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Instructions-Parts List 


AIR OPERATED, SINGLE COMPONENT DISPENSE VALVE 

IK Ultra-Lite™ 



GRACO 


308876L 

EN 


For dispensing a wide variety of single component sealants and adhesives. 

4000 psi (28 MPa, 276 bar) Maximum Fluid Working Pressure 
120 psi (0.84 MPa, 8.4 bar) Maximum Air Inlet Pressure 

See page 2 for Table of Contents 

Part No. 965766 

Stainless Steel Wetted Parts, Machine 
Mount Valve 

Part No. 965767 

Aluminum Wetted Parts, Hand-held 
Valve with internal air switch 

Part No. 965768 

Aluminum Wetted Parts, Hand-held 
Valve with electric switch for remote 
operation 

Part No. 965786 

Aluminum Wetted Parts, Automatic 
Machine Mount Valve 

Part No. 243482 

Stainless Steel Wetted Parts, 

Precision Swirl Orbiter Mounted with 
Nozzle Accessory 

Model 965768 shown 

Part No. 243666 

Stainless Steel Wetted Parts, 

PrecisionFlo® Control Valve 
Machine Mount Valve 



Important Safety Instructions 

Read all warnings and instructions in this manual. 
Save these instructions. 



PROVEN QUALITY. LEADING TECHNOLOGY. 







Table of Contents 


Warnings.2 

Features .5 

Installation.6 

Operation/Maintenance .8 

Troubleshooting.10 

Service .11 

Parts .16 

Accessories .25 

Technical Data.27 

Dimensions.28 

Graco Standard Warranty .30 

Graco Information .30 


Symbols 

Warning Symbol 


A WARNING 


This symbol alerts you to the possibility of serious 
injury or death if you do not follow the instructions. 

Caution Symbol 

A CAUTION 

This symbol alerts you to the possibility of damage to 
or destruction of equipment if you do not follow the 
instructions. 


A WARNING 



SKIN INJECTION HAZARD 

Spray from the valve, hose leaks, or ruptured components can inject fluid into your body and cause 

extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin 

can also cause serious injury. 

• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi¬ 
cal treatment. 

• Do not point the valve at anyone or at any part of the body. 

• Do not stop or deflect leaks with your hand, body, glove or rag. 

• Be sure the valve trigger safety operates before dispensing. 

• Lock the valve trigger safety when you stop dispensing. 

• If the nozzle clogs while dispensing, fully release the trigger immediately. 

• Follow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres¬ 
sure; stop dispensing; clean, check, or service the equipment; and install or clean the nozzle. 

• Tighten all fluid connections before operating the equipment. 

• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. 
Permanently coupled hoses cannot be repaired; replace the entire hose. 

• Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the 
hose from rupture caused by kinks or bends near the couplings. 


2 


308876 



















A WARNING 


i£ 

INSTRUCTIONS 


EQUIPMENT MISUSE HAZARD 

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury. 

• This equipment is for professional use only. 

• Read all instruction manuals, tags, and labels before operating the equipment. 

• Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco 
distributor. 


• Do not alter or modify this equipment. Use only genuine Graco parts and accessories. 

• Check equipment daily. Repair or replace worn or damaged parts immediately. 

• Do not exceed the maximum working pressure stated on the equipment or in the Technical Data 
for your equipment. Do not exceed the maximum working pressure of the lowest rated component 
in your system. 

• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech¬ 
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings. 

• Do not use hoses to pull equipment. 

• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose 
Graco hoses to temperatures above 180°F (82°C) or below-40°F (-40°C). 

• Comply with all applicable local, state, and national fire, electrical, and safety regulations. 

• Never use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or 
fluids containing such solvents in this equipment. Such use could result in a serious chemical 
reaction, with the possibility of explosion, which could cause death, serious injury, and/or substan¬ 
tial property damage. 


308876 


3 






A WARNING 


M 


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 and the object being sprayed. Refer to Grounding on page 6. 

• If there is any static sparking or you feel an electric shock while using this equipment, stop dis¬ 
pensing immediately. Do not use the equipment until you identify and correct the problem. 

• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid 
being dispensed. 

• Keep the dispense area free of debris, including solvent, rags, and gasoline. 

• Extinguish all open flames or pilot lights in the dispense area. 

• Do not smoke in the dispense area. 

• Do not turn on or off any light switch in the dispense area while operating or if fumes are present. 


• Do not operate a gasoline engine in the dispense area. 



TOXIC FLUID HAZARD 

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, 
inhaled, or swallowed. 


• Know the specific hazards of the fluid you are using. 

• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, 
state and national guidelines. 

• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and 
solvent manufacturer. 


308876 








Features 


• Adjustable forward travel to reduce material surge when 
valve opens 

• Severe-Duty™ needle and seat for longer operating life 

• Lubricated packings for longer seal life 

• Lightweight construction reduces operator/machinery 
fatigue 


• Compact size for small X-Y tables, working areas, and 
robots 

• Handle kit provides easy conversion from automatic to 
manual usage 

• Stainless steel housing to handle most materials 


4 Control Configurations 
1. 1/8 npt(f) ported manifold block 



Fig. 1 


8374 


308876 


5 




Installation 


NOTES: 

• Reference numbers and letters in parentheses in 
the text refer to the callouts in the figures and 
drawings. 

• Accessories are available from your Graco 
representative. If you supply your own accessories, 
be sure they are adequately sized and 
pressure-rated to meet the system’s requirements. 

Grounding 


A WARNING 

M 

FIRE AND EXPLOSION HAZARD 

To reduce the risk of fire, explosion, and 
serious injury, proper electrical ground¬ 
ing of every part of your system is es¬ 
sential. Read the warning section Fire 
and Explosion Hazard on page 4, and 
follow the grounding instructions below. 



