Graco FUSION A Series User manual

3A7314B
EN
Instructions
Fusion®PC Spray Gun
Plural component, impingement mix air purge spray gun with ProConnect™fluid cartridge
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.
WLD

2 3A7314B
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Round Pattern Guns . . . . . . . . . . . . . . . . . . . . . . 4
Flat Pattern Guns. . . . . . . . . . . . . . . . . . . . . . . . . 5
Bare Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important Isocyanate (ISO) Information . . . . . . . . . 9
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9
Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . 10
Keep Components A and B Separate . . . . . . . . 10
Moisture Sensitivity of Isocyanates . . . . . . . . . . 10
Foam Resins with 245 fa Blowing Agents . . . . . 10
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 10
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 11
Component Identification . . . . . . . . . . . . . . . . . . . 12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble the Spray Gun . . . . . . . . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Optional Configurations . . . . . . . . . . . . . . . . . . . 17
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Relief Procedure. . . . . . . . . . . . . . . . . 19
Piston Safety Lock . . . . . . . . . . . . . . . . . . . . . . . 20
Turn the Air Cap. . . . . . . . . . . . . . . . . . . . . . . . . 20
Loss of Air Pressure. . . . . . . . . . . . . . . . . . . . . . 20
Flush Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preventative Maintenance . . . . . . . . . . . . . . . . . 22
Clean Mix Chamber Nozzle . . . . . . . . . . . . . . . . 22
Inspect the Check Valves . . . . . . . . . . . . . . . . . 23
Clean Mix Chamber Impingement Ports . . . . . . 24
Remove the Fluid Cartridge . . . . . . . . . . . . . . . . 24
Reinstall or Replace the Fluid Cartridge . . . . . . 25
Inspect the Fluid Cartridge. . . . . . . . . . . . . . . . . 26
Test Fluid Cartridge Restriction . . . . . . . . . . . . . 26
Store the Fluid Cartridge . . . . . . . . . . . . . . . . . . 27
Clean Gun Surface . . . . . . . . . . . . . . . . . . . . . . 27
Clean Air Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspect the Piston Safety Lock. . . . . . . . . . . . . . 27
Clean Fluid Manifold. . . . . . . . . . . . . . . . . . . . . . 27
Clean Passages . . . . . . . . . . . . . . . . . . . . . . . . . 28
Clean Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect the Piston . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect the Air Valve. . . . . . . . . . . . . . . . . . . . . . 29
Remove Front End . . . . . . . . . . . . . . . . . . . . . . . 30
Attach Front End. . . . . . . . . . . . . . . . . . . . . . . . . 30
Supplied Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Detail Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mix Chamber Kits . . . . . . . . . . . . . . . . . . . . . . . . 38
Flat Tip Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check Valve Filter Screen Kits . . . . . . . . . . . . . . 39
Drill Bit Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Handle Cleanout Drill Kit . . . . . . . . . . . . . . . . . . 39
Acceptable Cartridge Storage Liquids . . . . . . . . 39
Cartridge Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fusion PC Cartridge Tools . . . . . . . . . . . . . . . . . 39
Drill Bit Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reamer Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Extension Tip Kits. . . . . . . . . . . . . . . . . . . . . . . . 42
Extension Tip Seal Kits. . . . . . . . . . . . . . . . . . . . 42
Extension Tip Air Cap Kit . . . . . . . . . . . . . . . . . . 42
Flat Pattern Stud Wall Kit . . . . . . . . . . . . . . . . . . 42
Pour Nozzle Kit. . . . . . . . . . . . . . . . . . . . . . . . . . 42
Gun Cleaning Kit . . . . . . . . . . . . . . . . . . . . . . . . 42
Hose Adapter Kits. . . . . . . . . . . . . . . . . . . . . . . . 43
Spatter Conversion Kit . . . . . . . . . . . . . . . . . . . . 43
Gun Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lubricant for Gun Rebuild. . . . . . . . . . . . . . . . . . 43
Grease Cartridge for Gun Shutdown . . . . . . . . . 43
Flushing Manifold . . . . . . . . . . . . . . . . . . . . . . . . 43
Solvent Flush Canister Kit . . . . . . . . . . . . . . . . . 43
Solvent Flush Pail Kit . . . . . . . . . . . . . . . . . . . . . 44
Tip Cleanout Tool . . . . . . . . . . . . . . . . . . . . . . . . 44
Circulation Manifold . . . . . . . . . . . . . . . . . . . . . . 44
Technical Specifications . . . . . . . . . . . . . . . . . . . . 45
Air Flow by Mix Chamber . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46

