Instructions - Parts 309550ZAE EN 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.
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 . . . . . . . .
List of Models/Mix Chamber Selection Guide List of Models/Mix Chamber Selection Guide Round Pattern Guns Mix Chamber Part No. Impingement Port Size in. (mm) Equivalent Size Seal Material Pattern at 24 in (61 cm) from target in. (mm) 246099, A AR2020 .020 (0.50) -000 SST 5 (127) 246100, A AR2929 .029 (0.70) -00 SST 8 (203) 248617, A AR3737 .037 (0.94) None SST 9 (227) 246101, A AR4242 .042 (1.00) -01 SST 11 (279) 246102, A AR5252 .052 (1.
List of Models/Mix Chamber Selection Guide Flat Pattern Guns Mix Chamber 4 Flat Tip Part No. Impingement Port Size in. (mm) Equivalent Size Part No. Pattern Size in. (mm) Orifice Size in. (mm) 247101, A AF2020 .020 (0.50) -000 FT0424 8-10 (203-254) .024 (0.61) 247102, A AF2020 .020 (0.50) -000 FT0438 8-10 (203-254) .038 (0.97) 247103, A AF2020 .020 (0.50) -000 FT0624 12-14 (305-356) .024 (0.61) 247104, A AF2020 .020 (0.50) -000 FT0638 12-14 (305-356) .038 (0.
List of Models/Mix Chamber Selection Guide Flat Pattern Guns, continued * To calculate flow in lb/min, multiply gpm rate by 10. Example: 2 gpm x 10 = 20 lb/min. FLOW RATE in gpm (lpm)* 3.0 (11.4) 2.25 (8.55) 25 AF5 2w TX it h F it 42 w A F4 2 1.5 (5.7) 9 AF292 h FT t ip XX3 with FT AF2020 w 0.75 (2.85) X48 8 tip XX38 ti ith FTXX24 p tip 0 500 (3.5, 35) 1000 (6.9, 69) 1500 (10.3, 103) 2000 2500 (13.8, 138) (17.4, 172.4) 3000 (20.7, 207) 3500 (24.
List of Models/Mix Chamber Selection Guide Spatter Pattern Gun Mix Chamber Gun Part No., Series 248408 A Part No. Impingement Port Size in. (mm) Equivalent Size AR7070 .070 (1.75) -04 Wide Round Pattern Gun Mix Chamber Equivalent Size Pattern Diameter at 24 in. (610 mm) to Target in. (mm) Equivalent Flow to Mix Chamber Size Reference Part No. Gun Part No., Series Part No. Impingement Port Size in. (mm) 249529 AW3939 .039 (0.99) -01 16 (406.4) AR4242 249530 AW4646 .046 (1.
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.
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.
Overall View Overall View K F R G L U D N V S C P B M A T H W E J TI2408A Key: A B C D E F G H J K L M N P R S T U V W A Side Fluid Valve (ISO) B Side Fluid Valve (RESIN) Air Cap Air Line Quick Coupler Muffler Fluid Housing Grease Fitting (under cap) Handle Optional Air Inlet Cleanoff Air Valve Piston Safety Lock Gun Fluid Manifold Mix Chamber Nozzle Optional Fluid Inlets (A Side Shown) Lock Ring Fluid Inlet Swivels (A Side Shown) Trigger Front Retaining Ring Gun Air Whip Hose Air Valve 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.
Turning Air Cap 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: WARNING Read warnings, page 7. 1. Follow Pressure Relief Procedure, page 15. 2. Close fluid valves A and B before turning air cap • Push in piston safety lock, see page 10. • Close fluid valves A and B. B (C).
Setup Setup 1. To change position of fluid manifold or use optional fluid inlets, see pages 16 and 17. Close fluid valves A and B. 5. Connect quick coupler (D). Turn on air. Open air valve (W*). Air should flow from nozzle (N). TI2411A 2. N Connect A (ISO) and B (RESIN) fluid hoses to fluid D manifold. W* TI2414-1A B (RESIN) To use optional air inlet, see page 17. 6. TI2417A A (ISO) 3. Disengage piston safety lock, page 10. Engage piston safety lock, page 10. TI2410A 7. TI2409A 4.