The following grounding instructions are minimum 
requirements for a basic dispensing system. Your 
system may include other equipment or objects which 
must be grounded. Check your local electrical code for 
detailed grounding instructions for your area and type 
of equipment. Your system must be connected to a 
true-earth ground. 

• Pump: ground the pump by connecting ground wire 
and clamp as described in your separate pump 
instruction manual. 

• Air compressors and hydraulic power supplies: 
ground the equipment according to the 
manufacturer’s recommendations. 

• Fluid hoses: use only grounded fluid hoses with a 
maximum of 500 feet (150 m) combined hose 
length to ensure grounding continuity. Check the 
electrical resistance of your fluid hoses at least 
once a week. If your hose does not have a tag on it 
which specifies the maximum electrical resistance, 
contact the hose supplier or manufacturer for the 
maximum electrical resistance limits, replace the 
hose immediately. 

• Dispensing valve: ground the valve by connecting it 
to a properly grounded fluid hose and pump. 


• Fluid supply container: ground according to your 
local code. 

• Flammable liquids in the spray area: must be in 
approved, grounded containers. Do not store more 
than the quantity needed for one shift. 

• All solvent pails used when flushing: ground 
according to local code. Use only metal pails, which 
are conductive. Do not place the pail on a 
non-conductive surface, such as paper or 
cardboard, which interrupts the grounding 
continuity. 

• To maintain grounding continuity when flushing or 
relieving pressure, hold a metal part of the valve 
firmly to the side of a grounded metal pail, then 
trigger the valve. 

How to Use the Valve Trigger Safety 


A WARNING 


SKIN INJECTION HAZARD 

To prevent accidental triggering of the 
gun and reduce the risk of a serious inju¬ 
ry, including fluid injection or splashing in 
the eyes or on the skin, lock the gun trigger safety 
when you stop dispensing. 



1. If you are using one of the hand-held versions of 
the valve, lock the valve trigger safety by turning 
the latch to a right angle with the gun body. See 
Fig. 2. 

2. To unlock the valve trigger safety, push the latch 
out and turn it parallel with the gun body. 




Locked 


Unlocked 




Fig. 2 


8459/ 


6 


308876 






Installation 


Connections 

• The fluid inlet is 1/4 npt(f). 

• The fluid outlet is 1/4 npt(f) or 3/4-16 unf(m). 

• Air inlets are 1/8 npt(f). 

• See Accessories, page 25, to order air control 
valves and tubing. 

Electric Switch Hand Held Valve 

Install a remote 4-way air control valve to operate the 
valve. Connect an OPEN air signal air line to the 1/8 
npt(f) port on the side of the valve. Connect a CLOSE 
air signal air line to the 1/8 npt(f) port on the opposite 
side of the valve. Wire the normally open valve switch 
to the system control. 


Machine Mount Valve 

Install a remote 4-way air control valve to operate the 
valve. Connect an open air signal air line to the 1/8 
npt(f) OPEN port. Connect a close air signal air line to 
the 1/8 npt(f) CLOSE port. 

Air Switch Hand Held Valve 

This valve has a single air inlet and an internal 4-way 
spool valve, which directly operates the air piston. 
Connect the air line to the 1/8 npt(f) air inlet. 




Solder to terminals in cable connectors as shown in Detail A. 



Normally open, momentary contact switch. 


Z3A 


Ground connection. 



Electric Switch Hand Held Valve shown 
Fig. 3_ 


8370A 


308876 


7 






Operation 


A WARNING 


COMPONENT RUPTURE HAZARD 

To reduce the risk of over-pressurization, 
lll B—*** which can cause component rupture and 
serious injury, never exceed 3000 psi (21 
MPa, 207 bar) fluid pressure, or 120 psi (0.84 MPa, 
8.4 bar) air pressure to the valve. 


Pressure Relief Procedure 


A WARNING 


SKIN INJECTION HAZARD 

The system pressure must be manually 
relieved to prevent the system from 
starting or spraying accidentally. Fluid 
under high pressure can be injected through the 
skin and cause serious injury. To reduce the risk of 
an injury from injection, splashing fluid, or moving 
parts, follow the Pressure Relief Procedure 
whenever you: 

• are instructed to relieve the pressure 

• stop dispensing 

• check or service any of the system equipment 

• install or clean the nozzle 



1. Shut off the air to the dispense valve, if applicable. 

2. Shut off the air to the supply pumps. 

3. Close the bleed-type master air valve (required in 
your system). 

4. Hold a metal part of the valve firmly to the side of a 
grounded metal pail, and trigger the dispense 
valve to relieve pressure. 

5. Open the fluid drain valve (required in your 
system), having a grounded metal container ready 
to catch the drainage. 

6. Leave the fluid drain valve open until you are ready 
to dispense again. 

If you suspect that the dispense needle or hose is 
completely clogged, or that pressure has not been fully 
relieved after following the steps above, very slowly 
loosen the needle retaining nut or hose end coupling 
and relieve pressure gradually, then loosen completely. 
Now clear the needle or hose. 


Electric Switch Hand Held Valve 

• Be sure the air supply lines are connected correctly 
to the OPEN and CLOSE valve air ports. 

• To open or close the valve and maintain the open or 
closed status, a minimum of 40 psi (280 kPa, 2.8 
bar) air pressure must be supplied and maintained 
at the OPEN or CLOSE port. 

• The trigger only activates the electrical switch in the 
handle, which turns the remote solenoid on and off. 

• Trigger the gun to turn the solenoid on. Release the 
trigger to turn the solenoid off. 

Machine Mount Valve 

• Be sure the air supply lines are connected correctly 
to the OPEN and CLOSE valve air ports. 

• To open or close the valve and maintain the open or 
closed status, a minimum of 40 psi (280 kPa, 2.8 
bar) air pressure must be supplied and maintained 
at the OPEN or CLOSE port. 