Related Manuals
3A7314B 3
Related Manuals
Manual in
English Description
309550 Fusion AP Spray Gun Instruction
Manual
3A7318 Fusion PC Conversion Kit
309963 Fusion Solvent Flush Kit
309818 Circulation Manifold Kit
311071 Stud Wall Foam Kit and TP100 Kit

Models
4 3A7314B
Models
Round Pattern Guns
Round Pattern Mix Chambers by Pressure and Flow Rate
Gun
(Part,
Series)
Mix Chamber
Part
Number
Impingement Port Size
in. (mm)
Equivalent
Size
Pattern at 24
in. (61 cm)
from target
in. (mm)
25P587, A PC29RD 0.029 (0.70) 00 8 (203)
25R084, A PC37RD 0.037 (0.94) 00-01 9 (227)
25P588, A PC42RD 0.042 (1) 01 11 (279)
25P590, A PC47RD 0.0469 (1.18) 01-02 11 (279)
25P589, A PC52RD 0.052 (1.3) 02 12 (305)
25R085, A PC60RD 0.060 (1.50) 03 14 (356)
FLOW RATE in gpm (lpm)*
PRESSURE in psi (MPa, bar)
5.0
(18.9)
4.0
(15.1)
3.0
(11.4)
1.0
(3.8)
2.0
(7.6)
0
PC42RD (01)
PC29 (00)
PC20RD (000)
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
2000
(13.8, 138)
2500
(17.4, 172.4)
3000
(20.7, 207)
3500
(24.1, 241)
* To calculate flow in lb/min, multiply gpm rate by 10. Example: 2 gpm x 10 = 20 lb/min.
PC60RD (03)
PC52RD (02)
PC70RD (04)
PC37
PC47RD

Models
3A7314B 5
Flat Pattern Guns
Flat Pattern Mix Chambers by Pressure and Flow Rate
Bare Gun
Gun Part,
Series
Mix Chamber Flat Tip
Part
Number
Impingement
Port Size
in. (mm)
Equivalent
Size
Part
Number
Pattern Size
in. (mm)
Orifice Size
in. (mm)
25R086, A PC29FL 0.029 (0.70) 00 FT0438 8-10 (203-254) 0.038 (0.97)
FLOW RATE in gpm (lpm)*
PRESSURE in psi (MPa, bar)
2.25
(8.55)
3.0
(11.4)
0.75
(2.85)
1.5
(5.7)
0
PC42FL with FTXX38
PC29FL with FTXX38 tip
PC20FL with FTXX24 tip
500
(3.5, 35)
1000
(6.9, 69)
1500
(10.3, 103)
2000
(13.8, 138)
2500
(17.4, 172.4)
3000
(20.7, 207)
3500
(24.1, 241)
* To calculate flow in lb/min, multiply gpm rate by 10. Example: 2 gpm x 10 = 20 lb/min.
Gun Part, Series
25P591, A
* Bare guns include the same
accessories as standard guns
without a mix chamber and drill
bits. A round air cap (C) is
provided.

Warnings
6 3A7314B
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.
WARNING
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 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.

Warnings
3A7314B 7
BURN HAZARD
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 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.
WARNING

Warnings
8 3A7314B
EQUIPMENT MISUSE HAZARD
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.
WARNING

Important Isocyanate (ISO) Information
3A7314B 9
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:
____________
____________

Important Isocyanate (ISO) Information
10 3A7314B
Material Self-Ignition
Keep Components A and B
Separate
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO
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.
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
Blowing Agents
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
circulation system.
Changing Materials
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
Safety Data Sheets (SDSs).
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage
equipment. To prevent cross-contamination:
•Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
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.
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

Overview
3A7314B 11
Overview
Theory of Operation
Gun Triggered (Fluid Spraying)
Mix chamber (19) moves back, shutting off purge air
flow. Impingement ports (IP) align with fluid ports of side
seals (18c), allowing fluid to flow through mix chamber
nozzle (N).
Key
NOTE: Flow paths are not shown to scale.
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).
Key
NOTE: Flow paths are not shown to scale.
Purge Air
Fluid
Cleanoff Air
Grease
TI3545a
19 18c
IP
NK
Purge Air
Fluid
Cleanoff Air
Grease
TI3546a
19 AC
IP
N
G

