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.


Setup
Using Fluid Set Charts
Turbine Spray Gun includes a #3 fluid set, part no.
240–113. The size of air cap, fluid nozzle, and fluid
needle are marked on parts.
Use fluid set charts on page 10 to order different size
fluid set or to find part number of individual compo -
nents of fluid set. Charts identify fluid sets used in
contractor and automotive applications.
Fluid sets include air cap (A), nozzle (B), and
needle assembly (D). See Fig. 1 1.
NOTE: T o order other replacement parts for gun, see
parts drawing and list for gun model on page 20.
Fig. 11 02981
A
B
C
Fluid Set
D
Selecting Fluid Set
Turbine spray gun fluid sets range in size to provide
dif ferent fluid flow rates. Selection charts on page 10
show recommended combinations based on fluid
viscosities, flow rates, and usage.
As a general guideline, use fluid nozzle that will give
required flow with needle fully triggered at lowest fluid
pressure.
For low flow rates or light viscosity fluid, select smaller
nozzle sizes.
For high flow rates or high viscosity fluid, select larger
nozzle sizes.
T o eliminate mist, use air cap one size larger than fluid
nozzle. Use of smaller size air cap produces finer
finish, but can increase mist.
For very fine finish work (automotive, furniture, etc.),
order air cap two sizes smaller than needle and nozzle.
0.5M mm or 0.7M mm multi-hole air caps are recom -
mended for automotive finishes. See Automotive
User Chart on page 10.
For narrow fan pattern (wood finishing) , order 0.5W
mm, 0.7W mm, or 1.0W mm narrow fan pattern air
cap. See chart below for part numbers.
Narrow Fan Pattern Air Caps
Air Cap P/N Size
M70–435 0.5W mm
M70–438 0.7W mm
M70–441 1.0W mm
Shutdown
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of a serious
injury from pressurized fluid, accidental spray from
the gun, or splashing fluid, follow the Pressure Re -
lief Procedure whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 or install or clean the fluid nozzles.
1. When spraying is finished, turn of f air supply to
gun.
2. T
urn of f turbine sprayer .
WARNING
The turbine hose outlet may be hot. Carefully
check the hose end before removing the hose.
3. If using remote pressure pot, relieve pressure by
following these steps:
a. T urn of f air supply to pressure pot.
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) about one turn. W ait until pressure
is completely relieved before removing cover
.
Close knob. See Fig. 12.

  
02882A
Fig. 12
206c
113
2 quart
2 1/2 gallon
8069A
NOTE: Elevate spray gun and pull trigger . This will
allow fluid in fluid hose to drain back into remote
pressure pot.
4. If using a spray gun cup, unlatch cup cover and
loosen or remove cup from cover to relieve cup
pressure.
5.
Clean spray gun and cup as instructed on
page 14.
Spraying T echniques
General Spraying Techniques
1. Select proper fluid set. T o determine correct fluid
set see charts on page 10.
2. When fluid is first applied, start with fluid nozzle
and air cap adjusted to “normal spray pattern”
position. Then adjust as needed. See Fig. 10 for
pattern size adjustment.
3. Keep gun perpendicular to surface and maintain
consistent distance of approximately 6 to 8 inches
(150 to 200 mm) from object being sprayed.
See Fig. 13.
4. Always have spray gun in motion before triggering.
Move spray gun across workpiece in straight,
smooth, stroke. Maintaining speed and distance.
Release trigger at end of stroke.
5. T o obtain even finish, overlap previous strokes
by 50%.
6. Apply full, wet coat whenever possible.
Automotive Spraying Techniques
1. When blending spots, work from outside in.
2. T wo lengths of 20 foot (6.1 m) hose are recom -
mended when applying automotive finish coats.
Additional hose allows air to cool for better flow .
WRONG
Fig. 13
0793
RIGHT 0793
6–8 in.
(150–
200mm)


Maintenance
Turbine Filter Maintenance
Turbine systems are lifetime lubricated. The only
maintenance required is filter cleaning and replace
-
ment.
T urbine main filter and pre-filter must be clean at all
times to provide suf ficient air flow to cool motor and
atomize fluid. Check turbine pre–filter daily for cleanli -
ness. Check the main paper filter weekly , minimum.
Clean as necessary .
NOTE: T o check filter , turn on turbine and place piece
of paper against pre–filter . If air intake holds paper in
place, filter is okay .
T
o clean main filter:
1. T urn of f and unplug turbine.
2. Loosen four main filter screws, remove filter retain -
er and pre–filter .
3.
Remove main filter and clean by following one of
the following three methods:
T ap filter gently on flat surface, dirty side
down.

