Graco 309550ZAE - Fusion Plural Component, Impingement Mix, Air Purge Spray Gun Instructions
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Instructions - Parts
Plural Component, Impingement Mix
Air Purge Spray Gun
For use with non-flammable foam and polyurea. For professional use only.
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
Read all warnings and instructions in this manual.
Save these instructions.
309550ZAE
EN
TI2408-1A
2
Manual Conventions
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Models/Mix Chamber Selection Guide . . . . 3
Round Pattern Guns . . . . . . . . . . . . . . . . . . . . . . 3
Flat Pattern Guns . . . . . . . . . . . . . . . . . . . . . . . . 4
Flat Pattern Guns, continued . . . . . . . . . . . . . . . 5
Flat Pattern Stud Wall Gun . . . . . . . . . . . . . . . . . 5
Spatter Pattern Gun . . . . . . . . . . . . . . . . . . . . . . 6
Wide Round Pattern Gun . . . . . . . . . . . . . . . . . . 6
Four-Hose Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Non 1:1 Ratio Guns . . . . . . . . . . . . . . . . . . . . . . 6
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 10
Keep A and B Components Separate . . . . . . . . . 10
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . 10
Turning Air Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loss of Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 15
Optional Configurations . . . . . . . . . . . . . . . . . . . . 16
Optional Fluid Manifold Position . . . . . . . . . . . . 16
Optional Hose Position . . . . . . . . . . . . . . . . . . . 17
Flat Spray Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 19
Keep Gun Clean . . . . . . . . . . . . . . . . . . . . . . . . 19
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Weekly to Monthly . . . . . . . . . . . . . . . . . . . . . . . 19
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean Outside of Gun . . . . . . . . . . . . . . . . . . . . 20
Clean Air Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean Fluid Manifold . . . . . . . . . . . . . . . . . . . . . 20
Clean Mix Chamber Nozzle . . . . . . . . . . . . . . . . 21
Clean Passages . . . . . . . . . . . . . . . . . . . . . . . . 21
Clean Impingement Ports . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 25
Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove Front End . . . . . . . . . . . . . . . . . . . . . . 27
Attach Front End . . . . . . . . . . . . . . . . . . . . . . . . 28
Mix Chamber and Side Seal Cartridges . . . . . . 29
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . 33
Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mix Chamber Kits . . . . . . . . . . . . . . . . . . . . . . . 37
Flat Tip Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gun Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check Valve Filter Screen Kits . . . . . . . . . . . . . 38
Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drill Bit Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Purge Handle Cleanout Drill Kit . . . . . . . . . . 40
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Conventions
Warning
WARNING
A warning alerts you to possible serious injury or death if you do not follow instructions.
Symbols, such as fluid injection (shown), alert you to a specific hazard and direct you to read the indicated
Caution
CAUTION
A caution alerts you to possible equipment damage or destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
List of Models/Mix Chamber Selection Guide
List of Models/Mix Chamber Selection Guide
Round Pattern Guns
Gun Part
No., Series
246099, A
246100, A
248617, A
246101, A
246102, A
246103, A
246104, A
246105, A
255201, A
255202, A
Part No.
AR2020
AR2929
AR3737
AR4242
AR5252
AR6060
AR7070
AR8686
AR4242
AR5252
Mix Chamber
Impingement
Port Size in. (mm)
Equivalent
Size
.020 (0.50)
.029 (0.70)
.037 (0.94)
.042 (1.00)
.052 (1.30)
.060 (1.50)
.070 (1.75)
.086 (2.15)
.042 (1.00)
.052 (1.30)
-000
-00
None
-01
-02
-03
-04
-05
-01
-02
Seal
Material
SST
SST
SST
SST
SST
SST
SST
SST
Polycarballoy
Polycarballoy
Pattern at 24 in
(61 cm) from target in. (mm)
5 (127)
8 (203)
9 (227)
11 (279)
12 (305)
14 (356)
15 (381)
18 (457)
11 (279)
12 (305)
5.0
(18.9)
4.0
(15.1)
3.0
(11.4)
2.0
(7.6)
W
82
82
AR
86
86
(0
5)
A
A
R
70
70
(0
4)
A
W
64
64
57
57
AR
60
60
(0
3)
AW
02)
, A
W4
AR
525
2 (
646
*
AR42
42 (
01),
AW
393
9*
333*
AR3
737,
AW3
AR292
9 (00),
AW28
28*
AR2020
(000)
1.0
(3.8)
0
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
2000
(13.8, 138)
2500
(17.4, 172.4)
PRESSURE in psi (MPa, bar)
3000
(20.7, 207)
3500
(24.1, 241)
*Accessory AW (wide pattern) mix chambers are available. See page 41.
3
4
List of Models/Mix Chamber Selection Guide
Gun Part
No., Series
247101, A
247102, A
247103, A
247104, A
247107, A
247108, A
247111, A
247112, A
247113, A
247114, A
247117, A
247118, A
247121, A
247122, A
247123, A
247124, A
247127, A
247128, A
247131, A
247132, A
247133, A
247134, A
247137, A
247138, A
AF2929
AF2929
AF2929
AF2929
AF2929
AF4242
AF4242
AF4242
Part No.
AF2020
AF2020
AF2020
AF2020
AF2020
AF2020
AF2929
AF4242
AF4242
AF4242
AF5252
AF5252
AF5252
AF5252
AF5252
AF5252
Flat Pattern Guns
Mix Chamber
Impingement
Port Size in. (mm)
.020 (0.50)
.020 (0.50)
.020 (0.50)
.020 (0.50)
.020 (0.50)
.020 (0.50)
.029 (0.70)
.029 (0.70)
.029 (0.70)
.029 (0.70)
.029 (0.70)
.029 (0.70)
.042 (1.00)
.042 (1.00)
.042 (1.00)
.042 (1.00)
.042 (1.00)
.042 (1.00)
.052 (1.30)
.052 (1.30)
.052 (1.30)
.052 (1.30)
.052 (1.30)
.052 (1.30)
-00
-00
-01
-01
-00
-00
-00
-00
Equivalent
Size
-000
-000
-000
-000
-000
-000
-02
-02
-02
-02
-01
-01
-01
-01
-02
-02
FT0438
FT0624
FT0638
FT0838
FT0848
FT0424
FT0438
FT0624
Part No.
