Operation - Maintenance GX-7 DI Auto-Robotic Spray Gun 313380B EN For use with non-flammable polyurethane foams, two-component coating systems (polyureas), and some two-component epoxy systems. For professional use only. See page 2 for model information. 3500 psi (24 MPa, 240 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. ti19777a
Models Contents Models................................... 2 Warnings................................. 3 Important Two-Component Material Information. 5 Isocyanate Conditions.................... 5 Material Self-ignition...................... 5 Keep Components A and B(R) Separate...... 5 Moisture Sensitivity of Isocyanates........... 5 Foam Resins with 245 fa Blowing Agents...... 5 Component Identification.................... 6 Centerline Components................... 7 Overview.................................. 8 Theory of Operation...................... 8 Safety Position.......................... 8 Loss Of Air Pressure...................... 9 Coupling Block......................... 10 Set Up................................... 11 Grounding............................. 11 Spray Gun............................. 11 Install Coupling Block.................... 11 Startup.................................. 12 Shutdown................................ 12 Pressure Relief Procedure.................. 13 Maintenance.............................. 14 Gun Service Kits........................ 14 Clean Spray Gun Procedure............... 15 Flush Gun............................. 15 Remove Coupling Block.................. 15 Models Repair................................... 16 Replace End Cap and Air Piston Assembly... 16 Service Screen Screw.................... 17 Remove Centerline Components........... 17 Install Centerline Components............. 18 Clean Mixing Module..................... 18 Install Mixing Module..................... 19 Valving Rod Adjustment.................. 20 Clean Pattern Control Disc................ 20 Replace Rear Seal Packing................ 21 Troubleshooting........................... 22 Parts.................................... 24 GX-7 DI Model, 22100A-AUTO-R........... 24 Coupling Block Assembly, 295383.......... 26 Coupling Block Assembly, 24N995,24N996... 27 Accessories.............................. 28 GX-7 DI Model Specifications.............. 28 Tip Kits................................ 29 Technical Data............................ 30 Graco Standard Warranty................... 32 Graco Information......................... 32 Part No. Description Includes: Mix Module Coupling Block Tip 22100A-AUTO-R GX-7 DI-Auto-R None None None 24N552 GX-7 DI-Auto-R 296903 (Qty 2) 24N995 296882 (Qty 2) 296883 (Qty 2) Intended for circulating spray applications. 2 313380B
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. WARNING PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: Protective eyewear, and hearing protection. Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer 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 MSDSs 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. Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment. SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. Engage trigger lock when not dispensing. Do not point dispensing device at anyone or at any part of the body. Do not put your hand over the fluid outlet. Do not stop or deflect leaks with your hand, body, glove, or rag. Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment. Tighten all fluid connections before operating the equipment. Check hoses and couplings daily. Replace worn or damaged parts immediately 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. Do not use pail liners unless they are antistatic or conductive. Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem. Keep a working fire extinguisher in the work area. 313380B 3
