EnergyComplete Spray Gun

Instructions & Parts r_256998_313294_10b US Patent Number 7,036,171 Korean Patent 338185 Australian Patent Number 152610 2004230905 EP 1610904 EnergyComplete Spray Gun Manual No: 313294H For use with EnergyComplete Air Infiltration Barrier with Flexible Seal Technology. Not for use in explosive atmospheres or with flammable materials. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 256998 EnergyComplete Spray Gun with Static Mixer Assembly 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

Contents Warnings................................. 3 Overall View............................... 5 Keep A and B Components Separate.......... 6 Grounding................................ 6 Piston Safety Lock (Trigger Lock).......................... 7 Loss of Air Pressure........................ 7 Setup..................................... 8 Shutdown................................. 9 Pressure Relief Procedure.................. 10 Optional Configurations.................... 11 Optional Fluid Manifold Position............ 11 Optional Hose Position................... 12 Maintenance.............................. 13 Supplied Tool Kit........................ 13 Compatible Solvents..................... 13 Keep Gun Clean........................ 13 As Needed............................ 13 Daily................................. 13 Weekly to Monthly....................... 13 Flush Gun............................. 14 Clean Outside of Gun.................... 14 Clean Air Cap.......................... 14 Clean Spray Tip........................ 14 Clean Muffler........................... 14 Clean Fluid Manifold..................... 14 Clean Mixer............................ 14 Clean Slip-Fit Polycarballoy Mix Module...... 15 Troubleshooting........................... 16 Repair................................... 18 Tools Required.......................... 18 Lubrication............................. 18 Disassemble Front End................... 18 Reassemble Front End................... 19 Slip-Fit Polycarballoy Mix Module........... 20 Rear Rod Seal.......................... 21 Adjust Rear Rod Seal.................... 21 Check Valves........................... 22 Piston and Purge Rod.................... 23 Piston Safety Lock....................... 24 Air Valve.............................. 24 Static Mixer Assembly.................... 25 Parts.................................... 26 Accessories.............................. 28 Gun Repair Kits........................... 28 Check Valve Filter Screen Kits (10 per kit)..... 28 Technical Data............................ 29 Graco Standard Warranty................... 30 Graco Information......................... 30 2 313294H

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 SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Do not 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. Do not spray without tip guard. Engage trigger lock when not spraying. Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. 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 MSDS s 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 impervious gloves when spraying 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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection 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. Wait until equipment/fluid has cooled completely. 313294H 3

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 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 EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. 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 damage. 4 313294H

Overall View Overall View L F K P T C M D V W R N U B G H A S r_256998_313294_7b Key: A A Side Fluid Valve (white) B B Side Fluid Valve (red) 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 Static Mixer Adapter N Optional Fluid Inlets (A Side Shown) P Lock Ring R Fluid Inlet Swivels (A Side Shown) S Trigger T Gun Air Whip Hose U Air Valve V Static Mixer W RAC tip J E 313294H 5

Keep A and B Components Separate Keep A and B Components Separate NOTICE To prevent cross-contamination of the gun s wetted parts, do not interchange A component (white fluid) and B component (red fluid) parts. The gun is shipped with the A side on the left. The fluid manifold, fluid housing, side seal cartridge, check valve cartridge, and mix chamber are marked on the A side. Grounding Check your local electrical code and proportioner manual 313221 for detailed grounding instructions. 6 313294H

Piston Safety Lock (Trigger Lock) Piston Safety Lock (Trigger Lock) Engage piston safety lock whenever you stop spraying, to avoid accidental triggering. Loss of Air Pressure In event of loss of air pressure while gun is triggered, gun will continue to spray. To shut off gun, do one of the following: Push hard or hit end of safety lock, to engage piston safety lock. To engage piston safety lock: push knob in and turn clockwise. If engaged, gun will not actuate. TI5003A Engaged Close fluid valves A and B. TI3850A FIG. 1 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. Disengaged B A FIG. 2 TI3849A 313294H 7

