Graco 309790ZAA User Manual

Page 1

Instructions - Parts

8900 Proportioner

309790ZAA

Configured product offering for dispensing fixed or variable ratio of two fluids. For professional use only. Not approved for use in European explosive atmosphere locations.

2000 psi (13.8 MPa, 138 bar) Maximum Working Pressure

Important Safety Instructions

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

See page 8 for pump model numbers, ratios and working pressures.

ENG

Fixed-ratio proportioner shown

TI2761A

Page 2

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 6

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Major Components . . . . . . . . . . . . . . . . . . . . . . . 6

Ratio Proportioning . . . . . . . . . . . . . . . . . . . . . . . 6

System Components and Operation Overview . . 6

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Set the Ratio (variable ratio models only) . . . . . 14

Output Charts/Ratio Settings . . . . . . . . . . . . . . 15

Before You Load Material . . . . . . . . . . . . . . . . . 18

Load Component A . . . . . . . . . . . . . . . . . . . . . . 19

Prime Pump A . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Load Component B . . . . . . . . . . . . . . . . . . . . . . 21

Prime with Component B . . . . . . . . . . . . . . . . . 24

Fill the 8900 Proportioner with Material . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pressure Relief Procedure . . . . . . . . . . . . . . . . 27

Dispense Mixed Material . . . . . . . . . . . . . . . . . . 28

Changing Component A Drum . . . . . . . . . . . . . 30

Changing Component B Pail . . . . . . . . . . . . . . . 31

Filling Component B Pressure Tank . . . . . . . . . 32

Daily Procedures . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8900 Proportioner Operating Pressures . . . . . . 36

Air Supply Troubleshooting Chart . . . . . . . . . . . 37

Pump Troubleshooting Overview . . . . . . . . . . . 38

Troubleshooting Guide: Feed pumps . . . . . . . . 39

Troubleshooting Guide: 8900 Proportioner . . . . 40

Troubleshooting Guide: Manifold/Mixer . . . . . . . 41

Preventive Maintenance . . . . . . . . . . . . . . . . . . 42

Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . 43

Repair the Cylinder (Fixed Ratio) . . . . . . . . . . . 43

Replace Air Valve . . . . . . . . . . . . . . . . . . . . . . . 45

Disassemble Fluid Valve . . . . . . . . . . . . . . . . . . . . 46

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8900 Proportioner, Fixed Ratio . . . . . . . . . . . . . 48

8900 Proportioner, Variable Ratio . . . . . . . . . . . 50

Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . 52

Limit Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pump Feed Module Selection for Component A or

Component B . . . . . . . . . . . . . . . . . . . . . . . 56

20:1 President on 5 Gallon Ram . . . . . . . . . . . . 56

34:1 Senator on 5 Gallon Ram . . . . . . . . . . . . . 58

23:1 Monark on 5 Gallon Ram . . . . . . . . . . . . . 60

20:1 President on 55 Gallon Ram . . . . . . . . . . . 62

34:1 Senator on 55 Gallon Ram . . . . . . . . . . . . 64

31:1 Bulldog on 55 Gallon Ram . . . . . . . . . . . . . 65

20:1 Senator on 55 Gallon Drum . . . . . . . . . . . . 66

9:1 DynaMite on 1 Gallon Can Ram . . . . . . . . . 67

10 Gallon Press Tank with 15:1 Booster . . . . . . 68

10:1 President 5 Gallon Pail Cover . . . . . . . . . . 69

Mix Kit Selection . . . . . . . . . . . . . . . . . . . . . . . . 70

Cartridge Fill Medium Viscosity Wide Ratio . . . 70

Cartridge Fill High Viscosity Wide Ratio . . . . . . 72

Brush Grade High Viscosity Wide Ratio . . . . . . 74

MD2 20 ft Automatic . . . . . . . . . . . . . . . . . . . . . 76

MD2 20 ft Hand Gun . . . . . . . . . . . . . . . . . . . . . 77

MD2 15 ft Hand Gun Wide Ratio Moisture Lock 78

High Volume Static Mix Manifold . . . . . . . . . . . . 79

High Volume Static Mix Kit with Pump Pilots . . . 80

Stanchion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 86

2 309790ZAA

Page 3

309790ZAA 3

Page 4

Warnings

Skin Injection Hazard

Spray from the gun, hose leaks, or ruptured components can inject fluid through skin and cause extremely serious injury, including need for amputation. Fluid splashed in the eyes or on skin can cause serious injury.

• Fluid injected into skin might look like just a cut, but it is a serious injury. Get immediate surgical

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

• Do not put hand or fingers over the spray tip/nozzle.

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

• Do not “blow back” fluid; this is not an air spray system.

• Always have tip guard and trigger guard on the gun when spraying.

• Check gun diffuser weekly. Refer to gun manual.

Warning

treatment.

• Check trigger safety operation before spraying. Lock trigger safety when you stop spraying.

• Follow the Pressure Relief Procedure, page 27, if the spray tip/nozzle clogs and before cleaning,

checking or servicing the equipment.

• Tighten fluid connections before operating equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; replace the entire hose.

• Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings.

Toxic Fluid Hazard

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

• Know specific hazards of the fluid. Read fluid manufacturer’s warnings.

• Wear appropriate protective clothing, gloves, eyewear, and respirator.

4 309790ZAA

Page 5

Warnings

Warning

Equipment Misuse Hazard

Equipment misuse can cause equipment to rupture, malfunction, or start unexpectedly and cause serious injury.

• This equipment is for professional use only.

• Read manuals, tags, and labels before operating equipment.

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

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

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

• Do not exceed maximum working pressure of lowest rated system component.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data sec-

tion of all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• 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).

• Do not kink or overbend hoses or use hoses to pull equipment.

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

• Do not use excessive drum separation air pressure as the drum could rupture. Make sure the drum is not damaged and the ram plate is free to exit the drum before applying air pressure.

Fire and Explosion Hazard

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

• Ground the equipment and object being sprayed. See Grounding, page 12.

• If you experience static sparking or electric shock, stop operation immediately. Identify and correct the problem.

• Provide fresh air ventilation to avoid building up flammable fumes.

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

• Extinguish all sources of flames in the spray area, including pilot lights and cigarettes.

• Do not turn on or off any light switch or plug or unplug electrical equipment in the spray area while operating or if fumes are present.

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

• Keep a fire extinguisher in the work area.

Moving Parts Hazard

Moving parts, such as priming piston and wiper plate, can pinch or amputate fingers. Keep clear of moving parts when starting or operating equipment and when equipment is pressurized.

• Keep hands and fingers away from the priming piston.

• Keep hands away from the ram wiper plate and pail lip.

• Before servicing, follow the Pressure Relief Procedure, page 27, to avoid equipment startup.

309790ZAA 5

Page 6

Theory of Operation

Use

The 8900 Proportioner is used with two component materials where one or both components is high viscosity. This is typically found in the sealant and adhesive industry, where special requirements for loading and pumping necessitate the use of the 8900 proportioning system.

Major Components

The major components of the 8900 Proportioner system include the:

• Component A or major volume metering cylinder

• Component B or minor volume metering cylinder

• Component A or major volume feed supply

• Component B or minor volume feed supply

Ratio Proportioning

The A and B cylinders are positive displacement metering cylinders. Positive displacement cylinders displace a defined volume of fluid for a given stroke length.

On fixed ratio units, the volumetric ratio is the ratio of the area of the component A displacement cylinder to the area of the component B displacement cylinder. At a 1:1 ratio, the displacement cylinders are the same size. On higher ratio units the component A cylinder is usually the larger of the two. The ratio of the components is the difference in effective area between the cylinders.

On variable ratio units, the component B cylinder has an adjustable stroke length. The component A cylinder has a fixed stroke length. By setting the stroke adjustment to different points on the connecting linkage, you can change the stroke length of the B cylinder, which changes the mix ratio. You can calculate the material mix ratio from the ratio of the cylinder displacement volume.

System Components and Operation Overview

Feed Systems - Feed Pumps

Load the Feed Pumps and Proportioner

The A and B feed pumps/cylinders must completely fill (prime) on both strokes to ensure accurate material displacement.

With high viscosity materials, it is difficult for material to flow into the pump. Individual feed pumps are used to supply these materials under pressure to the 8900 Proportioner. When air is trapped in the feed system due to improper loading, a condition called cavitation occurs.

If cavitation occurs, part of the downstroke will be used to fill the vacuum before any material is actually displaced. Since the total stroke length is used to calculate mix ratio, this may result in an off-ratio condition.

To prevent cavitation with higher viscosity materials, both cylinders are pressure fed. The A pump is pressurized by a pneumatic ram supply unit applying a downward force on a 55-gallon plate fitted into the drum. A shovel action pump fluid inlet further aids in pump priming. Component B is delivered to the B pump by pressure fed 5- or 55-gallon supply modules, depending on the volumetric ratio of the material.

Pneumatic ram assisted feed pumps may not be required for lower viscosity materials.

Feed Systems - Alternative Feed Supplies

Header or other feed systems may be used to supply A and B materials to the 8900 Proportioner. Generally these feed systems are provided by others and are not addressed in this manual. This manual applies only to the Graco Configured 8900 Proportioner system.

Note that the mix ratio of the 8900 Proportioner is achieved by volumetric ratio of component A to component B and not by weight. These two ratios are often different depending on material properties.

6 309790ZAA

Page 7

Theory of Operation

Pump Fluids to the Mixer

Fluid is pumped through the proportioner to a mix chamber or to a 2-component dispense gun, where component A and component B are first introduced before being mixed with a static mixer.

A fluid injector nozzle/check valve injects component B into component A at the mix chamber. When enough pressure builds up, the check valve opens and component B flows into the mix chamber. This means that during flow conditions with two positive displacement cylinders linked together, the pressures at the mix point are equal.

Any pressure differences noted on the gauges while running, reflect differences in the pressure lost by each fluid getting from the gauge to the mix point. These pressure drops are caused by hoses and fittings in conjunction with material viscosity.

Mix the Fluids

Both components leave the mix chamber and enter a static mixer where they are mixed to a homogeneous blend. The mixer consists of a series of left and right-hand spiral elements. This is true for both mix chamber and 2-component mix gun.

Some 8900 Proportioners use a 2K disposable mixer element dispense valve instead of the flow gun.

The 8900 Proportioner can be used in automatic assembly lines with the addition of a logic interface.

When the components are pumped through the mixer, they are progressively divided and recombined. Static mixers used on the 8900 Proportioner system include the tri-core mixer, flexible hose mixer, or disposable mixer.

Ratio Checks

On the variable ratio model, a ratio check station option verifies the volumetric mix ratio of the two components. It is located at the outlet blocks. With all outbound fluid valves closed, each component flows through individual ball valves opened by a common handle into containers.

Volumetric mix ratio can be calculated from the weight of each component or by direct measurement. Ratio checks are performed with the back pressures set to actual operating pressures to simulate the normal back pressures created by the mix chamber and gun.

Dispense Valve

An extrusion flow gun is commonly used as the applica- tion device. It has a final or clean up mixer installed in the handle. Various extrusion nozzles are available for caulking or sealing applications.

309790ZAA 7

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Models

Refer to form 684041 for selection information.

Model Description

890-D Power Valved Passive Proportioner

Code A Proportioner Selection (“A” Cyl. / “B” Cyl.) Module Number

1 1:1 Fixed (1000/1000) 570371 2 2:1 Fixed (1000/500) 570372 3 2.5:1 Fixed (250/100) 570373 4 4:1 Fixed (1000/250) 570374 5 5:1 Fixed (500/100) 570375 6 10:1 Fixed (1000/100) 570376 7 9:1 Fixed (1000/111) 246557 A 1:1 to 4:1 Variable (500/500) 570377 B 2:1 to 8:1 Variable (500/250) 570378

D 5:1 to 20:1 Variable (500/100) 570380

Code B Pump Feed Module Selection for Component A Module Number

A 20:1 President on 5 Gallon Ram 965571 B 34:1 Senator on 5 Gallon Ram 965597 C 23:1 Monark on 5 Gallon Ram 570142 D 20:1 President on 55 Gallon Ram 570114 E 34:1 Senator on 55 Gallon Ram 965572 F 31:1 Bulldog on 55 Gallon Ram 570141 G 20:1 Senator on 55 Gallon Drum 570309 H 9:1 DynaMite 1 Gallon Can Ram 570249

J 10 Gallon Press Tank with 15:1 Booster 570037 K 10:1 President 5 Gallon Pail Cover 570264 NNone

Code C Pump Feed Module Selection for Component B Module Number

J 10 Gallon Press Tank with 15:1 Booster 570037 K 10:1 President 5 Gallon Pail Cover 570264 NNone

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Code D Mix Kit Selection Module Number

1 Cart Fill Medium Viscosity Wide Ratio 570248 2 Cart Fill High Viscosity Wide Ratio 570318 3 Brush Grade High Viscosity Wide Ratio 570358 4 MD2 20 ft Automatic Wide Ratio 24H258 5 MD2 20 ft Automatic Close Ratio 24H259 6 MD2 20 ft Hand Gun Wide Ratio 24H260 7 MD2 20 ft Hand Gun Close Ratio 24H261 8 MD2 15 ft Hand Gun Wide Ratio Moisture Lock 24H243 9 High Volume Static Mix Kit with Pump Pilots 570263

NNone

Code E Mounting Type Selection Module Number

1 Stanchion 570071 2 Boom Assembly 246589

N None (mount on 3 in. 55 gallon ram)

Models

309790ZAA 9

Page 10

Installation

Typical Installation

Figures 1-3 are only guides for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to suit your needs.

Location

Position the feed modules so the pump and ram are easily accessible. Ensure that there is sufficient overhead clearance when the ram is fully raised. Refer to the ram manual for clearance dimensions.

Using the holes in the ram base as a guide, drill four holes for 1/2 in. (13 mm) anchors.

Key:Figs. 1 and 2

A System Air Shutoff Valve (bleed-type) B Main Air Filter C Component B Ram Directional Valve D Component B Ram Air Pressure Regulator E Component B Air Supply Valve (bleed-type) F Component B Air Supply Regulator G Component A Air Supply Valve H Component B Outlet Pressure Gauge J Component B Feed Pressure Gauge K Component A Feed Pressure Gauge

(behind)

Check that the ram base is level in all directions. If necessary, level the base using metal shims. Secure the base to the floor using 1/2 in. (13 mm) anchors that are long enough to prevent the ram from tipping.