Warnings WARNING 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 from distributor or retailer. Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only. Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards. Make sure all equipment is rated and approved for the environment in which you are using it. Use equipment only for its intended purpose. Call your distributor for information. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not kink or over bend hoses or use hoses to pull equipment. Keep children and animals away from work area. Comply with all applicable safety regulations. PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents. Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility. 4 313380B
Important Two-Component Material Information Important Two-Component Material Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Spraying or dispensing 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. Material Self-ignition Some materials may become self-igniting if applied too thick. Read material manufacturer s warnings and material MSDS. Keep Components A and B(R) 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(R) 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 crystals, which 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. NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90 F (33 C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. 313380B 5
Component Identification Component Identification J H A L E F G B D K C ti19778a FIG. 1: Overall View Key: A Gun Block B Air Cap C Manual Valves D Coupling Block E Valving rod F Lock Nut G Piston Rod H Air Cap Port J Safety Stop K Air Open Port L Air Closed Port 6 313380B
Component Identification Centerline Components AA AB AD AK AL AM AE AD AF AB AH AG AP AJ AR AR ti19779a AS FIG. 2: Centerline Components Key: AA R-Screen Screw AB Screen AC Gun Block AD Check Valve AE Mixing Module AF Mixing Module Retainer AG Pattern Control Disc (PCD) AH PCD Retainer AJ Air Cap AK Rear Seal Gland AL Rear Packing AM Rear Seal Retainer Assembly AP A-Screen Screw AR Coupling Block Gasket AS Coupling Block Mounting Screw 313380B 7
Overview Overview Theory of Operation The air open/close ports actuate the piston. When air is applied to the OPEN port, the air pressure forces the piston to the rear of the gun, retracting the valving rod and opening the impingement ports. This allows the material to mix and exit through the PCD. When air is applied to the CLOSE port, the air pressure forces the piston to the front of the gun, extending the valving rod and closing the impingement ports. The valving rod cleans the mix module and seats against the PCD. An optional air cap port is provided to aid in dispensing. It requires a controlled air source and is a constant output. Safety Position The gun has a two-position valving rod rear stop. The CLOSED (SERVICE) position allows for minimal rearward travel of the valving rod but will not allow chemical to discharge. The OPEN position allows full rearward travel of the valving rod and permits the gun to dispense. Whenever the gun is not spraying, set to CLOSED (SERVICE) position. Engage Safety Stop To engage safety stop, push in and turn the safety stop clockwise to place the gun in the CLOSED (SERVICE) position. Valving Rod Mixing Module CLOSED (SERVICE) When not spraying in safety position. PCD FIG. 4: Safety Stop - Closed FIG. 3: Mixing Module ti19780a 8 313380B
Overview Disengage Safety Stop To disengage the safety stop, push in and turn the safety stop counterclockwise to place the gun in the OPEN position (red band is exposed). Red Band Loss Of Air Pressure Valving rod actuation is controlled by air pressure. In the event of loss of air pressure, the valving rod will remain retracted, the impingement ports will remain open, and the gun will continue to dispense. To stop dispensing, do one of the following. Engage the piston safety stop. Refer to Engage Safety Stop, page 8. Close the manual valves. Refer to FIG. 6, page 9. OPEN Red band exposed when spraying. FIG. 5: Safety Stop - Open Close Manual Valves Closing the manual valves prevents material from entering gun. For your own safety, close manuals valves before servicing gun. FIG. 6: Close Manual Valves ti19781a 313380B 9