FT0424
FT0438
FT0624
FT0638
FT0838
FT0848
FT0424
FT0638
FT0838
FT0848
FT0424
FT0438
FT0624
FT0638
FT0838
FT0848
Flat Tip
Pattern Size in. (mm)
8-10 (203-254)
8-10 (203-254)
12-14 (305-356)
12-14 (305-356)
16-18 (406-457)
16-18 (406-457)
8-10 (203-254)
8-10 (203-254)
12-14 (305-356)
12-14 (305-356)
16-18 (406-457)
16-18 (406-457)
8-10 (203-254)
8-10 (203-254)
12-14 (305-356)
12-14 (305-356)
16-18 (406-457)
16-18 (406-457)
8-10 (203-254)
8-10 (203-254)
12-14 (305-356)
12-14 (305-356)
16-18 (406-457)
16-18 (406-457)
.024 (0.61)
.038 (0.97)
.038 (0.97)
.048 (1.22)
.024 (0.61)
.038 (0.97)
.024 (0.61)
.038 (0.97)
.038 (0.97)
.048 (1.22)
Orifice Size in. (mm)
.024 (0.61)
.038 (0.97)
.024 (0.61)
.038 (0.97)
.038 (0.97)
.048 (1.22)
.024 (0.61)
.038 (0.97)
.024 (0.61)
.038 (0.97)
.038 (0.97)
.048 (1.22)
.024 (0.61)
.038 (0.97)
List of Models/Mix Chamber Selection Guide
Flat Pattern Guns, continued
3.0
(11.4)
2.25
(8.55)
1.5
(5.7)
AF5
252
wit h F
TXX
48 t ip
AF4
242 with
FTX
X38 tip
AF292
9 with
FTXX3
8 tip
AF2020 w ith FTXX
24 tip
0.75
(2.85)
0
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
2000
(13.8, 138)
2500
(17.4, 172.4)
PRESSURE in psi (MPa, bar)
3000
(20.7, 207)
3500
(24.1, 241)
Flat Pattern Stud Wall Gun
See manual number 311071 for more information.
Gun Part
No., Series Part No.
249525
249526
AF4242
AF5252
Mix Chamber
Impingement
Port Size in. (mm)
Equivalent
Size
.042 (1.00)
.052 (1.30)
-01
-02
Part No.
FTM979
FTM979
Flat Tip Flow Data
Pattern Dia. at
24 in. (610 mm) to Target in. (mm)
Orifice Size in. (mm)
Approximate
Flow Rate at
1000 psi
(7.0 MPa, 70 bar)
22 (559)
22 (559)
.038 (0.97)
.038 (0.97)
11 lb/min
(4.99 kg/min)
15 lb/min
(6.81 kg.min)
5
6
List of Models/Mix Chamber Selection Guide
Spatter Pattern Gun
Gun Part
No., Series
248408 A
Part No.
AR7070
Mix Chamber
Impingement
Port Size in. (mm)
.070 (1.75)
Equivalent
Size
-04
Wide Round Pattern Gun
Gun Part
No., Series
249529
249530
Part No.
AW3939
AW4646
Mix Chamber
Impingement
Port Size in. (mm)
Equivalent
Size
.039 (0.99)
.046 (1.17)
-01
-02
Pattern Diameter at
24 in. (610 mm) to
Target in. (mm)
16 (406.4)
18 (457.2)
Equivalent Flow to
Mix Chamber Size
Reference Part No.
AR4242
AR5252
Four-Hose Gun
Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold
Gun Part
No., Series Part No.
Mix Chamber
Impingement
Port Size in. (mm)
Equivalent
Size
Pattern Diameter at
24 in. (610 mm) to
Target in. (mm)
249810 AW2222 .022 (0.56) NA
8-9 (203-229)
Approximate Flow
Rate at 1000 psi
(7.0 MPa, 70 bar)
4.5 lb/min
(204 kg/min)
Non 1:1 Ratio Guns
Gun Part
No., Series
253888
Mix
Chamber
AR2232
Warning
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• 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.
• Read Material Safety Data Sheet (MSDS) 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.
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 the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the gun fluid nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Follow
Pressure Relief Procedure , page 15, when you stop spraying and before cleaning, check-
ing, or servicing equipment.
• Use lowest possible pressure when flushing, priming, or troubleshooting.
• Engage piston safety lock when not spraying.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose.
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.
7
8
Warning
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).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Ground equipment and conductive objects. See
• Hold gun firmly to side of grounded pail when triggering into pail.
• Use only grounded hoses.
• If there is static sparking or you feel a shock, stop operation immediately.
Do not use equipment until you identify and correct the problem.
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment. Use only Graco parts and accessories.
• 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.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• 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 damage.
Overall View
Overall View
K F R G
U
N
C
P
S
D
L
B
M
A
T
J
E
H
Key:
A A Side Fluid Valve (ISO)
B B Side Fluid Valve (RESIN)
C Air Cap
D Air Line Quick Coupler
E Muffler
F Fluid Housing
G Grease Fitting (under cap)
H Handle
J Optional Air Inlet
K Cleanoff Air Valve
L Piston Safety Lock
M Gun Fluid Manifold
N Mix Chamber Nozzle
P Optional Fluid Inlets (A Side Shown)
R Lock Ring
S Fluid Inlet Swivels (A Side Shown)
T Trigger
U Front Retaining Ring
V Gun Air Whip Hose
W Air Valve
V
W
TI2408A
9
Isocyanate Hazard
Isocyanate Hazard Piston Safety Lock
Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.
Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.
WARNING
Read warnings, page 7.
To engage piston safety lock: push knob in and turn clockwise. If engaged, gun will not actuate.
Engaged
TI2409A
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.
Keep A and B
Components
Separate
CAUTION
To prevent cross-contamination of the gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) 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.
Disengaged
TI2410A
Grounding
WARNING
Check your local electrical code and proportioner manual for detailed grounding instructions.
Ground the spray gun through connection to a
Graco-approved grounded fluid supply hose.
10
Turning Air Cap
WARNING
Read warnings, page 7.
1.
Follow
Pressure Relief Procedure , page 15.
2.
Close fluid valves A and B before turning air cap
(C).
Turning Air Cap
Loss of Air Pressure
In event of loss of air pressure, gun will continue to spray. To shut off gun, do one of the following:
•
Push in piston safety lock, see page 10.
• Close fluid valves A and B.
B
TI2421A
A
C
B
TI2421A
A
11
Setup
Setup
1.
Close fluid valves A and B.
To change position of fluid manifold or use
optional fluid inlets, see pages 16 and 17.
5.
Connect quick coupler (D). Turn on air. Open air valve (W*). Air should flow from nozzle (N).
TI2411A
2.
Connect A (ISO) and B (RESIN) fluid hoses to fluid manifold.
B (RESIN)
N
D
W*
To use optional air inlet, see page 17.
6.
Disengage piston safety lock, page 10.
TI2414-1A
A (ISO) TI2417A
3.
Engage piston safety lock, page 10.
TI2410A
TI2409A
4.
Connect gun air whip hose (V) and air valve (W*) to main air hose. Attach fluid manifold (M) to gun.
7.
Trigger gun to check for full mix chamber travel.
Front of air cap (C) should be approximately flush with front retaining ring (U).
U
C
TI2414-1A
* (W) Not included with spatter gun.
M
W*
V
TI2554A
12
Setup
8.
Open cleanoff air valve (K) 1/4-1/2 turn and trigger gun to check that cleanoff air is flowing. Adjust as desired.This step does not apply with spatter spray gun 248408.
13.
Test spray onto cardboard. Adjust pressure and temperature to get desired results.
K
9.
Engage piston safety lock, page 10.
TI2409A
TI2413A
TI2645A
14.
Apply layer of lubricant over front of gun and lock ring, or use gun cover to prevent overspray
buildup and ease disassembly. See page 43 to
order lubricant and gun cover.
15.
Gun is ready to spray.
10.
Turn on proportioner.
