Instructions - Parts
309550U
Plural Component, Impingement Mix
Air Purge Spray Gun
For use with non-flammable foam and polyurea.
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.
US Patent Number D479,305
Korean Patent 338185
Australian Patent Number 152610
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
TI2408-1A
Manual Conventions
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Models/Mix Chamber Selection Guide . . . . 3
Round Pattern Guns . . . . . . . . . . . . . . . . . . . . . . 3
Flat Pattern Guns . . . . . . . . . . . . . . . . . . . . . . . . 4
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
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
Air Purge Handle Cleanout Drill Kit . . . . . . . . . . 40
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Conventions
Warning Caution
WAR NING
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
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
hazard warnings on pages 7-8.
2 309550U
Note
A note indicates additional helpful information.
CAUTION
List of Models/Mix Chamber Selection Guide
List of Models/Mix Chamber Selection Guide
Round Pattern Guns
Mix Chamber
Impingement
Gun Part
No., Series Part No.
246099, A AR2020 .020 (0.50) -000 SST
246100, A AR2929 .029 (0.70) -00 SST
248617, A AR3737 .037 (0.94) None SST
246101, A AR4242 .042 (1.00) -01 SST
246102, A AR5252 .052 (1.30) -02 SST
246103, A AR6060 .060 (1.50) -03 SST
Port Size
in. (mm)
Equivalent
Size
Seal
Material
246104, A AR7070 .070 (1.75) -04 SST
246105, A AR8686 .086 (2.15) -05 SST
255201, A AR4242 .042 (1.00) -01 Polycarballoy
255202, A AR5252 .052 (1.30) -02 Polycarballoy
5.0
(18.9)
4.0
(15.1)
3.0
(11.4)
2.0
(7.6)
1.0
(3.8)
(
6
8
6
8
R
A
2
8
2
8
W
A
)
5
0
(
0
7
0
7
R
A
4
6
4
6
W
A
)
4
0
0
(
0
6
0
6
R
A
2
5
2
5
R
A
4
AR
5
7
5
W
A
)
3
4
W
A
,
)
2
0
(
,
)
1
0
(
2
4
2
7
3
7
3
R
A
9
2
9
2
R
A
(
0
2
0
2
R
A
FLOW RATE in gpm (lpm)*
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
0
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
2000
(13.8, 138)
2500
(17.4, 172.4)
(20.7, 207)
PRESSURE in psi (MPa, bar)
7
4
6
AW3
A
,
0
0
(
0
0
3000
*
6
*
9
3
9
*
3
3
3
3
W
A
,
)
)
0
2
W
*
8
2
8
3500
(24.1, 241)
*Accessory AW (wide pattern) mix chambers are available. See page 41.
309550U 3
List of Models/Mix Chamber Selection Guide
Flat Pattern Guns
Mix Chamber Flat Tip
Impingement
Gun Part
No., Series Part No.
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 (0.97)
247107, A AF2020 .020 (0.50) -000 FT0838 16-18 (406-457) .038 (0.97)
247108, A AF2020 .020 (0.50) -000 FT0848 16-18 (406-457) .048 (1.22)
247111, A AF2929 .029 (0.70) -00 FT0424 8-10 (203-254) .024 (0.61)
247112, A AF2929 .029 (0.70) -00 FT0438 8-10 (203-254) .038 (0.97)
247113, A AF2929 .029 (0.70) -00 FT0624 12-14 (305-356) .024 (0.61)
Port Size
in. (mm)
Equivalent
Size Part No.
Pattern Size
in. (mm)
Orifice Size
in. (mm)
247114, A AF2929 .029 (0.70) -00 FT0638 12-14 (305-356) .038 (0.97)
247117, A AF2929 .029 (0.70) -00 FT0838 16-18 (406-457) .038 (0.97)
247118, A AF2929 .029 (0.70) -00 FT0848 16-18 (406-457) .048 (1.22)
247121, A AF4242 .042 (1.00) -01 FT0424 8-10 (203-254) .024 (0.61)
247122, A AF4242 .042 (1.00) -01 FT0438 8-10 (203-254) .038 (0.97)
247123, A AF4242 .042 (1.00) -01 FT0624 12-14 (305-356) .024 (0.61)
247124, A AF4242 .042 (1.00) -01 FT0638 12-14 (305-356) .038 (0.97)
247127, A AF4242 .042 (1.00) -01 FT0838 16-18 (406-457) .038 (0.97)
247128, A AF4242 .042 (1.00) -01 FT0848 16-18 (406-457) .048 (1.22)
247131, A AF5252 .052 (1.30) -02 FT0424 8-10 (203-254) .024 (0.61)
247132, A AF5252 .052 (1.30) -02 FT0438 8-10 (203-254) .038 (0.97)
247133, A AF5252 .052 (1.30) -02 FT0624 12-14 (305-356) .024 (0.61)
247134, A AF5252 .052 (1.30) -02 FT0638 12-14 (305-356) .038 (0.97)
247137, A AF5252 .052 (1.30) -02 FT0838 16-18 (406-457) .038 (0.97)
247138, A AF5252 .052 (1.30) -02 FT0848 16-18 (406-457) .048 (1.22)
4 309550U
Flat Pattern Guns, continued
3.0
(11.4)
2.25
(8.55)
1.5
(5.7)
0.75
(2.85)
FLOW RATE in gpm (lpm)*
* To calculate flow in lb/min, multiply gpm rate by 10.
