Graco SERIES F Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1968, Graco Inc. is registered to I.S. EN ISO 9001
1:1 MIX RATIO PRESIDENT
Plural Component
Proportioning Pump
For use in Hydra–Catand Foam–CatSprayers
1440 psi (9.2 MPa, 92 bar) Maximum Working Pressure
Part No. 208851, Series F
12:1 Pressure Ratio
Model 208851 meets certification.
Part No. 239389, Series A
12:1 Pressure Ratio
1:1 mix ration by volume. See page 10 for other possible mix ratios.
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Service 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List and Drawing 12. . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
306989L
Read warnings and instructions.
06915
Parts

2 306989
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
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction 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 usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 1440 psi (9.2 MPa, 92 bar) maximum working pressure.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull the equipment.
Use only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Wear hearing protection when operating this equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Do not operate the equipment with the air motor plates removed.
Keep clear of all moving parts when starting or operating the pump.
Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 6 to
prevent the equipment from starting unexpectedly.

306989 3
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray 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.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 6 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
Ground the equipment and the object being sprayed. See Grounding on page 5.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Before operating this equipment, electrically disconnect all equipment in the spray area.
Before operating this equipment, extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.

4 306989
WARNING
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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
Graco does not manufacture or supply any of the reactive chemical components that may be used
in this equipment and is not responsible for their effects. Graco assumes no responsibility for loss,
damage, expense or claims for personal injury or property damage, direct or consequential, arising
from the use of such chemical components.
Installation
General Information
NOTE:
Reference numbers and letters in parentheses in
the text refer to the callouts in the figures and the
parts drawing.
Use Genuine Graco Parts and Accessories, avail-
able from your Graco distributor.
This pump is designed to be part of a Hydra-Cator
Foam-Catsprayer that will proportion, mix, and spray
polyurethane material. Refer to the separate instruc-
tions supplied with each component in your system, as
well as any system manuals, for specific installation
instructions, or contact your Graco representative.
WARNING
Two accessories, a bleed-type master air valve,
and a fluid drain valve are required for your system
to reduce the risk of serious injury from moving
parts, fluid injection, or splashing in the eyes or on
the skin, when shutting off the pump.
The bleed-type master air valve relieves trapped air
between the valve and the pump, after the pump is
shut off. Trapped air can cause the pump to cycle
unexpectedly and result in serious injury if you are
adjusting or repairing the pump.
The fluid drain valve helps relieve fluid pressure in
the displacement pump, hose, and gun/dispensing
valve when shutting off the pump. Triggering the
gun/valve to relieve pressure may not be sufficient,
especially if there is a clog in the hose, gun/valve,
or tip/nozzle.

306989 5
Installation
Grounding
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 3.
1. Pump: To ground the pump, loosen the grounding
lug locknut (W) and washer (X). See Fig. 1. Insert
one end of a 12 gauge (1.5 mm2) minimum ground
wire (Y) into the slot in lug (Z) and tighten the
locknut securely. Connect the other end of the
ground wire to a true earth ground. Order part no.
222011, Ground Wire and Clamp.
2. Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 feet (150 m) com-
bined hose length to ensure maximum grounding
continuity.
3. Air compressor: follow the air compressor
manufacturer’s recommendations.
4. Spray gun or dispensing valve: ground by connect-
ing the gun/valve to a properly grounded fluid hose
and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.
0720
Fig. 1
W
X
Y
Z

6 306989
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
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.
1. Lock the gun/valve trigger safety.
2. Shut off the air to all pumps.
3. Close the bleed-type master air valve (required in
your system).
4. Close the fluid valves to your gun/valve, if so
equipped.
5. Unlock the gun/valve trigger safety.
6. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail, and trigger it to relieve
pressure.
7. Lock the gun/valve trigger safety.
8. Open the fluid drain valve (required in your sys-
tem); have a container ready to catch the drain-
age.
9. Leave the fluid drain valve open until you are ready
to spray again.
10. If you suspect that the spray tip or hose is com-
pletely clogged, or that pressure has not been fully
relieved after following the steps above, very
slowly loosen the tip guard retaining nut or hose
end coupling and relieve pressure gradually, then
loosen completely. Now clear the tip or hose.

