Graco 3A1602G User Manual

Instructions - PartsFor spraying 1:1 mix ratio formulated no-heat polyurethane foams and dispensing 1:1 mix ratio polyurea joint-fill materials. For p

Controls and Indicators 10 3A1602GControls and IndicatorsPower SwitchPowers the Reactor E-8p on and off.Motor/Pump Control Function KnobUse knob to se

Setup3A1602G 11SetupLocation• The Reactor E-8p should always be used on a level surface. • Do not expose the Reactor E-8p to rain. Electrical Requirem

Setup 12 3A1602GLock/Unlock HandleLock the handle when the sprayer is moved, laid on its side, or turned upside down.UnlockTo unlock the handle, remov

Setup3A1602G 13Install Optional Recirculation KitUse Hose Recirculation Kit 24M654 to help evenly dis-tribute heat when using supplemental heaters and

Setup 14 3A1602GConnect Fluid HosesConnect fluid supply hoses to outlet hose connections (FIG. 9 and FIG. 10). Red hoses for component A (ISO), blue f

Setup3A1602G 15FIG. 10: Hose and Air Connections - Recirculation Hose Kit 24M654B (RES)A (ISO)AirCompressedAir LineA (ISO)A RecirculationB (RES)B Reci

Setup 16 3A1602GFill Wet-cupsKeep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a ba

Setup3A1602G 176. Set function knob to Slow Recirc or Fast Recirc . 7. When material exits both recirculation tubes, set the function knob to Stop/P

Setup 18 3A1602G7. Set function knob to Slow Recirc or Fast Recirc . 8. When clean solvent exits both recirculation tubes, set the function knob to

Spraying3A1602G 19SprayingNOTE: For air operated guns, air is supplied to spray gun with gun piston safety lock engaged and gun fluid manifold valves

2 3A1602GContentsSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Proportioners . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 20 3A1602GPressure Relief ProcedureNOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual.1. Engage

Maintenance3A1602G 215. Use solvent to wipe down fluid inlet tubes.6. Install suction tube caps on each fluid inlet tube and rest in the containment t

Flushing 22 3A1602GFlushing• Generally, flush if you will be shut down for more than 3 days. Flush more often if material is moisture sensitive and hu

Flushing3A1602G 239. Purge gun hoses.a. Disconnect hoses from gun and secure to a pail of solvent.b. Turn Recirc/Spray valve A to Spray. c. Open gun i

Troubleshooting 24 3A1602GTroubleshootingStatus CodesDetermine the status code by counting the number of times the status indicator blinks.Status Code

Troubleshooting3A1602G 25Status Code 1 and 2 Settings1. Locate switch SW2 on the control board.2. Set the four DIP switches to the desired positions.

Troubleshooting 26 3A1602GStatus Code 6: High Motor TemperatureMotor is running too hot.1. Motor temperature too high. Reduce pressure duty cycle, gun

Troubleshooting3A1602G 27Troubleshooting ChartProblem Cause SolutionReactor E-8p does not operate. No power. Plug in power cord.Cycle Motor Power off

Troubleshooting 28 3A1602GPressure is higher on one side when setting pressure with function knob.Pump intake valve partially plugged. Clean pump inta

Troubleshooting3A1602G 29A side rich; lack of B side. A side gauge is low. B side restriction downstream of gauge. Check gun check valve screen, mix m

Systems3A1602G 3SystemsProportionersThe model no., series letter, and serial no. are located on the back of the Reactor E-8p™. * See page 11 for detai

Repair 30 3A1602GRepairBefore Beginning Repair1. Flush if possible, see page 22. If not possible, clean all parts with solvent immediately after remov

Repair3A1602G 31Displacement PumpNOTE: Use drop cloth or rags to protect Reactor E-8p and surrounding area from spills.See Before Beginning Repair, pa

Repair 32 3A1602GReplace Function Knob/Potentiometer1. See Before Beginning Repair, page 30. Relieve pressure, page 20.2. Insert pin through cart hand

Repair3A1602G 33Control BoardPower Bootup CheckNOTE: There is one red LED (D11) on the board. Power must be on to check. See FIG. 58 for location. Fun

