Graco 960P User manual

308336
Rev. J
First choice when
quality counts.
Model 960
Includes 1-quart (1-liter) cup
240080, without fluid set
240083, with #3 fluid set
240084, with #4 fluid set
240085, with #5 fluid set
243920, with 2.0 fluid set
Model 960GF.5
Includes 1/2-quart (1/2-liter) cup
240530, without fluid set
Model 960GF.75
Includes 3/4-quart (3/4-liter) cup
240532, without fluid set
05292A
Model 960P
240772, without fluid set
240773, with #3 fluid set
243592, with #1 fluid set
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Series 960
Turbine Spray Guns
50 psi (0.35 MPa, 3.5 bar) Maximum Inlet Fluid Pressure
100 psi (0.7 MPa, 7 bar) Maximum Inlet Air Pressure
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1993, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 308336
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spraying Techniques 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Model 960 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models 960GF.5 & 960GF.75 22. . . . . . . . . . . . . . . .
Model 960P 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 26. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment.
If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
When flammable liquid is sprayed or used for flushing or cleaning the equipment, the turbine
must be placed at least 20 feet (6.1 m) away from areas where hazardous concentrations of
flammable vapors are likely to occur.
Use additional air hose if necessary to ensure that the turbine is operated in a clean, dry,
well-ventilated area.
Never place the turbine inside a spray booth! Use this equipment outdoors or in extremely
well-ventilated areas.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
WARNING WARNING

308336 3
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction 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 not sure, call your 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.
Do not exceed the maximum working pressure of the lowest rated system component. See
Technical Data on page 25.
Use fluids and solvents which are compatible with the equipment wetted parts. See Technical
Data on page 25 for this information.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Wear hearing protection when operating this equipment.
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Do not point the gun at anyone or at any part of the body.
Follow the Pressure Relief Procedure on page 12 if the fluid nozzle clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
WARNINGWARNING
INSTRUCTIONS
TOXIC FLUID HAZARD
Hazardous fluid 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.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in the turbine spray system, which contains aluminum and/or
galvanized-coated parts. Such use could result in a serious chemical reaction, with the possibility
of explosion, which could cause death, serious injury, and/or substantial property damage.

Fig. 1 04958B
C
D
D
21/2-gallon remote pressure pot2-quart remote pressure pot
F
J
J
A
G
G
G
C
A
B
L
E
cup setup for spray gun
E
Z
Z
H
H
cup-over option
F
K
K
Y
X
X
Y
Y
Z
X
remote pressure pot
setup for spray gun
4 308336
Setup
Connect Fluid and Air Supply
NOTES:
The HVLP Cart/Compressor provides the air supply
for remote pressure pot.
The circled letters in Fig. 1 indicate hose line
connections.
1. Connect gun air supply hose (A) between turbine
air outlet (B) and gun air inlet (C). DO NOT use
wrench to tighten connections; hand tighten only.
See Fig. 1.
For GTS–4900:
The turbine uses quick connector at outlet (B). A
wrench is not required for hose connection.
2. If using a spray gun cup (D):
Connect cup to gun fluid inlet (E).
If using accessory remote pressure pots (F):
Connect fluid supply hose (G) between remote
pressure pot fluid outlet (H) and gun fluid inlet (E).
3. Connect pressure pot air hose (J) between pres-
sure pot air regulator inlet (K) and the cart com-
pressor air outlet.
Install Fluid Set
Complete spray guns are available with #1, #2, #3, #4,
or #5 fluid sets. To install other fluid sets, perform the
following steps. See Fig. 2.
1. Remove air cap retaining ring (29). Discard pack-
aging (not shown). Remove detente plate and
spring (25).
2. Remove fluid regulator assembly (20, 21, 22) and
spring (23) from back of gun.

Fig. 2 05289
29
25
6
23
22
21
20
14
27
308336 5
Setup
3. Fully insert needle assembly (14) into back of fluid
manifold (6).
4. Perform needle adjustment procedure steps 2 thru
5 of Adjusting Needle on page 16.
5. Perform needle packings adjustment procedure
steps 4 thru 8 of Adjusting Needle Packings on
page 16.
Prepare 960 Cup Gun for Pressure Feed
1. Remove air pressure tube (34) from air stem (33).
See parts drawing on page 20.
2. Hold fluid inlet fitting (7) with wrench and remove
cup assembly (59).
3. Remove air stem (33) from gun body (1).
4. Apply medium strength threadlocker to set screw
(61) and assemble to gun body.
Prepare Fluid
1. Always strain fluid before spraying; this includes
color, reducer, and hardeners.
2. Use slower drying reducer or thinner to compen-
sate for faster drying time from warm turbine air.
Do not over reduce.
Paint Reduction — Automotive Type Finishes
Reduce and catalyze all paint to manufacturer’s
specifications. Compensate for faster turbine drying
time by using reducer one-step slower than
conventional air spray.
Paint Reduction — Industrial or Domestic
Coatings
Reduce and catalyze all paint to manufacturer’s
specifications. If no reductions are given, first
thoroughly mix fluid to be sprayed. Gradually mix in
reducer, testing fluid for correct spraying consistency.
Test consistency, remove stir stick from thinned paint.
Consistency is right when first drops from stir stick are
about one second apart.