To open the valve: 

1. Apply air pressure to the OPEN air port on the 
valve, and remove air pressure from the CLOSE 
air port on the valve. 

2. Maintain air pressure on the OPEN air port to keep 
the valve open. 

To close the valve: 

1. Apply air pressure to the CLOSE air port on the 
valve, and remove air pressure from the OPEN air 
port on the valve. 

2. Maintain air pressure to the CLOSE air port to 
keep the valve closed. 


8 


308876 





Operation 


Air Switch Hand Held Valve 

The valve operation is such that there are only two 
valve conditions: either fully open or fully closed. 

The valve is opened and closed by the internal air 
control valve. Trigger the gun to open the valve. 
Release the trigger to close the valve. 

Shaft Stroke Adjustment (Models 965766, 
965767, 965768, and 965786 only) 

Adjust the shaft stroke to balance the valve between 
“snuff-back” and “push-out”. 

• A long stroke will give maximum snuff-back but it 
may cause push-out when the valve opens. 

• Shortening the stroke of the shaft will minimize the 
material pushed out when the valve opens and will 
also increase the material back pressure through 
the valve. 

To adjust the shaft stroke: 

1. Loosen the hex nut (44) from the adjustment nut 
(43). 

2. Adjust the nut (44) along the adjustment shaft (42) 
to the desired position. 


• The valve is at full stroke when the hex nut 
(44) is at the end of the adjustment shaft (42). 

• Adjusting the nut (44) on the shaft (42) 
towards the valve, or clockwise, will reduce the 
stroke length. 

• Adjusting the nut away from the valve, or 
counterclockwise, will lengthen the stroke. 

3. Tighten the hex nut (44) to the adjustment nut (43) 
to set the adjustment. 


42 



Fig. 4 


8460 


Maintenance 


Preventative Maintenance 

There is a grease filled secondary seal/bearing area on 
the valve shaft. Every 10,000 cycles, or twice each 
month, new grease should be flushed across this area. 
Each valve has two flush grease fittings. A small 
grease gun is provided with each valve. 


To grease the valve: 

1. Remove the grease fitting from one side of the 
gun. 

2. Pump grease (Part No. 115982) across the valve 
until clear grease comes out of the other side. 

3. Reinstall the grease fitting. 


308876 


9 



Troubleshooting 

1. Relieve the pressure. 

2. Check all possible causes to the problem before 
disassembling the pump. 


A WARNING 


SKIN INJECTION HAZARD 

To reduce the risk of serious injury 
whenever you are instructed to relieve 
pressure, always follow the Pressure 
Relief Procedure on page 8. 



PROBLEM 

CAUSE 

SOLUTION 

Valve does not open 

Insufficient air pressure 

Turn on or turn up air pressure. 

Air not exhausted from behind air cylin¬ 
der piston 

Use four-way, relieving-type air valve operator. 

Shaft adjustment too far closed 

Adjust the shaft stroke as instructed on page 9. 

Valve does not close 
(leaks) 

Insufficient air pressure 

Turn on or turn up air pressure. 

Air not exhausted from behind air cylin¬ 
der piston 

Use four-way, relieving-type air valve operator. 

Blockage between needle and seat 

Remove and clean needle and seat. 

Bad or missing gasket between seat 
and housing 

Replace gasket (38). 

Needle worn out 

Replace needle and seat. 

Higher than normal 
back-pressure 

Nosepiece plugging up 

Remove and clean. 


10 


308876 






























Service 


(Models 965766, 965767, 965768, and 965786 only) 


A WARNING 


SKIN INJECTION HAZARD 

To reduce the risk of serious injury 
whenever you are instructed to relieve 
pressure, always follow the Pressure 
Relief Procedure on page 8. 



12. Remove the pin (7), o-ring (9), and piston o-ring 

( 6 ). 

13. Use a 1/4 in. pin punch to knock out the bearings 
(5) and o-rings (4). 

Air Switch Handle (if equipped) 

1. Remove the trigger (56). 


Disassembly 

1. Relieve all air and fluid pressure. 

2. Disconnect the valve from the system. 

3. Remove the four nosepiece screws (15), and pull 
the nosepiece (40) away from the valve. Remove 
the snuff-back ring (41). See Fig. 5, page 14. 

4. Use an 1/8 in. pin punch in the needle hole (A) to 
unscrew the needle (27). If the shaft (3) spins, 
insert a dowel pin in the shaft hole (B) to hold it 
steady, then unscrew the needle (27). 

5. Remove the seat (25), gasket (38), and o-ring 
(39). 

6. Remove the two fluid housing screws (23) and 
remove the fluid housing (26). Remove the primary 
fluid seal (22) from the fluid housing (26). 

7. Pull the bearing/lube housing (19) from the air 
cylinder (1). Remove the bearing (21), bearing 
o-ring (16), and secondary fluid seal (20). Remove 
the grease fittings (18). 

8. Remove the C-clip (12) from the back of the air 
cylinder (1). Push the shaft (3) into the air cylinder 
to dislodge the air cylinder cap (11). Remove the 
cap o-ring. 

9. Remove the internal C-clip (12). Push the shaft (3) 
to dislodge the piston (10) assembly from the air 
cylinder (1). 

10. Remove the adjustment nut (44) from the shaft (3). 

11. Remove the adjustment shaft (42) from the shaft 
(3). 


2. Loosen the set screw above the trigger safety. Pull 
off the handle (55). 

3. Remove the four retaining screws (60). Pull the 
housing (50) and gasket (30) away from the air 
cylinder (1). 

Air Valve 

1. Unscrew the stem guide (58). 

2. Remove the trigger pin (59), o-ring (57), spool 
(49), spacers (51, 52), o-rings (46, 48) and spring 
(47). 

3. Remove the bushing (53) from the housing (50) 
with the screw (54). 

4. Remove the screws (60) and lock-washers (61) 
from the air cylinder (1). 

Electric Switch Handle (if equipped) 

1. Disconnect the power from the gun. 

2. The switch, housing, and cable are not repairable. 
Replace these parts as a complete assembly. 

3. Remove the trigger (56). 

4. Loosen the setscrew above the trigger safety. Pull 
off the handle (55). 

5. Remove the four manifold retaining screws (60). 
Pull the housing (50) and gasket (30) away from 
the air cylinder (1). 

