INSTRUCTIONS-PARTS LIST
308–341
Rev. G
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Supersedes F
First choice when
quality counts.t
INSTRUCTIONS
Optimiser 2Kt
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
02748
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1993, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
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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
.
D
D
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.
D
D
Never point the spray gun at anyone or at any part of the body
.
Never put hand or fingers over the spray nozzle.
D Tighten all fluid connections before operating the equipment.
D
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.
D
D
FIRE AND EXPLOSION HAZARD
Poor air ventilation, open flames or sparks can cause a hazardous condition and result in fire or explo
-
sion and serious injury
.
D
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
sprayed.
D
D
D
D
D
D
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.
D
D
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.
D
Dress appropriately for your application. Wear protective eyewear, noise protection for the ears, a
personal respirator, gloves and clothing.
308-341
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Selection Chart
Includes:
Needle/
Nozzle/Air
Cap Kit
P/N
Needle
Assembly
P/N
Replacement
Needle Tip
P/N
Air Cap
P/N
Nozzle
P/N
Orifice Size
949–276
949–277
949–278
949–279
949–280
949–281
949–282
238–703
238–703
238–703
238–217
238–218
238–219
238–220
185–794
185–794
185–794
185–794
185–794
185–795
185–796
185–756
185–757
185–700
185–701
185–702
185–703
185–704
191–564
191–564
191–564
191–016
191–017
191–018
191–019
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
Selection Problems and Solutions
The kits range in size to provide different fluid flow
rates.
PROBLEM
POSSIBLE
CAUSE
SOLUTION
Fluid pressure
required to achieve
flow rate is too high
Using set with
too small of an
orifice
Use needle/
nozzle/air cap
set with larger
orifice
D
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).
Using a low pres
sure setting, the
-
Using set with
too large of an
Use needle/
nozzle/air cap
fluid flow is too high, orifice
making it necessary
to restrict needle
travel to reduce fluid
flow
set with small
er orifice
-
D
D
D
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.
Fluid system will not Fluid regulator is Add low pres
-
operate at low
enough fluid pres
sure
not installed or
air regulator is
not sensitive
enough
sure fluid regu
lator or add
more sensitive
air regulator on
pressure pot
-
Using an air cap size that is smaller than the
nozzle/needle size is not recommended.
-
D 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.
D
See Service to install the parts.
4
308-341
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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
20
18
16
14
12
10
8
6
4
2
6
4
0
15 25 35 45 55 65 75 85 95
2
GUN AIR INLET PRESSURE (psi)
0
15 25 35 45 55 65 75 85 95
GUN AIR INLET PRESSURE (psi)
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)
Atomizing Pressure Versus
Activator Inlet Pressure
3.0 psi (0.22 bar)
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.
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
*
For compliant operation, operate at 65 psi (4.55 bar) or less
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)
308-341
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Installation
E
F
G
D
N
A
B
S
R
C
M
J
H
KEY
A
B
C
Optimiser 2K Spray Gun
Air Inlet; 1/4 npsm
Air Hose
Recommend 5/16” (7.9 mm) ID hose;
Optional 3/8” (9.5 mm) ID hose
Gun Air Shut-off Valve
L
K
J
H
Q
P
D
E
F
Gun Air Regulator
Air Filter
G
H
J
K
L
M
N
P
Q
R
S
Air Supply Line
Pressure Pot Air Shut-off Valve
Pressure Pot Air Regulator
Activator Pressure Pot
Activator Fluid Shut-off Valve
Activator Fluid Hose
Activator Inlet 1/8–27 npt(f)
Adhesive Pressure Pot
Adhesive Fluid Shut-off Valve
Adhesive Fluid Hose
Adhesive Inlet; 3/8 npsm (R3/8–19)
02750
Fig.
1
D
D
Some adhesives will coagulate in fluid pressure
regulators due to shear. Consult with the fluid
supplier for regulator recommendations.
