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Operation, Parts, Service and Repair
GAP Pro Spray Gun 311322J
ENG
For use with non-flammable polyurethane foams. For professional use only.
Not for use in explosive atmospheres.
See page 3 for model information.
3000 psi (20.7 MPa, 207 bar) Maximum Working Fluid Pressure
125 psi (0.86 MPa, 8.6 bar) Maximum Working Air Pressure
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
2
Contents
Gun Models . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . 6
Major Components . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Isocyanate Hazard . . . . . . . . . . . . . . . . . 8
Keep A and B Components Separate . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Stop . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Valves . . . . . . . . . . . . . . . . . . . . 9
Air Hose Configurations . . . . . . . . . . . . 10
Initial Set Up . . . . . . . . . . . . . . . . . . . . . 11
Daily Start-Up . . . . . . . . . . . . . . . . . . . . 11
Daily Shutdown . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . 12
Grease Gun . . . . . . . . . . . . . . . . . . . . . 12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Side Blocks . . . . . . . . . . . . . . . . . . . . . .13
Mixing Chamber and Gun Block . . . . . .15
End Cap and Air Piston . . . . . . . . . . . .17
End Cap O-ring and Safety Stop Seal .19
Trigger/Air Valve . . . . . . . . . . . . . . . . . .21
Air Passage Diagrams . . . . . . . . . . . . .23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
GAP Pro Spray Gun Assembly . . . . . . .26
GAP Pro Spray Gun Handle Assembly .30
Accessories . . . . . . . . . . . . . . . . . . . . .32
Technical Data . . . . . . . . . . . . . . . . . . . . .33
Graco Standard Warranty . . . . . . . . . . . .34
Graco Information . . . . . . . . . . . . . . . . . .34
311322J
Gun Models
Part No.
295550
★
295551
★
295552
★
295553
★
295554
★
295556
★
295557
295558
295559
295560
295561
295562
Description
Flat Pattern Gun
Flat Pattern Gun
Flat Pattern Gun
Flat Pattern Gun
Flat Pattern Gun
Flat Pattern Gun
Round Pattern Gun
Round Pattern Gun, Recirculating
Round Pattern Gun
Round Pattern Gun
Round Pattern Gun
Round Pattern Gun
Mix Module
#00 flat
#01 flat
#02 flat
#03 flat
#04 flat
#05 flat
#00 round
#00 round
#01 round
#02 round
#03 round
#04 round
★
Flat pattern guns are sold without a spray
tip. See Flat Spray Tip Kits, page 32 for tip
choices.
Gun Models
311322J 3
4
Warnings
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings.
When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point 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.
• Do not spray without tip guard and trigger guard installed.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
311322J
311322J
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
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 Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Tech-
nical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco/Gusmer replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco/Gusmer 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
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
5
6
Overall View
Overall View
Major Components
Safety Stop
A-Manual Valve
A-Screen
Screw
R-Manual
Valve
R-Screen
Screw
Trigger
F IG . 1. Major Components (shown with round spray tip)
Spray Tip
311322J
Overall View
R-Side Block
2
Gun Block
O-Ring
Mixing
Chamber
Flat Tip
Air Cap
!
Air Seal
Gun Block
Screws
A-Side
Block
F IG . 2. Front End Components (shown with flat spray tip assembly)
Side Block
Screws
311322J 7
8
Operation
Operation
Grounding
To prevent accidental gun operation, always disconnect air supply before servicing gun or anytime gun is not in use.
Isocyanate Hazard
Check your local electrical code and proportioner manual for detailed grounding instructions.
Ground the spray gun through connection to a
Graco-approved grounded fluid supply hose.
Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.
Keep A and B Components
Separate
CAUTION
To prevent cross-contamination of the gun’s wetted parts, do not interchange A component (isocyanate) and B component (resin) parts. The gun is shipped with the A side on the left.
311322J
Operation
Safety Stop Manual Valves
Manual valves located on the side blocks control flow of each chemical component to gun.
