Graco 965478, 965466, 965477, 965481, 965479 User Manual

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INSTRUCTIONS

ying

This manual contains important warnings and information. READ AND RETAIN FOR REFERENCE

Instructions

Air-Powered King and Premier

Hydra-Cat® H.P. Variable Ratio Proportioning Pump

100 PSI (7 bar) Maximum Working Air Pressure

5000 PSI (333 bar) Maximum Working Fluid Pressure

Model: See Chart

684025

Revision E

Assembly Ratio Ratio

Part # Min. Max.

965478 1.50 4.50

965466 3.00 9.00

965477 1.00 3.00

965479 2.00 6.00

965481 1.50 4.50

WARNING

MOVING PARTS HAZARD

Relieve fluid and air pressure to unit before servicin removed. Follow pressure relief procedure on page 11.

Graco Inc. does not manufacture or supply any of the reactive chemical components that are used in this equipment and is not responsible for their effects. Because of the vast number of chemicals that could be used and their var used, includin potential dan individual components or their resultant mixtures. Graco assumes no responsibilit claims for bodil components.

unit. Do not operate with panels

WARNING

chemical reactions, the buyer and user of this equipment should determine all factors relating to the fluids

any of the potential hazards involved. Particular inquiry and investigation should be made into

ers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings to the

for loss, damage, expense or

injury or property damage, direct or consequential, arising from the use of such chemical

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



Table of Contents

Symbols.............................................................................3

Definition of Terms ............................................................3

Warnings ...........................................................................3

Specification of Hydra-Cat H.P. Pumps ............................6

Installation .........................................................................6

Connect the Fluid Supply Line....................................6

Connect the Fluid Output Lines ..................................6

System Accessories ...................................................7

Connect the Air Supply Line .......................................7

Pressure Relief Valve .................................................7

Electrical Grounding ...................................................8

Ratio Adjustment...............................................................9

Terms .........................................................................9

Determine the Ratio..................................................10

Relationship Between the Primary and

Secondary Pumps .................................................10

Adjusting the Ratio Setting .......................................10

Operation...................................................................... 11

Pressure Relief Procedure..................................... 11

System Flushing ....................................................11

Start the Pump....................................................... 11

Standard Operating Flushing ................................. 11

Checking the Ratio ................................................ 12

Maintenance................................................................. 12

Wet Cups ............................................................... 12

Bearings................................................................. 12

Air Lubrication ........................................................ 13

Troubleshooting............................................................ 14

Troubleshooting Techniques ................................. 14

Troubleshooting Chart ...........................................15

Service ......................................................................... 16

Required Tools ...................................................... 16

Disconnecting the Displacement Pump................. 16

Reconnecting the Displacement Pump ................. 17

Disconnecting the Air Motor................................... 17

Reconnecting the Air Motor ...................................17

Replacing the Bearings.......................................... 18

Dimensions................................................................... 19

Air Consumption........................................................... 19

Technical Data ............................................................. 21

Graco Information ........................................................ 22

Graco Standard Warranty ............................................ 22

2 684025

Symbols

Warning Symbol Caution Symbol

WARNING CAUTION

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

Definition of Terms

WARNING: Alerts the user to avoid or correct conditions

which could cause serious injury.

CAUTION: Alerts the user to avoid or correct conditions which could damage or destroy equipment.

NOTE: Identifies helpful information.

VRHC: The abbreviation for Variable Ratio Hydra–Cat

Pump. This pump automatically proportions and mixes two fluids in a prescribed ratio, which is variable within the ranges listed on the cover.

WARNING

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

BASE: Also called polyol or resin, is one of two reactive chemicals used in a plural component system.

CATALYST: Also called hardener, is the fluid which reacts with the base fluid.

PART: An undefined unit of measurement. When you determine the size of the unit (ounce, pint, gallon), use that measurement consistently in setting up your system.

SPRAY GUN: This term refers to any type of spray gun or dispensin pumped.

valve used to spray or dispense the fluid bein

PLURAL COMPONENT FLUID HAZARD

Before usin fluids used, includin and exposure of human beings to the individual components of their resultant mixtures.

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

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

• Graco does not manufacture or supply any of the reactive chemical components that may be used in

this equipment and is not responsible for their effects. Graco assumes no responsibility for loss, dama from the use of such chemical components.

MOVING PARTS HAZARD

Movin

pinch or amputate fingers.

• Do not operate the equipment with the guards removed.

• Keep your body and tools clear of any moving parts when starting or operating the equipment.

this equipment, read the fluid manufacturer’s warnings and determine all facts relating to the

any of the potential hazards relating to toxic fumes, fires, explosions, reaction times,

e, expense or claims for personal injury or property damage, direct or consequential, arisin

parts, such as the air motor piston and the secondary pump lever and connecting rod area, can

684025 3

INSTRUCTION

g g

WARNING

FIRE AND EXPLOSION HAZARD

Improper

• Ground the equipment and the object being sprayed. See Electrical Grounding on page 8.

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

• Electrically disconnect all equipment in the spray area.

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

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

• Do not smoke in the spray area.

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

• If there is any static sparking while using this equipment, stop spraying immediately. Identify and

correct the problem.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in

• This equipment is for professional use only.