Fluid Compatibility of Accessories
When selecting system components to supply the
adhesive and activator, consider the following:
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.
D
D
Adhesives and activators are water-based and
corrosive. Avoid carbon steel, unplated brass,
copper, and aluminum. Stainless steel, nickel-
plated brass and most plastics are usually accept
able.
-
Ventilate the Spray Booth
WARNING
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.
FLAMMABLE/TOXIC FLUID HAZARD
o avoid hazardous concentrations of
T
flammable or toxic fumes, spray only in
a properly ventilated spray booth.
Comply with all applicable local, state
and national fire and safety regulations.
6
308-341
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Installation
Air Line Accessories
Fluid Line Accessories
D If you are using diaphragm pumps to supply adhe
-
D The gun air line must have an air regulator (E) to
sive or activator to the gun(s), install a fluid regula
-
control air pressure to the gun. See Fig. 1.
tor (T) on each gun fluid supply line to control fluid
pressure to the gun(s). See Fig. 9, page 9.
D
If the gun air source does not have a filter
filter (F) on the gun air line to ensure a dry, clean
air supply
,
install a
D
D
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.
.
D 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:
Q
L
02059
Fig. 2
D
D
D
D
Are instructed to relieve pressure
Stop spraying
Check, clean or service any system equipment
Install or clean fluid nozzles
1. Close the adhesive and activator shut-off valves
(Q and L). See Fig. 2.
02753
Fig. 3
2. Trigger the gun into the spray booth* to relieve the
fluid pressures and clear excess activator from the
gun. See Fig. 3.
D
*
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.
02780
Fig. 4
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Setup and Shutdown
Removing and Installing the Fluid Nozzle
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.
Follow this procedure whenever you remove and install
a fluid nozzle. See page 4 to select a nozzle or
needle/nozzle/air cap kit.
1. Follow the Pressure Relief Procedure on
page 7.
4. Apply PTFEradhesive 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).
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.
1
17
2
20
35
47
12, 19
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 NSm).
CAUTION
When tightening the fluid nozzle (20), do not exceed
150 in-lbs (17 NSm) torque. Over-tightening can
damage the nozzle, affect the spray pattern, and is
unnecessary to guarantee a seal.
1
2
Lightly lubricate baffle o-ring (17)
Apply PTFE adhesive to nozzle (20) threads. Trigger gun and
tighten to 125–150 in-lbs (14–17 NSm)
7. Install the air cap seal (47), air cap ring (12), and
air cap (19).
02757A
Fig. 5
8
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Setup and Shutdown
2. Flush the adhesive and activator fluid
WARNING
EQUIPMENT MISUSE HAZARD
This gun is for use with water-based contact adhe-
sives only. Any other use of the gun could cause
unsafe operating conditions or damage to the gun.
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
3/8–18 npsm [R 3/8–19]
compound thread
02752
1
1/4 npsm
Fig. 8
02751
Fig. 6
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).
B. Connect the other end of the air hose (C) to a
regulated air supply line (G). See Fig. 7.
NOTE: Fig. 9 shows the fluid supply line regulator
(T) and fluid shut-off valves (Q).
NOTE: Fig. 7 shows the air supply line filter (F), air
regulator (E), and air shut-off valve (D).
U
G
F
E
T
Q
R
C
D
01990
Fig. 7
02777
Fig. 9
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Setup and Shutdown
4. Connect the activator tube.
6. Adjust the spray pattern.
A. Connect the fitting (V) and tube (M) to the gun
WARNING
activator inlet. See Fig. 10.
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
B. Connect the other end of the fluid tube (M) to a
regulated fluid supply line or a pressure tank.
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.
V
M
8
02784
Fig. 10
Open
5. Position the Air Cap for a vertical or
horizontal spray pattern. See Fig. 11.
02784
Fig. 12
B. Open the adhesive fluid shut-off valve (Q). Ad
just 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
Vertical Pattern
Q
Horizontal Pattern
02020
Fig.
