Graco Heat Pump 965466 User Manual

684025  
INSTRUCTIONS  
Revision E  
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  
Assembly  
Part #  
Ratio  
Min.  
Ratio  
Max.  
965478  
965466  
965477  
965479  
965481  
1.50  
3.00  
1.00  
2.00  
1.50  
4.50  
9.00  
3.00  
6.00  
4.50  
WARNING  
MOVING PARTS HAZARD  
Relieve fluid and air pressure to unit before  
servicing unit. Do not operate with panels  
removed. Follow pressure relief procedure on  
page 11.  
WARNING  
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  
varying chemical reactions, the buyer and user of this equipment should determine all factors relating to the fluids  
used, including any of the potential hazards involved. Particular inquiry and investigation should be made into  
potential dangers relating to toxic fumes, fires, explosions, reaction times, and exposure of human beings to the  
individual components or their resultant mixtures. Graco assumes no responsibility for loss, damage, expense or  
claims for bodily injury or property damage, direct or consequential, arising from the use of such chemical  
components.  
GRACO INC.  
P.O. BOX 1441  
MINNEAPOLIS, MN  
55440-1441  
Copyright 1998 Graco Inc.  
 
Symbols  
Warning Symbol  
Caution Symbol  
WARNING  
This symbol alerts you to the possibility of serious injury  
or death if you do not follow the instructions  
CAUTION  
This symbol alerts you to the possibility of damage to or  
destruction of equipment if you do not follow the  
instructions.  
Definition of Terms  
WARNING: Alerts the user to avoid or correct conditions  
BASE: Also called polyol or resin, is one of two reactive  
which could cause serious injury.  
chemicals used in a plural component system.  
CAUTION: Alerts the user to avoid or correct conditions  
CATALYST: Also called hardener, is the fluid which reacts  
which could damage or destroy equipment.  
with the base fluid.  
NOTE: Identifies helpful information.  
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.  
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.  
SPRAY GUN: This term refers to any type of spray gun or  
dispensing valve used to spray or dispense the fluid being  
pumped.  
WARNING  
PLURAL COMPONENT FLUID HAZARD  
Before using this equipment, read the fluid manufacturer’s warnings and determine all facts relating to the  
fluids used, including any of the potential hazards relating to toxic fumes, fires, explosions, reaction times,  
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,  
damage, expense or claims for personal injury or property damage, direct or consequential, arising  
from the use of such chemical components.  
MOVING PARTS HAZARD  
Moving parts, such as the air motor piston and the secondary pump lever and connecting rod area, can  
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.  
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WARNING  
FIRE AND EXPLOSION HAZARD  
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and result in  
fire or explosion and serious injury.  
Ground the equipment and 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  
serious injury.  
This equipment is for professional use only.  
Read all instruction manuals, tags, and labels before operating the equipment.  
INSTRUCTIONS  
Use the equipment only for its intended purpose. If you are uncertain about the usage, call your Graco  
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 ratings printed on the pressure relief valve.  
The lever amplification or the secondary pump enables very high fluid pressures to be achieved. A  
5000 psi working pressure range relief valve is required on both cylinders to limit the fluid pressure. Do  
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 edges, moving parts, and hot surfaces. Do not  
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 manufacturers warnings.  
Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or  
bends near the couplings.  
Comply with all applicable local, state, and national fire, electrical, and safety regulations.  
4
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WARNING  
INJECTION HAZARD  
Spray from the spray gun, hose leaks or ruptured components can inject fluid into your body and cause  
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can  
also cause serious injury.  
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate 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 backfluid; 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).  
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5
 