Setup 8. Open cleanoff air valve (K) 1/4-1/2 turn and trigger 13. gun to check that cleanoff air is flowing. Adjust as desired.This step does not apply with spatter spray gun 248408. Test spray onto cardboard. Adjust pressure and temperature to get desired results. K TI2645A TI2413A 9. 14. Engage piston safety lock, page 10. 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.
Shutdown Shutdown For overnight shutdown: 3. 1. Follow Pressure Relief Procedure, page 15. 2. Leave air turned on and gun detriggered. 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. Y G Grease gun daily to prevent 2 component curing and keep fluid passages clean.
Pressure Relief Procedure Pressure Relief Procedure 4. WARNING 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. TI2409A WARNING Close fluid valves A and B. Leave air valve (W) open.
Optional Configurations Optional Configurations Optional Fluid Manifold Position 6. service. 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.
Optional Configurations Optional Hose Position 4. Fluid inlet swivels and air quick disconnect fitting point to rear. If desired, these positions can be changed so hoses travel downward. 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).
Flat Spray Tips Flat Spray Tips 1. Follow Pressure Relief Procedure, page 15. 4. Reposition tip horizontally or vertically, or install different tip size. 2. Remove air cap (10) and flat spray tip (39). Inspect o-ring (40). TI2649A 40 10 TI2557A 39 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.
Maintenance Maintenance Supplied Tool Kit • Hex Nut Driver; 5/16 • Screwdriver; 1/8 blade • Nozzle Drill Bit; various sizes depending on nozzle size. See TABLE 1, page 21. • Impingement Port Drill Bit; various sizes depending on port size. See TABLE 3, page 22. • 117661 Pin Vise; dual reversible chucks Reversible Reversible • 551189 Grease Gun; with 3 oz grease • 15B817 Flush Manifold Not included with spatter spray gun. 4. Clean Muffler, page 20. 5. Clean Fluid Manifold, page 20. 6.
Maintenance Flush Gun Clean Fluid Manifold If it is necessary to flush gun, use following procedure. 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. WARNING Read warnings, page 8. 1. Follow Pressure Relief Procedure, page 15. 2.
Maintenance Clean Mix Chamber Nozzle 1. Clean Passages If necessary, clean out passages in fluid housing and handle with drill bits. Refer to TABLE 2 and to Cutaway 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. Engage piston safety lock, page 10. Table 2: Passage Diameters TI2409A Passage Description Optional Air Inlet 2. Ref. Letter (page 26) Diameter, in.
Maintenance 5. Table 3: Impingement Port Drill Bit Sizes Push mix chamber forward until impingement ports (IP) are visible. See TABLE 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. Mix Chamber Part No. Impingement Port (IP) Drill Bit Size in. (mm) Counterbore (CB) Drill Bit Size in. (mm) AR2020 #76, .020 (0.50) #53, .060 (1.
Troubleshooting Troubleshooting 1. 2. Follow Pressure Relief Procedure, page 15, before checking or repairing gun. 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 Gun does not fully actuate when trig- Safety lock engaged. gered. SOLUTION Disengage safety lock, page 10. Plugged muffler (22). Clean, page 20.
Troubleshooting PROBLEM A and/or B fluid in gun air section. CAUSE SOLUTION Damaged side seals (18c). Replace, page 29. Damaged mix chamber (19). Replace, page 29. Damaged side seal o-rings (18d, 18e). Replace, page 29. Tightened air cap with fluid valves (12b) open. Close valves first. Damaged side seals (18c). Replace, page 29. Damaged side seal o-rings (18d, 18e). Replace, page 29. Damaged mix chamber (19). Replace, page 29. Excessive overspray. Too much cleanoff air. Reduce, page 13.
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. G KEY Purge Air 19 Fluid AC IP Cleanoff Air Grease TI3547a Flow paths are not shown to scale, for clarity.