6 308336
Setup
Fill Cup or Remote Pressure Pot
Spray Gun Cup
WARNING
The spray gun cup is pressurized by the gun’s air
supply. To reduce the risk of serious injury from
pressurized fluid or accidental spray from the gun,
always turn off the air supply to the gun before
removing the spray gun cup.
Fill cup 3/4 full to keep air pressure tube clean. Install
cover. Under-cup cover has latch (H) to secure it to
cup. Over-cup has ring with notches (J) that secure
cup hood when locked in place on cup.
Fig. 3
HJ
05292
05292A
Accessory Remote Pressure Pot
WARNING
The accessory remote pressure pots remain
pressurized until pressure is manually relieved. To
reduce the risk of serious injury from pressurized
fluid or accidental spray from the gun, always
relieve pressure in the pressure pot before
loosening or removing the cover.
1. Relieve remote pot pressure as follows:
a. Turn off air supply to pressure pot. See Fig. 4.
b. 21/2-gallon remote pressure pot:
Pull pressure relief valve ring (206c) until
pressure is completely relieved.
2-quart remote pressure pot:
Turn out pressure relief knob (113) one turn.
Wait until pressure is completely relieved
before removing cover. Close knob.
Fig. 4
206c
02882
113
02860
2 quart
21/2 gallon
2. Remove pressure pot cover and fill. Secure cover.
NOTE: 2-quart remote pressure pot only:
Lightly coat cover threads with petroleum jelly.
CAUTION
If the 2-quart remote pressure pot is accidentally
tipped over or held at too great of an angle, fluid
may leak into the air regulator and cause damage.
Take precautions to avoid this. If fluid does get into
the regulator, clean immediately.
CAUTION
Do not tighten the pressure pot cover more than
hand-tight. Excessive tightening may damage the
cover gasket.

308336 7
Setup
Prepare Surface
To achieve proper adhesion, make sure the surface to
be sprayed is completely clean.
Turbine Operation
Sparking can be expected in the normal operation
of the turbine motor. Sparks can ignite fumes from
flammable liquid, dust particles, and other
flammable substances in the spray area. This can
cause serious injury and property damage. Be sure
to follow the precautions below:
When flammable liquid is sprayed or used for
flushing or cleaning equipment, the turbine must
be placed at least 20 feet (6.1 m) away from
areas where hazardous concentrations of
flammable vapors are likely to occur.
Use additional air hose if necessary to ensure
that the turbine is operated in a clean, dry,
well-ventilated area.
Never use or place the turbine inside a spray
booth! Use this equipment outdoors or in
extremely well-ventilated areas.
Avoid all ignition sources such as static
electricity from plastic drop cloths, open flames
such as pilot lights, hot objects such as
cigarettes, arcs from connecting or
disconnecting power cords, and arcs from
turning light switches on and off. Extinguish or
remove all sources of ignition.
WARNING
1. Turn turbine on a few minutes before spraying to
warm-up.
NOTE: Turn turbine off when not in use. Turbine
does not shut off automatically.
2. Be sure the turbine filter is clean before operating.
See Turbine Filter Maintenance on page 13.
Cold Weather Operation
The HVLP compressor/cart uses a diaphragm
compressor. When new, the diaphragm may becomes
stiff in cold weather. If cold enough, the diaphragm will
not allow the compressor motor to start (the unit will
hum). If this occurs, follow these steps:
1. Turn turbine and compressor OFF.
2. Unplug turbine from power source.
3. Pinch and remove filter by hand. Clean or replace
if dirty.
4. Hand spin cooling fan on compressor for a few
revolutions.
5. Reinstall filter.
6. Plug in turbine.
7. Turn turbine and compressor ON. If necessary,
repeat procedure.
Adjust Pattern Direction and Shape
Spray pattern direction and shape are determined by
3 different positions the air cap. See Fig. 5. Rotate air
cap as needed to achieve desired pattern.
NOTE: Do not loosen air cap retaining ring to change
patterns unless air cap is set to its widest pattern. See
Fig. 10 on page 9.
Vertical Pattern
Horizontal Pattern
Fig. 5
Round Pattern
02847