Direct compressed air (100 psi [7 bar] maxi -
mum) through filter panel in opposite direction
of arrows on side of filter .

Soak filter for 15 minutes in water and mild
detergent. Rinse filter until clean. Air dry filter;
do not use compressed air .
WARNING
T o avoid damage to the turbine and possible electric
shock, never install a damp filter in the turbine.
Flushing Spray Gun Using Remote
Pressure Pot
WARNING
The spray gun cups and accessory remote pres -
sure 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 cup or
pressure pot before checking or servicing any part
of the spray system; before installing, cleaning or
changing fluid nozzles; before loosening or remov
-
ing the accessory remote pressure pot cover; and
whenever you stop spraying.
NOTES:

Check for any fluid leakage from gun and fluid
hoses. T ighten fittings or replace equipment as
needed.

Flush gun before changing colors and whenever
you are done spraying.
CAUTION
Clean all parts with a solvent compatible with the
fluid being sprayed and compatible with the spray
gun and cup or accessory remote pressure pot
wetted parts. See the T echnical Data on the back
cover.
1. T
urn of f air supply to gun.
2. Relieve pressure pot pressure as follows:
a. T urn of f air supply to pressure pot.
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) about one turn. W ait until pressure
is completely relieved before removing cover
.
Close knob. See Fig. 12.
3. Fill pressure pot with compatible solvent.
4. Flush spray gun, using compressor air only . Point
gun down into container and flush until solvent
runs clean.
5. Relieve pressure pot pressure, following steps 2.a
and b, above.
6. Disconnect air and fluid hoses from gun.
7. Clean and lubricate gun as instructed starting on
page 14.

14  308-810
Maintenance
Flushing Spray Gun and Cup
1. Turn of f air supply to gun.
2. Unlatch cup cover and remove cup from cover .
3. T
urn air cap to round pattern position. T urn air
control valve half open to reduce solvent mist. See
Fig. 14.
Fig. 14
Air Cap Round
Pattern Position
02847
4. Fill empty cup with about 1-1/2 inches (38.1 mm)
of compatible solvent and reinstall cup. Be sure
cover is secured.
5. T urn on air to gun.
6. Point gun down into and ground against container
and flush until solvent runs clean. See Fig. 15.
Fig. 15 8073A
7. T urn of f air to gun.
8. Disconnect air supply and remove cup from gun.
Clean and lubricate gun as instructed on pages 14
and 15.
Clean Spray Gun
1. Clean gun and cup by hand with compatible sol -
vent or place them in gun washer with trigger held
open; cycle washer as necessary to clean gun.
Fig. 16 8074A
2. Remove air cap retaining ring (28), air cap (29),
spring (26), and detent plate (26). See Fig. 17.
3. T rigger gun while removing fluid nozzle (25) with
nozzle wrench (P), provided. See Fig. 17.
4. Remove gun fitting (19) from back of gun. Remove
needle for cleaning.
CAUTION
T rigger the gun whenever you tighten or remove
the nozzle. This keeps the needle seat away from
the nozzle seating surface and prevents the seat
from being scratched.
8075A
Fig. 17
25
28
29
26
P
5. Soak air cap, detent plate and fluid nozzle in
solvent. At a minimum, clean air cap and fluid
nozzle daily . Use solvent and brush (R), provided.
See Fig. 18. Some applications require more
frequent cleaning. Keep all air cap holes clean.
CAUTION
Clean air cap horn holes with a non-metallic item to
avoid permanently damaging them.