11
02778
Fig. 13
10
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Setup and Shutdown
D. To further reduce the volume of adhesive out
put at the gun, turn the fluid adjustment knob
(8) clockwise as needed. See Fig. 16. How
-
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.
-
ever, 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.
CAUTION
Continuously spraying with the fluid adjustment knob
closed, will cause accelerated wear on the fluid
needle and trigger/air valve shaft interface.
1–6 in.
(25.4–152.4 mm)
straight fluid stream
If the fluid adjustment knob is fully closed, the gun
will emit only air and activator
.
02754
Fig. 14
8
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.
Close
Fluid Stream of Fluid Nozzles
at the Same Flow Rate
02784
Fig. 16
E. Open the pattern adjusting valve by turning the
knob (13a) fully counterclockwise. See Fig. 17.
0.042
0.055
0.070
0.086
0.110
(1.067) (1.397)
(1.778)
(2.184)
(2.794)
13a
Nozzle Orifice Size in inches (mm)
02755
Fig. 15
Close
(narrower
pattern)
Open
(wider
pattern)
02784
Fig. 17
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Setup and Shutdown
6. Adjust the spray pattern. (continued)
7. Adjust the activator fluid flow.
F. Set the gun air supply pressure at 40 psi
(2.8 bar), using the gun atomizing air regulator
(E). See Fig. 18.
CAUTION
When the activator is being supplied to the gun, the
atomizing air must be on before triggering the gun to
NOTE:
D
Use the fluid manufacturer recommendations if
available and refer to the Atomizing Pressure
avoid contaminating the atomizing air with activator
.
Versus Activator Inlet Pressure chart on
page 5 when adjusting the gun.
Open the activator supply valve (L) and increase
the fluid pressure until the desired amount of acti
vator 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.
D
Local laws may limit the maximum pressure to
10 psi (0.7 bar) at the air cap for HVLP com
pliance.
-
-
E
L
01997
Fig. 18
G. Hold the gun about 6 to 8 inches (150 to
02776
Fig. 19
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.
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.
-
NOTE: Some pattern air is required to supply the
activator; do not close the pattern adjustment knob
completely.
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.
I. Check the atomization quality again. If neces
sary, increase the gun air supply pressure with
the air regulator (E) in 5 psi (0.35 bar) incre
-
-
ments 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: o eliminate a fan pattern at low atomizing
T
pressures, it may help to remove the activator air
restrictor (55). See Fig. 34, page 19.
02785
Fig. 20
12
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Ratio Check
NOTE: You cannot sample the adhesive and activator
1
2
52
52
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.
54
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.
02786A
Fig. 21
H. Place the ratio check tube (54) into the beaker
2. Check the ratio of the activator.
as shown in Fig. 21.
A. Weigh an empty beaker
.
I. Direct the spray gun into the booth. Trigger the
gun for 1 minute to dispense the activator
B. Cover the beaker with a loose cover to deflect
through the tube and into the beaker
.
any over-spray. See Fig. 21.
J. Follow the Pressure Relief Procedure on
page 7.
C. Disconnect the red tube from the activator
valve.
K. Remove the beaker cover. Weigh the activator
and subtract the weight of the beaker to obtain
D. Connect the ratio check tube (54) (supplied
the weight per minute of the activator
.
with the gun) to the activator valve outlet fitting
1
(52 ) as shown in Fig. 21. Turn the front fitting
3. Adjust the ratio as needed.
2)
(52 toward the front of the gun.
Adjust the activator supply pressure to change the
ratio of adhesive to activator, then check the ratio
again.
E. Close the adhesive shut-off valve.
F. Open the atomizing air shut-off valve.
G. Open the activator shut-off valve.
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.
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Daily Gun Care, Flushing, and Cleaning
C. Point the gun down into the spray booth* and
spray until the water sprays clear. See Fig. 22.
CAUTION
D Do not point the gun up while cleaning it as this
*
If the gun is flushed with solvent, be sure to spray the
solvent into a grounded metal waste container
.
may allow fluid to enter the gun air passages.