L Component A and Component B Feed Pump Air

Motor Lubricator M Component B Ram Plate with Vent Stick or Valve N Component A Ram Plate with Drum Vent Valve O Component A Pump Air Regulator P Component A Ram Directional Valve Q MD2 Gun with Disposable Mixers R Component A Ram Air Pressure Regulator S Accessory/Gun Air Supply Valve

(behind)

WARNINGWARNING WARNINGWARNING

INSTRUCTIONS INSTRUCTIONS

READ MANUAL BEFORE OPERATING

DISPENSE MIXED MATERIAL

ADJUST FLOW RATE

DRUM OR PAIL CHANGE

"B" PUMP

PRESSURE ADJUSTMENT

BASE PURGE AND SHUT-DOWN

REFILLING PRESSURE POT

(IF EQUIPPED)

PUMPS

ONOFF

"A" PUMP

PRESSURE ADJUSTMENT

8900

PROPORTIONER

WARNINGWARNING

High pressure device for professional use only.

Read instruction manual before operating. Observe all warnings.

MAIN AIR

OFF ON

MAIN AIR

INLET

FIG. 1:

10 309790ZAA

ti16735a

Page 11

Installation

Supply header system supplied by others (not covered in this manual).

Component B Supply Header

Component B Fluid Regulator

FIG. 2:

Key:FIG. 3

Q2K Gun V Disposable Mixer Element W Component B Injector Valve

(behind)

INSTRUCTIONS INSTRUCTIONS

READ MANUAL BEFORE OPERATING

DISPENSE MIXED MATERIAL

ADJUST FLOW RATE

DRUM OR PAIL CHANGE

"B" PUMP

PRESSURE ADJUSTMENT

(behind)

Component A Supply Header

Component A Fluid Regulator

WARNINGWARNING WARNINGWARNING

8900

PROPORTIONER

WARNINGWARNING

High pressure device for professional use only.

Read instruction manual before operating. Observe all warnings.

MAIN AIR

OFF ON

MAIN AIR

INLET

BASE PURGE AND SHUT-DOWN

REFILLING PRESSURE POT

(IF EQUIPPED)

PUMPS

ONOFF

"A" PUMP

PRESSURE ADJUSTMENT

ti16759a

X Air Trigger Pilot Y Component B Supply Z Component A Supply

ti16737a

FIG. 3

309790ZAA 11

Page 12

Installation

Ground

WARNING

The system must be properly grounded. Read warnings, page 5. Follow the instructions below.

Pump: use the ground wire and clamp (supplied). There are two styles of ground connections on pump air motors.

If you have the ground screw (a) shown in F

(King air motor only), order part no. 222011 ground wire, ring terminal, and clamp assembly (b). To install 222011, remove the ground screw (a) and insert it through the eye of ring terminal (c), then tighten ground screw back into air motor as shown in F

IG. 4. Connect

the other end of the wire to a true earth ground.

IG. 4

Air and fluid hoses: use only electrically conductive

hoses with a maximum of 500

ft (150 m) combined hose

length to ensure grounding continuity. Check the electrical resistance of your air and fluid hoses. If the total resistance to ground exceeds 29 megohms, replace the hose immediately.

Air compressor: follow manufacturer’s recommendations.

Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow your local code.

Substrate: follow your local code.

Solvent pails used when flushing: follow your local

code. Use only conductive, metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold a metal part of the gun/dis-

pense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

IG. 4: Ground Screw (King air motors only)

If you have the ground screw (d) shown in F

IG. 5,

loosen the grounding lug locknut (g) and washer (f). Insert one end of the ground wire (e) into the slot in lug (d) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. Order 237569 ground wire and clamp assembly.

f d

IG. 5 Ground Screw

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Installation

Flush

WARNING

Read warnings, pages 4-5. Follow Ground instructions, page 12.

• The equipment was tested with light, soluble oil. Flush the system before loading material to avoid contamination.

• Flush at the lowest pressure possible and check connectors for leaks.

To flush the system:

1. On the ram-mounted component A supply units, you must remove the drum ram plate to immerse the A pump in a solvent pail. To remove the plate:

a. Disconnect the blow-off air line from the ram

plate.

b. Disconnect the tie rod nuts from the ram cross

beam.

2. Flush the system and all hoses by very slowly opening the motor control valves until 30 psi (207 kPa,

2.1 bar) is shown on the component A outlet pressure gauge.

Flush for 1-2 minutes, then close the motor control valves.

CAUTION

To avoid damaging the pump, open the motor control valves very slowly to prevent a pump runaway condition.

It is normal for the air valve to exhaust air when it is partially open.

3. Check connectors for leaks and tighten them if necessary.

4. Remove the solvent pail(s) from the pump inlets.

5. Operate the pump(s) at low pressure to remove excess solvent.

6. Reinstall the drum or pail ram plates.

c. Remove seal plates between the pump and

ram.

d. Loosen ram tie rods from plate and remove

plate.

e. If a pail ram is used with the component B sup-

ply, remove the pail plate by loosening the 2 set screws.

f. Position the solvent pail so the pump inlet is in

the solvent.

Use solvent that is compatible with the equipment wetted parts and the material you will dispense.

g. Support the ram(s) so that the pump inlet and

piston will not hit the base plate or pail bottom.

h. Make sure both component A and component B

outlet hoses are open.

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Page 14

Setup

WARNING

Read warnings, pages 4-5, before operating equipment.

Set the Ratio (variable ratio models only)

Adjust ratio

The ratio of this unit is produced partially by the difference in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Unibar linkage assembly. With the fulcrum point in the center, each meter cylinder strokes 3 in. (10.16 cm). In the center position, the dispense ratio is the same as the meter cylinder ratio.

The linkage is adjustable depending on the location of the fulcrum point. The linkage must be adjusted for each material application so the combined linkage and meter cylinder ratio equals the desired material mix ratio by volume. The ratio may be checked by weight, but the machine meters by volume and that ratio must be known before proceeding.

The initial linkage adjustment point can be calculated by inserting known values into the formula on page 35. The result is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder. For convenience, measure the distance between the grease fitting on the top of the fulcrum and the center of the component B cylinder meter rod.

FIG. 6

Set Scale

Refer to the 8900 Proportioner Output Charts on the following pages to set the scale. Make final adjustments after the material is loaded. See instructions on page 33 for detailed ratio check instructions.

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Page 15

Output Charts/Ratio Settings

8900 Proportioner, 1:1 - 4:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

1 5.63 3.00

1.5 7.13 2.00 2 8.13 1.50

2.5 8.85 1.20 3 9.38 1.00

3.5 9.80 0.86 4 10.13 0.75

Setup

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

1 1.5 2 2.5 3 3.5 4

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

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Page 16

Setup

8900 Proportioner, 2:1 - 8:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

2 5.63 3.00 3 7.13 2.00 4 8.13 1.50 5 8.85 1.20 6 9.38 1.00 7 9.80 0.86 8 10.13 0.75

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

2345678

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

16 309790ZAA

Page 17

8900 Proportioner, 5:1 - 20:1 Variable Ratio

Mix Ratio by Volume Scale Setting Minor Stroke

5 5.63 3.00 7 7.13 2.00

10 8.13 1.50 12 8.85 1.20 15 9.38 1.00 17 9.80 0.86 20 10.13 0.75

Setup

Setting in Inches from Pivot or Minor Stroke

Mix Ratio by Volume

Scale Settin

Minor Stroke

5 7 10 12 15 17 20

5.63 7.13 8.13 8.85 9.38 9.80 10.13

3.00 2.00 1.50 1.20 1.00 0.86 0.75

309790ZAA 17

Page 18

Setup

Before You Load Material

1. Check fluid and air lines and tighten if necessary.

2. Make sure there is a minimum overhead clearance of 110 in. (279 cm) for 55 gallon supply.

3. Fill air line lubricator for the 8900 Proportioner module with SAE 10 W non-detergent oil (not included).

4. Fill the pump A and B wet cups 2/3 full with Graco T.S.L. fluid (throat seal lubricant) or lubricant compatible with material being pumped.

ISO pump oil is used with moisture sensitive component B.

5. Close (turn fully counterclockwise) all air regulators.

6. Connect the 3/4 in. (19 mm) ID x 10 ft (3.05 m) air hose (provided) to your air supply.

Do not use a restrictive quick-disconnect. The air supply pressure must be consistently above the pressure you set on the main air motor regulator.

Wet Cup

TI3263Ax

IG. 7

18 309790ZAA

Page 19

Load Component A

1. Make sure all air regulators on proportioner module are fully closed.

Setup

2. Open the main air supply shutoff valve (A), F

3. Place the ram lever (P-F

IG. 10) in the UP position.

IG. 8.

CAUTION

As the ram rises, make sure hoses do not catch on any components. If a hose catches, immediately stop the ram (move lever to NEUTRAL position) and correct the problem. Lower the ram if necessary to redirect hoses.

4. Slowly turn the ram air regulator (R) clockwise until the ram begins rising.

FIG. 9

WARNING

When lowering the ram, keep hands and body away from the ram plate and material drum. Read warnings, page 5.

9. With hands away from the pail and wiper plate (N), set the ram lever (P-F

IG. 10) to NEUTRAL (horizon-

tal position). Let the ram lower until the wiper plate rests on the pail lip.

10. Lower the ram plate into the drum (move ram lever to DOWN position).

IG. 8

5. When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

6. Open the material container. Remove any packing materials, and inspect for material contamination. If the container has a plastic liner, pull it tightly over the sides of the container, and secure the liner in place with tape wrapped below the top drum rim.

7. Position the drum so it rests evenly between the centering guides and is fully backed into the stops located near the back of the ram base plate.

8. Open the drum vent valve (W), F

IG. 9.

CAUTION

Do not lower ram if a drum is not in place. Doing so can damage drum centering guides.

Ram Separation

Air Button

FIG. 10

11. After the ram plate seals contact the drum, adjust the ram air regulator (R) to about 30-50 psi (207-345 kPa, 2.1-3.4 bar).

12. When the ram stops and material fills the bleed port (or air stops bleeding out), close the drum vent valve (W), F

IG. 9.

13. Supply unit is now ready to fill lines to proportioner.

309790ZAA 19

Page 20

Setup

Prime Pump A

1. Place a waste container under the pump bleed valve located behind the displacement pump outlet, F

11. Using an adjustable wrench, open the bleed valve counterclockwise 1/3-1/2 turn.

Bleed Valve

IG. 11

IG.

2. Slowly open the component A air motor shutoff valve (G), F

IG. 7. Make sure the pump begins to

cycle and material flows from the bleed valve after several cycles of the pump, F

IG. 11.

If the pump does not cycle, close the air shutoff valve (G), adjust the air motor regulator (O-F

IG. 8)

up 5 psi (34 kPa, 0.3 bar) and repeat step 2. Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3. Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (G).

4. Close the bleed valve, F

IG. 11.

20 309790ZAA

Page 21

Setup

Load Component B

Follow the procedure for the type of supply equipment being used.

Pneumatic Pail Ram and Piston Pump

1. Close all air regulators and air valves.

2. Set the pail ram air regulator (D) to 40 psi (0.28 MPa, 2.8 bar), F

3. Push the ram directional lever (C) to the UP position and let the ram rise to its full height.

4. When ram is fully raised, apply a thin coating of lubricant to the ram plate drum seals.

5. Remove the component B pail cover. If the material has separated, carefully stir it with a metal or plastic rod until it is mixed. Do not use wood to stir as it can splinter and contaminate the material. Do not mix air into the material.

6. Set the pail on the ram base. Slide it back toward the ram tube and supports and center it under the wiper plate. To prevent air from being trapped under the wiper plate, scoop fluid from the center of the pail to the sides to make the surface concave.

IG. 12.

WARNING

When operating the pump or raising or lowering the ram, keep hands away from the wiper plate, fluid container lip, and pump intake. Read warnings, page 5.

7. With hands away from the pail and wiper plate, set the ram lever (C) to NEUTRAL (horizontal position). Let the ram lower until the wiper plate rests on the pail lip.

8. Ensure the pail is aligned with the wiper plate.

9. Push the ram directional lever (C) DOWN and increase ram air pressure until plate completely engages into the pail.

10. Slowly unscrew the vent stick until you hear air escaping. When air is evacuated, set the ram lever (C) to NEUTRAL and lower ram pressure to 20-30 psi (138-207 kPa, 1.4-2.1 bar).

11. Unscrew the vent stick and put the ram lever (M) in the DOWN position, keeping the vent stick over the vent port.

12. Slowly increase down pressure until material seeps from vent port, the quickly refasten vent stick.

309790ZAA 21

Page 22

Setup

FIG. 12

Wiper Plate

TI3260B

22 309790ZAA

Page 23

Setup

Pressure Tank with 15:1 Booster

1. Relieve tank pressure before opening.

2. Remove the pressure tank lid and any items shipped inside the tank. Make sure the tank is clean, or use the liner supplied.

3. Be sure the desiccant air dryer is mounted in the component B tank air supply of the proportioner air control module. See F

4. Gently roll an unopened pail of component B on the floor for several revolutions to mix it.

5. Open the pail outlet and carefully pour component B into the tank.

6. Immediately close the tank by tightening the Thandles (GG) evenly, F

IG. 28, page 32.

IG. 13.

7. Pressurize the tank with dried air by opening the component B air shutoff valve (S) and the pressure tank air shutoff valve (T), Figures 14 and 15.

IG. 14

8. Set the component B tank air regulator (U) to approximately 40 psi (276 kPa, 2.8 bar).

9. Check to ensure the air valve (E) to booster pump is turned off and material supply ball valve (KK) is closed.

10. Set feed pump regulator (F) on proportioner assembly to approximately 40 psi (276 kPa, 2.8 bar).

IG. 13

From component B pump air regulator on proportioner module.

To component B inlet on proportioner

11. The unit is ready to feed material to proportioner.

Pump

Booster

From air manifold on proportioner module.

TI3259Ay

FIG. 15

309790ZAA 23

Page 24

Setup

Prime with Component B

1. Place a waste container under the pump bleed valve located behind the displacement pump outlet, F

16. Using an adjustable wrench, open the bleed valve counterclockwise 1/3-1/2 turn.

Bleed Valve

IG. 16

2. Slowly open the component B air motor shutoff valve (E), F

IG. 15. Make sure the pump begins to

cycle and material flows from the bleed valve after several cycles of the pump, F

IG. 16.

