Graco AR2020 Instructions Manual Download

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309550ZAP

Instructions

Fusion

AP Spray Gun

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

Summary of Contents for AR2020

Page 1: ...re 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...

Page 2: ...ation 24 Inspect the Mix Chamber and Side Seal Cartridges 24 Inspect the Piston Safety Lock 26 Inspect the Check Valves 26 Clean Fluid Manifold 27 Clean Passages 27 Clean Muffler 27 Inspect the Piston 28 Inspect the Air Valve 28 Remove Front End 29 Attach Front End 29 Troubleshooting 30 Parts 33 Detail Views 35 Mix Chamber Kits 36 Flat Tip Kits 37 Gun Repair Kits 38 Check Valve Filter Screen Kits ...

Page 3: ...nual in English Description 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 ...

Page 4: ...ST 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 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 AR4242 01 AW3939 AR2929 00 AW2828 ...

Page 5: ...24 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 ...

Page 6: ...rate by 10 Example 2 gpm x 10 20 lb min AF5252 with FTXX48 tip Gun Part Number Mix Chamber Flat Tip Flow Data Part Number Impingement Port Size in mm Equivalent Size Part Number Pattern Diameter at 24 in 610 mm to Target in mm Orifice Size in mm Approximate Flow Rate at 1000 psi 7 0 MPa 70 bar 249525 AF4242 0 042 1 00 01 FTM979 22 559 0 038 0 97 11 lb min 4 99 kg min 249526 AF5252 0 052 1 30 02 FT...

Page 7: ...iameter at 24 in 610 mm to Target in mm Approximate Flow Rate at 1000 psi 7 0 MPa 70 bar Part Number Impingement Port Size in mm Equivalent Size 249810 AW2222 0 022 0 56 Not Available N A 8 9 203 229 4 5 lb min 204 kg min Gun Part Number Mix Chamber Part Number Impingement Port Size in mm Equivalent Size 248408 AR7070 0 070 1 75 04 Gun Part Number Mix Chamber 253888 AR2232 ...

Page 8: ...CTIVE 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 res...

Page 9: ...e 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...

Page 10: ...ify 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 hose...

Page 11: ...tory 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 authorit...

Page 12: ...d 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 lubrican...

Page 13: ...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 N K Purge Air Fluid Cleanoff Air Grease TI354...

Page 14: ...ap D Air Line Quick Coupler E Muffler F Fluid Housing G Grease Fitting under cap H Handle J Optional Air Inlet K Cleanoff Air Valve L Piston Safety Lock M Gun Fluid Manifold N Mix Chamber Nozzle P Optional Fluid Inlets A Side Shown R Lock Ring S Fluid Inlet Swivels A Side Shown T Trigger U Front Retaining Ring V Gun Air Whip Hose W Air Valve Air Valve W is not included with spatter pattern spray g...

Page 15: ...ld M to gun Air Valve W is not included with spatter pattern spray gun 5 Connect air line quick coupler D Turn on air Open air valve W Air should flow from nozzle N 6 Disengage piston safety lock L See Piston Safety Lock page 20 7 Trigger gun to check for full mix chamber travel Front of air cap C should be approximately flush with front retaining ring U The equipment must be grounded to reduce th...

Page 16: ...en B RESIN fluid valve about three half turns Then open A ISO fluid valve 12 Disengage piston safety lock L See Piston Safety Lock page 20 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 Lubricant for Gun Rebuild page 43 to order lu...

Page 17: ...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 preven...

Page 18: ...eturn gun to service Reposition or Replace Flat Spray Tips 1 Follow the Pressure Relief Procedure page 19 2 Remove air cap 10 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 Supplied Tool Kit page 22 Clean gently with tip cleanout tool 15D234 Refer to T...

Page 19: ...e 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 s...

Page 20: ...ent 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 Flu...

Page 21: ...ef 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 NOTE Do not over grease Use two shots maximum Do not spray grease mist on sprayed material 4 Replace the grease cap 5 Round and flat pattern guns only Turn off the air valve W Spatter pattern gun ...

Page 22: ...Applying a light coat of lubricant will make cleaning easier Wipe off outside of gun with compatible solvent Use N Methyl Pyrrolidone NMP Dynaloy brand Dynasolve CU 6 SB Versaflex brand Dzolv or equivalent to soften cured material 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 Ca...