Setup Setup 1. Assemble static mixer housing (60) and mix element (62) on front end of gun. 4. Connect A (white) and B (red) fluid hoses to fluid manifold. 65 64 60 62 B (Red) A (White) TI2417A gasket seat r_256998_313294_2b 5. Engage piston safety lock, page 7. 2. Assemble RAC tip and guard (64, 65) assembly. a. Use end of tip (65) to press gasket and seat into guard (64), with curve matching tip bore (T). Engaged TI3850A 65 seat T gasket b. Insert RAC tip (65) into tip bore (T). 64 6. Connect gun air whip hose and air valve to main air hose. Attach fluid manifold (M) to gun. c. Screw guard (64) onto static mixer housing (60) with wrench to properly seat gasket. d. Loosen guard (64) with wrench and tighten hand tight. 3. Close fluid valves A and B. M TI2411A 8 313294H

Shutdown 7. Connect quick coupler (D). Turn on air. Open air valve connected to whip hose. Air valve (K) should be screwed tight. There is no clean off air to adjust on the mechanical purge gun. K 65 exp1008a NOTE: To use optional air inlet, see Optional Hose Position on page 12. 8. Adjust Purge Rod Position, see page 23. 9. Turn on proportioner. 10. Open B (red fluid) fluid valve (about three half turns). Then open A (white fluid) fluid valve. D 13. Test spray onto cardboard. Adjust pressure and temperature to get desired results. 14. Apply layer of lubricant over front of gun and lock ring, or use gun cover to prevent overspray buildup and ease disassembly. See Accessories on page 28 to order lubricant and gun cover. 15. Gun is ready to spray. NOTICE Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved, page 10. Shutdown 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. B fluid valve A fluid valve 11. Disengage piston safety lock, page 7. Disengaged TI3849A 12. Turn RAC tip (65) to spray position. 313294H 9

Pressure Relief Procedure Pressure Relief Procedure 4. Ensure RAC tip (65) is in spray position. Relieve pressure before cleaning or repairing gun. 1. Engage piston safety lock, page 7. Engaged 65 exp1008a TI3850A NOTICE Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved. 2. Close fluid valves A and B. Leave air valve connected to whip hose open. 5. Trigger gun onto cardboard or into waste container to relieve pressure. If you suspect spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction. 6. Engage piston safety lock, page 7. Engaged TI3850A B A Fluid in the hose and proportioner is still under pressure. Follow the Pressure Relief Procedure in the proportioner manual. 3. Disengage piston safety lock, page 7. Disengaged To relieve pressure in the hose after the gun is removed, place the fluid manifold over containers, facing away from you. Very carefully open the fluid valves. Under high pressure, fluid will spray sideways from the fluid ports. TI3849A TI2484A 10 313294H

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. 3. Unscrew lock ring (P) until front end of gun is loose. 4. Rotate fluid housing (F) 180 and retighten lock ring very securely. 5. Attach fluid manifold. Connect air. Return gun to service. NOTICE To prevent cross-contamination of gun s wetted parts, do not interchange A component (white) and B component (red) parts. 1. Follow Pressure Relief Procedure, page 10. 2. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). F P D G 313294H 11

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. 42e 42c AA Fluid Hoses NOTICE To prevent cross-contamination of gun s wetted parts, do not interchange A component (white) and B component (red) parts. 1. Follow Pressure Relief Procedure, page 10. Also relieve system pressure and flush both fluid hoses, see proportioner manual. 2. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). 5. Connect appropriate hoses to A and B swivels. Air Hose 1. Remove quick disconnect fitting (D) and plug (J). Reverse positions. Apply thread sealant and torque to 125-135 in-lb (14-15 N m). N 42f r_256998_313294_8b D D G 3. Disconnect fluid hoses from inlet swivels (A, B). Remove swivels. Remove plugs from optional inlets (N). G J 2. Attach fluid manifold (G). Connect air. Return gun to service. B (Red) N A (White) TI2417A 4. Apply thread sealant to plugs (42c), elbows (AA), and male threads of swivels (42e, 42f). Install elbows (16) in optional inlets (N), facing down. Install swivels (A, B) in elbows. Be sure to install A swivel (larger) in A side. Install plugs (42c) where swivels had been. Torque all parts to 235-245 in-lb (26.6-27.7 N m). 12 313294H

