Graco RS Operating instructions

3A0232ZAA
EN
Operation - Repair
RS™Gun and
Cutter
For use with polyester resin and gel-coat.
For professional use only.
See page 3 for model information, including maxi-
mum working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
External Mix Chop Gun with Cutter shown
II 2 G Ex h T6 Gb

23A0232ZAA
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Two-Component Information . . . . . . . . 6
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 6
Keep Components A and B Separate . . . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6
Important Methyl Ethyl Ketone Peroxide (MEKP)
Safety Information . . . . . . . . . . . . . . . . . . . . . . 7
Component Identification . . . . . . . . . . . . . . . . . . . 10
External Mix Gel Gun, 258840 . . . . . . . . . . . . . 10
Internal Mix Gel Gun, 258853 . . . . . . . . . . . . . . 11
Internal Mix Chop Gun, 258854 . . . . . . . . . . . . 12
Internal Mix Chop Gun, 24P436, High Flow,
Carbide Seat . . . . . . . . . . . . . . . . . . . . . . . . 13
External Mix Chop Gun, 258852 . . . . . . . . . . . . 14
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . 15
External Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Internal Mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chop Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Impingement versus Airless Spray Tips . . . . . . 15
Air Assist Containment™(AAC™) . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Adjust AAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Internal Mix Flush . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 20
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 21
Long-Term Shutdown . . . . . . . . . . . . . . . . . . . . 23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Flush System . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fluid Leaking from Front of Gun . . . . . . . . . . . . 29
Adjust Trigger Clamp . . . . . . . . . . . . . . . . . . . 29
Fluid Leaking from Under Trigger
Clamp Assembly . . . . . . . . . . . . . . . . . . . . . 30
Adjust Needle Packing Tension . . . . . . . . . . . . 30
Adjust Actuator Pin Adjustment Screws . . . . . . 31
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove Hardened Material from
Internal Mix Front Head . . . . . . . . . . . . . . . 32
Replace Internal Mix Element . . . . . . . . . . . . . . 34
Replace External Mix Check Valve
and O-Rings . . . . . . . . . . . . . . . . . . . . . . . . 35
Replace Material Needle Assembly . . . . . . . . . . 36
Replace Center Needle Assembly . . . . . . . . . . . 36
Replace Needle Packing . . . . . . . . . . . . . . . . . . 37
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
External Mix Gel Gun, 258840 . . . . . . . . . . . . . 38
Internal Mix Gel Gun, 258853 . . . . . . . . . . . . . . 40
External Mix Chop Gun with Cutter, 258970 . . . 42
Internal Mix Chop Gun with Cutter, 258971 . . . 42
Internal Mix, High Flow, Chop Gun
with Cutter, 24P435 . . . . . . . . . . . . . . . . . . 42
Chop Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Front Head Assemblies . . . . . . . . . . . . . . . . . . . 49
Needle Assembly, 24E417 . . . . . . . . . . . . . . . . 52
O-ring Identification . . . . . . . . . . . . . . . . . . . . . . 53
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fusion®Grease . . . . . . . . . . . . . . . . . . . . . . . . . 54
INDy or Formula Adapter Kit, 125797 . . . . . . . . 54
LPA2 Adapter Kit, 125843 . . . . . . . . . . . . . . . . . 54
Universal Adapter Kit, 257754 . . . . . . . . . . . . . . 54
Resin Transfer Molding (RTM)
Nozzle Adapter Kit, 16T680 . . . . . . . . . . . . 54
Casting Nozzle Adapter Kit, 16T707 . . . . . . . . . 54
External Mix High-Flow Kit, 24H336 . . . . . . . . . 54
Internal Mix High-Flow Kit, 24H337 . . . . . . . . . . 54
AAC Regulators . . . . . . . . . . . . . . . . . . . . . . . . . 55
External Mix Gel Gun
to Chop Gun Conversion . . . . . . . . . . . . . . 55
Internal Mix Gel Gun
to Chop Gun Conversion . . . . . . . . . . . . . . 55
Pressure Fed Roller Adapter Kit, 16T708 . . . . . 56
Extension Gelcoat Spraying Kit, 16T709 . . . . . . 56
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Carbide Resin Seat, 16N889 . . . . . . . . . . . . . . . 56
External Mix Chopper Extension Kit, 24V096 . . 56
Impingement Spray Tips . . . . . . . . . . . . . . . . . . 58
Airless Spray Tips . . . . . . . . . . . . . . . . . . . . . . . 61
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 66
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 66