CAUTION
Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved,
11.
Open B (RESIN) fluid valve (about three half turns). Then open A (ISO) fluid valve.
12.
Disengage piston safety lock, page 10.
TI2414A
TI2410A
13
Shutdown
Shutdown
For overnight shutdown:
1.
Follow Pressure Relief Procedure , page 15.
2.
Leave air turned on and gun detriggered.
3.
Remove grease fitting cap. Using grease gun (Y), dispense grease into fitting (G) until grease mist sprays from mix chamber nozzle (N). Do not over-grease; use 2 shots maximum. Do not spray grease mist on sprayed material.
G
Y
Grease gun daily to prevent 2 component 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,
KEY
Purge Air
Fluid
Cleanoff Air
Grease
G
TI3547a
19
AC
IP
N
4.
Replace grease cap.
W
TI2415A
5.
Round and Flat pattern guns only:
Turn off air valve (W).
Spatter pattern gun only:
Shut down main air supply.
N
TI3546a
14
Pressure Relief Procedure
Pressure Relief Procedure
WARNING
4.
Trigger gun onto cardboard or into waste container to relieve pressure.
Read warnings, page 7. Relieve pressure before cleaning or repairing gun.
1.
Engage piston safety lock, page 10.
TI4722a
5.
Engage piston safety lock, page 10.
TI2409A
CAUTION
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 (W) open.
WARNING
TI2409A
Fluid in the hose and proportioner is still under pressure. Follow the Pressure Relief Procedure in the proportioner manual.
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.
B
W
A
3.
Disengage piston safety lock, page 10.
TI2421A
TI2484A
TI2410A
15
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 swivel, check valve, side seal cartridge, and mix chamber) to right.
6.
Attach fluid manifold. Connect air. Return gun to service.
CAUTION
To prevent cross-contamination of gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) parts.
1.
Follow Pressure Relief Procedure , page 15.
2.
Disconnect air (D) and remove fluid manifold (M).
M
3.
4.
Rotate fluid housing 180°.
5.
D
TI2554A
16
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.
4.
Apply thread sealant to plugs (12c), elbows (50*), and male threads of swivels (A, B). Install elbows
(50*) in optional inlets (P), facing down. Install swivels (A, B) in elbows. Be sure to install A swivel
(smaller) in A side. Install plugs where swivels had been. Torque all parts to 235-245 in-lb (26.6-27.7
N•m).
CAUTION
To prevent cross-contamination of gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) parts.
Elbows (50*) are not included with spatter spray gun.
1.
Follow Pressure Relief Procedure , page 15. Also
relieve system pressure, see proportioner manual.
B
12c
50*
2.
Disconnect air (D) and remove fluid manifold (M). P
A
TI2646A
5.
Connect A and B hoses to A and B swivels.
M
D
TI2554A
6.
Remove fitting (D) and plug (J). Reverse positions.
Apply thread sealant and torque to 125-135 in-lb
(14-15 N•m).
D
3.
Disconnect fluid hoses from inlet swivels (A, B).
Remove swivels. Remove plugs from optional inlets (P).
B
P
A
TI2540A
J
7.
Attach fluid manifold. Connect air. Return gun to service.
TI2417A
17
Flat Spray Tips
Flat Spray Tips
1.
Follow Pressure Relief Procedure , page 15.
2.
Remove air cap (10) and flat spray tip (39). Inspect o-ring (40).
4.
Reposition tip horizontally or vertically, or install different tip size.
TI2649A
10
39
40
TI2557A
If tip is stuck, pry off with small screwdriver or pull off with pliers. Tip is hardened to resist damage.
3.
To clean, soak tip in compatible solvent, see page
20. Clean gently with tip cleanout tool 15D234,
page 44, to fit tip configuration.
TI2648A
Tips marked on back with last 3 digits of part no.
See
Flat Tip Part No. Reference Guide
, page
5.
Reinstall air cap hand tight. Cleaning hole alignment to tip not important.
18
Maintenance
Maintenance
Supplied Tool Kit
• Hex Nut Driver; 5/16
• Screwdriver; 1/8 blade
• Nozzle Drill Bit; various sizes depending on nozzle size. See T ABLE 1, page 21.
• Impingement Port Drill Bit; various sizes depending on port size. See T ABLE 3, page 22.
• 117661 Pin Vise; dual reversible chucks
Reversible
4.
5.
Clean Fluid Manifold , page 20.
6.
7.
Clean Impingement Ports , page 21.
Reversible
TI3864a
Daily
• 551189 Grease Gun; with 3 oz grease
• 15B817 Flush Manifold
Not included with spatter spray gun.
Weekly to Monthly
Keep Gun Clean
Keep gun clean with accessory gun cover, page 40.
Applying a light coat of lubricant will make cleaning easier.
1.
Clean Mix Chamber and Side Seal Cartridges , page 29. Check o-rings.
2.
Clean Check Valves , page 31. Check o-rings and
filters.
As Needed
1.
Clean Outside of Gun , page 20.
2.
Clean Mix Chamber Nozzle , page 21, a minimum
of once a day.
3.
19
Maintenance
Flush Gun
If it is necessary to flush gun, use following procedure.
WARNING
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 (X) in the top mating surface.
Do not damage the flat sealing surfaces. Coat with grease if left exposed, to seal out moisture.
1.
Follow Pressure Relief Procedure , page 15.
X
2.
Flush with compatible solvent 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.
3.
Follow Pressure Relief Procedure , page 15.
TI2411-1
For a more thorough flush, Solvent Flush Kit
218669 is available as an accessory. The kit connects to Flush Manifold 15B817.
Clean Outside of Gun
Wipe off outside of gun with compatible solvent.
Use N Methyl Pyrrolidone (NMP), Dynasolve CU-6,
Dzolv, or equivalent to soften cured material.
CAUTION
These solvents are not recommended for flushing.
Clean Air Cap
Soak air cap in compatible solvent. Clean holes with #58
(.042) drill bit.
Clean Muffler
Remove and clean muffler with compatible solvent.
20
Maintenance
Clean Mix Chamber Nozzle Clean Passages
1.
Engage piston safety lock, page 10.
If necessary, clean out passages in fluid housing and
handle with drill bits. Refer to T ABLE 2 and to
View on page 26 for diameter and location of passages.
All drill bits are available in an accessory kit. Order kit
248969 for Air Purge Handle Drill Kit, see page 40.
N
TI2409A
2.
Refer to T
ABLE
1. Also see identification chart under
Drill Bit Kits , page 39. Use the appropriate
size drill bit to clean mix chamber nozzle (N). If necessary, clean air cap (C) gently with stiff brush.
Table 2: Passage Diameters
Passage Description
Optional Air Inlet
Ref. Letter
C
Purge Air
Piston Air
Air Exhaust
Air Valve Bore
Cleanoff Air
Check Valve Holes
Grease
D
E, F
G
H
Not Shown
Not Shown
Not Shown
Diameter, in. (mm)
7/16, 1/8
(11.0, 3.1)
1/8 (3.1)
1/8 (3.1)
11/32, 1/8
(8.7, 3.1)
9/32 (7.1)
3/32 (2.35)
3/32 (2.35)
3/32 (2.35)
Clean Impingement Ports
C
TI2418A 1.