Maintenance Maintenance Supplied Tool Kit Hex Nut Driver; 5/16 Screwdriver; 1/8 blade #77 drill bit 117661 Pin Vise; dual reversible chucks Reversible Reversible Compatible Solvents TI3864a As Needed 1. Clean Outside of Gun, page 14. 2. Clean Air Cap, page 14. 3. Clean Muffler, page 14. 4. Clean Fluid Manifold, page 14. 5. Clean Slip-Fit Polycarballoy Mix Module, page 15. Daily 1. Follow Shutdown, page 9. 2. Clean Check Valves, page 22. Check o-rings and screens. Use the following solvents for cleaning and flushing A and B fluid. Weekly to Monthly A and B Fluid A side (white) B side (red) Compatible Solvent Water Owens Corning B-Side Cleaner Check that piston safety lock threaded connection is tight, page 24. Keep Gun Clean Keep gun clean with accessory gun cover 244915. Applying a light coat of lubricant will make cleaning easier. Lubricate threads and outside of lock ring (11) to ease disassembly. Use Fusion Gun Lubricant (29). 313294H 13

Maintenance Flush Gun AB If it is necessary to flush the mix module, use following procedure. 1. Follow Pressure Relief Procedure, page 10. 2. Flush with a compatible solvent. 3. 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. Clean Mixer TI2411-1 The center mix element can be pressed out, front to back, even if fully cured. The mix element can then be cleaned with a wire brush. 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 Spray Tip Clean spray tip with a solvent soaked brush. Clean front of tip frequently to reduce fluid build up. Clean tip and tip guard at the end of each work day. Clean Muffler A partially plugged muffler (51) will slow gun actuation. Remove and clean muffler with compatible solvent. Clean Fluid Manifold Clean fluid manifold sealing faces with compatible solvent and a brush whenever removed from gun. Be sure to clean the two fluid ports (AB) in the top mating surface. Do not damage the flat sealing surfaces. Cover with Fusion Lubricant (29) if left exposed, to seal out moisture. 14 313294H

Maintenance Clean Slip-Fit Polycarballoy Mix Module 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Remove mix module, page 20. NOTICE To avoid damaging mix module, do not force drill bits when cleaning impingement ports. Some ports are offset or angled. TI3862a 4. See FIG. 3 and FIG. 4. Clean mix module impingement ports (IP) with appropriate size drill (supplied). FIG. 4: Cleaning Component B (Red) Ports NOTE: Component B (red) impingement ports, at rear of mix module, are angled toward front of gun. See FIG. 4. When cleaning do not scratch the sealing edges and ports. 5. Reassemble, page 20. FIG. 3: Cleaning Component A (White) Ports TI3863a 313294H 15

Troubleshooting Troubleshooting 1. Follow Pressure Relief Procedure, page 10, before checking or repairing gun. 2. Check all possible problems and causes before disassembling gun. NOTICE To prevent cross-contamination of the gun s wetted parts, do not interchange A component (white) and B component (red) parts. PROBLEM CAUSE SOLUTION Gun does not fully actuate when triggered. Piston safety lock engaged. Disengage piston safety lock, page 7. Plugged muffler (51). Clean, page 14. Damaged air valve o-rings (24). Replace, page 15. Fluid does not spray when gun is fully Closed fluid valves (42b). Open. actuated. Plugged impingement ports. Clean, page 15. Plugged check valves (36). Clean, page 22. Gun actuates slowly or with delayed Plugged muffler (51). Clean, page 14. action. Damaged piston o-rings (45, 48). Replace, page 23. Dirty air valve, or damaged o-rings (37d). Clean air valve or replace o-rings, page 24. Mix module nut (54) too tight. Loosen nut, then retighten, page 20. Loose lock ring (37b). Tighten, use tool if necessary. Purge rod will not actuate. No air pressure. Connect air supply. Low air pressure. Set air pressure above 80 psi (0.56 MPa, 5.6 bar). Buildup on purge rod (34). Clean purge rod. Pressure imbalance. Plugged impingement ports. Clean, page 15. Reinstall mix module, page 20. Plugged check valves (39). Clean, page 22. Viscosities not equal. Adjust temperature to compensate. 16 313294H

Troubleshooting PROBLEM CAUSE SOLUTION Fluid does not shut off when fluid Damaged fluid valves (42b). Replace. valves are closed. Air leakage around fluid housing. Damaged or missing o-ring (49). Replace. Air leakage from piston safety lock. Damaged or missing o-rings (47). Replace, page 23. Burst of air from muffler when gun is Normal. No action required. triggered. Steady air leakage from muffler. Damaged air valve o-rings (37d). Replace, page 24. Damaged piston o-rings (45, 48). Replace, page 23. Air leakage from front air valve. Damaged air valve o-rings (37d). Replace, page 24. Component B (resin) leak from fluid housing. Worn rear rod seal. Adjust Rear Rod Seal, page 21. Cross Contamination of A and B components. Air leakage from holes on solvent purge assembly. Fluid leakage from holes on solvent purge assembly. Worn out mix module. Sealing surface OD not clean. Cleanoff air valve open. Mix module nut is only handtight. Replace. Clean sealing surface on fluid housing. Close cleanoff air valve tightly. Cleanoff air valve should never be open when using solvent purge gun. Tighten mix module nut 1/12 with wrench. 313294H 17