Overview Coupling Block Chemical hoses are joined to the gun block by the coupling block to ease the installation and the removal of the gun. Open Manual Valves Use a 5/16 in. nut driver to turn the manual valve counterclockwise. Manual Valves Two manual valves located on the coupling block control the flow of each chemical component to the gun. NOTE: Actuating the gun with manual valves closed may cause crossover if any residual chemical remains in the gun ports. NOTICE Never open the manual valve unless the coupling block is secured to the gun or the coupling block is pointed into a waste container. FIG. 7: Open Manual Valves ti19782a Close Manual Valves Use a 5/16 in. nut driver to turn the manual valve fully clockwise. NOTICE To prevent accidental gun operation, always set the safety stop to CLOSED (SERVICE), close both manual valves, and disconnect the air supply. Installation and Removal To prevent release of pressurized chemicals, close both manual valves before removing the coupling block. 10 313380B
Set Up Set Up Grounding 8. Proceed with the Startup and Shutdown procedures. Install Coupling Block 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. Spray Gun 1. Replace nicked, damaged, or worn coupling block gaskets. 2. With gaskets in place, fit the coupling block to the gun block. 3. Insert the coupling block mounting screw and use a 5/16 in. nut driver to tighten to the gun block. 1. Close both manual valves on the coupling block. 2. Connect the coupling block to the A and B(R) fluid hose. 3. Pressurize both A and B(R) chemical hoses. Check for leaks. See Proportioner manual. 4. Bleed the air from the chemical hoses. a. Use a separate waste containers for A-ISO and B(R)-Resin. b. Hold the coupling block with the exit ports pointed into a waste container. c. Open one manual valve at a time to dispense into a waste container. d. Bleed each side until the chemical leaving hoses is free of air. e. Close both manual valves. 5. Use a cloth soaked in gun cleaner to clean the coupling block and mating surfaces. 6. Set the safety stop to CLOSED (SERVICE). 7. Install the coupling block to gun. Coupling Block Gaskets Coupling Block Mounting Screw FIG. 8: Install Coupling Block ti19783a 313380B 11
Startup Startup Shutdown Ensure the gun is attached to the coupling block and air is supplied to the open and close ports. Ensure the proportioning unit is at the desired temperature and pressure. Properly ground the equipment to avoid static sparking that may result in fire or explosion. 1. Connect the air supply to the open and close gun ports. 2. Adjust the air cap air pressure if being used. 3. Adjust the rear seal retainer. 4. Open both manual valves. See Coupling Block section, page 10. 5. Set the safety stop to OPEN. 6. Test the spray on a disposable surface. NOTE: Follow daily shutdown procedure when the gun is out of service for any length of time, or for mid- or end-of-day service. See Clean Spray Gun Procedure, page 15. 1. Set the safety stop to OPEN. 2. Close both manual valves. 3. Disconnect the air supply from the gun. 4. Shutdown the proportioning unit as required. See Proportioner manual. 5. Clean as required. See Clean Spray Gun Procedure, page 15. NOTE: Do not disassemble the gun daily for cleaning if it is operating properly. However, if the gun is removed from the coupling block, it must be flushed and cleaned thoroughly. 12 313380B
Pressure Relief Procedure Pressure Relief Procedure 4. Deactivate the gun and set the safety stop to CLOSED. Relieve pressure before cleaning or repairing gun. 1. Close both manual valves. If fluid in the hose and the proportioner is still under pressure, follow the Pressure Relief Procedure in proportioner manual. To relieve pressure in the hose after the gun is removed, place the fluid manifold over containers, facing away from you. Very carefully open the fluid valves. Under high pressure, fluid will spray sideways from fluid ports. See FIG. 11. ti19781a FIG. 9: Close Manual Valves 2. Set the safety stop to OPEN. 3. Actuate the gun onto cardboard or into a waste container to relieve pressure. FIG. 11: Open Manual Valves TI2484a ti19784a FIG. 10: Activate Gun 313380B 13
Maintenance Maintenance Gun Service Kits Use either the 1-Quart Gun Service Kit (296980) or 3-Gallon Gun Service Kit (296981) to perform daily flushing of the spray gun without disassembly. FIG. 12: 1-Quart Gun Service Kit FIG. 13: 3-Gallon Gun Service Kit For more information about the 1-Quart Gun Service Kit, see Manual 311340. For more information about the 3-Gallon Gun Service Kit, see Manual 311341. 14 313380B