Repair 34 3A1602GFIG. 58: Control Module Wiring ConnectionsJ1J7J10Motor Power On/Off (20 A Breaker)J11 (120 V Board)J4J11J9Function KnobSW2 (see page

Repair3A1602G 35Pressure Transducers1. See Before Beginning Repair, page 30. Relieve pressure, page 20.2. Insert pin through cart handle and lock with

Repair 36 3A1602G6. Disconnect cart handles.a. Remove screws (42) from handle (37).b. Hold pin (40) and remove screw (10).c. Gently tap the top-center

Repair3A1602G 37Cycle Counter Switch ReplacementFIG. 61: Drive HousingCrankshaft must be in line with crankshaft at other end of motor, so pumps move

Repair 38 3A1602GElectric MotorTest MotorIf motor is not locked up by pumps, it can be tested using a 9 V battery. 1. Open recirculating valves, disco

Repair3A1602G 39InstallationSee FIG. 62, page 38.1. If replacing motor, install fan assembly and fan mount threaded bushing on new motor.2. Place cart

Warnings 4 3A1602GWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point

Repair 40 3A1602GSpout AdapterThe sprayer is supplied with a 40 mm spout adapter. Follow these instructions to install 38 mm spout adapt-ers or repair

Parts3A1602G 41Parts120 V and 240 V Fusion Air Purge System Packages120 V and 240 V Fusion CS System Packages120 V and 240 V P2 System Packages120 V a

Parts 42 3A1602G259082 (120V) and 259083 (240V), Bare ProportionerTI17471b735749 (2x)47 (2x)48 (2x)616751 (2x)52 (4x)31 (2x)32 (2x)33 (2x)34 (2x)35 (2

Parts3A1602G 43259082 (120V) and 259083 (240V), Bare Proportioner (continued)TI17472a20211994216a85141523228786 168611 (4x)810 (4x)1213 (7x)6110 (4x)9

Parts 44 3A1602G259082 (120V) and 259083 (240V), Bare Proportioner (continued)384443 (2x)88 (2x)41 (4x)10 (2x)37 (2x)40 (2x)39439047 (4x)91 (2x)3 (2x)

Parts3A1602G 45259082 (120V) and 259083 (240V), Bare Proportioner (continued)▲ Replacement Danger and Warning labels, tags, and cards are available at

Parts 46 3A1602G24L885, 120 V Bare Proportioner24L979, 240 V Bare Proportioner* Included in 248231 Crankshaft Kit.† Included in 287057 Gear Reducer Ki

Parts3A1602G 473/8 in. ID x 50 ft Insulated Hose Bundle without Recirculation Lines with Air Hose, 24M65301/4 in. ID x 35 ft Non-Insulated Hose Bundle

Parts 48 3A1602GRecirculation Manifold, 24J147Torque to 250 in-lb (28 N•m).1Use blue threadlocker on valve cartridge threads into manifold.2Apply lubr

Parts3A1602G 49Pour Spout AdapterPart Description24J15540 mm A Side Pour Spout Adapter24J76640 mm B Side Pour Spout Adapter24M05238 mm B Side Pour Spo

Warnings3A1602G 5FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire

Suggested Spare Replacement Parts 50 3A1602GSuggested Spare Replacement PartsAccessoriesFusion Air Purge GunAir purge gun, available in round or flat

Dimensions3A1602G 51Dimensions34.58 in.(87.8 cm)24.12 in.(61.3 cm)15.06 in.(38.3 cm)TI17120a

Dimensions 52 3A1602G

Technical Data3A1602G 53Technical DataReactor E-8pUS MetricMaximum fluid working pressure 2000 psi 14 MPa, 138 barElectrical requirements Model 25908

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves th

Warnings 6 3A1602GMOVING PARTS HAZARDMoving parts can pinch, cut or amputate fingers and other body parts.• Keep clear of moving parts.• Do not operat

Important Two-Component Material Information3A1602G 7Important Two-Component Material InformationIsocyanate Conditions Material Self-ignition Keep Com

Overview 8 3A1602GChanging Materials• When changing materials, flush the equipment mul-tiple times to ensure it is thoroughly clean.• Check with your

Component Identification3A1602G 9Component IdentificationKey:A Pump AB Pump BC Fluid Pressure GaugesD Recirc/Spray and Overpressure Relief ValvesE Con