8 308336
Setup
Adjust Spray Pattern
Select fluid set for fluid to be sprayed. If needed, see
pages 10 and 11 to determine correct fluid set.
WARNING
Do not exceed the gun’s 50 psi (0.35 MPa,
3.5 bar) Maximum Inlet Fluid Pressure and
100 psi (0.7 MPa, 7 bar) Maximum Inlet Air
Pressure. Higher pressures can cause parts to
rupture and result in serious injury or property
damage.
To establish correct fluid flow:
1. Turn fluid adjustment knob (20) counterclockwise
until you cannot feel any restriction of trigger
movement. See Fig. 6.
Fig. 6
open
20
05292
2. For remote pressure pot, hold gun parallel to floor
and adjust fluid pressure at 8 to 10 inch (203 to
254 mm) fluid stream. See Fig. 7.
For 2-quart remote pressure pot:
Set at 4 to 6 psi (0.28 to 0.42 bar).
For 21/2-gallon remote pressure pot:
Set at 8 to 10 psi (0.56 to 0.70 bar).
Note: Heavier fluids or longer fluid hoses require
greater pressures.
WARNING
Over-pressurizing the accessory remote
pressure pots can cause serious injury. To
reduce the risk, never exceed 50 psi (0.35 MPa,
3.5 bar) Maximum Inlet Fluid Pressure.
05284
Fig. 7
8 to 10 in.
(203 to 254 mm)
3. If further gun fluid adjustment is needed, turn fluid
adjustment knob (20) clockwise to reduce volume
of fluid output. See Fig. 8.
05292
20
Fig. 8
close
CAUTION
Restricting the trigger and fluid needle travel by
continuously spraying with the fluid adjustment
knob closed (turned clockwise), will cause
accelerated abrasive wear on the fluid needle and
wear on the trigger.
For best results, adjust fluid flow at the pressure
source or use a different size needle/nozzle/air cap
combination.

308336 9
Setup
To establish correct air flow:
4. Test spray pattern and atomization while holding
gun about 6 to 8 inches (150 to 200 mm) from test
piece.
5. Air Control Valve (M) on end of turbine hose
controls both atomizing air and pressure in spray
gun cup. See Fig. 9. Adjust air control valve as
needed.
Fig. 9
M
02850
NOTES:
Control over-spray mist by using only as much air
as necessary to spray fluid. Lighter fluids require
less air.
If atomization is still unacceptable, fluids may be
thinned further or a different fluid set may be
required. See pages 10 and 11 to determine fluid
set or page 5 to prepare fluid.
Adjust Pattern Size
Change pattern size by turning air cap retaining ring in
for a wide pattern or out for a narrow pattern. See
Fig. 10.
Wider
Spray
Pattern
Turn Air Cap
Retaining
Ring In
Fig. 10
Normal
Spray
Pattern
Narrower
Spray
Pattern
Air Cap Flush
with Fluid
Nozzle
Turn Air Cap
Retaining
Ring Out
02851
1
2
Turning air cap in too far will retard atomization.
Turning air cap out too far, will stop fluid or
cause flutter.
1
2

10 308336
Setup
Contractor Fluid Set Chart
Use this chart to determine Fluid Set for specific contractor application. See Fig. 11.
Fluid Set Components
Fluid Set
P/N & Size
(A)
Air Cap
(B) Nozzle (C)
Needle
Type of
Fluid**
Fluid Usage
240112
#2 (0.8 mm)
240490 192911 192916 light
14 to 18 sec.
Fine finish work with stains, lacquers, water-
borne lacquers
240113*
#3 (1.3 mm)
240491 192912 192917 light – medium
18 to 22 sec.
Medium speed application with lacquers,
enamels, urethanes, and varnish
240114
#4 (1.8 mm)
240492 192913 192918 medium
20 to 26 sec.
Medium to high speed industrial finishes
240115
#5 (2.2 mm)
240493 192914 192919 heavy
22 to 26 sec.
Heavy output with lacquer and enamels, latex
and oil wall paints
240116
#6 (2.5 mm)
240494 192915 192920 heavy
26+ sec.
Wax base stripper, sound deadeners, latex
paint, multi-color
* Standard fluid set
** Fluid measured with a #4 Ford cup (Part No. M70702)
Automotive Fluid Set Chart
Use this chart to determine Fluid Set for specific automotive application. See Fig. 11.
Fluid Set Components
Fluid Set
P/N & Size
(A)
Air Cap
(B)
Nozzle
(C)
Needle
Fluid Usage
240117
0.5/0.5M mm
M70434
0.5 mm
M70446 M70453 Ultra fine finish with automotive touch-up,
spot jobs
240118
0.7/0.7M mm
M70437
0.7 mm
M70447 M70455 Fine finish work with all automotive finishes, color
matching, automotive base coat
240113*
#3 (1.3 mm)
240491 192912 192917 Normal output with enamels, urethanes, zinc
chromate, automotive primers
240119
#1 (1.0 mm)
M70439 M70448 M70457 Medium-speed application with all automotive
finishes
* Standard fluid set
Multi-hole air cap