Instructions

Fusion® AP Spray Gun 309550ZAR

EN

Plural component, impingement mix air purge spray gun for dispensing non-flammable
foam and polyurea. For professional use only.

Not approved for use in European explosive atmosphere locations.

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

See page 4 for model information.

Important Safety Instructions

Read all warnings and instructions in this
manual and in all related manuals before
using the equipment. Save these
instructions.

Important Medical Information

Read the medical alert card provided with
the gun. It contains injection injury
treatment information for a doctor. Keep it
with you when operating the equipment.

TI2408-1A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Clean Fluid Manifold. . . . . . . . . . . . . . . . . . . . . . 27
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clean Passages . . . . . . . . . . . . . . . . . . . . . . . . . 27
Round Pattern Guns . . . . . . . . . . . . . . . . . . . . . . 4 Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Flat Pattern Guns . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect the Piston . . . . . . . . . . . . . . . . . . . . . . . . 28
Flat Pattern Stud Wall Gun . . . . . . . . . . . . . . . . . 6 Inspect the Air Valve. . . . . . . . . . . . . . . . . . . . . . 28
Wide Round Pattern Gun . . . . . . . . . . . . . . . . . . . 6 Remove Front End . . . . . . . . . . . . . . . . . . . . . . . 29
Four-Hose Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Attach Front End. . . . . . . . . . . . . . . . . . . . . . . . . 29
Spatter Pattern Gun . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Non 1:1 Ratio Guns . . . . . . . . . . . . . . . . . . . . . . . 7 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Detail Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Important Isocyanate (ISO) Information . . . . . . . . 11 Mix Chamber Kits . . . . . . . . . . . . . . . . . . . . . . . . 36
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 11 Flat Tip Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . 12 Gun Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . 38
Keep Components A and B Separate . . . . . . . . 12 Check Valve Filter Screen Kits . . . . . . . . . . . . . . 38
Moisture Sensitivity of Isocyanates . . . . . . . . . . 12 Drill Bit Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Foam Resins with 245 fa Blowing Agents . . . . . 12 Handle Cleanout Drill Kit . . . . . . . . . . . . . . . . . . 38
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 12 Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Reamer Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 13 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Component Identification . . . . . . . . . . . . . . . . . . . 14 Fusion PC Conversion Kits. . . . . . . . . . . . . . . . . 41
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Side Seal Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Side Seal Cartridge Kits . . . . . . . . . . . . . . . . . . . 42
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Extension Tip Kits. . . . . . . . . . . . . . . . . . . . . . . . 42
Optional Configurations . . . . . . . . . . . . . . . . . . . 17 Extension Tip Seal Kits. . . . . . . . . . . . . . . . . . . . 42
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Extension Tip Air Cap Kit . . . . . . . . . . . . . . . . . . 42
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 19 Flat Pattern Stud Wall Kit . . . . . . . . . . . . . . . . . . 42
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . 20 Pour Nozzle Kit. . . . . . . . . . . . . . . . . . . . . . . . . . 43
Turn the Air Cap. . . . . . . . . . . . . . . . . . . . . . . . . 20 Gun Cleaning Kit . . . . . . . . . . . . . . . . . . . . . . . . 43
Loss of Air Pressure. . . . . . . . . . . . . . . . . . . . . . 20 Hose Adapter Kits. . . . . . . . . . . . . . . . . . . . . . . . 43
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Spatter Conversion Kit . . . . . . . . . . . . . . . . . . . . 43
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 21 Gun Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Lubricant for Gun Rebuild. . . . . . . . . . . . . . . . . . 43
Preventative Maintenance . . . . . . . . . . . . . . . . . 22 Grease Cartridge for Gun Shutdown . . . . . . . . . 43
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 22 Flushing Manifold . . . . . . . . . . . . . . . . . . . . . . . . 43
Clean Gun Surface . . . . . . . . . . . . . . . . . . . . . . 22 Adjustable Flow Cap Kit . . . . . . . . . . . . . . . . . . . 43
Clean Mix Chamber Nozzle . . . . . . . . . . . . . . . . 23 Solvent Flush Canister Kit . . . . . . . . . . . . . . . . . 44
Clean Air Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Solvent Flush Pail Kit . . . . . . . . . . . . . . . . . . . . . 44
Clean Impingement Ports . . . . . . . . . . . . . . . . . 23 Tip Cleanout Tool . . . . . . . . . . . . . . . . . . . . . . . . 44
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Circulation Manifold . . . . . . . . . . . . . . . . . . . . . . 44
Inspect the Mix Chamber and Side Technical Specifications . . . . . . . . . . . . . . . . . . . . 45
Seal Cartridges . . . . . . . . . . . . . . . . . . . . . . 24 Air Flow by Mix Chamber . . . . . . . . . . . . . . . . . . 45
Inspect the Piston Safety Lock. . . . . . . . . . . . . . 26 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Inspect the Check Valves . . . . . . . . . . . . . . . . . 26

2 309550ZAR
 Related Manuals

Related Manuals
Manual in Description
English
309963 Fusion Solvent Flush Kit
309818 Circulation Manifold Kit
3A5616 Fusion Adjustable Flow Cap Kit
311071 Stud Wall Foam Kit and TP100 Kit
3A7314 Fusion PC Spray Gun Instruction
Manual
3A7318 Fusion PC Conversion Kit

309550ZAR 3
Models

Models

Round Pattern Guns

Mix Chamber
Gun Part, Impingement Port Pattern at 24 in (61
Series Part Equivalent Seal
Size cm) from target
Number Size Material
in. (mm) in. (mm)
246099, A AR2020 0.020 (0.50) -000 SST 5 (127)
246100, A AR2929 0.029 (0.70) -00 SST 8 (203)
248617, A AR3737 0.037 (0.94) None SST 9 (227)
246101, A AR4242 0.042 (1.00) -01 SST 11 (279)
246102, A AR5252 0.052 (1.30) -02 SST 12 (305)
246103, A AR6060 0.060 (1.50) -03 SST 14 (356)
246104, A AR7070 0.070 (1.75) -04 SST 15 (381)
246105, A AR8686 0.086 (2.15) -05 SST 18 (457)
255201, A AR4242 0.042 (1.00) -01 Polycarballoy 11 (279)
255202, A AR5252 0.052 (1.30) -02 Polycarballoy 12 (305)

Round Pattern Mix Chambers by Pressure and Flow Rate

5.0
82
(18.9) 82 57
64
* To calculate flow in lb/min, multiply gpm rate by 10.

AW 64 W 57
) )A
(05 AW (03
4.0 86 4) 0 60
86 (0 R6 *
(15.1)
AR 70 A 646
0 W4
R7 ,A
FLOW RATE in gpm (lpm)*

A 2(02)
525
3.0 AR
(11.4) 747
Example: 2 gpm x 10 = 20 lb/min.

AR4 939*
1), AW3
24 2 (0
2.0 AR4 3333
*
7 3 7 , AW
(7.6) AR3 AW282
8*
9 (00),
AR292
1.0 00)
(3.8) AR2020 (0

0
500 1000 1500 2000 2500 3000 3500
(3.5, 35) (6.9, 69) (10.3, 103) (13.8, 138) (17.4, 172.4) (20.7, 207) (24.1, 241)
PRESSURE in psi (MPa, bar)

*Accessory AW (wide pattern) mix chambers are available. See Extension Tip Kits, page 42.

