The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the dispense outlet.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning,
checking, or servicing equipment.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
•Always wear impervious gloves when spraying or cleaning equipment.
•If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
•Hearing protection
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
4313876F
Warnings
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.
•Turn off and disconnect power cord before servicing equipment.
•Use only grounded electrical outlets.
•Use only 3-wire extension cords.
•Ensure ground prongs are intact on power and extension cords.
•Do not expose to rain. Store indoors.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. Many
solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property
damage. See Technica l Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s warnings.
313876F5
Product Configurator
Product Configurator
This system can be ordered with many different options as shown in the configurator below.
PD44C-A-BCD-EFG- H - I -J -K-L-M-NO-P-Q-RS-T-U-V-W- X
Configurator Series Level
Base Unit
High Volume Rod Material, Size
Low Volume Rod Material, Size
High Volume Spool
Low Volume Spool
Outlet Nose
Mixer
Controls
Power Cord
High Volume Feed
High Volume Feed Hose
High Volume Feed Options
Low Volume Feed
Low Volume Feed Hose
Low Volume Feed Options
Vacuum Pump(s)
Bench Stand
Seal Lubricant
The following table applies to the PD44 configurations and indicates all of the options available for each letter shown
above.
Code APartBase Unit
A964000 Micrometer PD44
B964001 Linear Resistive Transducer PD44
C964002 Motor Driven PD44
Code BPartHigh Volume Rod Material
NOTE: See code CD for last two digits of part number
NOTE: See code B for first four digits of part number
01____01 1.25 mm rod diameter
02____02 1.38 mm rod diameter
03____03 1.50 mm rod diameter
04____04 1.63 mm rod diameter
05____05 1.75 mm rod diameter
06____06 2.00 mm rod diameter
07____07 2.13 mm rod diameter
08____08 2.25 mm rod diameter
09____09 2.38 mm rod diameter
10____10 2.50 mm rod diameter
11____11 2.63 mm rod diameter
12____12 2.75 mm rod diameter
13____13 3.00 mm rod diameter
14____14 3.13 mm rod diameter
15____15 3.25 mm rod diameter
16____16 3.38 mm rod diameter
17____17 3.50 mm rod diameter
18____18 3.63 mm rod diameter
19____19 3.75 mm rod diameter
20____20 4.00 mm rod diameter
21____21 4.25 mm rod diameter
22____22 4.50 mm rod diameter
23____23 4.63 mm rod diameter
24____24 4.75 mm rod diameter
25____25 4.88 mm rod diameter
26____26 5.00 mm rod diameter
27____27 5.13 mm rod diameter
28____28 5.25 mm rod diameter
29____29 5.50 mm rod diameter
30____30 5.75 mm rod diameter
31____31 6.00 mm rod diameter
32____32 6.13 mm rod diameter
33____33 6.25 mm rod diameter
34____34 6.38 mm rod diameter
35____35 6.50 mm rod diameter
36____36 6.63 mm rod diameter
37____37 6.75 mm rod diameter
38____38 7.00 mm rod diameter
39____39 7.25 mm rod diameter
40____40 7.50 mm rod diameter
41____41 7.63 mm rod diameter
42____42 7.75 mm rod diameter
43____43 7.88 mm rod diameter
44____44 8.00 mm rod diameter
6313876F
Product Configurator
Code EPartLow Volume Rod Material
NOTE: See code FG for last two digits of part number
NOTE: See code E for first four digits of part number
01____01 1.25 mm rod diameter
02____02 1.38 mm rod diameter
03____03 1.50 mm rod diameter
04____04 1.63 mm rod diameter
05____05 1.75 mm rod diameter
06____06 2.00 mm rod diameter
07____07 2.13 mm rod diameter
08____08 2.25 mm rod diameter
09____09 2.38 mm rod diameter
10____10 2.50 mm rod diameter
11____11 2.63 mm rod diameter
12____12 2.75 mm rod diameter
13____13 3.00 mm rod diameter
14____14 3.13 mm rod diameter
15____15 3.25 mm rod diameter
16____16 3.38 mm rod diameter
17____17 3.50 mm rod diameter
18____18 3.63 mm rod diameter
19____19 3.75 mm rod diameter
20____20 4.00 mm rod diameter
21____21 4.25 mm rod diameter
22____22 4.50 mm rod diameter
23____23 4.63 mm rod diameter
24____24 4.75 mm rod diameter
25____25 4.88 mm rod diameter
26____26 5.00 mm rod diameter