IG.

Fill the 8900 Proportioner with Material

1. Place a material waste container under dispense gun (Q) and open gun. F

2. Open the main ball valve (A-F tioner assembly. This air valve supplies air to the proportioner control valving and to the feed pump assemblies. All other air shut-off valves on the manifold and feed pump assemblies should be off.

3. Open the feed pump main air valve (S). This allows the air supply to feed pump assemblies.

4. Adjust the component B supply pump air regulator (F) to allow smooth pumping action. Continue until component B flows from the dispense gun into the waste container.

The minor or component B side of material is filled first to minimize waste during initial startup.

5. Adjust the component A air regulator (O) to allow smooth pumping action.

IG. 1, page 10.

IG. 17) on the propor-

If the pump does not cycle, close the air shutoff valve (E), adjust the air motor regulator (F-F

IG.

17) up 5 psi (34 kPa, 0.3 bar) and repeat step 2. Never adjust the regulator by more than 5 psi (34 kPa, 0.3 bar) increments.

3. Operate the pump until it moves smoothly in both directions with no air popping or erratic movement, then close the air motor shutoff valve (E), F

4. Close the bleed valve, F

IG. 16.

IG. 15.

6. Pump until component A and component B flow from the gun into the waste container. When the material is bubble-free, all air has been purged from the system.

7. Turn off air supply valve (S).

8. Close dispense gun.

9. The 8900 Proportioner is now filled with components A and B and ready for operation.

OS A

IG. 17

24 309790ZAA

Page 25

MD2 Disposable Mixer Gun Models

Follow steps 10-12.

10. Fit the hose to the gun. Trigger the gun into a waste container.

Setup

11. Open the component B feed air shutoff valve (E-F

15). Component B will feed through the metering cylinder to the mix gun.

12. When bubble free material is dispensed, stop triggering the gun.

All Models

The system is now ready to dispense mixed material.

CAUTION

The materials will cure after mixing. Purge the mixer, hose, and gun with clean material before the material begins to cure.

IG.

309790ZAA 25

Page 26

Setup

26 309790ZAA

Page 27

Operation

Pressure Relief Procedure

WARNING

Read warnings, page 4, and follow the Pressure Relief Procedure whenever you:

• are instructed to relieve pressure

• stop dispensing

• check or service any of the equipment

• install or clean the nozzle.

1. Purge mixed material if necessary. See page 29.

2. Close the main air shutoff valve (A), F

IG. 18.

3. If a component B pressure tank is used, open its vent (refer to page 23).

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

5. For both component A and component B, open the respective pump bleed valves, having a waste container ready to catch the drainage, F

IG. 19

6. Manually activate the limit valve (item 26 on page

48), to cause the 4-way valve to shift, fully relieving pressure within the proportioner.

IG. 19.

Bleed Valve

IG. 18

7. If you suspect that the nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen

the tip retaining nut or hose end coupling and relieve pressure gradually, then loosen it completely, and clear the nozzle or hose.

309790ZAA 27

Page 28

Operation

Dispense Mixed Material

CAUTION

Make sure the component B relief valve is operational and free from blockage at all times. See manual

308547. If the relief valve fails, the overpressure rupture disc opens and component B is diverted to a waste container mounted on the ram base plate.

8900 Proportioner with Static Mix Chamber Kits

1. Load the material. See page 19.

2. On the variable ratio machine, set ratio (see page

14). On the fixed ratio machine, proceed to step 3.

3. Open the pump A and pump B air shutoff valve (S), F

IG. 20.

4. Adjust the component A and component B air regulators (F and O) until both outbound gauges (H and I) show the desired pressure, F

5. Trigger the gun to dispense mixed material.

IG. 20-21.

Adjust the Flow Rate

The dispensing flow rate for the system is controlled by the material pressure of component A and component B. The air pressure on pump A determines the flow rate from the material outlet. Perform the steps on page page 24 to set an initial flow rate. When the setup is complete, adjust flow to the correct rate.

The diagram in F meter cylinders in relation to the direction of rod movement. The material pressure gauges will represent either inlet or outlet pressure, depending on the direction of the rod. Inlet and outlet pressures are critical to establishing meter flow rates and balanced pressures.

IG. 22 shows the inlet and outlet of the

IG. 20

IG. 21

FIG. 22

Flow Rate Adjustment Example

A 20:1 fluid:air supply pump ratio with an air regulator setting at 100 psi (.7 MPa, 7 bar). The pump generates approximately 2000 psi (14 MPa, 140 bar). Fluid pressure, normal friction losses with mastic materials will use 5-15% of the force, resulting in actual stall pressure of 1700-1900 psi (13 MPa, 130 bar).

28 309790ZAA

Page 29

Operation

A/B Pump Relationship

As a rule of thumb, the pressures of the two components should be adjusted to as close to equal as possible under dynamic pressure. Adjust the A and B feed pressures to accomplish this. Differences on material viscosity, flow rates, hose diameter and length, dispense valve, and mixer size cause this setting to vary from application to application.

1. Adjust the component A air regulator (O) for desired flow rate, F

IG. 24.

2. Adjust the component B air regulator (F) to balance the A and B regulators.

Solvent-flush Mixed Material (for units using mix manifold gun kits)

1. Close the component A and component B valves on the mix chamber assembly. See F

2. Ensure solvent valve is closed.

3. Set solvent flush pump air regulator to approximately 25 psi (172 kPa, 1.7 bar) and open the air valve.

IG. 23.

8900 Proportioner with Disposable Mixer Gun

1. Load the material. See page 19.

2. Set ratio. (For variable ratio models, see page 14).

3. Install the mixer on the gun.

4. Open the pump A and pump B air shutoff valve (S), F

IG. 24.

FIG. 24

4. Open the solvent supply valve, ensuring that the dispense valve touches a grounded metal waste container and purge until solvent comes out clean.

5. Close solvent supply valve.

Component B Valve

TI3261A

Component A Valve Solvent Valve

IG. 23

5. Trigger the gun to dispense mixed material.

6. Adjust the component A air regulator (O) for the desired flow rate.

7. Adjust the component B supply air regulator (F) so that component B pressure is approximately equal to the component A pressure.

8. When you have finished dispensing, remove and dispose of the mixer, and install a red plastic cap (part no. 551327).

309790ZAA 29

Page 30

Operation

Changing Component A Drum

When the ram plate is extended fully to the bottom of the drum and the pump begins to cavitate, you need to change the drum. It is recommended that you check and refill the component B at the same time.

1. Close the air motor shutoff valve.

2. With the ram lever (PP) in the neutral position (F

25), adjust the ram regulator (R-F

IG. 25

IG. 26) to 0 psi.

3. Place the ram lever (PP) in the UP position, F

IG.

IG. 26.

6. Continue to hold the drum separation air button (PPP) just enough to keep the drum from rising with the ram plate.

7. Follow the procedure to load material, pages 19-24.

You only need to lubricate the ram plate tire seals the first time you load material.

PPP

IG. 26

WARNING

Do not use excessive drum separation air pressure. Make sure the drum is not damaged and the ram plate is free to exit the drum. Read warnings, page 5.

4. Push and hold the ram separation air button (PPP).

5. Adjust the ram regulator (R) to approximately 10-15 psi (69-103 kPa, 0.7-1 bar) or until the ram plate begins to rise.

30 309790ZAA

Page 31

Operation

Changing Component B Pail

If you are using a ram and pump to supply component B, the procedure to change the pail is the same as changing the Component A drum except that you use the controls on the back of the pail ram.

Pressure Relief Procedure

(For component B tank models only.)

WARNING

PRESSURIZED EQUIPMENT HAZARD

The pressure tanks remain pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized fluid or accidental spray from the gun, always follow this procedure to relieve pressure in the tank at the following times:

• Before you check or service any part of the spray system

• Before you loosen or remove the pressure tank cover or fill port.

• Whenever you stop spraying.

1. Shut off the air supply to the tank by closing the air inlet valve. Refer to F

IG. 27.

2. Open the drain cock fitting by turning it counterclockwise.

3. Wait until there is no air escaping through the drain cock fitting before removing the cover or opening the fill port.

4. Leave the drain cock fitting open until you have reinstalled the cover or fill port.

FIG. 27

Air inlet valve

Fill port cap

Drain cock fitting

03089C

309790ZAA 31

Page 32

Operation

Filling Component B Pressure Tank

If you are using a pressure tank to supply component B, check the tank level with a metal or plastic rod whenever the Component A drum is changed. To add component B to the tank, follow the procedure below.

1. Close the tank air supply shutoff valve, F

2. Relieve pressure in the tank (see page 27).

3. Open the fill port cap on top of cover.

CAUTION

Do not leave the pressure tank open. Component B will crystallize if exposed to the moisture in the air.The tank cover is normally removed only for tank cleaning.

Arrow points toward tank

IG. 28.

4. Gently roll an unopened pail of component B on the floor for several revolutions to mix it.

5. Open the pail outlet and carefully pour the material into the tank through a funnel.

6. Close the drain cock fitting and screw on the cap.

7. Make sure the silica-gel in the desiccant filter is blue. If the gel is pink, replace it (part no. 106498) or bake out the moisture.

The desiccant filter is an air dryer for moisturesensitive materials, it is not included with the package.

8. Pressurize the tank with dried air by opening the component B air shutoff valve and the pressure tank air shutoff valve.

IG. 28

Component B air supply valve

Dry Air Line

Tank air shutoff valve

Desiccant filter

ti3259ax

15:1 Component B pump

32 309790ZAA

Page 33

Operation

Adjust Ratio on Variable Ratio Machine

The ratio of this unit is determined partially by the difference in the area of the metering cylinders and partially by the position of the adjustable fulcrum point in the Unibar linkage assembly. With the fulcrum in the center, (next to stop at left of center), each meter cylinder strokes 3 in. In this center position, the dispense ratio is the same as the meter cylinder ratio. The ratio is adjustable from 1:1 to 20:1 depending on the location of the fulcrum point and cylinder size. There are three machines to accommodate these ratio ranges: 1:1-4:1, 2:1-8:1, and 5:1 to 20:1. The linkage must be adjusted for each material application so that the combination linkage and meter cylinder ratio equals the desired material mix ratio by volume. The ratio is checked by weight, but the machine meters by volume. Weight ratios must be known before proceeding. If weight ratios are not known, they can be calculated using the specific gravity and known volumetric ratio of each component.

The initial linkage adjustment point can be calculated by inserting known values into the following formula. The resulting value is the distance in inches from the center of the fulcrum point to the center of the component B meter cylinder. Measure the distance from the grease fitting on top of the fulcrum to the center of the component B cylinder meter rod. For reference, see the output charts on pages 15 through 17.

Ratio Adjustment Calculation Example:

DR = Required mix ratio by desired volume (X:1) PR = Selected cylinder ratio (1:1, 2:1, 5:1) LR = Linkage ratio LD = Linkage distance (component B cylinder center-

line to fulcrum center divided by LR+1)

LR=

Cylinder ratio 1:1-4:1 machine use PR = 1 Cylinder ratio 2:1-8:1 machine use PR = 2 Cylinder ratio 5:1-20:1 machine use PR = 5)

Verify the Ratio

1. Relieve pressure. See Pressure Relief Procedure

on page 27.

2. Remove gun and place a waste container under the component A and component B hoses.

3. Open air valve to turn on unit.

4. Activate the unit and using a collection container of known weight, collect a cup of component A and a proportionate amount of component B.

5. Weigh each component carefully and subtract the weight of the container.

6. Convert the manufacturer’s ratio to parts component B per 100 parts Component A, by weight (2:1 = 100:50).

7. Divide component B weight by component A weight.

8. Multiply the result of step 7 by 100. The product is the number of parts of component B the machine dispenses per 100 parts of Component A.

9. Compare ratio obtained to ratio desired. Always make several ratio checks to ensure accuracy at final setup. Any air in the system will cause inaccurate ratio checks. If ratio checks are not consistent, review setup procedure.

10. If the ratio is incorrect, loosen fulcrum screw (A) and turn the ratio adjustment screw/nut (B) clockwise to decrease and counterclockwise to increase the amount of component B.

11. If the ratio is correct, tighten the fulcrum nut and reattach hoses (7) to the dispensing gun.

Example:

• Desired volumetric mix ratio (DR) = 10:1

• Measured distance from grease fitting on top of the fulcrum to the center of the component B cylinder meter rod = 14.85 in.

LR=

measured distance

LD =

309790ZAA 33

LR + 1

=2:1

LD =

14.85 in. 2 + 1

or LD = 4.95 in.

Page 34

Operation

Daily Procedures

Daily Start-up Procedure

1. Perform daily maintenance operations, including:

a. Check oil level in main air lubricator.

b. Drain any water from filter in main air line.

c. Tighten pump packing nuts (daily the first week,

weekly thereafter).

d. Visually inspect system for leaks.

e. Grease zerk fittings.

2. Turn air pressure to the unit “ON”.

3. Check ratio on variable ratio models.

Steps 4 and 5 are applicable only to mix manifold models.

4. Open the coupled ball valves (push up).

5. Ensure that the component A purge ball valve is closed.

6. Place a material waste container under the gun outlet and open the dispense gun.

7. Dispense material until well mixed material is being dispensed.

8. The system is now ready to operate.

After the system is purged, do not open the dispense gun until the next system operation.

Disposable Mixer System

1. Remove and discard the mixer.

2. Trigger gun to ensure the outlet is clear.

3. Turn off the main air valve.

4. Wiper off gun nose.

5. If material is moisture-sensitive or dries out, protect the outlet with the night cap and ISO pump oil.

General Ratio Check Procedure

Checking the ratio allows the user to take samples of the metered material to ensure the equipment is operating properly.

The unit meters by volume but it is more convenient to check the ratio by weight. You must know the ratio by weight or the specific gravity of the materials to convert volumetric ratio to weight ratio.

1. Remove the hoses from the dispense gun. Take a material sample from the outlet of these hoses.

2. Open the air ball valves (push up) and collect a large material sample (approximately 1 pint of component A) in separate containers of known weight. Material flowing from each hose provides a sample for ratio check. When sample is collected, turn off air supply ball valve.