Always engage safety stop, close both manual valves, and disconnect air before cleaning, maintaining, or repairing gun, or any time gun is not in use.
The GAP Pro gun has a 2-position safety stop.
When engaged, it prevents accidental triggering of gun. When disengaged, it allows gun to dispense.
1. To engage the safety stop, push in and turn the safety stop knob clockwise. See
F
IG
. 3. Engage Safety Stop
2. To disengage the safety stop, push in and turn the safety stop knob counterclock-
Triggering gun with manual valves closed may cause crossover if gun ports contain residual chemical.
Always engage safety stop, close both manual valves, and disconnect air before cleaning, maintaining, or repairing gun, or any time gun is not in use.
Never open a manual valve unless side block is secured to gun or exit port is directed into flush pail.
1. Open manual valves using a 5/16 in. nut driver; turn manual valves counterclockwise approximately three full turns.
2. Close manual valves by turning fully clockwise.
Manual
Valves
2
!
F
IG
. 4. Disengage Safety Stop
Coupling
Blocks
F IG . 5. Manual Valves
311322J 9
Operation
Air Hose Configurations
The GAP Pro Gun has two possible air hose configurations. In the standard configuration, the air connection is at the base of the handle.
In the optional configuration, the air connection is at the rear of the gun.
Always engage safety stop, close both manual valves, and disconnect air before changing air hose configuration.
1. See F IG . 6. Remove air hose from nipple at
base of gun handle.
2. Remove nipple from gun handle.
3. Remove pipe plug from back of gun.
4. Install pipe plug in base of gun handle.
5. Install nipple in back of gun.
6. Connect air hose to nipple and use wrench to tighten.
Install Pipe Nipple Air Hose
2
!
Remove
Pipe Plug
Install Pipe Plug
Remove Long Pipe Nipple
F IG . 6. Air Hose Configuration
10 311322J
Operation
Initial Set Up Daily Start-Up
1. Close both manual valves.
2. Engage safety stop.
3. Install female quick disconnect fitting on air hose, which is bundled with fluid supply hoses.
4. Connect A-isocyanate hose (red-taped) to fitting on A-side block. Then connect
R-resin hose (blue-taped) to fitting on
R-side block.
Ensure side blocks are attached to gun, and proportioning unit is at desired temperature and pressure.
1. Connect air supply to gun, page 10.
2. Trigger gun multiple times to ensure proper mixing chamber movement.
3. Open both manual valves, page 9.
4. Disengage safety stop.
5. Test spray on disposable surface.
A and R side hoses are sized differently to prevent improper connection.
Daily Shutdown
5. Pressurize A and R chemical hoses and check for leaks. (See Proportioning Unit manual.)
6. Check proportioning unit for proper hose temperature, heater temperature, and pressure. (See Proportioning Unit manual.)
7. Connect air supply hose to gun.
8. Open both manual valves, page 9.
9. Disengage safety stop.
10. Test spray on disposable surface.
11. Proceed with Daily Start-up procedure or
Shutdown procedure as required.
Follow this procedure when gun is out of service for any length of time. Daily disassembly of gun for cleaning is not recommended if it has been operating properly.
However, if you remove gun from coupling block, flush and clean thoroughly.
1. Follow Pressure Relief Procedure, page
2. Shutdown proportioning unit as required.
311322J 11
Operation
Pressure Relief Procedure Grease Gun
Relieve pressure before cleaning or repairing gun.
1. Close both manual valves.
2. Engage safety stop.
3. Trigger gun once onto waste area to relieve fluid pressure in gun front end.
4. Disconnect gun air supply, page 10.
If fluid in hose and proportioner is still under pressure, follow Pressure Relief Procedure in proportioner manual.
To relieve pressure in hose after gun is removed, place fluid manifold over containers, facing away from you. Very carefully open fluid valves. Under high pressure, fluid will spray sideways from fluid ports.
