Graco 980S Operation manual

308–810
Rev. B
Supercedes Rev. A
First choice when
quality counts. 
Model 980P
240–100 Model 980P , without fluid set
240–103 Model 980P , with # 3 fluid set
Model 980S
Includes 1 quart (1 liter) cup
240–090 Model 980S, without fluid set
240–093 Model 980S, with # 3 fluid set
240–094 Model 980S, with #4 fluid set
240–095 Model 980S, with #5 fluid set
8065A
8066A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Series 980
Non–Bleed Style T urbine
Spray Gun
100 psi (7 bar) Maximum Inlet Air Pressure
50 psi (3.5 bar) Maximum Inlet Fluid Pressure
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

  
Table of Contents
Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spraying Techniques 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Model 980S 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 980P 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 of f 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


EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your distributor .
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure of the lowest rated system component. See the
T echnical Data on page 23.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
T echnical Data on page 23 for this information.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82 _ C (180 _ F) or below –40 _ C (–40 _F).
DW
ear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Do not point the gun at anyone or at any part of the body .
D
Follow the Pressure Relief Procedure on page 1 1 if the fluid nozzle clogs and before cleaning,
checking or servicing the equipment.
DT ighten all fluid connections before operating the equipment.
D 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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
D
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.

4  308-810
Setup
Information
CAUTION
Model 980 non–bleeder style spray guns are for
use with Graco GTS T urbine Systems. Do not use
with previous models of Graco or Croix turbines.
Use will dramatically shorten turbine life.
NOTE: Model 980 HVLP spray guns dif fer from tradi-
tional non–bleeder guns by the constant low velocity
airflow designed to prevent restriction and plugging of
aircap orifices.
Connect Fluid and Air Supply
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.
2. If using spray gun cup (D), connect cup to gun
fluid inlet (E).
3. If using accessory remote pressure pots (F),
connect fluid supply hose (G) between remote
pressure pot fluid outlet (H) and gun fluid inlet (E).
Connect pressure pot air hose (J) between pres -
sure pot air regulator inlet (K) and the cart com -
pressor air outlet (L).
NOTES:

The HVLP Cart/Compressor provides the air supply
for remote pressure pot.
 Circled letters in Fig. 1 indicate hose line connec -
tions.
Fig. 1 8068A
C
D
2-1/2 Gallon Remote Pressure Pot 2 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
F
K
K
Y
XX
Y
Y
Z
X

308-8105
Setup
Fluid Set Installation
Complete spray guns are available with #3, #4, or #5
fluid sets. T o install other fluid sets, perform the follow -
ing steps. See Fig. 2.
1. Remove air cap retaining ring (28). Discard pack -
aging (not shown). Remove detente plate and
spring (26).
2.
Remove fluid regulator assembly (18, 19, 20) and
spring (21) from back of gun.
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 980 Cup Gun for Pressure Feed
1. Remove air pressure tube (31) from air stem (34).
See parts drawing on page 20.
2. Hold fluid inlet fitting (7) with wrench and remove
cup assembly (32).
3. Remove air stem (34) from gun body (1).
4. Apply medium strength threadlocker to set
screw (30) 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 speci -
fications. Compensate for faster turbine drying time by
using reducer one-step slower than conventional air
spray.
Fig. 2

28
26
6
18
19
20
21
14
29

6  308-810
Setup
Paint Reduction – Industrial or Domestic Coatings
Reduce and catalyze all paint to manufacturer ’ s speci -
fications. If no reductions are given, first thoroughly
mix fluid to be sprayed. Gradually mix in reducer ,
testing fluid for correct spraying consistency .
T est consistency: Remove stir stick from thinned paint.
Consistency is right when first drops from stir stick are
about one second apart.
Fill Cup or Remote Pressure Pot
Spray Gun Cup
WARNING
The spray gun cup is pressurized by the gun’ s air
supply. T o reduce the risk of serious injury from
pressurized fluid or accidental spray from the gun,
always turn of f 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.
Fig. 3
H
8066A
Accessory Remote Pressure Pot
WARNING
The accessory remote pressure pots remain pres -
surized until pressure is manually relieved. T o
reduce the risk of serious injury from pressurized
fluid or accidental spray from the gun, always
relieve pressure in the pressure pot before loosen -
ing or removing the cover .
1. Relieve remote pressure pot pressure as follows:
a. T urn of f air supply to pressure pot. See Fig. 4.
b. 2 1/2 Gallon Remote Pot: Pull pressure relief
valve ring (206c) until pressure is completely
relieved.
2 Quart Remote Pot: Turn out pressure relief
knob (1
13) one turn. W ait until pressure is
completely relieved before removing cover .
Close knob.

