Graco 308341F Optimiser 2K HVLP Two Component Adhesive Spray Gun Owner's Manual

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Graco 308341F Optimiser 2K HVLP Two Component Adhesive Spray Gun Owner's Manual | Manualzz

INSTRUCTIONS-PARTS LIST

This manual contains important warnings and information.

READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

Optimiser 2K

HVLP Two Component

Adhesive Spray Gun

100 psi (7 bar) Maximum Working Fluid and Air Pressure

This gun is for use with water-based contact adhesives only

Part No. 949–239, Series C

U.S. Patent Pending

308–341

Rev. F

Supersedes E

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1993, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

02748

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Flow and Atomizing Pressure

Installation

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup and Shutdown

Ratio Check

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Gun Care, Flushing, and Cleaning . . . . . . . . . .

7

13

14

2

4

5

6

Troubleshooting

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

18

24

26

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number . . . . . . . . . . . . . . . . . .

26

Back Cover

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

WARNING

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

Equipment misuse can cause the equipment to rupture, malfunction or start unexpectedly and result in serious injury.

This equipment is for professional use only.

Read all instruction manuals, tags, and labels before operating the equipment.

Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco distributor.

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Check equipment daily. Repair or replace worn or damaged parts immediately.

Use this equipment only in low pressure, air spray systems.

Do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (7 bar) maximum working fluid and air pressure.

Do not lift pressurized equipment.

Use fluids or solvents that are compatible with equipment wetted parts. See the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Comply with all applicable local, state and national fire, electrical and other safety regulations.

WARNING

PRESSURIZED EQUIPMENT HAZARD

Spray from the gun, hose leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.

Do not stop or deflect fluid leaks with your hand, body, glove or rag.

Follow the Pressure Relief Procedure on page 7 when: you are instructed to relieve pressure; stop spraying; clean, check or servicing the equipment; and install or clean fluid nozzles.

Never point the spray gun at anyone or at any part of the body.

Never put hand or fingers over the spray nozzle.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes and couplings daily. Replace worn, damaged or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

Route hoses away from traffic areas, sharp edges, moving parts and hot surfaces.

Do not use the hoses to pull equipment.

FIRE AND EXPLOSION HAZARD

Poor air ventilation, open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being sprayed.

Extinguish all open flames or pilot lights in the spray area.

Electrically disconnect all equipment in the spray area.

Keep the spray area free of debris, including solvent, rags and gasoline.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not smoke in the spray area.

Do not operate a gasoline engine in the spray area.

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

Dress appropriately for your application. Wear protective eyewear, noise protection for the ears, a personal respirator, gloves and clothing.

Selection Chart

Needle/

Nozzle/Air

Cap Kit

P/N

949–276

949–277

949–278

949–279

949–280

949–281

949–282

Includes:

Needle

Assembly

P/N

238–703

238–703

238–703

238–217

238–218

238–219

238–220

Air Cap

P/N

185–794

185–794

185–794

185–794

185–794

185–795

185–796

Nozzle

P/N

185–756

185–757

185–700

185–701

185–702

185–703

185–704

Replacement

Needle Tip

P/N

191–564

191–564

191–564

191–016

191–017

191–018

191–019

Orifice Size

0.020” (0.508 mm)

0.026” (0.660 mm)

0.030” (0.762 mm)

0.042” (1.067 mm)

0.055” (1.397 mm)

0.070” (1.778 mm)

0.086” (2.184 mm)

Selecting a Needle/Nozzle/Air Cap Kit

The kits range in size to provide different fluid flow rates.

Use the fluid nozzle that will give the required flow with the fluid adjustment knob opened four full turns counterclockwise and an adhesive pressure of approximately 5 to 20 psi (0.35 to 1.4 bar).

For low flow rates or light viscosity fluid, select the smaller nozzle sizes.

For high flow rates or high viscosity fluid, select the larger nozzle sizes.

Using an air cap size that is smaller than the nozzle/needle size is not recommended.

To help select the proper needle/nozzle size, a fluid pressure gauge may be connected temporarily to the gun fluid inlet to determine the fluid pressure.

See Service to install the parts.

Selection Problems and Solutions

PROBLEM

Fluid pressure required to achieve flow rate is too high

POSSIBLE

CAUSE

Using set with too small of an orifice

Using a low pressure setting, the fluid flow is too high, making it necessary to restrict needle travel to reduce fluid flow

Fluid system will not operate at low enough fluid pressure

Using set with too large of an orifice

Fluid regulator is not installed or air regulator is not sensitive enough

SOLUTION

Use needle/ nozzle/air cap set with larger orifice

Use needle/ nozzle/air cap set with smaller orifice

Add low pressure fluid regulator or add more sensitive air regulator on pressure pot

Air Flow and Atomizing Pressure

NOTE: All tests completed with the fan air fully open.