Daily Shut-down/Purge Procedures

Component A Purge

1. Close the coupled ball valves (push down).

2. Open the component A purge ball valve.

3. Hold the dispense gun over a material waste container.

4. Hold the dispense gun open until only component A is evident.

5. Close the component A purge ball valve.

6. Close the main air valve located under the meter base plate to remove air pressure from the meter.

34 309790ZAA

3. Weigh the component A and component B samples and subtract the weight of the collection containers.

4. Convert the material manufacturer’s ratio to “parts component B per 100 parts component A by weight.” For example, a 2:1 ratio (component A: component B) becomes 100:50.

5. Divide component B sample weight by component A sample weight.

6. Multiply the result of previous step by 100. The product is the parts component B dispensed by the machine per 100 parts component A by weight.

7. Compare the weight ratio obtained to the desired weight ratio. Repeat to obtain several successful ratio checks.

8. Put new mix elements in the gun and reconnect the hoses to the gun.

Page 35

9. Ration check is complete and the unit is ready for operation

Ratio Check Example Conversion Formula:

Parts by Volume (PBV) to Parts by Weight (PBW)

PBV component B PBV component A

Specific gravity component B Specific gravity component A

X = 100:Parts component B by weight

Ratio Check Example

component B sample weight LESS container weight component A sample weight LESS container weight

PRODUCT = Parts component B per 100 parts component A

• Manufacture’s specified weight ratio = 4:1 or 100:25.

• Weight of component A in ratio check is 245 grams.

• Weight of component B in ratio check is 61.2 grams.

• 61.2 divided by 245 equals .2497 (61.2 / 245 = .2497).

X 100 = PRODUCT

100 =

Operation

Three ratio checks are recommended to ensure accuracy at final setup. The presence of any air (visible or not visible) in the material or system will cause inaccurate ratio checks. If the ratio check cannot be made with repetitive accuracy, review air bleed procedures.

Some materials contain substantial amounts of entrained air due to manufacturing, transportation, system setup, or drum change. Air must be removed by de-gassing, recirculation, or self removal over time, before accurate metering can be accomplished.

309790ZAA 35

Page 36

Troubleshooting

8900 Proportioner Operating Pressures

There are four fluid pressure gauges on a typical 8900 Proportioner system. They are mounted on:

• Component A inlet block

• Component B inlet block

• Component A outlet block

• Component B outlet block

What the fluid gauges tell you

Inlet Gauge

The pump A and pump B inlet pressure gauge shows whether there is sufficient material supply to reliably feed each metering pump during its intake stroke.These double- acting pumps dispense and load fluid on both strokes.

The pump A and pump B supply air pressure should be set high enough to maintain reliable pump feed pressures but no higher than necessary. If gauge pressure is not consistently steady, increase fluid pressure.

The difference in the gauge reading between the stall condition and running is the amount of dynamic friction loss from the pump assembly, plus the flow-induced pressure drop from the pump lower to the pressure gauge.

Viscosity, temperature, flow rate, and gun setup can affect the amount of gauge drop when the trigger is pulled. On a typical manual gun system, the gauge drops 100-400 psi (0.7-2.8 MPa, 7-28 bar).

Component B Pump Outlet Gauge

The component B pump gauge shows line pressure, but the component B outlet pressure is generated primarily as a reaction to component A pressure at the mix chamber.

For materials running at greater than 1:1 ratio, component B cannot open the check (injector) valve until its pressure equals the component A pressure at the check valve. Hoses and injector restriction are chosen to naturally balance the pressure drop while running and match the component B pressure in the line when stalled.

Changeovers

Outlet Gauge

The pump A and pump B outlet gauge displays one of two conditions, stalled and running.

• Stalled: With the pump air valve on and the gun

closed, the gauge will show full stall pressure. This pressure is the fluid to air pressure ratio of the pump assembly, times the air pressure from the main regulator, minus the friction loss of the motor and pump assembly.

The fluid to air pressure ratio changes with different motors, different supply pumps, and different ratio settings.

• Running: When running, the gauge reads the

flow-induced pressure drop between the gauge and the gun outlet. The motor power is used up by the time the fluid exits the gun. The pressure drop is a measure of friction loss caused by hoses, the 8900 Proportioner, fittings, mixers, and gun.

When the pumps change direction there is a momentary change in gauges. In general, the gauges will drop 5-15%, then return. However, many factors affect the actual fluctuation, such as pump selection, fluid characteristics, flow rate, temperature, and length of hoses.

Check valves near the pump outlets isolate the hoses to let them serve as momentary surge chambers. This is why flow from the gun is smooth during changeover.

Abnormal Readings

Since so many factors affect gauge readings, it is important to know what is normal. Note how your gauges read when the machine is setup and running a good mix with no soft spots. What are the stall pressures and what are the running pressures for a given inbound air pressure? How much drop is there on changeover?

If something goes wrong, a change on the gauges can indicate what the problem is. Note those changes and work through the troubleshooting guide, beginning on page 39.

36 309790ZAA

Page 37

Air Supply Troubleshooting Chart

Problem Cause Solution

Troubleshooting

Abnormal pressure loss on air motor pressure regulator gauge during both changeovers.

Abnormal A and B pump outlet pressure loss during both changeovers.

Reduced flow rate. Undersized air compressor. Replace with properly sized air comOff-ratio material.

During normal operating conditions, the feed pump (A and B) air motors are filled with air almost instantaneously on both changeovers.

However, if the feed pump air supply is restricted, it can take significantly longer for air to fill the air motor. To check for this, observe the gauge on the air motor pressure regulator during both changeovers:

• At the end of each stroke the air pressure will drop abnormally as the air motor begins to fill.

• At the same time the A and B pump outlet pressures will drop abnormally due to the feed pump’s respective air motor’s reduced pressure.

Air line restriction due to quick-disconnect pin fitting.

Air supply line ID to each feed pump is too small.

Remove quick-disconnect from the air line and replace it with bleed-type air shutoff valve.

Replace with minimum 3/4 in. (19 mm) ID hose.

pressor.

• The decrease in the pump outlet pressures causes the flow rate at the dispense gun to be reduced.

• Once the air motor has filled with air, all air pressures and flow rates will return to normal until the end of the next stroke.

• The decreased pump outlet pressure may affect the feed pumps’ checking action, and thus mix ratio, resulting in the dispense of what appears to be poorly mixed material.

• Changing air pressure changes the compression of the component A hose and material. This causes an off ratio condition until pressures stabilize. Equipment air supply pressure must always stay above the motor regulator setpoint.

309790ZAA 37

Page 38

Troubleshooting

Pump Troubleshooting Overview

Pump Cavitation

Under normal operation, when the feed pump pressures are balanced, component A and component B outlet pressures are consistent.

Some up or down adjustments in feed pressures will be necessary to keep the pumps’ outlet pressures balanced. This is due to viscosity differences in the two materials, volumetric ratio, and required flow rate. Because of the viscosity difference between the two materials, most of the balancing effect comes from adjusting the component A pressure. For ratios higher than 1:1, the component B pressure should be set only as high as necessary to avoid cavitation at the desired flow rate. For 1:1 ratio there is equal balancing from component A and component B pressure.

If either the A or B pump does not completely fill with material on intake, the failing pump’s material output is interrupted at the beginning of the next stroke. This is referred to as cavitation.

Pump Failure to Seal

Under normal operation, the output of the component A and component B pumps depends upon proper sealing of their internal packings.

If packings fail to seal properly, the pump material output, and thus the output pressure, is reduced. Depending on the location of the failure, the pressure reduction may occur on the pump upstroke, downstroke, or both strokes.

Component B Pressure Relief Valve

The proportioner includes a spring-loaded, overpressure relief valve, which bypasses component B back to the supply when pressures exceed 3400 psi (23 MPa, 234 bar).

Pump A cavitation is detected by observing the inlet pressure gauges on pump A and pump B immediately after changeover. When cavitation occurs, the proportioner pump outlet pressure gauge drops and the pump A outlet pressure gauge shows an increase in pressure, as described previously.

B pump cavitation is detected by observing the B pump inlet pressure gauge immediately after pump top changeover. When cavitation occurs, the B pump outlet pressure gauge drops.

If the amount of cavitation is moderate, the pressure gauges return to their normal readings at some point during the downstroke of the failing pump.

During pump A cavitation, the pressure drop may cause a noticeable reduction in flow rate at the dispense gun. Additionally, the interruption in the pump A material output may cause component B-rich material to dispense, which may appear as poorly mixed material.

During B pump cavitation, the interruption in the B pump material output may cause component A- rich material to dispense, which may appear as poorly mixed material.

38 309790ZAA

Page 39

Troubleshooting

Troubleshooting Guide: Feed pumps

Problem Cause Solution

Erratic feed pump speed. Pump cavitation. Bleed air from pump.

Pumping too fast. Turn down air pressure regulator. Improper pump loading. Increase ram down pressure

Ram valve not in down position.

Pump lower not performing. Rebuild pump

Material leaking from top of pump Loose packing nut. Retighten.

Worn throat seals. Rebuild pump, replace seals.

Feed pump fails to cycle Air supply off. Check air valves/line pressure. Turn

on if required.

Air pressure too low. Increase air pressure on respective

feed pump air regulator.

Stalled air motor. Motor icing (warm up).

Check air filter and lubrication.

Ram fails to move up and down Lack of air pressure. Turn on or increase air supply pres-

sure to ram.

Ram failure. Check and rebuild.

Material leaking past follower plate seal (small amount of leakage is normal)

Too much ram pressure. Reduce ram down pressure on ram

air pressure. Worn wiper seals. Replace. Dented container. Straighten or replace container.

309790ZAA 39

Page 40

Troubleshooting

Troubleshooting Guide: 8900 Proportioner

Problem Cause Solution

Inconsistent material mix Material inlet pressures are not set

correctly. Erratic feed pump. Mix elements not assembled cor-

rectly or need to be replaced. Cylinder cups are bypassing mate-

rial. Material outlet hoses are not sized

correctly (pressures not balanced). Material ball valves are bypassing. Rebuild/replace. Insufficient air supply to material sup-

ply pumps.

Purge valve open (if applicable). Close during operation. Meter pressures never change Broken material gauge(s). Replace. Meter will not shift at the end of the

stroke.

Meter will not move Material inlet pressure not high

Material leaking from meter end caps Worn seals. Replace.

Meters not balanced Improper operation of supply pumps. Check for proper operation of mate-

Meter outlet pressure too high, metering inaccurate, decreased flow rate, non-uniform mix (streaking)

Incorrect ratio check and reduced flow rate

Inaccurate metering Air in the material or trapped in the

Limit valve not working correctly. Rebuild/replace, see page 45.

No material inlet pressure. Verify.

No air supply to limit valve. Verify.

enough to drive meter.

4-way ball valve orientation incorrect. Check, fix.

Dispense valve closed. Open.

Blockage in material hose. Depressurize system and repair.

Blockage in meter assembly. Depressurize system and repair.

End caps loose. Hand tighten with wrench provided.

Inadequate material supply to

pumps.

Curing material in the mixer or block-

age of either mixer inlet port (check

valves/injector valves plugged).

Material may be bypassing rather

than flowing through the meter.

pumping and metering components.

Follow flow rate procedures and ram feed pump troubleshooting guide.

Fix or replace.

Replace cylinder cups.

Call Graco Tech Service (800) 543-0339

Verify consistent air supply.

Verify low pressure on the gauges before increasing.

rial supply pumps. Each should have adequate material supply. Reasonably constant and balanced meter inlet and outlet pressures indicate proper pump function. If flow rate is increased by increasing A pump pressure, increase B pump pressure proportionally to balance meter inlet and outlet pressures.

Clear blockage.

Check for leakage in meter seals and cups.

Bleed the air from the pump.

40 309790ZAA

Page 41

Troubleshooting

Troubleshooting Guide: Manifold/Mixer

Problem Cause Solution

Poor mix quality. Dirty mixer. Disassemble Tri-Core mixer, clean

housing and end caps, and replace mix elements.

Inadequate mixing. Add mixer with more elements or

larger ID mixer.

Dirty mixer and gun. Replace flex mixer or clean Tri-Core

mixer and gun.

Tri-core mixer assembled improperly. Reassemble with scribe lines on end

caps aligned.

Fouled or plugged component B injector.

Cavitation due to ram air control valve not in DOWN position.

Cavitation due to low ram pressure. Increase to required operating

Reduced flow rate. Dirty mixer. Disassemble Tri-Core mixer, clean

Dirty mixer and gun. Replace flex mixer or clean Tri-core

Leaking component B shutoff valve. Repair or replace valve.

Poor purge quality. Leaking component B shutoff valve. Repair or replace valve. May require

Abnormally high B pump outlet pressures.

Abnormally high pump A outlet pressures.

Soft spots or color change relating to changeovers.

Fouled or plugged component B injector.

Feed pressure too high. Reduce feed pressure. Restriction in gun or hose, plugged

check valve.

Pressures are out of balance. Adjust pressure settings on A and B

Clean or replace injector.

Place control valve in DOWN position.

pressure.

housing and end caps, and replace mix elements.

mixer and gun.

solvent flush after valve replacement. Clean or replace injector.

Clean out gun. Inspect for cured material in check valve.

supply pumps to balance outbound ram pressure too low on feed pump.

309790ZAA 41

Page 42

Troubleshooting

Component B Injector

In most dispense systems, an injector is included in the component B fluid line. This injector adds back pressure to the system and provides the necessary pressure balance between component A and component B to achieve the proper ratio and mix.

If the injector becomes fouled with mixed material, the pressure indicated on the B pump outlet gauge will increase and upset the pressure balance, resulting in the dispense of poorly mixed material.

If the injector becomes completely plugged, only component A is dispensed from the gun and the B pump outlet pressure will increase until the relief valve discharges.

If the injector valve sticks, it can react sluggishly causing soft spots after valve triggering or changeover.

Keep the injector clean. Inspect the housing tip and needle end for dents or scratches. Lapping the needle to the housing with automotive lapping compound will recondition the seat/needle. When reassembling the injector, tighten the nut 2-2.5 turns after the slack is taken up.

It is good practice to have a clean injector on hand. A fouled injector can then be replaced quickly, and thoroughly cleaned and held for future use.

Preventive Maintenance

1. Air supply: Oil level in main air line lubricator should be checked daily and refilled when necessary with SAE 10W non-detergent oil. Adjust to dispense 1 drop per minute during operation.

Main air line filter should be drained as required. Excessive amounts of water in the system will reduce machine performance.