6. Remove the bushing (53) from the housing (50) 
with the screw (54). 

7. Remove the screws (60) and lock-washers (61) 
from the air cylinder (1). 


308876 


11 




Service 

(Models 965766, 965767, 965768, and 965786 only) 


Reassembly 

Air Cylinder Section 

1. Lubricate the shaft o-rings (4) and the bearings (5) 
with grease supplied in the repair kit. Insert o-rings 
into the air cylinder (1) and air cap (11) cavities. 
See Fig. 5. 

2. Press the bearings (5) flush into the air cylinder 
housing and air cap, trapping the o-rings (4). 

3. Lubricate and reassemble the piston assembly; 
piston (10), o-ring (9), dowel pin (7), adjustment 
shaft (42), o-ring (6), and shaft (3). Use Loctite® 
Primer N7649 and Loctite® TL242, 243, or 
equivalent (“blue” Loctite) when assembling the 
adjustment shaft (42). Tighten the shaft to 15-20 
in-lb (1.7-2.2 N»m). The shaft (3) should hang 
with some play to be self-aligning in the bearing. 

4. Lubricate the air cylinder (1) ID with the grease 
supplied. Push the piston (10) assembly into the 
air cylinder. 

5. Orient the air inlet manifold (2) (if used) as shown. 
Match the gasket openings to the air ports. 


Fluid Section 

1. Lubricate the bearing (21), o-ring (16) and cup seal 
(20). Put the o-ring (16) on the bearing. Carefully 
insert the seal (20) into the bearing recess, with 
the lips of the o-ring facing into the bearing. Be 
careful not to damage the seal lips. 

2. Push the bearing (21) seal end first into the 
housing (19). Be sure that the grease hole in the 
side of the bearing lines up with the grease ports in 
the housing (19). 

3. Holding the bearing (21) in place, push the bearing 
assembly over the shaft (3). 

4. Lubricate the main fluid seal (22) and its cavity in 
the housing (26). Carefully press the seal, lip-first, 
into the housing. 

5. Push the housing (26) and seal (22) over the shaft 
(3) and up against the bearing housing. 

6. Apply anti-seize lubricant (Loctite 56765 or 
equivalent) to the fluid housing screws (23) and 
loosely install the screws to retain the housings. 

Do not tighten the screws yet. 

7. Insert the gasket (38) and seat (25). These items 
are reversible and can be installed in either 
direction. 

8. Use Loctite Primer N7649 and Loctite TL242, 243, 
or equivalent (“blue” Loctite) when assembling the 
needle (27) and tighten to 15-20 in-lb (1.7-2.2 
N»m). 

9. Apply air pressure to the CLOSE port, or to the 
pneumatic trigger valve if installed. This will align 
the shaft, seal, and bearing. Tighten the fluid 
housing screws (23) oppositely and evenly to 
40-45 in-lbs (4.5-5 N»m). 

10. Install the nosepiece (40) with the PTFE o-ring 
(39), screw (15), and snuff-back ring (41), if used. 
The snuff-back ring has an internal bevel on one 
end which faces into the nosepiece. Tighten the 
nosepiece screws to 15-20 in-lbs (1.7-2.2 N«m). 


12 


308876 



Service 


(Models 965766, 965767, 

Air Valve (if equipped) 

1. Insert the spring (51) into the housing (50). 

2. Lubricate and install an o-ring (46) into the 
housing. 

3. Install a spacer (52), internal bevel first, into the 
housing. 

4. Lubricate and install two o-rings (46) and the 
spacer (51). 

5. Lubricate and install a spacer (52) with the internal 
bevel out, and o-ring (46). 

6. Lubricate and install o-rings (48) on the spool (49). 
Insert the spool with the nub facing out. 

7. Lubricate the pin (59) and insert it into the guide 
(58). Screw the guide with o-ring (57) into the 
housing. Tighten it to 60-70 in-lbs (6.8-7.9 N»m). 


965768, and 965786 only) 

8. Orient the gasket (30) to the holes on the air 
cylinder (1). Screw the air valve assembly to the 
cylinder with the screws (60) and lock-washers 
(61). Tighten the screws evenly to 15-20 in-lbs 
(1.7-2.2 Nvn). 

9. Screw the bushing (53) to the housing (50) with 
the screw (54). Tighten the screw to 140-150 
in-lbs (15.8-16.9 Nvn). 

10. Attach the handle (55) with the setscrew. 

11. Attach the trigger (56) with the grease fittings (18). 

12. Test that the trigger safety works properly. 

Electric Switch 

1. The switch, housing, and cable are not repairable. 
Replace these parts as a complete assembly. 

2. The switch, housing, and cable assembly are not 
user serviceable and must be replaced as an 
assembly. 


308876 


13 



Service 


(Models 965766, 965767, 965768, and 965786 only) 



/ 4 \ / 4 \ 

47 46 48 49 



5A 58 59 


51 52 


4\ /4 


/4V4\/4\/4\ 


/4V4V4' 


6 7 5 4 3 B 28, 29 20 21 22 39 



/2\/A 23 /3\/8\ 





9 10 30 19 18 16 26 38 25 41 


Tighten to 15-20 in-lb (1.7-2.2 N»m). The shaft should hang 
with some play to be self-aligning in the bearing. 