Example: 2 gpm x 10 = 20 lb/min.
0
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
PRESSURE in psi (MPa, bar)
2000
(13.8, 138)
List of Models/Mix Chamber Selection Guide
2
5
F
A
F
A
F
A
F
A
2500
(17.4, 172.4)
w
2
5
2
4
2
4
2
9
2
0
2
0
2
4
X
X
T
F
h
t
i
X
T
F
h
t
i
w
T
F
h
t
i
w
9
X
T
F
h
t
i
w
3000
(20.7, 207)
p
i
t
8
8
3
X
3
X
X
4
2
X
p
i
t
p
i
t
8
p
i
t
3500
(24.1, 241)
Flat Pattern Stud Wall Gun
See manual number 311071 for more information.
Mix Chamber Flat Tip Flow Data
Impingement
Gun Part
No., Series Part No.
Port Size
in. (mm)
Equivalent
Size Part No.
249525 AF4242 .042 (1.00) -01 FTM979 22 (559) .038 (0.97) 11 lb/min
249526 AF5252 .052 (1.30) -02 FTM979 22 (559) .038 (0.97) 15 lb/min
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)
(4.99 kg/min)
(6.81 kg.min)
309550U 5
List of Models/Mix Chamber Selection Guide
Spatter Pattern Gun
Mix Chamber
Impingement
Gun Part
No., Series Part No.
248408 A AR7070 .070 (1.75) -04
Port Size
in. (mm)
Equivalent
Size
Wide Round Pattern Gun
Mix Chamber
Impingement
Gun Part
No., Series Part No.
249529 AW3939 .039 (0.99) -01 16 (406.4) AR4242
249530 AW4646 .046 (1.17) -02 18 (457.2) AR5252
Port Size
in. (mm)
Equivalent
Size
Pattern Diameter at
24 in. (610 mm) to
Targe t
in. (mm)
Equivalent Flow to
Mix Chamber Size
Reference Part No.
Four-Hose Gun
Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold
Mix Chamber
Impingement
Gun Part
No., Series Part No.
249810 AW2222 .022 (0.56) NA
Port Size
in. (mm)
Equivalent
Size
Pattern Diameter at
24 in. (610 mm) to
Targe t
in. (mm)
8-9 (203-229)
Non 1:1 Ratio Guns
Gun Part
No., Series
253888 AR2232
Mix
Chamber
Approximate Flow
Rate at 1000 psi
(7.0 MPa, 70 bar)
4.5 lb/min
(204 kg/min)
6 309550U
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.
309550U 7
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 Grounding, page 10.
• 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.
8 309550U
Overall View
Overall View
KL
FG
R
U
D
N
V
C
P
B
M
A
T
S
H
W
E
J
TI2408A
Key:
A A Side Fluid Valve (ISO)
B B Side Fluid Valve (RESIN)
C Air Cap
D Air Line Quick Coupler
EMuffler
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
WAir Valve
309550U 9
Isocyanate Hazard
Isocyanate Hazard
WARNING
Read Material Safety Data Sheet (MSDS) to know the
specific hazards of isocyanates. Use equipment in a
well-ventilated area. Wear respirator, gloves, and protective clothing when using isocyanates.
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.
Piston Safety Lock
Engage piston safety lock whenever you stop spraying, to avoid accidental triggering.
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.
Grounding
WARNING
Read warnings, page 8.
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.
Disengaged
TI2410A
10 309550U
Turning Air Cap
Turning Air Cap Loss of Air Pressure
WARNING
Read warnings, page 7.
1. Follow Pressure Relief Procedure, page 15.
2. Close fluid valves A and B before turning air cap
(C).
C
B
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
TI2421A
A
309550U 11
Setup
Setup
1. Close fluid valves A and B.
TI2411A
2. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold.
B (RESIN)
A (ISO)
TI2417A
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).
N
D
To use optional air inlet, see page 17.
W*
TI2414-1A
6. Disengage piston safety lock, page 10.
3. Engage piston safety lock, page 10.
TI2409A
4. Connect gun air whip hose (V) and air valve (W*)
to main air hose. Attach fluid manifold (M) to gun.
M
W*
V
TI2554A
TI2410A
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.
12 309550U
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.
K
TI2413A
9. Engage piston safety lock, page 10.
TI2409A
10. Turn on proportioner.
11. Open B (RESIN) fluid valve (about three half
turns). Then open A (ISO) fluid valve.
12. Disengage piston safety lock, page 10.
TI2410A
13. Test spray onto cardboard. Adjust pressure and
temperature to get desired results.
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.
CAUTION
Air supply is required for gun actuation. Do not disconnect gun air supply until fluid pressure is relieved,
page 15.
TI2414A
309550U 13
Shutdown
Shutdown
For overnight shutdown:
1. Follow Pressure Relief Procedure, page 15.
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.
2. Leave air turned on and gun detriggered.
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,
see page 43.