Repair Repair Proper attachment of front end is critical. Do not operate gun if front end is loose or lock ring is not snug against handle. 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 54 2 6. Remove mix module (66). 66 TI4986a Ti3846a Lubrication Liberally lubricate all o-rings, seals, and threads with Fusion Gun Lubricant (29). Lubricate threads and outside of lock ring (11). Disassemble Front End 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Remove RAC guard and tip (64, 65), static mixer housing (60), mixer element (62) from fluid head (59). NOTICE If lock ring (37b) is stuck due to material buildup, do not force it by turning entire front end. Locating tabs (Z) may break off. Soak front of gun in solvent to soften cured material and free lock ring. To prevent damage to purge rod (34), always pull front end straight off handle (1). 7. Unscrew lock ring (37b) to remove front end and mix module. Pull front end straight off handle. 37b Z 64, 65 62 61 59 34 TI3865b r_256998_313294_3b 4. Loosen air cap (61) and remove from gun. 5. Remove mix module nut (54), using a wrench. Remove front seal (2). 18 313294H

Repair Reassemble Front End 1. Check that o-rings (37e, 49) are in position. Liberally lubricate o-rings, threads of lock ring (37b) and handle (1), and outside of lock ring. until tightened very securely. When properly assembled, lock ring is snug against handle. 37a 37b 1 37b 37e 34 TI3866a TI3871a 4. Push mix module (66) onto rod (34) as far as possible. 2. Orient front end as required for desired fluid manifold mounting (bottom mounting shown). Align slots (Y) to engage tabs (Z). 66 34 Y 37 TI3845a TI3871a 49 NOTICE Do not overtighten mix module nut (54). Overtightening can deform impingement holes and cause slow gun actuation. 5. Lubricate all threads and reassemble mix module nut (54) fingertight. Tighten additional 1/12 turn with wrench. Install front seal (2) on rod (34). 54 Z 2 1/12 Turn 34 TI4986a TI3873a 6. Reinstall air cap (61) and fluid head (59). Lubricate all threads. Install mixer element (62), static mixer housing (60,) and RAC tip and guard (64,65). Tighten with wrench. NOTICE To prevent damage to purge rod (34), always slide front end straight onto purge rod. 64, 65 62 61 59 3. Carefully slide front end straight onto purge rod (34). Screw lock ring (37b) onto handle (1) as far as possible by hand. Push on front end to ensure it is properly seated. Continue screwing lock ring onto handle r_256998_313294_3b 313294H 19

Repair Slip-Fit Polycarballoy Mix Module 66 37b L 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Remove fluid manifold (G). Leave air connected. 37 TI3845a NOTE: If mix module (66) does not protrude from fluid housing (37), slightly loosen then retighten lock ring (37b), to allow gripping of edge for removal. 7. Push mix module (66) onto rod (34) as far as possible. G 66 34 4. Unscrew air cap (61) to remove RAC tip and guard (64, 65), static mixer housing (60), mixer element (62) and fluid head (59) from gun. 37 TI3845a 64, 65 60, 62 59 61 r_256998_313294_4b 5. Remove mix module nut (54), using a wrench. Remove front seal (2). NOTICE Do not overtighten mix module nut (54). Overtightening can deform impingement holes and cause slow gun actuation. 8. Lubricate all threads and reassemble mix module nut (54) fingertight. Tighten additional 1/12 turn with wrench. Install front seal (2) on rod (34). 2 54 2 54 1/12 Turn TI3843a 6. Disengage piston safety lock (L), page 7. Trigger and detrigger gun once to release mix module (66) from fluid housing (37). Remove mix module. Engage piston safety lock. TI4986a 20 313294H