Troubleshooting Cutaway View 16 23 19 14 4 17 15 8 24 10 D E F 26 H G 3 21 C 18 (A Side) B Side not shown 24 12b 22 26
Repair Repair Tools Required Remove Front End Tools needed for complete gun repair: WARNING • • • • adjustable wrench flat head screwdriver (included) 1/8 in. (3 mm) diameter rod 5/16 hex nut driver (included) Lubrication Liberally lubricate all o-rings, seals, and threads. Lubricate 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.
Repair Attach Front End 3. cate 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. 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.
Repair Mix Chamber and Side Seal Cartridges 6. Remove air cap (10) and retaining ring (9). Inspect o-ring (3) inside retaining ring. See page 3 for available mix chamber sizes. 3 9 10 1. Follow Pressure Relief Procedure, page 15. 2. Remove fluid manifold (M). Leave air connected. TI2424A 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. M 7. TI2543A 3.
Repair 8. Pull mix chamber (19) out rear of fluid housing. 11. Inspect for damage and clean ports, page 21. Inspect o-ring (23) in front of fluid housing. 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.
Repair Check Valves 5. Before disassembling, press on ball (26c) to test check valve for proper movement and spring action. 1. 2. Pry out check valves (26) at notch. WARNING 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. Remove fluid manifold (M). Leave air connected. 6. Clean Fluid Manifold, page 20. Slide filter (26d) off. Clean and inspect parts.
Repair Piston 6. 1. Follow Pressure Relief Procedure, page 15. 2. Disconnect air (D) and remove fluid manifold (M). Liberally lubricate piston o-rings. Reinstall piston. Shaft is keyed for proper assembly. Push firmly to seat piston. TI2432A 7. M D Install cylinder cap (5). TI2554A 3. Remove Front End, page 27. 4. Unscrew cylinder cap (5) and inspect o-ring (14). 5 TI2430A 5 8. Attach Front End, page 28. 14 9. Attach fluid manifold. Connect air. Return gun to service. TI2430A 5.
Repair Piston Safety Lock Air Valve 1. Follow Pressure Relief Procedure, page 15. 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 M D D TI2554A 3. Unscrew cylinder cap (5). Hold piston stop (28) TI2554A 3. with wrench and unscrew from safety lock (4). Inspect spring (30) and o-rings (14, 24). 24 30 Unscrew air valve plug (2) and remove spring (31).
Parts Parts Round Pattern Gun Shown; see page 36 for additional parts and detail views Seal Cartridge (18) Detail 4 4 30 28 16 5 14 24 ‡18e ‡18c ‡18b ‡18d ‡18a TI3926A 15 17 4 4 ‡37 Check Valve (26) Detail ‡25 19 ‡8 ‡26b 7‡ ‡24 ‡26e ‡11 ‡26c ‡18; see detail above 2 29 ‡26d 1 21‡ 27‡ ‡26g ‡26a ‡18; see detail above 23‡* 12e 3‡* ‡10 2 ‡26; 12c see detail at right 33 1 ‡26f 13 49 3 12d 1 Torque to 125-135 in-lb (14-15 N•m). 2 Torque to 20-30 in-lb (2.3-3.4 N•m).
Parts Ref. No. 1 2 3‡ 4★ 5★ 6 7‡ 8‡ 9‡ 10‡ ◆ 11‡ 12 Part No.
Parts Ref. No. 52 Part No. Description 15B817 MANIFOLD, gun flush; round and flat pattern guns only 117642 NUT DRIVER, hex; 5/16 118575 SCREWDRIVER; 1/8 blade 172479 TAG, warning; not shown 15D235 SIGN, instruction; not shown 117773 GREASE CARTRIDGE; 3 oz; not shown; MSDS sheet available at www.graco.com 53 54 55▲ 56▲ 57 Qty 1 Ref. No. 58◆ Part No. Description 15D972 RETAINER, tip; spatter pattern gun only 15D971 TIP; spatter pattern gun only 248019 SEAL, package of 5; spatter pattern gun only.