KEY
Purge Air
Fluid
Cleanoff Air
Grease
G
19
TI3547a
AC
IP
Y
G
N
W
TI2415A
4. Replace grease cap.
5. Round and Flat pattern guns only: Turn off air
valve (W).
Spatter pattern gun only: Shut down main air supply.
N
14 309550U
TI3546a
Pressure Relief Procedure
Pressure Relief Procedure
WAR NING
Read warnings, page 7. Relieve pressure before
cleaning or repairing gun.
1. 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.
4. Trigger gun onto cardboard or into waste container
to relieve pressure.
TI4722a
5. Engage piston safety lock, page 10.
TI2409A
WARNING
B
W
A
3. Disengage piston safety lock, page 10.
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.
TI2421A
TI2484A
TI2410A
309550U 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.
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
D
TI2554A
3. Remove Front End, page 27.
4. Rotate fluid housing 180°.
5. Attach Front End, page 28.
6. Attach fluid manifold. Connect air. Return gun to
service.
16 309550U
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.
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. Also
relieve system pressure, see proportioner manual.
2. Disconnect air (D) and remove fluid manifold (M).
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).
Elbows (50*) are not included with spatter spray
gun.
12c
B
P
50*
A
TI2646A
5. Connect A and B hoses to A and B swivels.
M
D
TI2554A
3. Disconnect fluid hoses from inlet swivels (A, B).
Remove swivels. Remove plugs from optional
inlets (P).
B
A
P
TI2417A
6. Remove fitting (D) and plug (J). Reverse positions.
Apply thread sealant and torque to 125-135 in-lb
(14-15 N•m).
D
TI2540A
J
7. Attach fluid manifold. Connect air. Return gun to
service.
309550U 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).
40
39
10
If tip is stuck, pry off with small screwdriver or pull
off with pliers. Tip is hardened to resist damage.
TI2557A
3. To clean, soak tip in compatible solvent, see page
20. Clean gently with tip cleanout tool 15D234,
page 44, to fit tip configuration.
4. Reposition tip horizontally or vertically, or install dif-
ferent tip size.
TI2649A
TI2648A
Tips marked on back with last 3 digits of part no.
See Flat Tip Part No. Reference Guide, page
38.
5. Reinstall air cap hand tight. Cleaning hole align-
ment to tip not important.
18 309550U
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
• Impingement Port Drill Bit; various sizes depending
on port size. See T
• 117661 Pin Vise; dual reversible chucks
Reversible
• 551189 Grease Gun; with 3 oz grease
• 15B817 Flush Manifold
Not included with spatter spray gun.
ABLE 1, page 21.
ABLE 3, page 22.
Reversible
TI3864a
2. Clean Mix Chamber Nozzle, page 21, a minimum
of once a day.
3. Clean Air Cap, page 20.
4. Clean Muffler, page 20.
5. Clean Fluid Manifold, page 20.
6. Clean Passages, page 21.
7. Clean Impingement Ports, page 21.
Keep Gun Clean
Keep gun clean with accessory gun cover, page 40.
Applying a light coat of lubricant will make cleaning easier.
As Needed
1. Clean Outside of Gun, page 20.
Daily
Follow Shutdown, page 14.
Weekly to Monthly
1. Clean Mix Chamber and Side Seal Cartridges,
page 29. Check o-rings.
2. Clean Check Valves, page 31. Check o-rings and
filters.
309550U 19
Maintenance
Flush Gun
If it is necessary to flush gun, use following procedure.
WAR NING
Read warnings, page 8.
1. Follow Pressure Relief Procedure, page 15.
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.
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.
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.
X
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.
TI2411-1
20 309550U
Clean Mix Chamber Nozzle Clean Passages
If necessary, clean out passages in fluid housing and
1. Engage piston safety lock, page 10.
handle with drill bits. Refer to T
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.
Table 2: Passage Diameters
Maintenance
ABLE 2 and to Cutaway
TI2409A
2. Refer to TABLE 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.
N
C
Table 1: Nozzle Drill Bit Sizes
Round Spray Flat Spray
Mix Chamber
Part No.
AR2020 #58, .042
Drill Size
in. (mm)
(1.00)
Mix Chamber
Part No.
AF2020 3/32, .094
TI2418A
Drill Size
in. (mm)
(2.35)
Ref. Letter
Passage Description
Optional Air Inlet C 7/16, 1/8
Purge Air D 1/8 (3.1)
Piston Air E, F 1/8 (3.1)
Air Exhaust G 11/32, 1/8
Air Valve Bore H 9/32 (7.1)
Cleanoff Air Not Shown 3/32 (2.35)
Check Valve Holes Not Shown 3/32 (2.35)
Grease Not Shown 3/32 (2.35)
(page 26)
Diameter,
in. (mm)
(11.0, 3.1)
(8.7, 3.1)
Clean Impingement Ports
1. Follow Pressure Relief Procedure, page 15.
2. Disconnect air (D) and remove fluid manifold (M).
AR2929 #55, .052
(1.30)
AR3737 #55, .052
(1.30)
AR4242 #53, .060
(1.50)
AR5252 #50, .070
(1.75)
AR6060 #44, .086
(2.15)
AR7070 3/32, .094
(2.35)
AR8686 #32, 0.116
(2.90)
AF2929 3/32, .094
(2.35)
AF4242 3/32, .094
(2.35)
AF5252 3/32, .094
(2.35)
M
D
TI2554A
3. Flush Gun, page 20. If gun will not flush, see page
29.