Repair 9. Reinstall air cap (61) and fluid head (59). Lubricate all threads. Install static mixer housing (60), mixer element (62), and RAC tip and guard (64, 65). Tighten with wrench. 7. Reassemble new rear seal (37h) in rear rod seal nut (37g). Lubricate threads and install in fluid housing (37a) with nut driver. 8. Reassemble Front End, page 19. 9. Attach fluid manifold. Connect air. Return gun to service. 64, 65 60, 62 61 59 r_256998_313294_4b 10. Attach fluid manifold. Return gun to service. Rear Rod Seal Adjust Rear Rod Seal 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Remove fluid manifold (G). Leave air connected. 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Remove fluid manifold (G). Leave air connected. G G 4. Disassemble Front End, page 18. 5. Assemble fluid housing (37a) backwards onto lubricated purge rod (34). Adjust rear rod seal nut (37g) with nut driver until drag is felt when sliding on rod. 4. Disassemble Front End, page 18. 5. Remove rear rod seal nut (37g) with nut driver (13). 37a 34 13 37g 23 TI3869a 6. Push out rear seal (37h) with screwdriver (27). 6. Remove fluid housing (37a) from rod (34). TI3831a 37h 27 7. Reassemble Front End, page 19. 8. Attach fluid manifold. Return gun to service. TI3872a 313294H 21

Repair Check Valves B NOTICE Damaged check valve o-rings (39f, 39g) may result in external leakage. Replace o-rings if any damage is seen. A 39b 39e 39c NOTE: Before disassembling, press on ball (36c) to test check valve for proper movement and spring action. 1. Follow Pressure Relief Procedure, page 10. 39 39d 39g 39a 39f TI4987a 2. Flush Gun, page 14. 3. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). Clean and inspect check valve mating surfaces and fluid ports. 6. Reassemble check valves. Screw (39b) should be flush (within 1/16 in. or 1.5 mm) of housing (39a) surface. Liberally lubricate o-rings (39f, 39g) and carefully reinstall in fluid housing. 7. Attach fluid manifold. Connect air. Return gun to service. D G 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. 4. Pry out check valves (39) at notch. 5. Slide filter (39d) off. Clean and inspect parts. Thoroughly inspect o-rings (39f, 39g). If necessary, remove screw (39b) and disassemble check valve. 22 313294H

Repair Piston and Purge Rod 40 34 33g 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 48 3. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). 16 TI3848a D 8. Liberally lubricate piston o-rings. Reinstall piston. Shaft is keyed for proper assembly. Push firmly to seat piston. Rotate piston/purge rod assembly clockwise with nut driver until piston is fully seated. G 4. Disassemble Front End, page 18. 5. Unscrew purge rod stop (33d) to remove piston safety lock assembly. Inspect o-rings (33f, 33g) in place. 33g 33d TI4988a 9. Install piston safety lock assembly until bottomed out. 33f TI3847a 6. Pull purge rod to remove piston (40). Inspect piston o-ring (45) and shaft o-ring (48). 10. Reassemble Front End, page 19. TI3847a 11. Attach fluid manifold. Connect air. Return gun to service. 40 48 45 TI4988a 7. Inspect purge rod (34) for scratches or damage. Unscrew rod from piston with nut driver. Inspect o-ring (33g). Liberally lubricate with Fusion Gun Lubricant. To reassemble, thread purge rod (34) into piston (40) until rod stops. 313294H 23

Repair Piston Safety Lock 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). Air Valve 1. Follow Pressure Relief Procedure, page 10. 2. Flush Gun, page 14. 3. Disconnect air hose from quick disconnect (D) and remove fluid manifold (G). D D G G 4. Unscrew cap (33a) from stop (33d), using two pair of channel-lock pliers. Inspect spring (33e), safety actuator (33b), bushing (33c), and o-rings (33f, 33g). 4. Unscrew air valve plug (32) and remove spring (55). Using small screwdriver (27), push spool (56) out from front. Inspect o-rings (53). 33f 33g 33d 33e 33b, 33c 33a TI3835b 5. Lubricate o-rings (33f, 33g) and piston safety lock actuator (33b), and reassemble. Use Fusion Gun Lubricant (29). Clean threads with solvent or alcohol. Apply medium-strength Loctite or equivalent to threads on stop (33d) and cap (33a), and reassemble. 6. Attach fluid manifold. Connect air. Return gun to service. 53 5. Liberally lubricate o-rings and reassemble. Use Fusion Gun Lubricant (29). Torque plug (32) to 125-135 in-lb (14-15 N m). 6. Attach fluid manifold. Connect air. Return gun to service. 56 55 32 TI4990a 24 313294H