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

• Use the equipment only for its intended purpose. If you are uncertain about the usa distributor.

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

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

• All system components must meet or exceed the pressure ratin

The lever amplification or the secondary pump enables very hi 5000 psi workin not tamper with the pressure relief valve or serious bodily injury could result.

• Do not lift pressurized equipment.

• Route the hoses away from the traffic areas, sharp ed

expose Graco hoses to temperatures above 180ºF (82ºC) or below -40ºF (-40ºC).

• Do not use hoses to pull equipment.

• Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical Data

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

• Fluid hoses must have sprin bends near the couplings.

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

rounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in

fire or explosion and serious injury.

serious injury.

e, call your Graco

s printed on the pressure relief valve.

h fluid pressures to be achieved. A

pressure range relief valve is required on both cylinders to limit the fluid pressure. Do

es, moving parts, and hot surfaces. Do not

uards on both ends to protect them from rupture caused by kinks or

4 684025

WARNING

INJECTION HAZARD

Spray from the spray extremely serious injury, includin also cause serious injury.

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

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

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

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

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

• Always have the tip guard and the trigger guard on the spray gun (if so equipped) when spraying.

• Check the spray gun diffuser (if so equipped) operation weekly. Refer to the gun manual.

• Be sure the spray gun trigger safety operates before operating the gun.

• Lock the spray gun trigger safety when you stop spraying.

• Follow the Pressure Relief Procedure on page 11 when you are instructed to relieve pressure, stop

spraying, check, clean or service any system equipment, or install or change spray tips.

• Tighten all fluid connections before each use.

• Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Permanently coupled hoses cannot be repaired.

• Handle and route hoses and tubes carefully. Keep hoses and tubes away from moving parts and hot surfaces. Do not use the hoses to pull equipment. Do not expose Graco hoses to temperatures above 180ºF (82ºC) or below -40ºF (-40ºC).

un, hose leaks or ruptured components can inject fluid into your body and cause

the need for amputation. Splashing fluid in the eyes or on the skin can

684025 5

Specifications of Hydra–Cat H.P. Pumps

96548

5333

368

3.8

696

9654792.00

6.00

3943.613

965

3.00

38032623.0

57043932.0

9654781.504.50

3.8

862.810.696

965466

3.00

9.00190

0228

The following chart gives specifications for the Hydra-Cat H.P. pumps, usin

No. 10 weight oil. The volumetric ratio is expressed as the proportion of the volume of fluid of the primary pump compared to the volume of fluid of the secondary pump.

Ratio At Minimum Ratio Settin

Air Motor AssemblyMin Max Stall StallOutputOutput Stall Stall

Part No. PSI Bar GPM LPM PSI Bar GPM LPM DF DF

Premier

Kin

Note: All Output Pressures Limited To 5000 PSI By Integral Pressure Relief Valves

Note: Pressure outputs calculated at 100 PSI Air Pressure for Premier and 90 PSI Air Pressure for King

Note: Volume outputs calculated at 40 cycles per minute.

11.504.

477 1.

4444

42 21

1131

74.617.

.1 23.

For example, Model 965477 has a minimum volumetric ratio of 1:1. At this settin pumps combined will deliver an output of 3.0 maximum volumetric ratio for Model 965477 is 3:1 and the combined output at that setting is 2.0 gpm.

At Maximum Ratio Settin

14.4 727

714

11.

14.4 41482

22.810.

2157

the primary and secondary

pm. The

Lower ID

utputOutput Master Slave

.4 12

7.7

.1 19.2 1

Installation

The Typical Installation shown is only a guide to setting up the complete Hydra-Cat H.P. system. For assistance in

ning a system to suit your particular needs, contact

desi your nearest Graco representative.

NOTE: The reference numbers and letters in the text correspond to the numbers and letters in the drawings.

Location

Sit the proportioner on a flat floor surface.

Connect the Fluid Supply Lines

Connect the grounded fluid hoses to the pump inlet fittings (P, R). If the unit will be pressure fed from separate supply units, install a fluid pressure gauge at each inlet.

NOTE: The pressurized fluid supplies must not exceed 1/4

of the operatin that level will feed ri rationing will result.

fluid pressure of the pump. Pressure above

ht through the pump and improper

Connect the Fluid Output Lines

Connect electronically conductive fluid hoses to the pump outlet fittings. Tighten all of the fittings.

Fig. 1

6 684025

KEY

A Bleeder Type

Main Air Valve B Air Regulator C Pressure Relief

Valve D Mix Manifold E Air Supply Line F Air Line Filter G Air Shutoff Valve H Air Line Lubricator J Base Supply Pump K Catalyst Supply

Pressure Pot L Solvent Supply

Pump M Mix Manifold Flush

Inlet N Static Mixer P Primary Pump Inlet R Secondary Pump

Inlet S Ratio Adjustment

Screw T Spray Gun U Ratio Indicator Plate V Ratio Indicator Pin

Fig. 2 Typical Installation

System Accessories Connect the Air Supply Line

Refer to Fig. 2.