4. Remove Front End, page 27.
309550U 21
Maintenance
5. Push mix chamber forward until impingement ports
(IP) are visible. See T
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.
IP
CB
Mix Chambers AR and AF,
2020 and 2929
ABLE 3 for appropriate size
TI2420A
CB
Mix Chambers AR and AF,
4242 or larger
IP
TI3533a
Table 3: Impingement Port Drill Bit Sizes
Mix Chamber
Part No.
AR2020 #76, .020 (0.50) #53, .060 (1.50)
AR2929 #69, .029 (0.70) #53, .060 (1.50)
AR3737 #63, .037 (0.94) N/A
AR4242 #58, .042 (1.00) N/A
AR5252 #55, .052 (1.30) N/A
AR6060 #53, .060 (1.50) N/A
AR7070 #50, .070 (1.75) N/A
AR8686 #44, .086 (2.15) N/A
AF2020 #76, .020 (0.50) #53, .060 (1.50)
AF2929 #69, .029 (0.70) #53, .060 (1.50)
AF4242 #58, .042 (1.00) N/A
AF5252 #55, .052 (1.30) N/A
Impingement Port (IP)
Drill Bit Size
in. (mm)
Counterbore (CB)
Drill Bit Size
6. Push mix chamber back in position.
in. (mm)
7. Attach Front End, page 28.
8. Attach fluid manifold. Connect air. Return gun to
service.
22 309550U
Troubleshooting
Troubleshooting
1. Follow Pressure Relief Procedure, page 15,
before checking or repairing gun.
PROBLEM CAUSE SOLUTION
Gun does not fully actuate when triggered.
Fluid does not spray when gun is fully
actuated.
Gun actuates slowly. Plugged muffler (22). Clean, page 20.
Gun delays, then actuates abruptly. Cured material around side seals
Loss of round pattern. Dirty mix chamber nozzle. Clean, page 21.
Loss of flat pattern. Plugged spray tip. Clean in compatible solvent, page 18.
Leakage between flat tip and mix
chamber.
Pressure imbalance. Plugged impingement ports. Clean, page 21.
Safety lock engaged. Disengage safety lock, page 10.
Plugged muffler (22). Clean, page 20.
Damaged air valve o-rings (24). Replace, page 33.
Closed fluid valves (12b). Open.
Plugged impingement ports. Clean, page 21.
Plugged check valves (26). Clean, page 31.
Damaged piston o-rings (16, 17). Replace, page 32.
Dirty air valve, or damaged o-rings
(24).
(18).
Retaining ring (9) not bottomed out. Tighten retaining ring until bottomed
Worn tip. Replace, page 18.
Dirty mix chamber nozzle. Clean, page 21.
Tip not seated properly. Reassemble, page 18.
Damaged/missing o-ring (40). Replace, page 18.
Plugged check valves (26). Clean, page 31.
Viscosities not equal. Adjust temperature to compensate.
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.
Clean air valve or replace o-rings,
page 33.
Inspect side seals (18c) and mix
chamber (19) for scratches. Replace,
page 29.
out.
309550U 23
Troubleshooting
PROBLEM CAUSE SOLUTION
A and/or B fluid in gun air section. Damaged side seals (18c). Replace, page 29.
Damaged mix chamber (19). Replace, page 29.
Damaged side seal o-rings (18d,
18e).
Tightened air cap with fluid valves
(12b) open.
Fluid mist from mix chamber or air
cap.
Excessive overspray. Too much cleanoff air. Reduce, page 13.
Rapid buildup of material on air cap. Plugged air cap holes. Clean, page 20.
Reduced cleanoff air. Damaged front o-ring (3). Replace, page 29.
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 air valve o-rings (24). Replace, page 33.
Air leakage from front air valve. Damaged air valve o-rings (24). Replace, page 33.
Air leak around lock ring. Damaged o-ring (21). Replace, page 29.
Cannot tighten retaining ring (9) until
it bottoms out.
Damaged side seals (18c). Replace, page 29.
Damaged side seal o-rings (18d,
18e).
Damaged mix chamber (19). Replace, page 29.
Too little cleanoff air. Increase, page 13.
Damaged/missing fluid housing
o-ring (23).
Damaged front o-ring (3). Replace, page 29.
Damaged/missing fluid housing
o-ring (23).
Damaged fluid valves (12b). Replace.
Normal. No action required.
Damaged piston o-rings (16, 17). Replace, page 32.
Air cap (10) assembled before retaining ring (9).
Replace, page 29.
Close valves first.
Replace, page 29.
Replace, page 29.
Replace, page 29.
Install retaining ring (9) first, then air
cap (10), page 30.
24 309550U
Theory of Operation
Troubleshooting
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
Flow paths are not shown to scale, for clarity.
19 18c
TI3547a
IP
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).
KEY
Purge Air
Fluid
Cleanoff Air
Grease
Flow paths are not shown to scale, for clarity.