Atomizing Air Pressure

(inlet pressure vs. atomizing pressure)

Air Flow

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

0

15 25 35 45 55 65 75 85 95

GUN AIR INLET PRESSURE (psi)

20

18

16

14

12

10

8

6

4

2

0

15 25 35 45 55 65 75 85 95

GUN AIR INLET PRESSURE (psi)

Atomizing Pressure Versus

Activator Inlet Pressure

Air flowing through the gun creates back pressure, which the activator must overcome before beginning to flow. The chart below shows the minimum activator pressure required to overcome the atomizing air pressure. Higher pressures may be necessary to maintain the mix ratio.

Gun Inlet Pressure

15 psi (1.05 bar)

25 psi (1.75 bar)

35 psi (2.45 bar)

45 psi (3.15 bar)

55 psi (3.85 bar)

65 psi (4.55 bar)*

75 psi (5.25 bar)

85 psi (5.95 bar)

95 psi (6.97 bar)

Nominal Atomizing Pressure

1.5 psi (0.11 bar)

3.0 psi (0.22 bar)

4.5 psi (0.33 bar)

6.0 psi (0.42 bar)

8.5 psi (0.62 bar)

10.0 psi (0.70 bar)

13.0 psi (0.95 bar)

15.5 psi (1.14 bar)

18.0 psi (1.32 bar)

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

0

15 25 35 45 55 65 75 85 95

GUN AIR INLET PRESSURE (psi)

* For compliant operation, operate at 65 psi (4.55 bar) or less

308-341 5

Installation

D

N

A

B

C

E F G

S

R

M J H

KEY

A Optimiser 2K Spray Gun

B Air Inlet; 1/4 npsm

C Air Hose

Recommend 5/16” (7.9 mm) ID hose;

Optional 3/8” (9.5 mm) ID hose

D Gun Air Shut-off Valve

E Gun Air Regulator

F Air Filter

G Air Supply Line

H Pressure Pot Air Shut-off Valve

J Pressure Pot Air Regulator

K Activator Pressure Pot

L Activator Fluid Shut-off Valve

M Activator Fluid Hose

N Activator Inlet 1/8–27 npt(f)

P Adhesive Pressure Pot

Q Adhesive Fluid Shut-off Valve

R Adhesive Fluid Hose

S Adhesive Inlet; 3/8 npsm (R3/8–19)

Q P L K J H

02750

Fig. 1

Fluid Compatibility of Accessories

When selecting system components to supply the adhesive and activator, consider the following:

Adhesives and activators are water-based and corrosive. Avoid carbon steel, unplated brass, copper, and aluminum. Stainless steel, nickelplated brass and most plastics are usually acceptable.

6

Piston pumps are not recommended for use with adhesives as they are often shear sensitive and will coagulate in your equipment. Stainless steel pressure pots function well in place of a pump and fluid pressure regulator. On drum or tote tank supplied systems, plastic diaphragm pumps are often used.

308-341

Some adhesives will coagulate in fluid pressure regulators due to shear. Consult with the fluid supplier for regulator recommendations.

Refer to Fig. 1 and see Form No. 305–591 for the accessories recommended to install the system.

Consult with the fluid supplier or Graco for specific recommendations.

Ventilate the Spray Booth

WARNING

FLAMMABLE/TOXIC FLUID HAZARD

To avoid hazardous concentrations of flammable or toxic fumes, spray only in a properly ventilated spray booth.

Comply with all applicable local, state and national fire and safety regulations.

Installation

Air Line Accessories Fluid Line Accessories

The gun air line must have an air regulator (E) to control air pressure to the gun. See Fig. 1.

If you are using diaphragm pumps to supply adhesive or activator to the gun(s), install a fluid regulator (T) on each gun fluid supply line to control fluid pressure to the gun(s). See Fig. 9, page 9.

If the gun air source does not have a filter, install a filter (F) on the gun air line to ensure a dry, clean air supply.

Install a fluid filter in the gun fluid supply lines to avoid clogging the fluid nozzle. A 100 mesh filter is recommended for the activator supply line to avoid clogging the activator needle and orifice.

To eliminate the need to shut off the air pressure at the air supply, install a quick-disconnect at the gun air inlet fitting.

Use 5/32 or 1/4 inch I.D. tubing for the activator supply line.

Setup and Shutdown

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid, accidental spray from the gun or splashing fluid, follow this procedure whenever you:

Are instructed to relieve pressure

Stop spraying

Check, clean or service any system equipment

Install or clean fluid nozzles

Fig. 2

Q L

02059

1. Close the adhesive and activator shut-off valves

(Q and L). See Fig. 2.

2. Trigger the gun into the spray booth* to relieve the fluid pressures and clear excess activator from the gun. See Fig. 3.

* If the gun has been flushed with solvent, be sure to spray the solvent into a grounded metal waste container .

3. Close the atomizing air shut-off valve (D). See

Fig. 4.

Fig. 3

Fig. 4

D

02753

02780

308-341 7

Setup and Shutdown

Removing and Installing the Fluid Nozzle

Follow this procedure whenever you remove and install a fluid nozzle. See page 4 to select a nozzle or needle/nozzle/air cap kit.

CAUTION

Trigger the gun whenever you tighten or remove the fluid nozzle (20) to pull the needle away from the nozzle seating surface and avoid scratching it.