Models
3A0232ZAA 3
Models
See Technical Data on page 63 for more specifications.
Related Manuals
The following is a list of component manuals written in
English. These manuals and any translated versions
available can be found at www.graco.com.
Model Description
Maximum Fluid
Working Pressure
psi (MPa, bar)
Maximum Catalyst
Working Pressure
psi (MPa, bar)
Air Inlet Working
Pressure Range
psi (MPa, bar)
Maximum Fluid
Temperature
°F (°C)
258853 Internal Mix
Gel Gun 2000 (14, 138) 2000 (14, 138) 0-125 (0-0.86, 0-8.6) 100 (38)
258854
Internal Mix
Chop Gun,
No Cutter
2000 (14, 138) 2000 (14, 138) 0-125
(0-0.86, 0-8.6) 100 (38)
258971
Internal Mix
Chop Gun,
Cutter
2000 (14, 138) 2000 (14, 138) 80-125
(0.55-0.86, 5.5-8.6) 100 (38)
24P435
Internal Mix
Chop Gun,
High Flow,
Cutter
2000 (14, 138) 2000 (14, 138) 80-125
(0.55-0.86, 5.5-8.6) 100 (38)
258840 External Mix
Gel Gun 2000 (14, 138) 200 (1.4, 14) 0-125 (0-0.86, 0-8.6) 100 (38)
258852
External Mix
Chop Gun,
No Cutter
2000 (14, 138) 200 (1.4, 14) 0-125
(0-0.86, 0-8.6) 100 (38)
258970
External Mix
Chop Gun,
Cutter
2000 (14, 138) 200 (1.4, 14) 80-125
(0.55-0.86, 5.5-8.6) 100 (38)
24P436
Internal Mix
Chop Gun,
High Flow
2000 (14, 138) 2000 (14, 138) 80-125
(0.55-0.86, 5.5-8.6) 100 (38)
Part Description
3A1226 Universal Adapter Kit 257754 Instructions
3A2054 Indy or Formula Adapter Kit 125797 Instructions
3A2079 LPA2 Adapter Kit 125843 Instructions
332574 RS Gun Cutter Assemblies Operation-Repair
334010 RS Gun External Mix Chopper Extension Kit 24V096 Instructions

Warnings
43A0232ZAA
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
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.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.

Warnings
3A0232ZAA 5
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss,
inhalation of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious
injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
WARNING

Important Two-Component Information
63A0232ZAA
Important Two-Component Information
Material Self-ignition
Keep Components A and B
Separate
Changing Materials
• When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical
compatibility.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (catalyst) and component B (resin)
parts.

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information
3A0232ZAA 7
Important Methyl Ethyl Ketone Peroxide (MEKP)
Safety Information
MEKP is among the more hazardous materials found in
commercial channels. Proper handling of the “unstable
(reactive)” chemicals presents a definite challenge to
the plastics industry. The highly reactive property which
makes MEKP valuable to the plastics industry in produc-
ing the curing reaction of polyester resins and gel-coats
also produces the hazards which require great care and
caution in its storage, transportation, handling, process-
ing and disposal.
Workers must be thoroughly informed of the hazards
that may result from improper handling of MEKP, espe-
cially in regards to contamination and heat. They must
be thoroughly instructed regarding the proper action to
be taken in the storage, use and disposal of MEKP and
other hazardous materials used in the laminating opera-
tion.
MEKP is flammable and potentially explosive, as
well as potentially damaging to the eyes and skin.
Read material manufacturer’s warnings and
material MSDS to know specific hazards and pre-
cautions related to MEKP.
Contaminated MEKP can become explosive. Pre-
vent contamination of MEKP with other materials,
which includes, but is not limited to polyester over-
spray, polymerization accelerators and promoters,
and non-stainless metals. Even small amounts of
contaminates can make MEKP explosive. This reac-
tion may start slowly, and gradually build-up heat,
which can accelerate until fire or an explosion result.
This process can take from seconds to days.
Heat applied to MEKP, or heat build-up from con-
tamination reactions can cause it to reach what is
called its Self-Accelerating Decomposition Tempera-
ture (SADT), which can cause fire or explosion. Spills
should be promptly removed, so no residues remain.
Spillage can heat up to the point of self-ignition. Dis-
pose in accordance with manufacturer's recommen-
dation.
Store MEKP in a cool, dry and well-ventilated area
in the original containers away from direct sunlight
and away from other chemicals. It is strongly recom-
mended that the storage temperature remain below
86° F (30° C). Heat will increase the potential for
explosive decomposition. Refer to NFPA 432. Keep
MEKP away from heat, sparks and open flames.
Current catalysts are premixed and do not require
any diluents. Graco strongly recommends that dilu-
ents not be used. Diluents add to the possibility of
contaminates entering the catalyst system. Never
dilute MEKP with acetone or any solvent since this
can produce an extremely shock-sensitive compound
which can explode.
Use only original equipment or equivalent parts
from Graco in the catalyst system (i.e.: hoses, fittings,
etc.) because a hazardous chemical reaction may
result between substituted parts and MEKP.
To prevent contact with MEKP, appropriate per-
sonal protective equipment, including chemically
impermeable gloves, boots, aprons and goggles are
required for everyone in the work area.