4 309550ZAR
 Models

Flat Pattern Guns

Mix Chamber Flat Tip
Gun Part, Impingement
Series Part Equivalent Part Pattern Size Orifice Size
Port Size
Number Size Number in. (mm) in. (mm)
in. (mm)
247101, A AF2020 0.020 (0.50) -000 FT0424 8-10 (203-254) 0.024 (0.61)
247102, A AF2020 0.020 (0.50) -000 FT0438 8-10 (203-254) 0.038 (0.97)
247103, A AF2020 0.020 (0.50) -000 FT0624 12-14 (305-356) 0.024 (0.61)
247104, A AF2020 0.020 (0.50) -000 FT0638 12-14 (305-356) 0.038 (0.97)
247107, A AF2020 0.020 (0.50) -000 FT0838 16-18 (406-457) 0.038 (0.97)
247108, A AF2020 0.020 (0.50) -000 FT0848 16-18 (406-457) 0.048 (1.22)
247111, A AF2929 0.029 (0.70) -00 FT0424 8-10 (203-254) 0.024 (0.61)
247112, A AF2929 0.029 (0.70) -00 FT0438 8-10 (203-254) 0.038 (0.97)
247113, A AF2929 0.029 (0.70) -00 FT0624 12-14 (305-356) 0.024 (0.61)
247114, A AF2929 0.029 (0.70) -00 FT0638 12-14 (305-356) 0.038 (0.97)
247117, A AF2929 0.029 (0.70) -00 FT0838 16-18 (406-457) 0.038 (0.97)
247118, A AF2929 0.029 (0.70) -00 FT0848 16-18 (406-457) 0.048 (1.22)
247121, A AF4242 0.042 (1.00) -01 FT0424 8-10 (203-254) 0.024 (0.61)
247122, A AF4242 0.042 (1.00) -01 FT0438 8-10 (203-254) 0.038 (0.97)
247123, A AF4242 0.042 (1.00) -01 FT0624 12-14 (305-356) 0.024 (0.61)
247124, A AF4242 0.042 (1.00) -01 FT0638 12-14 (305-356) 0.038 (0.97)
247127, A AF4242 0.042 (1.00) -01 FT0838 16-18 (406-457) 0.038 (0.97)
247128, A AF4242 0.042 (1.00) -01 FT0848 16-18 (406-457) 0.048 (1.22)
247131, A AF5252 0.052 (1.30) -02 FT0424 8-10 (203-254) 0.024 (0.61)
247132, A AF5252 0.052 (1.30) -02 FT0438 8-10 (203-254) 0.038 (0.97)
247133, A AF5252 0.052 (1.30) -02 FT0624 12-14 (305-356) 0.024 (0.61)
247134, A AF5252 0.052 (1.30) -02 FT0638 12-14 (305-356) 0.038 (0.97)
247137, A AF5252 0.052 (1.30) -02 FT0838 16-18 (406-457) 0.038 (0.97)
247138, A AF5252 0.052 (1.30) -02 FT0848 16-18 (406-457) 0.048 (1.22)

309550ZAR 5
Models

Flat Pattern Mix Chambers by Pressure and Flow Rate

3.0
(11.4)
* To calculate flow in lb/min, multiply gpm rate by 10.

ip
48 t
2.25 FTXX
with
(8.55) 252
AF5
FLOW RATE in gpm (lpm)*

38 tip
ith FTXX
242 w
Example: 2 gpm x 10 = 20 lb/min.

AF4
1.5 X38 tip
9w ith FTX
(5.7) AF292

4 tip
ith FTXX2
0.75 AF2020 w
(2.85)

0
500 1000 1500 2000 2500 3000 3500
(3.5, 35) (6.9, 69) (10.3, 103) (13.8, 138) (17.4, 172.4) (20.7, 207) (24.1, 241)
PRESSURE in psi (MPa, bar)

Flat Pattern Stud Wall Gun

Refer to the Stud Wall Foam Kit and TP100 manual for more information. See Related Manuals, page 3.

Mix Chamber Flat Tip Flow Data

Gun Pattern
Approximate
Part Impingement Diameter at 24 Orifice
Part Equivalent Part Flow Rate at
Number Port Size in. (610 mm) to Size
Number Size Number 1000 psi
in. (mm) Target in. (mm)
(7.0 MPa, 70 bar)
in. (mm)
249525 AF4242 0.042 (1.00) -01 FTM979 22 (559) 0.038 11 lb/min
(0.97) (4.99 kg/min)
249526 AF5252 0.052 (1.30) -02 FTM979 22 (559) 0.038 15 lb/min
(0.97) (6.81 kg/min)

Wide Round Pattern Gun

Mix Chamber
Pattern Diameter at 24 Reference Part
Gun Part Impingement
Part Equivalent in. (610 mm) to Target Number with
Number Port Size
Number Size in. (mm) Equivalent Flow
in. (mm)
249529 AW3939 0.039 (0.99) -01 16 (406.4) AR4242
249530 AW4646 0.046 (1.17) -02 18 (457.2) AR5252

6 309550ZAR
 Models

Four-Hose Gun
Wide Round Pattern Gun with Four-Hose Recirculating Gun Manifold

Mix Chamber
Pattern Diameter at 24 Approximate Flow
Gun Part Impingement
Part Equivalent in. (610 mm) to Target Rate at 1000 psi
Number Port Size
Number Size in. (mm) (7.0 MPa, 70 bar)
in. (mm)
249810 AW2222 0.022 (0.56) Not Available 8-9 (203-229) 4.5 lb/min
(N/A) (204 kg/min)

Spatter Pattern Gun Non 1:1 Ratio Guns

Mix Chamber Gun Part Mix
Gun Part Number Chamber
Impingement
Number Part Equivalent
Port Size 253888 AR2232
Number Size
in. (mm)
248408 AR7070 0.070 (1.75) -04

309550ZAR 7
Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.

TOXIC FLUID OR FUMES HAZARD

WARNING
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.

• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.

• Engage piston safety lock when not spraying.

• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

8 309550ZAR
 Warnings

BURN HAZARD
WARNING
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:

• Do not touch hot fluid or equipment.

FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.

309550ZAR 9
Warnings

EQUIPMENT MISUSE HAZARD

WARNING
Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.

10 309550ZAR
 Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized
particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheets (SDSs) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you
are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDSs.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which could
cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to
instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a
supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDSs.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory
authority. Follow all fluid manufacturer recommendations, including those regarding handling of
contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations
of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the
work area is recommended:

TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: ____________
TIME: ____________

309550ZAR 11
Important Isocyanate (ISO) Information

Material Self-Ignition NOTE: The amount of film formation and rate of

crystallization varies depending on the blend of ISO, the
humidity, and the temperature.

Foam Resins with 245 fa

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
Blowing Agents
Safety Data Sheets (SDSs). Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
Keep Components A and B circulation system.
Separate
Changing Materials
NOTICE
Cross-contamination can result in cured material in Changing the material types used in your equipment
fluid lines which could cause serious injury or damage requires special attention to avoid equipment damage
equipment. To prevent cross-contamination: and downtime.
• Never interchange component A and component • When changing materials, flush the equipment
B wetted parts. multiple times to ensure it is thoroughly clean.
• Never use solvent on one side if it has been • Always clean the fluid inlet strainers after flushing.
contaminated from the other side. • Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes or
Moisture Sensitivity of polyureas, disassemble and clean all fluid
Isocyanates components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
Exposure to moisture (such as humidity) will cause ISO often have amines on the B (resin) side.
to partially cure, forming small, hard, abrasive crystal
that become suspended in the fluid. Eventually a film will
form on the surface and the ISO will begin to gel,
increasing in viscosity.

NOTICE
Partially cured ISO will reduce performance and the life
of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and the
atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Always lubricate threaded parts with an appropriate
lubricant when reassembling.

12 309550ZAR
 Overview

Overview

Theory of Operation Gun Detriggered (Air Purging)

Mix chamber (19) moves forward, shutting off fluid flow.
Gun Triggered (Fluid Spraying) Impingement ports (IP) open to air chamber (AC),
allowing purge air to flow through mix chamber nozzle
Mix chamber (19) moves back, shutting off purge air (N).
flow. Impingement ports (IP) align with fluid ports of side
seals (18c), allowing fluid to flow through mix chamber Key
nozzle (N).
Purge Air
Key
Fluid
Purge Air
Cleanoff Air
Fluid
Grease
Cleanoff Air

Grease NOTE: Flow paths are not shown to scale.

NOTE: Flow paths are not shown to scale. G

19
19 18c AC
IP
IP

N TI3546a

K N TI3545a

309550ZAR 13
Component Identification

Component Identification
G

K F R L

U D

N
V

C
S

B
W*
M A
T

H E
J TI2408A

FIG. 1: Component Identification

Key Key
A A Side Fluid Valve (ISO) M Gun Fluid Manifold
B B Side Fluid Valve (RESIN) N Mix Chamber Nozzle
C Air Cap P Optional Fluid Inlets (A Side Shown)
D Air Line Quick Coupler R Lock Ring
E Muffler S Fluid Inlet Swivels (A Side Shown)
F Fluid Housing T Trigger
G Grease Fitting (under cap) U Front Retaining Ring
H Handle V Gun Air Whip Hose
J Optional Air Inlet W* Air Valve
K Cleanoff Air Valve
L Piston Safety Lock * Air Valve (W) is not included with spatter pattern
spray gun.

14 309550ZAR
 Installation

Installation

Grounding 4. Connect gun air whip hose (V) and air valve (W*) to
main air hose. Attach fluid manifold (M) to gun.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to V
ignite or explode. Grounding provides an escape wire M
for the electric current. W*
TI2554A
Spray gun: Ground through connection to a properly
grounded fluid hose and pump. * Air Valve (W) is not included with spatter pattern spray
gun.
Proportioner: Follow the instructions in your
proportioner manual. 5. Connect air line quick coupler (D). Turn on air. Open
air valve (W*). Air should flow from nozzle (N).