1. Follow the Pressure Relief Procedure on page 7.

4. Apply PTFE r adhesive to the threads of the fluid nozzle (20) you are installing.

2. Remove the air cap ring (12), air cap (19), and air cap seal (47). See Fig. 5.

5. Lubricate the baffle o-ring (17).

3. Trigger the gun while you remove the fluid nozzle

(20) with the gun wrench (35).

12, 19

47

35

2 20

1 17

CAUTION

Lubricate the baffle o-ring (17) before installing the fluid nozzle (20). A dry o-ring will prevent the nozzle from tightening properly and adhesive may leak inside the gun.

6. Trigger the gun while you install the fluid nozzle

(20) with the gun wrench (35). Tighten it to 125 to

150 in-lbs (14 to 17 N S m).

1

2

Fig. 5

Lightly lubricate baffle o-ring (17)

Apply PTFE adhesive to nozzle (20) threads. Trigger gun and tighten to 125–150 in-lbs (14–17 N S m)

02757A

CAUTION

When tightening the fluid nozzle (20), do not exceed

150 in-lbs (17 N S m) torque. Over-tightening can damage the nozzle, affect the spray pattern, and is unnecessary to guarantee a seal.

7. Install the air cap seal (47), air cap ring (12), and air cap (19).

Setup and Shutdown

WARNING

EQUIPMENT MISUSE HAZARD

This gun is for use with water-based contact adhesives only. Any other use of the gun could cause unsafe operating conditions or damage to the gun.

2. Flush the adhesive and activator fluid lines with water and blow them out with air before connecting them to the gun.

3. Connect the adhesive fluid hose.

A. Connect the fluid hose (R) to the gun adhesive inlet (S). See Fig. 8.

1. Connect the air line.

A. Connect the air hose (C) to the gun air inlet

(B). See Fig. 6.

1 S

R

1 B

C

1 1/4 npsm

Fig. 6 02751

B. Connect the other end of the air hose (C) to a regulated air supply line (G).

See Fig. 7.

NOTE: Fig. 7 shows the air supply line filter (F), air regulator (E), and air shut-off valve (D).

G F E

1

Fig. 8

3/8–18 npsm [R 3/8–19] compound thread

02752

B. Connect the other end of the fluid hose (R) to a regulated fluid supply line (U–see Fig. 9) or a pressure tank (P–see Fig. 1, page 6).

NOTE: Fig. 9 shows the fluid supply line regulator

(T) and fluid shut-off valves (Q).

T

U

Q

R

D C

Fig. 7 01990

Fig. 9 02777

308-341 9

Setup and Shutdown

4. Connect the activator tube.

A. Connect the fitting (V) and tube (M) to the gun activator inlet. See Fig. 10.

B. Connect the other end of the fluid tube (M) to a regulated fluid supply line or a pressure tank.

V

6. Adjust the spray pattern.

WARNING

COMPONENT RUPTURE HAZARD

Do not exceed the 100 psi (7 bar)

maximum fluid and air pressure of this gun.

Higher pressures can cause parts to rupture and result in serious injury.

NOTE: Refer to the Atomizing Pressure Versus

Activator Inlet Pressure chart on page 5 to help set air and activator pressures.

A. Close the fluid adjustment valve by turning the knob (8) fully clockwise. Then turn the knob counterclockwise four full turns to open it. See

Fig. 12.

M

8

02784 Fig. 10

Open

5. Position the Air Cap for a vertical or horizontal spray pattern. See Fig. 11.

Vertical Pattern

02784

Fig. 12

B. Open the adhesive fluid shut-off valve (Q). Adjust the fluid flow with the fluid regulator (T) installed in the gun fluid line (see Fig. 13) or the air regulator on the adhesive tank (see Fig.

1). Typical industrial flow rates will vary with regulator pressures from 5 to 20 psi (0.35 to

1.4 bar).

T

Q

Fig. 11

Horizontal Pattern

02020

Fig. 13

02778

Setup and Shutdown

6. Adjust the spray pattern. (continued)

C. Hold the gun parallel to the floor and adjust the adhesive fluid pressure until you have a 1 to 6 inch (25.4 to 152.4 mm) straight fluid stream before the stream falls off. See Fig. 14.

D. To further reduce the volume of adhesive output at the gun, turn the fluid adjustment knob

(8) clockwise as needed. See Fig. 16. However, for the best results, adjust the adhesive pressure or use a different size needle/nozzle/ air cap combination to change the fluid flow.

Refer to page 4.

1–6 in.

(25.4–152.4 mm) straight fluid stream

CAUTION

Continuously spraying with the fluid adjustment knob closed , will cause accelerated wear on the fluid needle and trigger/air valve shaft interface.

If the fluid adjustment knob is fully closed, the gun will emit only air and activator.

Fig. 14

02754

NOTE: A larger fluid nozzle at a reduced adhesive pressure will maintain the same flow rate, but slow down the fluid stream. See Fig. 15. This allows the atomizing air to act on the fluid longer and improve the atomization.