2. Housekeeping: Spilled materials on any part of the equipment should be cleaned up promptly. Your system is precision equipment and should be maintained as such. A light coating of petroleum jelly on components will often prevent spilled material from sticking to equipment.

3. Pumps: Pump packing should be tightened daily the first week of operation and weekly thereafter.

4. When using Throat Seal Lubricant (TSL) or ISO oil, the lubricant should be maintained at an adequate level in the pump packing reservoir. These lubricants prevent material from sticking to pump rods, extends packing life, and protects material from contamination from the atmosphere.

Use ISO oil when dispensing moisture-sensitive materials.

Meter: Maintain TSL or ISO oil in reservoir if used; grease zerk fitting. Clean up spills as soon as possible to prevent damage to the meter.

5. Mixer: With most materials, frequent use of equipment is all that is needed to prevent internal curing. Some materials have a tendency to cure slowly on the walls of the mixing chamber. Experience will dictate how often the mixer or mixer elements should be thoroughly cleaned or replaced.

6. O-rings/Seals: O-rings and seals will be damaged if soaked in solvents. When reusing, wipe with solvent and dry immediately.

42 309790ZAA

Page 43

Service and Repair

Repair the Cylinder (Fixed Ratio)

• Relieve pressure throughout the 8900 Proportioner assembly. Follow the pressure relief procedure on page 31.

• Reference numbers shown in parentheses in Service and Repair procedures refer to references in figures and parts lists.

116

113

IG. 29: Fixed Ratio 8900

1. Disconnect hose (17) on cylinder end manifold, FIG.

29.

2. Remove guard tube (116).

10, 11

8. Remove packing nut (103) from opposite cylinder end cap (106) and remove throat packings and glands (110, 111, 112).

9. Remove piston assembly (106, 107) from rods (101,

102).

10. Replace V packings and glands on both ends with new ones and reassemble in reverse order of disassembly.

11. Replace cylinder end o-rings (109) on each cylinder end cap. Apply grease to each to help hold o-ring into end cap.

12. Push piston assembly through cylinder block (113).

Use grease generously during reassembly.

13. Replace o-rings (114) on each packing nut and screw, then screw packing nut back into cylinder end caps. Hand tighten until firmly seated on packings, then wrench tighten 1/4 turn.

14. Push cylinder assembly back together.

15. Complete reassembly of the cylinder in reverse order of disassembly.

Use threadlocker (118) when reassembling rods (101, 102). Torque to 55 ft-lbs (74.25 N•m).

3. Loosen and remove 4 locknuts (30).

4. Loosen nut (10) on coupling (11) and disconnect pump rod from coupling.

If the entire cylinder needs to be removed and serviced at another location, loosen and remove screws (49). Then loosen union (9) to remove the cylinder assembly from unit. See page 49.

5. Pull on cylinder block (113), F come apart.

6. Remove rod and piston assembly from cylinder.

7. Remove packing nut (115) from cylinder block (113) and remove throat packings and glands (110, 111,

112).

309790ZAA 43

IG. 31. Cylinder should

IG. 30: Variable Ratio 8900

Page 44

Service and Repair

TI2761A

104

112

110

109

111

114

102103

106107

113

115

101

116

246558

FIG. 31

44 309790ZAA

Page 45

Service and Repair

Replace Air Valve

IG. 32

304 305303

1. Unscrew 2 socket head cap screws (311), FIG. 33.

2. Pull complete air valve assembly off cylinder and connecting rod assembly.

3. Remove retaining ring and plate off end and pull rod through.

4. Remove retaining ring off appropriate air valve (303), pull out valve (304) and replace with new valve.

5. Reassemble in reverse order of disassembly. Make sure not to remove spacer (305) during disassembly. This spacer sets correct alignment of valves.

6. Reattach air valve assembly to the 8900 cylinder block and connecting rod assembly.

311

FIG. 33

309790ZAA 45

Page 46

Disassemble Fluid Valve

IG. 34

1. Relieve pressure and turn off feed supply units. Close air valve.

4. Pull off end cap (413).

5. Pull out ball passage (411) with backup ring (409), packing o-ring (410), and bushing (408).

6. Remove packing assemblies consisting of seal (402), o-ring (403), bushing (404), o-rings (406,

407), and connector (405).

7. 4-way valve must be installed so that flow paths marked on shaft (see illustration below) are 90° out of phase with each other. Stamped indicators on shaft end of valves show material flow paths.The 8900 Proportioner will not cycle if the valves are not in proper phase with each other.

2. Remove valve assembly from 8900 cylinder. Take off hose (17), union (9), fitting in (5), fitting out (5). See F

IG. 31.

3. Remove 4 socket head cap screws (415, F

Enlarged detail of flow path marking

IG. 35.

When reassembling, apply grease to all o-rings and bearings.

403

402

408 409 410

411

407

405

406

404

415

IG. 35

46 309790ZAA

413

Page 47

Disassemble Fluid Valve

309790ZAA 47

Page 48

Parts

8900 Proportioner, Fixed Ratio

Item 7 Item 14

Part Number

570367

570369

570366

246558

Fixed Ratio

Assembly

No.

Quantity

C24145

1:1 570371 2 1:1 24C972 2 2:1 570372 1 1

2.5:1 570373 1 1 4:1 570374 1 1 5:1 570375 1 1 9:1 246557 1 1

10:1 570376 1 1

Ref. No. Part No. Description Qty.

1 C24016 ARM, trip 1 3 187877 TUBE, gauge 2 4 102814 GAUGE, fluid pressure 4 5 624545 T-FITTING; 3/4 npt(m) x 1/4 npt(f) 4 6 157785 UNION, swivel; 3/4 nps x 3/4 npt 4 7 CYLINDER; see table above; see

page 52 8 C19411 CONNECTOR; 3/8 npt x 3/8 tube 1 9 C24042 UNION; includes 9a 2 9a* 105802 • O-RING; fluoroelastomer 2 10 110343 SCREW; 1/2-13 UNC x 1.75 in. 1 11 C23016 COUPLING 1 12 C24013 SPACER 4 13 C24053 COUPLING 1 14 CYLINDER; see table above; see

page 52 15 16E304 COUPLING 1 17 552272 HOSE; 3/4 npt, 4000 psi (28 MPa,

276 bar) 19 100214 LOCKWASHER 4 20 C19829 SCREW; 5/16-18 x 2.5 in. 4 21 111303 NUT; hex 4 22 C24052 BRACKET, valve mounting 2 23 109212 SCREW; 3/8-24 x 3/4 in. 8 24 16E287 ACTUATOR, pneumatic 1 25 C24029 VALVE, 4-way 2 26 C24014 VALVE, limit 1 27 120753 ELBOW, 90°; 1/4 npt x 3/8 in. tube 1

570367

570366

Ref. No. Part No. Description Qty.

28 590385 TUBE, nylon; 0.375 OD; 6 ft * 30 101926 LOCKNUT; 1/2-20 NF 8 31 C29034 WRENCH, spanner 1 32 156172 FITTING, swivel; 3/4 nps x 3/4 npt 3 38 C03190 RING 2 39 C23269 CHAIN 1 40 C24140 MANIFOLD, lube 1 41 949666 AIR CONTROL; see page 53 1 42 C30021 U-BOLT; 3/8-16 UNC 2 43 237112 VALVE, relief 1 44 113344 UNION, swivel; 1/2-14 npt x 3/4

npsm

45 113187 CONNECTOR, tube, 1/2 OD x

1/2 npt

47 061134 HOSE, nylon; 1/2 in. OD, 1.4 MPa,

(14 bar, 200 psi), 6’ 48 105209 SCREW; 10-32 UNF x 7/8 in. 2 49 100101 SCREW; 3/8-16 UNC x 1 in. 10 50 100131 NUT; 3/8-16 UNC 6 51 100133 WASHER, lock; 7/16 in. 6 52 965785 BASE 1 57 100840 ELBOW; 1/4-18 npt 1

*EPDM replacement part available in kit 289401.

TI2763A

48 309790ZAA

Page 49

Parts

45, 46, 47

43, 44

23, 24

19, 20, 21

TI2761A

49, 50, 51

TI2762

40, 48

309790ZAA 49

Page 50

Parts

8900 Proportioner, Variable Ratio

Item 1 Item 2

Part Number

570367

570369

570366

570369

Variable

Ratio

1:1 - 4:1 570377 2 2:1 - 8:1 570378 1 1

5:1 - 20:1 570380 1 1

Ref. No. Part No. Description Qty.

1 CYLINDER; see table above and

2 CYLINDER; see table above and

4 624545 FITTING, TEE 3/4m run X 1/4f 4 6 157785 FITTING, union, swivel 4 7 102814 GAUGE, pressure, fluid 4 8 156172 FITTING, union, swivel 5 9 552272 HOSE, PTFE 3/4-18” 5000 psi npt(m) 2 12 C23016 COUPLING, pair 2 13 C19854 SCREW, cap, socket head 2 14 C24016 ARM, trip 1 15 C24422 ROD, tie 8 16 101926 NUT, locking, metallic 16 17 C23280 8841-4-A, beam assembly 1 18 C24420 SCREW, ratio adjusting 1 19 C24419 PLUNGER 2 20 C29031 BAR, uni 1 21 C29023 ASSEMBLY, fulcrum 1 22 C29037 STOP, unibar 2 23 C19852 SCREW, cap, socket head 2 24 16E287 ACTUATOR, pneumatic 1 25 16E324 COUPLER, long 1 26 C24418 BRACKET, 3/4 valve mounting 2 27 C24029 VALVE, 4-way 2 29 109212 SCREW, cap, socket head 8 30 C19829 SCREW, cap, socket head 4 31 111303 NUT, hex 4 32 100214 WASHER, lock 4 33 C23276 MONITOR, scale 1 34 C19798 SCREW, cap, socket head 2 35 100018 WASHER, lock, spring 3 36 100321 NUT 1 38 C24014 VALVE, limit 1 39* C24042 FITTING, union, assembly 2 40 C24417 STUD 2 41 16E321 COUPLER, 3/4 in. sq x 5/8 in. sq 1 43 100847 FITTING, lubrication 2 44 C24442 PLATE, designation 1 45 C29034 TOOL, spanner wrench 1

Assembly

No.

page 52

Quantity

570366

Ref. No. Part No. Description Qty.

46 C23269 CHAIN 1 47 C03190 RING 2 49 100840 ELBOW, street 4 53 C29043 BUSHING, ball 2 54 160327 FITTING, union, adapter, 90 degree 2 55 157191 FITTING, adapter 1 56 237112 VALVE, relief 1 57 156022 ADAPTER 1 58 205439 COUPLING, hose 1 59 061134 HOSE, nylon 6 60 C24140 MANIFOLD, lubrication 1 61 105209 SCREW, cap, socket head 2 62 949666 AIR CONTROL; see page 53 1 63 100004 SCREW, cap, hex head 8 64 100131 NUT, full hex 6 65 100133 WASHER, lock 6 66 965785 BASE, weld mount 8900 VR 1 67 C30021 BOLT, u 2 68 626814 SPACER, .75 od x .45 id x .50 lg alum 8 72 120753 FITTING, elbow, male, 90 degree 2 73 590385 TUBE, 3/8 in. OD nylon 3.6 ft * 74 120389 FITTING, tube 2 75 513754 COLLAR, shaft 1.250 cs split 2 79 113344 UNION, swivel 1

*EPDM replacement part available in kit 289401.

72, 73, 74

60, 61

62, 63, 64, 65

Top V ie w

50 309790ZAA

Page 51

Parts

30, 31, 32

53, 19

7, 49

33, 34

24, 25, 29, 25

12, 35, 36

23, 35

570378 and 570380 2

570377 1

309790ZAA 51

Page 52

Parts

Cylinder Assemblies

(ref. nos. 7 and 14 FR, 1 and 2 VR)

Part No. 246558

Model 246557 only

Part No. 570366

Models 570373 and 570374 only

Part No. 570367

Models 570372, 570375, and 570377 only

Part No. 570369

Models 570371 and 570376 only

Part No. C24145

Models 570371,570372, 570374, 246557,and 570376

Ref. No. Part No. Description Qty.

101 C24054 SHAFT, piston, outer 1 102 C24055 SHAFT, piston, inner 1 103 C24022 NUT, packing 1 104 C24026 BLOCK, cylinder, inside 1 105 15C180 CYLINDER, 111; 246558 only 1

C23171 CYLINDER, 250; 570366 only C23200 CYLINDER, 500; 570367 only C23137 CYLINDER, 100; 570369 only C23136 CYLINDER; 1000; C24145 only

Ref. No. Part No. Description Qty.

106 15C181 SPACER; 246558 only 1

C23431 SPACER, 570366 only C23460 SPACER, 570367 only C23398 SPACER; 570369 only C05031 SPACER; C24145 only

107 15C182 PACKING, cup; 246558 only 2

C23318 PACKING, cup; 570366 only C23350 PACKING, cup; 570367 only C23282 PACKING, cup; 570369 only C05032 PACKING, cup; C24145 only

108 15C183 RING, backup; 246558 only 2

C23547 RING, backup; 570366 only C23515 RING, backup; 570369 only C05029 RING, backup; C24145 only

C23574 RING, backup; 570367 only 109* C20278 O-RING; fluoroelastomer 2 110 C21002 V-PACKING; PTFE 10 111 C36244 GLAND, male 2 112 C36246 GLAND, female 2 113 C24023 BLOCK, cylinder, outside 1 114* 188554 O-RING, fluoroelastomer 2 115 C57617 NUT, packing 1 116 C57618 TUBE, guard 1 117 179788 LABEL, warning 1 118 SEALANT, thread lock 1

*EPDM replacement part available in kit 289402

104 105

114

110

112

109 110111 112

111

118

102103

106107108

109

113

114

115 116 117

105

101

C24145

106107108

52 309790ZAA

Page 53

Parts

Limit Valve

(ref. no. 26 FR, 38 VR)

Part No. C24014

Ref. No. Part No. Description Qty.

301 C20439 RING, retaining ext 4 302 C24008 WASHER 2 303 C20407 RING, retainer 2 304 C22064 VALVE 2 305 C24007 SPACER 1 306 C24051 MANIFOLD 1 307 100079 WASHER, lock, spring 2

302

301

303 304 305 306

Ref. No. Part No. Description Qty.