Setup
1. Close fluid valves A and B.

N
D W*
TI2414-1A

6. Disengage piston safety lock (L). See Piston

Safety Lock, page 20.

ti2411a
L
2. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold.

B (RESIN)
TI2410A

7. Trigger gun to check for full mix chamber travel.

Front of air cap (C) should be approximately flush
A (ISO)
TI2417A with front retaining ring (U).
3. Engage piston safety lock (L). See Piston Safety
Lock, page 20. U

C
L

TI2414-1A

TI2409A

309550ZAR 15
Installation

8. Open cleanoff air valve (K) 1/4-1/2 turn and trigger 13. Test spray onto cardboard. Adjust pressure and
gun to check that cleanoff air is flowing. Adjust as temperature to get desired results.
desired.This step does not apply with spatter
pattern spray gun 248408.

TI2413A

TI2645A
9. Engage piston safety lock (L). See Piston Safety
Lock, page 20. 14. Apply layer of lubricant over front of gun and lock
ring (R), or use gun cover to prevent overspray
buildup and aid disassembly. See Lubricant for
L Gun Rebuild, page 43, to order lubricant and gun
cover.

R
TI2409A

10. Turn on proportioner.

11. Open B (RESIN) fluid valve (about three half turns). 15. Gun is ready to spray.
Then open A (ISO) fluid valve.

TI2414A

12. Disengage piston safety lock (L). See Piston

Safety Lock, page 20.

TI2410A

16 309550ZAR
 Installation

Optional Configurations Change Hose Position

The fluid inlet swivels and air quick disconnect fitting
Change Fluid Manifold Position point to the rear of the gun. If desired, these positions
can be changed so hoses travel downward.
The fluid manifold is mounted to bottom of gun, with A
side on left, viewed from operator’s position at back of NOTICE
gun. If desired, manifold may be moved to top of gun. To prevent cross-contamination in the gun, do not
Doing this will reposition A side parts (fluid inlet swivel, interchange A component (isocyanate) and B
check valve, side seal cartridge, and mix chamber) to component (resin) parts. Cross-contamination can
the right. result in cured material in the gun. Cured material may
NOTICE damage the sealing surfaces, block fluid passages,
and prevent gun function.
To prevent cross-contamination in the gun, do not
interchange A component (isocyanate) and B
component (resin) parts. Cross-contamination can 1. Follow the Pressure Relief Procedure, page 19.
result in cured material in the gun. Cured material may
2. Relieve the system pressure. Follow the Pressure
damage the sealing surfaces, block fluid passages,
Relief Procedure in your proportioner manual.
and prevent gun function.
3. Disconnect air line (D) and remove fluid manifold
1. Follow the Pressure Relief Procedure, page 19. (M).

2. Disconnect air line quick coupler (D) and remove

fluid manifold (M).

M
D
TI2554A

4. Disconnect fluid hoses from fluid inlet swivels (S).

M Remove swivels. Remove plugs from optional inlets
D (P).

TI2554A
S
3. Follow the Remove Front End procedure, page 29.

4. Rotate the fluid housing (F) 180 degrees.

S
5. Follow the Attach Front End procedure, page 29. P TI2417A

6. Reattach fluid manifold. Reconnect air line. Return

gun to service.

309550ZAR 17
Installation

5. Apply thread sealant to plugs (12c), elbows (50*), Reposition or Replace Flat Spray Tips
and male threads of fluid inlet swivels (S). Install
elbows (50*) in optional fluid inlets (P), facing down. 1. Follow the Pressure Relief Procedure, page 19.
Install swivels (S) in elbows. Be sure to install A
2. Remove air cap (10) and flat spray tip (39). Inspect
swivel (smaller) in A side. Install included plugs
o-ring (40).
where swivels were located. Torque all parts to
235-245 in-lb (26.6-27.7 N•m).
12c

S 50*
40
39
10 TI2557A
P S TI2646A

* Elbows (50) are not included with spatter spray gun. NOTE: If tip is stuck, pry off with small screwdriver or
pull off with pliers. Tip is hardened to resist damage.
6. Connect A and B hoses to A and B swivels.
3. To clean, soak tip in compatible solvent, see
7. Remove air line quick coupler (D) and optional air Supplied Tool Kit, page 22. Clean gently with tip
inlet plug (J). Reverse positions. Apply thread cleanout tool 15D234. Refer to Tip Cleanout Tool,
sealant and torque to 125-135 in-lb (14-15 N•m). page 44, to fit tip configuration.
D 4. Reposition tip horizontally or vertically, or install
different tip size.

TI2540A
J
TI2649A

8. Reattach fluid manifold. Reconnect air. Return gun

to service.

TI2648A

NOTE: Tips marked on back with the last three digits of

the part number. See Flat Tip Part Reference Guide,
page 37.

5. Reinstall air cap hand tight.

NOTE: The alignment of the clean off air ports on the air
cap does not affect operation.

18 309550ZAR
 Operation

Operation

Pressure Relief Procedure 4. Trigger the gun onto cardboard or into a waste
container to relieve pressure.
Follow the Pressure Relief Procedure whenever
you see this symbol.

TI4722a

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from 5. Engage the piston safety lock (L). See Piston
pressurized fluid, such as skin injection, and Safety Lock, page 20.
splashing fluid, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment. L

1. Engage the piston safety lock (L). See Piston

Safety Lock, page 20. TI2409A

L
NOTE: After the pressure in the spray gun is relieved,
the fluid in the hose and proportioner remains under
pressure. Follow the Pressure Relief Procedure in
TI2409A your proportioner manual to relieve pressure in the
system.
2. Close fluid valves A and B. Leave air valve (W)
open.

B
W
TI2421A
A

3. Disengage the piston safety lock (L). See Piston

Safety Lock, page 20.

TI2410A

309550ZAR 19
Operation

Piston Safety Lock 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:

• Engage the piston safety lock. See Piston Safety

High-pressure fluid from dispensing devices can Lock.
pierce skin. To help prevent serious injury from
pressurized fluid, always engage the piston safety • Close fluid valves A and B.
lock and close the material shutoff valves to avoid
accidental triggering whenever you stop spraying.

To engage the piston safety lock: Push knob in and

turn clockwise. If engaged, gun will not actuate.

TI2421A
A
Engaged
r_257826_313266_1_2b

To disengage the piston safety lock: Push knob in

Flush Gun
and turn counterclockwise until it pops out. There will be
a gap between knob and gun body.

Disengaged
r_257826_313266_1_1b To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
Turn the Air Cap possible pressure.

1. Follow the Pressure Relief Procedure, page 19.

2. Disconnect the gun from the hose.

Always follow the Pressure Relief Procedure, page 19, 3. Connect the gun to the flush manifold block (52).
before turning the air cap (C).
4. Flush with compatible solvent into a grounded metal
pail, holding a part of fluid manifold (M) firmly to side
of pail. Use the lowest possible fluid pressure when
flushing.

C 5. Follow the Pressure Relief Procedure, page 19.

B 6. Disconnect the gun from the flush manifold block.

TI2421A
NOTE: For a more thorough flush, Solvent Flush Kits
248139 and 248229 are available as an accessory. The
kits connect to Flush Manifold 15B817. See your
Solvent Flush Kit manual for detailed flushing
instructions.

20 309550ZAR
 Operation

Daily Shutdown 1. Follow the Pressure Relief Procedure, page 19.

2. Leave the air turned on and gun detriggered.

3. Remove the grease fitting cap. Using the grease

gun (Y), dispense grease into fitting (G) until grease
mist sprays from mix chamber nozzle (N).
Grease your gun daily to prevent two component curing
and keep fluid passages clean. Purge air carries grease NOTE: Do not over-grease. Use two shots maximum.
mist through the air chamber (AC) and impingement Do not spray grease mist on sprayed material.
ports (IP) and out the mix chamber nozzle (N), coating
Y
all interior surfaces. G
Key
Purge Air N

Fluid

Cleanoff Air
TI2415A W
Grease
4. Replace the grease cap.

5. Round and flat pattern guns only: Turn off the air
AC
valve (W).
G IP Spatter pattern gun only: Shut down the main air
supply.

19

309550ZAR 21
Maintenance

Maintenance

Preventative Maintenance
Recommended
Schedule Maintenance Procedure
Daily Flush Gun, page 20.
Clean Mix Chamber Nozzle, page 23.
Clean Air Cap, page 23
Weekly Inspect the Mix Chamber and Side Seal Cartridges, page 24. Check o-rings.
Inspect the Check Valves, page 26. Check o-rings and filters.
Inspect the Piston Safety Lock, page 26.
Inspect the Check Valves, page 26.
As Needed Clean Impingement Ports, page 23.
Lubrication, page 24

Supplied Tool Kit Clean Gun Surface

• Hex nut driver, 5/16 Keep gun clean with accessory gun cover.