308-81015
Maintenance
Fig. 18
02856
R
6.
With gun pointed down, clean front of gun, using
brush and solvent.
7. T rigger gun while installing fluid nozzle (25) with
nozzle wrench (P). See Fig. 17.
8. Install spring (26) into front of gun.
9. Install detent plate (26) into gun housing with open
sockets (S) facing up; align detent plate tab (T)
with notch in gun housing. See Fig. 19.
10. Install air cap (29), aligning air cap balls (U) with
detent plate sockets (S). See Fig. 19. Secure air
cap with air cap retaining ring (28).
NOTE: If installed correctly, air cap will snap into four
definite positions, with no loose rotation.
Fig. 19
U
S
T
26
29
S
02966
11. Lubricate gun after cleaning it as instructed on
page 15.
Service
Lubricating Spray Gun
After cleaning or servicing gun, lubricate parts indi -
cated in Fig. 20 with silicone-free spray gun lubricant
or similar material.
 All threaded areas (A)
T rigger screws (B)
T rigger axle (C)
 Fluid needle assembly (D) – where indicated
Fig. 20
A A
C
B
D
02949
2 in. (50.8 mm)
DD
Fluid Needle Assembly
8076A

16  308-810
Service
Adjusting Needle
The needle may need to be adjusted whenever you
change nozzle/needle sizes or to compensate for
wear.
T o adjust needle:
1. Remove fitting (19) and spring (18-not shown)
from back of gun. See Fig. 21.
2. Loosen locking nut (17). See Fig. 22.
3. T urn drum (13) until trigger has about 1/16 in.
(1.59 mm) free travel before needle (14) is
engaged and starts to move. See Fig. 22.
4. Lock adjustment with nut (17).
5. Make sure spring (18) is in place in fitting (19),
then install housing with other parts. Hand-tighten
housing.
Fig. 21
18, 19
8076A
Fig. 22
171314
8077A
1/16 in.
(1.59 mm)
Free Travel
Adjusting Needle Packings
Needle packings require adjustment once a month
under normal use to ensure fluid does not leak back
through packings. Needle packings must also be
adjusted whenever the needle is removed or adjusted.
T o adjust needle packings:
1. First flush gun as instructed on page 14.
2. Remove air cap retaining ring (28), air cap (29),
spring (26), and detent plate (26). See Fig. 23.
3. T rigger gun while removing fluid nozzle (25) with
nozzle wrench (P), provided. Clean gun as
instructed on page 14.
CAUTION
T rigger the gun whenever you tighten or remove
the nozzle. This keeps the needle seat away from
the nozzle seating surface and prevents the seat
from being scratched.
Fig. 23
25
28
29
26
P
8075A
24
4. T
rigger gun while slightly turning packing nut (9)
clockwise with packing wrench (K), provided. See
Fig. 24. This will compress packings.
The packings need very little pressure to seal well.
If needle binds, packings are too tight; back pack -
ing nut of f 1/16 turn. Needle should then move
freely . If packings are over-tightened, they may be
damaged and need to be removed and replaced.

308-81017
Service
Fig. 24
K
DETAIL
8078A
8
9
5. T
rigger gun while installing fluid nozzle (25) with
nozzle wrench (P). See Fig. 23.
6. Install spring (26) into front of gun.
7. Install detent plate (26) into gun housing with open
sockets (S) facing up; align detent plate tab (T)
with notch in gun housing. See Fig. 25.
8. Install air cap (29), aligning air cap balls (U) with
detent plate sockets (S). See Fig. 25. Secure air
cap with air cap retaining ring (28).
NOTE: If installed correctly , air cap will snap into 4
definite positions, with no loose rotation.
U
S
T
26
29
S
Fig. 25 02966
Fig. 26 8231A
1
C
A
23
B
42
24
22
Replacing Air Valve
1. Loosen quick disconnect coupling (24) and remove
handle (23). See Fig. 26 and parts list.
2. Holding gun body (1) inverted, remove handle tube
(22) from gun body .
3. Using a needle–nose pliers, grasp valve assembly
(42) by installation/removal tab (A).
4. Clean valve seating shoulder (B) in gun body with
a brush and solvent.
5. Using installation/removal tab, insert valve assem -
bly (42) into gun body (1) with the hook of valve
(C) oriented towards the front of the gun. Make
sure valve assembly (42) is fully seated in the
locking flats in the gun body .
6.
Hand tighten handle tube (22) into gun body (1) to
capture valve assembly (42).
CAUTION
The use of tools to tighten handle tube will result in
severe damage to valve assembly .
7.
Install handle (23) and quick disconnect coupling
(24). T orque quick disconnect coupling to 60–80 in.
lbs.
CAUTION
Do not assemble and torque quick disconnect cou -
pling to handle tube without installing handle. Se -
vere damage to valve assembly will result.