Do not grease gun if gun will be serviced following shutdown.
1. Follow Pressure Relief Procedure, page
2. Insert GAP Gun Chamber Lubricant Needle into nozzle of mixing chamber. Dispense a small amount of lubricant into mixing chamber.
To determine correct amount of lubricant, remove air cap to view internal chamber area. When lubricant becomes visible, stop dispensing.
3. Connect gun air supply.
4. With safety stop engaged, trigger gun 2 or
3 times to discharge any excess lubricant.
5. Disconnect gun air supply, page 10.
12 311322J
Repair
Repair
Shutdown proportioner and allow chemicals to cool before performing any repair procedures.
Side Blocks
1. Follow Pressure Relief Procedure, page
Manual Valve Assembly
Side Block
Screen Screw Seal
2
2. See F IG . 7. Remove A-side screen screw,
seal, and screen. Inspect for damage.
Thoroughly rinse and dry screen. Hold screen up to a bright light; mesh must be free of particles and material buildup.
Replace as necessary. Repeat for R-side.
3. Alternately loosen side block mounting screws. Carefully separate side blocks from gun. Wipe mating surfaces with a rag soaked in gun cleaner.
4. Remove check valve retainer/side seal assembly from A-side block.
Check Valve Assembly
Spring
Check Valve Retainer
Side Seal
O-Ring
Screen Screw
Screen
Swivel Fitting
F IG . 7. Side Block Components
Side Seal Assembly
311322J 13
Repair
5. Remove check valve and clean with gun cleaner. Inspect and replace if damaged.
CAUTION
Clean side seals with a wooden or plastic scraper or a brass brush. Do not use a pocketknife, razor blade, or any tool that may scratch surface.
6. Remove side seal and o-ring. Replace if damaged.
7. Clean all components thoroughly. Use brass brushes or drill bits to remove residual chemical from the gun block. Thorough cleaning ensures unrestricted movement of mixing chamber. Use cotton swabs soaked in gun cleaner if necessary.
8. Repeat steps 4-7 for R-side block.
10. Check side seal for wear by measuring how far seal protrudes from side seal assembly insert. A worn side seal promotes chemical leakage. Replace side seal if it protrudes
0.065 in. (1.65 mm) or less. In addition, check seal for scratches, which also pro-
.065 in.
(1.65 mm)
11. Inspect check valve assembly for damage by measuring gap between mating surface of side block and bottom edge of side seal assembly insert. If gap measures 0.018 in.
(.46 mm) or less, the check valve assembly has been crushed due to overtightening
and it must be replaced. See F IG . 9.
.018 in.
(0.46 mm)
CAUTION
Do not overtighten check valve retainer.
Tightening more than 1/4 turn can damage check valve or retainer and cause leaking when gun is pressurized.
9. Place check valve assembly in check valve retainer and thread into side block finger tight. Use a 1/2 in. wrench to tighten
retainer 1/4 turn and no more. See F IG . 8.
One quarter of a full turn (max.)
F
IG
. 9: Side Seal
12. Place spring in check valve retainer.
13. Lightly coat o-ring with grease and install on side seal.
14. Push side seal into the check valve retainer until o-ring engages detent groove and remains in place.
15. Install side blocks to gun body with two mounting screws. Tighten screws alternately and evenly to prevent leakage.
16. Return gun to service. See Daily Start-Up, page 11.
F IG . 8. Tighten Check Valve Retainer
14 311322J
Repair
Mixing Chamber and Gun
Block
1. Follow Pressure Relief Procedure, page
8. Slide gun block over mixing chamber and up to gun. Install two mounting screws.
Tighten screws alternately and evenly to prevent leakage.
9. Install side blocks to gun body with two mounting screws. Tighten screws alternately and evenly to prevent leakage.
10. Return gun to service. See Daily Start-Up, page 11.
If your gun has a round pattern spray tip, skip step 2 and go to step 3.