Tighten to 15-20 in-lbs (1.7-2.2 N»m). 

Tighten oppositely and evenly to 40-45 in-lbs (4.5-5 N«m). 

Lubricate with grease supplied in the repair kit. 


/5\ Tighten to 60-70 in-lbs (6.8-7.9 N»m). 

A, Screw the bushing (53) to the housing (50) with screw (54). 
Tighten to 140-150 in-lbs (15.8-16.9 N*m). 

Apply Loctite Primer N7649 and Loctite TL242, 243, or 
equivalent (“blue” Loctite). 


8\ Apply anti-seize lubricant (Loctite 56765 or equivalent). 


308876 







Notes 


308876 


15 















Parts 


Model 965766 

Machine Mount Valve 

Stainless steel wetted parts 

Model 965786 

Automatic Machine Mount Valve 

Aluminum wetted parts 


Model 243482 

Orbiter Mounted Valve 

Stainless steel wetted parts 

Model 243666 

PrecisionFlo Control Valve 

Stainless steel wetted parts 


Ref. Part No. 
No. 

Description 

Qty. 

1 626702 

HOUSING, air cylinder 

1 

2 626069 

MANIFOLD, air control 

1 

3 626068 

SHAFT, air cylinder 

1 

4* 156454 

O-RING, 010 buna-n 

2 

5* 551181 

BEARING, air cylinder 

2 

6* 154662 

O-RING, 222 buna-n 

2 

7* 552164 

DOWEL PIN 

1 

9* 157628 

O-RING, 006 buna-n 

1 

10 626703 

PISTON, air cylinder 

1 

11 626704 

CAP, air cylinder CAP, air 
cylinder; Models 965766 
and 965786 only 

1 

196018 

CAP, air cylinder; Models 
243482 and 243666 only 

1 

12 552163 

CLIP, internal 1.75 

2 

15 104371 

SCREW, 10-32 x 0.375 

4 

16*t 103610 

O-RING, 014 
fluoroelastomer 

1 

18 551188 

FLUSH GREASE FITTING 

2 

19 626705 

LUBE HOUSING 

1 

20*t 551191 

U-CUP, urethane/EPR 

1 

21* 626064 

BEARING, lube 

1 

22*f 551190 

U-CUP, Polymite™/EPR 

1 

23y 103926 

SCREW, 1/4-20x2.25 

2 

25* 185467 

SEAT, C2 carbide 

1 

26 626731 

HOUSING, fluid; stainless 
steel; Model 965766 and 
243282 only 

1 

626706 

HOUSING, fluid; aluminum; 
Model 965786 only 

1 

21*% 626062 

NEEDLE, hardened stain¬ 
less steel 

1 

28A 188377 

LABEL, skin injection haz¬ 
ard 

1 

29A 188378 

LABEL, read instruction 
manual 

1 


Ref. 

No. 

Part No. 

Description 

Qty. 

30* 

626057 

GASKET, air cylinder 

1 

31 

104459 

SCREW, 10-32 x 1.75 

4 

35* 

551186 

GREASE, 3 oz. tube (not 
shown) 

1 

36 

115982 

GUN, grease (not shown) 

1 

37 

551187 

COUPLER, flush grease 
(not shown) 

1 

38*t 

171860 

GASKET, seat 

1 

39*t 

104319 

O-RING, 014 PTFE 

1 

40 

626732 

NOSEPIECE, stainless 
steel; Models 965766 and 
243666 only 

1 


626707 

NOSEPIECE; aluminum; 
Model 965786 only 

1 


195957 

NOSEPIECE; stainless 
steel; Model 243482 only 

1 

41* 

626060 

RING, snuff-back 

1 

421: 

626708 

SHAFT, adjustment Models 
965766 and 965786 only 

1 

43 

626709 

NUT, adjustment Models 
965766 and 965786 only 

1 

44 

100166 

NUT, full hex, 10-32 Mod¬ 
els 965766 and 965786 only 

1 

45 

102920 

NUT, jam, 10-32 Models 
243482 and 2436666 only 

1 


* Included in Rebuild Kit 570268. 

t Included in Section Seal Kit 570267. 

A Replacement Instruction and Warning Labels are 
available at not cost. 

t Use Loctite Primer N7649 and Loctite TL242, 243, 
or equivalent (“blue” Loctite) when assembling this 
part. 


y Use anti-seize lubricant (Loctite 56765 or 

equivalent) when assembling 965766 and 965786. 
Use Loctite TL242, 243, or equivalent (“blue” 
Loctite) when assembling 243482 and 243666. 


308876 


17 














Service 


(Models 243482 and 243666 only) 


A WARNING 


SKIN INJECTION HAZARD 

To reduce the risk of serious injury 
whenever you are instructed to relieve 
pressure, always follow the Pressure 
Relief Procedure on page 8. 



6. Remove the two fluid housing screws (23) and 
remove the fluid housing (26). Remove the primary 
fluid seal (22) from the fluid housing (26). 

7. Pull the bearing/lube housing (19) from the air 
cylinder (1). Remove the bearing (21), bearing 
o-ring (16), and secondary fluid seal (20). Remove 
the grease fittings (18). 


Disassembly 

1. Relieve all air and fluid pressure. 

2. Disconnect the valve from the system. 

3. Remove the four nosepiece screws (15), and pull 
the nosepiece (40) away from the valve. Remove 
the snuff-back ring (41). See Fig. 5, page 14. 

4. Use an 1/8 in. pin punch in the needle hole (A) to 
unscrew the needle (27). If the shaft (3) spins, 
insert a dowel pin in the shaft hole (B) to hold it 
steady, then unscrew the needle (27). 

5. Remove the seat (25), gasket (38), and o-ring 
(39). 


8. Remove the C-clip (12) from the back of the air 
cylinder (1). Push the shaft (3) into the air cylinder 
to dislodge the air cylinder cap (11). Remove the 
cap o-ring. 