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information
83A0232ZAA
Polyester Resins and Gel-Coats
Spraying and Lamination Operations
NOTE: Graco recommends that you consult OSHA Sec-
tions 1910.94, 1910.106, 1910.107 and NFPA No. 33,
Chapter 16,17, and NFPA No. 91 for further guidance.
Spraying materials containing polyester resin and
gel-coats creates potentially harmful mist, vapors and
atomized particulates. Prevent inhalation by provid-
ing sufficient ventilation and the use of respirators in
the work area.
Read the material manufacturer’s warnings and
material MSDS to know specific hazards and precau-
tions related to polyester resins and gel-coats.
To prevent contact with polyester resins and
gel-coats, appropriate personal protective equip-
ment, including chemically impermeable gloves,
boots, aprons and goggles are required for everyone
in the work area.
Remove all accumulations of overspray, FRP
sandings, etc. from the building as they occur. If this
waste is allowed to build up, spillage of catalyst is
more likely to start a fire.
If cleaning solvents are required, read material
manufacturer's warnings and material MSDS to know
specific hazards and precautions. (Graco recom-
mends that clean-up solvents be nonflammable.)

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information
3A0232ZAA 9

Component Identification
10 3A0232ZAA
Component Identification
External Mix Gel Gun, 258840
FIG. 1
Key:
A Trigger Clamp Assembly
B Gun Mount
C Front Head Locking Ring
D Air Cap Retaining Ring
E External Mix Aircap
F External Mix Front Head
GSprayTip
H Trigger guard
J Trigger
K Trigger lock
L Handle
M Actuator Pin
A
B
C
H
J
K
L
M
E
D
G
F
258840_3A0232_1g

Component Identification
3A0232ZAA 11
Internal Mix Gel Gun, 258853
NOTE: On internal mix guns, the tip rotates to allow a
vertical or horizontal spray pattern.
FIG. 2
Key:
A Trigger Clamp Assembly
BGunMount
C Front Head Locking Ring
D Air Cap Retaining Ring
E Internal Mix Aircap
F Internal Mix Front Head
G Spray Tip
H Trigger guard
J Trigger
K Trigger lock
L Handle
M Actuator Pin
A
B
ti21003a
C
D
E
F
H
J
K
G
L
M

Component Identification
12 3A0232ZAA
Internal Mix Chop Gun, 258854
NOTE: On internal mix guns, the tip rotates to allow ver-
tical or horizontal spray pattern.
FIG. 3
Key:
A Trigger Clamp Assembly
B Cutter Mount
C Front Head Locking Ring
D Air Cap Retaining Ring
E Internal Mix Aircap
F Internal Mix Front Head
G Spray Tip
H Trigger guard
J Trigger
K Trigger lock
L Handle
MActuatorPin
ti21004b
A
B
C
D
E
F
H
J
K
G
L
M

