Page 1
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.
311322L
EN
Page 2
Contents
Gun Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Two-Component Material Information . 6
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 6
For all applications except spray foam . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7
Foam Resins with 245 fa Blowing Agents . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Major Components . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . 11
Keep A and B Components Separate . . . . . . . . 11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Valves . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air Hose Configurations . . . . . . . . . . . . . . . . . . 13
Initial Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Daily Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Daily Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Procedure . . . . . . . . . . . . . . . . 15
Grease Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Side Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mixing Chamber and Gun Block . . . . . . . . . . . . 18
End Cap and Air Piston . . . . . . . . . . . . . . . . . . . 20
End Cap O-ring and Safety Stop Seal . . . . . . . 22
Trigger/Air Valve . . . . . . . . . . . . . . . . . . . . . . . . 24
Air Passage Diagrams . . . . . . . . . . . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GAP Pro Spray Gun Assembly . . . . . . . . . . . . . 28
GAP Pro Spray Gun Handle Assembly . . . . . . . 30
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 311322L
Page 3
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
311322L 3
Page 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
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury,
including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction;
burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically
impermeable gloves, protective clothing and foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled or
swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards
of the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
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 surgi-
cal 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.
4 311322L
Page 5
Warnings
WARNING
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.
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 Technical
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.
311322L 5
Page 6
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized
particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you
are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area
must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include
a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period
specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside
the work area is recommended:
6 311322L
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE:
TIME:
____________
____________
Page 7
Important Two-Component Material Information
For all applications except spray
foam
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you
are trained, qualified, and have read and understood
the information in this manual and in the fluid manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors, and
atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a
properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according
to instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in
the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer
recommendations, including those regarding handling
of contaminated clothing. After spraying, wash hands
and face before eating or drinking.
Material Self-ignition
Keep Components A and B
Separate
Cross-contamination can result in cured material in fluid
lines which could cause serious injury or damage equipment. To prevent cross-contamination:
• Never interchange component A and component B
wetted parts.
• Never use solvent on one side if it has been contaminated from the other side.
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become
suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all
wetted parts.
• Always use a sealed container with a desiccant dryer in
the vent, or a nitrogen atmosphere. Never store ISO in
an open container.
• Keep the ISO pump wet cup or reservoir (if installed)
filled with appropriate lubricant. The lubricant creates a
barrier between the ISO and the atmosphere.
• Use only moisture-proof hoses compatible with ISO.
• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in
use.
• Always lubricate threaded parts with an appropriate
lubricant when reassembling.
Some materials may become self-igniting if applied too
thick. Read material manufacturer’s warnings and Safety
Data Sheet (SDS).
311322L 7
NOTE: The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity, and the
temperature.
Page 8
Important Two-Component Material Information
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures above
90°F (33°C) when not under pressure, especially if agitated.
To reduce frothing, minimize preheating in a circulation system.
Changing Materials
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have
amines on the B (hardener) side. Polyureas often
have amines on the B (resin) side.
8 311322L
Page 9
Overall View
Major Components
Safety Stop
Overall View
A-Manual Valve
A-Screen
Screw
R-Manual
Valve
Trigger
FIG. 1. Major Components (shown with round spray tip)
Spray Tip
R-Screen
Screw
311322L 9
Page 10
Overall View
O-Ring
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)
10 311322L
Page 11
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.
Operation
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.
311322L 11
Page 12
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,
turn the safety stop knob clockwise. See
FIG. 3.
push in and
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
To disengage the safety stop,
2.
push in
and turn the safety stop knob counterclockwise. See FIG. 4.
F
IG
. 4. Disengage Safety Stop
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
12 311322L
FIG. 5. Manual Valves
Page 13
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
311322L 13
Page 14
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 13.
2. Trigger gun multiple times to ensure proper
mixing chamber movement.
3. Open both manual valves, page 12.
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 12.
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
15.
2. Shutdown proportioning unit as required.
3. Grease gun, page 15.
14 311322L
Page 15
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 13.
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
15.
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 13.
311322L 15
Page 16
Repair
Repair
Shutdown proportioner and allow chemicals
to cool before performing any repair procedures.
Side Blocks
1. Follow Pressure Relief Procedure, page
15.
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
16 311322L
Page 17
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.
FIG. 8. Tighten Check Valve Retainer
311322L 17
One quarter of a
full turn (max.)
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 14.
Page 18
Repair
Mixing Chamber and Gun
Block
1. Follow Pressure Relief Procedure, page
15.
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 14.
To repair side blocks, see Side Blocks,
page 16.
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.
18 311322L
Page 19
R-Side Block
Repair
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
311322L 19
Page 20
Repair
End Cap and Air Piston
1. Follow Pressure Relief Procedure, page
15.
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 16.
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 18.
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 18.
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
20 311322L
Mixing Chamber
Cylinder
Clamp
Page 21
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.
Repair
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 FIG. 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.
Piston O-Ring
FIG. 12. Piston Assembly
311322L 21
Piston
Piston Shaft
O-Rings
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 14.
Page 22
Repair
End Cap O-ring and Safety
Stop Seal
1. Follow Pressure Relief Procedure, page
15.
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 16.
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
22 311322L
Page 23
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.
Repair
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 14.
FIG. 14. Safety Stop Assembly
311322L 23
Page 24
Repair
Trigger/Air Valve
1. Follow Pressure Relief Procedure, page
15.
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 16.
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 14.
24 311322L
Page 25
O-Rings
Valve Spool
Valve Liner
Spring
Seat
Optional Air Hose and Nipple
1/8 in. Pipe
Plug
1/16 in.
Pipe Plug
Repair
Valve Spring
Valve Retainer Nut
FIG. 15. Trigger/Air Valve Assembly
Lock Nut
Trigger Mounting Screw
Trigger Lever
311322L 25
Page 26
Repair
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.
.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
26 311322L
Page 27
1/8 in. drill
10-32 UNC-2B TAP
Repair
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
311322L 27
Page 28
Parts
Parts
GAP Pro Spray Gun Assembly
9
29
27
16 22
19
18
Round Spray
28
33
34
32
35
1
29
28
1
2
11
8
23
26
14
15
31
23
1513
14
27
26
20
!
21
7
12
31
9
2
FIG. 18: GAP Pro Final Assembly
28 311322L
10
17
19
13
16
6
2
3, 42
54
Page 29
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
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.
311322L 29
295557 295558◆ 295559 295560 295561 295562
(00 Round) (00 Recirc) (01 Round) (02 Round) (03 Round) (04 Round)
Round Pattern Gun Model No.
Page 30
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
30 311322L
Page 31
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).
311322L 31
Page 32
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
32 311322L
Page 33
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
311322L 33
Page 34
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,
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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2006, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
contact your Graco distributor or call to identify the nearest distributor.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 311322
International Offices: Belgium, China, Japan, Korea
Graco Headquarters: Minneapolis
www.graco.com
Revised July 2015
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