Specifications of HydraCat H.P. Pumps  
The following chart gives specifications for the Hydra-Cat  
H.P. pumps, using 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.  
For example, Model 965477 has a minimum volumetric  
ratio of 1:1. At this setting the primary and secondary  
pumps combined will deliver an output of 3.0 gpm. The  
maximum volumetric ratio for Model 965477 is 3:1 and the  
combined output at that setting is 2.0 gpm.  
Ratio  
Min Max  
At Minimum Ratio Setting  
Stall Stall Output Output  
At Maximum Ratio Setting  
Lower ID  
Air Motor  
Assembly  
Part No.  
Stall  
PSI  
Stall  
Bar  
Output  
GPM  
Output  
LPM  
Master  
Slave  
DF  
PSI  
Bar  
368  
307  
GPM  
3.8  
LPM  
14.4  
17.3  
DF  
9
Premier  
Premier  
965481  
965479  
1.50 4.50  
2.00 6.00  
5333  
4444  
7273  
5714  
502  
394  
2.8  
3.6  
10.6  
13.4  
6
6
4.6  
12  
King  
King  
King  
965477  
965478  
965466  
1.00 3.00  
1.50 4.50  
3.00 9.00  
3803  
3042  
1901  
262  
210  
131  
3.0  
3.8  
6.1  
11.5  
14.4  
23.0  
5704  
4148  
2282  
393  
286  
157  
2.0  
2.8  
5.1  
7.7  
6
9
6
6
6
10.6  
19.2  
18  
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.  
Installation  
Connect the Fluid Output Lines  
Connect electronically conductive fluid hoses to the pump  
outlet fittings. Tighten all of the fittings.  
The Typical Installation shown is only a guide to setting up  
the complete Hydra-Cat H.P. system. For assistance in  
designing a system to suit your particular needs, contact  
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 operating fluid pressure of the pump. Pressure above  
that level will feed right through the pump and improper  
rationing will result.  
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.  
Connect an electrically conductive air supply hose to the  
3/4npt(f) port of the air manifold (B). Open the bleed-type  
master air valve (A) and, using the pressure gauge, set the  
air regulator (B) to the desired pressure. See the Typical  
Installation and the Parts Drawing.  
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 genuine Graco parts and  
accessories.  
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  
regulator (B) and the bleed-type master air valve (A). A  
lubricator will provide automatic lubrication to the air motor.  
All components have rated working pressures of 5000 psi  
(345 bar) or greater. 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, resulting in  
possible serious injury, including amputation.  
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7
 
Electrical Grounding  
4. Spray gun or dispensing valve: Obtain grounding  
through connection to a properly grounded fluid hose  
and pump.  
WARNING  
5. Fluid supply container: according to your local code.  
6. Object being sprayed: according to local code.  
FIRE AND EXPLOSION HAZARD  
Static electricity is created by the high velocity  
flow of fluid through the pump and hose. If your  
system is not properly grounded, sparking may  
occur and the system may become hazardous.  
7. All solvent pails used when flushing, according to local  
code. Use only metal pails which are conductive,  
placed on a positively grounded surface. Do not place  
the pail on a non-conductive surface, such as paper or  
cardboard, which interrupts the grounding continuity.  
To reduce the risk of static sparking which can  
result in a fire or explosion and cause serious  
injury, follow these recommendations for  
providing electrical continuity throughout your  
system.  
8. To maintain grounding continuity when flushing or  
relieving pressure, always hold a metal part of the gun  
or dispensing valve firmly to the side of a grounded  
metal pail, then trigger the gun.  
Also, read the WARNING section, FIRE AND  
EXPLOSION HAZARD on page 4.  
1. Pump: Loosen the grounding lug locknut (A) and  
2
washer. Insert one end of a 12 ga (1.5 m ) minimum  
ground wire (B) into the slot in the lug (C). Tighten the  
locknut securely. See Fig. 3. Connect the other end of  
the ground wire to a true earth ground. Order a  
Grounding Clamp, P/N 103538, and a Grounding Wire,  
P/N 208950, (25 feet (7.6 m) long, 12 ga.).  
0720  
2. Air and fluid hoses: Use only electrically conductive  
hoses with a maximum of 500 feet (150 m) combined  
hose length to ensure grounding continuity.  
3. Air  
compressor:  
follow  
the  
air  
compressor  
manufacturers recommendations  
8
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Ratio Adjustment  
Understanding the terms used with the HydraCat (H.P.)  
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.  
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 following information  
before operating the equipment.  
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.  
Terms  
Ratio refers to the simultaneous output of a certain volume  
of fluid by the primary and secondary pumps.  
D Wet Cups  
H Air Motor  
Key  
A
E Fulcrum and Arm  
F Primary Pump Output  
G Secondary Pump Output  
I
Air Input  
J Bleed Type Master Air Valve  
Primary Pump  
B
Secondary Pump  
Ratio Adjustment Screw  
C
Fig. 4  
684025  
9
 