308 C19977 SCREW, cap 2 309 C24012 VALVE, 4-way 1 310 C20852 FITTING, plug, 10-32 5 311 C19835 SCREW, cap socket head 2 312 C24017 ROD, trip, valve 1 313 C24009 SPRING, compression 2 314 C20068 PIN, spring 2 315 C24018 COLLAR, stop 2 316 C24019 INDICATOR, scale 1 317 C19146 SCREW, mach, slotted round head 2 318 C24020 COLLAR, clamp 1 319 C19264 PLUG, pipe plug 1/4 in. 3 320 C24016 ARM, trip 1

319 319

307 308

309

310

311

312

313

314

315

320

316

318

317

309790ZAA 53

Page 54

Parts

Air Control

(ref. no. 41 FR, 62 VR)

Part No. 949666

Ref. No. Part No. Description Qty.

201 626086 BRACKET 1 202 624225 AIR MANIFOLD 1 203 157191 ADAPTER; 3 204 206197 AIR REGULATOR; 1/2 x 3/4 npt 2 205 100840 ELBOW; 1/4-18 npt 2 206 160430 GAUGE, air pressure 2 207 1554701 UNION, 90° swivel; 1/2-14 npsm x

1/4-14 npt 208 105170 SCREW; 1/4-20 UNC x 2 in. 3 209 100015 NUT; 1/4-20 UNC 5 210 100016 WASHER, lock 5 211 110225 VALVE, 2-way, vented; 1/2-14 npt 2

208

221

226

209

210

Ref. No. Part No. Description Qty.

212 103475 TEE; 1/2 npt 1 213 100122 NIPPLE; 1/2-14 npt 2 214 214848 LUBRICATOR, air line 1 215 106149 FILTER, air; 1/2 npt 1 216 172124 NIPPLE; 1/2-14 x 3/8-18 npt 1 219▲ 551206 WARNING LABEL 1 220▲ 551207 INSTRUCTION LABEL 1 221 158990 AIR MANIFOLD 1 222 158491 NIPPLE; 1/2-14 npt 1 223 155495 UNION, 90° swivel; 1/4 npsm x 3/8

npt 224 162453 NIPPLE; 1/4 npsm x 1/4 npt 2 225 101748 PLUG; 3/8-18 npt 2

226 100361 PLUG; 1/2-14 npt 1 227 C19411 CONNECTOR; 3/8 tube x 3/8 npt 1 228 106285 U-BOLT; 1/4-20 UNC 2 229 C19394 ELBOW, 90°; 3/8 tube x 3/8 npt 1

225

223

229

202

227

201

223

222

203

(behind)

206

204

205

207

220

203

211

224

213

212

213

214

219

216 225

215

222

210

228

211

207

210 228

54 309790ZAA

Page 55

Parts

4-Way Valve

(ref. no. 25 FR, 27 VR)

Part No. C24029

Ref. No. Part No. Description Qty.

401 C24030 BODY, valve 1 402 C24031 SEAL 4 403* C24036 PACKING, o-ring 4 404 C24033 BUSHING 4 405 C24034 FITTING, connector 4 406* C24035 PACKING, o-ring 4 407* C24032 PACKING, o-ring 4

Ref. No. Part No. Description Qty.

408 C24037 BUSHING 2 409 C24038 RING, backup 4 410* 103611 PACKING, o-ring 2 411 C07068 BALL, passage 1 412* C24040 PACKING, o-ring 1 413 C24041 CAP, end 1 414 100133 WASHER, lock 4 415 C19839 SCREW, cap, socket head 4

*EPDM replacement part available in kit 289401.

401

402

403

404

405

406

407

414

415

408 409

410

409

411

409 410

409

408

412

413

405406407

309790ZAA 55

Page 56

Parts

Pump Feed Module Selection for Component A or Component B

20:1 President on 5 Gallon Ram

(See Graco Manuals 308026 and 306838)

Module No. 965571

Ref. No. Part No. Description Qty.

4 237207 PUMP, President, 20:1 1 13 222812 PLATE, wiper, 5 gallon 1 22 102556 RIVET, blind 4 24 156823 UNION, swivel 1 27 184147 SHIELD, 5 gallon ram 1 35 113269 VALVE, ball, vented, .500 1 36 155865 UNION, adapter 1 37 237569 WIRE, assy, 25 ft 1 42 156971 NIPPLE, short 1 43 104984 TEE, pipe 1 44 113286 VALVE, safety 1 45 160701 ELBOW, street 1 47 237562 SUPPORT, pump 1 48 113208 FITTING, tube 2 49 113896 VALVE, control 1 51 104765 PLUG, pipe headless 1 52 110318 REGULATOR, air, 1/4 in.npt 1 53 110319 GAUGE, pressure, air, 1/8 in. npt 1 54 160107 NUT, cap 1

Ref. No. Part No. Description Qty.

55 101533 WASHER, spring lock 1 56 190265 SPACER 1 57 238925 PISTON, ram, 5 gallon 1 58 166552 CAP, cylinder 1 59 206726 BASE, and cylinder 1 63 054123 TUBE, nylon 3.7 ft * 65 190256 CLAMP, support 2 66 100680 SCREW, cap, hex head 4 67 101566 NUT, lock 4 68 100023 WASHER, flat 4 70 114320 FITTING, connector, 1/8 npt(f) 1 71 115901 TRIM, edge, protection 2 72 160327 UNION, adapter, 90° 2 73 235497 VALVE, check 1 74 100896 FITTING, bushing, pipe 2 75 H45010 HOSE, fluid; nylon; 1/2 in. (13 mm)

ID; 1/2 npsm(fbe); 10 ft (3.05 m)

long 76 214656 HOSE, coupled, 61209, 10 ft 1 77 109126 HOSE coupled, 10 ft 1 79 155470 UNION, swivel, 90° 1 80 158491 FITTING, nipple 2

56 309790ZAA

Page 57

Parts

24 52

76, 36

72, 73, 74, 80, 75

06537

309790ZAA 57

Page 58

Parts

34:1 Senator on 5 Gallon Ram

(See Graco Manuals 308026 and 306838)

Module No. 965597

Ref. No. Part No. Description Qty.

1 222769 PUMP, senator (4.5 cm) 1 2 100468 SCREW, cap, hex head 4 3 100133 WASHER, lock 4 4 222812 PLATE, wiper, 5 gallon 1 7 101154 PIN, driv-lok 1 10 102556 RIVET, blind 4 12 107144 SCREW, cap, hex head 1 15 184150 SPACER, rod, elevator 1 17 184147 SHIELD, 5 gallon ram 1 22 206726 BASE, and cylinder 1 23 101533 WASHER, spring lock 1 24 166552 CAP, cylinder 1 25 113208 FITTING, tube 2 26 113896 VALVE, control 1 29 160107 NUT, cap 1 30 054123 TUBE, nylon 3.7 ft * 34 110318 REGULATOR, air, 1/4 in. npt 1

Ref. No. Part No. Description Qty.

35 110319 GAUGE, pressure, air, 1/8 in. npt 1 36 104765 PLUG, pipe, headless 1 37 155541 UNION, swivel, 90° 1 38 238925 PISTON, ram, 5 gal. 1 39 166533 SUPPORT, pump 1 40 110225 VALVE, ball, vented 1 45 237569 WIRE, assy, 25 in. 1 46 180916 MANIFOLD, adapter 1 47 114003 VALVE, safety 1 50 114320 FITTING, connector, 1/8 npt(f) 1 52 160327 UNION, adapter, 90° 3 53 115901 TRIM, edge, protection 2 55 235497 VALVE, check 1 56 157191 FITTING, bushing, pipe 1 57 215238 HOSE, coupled, 61220 1 58 214656 HOSE, coupled, 61209, 10 in. 1 59 109126 HOSE, coupled, 10 in. 1 60 156684 UNION, adapter, swivel 1

58 309790ZAA

Page 59

Parts

37 36

23,29

05687x

309790ZAA 59

Page 60

Parts

23:1 Monark on 5 Gallon Ram

(See Graco Manuals 308026 and 306838)

Module No. 570142

Ref. No. Part No. Description Qty.

1 184147 SHIELD, 5 gallon ram (not shown) 1 2 206994 FLUID, TSL 8 oz bottle (not shown) 1 4 222782 PUMP, Monark 1 11 222812 PLATE, wiper, 5 gallon 1 19 156823 UNION, swivel 1 25 155470 UNION, swivel, 90° 1 27 113269 VALVE, ball, vented .500 1 28 155865 UNION, adapter 1 29 237569 WIRE, assy, 25 ft 1 34 156971 NIPPLE, short 1 35 104984 TEE, pipe 1 36 113286 VALVE, safety 1 37 160701 ELBOW, street 1 41 238925 PISTON, ram, 5 gallon 1 42 237562 SUPPORT, pump 1 43 160107 NUT, cap 1 44 101533 WASHER, spring lock 1 45 190265 SPACER 1 47 054123 TUBE, nylon 3.7 ft * 49 110319 GAUGE, pressure, air, 1/8 in. npt 1

Ref. No. Part No. Description Qty.

50 110318 REGULATOR, air, 1/4 in. npt 1 51 104765 PLUG, pipe, headless 1 52 113896 VALVE, control 1 53 166552 CAP, cylinder 1 54 206726 BASE, and cylinder 1 55 113208 FITTING, tube 2 58 190256 CLAMP, support 2 59 100680 SCREW, cap, hex head 4 60 101566 NUT, lock 4 61 159239 FITTING, nipple, pipe, reducing 1 62 100023 WASHER, flat 4 64 114320 FITTING, connector 1/8 npt(f) 1 65 115901 TRIM, edge, protection 2 66 100896 FITTING, bushing, pipe 3 67 160327 UNION, adapter, 90° 2 68 235497 VALVE, check 1 69 H45010 HOSE, fluid; nylon; 1/2 in. (13 mm)

ID; 1/2 npsm(fbe); 10 ft (3.05 m)

long 70 214656 HOSE, coupled, 61209, 10 ft 1 71 109126 HOSE, coupled, 10 ft 1 73 158491 FITTING, nipple 2

60 309790ZAA

Page 61

Parts

47 41

05689C

309790ZAA 61

Page 62

Parts

20:1 President on 55 Gallon Ram

(See Graco Manuals 306934 and 308027)

Module No. 570114

Ref. No. Part No. Description Qty.

1 215335 BASE, ram 1 2 222768 PUMP, President (4.5 cm) 1 3 276025 CLAMP 4 5 206537 CLAMP, drum 1 7 184140 PLATE, mounting 1 9 237569 WIRE, assy, 25 ft 1 10 104984 TEE, pipe 1 11 113286 VALVE, safety 1 12 156971 NIPPLE, short 1 16 102637 SCREW, cap 4 18 100101 SCREW, cap, hex head 4 19 100122 NIPPLE, close 1 20 100133 WASHER, lock 4 22 100672 SCREW, set 4 23 100132 WASHER, flat 4 24 100464 SCREW, lag 4 25 101533 WASHER, spring lock 4 26 101535 NUT, full hex 4 28 189559 CAP, end 2 29 160701 ELBOW, street 1 31 157416 UNION, swivel, 90° 1 32 158979 FITTING, nipple, pipe, reducing 1 36 110319 GAUGE, pressure, air, 1/8 in. npt 1 37 155541 UNION, swivel, 90° 1 38 110318 REGULATOR, air, 1/4 in. npt 1

Ref. No. Part No. Description Qty.

40 158256 UNION, swivel 1 41 113269 VALVE, ball, vented, .500 1 45 161822 PLATE, mounting 2 46 054123 TUBE, nylon 3.6 ft * 47 111162 FITTING, elbow 1 48 167652 ROD, tie ram 2 49 238928 PISTON, 55 gallon ram 2 50 114363 VALVE, ball, fluid 1 51 167646 BEAM, ram 1 52 166552 CAP, cylinder 2 55 238929 PLATE, 55 gallon ram 1 56 109495 PACKING, o-ring 1 58 208048 HOSE, coupled 61089 1 64 100403 PLUG, pipe 1 69 113896 VALVE, control 1 75 100270 SCREW, cap, hex head 2 76 100016 WASHER, lock 2 77 114243 VALVE, check 1 78 156849 UNION, adapter, 90° 1 79 113915 FITTING, union 1 80 158212 BUSHING 1 81 235497 VALVE, check 1 82 160327 UNION, adapter 90 2 83 215238 HOSE, coupled, 61220 1 84 214651 HOSE, coupled, 61209, 17 ft 1 85 109126 HOSE, coupled, 72 in. 1 87 184037 FITTING, outlet (6 cm) 1

62 309790ZAA

Page 63

Parts

25,26

52 46

20,18

0717E

309790ZAA 63

Page 64

Parts

34:1 Senator on 55 Gallon Ram

(See Graco Manual 308027)

Module No. 965572

Ref. No. Part No. Description Qty.

3 235497 VALVE, check 1 4 160327 UNION, adapter, 90° 2 5 215238 HOSE, coupled, 61220 1 6 214651 HOSE, coupled, 61209, 17 ft 1 7 109126 HOSE, coupled, 10 ft 1 9 222769 PUMP, Senator (4.5 cm) 1 10 241253 RAM, pneumatic, EPDM, 55 gallon 1 11 276025 CLAMP 4 12 102637 SCREW, cap 4 15 113269 VALVE, ball, vented, .500 1

Ref. No. Part No. Description Qty.

20 109495 PACKING, o-ring 1 21 111803 SCREW, cap, hex head 4 22 100133 WASHER, lock 4 23 158979 FITTING, nipple, pipe, reducing 1 25 114363 VALVE, ball 1 30 158256 SWIVEL, union assembly 1 31 100896 FITTING, bushing, pipe 1 34 206537 CLAMP, drum 1 35 155541 UNION, swivel 1 36 158212 BUSHING 1

22 9

12 11

0717E

64 309790ZAA

Page 65

Parts

31:1 Bulldog on 55 Gallon Ram

Module No. 570141

Ref. No. Part No. Description Qty.

2 237261 PUMP, Bulldog, 31:1 1 3 235497 VALVE, check 1 4 160327 UNION, adapter, 90° 2 5 215238 HOSE, coupled, 61220 1 6 214651 HOSE, coupled, 61209, 17 ft 1 7 109126 HOSE, coupled, 10 ft 1 8 158212 BUSHING 1 15 158555 NIPPLE, reducing 1 17 241253 RAM, pneumatic, EPDM, 55 gallon 1

Ref. No. Part No. Description Qty.

