 9 203 229 4 5 Ib min at 1000 psi 9 CSO0WD B WDO0OOO 0 028 0 71 15 381 0 RD0000 16 406 4 CSO1WD B WDO101 0 039 0 99 406
18. allation 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 l
19. amage 8 312666R Overall View FiG 1 Key Uzzr ITIQOTnmuoocou A Side Fluid Valve ISO B Side Fluid Valve RESIN not shown Front Cover Retainer Air Line Quick Coupler Breather Plug Fluid Housing under cover Grease Fitting under cover Handle Piston Safety Lock Flow Selector Knob Gun Fluid Manifold Mix Chamber Nozzle Optional Fluid Inlets A Side Shown 312666R R o T U V W X Y Overall View ell J F A Y o n ud ACK yp A S A Neem TI11324a ClearShot Liquid Cartridge Fluid Inlet Swivels A Side Shown Trigger Front Cover Gun Air Whip Hose Air Valve Variable Flow Adjustment Knob Manifold Check Valve Inlet Screen Housing ClearShot Liquid ClearShot Liquid A me Read material MSDS to know specific haz ards and precautions related to ClearShot Liquid Isocyanate Hazard P uu ANE e opraying materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Head 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 provid ing sufficient ventilation in the work area If sufficient ventilation is not available a sup plied air respirator is required for everyone in the work area To prevent conta
20. amination of the check valves do not interchange A component and B component parts The A component check valve is marked with an A 4 Clean or replace fluid screens See Acces sories page 55 5 Carefully inspect o rings and fluid screen surfaces Replace if worn or damaged 6 Liberally lubricate o rings and reassemble Use a hex nut driver to tighten Adjust Fluid Valve Packings Periodic adjustment may be necessary to stop fluid leakage If fluid valve is leaking adjust the packings 1 Follow Pressure Relief Procedure page 17 2 Loosen set screw and remove valve han dle 3 Turn valve packing nut clockwise in 1 8 turn increments until leak is corrected 4 Re pressurize system then check for leaks Repeat procedure as necessary FIG 38 27 Maintenance Clean Mix Chamber Nozzle 2 Refer to Table 1 Also see identification chart under Drill Bit Kits page 53 Use 1 Engage piston safety lock page 12 appropriate size drill bit to clean mix cham ber nozzle N T111326a 1112090a FIG pipe COC en Table 1 Nozzle Drill Bit Sizes Round Spray Flat Spray Mix Drill Size Mix Drill Size Chamber in mm Chamber in mm RD2020 58 042 FL2020 3 32 094 1 00 2 35 RDOOOO 55 052 FLOOOO 3 82 094 1 30 2 35 RDO101 53 060 FLO101 3 32 094 1 50 2 35 RDO202 50 070 FLO202 3 32 094 1 75 2 35 RDO303 44 086 2 15 28 3
21. ays lubricate threaded parts with Part 217374 ISO pump oil or grease when reas sembling 312666R Keep Components A and B Separate CAUTION To prevent cross contamination of the equip ment s wetted parts never interchange com ponent 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 Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at tempera tures above 90 F 33 C when not under pres sure especially if agitated To reduce frothing minimize preheating in a circulation system 312666R Keep Components A and B Separate Changing Materials When changing materials flush the equip ment multiple times to ensure it is thor oughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side e Epoxies often have amines on the B hard ener side Polyureas often have amines on the B resin side 11 Grounding Grounding Disengage To disengage piston safety lock push knob in W and turn counterclockwise until it pops out There will be a gap between knob and gun body Check your local electrical code and propor tioner manual for detailed g