Page 23: ... 5 Push mix chamber 19 forward until impingement ports IP are visible Some mix chambers have counterbored holes CB and require two drill sizes to clean impingement ports completely See TABLE 2 page 24 to select the appropriate drill bit size Also see Drill Bit Kits page 39 Table 1 Nozzle Drill Bit Sizes Round Spray Flat Spray Mix Chamber Part Number Drill Size in mm Mix Chamber Part Number Drill S...

Page 24: ...dure page 29 6 Remove air cap 10 and retaining ring 9 Inspect o ring 3 inside retaining ring Table 2 Impingement Port Drill Bit Sizes MixChamber Part Number Impingement Port IP Drill Bit Size in mm Counterbore CB Drill Bit Size in mm AR2020 76 0 020 0 50 53 0 060 1 50 AR2929 69 0 029 0 70 53 0 060 1 50 AR3737 63 0 037 0 94 N A AR4242 58 0 042 1 00 N A AR4747 56 0 0165 1 18 N A AR5252 55 0 052 1 30...

Page 25: ...d trigger the gun a few times to check for leaks If either check valve pops out of its seated position there is a poor fluid seal on that side of the mix chamber or side seal cartridge components Correct the problem before attaching the fluid manifold 15 Attach fluid manifold Connect air Return gun to service NOTICE To prevent cross contamination in the gun do not interchange A component isocyanat...

Page 26: ...1 Follow the Pressure Relief Procedure page 19 2 Follow the Flush Gun procedure page 20 to remove residual chemical 3 Remove fluid manifold M Leave air connected 4 Disconnect gun air whip hose V from air line quick coupler D 5 Pry out check valves 26 at notch M D TI2554A 4 30 24 5 14 28 TI2433A NOTICE To prevent cross contamination in the gun do not interchange A component isocyanate and B compone...

Page 27: ...ace Do not damage the flat sealing surfaces Coat with grease if left exposed to seal out moisture Clean Passages If necessary clean out passages in fluid housing and handle with drill bits Refer to TABLE 3 and to FIG 2 for diameter and location of passages All drill bits are available in an accessory kit see Accessories page 41 Clean Muffler Remove and clean muffler with compatible solvent A B 26b...

Page 28: ...mbly Push firmly to seat piston 8 Install cylinder cap 5 9 Follow the Attach Front End procedure page 29 10 Attach fluid manifold Connect air Return gun to service Inspect the Air Valve 1 Follow the Pressure Relief Procedure page 19 2 Disconnect air line D and remove fluid manifold M 3 Unscrew air valve plug 2 and remove spring 31 Using a small diameter tool push spool 32 out from front Inspect o ...

Page 29: ...d mounting bottom mounting is shown 4 Insert keyed end of mix chamber 19 in socket X Screw lock ring onto handle as far as possible by hand 5 Turn fluid housing 1 8 turn clockwise to engage slots Y and tabs Z Push on front end to ensure it is properly seated Continue screwing lock ring R onto handle H very securely When properly assembled lock ring is snug against handle NOTICE If lock ring R is s...

Page 30: ...id does not spray when the gun is fully actuated The fluid valves are closed 12b Open the fluid valves 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 ring...

Page 31: ...e 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 18d 18e Replace the side seal o rings See Inspect the Mix Chamber and Side...

Page 32: ...3 Fluid does not shut off when fluid valves are closed The fluid valves 12b are damaged Replace the fluid valves Burst of air from muffler when gun is triggered Normal No action required Steady air leakage from muffler The air valve o rings 24 are damaged Replace the valve o rings See Inspect the Air Valve page 28 The piston o rings 16 17 are damaged Replace the piston o rings See Parts page 33 Ai...

Page 33: ...6 see details at right 11a 10 9 3 23 19 7 11 24 8 25 37 17 28 15 16 14 5 24 30 4 18 see detail above 1 2 4 3 4 4 3 3 5 4 Seal Cartridge 18 Detail Check Valve 26 Detail 26b 26e 26c 26d 26g 26a 26f 18e 18c 18b 18d 18a Torque to 125 135 in lb 14 15 N m 1 2 Torque to 20 30 in lb 2 3 3 4 N m Torque to 235 245 in lb 26 6 27 7 N m 3 Torque to 35 45 in lb 4 5 N m 4 Torque to 32 40 ft lb 43 54 N m 5 TI3926...

Page 34: ... KIT see Side Seal Kits page 42 1 18d 248130 O RING cartridge body package of 6 1 18e 248128 O RING side seal package of 6 1 19 CHAMBER mix see Mix Chamber Kits page 36 1 20 15C480 WASHER wave 1 21 248132 O RING package of 6 1 22 119626 MUFFLER 1 23 248131 O RING package of 6 1 24 246354 O RING package of 6 1 25 100846 FITTING grease 1 26 246731 VALVE check A side includes 26a 26g 1 246352 VALVE c...