Fluid Stream of Fluid Nozzles at the Same Flow Rate

Close

8

0.042

(1.067)

0.055

(1.397)

0.070

(1.778)

0.086

(2.184)

Nozzle Orifice Size in inches (mm)

0.110

(2.794)

Fig. 15 02755

Fig. 16

02784

E. Open the pattern adjusting valve by turning the knob (13a) fully counterclockwise. See Fig. 17.

13a

Open

(wider pattern)

Close

(narrower pattern)

02784

Fig. 17

Setup and Shutdown

7. Adjust the activator fluid flow.

6. Adjust the spray pattern. (continued)

F. Set the gun air supply pressure at 40 psi

(2.8 bar), using the gun atomizing air regulator

(E). See Fig. 18.

NOTE:

Use the fluid manufacturer recommendations if available and refer to the Atomizing Pressure

Versus Activator Inlet Pressure chart on page 5 when adjusting the gun.

Local laws may limit the maximum pressure to

10 psi (0.7 bar) at the air cap for HVLP compliance.

CAUTION

When the activator is being supplied to the gun, the atomizing air must be on before triggering the gun to avoid contaminating the atomizing air with activator.

Open the activator supply valve (L) and increase the fluid pressure until the desired amount of activator is sprayed with the adhesive. The typical fluid pressure range is 8 to 20 psi (0.56 to 1.40 bar).

See Ratio Check, page 13.

E

01997

Fig. 18

G. Hold the gun about 6 to 8 inches (150 to

200 mm) from the test piece and test the spray pattern and atomization.

H. The spray pattern may be too wide with the pattern adjustment knob (13a) fully open. Turn the pattern adjustment knob clockwise until you have the desired pattern size. See Fig. 17, page 11.

NOTE: Some pattern air is required to supply the activator; do not close the pattern adjustment knob completely.

I.

Check the atomization quality again. If necessary, increase the gun air supply pressure with the air regulator (E) in 5 psi (0.35 bar) increments until you have the desired atomization.

J. If the atomization is still unacceptable, install a larger fluid nozzle size to reduce the fluid stream. Refer to Fig. 15. See page 8 to remove and install a fluid nozzle.

K. Repeat steps 6.E to 6.J until you have the desired spray pattern and atomization.

NOTE: To eliminate a fan pattern at low atomizing pressures, it may help to remove the activator air restrictor (55). See Fig. 34, page 19.

Fig. 19

8. Shut down the system

at the end of the work-shift and before checking, adjusting, cleaning or repairing the system. Follow the Pressure Re-

lief Procedure on page 7.

9. Place the gun nozzle in soapy water over-night

to avoid having the tip clog with hardened material. Do not immerse the entire gun.

Fig. 20

L

02776

02785

Ratio Check

NOTE: You cannot sample the adhesive and activator at the same time. The adhesive must be checked with the atomizing air off, while the activator must be checked with the atomizing air on.

1. Check the ratio of the adhesive.

A. Weigh an empty beaker.

B. Close the atomizing air shut-off valve.

C. Close the activator shut-off valve.

D. Trigger the gun into the beaker for 15 seconds to dispense the adhesive.

E. Follow the Pressure Relief Procedure on page 7.

F. Weigh the adhesive, subtract the weight of the beaker, then multiply the figure by 4 to obtain the weight per minute of the adhesive.

2. Check the ratio of the activator.

A. Weigh an empty beaker.

B. Cover the beaker with a loose cover to deflect any over-spray. See Fig. 21.

C. Disconnect the red tube from the activator valve.

D. Connect the ratio check tube (54) (supplied with the gun) to the activator valve outlet fitting

(52 1 ) as shown in Fig. 21. Turn the front fitting

(52 2) toward the front of the gun.

E. Close the adhesive shut-off valve.

F. Open the atomizing air shut-off valve.

G. Open the activator shut-off valve.

52 1 52 2

54

02786A

Fig. 21

H. Place the ratio check tube (54) into the beaker as shown in Fig. 21.

I.

Direct the spray gun into the booth. Trigger the gun for 1 minute to dispense the activator through the tube and into the beaker.

J. Follow the Pressure Relief Procedure on page 7.

K. Remove the beaker cover. Weigh the activator and subtract the weight of the beaker to obtain the weight per minute of the activator.

3. Adjust the ratio as needed.

Adjust the activator supply pressure to change the ratio of adhesive to activator, then check the ratio again.

Once the ratio is set, do not change the adhesive or activator supply pressure settings or turn the gun fluid adjustment knob. Any change to the flow of either fluid will change the mix ratio.

Daily Gun Care, Flushing, and Cleaning

CAUTION

Do not point the gun up while cleaning it as this may allow fluid to enter the gun air passages.

C. Point the gun down into the spray booth* and spray until the water sprays clear. See Fig. 22.

* If the gun is flushed with solvent, be sure to spray the solvent into a grounded metal waste container .

Do not use metal tools to clean the air cap holes as this may scratch them and distort the spray pattern.

Do not immerse the gun.

Squeeze the excess fluid out of the cleaning cloth before wiping the gun.

Typically the gun should be flushed or cleaned with soap and water. If solvent is used, do not use methylene chloride with formic or propionic acid as it will damage nylon components.