22. ct with isocyanates appro priate personal protective equipment includ ing chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area 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 perfor mance and the life of all wetted parts The amount of film formation and rate of o crystallization varies depending on the blend of ISO the humidity and the tem perature To prevent exposing ISO to moisture e Always use a sealed container with a des iccant dryer in the vent or a nitrogen atmo sphere Never store ISO in an open container e Keep the ISO lube pump reservoir filled with Graco Throat Seal Liquid TSL Part 206995 The lubricant creates a barrier between the ISO and the atmosphere e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent con tainers closed when not in use e Never use solvent on one side if it has been contaminated from the other side e Always park pumps when you shutdown e Alw
23. d manifold check valves TI11337a FiG 8 4 Engage piston safety lock page 12 5 Install ClearShot Liquid cartridge See ClearShot Liquid Cartridge Installa tion Removal page 23 6 Connect gun air whip hose V air valve W to main air hose Assemble fluid manifold M to gun by hand and then tighten bolt 7 Connect air line to quick coupler D Turn on air Open air valve W Air should flow from nozzle N RA ARS N 8 Spy w M D TI11331a FiG 9 8 Apply layer of lubricant over front cover of gun and front cover retainer or use gun cover to prevent overspray buildup and ease disassembly 312666R 9 Disengage piston safety lock page 12 T112240a FiG 10 10 Trigger gun to check for full mix chamber travel and to prime ClearShot Liquid dosing pump See ClearShot Liquid Cartridge Installation Removal page 23 11 Engage piston safety lock page 12 Fic 11 12 Turn on proportioner 13 Open B RESIN fluid valve Then open A ISO fluid valve Lack t SA z 9 Ai iby Ao 2 x T1113338a Fic 12 312666R Setup 14 Disengage piston safety lock page 12 TI12240a FiG 13 15 Test spray onto cardboard Adjust pressure and temperature to get desired results TI11334a Fic 14 16 The gun is now ready to spray CAUTION Air supply is required for gun actuation Do not disconnect gun air supply until fluid pres
24. eck valves 44 45 6 Disassemble check valves using a flat head screwdriver 44e E FiG 58 CAUTION Damaged check valve o rings 44e 44f may result in external leakage Replace o rings if they are damaged 7 Clean and inspect all parts Thoroughly inspect o rings 44e 44f Press on ball 44b to test check valve for proper move ment and spring action Replace individual check valve parts as needed T 12099a FiG 59 41 Repair 8 Liberally lubricate o rings 44e 44f and 5 Push piston shaft to remove piston 4b carefully reinstall in fluid housing F Use Inspect piston o ring 4c and shaft o rings hex nut driver to tighten 4a 9 Attach fluid manifold M Connect air D Return gun to service Piston 1 Follow Pressure Relief Procedure page 17 2 Disconnect air D and remove fluid mani fold M Fic 62 T112101a 6 Remove dosing piston a Use supplied screw driver to remove spiral retaining ring 49 b Use screw driver to push dosing piston 4e out back of piston 4b through access hole on front side 7 Clean and inspect o rings on dosing piston 4e Clean dosing bore in piston 4b with a nylon brush and compatible solvent TI11330a Fic 60 8 Lubricate dosing piston 46e o rings with 3 Remove Front End page 36 ClearShot Liquid prior to reassembly 9 Liberally lubricate piston o ring 4c and 4 Unscrew variable flow adjustmen
25. ed by mix cham ber size and a user defined reduced flow pattern Safety Stop Flow Selector Knob Variable Flow Adjustment Knob FIG 26 BW 12240a Reduced Flow To spray a reduced flow pattern push in and turn flow selector knob to variable flow posi tion See FIG 27 Full Flow To return to a full flow pattern push in and turn flow selector knob to full flow position See FIG 27 20 Change Variable Flow Adjustment Knob 1 Turn air valve W OFF 2 Turn flow selector knob to variable flow position See FIG 27 OFF Safety Stop Flow Selector Knob Full Flow Variable Flow Adjustment Knob Variable Flow T111345a FIG 27 312666R 3 To