Graco Hydra-Cat H.P. Series User manual

INSTRUCTIONS 684025
Revision E
Instructions
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
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
WARNING
MOVING PARTS HAZARD
Relieve fluid and air pressure to unit before
servicin
g
unit. Do not operate with panels
removed. Follow pressure relief procedure on
page 11.
WARNING
Graco Inc. does not manufacture or suppl
y
an
y
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
y
in
g
chemical reactions, the bu
y
er and user of this equipment should determine all factors relatin
g
to the fluids
used, includin
g
an
y
of the potential hazards involved. Particular inquir
y
and investi
g
ation should be made into
potential dan
g
ers relatin
g
to toxic fumes, fires, explosions, reaction times, and exposure of human bein
g
s to the
individual components or their resultant mixtures. Graco assumes no responsibilit
y
for loss, dama
g
e, expense or
claims for bodil
y
injur
y
or propert
y
dama
g
e, direct or consequential, arisin
g
from the use of such chemical
components.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 1998 Graco Inc.
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

2 684025
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

684025 3
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
This symbol alerts you to the possibility of dama
g
e to or
destruction of equipment 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.
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
g
valve used to spray or dispense the fluid bein
g
pumped.
WARNING
PLURAL COMPONENT FLUID HAZARD
Before usin
g
this equipment, read the fluid manufacturer’s warnin
g
s and determine all facts relatin
g
to the
fluids used, includin
g
any of the potential hazards relatin
g
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,
dama
g
e, expense or claims for personal injury or property dama
g
e, direct or consequential, arisin
g
from the use of such chemical components.
MOVING PARTS HAZARD
Movin
g
parts, such as the air motor piston and the secondary pump lever and connectin
g
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.

4 684025
WARNING
FIRE AND EXPLOSION HAZARD
Improper
g
roundin
g
, 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.
INSTRUCTIONS
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.
•Use the equipment only for its intended purpose. If you are uncertain about the usa
g
e, 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 ratin
g
s printed on the pressure relief valve.
The lever amplification or the secondary pump enables very hi
g
h fluid pressures to be achieved. A
5000 psi workin
g
pressure ran
g
e 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 ed
g
es, movin
g
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 manufacturer’s warnings.
•Fluid hoses must have sprin
g
g
uards 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.

684025 5
WARNING
INJECTION HAZARD
Spray from the spray
g
un, hose leaks or ruptured components can inject fluid into your body and cause
extremely serious injury, includin
g
the need for amputation. Splashin
g
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 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).

6 684025
Specifications of Hydra–Cat H.P. Pumps
The followin
g
chart
g
ives specifications for the Hydra-Cat
H.P. pumps, usin
g
No. 10 wei
g
ht 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 settin
g
the primary and secondary
pumps combined will deliver an output of 3.0
g
pm. The
maximum volumetric ratio for Model 965477 is 3:1 and the
combined output at that setting is 2.0 gpm.
Ratio At Minimum Ratio Settin
g
At Maximum Ratio Settin
g
Lower ID
Air Motor Assembl
y
Min Max Stall Stall
O
utput
O
utput Stall Stall
O
utput
O
utput Master Slave
Part No. PSI Bar GPM LPM PSI Bar GPM LPM DF DF
Premier
965
4
8
11.
50
4.
50
5333
368
3
.
8
14.4 727
3
50
22.
8
1
0
.
6
9
6
Premier
965
47
9
2.
00
6
.
00
4444
30
74.
6
17.
3
5
714
39
4
3
.
6
1
3
.4 12
6
Kin
g
965
477 1.
00
3
.
00
3803
2
6
2
3
.
0
11.
5
5
7
0
4
393
2.
0
7.7
6
6
Kin
g
965
47
8
1.
50
4.
50
30
42 21
0
3
.
8
14.4 414
8
2
86
2.
8
1
0
.
6
9
6
Kin
g
965
4
66
3
.
00
9
.
00
1
90
11
3
1
6
.1 2
3
.
0
22
8
21
5
7
5
.1 1
9
.2 1
8
6
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
The Typical Installation shown is only a
g
uide to settin
g
up
the complete Hydra-Cat H.P. system. For assistance in
desi
g
nin
g
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
g
rounded fluid hoses to the pump inlet fittin
g
s
(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
g
fluid pressure of the pump. Pressure above
that level will feed ri
g
ht throu
g
h the pump and improper
rationing will result.
Connect the Fluid Output Lines
Connect electronically conductive fluid hoses to the pump
outlet fittings. Tighten all of the fittings.
Fig. 1

684025 7
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
g
enuine Graco parts and
accessories.
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
re
g
ulator (B) and the bleed-type master air valve (A). A
lubricator will provide automatic lubrication to the air motor.
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
g
the pressure
g
au
g
e, set the
air re
g
ulator (B) to the desired pressure. See the Typical
Installation and the Parts Drawing.
Pressure Relief Valve
All components have rated workin
g
pressures of 5000 psi
(345 bar) or
g
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
g
in
possible serious injury, including amputation.