27____27 5.13 mm rod diameter
28____28 5.25 mm rod diameter
29____29 5.50 mm rod diameter
30____30 5.75 mm rod diameter
31____31 6.00 mm rod diameter
32____32 6.13 mm rod diameter
33____33 6.25 mm rod diameter
34____34 6.38 mm rod diameter
35____35 6.50 mm rod diameter
36____36 6.63 mm rod diameter
37____37 6.75 mm rod diameter
38____38 7.00 mm rod diameter
39____39 7.25 mm rod diameter
40____40 7.50 mm rod diameter
41____41 7.63 mm rod diameter
42____42 7.75 mm rod diameter
43____43 7.88 mm rod diameter
44____44 8.00 mm rod diameter
Code HPartHigh Volume Spool
1964003 High viscosity, HS
2964004 High viscosity, Stainless Steel/UHMWPE
3964005 High viscosity, TC/UHMWPE
4964006 Low viscosity, Stainless Steel
Code IPartLow Volume Spool
1964011 High viscosity, HS
2964012 High viscosity, Stainless Steel/UHMWPE
3964013 High viscosity, TC/UHMWPE
4964014 Low viscosity, Stainless Steel
Code JPar tOutlet Nose
1964020 Luer lock, equal ports, no check valves
2964021 Luer lock, equal ports, dual check valves
3964022 Equal ports, 7/8-9, no check valves
4964023 Large and small ports, 7/8-9, no check
valves
5964024 Large and small ports, 7/8-9, single
check valve
6964025 Dual small ports, 7/8-9, no check valves
7964026 Dual small ports, 7/8-9 dual check valves
Code KPartMixer
1964027 1/8-24 Luer Lock inlet and outlet, 0.5 cc
2964028 3/16-32 bell mouth inlet, luer lock outlet,
2.0 cc
3964029 1/4-24 bell mouth inlet, luer lock outlet,
4.0 cc
4964030 1/4-32 bell mouth inlet, luer lock outlet,
5.5 cc
5964031 1/4-48 bell mouth inlet, luer lock outlet,
8.0 cc
6964032 3/16-32 bell mouth inlet, tapered outlet,
1.5 cc
7964033 1/4-24 bell mouth inlet, tapered outlet,
3.5 cc
8964034 3/16-24 bell mouth inlet, tapered outlet,
1.0 cc
313876F7
Product Configurator
Code LPartControls
1964035 Pneumatic, micrometer, wire harness
only
2964036 Pneumatic, micrometer, HMI controls, low
level
3964037 Pneumatic, micrometer, HMI controls, low
level, I/O package
4964038 Pneumatic, micrometer, HMI controls, low
level, high level
5964039 Pneumatic, micrometer, HMI controls, low
level, high level, I/O package
6964040 Pneumatic, linear resistive transducer,
wire harness only
7964041 Pneumatic, linear resistive transducer,
HMI controls, low level
8964042 Pneumatic, linear resistive transducer,
HMI controls, low level, I/O package
9964043 Pneumatic, linear resistive transducer,
HMI controls, low level, high level
A964044 Pneumatic, linear resistive transducer,
HMI controls, low level, high level, I/O
package
B964045 Motor driven, I/O, wire harness only
C964046 Stepper motor, HMI control, low level,
high level, I/O package
Code MPartPower Cord
1121055 120 VAC, North American cord set
2121054 250 VAC, 1 phase, no plug
3121056 10 amp, 250 volt, continental Europe
4121057 10 amp, 250 volt, United Kingdom and
Ireland
5121058 10 amp, 250 volt, Israel
6124864 10 amp, 250 volt, Australia
7124861 10 amp, 250 volt, Italy
8124863 10 amp, 250 volt, Switzerland
9124862 10 amp, 250 volt, Denmark
A121060 10 amp, 250 volt, India
N--None
Code
NOPartHigh Volume Feed
01964050 20 oz cartridge feed with mounting post
02964051 1 gallon pail Ram and transfer pump
03964052
04964053
05964054
06964055
07964056 5 gallon single post Ram with 11:1 pump,
08964057 5 gallon single post Ram with 11:1 pump,
09964058 5 gallon tank, support and diaphragm
10964059
11964060 5 gallon tank, support, diaphragm pump,
12964061 5 gallon tank, support, diaphragm pump,
13964062 5 gallon tank, support, diaphragm pump,
14964063 5 gallon tank, support, diaphragm pump,
15964064 5 gallon tank, support and 5:1 pump, mild
A964088 Dessicant dryers for tank lids
B964089 Nitrogen harness assembly for tank lids
C964090 Low level sensor 11:1 Ram only
N--None
Code VPartVacuum Pump(s)
1964091 1-115V, 1 phase, 6.9 cfm, inlet and outlet
2964092 1-115V, 1 phase, 6.9 cfm, inlet and outlet
3964093 1-230V, 1 phase, 6.9 cfm, inlet and outlet
4964094 1-230V, 1 phase, 6.9 cfm, inlet and outlet
N--None
5 gallon tank, support, 5:11 pump, agita-
tor, stainless steel
5 gallon tank, support, 5:1 pump, agitator,
vacuum fill, stainless steel
pump, mild steel