NOTE:

To ensure the maximum pump performance and safety, be sure that all the accessories used are properly sized to meet your system requirements and the pressure limits of the pump. Use only

enuine Graco parts and

accessories.

Connect an electrically conductive air supply hose to the 3/4” npt(f) port of the air manifold (B). Open the bleed-type master air valve (A) and, usin

ulator (B) to the desired pressure. See the Typical

air re Installation and the Parts Drawing.

Pressure Relief Valve

In the air line, install an air filter (F) to remove harmful dirt and moisture from the compressed air supply. Install an air line lubricator (H) downstream from the air filter, the air

ulator (B) and the bleed-type master air valve (A). A

re lubricator will provide automatic lubrication to the air motor.

All components have rated working pressures of 5000 psi (345 bar) or

reater. For more information about the

pressure relief valve, see instruction manual 308547.

WARNING

A bleed-type master air valve (A) is required in your system to relieve the air trapped between the valve and the pump after the pump is shut off. Trapped air can cause the pump to cycle unexpectedly, resultin possible serious injury, including amputation.

the pressure gauge, set the

684025 7

Electrical Grounding

WARNING

Spray gun or dispensing valve:

h connection to a properly grounded fluid hose

throu and pump.

Obtain grounding

FIRE AND EXPLOSION HAZARD

Static electricity is created by the hi flow of fluid throu system is not properly occur and the system may become hazardous.

To reduce the risk of static sparkin result in a fire or explosion and cause serious injury, follow these recommendations for providin system.

Also, read the WARNING section, FIRE AND EXPLOSION HAZARD on page 4.

Pump:

Loosen the grounding lug locknut (A) and

washer. Insert one end of a 12

round wire (B) into the slot in the lug (C). Tighten the

locknut securely. See Fi

round wire to a true earth ground. Order a

the Groundin P/N 208950, (25 feet (7.6 m) long, 12 ga.).

Air and fluid hoses:

2. hoses with a maximum of 500 feet (150 m) combined hose length to ensure grounding continuity.

Air compressor:

3. manufacturer’s recommendations

electrical continuity throughout your

Clamp, P/N 103538, and a Grounding Wire,

follow the air compressor

h the pump and hose. If your

rounded, sparking may

which can

a (1.5 m2) minimum

. 3. Connect the other end of

Use only electrically conductive

h velocity

Fluid supply container:

Object being sprayed:

All solvent pails

7. code. placed on a positively the pail on a non-conductive surface, such as paper or cardboard, which interrupts the grounding continuity.

To maintain grounding continuity when flushing or

Use only metal pails

relieving pressure,

or dispensin metal pail, then trigger the gun.

valve firmly to the side of a grounded

according to your local code.

according to local code.

used when flushing, according to local

which are conductive,

rounded surface. Do not place

always hold a metal part of the gun

Fig.3

0720

8 684025

Ratio Adjustment

Understanding the terms used with the Hydra–Cat (H.P.) System, how it functions, and how to find and set the correct ratios for your application is the key to easier, more versatile operation of your proportional system.

Be sure to read and understand the followin before operating the equipment.

information

Terms

Ratio refers to the simultaneous output of a certain volume of fluid by the primary and secondary pumps.

Key

A Primary Pump B Secondary Pump C Ratio Adjustment Screw

D Wet Cups E Fulcrum and Arm F Primary Pump Output G Secondary Pump Output

The primary pump (A) is directly under the air motor (H); it usually pumps the base fluid. The secondary pump (B) is on the opposite end of the lever arm (E); it usually pumps the catalyst. The ratio of the secondary pump(s) can be changed by adjusting the ratio adjustment screw (C). See Fig. 4.

There are three main steps when applying the use of ratios: (1) determine the ratio that is required, (2) calculate the ratio setting, and (3) set the ratio on the Hydra-Cat H.P. system.

H Air Motor I Air Input J Bleed Type Master Air Valve

Fig. 4

684025 9

Determine the Ratio

Set the ratio based on your situation. If :

• The fluids are supplied at a ready–to–spray viscosity, simply set the ratio as explained under Adjusting the Ratio.

• The fluids are NOT supplied at ready–to–spray viscosity, the ratio must be determined after the

reducer is added to the base, as instructed in

Procedure 1, below.

NOTE: Evaporation of the reducer in the base causes

es in the ratio. To prevent evaporation, store

chan the base in a closed container.

NOTE: Some reducers have very little ability to lubricate

and many cause seals to dry out. To prolon seal life, be sure your pump seals are compatible with the base’s reducer. Contact your Graco representative for the correct seals to use.

the

Procedure 1: Base is not pre-reduced

When adding the reducer to the base before proportionin with the VRHC system, determine the ratio of the base/reducer mixture to the catalyst in order to set the proper ratio.

Example: The instructions on the can say “Mix 5 parts base to 1 part catalyst. Then reduce 3 parts of this mixture to 1 part reducer.”

1. Add the parts of the base and catalyst to find the parts

mixture.

5 parts base

+ 1 parts catalyst

6 parts mixture

2. The next statement on the can says, “Reduce 3 parts of

the mixture.” So divide the parts of the mixture by 3 parts

to reduce to find the parts reducer.