8 684025
Electrical Grounding
WARNING 4.
Spray gun or dispensing valve: Obtain grounding
throu
g
h connection to a properly
g
rounded fluid hose
and pump.
FIRE AND EXPLOSION HAZARD
Static electricity is created by the hi
g
h velocity
flow of fluid throu
g
h the pump and hose. If your
system is not properly
g
rounded, sparkin
g
may
occur and the system may become hazardous.
To reduce the risk of static sparkin
g
which can
result in a fire or explosion and cause serious
injury, follow these recommendations for
providin
g
electrical continuity throu
g
hout your
system.
Also, read the WARNING section, FIRE AND
EXPLOSION HAZARD on page 4.
5.
Fluid supply container: according to your local code.
6.
Object being sprayed: according to local code.
7.
All solvent pails used when flushing, according to local
code.
Use only metal pails which are conductive,
placed on a positively
g
rounded surface. Do not place
the pail on a non-conductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
8.
To maintain grounding continuity when flushing or
relieving pressure,
always hold a metal part of the gun
or dispensin
g
valve firmly to the side of a
g
rounded
metal pail, then trigger the gun.
1. Pump: Loosen the grounding lug locknut (A) and
washer. Insert one end of a 12
g
a (1.5 m2) minimum
g
round wire (B) into the slot in the lu
g
(C). Ti
g
hten the
locknut securely. See Fi
g
. 3. Connect the other end of
the
g
round wire to a true earth
g
round. Order a
Groundin
g
Clamp, P/N 103538, and a Groundin
g
Wire,
P/N 208950, (25 feet (7.6 m) long, 12 ga.).
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
manufacturer’s recommendations
Fi
g
.3
0720
A
B
C

684025 9
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
g
information
before operating the equipment.
Terms
Ratio refers to the simultaneous output of a certain volume
of fluid by the primary and secondary pumps.
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.
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
H Air Motor
I Air Input
J Bleed Type Master Air Valve
Fig. 4

10 684025
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
chan
g
es 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 prolon
g
the
seal life, be sure your pump seals are compatible
with the base’s reducer. Contact your Graco
representative for the correct seals to use.
Procedure 1: Base is not pre-reduced
When addin
g
the reducer to the base before proportionin
g
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.
5parts base
+ 1parts catalyst
6parts 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.
6parts mixture
/ 3parts to reduce
2parts 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.
5parts base
+ 2parts reducer
7parts combined base/reducer to
1 part catalyst
The ratio of the pump is 7:1.
Relationship Between the Primary and
Secondary Pumps
Movin
g
the fulcrum point away from the primary pump
reduces the secondary stroke len
g
th, reducin
g
its fluid
output. Movin
g
the fulcrum point closer to the primary pump
increases the secondary stroke len
g
th, increasin
g
its fluid
output.
Fi
g
. 5 shows the relationship between the primary pump
and the secondary pump.
Adjusting the Ratio
See Fi
g
. 2. Use a wrench to rotate the ratio adjustment
screw (S). Rotatin
g
the screw clockwise will increase the
ratio. Rotatin
g
the screw counterclockwise will decrease
the ratio. The indicator pin (V) will move alon
g
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.
Fig. 5

684025 11
Operation
WARNING System Flushing
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from starting or
sprayin
g
accidentally. Fluid under hi
g
h
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
equipment,
•or install or clean the spray tips.
The pumps were tested with li
g
htwei
g
ht oil at the factory.
Before operating the pump, thoroughly flush the Hydra-Cat
H.P. to prevent contamination of your fluids.
NOTE:
Flush the mixer, hose and
g
un often enou
g
h to prevent
fluid from reactin
g
or curin
g
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
g
allon (20 liter)
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
g
un firmly to the side of a
g
rounded metal pail. Usin
g
the lowest possible air pressure to the air motor that
will activate the pump, trigger the gun into the pail.
Pressure Relief Procedure
1. Lock the spray gun’s trigger safety.
2. Shut off ALL fluid supplies to the pump.
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
g
the steps above,
follow this procedure: Very slowly loosen the tip
guard retaining nut or hose end coupling and relieve
pressure
g
radually, then loosen completely. Now
clear the obstruction.
4. When clean solvent comes from the spray
g
un,
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.
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,
tri
gg
er the
g
un, slowly open the bleed-type master air
valve, and turn the air re
g
ulator knob clockwise until
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
g
un. 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.