Repair Static Mixer Assembly 1. Follow Pressure Relief Procedure, page 10. 6. Use needle nose pliers to remove mixer element (62) from static mixer housing (60). Inspect parts for damage, replace if necessary. 2. Flush Gun, page 14. 3. Disconnect air hose from fitting (D) and remove fluid manifold (G). 60 62 r_256998_313294_5b 7. Reassemble static mixer assembly. D 8. Install RAC tip, guard (64, 65) and static mixer on fluid housing (59). G 9. Tighten air cap (61) on front of gun. 10. Attach fluid manifold. Connect air. Return gun to service. 4. Disassemble RAC tip, guard (64, 65) and static mixer housing (60) from fluid head (59). 64, 65 62 61 59 r_256998_313294_3b 5. Loosen air cap (61) and remove from gun. 313294H 25

Parts Parts 256998 EnergyComplete Spray Gun 2 66 Supplied Tools 26 ti18660a 62 61 81 59 54 33c 33e 33h 33j 33b 27 13 60 33d 33a 33g 33f 34 47 64 48 65 40 38 45 49 37e 37h 37g 37b 37f 1 37c 37d 2 35 58 51 4 37a 39b 39e 39c 43 36 2 1 11 12 1 14 39d 39g 39a 39f 39 42a 42e 42f 1 1 53 56 55 32 1 15 17 42b 42c 3 1 42d 1 2 Torque to 125-135 in-lb (14-15 N m). Torque to 20-30 in-lb (2.3-3.4 N m). 16 3 Torque to 32-40 ft-lb (43-54 N m). 42g 4 Torque to 35-45 in-lb (4-5 N m). 26 313294H

Parts 256998 EnergyComplete Spray Gun Ref. Part Description Qty. 1 248002 HANDLE 1 2 248003 SEAL KIT, purge rod; includes 4 1 seals 5 246816 TOOL, cleanout, #77 1 10 172479 TAG, warning 1 11 100721 PLUG, pipe 2 12 117509 FITTING, line, air, 1/4 NPT 2 13 117642 TOOL, nut driver 1 14 117510 COUPLER, line, air, 1/4 NPT 1 15 15B772 HOSE, air, 18 in. 1 16 112307 ELBOW, street 2 17 15B565 VALVE, ball 1 18 15B817 MANIFOLD, gun, flush 1 25 222385 TAG, warning; not shown 1 26 117661 PIN, vise 1 27 118575 TOOL, screw driver, 1/8 blade 1 29 118665 TUBE, grease, FUSION gun, 4 oz. 1 32 15B208 PLUG, air valve 1 33 248028 STOP, assy, safety 1 33a 15C373 CAP, REAR 1 33b 15C374 ACTUATOR, safety 1 33c 15C390 BUSHING, safety 1 33d 15C372 CAP, purge rod stop 1 33e 118144 SPRING, compression, safety 1 33f 248136 O-RING; package of 6 1 33g 113746 PACKING, o-ring 1 33h 115452 RING, RETAINING, internal 1 33j 15D329 STOP, rod 1 34 248001 ROD, purge, assembly 1 35 203953 SCREW, cap hex hd 1 36 192272 PIN, pivot 1 37 246875 FLUID, housing assy; 1 includes 39, 37a-37j 37a FLUID, housing 1 37b 15B215 RING, lock 1 37c 15C382 VALVE, clean off air 1 37d 246354 O-RING; package of 6 1 37e 248132 O-RING; package of 6 1 37f 116550 RING, retaining 1 37g 15C378 RETAINER, rod seal 1 37h 248003 SEAL KIT, purge rod; includes 4 1 seals 38 118145 SPRING, compression, purge rod 1 39 246731 VALVE, check, A side; includes 39a-39g 246352 VALVE, check, B side; includes 39a-39g 39a HOUSING 1 39b 15B214 SCREW, retaining spring 1 39c 104396 BALL, carbide 1 39d SCREEN; see page 28 1 39e 117490 SPRING 1 39f 248133 O-RING; package of 6 1 39g 248129 O-RING; package of 6 1 40 15C371 PISTON 1 Ref. Part Description Qty. 42 257436 MANIFOLD, fluid; 1 includes 42a-42g 42a MANIFOLD 1 42b 246356 VALVE, fluid 2 42c 100139 PLUG, pipe; 1/8-27 npt 2 42d 15B221 BOLT; 5/16-24 1 42e 117634 SWIVEL, A side; 1/8 npt (m) x 1 no. 6 JIC (f) 42f 117635 SWIVEL, B side; 1/8 npt (m) x 1 no. 5 JIC (f) 42g 15B993 SPRING, ring, lock 1 43 15B209 TRIGGER, gun 1 44 112385 SCREW, set, socket hd 1 45 248135 O-RING; package of 6 1 47 248095 PACKING, o-ring; package of 6 1 48 248096 PACKING, o-ring; package of 6 1 49 248138 O-RING; package of 6 1 51 119626 MUFFLER 1 53 246354 O-RING; package of 6 3 54 15C377 NUT, impingement chamber 1 55 117485 SPRING, compression 1 56 15B202 VALVE, spool 1 58 15C480 WASHER, wave 1 59 15U828 HEAD, fluid 1 60 16F457 HOUSING 1 61 15E130 CAP, air 1 62 24F656 MIXER, static 4.5in.; package of 10 1 64 XHD001 GUARD, RAC, XHD 1 65 XHD121 TIP, spray, cylinder; see page 28 1 66 257417 MODULE, mix 1 71 XHD025 TIP, spray, cylinder; see page 28 1 72 XHD225 TIP, spray, cylinder; see page 28 1 73 257417 KIT, repair, mix module 1 81 119796 GASKET 1 Replacement Danger and Warning labels, tags, and cards are available at no cost. These parts are only available in repair kits. To select a kit, refer to Gun Repair Kits on page 28. Available in 248279 Kit, package of 10. Available in Fluid Housing Assembly Kit 248004. Not shown. 313294H 27