D
Do not use metal tools to clean the air cap holes
as this may scratch them and distort the spray
pattern.
D
D
Do not immerse the gun.
Squeeze the excess fluid out of the cleaning cloth
before wiping the gun.
D Typically the gun should be flushed or cleaned with
soap and water. If solvent is used, do not use me-
thylene chloride with formic or propionic acid as it
will damage nylon components.
2753
Fig. 22
D. Turn off the fluid supplies.
E. Follow the Pressure Relief Procedure on
page 7.
1. General system maintenance.
A. Clean the fluid and air line filters daily
.
3. Clean the gun.
A. After relieving pressure, disconnect the activa
tor and adhesive supply lines (M and R) from
the gun. See Fig. 23.
-
B. Check for fluid leakage from the gun and the
fluid hoses. Tighten fittings or replace equip
ment as needed.
-
C. Flush the gun with water if it will not be used in
the next three days. Follow the flushing proce
dure below
-
.
M
R
2. Flush the gun.
A. Follow the Pressure Relief Procedure on
page 7.
B. Disconnect the adhesive and activator sup
-
plies and connect the supply lines to a water
supply.
02799
Fig. 23
14
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Daily Gun Care, Flushing, and Cleaning
3.
Clean the gun. (continued)
B. Disconnect the air supply line (C). See Fig. 24.
C
02775A
02800
Fig. 26
Fig. 24
C. Remove the air cap ring (12), air cap (19), air
cap seal (47), and fluid nozzle (20) as
instructed on page 8.
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 im
-
plement, such as a toothpick, to avoid damag
ing surfaces.
-
20
35
47
12, 19
02757A
Fig. 25
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.
02011
Fig. 27
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Daily Gun Care, Flushing, and Cleaning
D
Fluid needle shaft
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.
D
Activator nuts, in the area where they contact
the trigger
Lubricate
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
02782A
Fig. 28
4. Lubricate the following gun parts daily,
using Part No. 1
1
1–265 lubricant. See Fig. 29.
Pattern adjustment valve threads
Fluid adjustment knob threads
rigger pivot pin
D
D
D
02756B
Fig. 29
T
16
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Troubleshooting
PROBLEM
CAUSE
SOLUTION
Fluid flow is fluttering while
spraying
1. Fluid nozzle is not tight enough
1. See page 8 to install the fluid nozzle
correctly
2. Fluid filter is clogged
2. Check the fluid filter
3. Fluid adjustment knob is not
properly set
3. Adjust the fluid adjustment knob for
less feathering or use a larger size
nozzle
4. Baffle (item 11) is installed wrong or 4. Check if the baffle protrusion is proper
damaged ly inserted into the gun insert hole, see
page 19; replace the baffle if damaged
-
Fluid flow fades while spraying
high viscosity fluids
1. Air hose size is too restricted for higher 1. Use larger 3/8 in. ID air hose; order part
air flows
no. 185–353
2. Fluid pressure is too low
2. Raise the fluid supply pressure or use
a
smaller fluid nozzle
Pattern becomes off-set or heavy
on ends
1. Fluid nozzle is too tight
1. See page 8 to install the fluid nozzle
correctly; replace the nozzle if
damaged
2. Air cap is too tight
2. Loosen the air cap retaining ring
3. Air cap horn holes are plugged
3. Clean the air cap horn holes with a
non-metallic item, such as a toothpick
Fluid system will not operate at low
enough fluid pressure [below
10 psi (0.7 bar)]
There is no fluid regulator, or the air regu
lator on the pressure pot is not sensitive
enough at low pressures
-
Add a low pressure fluid regulator on the
fluid line or add a more sensitive air regu
lator on the pressure pot.