G
19
TI3547a
AC
IP
N
NK
TI3545a
TI3546a
309550U 25
Troubleshooting
Cutaway View
10
26
16
23
8
19
17 15
14 4
24
DEF
H
G
3
21
C
12b
18 (A Side)
B Side not shown
24
22
26 309550U
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)
Lubrication
Liberally lubricate all o-rings, seals, and threads. Lubricate threads and outside of lock ring (11). See page 43
to order lubricant.
Remove 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. Follow Pressure Relief Procedure, page 15.
2. Flush Gun, page 20.
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
309550U 27
Repair
Attach Front End
WAR NING
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.
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.
C
3. Check that o-ring (21) is in position. Liberally lubri-
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.
YZ
F 21
WX
RH
TI2416A
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.
TI2422A
RH
TI2423A
28 309550U
Repair
Mix Chamber and Side Seal
Cartridges
See page 3 for available mix chamber sizes.
1. Follow Pressure Relief Procedure, page 15.
2. Remove fluid manifold (M). Leave air connected.
M
TI2543A
5. Remove Front End, page 27.
6. Remove air cap (10) and retaining ring (9). Inspect
o-ring (3) inside retaining ring.
9
3
10
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.
3. Flush gun to remove residual A and B compo-
nents, page 20. Follow Pressure Relief Procedure, page 15.
4. Disconnect air.
TI2540A
7. Pull out side seal cartridges (18). Also inspect
o-ring (24) on cleanoff air valve (8).
24
18
Continued on page 30.
B
18
A
TI2426A
309550U 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.
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.
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.
19
B
11. Liberally lubricate and reinstall side seal car-
tridges (18).
24
18
B
18
A
TI2426A
12. Lubricate all threads and reinstall retaining ring
(9). Install air cap (10).
9
10
A
N
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.
TI2428A
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.
18e
18c
18b
18d
TI2427A
TI2424A
13. Attach Front End, page 28.
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.
15. Attach fluid manifold. Connect air. Return gun to
service.
30 309550U
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.
2. Remove fluid manifold (M). Leave air connected.
Clean Fluid Manifold, page 20.
M
TI2543A
3. Flush gun to remove residual A and B compo-
nents, page 20. Follow Pressure Relief Procedure, page 15.
5. Pry out check valves (26) at notch.
WARNING
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. Thor-
oughly inspect o-rings (26f, 26g). If necessary,
remove screw (26b) and disassemble entire check
valve.
B
A
26b
26e
26c
26d
26
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.
8. Attach fluid manifold. Connect air. Return gun to
TI2540A
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.
309550U 31
service.
Repair
Piston
1. Follow Pressure Relief Procedure, page 15.
2. Disconnect air (D) and remove fluid manifold (M).
M
D
TI2554A
3. Remove Front End, page 27.
5. Push piston shaft to remove piston (15). Inspect
piston o-ring (16) and shaft o-ring (17).
15
16
17
TI2431A
6. Liberally lubricate piston o-rings. Reinstall piston.
Shaft is keyed for proper assembly. Push firmly to
seat piston.
4. Unscrew cylinder cap (5) and inspect o-ring (14).
5
14
TI2430A
TI2432A
7. Install cylinder cap (5).
5
TI2430A
8. Attach Front End, page 28.
9. Attach fluid manifold. Connect air. Return gun to
service.
32 309550U
Piston Safety Lock Air Valve
Repair
1. Follow Pressure Relief Procedure, page 15.
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).
1. Follow Pressure Relief Procedure, page 15.
2. Disconnect air (D) and remove fluid manifold (M).
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).
24 30 4
32
5
1428
TI2433A
24
31
2
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.
5. Attach fluid manifold. Connect air. Return gun to
service.
309550U 33
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.
Parts
Parts
Round Pattern Gun Shown; see page 36
for additional parts and detail views
14
28
16
15
17
‡37
4
‡25
4
‡11
‡18; see
detail above
‡9‡10
‡8
‡24
3
‡26;
see detail
at right
‡*
23
‡*
7‡
29
2
‡18; see
detail above
12e
3
12f
12c
3
50
3
19
20
245
21
27‡
2
Seal Cartridge (18) Detail
4
4
30
‡18e ‡18c ‡18b ‡18d ‡18a
TI3926A
Check Valve (26) Detail
‡26b
‡26e
‡26c
‡
1
22
4
‡26d
‡26g
‡26a
‡26f
TI3927A
6
33
13
1
49
51
12a
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).
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).
12b
12g
2
5
24
32
31
1
35
1
TI2435C
34 309550U
47
Parts
Ref.