increase variable flow push in and turn variable flow knob counterclockwise To decrease variable flow push in and turn variable flow knob clockwise Variable Flow Adjustment Knob TI11344a FiG 28 Ag The variable flow adjustment knob cannot be adjusted when the flow selector knob is in the safety stop position See FIG 27 The variable flow adjustment knob locks into detents every 15 Ensure knob is locked into a detent before proceeding to step 5 312666R Variable Flow 4 Turn air valve ON and open fluid valves Verify that flow selector knob is set to the variable flow position See FIG 27 5 Test spray pattern on cardboard Repeat steps 1 through 6 until desired spray pat tern is reached TI11334a F
26. epmp 0 312666R 53 Parts Qty in Cj Bit Ear Kit C Kai p 246815 2 6984 ind 023 id LLL r e m emos 246816 246817 ClearShot Handle Cleanout Drill Kit 256526 Kit includes all 7 drill bits of extra length needed to clean out all air passages in the Fusion CS gun handle and fluid housing See Clean Passages page 29 54 312666R Accessories Stainless Steel Side Seal Kit Kit 256464 includes 2 stainless steel side seals and 2 o rings Polycarballoy Side Seal Kits Kits include a packing o ring for each polycar balloy side seal The optional high wear non metallic polycarballoy seals are for alter nate fluids Number of Seals Per Kit SEAL KIT SEAL KIT Flat Pattern Stud Wall Kits Use to spray wall insulation foam into stud walls with a single pass Description Description 256569 Includes TP100 256570 Includes FTM979 Gun Cover 244914 Covers Keeps gun clean while spraying Pack of 10 Lubricant for Gun Rebuild 248279 4 oz 113 gram 10 High adhesion water resistant lithium based lubricant MSDS sheet available at www graco com 312666R Accessories Grease Cartridge for Gun Shutdown 248280 Cartridge 3 oz 10 Specially formulated low visco
27. f Procedure 16 Optional Hose Position 17 Flat Spray TIDS 2E mE ERELER IS 18 Variable FIOW Juro P a ated C 19 Gier TCI 19 Change Variable Flow Adjustment Knob 19 ClearShot Liquid Cartridge Installation Removal 22 Iristallallohi i33 a aid ie a E REDIERE eda 22 Removal iut ta cach CS Bee Med a o AR Oe hee 23 Troubleshooting 000 eee eee 23 Maintenance uie wat gs dea attire Da 24 Supplied Tool Kit 0 0 2 eee 24 Keep Gun Clean ee eee 24 AS Needed elation a do Rc ee ICE RODA 24 PE CLP 24 Weekly to Monthly 0005 24 FIUSDOUD due d ira dea READER a D RAD DU eio 25 Clean Outside of Gun lusu 25 Clean or Replace Front Cover and Retainer 25 Clean Breather Plug lsss 25 Clean Fluid Manifold 26 Adjust Fluid Valve Packings 26 Clean Mix Chamber Nozzle 27 Clean Passages ll 28 Clean Impingement Ports 28 Troubleshooting 30 Theory of Operation 33 Cutaway View eee 34 PROD OIG uiu netu i qu d od Mc dg d e fA e e 35 Tools Hequiled 2 3 2 55 7723 ERE eas 35 Lubricatlofi 5 x x TRECE ie ee e 35 Remove FIOBnbEnDO eddaeua diee ee Ca Ot 35 Attach Front End 000 36 Mix Chamber and Side Seal Assemblies 97 Check Valves um aao dope nie acere be s
28. iG 29 21 Variable Flow 22 312666R ClearShot Liquid Cartridge Installation Removal ClearShot Liquid Cartridge Installation Removal 3 Insert cartridge into gun handle Ensure cartridge tabs are aligned correctly with cartridge tab recesses in gun handle If ClearShot Liquid cartridge removal or installation is difficult lubricate cartridge o rings and or cartridge bore with a few drops of ClearShot Liquid Water based lubricants can be used as well Do not use Fusion grease or other petro leum or vegetable based lubricants They will cause cartridge o rings to swell and stick inside gun handle TI113341a FIG 31 Installation 4 After cartridge is fully inserted turn car 1 Follow Pressure Relief Procedure page tridge 1 4 turn clockwise to lock it into gun 17 handle 2 Remove plastic cap from new ClearShot Liquid cartridge Sed Lata ES W 311133420 FIG 32 Bones 5 Turn air valve ON and prime ClearShot Liq Fic 30 uid dosing pump a Trigger gun 20 times to prime dosing pump b Trigger gun onto cardboard to see dosed ClearShot Liquid 6 Resume spraying 312666R 23 ClearShot Liquid Cartridge Installation Removal Removal 1 Follow Pressure Relief Procedure page 17 2 Turn air valve W OFF 3 Push in and turn cartridge 1 4 turn counter clockwise viewed from bottom TI11338a FiG 33 4 Pull cartridge out of gun handle TI11339a FiG 34 24 Trouble