2. Remove flat tip assembly from end of mix module.
3. Remove air cap.
4. Use a 5/16 in. nut driver to alternately loosen side block mounting screws. Carefully separate side blocks from gun. Wipe mating surfaces with a rag soaked in gun cleaner.
To repair side blocks, see Side Blocks, page 13.
5. Remove gun block bolts. Slide gun block away from gun. Wipe mating surfaces with a rag soaked in gun cleaner. Clean gun block with gun cleaner and brass brushes to remove residual chemical and built-up material. This ensures unrestricted movement of mixing chamber.
6. Use a 3/16 in. wrench or needle-nose pliers to hold end of piston shaft while unscrewing mixing chamber by hand. Clean mixing chamber with gun cleaner and drill bits.
Inspect for damage and replace if necessary.
7. Hold end of piston shaft with a 3/16 in. wrench or needle-nose pliers. Screw mixing chamber onto shaft by hand.
311322J 15
Repair
R-Side Block
2
O-Ring
Mixing Chamber
Gun Block
Air Cap
Flat Tip
!
Air Seal
Gun Block
Screws
F IG . 10. Mixing Chamber and Gun Block
A-Side Block
Side Block
Screws
16 311322J
Repair
End Cap and Air Piston
To repair gun block, see Mixing Chamber
4. See F IG . 11. Use a 3/16 in. wrench or nee-
dle-nose pliers to hold end of piston shaft while unscrewing mixing chamber by hand.
1. Follow Pressure Relief Procedure, page
2. Use a 5/16 in. nut driver to alternately loosen side block mounting screws. Carefully separate side blocks from gun. Wipe mating surfaces with a rag soaked in gun cleaner.
To repair side blocks, see Side Blocks, page 13.
3. Use a 5/16 in. nut driver to remove gun block mounting screws. Slide gun block away from gun. Wipe mating surfaces with a rag soaked in gun cleaner. Be sure to retain o-ring located between gun block and mounting flange.
To repair mixing chamber, see Mixing
Chamber and Gun Block, page 15.
5. Disengage safety stop.
6. Use a 9/64 in. ball point hex key to remove socket head screw and clamp from rear of air cylinder.
7. Use a retaining ring pliers to remove retaining ring. Ring retains end cap position in air cylinder.
Piston Assembly
Piston Spring
End Cap/Safety
Stop Assembly
Socket Head
Cap Screw
Retaining Ring
F IG . 11. End Cap and Piston Assembly
Cylinder
Clamp
311322J
Mixing Chamber
17
Repair
Removing safety stop and end cap requires some force because o-ring is tightly compressed.
8. Pull safety stop until it and attached end cap come free from air cylinder. Be sure to retain piston spring, located inside cylinder.
9. Inspect end cap o-ring and remove if damaged. Lightly coat new o-ring with Lubriplate grease and install on end cap.
10. Pull piston assembly out of air cylinder.
11. See F IG . 12. Remove retaining ring and
slide piston shaft out from the back of piston.
12. Inspect shaft and piston o-rings and replace if damaged. Lightly coat new o-rings with Lubriplate grease before installing.
13. Slide piston shaft into the back of piston, being careful not to damage shaft o-rings.
Secure with retaining ring.
Retaining Ring
Piston Shaft
Piston
Piston Shaft
O-Rings
14. Install piston assembly into the air cylinder.
Be sure to insert retaining ring completely into groove so end cap will remain in air cylinder when gun is pressurized. Keep clear of end cap when reapplying air pressure or triggering gun after reassembly in case of improper retaining ring installation
15. Center piston spring over raised portion of piston. Align raised portion of end cap with inside diameter of piston spring. Insert end cap into air cylinder. Press end cap until it moves past the undercut groove in air cylinder, which is where retaining ring nests.
Maintain pressure on end cap, ensure groove remains visible, and install retaining ring using retaining ring pliers.