No. Part No. Description Qty
1 15B201 HANDLE 1
2 15B208 PLUG, air valve 1
3
‡ 248137 O-RING; PTFE; package of 6 1
4
★ 15B206 LOCK, safety 1
5
★ 15B204 CAP, cylinder 1
6 192272 PIN 1
7
‡ 15B215 RING, lock 1
8‡ 15B223 VALVE, cleanoff air 1
9
‡ 15B211 RING, retaining 1
10
‡ 15B210 AIR CAP; for round pattern guns 1
15B801 AIR CAP; for flat pattern guns;
1
not included in Front End Replacement Kit 246361; see Detail
Views, page 36
◆ 15D973 AIR CAP, for spatter pattern gun;
1
not included in Front End Replacement Kit 246361; see Detail
Views, page 36
11
‡ 246491 HOUSING, fluid 1
12 246012 MANIFOLD, fluid, 2-hose;
1
includes 12a-12g
249523 MANIFOLD, fluid, 4-hose;
1
includes 12a, 12b, 12d-12g, 50;
see Detail Views, page 36
† .MANIFOLD 1
12a
12b 246356 . VALVE, fluid 2
12c 100139 . PLUG, pipe; 1/8-27 npt 2
12d 15B221 . BOLT; 5/16-24 1
12e 117634 . SWIVEL, B side; 1/8 npt(m) x
1
no. 6 JIC(f); for 2-hose manifold
117634 . SWIVEL, B side; 1/8 npt(m) x
2
no. 6 JIC(f); for 4-hose manifold;
see Detail Views, page 36
12f 117635 . SWIVEL, A side; 1/8 npt(m) x
1
no. 5 JIC(f); for 2-hose manifold
117635 . SWIVEL, A side; 1/8 npt(m) x
2
no. 5 JIC(f); for 4-hose manifold;
see Detail Views, page 36
12g 15B993 . SPRING, ring, lock 1
13 15B209 TRIGGER 1
14*
★ 248136 O-RING, cylinder cap;
1
package of 6
15 15B203 PISTON 1
16* 248135 O-RING, piston; package of 6 1
17* 248134 O-RING, piston shaft;
1
package of 6
18
‡ 246349 CARTRIDGE, seal, A side, SST;
1
includes 18a-18e
246350 CARTRIDGE, seal, B side, SST;
1
includes 18a-18e
18a
† . CARTRIDGE BODY 1
18b 117491 . SPRING 1
18c*
† . SEAL KIT; see page 41 1
18d* 248130 . O-RING, cartridge body;
1
package of 6
18e* 248128 . O-RING, side seal;
1
package of 6
19 CHAMBER, mix, round; see
1
Round Pattern Guns, page 37
CHAMBER, mix, flat;
1
see Flat Pattern Guns, page 37
20 15C480 WASHER, wave 1
Ref.
No. Part No. Description Qty
21
‡* 248132 O-RING; package of 6 1
22 119626 MUFFLER 1
23
‡* 248131 O-RING; package of 6 1
24
‡*★ 246354 O-RING; package of 6 1
25
‡ 100846 FITTING, grease 1
26
‡ 246731 VALVE, check, A side; includes
1
26a-26g
246352 VALVE, check, B side; includes
1
26a-26g
26a
‡† .HOUSING 1
26b
‡† 15B214 . SCREW; 5/16-18 x
1
1/2 in. (13 mm)
26c
‡ 104396 . BALL; carbide 1
26d
‡ . SCREEN; see page 38 1
26e
‡ 117490 . SPRING 1
26f‡* 248133 . O-RING, check valve face;
1
package of 6
26g
‡* 248129 . O-RING, check valve housing;
1
package of 6
27
‡ 116550 RING, retaining 1
28
★ 15B205 STOP, piston 1
29 203953 SCREW; 10-24 x 3/8 in. (10 mm) 1
30
★ 114070 SPRING 1
31 117485 SPRING 1
32 15B202 SPOOL, valve 1
33 100721 PLUG, pipe; 1/4-18 npt;
1
round and flat pattern guns only
35 117509 QUICK-DISCONNECT, male, air;
1
1/4 npt(m); round and flat pattern
guns only
36▲ 222385 CARD, warning; not shown 1
37
‡ 15B689 COVER, grease fitting 1
39 FTxxxx TIP, flat; see Flat Tip Kits,
1
page 38
40* 246360 O-RING; PTFE; flat tip models
1
only; package of 3;
See Flat Pattern Guns, page 37
43 117661 VISE, pin; dual reversible chucks;
1
see Supplied Tools, page 36
46 117792 GREASE GUN; not shown 1
47 117510 COUPLER, air line 1
49 15B772 HOSE, air; 1/4 npsm (fbe);
1
18 in. (0.46 m)
50 112307 ELBOW, street; 1/8 npt (m x f);
2
round and flat pattern guns only
51 15B565 VALVE, ball; 1/4 npt (m x f); round
1
and flat pattern guns only
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).
309550U 35
Parts
Ref.
No. Part No. Description Qty
52 15B817 MANIFOLD, gun flush; round and
1
flat pattern guns only
53 117642 NUT DRIVER, hex; 5/16 1
54 118575 SCREWDRIVER; 1/8 blade 1
55▲ 172479 TAG, warning; not shown 1
56▲ 15D235 SIGN, instruction; not shown 1
57 117773 GREASE CARTRIDGE; 3 oz;
1
not shown; MSDS sheet available
at www.graco.com
Detail Views
Flat Pattern Detail
1910 39 40†*
Flat Pattern Stud Wall Foam Detail
❖61
Ref.
No. Part No. Description Qty
58◆ 15D972 RETAINER, tip;
spatter pattern gun only
59◆ 15D971 TIP; spatter pattern gun only 1
60◆ 248019 SEAL, package of 5;
spatter pattern gun only.