Component Identification
12 3A7314B
Component Identification
FIG. 1 Component Identification
WLE
=$
'9
:
*
.
3
%
$
0
7-
;
(
6
+
1
8
&
)
5/
<
=
Key
AA Side Fluid Valve (ISO)
BB Side Fluid Valve (RESIN)
CAir Cap
DAir Line Quick Coupler
EMuffler
FFluid Housing
GGrease Fitting (under cap)
HHandle
JJack Screw Holder/Optional Air Inlet
KCleanoff Air Valve
LPiston Safety Lock
MGun Fluid Manifold
NMix Chamber
POptional Fluid Inlets (A Side Shown)
RLock Ring
SFluid Inlet Swivels (A Side Shown)
TTrigger
UFront Retaining Ring
VGun Air Whip Hose
WAir Valve
X Jack Screw
Y PC Fluid Cartridge
Z Grease Tool
ZA Divider Tool
Key

Installation
3A7314B 13
Installation
Grounding
Spray gun: Ground through connection to a properly
grounded fluid hose and pump.
Proportioner: Follow the instructions in your
proportioner manual.
Assemble the Spray Gun
1. Install the mix chamber (N).
a. Lubricate the fluid housing (F) and mix chamber
(N) sealing surfaces and ramp. See Lubricant
for Gun Rebuild, page 43.
b. Match A and B sides of the mix chamber (N) to
corresponding sides of the fluid housing (F).
Insert keyed end of the mix chamber into the
socket on the handle (H).
NOTE: The slot on the mix chamber should be facing
downward.
2. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
3. Install the PC fluid cartridge (Y).
a. Align the cartridge so it slides over the mix
chamber (N) until the side seals engage the
ramp.
b. Press the PC fluid cartridge (Y) onto the mix
chamber (N). The fluid ports on the cartridge will
engage the fluid housing (F). Resistance will be
felt as the side seals are depressed.
c. Fully engage the fluid cartridge (Y) into the fluid
housing (F) until the back face of the cartridge is
flush with the fluid housing.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
N
N
F
H
TI2409A
L
WLE
N
F
Y

Installation
14 3A7314B
4. Install the front retaining ring (U).
a. Lubricate the front retaining ring (U). See
Lubricant for Gun Rebuild, page 43.
b. Tighten the front retaining ring (U) until the PC
fluid cartridge (Y) is fully engaged and secure in
the fluid housing (F).
5. Install the air cap (C).
Setup
1. Close fluid valves A and B.
2. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold (M).
3. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
4. Connect gun air whip hose (V) and air valve (W) to
main air hose. Attach fluid manifold (M) to gun.
To prevent damage to the fluid o-ring or injury from
splashing chemical, verify that the fluid cartridge (Y) is
fully engaged into the fluid housing (F), and the front
retaining ring (U) is tight.
WLE
U
F
WLE
C
ti2411a
A (ISO)
B (RESIN)
TI2417A
M
TI2409A
L
W
V
M
TI2554A

Installation
3A7314B 15
5. Connect the air line quick coupler (D). Turn on air.
Open air valve (W). Air should flow from the mix
chamber nozzle (N).
NOTE: If excessive noise is heard, or air is felt coming
from behind the retaining ring (U), the fluid cartridge (Y)
is not fully engaged into the fluid housing (F).
6. Disengage the piston safety lock (L).See Piston
Safety Lock, page 20.
7. Trigger gun to check for full mix chamber travel. The
front of the air cap (C) should be approximately
flush with the front retaining ring (U).
8. Open cleanoff air valve (K) 1/4-1/2 turn and trigger
gun to check that cleanoff air is flowing. Adjust as
desired.
9. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
10. Turn on proportioner.
11. Open B (RESIN) fluid valve (about three half turns).
Then open A (ISO) fluid valve.
12. Disengage the piston safety lock (L).See Piston
Safety Lock, page 20.
A loose fluid cartridge can result in equipment
damage and splashing chemical.To prevent damage
to the fluid o-ring or injury from splashing chemical,
verify that the cartridge is fully engaged into the fluid
housing, and the front retaining ring (U) is tight.
DW
N
TI2414-1A
TI2410A
L
C
U
TI2414-1A
K
TI2413A
TI2409A
L
TI2414A
TI2410A
L

Installation
16 3A7314B
13. Test spray onto cardboard. Adjust pressure and
temperature to get desired results.
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 page Lubricant
for Gun Rebuild, page 43, to order lubricant and
gun cover.
15. Gun is ready to spray.
TI2645A
R