• Screwdriver, 1/8 blade Applying a light coat of lubricant will make cleaning
easier.
• Nozzle drill bit. Various sizes depending on nozzle
size. Wipe off outside of gun with compatible solvent.

• Impingement port drill bit, various sizes depending Use N Methyl Pyrrolidone (NMP), Dynaloy®-brand
on port size. See TABLE 1, page 23.
Dynasolve CU-6, SB Versaflex-brand Dzolv®, or
equivalent to soften cured material.
• 117661 pin vise, dual reversible chucks

Reversible

Reversible
TI3864a

• 551189 grease gun, with 3 oz grease

• 15B817 flush manifold (not included with spatter

spray gun).

22 309550ZAR
 Maintenance

Clean Mix Chamber Nozzle Clean Air Cap

1. Follow the Pressure Relief Procedure, page 19. Soak air cap in compatible solvent. Clean holes with #58
(0.042) drill bit.
2. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
Clean Impingement Ports
1. Follow the Pressure Relief Procedure, page 19.
L
2. Disconnect air line quick coupler (D) and remove
fluid manifold (M).
TI2409A

3. Follow the Flush Gun procedure, page 20. If the

3. Use the appropriate size drill bit to clean mix gun will not flush, see Inspect the Mix Chamber
chamber nozzle (N). If necessary, clean air cap (C) and Side Seal Cartridges, page 24.
gently with stiff brush.

NOTE: Refer to TABLE 1, and Drill Bit Kits, page 39.

Table 1: Nozzle Drill Bit Sizes

Round Spray Flat Spray
Mix Chamber Drill Size Mix Drill Size M
Part Number in. (mm) Chamber in. (mm) D
TI2554A
Part Number
AR2020 #58, 0.042 AF2020 3/32, 0.094 4. Follow the Remove Front End procedure, page 29.
(1.00) (2.35)
AR2929 AF2929 5. Push mix chamber (19) forward until impingement
#55, 0.052 3/32, 0.094
(1.30) (2.35) ports (IP) are visible. Some mix chambers have
counterbored holes (CB) and require two drill sizes
AR3737 #55, 0.052 to clean impingement ports completely. See TABLE
(1.30)
2, page 24, to select the appropriate drill bit size.
AR4242 #53, 0.060 AF4242 3/32, 0.094 Also see Drill Bit Kits, page 39.
(1.50) (2.35)
AR4747 1/16, 0.0625 19
(1.59)
AR5252 #50, 0.070 AF5252 3/32, 0.094
(1.75) (2.35)
AR6060 #44, 0.086
(2.15)
AR7070 3/32, 0.094 TI2420A
(2.35)
IP IP
AR8686 #32, 0.116 CB
(2.90)
AR2237 0.47 (1.2) AF2033 3/32, 0.094 CB
(2.35)
AR2924 #55, 0.052 AF2942 3/32, 0.094
(1.30) (2.35)
AR3729 #55, 0.052
(1.3 mm)
TI3533a

Mix Chambers AR and AF, Mix Chambers AR and AF,

2020 and 2929 4242 or larger

309550ZAR 23
Maintenance

Table 2: Impingement Port Drill Bit Sizes Inspect the Mix Chamber and
Mix Chamber Impingement Port (IP)
Counterbore Side Seal Cartridges
Drill Bit Size (CB) Drill Bit Size
Part Number in. (mm) See Models, page 4, for available mix chamber sizes.
in. (mm)
AR2020 #76, 0.020 (0.50) #53, 0.060 (1.50)
1. Follow the Pressure Relief Procedure, page 19.
AR2929 #69, 0.029 (0.70) #53, 0.060 (1.50)
AR3737 #63, 0.037 (0.94) N/A 2. Follow the Flush Gun procedure, page 20, to
AR4242 N/A remove residual chemical.
#58, 0.042 (1.00)
AR4747 #56, 0.0165 (1.18) N/A 3. Remove fluid manifold (M). Leave air connected.
AR5252 #55, 0.052 (1.30) N/A
AR6060 #53, 0.060 (1.50) N/A
AR7070 #50, 0.070 (1.75) N/A
AR8686 #44, 0.086 (2.15) N/A
M
AF2020 #76, 0.020 (0.50) #53, 0.060 (1.50) TI2543A

AF2929 #69, 0.029 (0.70) #53, 0.060 (1.50)

AF4242 #58, 0.042 (1.00) N/A
4. Disconnect gun air whip hose (V) from air line quick
AF5252 #55, 0.052 (1.30) N/A coupler (D).
Non 1:1 Ratio Mix Chamber Kits
D
AR2232 #74, 0.023 (0.59) #53, 0.060 (1.50)
#61, 0.032 (0.81)
V
AR2942 #58, 0.042 (1.07) #53, 0.060 (1.50)
#69, 0.029 (.74)
AR3729 #63, 0.037 (0.94) #53, 0.060 (1.50)
#69, 0.029 (.74) TI2540A

AR2033 #76, 0.020 (.50) #53, 0.060 (1.50)

#66, 0.033 (.84) 5. Follow the Remove Front End procedure, page 29.
AR2942 #69, 0.029 (.74) #53, 0.060 (1.50) 6. Remove air cap (10) and retaining ring (9). Inspect
#58, 0.042 (1.07) o-ring (3) inside retaining ring.
6. Push mix chamber (19) back in position. 9
3
7. Follow the Attach Front End procedure, page 29. 10
8. Reattach fluid manifold (M). Reconnect air. Return
gun to service.
TI2424A

Lubrication
Liberally lubricate all o-rings, seals, and threads.
Lubricate threads and outside of lock ring (11). See
Lubricant for Gun Rebuild, page 43 to order lubricant.

24 309550ZAR
 Maintenance

7. Pull out side seal cartridges (18). 11. Lubricate and reinstall side seal cartridges (18).

24 NOTICE
K
18 B To prevent cross-contamination in the gun, do not
interchange A component (isocyanate) and B
component (resin) parts. Cross-contamination can
18
result in cured material in the gun. Cured material may
A damage the sealing surfaces, block fluid passages,
and prevent gun function.
19
TI2426A

24
8. Pull mix chamber (19) out rear of fluid housing.
Inspect for damage. Follow the Clean
Impingement Ports procedure, page 23.
18 B
9. Apply thin coat of lubricant to mix chamber (19).
Install mix chamber. Etched A and notch (N) must A 18
be on same side as A on fluid housing. Mix chamber
is keyed to fit in fluid housing.
TI2426A

19
12. Lubricate all threads and reinstall retaining ring (9).
B Install air cap (10).

A 9

TI2428A 10
N

NOTICE
To prevent cross-contamination in the gun, do not TI2424A
interchange A component (isocyanate) and B
component (resin) parts. Cross-contamination can 13. Follow the Attach Front End procedure, page 29.
result in cured material in the gun. Cured material may
damage the sealing surfaces, block fluid passages, 14. Connect air and trigger the gun a few times to check
and prevent gun function. 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.
10. Carefully inspect side seal cartridge o-rings and
Correct the problem before attaching the fluid
surfaces. Replace worn or damaged parts. Liberally
manifold.
lubricate o-rings (18d, 18e) and reassemble. Press
on side seal (18c) to check proper spring (18b) 15. Attach fluid manifold. Connect air. Return gun to
operation. service.

18e
18c
18b
18d TI2427A

309550ZAR 25
Maintenance

Inspect the Piston Safety Lock Inspect the Check Valves

1. Follow the Pressure Relief Procedure, page 19. 1. Follow the Pressure Relief Procedure, page 19.

2. Disconnect air line quick coupler (D) and remove 2. Follow the Flush Gun procedure, page 20, to
fluid manifold (M). remove residual chemical.

3. Remove fluid manifold (M). Leave air connected.

M
D M

TI2554A TI2543A

3. Unscrew cylinder cap (5). Hold piston stop (28) with 4. Disconnect gun air whip hose (V) from air line quick
wrench and unscrew from safety lock (4). Inspect coupler (D).
spring (30) and o-rings (14, 24).
D

TI2540A
4
30
24 NOTICE
5
14 To prevent cross-contamination in the gun, do not
28 TI2433A
interchange A component (isocyanate) and B
component (resin) parts. Cross-contamination can
4. Liberally lubricate o-rings and reassemble. Clean
result in cured material in the gun. Cured material may
threads with solvent or alcohol. Apply
damage the sealing surfaces, block fluid passages,
medium-strength Loctite® or equivalent to threads
and prevent gun function.
on stop (28) and reassemble.