12 684025
Checking the Ratio
Note: The mix ratio must be checked at the normal
operatin
g
fluid pressure of the pump. Most mixer
manifolds provide a means for checkin
g
mix ratio
that includes needle valves for adjustin
g
the fluid
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
g
pressure. After determinin
g
the
operatin
g
pressure, release the spray
g
un tri
gg
er and
engage the safety latch.
3. Close the mixer manifold inlet valves.
4. Sli
g
htly open the samplin
g
valve on the secondary
pump side. Sli
g
htly open the samplin
g
valve on the
primary pump side. This will prevent pressure from
buildin
g
up on the secondary pump, causin
g
the relief
valve to open.
5. Place a
g
rounded waste container under the samplin
g
valve.
6. Open the mixer manifold. Use the sampling valves to
adjust the pressures to your
normal operatin
g
pressures.
7. Close the mixer manifold. Put the samplin
g
containers under the sampling valves.
8. Open the mixer manifold. Check the ratio; make sure
the pressure is within 20% of your normal operatin
g
pressure. Close the mixer manifold when enou
g
h
fluid has been dispensed into the samplin
g
containers.
NOTE: If the pressure readings are not within 20% of
your normal operatin
g
pressure, follow the
flushin
g
procedure on pa
g
e 11, then take a
sample a
g
ain. If your sample ratio is incorrect,
there is a problem with the sampling valves, ratio
settin
g
, or pump operation. Check the ratio
setting or service the sampling valves or pump.
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.
Bearings
Many of the bearin
g
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 bearin
g
s, 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.
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)
usin
g
the supplied wrench (20). Do this whenever
necessary. Do not over tighten the packing nut.
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
g
or dama
g
in
g
the
sensor or cable. The four main bearin
g
s (21) are now
exposed. Use the adapter (205532) provided to grease all
four bearin
g
s. One or two squirts (2-3 cc) will be
sufficient.

684025 13
Air Lubrication
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
g
reasin
g
,
and before startin
g
the machine. The covers (17) are
safety guards and must be in place when the proportioner
is in operation.
If your air supply Is very dry, install an air line lubricator
between the air re
g
ulator and the pump air motor for
automatic lubrication. Refer to the air motor manual for
details.
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
Fig. 6

14 684025
Troubleshooting
Troubleshooting Techniques
Because the pumps are mechanically linked, the action of
one pump can affect the readin
g
s of the second pump.
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
g
au
g
e, is low and slu
gg
ish durin
g
the pump
chan
g
eover. The most likely problem is a bindin
g
primary
pump. To isolate the problem:
1. Relieve the pressure.
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 fi
g
ure 6. Increase
the re
g
ulator settin
g
until the pump just be
g
ins 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.
8. With the main bleed-type air valve (1) off, remove
the thumb screws (14) and
g
uards (15) from each
side of the proportioner.
9. Unscrew the connectin
g
rod nut (10) from the
primary pump. Now you can verify the operation of
the secondary pump alone.
Reinstall the
g
uards (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:
A. Open and close the samplin
g
valves and check
for pump stallin
g
on both the up and down
strokes.
B. Check for rapid
g
au
g
e response durin
g
the
pump changeover
11. When the operation of the secondary side has been
verified, reconnect the connectin
g
rod (10) of the
primary pump.
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.
Use very low air pressure to the air motor when
troubleshootin
g
the system. This system can produce
very high fluid pressure, which can cause serious injury,
3. With the main bleed-type air valve (1) off, remove
the thumb screws (14) and
g
uards (15) from each
side of the proportioner.
4. Unscrew the connectin
g
rod nut (11) from the
secondary pump. Now you can verify the operation
of the primary pump alone.
includin
g
injection, splashin
g
in the eyes or on the skin,
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.
Reinstall the
g
uards (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: WARNING
A. Open and close the samplin
g
valves and check
for pump stallin
g
on both the up and down
strokes.
B. Check for rapid
g
au
g
e response durin
g
the
pump changeover
To reduce the risk of injurin
g
or amputatin
g
your hands,
fin
g
ers, or other body parts, never place your hands,
body or tools inside the safety panels for any reason
while the unit is operating.
6. When the operation of the primary side has been
verified, reconnect the connectin
g
rod (11) of the
secondary.
7. 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 be
g
ins 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.