-
Adhesive residue forms on spray
nozzle
1. Activator is dispensing in the atomizing 1. Do not trigger the gun with the activator
air on and atomizing air of
f
2. Activator valve is leaking or not seating 2. Clean the needle, seat, and packings;
properly
lubricate packings and re-assemble
3. Baffle (item 11) is leaking at baffle pro
-
3. Clean and re-assemble the baffle with
trusion
a
small amount of PTFErpipe sealant
on the baffle protrusion or replace the
baffle. Make sure that the baffle protru
-
sion is properly inserted into the gun
insert hole, see page 19
4. Baffle is leaking at nozzle seal
4. Clean the baffle and replace the
nozzle seal
5. Air cap taper is not sealing to nozzle 5. Clean and re-tighten the air cap
taper
Adhesive collecting in air passages The adhesive nozzle’s internal seal is
leaking
Clean the nozzle and seat; see page 8
to install the fluid nozzle correctly
When the gun is triggered, the
adhesive dispenses before the ac
tivator or the activator dispenses
before the adhesive
Activator needle hex nuts are not tight
Adjust the activator needle hex nuts until
the adhesive and activator needles open
together
-
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Service
8. Insert a thin-blade screw driver (A) through the
Items Needed for Service
back of the gun and into the packing adjustment
nut (31) and remove the screw. See Fig. 31.
D Gun
Wrench – provided
D
D
D
D
D
Seal Installation Tool – provided
Adjustable Wrench
Screw Driver
A
Part No. 111–265 Lubricant
Soap and water
31
NOTE: Gun Repair Kit 949–285 is available; see page
25. The following procedure covers the replacement of
all the kit parts.
Disassemble
02762
1. Follow the Pressure Relief Procedure on
Fig. 31
page 7.
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.
2. Remove the air cap ring (12), air cap (19), air cap
seal (47), and fluid nozzle (20) as instructed on
page 8.
CAUTION
20
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.
35
47
12, 19
21
02757A
Fig. 30
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).
02759
Fig. 32
18
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Service
10. Use the threaded end of the fluid needle (21) to
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.
push out the u-cup seal (33). See Fig. 33.
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.
02760
14. Lightly lubricate the parts indicated in Fig. 34 with
Fig. 33
Part No. 111–265 lubricant.
1
49m
49p
49j
49f
1
49d
49q
49h
49e
49c
49r
49g
49a
53
49k
3
49b
48
49
51
52
55
4
1
49e
2
12
1
49e
19
5
1
47
20
1
17
11
52
33
14
1
1
21
1
4
3
1
39
1
Lightly lubricate
Lightly lubricate threads
Lightly lubricate contact area on trigger face
31
15
1
2
3
4
2
8
1
16
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.
32
22
05885
6
Fig. 34
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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.
02762
Fig. 36
4. Place the new u-cup seal (33) on the seal installa
tion tool (42) with the u-cup lips facing the tool.
See Fig. 37.
-
1
2
5. Push the u-cup seal (33) into the gun until a defi
-
nite snap is felt.
39
3
CAUTION
Apply even pressure to the u-cup seal (33) when
installing it to avoid damaging the seal.
1
2
3
Washer
U-cup; lips face
down
21
Spreader
1
33
02763
Fig. 35
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
02023
Fig. 37
20
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Service
6. Slide the new air valve (14) onto the fluid needle
9. Remove the u-cup seal (32) from the fluid adjust-
(21) until it is against the nut (B). See Fig. 38.
ment 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 installa
tion tool (42) with the u-cup lips facing the tool.
See Fig. 40.
-
11. Push the u-cup seal (32) into the fluid adjustment
nut (6) until a definite snap is felt.
21
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
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Service
13. Install the spring (15) and fluid adjustment nut (6).
18. Secure the activator valve (49) to the plate (2) with
T
ighten the nut to 25 to 35 in-lbs (2.8 to 4.0 NSm).
the two screws (53). Tighten the screws to 10 to
15 in-lbs (1.1 to 1.7 NSm).
See Fig. 42.