  
Troubleshooting
Spray Finish Problems
PROBLEM CAUSE SOLUTION
Orange peel finish – Paint
surface not smooth
Paint droplets too large.  Maintain proper spraying distance;
see page 12.
 Keep the turbine air filters clean to
allow full air flow . See page 13.
 Do not use an air hose that is too
long to provide suf ficient atomiza -
tion pressure.
 If droplets are still too large, reduce
the fluid or use a smaller air cap.
Paint droplets drying too fast to proper -
ly flow out of gun.
Keep the object being sprayed out of
direct sunlight. When spraying in
warmer temperatures, use a slower
evaporating solvent or a retarder
.
Cold weather spraying. Keep the fluid and the object being
sprayed as close to room temperature
as possible. When sprayed on a cold
surface, most paints will become too
thick to flow properly
.
Blushing – Clear coatings
appear milky
Moisture condensation is trapped in
the lacquer when spraying in hot, hu -
mid conditions.
 Allow the turbine to warm up a few
minutes before spraying.
 Store the lacquer of f concrete
floors, at room temperature.
 Apply lighter coats and allow for
proper drying time.
 Use a slower evaporating solvent
or retarder.

Do not spray in windy conditions.
Fish eyes – Small pools on
painted surface that will not
fill
Silicone contamination from lubricants,
grease, polish, or waxes on the sur -
face being sprayed.
Clean all parts with a cleaning solvent;
use a solvent rag and a clean rag to
wipe with. Replace rags as needed. If
the problem persists, use a fish eye
eliminator.
Runs and sags Applying too much paint per pass for
the drying conditions.
 Move the gun faster or decrease
the fluid flow .

Maintain proper spraying distance;
see page 12.
 Reduce the amount of thinner or
use a faster drying thinner
.
Solvent pops or bubbles Sprayed surface drying before solvent
gas can be released.
 Apply fluid in lighter coats to allow
for proper evaporation.
 Use the recommended thinners.
 Follow the solutions, above, for
Orange peel finish–paint droplets
too large .

308-81019
Troubleshooting
Spray Gun Problems
PROBLEM CAUSE SOLUTION
No or slow fluid flow , inter -
mittent spray , or fluttering
spray
Proper size fluid set is not being used. Select the proper fluid set for the fluid
being sprayed. See page 10.
Air cap is adjusted too far forward. Adjust the air cap to “normal” position.
See page 9.
Gun fluid nozzle is not tight enough, is
blocked by dried paint, or is damaged.
T ighten, clean or replace fluid nozzle.
Cup or pressure pot cover is not tight
enough or gasket is damaged.
T ighten cover or replace gasket.
Cup or pressure pot fluid tube blocked
by dried paint or is damaged.
Clean or replace fluid tube.
Air flow to cup is blocked. T o check: remove the cup (leave
cover connected), trigger the gun and
check for air flow out of the cup lower
pressure tube. If air is not flowing
freely , clean the air passage tubes.
Needle packings are not properly ad -
justed. Fluid loss though the packings
will ef fect fluid pressure and cause a
fluid build-up in the gun body
.
Clean the gun body with solvent and
the brush provided. Adjust the needle
packings as instructed on page 17.
Needle is not properly adjusted. Fluid
flow will be restricted if there is too
much free travel between the trigger
and needle.
Adjust the needle as instructed on
page 16.
Fluid leaks at fluid nozzle
after the trigger is released
Needle is not seating in the fluid
nozzle.
 Check for a loose fluid nozzle or a
bent nozzle or needle; tighten the
nozzle or replace parts as needed.
 Check the needle adjustment; see
page 16.
 Check the needle packings adjust -
ment; see page 17.
Poor spray pattern Air cap horn holes and/or fluid nozzle
plugged.
Soak air cap and/or fluid nozzle in sol -
vent. Clean air cap horn holes with
non-metallic item to avoid permanently
damaging them. See page 14.

  
Parts for Model 980S
28
29
26 3 1 2
17
13
14
23
15
16
18
19
20
21
42
22
24
30
6
7
8
9
25 5
4
43
10
11
32b
32a
32c
30
31
34
8080A
32
NOTE:
The air cap (29), fluid
nozzle (25), and fluid needle
parts (13–17) are available as
complete fluid sets. See page
10 for part numbers.
52