Maintenance Clean Spray Gun Procedure To avoid static sparking that may result in fire or explosion, ensure all equipment in the cleaning procedure is grounded. Do not clean on or near foamed or coated surfaces or any other flammable surfaces or objects. NOTE: Inspect the air cap, PCD, mixing module, and the gun block for build up of material and clean as required. Do not use metal cleaning devices to clean plastic components. Flush Gun Thoroughly flush the gun block with gun cleaner before removing the valving rod or mixing components from the gun block. Also allow the chemicals in the spray gun to cool before cleaning. This procedures makes use of the 1-Quart or 3-Gallon Gun Service Kit. 1. Perform Pressure Relief Procedure, page 13. 2. Remove the gun from the coupling block. 3. Attach the service block of the gun service kit to the spray gun, and then tighten using 5/16 in. nut driver. 4. Pressurize the Service Kit container up to 100 psi. DO NOT EXCEED 100 psi (0.7 MPa, 7 bar). 5. Open one manual valve on the service block. 6. Connect air to the gun. Set the safety stop to OPEN. 7. Hold the gun against a grounded waste container. 8. Activate the gun and Gun Service Kit. Spray into a waste container until there is a fine, unobstructed mist of gun cleaner. 9. Release both triggers and close the manual valve on the service block. 10. Repeat steps 5-7 for other side of the gun. 11. After initial cleaning, remove the air cap, PCD retainer, and PCD. Flush a second time to ensure thorough cleaning. 12. Remove the service block of the gun service kit from spray gun. 13. Set the safety to CLOSED (SERVICE). 14. Disconnect the air supply. To avoid static sparking that may result in fire or explosion, ensure all equipment in the flushing procedure is grounded. Do not flush on or near foamed or coated surfaces. 1. Perform Pressure Relief Procedure, page 13. 2. Loosen the B(R)-Screen screw and then remove by hand. 3. Use the flush can to thoroughly flush the screen screw and screen screw cavity. 4. Loosen the A-Screen screw and then remove by hand. 5. Use the flush can to thoroughly flush the screen screw and screen screw cavity. 6. Service the gun by following Maintenance procedures, page 14. Remove Coupling Block 1. Perform Pressure Relief Procedure, page 13. 2. Set the safety stop to CLOSED (SERVICE). 3. Disconnect the air hose. 4. Close both manual valves. 5. Remove the coupling block mounting screw. 6. Separate the coupling block from the gun. 7. Wipe the mating surfaces of the gun block and the coupling block to remove residual chemical. 8. Cover exposed openings with grease. 15. Clean screens, check valves and screen screw as required. Refer to Service Screen Screw, page 17. 313380B 15
Repair Repair 7. Remove the end cap from the air cylinder. Shutdown the proportioner and allow chemicals to cool before servicing gun. Clean A and B(R) components in separate containers to avoid cross contamination. Replace End Cap and Air Piston Assembly Piston Assembly End Cap 8. Inspect the end cap o-ring. Replace if damaged. Install the new end cap o-ring after lightly coating it with grease. 9. Inspect the rear U-cup seal or o-ring for damage. Replace if necessary. If removed, ensure cup faces the front of the air cylinder when replacing. 10. By hand, pull the piston assembly out of the air cylinder and inspect the o-ring for damage. Replace if necessary. Apply grease prior to installation. 11. If air was escaping around the piston rod during operation, replace the front u-cup seal or o-ring. Apply grease and ensure cup faces rear of the air cylinder. 12. Insert the piston and rod assembly into the air cylinder. Take care to not damage the front cup seal as the rod passes through. Spacer Rear U-Cup Seal 13. Insert the piston spring and the piston spacer. 14. Reinstall the end cap into the air cylinder. 15. Retighten the rear socket head cap screw and the cylinder clamp to the handle. ti19785a Piston Spring Cylinder Clamp and Screw FIG. 14: End Cap and Air Piston Assembly 1. Perform Pressure Relief Procedure, page 13. 2. Clean the gun according to Clean Spray Gun Procedure, page 15. 16. Adjust the valving rod; see Valving Rod Adjustment, page 20. 17. Slide the safety stop onto rear of the air cylinder. Push the safety stop partially forward and rotate clockwise to set to OPEN. 18. Set the safety stop to CLOSED (SERVICE). 19. Tighten the rear packing nut. 3. Loosen the rear packing nut 1-2 turns. 4. Push the safety stop partially forward, rotate counterclockwise, and slide the safety stop off air cylinder. 5. Disconnect the air supply from the gun. 6. Remove the rear head cap screw and the cylinder clamp from the air manifold. 16 313380B