14. Install the spring (16) and fluid adjustment knob (8).
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
15. Re-assemble the activator valve assembly. See
Fig. 42.
the gun body
.
a. Make sure the thin end of the needle (49d) is
straight to avoid scratching the inside of the
nozzle.
20. Install the gun and activator triggers (3 and 48).
ighten the screw (5) to 25 to 35 in-lbs (2.8 to 4.0
T
NSm).
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 NSm).
21. Trigger the gun to test the fluid needle (21) move
ment. 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).
22. Adjust the two activator needle hex nuts (49j and
49p) as follows:
49h
1
49r
a. Pull the gun trigger (3) back until you feel
resistance against the main fluid needle (21).
49g
49b
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 posi
tion.
-
1
Spreader taper faces
away from o-ring
c. When properly adjusted, both fluid needles (21
and 49d) will unseat at the same time as you
02781A
Fig. 41
c. Assemble the remaining parts.
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.
d. Secure the activator housings (49b and 49a)
with the four screws (49k). Tighten them
evenly to 5 in-lbs (0.6 NSm).
25. Connect the nylon tube (51) between the activator
valve outlet elbow (52) and the spray gun elbow
(52).
CAUTION
o avoid damaging the plastic threads, do not over-
T
tighten the screws (49k).
26. Make sure the adhesive packing assembly (39) is
sealing by spraying water at low pressure before
fully pressurizing the gun.
16. Install the restrictor (55), flat side up, into the
activator outlet housing (49a).
If the fluid packings leak, tighten the packing
adjustment nut (31) slightly and retest until the
17. Place the o-ring (49e) in the groove in the activator
outlet housing (49a). Lightly lubricate the o-ring.
packings seal completely
.
22
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Service
8
49m
48
49f
49p
49d
49j
49q
49h
49e
49c
49r
49g
49a
2
53
9
49k
49b
49
51
9
7
52
55
49e
2
12
49e
19
47
1
5
6
20
17
11
9
3
52
33
14
21
4
3
39
5
31
15
1
8
16
4
32
22
NOTE: See Fig. 34, page 19, for the parts that
1
6
need to be lubricated.
1
6
Tighten to 25–35 in-lbs (2.8–4.0 NSm)
Apply PTFE adhesive to nozzle (20) threads. Trigger gun
and tighten to 125–150 in-lbs (14–17 NSm)
2
Tighten to 10–15 in–lb (1.1–1.7 N.m)
7
8
9
Flat side up
3
4
5
U-cup (33) lips face air valve (14)
U-cup (32) lips face spring (16)
Tighten to 20 in-lbs (2.3 NSm)
Tighten to 5 in-lbs (0.6 NSm)
Tighten packing nut as needed for fluid tight seal
05885
Fig. 42
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Parts Drawing
49m
49p
49j
49q
49h
49r
Ref No. 13
Fan Air Valve Assembly
Includes items 13a–13d
49g
49b
49f
49d
Ref No. 49
Activator Valve Assembly
Includes items 49a–49r
49n
49e
49c
53
49a
49k
48
51
49
52
52
55
12
19
49e
2
47
20
49e
5
13d
17
11
1
13b
25
13c
13a
33
4
21
14
3
39
31
1
15
16
32
22
6
8
35
1
Tighten to 25–35 in–lb (2.8–4.0 N.m)
42
NOTE: See the Service section for additional assembly
information.
02765A
24
308-341
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Parts List
Part No. 949–239, Series C
Optimiser 2K HVLP Spray Gun
Ref
Ref
No.
Part No. Description
Qty
No.
Part No. Description
Qty
1
2
3
4
5
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
1
1
1
1
49n 949–217 ACTIVATOR VALVE ASSY
.
Includes items 49a–49r
625–730 SHOUSING, activator outlet
625–729 SHOUSING, activator inlet
188–762 SINSERT, nozzle
1
1
1
1
1
3
1
1
1
1
49a
49b
49c
1
1
1
1
1
6
8
11
12
13
49dn 949–295 SNEEDLE ASSY., activator valve
49e* 106–555 SO-RING; Vitonr
49f* 112–931 SSPRING, compression
49g* 103–154 SO-RING; ethylene propylene
276–278 RETAINING RING, air cap
236–006
FAN AIR VALVE ASSY
.