6 parts mixture

/ 3 parts to reduce

2 parts reducer

3. To determine the ratio of the secondary pump, add the

appropriate parts of base and reducer to find the parts

combined base/reducer.

5 parts base

+ 2 parts reducer

7 parts combined base/reducer to

1 part catalyst

The ratio of the pump is 7:1.

Relationship Between the Primary and Secondary Pumps

Moving the fulcrum point away from the primary pump reduces the secondary stroke len output. Movin increases the secondary stroke len output.

. 5 shows the relationship between the primary pump

and the secondary pump.

the fulcrum point closer to the primary pump

th, reducing its fluid

th, increasing its fluid

Adjusting the Ratio

See Fig. 2. Use a wrench to rotate the ratio adjustment

screw (S). Rotatin

ratio. Rotatin

the ratio. The indicator pin (V) will move alon

indicator scale (U) as the ratio adjustment screw is rotated.

When the pin is above the desired ratio, remove the

wrench and perform a ratio test as described on page 12.

the screw clockwise will increase the

the screw counterclockwise will decrease

the ratio

Fig. 5

10 684025

Operation

WARNING

INJECTION HAZARD

The system pressure must be manually

relieved to prevent the system from starting or sprayin pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection. To reduce the risk of parts, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure,

• stop spraying,

• check or service any of the system

• or install or clean the spray tips.

Pressure Relief Procedure

1. Lock the spray gun’s trigger safety.

2. Shut off ALL fluid supplies to the pump.

accidentally. Fluid under high

equipment,

System Flushing

The pumps were tested with li Before operating the pump, thoroughly flush the Hydra-Cat H.P. to prevent contamination of your fluids.

NOTE:

Flush the mixer, hose and fluid from reactin manufacturer for the effective pot life of the fluid you are using.

1. Put the pump intake hoses into a 5 container of a compatible solvent. Refer to the fluid manufacturer’s recommendations.

2. Start the pump as explained below.

3. Do not install a spray tip yet. Hold a metal part of the un firmly to the side of a grounded metal pail. Usin

the lowest possible air pressure to the air motor that will activate the pump, trigger the gun into the pail.

4. When clean solvent comes from the spray release the trigger and carefully check all connections in the system for leaks.

5. Take the hoses out of the solvent, and trigger the gun until all the solvent has been pumped out of the hoses. Immediately turn off the bleeder-type master air valve.

or curing in them. Contact your fluid

htweight oil at the factory.

un often enough to prevent

allon (20 liter)

un,

3. Close the bleed-type master air valve.

4. Unlock the spray gun’s trigger safety.

5. Hold a metal part of the spray gun firmly to the side of a grounded metal pail. Trigger the spray gun into the pail to relieve pressure.

6. Lock the spray gun’s trigger safety.

7. Open the sampling valves, having a container ready to catch the drainage.

8. If you suspect that the spray tip or nozzle or the hose is completely clogged or that pressure has not been fully relieved after followin follow this procedure: Very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure clear the obstruction.

radually, then loosen completely. Now

the steps above,

Start the Pump

1. Close the bleed-type master air valve, and turn the air regulator knob all the way out (counterclockwise).

2. Turn on the main air supply.

3. With the mixer manifold handle in the open position,

er the gun, slowly open the bleed-type master air

tri valve, and turn the air re the pump starts.

4. Allow the pump to cycle slowly until all the air is pushed out of the lines. Release the trigger. The pump will stall against the pressure.

5. The manifold handle controls fluid flow. With the lever of the manifold in the open (down) position, base and catalyst are supplied to the move the handle to the closed (up) position.

ulator knob clockwise until

un. To stop the flow,

Standard Operating Flushing

Use the solvent valves to flush contaminants and mixed fluids from the mixer manifold, hose and spray gun. Follow the procedure provided with the mix manifold assembly.

684025 11

Checking the Ratio

Note: The mix ratio must be checked at the normal

operatin manifolds provide a means for checkin that includes needle valves for adjustin pressure during the test. The following procedure is an example of how to properly check the mix ratio.

1. Open the mixer manifold and trigger your spray gun.

2. Set your operatin operatin engage the safety latch.

3. Close the mixer manifold inlet valves.

4. Sli

5. Place a

htly open the sampling valve on the secondary pump side. Sli primary pump side. This will prevent pressure from buildin valve to open.

valve.

fluid pressure of the pump. Most mixer

mix ratio

the fluid

pressure. After determining the

pressure, release the spray gun trigger and

htly open the sampling valve on the

up on the secondary pump, causing the relief

rounded waste container under the samplin

6. Open the mixer manifold. Use the sampling valves to adjust the pressures to your

normal operatin

pressures.

7. Close the mixer manifold. Put the samplin containers under the sampling valves.

8. Open the mixer manifold. Check the ratio; make sure the pressure is within 20% of your normal operatin pressure. Close the mixer manifold when enough fluid has been dispensed into the samplin containers.