Fig. 22

2753

1. General system maintenance.

A. Clean the fluid and air line filters daily.

B. Check for fluid leakage from the gun and the fluid hoses. Tighten fittings or replace equipment as needed.

D. Turn off the fluid supplies.

E. Follow the Pressure Relief Procedure on page 7.

3. Clean the gun.

A. After relieving pressure, disconnect the activator and adhesive supply lines (M and R) from the gun. See Fig. 23.

C. Flush the gun with water if it will not be used in the next three days. Follow the flushing procedure below.

2. Flush the gun.

A. Follow the Pressure Relief Procedure on page 7.

B. Disconnect the adhesive and activator supplies and connect the supply lines to a water supply.

Fig. 23

M

R

02799

Daily Gun Care, Flushing, and Cleaning

3.

Clean the gun. (continued)

B. Disconnect the air supply line (C). See Fig. 24.

C

Fig. 24 02800

C. Remove the air cap ring (12), air cap (19), air cap seal (47), and fluid nozzle (20) as instructed on page 8.

Fig. 26 02775A

F. Clean the air cap ring, air cap, and fluid nozzle daily, minimum, using a soft-bristle brush. See

Fig. 27. Clean out air cap holes with a soft implement, such as a toothpick, to avoid damaging surfaces.

12, 19

47

35

20

Fig. 25 02757A

D. Soak the air cap ring (12), air cap (19), and fluid nozzle (20) in soapy water.

E. Dip a soft-bristle brush into soapy water, point the gun down, and clean the front of the gun.

Do not use a wire brush. See Fig. 26.

Fig. 27 02011

308-341 15

Daily Gun Care, Flushing, and Cleaning

3.

Clean the gun. (continued)

G. Install the fluid nozzle (20) air cap seal (47), air cap ring (12), and air cap (19) as instructed on page 8.

Fluid needle shaft

Activator nuts, in the area where they contact the trigger

Lubricate

H. Dampen a soft cloth with soapy water; squeeze out the excess water. Point the gun down and wipe off the outside of it.

Lubricate

Lubricate

Fig. 28

02782A

4. Lubricate the following gun parts daily,

using Part No. 111–265 lubricant. See Fig. 29.

Pattern adjustment valve threads

Fluid adjustment knob threads

Trigger pivot pin Fig. 29

02756B

16 308-341

Troubleshooting

PROBLEM

Fluid flow is fluttering while spraying

Fluid flow fades while spraying high viscosity fluids

Pattern becomes off-set or heavy on ends

CAUSE

1.

Fluid nozzle is not tight enough

2.

Fluid filter is clogged

3.

Fluid adjustment knob is not properly set

4.

Baffle (item 1 1) is installed wrong or damaged

1.

Air hose size is too restricted for higher air flows

2.

Fluid pressure is too low

1.

Fluid nozzle is too tight

2.

Air cap is too tight

3.

Air cap horn holes are plugged

Fluid system will not operate at low enough fluid pressure [below

10 psi (0.7 bar)]

Adhesive residue forms on spray nozzle

There is no fluid regulator, or the air regulator on the pressure pot is not sensitive enough at low pressures

1.

Activator is dispensing in the atomizing air

2.

Activator valve is leaking or not seating properly

3.

Baffle (item 11) is leaking at baffle protrusion

4.

Baffle is leaking at nozzle seal

5.

Air cap taper is not sealing to nozzle taper

Adhesive collecting in air passages The adhesive nozzle’s internal seal is leaking

Activator needle hex nuts are not tight When the gun is triggered, the adhesive dispenses before the activator or the activator dispenses before the adhesive

SOLUTION

1.

See page 8 to install the fluid nozzle correctly

2.

Check the fluid filter

3.

Adjust the fluid adjustment knob for less feathering or use a larger size nozzle

4.

Check if the baffle protrusion is properly inserted into the gun insert hole, see page 19; replace the baffle if damaged

1.

Use larger 3/8 in. ID air hose; order part no. 185–353

2.

Raise the fluid supply pressure or use a smaller fluid nozzle

1.

See page 8 to install the fluid nozzle correctly; replace the nozzle if damaged

2.

Loosen the air cap retaining ring

3.

Clean the air cap horn holes with a non-metallic item, such as a toothpick

Add a low pressure fluid regulator on the fluid line or add a more sensitive air regulator on the pressure pot.

1.

Do not trigger the gun with the activator on and atomizing air off

2.

Clean the needle, seat, and packings; lubricate packings and re-assemble

3.

Clean and re-assemble the baffle with a small amount of PTFE pipe sealant on the baffle protrusion or replace the baffle. Make sure that the baffle protrusion is properly inserted into the gun insert hole, see page 19

4.

Clean the baf fle and replace the nozzle seal

5.

Clean and re-tighten the air cap

Clean the nozzle and seat; see page 8 to install the fluid nozzle correctly

Adjust the activator needle hex nuts until the adhesive and activator needles open together

308-341 17

Service

Items Needed for Service

Gun Wrench – provided

Seal Installation Tool – provided

Adjustable Wrench

Screw Driver

Part No. 111–265 Lubricant

Soap and water

NOTE: Gun Repair Kit 949–285 is available; see page

25. The following procedure covers the replacement of all the kit parts.

Disassemble

1. Follow the Pressure Relief Procedure on page 7.

8. Insert a thin-blade screw driver (A) through the back of the gun and into the packing adjustment nut (31) and remove the screw. See Fig. 31.