16. Reinstall socket head screw and cylinder clamp in rear of air cylinder.
17. Hold end of piston shaft with a 3/16 in. wrench or needle-nose pliers. Screw the mixing chamber onto shaft by hand.
18. Slide gun block over mixing chamber and up to gun. Install two mounting screws.
Tighten screws alternately and evenly to prevent leakage.
19. Install side blocks to gun body with two mounting screws. Tighten screws alternately and evenly to prevent leakage.
20. Return gun to service. See Daily Start-Up, page 11.
Piston O-Ring
F
IG
. 12. Piston Assembly
18 311322J
Repair
End Cap O-ring and Safety
Stop Seal
3. Remove socket head screw and clamp from rear of air cylinder.
4. See F IG . 13. Use a retaining ring pliers to
remove retaining ring. Ring retains end cap position in air cylinder.
1. Follow Pressure Relief Procedure, page
2. Use a 5/16 in. nut driver to alternately loosen side block mounting screws. Carefully separate side blocks from gun. Wipe mating surfaces with a rag soaked in gun cleaner.
To repair side blocks, see Side Blocks, page 13.
Removing safety stop and end cap requires some force because o-ring is tightly compressed.
5. Pull safety stop until it and attached end cap come free from air cylinder. Be sure to retain piston spring, which is located inside cylinder.
6. Inspect end cap o-ring and replace if damaged. Lightly coat new o-ring with Lubriplate grease and install on end cap.
Retaining Ring
End Cap/Safety
Stop Assembly
Socket Head
Cap Screw
F IG . 13. End Cap Assembly
Cylinder Clamp
311322J 19
Repair
7. See F IG . 14. Use a 5/64 in. hex key to
loosen two setscrews on stop knob. Slide knob off shaft of stop pin. Retain shaft spring. Pull stop pin out of end cap.
8. Remove u-cup seal from end cap and replace if damaged. Lightly coat new seal with Lubriplate grease before installing; u-cup lips must face the air cylinder.
9. Insert stop pin into end cap. Slide shaft spring and stop knob onto shaft of stop pin.
Use a 5/64 in. hex key to install two set screws in stop knob. Ensure knob set screws are aligned to flats on stop pin and tighten securely.
End Cap
Stop Pin
Stop Spring
Stop Knob
Set Screws
Be sure to insert retaining ring completely into groove to ensure end cap remains in air cylinder when gun is pressurized. Keep clear of end cap when reapplying air pressure or triggering gun after reassembly in case of improper retaining ring installation
10. Center piston spring over raised portion of piston. Align raised portion of end cap with inside diameter of piston spring. Insert end cap into air cylinder. Press end cap until it moves past undercut groove in air cylinder, which is where retaining ring nests. Maintain pressure on end cap, ensure groove remains visible, and install retaining ring
using retaining ring pliers. See F IG . 13.
11. Reinstall socket head screw and cylinder clamp in rear of air cylinder.
12. Install side blocks to gun body with two mounting screws. Tighten screws alternately and evenly to prevent leakage.
13. Return gun to service. See Daily Start-Up, page 11.
Cup Seal
End Cap O-Ring
F
IG
. 14. Safety Stop Assembly
20 311322J
Repair
Trigger/Air Valve
1. Follow Pressure Relief Procedure, page
2. Use a 5/16 in. nut driver to alternately loosen side block mounting screws. Carefully separate side blocks from gun. Wipe mating surfaces with a rag soaked in gun cleaner.
To repair side blocks, see Side Blocks, page 13.
3. If gun is configured with air inlet at base of handle (standard), remove 1/8 npt pipe plug at rear of gun.
If gun is configured with air inlet at rear, remove air hose and nipple.
4. Remove screw and locknut holding trigger lever in place. Remove trigger lever.
5. Remove valve retainer hex nut, which holds brass valve spool in place.
6. Carefully grip end of valve spool with a pliers and remove it. Valve spring, which fits into spool, will come out with it. Be careful not to lose spring.