pump, agitator, mild steel
pump, agitator, vacuum fill, mild steel
pump, stainless steel
pump, agitator, stainless steel
pump, agitator, vacuum fill, stainless steel
10 gallon tank, support, 5:1 pump, mild
steel
tor, mild steel
tor, vacuum fill, mild steel
less steel
tor, stainless steel
tor, vacuum fill, stainless steel
hose, stainless steel fittings
hose, stainless steel fittings
hose, stainless steel fittings
filter, 1 in. hose to single tank
filter, 1 in. hose to two tanks
filter, 1 in. hose to single tank
filter, 1 in. hose to two tanks
Code WPartBench Stand
A964095 Adjustable height bench stand
N--None
Code XPartSeal Lubricant
A964096 Non-silicone seal lubricant
B964097 Silicone seal lubricant
10313876F
Accessories
Mixer Kits with Shroud
PartDescription
964034Mixer, Kit, 3/16 in. (4.8mm) x 24, 10
taper tip mixers with shroud
964032Mixer, Kit, 3/16 in. (4.8mm) x 32, 10
taper tip mixers with shroud
964028Mixer, Kit, 3/16 in. (4.8mm) x 32, 10
Luer Lock tip mixers with shroud/sleeve
964033Mixer, Kit, 1/4 in. (6.5mm) x 24, 10
taper tip mixers with shroud
964029Mixer, Kit, 1/4 in. (6.5mm) x 24, 10 Luer
Lock tip mixers with shroud/sleeve
964030Mixer, Kit, 1/4 in. (6.5mm) x 32, 10 Luer
Lock tip mixers with shroud/sleeve
964031Mixer, Kit, 1/4 in. (6.5mm) x 48, 10 Luer
Lock tip mixers with shroud/sleeve
Accessories
Mixer Packs
PartDescription
964027Mixer, 1/8 in. (3.2mm) x 24 Luer Lock
inlet/tip, 10 Pack
16D962Mixer, 1/8 in. (3.2mm) x 24 Luer Lock
inlet/tip, 50 Pack
16D963Mixer, 1/8 in. (3.2mm) x 24 Luer Lock
inlet/tip, 250 Pack
16D978Mixer, 3/16 in. (4.8mm) x 24 taper tip,
50 Pack
16D979Mixer, 3/16 in. (4.8mm) x 24 taper tip,
250 Pack
LC0077Mixer, 3/16 in. (4.8mm) x 32 taper tip,
50 Pack
LC0084Mixer, 3/16 in. (4.8mm) x 32 taper tip,
250 Pack
LC0082Mixer, 3/16 in. (4.8mm) x 32 Luer Lock
tip, 50 Pack
LC0090Mixer, 3/16 in. (4.8mm) x 32 Luer Lock
tip, 250 Pack
LC0078Mixer, 1/4 in. (6.5mm) x 24 taper tip
mixer, 50 Pack
LC0085Mixer, 1/4 in. (6.5mm) x 24 taper tip
mixer, 250 Pack
LC0083Mixer, 1/4 in. (6.5mm) x 24 Luer Lock
tip, 50 Pack
PartDescription
LC0089Mixer, 1/4 in. (6.5mm) x 24 Luer Lock
tip, 250 Pack
16D968Mixer, 1/4 in. (6.5mm) x 32 Luer Lock
tip, 50 Pack
16D969Mixer, 1/4 in. (6.5mm) x 32 Luer Lock
tip, 250 Pack
16D970Mixer, 1/4 in. (6.5mm) x 48 Luer Lock
tip, 50 Pack
16D973Mixer, 1/4 in. (6.5mm) x 48 Luer Lock
tip, 250 Pack
313876F11
Accessories
O-Rings and Seals
PartDescription
24E247Kit, O-ring, chemical resistant, PD44
24E248Kit, Seal, Spool, H.V., PD44
24E249Kit, Seal, Spool, L.V., PD44
16B265Seal, Posipack, 1.25, ZAP
16B266Seal, Posipack, 1.38, ZAP
16B267Seal, Posipack, 1.50, ZAP
16B268Seal, Posipack, 1.63, ZAP
16B269Seal, Posipack, 1.75, ZAP
16B270Seal, Posipack, 2.00, ZAP
16B271Seal, Posipack, 2.13, ZAP
16B272Seal, Posipack, 2.25, ZAP
16B273Seal, Posipack, 2.38, ZAP
16B274Seal, Posipack, 2.50, ZAP
16B275Seal, Posipack, 2.63, ZAP
16B276Seal, Posipack, 2.75, ZAP
16B277Seal, Posipack, 3.00, ZAP
16B278Seal, Posipack, 3.13, ZAP
16B279Seal, Posipack, 3.25, ZAP
16B280Seal, Posipack, 3.38, ZAP
16B281Seal, Posipack, 3.50, ZAP
16B282Seal, Posipack, 3.63, ZAP
16B283Seal, Posipack, 3.75, ZAP
16B284Seal, Posipack, 4.00, ZAP
16B285Seal, Posipack, 4.25, ZAP
PartDescription
16B286Seal, Posipack, 4.50, ZAP
16B287Seal, Posipack, 4.63, ZAP
16B288Seal, Posipack, 4.75, ZAP
16B289Seal, Posipack, 4.88, ZAP
16B290Seal, Posipack, 5.00, ZAP
16B291Seal, Posipack, 5.13, ZAP
16B292Seal, Posipack, 5.25, ZAP
16B293Seal, Posipack, 5.50, ZAP
16B294Seal, Posipack, 5.75, ZAP
16B295Seal, Posipack, 6.00, ZAP
16B296Seal, Posipack, 6.13, ZAP
16B297Seal, Posipack, 6.25, ZAP
16B298Seal, Posipack, 6.38, ZAP
16B299Seal, Posipack, 6.50, ZAP
16B300Seal, Posipack, 6.63, ZAP
16B301Seal, Posipack, 6.75, ZAP
16B302Seal, Posipack, 7.00, ZAP
16B303Seal, Posipack, 7.25, ZAP
16B304Seal, Posipack, 7.50, ZAP
16B305Seal, Posipack, 7.63, ZAP
16B306Seal, Posipack, 7.75, ZAP
16B307Seal, Posipack, 7.88, ZAP
16B450Seal, Posipack, 8.00, ZAP
Needles
PartDescription
E4000025-50Needle, Luer Lock, Sampler Package
(10 each 14 ga x 1/2 in., 16 ga x
1/2 in., 18 ga x 1/2 in., 20 ga x 1/2 in.,
22 ga x 1/2 in.)
