Graco Hydra-Cat Xtreme XL Parts list manual

Instructions-Parts
Hydra Hydra
Hydra- - -Cat® Cat® Cat®H.P. H.P. H.P.Variable Variable VariableRatio Ratio Ratio
Proportioning Proportioning
ProportioningPump Pump Pump3A3092A
EN
Adjustable Adjustable
Adjustable- - -ratio ratio ratioproportioner proportioner proportionerfor for forapplying applying applyinghigh high highsolids solids solidsprotective protective protectivecoatings. coatings. coatings.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinrelated
manuals.Savetheseinstructions.
SeeModels,page6.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Warnings...........................................................3
Models...............................................................6
RelatedManuals................................................6
Installation..........................................................7
Location......................................................7
ConnecttheFluidSupplyLines.....................7
ConnecttheFluidOutputLines.....................7
SystemAccessories.....................................8
ConnecttheAirSupplyLine..........................8
PressureReliefValve...................................8
Grounding..........................................................8
AdjustRatio........................................................9
DeterminetheRatio.....................................10
Procedure1:AddReducertothe
Base..............................................10
AdjustingtheRatio.......................................11
PressureReliefProcedure..................................12
Flushing.............................................................12
StartthePump...................................................12
StandardOperationFlushing...............................13
CheckTheRatio.................................................13
Maintenance......................................................14
WetCupMaintenance..................................14
BearingMaintenance...................................14
AirLubricationMaintenance..........................15
Troubleshooting..................................................16
LowSecondaryPumpPressure....................16
Repair................................................................19
DisconnecttheDisplacementPump..............19
ReconnecttheDisplacementPump...............20
DisconnecttheAirMotor..............................20
ReconnecttheAirMotor...............................20
ReplacetheBearings...................................21
Parts..................................................................22
Dimensions........................................................23
TechnicalSpeci󰘰cations......................................24
Notes...............................................................25
GracoStandardWarranty....................................26
23A3092A

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
3A3092A3

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
43A3092A

Warnings
WARNING WARNING
WARNING
SPLATTER SPLATTER
SPLATTERHAZARD HAZARD HAZARD
Hotortoxic󰘱uidcancauseseriousinjuryifsplashedintheeyesoronskin.Duringblowoffof
platen,splattermayoccur.
•Useminimumairpressurewhenremovingplatenfromdrum.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipment
includesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A3092A5

Models
Models Models
Models
Thefollowingchartgivesspeci󰘰cationsfortheHydra-CatH.P.pumps,usingNo.10weightoil.Thevolumetric
ratioisexpressedastheproportionofthevolumeof󰘱uidoftheprimarypumpcomparedtothevolumeof
󰘱uidofthesecondarypump.
Ratio Ratio
RatioAt At
AtMinimum Minimum MinimumRatio Ratio RatioSetting Setting SettingAt At AtMaximum Maximum MaximumRatio Ratio RatioSetting Setting SettingLower Lower
LowerID ID ID
Stall Stall
StallStall Stall StallOutput Output OutputOutput Output OutputStall Stall StallStall Stall StallOutput Output OutputOutput Output OutputMaster Master
MasterSlave Slave
Slave
Air Air
AirMotor Motor MotorAssem- Assem- Assem-
bly bly
blyPart Part Part
No. No.
No.Min Min
MinMax Max Max
PSI PSI
PSIBar Bar
BarGPM GPM
GPMLPM LPM
LPMPSI PSI
PSIBar Bar
BarGPM GPM
GPMLPM LPM
LPMDF DF DFDF DF DF
Xtreme
XL
9654811.504.5053333683.814.472735022.810.696
Xtreme
XL
9654792.006.0044443074.617.357143943.613.4126
Note:AllOutputPressuresLimitedTo5000PSIByIntegralPressureReliefValves
Note:Pressureoutputscalculatedat100PSIAirPressure
Note:Volumeoutputscalculatedat40cyclesperminute.
Approvals Approvals
Approvals
II 2 G c 230°C (T2)
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualDescription Description Description
334644XtremeXLAirMotor
311762XtremeLower
308547PressureReliefValve
63A3092A

Installation
Installation Installation
Installation
Location Location
Location
Sittheproportionerona󰘱at󰘱oorsurface.
Connect Connect
Connectthe the theFluid Fluid FluidSupply Supply SupplyLines Lines Lines
1.Connectthegrounded󰘱uidhosestothepump
inlet󰘰ttings(P,R).Iftheunitwillbepressure
fedfromseparatesupplyunits,installa󰘱uid
pressuregaugeateachinlet.
Note
Thepressurized󰘱uidsuppliesmust
notexceed1/4oftheoperating󰘱uid
pressureofthepump.Pressureabove
thatlevelwillfeedrightthroughthepump
andimproperrationingwillresult.
Connect Connect
Connectthe the theFluid Fluid FluidOutput Output OutputLines Lines Lines
1.Connectelectronicallyconductive󰘱uidhosesto
thepumpoutlet󰘰ttings.Tightenallofthe󰘰ttings.
Figure1
Key: Key:
Key:
ABleedTypeMainAirValve
BAirRegulator
CPressureReliefValve
DMixManifold
EAirSupplyLine
FAirLineFilter
GAirShutoffValve
HAirLineLubricator
JBaseSupplyPump
KCatalystSupplyPressurePot
LSolventSupplyPump
MMixManifoldFlushInlet
NStaticMixer
PPrimaryPumpInlet(Base)
RSecondaryPumpInlet(Catalyst)
SRatioAdjustmentScrew
TSprayGun
URatioIndicatorPlate
VRatioIndicatorPin
3A3092A7

Grounding
System System
SystemAccessories Accessories Accessories
Ableed-typemasterairvalve(A)isrequiredinyour
systemtorelievetheairtrappedbetweenthevalve
andthepumpafterthepumpisshutoff.Trappedair
cancausethepumptocycleunexpectedly,resulting
inpossibleseriousinjury,includingamputation.
Note
Toensurethemaximumpumpperformance
andsafety,besurethatalltheaccessories
usedareproperlysizedtomeetyoursystem
requirementsandthepressurelimitsofthe
pump.UseonlygenuineGracopartsand
accessories.
Intheairline,installanair󰘰lter(F)toremove
harmfuldirtandmoisturefromthecompressedair
supply.Installanairlinelubricator(H)downstream
fromtheair󰘰lter,theairregulator(B)andthe
bleed-typemasterairvalve(A).Alubricatorwill
provideautomaticlubricationtotheairmotor.
Connect Connect
Connectthe the theAir Air AirSupply Supply SupplyLine Line Line
1.Connectanelectricallyconductiveairsupply
hosetothe3/4”npt(f)portoftheairregulator(B).
Openthebleed-typemasterairvalve(A)and,
usingthepressuregauge,settheairregulator
(B)tothedesiredpressure.
Pressure Pressure
PressureRelief Relief ReliefValve Valve Valve
Allcomponentshaveratedworkingpressuresof
5000psi(345bar)orgreater.Formoreinformation
aboutthepressurereliefvalve,seeinstruction
manual308547.
Grounding Grounding
Grounding
Theequipmentmustbegroundedtoreducetherisk
ofstaticsparking.Staticsparkingcancausefumes
toigniteorexplode.Groundingprovidesanescape
wirefortheelectriccurrent.
Pump: SeeXLAirMotorinstructionmanualfor
completegroundinginstructions.
Airand󰘱uidhoses: Useonlyelectricallyconductive
hoseswithamaximumof500feet(150m)combined
hoselengthtoensuregroundingcontinuity.
Aircompressor: Followtheaircompressor
manufacturer’srecommendations.
Spraygunordispensingvalve: Obtaingrounding
throughconnectiontoaproperlygrounded󰘱uidhose
andpump.
Fluidsupplycontainer: followlocalcode.
Objectbeingsprayed: followlocalcode.
Allsolventpailsusedwhen󰘱ushing: Accordingto
localcode.Useonlyconductivemetalpailswhichare
conductive,placedonagroundedsurface.Donot
placethepailonanon-conductivesurface,suchas
paperorcardboard,whichinterruptsthegrounding
continuity.
Tomaintaingroundingcontinuitywhen󰘱ushingor
relievingpressure: Holdametalpartofthegunor
dispensingvalve󰘰rmlytothesideofagrounded
metalpail,thentriggerthegun.
83A3092A

AdjustRatio
Adjust Adjust
AdjustRatio Ratio Ratio
UnderstandingthetermsusedwiththeHydra–Cat Hydra–Cat
Hydra–Cat
(H.P.) (H.P.)
(H.P.)System System System,howitfunctions,andhowto󰘰ndand
setthecorrectratios ratios
ratiosforyourapplicationisthekeyto
easier,moreversatileoperationofyourproportional
system.
Besuretoreadandunderstandthefollowing
informationbeforeoperatingtheequipment.
Table Table
Table1 1 1Terms Terms Terms
Term Term
TermDe󰘰nition De󰘰nition
De󰘰nition
RatioRatio Ratio
Ratioreferstothe
simultaneousoutput
ofacertainvolumeof
󰘱uidbytheprimary primary
primaryand
secondary secondary
secondarypumps pumps pumps.
PrimaryPump(A)Theprimary primary
primarypump pump pump(A) (A) (A)
isdirectlyunderthe
air air
airmotor motor motor(H) (H) (H);itusually
pumpsthebase base
base󰘱uid.
SecondaryPump(B)Thesecondary secondary
secondarypump pump pump
(B) (B)
(B)isontheopposite
endofthelever lever
leverarm arm arm
(E); (E);
(E);itusuallypumpsthe
catalyst catalyst
catalyst.Theratioofthe
secondarypump(s)can
bechangedbyadjusting
theratio ratio
ratioadjustment adjustment adjustment
screw screw
screw(C). (C). (C).
Therearethreemainstepswhenapplyingtheuse
ofratios:
1.Determinetheratiothatisrequired,
2.Calculatetheratiosetting.
3.SettheratioontheHydra-CatH.P.system.
Figure2
APrimaryPump
BSecondaryPump
CRatioAdjustmentScrew
DWetCups
EFulcrumandArm
FPrimaryPumpOutput
GSecondaryPumpOutput
HAirMotor
JAirInput
KBleedTypeMasterAirValve
3A3092A9

AdjustRatio
Determine Determine
Determinethe the theRatio Ratio Ratio
Settheratiobasedonyoursituation.If:
•The The
The󰘱uids 󰘱uids 󰘱uidsare are aresupplied supplied suppliedat at ata a aready–to–spray ready–to–spray ready–to–spray
viscosity viscosity
viscosity,simplysettheratioasexplainedunder
AdjustingtheRatio,page11.
•The The
The󰘱uids 󰘱uids 󰘱uidsare are areNOT NOT NOTsupplied supplied suppliedat at atready–to–spray ready–to–spray ready–to–spray
viscosity viscosity
viscosity,theratiomustbedeterminedafterthe
reducerisaddedtothebase,asinstructedin
Procedure Procedure
Procedure1 1 1,below.
Note
Evaporationofthereducerinthebase
causeschangesintheratio.Toprevent
evaporation,storethebaseinaclosed
container.
Note
Somereducershaveverylittleabilityto
lubricateandmanycausesealstodryout.
Toprolongtheseallife,besureyourpump
sealsarecompatiblewiththebase’sreducer.
ContactyourGracorepresentativeforthe
correctsealstouse.
Procedure Procedure
Procedure1: 1: 1:Add Add AddReducer Reducer Reducerto to tothe the the
Base Base
Base
Whenaddingthereducertothebasebefore
proportioningwiththeHydra–Catsystem,determine
theratioofthebase/reducermixturetothecatalystin
ordertosettheproperratio.
Example:
Theinstructionsonthecansay“Mix5partsbaseto
1partcatalyst.Thenreduce3partsofthismixture
to1partreducer.”
1.Addtheparts parts
partsof of ofthe the thebase base baseand and andcatalyst catalyst catalystto󰘰ndthe
parts parts
partsmixture mixture mixture.
5partsbase
+1partscatalyst
6partsmixture
2.Thenextstatementonthecansays,“Reduce3
partsofthemixture.”Sodividetheparts parts
partsof of ofthe the the
mixture mixture
mixtureby3 3 3parts parts partsto to toreduce reduce reduceto󰘰ndtheparts parts parts
reducer reducer
reducer.
6partsmixture
/3partstoreduce
2partsreducer
3.Todeterminetheratioofthesecondarypump,
addtheappropriateparts parts
partsof of ofbase base baseand and andreducer reducer reducerto
󰘰ndtheparts parts
partscombined combined combinedbase/reducer base/reducer base/reducer.
5partsbase
+2partsreducer
7partscombinedbase/reducerto1 1
1
partcatalyst
Theratioofthepumpis7:1.
103A3092A

AdjustRatio
Adjusting Adjusting
Adjustingthe the theRatio Ratio Ratio
Movingthefulcrumpointawayfromtheprimary
pumpreducesthesecondarystrokelength,reducing
its󰘱uidoutput.Movingthefulcrumpointclosertothe
primarypumpincreasesthesecondarystrokelength,
increasingits󰘱uidoutput.
1.Useawrenchtorotatetheratioadjustmentscrew
(S).Rotatethescrewclockwisetoincreasethe
ratio.Rotatethescrewcounterclockwiseto
decreasetheratio.Theindicatorpin(V)willmove
alongtheratioindicatorscale(U)astheratio
adjustmentscrewisrotated.SeeFig1,page7.
2.Whenthepinisabovethedesiredratio,remove
thewrenchandperformaratiotest.See
CheckTheRatio,page13.
3A3092A11

PressureReliefProcedure
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicing
equipment.
1.Lockthespraygun’striggersafety.
2.ShutoffALL ALL
ALL󰘱uidsuppliestothepump.
3.Closethebleed-typemasterairvalve.
4.Unlockthespraygun’striggersafety.
5.Holdametalpartofthespraygun󰘰rmlytothe
sideofagroundedmetalpail.Triggerthespray
gunintothepailtorelievepressure.
6.Lockthespraygun’striggersafety.
7.Openthesamplingvalves,havingacontainer
readytocatchthedrainage.
8.Ifyoususpectthatthespraytipornozzleorthe
hoseiscompletelycloggedorthatpressurehas
notbeenfullyrelievedafterfollowingthesteps
above,followthisprocedure:Veryslowlyloosen
thetipguardretainingnutorhoseendcoupling
andrelievepressuregradually,thenloosen
completely.Nowcleartheobstruction.
Flushing Flushing
Flushing
Toavoid󰘰reandexplosion,alwaysground
equipmentandwastecontainer.Toavoidstatic
sparkingandinjuryfromsplashing,always󰘱ushat
lowerpossiblepressure.
Thepumpsweretestedwithlightweightoilatthe
factory.Beforeoperatingthepump,thoroughly󰘱ush
theHydra-Catsystemtopreventcontaminationof
your󰘱uids.
Note
Flushthemixer,hoseandgunoftenenough
toprevent󰘱uidfromreactingorcuringin
them.Contactyour󰘱uidmanufacturerforthe
effectivepotlifeofthe󰘱uidyouareusing.
1.Putthepumpintakehosesintoa5gallon(20
liter)containerofacompatiblesolvent.Referto
the󰘱uidmanufacturer’srecommendations.
2.Startthepump.SeeStartthePump,page12.
3.Donotinstallaspraytipyet.Holdametalpart
ofthegun󰘰rmlytothesideofagroundedmetal
pail.Usingthelowestpossibleairpressuretothe
airmotorthatwillactivatethepump,triggerthe
gunintothepail.
4.Whencleansolventcomesfromthespray
gun,releasethetriggerandcarefullycheckall
connectionsinthesystemforleaks.
5.Takethehosesoutofthesolvent,andtriggerthe
gununtilallthesolventhasbeenpumpedoutof
thehoses.Immediatelyturnoffthebleeder-type
masterairvalve.
Start Start
Startthe the thePump Pump Pump
1.Closethebleed-typemasterairvalve,and
turntheairregulatorknoballthewayout
(counterclockwise).
2.Turnonthemainairsupply.
3.Withthemixermanifoldhandleintheopen
position,triggerthegun,slowlyopenthe
123A3092A

StandardOperationFlushing
bleed-typemasterairvalve,andturntheair
regulatorknobclockwiseuntilthepumpstarts.
4.Allowthepumptocycleslowlyuntilalltheairis
pushedoutofthelines.Releasethetrigger.The
pumpwillstallagainstthepressure.
5.Themanifoldhandlecontrols󰘱uid󰘱ow.Withthe
leverofthemanifoldintheopen(down)position,
baseandcatalystaresuppliedtothegun.To
stopthe󰘱ow,movethehandletotheclosed(up)
position.
Standard Standard
StandardOperation Operation Operation
Flushing Flushing
Flushing
Usethesolventvalvesto󰘱ushcontaminantsand
mixed󰘱uidsfromthemixermanifold,hoseandspray
gun.Followtheprocedureprovidedwiththemix
manifoldassembly
Check Check
CheckThe The TheRatio Ratio Ratio
Themixratiomustbecheckedatthenormal
operating󰘱uidpressureofthepump.Mostmixer
manifoldsprovideameansforcheckingmixratio
thatincludesneedlevalvesforadjustingthe󰘱uid
pressureduringthetest.Thefollowingprocedureis
anexampleofhowtoproperlycheckthemixratio.
1.Openthemixermanifoldandtriggeryourspray
gun.
2.Setyouroperatingpressure.Afterdetermining
theoperatingpressure,releasethespraygun
triggerandengagethesafetylatch.
3.Closethemixermanifoldinletvalves.
4.Slightlyopenthesamplingvalveonthe
secondarypumpside.Slightlyopenthesampling
valveontheprimarypumpside.Thiswillprevent
pressurefrombuildinguponthesecondary
pumpandcausingthereliefvalvetoopen.
5.Placeagroundedwastecontainerunderthe
samplingvalve.
6.Openthemixermanifold.Usethesampling
valvestoadjustthepressurestoyour
normal normal
normal
operating operating
operatingpressures pressures pressures
.
7.Closethemixermanifold.Putthesampling
containersunderthesamplingvalves.
8.Openthemixermanifold.Checktheratio;make
surethepressureiswithin20%ofyournormal
operatingpressure.Closethemixermanifold
whenenough󰘱uidhasbeendispensedintothe
samplingcontainers.
Note
Ifthepressurereadingsarenotwithin20%
ofyournormaloperatingpressure,follow
Flushing,page12,thentakeasampleagain.
Ifyoursampleratioisincorrect,thereis
aproblemwiththesamplingvalves,ratio
setting,orpumpoperation.Checktheratio
settingorservicethesamplingvalvesor
pump.
3A3092A13

Maintenance
Maintenance Maintenance
Maintenance
Wet Wet
WetCup Cup CupMaintenance Maintenance Maintenance
Eachofthe󰘱uidcylindershasawetcup(U)atthe
topthatmustbekeptlubricated.SeeFigure3,page
15.Thewetcupsshouldbeinspectedand󰘰lledona
weeklybasis,ormorefrequentlyiffoundtobedry.
1.FollowPressureReliefProcedure,page12.
2.Withthebleedertypemainairvalve(A)turned
off,removethethumbscrews(P)andthetwo
guards(R)fromthesidesoftheproportioner.
Thewetcups(U)shouldbe󰘰lledto1/3fullwith
GracoThroatSealLiquid(TSL)orcompatible
solvent.
3.Thepackingnuts(V)aretorquedatthefactory
andarereadyforoperation.Ifonebecomes
looseandthereisleakingfromthethroat
packings,torquethenutto136–149N.m
(100–110ft-lb)usingthesuppliedwrench(W).
Dothiswhenevernecessary.Donotovertighten
thepackingnut.
Bearing Bearing
BearingMaintenance Maintenance Maintenance
Manyofthebearingsurfacesontheproportioner
arepermanentlylubricatedorareselflubricating.
However,therearefourmainbearings(X)onthe
leverarm
that that
thatmust must mustbe be belubricated lubricated lubricated
onaregular
interval.Thelubricationintervaliseverysixmonths
insingleshiftoperation.Tolubricatethebearings:
1.FollowPressureReliefProcedure,page12
2.Withthebleedertypemainairvalveturnedoff,
removethetwentyhexbolts(S)witha13mm
wrenchorsocketandthenremovethefoursheet
metalcovers(T)fromthefrontandbackofthe
proportioner.SeeFigure3,page15.
3.Theleftrearcovermaycontainasensorattached
toacable.Donotremovethesensor,but
carefullysetthecovertothesidewithoutstraining
ordamagingthesensororcable.Thefourmain
bearings(X)arenowexposed.Usetheadapter
(205532)providedtogreaseallfourbearings.
Oneortwosquirts(2-3cc)willbesuf󰘰cient.
143A3092A

Maintenance
Air Air
AirLubrication Lubrication LubricationMaintenance Maintenance Maintenance
1.MakesuretouseanIndustrialGrade1,Heavy
Duty,ExtremePressure,LithiumSoapGrease,
GracoPartNumber110293orequivalent.
2.Replacethecovers(T)andthehexbolts(S)
aftergreasing,andbeforestartingthemachine.
Thecovers(T)aresafetyguardsandmustbein
placewhentheproportionerisinoperation.
3.IfyourairsupplyIsverydry,installanairline
lubricatorbetweentheairregulatorandthepump
airmotorforautomaticlubrication.Refertothe
airmotormanualfordetails.
Figure3
Key: Key:
Key:
ABleederTypeMainAirValve
BAirMotor
CPrimaryCylinder
DSecondaryCylinder
EFrame
FAirMotorTieRods
GFluidCylinderTieRods
HTieRodNuts
JConnectingRodNut,AirMotor
KConnectingRodNut,Primary
LConnectingRodNut,Secondary
MCouplingCollars
NRodAdapter
PThumbScrews
RGuards
SHexBolts
TCovers
UWetCups
VPackingNuts
WPackingNutWrench
XMainBearings
YSnapRing
ZFluidOutlet,Primary
AAFluidOut,Secondary
3A3092A15

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
Low Low
LowSecondary Secondary SecondaryPump Pump PumpPressure Pressure Pressure
Becausethepumpsaremechanicallylinked,the
actionofonepumpcanaffectthereadingsofthe
secondpump.Therefore,thekeytosuccessful
troubleshootingistobe be
besure sure sureto to toisolate isolate isolatethe the theproblem problem problem.
Forexample,ifthesecondarypumppressureon
thegaugeislowandsluggishduringthepump
changeover,themostlikelyproblemisabinding
primarypump.Toisolatetheproblem:
1.FollowPressureReliefProcedure,page12.
2.Withthesamplingvalvesstillopen,settheair
supplyregulatortothelowestsettingandopen
thebleed-typemainairvalve(A).RefertoFig
3.Increasetheregulatorsettinguntilthepump
justbeginstomove.Noticethepositionofthe
secondarypump(L).Turnoffthebleeder-type
mainairvalve(A)sothatthesecondarypump
rodisatitslowestpositionwhenthepumpstops.
3.Withthemainbleed-typeairvalve(A)off,remove
thethumbscrews(P)andguards(R)fromeach
sideoftheproportioner.
4.Unscrewtheconnectingrodnut(L)fromthe
secondarypump.Nowyoucanverifythe
operationoftheprimarypumpalone.
5.Reinstalltheguards(R)onbothsidesofthe
proportioner.Turnthemainairvalve(A)backon
andcarefullyincreasetheairpressure.
6.Usingthesamplingvalvesatthemixermanifold:
a.Openandclosethesamplingvalvesand
checkforpumpstallingonboththeupand
downstrokes.
b.Checkforrapidgaugeresponseduringthe
pumpchangeover.
7.Whentheoperationoftheprimarysidehasbeen
veri󰘰ed,reconnecttheconnectingrod(L)ofthe
secondary.
8.Withthesamplingvalvesstillopen,settheair
supplyregulatortothelowestsettingandopen
thebleed-typemainairvalve(A).Increasethe
regulatorsettinguntilthepumpjustbeginsto
move.Noticethepositionoftheprimarypump.
Turnoffthebleeder-typemainairvalve(A)so
thattheprimarypumprod(K)isatitslowest
positionwhenthepumpstops.
9.Withthemainbleed-typeairvalve(A)off,remove
thethumbscrews(P)andguards(R)fromeach
sideoftheproportioner.
10.Unscrewtheconnectingrodnut(K)fromthe
primarypump.Nowyoucanverifytheoperation
ofthesecondarypumpalone.Reinstallthe
guards(R)onbothsidesoftheproportioner.
Turnthemainairvalve(A)backonandcarefully
increasetheairpressure.
11.Usingthesamplingvalvesatthemixermanifold:
a.Openandclosethesamplingvalvesand
checkforpumpstallingonboththeupand
downstrokes.
b.Checkforrapidgaugeresponseduringthe
pumpchangeover.
12.Whentheoperationofthesecondarysidehas
beenveri󰘰ed,reconnecttheconnectingrod(K)
oftheprimarypump.
163A3092A

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
PROBLEM PROBLEM
PROBLEMCAUSE CAUSE CAUSESOLUTION SOLUTION SOLUTION
Airpressureorairvolumeistoo
low.
Increaseairpressure.Checkair
compressorandairsupply󰘰lters
regulator,lubricatorvalvesand
othercomponentsforblockages
andrestrictions.Ifthisisanew
system,besurethatairsupply
componentshavebeensized
properly.
The󰘱uidvalvesorhosesare
closedorrestricted.
Checkthegun,󰘱uidhoses,mix
manifold,staticmixer,󰘱uid󰘰lters,
regulators,valvesandother󰘱uid
linecomponentsforblockagesand
restrictions.Ifthisisanewsystem,
besurethatthe󰘱uidcomponents
havebeensizedproperly.
Theairmotoriswornordamaged.Servicetheairmotor.See
DisconnecttheAirMotor,page20.
Systemwillnotrunorstopswhile
running.
Thedisplacementcylinder(s)is
damagedorhasseized
Seetroubleshootingtechniques
belowtoisolatetheproblem
cylinder.SeeDisconnectthe
DisplacementPump,page19.
Airvolumeistoolow.Verifythatairpressureattheair
motorinletisnotdroppingduring
pumpchangeover.Checkair
compressorandairsupply󰘰lters
regulator,lubricatorvalvesand
othercomponentsforblockages
andrestrictions.Ifthisisanew
system,besurethatairsupply
componentshavebeensized
properly.1”NPThoses,󰘰ttings
andaccessoriesarerequiredto
providethenecessaryairvolume.
Feedpumppressureistoohigh.Reducefeedpumppressure.
Feedpumppressuresmustbe
lessthan25%ofproportioner
outputpressure.
The󰘱uidpressurebounces
signi󰘰cantly(>500psi)whilepump
isrunning
Thedisplacementcylinder(s)
checkvalvesarenotseating.
Seetroubleshootingtechniques
belowtoisolatetheproblem
cylinder.SeeDisconnectthe
DisplacementPump,page19.
3A3092A17

Troubleshooting
PROBLEM PROBLEM
PROBLEMCAUSE CAUSE CAUSESOLUTION SOLUTION SOLUTION
Mixratiotestwasnotperformed
atthenormaloperatingpressure
ofthepump
Performratiotestagainfollowing
ratiotestprocedure.See
CheckTheRatio,page13.
Runningoutofonematerial.Checkandre󰘰llmaterial
reservoirs.Repeatthetest
aftertheairhasbeenremoved
fromthesystem.
Mixratiotestissigni󰘰cantly
differentfromthemixratiosetting.
Thedisplacementcylinder(s)are
wornorthecheckvalvesarenot
seating.
Seetroubleshootingtechniques
belowtoisolatetheproblem
cylinder(s).SeeDisconnectthe
DisplacementPump,page19.
Runningoutofonematerial.Checkandre󰘰llmaterial
reservoirs.Rememberthat
onceairisinthe󰘱uidsystemit
maytakeawhileforallofitto
escape.
Sprayoutputisspitting
Siphonhosesareleakinginair.Tightenandsealallsiphon󰘰ttings
onproportioningpumpandfeed
pumps.
Asqueakingorknockingnoiseis
heard.
Thebearingsaredryorworn.Lubricatethebearingsor
replacethemifrequired.See
ReplacetheBearings,page21.
Runningoutofonematerial.Checkandre󰘰llmaterial
reservoirs.
Theproportionerspeedsupor
runserratically
Thecylindersarewornor
damaged.
Seetroubleshootingtechniques
belowtoisolatetheproblem
cylinder(s).SeeDisconnectthe
DisplacementPump,page19.
183A3092A

Repair
Repair Repair
Repair
Required Required
RequiredTools Tools Tools
•Setoflargeadjustablewrenches
•Setofmetricsocketsorwrenches
•Largepipewrench
•Torquewrench
•Rubbermallet
•Flatendpunch
Disconnect Disconnect
Disconnectthe the theDisplacement Displacement DisplacementPump Pump Pump
1.FollowFlushing,page12.
2.FollowPressureReliefProcedure,page12.
3.Disconnectthesiphonhoseandthe󰘱uidoutlet
hose.
4.Withthebleedertypemainairvalve(A)turned
off,removethethumbscrews(P)andthetwo
guards(R)fromthesidesoftheproportioner.
5.Disconnectthedisplacementpump(C,D)from
theframe(E)asfollows:
Note
Notetherelativepositionofthepump’s
󰘱uidoutlet(Z)totheframeandalsonote
theframelocationofdisplacementpump
beingremoved.Eachdisplacement
pumpmustbereturnedtoitsoriginal
positionandorientation.
NOTICE NOTICE
NOTICE
Topreventdamagetothedisplacement
pump,usetwopeoplewhenlifting,moving,
ordisconnectingthepump.Thispumpistoo
heavyforoneperson.Securelybracethe
pumporhavealeasttwopeopleholditwhile
anotherdisconnectsit.
6.Usinganadjustablewrench(orhammerand
punch),unscrewthecouplingnut(K,L)fromthe
rodadapter(N).Donotloseordropthecoupling
collars(M).SeeFig.3.
7.Holdthetierod󰘱atswithawrenchtokeepthe
rodsfromturning.Unscrewthenuts(H)fromthe
tierods(G).Carefullyremovethedisplacement
pump(C,D)fromtheframe.
8.Refertotheseparatemanualsuppliedfor
displacementpumpservice.Somemodels
usetwodifferentdisplacementpumps.Be
suretolookatthemodelnumberandusethe
appropriatemanualforserviceandreference.
3A3092A19

Repair
Reconnect Reconnect
Reconnectthe the theDisplacement Displacement DisplacementPump Pump Pump
1.Makesurethecouplingnuts(K,L)and
thecouplingcollars(M)areinplaceonthe
displacementrod.SeeFig3,page15.
2.Useatleasttwopeopletoholdthedisplacement
pumpwhileanotherreconnectsittotheframe.
3.Positionandorientthedisplacementpump(C,
D)totheframe(E)aswasnotedinstep7under
DisconnecttheDisplacementPump,page19.
4.Positionthedisplacementpump(C,D)onthe
tierods(G).
5.Screwthenuts(H)ontothetierods(G)and
torqueto81–89N.m(60–66ft-lb).
6.Screwthecouplingnut(K,L)ontotherodadapter
(N)loosely.Holdtherodadapter󰘱atswitha
wrenchtokeepitfromturning.Useanadjustable
wrenchtotightenthecouplingnut.Torqueto
196–210N.mft-lb).
7.Fillthewetcup(U)1/3fullwithGracoThroat
SealLubricantorcompatiblesolvent.
8.Reconnectallhoses.
9.Replacethetwoguards(R)andthethumb
screws(P)fromthesidesoftheproportioner.
10.Turnontheairsupply.Followtheprocedurefor
startingthepumponpage11.Runthepump
slowlyat󰘰rsttoensureproperoperation.
11.Beforereturningthepumptoproduction,relieve
thepressureandre-torquethepackingnut(B)
to136–149N.m(100–110ft-lb).Themustbe
performedafterthepumphasbeencycleda
numberoftimes
Disconnect Disconnect
Disconnectthe the theAir Air AirMotor Motor Motor
1.FollowPressureReliefProcedure,page12.
2.Withthebleedertypemainairvalveturnedoff,
disconnecttheairhosefromtheairmotor.
3.Removethethumbscrews(P)andthetwo
guards(R)fromthesidesoftheproportioner.
NOTICE NOTICE
NOTICE
Besuretouseanoverheadhoistwhenlifting,
movingordisconnectingtheairmotor.Thisair
motorweighs145lbs.andistooheavyforone
persontohandle.Aliftringisprovidedonthe
motorforthispurpose.
4.Notetherelativepositionoftheairmotor’sair
connectiontotheframe(E).Theairmotor(B)
mustbereturnedtoitsoriginalorientation.
5.Usinganadjustablewrench(orhammerand
punch),unscrewthecouplingnut(J)fromtherod
adapter(N).Donotloseordropthecoupling
collars(M).SeeFig.6.
6.Holdthetierod󰘱atswithawrenchtokeepthe
rodsfromturning.Unscrewthenuts(H)fromthe
tierods(F).Carefullyremovetheairmotor(B)
fromtheframe.
7.Refertotheseparatemanualsuppliedforair
motorservice.Besuretolookatthemodel
numberstampedontheairmotorandusethe
appropriatemanualforserviceandreference.
Reconnect Reconnect
Reconnectthe the theAir Air AirMotor Motor Motor
1.Iftheconnectingrodhasbeenremovedfromthe
AirMotorStudasapartofservicing,besure
tousethreadadhesivewhenreinstallingthe
connectingrodontotheAirMotorStud.
2.Makesurethecouplingnut(J)andthecoupling
collars(M)areinplaceontherodadapter(N).
3.Useanoverheadhoisttopositiontheairmotor
ontheframeinthesameorientationasnotedin
step5ofdisconnectingtheairmotor.
4.Positiontheairmotor(B)onthetierods(F).
5.Screwthenuts(H)ontothetierods(F)and
torqueto81–89N.m(60–66ft-lb).
6.Screwthecouplingnut(J)ontotherodadapter
(N)loosely.Holdtherodadapter󰘱atswitha
wrenchtokeepitfromturning.Useanadjustable
wrenchtotightenthecouplingnut.Torqueto
196–210N.mft-lb).
7.Reconnecttheairhose.
8.Replacethetwoguards(R)andthethumb
screws(P)ontothesidesoftheproportioner.
9.Turnontheairsupply.Followtheprocedurefor
startingthepumponpage11.Runthepump
slowlyat󰘰rsttoensureproperoperation.
203A3092A