29. il 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 e Do not operate the unit when fatigued or under the influence of drugs or alcohol e 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 Tech nical Data in all equipment manuals Read fluid and solvent manufacturer s warn ings For complete information about your material request MSDS forms from distributor or retailer 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 Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property d
30. includes Nozzle Drill Bit Impinge Drill Bit bore Drill drill bits and RU Orifice Size ment Port Size in Counter Bit Size O ong AMEN i Size in mm Size mm bore Size in aon FL2020 246360 0 094 3 32 0 020 76 0 50 0 060 53 1 50 1 50 2 35 FLOOO00 246360 0 094 3 32 0 029 69 0 70 0 060 53 1 50 2 35 FLO101 246360 0 094 3 32 0 042 58 1 00 N A N A 2 35 FLO202 246360 0 094 3 32 0 052 55 1 30 N A N A 2 35 1 Available only in flat mix chamber kits or in 246360 multi pack kit Mix Chamber Part Reference Flat Tip Kits Guide Flat Sample part RDO101 Pattern Model Pattern Size in pnaternsize mm n CSxxF1 FTO424 low flow 8 10 203 254 flow 8 10 203 254 CSxxF2 FT0438 medium flow 8 10 203 254 CSxxF3 FTO624 low flow 12 14 305 356 CSxxF4 FT0638 medium flow 12 14 305 356 CSxxF5 FT0838 medium flow 16 18 406 457 CSxxF6 FT0848 high flow 16 18 406 457 Flat Tip Part Reference Guide Sample part FT0848 ii o 49 FT Flat tip x2 pattern Equivalent orifice RD round pattern A orifice B orifice size 0 042 size 0 042 FL flat pattern in in WD wide pattern length diameter size 8x2 16 in 048 in 50 312666R Parts O ring Repair Kits The following table indicates the specific o ring s reference number and quantity included in each o ring kit Reference Number 1b 2b 42d 42e 44e 44f 43d 43e
31. ite de ou en rapport directement ou indirectement avec les proc dures concern es 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 For patent information see www graco com patents Original instructions This manual contains English MM 312666 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2008 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Hevised January 2015
32. luid valve assemblies Remove plugs from optional inlets P T111329a 18 312666R Flat Spray Tips 1 Follow Pressure Relief Procedure page 17 2 Unscrew and remove front cover retainer C 3 Remove front cover U and o ring 2b Inspect o ring 4 Remove tip retainer 46 and tip 21 Inspect o ring 47 5 Remove fluid housing F Loosen A and B side seals Slide flat mix chamber 14 out rear of fluid housing gg 46 F U T112087a FiG 24 us If tip is stuck pry off with small screwdriver or pull off with pliers Tip is hardened to resist damage 6 Toclean soak tip in compatible solvent Clean gently with tip cleanout tool 15D234 page 56 for details of tool 7 Reassemble in reverse order a Insert mix chamber 14 from rear of fluid housing b Tighten A and B side seals on fluid housing 312666R Flat Spray Tips c Assemble o ring 47 tip 21 and tip retainer 46 to front of mix chamber 14 8 Reposition tip horizontally or vertically or install different tip size T112088a TI2648a FiG 25 Ag iPS marked on back with last three digits of part number See Flat Tip Kits page 50 9 Reinstall fluid housing F to handle 10 Reinstall front cover U and front cover retainer C 19 Variable Flow Variable Flow Operation Aw The variable flow feature is designed to provide immediate adjustment between a full flow pattern determin