20 C20487 FITTING, nipple, hex 1 26 113332 VALVE, ball, vented, .750 1 28 155541 UNION, swivel, 90° 1 29 276025 CLAMP 4 30 102637 SCREW, cap 4 31 109495 PACKING, o-ring 1 32 100101 SCREW, cap, hex head 4 33 100133 WASHER, lock 4 37 237569 WIRE, assy, 25 ft 1 39 100505 FITTING, bushing, pipe 1 40 158979 FITTING, nipple, pipe, reducing 1 41 114363 VALVE, ball 1

29 30

9348C

309790ZAA 65

Page 66

Parts

20:1 Senator on 55 Gallon Drum

Module No. 570309

Ref. No. Part No. Description Qty.

1 570308 PUMP, 20:1 Senator Dura-Flo 750 1 2 207408 ELEVATOR, stationary 1 3 237579 KIT, repair 1 6 514944 VALVE, needle sst 1/2 MF 6000 1 7 159842 ADAPTER 1 8 100380 BUSHING, pipe 1 9 501764 FITTING, elbow 90°

1 in. npt(f) x 1 in. n 10 237309 COVER, drum 1 11 208536 COUPLER, line, air 1 12 158491 FITTING, needle 1 13 237578 SUPPORT, cover assy, sst 1 14 215239 HOSE, coupled 61220 1 22 160327 UNION, adapter, 90° 2 23 160032 NIPPLE 2

Ref. No. Part No. Description Qty.

24 102644 VALVE, ball 2 25 157785 UNION, swivel 1 26 214656 HOSE, coupled 61209, 10 ft 1 28 102471 SCREW, cap hex head 3 29 102021 NUT, lock 3 31 205349 HOSE, coupled 61120, 15 ft 1 32 162449 FITTING, nipple, reducing 2 33 157785 FITTING, union, swivel 1 34 180916 FITTING, tee 3/4(m) run x 1/4(f)

branch 35 214037 VALVE, ball 3 36 109126 HOSE, coupled, 10 ft 1

38 187614 NUT, jam 1 39 159446 GASKET, vellumoid 1 40 15C321 PLATE, cover 1 41 100896 FITTING, bushing, pipe 1 42 15C322 RETAINER, siphon tube 1 43 190999 NUT, retainer 1 44 238161 TUBE, siphon, hd agitator 1 45 113218 VALVE, ball, vented, .750 1

24 23 22

2,3

Detail A

See Detail A

66 309790ZAA

Page 67

9:1 DynaMite on 1 Gallon Can Ram

Module No. 570249

Ref. No. Part No. Description Qty.

1 235871 PUMP, extruder, sst, 190 1 2 217298 BRACKET, mounting 1 3 514518 HOSE, coupled 3/16 in. x 3 ft 1 4 109125 HOSE, coupled 72 in. 1 5 224908 INDUCTOR, assy, 1 gal. 1 6 156823 UNION, swivel 2 7 156971 NIPPLE, short 2

Parts

Ref. No. Part No. Description Qty.

8 C24332 BOLT, “U” 2 9 100615 BUSHING, hex steel 1 10 101885 SCREW, cap sch 2 11 102040 NUT, lock, hex 2 12 100086 WASHER, plain 1 13 155541 UNION, swivel, 90° 1 14 100206 BUSHING, pipe 1

10,11,12

309790ZAA 67

Page 68

Parts

10 Gallon Press Tank with 15:1 Booster

Module No. 570037

Ref. No. Part No. Description Qty.

2 101946 PIN, cotter, sst 1 3 102325 ELBOW, 90° 1 5 156082 PACKING, o-ring 1 6 156823 UNION, swivel 1 7 157785 UNION, swivel 2 8 217296 FRAME, pump 1 9 167682 ROD, tie 3 10 207352 MOTOR, air, pres 1 11 207370 ROD, connecting 1 12 215930 PUMP, displ, recip 1 13 221170 HOSE, coupled, 061260, 3 ft 1 14 236150 TANK, high pressure 10 gallon 1

21,22,23,24,25

2,5,11,26

Ref. No. Part No. Description Qty.

15 236662 AGITATOR, heavy duty, 10 gallon 1 16 236677 KIT, repair 1 17 501603 VALVE, check 1/2 in. npt mbe sst tf 1 18 512484 VALVE, ball, sst 1 19 620198 PLATE, mounting 1 21 100101 SCREW, cap, hex head 4 22 100133 WASHER, lock 4 23 100131 NUT, full hex 4 24 100016 WASHER, lock 2 25 100022 SCREW, cap, hex head 2 26 150707 PLATE, designation 1 27 H45010 HOSE, fluid; nylon; 1/2 in. (13 mm)

ID; 1/2 npsm(fbe); 10 ft (3.05 m)

long 28 100896 FITTING, bushing, pipe 1 29 160327 UNION, adapter, 90° 1 30 214656 HOSE, coupled, 61209, 10 ft 1 31 109126 HOSE, coupled, 10 ft 1 32 158491 FITTING, nipple 3 33 107142 VALVE, ball, vented 1

8, 19

68 309790ZAA

Page 69

10:1 President 5 Gallon Pail Cover

Module No. 570264

Parts

Ref. No. Part No. Description Qty.

1 903295 PUMP, 10:1 President, sst 1 3 100035 SCREW, machine, panhead 1 4 206755 CHAIN 1 5 165096 PLUG 1

See

Detail A

Ref. No. Part No. Description Qty.

6 165516 PACKING, o-ring 1 7 101962 SCREW, set sch 2 8 100220 SCREW, thumb 3

15,16

Detail A

309790ZAA 69

Page 70

Parts

Mix Kit Selection

Cartridge Fill Medium Viscosity Wide Ratio

Module No. 570248

Ref. No. Part No. Description Qty.

4 626748 BRACKET, mount disp valv C24342 1 5 552204 ACTUATOR, air, 8900 metered shot 1 6 C30021 BOLT, u 1 10 504327 HOSE, nylon 3/4 in. id 4 11 504621 COUPLING, hose 4 12 166590 ELBOW, street 2 13 160327 UNION, adapter, 90° 2 14 175013 NIPPLE, pipe 1 15 512442 HOSE, bulk 1/2 in. nylon 3500 psi 8 16 503917 COUPLING, hose 1/2 ft npt(m) x

1/2, 3903 17 105281 UNION, swivel, 90° 1 18 512616 HOSE, PTFE 1/4 x 18 in. 1/4 npsm 1 19 500517 FITTING, tee 3/4 in. npt 1 20 158683 FITTING, elbow 3/4 in. npt 4 24 100896 FITTING, bushing, pipe 5 25 155470 UNION, swivel, 90° 1 26 156684 UNION, adapter, 2 27 100840 ELBOW, street 2 32 156971 NIPPLE, short 4 33 626758 MANIFOLD, block 8900 meter, shot 1 34 626757 BLOCK, check 8900 metered shot 1 35 C26088 VALVE, cone extension 1 36 C26086 STOP, cone, assembly 1 37 103374 SCREW, machine, rdh 4 38 105192 SCREW, cap, hex head 1 40 C24017 ROD, trip, valve 1 41 C20068 PIN, spring 2 42 C24018 COLLAR, stop 2 43 C24020 COLLAR, clamp 1 44 120753 FITTING, elbow, male, 90° 4 45 513066 TUBE, 3/8 ft OD nylon 3 46 C12509 TUBE, nylon 20

Ref. No. Part No. Description Qty.

47 597151 FITTING, elbow 6 48 552211 VALVE, pulse pneumatic 2 49 593538 VALVE, shuttle 1/8 npt(f) 1 50 503028 VALVE, air, push-pull 1 51 104631 KIT, accessory 1 52 100730 BUSHING 2 53 104984 TEE, pipe 2 54 C19391 FITTING, elbow 1/4 npt(m) x 1/4 od

56 512420 FITTING, cross steel 3/8 npt 1

57 100195 NIPPLE, pipe 1 58 103656 FITTING, pipe, hex 2 59 599433 FITTING, elbow, male 1 60 501014 ACTUATOR, air 1/8 npt(f) 2 63 114372 MIXER, static, 1/2 npt 2 64 158581 COUPLING, hex 2 65 948081 MIXER, tri-core 1/2(m) x 1/2(f) 1 66 159153 UNION, swivel 1 67 690270 ADAPTER, luer lock 1/4 in. npt 2 68 112012 NOZZLE, needle 2 69 112019 NOZZLE, needle 2 70 205324 HOSE, coupled, 61120, 1 ft 1 71 164672 ADAPTER 2 73 159239 FITTING, nipple, pipe, reducing 1 74 552208 VALVE, ball 3-way 1 75 100206 BUSHING, pipe 2 76 552205 MIXER, pipe, sst 1/4-4.2 in. 12 el 2 77 626760 MANIFOLD, ratio check 8900 shot 1 79 102646 VALVE, ball 1 80 156877 NIPPLE, long 1 81 112013 NOZZLE, needle 2 82 112014 NOZZLE, needle 2 83 112015 NOZZLE, needle 2 84 112020 NOZZLE, needle 2 85 112021 NOZZLE, needle 2 86 112022 NOZZLE, needle 2 87 162449 FITTING, nipple, reducing 2 88 100403 PLUG, pipe 2 90 158491 FITTING, nipple 1

tube

70 309790ZAA

Page 71

Parts

47 (2) V1 front V2 rear

24 87 32

32 31

13 12

15,16

10,11

88 (2)

4,37

34,35,36,38

68,81,82,83

69,84,85,86

13,24

See Detail C

47,48

Detail C

To bottom front

To bottom rear

309790ZAA 71

Page 72

Parts

Cartridge Fill High Viscosity Wide Ratio

Module No. 570318

Ref. No. Part No. Description Qty.

1 552204 ACTUATOR, air, 8900 metered shot 1 2 626748 BRACKET, mount disp valv C24342 1 3 103374 SCREW, machine, rdh 4 4 100896 FITTING, bushing, pipe 1 5 156877 NIPPLE, long 1 6 105192 SCREW, cap, hex head 1 7 626757 BLOCK, check 8900 metered shot 1 8 626758 MANIFOLD, block 8900 meter shot 1 9 166590 ELBOW, street 1 10 513375 MIXER, pipe sst 3/4-16.4 in. 2 el 2 11 100349 FITTING, elbow 3 12 160032 NIPPLE 1 13 552208 VALVE, ball 3-way 1 14 100206 BUSHING, pipe 2 15 552205 MIXER, pipe sst 1/4-4.2 in. 24 el 2 16 100840 ELBOW, street 4 17 157350 ADAPTER, 3/8 npt x 1/4 npt 2 18 205324 HOSE, coupled, 61120, 1 ft 1 19 162449 FITTING, nipple, reducing 1 20 100040 PLUG, pipe 1 21 155699 ELBOW, street 1 22 159239 FITTING, nipple, pipe, reducing 1 23 102646 VAVLE, ball 1 24 158491 FITTING, nipple, 1/2 npt 1 25 C26088 VALVE, cone extension 1 26 C26086 STOP, cone assembly 1 27 151249 NIPPLE, pipe 1 28 112698 ELBOW, male, swivel 1

Ref. No. Part No. Description Qty.

29 C12509 TUBE, nylon 30 30 503028 VALVE, air, push-pull 1 31 157191 FITTING, adapter 4 32 596832 FITTING, tee, tube 1 33 501014 ACTUATOR, air 1/8 npt(f) 2 34 103656 FITTING, pipe, hex 1 35 593538 VALVE, shuttle 1/8 npt(f) 1 36 552211 VALVE, pulse, pneumatic 2 37 C19391 FITTING, elbow 1/4 npt(m) x 1/4 od

tube 38 104631 VALVE. foot 1 40 626760 MANIFOLD, ratio check 8900 shot 1 42 H55033 HOSE, bulk 1/2 in. nylon 5600 psi 6 47 100133 WASHER, lock 2 48 100131 NUT, full hex 2 50 104172 FITTING, tube 2 51 512231 CONNECTOR, 1/4 od x 1/8 in.

npt(f) 54 156971 NIPPLE, short 5 55 233415 KIT, accessory, ratio check 1 58 157785 UNION, swivel 1 60 160327 UNION, adapter, 90° 2 61 166466 TEE, pipe, female 1 63 104984 TEE, pipe 2 64 120753 FITTING, elbow, male, 90° 2 65 100003 SCREW, cap, hex head 2 66 100176 BUSHING, hex 1 68 512616 HOSE, coupled 61120, 1.5 ft 1 69 100615 BUSHING, hex 1

72 309790ZAA

Page 73

Parts

Detail C

24 23

See Detail C

17 18 11

See Detail A

See Detail C

2,3

2, 3

31 6

7 21

20 8

50 28

This view rotated 90° for clarity

1918141391416 15

Detail A

309790ZAA 73

Page 74

Parts

Brush Grade High Viscosity Wide Ratio

Module No. 570358

Ref. No. Part No. Description Qty.

1 159841 ADAPTER 3 2 114112 FITTING, connector, female 1 3 100030 BUSHING 1 4 626748 BRACKET, mount disp valv C24342 1 5 552204 ACTUATOR, air 8900 metered shot 1 6 C30021 BOLT, u 2 7 155699 ELBOW, street 1 8 100615 BUSHING, hex steel 1 9 159801 UNION, swivel, 90° 1 10 504327 HOSE, nylon 3/4 in. id 4 11 504621 COUPLING, hose 4 12 166590 ELBOW, street 2 13 160327 UNION, 2 14 175013 NIPPLE, pipe 1 15 512442 HOSE, bulk 1/2 in. nylon 3500 psi 8 16 503917 COUPLINE, hose, 1/2 npt(m) x 1/2,

3903 17 105281 UNION, swivel 45° 1 18 512616 HOSE, PTFE 1/4 x 18 ft 1/4 npsm 1 19 500517 FITTING, tee 3/4 in. npt 1 20 158683 FITTING, elbow, 90° 5 24 100896 FITTING, bushing, pipe 5 25 155470 UNION, swivel, 90° 1 26 156684 UNION, adapter 2 27 100840 ELBOW, street 4 31 512912 MUFFLER, polyethylene 1/2 npt 2 32 156971 NIPPLE, short 5 33 626758 MANIFOLD, block 8900 meter shot 1 34 626757 BLOCK, check 8900 metered shot 1 35 C26088 VALVE, cone extension 1 36 C26086 STOP, cone, assembly 1 37 133374 SCREW, machine, rdh 4 38 105192 SCREW, cap, hex head 1 40 C24017 ROD, trip, valve 1 41 C20068 PIN, spring 2 42 C24018 COLLAR, stop 2 43 C24020 COLLAR, clamp 1 44 120753 FITTING, elbow, male, 90° 6 45 513066 TUBE, 3/8 in. OD nylon 6 46 C12509 TUBE, nylon 20 47 597151 FITTING, elbow 11 48 552211 VALVE, pulse pneumatic 2 49 593538 VALVE, shuttle 1/8 npt(f) 2 50 503028 VALVE, air, push-pull 1 51 212099 KIT, accessory 1 52 100730 BUSHING 2 53 104984 TEE, pipe 2 54 C19391 FITTING, elbow 1/4 npt(m) x 1/4 od

tube 56 512420 FITTING, cross steel 3/8 npt(f) 1 57 100195 NIPPLE, pipe 1

Ref. No. Part No. Description Qty.