Repair Service Screen Screw 1. Flush the gun according to Clean Spray Gun Procedure, page 15. 2. Unthread the screen screw from the gun block. 3. Remove the check valve from the screen screw. Clean the valve with gun cleaner and inspect for damage. Replace if necessary. 4. Remove screen from screen screw. Soak in gun cleaner or replace if clogged or dirty. 5. Clean the screen screw cavity. If any particles are visible, clean with clean out drills and flush with gun cleaner. NOTICE Any material left in the cavity on the downstream side of the screen will clog the mixing module. Ensure no there are no foreign material is left after cleaning. 6. Inspect the screen screw seal for damage. Replace if necessary. 7. Reinstall the screen screw in the gun block. Torque to 160 in-lb (18 N m). 8. Flush the gun with the mixing module removed. Remove Centerline Components Refer to FIG. 2 for diagrams of centerline components. 1. Flush the gun according to Clean Spray Gun Procedure, page 15. NOTE: To remove PCD that is stuck, set the safety stop to OPEN, activate the gun to unseat it. Set the safety stop to CLOSED (SERVICE). 7. Remove the mixing module retainer. 8. Set the safety stop to OPEN. Activate and deactivate the gun to unseat it. Remove the mixing module off the end of the valving rod. Set the safety stop to CLOSED (SERVICE). 9. Remove air from gun. NOTICE To avoid damage, do not use sharp object or metal tools to remove the mixing module. 10. Remove the gun block from the cylinder assembly by removing the four socket head screws. 11. Slide the gun block away from the air cylinder assembly. Take caution not to damage the valving rod. 12. Inspect the valving rod for damage and replace as required. Clean and remove any buildup of mixed material from the rod using a cloth soaked in gun cleaner or fine steel wool. NOTE: If the valving rod is replaced, perform Valving Rod Adjustment, page 20. 13. Clean all components thoroughly. Use brushes and clean-out tools to remove the residual chemical from metal components. Use cotton swabs soaked in gun cleaner to clean plastic components. 14. Coat the threads and mating surfaces of the gun block and the gun block bracket with grease, and reassemble. 15. Inspect the gun block for damage. 2. Connect the air supply to the gun. Set the safety stop to OPEN. 3. Remove the air cap. 4. Activate the gun and hold it to relieve pressure on the PCD retainer. 5. Remove the PCD retainer by turning it counterclockwise. 6. Remove the PCD from mixing module retainer. 313380B 17
Repair Install Centerline Components Before installation, ensure all gun components are clean and dry. Lubricate all moving parts and threads. 1. Install the rear packing gland with a packing wrench. Tighten onto the gun block. 2. Install the rear packing retainer loosely. 3. Carefully slide the gun block onto the valving rod toward the air cylinder. Install the gun block onto the gun block mounting bracket. 4. Connect the air supply to the gun. 5. Activate the gun and slide the mixing module over the end of valving rod. 6. Ensure the valving rod alignment pin enters the alignment slot in gun block. Keep the gun activated. 7. With the gun activated, thread the mixing module retainer or PCD body with packing installed, by hand, and then wrench tighten. Torque to 150 in-lb (17 N m). Clean Mixing Module 1. Flush the gun according to Clean Spray Gun Procedure, page 15. 2. Connect the air supply to gun. Set the safety stop to OPEN. 3. Remove the air cap by hand. 4. Activate the gun and hold it to relieve pressure on the PCD retainer. 5. Remove the PCD retainer by turning it counterclockwise. 