NOTE: If the pressure readings are not within 20% of

your normal operatin flushin sample a there is a problem with the sampling valves, ratio settin setting or service the sampling valves or pump.

procedure on page 11, then take a

ain. If your sample ratio is incorrect,

, or pump operation. Check the ratio

pressure, follow the

Maintenance

Pump Lubrication

Wet Cups

Each of the fluid cylinders has a wet cup (18) at the top that must be kept lubricated. See figure 6. The wet cups should be inspected and filled on a weekly basis, or more frequently if found to be dry. To inspect the wet cups, follow the pressure relief procedure on page 11.

WARNING WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

With the bleeder type main air valve (1) turned off, remove the thumb screws (14) and the two guards (15) from the sides of the proportioner. The wet cups (18) should be filled to 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent.

The packing nuts (19) are torqued at the factory and are ready for operation. If one becomes loose and there is leaking from the throat packings, relieve the pressure, then torque the nut to 136–149 N.m (100–110 ft-lb)

the supplied wrench (20). Do this whenever

usin necessary. Do not over tighten the packing nut.

Bearings

Many of the bearing surfaces on the proportioner are permanently lubricated or are self lubricating. There are four main bearings (21) on the lever arm

lubricated

is every six months in single shift operation. To lubricate the bearin page 11.

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

With the bleeder type main air valve turned off, remove the twenty hex bolts (16) with a 13mm wrench or socket and then remove the four sheet metal covers (17) from the front and back of the proportioner.

The left rear cover may contain a sensor attached to a cable. Do not remove the sensor, but carefully set the cover to the side without strainin sensor or cable. The four main bearin exposed. Use the adapter (205532) provided to grease all four bearin sufficient.

on a regular interval. The lubrication interval

s, follow the pressure relief procedure on

s. One or two squirts (2-3 cc) will be

that must be

or damaging the

s (21) are now

12 684025

Air Lubrication

Make sure to use an Industrial Grade 1, Heavy Duty, Extreme Pressure, Lithium Soap Grease, Graco Part Number 110293 or equivalent.

If your air supply Is very dry, install an air line lubricator between the air re

ulator and the pump air motor for

automatic lubrication. Refer to the air motor manual for

details

Replace the covers (17) and the bolts (16) after and before startin

the machine. The covers (17) are

reasing,

safety guards and must be in place when the proportioner is in operation.

Fig. 6

KEY

1 BLEEDER TYPE MAIN AIR VALVE 13 ROD ADAPTER 2 AIR MOTOR 14 THUMB SCREWS 3 PRIMARY CYLINDER 15 GUARDS 4 SECONDARY CYLINDER 16 HEX BOLTS 5 FRAME 17 COVERS 6 AIR MOTOR TIE RODS 18 WET CUPS 7 FLUID CYLINDER TIE RODS 19 PACKING NUTS 8 TIE ROD NUTS 20 PACKING NUT WRENCH

9 CONNECTING ROD NUT, AIR MOTOR 21 MAIN BEARINGS 10 CONNECTING ROD NUT, PRIMARY 22 SNAP RING 11 CONNECTING ROD NUT, SECONDARY 23 FLUID OUTLET, PRIMARY 12 COUPLING COLLARS 24 FLUID OUTLET, SECONDARY

684025 13

Troubleshooting

gaug

Troubleshooting Techniques

Because the pumps are mechanically linked, the action of one pump can affect the readin Therefore, the key to successful troubleshooting is to be

sure to isolate the problem.

For example, if the secondary pump pressure, as read on the chan pump. To isolate the problem:

1. Relieve the pressure.

2. With the sampling valves still open, set the air supply

e, is low and sluggish during the pump

eover. The most likely problem is a binding primary

regulator to the lowest setting and open the bleedtype main air valve (1). Refer to fi the re move. Notice the position of the secondary pump (11). Turn off the bleeder-type main air valve (1) so that the secondary pump rod is at its lowest position when the pump stops.

ulator setting until the pump just begins to

s of the second pump.

ure 6. Increase

WARNING WARNING

To reduce the risk of a serious injury, always follow the Pressure Relief Procedure on page 11 whenever you are instructed to relieve the pressure.

3. With the main bleed-type air valve (1) off, remove the thumb screws (14) and side of the proportioner.

4. Unscrew the connectin secondary pump. Now you can verify the operation of the primary pump alone.

uards (15) from each

rod nut (11) from the

8. With the main bleed-type air valve (1) off, remove the thumb screws (14) and side of the proportioner.

9. Unscrew the connectin primary pump. Now you can verify the operation of the secondary pump alone.

Reinstall the proportioner. Turn the main air valve (1) back on and carefully increase the air pressure.

10. Using the sampling valves at the mixer manifold:

A. Open and close the samplin

for pump stallin strokes.

B. Check for rapid

pump changeover

11. When the operation of the secondary side has been verified, reconnect the connectin primary pump.

Use very low air pressure to the air motor when troubleshootin very high fluid pressure, which can cause serious injury,

includin and injury from moving parts.

To reduce the risk of a serious injury, always follow the Pressure Relief Procedure on page 11 if the problem you are checking does not require air.

injection, splashing in the eyes or on the skin,

uards (15) on both sides of the

on both the up and down

the system. This system can produce

uards (15) from each

rod nut (10) from the

valves and check

e response during the

rod (10) of the

Reinstall the guards (15) on both sides of the proportioner. Turn the main air valve (1) back on and carefully increase the air pressure.