58 103656 FITTING, pipe, hex 4 59 599433 FITTING, elbow, male 1 60 501014 ACTUATOR, air 1/8 npt(f) 3 63 114372 MIXER, static, 1/2 npt 2 54 158581 COUPLING, hex 2 65 948081 MIXER, tri-core 1/2(m) x 1/2(f) 1 66 159153 UNION, swivel 1 67 690270 ADAPTER, luer lock 1/4 in. npt 2 68 112012 NOZZLE, needle 2 69 112019 NOZZLE, needle 2 70 205324 HOSE, coupled, 61120, 1 ft 1 71 164672 ADAPTER 2 72 162449 FITTING, nipple, reducing 1 73 159239 FITTING, nipple, pipe, reducing 1 74 552208 VALVE, ball, 3-way 1 75 100206 BUSHING, pipe 3 76 552205 MIXER, pipe sst 1/4-4.2 in. 12 el 2 77 626760 MANIFOLD, ratio check 8900 shot 1 79 102646 VALVE, ball 1 80 156877 NIPPLE, long 1 82 100175 COUPLING, pipe 2 83 511351 MIXER, static 2 84 108233 VALVE, needle 1

85 156823 UNION, swivel 1 86 965766 VALVE, 1k-ul, machine mount 1 90 101353 NIPPLE, pipe 1 91 157416 UNION, swivel, 90° 1 92 158491 FITTING, nipple 1 93 501459 VALVE, toggle, air 1 94 110460 FITTING, el male swivel,

95 598140 FITTING, elbow 5/32t x 1/8 in.

96 510220 VALVE, air 4-way spring 1/4 npt 1 97 104165 FITTING, tube 2 98 164815 FITTING, adapter, tee 1 99 503279 FITTING, union straight 1/8 in. mxf sw1

100 112013 NOZZLE, needle 1 101 112014 NOZZLE, needle 2 102 112015 NOZZLE, needle 2 103 112020 NOZZLE, needle 2 104 112021 NOZZLE, needle 2 105 112022 NOZZLE, needle 2

10-32x5/32

npt(m)

74 309790ZAA

Page 75

Parts

9 8 7

32 31

13 12

15,16

10,11

4,37

7, 73

34,35,36,38

15,16

13,24

47 52

47,48

309790ZAA 75

Page 76

Parts

MD2 20 ft Automatic

(See Graco Manual 312185)

Wide Ratio Module No. 24H258 Close Ratio Module No. 24H259

Ref. No. Part No. Description Qty.

1 255182 VALVE, MD2, 1:1, hard seats

(24H258)

255180 VALVE, MD2, 10:1, hard (24H259) 1 2 15K688 NUT, retainer, ratio check 2 3 LC0079 MIXER, static, 3/8 x 24 50 4 157350 ADAPTER, 3/8 npt x 1/4 npt 1 5 122969 FITTING, elbow, 1/4 npt x SAE 06

(9/16-18 thread)

8 H52525 HOSE, fluid; nylon; 1/2 in. (13 mm)

ID; 3/8 npsm(fbe); 25 ft (7.6 m) long 9 503536 FITTING, nipple, reducing, mod. 1 10 207946 SWIVEL, straight 1 11 552026 HOSE, PTFE/sst-10 hp 20 ft 1 12 16G003 FITTING, adapter 2

Ref. No. Part No. Description Qty.

13 617467 BUSHING, hex reducing 3/4 x 12 1

14 160327 UNION, adapter, 90° 2 15 189018 SWIVEL, 5800 psi 1 16 598140 FITTING, elbow 5/32T x 1/8 in.

npt(m) 17 514607 TUBE, nylon 2.5mm id red 60 18 552071 SLEEVE, protective 25

19 156971 NIPPLE, short, 1/4-18 npt 2 21 947937 VALVE, injector #40 1/4 npt 1

23 155570 SWIVEL, union 1 24 C19008 FITTING, adapter, swivel 1

ti16738a

76 309790ZAA

Page 77

MD2 20 ft Hand Gun

Wide Ratio Module No. 24H260 Close Ratio Module No. 24H261

Ref. No. Part No. Description Qty.

1 255445 VALVE, MD2, 10:1, hard seats,

gun, air (24H260)

255442 VALVE, MD2, 1:1, hard seats, gun,

air (24H261) 2 15K688 NUT, retainer, ratio check 2 3 LC0080 MIXER, static, 3/8 x 36 50 5 122969 FITTING, elbow, 1/4 npt x SAE 06

(9/16-18 thread) 6 501867 VALVE, check 2 7 205324 HOSE, coupled, 61120, 1 ft 1 8 H52525 HOSE, fluid nylon; 1/4 in. (6.4 mm)

ID; 1/4 npsm(fbe); 25 ft (7.6 m) long

Ref. No. Part No. Description Qty.

9 157350 ADAPTER, 3/8 npt x 1/4 npt 1

10 207946 SWIVEL, straight 1 11 H45010 HOSE, coupled; 1/2 in. (13 mm) ID;

12 158491 FITTING, nipple 3 13 617467 BUSHING, hex reducing 3/4 x 12 1 14 160327 UNION, adapter, 90° 2

15 503536 FITTING, nipple, reducing, mod. 1 16 598140 FITTING, elbow 5/32t x 1/8 in.

17 514607 TUBE, nylon 2.5mm id red 30

18 552071 SLEEVE, protective 25 19 189018 SWIVEL, 5800 psi 2

1/2-14 npsm; 50 ft (15.2 m) long

npt(m)

Parts

ti16739a

309790ZAA 77

Page 78

Parts

MD2 15 ft Hand Gun Wide Ratio Moisture Lock

Module No. 24H243

Ref. No. Part No. Description Qty.

1 255445 VALVE, MD2, 10:1, hard seats,

gun, air 2 189018 SWIVEL, 5800 psi 1 4 162453 NIPPLE, (1/4 nps(m) x 1/4 npt) 4 5 122969 FITTING, elbow, 1/4 npt x SAE 06

(9/16-18 thread) 6 501684 VALVE, check 1 7 235905 HOSE, coupled, 2.5 ft 1 8 514428 HOSE, 1/4 in. PTFE x 10 ft 2 9 162024 COUPLING 1 10 161490 COUPLING, reducing 1 11 512247 HOSE, 5/8 PTFE 7.5 ft 3/4 npt(m) 2

Ref. No. Part No. Description Qty.

12 156172 FITTING, union, swivel 1

13 214925 SWIVEL, hose 2 14 160327 UNION, adapter, 90° 1 15 503536 FITTING, nipple, reducing, mod. 2 16 598140 FITTING, elbow 5/32t x 1/8 in.

17 514607 TUBE, nylon 2.5mm id red 15 18 552071 SLEEVE, protective 1 19 LC0057 MIXER, shroud, 1/4-24 1 20 155570 UNION, swivel 1 21 947937 VALVE, injector #40 1/4 in. not 1 22 100730 BUSHING 1

npt(m)

ti16737a

78 309790ZAA

Page 79

High Volume Static Mix Manifold

Module No. 570391

Parts

Ref. No. Part No. Description Qty.

1 157785 UNION, swivel 2 2 512151 VALVE, ball 2 3 175013 NIPPLE, pipe 4 4 235497 VALVE, check 2 5 160327 UNION, adapter,

90° 2

6 100615 BUSHING, hex steel 1

Ref. No. Part No. Description Qty.

7 501392 FITTING, cross 3/4 in. npt cs 2000

psi 8 100896 FITTING, bushing, pipe 1 9 156823 UNION, swivel 1 10 214037 VALVE, ball 1 11 204938 HOSE, coupled, 61120, 25 ft 1

TI3261A

309790ZAA 79

Page 80

Parts

High Volume Static Mix Kit with Pump Pilots

Module No. 570263

Ref. No. Part No. Description Qty.

1 504704 FITTING, nipple, hex 1 2 512152 VALVE, ball 2000 psi 1 in. npt(f) 1 3 514058 MIXER, pipe 1 in. x 12 3 4 158383 FITTING, union, adapter, straight 2 5 500946 HOSE, 1 in. mbe 1 6 502766 FITTING, cross 1 in. npt(f) sst 1 7 160327 UNION, adapter

90° 2

8 175013 NIPPLE, pipe 4 9 235497 VALVE, check 2 10 157785 UNION, swivel 2 11 100615 BUSHING, hex steel 1 12 156823 UNION, swivel 1 13 214037 VALVE, ball 1 14 204938 HOSE, coupled, 61120, 25 ft 1

Ref. No. Part No. Description Qty.

15 158586 FITTING, bushing 3 16 597151 FITTING, elbow 3 18 C12509 TUBE, nylon 80 20 104632 VALVE, piloted 2 21 512912 MUFFLER, polyethylene 1/2 npt 2 22 158491 FITTING, nipple 2 23 C20344 FITTING, tee 1/8 brass 1 26 104631 VALVE, foot 1 27 522071 SLEEVE, protective; 2.1 ft 1 28 C19391 FITTING, elbow 1/4 npt x 1/4 od

tube 30 100474 COUPLING; pipe 1 32 512151 VALVE, ball 2 33 215238 HOSE, coupled 61220 2 34 241358 KIT, accessory 1

14 34

898321033

715

33 101132 8 9 8

63 3034 5 4 3 2

15 12

23 17 16

2022

80 309790ZAA

Page 81

Stanchion

Module No. 570071

Ref. No. Part No. Description Qty.

1 167636 BASE, ram 1 2 167639 BRACKET, cylinder 4 3 176629 CYLINDER, ram 1 4 166552 CAP, cylinder 1

Parts

309790ZAA 81

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Parts

Boom Assembly

Module No. 246589

Ref. No. Part No. Description Qty.

1 947039 FRAME, boom, swivel, 55 gal 1 2 158383 FTIING, union, adapter, straight 1 3 157262 WASHER, plain 4 4 158555 NIPPLE, reducing 2 5 156971 NIPPLE, short 2 6 155495 UNION, swivel,

90° 1

7 156175 FITTING, union, swivel 2 8 552231 HOSE, PTFE 1/4 x 12 ft 3000 psi 1 9 500946 HOSE, 1 in. mbe 1

See Detail A

Detail C

See Detail B

17 4

Ref. No. Part No. Description Qty.

10 622070 BRACKET, boom 1 11 166590 ELBOW, street 2 13 103473 STRAP, tie, wire 3 14 570071 BASE, stancion mounting 1 15 606937 FITTING, bulkhead 1 16 100056 NUT, jam hex 1 17 202966 FITTING, union, adapter 1 18 100896 FITTING, bushing, pipe 1 19 160032 NIPPLE 1 20 166999 FITTING, elbow, street

Detail A

Detail B

See Detail C

82 309790ZAA

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Parts

309790ZAA 83

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Technical Data

Maximum system working pressure . . . . . . . . . . . . . . . . . 2000 psi (13.8 MPa, 138 bar)

Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Main air inlet size (8900 Proportioner) . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner outlet size

Component A Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

Component B Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner inlet size

Component A Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

Component B Pump. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)

8900 Proportioner wetted parts Carbon steel, stainless steel, zinc, black oxide, PTFE,

fluoroelastomer, electroless nickel, aluminum, nylon

• Refer to pump Output Charts on pages 15-17 for ratio adjustment and displacement pump part number information.

• For additional wetted parts information and technical data, refer to your separate component manuals.

Accessories

570264 President 10:1 mounted on a 5 gallon (19 liter) pail. Used for solvent flush of mix kit assembly.

Repair Kits for A and B Metering Cylinders

Cup

Size Meter Repair Kit

#1000 C24166 or 289402 C05032 C23136 C23041 #500 C24166 or 289402 C23350 C23200 C23087 #250 C24166 or 289402 C23318 C23171 C23067 #111 C24166 or 289402 15C181 15C180 #100 C24166 or 289402 C22282 C23137 C23042

Cylinder Repair Kits Cross Reference 289402 Repair Kit

EDPM 8900 Cylinder

15R212 188554 2 PACKING, o-ring 15R213 C20278 2 PACKING, o-ring C21002 C21002 10 PACKING, vee C36244 C36244 2 GLAND, male C36246 C36246 2 GLAND, female

(Order 2)

C24166 Repair Kit Qty. Description

Ratio Cylinder Ratio Kit*

84 309790ZAA

Page 85

Repair Kits for All Proportioners For Part Number Repair Kit Replacement Parts

Actuator 16E287 C24047 4-Way Valve, 3/16 in. C24039 C07067 or 289401 C07069 Trunion 3/16 in. inside port 4-Way Valve, 5/8 in. C24029 C07067 or 289401 C07068 Trunion 5/8 in. inside port.

4-Way Valve Repair Kits Cross Reference 289401 Repair Kit

EDPM 8900 Cylinder

C07067 Repair Kit

Qty. Description

15R207 C24032 4 PACKING, o-ring 15R208 C24035 4 PACKING, o-ring 15R209 C24036 4 PACKING, o-ring 15R210 C24040 1 PACKING, o-ring 15R211 103611 2 PACKING, o-ring 15R214* 2 PACKING, o-ring C24031 C24031 4 SEAL C24037 C24037 2 BUSHING C24038 C24038 4 RING, backup * This part is equivalent to 105802

Technical Data

309790ZAA 85

Page 86

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is 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 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 Information

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

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

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.

Original instructions. This manual contains English. MM 309790

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revised 07/2011