Follow Pressure Relief Procedure , page 15.
Table 1: Nozzle Drill Bit Sizes
Round Spray
Mix Chamber
Part No.
Drill Size in. (mm)
AR2020
AR2929
#58, .042
(1.00)
#55, .052
(1.30)
AR3737
AR4242
AR5252
AR6060
#55, .052
(1.30)
#53, .060
(1.50)
#50, .070
(1.75)
#44, .086
(2.15)
AR7070
AR8686
3/32, .094
(2.35)
#32, 0.116
(2.90)
Flat Spray
Mix Chamber
Part No.
Drill Size in. (mm)
AF2020
AF2929
3/32, .094
(2.35)
3/32, .094
(2.35)
AF4242
AF5252
3/32, .094
(2.35)
3/32, .094
(2.35)
2.
3.
4.
Disconnect air (D) and remove fluid manifold (M).
M
, page 20. If gun will not flush, see page
D
TI2554A
21
Maintenance
5.
Push mix chamber forward until impingement ports
(IP) are visible. See T ABLE 3 for appropriate size drill to clean ports. Also see identification chart
under Drill Bit Kits , page 39. Some mix chambers
have counterbored holes (CB) and require two drill sizes to clean impingement ports completely.
CB
IP
CB IP
TI2420A
Table 3: Impingement Port Drill Bit Sizes
AR2020
AR2929
AR3737
AR4242
AR5252
AR6060
AR7070
AR8686
AF2020
AF2929
AF4242
AF5252
Mix Chamber
Part No.
Impingement Port (IP)
Drill Bit Size in. (mm)
#76, .020 (0.50)
#69, .029 (0.70)
#63, .037 (0.94)
#58, .042 (1.00)
#55, .052 (1.30)
#53, .060 (1.50)
#50, .070 (1.75)
#44, .086 (2.15)
#76, .020 (0.50)
#69, .029 (0.70)
#58, .042 (1.00)
#55, .052 (1.30)
Counterbore (CB)
Drill Bit Size in. (mm)
#53, .060 (1.50)
#53, .060 (1.50)
N/A
N/A
N/A
N/A
N/A
N/A
#53, .060 (1.50)
#53, .060 (1.50)
N/A
N/A
6.
Push mix chamber back in position.
TI3533a
Mix Chambers AR and AF,
2020 and 2929
Mix Chambers AR and AF,
4242 or larger
7.
8.
Attach fluid manifold. Connect air. Return gun to service.
22
Troubleshooting
Troubleshooting
1.
Follow
Pressure Relief Procedure , page 15,
before checking or repairing gun.
2.
Check all possible problems and causes before disassembling gun.
CAUTION
To prevent cross-contamination of the gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) parts.
PROBLEM CAUSE SOLUTION
Gun does not fully actuate when triggered.
Leakage between flat tip and mix chamber.
Safety lock engaged.
Disengage safety lock, page 10.
Plugged muffler (22).
Damaged air valve o-rings (24).
Open.
Fluid does not spray when gun is fully actuated.
Closed fluid valves (12b).
Plugged impingement ports.
Gun actuates slowly.
Plugged check valves (26).
Plugged muffler (22).
Damaged piston o-rings (16, 17).
Dirty air valve, or damaged o-rings
(24).
Gun delays, then actuates abruptly.
Cured material around side seals
(18).
Inspect side seals (18c) and mix chamber (19) for scratches. Replace,
Retaining ring (9) not bottomed out.
Tighten retaining ring until bottomed out.
Loss of round pattern.
Loss of flat pattern.
Dirty mix chamber nozzle.
Plugged spray tip.
Clean air valve or replace o-rings,
Clean in compatible solvent, page
Worn tip.
Dirty mix chamber nozzle.
Tip not seated properly.
Pressure imbalance.
Damaged/missing o-ring (40).
Plugged impingement ports.
Plugged check valves (26).
Viscosities not equal.
Adjust temperature to compensate.
23
Troubleshooting
PROBLEM CAUSE SOLUTION
A and/or B fluid in gun air section.
Damaged side seals (18c).
Damaged mix chamber (19).
Damaged side seal o-rings (18d,
18e).
Tightened air cap with fluid valves
(12b) open.
Fluid mist from mix chamber or air cap.
Damaged side seals (18c).
Damaged side seal o-rings (18d,
18e).
Damaged mix chamber (19).
Too much cleanoff air.
Excessive overspray.
Rapid buildup of material on air cap.
Plugged air cap holes.
Too little cleanoff air.
Reduced cleanoff air.
Excessive cleanoff air when fluid valves are closed and gun is triggered.
Fluid does not shut off when fluid valves are closed.
Burst of air from muffler when gun is triggered.
Steady air leakage from muffler.
Damaged/missing fluid housing o-ring (23).
Damaged front o-ring (3).
Damaged front o-ring (3).
Damaged/missing fluid housing o-ring (23).
Damaged fluid valves (12b).
Normal.
Air leakage from front air valve.
Air leak around lock ring.
Cannot tighten retaining ring (9) until it bottoms out.
Close valves first.
Replace.
No action required.
Damaged air valve o-rings (24).
Damaged piston o-rings (16, 17).
Damaged air valve o-rings (24).
Damaged o-ring (21).
Air cap (10) assembled before retaining ring (9).
Install retaining ring (9) first, then air
24
Troubleshooting
Theory of Operation
Gun Triggered (Fluid Spraying)
Mix chamber (19) moves back, shutting off purge air flow. Impingement ports (IP) align with fluid ports of side seals (18c), allowing fluid to flow through mix chamber nozzle (N).
See page 13 to adjust cleanoff air valve (K).
KEY
Purge Air
Fluid
Cleanoff Air
Grease
TI3547a
Flow paths are not shown to scale, for clarity.
19 18c
IP
KEY
Purge Air
Fluid
Cleanoff Air
Grease
TI3547a
Flow paths are not shown to scale, for clarity.
G
19
AC
IP
N
TI3546a
K N
TI3545a
Gun Detriggered (Air Purging)
Mix chamber (19) 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 page 14 for use of grease fitting (G).
25
Troubleshooting
Cutaway View
8
23 19 17 15
16 14 4
10
26
3
21
18 (A Side)
B Side not shown
D E F
C
H
G
24
24
26
12b
22
Repair
Repair
Tools Required
Tools needed for complete gun repair:
• adjustable wrench
• flat head screwdriver (included)
• 1/8 in. (3 mm) diameter rod
• 5/16 hex nut driver (included)
Remove Front End
WARNING
Lubrication
Liberally lubricate all o-rings, seals, and threads. Lubri-
cate threads and outside of lock ring (11). See page 43
to order lubricant.
Read warnings, page 7. Proper attachment of front end is critical. Do not operate gun if front end is loose or lock ring is not snug against handle.
1.
Follow Pressure Relief Procedure , page 15.
2.
CAUTION
If lock ring (R) 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.
3.
Unscrew lock ring (R) until front end of gun is loose. Turn fluid housing (F) 1/8 turn counterclockwise. Unscrew lock ring completely and remove front end of gun.