684025 15
Troubleshooting Chart
PROBLEM CAUSE SOLUTION
System will not run or
stops while running.
Air pressure or air
volume is too low.
Increase air pressure. Check air compressor and air supply filters
re
g
ulator, lubricator valves and other components for blocka
g
es
and restrictions. If this is a new system, be sure that air supply
components have been sized properly.
The fluid valves or
hoses are closed or
restricted.
Check the
g
un, fluid hoses, mix manifold, static mixer, fluid filters,
re
g
ulators, valves and other fluid line components for blocka
g
es
and restrictions. If this is a new system, be sure that the fluid
components have been sized properly.
The air motor is
worn or damaged.
Service the air motor. See “servicing the Air Motor”on page 17.
The displacement
cylinder(s) is
damaged or has
seized
See troubleshootin
g
techniques below to isolate the problem
cylinder. See “Service the cylinders”on page 16.
The fluid pressure
bounces significantly
(>500 psi) while pump is
running
Air volume is too
low.
Verify that air pressure at the air motor inlet is not droppin
g
durin
g
pump chan
g
eover. 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
g
s 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 troubleshootin
g
techniques below to isolate the problem
cylinder. See “Service the cylinders”on page 16.
Mix ratio test is
significantly different from
the mix ratio setting.
Mix ratio test was
not performed at
the normal
operating pressure
of the pump
Perform ratio test again following ratio test procedure on page 12.
Running out of one
material.
Check and refill material reservoirs. Repeat the test after the air has
been removed from the system.
The displacement
cylinder(s) are worn
or the check valves
are not seating.
See troubleshootin
g
techniques below to isolate the problem
cylinder(s). See “Service the cylinders”on page 16.
Spray output is spitting Runnin
g
out of one
material.
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..
Siphon hoses are
leaking in air.
Ti
g
hten and seal all siphon fittin
g
s on proportionin
g
pump and feed
pumps.
A squeaking or knocking
noise is heard.
The bearin
g
s are
dry or worn.
Lubricate the bearin
g
s or replace them if required. See “service the
bearings”on page 18.
The proportioner speeds
up or runs erratically
Runnin
g
out of one
material.
Check and refill material reservoirs.
The cylinders are
worn or damaged.
See troubleshootin
g
techniques below to isolate the problem
cylinder(s). See “Service the cylinders”on page 16.

16 684025
Service
Required Tools
•Set of large adjustable wrenches
•Set of metric sockets or wrenches
•Large pipe wrench
•Torque wrench
•Rubber mallet
•Flat end punch
4. With the bleeder type main air valve turned off (1),
remove the thumb screws (14) and the two
g
uards
(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
g
removed. Each
displacement pump must be returned to its ori
g
inal
position and orientation.
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
g
ANY
guards or covers from the proportioner.
Be sure to use two people when liftin
g
, movin
g
, or
disconnecting the pump. This pump is too heavy for one
person. Be sure to support the displacement pump while
it is bein
g
disconnected, to prevent it from fallin
g
and
causin
g
injury or property dama
g
e. Do this by securely
bracing the pump, or by having at least two people hold it
while another disconnects it.
Disconnecting the Displacement Pump(s)
1. Flush the System. Follow the procedure on page
11.
2. Relieve the pressure.
7. Usin
g
an adjustable wrench (or hammer and punch),
unscrew the couplin
g
nut (10,11) from the rod adapter
(13). Do not lose or drop the couplin
g
collars (12). See
Fig. 6.
8. Hold the tie rod flats with a wrench to keep the rods
WARNING from turnin
g
. Unscrew the nuts (8) from the tie rods
(7). Carefully remove the displacement pump (3)
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
3. Disconnect the siphon hose and the fluid outlet hose. 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.