Fig. 31

A

31

02762

2. Remove the air cap ring (12), air cap (19), air cap seal (47), and fluid nozzle (20) as instructed on page 8.

9. Push the three piece packing assembly (39) out the back of the gun with the threaded end of the fluid needle (21). See Fig. 32.

12, 19

47

35

20

CAUTION

Do not use excessive force to push out the packing assembly (39) or the u-cup seal (33) as this may bend the fluid needle (21). Refer to Fig. 32 and 33. If packings are difficult to remove, use a 3/16 in. plastic rod to push them out.

21

Fig. 30 02757A

3. Remove the nozzle seal (17). See Fig. 34.

4. Remove the fluid adjustment knob (8) and spring

(16).

5. Pull the fluid needle (21) out the back of the gun.

6. Remove the gun and activator triggers (3 and 48).

7. Remove the fluid adjustment nut (6), spring (15), and air valve (14).

Fig. 32

02759

Service

10. Use the threaded end of the fluid needle (21) to push out the u-cup seal (33). See Fig. 33.

11. Remove and disassemble the activator valve (49).

See Fig. 34. Use the threaded end of the activator needle (49d) to push out the needle packings (49g and 49r). Do not bend the end of the needle.

12. Clean the parts. Check the fluid needles (21 and

49d) for damage or excessive wear. Replace if necessary.

21

13. Check the baffle (11) for damage. If it is damaged, carefully pry it off with a screwdriver and replace it.

Apply part no. 514–767 Form-A-Gasket Sealant to the front area of the gun where the baffle sits and to the baffle protrusion. Insert the baffle protrusion into the gun insert hole.

Fig. 33

3

02760

49m

49p

49j

49q

49h

49r 49g

53

48

49

14. Lightly lubricate the parts indicated in Fig. 34 with

Part No. 111–265 lubricant.

1

49b

49f

49d 1

49e

49c

49a

49k

51

4

12

19

1 47

20

1 17

11

52

52

55

49e

2

49e

5

1

1

33

14 1

21 1

1 4

3

Lightly lubricate

1 39

1

31

2

3

Lightly lubricate threads

Lightly lubricate contact area on trigger face

1

4

Fig. 34

Apply part no. 514–767 Form-A-Gasket Sealant to the front area of the gun where the baffle sits and to the baffle protrusion. Insert the baffle protrusion into the gun insert hole.

15

1 16

32

22

6

308-341

8 2

05885

19

Service

Assemble

NOTE: See Fig. 34, page 19, for the parts that need to be lubricated.

A

31

1. Insert the fluid needle (21) through the front of the gun as shown in Fig. 35. Install the new packing assembly (39) by placing them on the end of the needle tip. Orientate the packings as shown in Fig.

35.

Fig. 35

39

21

1

2

3

1

2

3

Washer

U-cup; lips face down

Spreader

02763

02762

Fig. 36

4. Place the new u-cup seal (33) on the seal installation tool (42) with the u-cup lips facing the tool.

See Fig. 37.

5. Push the u-cup seal (33) into the gun until a definite snap is felt.

CAUTION

Apply even pressure to the u-cup seal (33) when installing it to avoid damaging the seal.

33 1

42

2. Place the packing adjustment nut (31) over the packing assembly and start the threads into the gun, then remove the needle.

3. Insert a thin-blade screw driver (A) through the back of the gun and into the packing adjustment nut (31). See Fig. 36. Do not nick or damage parts with the tool. Turn the screw with the screw driver

(about 3 turns); the packing will still be loose.

1 U-cup lips face the tool

Fig. 37

02023

Service

6. Slide the new air valve (14) onto the fluid needle

(21) until it is against the nut (B). See Fig. 38.

9. Remove the u-cup seal (32) from the fluid adjustment nut (6). See Fig. 40. Do not damage the seal surface or the nut’s internal threads.

7. Install the fluid needle (21) and air valve (14) into the back of the gun.

10. Place the new u-cup seal (32) on the seal installation tool (42) with the u-cup lips facing the tool.

See Fig. 40.

21

11. Push the u-cup seal (32) into the fluid adjustment nut (6) until a definite snap is felt.

14

B

CAUTION

Apply even pressure to the u-cup seal (32) when installing it to avoid damaging the seal.

12. Install the new packing ring (22).

02764

Fig. 38

8. Tighten the packing adjustment nut (31) with the gun wrench (35) until you can feel a slight drag on the fluid needle. See Fig. 39. Do not over-tighten the screw as this may bind the needle movement.

1 U-cup lips face the tool

42

22

32 1 31

35

6

02021

02758

Fig. 40

Fig. 39

Service

13. Install the spring (15) and fluid adjustment nut (6).

Tighten the nut to 25 to 35 in-lbs (2.8 to 4.0 N m).