Parts Mix Chamber Kits Round Pattern Guns Mix Chamber Kit (includes drill bits) 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) AR2020 0.042 #58 (1.00) 0.020 #76 (0.50) 0.060 #53 (1.50) AR2929 0.052 #55 (1.30) 0.029 #69 (0.70) 0.060 #53 (1.50) AR3737 0.052 #55 (1.30) 0.037 #63 (0.94) N/A N/A AR4242 0.060 #53 (1.50) 0.042 #58 (1.00) N/A N/A AR5252 0.
Parts Flat Tip Kits Flat Tip Part No. Reference Guide Ref. No. 39, Flat Spray Tip Pattern Size, in. (mm) FT0424 low flow, 8-10 (203-254) FT0438 medium flow, 8-10 (203-254) FT0624 low flow, 12-14 (305-356) FT0638 medium flow, 12-14 (305-356) FT0838 medium flow, 16-18 (406-457) FT0848 high flow, 16-18 (406-457) Sample part no. FT0848: FT 08 48 FT=Flat tip x2=pattern length (8x2=16 in.) Equivalent orifice diameter size (.048 in.
Parts Drill Bit Kits For cleaning gun ports and orifices. Illustrations are for diameter comparison. Actual length may vary. 1 in. (25.4 mm) 1 in. (25.4 mm) Not all sizes are used with your gun. Kit Part No. Qty in Kit 249115 Drill Bit Size nominal in. mm 6 1/8 .125 3.18 246623 3 #32 0.116 2.90 246810 3 7/64 0.109 2.77 246813 3 #39 .099 2.51 246624 3 3/32 .094 2.39 246812 3 #43 .089 2.26 246625 3 #44 .086 2.18 248639 6 2.15 mm .085 2.15 249114 6 #45 .
Parts Kit Part No. Qty in Kit 246629 Drill Bit Size nominal in. mm 6 #58 .042 1.07 246808 6 #60 .040 1.02 248640 6 #61 .039 0.99 248618 6 #63 .037 0.94 248891 6 #66 .033 0.84 246807 6 #67 .032 0.81 246630 6 #69 .029 0.74 248892 6 #70 .028 0.71 246815 6 #73 .024 0.61 276984 6 #74 .023 0.57 246631 6 #76 .020 0.51 246816 6 #77 .018 0.46 246817 6 #81 .013 0.
Accessories Accessories Wide Pattern Mix Chamber Kits Kits include mix chamber and cleanout drills. To spray larger diameter patterns than the standard mix chambers. Pattern Diameter at 24 in. (609.6 mm) to target Equivalent flow to Nozzle Drill Bit Size Impingement Drill Bit Size in (mm) mix chamber size in (mm) * in. (mm) * Kit Part No. AW2222 8 (203.2) NA .047 (1.20) #74, .022 (0.56) AW2828 15 (381.0) Ref. AR2929 1/16, .062 (1.59) #70, .028 (0.71) AW3333 15 (381.0) Ref. AR3737 #53, .060 (1.
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). Spray Pattern Distance, Diameter, ft (m) * in. (mm) * Kit Part No. Hole Diameter x Length, in. (mm) Recommended Mix Chambers 248010 .042 x 0.50 (1.06 x 12.7) AR2020/AF2929 15 (4.57) 10 (254) 248011 .052 x 0.50 (1.32 x 12.7) AR2929/AF2929 12 (3.66) 10 (254) 248012 .060 x 0.50 (1.52 x 12.
Accessories Spatter Conversion Kit Solvent Flush Canister Kit 248414 248139, 1 qt (0.95 liter) Solvent Cup 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. Complete with15B817 Flushing Manifold to flush gun with solvent. Portable for remote flushing. See manual 309963. Pour Nozzle Kit 248528 To convert air purge gun for pour applications.
Accessories Tip Cleanout Tool Gun Cleaning Kit 15D234 15D546 Designed to fit CeramTip internal dome and flat tip slits. Kit includes 11 tools and brushes to clean the gun. End for Air Purge Tips End for Mechanical Purge Tips Circulation Manifold 246362 TI4244a Attach to gun fluid manifold to enable preheating of hose. See manual 309818.
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 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 See chart page 3.
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.