Component Identification
3A0232ZAA 13
Internal Mix Chop Gun, 24P436, High Flow, Carbide Seat
NOTE: On internal mix guns, the tip rotates to allow ver-
tical or horizontal spray pattern.
FIG. 4
Key:
A Trigger Clamp Assembly
B Cutter Mount
C Front Head Locking Ring
D Air Cap Retaining Ring
E Internal Mix Aircap
F Internal Mix Front Head,
High Flow
G Spray Tip
H Trigger guard
J Trigger
K Trigger lock
L Handle
MActuatorPin
ti21005b
A
B
C
D
E
F
H
J
K
G
L
M

Component Identification
14 3A0232ZAA
External Mix Chop Gun, 258852
FIG. 5
Key:
A Trigger Clamp Assembly
B Cutter Mount
C Front Head Locking Ring
D Air Cap Retaining Ring
E External Mix Aircap
F External Mix Front Head
G Spray Tip
H Trigger guard
J Trigger
K Trigger lock
L Handle
M Actuator Pin
ti21006b
AB
C
D
E
F
H
J
K
G
L
M

Theory of Operation
3A0232ZAA 15
Theory of Operation
External Mix
The resin or gelcoat stream and the catalyst stream
impinge when they exit the spray tip. The catalyst is
atomized with air pressure by the AAC air to achieve
high mix quality. External mixing reduces internal clogs
from cured material.
Internal Mix
The material and catalyst pass through an internal static
mixer where they mix. The mixed solution is dispensed.
Chop Guns
Fiberglass is pulled through cutter and cut into small
strands. The cut strands are then dispensed into the
mixed material stream.
Impingement versus Airless
Spray Tips
Impingement spray tips are typically for chop guns. This
utilizes multiple impinging streams to create the fan pat-
tern.
Airless spray tips are typically for gel guns. This utilizes
a single cat-eye shaped orifice to create the fan pattern.
Air Assist Containment™
(AAC™)
When material exits the spray tip, air is sprayed against
the material stream to shape it into a more consistent
pattern.
Grounding
Introduction
To have the optimal RS gun experience, the most
important procedures to understand and perform as
specified are:
•Startup on page 18
•Adjust Trigger Clamp on page 29
•Adjust Anvil to Blade Cartridge Tension. Refer to
RS Gun Cutter Assemblies Operation-Repair man-
ual for details.
•Daily Shutdown on page 21
This equipment must be grounded.
Grounding reduces the risk of static shock by providing
an escape wire for electrical current due to static build
up or in the event of short circuit.
NOTE: Grounding wire and clamp assembly 17440-00
is included with Graco FRP proportioner. If using a dif-
ferent proportioner that does not come with a ground-
ing wire and clamp assembly, order 17440-00 or
provide your own.
Ground the dispense gun through connection to a
Graco approved grounded fluid supply hose.
Check your local electrical code and related manuals
for detailed grounding instructions of all equipment in
the work area.
NOTICE
Failure to perform these procedures correctly and
according to the prescribed schedule can result in
poor mixing, fluid leaking, cured material in the gun,
and premature component wear.

Setup
16 3A0232ZAA
Setup
1. Before first use, flush the gun. See Flush System,
page 24.
NOTE: The recommended solvent pressure during
flushing is 80-100 psi (550-700 kPa, 5.5-7.0 bar).
2. Engage trigger lock.
3. For guns with cutters, install cutter:
a. If necessary, use a crescent wrench to adjust
pivot (541) so that it is parallel to gun front end
and the open end points to the front of the gun.
See FIG. 6.
b. Back out screws (630). See FIG. 6.
c. Install cutter onto pivot so glass feed holes are
on top.
NOTE: Ensure proper engagement of o-ring (542) into
the cutter assembly. Verify there is no excess air leak-
age because it will greatly reduce the performance of
the air motor. See FIG. 6.
d. Tighten screws (630) to lock cutter in place.
e. Adjust cutter dispensing angle and chute angle
as desired.
4. For internal mix guns, verify solvent knob (BD) is
adjusted to the fully closed position. See FIG. 7 on
page 17.
5. Attach gun connections as described in FIG. 7 on
page 17. See Technical Data on page 63 for fitting
sizes.
6. For internal mix guns, prime the solvent line. Turn
solvent adjustment knob (BD) until solvent dis-
charges from the front of the gun. See FIG. 7 on
page 17.
NOTE: The recommended solvent line pressure is
80-100 psi (550-700 kPa, 5.5-7.0 bar).
7. For guns with cutters, insert glass strands into
feed.
8. For guns with cutters, adjust anvil to blade ten-
sion. Refer to RS Gun Cutter Assemblies Opera-
tion-Repair for part identification:
a. Release lockdown.
b. Adjust tension knob as desired.
c. Tighten lockdown.
d. Release idler lock down.
e. Adjust idler lock down until it touches anvil.
f. Tighten idler lock down.
g. Perform test spray to verify proper cutting of
glass strands.
h. Adjust tension as necessary.
9. For external mix guns, adjust AAC knob (BD) to
middle of possible range of movement. See FIG. 7
on page 17.
NOTICE
The equipment was tested with lightweight oil,
which is left in the fluid passages to protect parts.
To avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using
the equipment. See Flush System, page 24.
FIG. 6
541 542 630
ti21008a
NOTICE
Internal mix guns: To prevent material curing inside
the gun, do not trigger gun if solvent is not primed.