See Fig. 42.

18. Secure the activator valve (49) to the plate (2) with the two screws (53). Tighten the screws to 10 to

15 in-lbs (1.1 to 1.7 N m).

14. Install the spring (16) and fluid adjustment knob (8).

15. Re-assemble the activator valve assembly. See

Fig. 42.

a. Make sure the thin end of the needle (49d) is straight to avoid scratching the inside of the nozzle.

19. Place the o-ring (49e) in the groove on the plate

(2). Lightly lubricate the o-ring, and slide the plate, with the activator valve assembly, onto the top of the gun body.

b. Install the o-ring (49g), spreader (49r), and activator packing nut (49h) into the housing

(49b), orientated as shown in Fig. 41. Start the packing nut threads, then install the needle

(49d). Tighten the packing nut to 20 in-lbs

(2.3 N m).

20. Install the gun and activator triggers (3 and 48).

Tighten the screw (5) to 25 to 35 in-lbs (2.8 to 4.0

N m).

21. Trigger the gun to test the fluid needle (21) movement. If the fluid needle does not return after the trigger (3) is released or returns slowly, loosen the packing adjustment nut (31) until the needle returns freely. See Fig. 39. Repeat this process to test the activator needle (49d).

Fig. 41

1

49h

49r 1

49g

49b

Spreader taper faces away from o-ring

02781A c. Assemble the remaining parts.

d. Secure the activator housings (49b and 49a) with the four screws (49k). Tighten them evenly to 5 in-lbs (0.6 N m).

CAUTION

To avoid damaging the plastic threads, do not overtighten the screws (49k).

16. Install the restrictor (55), flat side up, into the activator outlet housing (49a).

17. Place the o-ring (49e) in the groove in the activator outlet housing (49a). Lightly lubricate the o-ring.

22. Adjust the two activator needle hex nuts (49j and

49p) as follows: a. Pull the gun trigger (3) back until you feel resistance against the main fluid needle (21).

b. With the activator trigger (48) resting against the gun trigger (3), screw the nuts (49j and

49p) up against the activator trigger. Tighten the two nuts against each other in this position.

c. When properly adjusted, both fluid needles (21 and 49d) will unseat at the same time as you pull back on the trigger.

23. Lubricate and install the fluid nozzle seal (17).

24. Install the fluid nozzle (20), air cap seal (47), air cap ring (12) and air cap (19) as instructed on page 8.

25. Connect the nylon tube (51) between the activator valve outlet elbow (52) and the spray gun elbow

(52).

26. Make sure the adhesive packing assembly (39) is sealing by spraying water at low pressure before fully pressurizing the gun.

If the fluid packings leak, tighten the packing adjustment nut (31) slightly and retest until the packings seal completely.

12

19

47

6 20

17

11

9 52

51

Service

49m

49p

49j

49q

49h

49r 49g

2 53

48

49

8

49b

49f

49d

49e

49c

49a

49k 9

52 9

55

49e

2

7

49e

5 1

33 3

14

21

4

3

39

5 31

1 15

16

4 32

22

1 6

NOTE: See Fig. 34, page 19, for the parts that need to be lubricated.

1

2

3

4

5

Fig. 42

Tighten to 25–35 in-lbs (2.8–4.0 N m)

Tighten to 10–15 in–lb (1.1–1.7 N.m)

U-cup (33) lips face air valve (14)

U-cup (32) lips face spring (16)

Tighten packing nut as needed for fluid tight seal

8

6

7

8

9

Apply PTFE adhesive to nozzle (20) threads. Trigger gun and tighten to 125–150 in-lbs (14–17 N m)

Flat side up

Tighten to 20 in-lbs (2.3 N m)

Tighten to 5 in-lbs (0.6 N m)

05885

Ref No. 13

Fan Air Valve Assembly

Includes items 13a–13d

Ref No. 49

Activator Valve Assembly

Includes items 49a–49r

12

19

47

20

17

11

25

4

3

52

39

51

Parts Drawing

49m

49p

49j

49q

49h

49r

49g

49b

49f

49d

49n

49e

49c

49a

49k

48

53

49

5

52

50

55

2

13d

13b 1

13c

13a

33

21

14

31

1

15

16

32

22

6

35 8

1 Tighten to 25–35 in–lb (2.8–4.0 N.m)

NOTE: See the Service section for additional assembly information.

42

02765A

Parts List

Part No. 949–239, Series C

Optimiser 2K HVLP Spray Gun

Ref

No.

Part No.

Description Qty

3

4

1

2

5

6

8

11

12

13

238–139 GUN BODY

190–247 PLATE, gun

185–761 TRIGGER, gun

625–723 PIN, pivot

203–953 SCREW, lock; No. 10–24 UNC-2A x 0.375”

188–490 NUT, fluid adjustment

185–745 KNOB, fluid adjustment

275–851 BAFFLE, pattern

276–278 RETAINING RING, air cap

236–006 FAN AIR VALVE ASSY.