9. Remove the internal C-clip (12). Push the shaft (3) 
to dislodge the piston (10) assembly from the air 
cylinder (1). 

10. Remove the pin (7), o-ring (9), and piston o-ring 

( 6 ). 

11. Use a 1/4 in. pin punch to knock out the bearings 
(5) and o-rings (4). 


308876 


19 




Service 

(Models 243482 and 243666 only) 


Reassembly 
Air Cylinder Section 

1. Lubricate the shaft o-rings (4) and the bearings (5) 
with grease supplied in the repair kit. Insert o-rings 
into the air cylinder (1) and air cap (11) cavities. 
See Fig. 5. 

2. Press the bearings (5) flush into the air cylinder 
housing and air cap, trapping the o-rings (4). 

3. Lubricate and reassemble the piston assembly; 
piston (10), o-ring (9), dowel pin (7), o-ring (6), and 
shaft (3). Tighten the jam nut (45) to 15-20 in-lb 

(1.7-2.2 N»m). The shaft (3) should hang with 
some play to be self-aligning in the bearing. 

4. Lubricate the air cylinder (1) ID with the grease 
supplied. Push the piston (10) assembly into the 
air cylinder. 

5. Orient the air inlet manifold (2) (if used) as shown. 
Match the gasket openings to the air ports. 


Fluid Section 

1. Lubricate the bearing (21), o-ring (16) and cup seal 
(20). Put the o-ring (16) on the bearing. Carefully 
insert the seal (20) into the bearing recess, with 
the lips of the o-ring facing into the bearing. Be 
careful not to damage the seal lips. 

2. Push the bearing (21) seal end first into the 
housing (19). Be sure that the grease hole in the 
side of the bearing lines up with the grease ports in 
the housing (19). 

3. Holding the bearing (21) in place, push the bearing 
assembly over the shaft (3). 

4. Lubricate the main fluid seal (22) and its cavity in 
the housing (26). Carefully press the seal, lip-first, 
into the housing. 

5. Push the housing (26) and seal (22) over the shaft 
(3) and up against the bearing housing. 

6. Apply Loctite Primer N7649 and Loctite TL242, 

243, or equivalent (“blue” Loctite) to the fluid 
housing screws (23) and loosely install the screws 
to retain the housings. Do not tighten the screws 
yet. 

7. Insert the gasket (38) and seat (25). These items 
are reversible and can be installed in either 
direction. 

8. Apply Loctite Primer N7649 and Loctite TL242, 
243, or equivalent (“blue” Loctite) to needle (27) 
and tighten to 15-20 in-lb (1.7-2.2 N»m). 

9. Apply air pressure to the CLOSE port, or to the 
pneumatic trigger valve if installed. This will align 
the shaft, seal, and bearing. Tighten the fluid 
housing screws (23) oppositely and evenly to 
40-45 in-lbs (4.5-5 N»m). 

10. Install the nosepiece (40) with the PTFE o-ring 
(39), screw (15), and snuff-back ring (41), if used. 
The snuff-back ring has an internal bevel on one 
end which faces into the nosepiece. Tighten the 
nosepiece screws to 15-20 in-lbs (1.7-2.2 N«m). 


20 


308876 

































Parts 


Model 965767 

Hand Held Valve with Pneumatic Trigger 

Aluminum wetted parts 

See page 16 for illustration of items 1-44. See page 18 for illustration of items 46-62. 


Ref. 

No. 

Part No. 

Description 

Qty. 

1 

626702 

HOUSING, air cylinder 

1 

3 

626068 

SHAFT, air cylinder 

1 

4* 

156454 

O-RING, 010 buna-n 

2 

5* 

551181 

BEARING, air cylinder 

2 

6* 

154662 

O-RING, 222 buna-n 

2 

7* 

552164 

DOWEL PIN 

1 

9* 

157628 

O-RING, 006 buna-n 

1 

10 

626703 

PISTON, air cylinder 

1 

11 

626704 

CAP, air cylinder 

1 

12 

552163 

CLIP, internal 1.75 

2 

16*t 

103610 

O-RING, 014 
fluoroelastomer 

1 

18 

551188 

FLUSH GREASE FITTING 

2 

19 

626705 

LUBE HOUSING 

1 

20*f 

551191 

U-CUP, urethane/EPR 

1 

21* 

626064 

BEARING, lube 

1 

22*f 

551190 

U-CUP, Polymite™/EPR 

1 

23f^ 

103926 

SCREW, 1/4-20x2.25 

2 

25* 

185467 

SEAT, C2 carbide 

1 

26 

626706 

HOUSING, fluid; aluminum 

1 

27*$ 

626062 

NEEDLE, hardened stain¬ 
less steel 

1 

28A 

188377 

LABEL, skin injection haz¬ 
ard 

1 

29A 

188378 

LABEL, read instruction 
manual 

1 

30* 

626057 

GASKET, air cylinder 

1 

31 

104459 

SCREW, 10-32 x 1.75 

4 

35* 

115982 

GREASE, 3 oz. tube (not 
shown) 

1 

36 

551189 

GUN, grease (not shown) 

1 

37 

551187 

COUPLER, flush grease 
(not shown) 

1 

38*t 

171860 

GASKET, seat 

1 

39*t 

104319 

O-RING, 014 PTFE 

1 


Ref. 

No. 

Part No. 

Description 

Qty. 