61❖ 15F240 ADAPTER, stud wall 1
62❖ 15F854 PACKING, tip; stud wall 1
63❖ 15F241 CAP, air; stud wall 1
64❖ FTM979 TIP, flat; stud wall 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.
Spatter Tip Detail
10◆
19 (Ref)
◆58
◆
59
60
◆
1
1
TI2557A
Supplied Tools
53
43
54
TI3870A
❖63 ❖64 ❖62
4-Hose Fluid Manifold Detail
12a
50
12e
3
12b
12d
12g
TI4660C-1
5
12e
3
12f
50
12f
TI7134A
TI4555B
Flush Manifold Detail
33 (Ref)
1
3
3
52
35 (Ref)
1
12d (Ref)
TI2647A
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).
36 309550U
Mix Chamber Kits
Round Pattern Guns
Parts
Mix Chamber Kit
(includes drill bits)
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 0.070 #50 (1.75) 0.052 #55 (1.30) N/A N/A
AR6060 0.086 #44 (2.15) 0.060 #53 (1.50) N/A N/A
AR7070 0.094 3/32 (2.35) 0.070 #50 (1.75) N/A N/A
AR8686 0.116 #32 (2.90) 0.086 #44 (2.15) N/A N/A
Nozzle
Orifice
Size
Nozzle Drill
Bit Size,
in. (mm)
Impingement
Port Siz e
Impingement
Port Drill Bit
Size, in. (mm)
Counterbore
Size
Counterbore
Drill Bit Size,
in. (mm)
Flat Pattern Guns
Mix Chamber
Kit (includes
drill bits and
o-ring)
AF2020 246360 0.094 3/32 (2.35) 0.020 #76 (0.50) 0.060 #53 (1.50)
Ref. No.
40†,
O-ring
Nozzle
Orifice
Size
Nozzle Drill
Bit Size,
in. (mm)
Impingement
Port Siz e
Impingement
Port Drill Bit
Size, in. (mm)
Counterbore
Size
Counterbore
Drill Bit Size,
in. (mm)
AF2929 246360 0.094 3/32 (2.35) 0.029 #69 (0.70) 0.060 #53 (1.50)
AF4242 246360 0.094 3/32 (2.35) 0.042 #58 (1.00) N/A N/A
AF5252 246360 0.094 3/32 (2.35) 0.052 #55 (1.30) N/A N/A
† Available only in flat mix chamber kits or in 246360 multi-pack kit.
Mix Chamber Part No. Reference Guide
Sample part no. AR4242:
AR 42 42
AR=Air purge
round pattern
AF=Air purge
flat pattern
A orifice size
(.042 in.)
B orifice size
(.042 in.)
309550U 37
Parts
Flat Tip Kits
Ref. No. 39,
Flat Spray Tip
Pattern Size, in. (mm)
Flat Tip Part No. Reference Guide
Sample part no. FT0848:
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)
FT 08 48
FT=Flat tip 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.
Ref.
No.
3 248137 (6) 1
14 248136 (6) 1
16 248135 (6) 1
Bulk O-ring
Kits, (qty)
246347
Side Seal
Cartridge
O-ring Kit
246348
Side
Seal Kit
246351
Check
Valve
O-ring Kit
246355
Complete
O-ring Kit
Equivalent orifice
diameter size
(.048 in.)
17 248134 (6) 1
18c 2
18d 248130 (6) 4 4
18e 248128 (6) 2 2 2
21 248132 (6) 1
23 248131 (6) 1
24 246354 (6) 5
26f 248133 (6) 2 2
26g 248129 (6) 2 2
40 246360 (3)
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 309550U
Drill Bit Kits
For cleaning gun ports and orifices. Illustrations are actual size, for comparison.
Not all sizes are used with your gun.
Parts
Kit Part No. Qty in Kit
Drill Bit Size
nominal in. mm
249115 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 .082 2.08
246811 3 2 mm .079 2.00
246626 6 #50 .070 1.78
Illustration
249113 6 #52 0.64 1.63
248893 6 1/16 .062 1.59
246627 6 #53 .060 1.52
249112 6 1.45 mm .057 1.45
246809 6 #54 .055 1.40
246628 6 #55 .052 1.32
249764 6 1.20 mm .047 1.20
246814 6 #56 .046 1.18
309550U 39
Parts
Kit Part No. Qty in Kit
Drill Bit Size
nominal in. mm
246629 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
Illustration
246631 6 #76 .020 0.51
246816 6 #77 .018 0.46
246817 6 #81 .013 0.33
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, page 21.
40 309550U
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
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 (1.52) #66, .033 (0.84)
AW3939 16 (406.4) Ref. AR4242 #50, .070 (1.78) #61, .039 (0.99)
AW4646 18 (457.2) Ref. AR5252 .085 (2.15) #56, .046 (1.17)
AW5757 18 (457.2) Ref. AR6060 #42, .089 (2.26) 1.45 mm, .057 (1.45)
in (mm)
Equivalent flow to
mix chamber size
Nozzle Drill Bit Size
in (mm) *
Impingement Drill Bit Size
in. (mm) *
AW6464 22 (563.9) Ref. AR7070 7/64, .109 (2.77) #52, .064 (1.63)
AW8282 24 (609.6) Ref. AR8686 1/8, .125 (3.18) #45, .082 (2.08)
Stainless Steel Side Seal Kits
Kits include a packing o-ring for each stainless steel seal.