33. ly to gun Regulate air supply to gun ing producing less than 1000 Excessive air pressure at gun Regulate air supply to 80 psi 0 56 doses per cartridge MPa 5 6 bar Damaged or dirty o rings on air Repair or clean o rings See Pis piston and or dosing piston ton page 42 ClearShot Liquid cartridge instal Friction between cartridge o rings Lubricate cartridge o rings and or lation or removal is difficult and cartridge bore cartridge bore with a few drops of ClearShot Liquid See page 22 ClearShot Liquid cartridge is Cartridge is empty Temporary Engage piston safety lock and pressure locked in cartridge bore cartridge pressure lock trigger gun 20 times to bleed pressure in cartridge See Clear Shot Liquid Cartridge Installa tion Removal page 23 312666R 33 Theory of Operation Theory of Operation Gun Triggered Fluid Spraying Mix chamber 14 moves back shutting off purge air flow Impingement ports IP align with fluid ports of side seals 42 43 allowing fluid to flow through mix chamber nozzle N NN paths are not shown to scale for clarity CSL is dosed into purge air T112123a 1 34 Gun Detriggered Air Purging Mix chamber 14 moves forward shutting off fluid flow Impingement ports IP open to air chamber AC allowing purge air to flow through mix chamber nozzle N See Shutdown page 16 for use of grease fit ting G Flow paths are not shown
34. o ring 2b or 2c Damaged front o ring 2b Replace See Parts page 44 Reduced cleanoff air Damaged fluid housing o ring Replace See Parts page 44 2d Excessive purge air when fluid Damaged missing fluid housing Replace See Parts page 44 valves are closed and gun is o ring 2c de triggered Fluid does not shut off when fluid Damaged fluid valves 1b Replace See Parts page 44 valves are closed Burst of air from muffler when gun Normal No action required is triggered 32 312666R Troubleshooting Steady air leakage from muffle Air leak between handle and fluid Damaged o ring 2c or 2d Replace See Parts page 44 housing Cannot tighten front cover retainer Installing round mix chamber front Inspect front cover for flat tips 20 until it bottoms out cover on a flat tip gun 256416 and for round tips 256414 Gun does not dose ClearShot Liq Empty ClearShot Liquid cartridge Replace See ClearShot Liquid Cartridge Installation Removal page 23 ClearShot Liquid dosing pump is Prime dosing pump See Clear not primed Shot Liquid Cartridge Installa tion Removal page 23 Damaged cartridge o rings Replace See ClearShot Liquid Cartridge Installation Removal page 23 Damaged or cracked cartridge Replace See ClearShot Liquid Cartridge Installation Removal page 23 Damaged dosing piston Repair See Piston page 42 Excessive ClearShot Liquid dos Non regulated air supp
35. ost 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 redaction du presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires executes donn s ou intent s la su
36. page 38 Loss of round pattern Dirty mix chamber 14 nozzle Clean Mix Chamber Nozzle page 28 Empty ClearShot Liquid cartridge Replace See ClearShot Liquid Cartridge Installation Removal page 23 ClearShot Liquid dosing pump is Prime dosing pump See Clear not primed Shot Liquid Cartridge Installa tion Removal page 23 Loss of flat pattern Plugged spray tip Clean in compatible solvent page 19 Empty ClearShot Liquid cartridge Replace See ClearShot Liquid Cartridge Installation Removal page 23 Dirty mix chamber 14 nozzle Clean Mix Chamber Nozzle page 28 312666R 31 Troubleshooting PROBLEM CAUSE SOLUTION Leakage between flat tip and mix Tip not seated properly Heassemble See Flat Spray chamber Tips page 19 Damaged missing o ring 47 Heplace See Flat Spray Tips page 19 29 41 sate Fluid Screens page 27 Side Seal Assemblies page 38 Side Seal Assemblies page 38 Damaged side seal o rings 42d 42e Side Seal Assemblies page 38 Tightened flat tip retainer with fluid valves 1b open Fluid mist from mix chamber Damaged side seals 42 43 Side Seal Assemblies page 38 Damaged side seal o rings 42d 42e Side Seal Assemblies page 38 Side Seal Assemblies page 38 Rapid buildup of material on air Plugged front cover holes Clean or Replace Front Cover cap and Retainer page 26 Damaged missing fluid housing Replace See Parts page 44