Setup
3A0232ZAA 17
10. Adjust AAC pressure on proportioner.
11. Perform test spray. Adjust system and gun settings
as necessary to get desired results.
FIG. 7: Fitting Details
BB
BABE
BF
258840_3A0232_2g
Ref External Mix Internal Mix Chop Internal Mix Gel Fitting Size
BA Atomized Air
(Catalyst)
Air Assist Contain-
ment (AAC) Plugged 1/4 tube
BB Resin Inlet 1/4 NPSM
BC Air Assist Con-
tainment (AAC) Solvent 1/8 NPSM
BD Adjustment Knob --
BE Chop Air Inlet Air Assist Contain-
ment (AAC) 3/8 tube
BF Catalyst Inlet #4 JIC
BC
BD

Startup
18 3A0232ZAA
Startup
1. Inspect o-rings on housings. Replace as needed.
See FIG. 8.
2. Prime the system as required.
3. Align front head with housings and install front head.
Tighten front head locking ring (C).
4. Verify air cap retaining ring (D) is tight.
5. Verify fluid and air lines are at the desired pressures
then begin using the gun.
FIG. 8
NOTICE
Gun damage can occur when the system is primed
with the front head installed. To avoid damage, only
prime the system with the front head removed.
Ensure locking ring (C) and retaining ring (D) are tight
before spraying. Spraying while either item is loose
may result in skin injection.
258840_3A0232_3g
C
D
Housing O-rings

Operation
3A0232ZAA 19
Operation
Trigger Lock
Adjust AAC
If the spray pattern is not even, the AAC air pressure
may need to be adjusted. For all guns, the AAC air pres-
sure is set at the system. The external mix gun includes
an AAC air pressure adjustment on the gun also, see
AAC reference in FIG. 7 on page 17. To increase AAC
air pressure on the external mix gun, turn knob
counter-clockwise. To decrease air pressure, turn knob
clockwise. For large changes in AAC air pressure,
adjust the pressure at the system.
Internal Mix Flush
NOTE: The recommended solvent line pressure is
80-100 psi (550-700 kPa, 5.5-7.0 bar).
After spraying, open the solvent knob (BC) to allow sol-
vent to flow through the gun. See FIG. 7 on page 17.
While flushing, hold a metal part of the gun firmly to a
grounded metal pail.
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 amputa-
tion. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the
body.
• Do not put your hand over the dispense outlet.
• Do not stop or deflect leaks with your hand, body,
glove, or rag.
• Follow Pressure Relief Procedure when you
stop dispensing and before cleaning, checking, or
servicing equipment.
Engage trigger lock whenever you stop spraying to
avoid accidental triggering.
Engage Disengage
TI10442a TI10441a
FIG. 9
Bad
Good

Pressure Relief Procedure
20 3A0232ZAA
Pressure Relief
Procedure
1. Shutdown proportioner.
2. Relieve proportioner pressure. See proportioner
manual.
3. Engage gun trigger lock.
4. Close the bleed-type master air valve.
5. Disengage the trigger lock.
6. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
7. Engage the trigger lock.
8. With a waste container in place, open all fluid drain
valves in the system. Leave drain valve(s) open until
you are ready to spray again.
9. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, VERY SLOWLY loosen retain-
ing ring (D) or loosen hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction. See FIG. 1 on page 10 for
part references.