Operation, Parts, Service and Repair
GAP Pro Spray Gun
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.
311322K
EN
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 . . . . . . . 28
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 311322K
Gun Models
Part No. Description Mix Module
Gun Models
295557
295558
295559
295560
295561
295562
Round Pattern Gun #00 round
Round Pattern Gun, Recirculating #00 round
Round Pattern Gun #01 round
Round Pattern Gun #02 round
Round Pattern Gun #03 round
Round Pattern Gun #04 round
311322K 3
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.
4 311322K
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.
311322K 5
Overall View
Overall View
Major Components
Safety Stop
A-Manual Valve
A-Screen
Screw
R-Manual
Valve
Trigger
FIG. 1. Major Components (shown with round spray tip)
Spray Tip
R-Screen
Screw
6 311322K
O-Ring
Overall View
R-Side Block
Flat Tip
Air Cap
2
Air Seal
Gun Block
Gun Block
Screws
Mixing
Chamber
!
Side Block
Screws
A-Side
Block
FIG. 2. Front End Components (shown with flat spray tip assembly)
311322K 7
Operation
Operation
To prevent accidental gun operation, always
disconnect air supply before servicing gun or
anytime gun is not in use.
Isocyanate Hazard
Spraying materials containing isocyanates
creates potentially harmful mists, vapors,
and atomized particulates.
Grounding
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.
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.
8 311322K
Operation
Safety Stop
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
FIG. 3.
Manual Valves
Manual valves located on the side blocks control flow of each chemical component to gun.
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.
FIG. 3. Engage Safety Stop
2. To disengage the safety stop, push in
and turn the safety stop knob counterclockwise. See FIG. 4.
IG. 4. Disengage Safety Stop
F
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
!
Coupling
Blocks
FIG. 5. Manual Valves
311322K 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.
2
1. See FIG. 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
FIG. 6. Air Hose Configuration
!
Install Pipe Plug
Remove Long Pipe Nipple
Remove
Pipe Plug
10 311322K
Operation
Initial Set 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.
A and R side hoses are sized differently to
prevent improper connection.
Daily Start-Up
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.
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
12.
2. Shutdown proportioning unit as required.
3. Grease gun, page 12.
311322K 11
Operation
Pressure Relief Procedure
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.
Grease Gun
Do not grease gun if gun will be serviced
following shutdown.
1. Follow Pressure Relief Procedure, page
12.
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.
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.
5. Disconnect gun air supply, page 10.
12 311322K
Repair
Shutdown proportioner and allow chemicals
to cool before performing any repair procedures.
Side Blocks
1. Follow Pressure Relief Procedure, page
12.
Repair
2. See FIG. 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.
Manual Valve Assembly
Side Block
Screen Screw Seal
Screen Screw
Swivel Fitting
FIG. 7. Side Block Components
Screen
2
Side Seal Assembly
Check Valve Assembly
Spring
Check Valve Retainer
Side Seal
O-Ring
311322K 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.
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 FIG. 8.
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 promote leakage. See FIG. 9.
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 FIG. 9.
.065 in.
(1.65 mm)
.018 in.
(0.46 mm)
FIG. 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.
FIG. 8. Tighten Check Valve Retainer
14 311322K
One quarter of a
full turn (max.)
16.Return gun to service. See Daily Start-Up,
page 11.
Repair
Mixing Chamber and Gun Block
1. Follow Pressure Relief Procedure, page
12.
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.
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.
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.
311322K 15
Repair
R-Side Block
O-Ring
Mixing Chamber
2
Gun Block
Air Cap
Flat Tip
Air Seal
Gun Block
Screws
FIG. 10. Mixing Chamber and Gun Block
!
Side Block
Screws
A-Side Block
16 311322K
Repair
End Cap and Air Piston
1. Follow Pressure Relief Procedure, page
12.
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 gun block, see Mixing Chamber
and Gun Block, page 15.
4. See FIG. 11. Use a 3/16 in. wrench or needle-nose pliers to hold end of piston shaft
while unscrewing mixing chamber by hand.
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
FIG. 11. End Cap and Piston Assembly
311322K 17
Cylinder
Clamp
Mixing Chamber
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.
14.Install piston assembly into the air cylinder.
See FIG. 11.
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
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.