Fig. 4
206c 113
2 quart
2 1/2 gallon
8069A
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 . T ake 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.

308-8107
Setup
Prepare Surface
Completely clean surface to be sprayed.
Turbine Operation
WARNING
Sparking can be expected in the normal operation
of the turbine motor . Sparks can ignite fumes from
flammable liquid, dust particles, and other flamma -
ble 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.
A void all ignition sources such as static electric -
ity 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 of
f.
Extinguish or remove all sources of ignition.
1. T urn turbine on a few minutes before spraying to
warm-up. T urn turbine of f when not in use. T urbine
does not shut of f automatically .
2.
Be sure the turbine filter is clean before operating.
See page 13 to check and clean filter .
HVLP Compressor/Cart Cold W eather Operation
The HVLP compressor/cart uses a diaphragm com -
pressor
. When new , the diaphragm may becomes stif f
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. T urn 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. T urn turbine and compressor ON. If necessary ,
repeat procedure.
Adjust Pattern Direction and Shape
Spray pattern direction and shape are determined by
3 dif ferent 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.
Vertical Pattern
Horizontal Pattern
Fig. 5
Round Pattern
02847

  
Setup
Adjust Spray Pattern
Select fluid set for fluid to be sprayed. If needed, see
page 10 to determine correct fluid set.
WARNING
Do not exceed the gun’ s 50 psi (3.5 bar) Maxi -
mum Fluid Inlet Pressure and 100 psi (7 bar)
Maximum Air Inlet Pressure . Higher pressures
can cause parts to rupture and result in serious
injury or property damage.
T o establish correct fluid flow:
1. T urn fluid adjustment knob (21) counterclockwise
until no restriction of trigger movement is felt.
See Fig. 6.
8070A
Fig. 6
21
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 2 1/2 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 pres -
sure pots can cause serious injury . T o reduce
the risk, never exceed 50 psi (3.5 bar) Maximum
Air Inlet Pressure .
Fig. 7 8071A
8–10 in.
(203–254 mm)
3. If further gun fluid adjustment is needed, turn fluid
adjustment knob (21) clockwise to reduce volume
of fluid output. See Fig. 8.
21
Fig. 8 8072A

308-8109
Setup
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 dif ferent size needle/nozzle/air cap
combination.
T o establish correct air flow:
4. T est spray pattern and atomization while holding
gun about 6 to 8 inches (150 to 200 mm) from test
piece.
5.
Air Control V alve (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:
1. Control over-spray mist by using only as much air
as necessary to spray fluid. Lighter fluids require
less air .
2.
If atomization is still unacceptable, fluids may be
thinned further or a dif ferent fluid set may be
required. Refer to page 10 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.
T urning air cap out too far , will stop fluid or
cause flutter .
1
2

  
Setup
Contractor Fluid Set Chart
Use this chart to determine Fluid Set for specific contractor application. See Fig. 1 1.
Fluid Set Components
Fluid Set
P/N & Size
(A)
Air Cap
(B)
Nozzle
(C)
Needle
Type of
Fluid**
Fluid Usage
240–112
#2
(0.8 mm)
240–490 192–911 192–916 Light
14–18 sec.
Fine finish work with stains, lacquers, water-
borne
lacquers
240–113*
#3
(1.3 mm)
240–491 192–912 192–917 Light–Medium
18–22 sec.
Medium speed application with lacquers,
enamels, urethanes, and varnish
240–114
#4
(1.8 mm)
240–492 192–913 192–918 Medium
20–26 sec.
Medium to high speed industrial finishes
240–115
#5
(2.2 mm)
240–493 192–914 192–919 Heavy
22–26 sec.
Heavy output with lacquer and enamels, latex
and oil wall paints
240–116
#6
(2.5 mm)
240–494 192–915 192–920 Heavy
26+ sec.
W ax 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. 1 1.
Fluid Set Components
Fluid Set
P/N & Size
(A)
Air Cap
(B)
Nozzle
(C)
Needle
Fluid Usage
240–117
0.5/0.5M
M70–434
0.5 mm
M70–446 M70–453 Ultra fine finish with automotive touch-up,
spot jobs
240–118
0.7/0.7M
M70–437
0.7 mm
M70–447 M70–455 Fine finish work with all automotive finishes, color
matching, automotive base coat
240–113*
#3 (1.3 mm)
240–491 192–912 192–917 Normal output with enamels, urethanes, zinc
chromate, automotive primers
* Standard fluid set.  Multi-hole air cap.