E4000001-50Needle, Luer Lock, 14 Gauge x 1/2 in.,
50 Pack
E4000004-50Needle, Luer Lock, 15 Gauge x 1/2 in.,
50 Pack
E4000005-50Needle, Luer Lock, 16 Gauge x 1 in.,
50 Pack
12313876F
PartDescription
E4000006-50Needle, Luer Lock, 18 Gauge x 1 in.,
50 Pack
E4000011-50Needle, Luer Lock, 22 Gauge x 1/2 in.,
50 Pack
E4000014-50Needle, Luer Lock, 14 Gauge x 1 in.,
50 Pack
E4000024-50Needle, Luer Lock, 23 Gauge x 1/2 in.,
50 Pack
E4000088-50Needle, Luer Lock, 16 Gauge x 1/2 in.,
50 Pack
Isocyanate Conditions
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
To prevent exposing ISO to moisture:
•Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
•Keep the ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid (TSL), Part 206995.
The lubricant creates a barrier between the ISO and
the atmosphere.
•Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
•Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
•Never use solvent on one side if it has been contaminated from the other side.
•Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Keep Components A and
B Separate
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocyanate) and component B (resin) parts.
Foam Resins with 245 fa
Moisture Sensitivity of
Blowing Agents
Some foam blowing agents will froth at temperatures
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
313876F13
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
•When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•Always clean the fluid inlet strainers after flushing.
•Check with your material manufacturer for chemical
compatibility.
•Most materials use ISO on the A side, but some use
ISO on the B side.
•Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
Grounding
Grounding
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric
shock by providing an escape wire for the electric current.
Metering valve: attach ground wire from grounding lug
to true earth ground. See Component Identification
starting on page 15.
Fluid hoses: use only electrically conductive hoses.
Feed system components: attach ground wire from
grounding lug to true earth ground. See feed system
manual for grounding points. See Related Manuals on
page 3.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow 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.
Overview
This plural component meter, mix, and dispense device
accurately meters liquid and semi-paste materials.
The machine is ideal for a two-component application
requiring very small and precisely mixed shots.
The ratio of the pneumatic cylinder area to pump shaft
area provides the adjustable pressure intensification
needed to move the separate liquids through the mixer
with a flow rate suitable for production requirements.
The complete system is enclosed. Mixing of the two
materials takes place only in the mixer at the final stage
of metering valve operation. See Sequence of Opera-tion on page 27.
14313876F
Component Identification
Typical System Configurations
Base Unit
Component Identification
A Side Feed
A Side Feed
1
Liquid Control Corp.
8400 PORT JACKSON AVE. N.W.
NORTH CANTON, OH 44720 USA
SERIAL
NUMBER
10 56 9078234
MODEL
NUMBER
B Side Feed
WARNING
Do Not service without
removing air pressure and
waring saftey glasses.
Controls
PUSH TO
LOCK
PULL TO
RELEASE
B Side Feed
Base Unit
Controls
CONTROL POWER
Liquid Control Corp.
8400 PORT JACKSON AVE. N.W.
NORTH CANTON, OH 44720 USA
MODEL
SERIAL
NUMBER
NUMBER
FIG. 1
313876F15
Component Identification
Typical Feed System Components
5 Gallon Pail Cover
with Diaphragm Pump
20 oz Cartridge Feed
with Mounting Post
1 Gallon Ram
and Pump
WARNING
DO NOT SERVICE WITHOUT
REMOVING AIR PRESSURE AND
WEARING SAFETY GLASSES.