Includes items 13a–13d

13a 188–492 S VALVE, fan air

13b 188–700 S NUT, air adjustment

13c* 187–699 S O-RING, split; PTFE

13d* 105–456 S RETAINING RING

14* 236–009 AIR VALVE ASSY.

r

15

16

111–291 SPRING, compression

110–402 SPRING, compression

17* 103–413 SEAL, fluid nozzle

19 l 185–794 AIR CAP; 0.020–0.055 size

20 l 185–702 FLUID NOZZLE; 0.055 size

21 l 238–218 FLUID NEEDLE; 0.055 size

Includes item 21a

21a 191–017 S NEEDLE TIP; replacement

22* 188–694 RING PACKING; PTFE

25 108–382 PLUG

31 n 188–665 NUT, packing adjustment

32* 110–453 SEAL, u-cup; UHMWPE

33* 188–493 SEAL, u-cup; UHMWPE

35 188–666 WRENCH, gun

39* 236–008 PACKING ASSY.; includes u-cup spreader, u-cup seal and packing washer

42 276–268 TOOL, seal installation

47* 625–722 SEAL, air cap

48 625–725 TRIGGER, activator valve

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref

No.

Part No.

Description

* These parts are included in Repair Kit 949–285, which may be purchased separately .

Qty

49 n 949–217 ACTIVATOR VALVE ASSY.

Includes items 49a–49r 1

49a 625–730 S HOUSING, activator outlet

49b 625–729 S HOUSING, activator inlet

1

1

49c 188–762 S INSERT, nozzle 1

49d n 949–295 S NEEDLE ASSY., activator valve 1

3 49e* 106–555 S O-RING; Viton r

49f* 112–931 S SPRING, compression

49g* 103–154 S O-RING; ethylene propylene

49h 188–665 S NUT, packing

49j 188–772 S NUT, hex

49k 113–411 S SCREW, cap, SST;

10–24 x 3/4”

1

1

4

1

1

49m 514–619 S NUT, acorn; nylon

49p 112–930 S NUT, hex

49q 112–929 S WASHER

49r* 188–494 S SPREADER

51* 187–169 TUBE; nylon;

5/32 in. (3.97 mm) O.D.

52

53 n 514–581 CONNECTOR, tube

514–655 SCREW, cap; 10–32 x 1”

54 625–779 TUBE, ratio check;

24” (609.6 mm); not shown

55* 191–015 RESTRICTOR, orifice

1

1

1

1

1

4

2

1

1 n Keep these spare parts and the Repair Kit on hand to reduce down time.

l See chart on page 4 for other available Needles,

Nozzles, and Air Caps.

Technical Data

Maximum Working Fluid and Air Pressure

Weight

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

100 psi (7 bar)

17.5 oz. (0.5 kg)

Air Inlet . . . . . . . . . . . . . . . . . . . 1/4–18 npsm (R1/4–19) compound thread

Adhesive Inlet

Activator Inlet

Wetted Parts

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Adhesive and Activator . . .

3/8–18 npsm (R3/8–19) compound thread

1/8–27 npt(f)

304 and 17–4 Stainless

Steel, Acetal, Nylon,

Ultra High Molecular

Activator Only . . . . . . . . . . . .

Weight Polyethylene

Buna-N, Nickel-plated

Brass, Anodized

Nylon (air cap only)

Dimensions

6.39 in.

(163 mm)

8.0 in.

(203 mm)

Manual Change

Summary

Assembly

Changed

949–239

Gun, series

B to series C

Part

Status

Old

New

Old

New

Old

New

Added

Old

New

Added 2

Old

New

Deleted

Deleted

Old

New

Added 2

Old

New

Miscellaneous Changes:

1.

Selection Chart on page 4 :

Ref.

No.

49d

49d

49e

49k

49k

49n

50

51

51

52

55

55

1

1

19

19

21

21

21a

Part No.

Name

625–724

238–139

188–754

185–794

236–124

238–218

191–017

625–727

949–295

106–555

514–527

113–411

625–726

625–731

625–778

187–169

514–581

514–762

191–015 a.

Changed needle shaft assembly 224–849 to needle assembly 238–703, 236–123 to 238–217, 236–124 to 238–218, 236–125 to 238–219, and 236–126 to

238–220.

b.

Added part no. for needle tips previously not available as replacement parts and changed needle tip

185–854, 185–855, and 185–730 to 191–564.

Gun Body

Gun Body

Air Cap

Air Cap

Fluid Needle

Fluid Needle

Needle Tip

Needle

Needle

O-Ring

Screw

Screw

Needle Tip

Seal

Tube

Tube

Connector

Restrictor

Restrictor c.

Changed air cap 188–754 to 185–794, 188–755 to

185–795, and 188–756 to 185–796.

d.

Deleted Needle/Nozzle/Air Cap Kit part no. 949–283 and 949–284.

2.

Changed torque on items 49k and 52 to 5 in-lbs (0.6

N m).

Notes

The Graco Warranty and Disclaimers

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven 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, 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 with Graco equipment of 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 claim. 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.

Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, 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.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: 1–800–367–4023 Toll Free

Sales Offices: Atlanta, Chicago, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

PRINTED IN U.S.A. 308–341 December 1993, Revised January 1996

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