37. rounding instruc tions Ground the spray gun through connection to a Graco approved grounded fluid supply hose Disengaged Piston Safety Lock ri2240a FiG 3 Engage piston safety lock whenever you stop spraying to avoid accidental triggering We Engage To engage piston safety lock push knob in and turn clockwise If engaged gun will not actuate FIG 2 12 312666R Remove Front Cover We 1 Follow Pressure Relief Procedure page 17 2 Ensure fluid valves A and B are closed before turning front cover retainer C L AA AOL ee XLI LM Ore S o TI11327a Fic 4 312666R Remove Front Cover Loss of Air Pressure In event of loss of air pressure gun will con tinue to spray To shut off gun do one of the following e Push in piston safety lock see page 12 e Close fluid valves A and B S B e ie CLA AN A N A 4 Eh TH 1327a FIG 5 13 Setup Setup 1 Close fluid valves A and B TI11328a FiG 6 2 Connect A ISO and B RESIN fluid hoses to fluid manifold TI11329a FiG 7 3 Purge air from fluid lines using feed pump pressure only less than 500 psi 3 5 MPa 35 bar a Ensure fluid valves are closed Open fluid manifold check valves 2 to 2 1 2 turns b Open fluid valves and wait for all air to bleed from fluid hoses c Close fluid valves and retighten flui
38. shooting For ClearShot Liquid cartridge troubleshooting see Troubleshooting on page 31 312666R Maintenance Supplied Tool Kit e Hex Nut Driver 5 16 e Screwdriver 1 8 blade e Nozzle Drill Bit various sizes depending on nozzle size See Table 1 e Impingement Port Drill Bit various sizes depending on port size See Table 3 e 117661 Pin Vise dual reversible chucks Reversible Reversible TI3684a FiG 35 e 117792 Grease Gun with 3 oz grease e 15B817 Flush Manifold Keep Gun Clean Keep gun clean with accessory gun cover page 55 Applying a light coat of lubricant will make cleaning easier 312666R Maintenance As Needed 1 Pe w e Clean Outside of Gun page 26 Clean Mix Chamber Nozzle page 28 a minimum of once a day Clean Breather Plug page 26 Clean Fluid Manifold page 27 Clean Passages page 29 Clean Impingement Ports page 29 Adjust Fluid Valve Packings page 27 Daily Follow Shutdown page 16 Weekly to Monthly 1 Clean Mix Chamber and Side Seal Assemblies page 38 Check o rings Clean Check Valves page 41 Check o rings and filters 25 Maintenance Flush Gun WN wi 1 Follow Pressure Relief Procedure page 17 2 Flush with compatible solvent into a grounded metal pail holding a metal part of fluid manifold firmly to side of pail Use low est possible fluid pressure when flushing 3 Follow Pressure
39. side seal and that the seal 42c rotates slightly in the assemblies 42 43 Use hex nut driver to seal housing 42a detents tighten When the seal is installed correctly the spring will be flexible and all four cross holes of the seal will be completely visible See FiG 54 for an example of the correct and incorrect seal installation Correct Seal Installation Cross Hole 42 T112096b FIG 55 14 Attach Front End page 37 15 Connect air and trigger the gun a few times to check for leaks If purge air leaks T112639a from mix chamber nozzle when gun is trig gered inspect mix chamber and side seals Incorrect Seal Installation Correct the problem before attaching fluid manifold Cross Hole 16 Attach fluid manifold F Connect air Return gun to service T 12640a FiG 54 40 312666R Check Valves 1 Follow Pressure Relief Procedure page 17 2 Remove fluid manifold M Leave air con nected Clean Fluid Manifold page 27 Li a a Ai MUT m ET CHIC Y APA rw m JU TI12095a FiG 56 3 Flush gun to remove residual A and B com ponents See Flush Gun page 26 Follow Pressure Relief Procedure page 17 4 Disconnect air D TI12086a FiG 57 CAUTION 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 312666R Repair 5 Use hex nut driver to remove ch