40 

626707 

NOSEPIECE, aluminum 

1 

41* 

626060 

RING, snuff-back 

1 

421; 

626708 

SHAFT, adjustment 

1 

43 

626709 

NUT, adjustment 

1 

44 

100166 

NUT, full hex, 10-32 

1 

46 

106559 

O-RING, No. 905 
fluoroelastomer 

5 

47 

106561 

SPRING 

1 

48 

106560 

O-RING, 007 
fluoroelastomer 

3 

49 

178651 

SPOOL, 4-way 

1 

50 

626056 

HOUSING, air valve 

1 

51 

178652 

SPACER, u-shape 

1 

52 

178653 

SPACER, air valve 

2 

53 

626055 

BUSHING, handle 

1 

54 

551204 

SCREW, 3/8-16 x 3/4 

1 

55 

626075 

HANDLE 

1 

56 

626083 

TRIGGER 

1 

57 

106551 

O-RING, 0.5 x 0.6 
fluoroelastomer 

1 

58 

178654 

GUIDE, stem 

1 

59 

626053 

PIN, trigger 

1 

60 

119156 

SCREW, 10-32x0.8125 

4 

61 

100020 

WASHER, lock, #10 

2 

62 

104765 

PLUG, pipe, headless, 

1/8 npt (not shown) 

1 


* Included in Rebuild Kit 570268. 

t Included in Section Seal Kit 570267. 

A Replacement Instruction and Warning Labels are 
available at no cost. 

$ Loctite Primer N7649 and Loctite TL242, 243, or 
equivalent (“blue” Loctite) should be used when 
installing this part. 

v* Anti-seize lubricant (Loctite 56765 or equivalent) 
should be used when installing this part. 


308876 


23 



Parts 


Model 965768 

Hand Held Valve with Electric Switch 

Aluminum wetted parts 

See page 16 for illustration of items 1-44. See page 18 for illustration of items 53-63. 


Ref. Part No. 
No. 

Description 

Qty. 

1 626702 

HOUSING, air cylinder 

1 

3 626068 

SHAFT, air cylinder 

1 

4* 156454 

O-RING, 010 buna-n 

2 

5* 551181 

BEARING, air cylinder 

2 

6* 154662 

O-RING, 222 buna-n 

2 

7* 552164 

DOWEL PIN 

1 

9* 157628 

O-RING, 006 buna-n 

1 

10 626703 

PISTON, air cylinder 

1 

11 626704 

CAP, air cylinder 

1 

12 552163 

CLIP, internal 1.75 

2 

15 104371 

SCREW, 10-32x0.375 

4 

16*t 103610 

O-RING, 014 
fluoroelastomer 

1 

18 551188 

FLUSH GREASE FITTING 

2 

19 626705 

LUBE HOUSING 

1 

20*t 551191 

U-CUP, urethane/EPR 

1 

21* 626064 

BEARING, lube 

1 

22*f 551190 

U-CUP, Polymite™/EPR 

1 

23r^ 103926 

SCREW, 1/4-20x2.25 

2 

25* 185467 

SEAT, 02 carbide 

1 

26 626706 

HOUSING, fluid; aluminum 

1 

27** 626062 

NEEDLE, hardened stain¬ 
less steel 

1 

28A 188377 

LABEL, skin injection haz¬ 
ard 

1 

29A 188378 

LABEL, read instruction 
manual 

1 

30* 626057 

GASKET, air cylinder 

1 

31 104459 

SCREW, 10-32 x 1.75 

4 

35* 115982 

GREASE, 3 oz. tube (not 
shown) 

1 


Ref. 

No. 

Part No. 

Description 

Qty. 

36 

551189 

GUN, grease (not shown) 

1 

37 

551187 

COUPLER, flush grease 
(not shown) 

1 

38*t 

171860 

GASKET, seat 

1 

39*t 

104319 

O-RING, 014 PTFE 

1 

40 

626707 

NOSEPIECE, aluminum 

1 

41* 

626060 

RING, snuff-back 

1 

42 £ 

626708 

SHAFT, adjustment 

1 

43 

626709 

NUT, adjustment 

1 

44 

100166 

NUT, full hex, 10-32 

1 

53 

626055 

BUSHING, handle 

1 

54 

551204 

SCREW, 3/8-16 x 3/4 

1 

55 

626075 

HANDLE 

1 

56 

626083 

TRIGGER 

1 

60 

119156 

SCREW, 10-32x0.8125 

4 

61 

100020 

WASHER, lock, #10 

2 

63 

949706 

SWITCH ASSEMBLY 

1 


* Included in Rebuild Kit 570268. 

t Included in Section Seal Kit 570267. 

± Replacement Instruction and Warning Labels are 
available at not cost. 

t Loctite Primer N7649 and Loctite TL242, 243, or 
equivalent (“blue” Loctite) should be used when 
installing this part. 

v* Anti-seize lubricant (Loctite 56765 or equivalent) 
should be used when installing this part. 


24 


308876 



Accessories 


Plastic Tube Fittings to Connect Air Signals 


Tube OD 

1/8 NPT (M) Straight 

1/8 NPT (M) 90° Swivel 

Tube Tee 

1/8 in. 

598329 

513826 

551203 

5/32 in. 

104172 

598140 

514435 

1/4 in. 


597151 

111167 

Tube OD 

1/4 NPT (M) Straight 

1/4 NPT (M) 90° Swivel 


5/32 in. 

598252 

598327 


1/4 in. 

104165 

Cl 9391 



Plastic Tubing for Air Signal Lines 

Part No. Description 

513063 1/8 in. O.D. Nylon 

514607 5/32 in. O.D. Nylon 

Cl2509 1/4 in. O.D. Nylon 

Air Signal Accessories 

551201 Air Cylinder Speed Control 90° Fitting 

1/8 npt(f) inlet, 1/8 npt(m) outlet 

Mount on CLOSE port to control opening speed for 
soft start. Mount on OPEN port to control closing 
speed for less snuff-back. 