Kit Part No. Description No. of Seals Per Kit
246348 SEAL KIT, SST 2
277299 SEAL KIT, SST 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 No. of Seals Per Kit
249990 SEAL KIT, Polycarballoy 2
277298 SEAL KIT, Polycarballoy 50
309550U 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 .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 12.7) AR4242/AF4242 12 (3.66) 12 (305)
248013 .070 x 0.50 (1.78 x 12.7) AR5252/AF5252 8 (2.44) 20 (508)
248014 .042 x 1.0 (1.06 x 25.4) AR2020/AF2929 15 (4.57) 10 (254)
248015 .052 x 1.0 (1.32 x 25.4) AR2929/AF2929 12 (3.66) 8 (203)
248016 .060 x 1.0 (1.52 x 25.4) AR4242/AF4242 12 (3.66) 8 (203)
248017 .070 x 1.0 (1.78 x 25.4) AR5252/AF5252 8 (2.44) 8 (203)
* Measured with less than 8 in. (203 mm) drop in stream center at 1200 psi (8.4 MPa, 84 bar) static pressure.
Hole Diameter x Length,
in. (mm)
Recommended
Mix Chambers
Extension Tip Seal Kits
Kits include 5 seals.
Kit Part No. Description
248018 Flat Extension Tip Seal Kit
Spray
Distance,
ft (m) *
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.
Pattern
Diameter,
in. (mm) *
248019 Round Extension Tip Seal Kit
Extension Tip Air Cap Kit
• Flat pattern mix chamber not included. Order
separately.
• Optional tip FTM762 available for lower flow
and smaller pattern application.
248020
Includes air cap for use with extension tip kits
248010-248017.
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 309550U
Accessories
Spatter Conversion 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.
Pour Nozzle Kit
248528
To convert air purge gun for pour applications. Includes
nozzle, seals, tubing, and cleanout drill bits.
Gun Cover
244914 Covers
Keeps gun clean while spraying. Pack of 10.
Flushing Manifold
15B817 Manifold Block
See ref. no. 52, page 34.
Solvent Flush Canister Kit
248139, 1 qt (0.95 liter) Solvent Cup
Complete with15B817 Flushing Manifold to flush gun
with solvent. Portable for remote flushing. See manual
309963.
TI4165a
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.
Solvent Flush Pail Kit
248229 5.0 gal. (19 liter) Pail
Includes flush manifold with individual A and B shutoff
valves, and air regulator. See manual 309963.
TI4211b
309550U 43
Accessories
Tip Cleanout Tool
15D234
Designed to fit CeramTip internal dome and flat tip slits.
End for
Mechanical
End for Air
Purge Tips
Purge Tips
TI4244a
Circulation Manifold
246362
Attach to gun fluid manifold to enable preheating of
hose. See manual 309818.
TI3877a
44 309550U
Technical Data
Technical Data
Category Data
Maximum Fluid Working Pressure 3500 psi (24.5 MPa, 245 bar)
Minimum Air Inlet Pressure 80 psi (0.56 MPa, 5.6 bar)
Maximum Air Inlet Pressure 130 psi (0.9 MPa, 9 bar)
Air Flow Range See chart below
Typical Flow Rate of Round Pattern Guns See chart page 3.
Typical Flow Rate of Flat Pattern Guns See chart page 6.
Maximum Fluid Temperature 200° F (94° C)
Air Inlet Size 1/4 npt Quick Disconnect Nipple
A Component (ISO) Inlet Size -5 JIC; 1/2-20 UNF
B Component (Resin) Inlet Size -6 JIC; 9/16-18 UNF
Sound Pressure 81.1 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
Sound Power, measured per ISO 9416-2 91.0 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
Dimensions 7.5 x 8.1 x 3.3 in. (191 x 206 x 84 mm)
Weight 2.5 lb (1.1 kg)
Wetted Parts
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 (m3/min)
Air Pressure
(detriggered)
psi (MPa, bar) AR2020 AR2929 AR3737 AR4242 AR5252 AR6060 AR7070 AR8686
80 (0.56, 5.6)
100 (0.7, 7)
130 (0.9, 9)
0.8
(.022)
0.9
(.025)
1.2
(.034)
1.4
(.039)
1.7
(.048)
2.3
(.064)
2.0
(.056)
2.9
(.081)
3.2
(.090)
Mix Chamber Sizes
2.6
(.073)
3.1
(.087)
4.1
(0.115)
3.7
(0.104)
4.6
(0.129)
5.9
(0.165)
4.6
(0.129)
5.7
(0.160)
7.3
(0.204)
5.7
(0.160)
7.1
(0.200)
9.2
(0.258)
7.1
(0.200)
8.8
(0.246)
11.3
(0.316)
309550U 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
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-328-0211 Toll Free
612-623-6921
612-378-3505 Fax
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. (SRC309550)
This manual contains English MM 309550
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
309550U
8/2004 Revised 8/2007
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