7. Inspect spool o-rings and replace if damaged. Liberally coat new o-rings with Lubriplate grease before installing.
8. Remove 1/16 npt pipe plug from deep in port at rear of gun.
9. Brass spring seat is visible inside port at rear of gun. Use a 1/4 in. diameter (maximum) punch and hammer to gently tap seat until valve liner and seat are pushed out of valve cavity.
10. Inspect the four o-rings on valve liner and replace if necessary. Apply Lubriplate grease liberally to o-rings before installing.
11. Ensure that valve cavity is free of debris.
Apply a thin film of Lubriplate grease inside cavity.
12. Slide spring seat into cavity, tapered end first. Ensure it bottoms out in cavity.
13. There will be some resistance from the o-rings when installing valve liner. Push valve liner into cavity until 2 or 3 of the cavity’s internal threads are visible.
Threads allow engagement with valve retainer nut, which aligns valve liner and spool to proper depth.
14. Apply a small amount of thread sealant to
1/16 npt pipe plug and reinstall. This seals threads to prevent air leaks.
15. Reinstall 1/8 npt pipe plug, or nipple and air hose, at rear of gun.
16. Ensure that valve spring is in place, and insert valve spool into valve liner. Screw in valve retainer nut until snug. Do not overtighten.
17. Reinstall trigger lever, screw, and locknut.
18. Install side blocks to gun body with two mounting screws. Tighten screws alternately and evenly to prevent leakage.
19. Return gun to service. See Daily Start-Up, page 11.
311322J 21
Repair
Optional Air Hose and Nipple
Valve Liner
O-Rings
Valve Spool
Spring
Seat
Valve Spring
Lock Nut
Valve Retainer Nut
F IG . 15. Trigger/Air Valve Assembly
1/16 in.
Pipe Plug
1/8 in. Pipe
Plug
Trigger Mounting Screw
Trigger Lever
22 311322J
Air Passage Diagrams
Use thread sealant when reinstalling any threaded components. In addition, reinstall all set screws flush to outside surface of gun handle.
.250 dia.
.3125 dia.
.375 dia.
.687 dia.
.3125 dia.
1/8 in. drill
8-32 UNC-GH3 TAP
1.858 dia.
1.750 dia.
1/8 in. drill
F
IG
. 16: Air Cylinder Air Passages
5/32 in. drill 8-32 UNC-2B TAP
Repair
311322J 23
Repair
1/8 in. drill
10-32 UNC-2B TAP
1/8 in. drill
5/32 in. drill
10-32 UNC-2B TAP
5/32 in. drill
1/8 in. drill
10-32 UNC-2B TAP
5/32 in. drill
5/32 in. drill
1/8 in. drill
10-32 UNC-2B TAP
5/32 in. drill (3)
10-32 UNC-2B TAP
1/2 in. dia.
5/8-18 UNC-2B TAP
1/8 in. drill
1/8 NPT TAP
1/8 in. NPT TAP
1/16 in. NPT TAP
5/32 in. drill
F IG . 17: Handle Air Passages
24 311322J
Notes
Repair
311322J 25
Parts
Parts
GAP Pro Spray Gun Assembly
9
18
19
16 22
2 31
13 15
14
26
7
27
35
29
34
1
28
Round Spray
28
8
11
33
29
32
34
35
23
26
14
15
Spatter Spray
29
13
23
27
16
28
17
19
33
32
2
27
20
21
!
1
6
4
10
5
31
12
2
9
3, 42
F
IG
. 18: GAP Pro Final Assembly
26 311322J
Parts
GAP Pro Spray Gun Assembly
Ref.
No. Part No. Description Qty.