Installation
3A7314B 17
Optional Configurations
Change Fluid Manifold Position
The 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
the right.
1. Follow the Pressure Relief Procedure, page 19.
2. Disconnect air line quick coupler (D) and remove
fluid manifold (M).
3. Remove Front End, page 30.
4. Rotate the fluid housing (F) 180 degrees.
5. Attach Front End, page 30.
6. Reattach fluid manifold. Reconnect air line. Return
gun to service.
Change Hose Position
The fluid inlet swivels and air quick disconnect fitting
point to the rear of the gun. If desired, these positions
can be changed so hoses travel downward.
1. Follow the Pressure Relief Procedure, page 19.
2. Relieve the system pressure. Follow the Pressure
Relief Procedure in your proportioner manual.
3. Disconnect air line (D) and remove fluid manifold
(M).
4. Disconnect fluid hoses from fluid inlet swivels (S).
Remove swivels. Remove plugs from optional inlets
(P).
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.
D
M
TI2554A
F
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.
D
M
TI2554A
S
P
S
TI2417A

Installation
18 3A7314B
5. Apply thread sealant to plugs (12c), elbows (50),
and male threads of fluid inlet swivels (S). Install
elbows (50) in optional fluid inlets (P), facing down.
Install swivels (S) in elbows. Be sure to install A
swivel (smaller) in A side. Install included plugs
where swivels were located. Torque all parts to
235-245 in-lb (26.6-27.7 N•m).
6. Connect A and B hoses to A and B swivels.
7. Remove air line quick coupler (D) and optional air
plug (J). Reverse positions. Apply thread sealant
and torque to 125-135 in-lb (14-15 N•m).
8. Reattach the fluid manifold. Reconnect air. Return
gun to service.
Reposition or Replace Flat Spray Tips
1. Follow the Pressure Relief Procedure, page 19.
2. Remove air cap (C) and flat spray tip (39). Inspect
o-ring (40).
NOTE: If tip is stuck, pry off with small screwdriver or
pull off with pliers. Tip is hardened to resist damage.
3. To clean, soak tip in compatible solvent, see Clean
Mix Chamber Nozzle, page 22. Clean gently with
tip cleanout tool 15D234, Tip Cleanout Tool, page
44, to fit tip configuration.
4. Reposition tip horizontally or vertically, or install
different tip size.
NOTE: Tips marked on back with the last three digits of
the part number. See Flat Tip Part Reference Guide,
page 39.
5. Reinstall the air cap hand tight.
NOTE: The alignment of the clean off air ports on the air
cap does not affect operation.
S
50
12c
S
PTI2646A
D
JTI2540A
WLD
40
39
C
TI2648A
WLD

Operation
3A7314B 19
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
2. Close fluid valves A and B. Leave air valve (W)
open.
3. Disengage the piston safety lock (L). See Piston
Safety Lock, page 20.
4. Trigger the gun onto cardboard or into a waste
container to relieve pressure.
5. Engage the piston safety lock (L). See Piston
Safety Lock, page 20.
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
your proportioner manual to relieve pressure in the
system.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, and
splashing fluid, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
TI2409A
L
W
A
B
TI2421A
TI2410A
L
TI4722a
TI2409A
L

Operation
20 3A7314B
Piston Safety Lock
To engage the piston safety lock: Push knob in and
turn clockwise. If engaged, gun will not actuate.
To disengage the piston safety lock: Push knob in
and turn counterclockwise until it pops out. There will be
a gap between knob and gun body.
Turn the Air Cap
Always follow the Pressure Relief Procedure, page 19,
before turning the air cap (C).
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 Flush Gun,
page 20.
• Close fluid valves A and B.
Flush Gun
1. Follow the Pressure Relief Procedure, page 19.
2. Disconnect the gun from the hose.
3. Connect the gun to the flush manifold block (52).
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.
5. Follow the Pressure Relief Procedure, page 19.
6. Disconnect the gun from the flush manifold block.
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.
High-pressure fluid from dispensing devices can
pierce skin. To help prevent serious injury from
pressurized fluid, always engage the piston safety
lock and close the material shutoff valves to avoid
accidental triggering whenever you stop spraying.
Engaged
r_257826_313266_1_2b
Disengaged
r_257826_313266_1_1b
C
B
TI2421A
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure.
B
ATI2421A