306989 7
Operation
WARNING
MOVING PARTS HAZARD
To reduce the risk of serious injury,
never operate the pump with the air
motor plates removed. The moving
piston behind the plates can pinch or amputate
fingers.
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 6 before checking or servicing
any part of the system, whenever you stop spray-
ing, install or clean the spray tip, or are instructed
to relieve the pressure.
Flush the Pump Before Using
Pumps are tested with lightweight oil which is left in to
protect pump parts. To prevent contamination of fluid,
flush the pump with a compatible solvent before using
it. If the pump is being used to supply a circulating
system, allow the solvent to circulate until the pump is
thoroughly flushed. After flushing, relieve the pressure
as instructed on page 6.
Keep the wet-cup/packing nut (E) filled with Graco
Throat Seal Liquid (TSL) to help prolong the packing
life. See Fig. 2. Check the tightness of the packing nut
weekly. The packing nut should be tight enough to
prevent leakage, but no tighter. Always relieve the
pressure before adjusting the packing nut.
Startup and Priming
If you have purchased a foam sprayer, refer to the
separate system instruction manual for your sprayer
(307106 or 307542) for complete startup and priming
procedures.
If this pump is not used in a Graco Hydra-Cat or
Foam-Cat sprayer, follow these operating instructions
for the proportioning pump.
1. Use proper moisture control equipment for your
feed/supply pumps.
2. Place the RES (Resin) hose in the RES supply
container and ISO (Isocyanate) hose in the ISO
supply container.
3. Open the air supply valve to the pump, and set the
pump air regulator to 40 psi (280 kPa, 2.8 bar).
4. Operate the pump until all air is purged from the
hoses, then close the air valve.
5. Prime the pump and hoses fully before connecting
to the gun or valve.
6. Relieve the pressure.
7. Connect the gun or valve.
Fig. 2 06915
E

8 306989
Operation
Using the Proportioning Pump System
When the system is primed and operating, check the
fluid outlet pressure gauges. Check the gauges fre-
quently while using the system, and note the pres-
sures. These notes will be helpful in analyzing prob-
lems that may occur, as a change in the displacement
pump performance will be indicated by a change in the
pressure gauge readings.
NOTE: A pressure drop does occur during pump
stroke changeover.
WARNING
EQUIPMENT MISUSE HAZARD
To reduce the risk of serious injury,
including fluid injection:
Do not exceed the maximum air and fluid work-
ing pressure of the lowest rated component in
your system.
Always close the air supply valve to the pump
before opening the fluid drain valves to relieve
system pressure. This will reduce the risk of
excessive pressure buildup in the opposite
component hose and fittings.
If a supply container is dry, stop the pump immediately,
and relieve the pressure. Refill the container, and
prime the system. Be sure to eliminate all of the air
from the system.
CAUTION
Do not allow the supply containers to run dry of the
fluid being pumped. A dry container allows air to be
pumped into the system and can cause incorrect
proportioning. One dry displacement pump can
damage the other displacement pump by causing a
pressure rise in the other pump.
Maintenance
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 6 before checking or servicing
any part of the system, whenever you stop spray-
ing, install or clean the spray tip, or are instructed
to relieve the pressure.
Shutdown and Care of the Pump
Stop the pump at the bottom of its stroke to keep fluid
from drying on the exposed displacement rod and
damaging throat packings. Relieve the pressure as
instructed on page 6.
Flushing
Flush the pump with a compatible solvent before the
fluid dries in the pump and hoses. If the pump is to be
stored for any period of time, and you are pumping
water-based fluid, first flush it with water, then with
mineral spirits to protect the pump parts.
1. Relieve the pressure as instructed on page 6,
and remove the spray tip (spray guns or spray
valves only) before flushing.
2. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail and use the lowest pos-
sible fluid pressure during flushing.
3. Relieve the pressure.
Lubrication
An accessory air line lubricator provides automatic air
motor lubrication. For daily, manual lubrication, discon-
nect the regulator; place about 15 drops of light ma-
chine oil in the pump air inlet; reconnect the regulator;
and turn on the air supply to blow oil into the motor.
Corrosion Protection
Water or moist air can cause the pump to corrode. To
help avoid corrosion, never leave the pump filled with
water or air. After normal flushing, flush the pump
again with mineral spirits or oil-based solvent; relieve
the pressure; and leave the mineral spirits in the pump.