1 117634 FITTING, R-swivel
2 117635 FITTING, A-swivel
3 15B772 HOSE, air; 1/4 npt (fbe) x
4
5
23 in. (584 mm)
295596 PLUG, coupler
295597 COUPLER
6 296964 BOLT, side block (pack of 2) -
7 115719 O-RING, fluoroelastomer 1
1
1
8 296963 BOLT, gun block (pack of 2) -
9 296970 VALVE ASSEMBLY, manual 2
10 103656 NIPPLE, hex; brass; 1/8 npt 1
11 296952 BLOCK, gun 1
12 296960 HANDLE, gun 1
13 296953 CHECK VALVE ASSEMBLY 2
14 296957 RETAINER, check valve
15 296959 SPRING (pack of 2)
16 296939 SCREEN; 80 mesh
2
-
-
1
1
1
(pack of 10)
17 296940 SCREW, screen, A-side
18 296941 SCREW, screen, R-side
19 296942 SEAL, screw, screen
(pack of 2)
1
1
-
Ref.
No. Part No. Description Qty.
20 295693 PLUG, seal, flush; 1/16 npt 2
21 296965 BLOCK, A-side 1
22 296966 BLOCK, R-side
23 248128 O-RING, side seal
1
2
26
27
28
29
30
31
32
(pack of 6)
❖
SEAL, side
❖ MIXING CHAMBER
❖
SEAL, air
❖ CAP, air
❖
FITTING, straight
❖ PLUG or ELBOW
❖
FLAT TIP;
33
34
35
40
41
❖ ADAPTER
❖
SEAL
❖ NUT, retaining
❖
TOOL, cleanout
❖ TOOL, cleanout
42 100030 Fitting
4
2
1
1
1
2
1
1
1
1
1
1
1
❖
See Table 1 or Table 2 for part numbers by
model.
311322J 27
Parts
Ref. No.
Output
(lbs/min)
❄
26
32
33
34
35
27
28
29
31
40
41
Table 1: Flat Pattern Guns, Parts by Model Number
Flat Pattern Gun Model No.
295550 295551 295552 295553 295554 295555 295556
(00 Flat) (01 Flat) (02 Flat) (03 Flat) (04 Flat) (04 Spatter) (05 Flat)
3-6 5-9 10-20 12-30 20-45 14-22 30-60
296956 ✖ 296956 ✖ 296956 ✖ 296956 ✖ 296956 ✖
296840† 296841† 296842† 296843† 296844†
296945
296950
295662
296945
296950
295662
296945
296950
295662
296945
296950
295662
296945
296950
295662
296473
295409
295423
118369
296289
296473
295409
295423
296293
296296
296473
295409
295423
118369
296297
296473
295409
295423
296296
296302
296474
295409
295423
296297
296490
296956 ✖
296844†
296945
296950
295662
296496
296297
296490
296956 ✖
296845†
296945
296950
295662
296474
296409
296423
296491
296302
❄
Output specifications are based upon in-house test data, which may vary depending on specific chemi- cal system, application, and mixing chamber.
✖
Kit includes qty. 2 each of items 23 and 26.
† Kit includes (1) 27, (1) 28, and cleanout tools 40 and 41.
Ref.
No.
26
27
28
29
31
40
41
295557
Table 2: Round Pattern Guns, Parts by Model Number
Round Pattern Gun Model No.
295558
◆
295559 295560 295561
(00 Round) (00 Recirc)
296956
✖
296846†
296946
296951
295662
118369
296289
296956
✖
296846†
296946
296951
112307
118369
296289
(01 Round)
296956
✖
296847†
296946
296951
295662
296293
296296
◆
This model uses qty. 2 each of items 1 and 2.
(02 Round)
296956
✖
296848†
296946
296951
295662
118369
296297
(03 Round)
296956
✖
296849†
296946
296951
295662
296296
296302
✖
Kit includes qty. 2 each of items 23 and 26.
† Kit includes (1) 27, (1) 28, and cleanout tools 40 and 41.
295562
(04 Round)
296956
✖
296850†
296946
296487
295662
296297
296490
28 311322J
Notes
Parts
311322J 29
Parts
GAP Pro Spray Gun Handle Assembly
76
66 75
77
78
51
79
82
81
85
57
55
67
52
57
68
72
71
60
61
73
F IG . 19: GAP Pro Handle Assembly
69
58
57
64
57
74
80
54
84
59
65
83
56
86
63
62
53
70
30 311322J
Parts
GAP Pro Spray Gun Handle Assembly
Ref.