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.  
Determine the Ratio  
Set the ratio based on your situation. If :  
The fluids are supplied at a readytospray  
viscosity, simply set the ratio as explained under  
Adjusting the Ratio.  
6
3
2
parts mixture  
parts to reduce  
parts reducer  
/
The fluids are NOT supplied at readytospray  
viscosity, the ratio must be determined after the  
reducer is added to the base, as instructed in  
Procedure 1, below.  
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
2
7
parts base  
parts reducer  
parts combined base/reducer to  
1 part catalyst  
NOTE: Evaporation of the reducer in the base causes  
changes in the ratio. To prevent evaporation, store  
the base in a closed container.  
+
NOTE: Some reducers have very little ability to lubricate  
and many cause seals to dry out. To prolong the  
seal life, be sure your pump seals are compatible  
with the bases reducer. Contact your Graco  
representative for the correct seals to use.  
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 length, reducing its fluid  
output. Moving the fulcrum point closer to the primary pump  
increases the secondary stroke length, increasing its fluid  
output.  
Procedure 1: Base is not pre-reduced  
When adding the reducer to the base before proportioning  
with the VRHC system, determine the ratio of the  
base/reducer mixture to the catalyst in order to set the  
proper ratio.  
Fig. 5 shows the relationship between the primary pump  
and the secondary pump.  
Example:  
Adjusting the Ratio  
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.”  
See Fig. 2. Use a wrench to rotate the ratio adjustment  
screw (S). Rotating the screw clockwise will increase the  
ratio. Rotating the screw counterclockwise will decrease  
the ratio. The indicator pin (V) will move along the ratio  
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.  
1. Add the parts of the base and catalyst to find the parts  
mixture.  
5
1
6
parts base  
parts catalyst  
parts mixture  
+
Fig. 5  
10 684025  
 
Operation  
WARNING  
System Flushing  
The pumps were tested with lightweight oil at the factory.  
Before operating the pump, thoroughly flush the Hydra-Cat  
H.P. to prevent contamination of your fluids.  
INJECTION HAZARD  
The system pressure must be manually  
relieved to prevent the system from starting or  
spraying accidentally. Fluid under high  
pressure can be injected through the skin and  
cause serious injury. To reduce the risk of an  
injury from injection. To reduce the risk of  
parts, follow the Pressure Relief Procedure  
whenever you:  
NOTE:  
Flush the mixer, hose and gun often enough to prevent  
fluid from reacting or curing in them. Contact your fluid  
manufacturer for the effective pot life of the fluid you are  
using.  
1. Put the pump intake hoses into a 5 gallon (20 liter)  
container of a compatible solvent. Refer to the fluid  
manufacturers recommendations.  
are instructed to relieve the pressure,  
stop spraying,  
2. Start the pump as explained below.  
check or service any of the system  
equipment,  
3. Do not install a spray tip yet. Hold a metal part of the  
gun firmly to the side of a grounded metal pail. Using  
the lowest possible air pressure to the air motor that  
will activate the pump, trigger the gun into the pail.  
or install or clean the spray tips.  
4. When clean solvent comes from the spray gun,  
release the trigger and carefully check all connections  
in the system for leaks.  
Pressure Relief Procedure  
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.  
1. Lock the spray guns trigger safety.  
2. Shut off ALL fluid supplies to the pump.  
3. Close the bleed-type master air valve.  
4. Unlock the spray guns trigger safety.  
Start the Pump  
1. Close the bleed-type master air valve, and turn the air  
regulator knob all the way out (counterclockwise).  
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.  
2. Turn on the main air supply.  
3. With the mixer manifold handle in the open position,  
trigger the gun, slowly open the bleed-type master air  
valve, and turn the air regulator knob clockwise until  
the pump starts.  
6. Lock the spray guns trigger safety.  
7. Open the sampling valves, having a container ready  
to catch the drainage.  
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.  
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 following the steps above,  
follow this procedure: Very slowly loosen the tip  
guard retaining nut or hose end coupling and relieve  
pressure gradually, then loosen completely. Now  
clear the obstruction.  
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 gun. To stop the flow,  
move the handle to the closed (up) position.  
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  
 