Page 35: ...t see Flat Tip Kits page 37 1 40 246360 O RING PTFE flat tip models only package of 3 see Flat Tip Kits page 37 1 43 117661 VISE pin dual reversible chucks 1 52 15B817 MANIFOLD gun flush round and flat pattern guns only 1 53 117642 NUT DRIVER hex 5 16 1 54 118575 SCREWDRIVER 1 8 blade 1 58 15D972 RETAINER tip spatter pattern gun only 1 59 15D971 TIP spatter pattern gun only 1 60 248019 SEAL packag...

Page 36: ... 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 includes drill bits Nozzle Orifi...

Page 37: ...ounterbore Drill Bit Size in mm AF2033 0 094 3 32 2 35 0 035 0 021 66 0 033 0 84 76 0 020 0 51 0 061 53 0 0595 1 50 AF2942 0 094 3 32 2 35 0 042 0 031 58 0 042 1 07 69 0 029 0 74 0 061 53 0 0595 1 50 Kit Pattern Diameter at 24 in 609 6 mm to target in mm Equivalent flow to mix chamber size Nozzle Drill Bit Size in mm Impingement Drill Bit Size in mm AW2222 8 203 2 N A 0 047 1 20 74 0 022 0 56 AW28...

Page 38: ...ages in the Air Purge gun handle and fluid housing Ref Includes Bulk O ring Kits quantity 246347 Side Seal Cartridge O ring Kit 246348 Side Seal Kit 246351 Check Valve O ring Kit 246355 Complete O ring Kit 25M221 High Temperature Pressure O ring Kit 3 248137 6 25M244 50 1 10 129209 10 1 14 248136 6 1 16 248135 6 25M245 25 1 17 248134 6 1 18c 2 18d 248130 6 25M242 50 4 4 18e 248128 6 298790 50 2 2 ...

Page 39: ...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 24...

Page 40: ... 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 Kit Part Qty Drill Bit Size Illustration nominal in mm Kit Part Qty Reamer Size Illustration nominal in mm 25B041 1 32 0 116 2 90 25B040 1 3 32 0 094 2 39 25B039 1 44 0 086 2 18 25B038 1 50 0 070 1 78 25B037 1 1 16 0 062 1 59 25B035 1 53 0 060 1 52 25B034 1 55 0 052 1 32 25B032 1 58 0 042 1 0...

Page 41: ... provided Conversion Kit Mix Chamber Part Number Impingement Port Size in mm Equivalent Size Pattern at 24 in 61 cm 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 Conversion Kit Mix Chamber Flat Tip Part Number Impinge...

Page 42: ...lation foam into stud walls See Related Manuals page 3 Material Kit Description Qty Stainless Steel 246348 SEAL KIT 2 277299 SEAL KIT 50 Polycarballoy 249990 SEAL KIT 2 277298 SEAL KIT 50 Chromex 25N573 SEAL KIT 2 Material Kit Part Description Qty Stainless Steel 246349 CARTRIDGE KIT A side 1 246348 CARTRIDGE KIT B side 1 Polycarballoy 277297 CARTRIDGE KIT A side 1 277296 CARTRIDGE KIT B side 1 Ch...

Page 43: ...et low overspray applications Includes air cap tip retainer seal and cleanout drill bits See Related Manuals page 3 Gun Cover 244914 Keeps gun clean while spraying Pack of 10 Lubricant for Gun Rebuild 248279 4 oz 113 gram Qty 10 High adhesion water resistant lithium based lubricant SDS available at www graco com Grease Cartridge for Gun Shutdown 248280 Cartridge 3 oz Qty 10 Specially formulated lo...

Page 44: ...Pail 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 Tip Cleanout Tool 15D234 Designed to fit CeramTip internal dome and flat tip slits Circulation Manifold 246362 Attach to gun fluid manifold to enable preheating of hose Refer to Circulation Manifold Kit Instruction Manual See Related Manuals page 3 ...

Page 45: ... 18 UNF Dimensions 7 5 x 8 1 x 3 3 in 191 x 206 x 84 mm Weight 2 5 lb 1 1 kg Wetted Parts Aluminum stainless steel carbon steel carbide chemically resistant o rings 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 ...

Page 46: ...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 war...

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