104661 Quick Exhaust Valve 

1/8 npt(f) inlet and outlet, 1/4 npt(f) exhaust 

Used to speed up opening or closing action of the 1K 
Ultra-Lite Valve 

104632 Pump Pilot Valve 

1/2 npt (f) line ports, 1/8 npt(f) pilot port 

3-way air piloted air valve to turn air powered 
proportioning pump on with hand gun signal. 


4-Way Solenoids and Solenoid 
Accessories 

626144 Manifold 

To direct mount solenoid to IK Ultra-Lite Valve. 

551316 120 Volt ac Solenoid 

For use with 626144 Manifold. 

551317 24 Volt dc Solenoid 

For use with 626144 Manifold. 

551347 120 Volt ac Solenoid 

Remote mount, 1/8 npt (f) ports 

551348 24 Volt dc Solenoid 

Remote mount, 1/8 npt(f) ports 

551349 120 Volt ac Din Plug 

With screw terminals for above solenoids 

551350 24 Volt dc Din Plug 

With screw terminals for above solenoids 


Optional Main Fluid Needle Packings (22) 

Part No. Description 

551192 Urethane U-Cup with EPDM o-ring 

spreader 

551193 Reinforced PTFE U-Cup with 302 

stainless steel spreader 


308876 


25 




Accessories 


Fluid Nozzles 168683 Nozzle Bushing 

Zinc-plated steel nozzles, 1/8 npt* Zinc-plated steel, 1/8 npt 


Part No. Orifice Length 

607665 0.125 in. (3.17 mm) 2 in. (51 mm) 

161505 0.09 in. (2.28 mm) 2 in. (51 mm) 

164799 0.055 in. (1.39 mm) 2-1/8 in. (54 mm) 

* Requires a 1/8 npt(f) bushing. Order 168683 Nozzle 
Bushing. 

Nozzles for use with 188253 
flange nut. 


8462A 


Part No. 

Orifice 

Length 

C00005 

0.187 in. (4.75 mm) 

1.656 in. (42 mm) 

C00007 

0.093 in. (2.36 mm) 

2 in. (51 mm) 

C00008 

0.250 in. (2.28 mm) 

2 in. (51 mm) 

C00009 

0.172 in. (4.37 mm) 

2 in. (51 mm) 

C00010 

0.062 in.(1.57 mm) 

2 in. (51 mm) 

C00011 

0.375 in. (9.53 mm) 

2 in. (51 mm) 

C00012 

0.156 in. (3.96 mm) 

2 in. (51 mm) 

C00013 

0.046 in. (1.17 mm) 

2 in. (51 mm) 

C00014 

0.031 in. (0.79 mm) 

2 in. (51 mm) 

C00015 

0.156 in. (3.96 mm) 

1.812 in. (46 mm) 



Kits 

949631 Conversion Kit 

Pneumatic 4-way valve with housing, handle, and 
trigger and other parts necessary to convert 965766 or 
965786 to a hand held valve. 

949632 Conversion Kit 

Electric switch style handle kit to convert 965766 or 
965786 to a hand held valve. 

570267 Seal Kit 

With Polymite™ main packing (standard) 

570268 Rebuild Kit 

With Polymite™ main packing (standard) 

570299 Seal Kit 

With PTFE main packing (optional) 

570300 Rebuild Kit 

With PTFE main packing (optional) 


512135 Plastic Fluid Nozzle 

1/4 npt, 0.062 in. (1.57 mm) orifice, 2-1/2 in. 
(63.5 mm) long 


26 


308876 





Technical Data 


Category 

Data 

Maximum Fluid Pressure 

4000 psi (28 MPa, 276 bar) 

Maximum Cylinder Air Pressure 

120 psi (0.84 MPa, 8.4 bar) 

Air inlets (open and close ports) 

1/8 npt(f) 

Fluid Inlet 

1/4 npt(f) 

Fluid Outlet 

1/4 npt(f) and 3/4-16 unf(m) 

Fluid Viscosity Range 

20 cps to 1 million cps 

Snuffer Action Fluid Section 

Isolation chamber with zerk fittings 

Divorced Air Cylinder 

Piston cylinder, EP o-rings 

Weight 


Aluminum Valve 

Stainless Steel Valve 

Handle Kit 

1.43 lb (0.65 kg) 

2.07 lb (0.94 kg) 

0.77 lb (0.35 kg) 

Wetted Parts 


Aluminum Valve 

aluminum, 303 stainless steel, 17-4 PH stainless steel, C2 car¬ 
bide, hard chrome, ethylene propylene, Parker Polymite™, PTFE 

Stainless Steel Valve 

303 stainless steel, 17-4 PH stainless steel, C2 carbide, hard 
chrome, ethylene propylene, Parker Polymite™, PTFE 

Severe-duty Components 

Shaft 

Snuffer Needle 

Seat 

Shaft Seal, standard 

Shaft Seal, optional 

Hard chrome over 303 stainless steel 

Hardened 440-C stainless steel 

Reversible, solid C2 carbide inserts 

High density Parker Polymite™ 

PTFE 


Loctite® is a registered trademark of the Loctite Corporation. 


308876 


27 

















































Notes 


308876 


29 



Graco Standard Warranty 


Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the 
date of sale 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 of 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. 

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT 
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. 

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, 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 redaction du presente document sera en Anglais, ainsi que tous documents, avis et procedures 
judiciaires executes, donnes ou intentes a la suite de ou en rapport, directement ou indirectement, avec les procedures concernees. 

Graco Information 


For the latest information about Graco products, visit www.graco.com. 

TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers 

to identify the distributor closest to you: 

1-800-328-0211 Toll Free 
612-623-6921 
612-378-3505 Fax 


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. 

For patent information, see www.graco.com/patents. 

Original instructions. This manual contains English. MM 308876 


Graco Headquarters: Minneapolis 
International Offices: Belgium, China, Japan, Korea 

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA 

Copyright 1998, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. 

www.graco.com 

Revised 12 June 2012 


30 


308876