5. Attach fluid manifold. 5. Pry out check valves (26) at notch.

6. Connect air. Return gun to service.

Damaged check o-rings (26f, 26g) may result in

external leakage. To avoid potential leakage and
serious injury from skin injection, replace any
damaged o-rings.

26 309550ZAR
 Maintenance

6. Slide filter (26d) off. Clean and inspect parts. Clean Passages
Thoroughly inspect o-rings (26f, 26g). If necessary,
remove screw (26b) and disassemble entire check If necessary, clean out passages in fluid housing and
valve. handle with drill bits. Refer to TABLE 3 and to FIG. 2 for
diameter and location of passages. All drill bits are
B available in an accessory kit see Accessories, page 41.

Table 3: Passage Diameters

A 26b Diameter
Passage Description Ref. Letter
in. (mm)
26e Optional Air Inlet C 7/16, 1/8
(11.0, 3.1)
26c
Purge Air D 1/8 (3.1)
26d Piston Air 1/8 (3.1)
26 E, F
26g Air Exhaust G 11/32, 1/8
(8.7, 3.1)
26a Air Valve Bore H 9/32 (7.1)
26f Cleanoff Air Not Shown 3/32 (2.35)
TI2429A
Check Valve Holes Not Shown 3/32 (2.35)
7. Reassemble check valves. Screw (26b) should be Grease Not Shown 3/32 (2.35)
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

service.

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 (FP) in the top mating D E F
surface. Do not damage the flat sealing surfaces. Coat H
with grease if left exposed, to seal out moisture.
G
FP
C
FIG. 2 Gun Passages
TI2411-1
Clean Muffler
Remove and clean muffler with compatible solvent.

309550ZAR 27
Maintenance

Inspect the Piston 8. Install cylinder cap (5).

1. Follow the Pressure Relief Procedure, page 19.

2. Disconnect air line (D) and remove fluid manifold

(M).
5

TI2430A

9. Follow the Attach Front End procedure, page 29.

M
D 10. Attach fluid manifold. Connect air. Return gun to
TI2554A service.

3. Follow the Remove Front End procedure, page 29.

Inspect the Air Valve
4. Unscrew cylinder cap (5) and inspect o-ring (14).
1. Follow the Pressure Relief Procedure, page 19.

2. Disconnect air line (D) and remove fluid manifold

5
(M).

14

TI2430A

5. Push piston shaft to remove piston (15). M

D
6. Inspect piston o-ring (16) and shaft o-ring (17).
TI2554A
Replace o-rings if warn or damaged.
3. Unscrew air valve plug (2) and remove spring (31).
Using a small diameter tool, push spool (32) out
15 from front. Inspect o-rings (24).

16
17
32 31 2
TI2431A
24

7. Liberally lubricate piston o-rings. Reinstall piston.

TI2434A
Shaft is keyed for proper assembly. Push firmly to
seat piston.
4. Liberally lubricate o-rings and reassemble. Torque
plug (2) to 125-135 in-lb (14-15 N•m).

5. Attach fluid manifold.

6. Connect air. Return gun to service.

TI2432A

28 309550ZAR
 Maintenance

Remove Front End 2. Push on air cap (C) until it is flush with front of gun.
This ensures that mix chamber is all the way back.
1. Follow the Pressure Relief Procedure, page 19.
C
2. Follow the Flush Gun procedure, page 20.

NOTICE
TI2422A
If lock ring (R) is stuck due to material buildup, do not
force it by turning entire front end. Locating tabs (Z) 3. Check that o-ring (21) is in position. Liberally
may break off. Soak front of gun in solvent to soften lubricate o-ring, threads of lock ring (R) and handle
cured material and free lock ring. (H), and outside of lock ring. Orient front end (F) as
required for desired fluid manifold mounting (bottom
mounting is shown).
3. Unscrew lock ring (R) until front end of gun is loose.
Turn fluid housing (F) 1/8 turn counterclockwise. 4. Insert keyed end of mix chamber (19) in socket (X).
Unscrew lock ring completely and remove front end Screw lock ring onto handle as far as possible by
of gun. hand.
Y 19 X Z

F R TI2416A

Attach Front End

F 21 H
TI2416A R

5. Turn fluid housing 1/8 turn clockwise to engage

slots (Y) and tabs (Z). Push on front end to ensure it
Improper attachment of the front end may result in is properly seated. Continue screwing lock ring (R)
serious injury from skin injection. To avoid injury, onto handle (H) very securely. When properly
check that the front end is securely attached and the assembled, lock ring is snug against handle.
lock ring is snug against the handle before gun
R H
operation.

1. Engage the piston safety lock (L). See Piston

Safety Lock, page 20.

TI2409A TI2423A

309550ZAR 29
Troubleshooting

Troubleshooting
1. Follow the Pressure Relief Procedure, page 19,
before checking or repairing the gun.

2. Check all possible problems and causes before

disassembling the gun.
NOTICE
To prevent cross-contamination in the gun, do not
interchange A component (isocyanate) and B
component (resin) parts. Cross-contamination can
result in cured material in the gun. Cured material may
damage the sealing surfaces, block fluid passages,
and prevent gun function.

Problem Cause Solution

Gun does not fully actuate when The safety lock is engaged. Disengage safety lock. See Piston
triggered Safety Lock, page 20.
The muffler is plugged (22). Clean the muffler. See Clean
Muffler, page 27.
The air valve o-rings are damaged Replace the air valve o-rings. See
(24). Inspect the Air Valve, page 28.
Fluid does not spray when the gun is The fluid valves are closed (12b). Open the fluid valves.
fully actuated The impingement ports are plugged. Clean the impingement ports. See
Clean Impingement Ports, page 23.
The check valves are plugged (26). Clean the check valves. See Inspect
the Check Valves, page 26.
Gun actuates slowly The muffler is plugged (22). Clean the muffler. See Clean
Muffler, page 27.
The piston o-rings are damaged (16, Replace the piston o-rings. See
17). Parts, page 33.
The air valve is dirty, or the o-rings Clean air valve or replace o-rings.
are damaged (24). See Inspect the Air Valve, page 28.
Gun delays, then actuates abruptly The material around side seals is Inspect side seals (18c) and mix
cured (18). chamber (19) for scratches. Replace.
See Inspect the Mix Chamber and
Side Seal Cartridges, page 24.
The retaining ring (9) is not bottomed Tighten retaining ring until bottomed
out. out.
Loss of round pattern The mix chamber nozzle is dirty. Clean the mix chamber nozzle. See
Clean Mix Chamber Nozzle, page
23.

30 309550ZAR
 Troubleshooting

Problem Cause Solution

Loss of flat pattern The spray tip is plugged. Clean in compatible solvent. See
Reposition or Replace Flat Spray
Tips, page 18.
The tip is worn. Replace the flat spray tip. See
Reposition or Replace Flat Spray
Tips, page 18.
The mix chamber nozzle is dirty. Clean the mix chamber nozzle. See
Clean Mix Chamber Nozzle, page
23.
Leakage between flat tip and mix The tip is not seated properly. Reassemble. See Reposition or
chamber Replace Flat Spray Tips, page 18.
The o-ring is damaged or missing Replace the flat spray tip o-ring. See
(40). Reposition or Replace Flat Spray
Tips, page 18.
Pressure imbalance The impingement ports are plugged. Clean the impingement ports. See
Clean Impingement Ports, page 23.
The check valves are plugged (26). Clean the check valves. See Inspect
the Check Valves, page 26.
The viscosities not equal. Adjust temperature to compensate.
A and/or B fluid in gun air section The side seals are damaged (18c). Replace. See Inspect the Mix
Chamber and Side Seal
Cartridges, page 24.
The mix chamber is damaged(19). Replace. See Inspect the Mix
Chamber and Side Seal
Cartridges, page 24.
The side seal o-rings are damaged Replace the side seal o-rings. See
(18d, 18e). Inspect the Mix Chamber and Side
Seal Cartridges, page 24.
The air cap is tightened while the Close valves first.
fluid valves (12b) are open.
Fluid mist from mix chamber or air The side seals (18c) are damaged. Replace the side seals. See Inspect
cap the Mix Chamber and Side Seal
Cartridges, page 24.
The side seal o-rings (18d, 18e) are Replace the side seal o-rings. See
damaged. Inspect the Mix Chamber and Side
Seal Cartridges, page 24.
The mix chamber (19) is damaged. Replace the mix chamber. See
Inspect the Mix Chamber and Side
Seal Cartridges, page 24.
Excessive overspray Too much cleanoff air. Reduce cleanoff air. See Setup,
page 15.