Piston Shaft
Retaining Ring
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 alter-
Piston Shaft
O-Rings
Piston
Piston O-Ring
FIG. 12. Piston Assembly
18 311322K
nately and evenly to prevent leakage.
20.Return gun to service. See Daily Start-Up,
page 11.
Repair
End Cap O-ring and Safety Stop Seal
1. Follow Pressure Relief Procedure, page
12.
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. Remove socket head screw and clamp
from rear of air cylinder.
4. See FIG. 13. Use a retaining ring pliers to
remove retaining ring. Ring retains end cap
position in air cylinder.
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
Socket Head
Cap Screw
FIG. 13. End Cap Assembly
End Cap/Safety
Stop Assembly
Cylinder Clamp
311322K 19
Repair
7. See FIG. 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.
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
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.
Stop Knob
Stop Spring
End Cap
Stop Pin
Set Screws
Cup Seal
End Cap O-Ring
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 FIG. 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.
FIG. 14. Safety Stop Assembly
20 311322K
Repair
Trigger/Air Valve
1. Follow Pressure Relief Procedure, page
12.
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.
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.
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
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.
311322K 21
Repair
O-Rings
Valve Spool
Valve Liner
Spring
Seat
Optional Air Hose and Nipple
1/8 in. Pipe
Plug
1/16 in.
Pipe Plug
Valve Spring
Valve Retainer Nut
FIG. 15. Trigger/Air Valve Assembly
Lock Nut
Trigger Mounting Screw
Trigger Lever
22 311322K
Air Passage Diagrams
Use thread sealant when reinstalling any
threaded components. In addition, reinstall
all set screws flush to outside surface of
gun handle.
Repair
.250 dia.
.687 dia.
.3125 dia.
1/8 in. drill
1/8 in. drill
.3125 dia.
.375 dia.
8-32 UNC-GH3 TAP
1.750 dia.
5/32 in. drill
1.858 dia.
8-32 UNC-2B TAP
FIG. 16: Air Cylinder Air Passages
311322K 23
Repair
1/8 in. drill
10-32 UNC-2B TAP
1/8 in. drill
5/32 in. drill
1/8 in. drill
10-32 UNC-2B TAP
5/32 in. drill
1/2 in. dia.
5/8-18 UNC-2B TAP
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 (3)
10-32 UNC-2B TAP
1/8 in. NPT TAP
1/16 in. NPT TAP
5/32 in. drill
FIG. 17: Handle Air Passages
1/8 in. drill
1/8 NPT TAP
24 311322K
Notes
Repair
311322K 25
Parts
Parts
GAP Pro Spray Gun Assembly
9
29
27
16 22
19
18
Round Spray
28
33
34
32
35
1
2
1
11
8
28
29
23
26
14
15
31
23
1513
14
27
26
20
!
21
7
12
31
9
2
10
17
19
13
6
16
2
3, 42
54
FIG. 18: GAP Pro Final Assembly
26 311322K
GAP Pro Spray Gun Assembly
Parts
Ref.
No. Part No. Description Qty.
1 117634 FITTING, R-swivel 1
2 117635 FITTING, A-swivel 1
3 15B772 HOSE, air; 1/4 npt (fbe) x
23 in. (584 mm)
4 295596 PLUG, coupler 1
5 295597 COUPLER 1
6 296964 BOLT, side block (pack of 2) 7 115719 O-RING, fluoroelastomer 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 2
15 296959 SPRING (pack of 2) 16 296939 SCREEN; 80 mesh
(pack of 10)
17 296940 SCREW, screen, A-side 1
18 296941 SCREW, screen, R-side 1
19 296942 SEAL, screw, screen
(pack of 2)
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 1
1
23 248128 O-RING, side seal
(pack of 6)
26 SEAL, side 2
27 MIXING CHAMBER 1
28 SEAL, air 1
29 CAP, air 1
30 FITTING, straight 4
31 PLUG or ELBOW 2
40 TOOL, cleanout 1
41 TOOL, cleanout 1
42 100030 Fitting 1
See Table 1 for part numbers by model.
-
-
2
Table 1: Round Pattern Guns, Parts by Model Number
Round Pattern Gun Model No.
Ref.
No.