40. sity grease flows easily through gun passages to prevent two component curing and keep fluid pas sages clean Flushing Manifold 256641 Manifold Block See page 48 Fluid Inlet Cover Kit 256642 includes 15R910 and 15B221 See page 48 Gun Cleaning Kit 15D546 Kit includes 11 tools and brushes to clean the gun ClearShot Liquid Cartridges See MSDO6O Description 256385 Package of 25 cartridges 256386 Package of 50 cartridges 256387 Package of 100 cartridges 55 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 TI12110a 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 TI12111a Tip Cleanout Tool 15D234 Designed to fit CeramTip internal dome and flat tip slits End for Mechanical End for Air Purge Tips Purge Tips DA CA T14244a 56 Circulation Manifold 256566 Attach to gun fluid manifold to enable preheat ing of hose See manual 313058 T112109a Fusion AP Manifold Adapter 258996 Allows Fusion CS gun to fit onto existing Fusion manifold ti18633a 312666R Technical Data Technical Data Category Data Maximum Fluid Working Pressure 3500 psi 24 5 MPa 245 bar Minimum Air Inlet Pressure 80 psi 0 56 MPa 5 6 bar
41. t 40 PISIONS esu cis eho TETTE 41 Pl VN gt acest sans ts aoa hiv ee Pea ndi ee sodas ass 42 Pars us Du appa ade Se meee Ue eee 43 Mix Chamber Kits 1214 e mu dt Porter res 48 FIaETID TONG vestir etes P LRSSURP ESSE ES 49 O ring Repair Kits 0 000 eee 50 Check Valve Filter Screen Kits 51 Drill Bit Kits lh 52 Accessories 6 4 6tecen o whit Eae Ed eae ele ee eee 54 Stainless Steel Side Seal Kit 54 Polycarballoy Side Seal Kits 54 Flat Pattern Stud Wall Kits 54 GUI GOVERN 2x aote Hehe ees Not ea Bees 54 Lubricant for Gun Rebuild 54 Grease Cartridge for Gun Shutdown 54 Flushing Manifold LL 54 Fluid Inlet Cover aas tu irestacm annann ennan 54 Gun Cleaning Kit 0 00 ee eee 54 ClearShot Liquid Cartridges 54 Solvent Flush Canister Kit 55 Solvent Flush Pail Kit 55 Tip Cleanout Tool 000008 55 Circulation Manifold sess 55 Fusion AP Manifold Adapter 55 Technical Dalai oii i vx REY oo ew eis 56 Graco Standard Warranty 57 Graco Information es 57 312666H Related Manuals The following manuals are for accessories used with the Fusion CS spray gun Visit www graco com for the most current manual revisions Power Lock Heated Hose 309572 Instructions
42. t interchange A compo nent and B component parts The A compo nent assembly is marked with an A 6 Use hex nut driver to remove side seal assemblies 42 43 G TI12096b FiG 51 7 Push on front of mix chamber 14 to loosen Pull mix chamber out rear of fluid housing F Inspect for damage and Clean Impingement Ports page 29 CAUTION To prevent cross contamination of the gun s wetted parts mix chamber is marked with an A and a notch on back edge Be sure the A side of mix chamber is on the A side of gun 312666R 8 Apply thin coat of lubricant to mix chamber 14 Install mix chamber Etched A and notch must be on same side as A on fluid housing Mix chamber is keyed to fit in fluid housing TI12097b FiG 52 CAUTION To prevent cross contamination of side seal assemblies do not interchange A compo nent and B component parts The A compo nent assembly is marked with an A 9 Push down on seal housing 42a and turn SO side seal detents unlock and remove 10 Carefully inspect side seal assembly o rings and surfaces Replace worn or damaged parts Liberally lubricate o rings 42d 42e and reassemble 312666R Repair 11 Line up tabs on seal 42c and seal housing 42a insert seal into housing Push down on seal and turn to lock in place Line up tabs 42a TI12098b FiG 53 39 Repair 12 Check for proper spring 42b operation 13 Liberally lubricate and reinstall