309550ZAR 31
Troubleshooting

Problem Cause Solution

Rapid buildup of material on air cap. The air cap holes are plugged. Clean the air cap holes. See Clean
Air Cap, page 23.
Too little cleanoff air. Increase cleanoff air. See Setup,
page 15.
The fluid housing o-ring (23) is Replace the fluid housing o-ring. See
damaged or missing. Parts, page 33.
The front o-ring (3) is damaged. Replace the front o-ring.See Parts,
page 33.
Reduced cleanoff air. The front o-ring (3) is damaged. Replace the front o-ring. See Parts,
page 33.
Excessive cleanoff air when fluid The fluid housing o-ring (23) is Replace the fluid housing o-ring. See
valves are closed and gun is damaged or missing. Parts, page 33.
triggered.
Fluid does not shut off when fluid The fluid valves (12b) are damaged. Replace the fluid valves.
valves are closed.
Burst of air from muffler when gun is Normal. No action required.
triggered.
Steady air leakage from muffler. The air valve o-rings (24) are Replace the valve o-rings. See
damaged. Inspect the Air Valve, page 28.
The piston o-rings (16, 17) are Replace the piston o-rings. See
damaged Parts, page 33.
Air leakage from front air valve. The air valve o-rings (24) are Replace the valve o-rings. See
damaged Inspect the Air Valve, page 28.
Air leak around lock ring. The o-ring (21) is damaged Replace the o-ring. See Parts, page
33.
Cannot tighten retaining ring (9) until The air cap (10) was assembled Install retaining ring (9) first, then air
it bottoms out. before retaining ring (9). cap (10). See Inspect the Mix
Chamber and Side Seal
Cartridges, page 24.

32 309550ZAR
 Parts

Parts
NOTE: The round pattern gun is shown below. Refer to Detail Views, page 35, for parts specific to other models.

Seal Cartridge (18) Detail

4 4 18e‡
30
5 24 18b‡
14 18c‡ 18d‡
28 18a‡
16 TI3926A

15
17 Check Valve
‡37
(26) Detail
4
‡25 26b‡
4
‡8 19
26e‡
7‡
‡24
26c‡
‡11
26d‡
‡18; see
detail above 1
21‡ 26g‡
27‡
2 29
26a‡
18
23 26f‡ TI3927A
22 4
3 12e 3 20 6

9 12f 3 33
10 1
13
11a 12c 3
49
‡26; see 50
details at
right 47 51
12a
12b 5

12d 32 31 2 35
12g 24‡
TI2435C

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).

309550ZAR 33
Parts

Ref. Part Description Qty. Ref. Part Description Qty.

1 15K365 HANDLE 1 26‡ 246731 VALVE, check, A side, includes 1
2 15B208 PLUG, air valve 1 26a-26g
3‡ 248137 O-RING, PTFE, package of 6 1 246352 VALVE, check, B side, includes 1
4 15B206 LOCK, safety 1 26a-26g
5 15B204 CAP, cylinder 1 26a‡ ---- HOUSING 1
6 192272 PIN 1 26b‡ 15B214 SCREW, 5/16-18 x 1/2 in. (13 mm) 1
7‡ 15B215 RING, lock 1 26c‡ 257420 BALL; carbide, package of 10 1
8‡ 15B223 VALVE, cleanoff air 1 26d‡ ---- SCREEN, see Check Valve Filter 1
Screen Kits, page 38
9‡ 15B211 RING, retaining 1
26e‡ 117490 SPRING 1
10‡ 15B210 AIR CAP, for round pattern guns 1
26f‡ 248133 O-RING, check valve face, package of 1
11‡ 246491 HOUSING, fluid 1 6
11a 248860 KIT, thread insert, fusion 1 26g‡ 248129 O-RING, check valve housing; 1
12 246012 MANIFOLD, fluid, 2-hose, includes 1 package of 6
12a-12g 27‡ 116550 RING, retaining 1
249523 MANIFOLD, fluid, 4-hose, includes 1 28 15B205 STOP, piston 1
12a, 12b, 12d-12g, 50; see Detail
Views, page 35 29 203953 SCREW, 10-24 x 3/8 in. (10 mm) 1
12a ---- MANIFOLD 1 30 114070 SPRING 1
12b 246356 VALVE, fluid 2 31 117485 SPRING 1
12c 100139 PLUG, pipe; 1/8-27 npt 2 32 15B202 SPOOL, valve 1
12d 15B221 BOLT, 5/16-24 1 33 100721 PLUG, pipe, 1/4-18 npt; 1
round and flat pattern guns only
12e 117634 SWIVEL, B side; 1/8 npt(m) x number 1
6 JIC(f), for 2-hose manifold 35 117509 QUICK-DISCONNECT, male, air, 1/4 1
npt(m), round and flat pattern guns
12f 117635 SWIVEL, A sid,; 1/8 npt(m) x number 1 only
5 JIC(f), for 2-hose manifold
36 222385 CARD, warning, not shown 1
12g 15B993 SPRING, ring, lock 1
37‡ 15B689 COVER, grease fitting 1
13 15B209 TRIGGER 1
46 117792 GREASE GUN, not shown 1
14 248136 O-RING, cylinder cap, package of 6 1
47 117510 COUPLER, air line 1
15 15B203 PISTON 1
49 15B772 HOSE, air; 1/4 npsm (fbe); 18 in. 1
16 248135 O-RING, piston; package of 6 1 (0.46 m)
17 248134 O-RING, piston shaft; 1 50 112307 ELBOW, street; 1/8 npt (m x f), round 2
package of 6 and flat pattern guns only
18‡ 246349 CARTRIDGE, seal, A side, SST; 1 51 15B565 VALVE, ball, 1/4 npt (m x f), round and 1
includes 18a-18e flat pattern guns only
246350 CARTRIDGE, seal, B side, SST; 1 55 172479 TAG, warning, not shown 1
includes 18a-18e
56 15D235 SIGN, instruction, not shown 1
18a ---- CARTRIDGE BODY 1
57 117773 GREASE CARTRIDGE, 3 oz, not 1
18b 117491 SPRING 1
show; SDS sheet available at
18c ---- SEAL KIT, see Side Seal Kits, page 1 www.graco.com
42
65 248279 GREASE, tube, 4 oz, not shown; SDS 1
18d 248130 O-RING, cartridge body; package of 6 1
sheet available at www.graco.com
18e 248128 O-RING, side seal, package of 6 1
19 ---- CHAMBER, mix; see Mix Chamber 1
Kits, page 36 NOTE: See Detail Views, page 35, for additional parts.
20 15C480 WASHER, wave 1  Replacement safety labels, tags, and cards are
21‡ 248132 O-RING; package of 6 1 available at no cost.
22 119626 MUFFLER 1
‡ Included in Front End Replacement Kit 246361.
23‡ 248131 O-RING, package of 6 1
24‡ 246354 O-RING, package of 6 1  For date code B17 or prior, see manual 310767.
25‡ 100846 FITTING, grease 1  Included in Safety Stop Assembly 248064 (includes 1 of
item 24).

34 309550ZAR
 Parts

Detail Views
Flat Pattern Detail Flat Pattern Stud Wall Foam Detail Splatter Tip Detail
19 10
60
19
10 39 40 59
61
58

TI2557A TI4555B

62
Supplied Tools 64 Flush Manifold
63
53 TI4660C-1
1 33 (Ref)
52
35 (Ref)

4-Hose Fluid Manifold Detail

43
1
12e 3
54
TI3870A 12f 3
50 12d (Ref)
TI2647A
50
12f

3
12e
3
1 Torque to 125-135 in-lb
(14-15 N•m). 12b 5
3 Torque to 235-245 in-lb
(26.6-27.7 N•m).
12d 12g
5 Torque to 32-40 ft-lb
(43-54 N•m). TI7134A

Ref. Part Description Qty. Ref. Part Description Qty.

39 FTxxxx TIP, flat, see Flat Tip Kits, page 37 1 62 15F854 PACKING, tip, stud wall 1
40 246360 O-RING, PTFE, flat tip models only; 1 63 15F241 CAP, air, stud wall 1
package of 3; see Flat Tip Kits, 64 FTM979 TIP, flat, stud wall 1
page 37 10 15B801 AIR CAP, for flat pattern guns, not 1
43 117661 VISE, pin, dual reversible chucks 1 included in Front End Replacement
52 15B817 MANIFOLD, gun flush; round and 1 Kit 24636
flat pattern guns only  15D973 AIR CAP, for spatter pattern gun, not 1
53 117642 NUT DRIVER, hex, 5/16 1 included in Front End Replacement
54 118575 SCREWDRIVER, 1/8 blade 1 Kit 246361
58 15D972 RETAINER, tip, spatter pattern gun 1
only  Included in Spatter Tip Kit 248414.
59 15D971 TIP, spatter pattern gun only 1  Included in Stud Wall Foam Kit 249421.
60 248019 SEAL, package of 5, spatter pattern 1
gun only.
61 15F240 ADAPTER, stud wall 1

309550ZAR 35
Parts

Mix Chamber Kits

Mix Chamber Part Reference Guide

Example part number AR4242:

AR 42 42
AR=Air purge round pattern A orifice size B orifice size
AF=Air purge flat pattern (0.042 in.) (0.042 in.)