5. Using the sampling valves at the mixer manifold:

A. Open and close the sampling valves and check

for pump stallin strokes.

B. Check for rapid

pump changeover

6. When the operation of the primary side has been verified, reconnect the connectin secondary.

7. With the sampling valves still open, set the air supply regulator to the lowest setting and open the bleedtype main air valve (1). Increase the regulator setting until the pump just be position of the primary pump. Turn off the bleedertype main air valve (1) so that the primary pump rod (10) is at its lowest position when the pump stops.

on both the up and down

e response during the

rod (11) of the

ins to move. Notice the

WARNING

To reduce the risk of injurin

ers, or other body parts, never place your hands,

fin body or tools inside the safety panels for any reason while the unit is operating.

or amputating your hands,

14 684025

Troubleshooting Chart

PROBLEM CAUSE SOLUTION

System will not run or stops while running.

The fluid pressure bounces significantly (>500 psi) while pump is running

Mix ratio test is significantly different from the mix ratio setting.

Spray output is spitting Running out of one

A squeaking or knocking noise is heard.

The proportioner speeds

up or runs erratically

Air pressure or air

volume is too low.

The fluid valves or hoses are closed or restricted.

The air motor is worn or damaged.

The displacement cylinder(s) is damaged or has seized

Air volume is too

low.

Feed pump

pressure is too

high.

The displacement

cylinder(s) check

valves are not

seating.

Mix ratio test was

not performed at

the normal

operating pressure

of the pump

Running out of one

material.

The displacement cylinder(s) are worn or the check valves are not seating.

material.

Siphon hoses are

leaking in air.

The bearings are

dry or worn.

Running out of one material.

The cylinders are worn or damaged.

Increase air pressure. Check air compressor and air supply filters

ulator, lubricator valves and other components for blockages

re and restrictions. If this is a new system, be sure that air supply components have been sized properly.

Check the

ulators, valves and other fluid line components for blockages

re and restrictions. If this is a new system, be sure that the fluid components have been sized properly.

Service the air motor. See “servicing the Air Motor” on page 17.

See troubleshootin cylinder. See “Service the cylinders” on page 16.

Verify that air pressure at the air motor inlet is not droppin pump changeover. Check air compressor and air supply filters regulator, lubricator valves and other components for blockages and restrictions. If this is a new system, be sure that air supply components have been sized properly. 1” NPT hoses, fittin accessories are required to provide the necessary air volume.

Reduce feed pump pressure. Feed pump pressures must be less

than 25% of proportioner output pressure.

See troubleshootin

cylinder. See “Service the cylinders” on page 16.

Perform ratio test again following ratio test procedure on page 12.

Check and refill material reservoirs. Repeat the test after the air has

been removed from the system.

See troubleshootin

cylinder(s). See “Service the cylinders” on page 16.

Check and refill material reservoirs. Remember that once air is in the fluid system it may take a while for all of it to escape..

Tighten and seal all siphon fittings on proportioning pump and feed pumps.

Lubricate the bearings or replace them if required. See “service the bearings” on page 18.

Check and refill material reservoirs.

See troubleshooting techniques below to isolate the problem

cylinder(s). See “Service the cylinders” on page 16.

un, fluid hoses, mix manifold, static mixer, fluid filters,

techniques below to isolate the problem

durin

s and

techniques below to isolate the problem

684025 15

Service

Required Tools

• Set of large adjustable wrenches

• Set of metric sockets or wrenches

• Large pipe wrench

• Torque wrench

• Rubber mallet

• Flat end punch

WARNING CAUTION

To reduce the risk of serious injury or amputation, carefully follow all instructions listed below. In addition, be sure that the pressure relief procedure has been completed and that the main bleeder-type air valve has been turned off and locked out before removin guards or covers from the proportioner.

ANY

Disconnecting the Displacement Pump(s)

1. Flush the System. Follow the procedure on page

11.

Relieve the pressure.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

3. Disconnect the siphon hose and the fluid outlet hose.

4. With the bleeder type main air valve turned off (1), remove the thumb screws (14) and the two (15) from the sides of the proportioner.

5. Disconnect the displacement pump (3) from the frame (5) as follows:

6. Note the relative position of the pump’s fluid outlet (23) to the frame and also note the frame location of displacement pump bein displacement pump must be returned to its ori position and orientation.

Be sure to use two people when liftin disconnecting the pump. This pump is too heavy for one person. Be sure to support the displacement pump while it is bein causin bracing the pump, or by having at least two people hold it while another disconnects it.

7. Using an adjustable wrench (or hammer and punch), unscrew the couplin (13). Do not lose or drop the couplin Fig. 6.

8. Hold the tie rod flats with a wrench to keep the rods

from turning. Unscrew the nuts (8) from the tie rods (7). Carefully remove the displacement pump (3)

from the frame.

9. Refer to the separate manual supplied for

disconnected, to prevent it from falling and

injury or property damage. Do this by securely

nut (10,11) from the rod adapter

displacement pump service. Some models use two different displacement pumps. Be sure to look at the model number and use the appropriate manual for service and reference.

removed. Each

, moving, or

collars (12). See

uards

inal

16 684025

Reconnecting the Displacement Pump

CAUTION

1. Make sure the coupling nut (10,11) and the couplin collars (12) are in place on the displacement rod. See Fig. 6.

2. Use at least two people to hold the displacement pump while another reconnects it to the frame (see the CAUTION in the removal procedure above).