0
psi
200
5 Gallon Pail Cover
with Diaphragm
Pump and Agitator
F
FIG. 2
5 Gallon Pail Cover
with 5:1 Transfer
Pump
5 Gallon Pail Cover
with Diaphragm
Pump
5 Gallon Ram and
11:1 Transfer Pump
16313876F
Typical Feed System Components (continued)
Component Identification
R
5 Gallon Tank with Diaphragm Pump and Stand5 Gallon Tank with 5:1 Pump and Stand
15
19
12
15
19
12
22
8
26
4
0
30
psi
22
8
26
4
0
30
psi
R
10 Gallon Tank with Diaphragm Pump, Agitator,
Vacuum, and Stand
10 Gallon Tank with 5:1 Pump, Agitator, Vacuum,
and Stand
FIG. 3
313876F17
Component Identification
Micrometer PD44 Metering Valve
T
G
S
L
H
P
N
C
R
M
E
F
R
AB
K
J
D
D
Side ViewFront View
Key:
AA Material Inlet
BB Material Inlet
CGrounding Lug
DSpool Assemblies
EMetering Rods
FOil Cup Retaining Block
GExtend Air Inlet
HRetract Air Inlet
JDispense Air Inlet
KReload Air Inlet
AA Material Inlet
BB Material Inlet
CGrounding Lug
DSpool Assemblies
EMetering Rods
FOil Cup Retaining Block
GExtend Air Inlet
HRetract Air Inlet
JDispense Air Inlet
AA Material Inlet
BB Material Inlet
CGrounding Lug
DSpool Assemblies
EMetering Rods
FOil Cup Retaining Block
JDispense Air Inlet
KReload Air Inlet
LExtend Air Flow Adjustment
Knob
MRetract Air Flow Adjustment
Knob
NOver-travel Proximity Switch
PHome Proximity Switch
RSpool Valve Proximity Switch
VOptional Motor (provided with
configured controls)
W Over-travel Proximity Switch
XMain Air Inlet (on far side of
valve as shown)
FIG. 6
20313876F
Setup
Setup
NOTE: See Typical Installation diagram.
2.
1. Perform Setup procedure for feed system components. See feed system manuals. See Related Manuals on page 3.
2. Place an in-line air pressure regulator, air-water
separator/filter, and shut-off/bleed valve between
the air supply and the control solenoids.
3. Connect each 1/4 in. outside diameter supplied air
line to the corresponding control solenoid. See
Component Identification starting on page 15.
Typical Installation
Air Supply
4. On the Motor Driven PD44, if a non-Graco motor is
used, install the motor onto the metering valve. See
Motor Mounting Diagram, page 23.
5. On the Motor Driven PD44, connect the required
electrical power to the metering valve. See Motor Specifications, page 43.
6. Connect chemical lines from feed system to metering valve material inlets. See Component Identifi-
cation starting on page 15.
User Supplied
Air Shut-off and Bleed Valve
Air-Water Separator/Filter
Air Pressure Regulator
A Side Material Tank (optional)
A Side Pump
B Side Pump
B Side Material Tank
FIG. 7
313876F21
A Side Fluid Shut-Off Valve
B Side Fluid Shut-Off Valve
Control Solenoids
Metering Valve
Setup
Tank Level Sensor Wiring
Schematic
TANK LEVEL
12
345
67
PIN
1
2
3
4
5
6
7
PIN USAGE
BROWN
BLACK
BLUE
BROWN
BLACK
BLUE
BLUE
NUMBER
JUMPER PIN 6 AND 7
24 VDC+
BRN
TYPICAL LEVEL SENSOR WIRING
BLK
BLU
USAGE
HIGH
HIGH
HIGH
LOW
LOW
LOW
LOW
SIGNAL
COM
Valve Mounting Diagram
As desired, use the following diagram to mount the
metering valve.
Front of Metering Valve
1.75
0.563
4X 10-24 X 0.5 DP
0.38
4X Ø 0.188
0.862
0.75
1.50
1.06
C
L
DOWEL PINS
1.63
0.190
3.25
3.75
Bottom View
(Spool Assembly Not Shown)
FIG. 8
22313876F
Motor Mounting Diagram
If using a non-Graco motor with the Motor Driven PD44,
use the following diagram to install the non-Graco motor
onto the Motor Driven PD44 metering valve. See Motor Specifications, page 43.
0.182
Setup
2.22
2.039
0.182
Ø 0.251
STANDARD
2.039
Top View of Drive Assembly
F
2.22
IG. 9
Custom Drive Mounting Diagram
If using a non-Graco lead screw or housing, use the following diagram to ensure that the guide rods will align
properly with the custom housing.
2X #30 (0.129Ø)
FLAT BTTM DRILL X .25 DP
1.31
4X 10-32
1.56
1.75
.44
.19
1.75
Bottom View of Lead Screw Housing
IG. 10
F
313876F23
Startup
Startup
1. Lubricate the metering rod ports in the oil cup
retaining block and fill the spool valve ports with
compatible lubricant. Consult with your material
supplier to select an acceptable lubricant. Regularly
verify that lubricant is present.
NOTICE
Testing has shown that failure to lubricate the valve
will significantly reduce seal life.
Metering Rod Ports
Spool Valve Ports
F
IG. 11: Top View of Metering Valve with Top Section
Removed
5. Dispense several full stroke shots until material is
air-free and has good shut-off at the nose.
NOTE: Very viscous, compressible materials may continue to droll after system is primed. Reduce flow rate as
required to produce air-free dispense.
NOTE: Very thin materials may require tilting the valve
greater than 45 degrees and dispensing shots until
material is air-free. Remove oil from cups before proceeding.