306989 9
Troubleshooting
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 6 before checking or servicing
any part of the system.
NOTE: Check all possible problems and solutions
before disassembling the pump.
Problem Cause Solution
Pump fails to operate Not enough air pressure or volume Check air pressure; increase as
needed.
Closed or clogged air valve or line Open or clear valve or line.
Air motor inoperative Service air motor. See manual
306982.
Pump operates, but part A output
low on up stroke*
Dirty, worn, or damaged part A pump
piston valve
Service piston valve. See manual
307944.
p
Worn or damaged part A pump piston
packings
Replace packings. See manual
307944.
Pump operates, but part A output
low on down stroke*
Dirty, worn, or damaged part A pump
intake valve
Clean or service intake valve. See
manual 307944.
Pump operates, but part A output
low on both strokes*
Dirty, worn, or damaged part A pump
intake valve
Clean or service intake valve. See
manual 307944.
Empty or inadequate fluid supply
container
Refill or change container.
Pump operates, but part B output
low on up stroke*
Dirty, worn, or damaged part B pump
piston valve
Clean or service piston valve. See
manual 307944.
p
Worn or damaged part A pump piston
packings
Replace packings. See manual
307944.
Pump operates, but part B output
low on down stroke*
Dirty, worn, or damaged part B pump
intake valve
Clean or service intake valve. See
manual 307944.
Pump oeprates, but part B output
low on both strokes*
Dirty, worn, or damaged part B pump
intake valve
Clean or service intake valve. See
manual 307944.
Empty or inadequate fluid supply
container
Refill or change container.
Fluid leaks around fluid pump
packing nut
Loose packing nut, or worn throat
packings
Tighten packing nut, or replace throat
packings. See manual 307944.
Pump operates erratically, or dis-
placement rod moving up and
Empty or inadequate fluid supply
container
Refill or change container.
pgp
down too quickly Air in fluid lines Purge system. Check hose and fitting
connections.
* This will cause an inaccurate ratio.

10 306989
Service
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
follow the Pressure Relief Procedure
on page 6 before checking or servicing
any part of the system and whenever you are
instructed to relieve the pressure.
Displacement Pump Service (See Fig. 3)
1. Relieve the pressure as instructed on page 6.
2. Flush the pump as instructed on page 8.
3. Relieve the pressure.
4. Remove the tie rod locknuts (19) from beneath the
tie plate (18). See Fig. 3.
5. Remove the locknuts (14) from above the yoke
(16). Pull the displacement pumps (20) and the tie
plate (18) straight down and off the yoke.
6. Remove the washers (15) and unscrew the retain-
ing rings (17) to remove the displacement pumps
from the tie plate (18).
7. Refer to instruction manual 307944 to service the
displacement pumps.
8. Reassemble the pump as instructed on page 11.
Changing the Fluid Mix Ratio
To change the fluid mix ration of the proportioning
pump, three displacement pumps must be used. The
standard tie plate (18) and yoke (16) will accept a third
displacement pump. Order one each of part no.
164417 Retaining Ring (17), and 164416 Washer (15)
to connect the third pump.
Always use the two outer displacement pumps to
supply the Resin and the middle displacement pump to
supply the Isocyanate parts of the polyurethane chemi-
cal. See the Mix Ratio – Pump Combination Chart
for the pump combinations.
CAUTION
To avoid stress on the yoke, which can break the
pump displacement rod:
1. Do not use combinations of only two pumps to
change ratios.
2. The outer two pumps must be identical.
Mix Ratio – Pump Combination Chart
For ratios other than 1:1, use three displacement
pumps in the following combinations.
Mix
Ratio
Displacement Pump Part No.
Ratio Pump 1 Pump 2* Pump 3
1.25:1 222019 222015 222019
1.33:1 222017 222012 222017
1.50:1 222019 222017 222019
1.66:1 222017 222015 222017
2:1 222012 222012 222012
2.40:1 222015 222017 222015
2.50:1 222012 222015 222012
2.66:1 222017 222019 222017
3:1 222012 222017 222012
3.2:1 222015 222019 222015
4:1 222012 222019 222012
* Pump 2 is the center pump.
NOTE: Displacement pump part no. 239388 can be
used wherever 222012 is listed and obtain the same
ratio.
Installing Three Displacement Pumps
CAUTION
If you are changing to a different type of fluid, thor-
oughly flush and clean all of the equipment and the
hoses. Make sure that none of the previously used
fluid remains in any part of the system.
1. Relieve the pressure as instructed on page 6.
2. Flush the pump as instructed on page 8.
3. Relieve the pressure.
4. Remove the displacement pumps as instructed in
steps 4 to 6 in Displacement Pump Service.
5. Install the center displacement pump first, then the
two outer pumps. Refer to Pump Reassembly on
page 11.