Graco 965022 User manual

Instructions
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001
AIRLESS SPRAY GUN
STAINLESS STEEL, PLURAL COMPONENT
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
Model 965022
684002 Rev.G
Read warnings and instructions.
See page 17 for model numbers and maximum
working pressures.
Includes standard (non–reversing)
DripLesstTip Guard. Spray tip not
included. Order separately. (Mixer not
included in the 965022 assembly.)
TI0662
Parts

2 684002
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 7. . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 9. . . . . . . . . . . . . . . . . . .
Gun Safety Latch 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip Guard 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger Guard 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Spray Pattern 10. . . . . . . . . . . . . . . . .
Cleaning and Clearing the Spray Tip 10. . . . . . . . . .
Flushing the Gun 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Needle Replacement 11. . . . . . . . . . . . . . . . . . . . . . .
Reassembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Needles 12. . . . . . . . . . . . . . . . . . . . . .
Hose Safety 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kit 949097 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Static Mixers 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Order 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 18. . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 18. . . . . . . . . . . . . . . . . . . . . . . .
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.

684002 3
Warnings
WARNING
PLURAL COMPONENT MATERIALS HAZARD
Graco Inc. does not manufacture or supply any of the reactive chemical components that are used in this equip-
ment and is not responsible for their effects. Because of the vast number of chemicals that could be used and
their varying chemical reactions, the buyer and user of this equipment should determine all facts relating to the
materials used, including any of the potential hazards involved. Particular inquiry and investigation should be
made into potential dangers relating to toxic fumes, fires, explosions, reaction times and exposure of human
beings to the individual components or their resultant mixtures.
Graco assumes no responsibility for loss, damage, expense or claims for bodily injury or property damage, direct
or consequential, arising from use of such chemical components.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and
result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, warnings, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your
Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DNever exceed the recommended working pressure or the maximum air inlet pressure stated on
your pump or in the Technical Data on page 17.
DBe sure that all spray/dispensing equipment and accessories are rated to withstand the maxi-
mum working pressure of the pump. Do not exceed the maximum working pressure of any
component or accessory used in the system.
DRoute the hoses away from the 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).
DDo not use the hoses to pull the equipment.
DUse fluids and solvents that are chemically compatible with the equipment wetted parts. See
the Technical Data sections of all the equipment manuals. Always read the material manufac-
turer’s literature before using fluid or solvent in this pump.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturers.
DWear hearing protection when operating this equipment.
DComply with all applicable local, state and national fire, electrical and other safety regulations.

4 684002
Warnings
WARNING
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DExtinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while operating or if fumes are present.
DDo not operate a gasoline engine in the dispense area.
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

684002 5
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts, such as the piston in the air motor, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the sprayer.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the
equipment from starting unexpectedly.
DKeep hands and fingers away from the moving parts during operation.
INJECTION HAZARD
Spray from the spray gun, hose leaks, or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the
skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention. Tell the doctor EXACTLY what fluid was injected.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DAlways have the trigger guard on the gun when dispensing.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe s re the g n/valve trigger safety o
p
erates before dis
p
ensing
DB
e sure
th
e gun
/
va
l
ve
t
r
i
gger sa
f
e
t
y opera
t
es
b
e
f
ore
di
spens
i
ng.
DLock the gun/valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 7 if the nozzle clogs, and before cleaning, check-
ing or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.