6. Open the mixer manifold. Use the sampling valves to  
adjust the pressures to your normal operating  
pressures.  
Checking the Ratio  
Note: The mix ratio must be checked at the normal  
operating fluid pressure of the pump. Most mixer  
manifolds provide a means for checking mix ratio  
that includes needle valves for adjusting the fluid  
pressure during the test. The following procedure is  
an example of how to properly check the mix ratio.  
7. Close the mixer manifold. Put the sampling  
containers under the sampling valves.  
8. Open the mixer manifold. Check the ratio; make sure  
the pressure is within 20% of your normal operating  
pressure. Close the mixer manifold when enough  
fluid has been dispensed into the sampling  
containers.  
1. Open the mixer manifold and trigger your spray gun.  
2. Set your operating pressure. After determining the  
operating pressure, release the spray gun trigger and  
engage the safety latch.  
NOTE: If the pressure readings are not within 20% of  
your normal operating pressure, follow the  
flushing procedure on page 11, then take a  
sample again. If your sample ratio is incorrect,  
there is a problem with the sampling valves, ratio  
setting, or pump operation. Check the ratio  
setting or service the sampling valves or pump.  
3. Close the mixer manifold inlet valves.  
4. Slightly open the sampling valve on the secondary  
pump side. Slightly open the sampling valve on the  
primary pump side. This will prevent pressure from  
building up on the secondary pump, causing the relief  
valve to open.  
5. Place a grounded waste container under the sampling  
valve.  
Maintenance  
Pump Lubrication  
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 that must be  
lubricated on a regular interval. The lubrication interval  
is every six months in single shift operation. To lubricate  
the bearings, follow the pressure relief procedure on  
page 11.  
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  
To reduce the risk of serious injury whenever you are  
instructed to relieve pressure, always follow the Pressure  
Relief Procedure on page 11.  
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.  
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 straining or damaging the  
sensor or cable. The four main bearings (21) are now  
exposed. Use the adapter (205532) provided to grease all  
four bearings. One or two squirts (2-3 cc) will be  
sufficient.  
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 136149 N.m (100110 ft-lb)  
using the supplied wrench (20). Do this whenever  
necessary. Do not over tighten the packing nut.  
12 684025  
 
Air Lubrication  
If your air supply Is very dry, install an air line lubricator  
between the air regulator and the pump air motor for  
automatic lubrication. Refer to the air motor manual for  
details.  
Make sure to use an Industrial Grade 1, Heavy Duty,  
Extreme Pressure, Lithium Soap Grease, Graco Part  
Number 110293 or equivalent.  
Replace the covers (17) and the bolts (16) after greasing,  
and before starting the machine. The covers (17) are  
safety guards and must be in place when the proportioner  
is in operation.  
KEY  
1
2
3
4
5
6
7
8
9
BLEEDER TYPE MAIN AIR VALVE  
AIR MOTOR  
13 ROD ADAPTER  
14 THUMB SCREWS  
15 GUARDS  
16 HEX BOLTS  
17 COVERS  
PRIMARY CYLINDER  
SECONDARY CYLINDER  
FRAME  
AIR MOTOR TIE RODS  
FLUID CYLINDER TIE RODS  
TIE ROD NUTS  
18 WET CUPS  
19 PACKING NUTS  
20 PACKING NUT WRENCH  
21 MAIN BEARINGS  
22 SNAP RING  
23 FLUID OUTLET, PRIMARY  
24 FLUID OUTLET, SECONDARY  
CONNECTING ROD NUT, AIR MOTOR  
10 CONNECTING ROD NUT, PRIMARY  
11 CONNECTING ROD NUT, SECONDARY  
12 COUPLING COLLARS  
Fig. 6  
684025 13  
 