3. Position and orient the displacement pump (3,4) to the frame (5) as was noted in step 6 under Disconnectin the Displacement Pump.

4. Position the displacement pump (3,4) on the tie rods (7).

5. Screw the nuts (8) onto the tie rods (7) and torque to 81–89 N.m (60–66 ft-lb).

6. Screw the couplin loosely. Hold the rod adapter flats with a wrench to keep it from turnin tighten the coupling nut. Torque to 196–210 N.m ft-lb).

7. Fill the wet cup (18) 1/3 full with Graco Throat Seal Lubricant or compatible solvent.

8. Reconnect all hoses.

9. Replace the two (14) from the sides of the proportioner.

10. Turn on the air supply. Follow the procedure for startin first to ensure proper operation.

the pump on page 11. Run the pump slowly at

nut (10) onto the rod adapter (13)

. Use an adjustable wrench to

uards (15) and the thumb screws

Be sure to use an overhead hoist when lifting, moving or disconnectin lbs. and is too heavy for one person to handle. A lift ring is provided on the motor for this purpose.

5. Note the relative position of the air motor’s air connection to the frame. The air motor must be returned to its original orientation.

6. Usin unscrew the couplin (13). Do not lose or drop the coupling collars (12). See Fig. 6.

7. Hold the tie rod flats with a wrench to keep the rods from turnin (6). Carefully remove the air motor (2) from the frame.

8. Refer to the separate manual supplied for air motor service. Be sure to look at the model number stamped on the air motor and use the appropriate manual for service and reference.

Reconnecting the Air Motor

1. If the connectin Motor Stud as a part of servicin thread adhesive when reinstallin on to the Air Motor Stud.

2. Make sure the couplin collars (12) are in place on the rod adapter (13).

the air motor. This air motor weighs 145

an adjustable wrench (or hammer and punch),

nut (9) from the rod adapter

. Unscrew the nuts (8) from the tie rods

rod has been removed from the Air

, be sure to use

the connecting rod

nut (9) and the couplin

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

11. Before returning the pump to production, relieve the pressure and re-torque the packing nut (2) to 136– 149 N.m (100–110 ft-lb). The must be performed after the pump has been cycled a number of times

Disconnecting the Air Motor

1. Relieve the pressure.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

2. With the bleeder type main air valve turned off,

disconnect the air hose from the air motor.

3. Remove the thumb screws (14) and the two

(15) from the sides of the proportioner.

4. Disconnect the air motor (2) from the frame (5) as

follows:

uards

3. Use an overhead hoist to position the air motor on the frame in the same orientation as noted in step 5 of disconnecting the air motor. (see the CAUTION in the removal procedure above).

4. Position the air motor (2) on the tie rods (6).

5. Screw the nuts (8) onto the tie rods (6) and torque to

81–89 N.m (60–66 ft-lb).

6. Screw the couplin

loosely. Hold the rod adapter flats with a wrench to keep it from turnin tighten the coupling nut. Torque to 196–210 N.m ft-lb).

7. Reconnect the air hose

8. Replace the two guards (15) and the thumb screws

(14) onto the sides of the proportioner.

9. Turn on the air supply. Follow the procedure for startin

the pump on page 11. Run the pump slowly at first to ensure proper operation

nut (9) onto the rod adapter (13)

. Use an adjustable wrench to

684025 17

Replacing the Bearings

ging

1. Relieve the Pressure. Refer to Figure 6 and Figure 7.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 11.

2. With the bleeder type main air valve (1) turned off, remove the twenty hex bolts (16) with a 13mm wrench or socket and then remove the four sheet metal covers (17) from the front and back of the proportioner. The left rear cover may contain a sensor attached to a cable. Do not remove the sensor, but carefully set the cover to the side without strainin dama bearings (21) are now exposed.

3. Remove the thumb screws (14) and the two (15) from the sides of the proportioner.

4. Usin unscrew the couplin the rod adapters (13) on the two displacement pumps and the air motor. Do not lose or drop the couplin collars (12). See Fig. 6.

5. The left rear bearin end. Remove the ma Use a snap rin (22) from the shafts and remove the retainin washers.

6. You should now be able to slide the bearin of the shaft ends.

7. Replace the bearin replacement parts. Pack the bearin Grade 1, Heavy Duty, Extreme Pressure, Lithium Soap Grease, Graco Part Number 110293 or equivalent.

the sensor or cable. The (4) four main

an adjustable wrench (or hammer and punch),

nuts (10, 11, 12) from each of

shaft has a magnet stuck on its

net and put it in a safe place.

pliers to remove the four snap rings

s only with identical Graco

s in Industrial

uards

s (21) off

8. Re-install the new bearin so may require slightly shifting the shaft

Doin assembly which may have dropped durin removal.

9. Re-install the four retainin

rings (22).

10. Replace the ma

bearing shaft.