Round Pattern
Stainless Chromex Nozzle Nozzle Drill Impingement Impingement Counterbore Counterbore
Steel Mix Mix Orifice Size Bit Size, Port Size Port Drill Bit Size Drill Bit Size,
Chamber Chamber in. (mm) Size, in. (mm)
Kit Kit in. (mm)
AR2020 AR20CX 0.042 #58 (1.00) 0.020 #76 (0.50) 0.060 #53 (1.50)
AR2929 AR29CX 0.052 #55 (1.30) 0.029 #69 (0.70) 0.060 #53 (1.50)
AR3737 AR37CX 0.052 #55 (1.30) 0.037 #63 (0.94) N/A N/A
AR4242 AR42CX 0.060 #53 (1.50) 0.042 #58 (1.00) N/A N/A
AR4747 AR47CX 0.0635 1/16 (1.59) 0.0469 #56 (1.18) N/A N/A
AR5252 AR52CX 0.070 #50 (1.75) 0.052 #55 (1.30) N/A N/A
AR6060 AR60CX 0.086 #44 (2.15) 0.060 #53 (1.50) N/A N/A
AR7070 AR70CX 0.094 3/32 (2.35) 0.070 #50 (1.75) N/A N/A
AR8686 AR86CX 0.116 #32 (2.90) 0.086 #44 (2.15) N/A N/A

Non 1:1 Ratio Round Mix Chamber Kits

Mix Chamber Kit Nozzle Orifice Nozzle Drill Impingement Impingement Port Counterbore Counterbore
(includes drill bits) Size Bit Size, Port Size Drill Bit Size, Size Drill Bit Size,
in. (mm) in. (mm) in. (mm)
AR2232 0.094 0.047 (1.2) 0.024 #74, 0.023 (0.57) 0.061 #53, 0.0595 (1.5)
0.0325 #67, 0.032 (0.81)
AR2942 0.053 #55 (1.3) 0.043 #58, 0.042 (1.07) 0.061 #53, 0.0595 (1.5)
0.031 #69 0.029 (0.74)
AR3729 0.053 #55 (1.3) 0.038 #63, 0.037 (0.94) 0.061 #53, 0.0595 (1.5)
0.031 #69, 0.029 (0.74)

36 309550ZAR
 Parts

Flat Pattern
Mix Chamber Nozzle Orifice Nozzle Drill Impingement Impingement Port Counterbore Counterbore Drill
Kit (includes Size Bit Size, Port Size Drill Bit Size, Size Bit Size,
drill bits and in. (mm) in. (mm) in. (mm)
o-ring)
AF2020 0.094 3/32 (2.35) 0.020 #76 (0.50) 0.060 #53 (1.50)
AF2929 0.094 3/32 (2.35) 0.029 #69 (0.70) 0.060 #53 (1.50)
AF4242 0.094 3/32 (2.35) 0.042 #58 (1.00) N/A N/A
AF5252 0.094 3/32 (2.35) 0.052 #55 (1.30) N/A N/A

Non 1:1 Ratio Flat Mix Chamber Kits

Mix Chamber Nozzle Orifice Nozzle Drill Impingement Impingement Port Counterbore Counterbore Drill
Kit (includes Size Bit Size, Port Size Drill Bit Size, Size Bit Size,
drill bits) in. (mm) in. (mm) in. (mm)
AF2033 0.094 3/32 (2.35) 0.035 #66, 0.033 (0.84) 0.061 #53, 0.0595 (1.50)
0.021 #76 0.020 (0.51)
AF2942 0.094 3/32 (2.35) 0.042 #58, 0.042 (1.07) 0.061 #53, 0.0595 (1.50)
0.031 #69 0.029 (0.74)

Wide Pattern
Kits include mix chamber and cleanout drills. Spray guns with wide pattern mix chambers spray larger diameter
patterns than guns with 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
Kit in. (mm) mix chamber size in. (mm) in. (mm)
AW2222 8 (203.2) N/A 0.047 (1.20) #74, 0.022 (0.56)
AW2828 15 (381.0) AR2929 1/16, 0.062 (1.59) #70, 0.028 (0.71)
AW3333 15 (381.0) AR3737 #53, 0.060 (1.52) #66, 0.033 (0.84)
AW3939 16 (406.4) AR4242 #50, 0.070 (1.78) #61, 0.039 (0.99)
AW4646 18 (457.2) AR5252 0.085 (2.15) #56, 0.046 (1.17)
AW5757 18 (457.2) AR6060 #43, 0.089 (2.26) 1.45 mm, 0.057 (1.45)
AW6464 22 (563.9) AR7070 7/64, 0.109 (2.77) #52, 0.064 (1.63)
AW8282 24 (609.6) AR8686 1/8, 0.125 (3.18) #45, 0.082 (2.08)

Flat Tip Kits

Flat Tip Part Reference Guide Flat Tip

Example part number FT0848: Flat Spray Tip Pattern Size, in. (mm)
(Ref. 39)
FT 08 48 FT0424 low flow, 8-10 (203-254)
FT=Flat tip x2=pattern length Equivalent orifice FT0438 medium flow, 8-10 (203-254)
(8x2=16 in.) diameter size (0.048 in.) 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)

309550ZAR 37
Parts

Gun Repair Kits

Read the chart left to right and top to bottom to find the quantity of each part in the kits.

Includes
246347 246351 246355 25M221
Bulk O-ring Side Seal Cartridge 246348 Check Valve Complete High Temperature
Ref. Kits (quantity) O-ring Kit Side Seal Kit O-ring Kit O-ring Kit /Pressure O-ring Kit
3 248137 (6) 1
25M244 (50)
10 129209 (10) 1
14 248136 (6) 1
16 248135 (6) 1
25M245 (25)
17 248134 (6) 1
18c ---- 2
18d 248130 (6) 4 4
25M242 (50)
18e 248128 (6) 2 2 2
298790 (50)
21 248132 (6) 1
23 248131 (6) 1
25M243 (50)
24 246354 (6) 5
25M239 (50)
26f 248133 (6) 2 2
26g 248129 (6) 2 2
25M247 (25)
40 246360 (3)
25M248 (25)

Check Valve Filter Screen Kits Drill Bit Kit

Each kit includes ten filter screens.
119386
The gun is shipped with 80 mesh filter screens. Kit includes 20 cleanout drill bits ranging in sizes of #61
through #80.
Part Description
246357 40 mesh (0.015 in., 375 micron) Handle Cleanout Drill Kit
246358 60 mesh (0.010 in., 238 micron)
246359 80 mesh (0.007 in., 175 micron) 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.

38 309550ZAR
 Parts

Drill Bit Kits

For cleaning gun ports and orifices. Illustrations are for 1 in.
diameter comparison. Actual length may vary. (25.4 mm)

NOTE: Not all sizes are used with your gun. 1 in.
(25.4 mm)

Drill Bit Size

Kit Part Qty. nominal in. mm Illustration
249115 6 1/8 0.125 3.18

246623 3 #32 0.116 2.90

246810 3 7/64 0.109 2.77

246813 3 #39 0.099 2.51

246624 3 3/32 0.094 2.39

246812 3 #43 0.089 2.26

246625 3 #44 0.086 2.18

248639 6 2.15 mm 0.085 2.15

249114 6 #45 0.082 2.08

246811 3 2 mm 0.079 2.00

246626 6 #50 0.070 1.78

249113 6 #52 0.64 1.63

248893 6 1/16 0.062 1.59

246627 6 #53 0.060 1.52

249112 6 1.45 mm 0.057 1.45

246809 6 #54 0.055 1.40

246628 6 #55 0.052 1.32

249764 6 1.20 mm 0.047 1.20

246814 6 #56 0.046 1.18

246629 6 #58 0.042 1.07

309550ZAR 39
Parts

Drill Bit Size

Kit Part Qty. nominal in. mm Illustration
246808 6 #60 0.040 1.02

248640 6 #61 0.039 0.99

248618 6 #63 0.037 0.94

248891 6 #66 0.033 0.84

246807 6 #67 0.032 0.81

246630 6 #69 0.029 0.74

248892 6 #70 0.028 0.71

246815 6 #73 0.024 0.61

276984 6 #74 0.023 0.57

246631 6 #76 0.020 0.51

246816 6 #77 0.018 0.46

246817 6 #81 0.013 0.33

Reamer Kits
Reamer Size

Kit Part Qty. nominal in. mm Illustration

25B041 #32 0.116 2.90
1
25B040 3/32 0.094 2.39
1
25B039 #44 0.086 2.18
1
25B038 #50 0.070 1.78
1
25B037 1/16 0.062 1.59
1
25B035 #53 0.060 1.52
1
25B034 #55 0.052 1.32
1
25B032 #58 0.042 1.07
1

40 309550ZAR
 Accessories

Accessories

Fusion PC Conversion Kits

For converting the Fusion AP spray gun to a Fusion PC spray gun for use with ProConnect™ fluid cartridges. See
Related Manuals, page 3.