6. Remove the PCD from the mixing module retainer. NOTE: To remove a PCD that is stuck, set the safety stop to OPEN, activate the gun to unseat it. Set the safety stop to CLOSED (SERVICE). 7. Remove the mixing module retainer. 8. Set the safety stop to OPEN. Activate the gun to unseat it. Remove the mixing module from the end of valving rod. Set the safety stop to CLOSED (SERVICE). NOTICE To avoid damage to the module and gun block, do not overtighten the mixing module retainer. 8. Deactivate the gun. 9. Install the PCD over the end of the mixing module retainer. 10. Thread the PCD retainer onto the gun block. Hand tight. 11. Rotate flat PCD to adjust the orientation as required. 12. Adjust the valving rod. See Valving Rod Adjustment, page 20. 13. Thread the air cap into place; hand tight. 18 313380B
Repair 9. Inspect the valving rod for damage and replace as required. Use a cloth soaked in gun cleaner or steel wool to clean and remove the buildup of mixed material from the rod. NOTE: If the valving rod is replaced, reset the forward stop. 10. Clean the mixing module. NOTE: Ensure the cleanout tool size matches the module size used. a. Insert the cleanout tool into a pin vise. b. Use the cleanout tool to clean the module ports. Take care not to insert the tool too far, causing damage to the inside bore of the module. Use a cotton swab soaked in gun cleaner to clean the bore of the module. Install Mixing Module 1. Install safety stop; leave it in OPEN position. 2. Connect the air supply to gun. 3. Activate the gun and slide the mixing module over the end of the valving rod. 4. Ensure the valving rod alignment pin enters the alignment slot in gun block. Keep the gun activated. 5. With the gun activated, thread the mixing module retainer or PCD body with packing installed, by hand, and then wrench tighten. NOTICE To avoid damage to the module and gun block, do not overtighten the mixing module retainer. 6. Deactivate the gun. 7. Install the PCD over the end of the mixing module retainer. 8. Thread the PCD retainer onto the gun block. Hand tight. 9. Rotate flat PCD to adjust orientation as required. FIG. 15: Clean Module Ports 10. Adjust the valving rod. See Valving Rod Adjustment, page 20. 11. Thread the air cap into place; hand tight. 12. Slide the safety stop onto the rear of the air cylinder. Push the safety stop partially forward and rotate clockwise to set to OPEN. Module PCD Body Retainer O-ring Air Cap PCD (Note orientation of fan tip) PCD Retainer ti19786a FIG. 16: Install Mixing Module 313380B 19
Repair Valving Rod Adjustment The valving rod requires adjustment in only the following instances: disassembly and service of air cylinder changing valving rod changing mixing module 1. Clean the gun according to Clean Spray Gun Procedure, page 15. 2. Connect the air supply to the gun. 3. Loosen the rear seal retainer assembly one or two turns. 4. Loosen the locknut from the valving rod three or four turns. Clean Pattern Control Disc 1. Set the safety stop to CLOSED (SERVICE). 2. Close both manual valves. 3. Turn off the air to the air cap. 4. Use a cotton swab soaked in gun cleaner to clean external surface of material build up. Light scrubbing with a impinger cleanout brush may also be required. a. Activate the gun to clean the orifice area. NOTE: It is not always possible to clean all material build-up from the PCD while assembled to the gun. In this case, remove the PCD and clean the inside radius of the disc. 5. Remove the safety stop. 6. Use a 5/16 in. nut driver through the rear of the gun to thread the valving rod forward to engage the PCD. When the valving rod contacts the PCD tighten another 1/10 turn. 7. Carefully maintain position of the valving rod and tighten the locknut against the piston rod. 8. Retighten the rear seal retainer assembly. ti19787a FIG. 17: Pattern Control Disc (PCD) 20 313380B
Repair Replace Rear Seal Packing ti19788a FIG. 18: Rear Seal Packing 1. Perform Pressure Relief Procedure, page 13. 2. Perform Remove Centerline Components, page 17. 3. Unscrew the rear seal retainer from the rear seal gland. 4. Remove and replace the rear seal packing. Apply grease prior to installation. 5. Screw the rear seal retainer onto the rear seal gland. Finger tight only. 6. Slide the gun block onto the valving rod. 7. Fasten the gun block onto the gun block mount. Use medium strength thread locker on screw threads. 8. Screw the air cap hose assembly onto the gun block. 313380B 21