Troubleshooting  
8.  
With the main bleed-type air valve (1) off, remove  
Troubleshooting Techniques  
the thumb screws (14) and guards (15) from each  
side of the proportioner.  
Because the pumps are mechanically linked, the action of  
one pump can affect the readings of the second pump.  
Therefore, the key to successful troubleshooting is to be  
sure to isolate the problem.  
9.  
Unscrew the connecting rod nut (10) from the  
primary pump. Now you can verify the operation of  
the secondary pump alone.  
For example, if the secondary pump pressure, as read on  
the gauge, is low and sluggish during the pump  
changeover. The most likely problem is a binding primary  
pump. To isolate the problem:  
Reinstall the guards (15) on both sides of 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:  
1. Relieve the pressure.  
A. Open and close the sampling valves and check  
for pump stalling on both the up and down  
strokes.  
2. With the sampling valves still open, set the air supply  
regulator to the lowest setting and open the bleed-  
type main air valve (1). Refer to figure 6. Increase  
the regulator setting until the pump just begins to  
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.  
B. Check for rapid gauge response during the  
pump changeover  
11. When the operation of the secondary side has been  
verified, reconnect the connecting rod (10) of the  
primary pump.  
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.  
WARNING  
Use very low air pressure to the air motor when  
troubleshooting the system. This system can produce  
very high fluid pressure, which can cause serious injury,  
including injection, splashing in the eyes or on the skin,  
and injury from moving parts.  
3.  
With the main bleed-type air valve (1) off, remove  
the thumb screws (14) and guards (15) from each  
side of the proportioner.  
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.  
4.  
Unscrew the connecting rod nut (11) from the  
secondary pump. Now you can verify the operation  
of the primary pump alone.  
Reinstall the guards (15) on both sides of the  
proportioner. Turn the main air valve (1) back on  
and carefully increase the air pressure.  
WARNING  
5.  
Using the sampling valves at the mixer manifold:  
A. Open and close the sampling valves and check  
for pump stalling on both the up and down  
strokes.  
To reduce the risk of injuring or amputating your hands,  
fingers, or other body parts, never place your hands,  
body or tools inside the safety panels for any reason  
while the unit is operating.  
B. Check for rapid gauge response during the  
pump changeover  
6.  
7.  
When the operation of the primary side has been  
verified, reconnect the connecting rod (11) of the  
secondary.  
With the sampling valves still open, set the air supply  
regulator to the lowest setting and open the bleed-  
type main air valve (1). Increase the regulator setting  
until the pump just begins to move. Notice the  
position of the primary pump. Turn off the bleeder-  
type main air valve (1) so that the primary pump rod  
(10) is at its lowest position when the pump stops.  
14 684025  
 