F R TI2416A
27
Repair
Attach Front End
WARNING
Read warnings, page 7. Proper attachment of front end is critical. Do not operate gun if front end is loose or lock ring is not snug against handle.
1.
Engage piston safety lock, page 10.
3.
Check that o-ring (21) is in position. Liberally lubricate o-ring, threads of lock ring (R) and handle (H), and outside of lock ring. Orient front end (F) as required for desired fluid manifold mounting (bottom mounting is shown). Insert keyed end (W) of mix chamber in socket (X). Screw lock ring onto handle as far as possible by hand.
Y W X Z
TI2416A F 21 R H
TI2409A
2.
Push on air cap (C) until it is flush with front of gun.
This ensures that mix chamber is all the way back.
4.
Turn fluid housing 1/8 turn clockwise to engage slots (Y) and tabs (Z). Push on front end to ensure it is properly seated. Continue screwing lock ring
(R) onto handle (H) very securely. When properly assembled, lock ring is snug against handle.
C
R H
TI2422A
TI2423A
28
Repair
Mix Chamber and Side Seal
Cartridges
See page 3 for available mix chamber sizes.
1.
Follow
Pressure Relief Procedure , page 15.
6.
Remove air cap (10) and retaining ring (9). Inspect o-ring (3) inside retaining ring.
10
3
9
2.
Remove fluid manifold (M). Leave air connected.
TI2424A
M
TI2543A
3.
Flush gun to remove residual A and B compo-
nents, page 20. Follow Pressure Relief Procedure , page 15.
4.
Disconnect air.
CAUTION
To prevent cross-contamination of side seal cartridges, do not interchange A component and B component parts. The A component cartridge is marked with an A.
7.
Pull out side seal cartridges (18). Also inspect o-ring (24) on cleanoff air valve (8).
24
18 B
A
18
TI2426A
Continued on page 30.
TI2540A
5.
29
Repair
8.
Pull mix chamber (19) out rear of fluid housing.
Inspect for damage and clean ports, page 21.
Inspect o-ring (23) in front of fluid housing.
11.
Liberally lubricate and reinstall side seal cartridges (18).
24
CAUTION
To prevent cross-contamination of the gun’s wetted parts, mix chamber is marked with an A and a notch
(N) on back edge. Be sure the A side of mix chamber is on the A side of gun.
18 B
A
18
TI2426A
9.
Apply thin coat of lubricant to mix chamber (19).
Install mix chamber. Etched A and notch (N) must be on same side as A on fluid housing. Mix chamber is keyed to fit in fluid housing.
12.
Lubricate all threads and reinstall retaining ring
(9). Install air cap (10).
9
19
B
10
A
N
TI2428A
TI2424A
13.
CAUTION
To prevent cross-contamination of side seal cartridges, do not interchange A component and B component parts. The A component cartridge is marked with an A.
14.
Connect air, and trigger the gun a few times to check for leaks. If either check valve pops out of its seated position, there is a poor fluid seal on that side of the mix chamber or side seal/cartridge components. Correct the problem before attaching the fluid manifold.
10.
Carefully inspect side seal cartridge o-rings and surfaces. Replace worn or damaged parts. Liberally lubricate o-rings (18d, 18e) and reassemble. Press on side seal (18c) to check proper spring (18b) operation.
15.
Attach fluid manifold. Connect air. Return gun to service.
30
18e
18c
18b
18d
TI2427A
Repair
Check Valves
Before disassembling, press on ball (26c) to test check valve for proper movement and spring action.
1.
Follow
Pressure Relief Procedure , page 15.
5.
Pry out check valves (26) at notch.
WARNING
2.
Remove fluid manifold (M). Leave air connected.
Clean Fluid Manifold , page 20.
3.
M
TI2543A
Flush gun to remove residual A and B compo-
nents, page 20. Follow Pressure Relief Procedure , page 15.
Read warnings, page 7. Damaged check valve o-rings
(26f, 26g) may result in external leakage. Replace o-rings if any damage is seen.
6.
Slide filter (26d) off. Clean and inspect parts. Thoroughly inspect o-rings (26f, 26g). If necessary, remove screw (26b) and disassemble entire check valve.
B
26
A
26b
26e
26c
26d
26g
26a
26f
TI2429A
4.
Disconnect air.
7.
Reassemble check valves. Screw (26b) should be flush (within 1/16 in. or 1.5 mm) of housing (26a) surface. Liberally lubricate o-rings (26f, 26g) and carefully reinstall in fluid housing.
TI2540A
8.
Attach fluid manifold. Connect air. Return gun to service.
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.
31
Repair
Piston
1.
Follow Pressure Relief Procedure , page 15.
2.
Disconnect air (D) and remove fluid manifold (M).
6.
Liberally lubricate piston o-rings. Reinstall piston.
Shaft is keyed for proper assembly. Push firmly to seat piston.
TI2432A
M
7.
Install cylinder cap (5).
D
TI2554A
3.
5
TI2430A 4.
Unscrew cylinder cap (5) and inspect o-ring (14).
8.
5
14
TI2430A
5.
Push piston shaft to remove piston (15). Inspect piston o-ring (16) and shaft o-ring (17).
15
9.
Attach fluid manifold. Connect air. Return gun to service.
16
17
TI2431A
32
Air Valve
1.
Follow Pressure Relief Procedure , page 15.
Repair
Piston Safety Lock
1.
Follow
Pressure Relief Procedure , page 15.
2.
Disconnect air (D) and remove fluid manifold (M).
2.
Disconnect air (D) and remove fluid manifold (M).
M
D
TI2554A
3.
Unscrew cylinder cap (5). Hold piston stop (28) with wrench and unscrew from safety lock (4).
Inspect spring (30) and o-rings (14, 24).
M
D
TI2554A
3.
Unscrew air valve plug (2) and remove spring (31).
Using a small diameter tool, push spool (32) out from front. Inspect o-rings (24).
5
24 30 4
TI2433A
24
32
31
2
28 14
TI2434A 4.
Liberally lubricate o-rings and reassemble. Clean threads with solvent or alcohol. Apply medium-strength Loctite® or equivalent to threads on stop (28) and reassemble.
4.
Liberally lubricate o-rings and reassemble. Torque plug (2) to 125-135 in-lb (14-15 N•m).
5.
Attach fluid manifold. Connect air. Return gun to service.
5.
Attach fluid manifold. Connect air. Return gun to service.
33
Parts
Parts
Round Pattern Gun Shown; see page 36
for additional parts and detail views
Seal Cartridge (18) Detail
4 ‡ 37
4
‡ 25
‡ 11
‡ 24
‡ 8
‡ 18; see detail above
17
15
‡ 10
3 ‡ *
‡ 9
‡ 26; see detail at right
23 ‡ *
12d
12a
16
28
7 ‡
14
5
19
24
30
4
4
‡ 18e ‡ 18c ‡ 18b ‡ 18d ‡ 18a
TI3926A
12b
2
29
‡ 18; see detail above
12e
3
12f
3
12c
3
50
12g
5
21 ‡
27
20
2
‡
6
13
47
24
32
31
2
1
35
1
1
22
4
33
1
Check Valve (26) Detail
‡
‡
26b
‡ 26e
‡ 26c
‡ 26d
‡ 26g
‡ 26a
26f
49
TI2435C
51
TI3927A
1 Torque to 125-135 in-lb (14-15 N•m).
2 Torque to 20-30 in-lb (2.3-3.4 N•m).
3 Torque to 235-245 in-lb (26.6-27.7 N•m).
4 Torque to 35-45 in-lb (4-5 N•m).
5 Torque to 32-40 ft-lb (43-54 N•m).
34
Parts
Ref.