2. Perform Ratio Check, page 26.
3. Install mixer and shroud.
4. Pressurize the A and B material feed systems connected to the metering valve to prime the system.
See page 3 for maximum inlet feed pressures.
24313876F
Adjusting the Shot Size
Adjusting the Shot Size
Micrometer PD44 Only
1. Rotate the shot size locking ring counterclockwise to
loosen.
2. Rotate the shot size adjuster to adjust shot size.
6. If LED on the extend proximity switch is not illu-minated, slide the proximity switch until the LED on
the proximity switch is illuminated.
Extend
Proximity
Switch
Retract
Proximity
Switch
NOTE: The retract proximity switch (PX-RET) is factory
preset and does not need to be adjusted. If the lower
proximity switch is changed from the factory setting, see
the assembly drawings for more information on readjustment. This switch is marked with a RET tag on the wire.
LRT and Motor Driven PD44
3. Rotate the shot size locking ring clockwise to
tighten.
4. Dispense into waste container to test shot size.
5. Repeat until desired shot size is achieved.
On LRT and Motor Driven PD44s, shot size is controlled
by the PD44 Control Box. See the PD44 Control Box
manual. See Related Manuals on page 3.
313876F25
Ratio Check
Ratio Check
Perform ratio check procedure at startup and after
rebuild.
1. Weigh six small cups and label as indicated. Record
weights.
2. Remove mixer.
3. Install the ratio check nozzle.
4. Dispense into a waste container to prime the ratio
check nozzle.
8. Subtract weight of empty cups from weight of filled
cups to get material weights.
9. Complete ratio calculations.
5. Place cups as indicated under ratio check nozzle
and cycle machine once.
6. Repeat until all three sets of cups have been used.
7. Re-weigh all six cups and record weights.
26313876F
Operation
Operation
The operation of the PD44 metering valve is controlled
by an external source. If a PD44 Control Box was purchased, see the PD44 Control Box manual for operation
instructions. See Related Manuals on page 3.
Sequence of Operation
Step 1: Reload
•Spools shift to the right
•Material feed inlets are opened
•Materials are transferred into the metering chambers by a pressurized feed system
•Outlet ports are blocked
•Metering rods are retracted to a precise position
determining the volume of each material
Step 3: Dispense
•Metering rods extend
•A and B materials are simultaneously dispensed
from the metering chamber into the disposable
mixer
•A and B materials are dispensed at the predetermined volume ratio.
Upon completion of the dispense stroke, the metering
rod and spool assemblies shift back to the reload position.
Step 2: Shift
•The balanced spool assemblies shift to the dispense position
•Material path to the mixer inlet is opened
•Material feed inlet ports are blocked
•Metering rods remain in the retracted position
313876F27
Pressure Relief Procedure
Pressure Relief
Procedure
1. Retract the metering rods. See the PD44 Control
Box manual. See Related Manuals on page 3.
2. Close both the A side and B side fluid shut-off
valves.
3. Remove static mixer.
4. Dispense 5 shots. Shots should be at least 75% of
the full stroke.
5. Extend the metering rods into the tubes. If Graco
controls are provided with the system, see the PD44
Controls manual. See Related Manuals on page 3.
6. Close the incoming air shut-off/bleed valve that supplies air to the metering valve.
Maintenance
Perform the following procedures once a shift.
NOTE: If material is leaking, see Troubleshooting on
page 29.
Material Reservoirs
Check material levels and refill as necessary. Ensure
that the material reservoirs are properly vented.
Air Dryer
Check the condition of the desiccant air dryer. Replace
as necessary.
Metering Rod Ports
Lubricate with compatible lubricant such as mesamoll or
silicone oil. See F
IG. 11 on page 24.
7. Close the incoming air shut-off/bleed valve that supplies the A feed system. Repeat for the B side feed
system. Refer to feed system manual for pressure
relief procedure. See Related Manuals on page 3.
Shutdown
1. Perform Pressure Relief Procedure.
2. Inspect the metering rods for material buildup.
Clean as necessary.
3. Lubricate the metering rods with compatible lubricant such as mesamoll or silicone oil.
4. Install storage cap on outlet nose.
Spool Valve Ports
Fill with compatible lubricant such as mesamoll or silicone oil. See F
IG. 11 on page 24.
Ratio Check
See Ratio Check on page 26.
28313876F
Troubleshooting
Troubleshooting
Perform Pressure Relief Procedure before performing any troubleshooting procedure.
ProblemCauseSolution
Metering valve stalling and no material being dispensed despite adequate input pressure
Metering valve not discharging normal or full volume
Material leaks past spool valvesSpool valve worn or damagedReplace the spool valve and sleeve
Improper material mixingMixer not clean or freeRemove and replace the mixer
Material leaks around mixer while
dispensing
Blocked mixerCheck mixer for cured material,
replace mixer as required
Flow control valve closedOpen
Low material level in reservoirs Fill material reservoirs and prime the
machine
Air in material tanksFill reservoirs and prime machine
Cured material in mixerCheck mixer for cured material,
replace mixer
Schematics
For standard machines, the schematics will be included in the PD44 Parts manual. See Related Manuals on page 3.