Troubleshooting Chart  
PROBLEM  
CAUSE  
SOLUTION  
System will not run or Air pressure or air Increase air pressure. Check air compressor and air supply filters  
stops while running.  
volume is too low.  
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.  
The fluid valves or Check the gun, fluid hoses, mix manifold, static mixer, fluid filters,  
hoses are closed or regulators, valves and other fluid line components for blockages  
restricted.  
and restrictions. If this is a new system, be sure that the fluid  
components have been sized properly.  
The air motor is Service the air motor. See servicing the Air Motoron page 17.  
worn or damaged.  
The displacement  
cylinder(s) is  
damaged or has  
seized  
See troubleshooting techniques below to isolate the problem  
cylinder. See Service the cylinderson page 16.  
The fluid pressure  
bounces significantly  
(>500 psi) while pump is  
running  
Air volume is too Verify that air pressure at the air motor inlet is not dropping during  
low.  
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. 1NPT hoses, fittings and  
accessories are required to provide the necessary air volume.  
Feed pump  
pressure is too  
high.  
Reduce feed pump pressure. Feed pump pressures must be less  
than 25% of proportioner output pressure.  
The displacement  
cylinder(s) check  
valves are not  
seating.  
See troubleshooting techniques below to isolate the problem  
cylinder. See Service the cylinderson page 16.  
Mix ratio test is  
significantly different from  
the mix ratio setting.  
Mix ratio test was  
not performed at  
the normal  
Perform ratio test again following ratio test procedure on page 12.  
operating pressure  
of the pump  
Running out of one  
material.  
Check and refill material reservoirs. Repeat the test after the air has  
been removed from the system.  
The displacement  
See troubleshooting techniques below to isolate the problem  
cylinder(s) are worn cylinder(s). See Service the cylinderson page 16.  
or the check valves  
are not seating.  
Spray output is spitting  
Running out of one Check and refill material reservoirs. Remember that once air is in  
material.  
Siphon hoses are Tighten and seal all siphon fittings on proportioning pump and feed  
leaking in air. pumps.  
The bearings are Lubricate the bearings or replace them if required. See service the  
dry or worn. bearingson page 18.  
the fluid system it may take a while for all of it to escape..  
A squeaking or knocking  
noise is heard.  
The proportioner speeds Running out of one Check and refill material reservoirs.  
up or runs erratically  
material.  
The cylinders are See troubleshooting techniques below to isolate the problem  
worn or damaged.  
cylinder(s). See Service the cylinderson page 16.  
684025 15  
 
Service  
4. With the bleeder type main air valve turned off (1),  
Required Tools  
remove the thumb screws (14) and the two guards  
(15) from the sides of the proportioner.  
Set of large adjustable wrenches  
Set of metric sockets or wrenches  
Large pipe wrench  
Torque wrench  
5. Disconnect the displacement pump (3) from the frame  
(5) as follows:  
6. Note the relative position of the pumps fluid outlet (23)  
to the frame and also note the frame location of  
displacement  
displacement pump must be returned to its original  
position and orientation.  
Rubber mallet  
pump  
being  
removed.  
Each  
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 removing ANY  
guards or covers from the proportioner.  
Be sure to use two people when lifting, moving, or  
disconnecting the pump. This pump is too heavy for one  
person. Be sure to support the displacement pump while  
it is being disconnected, to prevent it from falling and  
causing injury or property damage. Do this by securely  
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 coupling nut (10,11) from the rod adapter  
(13). Do not lose or drop the coupling collars (12). See  
Fig. 6.  
Disconnecting the Displacement Pump(s)  
1. Flush the System. Follow the procedure on page  
11.  
2. Relieve the pressure.  
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)  
WARNING  
To reduce the risk of serious injury whenever you are  
instructed to relieve pressure, always follow the Pressure  
Relief Procedure on page 11.  
from the frame.  
9. Refer to the separate manual supplied for  
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.  
3. Disconnect the siphon hose and the fluid outlet hose.  
16 684025  
 