Troubleshooting Troubleshooting Follow Pressure Relief Procedure, page 13, before checking or repairing gun. NOTICE To prevent cross-contamination of the equipment s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. The gun is shipped with the A side on the left. The gun block and the screen screw are marked. Use the following table to check all possible problems and causes before disassembling gun. See Maintenance on page 14 for referenced procedures. Problem Cause Solution Gun does not fully actuate Safety lock engaged Disengage piston safety lock Air not vented on open/close ports Vent open air port when closing, vent close air port when opening Loss of air Check air source Fluid does not pour when gun is fully Closed manual valves Open valves actuated Plugged orifice ports Clean orifice ports Plugged check valves Clean check valves Safety lock engaged Disengage piston safety lock Gun actuates slowly Loss of air pressure Check air source Damaged piston o-rings Replace air piston o-rings Gun delays, then actuates abruptly Cured material around the purge rod Inspect purge rod, mix module, and orifices. Replace if necessary Gun does not actuate Air supply to gun is shut off Open air supply Foam build-up around front tip Clean off front tip. Pressure imbalance Plugged orifice ports Clean orifice ports Plugged check valves Clean check valves Plugged fluid screens Clean screens Fluid does not shut off when fluid Damaged fluid valves Replace valves are closed Leak between air cylinder and fluid housing Damaged o-ring Replace Material leaking out weep ports in fluid housing near air cylinder Mix module and rear seal worn Inspect and replace mix module and rear seal, clean fluid housing 22 313380B
Troubleshooting 313380B 23
Parts Parts GX-7 DI Model, 22100A-AUTO-R 16 27 9 15 18 22 12 1 41 40 39 21 29 45 42 44 43 2 30 36 34 23 33 32 31 38 37 53 17 36 7 5 46 30 35 28 48 5 13 ti19789a 6 25 3 7 24 4 14 4 47 26 19 20 11 8 52 50 48 49 48 49 51 10 1 Torque to 150 in-lb (17 N m) 24 313380B
Parts GX-7 DI Model, 22100A-AUTO-R Ref Part Description Quantity 001 96/0270/99 SCREW, shc, 8-32x0.75, ms 2 002 06105A FITTING, 10-32mx10-32f 1 elbow 003 556553 O-RING, -008, 75 duro 2 004 103337 PACKING, o-ring 4 005 295684 SCREW, cap, sockethead 8 006 557773 O-RING, (-009) brown 2 007 295496 SEAL, u-cup 2 008 102598 SCREW, cap, socket 1 head 009 295676 SPRING 1 010 295681 O-RING 1 011 295683 O-RING 1 012 295714 CAP, end, cylinder 1 013 16T717 CYLINDER, air 1 014 295690 CLAMP, cylinder 1 015 295716 STOP, stroke, long 1 016 295717 BODY, stop, two-position 1 017 295718 SPACER, stroke 1 018 296736 KIT, valving rod holder 1 019 295720 SPRING 1 020 295712 PISTON 1 021 06336 WASHER, seal 1 022 296863 KIT, 125 valvin rod 1 023 295431 NUT, lock 1 024 296896 KIT, mount, valve 1 025 22121-2 SUPPORT, cylinder 1 026 260761 PLATE, gx7 adapter 1 027 96/0458/99 SCREW, fhsc, 10-32x0.50, ms, e 1 028 122747 SCREW, shc, 10x0.75, 2 ms 029 295835 SCREW, screw, r 1 030 295794 SCREEN, 80 mesh 2 031 IP22101-1 HOUSING, gun 1 R block-machined 032 295836 GLAND, seal, rear 1 033 295417 PACKING, seal, rear 1 034 296864 KIT, retainer, rear seal 1 035 295834 SCREW, screen, a 1 036 296713 KIT, valve, check 1 037 295433 SCREW, mounting, block, 1 coupling 038 296128 KIT, gasket, block, coupling 1 Ref Part Description Quantity 039 22184NA AIR CAP, gx7di-auto 1 040 295429 RETAINER, pcd 1 041 295837 RETAINER, module 1 042 6310-113 CLAMP, 1/8 id hose 1 clamp 043 06108A GASKET, nylon 10-32 ftg. 1 044 299534 FITTING, 10-32ma x 1/8 1 hose barb 045 IP6310-30 TUBE, 1/8idx1/4od ureth 36 -ft 046 103808 SCREW, cap, sch 2 047 22121-4 PLATE, manifold cover 1 048 100020 WASHER, lock 4 049 96/0834/99 SCREW, shc, 10-32x1.25, ms, e 2 050 123371 FITTING, connector, 1 1/4tubx1/8npt, b 051 125383 FITTING, elbow, 1/8npt, 1 3/8tube, bras 052 295693 PLUG, pipe 1 053 296893 KIT, gun block mount 1 313380B 25