No.
Part No. Description Qty
1
2
3 ‡
4 ★
5 ★
6
15K365 HANDLE
15B208 PLUG, air valve
248137 O-RING; PTFE; package of 6
15B206 LOCK, safety
7 ‡
8 ‡
15B204 CAP, cylinder
192272 PIN
15B215 RING, lock
15B223 VALVE, cleanoff air
9 ‡ 15B211 RING, retaining 1
10 ‡ 15B210 AIR CAP; for round pattern guns 1
1
1
1
1
1
1
1
1
15B801 AIR CAP; for flat pattern guns; not included in Front End Replace-
1 ment Kit 246361; see
◆
15D973 AIR CAP, for spatter pattern gun; not included in Front End Replace-
1 ment Kit 246361; see
11 ‡ 246491 HOUSING, fluid
12 246012 MANIFOLD, fluid, 2-hose; includes 12a-12g
249523 MANIFOLD, fluid, 4-hose; includes 12a, 12b, 12d-12g, 50; see
12a † . MANIFOLD
12b 246356 . VALVE, fluid
1
1
1
12c 100139 . PLUG, pipe; 1/8-27 npt
12d 15B221 . BOLT; 5/16-24
12e 117634 . SWIVEL, B side; 1/8 npt(m) x no. 6 JIC(f); for 2-hose manifold
117634 . SWIVEL, B side; 1/8 npt(m) x no. 6 JIC(f); for 4-hose manifold;
2
2
1
1
2
1
12f
117635 . SWIVEL, A side; 1/8 npt(m) x no. 5 JIC(f); for 2-hose manifold
117635 . SWIVEL, A side; 1/8 npt(m) x no. 5 JIC(f); for 4-hose manifold;
12g 15B993 . SPRING, ring, lock
13 15B209 TRIGGER
14* ★ 248136 O-RING, cylinder cap; package of 6
1
2
1
1
1
1
1
1
15
16*
17*
15B203 PISTON
248135 O-RING, piston; package of 6
248134 O-RING, piston shaft; package of 6
18 ‡ 246349 CARTRIDGE, seal, A side, SST; includes 18a-18e
246350 CARTRIDGE, seal, B side, SST; includes 18a-18e
18a † . CARTRIDGE BODY
18b 117491 . SPRING
18c* † . SEAL KIT; see page 41
18d* 248130 . O-RING, cartridge body; package of 6
18e* 248128 . O-RING, side seal;
19 package of 6
CHAMBER, mix, round; see
CHAMBER, mix, flat;
20 see
15C480 WASHER, wave
21 ‡ * 248132 O-RING; package of 6
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No. Description Qty
22 119626 MUFFLER
23 ‡ * 248131 O-RING; package of 6
24 ‡ * ★ 246354 O-RING; package of 6
25 ‡ 100846 FITTING, grease
26 ‡ 246731 VALVE, check, A side; includes
26a-26g
246352 VALVE, check, B side; includes
26a-26g
1
26a ‡† . HOUSING
26b ‡† 15B214 . SCREW; 5/16-18 x
1/2 in. (13 mm)
26c ‡ 257420 . BALL; carbide; package of 10 1
1
1
26d
26e
26f ‡
‡
‡
*
117490 . SPRING
248133 . O-RING, check valve face; package of 6
1
1
1
1
1
1
1
1
26g ‡* 248129 . O-RING, check valve housing; package of 6
1
27 ‡ 116550 RING, retaining
28 ★ 15B205 STOP, piston
1
1
29 203953 SCREW; 10-24 x 3/8 in. (10 mm) 1
30 ★ 114070 SPRING 1
31 117485 SPRING 1
1
1
32
33
15B202 SPOOL, valve
100721 PLUG, pipe; 1/4-18 npt; round and flat pattern guns only
117509 QUICK-DISCONNECT, male, air; 35 guns only
36 ▲ 222385 CARD, warning; not shown
37 ‡ 15B689 COVER, grease fitting
39 FTxxxx
1/4 npt(m); round and flat pattern
TIP, flat; see
1
1
1
1
40* 246360 O-RING; PTFE; flat tip models only; package of 3;
43
See Flat Pattern Guns , page 37
117661 VISE, pin; dual reversible chucks;
46
47
49
50
51 see
117792 GREASE GUN; not shown
117510 COUPLER, air line
15B772 HOSE, air; 1/4 npsm (fbe);
1
1
18 in. (0.46 m)
112307 ELBOW, street; 1/8 npt (m x f); round and flat pattern guns only
15B565 VALVE, ball; 1/4 npt (m x f); round and flat pattern guns only
2
1
1
1
1
See Detail Views , page 36, for additional parts.
* These parts are only available in repair kits. To
select a kit, refer to page 38.
†
‡
★
These parts are not available singly.
Included in Front End Replacement Kit 246361.
Included in Safety Stop Assembly 248064 (includes
1 of item 24).
▲
Replacement Danger and Warning labels, tags, and cards are available at no cost.
◆
Included in Spatter Tip Kit 248414 (see page 36).
35
Parts
Ref.
No.
Part No. Description
52 15B817 MANIFOLD, gun flush; round and flat pattern guns only
53 117642 NUT DRIVER, hex; 5/16
54 118575 SCREWDRIVER; 1/8 blade
55
▲
172479 TAG, warning; not shown
56
▲
15D235 SIGN, instruction; not shown
57 117773 GREASE CARTRIDGE; 3 oz; not shown; MSDS sheet available at www.graco.com
1
1
1
1
1
Qty
1
Ref.
No.
Part No. Description
58 ◆ 15D972 RETAINER, tip; spatter pattern gun only
59 ◆ 15D971 TIP; spatter pattern gun only
60 ◆ 248019 SEAL, package of 5; spatter pattern gun only.
61 ❖ 15F240 ADAPTER, stud wall
62 ❖ 15F854 PACKING, tip; stud wall
63 ❖ 15F241 CAP, air; stud wall
64 ❖ FTM979 TIP, flat; stud wall
1
1
1
1
1
1
Qty
1
▲
◆
❖
Replacement Danger and Warning labels, tags, and cards are available at no cost.
Included in Spatter Tip Kit 248414.
Included in Stud Wall Foam Kit 249421.