Reconnecting the Displacement Pump  
CAUTION  
Be sure to use an overhead hoist when lifting, moving or  
disconnecting the air motor. This air motor weighs 145  
lbs. and is too heavy for one person to handle. A lift ring  
is provided on the motor for this purpose.  
1. Make sure the coupling nut (10,11) and the coupling  
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).  
5. Note the relative position of the air motors air  
connection to the frame. The air motor must be  
returned to its original orientation.  
3. Position and orient the displacement pump (3,4) to the  
frame (5) as was noted in step 6 under Disconnecting  
the Displacement Pump.  
6. Using an adjustable wrench (or hammer and punch),  
unscrew the coupling nut (9) from the rod adapter  
(13). Do not lose or drop the coupling collars (12). See  
Fig. 6.  
4. Position the displacement pump (3,4) on the tie rods  
(7).  
7. Hold the tie rod flats with a wrench to keep the rods  
from turning. Unscrew the nuts (8) from the tie rods  
(6). Carefully remove the air motor (2) from the frame.  
5. Screw the nuts (8) onto the tie rods (7) and torque to  
8189 N.m (6066 ft-lb).  
6. Screw the coupling nut (10) onto the rod adapter (13)  
loosely. Hold the rod adapter flats with a wrench to  
keep it from turning. Use an adjustable wrench to  
tighten the coupling nut. Torque to 196210 N.m ft-lb).  
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.  
7. Fill the wet cup (18) 1/3 full with Graco Throat Seal  
Lubricant or compatible solvent.  
Reconnecting the Air Motor  
8. Reconnect all hoses.  
1. If the connecting rod has been removed from the Air  
Motor Stud as a part of servicing, be sure to use  
thread adhesive when reinstalling the connecting rod  
on to the Air Motor Stud.  
9. Replace the two guards (15) and the thumb screws  
(14) from the sides of the proportioner.  
10. Turn on the air supply. Follow the procedure for  
starting the pump on page 11. Run the pump slowly at  
first to ensure proper operation.  
2. Make sure the coupling nut (9) and the coupling  
collars (12) are in place on the rod adapter (13).  
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. 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).  
11. Before returning the pump to production, relieve the  
pressure and re-torque the packing nut (2) to 136–  
149 N.m (100110 ft-lb). The must be performed  
after the pump has been cycled a number of times  
4. Position the air motor (2) on the tie rods (6).  
5. Screw the nuts (8) onto the tie rods (6) and torque to  
8189 N.m (6066 ft-lb).  
6. Screw the coupling nut (9) onto the rod adapter (13)  
loosely. Hold the rod adapter flats with a wrench to  
keep it from turning. Use an adjustable wrench to  
tighten the coupling nut. Torque to 196210 N.m ft-lb).  
Disconnecting the Air Motor  
1.  
Relieve the pressure.  
7. Reconnect the air hose  
WARNING  
To reduce the risk of serious injury whenever you are  
instructed to relieve pressure, always follow the Pressure  
Relief Procedure on page 11.  
8. Replace the two guards (15) and the thumb screws  
(14) onto the sides of the proportioner.  
2. With the bleeder type main air valve turned off,  
disconnect the air hose from the air motor.  
9. Turn on the air supply. Follow the procedure for starting  
the pump on page 11. Run the pump slowly at first to  
ensure proper operation  
3. Remove the thumb screws (14) and the two guards  
(15) from the sides of the proportioner.  
4. Disconnect the air motor (2) from the frame (5) as  
follows:  
684025 17  
 
Replacing the Bearings  
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 straining or  
damaging the sensor or cable. The (4) four main  
bearings (21) are now exposed.  
8. Re-install the new bearings (21) onto the shafts.  
Doing so may require slightly shifting the shaft  
assembly which may have dropped during bearing  
removal.  
9. Re-install the four retaining washers and their snap  
rings (22).  
10. Replace the magnet onto the end of the left rear  
bearing shaft.  
11. Make sure the coupling nuts (10, 11, 12) and the  
coupling collars (12) are in place on all three rod  
adapters.  
3. Remove the thumb screws (14) and the two guards  
(15) from the sides of the proportioner.  
4. Using an adjustable wrench (or hammer and punch),  
unscrew the coupling nuts (10, 11, 12) from each of  
the rod adapters (13) on the two displacement pumps  
and the air motor. Do not lose or drop the coupling  
collars (12). See Fig. 6.  
12. Screw all three (3) coupling nuts (10, 11, 12) onto  
the rod adapters (13) loosely. Hold each rod  
adapters flats with a wrench to keep it from turning.  
Use an adjustable wrench to tighten the coupling  
nuts. Torque to 196210 N.m ft-lb).  
5. The left rear bearing shaft has a magnet stuck on its  
end. Remove the magnet and put it in a safe place.  
Use a snap ring pliers to remove the four snap rings  
(22) from the shafts and remove the retaining  
washers.  
13. Replace the covers (17) and the bolts (16).  
14. Replace the two guards (15) and the thumb screws  
(14) onto the sides of the proportioner.  
15. Turn on the air supply. Follow the procedure for  
starting the pump on page (11). Run the pump  
slowly at first to ensure proper operation.  
6. You should now be able to slide the bearings (21) off  
of the shaft ends.  
7. Replace the bearings only with identical Graco  
replacement parts. Pack the bearings in Industrial  
Grade 1, Heavy Duty, Extreme Pressure, Lithium  
Soap Grease, Graco Part Number 110293 or  
equivalent.  
Bearing Inset  
Fig. 7  
18 684025  
 