684025 17
Reconnecting the Displacement Pump CAUTION
1. Make sure the couplin
g
nut (10,11) and the couplin
g
collars (12) are in place on the displacement rod. See
Fig. 6.
Be sure to use an overhead hoist when lifting, moving or
disconnectin
g
the air motor. This air motor wei
g
hs 145
lbs. and is too heavy for one person to handle. A lift ring
is provided on the motor for this purpose.
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
g
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
g
nut (10) onto the rod adapter (13)
loosely. Hold the rod adapter flats with a wrench to
keep it from turnin
g
. Use an adjustable wrench to
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
g
uards (15) and the thumb screws
(14) from the sides of the proportioner.
10. Turn on the air supply. Follow the procedure for
startin
g
the pump on pa
g
e 11. Run the pump slowly at
first to ensure proper operation.
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
g
an adjustable wrench (or hammer and punch),
unscrew the couplin
g
nut (9) from the rod adapter
(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
g
. Unscrew the nuts (8) from the tie rods
(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
g
rod has been removed from the Air
Motor Stud as a part of servicin
g
, be sure to use
thread adhesive when reinstallin
g
the connectin
g
rod
on to the Air Motor Stud.
2. Make sure the couplin
g
nut (9) and the couplin
g
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 returnin
g
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
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).
Disconnecting the Air Motor
1. Relieve the pressure.
6. Screw the couplin
g
nut (9) onto the rod adapter (13)
loosely. Hold the rod adapter flats with a wrench to
keep it from turnin
g
. Use an adjustable wrench to
tighten the coupling nut. Torque to 196–210 N.m ft-lb).
WARNING 7. Reconnect the air hose
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
g
uards (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.
3. Remove the thumb screws (14) and the two
g
uards
(15) from the sides of the proportioner.
4. Disconnect the air motor (2) from the frame (5) as
follows:
9. Turn on the air supply. Follow the procedure for startin
g
the pump on pa
g
e 11. Run the pump slowly at first to
ensure proper operation

18 684025
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 strainin
g
or
dama
g
in
g
the sensor or cable. The (4) four main
bearings (21) are now exposed.
3. Remove the thumb screws (14) and the two
g
uards
(15) from the sides of the proportioner.
4. Usin
g
an adjustable wrench (or hammer and punch),
unscrew the couplin
g
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 couplin
g
collars (12). See Fig. 6.
5. The left rear bearin
g
shaft has a ma
g
net stuck on its
end. Remove the ma
g
net and put it in a safe place.
Use a snap rin
g
pliers to remove the four snap rin
g
s
(22) from the shafts and remove the retainin
g
washers.
6. You should now be able to slide the bearin
g
s (21) off
of the shaft ends.
7. Replace the bearin
g
s only with identical Graco
replacement parts. Pack the bearin
g
s in Industrial
Grade 1, Heavy Duty, Extreme Pressure, Lithium
Soap Grease, Graco Part Number 110293 or
equivalent.
8. Re-install the new bearin
g
s (21) onto the shafts.
Doin
g
so may require sli
g
htly shiftin
g
the shaft
assembly which may have dropped durin
g
bearin
g
removal.
9. Re-install the four retainin
g
washers and their snap
rings (22).
10. Replace the ma
g
net onto the end of the left rear
bearing shaft.
11. Make sure the couplin
g
nuts (10, 11, 12) and the
couplin
g
collars (12) are in place on all three rod
adapters.
12. Screw all three (3) couplin
g
nuts (10, 11, 12) onto
the rod adapters (13) loosely. Hold each rod
adapters flats with a wrench to keep it from turnin
g
.
Use an adjustable wrench to ti
g
hten the couplin
g
nuts. Torque to 196–210 N.m ft-lb).
13. Replace the covers (17) and the bolts (16).
14. Replace the two
g
uards (15) and the thumb screws
(14) onto the sides of the proportioner.
15. Turn on the air supply. Follow the procedure for
startin
g
the pump on pa
g
e (11). Run the pump
slowly at first to ensure proper operation.
Bearing Inset
Fig. 7

684025 19
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, 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 M3/min
At 70 PSI (4.9 bar)
CFM M3/min
At 100 PSI (7.0 bar)
CFM M3/min
At cycles
per min
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
King Air Consumption
At 40 PSI (2.8 bar)
CFM M3/min
At 70 PSI (4.9 bar)
CFM M3/min
At 100 PSI (7.0 bar)
CFM M3/min
At cycles
per min
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
A
BC

20 684025
NOTES