Detail Views
Flat Pattern Detail
10 39 40 † * 19
Flat Pattern Stud Wall Foam Detail
19 (Ref)
Spatter Tip Detail
◆
58
◆
59
10 ◆
60
◆
36
TI2557A
Supplied Tools
53
64 62
TI4660C-1
43
54
TI3870A
4-Hose Fluid Manifold Detail
12a
50
3
12e
12e
3
12f
3
50
12f
3
12b
5
12d
12g
TI7134A
1 Torque to 125-135 in-lb (14-15 N•m).
3 Torque to 235-245 in-lb (26.6-27.7 N•m).
5 Torque to 32-40 ft-lb (43-54 N•m).
TI4555B
Flush Manifold Detail
33 (Ref)
1
52
35 (Ref)
1
12d (Ref)
TI2647A
Parts
Mix Chamber Kits
Round Pattern Guns
AR2020
AR2929
AR3737
AR4242
AR5252
AR6060
AR7070
AR8686
Mix Chamber Kit
(includes drill bits)
Nozzle
Orifice
Size
0.042
0.052
0.052
0.060
0.070
0.086
0.094
0.116
Nozzle Drill
Bit Size, in. (mm)
#58 (1.00)
#55 (1.30)
#55 (1.30)
#53 (1.50)
#50 (1.75)
#44 (2.15)
3/32 (2.35)
#32 (2.90)
Impingement
Port Size
0.020
0.029
0.037
0.042
0.052
0.060
0.070
0.086
Impingement
Port Drill Bit
Size, in. (mm)
#76 (0.50)
#69 (0.70)
#63 (0.94)
#58 (1.00)
#55 (1.30)
#53 (1.50)
#50 (1.75)
#44 (2.15)
N/A
N/A
N/A
N/A
0.060
0.060
N/A
N/A
Counterbore
Size
N/A
N/A
N/A
N/A
Counterbore
Drill Bit Size, in. (mm)
#53 (1.50)
#53 (1.50)
N/A
N/A
Flat Pattern Guns
Mix Chamber
Kit (includes drill bits and o-ring)
AF2020
AF2929
AF4242
AF5252
Ref. No.
40 † ,
O-ring
Nozzle
Orifice
Size
Nozzle Drill
Bit Size, in. (mm)
Impingement
Port Size
Impingement
Port Drill Bit
Size, in. (mm)
Counterbore
Size
Counterbore
Drill Bit Size, in. (mm)
246360 0.094
246360 0.094
246360 0.094
246360 0.094
3/32 (2.35)
3/32 (2.35)
3/32 (2.35)
3/32 (2.35)
0.020
0.029
0.042
0.052
†
Available only in flat mix chamber kits or in 246360 multi-pack kit.
#76 (0.50)
#69 (0.70)
#58 (1.00)
#55 (1.30)
0.060
0.060
N/A
N/A
#53 (1.50)
#53 (1.50)
N/A
N/A
Mix Chamber Part No. Reference Guide
Sample part no. AR4242:
AR
AR=Air purge round pattern
AF=Air purge flat pattern
42
A orifice size
(.042 in.)
42
B orifice size
(.042 in.)
37
Parts
Flat Tip Kits
Ref. No. 39,
Flat Spray Tip
FT0424
FT0438
FT0624
FT0638
FT0838
FT0848
Pattern Size, in. (mm) low flow, 8-10 (203-254) medium flow, 8-10 (203-254) low flow, 12-14 (305-356) medium flow, 12-14 (305-356) medium flow, 16-18 (406-457) high flow, 16-18 (406-457)
Flat Tip Part No. Reference Guide
Sample part no. FT0848:
FT
FT=Flat tip
08 x2=pattern length
(8x2=16 in.)
Gun Repair Kits
Read the chart left to right and top to bottom to find the quantity of each part in the kits.
48
Equivalent orifice diameter size
(.048 in.)
18c
18d
18e
21
3
14
16
17
23
24
26f
26g
40
Ref.
No.
Bulk O-ring
Kits, (qty)
246347
Side Seal
Cartridge
O-ring Kit
248137 (6)
248136 (6)
248135 (6)
248134 (6)
246348
Side
Seal Kit
2
248130 (6)
248128 (6)
248132 (6)
248131 (6)
246354 (6)
248133 (6)
248129 (6)
246360 (3)
4
2 2
2
2
246351
Check
Valve
O-ring Kit
246355
Complete
O-ring Kit
1
1
1
1
4
2
1
1
5
2
2
Check Valve Filter Screen Kits
Kits include 10 filter screens.
80 mesh filter screen is standard with gun.
246357 40 mesh (.015 in., 375 micron)
246358 60 mesh (.010 in., 238 micron)
246359 80 mesh (.007 in., 175 micron)
38
Drill Bit Kits
For cleaning gun ports and orifices. Illustrations are for diameter comparison. Actual length may vary.
Not all sizes are used with your gun.
1 in.
(25.4 mm)
248893
246627
249112
246809
246628
249764
246814
Kit Part No.
Qty in Kit
249115 6
Drill Bit Size nominal
1/8 in.
mm
.125
3.18
Illustration
246623
246810
3
3
#32
7/64
0.116
0.109
2.90
2.77
246813
246624
246812
246625
3
3
3
3
#39
3/32
#43
#44
.099
.094
.089
.086
2.51
2.39
2.26
2.18
248639
249114
246811
246626
249113
3
6
6
6
6
2.15 mm
#45
2 mm
#50
#52
.085
2.15
.082
2.08
.079
2.00
.070
1.78
0.64
1.63
6
6
6
6
6
6
6
1/16
#53
1.45 mm
#54
#55
1.20 mm
#56
.062
1.59
.060
1.52
.057
1.45
.055
1.40
.052
1.32
.047
1.20
.046
1.18
1 in.
(25.4 mm)
Parts
39
Parts
Kit Part No.
Qty in Kit
246629 6
Drill Bit Size nominal
#58 in.
mm
.042
1.07
Illustration
246808
248640
6
6
#60
#61
.040
.039
1.02
0.99
248618
248891
6
6
#63
#66
.037
0.94
.033
0.84
246807
246630
248892
6
6
6
#67
#69
#70
.032
0.81
.029
0.74
.028
0.71
246815
276984
246631
246816
246817
6
6
6
6
6
#73
#74
#76
#77
#81
.024
0.61
.023
0.57
.020
0.51
.018
0.46
.013
0.33
Drill Bit Kit
119386
Kit includes 20 cleanout drill bits ranging in sizes of #61 through #80.
Air Purge Handle Cleanout
Drill Kit
248969
Kit includes all 5 drill bits of extra long length needed to clean out the air passages in the Air Purge gun handle and fluid housing. See Clean Passages
40
Accessories
Accessories
Wide Pattern Mix Chamber Kits
Kits include mix chamber and cleanout drills. To spray larger diameter patterns than the standard mix chambers.
Kit Part No.