No. Part No. Description
51 ❄ 295435 SEAL, u-cup
52 295422 RING, retaining
53 296537 SCREW, cap, socket hd
54 106245 SCREW, cap, socket hd
55 296536 SCREW, set; socket hd
56 295662 PLUG, pipe
57 ❄ C20988 O-RING
58 112085 O-RING
59 ❄ 103337 O-RING
60 C02032 NUT
61 295692 TRIGGER
62 116624 SCREW, set; socket hd
63 102279 SCREW, set; socket hd
64 296971 SPRING
65 296535 CLAMP, cylinder
66
❄
108103 O-RING
67 ❄ 168518 O-RING
68 295695 SCREW, cap; button hd
69 295671 SCREW, trigger
Qty.
1
1
2
2
1
1
4
1
1
1
1
1
1
6
2
1
1
1
1
Ref.
No. Part No. Description
70
71
72
73
74
75
76
77
78
79
80
81
82
83
86
296538 RING, retaining
296866 LINER, valve
296527 SPOOL, valve
296867 NUT, retainer, valve
295434 SEAT, spring
295436 SPRING
296529 CAP, end
296530 KNOB
296526 PIN, stop
295416 SPRING, piston
296961 HANDLE, gun
296531 PISTON
296937 SHAFT, piston
295693 PLUG, pipe
84 296962 CYLINDER, air
85 ❄ 114054 O-RING
295665 NIPPLE
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
❄
Included in Handle Seal Repair Kit 296938
(purchase separately).
311322J 31
Parts
Accessories
Tool kit 296968 for GAP Pro spray gun.
Grease syringe 296382; syringe filled with grease for gun maintenance.
Flat Spray Tip Kits
Part Number Spray Width
✖
10-14 in. at 1500 psi 296948
296949 12-16 in. at 1500 psi
✖
Approximately 20 in. from surface.
Kit Ref.
1
2
Gun Wand Kit
Kit 296984; extends GAP spray gun front-end
21 in.
Pour Package (296983) Components
Includes:
Pour fitting
Polyflow tubing (3/8 in. diameter x 1 ft. length)
297078
296165
1
1
29
(flat air cap required)
28
27
(flat mix chamber required)
F IG . 20: Pour Package Components
Mixing Chamber Cleanout Drills
Flat Mixing
Chamber (27)
296840
296841
296842
296843
296844
296845
Round Mixing
Chamber (27)
296846
296847
296848
296849
296850
296851
Mixing Chamber
Nozzle Cleanout Drill
118369
296296
296297
296302
296490
296491
Mixing Chamber
Port Cleanout Drill
296289
296293
118369
296296
296297
296302
32 311322J
Technical Data
Category
Maximum Fluid Working Pressure
Minimum Air Inlet Pressure
Maximum Air Inlet Pressure
Maximum Output (flow rate)
Air Inlet Size
A Component (ISO) Inlet Size
R Component (Resin) Inlet Size
Length
Height
Width
Weight
Wetted Parts
Technical Data
Data
3000 psi (20.7 MPa, 207 bar)
100 psi (0.7 MPa, 7 bar)
125 psi (0.9 MPa, 9 bar)
40 lb/min (18 kg/min)
1/8 npt
-5 JIC; 1/2-20 UNF
-6 JIC; 9/16-18 UNF
7 in. (17.8 cm)
7.25 in. (18.4 cm)
4.4 in. (11.2 cm)
2.34 lb (1.06 kg)
Stainless steel, carbon steel, brass, nylon, acetal, PTFE, aluminum
311322J 33
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.
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 311322
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2006, Graco Inc. is registered to ISO 9001 www.graco.com
Revised 02/2010
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