Dimensions  
(A) Height.......................................... 66.0 inch 1676 mm)  
(B) Length.......................................... 31.5 inch (800 mm)  
(C) Width ........................................... 33.0 inch (838 mm)  
(D) Air Inlet..........................................................3/4 npt(f)  
(E) Fluid Inlets..............................................Two, 2npt(f)  
(G) Fluid Outlet..........................................Two 1/2npt(f)  
(H) Relief Valve Outlets...........................Two, 1/4 npt(m)  
Net Weight....................................... 700 pounds (320 kg)  
A
B
C
Premier Air Consumption  
At 40 PSI (2.8 bar)  
CFM  
M3/min  
At 70 PSI (4.9 bar)  
CFM  
At 100 PSI (7.0 bar)  
CFM  
At cycles  
per min  
M3/min  
M3/min  
13  
25  
38  
50  
63  
75  
88  
100  
0.36  
0.71  
1.07  
1.42  
1.78  
2.13  
2.49  
2.84  
20  
40  
60  
0.56  
1.13  
1.69  
2.26  
2.82  
3.39  
3.95  
4.52  
26  
52  
78  
104  
130  
156  
183  
209  
0.74  
1.48  
2.22  
2.95  
3.69  
4.43  
5.17  
5.91  
5
10  
15  
20  
25  
30  
35  
40  
80  
100  
120  
140  
160  
King Air Consumption  
At 40 PSI (2.8 bar)  
CFM  
At 70 PSI (4.9 bar)  
CFM  
At 100 PSI (7.0 bar)  
CFM  
At cycles  
per min  
M3/min  
M3/min  
M3/min  
8
0.23  
0.45  
0.68  
0.90  
1.13  
1.35  
1.58  
1.80  
13  
25  
38  
51  
63  
76  
88  
101  
0.36  
0.72  
1.07  
1.43  
1.79  
2.15  
2.51  
2.86  
15  
31  
46  
61  
77  
92  
107  
123  
0.43  
0.87  
1.30  
1.74  
2.17  
2.61  
3.04  
3.48  
5
16  
24  
32  
40  
48  
56  
64  
10  
15  
20  
25  
30  
35  
40  
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; PTFEGlass-Filled PTFE;Leather  
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  
Tungsten carbide (Nickel binder)  
Premier Noise level at 90 psi (6.3 bar) inlet air and at 40 cpm maximum load ..........................86 dB(A)  
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 purchasers 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 Gracos 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 purchasers sole and exclusive remedy and are in lieu of any other  
warranties (express or implied), including warranty of merchantability or warranty of fitness for a  
particular purpose, and of any non-contractual liabilities, including production liabilities, based on  
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 Gracos 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 warranties of merchantability and fitness for a  
particular purpose, with respect to accessories, equipment, materials, or components sold but not  
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  
Sales Offices: Minneapolis, Detroit  
International Offices: Belgium, Korea, Hong Kong, Japan  
GRACO INC.  
P.O. BOX 1441  
MINNEAPOLIS, MN  
55440-1441  
PRINTED IN U.S.A. 684025 Revised 06/2003  
22 684025  
 

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