Pattern Diameter at
24 in. (609.6 mm) to target in (mm)
Equivalent flow to Nozzle Drill Bit Size mix chamber size in (mm) *
Impingement Drill Bit Size in. (mm) *
AW2222 8 (203.2) NA .047 (1.20) #74, .022 (0.56)
AW2828
AW3333
15 (381.0)
15 (381.0)
Ref. AR2929
Ref. AR3737
1/16, .062 (1.59)
#53, .060 (1.52)
#70, .028 (0.71)
#66, .033 (0.84)
AW3939
AW4646
AW5757
AW6464
AW8282
16 (406.4)
18 (457.2)
18 (457.2)
22 (563.9)
24 (609.6)
Ref. AR4242
Ref. AR5252
Ref. AR6060
Ref. AR7070
Ref. AR8686
#50, .070 (1.78)
.085 (2.15)
#42, .089 (2.26)
7/64, .109 (2.77)
1/8, .125 (3.18)
#61, .039 (0.99)
#56, .046 (1.17)
1.45 mm, .057 (1.45)
#52, .064 (1.63)
#45, .082 (2.08)
Stainless Steel Side Seal Kits
Kits include a packing o-ring for each stainless steel seal.
Kit Part No. Description
246348 SEAL KIT, SST
277299 SEAL KIT, SST
No. of Seals Per Kit
2
50
Polycarballoy Side Seal Kits
Kits include a packing o-ring for each polycarballoy seal. The optional high wear, non-metallic polycarballoy seals are for alternate fluids.
Kit Part No. Description
249990 SEAL KIT, Polycarballoy
277298 SEAL KIT, Polycarballoy
No. of Seals Per Kit
2
50
41
Accessories
Extension Tip Kits
Kits include extension, flat tip seal and round tip seal, cleanout drill bit, and instructions.
Requires 248020 Extension Tip Air Cap Kit (order separately).
Kit Part
No.
248010
248011
248012
248013
248014
248015
248016
248017
Hole Diameter x Length, in. (mm)
.042 x 0.50 (1.06 x 12.7)
.052 x 0.50 (1.32 x 12.7)
.060 x 0.50 (1.52 x 12.7)
.070 x 0.50 (1.78 x 12.7)
.042 x 1.0 (1.06 x 25.4)
.052 x 1.0 (1.32 x 25.4)
.060 x 1.0 (1.52 x 25.4)
.070 x 1.0 (1.78 x 25.4)
Recommended
Mix Chambers
AR2020/AF2929
AR2929/AF2929
AR4242/AF4242
AR5252/AF5252
AR2020/AF2929
AR2929/AF2929
AR4242/AF4242
AR5252/AF5252
Spray
Distance, Diameter, ft (m) *
Pattern in. (mm) *
15 (4.57) 10 (254)
12 (3.66) 10 (254)
12 (3.66) 12 (305)
8 (2.44) 20 (508)
15 (4.57) 10 (254)
12 (3.66)
12 (3.66)
8 (2.44)
8 (203)
8 (203)
8 (203)
* Measured with less than 8 in. (203 mm) drop in stream center at 1200 psi (8.4 MPa, 84 bar) static pressure.
Extension Tip Seal Kits
Kits include 5 seals.
Kit Part No. Description
248018 Flat Extension Tip Seal Kit
248019 Round Extension Tip Seal Kit
Extension Tip Air Cap Kit
248020
Includes air cap for use with extension tip kits
248010-248017.
Flat Pattern Stud Wall Kit
249421
To spray high-flow, flat patterns. For use with flat mix chambers only: AF2929, AF4242, AF5252. Includes adapter parts and cleanout tool.
• Flat pattern mix chamber not included. Order separately.
• Optional tip FTM762 available for lower flow and smaller pattern application.
Hose Adapter Kits
246944
To connect non-Graco gun to Graco heated hose.
248029
To connect Graco Fusion gun to non-Graco D-gun hose set.
246945
To connect Graco Fusion gun to non-Graco heated hose.
42
Accessories
Spatter Conversion Kit
248528
To convert air purge gun for pour applications. Includes nozzle, seals, tubing, and cleanout drill bits.
Solvent Flush Canister Kit
248414
To convert Fusion air purge gun to spray, round pattern only, large droplet, low overspray applications. Includes air cap, tip, retainer, seal, and cleanout drill bits.
248139, 1 qt (0.95 liter) Solvent Cup
Complete with15B817 Flushing Manifold to flush gun with solvent. Portable for remote flushing. See manual
309963.
Pour Nozzle Kit
TI4165a
Solvent Flush Pail Kit
Gun Cover
244914 Covers
Keeps gun clean while spraying. Pack of 10.
248229 5.0 gal. (19 liter) Pail
Includes flush manifold with individual A and B shutoff valves, and air regulator. See manual 309963.
Lubricant for Gun Rebuild
248279, 4 oz (113 gram) [10]
High adhesion, water resistant, lithium-based lubricant.
MSDS sheet available at www.graco.com.
Grease Cartridge for Gun
Shutdown
248280 Cartridge, 3 oz [10]
Specially formulated low viscosity grease flows easily through gun passages, to prevent 2 component curing
and keep fluid passages clean. See page 14.
Flushing Manifold
15B817 Manifold Block
TI4211b
43
Accessories
Tip Cleanout Tool
15D234
Designed to fit CeramTip internal dome and flat tip slits.
Gun Cleaning Kit
15D546
Kit includes 11 tools and brushes to clean the gun.
End for Air
Purge Tips
End for
Mechanical
Purge Tips
TI4244a
Circulation Manifold
246362
Attach to gun fluid manifold to enable preheating of hose. See manual 309818.
TI3877a
44
Technical Data
Technical Data
Category
Maximum Fluid Working Pressure
Minimum Air Inlet Pressure
Maximum Air Inlet Pressure
Air Flow Range
Typical Flow Rate of Round Pattern Guns
Typical Flow Rate of Flat Pattern Guns
Maximum Fluid Temperature
Air Inlet Size
A Component (ISO) Inlet Size
B Component (Resin) Inlet Size
Sound Pressure
Sound Power, measured per ISO 9416-2
Dimensions
Weight
Wetted Parts
Data
3500 psi (24.5 MPa, 245 bar)
80 psi (0.56 MPa, 5.6 bar)
130 psi (0.9 MPa, 9 bar)
See chart below
200° F (94° C)
1/4 npt Quick Disconnect Nipple
-5 JIC; 1/2-20 UNF
-6 JIC; 9/16-18 UNF
81.1 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
91.0 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
7.5 x 8.1 x 3.3 in. (191 x 206 x 84 mm)
2.5 lb (1.1 kg)
Aluminum, stainless steel, carbon steel, carbide, 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 in scfm (m
3
/min)
Mix Chamber Sizes Air Pressure
(detriggered) psi (MPa, bar)
80 (0.56, 5.6)
100 (0.7, 7)
130 (0.9, 9)
AR2020 AR2929 AR3737 AR4242 AR5252 AR6060 AR7070 AR8686
0.8
(.022)
1.4
(.039)
2.0
(.056)
2.6
(.073)
3.7
(0.104)
4.6
(0.129)
5.7
(0.160)
7.1
(0.200)
0.9
(.025)
1.2
(.034)
1.7
(.048)
2.3
(.064)
2.9
(.081)
3.2
(.090)
3.1
(.087)
4.1
(0.115)
4.6
(0.129)
5.9
(0.165)
5.7
(0.160)
7.3
(0.204)
7.1
(0.200)
9.2
(0.258)
8.8
(0.246)
11.3
(0.316)
45
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.
For patent information, see www.graco.com/patents.
Original instructions.
This manual contains English. MM 309550
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2002, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised August 2014
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