49h
49j
49k
188–665 SNUT, packing
188–772 SNUT, hex
Includes items 13a–13d
1
1
1
1
1
1
1
1
1
1
1
13a
13b
188–492 SVALVE, fan air
113–411 SSCREW, cap, SST
;
188–700 SNUT, air adjustment
10–24 x 3/4”
4
1
1
1
1
13c* 187–699 SO-RING, split; PTFE
r
49m 514–619 SNUT, acorn; nylon
13d* 105–456 SRETAINING RING
49p
49q
112–930 SNUT, hex
112–929 SWASHER
14*
15
16
236–009 AIR VALVE ASSY
.
111–291 SPRING, compression
110–402 SPRING, compression
103–413 SEAL, fluid nozzle
49r* 188–494 SSPREADER
51*
187–169 TUBE; nylon;
17*
5/32 in. (3.97 mm) O.D.
1
4
2
19l 185–794 AIR CAP; 0.020–0.055 size
20l 185–702 FLUID NOZZLE; 0.055 size
21l 238–218 FLUID NEEDLE; 0.055 size
Includes item 21a
21a
22*
25
52n 514–581 CONNECTOR, tube
53
54
514–655 SCREW, cap; 10–32 x 1”
625–779 TUBE, ratio check;
24” (609.6 mm); not shown
1
1
1
1
1
1
1
1
1
1
191–017 SNEEDLE TIP; replacement
188–694 RING PACKING; PTFE
108–382 PLUG
55*
191–015 RESTRICTOR, orifice
*
These parts are included in Repair Kit 949–285
,
31n 188–665 NUT, packing adjustment
which may be purchased separately
.
32*
33*
35
110–453 SEAL, u-cup; UHMWPE
188–493 SEAL, u-cup; UHMWPE
188–666 WRENCH, gun
n
l
Keep these spare parts and the Repair Kit on hand
to reduce down time.
39*
236–008
PACKING ASSY.; includes
u-cup spreader, u-cup seal
and packing washer
1
1
1
1
42
47*
48
276–268
TOOL, seal installation
625–722 SEAL, air cap
625–725 TRIGGER, activator valve
See chart on page 4 for other available Needles,
Nozzles, and Air Caps.
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Technical Data
Dimensions
6.39 in.
Maximum
and Air Pressure
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 oz. (0.5 kg)
Working Fluid
(163 mm)
.
. . . . . . . . . . . . . . . . . . . 100 psi (7 bar)
Air Inlet
.
. . . . . . . . . . . . . . . . . . 1/4–18 npsm (R1/4–19)
compound thread
Adhesive Inlet
.
. . . . . . . . . . . . 3/8–18 npsm (R3/8–19)
compound thread
Activator Inlet
Wetted Parts
.
. . . . . . . . . . . . . . . . . . . . . . 1/8–27 npt(f)
8.0 in.
(203 mm)
Adhesive and Activator
.
. . 304 and 17–4 Stainless
Steel, Acetal, Nylon,
Ultra High Molecular
W
eight Polyethylene
02749A
Activator Only
.
. . . . . . . . . . . Buna-N, Nickel-plated
Brass, Anodized
Nylon (air cap only)
Manual Change
Summary
Corrected the reference numbers in the parts drawing.
26
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Notes
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The Graco Warranty and Disclaimers
Graco warrants all equipment listed in this manual which is manufactured by Graco 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. With the exception of
any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or
replace any part of the equipment determined by Graco to be 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 general wear and tear, or 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 of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance or 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 claimed defect. 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.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A
PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
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.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco dis
-
tributor, or call this number to identify the distribu
-
tor closest to you: 1–800–367–4023 Toll Free
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, 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 April 1997
28
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