For custom machines, the schematics will be included
in the assembly drawings manual.
313876F29
Rebuild
Rebuild
Wetted Section Disassembly
1. Perform Pressure Relief Procedure, page 28.
2. On Motor Driven PD44s, remove electrical power.
3. Mark and disconnect all material feed lines, pneumatic lines, and proximity switch wiring. Remove the
metering valve from mounts.
NOTE: On Micrometer and Motor Driven PD44s, the
rear tie plate is the tie plate with the proximity switches.
NOTE: On LRT PD44s, the rear tie plate is the tie plate
on the same side of the metering valve as the main air
inlets.
4. Remove the four cap screws to remove the rear tie
plate.
6. Loosen set screws on top of the connecting block.
7. Slide the metering rod retaining plate until the larger
hole position is in-line with the metering rod. See
F
IG. 12 in the following step.
8. Once the metering rod plate is in position, manually
move connecting block up. Rods will remain in position and connecting block is separated from rods.
Connecting Block
Metering Rod Retaining Plate
Cap Screws
5. Manually move the connecting block down so that
rods are in the extended position.
Metering Rod
FIG. 12
9. Once the metering rods are disconnected from the
retaining plate, remove the four cap screws from the
front tie plate.
Cap Screws
10. Separate the drive cylinder and the valve guides
from the oil cup retaining block.
30313876F
Rebuild
11. Remove the four cap screws located at the top of
the oil cup retaining block.
Oil Cup Retaining Block
Cap Screws
12. Remove the metering rods and oil cup retaining
block.
Oil Cup Retaining Block
14. Remove the two metering rods and tubes. Always
keep rods and tubes together as they are a matched
set.
Tu be
15. Remove the protruding cap screws on the each
spool block.
Spool Block
Cap Screws
Metering Rod
13. Remove the eight cap screws attaching the material
inlet blocks. Remove the material inlet blocks.
Material Inlet Blocks
16. Remove the two pneumatic spools.
313876F31
Rebuild
Wetted Section Reassembly
1. Install the pneumatic spool rod drive. Torque fasteners to 67-70 in-lb (7.5-7.9 N•m).
2. Repeat for other side.
4. Install drive assembly to the guides.
Micrometer PD44 shown
5. Attach the front plate to the serial number side of the
metering body.
6. On Micrometer and LRT PD44s, ensure the air
inlet ports are pointed towards the front plate.
7. Install the cap head screws to the back plate.
3. Install guide rods. Refer to Wetted Section Rebuild
on page 34 for details on spool valve and metering
rod assembly.
Guide Rods
Cap Screws
8. Slide connecting block down until rod heads are
inserted into retaining plate keyway.
9. Slide the metering rod retaining plate to the locked
position.
Retaining Plate
10. Tighten set screw located on top of connecting block
until it contacts the top of the metering rod head.
Evenly torque the A and B set screws to 4-8 in-lb
(0.45-0.9 N•m).
32313876F
Rebuild
11. Manually move connecting block up and down to
insure rods are properly installed.
12. Install the back plate and cap screws.
Back Plate
Cap Screws
13. Install material inlet blocks with new o-rings.
Material Inlet Block
O-Ring
Spool Valve Rebuild
1. Perform Wetted Section Disassembly, page 30.
2. Remove the two cap screws.
Cap Screws
3. Disassemble the spool cylinder.
14. Install material nose assembly with new o-rings.
4. Remove the piston from the cylinder.
O-Rings
Nose
15. Attach material line, pneumatic line, and electrical
harness.
16. Perform Startup procedure, page 24.
313876F33
5. Install new u-cup seal on piston.
Rebuild
6. Insert new o-ring into spool air cylinder end cap.
7. Install proximity switch.
8. Apply Krytox or compatible lubricant to cylinder.
9. Insert piston into cylinder with the u-cup lip pointed
in the direction of the tapered end of the cylinder.
The “U” points toward the air inlet.
Air Inlet O-ring
10. Careful not to cut the o-ring, install pneumatic spool
blocks.
11. Install the two cap screws.
2. Remove spool rods and sleeves from the metering
block.
NOTE: The spool sleeve can be removed by sliding the
sleeve in the direction of the identification marking.
3. Remove the pneumatic drive spool bearing, seals,
and seal retainer for both spools.
4. Inspect the metering rod and sleeve assemblies and
the spool rod and sleeve assemblies for excessive
wear. If there are any scratches on the rod that can
be felt by a fingernail, replace the rod and sleeve
assembly.
Cap Screws
12. Repeat for opposite side pneumatic spool rod drive.
Wetted Section Rebuild
1. Perform Wetted Section Disassembly, page 30.
5. Clean all wetted components thoroughly with compatible solvent.
34313876F
Rebuild
6. For each pneumatic drive spool block, install new
zap seals and o-rings onto o-ring retainer.
Low Viscosity Spool
High Viscosity Spool
NOTE: Correct orientation of seals shown.