6 684002
Installation
Ground The System
To reduce the risk of static sparking, ground the pump
and all the spray equipment used or located in the
spray area. CHECK your local electrical code for
detailed grounding instruction for your area and type of
equipment. BE SURE to ground the system as
instructed here and in the individual component manu-
als.
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of a fire, explosion,
and serious injury, proper electrical
grounding of every part of your system is
essential. Read the warning section,
FIRE AND EXPLOSION HAZARD, on
page 4 and follow the grounding
instructions below.
The following grounding instructions are minimum
requirements for a basic dispensing system. Your
system may include other equipment or objects which
must be grounded. Check your local electrical code
for detailed grounding instructions for your area and
type of equipment. Your system must be connected to
a true earth ground.
1. Pump: connect a ground wire and clamp to a true
earth ground as shown in separate pump manual.
2. Applicator: obtain grounding through the motor
cable assembly.
3. Fluid and air hoses: use only electrically conduc-
tive material and air hoses.
4. Dispense gun: obtain grounding through the con-
nection of the hose, or cable.
5. Air compressor: follow the manufacturer’s recom-
mendations.
6. Object being sprayed: according to local code.
7. Fluid supply container: according to local code.
WARNING
SPRAY GUN AND DISPENSING VALVE SAFETY
DEVICES
Be sure all safety devices are operating properly
before each use. Do not remove or modify any
part of the gun; this can cause a malfunction and
result in serious bodily injury..
NOTE: Read this manual thoroughly before installing
the flow gun.

684002 7
Installation
Pressure Relief Procedure
This procedure describes how to relieve pressure for
the pistol grip flow gun. Use this procedure whenever
you shut off the flow gun and before checking or
adjusting any part of the gun, to reduce the risk of
serious injury.
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause a serious injury. To reduce the risk
of an injury from injection, splashing fluid, moving
parts, or electric shock follow the Pressure Relief
Procedure whenever you:
Dshut off the sprayer,
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the nozzle.
1. Engage the gun safety latch.
2. Shut off the fluid supply to the flow gun.
3. Disengage the gun safety latch.
4. Place a waste container beneath the nozzle to
catch the drainage.
5. Actuate the flow gun. Wait until the fluid stops
flowing from the hose and gun.
6. Shut off power to the fluid supply system.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
nozzle or hose end coupling to relieve pressure gradu-
ally, then loosen completely. Now clear the nozzle or
hose.

8 684002
Installation
NOTE: Numbers and letters in parentheses in the
text correspond to the reference numbers and
letters in the drawings and parts list.
WARNING
Be sure your system has a bleed–type
master air valve (pneumatic pumps only)
and a fluid drain valve. These two ac-
cessories help to reduce the risk of a serious injury,
including fluid injection or splashing in the eyes or
on the skin, or injury from moving parts, if you are
adjusting or repairing the pump or gun.
INJECTION HAZARD
Basic Guidelines
The bleed–type master air valve relieves air trapped
between this valve and the pump after the air regulator
s shut off. Trapped air can cause the pump to cycle
unexpectedly.
The fluid drain valve assists in relieving fluid pressure
in the displacement pump hose and gun; triggering the
gun to relieve pressure may not be sufficient.
NOTE: Whenever you stop spraying for a
moment, engage the gun safety latch. See Figure
1.
Fig. 1
TI0660
TI0660
Safety latch
disengaged or
in OFF
SAFE position
Safety latch
engaged or
in ON
SAFE position
1. Connect the grounded fluid hoses to the gun inlets.
2. With no tip installed, start the pump/sprayer. Flush
it according to the instructions supplied with it.
Prime the sprayer with the fluid you are using.
3. Follow the Pressure Relief Procedure described on
page 7.
4. With the gun safety latch engaged, unscrew the tip
guard (23) and install the tip and gasket (51) in the
back of the tip guard. Screw the assembly firmly
onto the mixer. Install o–ring (10) into nut of the
mixer. Screw and assemble firmly onto the gun.
Tighten both connections with a wrench. See
Figure 2.
NOTE: Failure to install the tip gasket (51) when
using a flat tip (only) will result in leaking.
5. Strain the fluid you are spraying if it contains
particles which could clog the spray tip.
Fig. 2
10
10
23