Round Pattern
Mix Chamber

Conversion Pattern at 24
Kit Part Impingement Port Size Equivalent in. (61 cm)
Number in. (mm) Size from target
in. (mm)
25P700 PC29RD 0.029 (0.70) 00 8 (203)
25R087 PC37RD 0.037 (0.94) 00-01 9 (227)
25P701 PC42RD 0.042 (1) 01 11 (279)
25P703 PC47RD 0.0469 (1.18) 01-02 11 (279)
25P702 PC52RD 0.052 (1.3) 02 12 (305)
25R088 PC60RD 0.060 (1.50) 03 14 (356)

Flat Pattern

Mix Chamber Flat Tip

Conversion Impingement
Kit Part Equivalent Part Pattern Size Orifice Size
Port Size
Number Size Number in. (mm) in. (mm)
in. (mm)
25R089 AF2929 0.029 (0.70) 00 FT0438 8-10 (203-254) 0.038 (0.97)

Bare
NOTE: Bare conversion kits include the same accessories as standard conversion kits, without a mix chamber and
drill bits. A round air cap is provided.

Conversion Kit
25P704

309550ZAR 41
Accessories

Side Seal Kits Side Seal Cartridge Kits

Kits includes a packing o-ring for each seal.
Material Kit Part Description Qty.
Stainless 246349 CARTRIDGE KIT, A side 1
Material Kit Description Qty. Steel 246348 CARTRIDGE KIT, B side 1
Stainless Steel 246348 SEAL KIT 2 Polycarballoy 277297 CARTRIDGE KIT, A side 1
277299 SEAL KIT 50 277296 CARTRIDGE KIT, B side 1
Polycarballoy 249990 SEAL KIT 2 Chromex 25N571 CARTRIDGE KIT, A side 1
277298 SEAL KIT 50 25N752 CARTRIDGE, B side 1
Chromex 25N573 SEAL KIT 2

Extension Tip Kits

Kits include extension, flat tip seal and round tip seal, cleanout drill bit, and instructions.

NOTE: Extension tip kits require 248020 Extension Tip Air Cap Kit (purchased separately).

Hole Diameter x Length, Recommended Spray Distance, Pattern Diameter,

Kit in. (mm) Mix Chambers ft (m) in. (mm)
248010 0.042 x 0.50 (1.06 x 12.7) AR2020/AF2929 15 (4.57) 10 (254)
248011 0.052 x 0.50 (1.32 x 12.7) AR2929/AF2929 12 (3.66) 10 (254)
248012 0.060 x 0.50 (1.52 x 12.7) AR4242/AF4242 12 (3.66) 12 (305)
248013 0.070 x 0.50 (1.78 x 12.7) AR5252/AF5252 8 (2.44) 20 (508)
248014 0.042 x 1.0 (1.06 x 25.4) AR2020/AF2929 15 (4.57) 10 (254)
248015 0.052 x 1.0 (1.32 x 25.4) AR2929/AF2929 12 (3.66) 8 (203)
248016 0.060 x 1.0 (1.52 x 25.4) AR4242/AF4242 12 (3.66) 8 (203)
248017 0.070 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.

Extension Tip Seal Kits Flat Pattern Stud Wall Kit

Kits include 5 seals.
249421
Kit Part Description To spray high-flow, flat patterns. For use with flat mix
chambers only: AF2929, AF4242, AF5252. Includes
248018 Flat Extension Tip Seal Kit
adapter parts and cleanout tool. See Related Manuals,
248019 Round Extension Tip Seal Kit
page 3.

Extension Tip Air Cap Kit NOTE: Flat pattern mix chamber not included. Order
separately.

248020 NOTE: Optional tip FTM762 available for lower flow and
Includes air cap for use with extension tip kits smaller pattern application
248010-248017.
24C358
TP100 stud wall option to spray wall insulation foam into
stud walls. See Related Manuals, page 3.

42 309550ZAR
 Accessories

Pour Nozzle Kit Lubricant for Gun Rebuild

248528 248279, 4 oz (113 gram) (Qty. 10)
To convert air purge gun for pour applications. Includes High adhesion, water resistant, lithium-based lubricant.
nozzle, seals, tubing, and cleanout drill bits. SDS available at www.graco.com

Gun Cleaning Kit Grease Cartridge for Gun

Shutdown
15D546
Kit includes eleven tools and brushes to clean the gun. 248280 Cartridge, 3 oz (Qty. 10)
Specially formulated low viscosity grease flows easily
Hose Adapter Kits through gun passages, to prevent two component curing
and keep fluid passages clean.

246944
To connect non-Graco gun to Graco heated hose.
Flushing Manifold

248029 15B817 Manifold Block

To connect Graco Fusion gun to non-Graco D-gun hose See Ref. 52.
set.

246945
Adjustable Flow Cap Kit
To connect Graco Fusion gun to non-Graco heated 25D632
hose.
To allow variable flow to the Fusion AP gun. Refer to the
Fusion Adjustable Flow Cap Kit manual. See Related
Spatter Conversion Kit Manuals, page 3.

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. See
Related Manuals, page 3.
WLE

Gun Cover
244914
Keeps gun clean while spraying. Pack of 10.

309550ZAR 43
Accessories

Solvent Flush Canister Kit Tip Cleanout Tool

248139, 1 qt (0.95 l) Solvent Cup 15D234
Complete with 15B817 Flushing Manifold to flush gun Designed to fit CeramTip internal dome and flat tip slits.
with solvent. Portable for remote flushing. Refer to the
Solvent Flush Kit manual. See Related Manuals, page End for
3. Mechanical
End for Air Purge Tips
Purge Tips

TI4244a

Circulation Manifold
TI4165a

246362
Solvent Flush Pail Kit Attach to gun fluid manifold to enable preheating of
hose. Refer to Circulation Manifold Kit Instruction
248229 5 gal. (19 l) Pail Manual. See Related Manuals, page 3.

Includes flush manifold with individual A and B shutoff

valves, and air regulator. Refer to the Solvent Flush Kit
manual. See Related Manuals, page 3.

TI3877a

TI4211b

44 309550ZAR
 Technical Specifications

Technical Specifications
Fusion Air Purge Spray Gun
US Metric
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 Round Pattern Guns chart, page 4
Typical Flow Rate of Flat Pattern Guns See Flat Pattern Guns chart, page 5
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
Dimensions 7.5 x 8.1 x 3.3 in. 191 x 206 x 84 mm
Weight 2.6 lb 1.2 kg
Aluminum, stainless steel, carbon steel, carbide,
Wetted Parts
chemically resistant o-rings
Noise
Maximum sound pressure 81.1 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
Maximum sound power 91.0 dB(A), using AR5252 at 100 psi (0.7 MPa, 7 bar)
Sound power measured per ISO-9416-2.
Notes
All trademarks or registered trademarks are the property of their respective owners.

Air Flow by Mix Chamber

Air Pressure
(detriggered) Mix Chamber Sizes (scfm (m3/min))

psi (MPa, bar) AR2020 AR2929 AR3737 AR4242 AR5252 AR6060 AR7070 AR8686

0.8 1.4 2.0 2.6 3.7 4.6 5.7 7.1

80 (0.56, 5.6)
(0.022) (0.039) (0.056) (0.073) (0.104) (0.129) (0.160) (0.200)

0.9 1.7 2.9 3.1 4.6 5.7 7.1 8.8

100 (0.7, 7)
(0.025) (0.048) (0.081) (0.087) (0.129) (0.160) (0.200) (0.246)

1.2 2.3 3.2 4.1 5.9 7.3 9.2 11.3

130 (0.9, 9)
(0.034) (0.064) (0.090) (0.115) (0.165) (0.204) (0.258) (0.316)

309550ZAR 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.
For patent information, see www.graco.com/patents.
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.
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 2020, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision ZAR, February 2020