43. t knob X lightly lubricate shaft o rings 4a and inspect o ring 3a 10 Reinstall retaining ring 4g Press it into groove of dosing piston 4e TI12100a FiG 61 42 312666R 11 Reinstall piston Shaft is keyed for proper assembly Push firmly to seat piston T112102a FIG 63 12 Install variable flow adjustment knob X TI12100a Fic 64 13 Attach Front End page 37 14 Attach fluid manifold M 15 Install ClearShot Liquid cartridge See ClearShot Liquid Cartridge Installa tion Removal page 23 16 Connect air Return gun to service Air Valve 1 Follow Pressure Relief Procedure page 17 312666R Repair 2 Disconnect air D and remove fluid mani fold M TI11330a FIG 65 3 Unscrew air valve plug 13 and remove spring 16 Using a small diameter tool push spool 17 out from front Inspect all five o rings 15 TI12103a FiG 66 4 Liberally lubricate o rings and reassemble Torque plug 13 to 25 135 in Ib 14 15 Nem 5 Attach fluid manifold M Connect air D Return gun to service 43 Parts N Apply light coating of Fusion grease 31 EN Apply sealant to threads A Torque to 20 30 in Ib 2 3 3 4 Nem A Torque to 35 40 in Ib 4 0 4 5 Nem TI12104a 34 1 see page 48 for details E N 3b Variable Flow Adjuster 3 Detail r 256366 312666 T112105a 44 312666R Parts Ref 1b 2a 2bv OCA 2d 2f
44. tainer C 5 Remove front cover U T112092a FiG 43 6 Turn fluid housing F 1 4 turn counter clockwise to disengage slots Remove fluid housing T112093a FIG 44 7 Inspect fluid housing o rings for wear or damage Replace if necessary 312666R Attach Front End Ine Proper attachment of front end is critical Do not operate gun if front end is loose or not snug against handle 1 Engage piston safety lock page 12 TI11326a FiG 45 2 Liberally lubricate o rings 2c 2d and reas semble on fluid housing Insert keyed end of mix chamber 14 in socket of piston assembly 4 1H2129a FiG 46 3 Push fluid housing F flush to handle 312666R Repair 4 Turn fluid housing 1 4 turn clockwise to engage slots TI12094a Fic 47 5 Replace front cover U 6 Screw on front cover retainer C T112092a 37 Repair Mix Chamber and Side Seal Assemblies See Models Mix Chamber Selection Guide page 4 for available mix chamber sizes 1 Follow Pressure Relief Procedure page 17 2 Remove fluid manifold M Leave air con nected TI12095a FiG 49 3 Flush gun to remove residual A and B com ponents See Flush Gun page 26 Follow Pressure Relief Procedure page 17 4 Disconnect air D TI12086a FiG 50 38 5 Remove Front End page 36 CAUTION To prevent cross contamination of side seal assemblies do no
45. to scale for Clarity CSL is dosed into purge air s Fluid nnn n nnn dn Grease T112124a 312666R Theory of Operation Cutaway View 3 4 Piston Assy see page 44 2 Fluid Housing Assy see page 44 14 _ 19 st 2 7 20 s ap s m 2 agal l Sna a TZ SEA oF ap AC et D t a i w E irr eT D D E E RIN K APAN OG Dj d a AW SC S E MA 1 Hose Manifold Assy see page 48 TI12091a 312666R 35 Repair Repair Tools Required Tools required to complete gun repair proce dures e adjustable wrench e flat head screwdriver included e 5 16 hex nut driver included Lubrication See page 55 to order lubricant Liberally lubri cate all o rings seals and threads Do not lubricate o ring seals and threads on ClearShot Liquid cartridge Remove Front End NY Proper attachment of front end is critical Do not operate gun if front end is loose or not snug against handle 1 Follow Pressure Relief Procedure page page 17 2 Flush Gun page 26 CAUTION If front cover retainer C and front cover U are stuck due to material buildup do not force it by turning entire front end Soak front of gun in solvent to soften cured material and free front cover and front cover retainer 3 Use hex nut driver to remove fluid manifold M 36 4 Unscrew and remove front cover re
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