684002 9
Operation
WARNING
SYSTEM PRESSURE
DO NOT exceed 3000 PSI (210 bar) MAXIMUM
WORKING PRESSURE to the gun. Be sure all
accessory items and system components are rated
to withstand the pressure developed. NEVER
exceed the pressure rating of any component in the
system.
WARNING
PRESSURIZED EQUIPMENT HAZARD
To reduce the risk of serious injury, including fluid
injection or splashing in the eyes or on the skin,
always follow the Pressure Relief Procedure
described below before checking, servicing, instal-
ling, removing, changing or cleaning spray tips or
any part of the gun or system.
WARNING
WARNING CARD
The wallet–sized warning provided with this gun
should be kept with the operator at all times. The
card contains important treatment information
should an injection injury occur. Additional cards
are available at no charge from Graco Inc.
Pressure Relief Procedure
1. Start the pump. Adjust the fluid pressure so the
spray is completely atomized. Always use the
lowest pressure necessary to get the desired
results. Higher pressure may not improve the
spray pattern and will cause premature tip and
pump wear.
2. If adjusting the pressure does not give a good
spray pattern, try another tip size. Be sure to
relieve pressure completely before changing tips.
3. Use a full–open, full–close trigger action. Hold the
gun for about 14”(350 mm) from and at right
angles to the work surface. Don’t swing the gun in
an arc. Practice to find the best length and speed
of stroke.
Gun Safety Latch
Whenever you stop spraying, even for a moment,
always set the gun safety latch in the closed or “safe”
position, making the gun inoperative. Failure to set the
safety latch can result in accidental triggering of the
gun.
Tip Guard
ALWAYS have the tip guard in place on the gun while
spraying. The tip guard alerts you to the fluid injection
hazard and help reduce, but does not prevent, the risk
of accidentally placing your fingers or any part of your
body close to the spray tip.
Trigger Guard
ALWAYS have the trigger guard in place on the gun
when spraying to reduce the risk of accidentally trig-
gering the gun if it is dropped or bumped.

10 684002
Operation
Adjust the Spray Pattern
1. To adjust the spray pattern direction, follow the
Pressure Relief Procedure. Engage the safety
latch and loosen the tip guard retaining nut. Turn
the spry tip so the groove is horizontal for a hori-
zontal spray pattern, and vertical for a vertical
spray pattern. Tighten the nut.
2. The spray tip orifice size and spray angle deter-
mine the coverage and size of pattern. When
more coverage is needed, use a larger spray tip
rather than increasing the fluid pressure.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury by
fluid injection or splashing in the eyes or
on the skin, NEVER use the gun with the
tip guard removed.
CAUTION
Openings in the tip guard are designed to reduce
material buildup on the guard while spraying. Any
damage to the sharp edges of the openings causes
paint to collect at that area. To reduce the risk of
damage, never hang the gun by the tip guard.
Cleaning and Clearing the Spray Tip
WARNING
To reduce the risk of a fluid injection or
splashing in the eyes or on the skin, DO
NOT hold your hand, body, or a rag in
front of the spray tip when cleaning or checking a
clogged tip. Always point the gun toward the
ground or into a waste container when checking to
see if the spray tip is cleared.
INJECTION HAZARD
DO NOT try to “blow back”paint; this is NOT an
air spray gun.
DO NOT wipe fluid build–up off the gun or spray
tip until the pressure is relieved. See the Pressure
Relief Procedure.
Clean off the front of the tip frequently during the day’s
operation and at the end of the work day. Always
follow the Pressure Relief Procedure on page 9.
Then use a solvent soaked brush to clean the spray tip
and to keep fluid buildup from drying and clogging the
spray tip.
If the spray tip clogs while spraying, release the spray
gun trigger, engage the trigger safety, shut off the
pump, and follow the Pressure Relief Procedure on
page 9. Then remove the spray tip and blow out the
obstruction with air from the front of the spray tip, or let
the spray tip and gun nozzle soak long enough to
dissolve the obstruction. If it won’t dissolve, jar it out
by tapping the back of the spray tip against a flat
surface.
CAUTION
NEVER soak the entire gun in solvent. Prolonged
exposure to solvent can ruin the packings.