Accessories Accessories XHD RAC Tips The following XHD tips are recommended for the applications listed below. Pattern and orifice size are dependent on the desired flowrate. Part No. XHD121 XHD121 XHD225 XHD025 Pour Tip NOTE: Material can harden and plug the disposable mixer nozzle after 30 minutes of inactivity. Replace plugged mixer nozzle to continue spraying with pour tip. Gun Cover, 244915 Application Window, door, or top plate Wall cavity and band joist High areas Part No. Description 122359 Aluminum Jacket 122358 Disposable Mixer Nozzle Keep 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. MSD025 available at www.graco.com Gun Repair Kits Read the chart left to right and top to bottom to find the quantity of each part in the kits. Ref. No. Bulk O-ring Kits, (qty) 246351 Check Valve O-ring Kit 33f 248136 (6) 1 45 248135 (6) 1 47 248095 (6) 2 48 248096 (6) 1 49 248138 (6) 1 37e 248132 (6) 1 37d 246354 (6) 4* 39f 248133 (6) 2 2 39g 248129 (6) 2 2 37h 248003 (4) 2 Check Valve Filter Screen Kits (10 per kit) 80 mesh filter screen is standard with gun. 248887 Complete O-ring Kit 246357 40 mesh (.015 in., 375 micron) 246358 60 mesh (.010 in., 238 micron) 246359 80 mesh (.007 in., 175 micron) 28 313294H

Technical Data Technical Data 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 Inlet Pressure 130 psi (0.9 MPa, 9 bar) Maximum Fluid Temperature 200 F (94 C) Air Inlet Size 1/4 npt Quick Disconnect Nipple A Component (White) Inlet Size -6 JIC; 9/16-18 UNF female swivel in 1/8 npt (f) port B Component (Red) Inlet Size -5 JIC; 1/2-20 UNF female swivel in 1/8 npt (f) port Sound Pressure 70 db(a), at 100 psi (0.7 MPa, 7 bar) Sound Power, measured per ISO 79.9 db(a), at 100 psi (0.7 MPa, 7 bar) 9416-2 Length 9 in. (228 mm) Height 8.1 in. (206 mm) Width 3.5 in. (89 mm) Weight 3.7 lb (1.68 kg) Aluminum, stainless steel, carbon steel, chemically resistant o-rings, Wetted Parts ultra-high molecular weight polyethylene (UHMWPE), Polycarballoy, Nylon Approvals 313294H 29

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. Original instructions. This manual contains English. MM 313294 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 Revised 01/2012