Low Viscosity Spool Sleeve Seals
High Viscosity Spool Sleeve Cutout View
11. Carefully install the spool sleeves into the metering
block. Make sure the notched edge will align with
the pin in the metering block and not cut the spool
sleeve o-rings.
7. Lubricate o-rings and bearing surfaces with Krytox
or compatible lubricant.
8. Re-install the rod bearings, zap seals, and o-rings
retainers into each spool block.
NOTE: Typically, the spring in the zap seal and the
o-rings in the retainers point toward the metering block
which is in the direction of the material.
9. On each spool sleeve, install new zap seal (on low
viscosity spool), and o-rings on the outside of the
sleeves.
10. Lubricate o-rings and bearing surfaces with Krytox
or compatible lubricant.
Metering Block
Spool Sleeve
Spool Sleeve Notch
313876F35
Rebuild
12. Apply Krytox to spool rod then carefully install the
spool rod into the spool sleeve (inside the metering
block). Make sure not to cut the spool sleeve zap
seals (on low viscosity spools).
13. Torque bolts 67-70 in-lb (7.6-7.9 N•m)
14. Install new zap seal in the metering tube sleeve with
the spring facing down or toward the material pressure side of the sleeve.
17. Install the wetcup sleeve onto the metering sleeve.
Wetcup Sleeve
18. Install the oil cup retaining block. Torque to 77 in-lb
(8.7 N•m).
Oil Cup Retaining Block
19. Apply Krytox grease to chamfer of metering rod.
NOTE: Seals are individually packaged with part number and size. Verify rod nominal size matches seal prior
to installation.
Metering Sleeve PTFE Seal
15. Install the metering sleeve PTFE seal in the metering block. Replace the metering sleeve PTFE seal
with a new one every rebuild.
16. Install metering tube sleeve into the metering block.
Metering Block
20. Carefully insert metering rod through bearing, seal,
and metering tube. Make sure not to cut the metering sleeve zap seals.
21. Move connecting block to extended position.
22. Move slide plate to capture the metering rods.
23. Install the set screw until it contacts the top of the
metering rod. Torque set screw to 4-8 in-lb
(0.45-0.90 N•m).
Set Screw
"A" Side
Front
Metering Tube Sleeve
36313876F
Rebuild
Micrometer Drive Rebuild
(Micrometer PD44 Only)
1. Perform Wetted Section Disassembly, page 30.
2. Remove the four cap screws located at the top of
the pneumatic drive assembly.
Cap Screws
3. Remove the drive top cap.
5. Slide the pneumatic drive piston off the drive rod.
6. Slide the air cylinder mounting block off the drive
rod.
Drive Top Cap
4. Slide the drive rod into the open slot.
7. Install new seals on the drive piston. Make sure the
lip of the seal points toward the pressure side of the
drive. See the following illustration and the assembly
drawings for more information.
8. Remove retaining ring, washer, and posipak seal
from the air cylinder mounting block.
Retaining Ring
Washer
Posipak Seal
313876F37
Rebuild
9. Install new posipak seal with the o-ring pointed
towards the drive piston, then install washer and
retaining ring.
Retaining Ring
Washer
Posipak Seal
10. Apply Krytox or compatible lubricant to drive rod.
11. Careful not to cut the posipak seal, install drive rod
into the block.
13. Slide the drive rod into the closed slot in the piston.
14. Install the cylinder o-ring then, careful not to cut the
piston seal, install the drive rod into the block.
15. Install the upper cylinder o-ring.
12. Install the drive rod into the piston.
16. Install top cap block to cylinder.
17. Install drive housing bolts to the cylinder mounting
block.
38313876F
Electrical Requirements
Electrical Requirements
Electrical requirements for pneumatically driven and
stepper driven control boxes can be found in the PD44
Control Box manual. See Related Manuals, page 3.
PX-RET
USE SENSOR
HARDWARE
PX-EXT
3-7/8
1-7/16
VIEW A-A
RED
(48")
PD44 metering valve only: Wiring harness sensors are
24 VDC normally open PNP. See F
*Sound data measured per standard ISO 11202 (1993) & ISO3746 (1995).
42313876F
Motor Specifications
If a non-Graco motor is used with the Motor Driven
PD44 Metering Valve, it must meet the following specifications.
Frame: NEMA 23
Torque at Typical Dispense Speed: 180 oz-in.
(11.25 in-lb) at 10 revolutions per second (1/2 in. rod
travel per second) or less. Above 10 revolutions per second, the power declines.
Torque at Maximum Speed: 117 oz-in (7.3 in-lb) at 20
revolutions per second (1 in. of rod travel per second).
Motor Face Pilot Boss: 1.5 in. diameter by 0.0625 in.
projection from motor face flange.
Shaft Size: 0.25 diameter by 0.75 in. projection from
motor face pilot boss to end of shaft.
Technical Data
313876F43
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.
Toll Free: 1-800-746-1334 or Fax: 330-966-3006
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO OHIO INC. 8400 PORT JACKSON AVE NW, NORTH CANTON, OH 44720
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313876
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
Copyright 2009, Graco Ohio Inc. is registered to ISO 9001
www.graco.com
Revised 07/2011
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