26 296956 296956 296956 296956 296956 296956
27 296846† 296846† 296847† 296848† 296849† 296850†
28 296946 296946 296946 296946 296946 296946
29 296951 296951 296951 296951 296951 296487
31 295662 112307 295662 295662 295662 295662
40 118369 118369 296293 118369 296296 296297
41 296289 296289 296296 296297 296302 296490
This model uses qty. 2 each of items 1 and 2.
Kit includes qty. 2 each of items 23 and 26.
† Kit includes (1) 27, (1) 28, and cleanout tools 40 and 41.
311322K 27
295557 295558 295559 295560 295561 295562
(00 Round) (00 Recirc) (01 Round) (02 Round) (03 Round) (04 Round)
Parts
GAP Pro Spray Gun Handle Assembly
67
52
81
85
57
57
55
68
82
72
79
57
64
78
57
51
74
76
77
7566
84
63
59
65
56
83
70
62
53
71
73
60
80
61
58
54
69
86
FIG. 19: GAP Pro Handle Assembly
28 311322K
GAP Pro Spray Gun Handle Assembly
Parts
Ref.
No. Part No. Description Qty.
51 295435 SEAL, u-cup 1
52 295422 RING, retaining 1
53 296537 SCREW, cap, socket hd 1
54 106245 SCREW, cap, socket hd 2
55 296536 SCREW, set; socket hd 1
56 295662 PLUG, pipe 1
57 C20988 O-RING 6
58 112085 O-RING 4
59 103337 O-RING 1
60 C02032 NUT 1
61 295692 TRIGGER 1
62 116624 SCREW, set; socket hd 2
63 102279 SCREW, set; socket hd 2
64 296971 SPRING 1
65 296535 CLAMP, cylinder 1
66 108103 O-RING 1
67 168518 O-RING 1
68 295695 SCREW, cap; button hd 1
69 295671 SCREW, trigger 1
Ref.
No. Part No. Description Qty.
70 296538 RING, retaining 1
71 296866 LINER, valve 1
72 296527 SPOOL, valve 1
73 296867 NUT, retainer, valve 1
74 295434 SEAT, spring 1
75 295436 SPRING 1
76 296529 CAP, end 1
77 296530 KNOB 1
78 296526 PIN, stop 1
79 295416 SPRING, piston 1
80 296961 HANDLE, gun 1
81 296531 PISTON 1
82 296937 SHAFT, piston 1
83 295693 PLUG, pipe 1
84 296962 CYLINDER, air 1
85 114054 O-RING 1
86 295665 NIPPLE 1
Included in Handle Seal Repair Kit 296938
(purchase separately).
311322K 29
Parts
Accessories
Tool kit 296968 for GAP Pro spray gun.
Grease syringe 296382; syringe filled with
grease for gun maintenance.
Gun Wand Kit
Kit 296984; extends GAP spray gun front-end
21 in.
Pour Package (296983) Components
Includes:
Pour fitting 297078 1
Polyflow tubing (3/8 in.
diameter x 1 ft. length)
28
29
(flat air cap required)
296165 1
(flat mix chamber required)
27
Mixing Chamber Cleanout Drills
Round Mixing
Chamber (27)
296846 118369
296847 296296
296848 296297
296849 296302
296850 296490
296851 296491
Mixing Chamber
Nozzle Cleanout Drill
FIG. 20: Pour Package Components
Mixing Chamber
Port Cleanout Drill
296289
296293
118369
296296
296297
296302
30 311322K
Technical Data
Technical Data
Category Data
Maximum Fluid Working Pressure 3000 psi (20.7 MPa, 207 bar)
Minimum Air Inlet Pressure 100 psi (0.7 MPa, 7 bar)
Maximum Air Inlet Pressure 125 psi (0.9 MPa, 9 bar)
Maximum Output (flow rate) 40 lb/min (18 kg/min)
Air Inlet Size 1/8 npt
A Component (ISO) Inlet Size -5 JIC; 1/2-20 UNF
R Component (Resin) Inlet Size -6 JIC; 9/16-18 UNF
Length 7 in. (17.8 cm)
Height 7.25 in. (18.4 cm)
Width 4.4 in. (11.2 cm)
Weight 2.34 lb (1.06 kg)
Wetted Parts Stainless steel, carbon steel, brass, nylon,
acetal, PTFE, aluminum
311322K 31
Graco Standard Warranty
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
32 311322K
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