11. Make sure the couplin

couplin adapters.

12. Screw all three (3) couplin

the rod adapters (13) loosely. Hold each rod adapters flats with a wrench to keep it from turnin Use an adjustable wrench to ti nuts. Torque to 196–210 N.m ft-lb).

13. Replace the covers (17) and the bolts (16).

14. Replace the two

(14) onto the sides of the proportioner.

15. Turn on the air supply. Follow the procedure for

startin slowly at first to ensure proper operation.

collars (12) are in place on all three rod

the pump on page (11). Run the pump

net onto the end of the left rear

uards (15) and the thumb screws

s (21) onto the shafts.

bearin

washers and their snap

nuts (10, 11, 12) and the

nuts (10, 11, 12) onto

hten the couplin

18 684025

Fig. 7

Bearing Inset

Dimensions

(A) Height.......................................... 66.0 inch 1676 mm)

(B) Length.......................................... 31.5 inch (800 mm)

(D) Air Inlet..........................................................3/4 npt(f)

(E) Fluid Inlets..............................................Two, 2” npt(f)

(G) Fluid Outlet ..........................................Two 1/2” npt(f)

(H) Relief Valve Outlets ........................... Two, 1/4 npt(m)

Net Weight....................................... 700 pounds (320 kg)

Premier Air Consumption

At 40 PSI (2.8 bar)

CFM M

13 0.36 20 0.56 26 0.74 5 25 0.71 40 1.13 52 1.48 10 38 1.07 60 1.69 78 2.22 15 50 1.42 80 2.26 104 2.95 20 63 1.78 100 2.82 130 3.69 25 75 2.13 120 3.39 156 4.43 30 88 2.49 140 3.95 183 5.17 35

100 2.84 160 4.52 209 5.91 40

/min

At 70 PSI (4.9 bar)

CFM M3/min

At 100 PSI (7.0 bar)

CFM M3/min

At cycles

per min

King Air Consumption

At 40 PSI (2.8 bar)

CFM M

8 0.23 13 0.36 15 0.43 5 16 0.45 25 0.72 31 0.87 10 24 0.68 38 1.07 46 1.30 15 32 0.90 51 1.43 61 1.74 20 40 1.13 63 1.79 77 2.17 25 48 1.35 76 2.15 92 2.61 30 56 1.58 88 2.51 107 3.04 35 64 1.80 101 2.86 123 3.48 40

/min

At 70 PSI (4.9 bar)

CFM M3/min

At 100 PSI (7.0 bar)

CFM M3/min

At cycles

per min

684025 19

NOTES

20 684025

Technical Data

Air motor effective diameter ....................................................................................Premier 12.64” (321 mm)

............................................................................................................................ King 10.00” (254 mm)

Air motor stroke ...................................................................................................................... 4.75” (120 mm)

Operating air pressure range 20 to 100 psi (1.4 to 7 bar)

Recommended pump speed ......................................................................... 40 cycles per minute maximum

Maximum fluid inlet pressure ....................................................................... 25% of Output or 1000 psi max.

Maximum pump operating temperature ..................................................................................... 180°F (82°C)

Wetted parts:

Carbon Steel Models

Primary and secondary displacement pumps ................... Carbon Steel; Chrome Steel; Alloy Steel;

Chrome, Zinc, and Nickel Plating; 550 and 17-4 PH Grades of Stainless Steel;

Ductile Iron; Tungsten Carbide; PTFE

Stainless Steel Models

Primary and secondary displacement pumps ...... 316, 440 and 17-4 PH Grades of Stainless Steel;

Tungsten Carbide; PTFE; Glass-Filled PTFE; Leather

All Models

Fluid hoses ................................................................................... Nylon, Zinc-plated steel couplings

Pressure relief valves ..................................................... 304 Stainless Steel, Graphite-filled PTFE

Premier Noise level at 90 psi (6.3 bar) inlet air and at 40 cpm maximum load ..........................86 dB(A)



Glass-Filled PTFE;

Tungsten carbide (Nickel binder)



Leather

King Noise level at 90 psi (6.3 bar) inlet air and 15 cpm maximum load................. 90.5 dB(A) Pressure

97.7 dB(A) Power

684025 21

Graco Standard Warranty

WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twelve months or two thousand hours of operation from time of sale, repair or replace any part of the equipment proven 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, 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 with Graco equipment of 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 claim. 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 includes the costs of parts, labor and transportation.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied),

particular purpose

, and of any non-contractual liabilities, including production liabilities, based on

including warranty of merchantability or warranty of fitness for a

negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

Graco makes no warranty, and disclaims all implied

particular purpose

, with respect to accessories, equipment, materials, or components sold but not

warranties of merchantability and fitness for a

manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motor, 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.

Graco Information

FOR TECHNICAL ASSISTANCE

, contact your Graco distributor or call one of the following numbers:

1-800-367-4023

612-623-6921

612-378-3505 Fax

22 684025

Sales Offices:

International Offices:

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

PRINTED IN U.S.A. 684025 Revised 06/2003

Minneapolis, Detroit

Belgium, Korea, Hong Kong, Japan

Graco 965478, 965466, 965477, 965481, 965479 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual