Graco PRESIDENT HYDRA-CAT 231657 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1993, Graco Inc. is registered to I.S. EN ISO 9001
PRESIDENT HYDRA-CATrFIXED RATIO
Proportioning Pumps
3000 psi (21 MPa, 210 bar) Maximum Working Pressure
Two or Three Displacement Pump Models in Various Mix Ratios,
Pressure Ratios, and Flow Volume
Available as Bare Pumps, or as Wall-Mounted* or Free-Standing
Models
*Includes Mixing Manifolds, Automatic Pressure Relief Valves, Check Valves, Pressure Gauges, and
Regulators.
For models that are certified and approved
see pages 6 and 7.
308224E
Read warnings and instructions.
See page 2 for Table of Contents and
page 6 for List of Models.
02884A
Parts

3082242
Table of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation – Optional Fluid Heaters 13. . . . . . . . . . . . . .
Installation – Optional Solvent Pump 15. . . . . . . . . . . . .
Flushing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown and Care of the System 21. . . . . . . . . . . . . . .
Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service – Displacement Pump 24. . . . . . . . . . . . . . . . . .
Parts – Bare, Two Pumps 26. . . . . . . . . . . . . . . . . . . . . .
Parts – Bare, Three Pumps 28. . . . . . . . . . . . . . . . . . . . .
Parts – Wall Mount, Two Pumps 30. . . . . . . . . . . . . . . . .
Parts – Wall Mount, Three Pumps 32. . . . . . . . . . . . . . .
Parts – Stand Mount, Two Pumps 34. . . . . . . . . . . . . . .
Parts – Stand Mount, Three Pumps 36. . . . . . . . . . . . . .
Accessories 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout for Air Motor 42. . . . . . . . . . . . . .
Technical Data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 44. . . . . . . . . . . . . . . . . . . . . .
Graco Information 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
Plural Component Materials Hazard
Graco, Inc. does not manufacture or supply any of the reactive chemical materials that may be used in this equip-
ment and is not responsible for their effects. Because of the vast number of chemicals that could be used and
their varying chemical reactions, before using this equipment, the buyer and the user should determine all facts
relating to the materials used, including any of the potential hazards involved. Particular inquiry and investigation
should be made into the 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.

308224 3
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

3082244
WARNING
INJECTION HAZARD
Spray from the valve, leaks or ruptured components can inject fluid into your body and cause ex-
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can
also cause serious injury.
DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
DDo not point the valve at anyone or at any part of the body.
DDo not put your hand or fingers over the valve tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the valve when spraying.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 21 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DKeep hands and fingers away from the piston during operation and whenever the pump is charged
with air.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 21 to
prevent the equipment from starting unexpectedly.

308224 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
DGround the equipment and the object being sprayed. Refer to Ground the Pumps on page 10.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DBefore operating this equipment, electrically disconnect all equipment in the spray area.
DBefore operating this equipment, extinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while spraying or while operating if fumes
are present.
DDo not operate a gasoline engine in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

3082246
List of Models
Pressure and Ratio Ratings for President Pumps
WARNING
To reduce the risk of over pressurizing a component, which can result in an explosion and serious injury, never
operate the system at a working pressure higher than the lowest rated component in the system. All fluid side
components such as dispensing valves, regulators, and hoses must have a working pressure equal to or greater
than the pressure given in Column B for each pump model.
Column A gives the maximum fluid pressure developed at 100 psi (0.7 MPa, 7 bar) of incoming air pressure.
Column B gives the minimum working pressure required for all system components, based on the automatic
relief valve settings. Components included by Graco with the models listed meet or exceed this requirement.
Models with Two Displacement Pumps
A B
Model No.
Maximum Pump
Fluid Pressure
at 100 psi (7 bar) Air
Minimum
Component
Working Pressure
Normal
Pressure
Ratio
Nominal Flow
Volume
@ 40 cpm
Mix Ratio Bare Wall Stand psi bar psi bar
Ratio
(Fluid to Air) gpm lpm
1:1 231643** 231593** 231618** 1280 89 1800 124 12.80 1.5 5.7
1:1 231644 1601 112 1800 124 16.01 1.2 4.5
1:1 231645** 231595** 1921 135 2300 159 19.21 1.0 3.8
1:1 231646** 2561 179 2900 200 25.61 0.75 2.8
** CE approved and certified.

308224 7
List of Models
Models with Three Displacement Pumps
A B
Model No.
Maximum Pump
Fluid Pressure
at 100 psi (7 bar) Air
Minimum
Component
Working Pressure
Normal
Pressure
Ratio
Nominal Flow
Volume
@ 40 cpm
Mix Ratio Bare Wall Stand psi bar psi bar
Ratio
(Fluid to Air) gpm lpm
2:1 231657** 231607** 231632** 1280 88 1800 124 12.80 1.50 88
4:1 231663** 231613** 231638** 1024 71 1150 79 10.24 1.87 71
**CE approved and certified

3082248
Typical Installation
About the Typical Installations
These pumps are designed to be part of a Hydra-Cat
dispensing system that will proportion, mix, and
dispense two-component fluids. The typical installa-
tions shown below and on page 9 are only guidelines
to setting up a complete proportioning system. For
clarity, various components are shown in the correct
order but may not be shown in exactly the position of
the installed system. For assistance in designing your
system, contact your Graco distributor.
NOTE: When pressure feeding the proportioning
pump, mount fluid pressure gauges (J) at the propor-
tioning pump inlets to monitor proper adjustment of the
feed pump pressures. Never exceed 25% of the
Hydra-Cat pump outbound fluid pressure on the feed
supply.
Light Viscosity System
Two Displacement Pumps,
5:1 Ratio Feed Pumps
1See note above
Connect to drain bottle.
See Fig. 5, page 11
2
KEY
A Bleed-type master
air valve
B Air filter
C Air lubricator
D Pump runaway valve
E Pump air regulator
F Feed pump
G Ground wire
H Proportioning pump
J Fluid pressure gauge
K Check valve
L Automatic pressure relief
valve
M Fluid filter
N Mixer manifold
P Fluid drain valve
Q Fluid shutoff valve
R Static mixer
S Dispense valve
T Fluid regulator
U Solvent pump
V Fluid strainer
* Included with wall or stand models
Fig. 1
D
BA
C
FG
A
E
2
HJ*K* L*
M
N*
P*
Q
R
Q*
K
S
M
J*
T
Q*
A*
E*
V*
U
1
02885
RES
HARD
RES
HARD
HARDENER RESIN

308224 9
Typical Installation
About the Typical Installations
These pumps are designed to be part of a Hydra-Cat
dispensing system that will proportion, mix, and
dispense two-component fluids. The typical installa-
tions shown below and on page 8 are only guidelines
to setting up a complete proportioning system. For
clarity, various components are shown in the correct
order but may not be shown in exactly the position of
the installed system. For assistance in designing your
system, contact your Graco distributor.
NOTE: When pressure feeding the proportioning
pump, mount fluid pressure gauges (J) at the propor-
tioning pump inlets to monitor proper adjustment of the
feed pump pressures. Never exceed 25% of the
Hydra-Cat pump outbound fluid pressure on the feed
supply.
Heavy Viscosity Heated System
Three Displacement Pumps,
10:1 Ratio Feed Pumps
1
2
See note above
Connect to drain bottle.
See Fig. 5, page 11
KEY
A Bleed-type master air valve
B Air filter
C Air lubricator
D Pump runaway valve
E Pump air regulator
F Feed pump
G Ground wire
H Proportioning pump
J Fluid pressure gauge
K Check valve
L Automatic pressure
relief valve
M Fluid filter
N Mixer manifold
P Fluid drain valve
Q Fluid shutoff valve
R Static mixer
S Dispense valve
T Fluid regulator
U Solvent pump
V Fluid strainer
W Fluid heater
X Supply manifold
* Included with wall or stand models
Fig. 2 02886
D
BA
C
FG
A
E
2
HJ* K* L* M
N*
P*
Q
R
Q*
K
S
M
J*
T
Q*
A*
E*
V*
U
1
W
X
2

30822410
Installation
Bare Pumps
Bare pumps are available for those installations which
require a highly customized system. For a safe and
efficient system, Graco recommends that the air and
fluid components supplied with the Wall Mount and
Cart Mount models also be used in customized
systems. Refer to the Parts Drawings on pages 26–37
for part numbers. In addition, the accessories shown in
the Typical Installation drawings and discussed in the
following pages of this manual should be used.
Be sure all accessories are sized properly for the air
and fluid requirements of your system.
Read all instructions in the Installation section for
further details.
NOTES:
1. Models with three displacement pumps always use
the two outer displacement pumps to supply the
resin and the middle displacement pump to supply
the hardener.
1. These pumps always use the two outer displace-
ment pumps to supply the resin and the middle
displacement pump to supply the hardener.
2. Label all pumps, hoses, fluid regulators, etc. to
indicate whether they are for the resin side or
hardener side of the system.
Mounting the Pump
Mount the pump to suit your installation. The bare
pump can be mounted on a wall bracket or on a cart.
See the Mounting Hole Layout on page 42. The Presi-
dent pump and accessories weigh approximately 65 lb
(30 kg). The pump stand and accessories weigh
approximately 55 lb (25 kg).
For a wall mount, be sure the bracket and wall are
strong enough to support the pump, accessories,
plumbing and stress caused by pump operation.
Locate the bracket about 5 ft (1.5 m) above the floor.
Ground the Pumps
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 5.
1. Loosen the grounding lug locknut (BB) and washer
(AA).
2. Insert one end of a 14 ga (1.5 mm@) minimum
ground wire (G) into the slot in lug (CC) and tight-
en the locknut securely. See Fig. 3.
3. Connect the other end of the ground wire to a true
earth ground. Order part number 237569 Ground-
ing Clamp and wire.
Fig. 3
G
BB
AA CC

308224 11
Installation
Air Control Accessories
Install the accessories in the order shown in Fig. 4.
Mount only the air regulator (E) and a master air valve
(A) at the pump. Mount all other accessories on sepa-
rate wall brackets to reduce stress on the pump inlet.
Note that one air filter (B) can serve multiple pumps by
using an air manifold downstream from the air filter.
WARNING
Bleed-type master air valves (A) are required in the
system in the positions shown in the Typical Instal-
lation drawings. These valves are used during
system pressure relief to relieve air trapped in the
air line. Trapped air can cause the pump to cycle
unexpectedly and result in serious injury from
moving parts, fluid injection, or fluid splashing.
1. Install a bleed-type master air valve (A) in the
pump air inlet.
2. Install an air regulator and gauge (E) to control
pump outlet pressure.
3. Install a pump runaway valve (D) for each feed
pump to automatically shut off the air to the pump
if the pump accelerates beyond the pre-adjusted
setting. A pump which runs too fast can be seri-
ously damaged.
4. Install an air line lubricator (C) for automatic air
motor lubrication.
5. Install an air filter (B) to remove harmful dirt and
moisture from the compressed air supply.
02887
Fig. 4
D
BA
C
G
A
E
Automatic Pressure Relief Valves
WARNING
To reduce the risk of component rupture, which
could cause serious injury and property damage,
the appropriate automatic pressure relief valve is
required for each fluid on a plural component
pump.
These valves automatically relieve fluid pressure if
the pump output pressure exceeds the valve’s
preset pressure. Over pressurization may occur if
there is a fluid line clog upstream from the valve or
if any other condition exists that causes one of the
pumps to cavitate and direct all fluid pressure to
the other pump(s).
See the List of Models on page 6 to determine
the preset pressure in your system.
Two drainage bottle kits (38) are included with wall
models (unassembled) and stand mount models
(assembled) to catch the drainage if the automatic
pressure relief valves open.
For the wall mount models, assemble the kit as shown
in Fig. 5 and mount it securely to a wall or bracket.
Use the tie wrap, supplied, to hold the hoses out of the
way, if necessary.
WARNING
Fluid emitted from the automatic pressure drain
valves may be at pressures over 3000 psi (21
MPa, 210 bar). Make sure the drain bottles are
securely fastened to the frame or wall so that they
can handle a sudden spurt of pressurized fluid.
Fig. 5
38h
38g
38f
38a
38b
38c
02888A
18

30822412
Installation
NOTE: If you mount the pump on a wall, turn the
displacement pump inlet assemblies (CC) to face
forward, rather than backwards as shown in Fig. 6.
Connect Fluid Supply Hoses
For Two Displacement Pump Models
1. Connect the resin supply hose (EE) to the 3/4 npt
swivel inlet (37B) for the resin displacement pump.
See Fig. 6.
2. Connect the hardener supply hose (DD) to the
3/4 npt swivel inlet (37A) for the hardener displace-
ment pump. See Fig. 6.
For Three Displacement Pump Models
1. Connect the resin supply hose (EE) to the 3/4 npt
swivel inlet (37B) for the resin displacement
pumps. See Fig. 7.
2. Connect the hardener supply hose (DD) to the 3/4
npt swivel inlet (37) for the center (hardener)
displacement pump. See Fig. 7.
Additional System Components
Install and connect the feed pumps, solvent pump,
heaters, etc. Refer to the Typical Installation (Fig. 1–2)
and Accessories on pages 38–39 for parts informa-
tion.
Use a dry air kit or a nitrogen regulator kit to protect
the fluid in the supply containers from moisture that
can crystallize the fluid and cause the ball checks to
malfunction. See Accessories on page 39.
Fig. 6
DD
EE
CC
RES
HARD
02889
37B
37A
Fig. 7
DD
EE
HARD
37B
37A
02890
RES
RES

308224 13
Installation – Optional Fluid Heaters
Fig. 8
201
202
203
20
4
10
201a
201b
IN
OUT
02891A
WARNING
To reduce the risk of serious injury, follow the
Pressure Relief Procedure on page 21 before
installing the heaters.
All Models
NOTE: For systems requiring one heater for each
fluid, see page 38 to order the heaters and required
plumbing (items 201 to 205).
1. Mount a heater to each side of the mounting
bracket using the three screws (201a) and lock-
washers (201b) supplied with each heater. See
Fig. 8.
2. Connect a swivel union (202) to the outlet of each
heater. See Fig. 8.
3. Connect a swivel union (203) to the inlet of each
heater. See Fig. 8.
For Two Displacement Pump Models
1. Disconnect the existing hardener hose (10B) from
the inlet of the mixer manifold (23). See Fig. 8.
Connect the free end of the hose to the swivel
(203) at the hardener heater inlet. See Fig. 9.
2. Install a new fluid hose (204B) between the
hardener heater outlet (202B) and the hardener
mixer manifold. See Fig. 8–9.
3. Repeat Steps 1 and 2 for the resin pump
(the “A” side).
RE
S
HAR
D
RES
RES HARD
HARD
RES
HARD
Fig. 9
202A 202B
203B203A
23 (N)
02893
204B
204A
10B10A
IN IN
OUT
OUT

30822414
Installation – Optional Fluid Heaters
IN
OUT
RES
HEATE
R
IN
OUT
HARD
HEATE
R
RES
HARD
RES
RES HARD
RES HARD
Fig. 10
17A 17B
202A 202B
203B203A
23 (N)
204B
205A
FA FB
02894
For Three Displacement Pump Models
NOTE: You must provide two hoses (FA, FB in Fig.10)
and fittings to run from the heater outlets to the mixer
manifold inlets.
NOTE: To accommodate two resin fluid hoses, the
mixer manifold (23) must be disconnected from the
bracket and mounted remotely.
1. Loosen the swivel of the unions (17A, 17B) to
remove the elbow (16A, 16B) on each side of the
mixer manifold (23). Turn the unions (17A, 17B) so
the outlet faces up. See Fig. 10 and 11.
2. Connect a new hardener fluid hose (204B)
between the union (17B) and the swivel (203B) at
the heater inlet. See Fig. 10.
3. Install another hardener fluid hose (FB) between
the heater outlet elbow (202B) and the hardener
side of the mixer manifold (23). See Fig. 10.
4. Repeat Steps 1 to 3 for the resin side of the
system (the “A” side).
02892A
Fig. 11
16B
16A
17B
17A
(N) 23
RES
HARD

308224 15
Installation – Optional Solvent Pump
NOTE: The optional solvent pump is not offered as a
kit; order parts as needed. The optional parts shown
here are listed on page 39. These instructions assume
that the pump is being mounted to the back of the
stand offered in this manual. The Typical Installations
on pages 8–9 show alternate installations. Adjust
your installation according to your specific needs.
1. Mount the solvent pump bracket (301) on the back
of the stand.
2. Mount the pump (306) to the bracket using the
hardware supplied with the pump.
3. Use the existing proportioning pump air regulator
(5) to supply air to the solvent pump. Remove the
plug from the back of the swivel union (3) and
install the adapter (301). Rotate the regulator
gauge elbow (4) so the gauge is facing the
operator.
4. Couple the hose (303) and couplings (302).
Connect the hose (303) to the adapter (301).
5. Install the other adapter (301), needle valve (304)
and adapter (305) to the pump inlet.
6. Connect the adapter (307), elbow (308) and fluid
hose (309) to the pump outlet.
7. Install a fluid shutoff valve (311) at the mixer
manifold swivel union (15). This valve is used to
prevent resin or hardener from backing up into the
solvent system, and to isolate the solvent system
for service. Connect the solvent inlet hose (309).
8. Connect the suction hose assembly (312) to the
pump intake.
309
310
312
308
307
305
303
301
304
314
313
301
309
311
15
306
316
315
Fig. 12
302,
303
302
5
4
3
A
B
A
02902
B

30822416
Flushing
When to Flush the System
DFlush the system before its first use to remove the
light oil which was left in after factory testing.
DFlush the manifold mixer (N), using the solvent
pump, as frequently during the day as necessary to
avoid exceeding the pot life limit of the material
being pumped.
DFlush frequently enough during regular operation to
prevent clogged passages due to material being
overheated or dried out in any part of the system.
Clogged passages in the heater can be very difficult
to clean and can reduce heating efficiency, flow rate
and pressure.
DFlush the entire system when the system is shut
down for a long period of time. Keep in mind that
some moisture may get into the lines, which could
contaminate the hardener, so flush again before
restarting the system.
How to Operate the Mixer Manifold
To open or close the mixer manifold (N) fluid valves
(LL) push the handle (KK) down to open and up to
close. See Fig. 13.
Fig. 13
1
2
UP – closed
DOWN – open
1
2
KK
LL
LL
N2
N1
N
P2
P1
02895
RES
HARD
RES
HARD
HARD
RES
Fig. 14
KEY
A Bleed-type master air valve
A1 Hardener feed pump
A2 Resin feed pump
A3 Proportioning pump
A4 Solvent pump
A5 Feed & Proportioning pump
master air valve
A6 Solvent pump master air valve
E Pump air regulator
E1 Hardener feed pump
E2 Resin feed pump
E3 Proportioning pump
E4 Solvent pump
J Fluid pressure gauge
J1 Proportioning pump intake
J2 Proportioning pump outlet
H Proportioning pump
N Mixer manifold
Q Fluid shutoff valve
Q1 Proportioning pump intake
Q2 Mixer manifold solvent inlet
02896
A1
E1
A3E3
A2
E2
H
J1
J2
A5
A4
E4
N
A6
Q2
Q1

308224 17
Flushing
How to Flush the System
WARNING
If your system is equipped with heaters, always
shut off the main power to the heaters before
flushing. Circulate the fluid through the system for
at least 10 minutes to cool the fluid and the heater.
This reduces the risk of serious injury from burns.
NOTE: For the first time flushing, we recommend
using mineral spirits to flush out the oil. Then flush
again using a solvent that is compatible with the fluid
you will be dispensing. However, be sure the mineral
spirits is compatible with the material you will be
pumping. If it is not, check with your fluid supplier to
determine an appropriate solvent for flushing out the
light oil.
For flushing only . . .
NOTE: The proportioning pump is not operated during
flushing. The solvent from the feed pumps will flush the
proportioning pump displacement pumps.
1. Place each feed pump intake into a separate 5
gallon grounded pail, containing about 3 gallons
(12 liters) of solvent.
To flush or prime . . .
2. Be sure both of the fluid shutoff valves (Q1) are
open. See Fig. 14.
3. Place a container under the drain valves (P1,P2)
of the mixer manifold (N). See Fig. 13.
4. Be sure the feed pump air regulators (E1,E2) are
at minimum pressure. See Fig. 14.
5. Open the main master air valve (A5). See Fig. 14.
6. Open the hardener pump master air valve (A1).
See Fig. 14.
7. Slowly increase the air regulator (E1) setting until
the pump is running slowly.
8. Open the hardener side drain valve (P1). Open the
mixer manifold handle (KK). See Fig. 13.
9. When the hardener lines are flushed, close the
mixer manifold handle and close the drain valve
(P1). Close the air valve (A1). See Fig. 14.
10. Repeat Steps 6 to 9 for the resin feed pump. The
resin sides uses these parts: regulator (E2), air
valve (A2), drain valve (P2).
To flush the solvent valves . . .
11. Open the hardener solvent flush valve (N1) on the
mixer manifold (N). See Fig. 13.
a. Be sure the solvent pump air regulator (E4) is
at minimum pressure. See Fig. 14.
b. Open the solvent pump main master air valve
(A6) and then open the pump air valve (A4).
See Fig. 14.
c. Release the dispensing valve safety latch.
Hold the dispensing valve firmly against a
grounded pail and trigger it while slowly
opening the solvent pump air regulator (E4).
Operate the pump slowly until the dispense
line is flushed. Release the dispensing valve
trigger and engage its safety latch. Close the
hardener solvent flush valve (N1).
d. Open the resin solvent flush valve (N2) and
repeat Step c. See Fig. 13.
e. Close the solvent line shutoff valve (Q2). See
Fig. 14.
CAUTION
Always close the solvent line fluid shutoff valve (Q2)
after the flushing procedure has been completed.
This will prevent the other fluids from leaking into the
flushing line.
If this is a first time flush . . .
12. Repeat the flushing procedure using a solvent
compatible with the fluid you are going to
dispense.
When you are done flushing . . .
13. Remove the solvent supply from the feed pumps.
Operate the pumps slowly to push all the solvent
out of the lines, then stop the pumps.
If you are not going to use the system . . .
14. Close all air regulators, master air valves and fluid
shutoff valves. Follow the Pressure Relief Proce-
dure on page 21.
WARNING
Always close the air valve (A4) to the solvent pump
before opening the fluid drain valves (P2) to relieve
system pressure. This will reduce the risk of exces-
sive pressure buildup in the opposite component
hose and fittings.

30822418
Operation
WARNING
Handling Plural Component Materials
Be extremely cautious when handling plural com-
ponent materials and solvents used with them.
Some are extremely toxic. See the WARNING on
the front cover. Read and follow the coating and
solvent manufacturer’s safety precautions and
warnings, including information regarding protective
clothing, eyewear, and respirators.
When spraying reactive fluids, wear the proper
protective clothing, eye protection, gloves, and
clean air breathing apparatus as prescribed by the
fluid manufacturers recommendations, O.S.H.A.
regulations and as approved by N.O.I.S.H. for the
chemicals being used.
Observe the Pot Life Limit
Flush the mixed fluid out of the mixer, dispensing lines
and equipment before it hardens. Flush the complete
system when necessary to prevent the fluids from
hardening in the equipment and hoses. Check the fluid
manufacturer’s instructions for fluid shelf life, and flush
the entire system before this time is reached. Flush the
system with a compatible solvent as explained on page
17.
Fill the Throat Packing Nuts
Keep each displacement pump throat packing nut (JJ)
filled with Graco ISO Pump Oil to help prevent fluid
from drying on the displacement rod and damaging the
pump packings. See Fig. 15.
Verify compatibility of the pump oil with the fluids being
used in the pumps. During operation very small
amounts of this fluid are dragged past the seals and
into the pump.
Fig. 15
JJ
02897
Check the Drainage Bottles and Hoses
WARNING
To reduce the risk of serious injury and property
damage, regularly check and clean the drain hose
and bottle for the automatic pressure relief valve.
If material is allowed to dry in and clog the drain
hose, the automatic pressure relief valve may not
fully release the fluid pressure if it opens or may
cause the drain hose to burst.
Check the drain hose and bottle (38) at the start of
each shift, and whenever there is an imbalance of
material, to see if the automatic pressure drain valve
has released material into the bottles. Clean the hose
and bottle as needed. Regularly check the drain hose
for cuts, leaks, or bulges and replace damaged
components before using the system. See Fig. 16.
Fig. 16
38
02948A
Monitor the Material Supply
CAUTION
Establish a rigid system for monitoring the material
supply to prevent the pumps from running dry. A
sudden lack of material in one pump may cause
many system problems, including air entrapment,
spitting of the fluids, fluid “crossovers”, pump
damage, downtime, and added system stresses.
Never allow the feed pump or solvent pump containers
to run dry. A dry container allows air to be pumped into
the system and causes incorrect proportioning. A dry
pump will quickly accelerate to a high speed, and may
damage itself and the other displacement pump be-
cause it causes a pressure rise in the other pump. If a
supply container becomes dry, stop the pump immedi-
ately, refill the container, and prime the system. Be
sure to eliminate all the air from the system.
NOTE: The pump runaway valve mentioned on page
11 of the Installation section shuts off the pump if the
pump speed accelerates quickly.

308224 19
Operation
Startup
WARNING
To reduce the risk of serious bodily injury, including
fluid injection, splashing in the eyes or the skin, and
property damage, never exceed the maximum air
and fluid working pressure of the lowest rated
component in your system. See Equipment Mis-
use Hazard, System Pressure, on page 3.
1. Install full containers of resin and hardener at the
feed pumps.
2. To prime the system, follow Steps 2 to 11 of the
Flushing procedure on page 17.
3. Turn on the heaters, if used, and allow them to
warm up for 10 minutes.
4. Open the feed pump air valves (A1,A2). Adjust the
air regulators (E1,E2) just enough to start the
pumps operating slowly.
5. Open the proportioning pump air valve (A3) and
slowly open the regulator (E3) to start the propor-
tioning pump.
6. Open the mixer manifold (N) and trigger the
dispense valve (S).
7. Set the air pressure to the feed pumps at 88 psi
(0.6 MPa, 6 bar) or 25% of proportional pressure
at the fluid outlets, whichever is less. Use the
gauges (J1) to monitor this pressure. Higher
pressures may prevent the proportioning pump
inlet ball checks from setting properly.
8. Set the air pressure to the proportioning pump (H)
to obtain the required fluid pressure. Refer to the
proportioning pump chart on page 6 for the fluid
to air pressure.
9. While triggering the dispensing valve, check the
fluid outlet pressure gauges (J2) and make note of
the pressures indicated. Check the gauges
frequently during operation. These notes will help
to analyze any problems that may occur since a
change in displacement pump performance will be
indicated by a change in pressure gauge
readings.
NOTE: A pressure drop does occur during pump
stroke changeover.
NOTE: Flush the mixer manifold frequently during the
day’s operation. Follow Step 11 on page 17.
Fig. 17 02886
KEY
A Bleed-type master
air valve
A1 Hardener feed pump
A2 Resin feed pump
A3 Proportioning pump
E Pump air regulator
E1 Hardener feed pump
E2 Resin feed pump
E3 Proportioning pump
H Proportioning pump
N Mixer manifold
S Dispense valve
A1
E1
A3
E3
A2
E2
H
N
S

30822420
Operation
Checking the Mix Ratio
NOTE: Since this is a fixed ratio system, you typically
do not have to check the mix ratio.
If the mixed fluid does not cure or harden properly,
check the ratio of resin to hardener.
1. Flush the mixer manifold; see Step 11 on page 17.
2. Follow the Pressure Relief Procedure on page .
3. Open the mixer manifold (N).
4. Set the operating pressure for the pumps. See
Steps 7 and 8 on page 19.
5. Release the dispensing valve trigger and engage
the safety latch.
6. Close the mixer manifold (N).
7. Open the hardener side drain valve (P2) about
three turns. Open the resin side drain valve (P1)
about 1 turn. This prevents the pressure from
building up on the hardener pump, which would
cause the automatic pressure relief valve to open.
8. Place a grounded metal pail under the drain
valves.
9. Open the mixer manifold.
10. While observing the pump outlet gauges (J2),
adjust the resin and hardener drain valves (P1,P2)
until the gauges show your normal operating
pressure.
NOTE: The pressure must be within 20% of the orig-
inal spraying pressure to get a usable test.
11. Close the mixer manifold. Put a separate sampling
container under each drain valve.
12. Open the mixer manifold to draw a sufficient
sample.
13. As you close the mixer manifold, check the pump
outlet gauges (J2) again to make sure they are at
your normal operating pressure.
NOTE: If the fluid pressure is not within 20% of the
normal operating pressure, flush the mixer manifold
again and take another sample. If the sample ratio is
incorrect, refer to the Troubleshooting chart on page
22. If the ratio is correct, the problem is with one of the
other system components.
14. Compare the volume of the sampling containers. If
the ratio is not correct, refer to the Troubleshooting
chart on page 22. If the ratio is correct the problem
is one of the other components.
15. Close the drain valves (P1,P2).
Fi
g
. 18
N
P1
KK
P2
J2
J2
02898A