Parts Coupling Block Assembly, 295383 105 101 101 102 106 104 103 ti19790a Ref Part Description Quantity 101 295662 Pipe plug, flush seal, 1/8 in. 2 102 117634 R-swivel fitting 1 103 117635 A-swivel fitting 1 104 295693 Pipe plug, flush seal, 1/16 in. 2 105 296970 Manual valve assembly 2 106 296215 Coupling block 1 26 313380B
Parts Coupling Block Assembly, 24N995,24N996 208 206 202 205 209 205 205 201 204 207 205 Apply pipe sealant to all male threads prior to assembly. Torque fittings to 120-130 in-lb (14-15 N m) ti19795a 204 203 Quantity 24N995, BLOCK, coupling, gx7di, bed, sst 24N996, BLOCK, coupling, gx8, pu, cs Ref Part Description 201 296215 BLOCK, coupling, ss 1 1 202 295430 VALVE, manual 2 2 203 104071 PLUG, pipe 2 2 204 297085 FITTING, elbow,.125", st 2 112307 FITTING, street elbow 2 205 6301-61-SS FITTING, rducr, 1/4nptx1/8npt, fm, ss 4 C20895 FITTING, bushing, 1/4 x 1/8 4 206 262206 FITTING, swivel, 1/4npt x 6 jic 1 117506 FITTING, swivel, 1/4 npt x #6 jic 1 207 122991 ADAPTER, jic06x1/4, mm, ss, 6k, 316 1 122722 ADAPTER, jic06x1/4npt, mm, ms, 6k 1 208 262205 FITTING, swivel, npt x jic 1 122963 ADAPTER, swvl, jic05x1/4npt, fm, ms, 6 1 209 122727 ADAPTER, jic05x1/4npt, mm, ss, 6k, 316 1 117455 FITTING, nipple, 1/4 npt x #5 jic 1 313380B 27
Accessories Accessories GX-7 DI Model Specifications Module/Tip Data for Chemical Sprayed at 2500 PSI Module Kit Cleanout Drill Ref. No. Pattern Output (lbs/min) 296900 (#2) 246625 (.086 diameter) 296901 (#4) 248892 (.028 diameter) 296903 (#5) 246816 (.018 diameter) 296903 (#5) 246816 (.018 diameter) Fan Spray Pattern 212 12 in. wide 12 206 20 in. wide 22 213 12 in. wide 12 204 20 in. wide 21 212 10 in. wide 8 206 24 in. wide 11 204 18 in. wide 10 212 11 in. wide 4 213 12 in. wide 4 208 8 in. wide 4 Round Spray Pattern 40 4 in. diameter 8 55 7 in. diameter 9.5 70 8 in. diameter 9.75 90 10 in. diameter 9.75 Actual results may vary due to chemical system characteristics, temperature, pressure, and ratio. Includes appropriate cleanout drills. Mix Module Kit Part No. Size Ref. Quantity 296898 PEEK 018/018 1 296899 PEEK 028/028 1 Module Only Part No. Size Ref. 296902 #5 28 313380B
Accessories Tip Kits Round Tip Kits Part No. Size Quantity 296708 40 1 296709 46 1 296717 55 5 296710 70 1 296718 70 5 296711 80 1 296719 80 5 296712 90 1 296720 90 5 296694 100 1 296714 100 5 296695 110 1 296696 110 5 296697 125 1 296877 140 1 Part No. Flat Tip Kits No. Ref. Qty. 296698 202 1 296699 203 1 296700 204 1 296701 206 1 296702 208 1 296703 209 1 296704 210 1 296715 210 5 212.5 1 296882 SPEC 296705 212 1 296716 212 5 296706 213 1 213-1 296883 SPEC 296707 215 1 313380B 29
Technical Data Technical Data GX-7 DI Auto-Robotic Spray Gun US Metric Maximum fluid working pressure 3500 psi 24 MPa, 240 bar Air pressure operating range 100-125 psi 0.7-0.9 MPa, 6.9-8.6 bar Maximum fluid output 21 lb/min 9.5 kg/min Minimum fluid output 4 lb/min 1.8 kg/min Noise db(a) Maximum sound pressure* 77.4 db(a) 100 psi (0.7 MPa, 7 bar) @ 1.5 SCFM Maximum sound power** 84.4 db(a) 100 psi (0.7 MPa, 7 bar) @ 1.5 SCFM Inlet/Outlet Sizes Air open 3/8 tube push-lok Air close 1/4 tube push-lok 295383 Coupling Block: A-component inlet Female -05 JIC (1/2-20 UNF) B-component inlet Female -06 JIC (9/16-18 UNF) 24N995 Coupling Block: A-component inlet Female -05 JIC (1/2-20 UNF) A-component outlet Male -05 JIC (1/2-20 UNF) B-component inlet Female -06 JIC (9/16-18 UNF) B-component outlet Male -06 JIC (9/16-18 UNF) Materials of Construction Wetted materials on all models stainless steel, carbon steel, acetal, nylon, UHMW Weight 22100A-AUTO-R 6.5 lb 2.9 kg Dimensions Height 6.25 in. (16 cm) Length 9.5 in. (24 cm) Width 4.5 in. (11 cm) Notes * Sound pressure measured 3 feet (1 meter) from equipment. ** Sound power measured per ISO-9416-2. 30 313380B
Technical Data 313380B 31
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: 1-800-746-1334 or Fax: 330-966-3006 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. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 313380 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES P.O. BOX 1441 MINNEAPOLIS MN 55440-1441 USA Copyright 2005, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised September 2012